BOILERS LIMITED - Calypso Ltd · 2014. 3. 7. · December 2011. Page 2 CONTENTS Genie C Wiring 3...

BOILERS LIMITED

Training notes for the following Certikin pool heaters:

Genie SGenie C

Genie DualMB055 - MB405

COH110 - COH280

December 2011

CONTENTS

Genie C Wiring 3 Genie C Schematic 4Genie S Wiring 5Genie S Schematic 6Genie Dual Wiring 7Genie Dual Schematic 8Genie C & S Setup & Service Modes 9Genie Dual Setup & Service Modes 11Genie C & S Engineering Modes 13Genie C, S & Dual Fault Guide 15Genie C, S & Dual Parts Identifi cation 18Genie C, S & Dual Microcom Software 20MB 055, 105 & 155 Wiring 22MB 185, 265 & 405 Wiring 24MB 055, 105 & 155 Troubleshooting 26MB 185, 265 & 405 Troubleshooting 28MB All Models Control Panel Lights 30COH 100 - 275 Mk1 Wiring 31COH 100 - 275 Mk1 Parts Identifi cation 32COH 110 - 280 Mk2 Wiring 34COH 110 - 280 Mk2 Electrical Parts Idenifi cation 35COH 110 - 280 Flueing options 37Oil Nozzle Sizing 38Networking 39Useful Multimeter Values 41

GENIE C - WIRING

12

34

56

78

910

1112

1314

1516

1718

1920

21 22

ON/OFFSWITCH

WITH THERMAL FUSETRANSFORMER

24 V

Y

3 Amps

POOL SENSOR

Pool Thermostat

CONDENSATE PS

FLOW SENSOR

EXCHANGER SENSOR

2B

2C

230 V

Y

60 C

X1.1

X1.3

X1.5

X1.8

X1.10

FAN

Br

B

X12.1

X12.8

X12.16

X12.3

X12.12

Hi L

imit

X12.4

X12.14

X12.5W

X12.11

Y

910

ohm

s

X12.13

Bk

B1%

240v 3 Wire

X12.2

X12.10

X1.7

X1.9

X1.2

Flu

e

230V/50Hz

LN

SL

LINK: Remove if seperate switched live provided

WATER PRESSURE SWITCH

Gy

P

P

Gy

Gy

Bk

OrVP

R/BR/B

Gy/Bk

P

V

Or

Gy

V

B

Br

G/Y

Br

BBr

B

B

Y Y

BkBr

Br

BkR

Gy

R

Bk

W

W

G

G

Gy/Bk

Bk

Bk

W

V

Gy

H E A T D E M A N DLO C K O U T A LA R M

FA N 23 0v

L

N

N

FA N TA C H O

R E S E T +v e

H I LIM I T

H I LIM I T

FA N P W M

M O D U LA T IO N +v e

R E S E T -v e

FA N +v e

FA N -v e

M O D U LA T IO N -v e

Gy/Bk

Br

B

2D

Bk B lackB Blue

Gy GreyGy/Bk Grey/Black

Br Brown

P Pink

V Violet

Y Yellow

R/B Red/Blue

Or Orange

W White

G/Y Green/Yellow

R Red

C o ntro l S ta t

CVBC

GENIE C - SCHEMATIC

Tf = Overheat stat, Flue 100C

Th = Overheat stat, Heat exchanger 150C

Tc = Limit temp control stat Flow 80C

Tfl = Temperature Sensor Flow

Tp = Temperature Sensor Pool

Pw = Pressure Switch Pool fl ow

TfTh

Tfl

Tc

Pw

Tp

GENIE S - WIRING

12

34

56

78

91

01

11

21

31

41

51

61

71

81

92

02

1

22

O N /O F FS W ITC H

W I TH TH E R M A L F U S ET R A N S FO R M E R

Y

3 A mps

P OOL S E N S OR

P ool Thermostat

C O N D E N S A TE P S

FLOW S E N S OR

E X C H A N GE R S E N S OR

2B2C

Y

8 0C Co nt rol Sta t

X 1.1

X 1.3

X 1.5

X 1.8

X 1.10

FA N

GyB k

B

X 12.1

X 12.8

X 12.16

X 12.3

X 12.12

Hi L

imit

X 12.4

X 12.14

X 12.5Or

X 12.11

Y

910

ohm

s

X 12.13

B k

B1%

X 12.2

X 12.10

X 1.7

X 1.9

X 1.2

Flue

230V/50Hz

LN

SL

LIN K : R emove i f seperate sw itched li ve prov ided

W A TE R P R E S S U R E S W ITC H

G y

P

B k

OrVP

R /B

Gy/B k

Gy

V

G/Y

B r

B

B

R R

B r

B kR

G y

R

B k

W

W

G

G

B r

B k

B kOr

V

P

HEAT DEM ANDL OCKOUT AL ARM

FAN 2 3 0v

L

N

N

FAN TACHO

RESET +v e

HI L IM I T

HI L IM I T

FAN PWM

M ODUL ATION +v e

RESET -v e

FAN +v e

FAN -ve

R /BGy/B k

Y

2D

B k B lackB B lue

Gy GreyGy/B k Grey/B lack

B r B rown

P P ink

V V iolet

Y Y el low

R /B R ed/B l ue

Or Orange

W W hite

G/Y Green/Y ellow

R R ed

G Green

P

Gy

PV

M ODUL ATION -v e

G/Y

P U M P

B P U M P R E L A YGyB k

B

B r

B r

B r

Hi L

imit

Wat

er

Gy

P U MP P R IME R

24 V

B rB k

B B r Y

B r B r B

BB rB rYOrG y

IGNITIONCONTROL

GENIE S - SCHEMATIC

TfTh

To

Tc

Tfl

PwTp



To = Overheat stat Flow 100C





GENIE DUAL- WIRING

NCN

L

PL DM DHT G D M D

HT R P M P3 P VL V

NCBU RNE R

L K OUT

NC

RE SET

M ODU L AT ION

CO M B ' SE NSO R

++

--

SE NSO R R T NB ' SEN SOR

PL SE NSO RPR ESS URE

CO ND' HI

W

Or

R

BBrGr

V

P

Bk Bl ac kBl ueBr ownGr eyOr ang ePi nkRe dVi o le tW hi te

KEY

Y Ye l low

Fl ow s ens or

Po ol s ens or

Co m b us ti on s ens or

Co nde ns a teLe v el Swi tc h

NC

Po ol d em and

He atin g d em a ndE N

Pe rm a nen t L i v e

>>> >>

Factory Fit ted Link

Rem ove when seperateswit ched live supplied

He ate r pu m pE

N

EN

3 Port Val v e

Co ntro l St at

X1 .1

X1 .3

X1 .5

X1 .8

X1 .10

FA N

Gy Bk

B

X1 2.1

X1 2.8

X1 2.1 6

X1 2.3

X1 2.1 2

Hi

Lim

it

X1 2.4

X1 2.1 4

X1 2.5Or

X1 2.1 1

Y

91

0 o

hm

s

X1 2.1 3

Bk

B

1%

X1 2.2

X1 2.1 0

X1 .7

X1 .9

X1 .2

Flu

e

Gy

V

R

G

WG

Br

Bk

BkOr

V

P

HEAT DEM AND

LO CKOUT ALARM

FAN 230v

L

N

N

FAN TACHO

RESET +ve

HI LIMIT

HI LIMIT

FAN PWM

MO DULATION +ve

RESET -ve

FAN +ve

FAN -ve

MO DULATION - ve

Hi

Lim

it

Wa

ter

Gy

IGNITIONC ON TROL

100609

Pr es s ure Swi t c h

WG

RP

GyBk

Br

B

P

R

B

Gy

Br BkG/ Y BGy

Bk

GY

R

Gy /Bk

R/ B

P

P

Or V Gy

VOr

G Gr een

Br

315 mA

GENIE DUAL - SCHEMATIC



To = Overheat stat Flow 100C





To

Tc

Tfl

PwTp

TfTh

Lock/ResetButton

On / OffSwitch

TemperatureDisplay

Pool TemperatureControl Knob

Fig. 9.0

Pressure Gauge

GENIE C & S - SETUP & SERVICE MODES

WARNING: BEFORE COMMENCING OR COMPLETING ANY ELECTRICAL WORK ON THE APPLIANCE, IT IS RECOMMENDED THAT THE BASIC SAFETY CHECKS FOR EARTH CONTINUITY, SHORT CIRCUIT, POLAR-ITY AND RESISTANCE TO EARTH ARE MADE. ALL WORK CARRIED OUT SHOULD FOLLOW GUIDELINES LAID DOWN BY THE I.E.E.

OperationThe Heater requires Mains on both the Live (L) and Switched Live (SL) connection to be able to run. It is delivered with a link between them which can be removed if a separate Heater switched live is going to be used.To run, the Heater must have a Mains supply, Gas, Pool Pump pressure suffi cient to activate the Pressure Switch, all safety switches closed and a pool temperature below the set point.If all the above are correct then the Gas Ignition Control starts the Ignition sequence:1. The Fan and internal Pump runs as a pre-purge of the Heat Exchanger2. After a few seconds a spark is created at the electrode and the burner is lit.3. The burner fl ame is sensed and the spark is removed.4. The Fan speed is then changed to the required speed according to the modulation curve.5. If it fails to light the burner the spark will stop and the Fan and internal Pump will run on as a post-purge of the Heat Exchanger.6. The ignition sequence will be repeated up to fi ve times, then the control will lockout and will require a reset to start again.

Safety Controls & LockoutsThe Pool Thermostat Control indicates the actual and set temperature of the pool and also displays all the lock-outs. The next pages detail the fault conditions, the indicators, the display and the actions required.

User Setup ModeTurn off on the Panel Switch. Turn on with the Panel Switch whilst pressing the Lock/Reset Button.The Control is now in User Setup Mode.

The control can now be altered by rotating the Pool Temperature Control Knob to a certain position and then pressing the Lock/Reset button, then switching off. (See Fig. 9.0)

Example:To change from Fahrenheit to Centigrade: Turn Panel Switch OFF then back ON whilst pressing the Lock/Reset button. Turn the Pool Temperature Control Knob until the display shows ‘F’. Press the Lock/Reset button once and the display will show ‘C’. Switch the Panel Switch OFF then back ON again. The Control will now display in Centigrade.

GENIE C & S - SETUP & SERVICE MODES

Service ModeThis is a special mode used to set the operation of the Control and to investigate fault conditions, it is entered from User Setup Mode. Rotate Pool Thermostat knob fully clockwise to show the software version number. Press the Lock/Reset Button for 3 seconds. The control is now in Service Mode. It is now possible to change some of the Control’s parameters. To show them, rotate the Pool Thermostat Potentiometer. To zero or change them, press the Reset/Lock button To exit, turn the Panel Switch off then back on again.

Test Temperature Display Mode 1 (td1).

Temperatures are displayed to 0.1 degree resolution, not the normal 1 degree.The display will now show each sensor temperature and cycle around them for each press of the Lock/Reset button.

1. Pool temperature as normally displayed. The green LED will be alight. 2. Pool temperature is dispayed to 0.1 degrees. The green LED will be alight. 3. Heat exchanger fl ow temperature. The yellow LED will fl ash rapidly. 4. Heat exchanger combustion temperature. The red LED will fl ash rapidly. 5. Aproximate pool water fl ow in l/m for Genie 50 multiply by 0.738 for Genie 35. the red and yellow LEDs alternate. Rotating the potentiometer will change the set temperature. Pressing and holding the button whilst one of the tem-peratures is displayed will ‘lock/unlock’ it on the display for continuous observation.

Service Mode Setting Factory Setting Reset press Display Indicator

1 Pressure Log Number of Operations Resets to zero Yellow LED ON

2 Overheat Log Number of Operations Resets to zero Red LED ON

3 Combustion Gas Log Number of Operations Resets to zero Count, Red LED fl ashing

4 Gas Lockout Log Number of Operations Resets to zero Count, Red & Yellow LED ON

5 Condensate Blocked Log Number of Operations Resets to zero Count, Front Red PCB LED ON

6 Unused Rear Red PCB LED ON

7 Hours run 0 Press resets to zero 156 =1560 hrs both PCB LEDs on

8 Pool Temperature Offset 0.5 C (0.9 F) Steps of 0.5C (0.9F) -3.0C to 3.0C (-5.4 F to 5.4F)

9 Display td0 td1 td0 / td1

Genie S only

Genie C only

User Setup Mode Setting Factory Setting Alternative Display Indicator

1 Display units ° F = Fahrenheit ° C = Centigrade ° F or ° C2 Maximum temperature 32 °C (90 °F) 41 °C ( 106 °F) PL or SPA3 Software Version e.g 018

GENIE DUAL - SETUP & SERVICE MODES

GENIE C (up to V10) - FACTORY MODEGenie Pool Thermostat, Engineering Mode

BackgroundAs detailed in the Installation Instructions, it is possible, with the aid of a special setup plug, to enter intoan Engineering mode on this control.

Engineering ModeTurn the Heater OFF with the Panel SwitchRemove the Front Top Panel and the Electrical Chassis Cover, remove the knob and Pcb retainer.Pull off the PCB connector for the Sensors and replace with the Special Connector. (See Fig. 2.0)Turn the Heater back ON.Select the Parameter required by pressing the button, alter by rotating the potentiometer, then power off.Replace the Sensor Connector and power back on

ParametersNB. The following explanation uses Centigrade, if the control is setup for Fahrenheit the values will bethe equivelant.

1. bt1 or bt3. This sets the controls boilertype. bt1 is non-condensing, bt3 is condensing.2. td0 and td1. This sets the display type, td0 is the default. td1 allows the temperatures of

the other sensors to be displayed to one decimal place.Each press of the lock button moves the display to the next one.a. Pool Temperature as normally displayed.. The Green LED will be alight.b. Pool Temperature is dispayed to 0.1 degrees. The Green LED will be alight.c. Heat Exchanger Flow Temperature. The Yellow LED will flash rapidly.d. Heat Exchanger Combustion Temperature. The Red LED will flash rapidly.

Rotating the potentiometer will change the set temperature. Pressing and holding thebutton whilst one of the temperatures is displayed will ‘lock/unlock’ it on the display forcontinuous observation.

3. The proportional band. 0.0 to 7.9 degrees, the default is 1.0. This is the number of degreesbelow setpoint modulation can start.

4. The DeltaT modulation point. 0 to 50 degrees, the default is 12. This also determines themodulation charactersistic of the Heater. It is the temperature difference across the heat exchangerwhere modulation will start.

Example: Default settings, 1 and 12. Required Pool temperature 30C.At 28.9 pool temperature, no modulation in any circumstancesAt 29.0 pool temperature and 10 degrees across the heat exchanger, no modulation.At 29.0 poool temperature and 15 degrees across the heat exchanger, modulation.

If the propotional band is set to 0.0, there will be no modulation irrespective of the DeltaT setting.If the DeltaT setting is 50, the Heater will always be in modulation.It is recommended that the modulation points are not altered without consultation with the manufacturer.

.

Fig. 2.0

GENIE C & S (from V10) - FACTORY MODE

Genie Pool Thermostat, Engineering Mode

BackgroundAs detailed in the Installation Instructions, it is possible, with the aid of a special setup plug, to enter intoan Engineering mode on this control.

Engineering ModeTurn the Heater OFF with the Panel SwitchRemove the Front Top Panel and the Electrical Chassis Cover, remove the knob and Pcb retainer.Pull off the PCB connector for the Sensors and replace with the Special Connector. (See Fig. 2.0)Turn the Heater back ON.Select the Parameter required by pressing the button, alter by rotating the potentiometer, then power off.Replace the Sensor Connector and power back on

ParametersNB. The following explanation uses Centigrade, if the control is setup for Fahrenheit the values will bethe equivelant.

1. bt1 or bt3. This sets the controls boilertype. bt1 is non-condensing, bt3 is condensing.2. td0 and td1. This sets the display type, td0 is the default. td1 allows the temperatures of

the other sensors to be displayed to one decimal place.Each press of the lock button moves the display to the next one.a. Pool Temperature as normally displayed.. The Green LED will be alight.b. Pool Temperature is dispayed to 0.1 degrees. The Green LED will be alight.c. Heat Exchanger Flow Temperature. The Yellow LED will flash rapidly.d. Heat Exchanger Combustion Temperature. The Red LED will flash rapidly.

Rotating the potentiometer will change the set temperature. Pressing and holding thebutton whilst one of the temperatures is displayed will ‘lock/unlock’ it on the display forcontinuous observation.

3. The proportional band. 0.0 to 7.9 degrees, the default is 1.0. This is the number of degreesbelow setpoint modulation can start.

4. The DeltaT modulation point. 0 to 50 degrees, the default is 12. This also determines themodulation charactersistic of the Heater. It is the temperature difference across the heat exchangerwhere modulation will start.

Example: Default settings, 1 and 12. Required Pool temperature 30C.At 28.9 pool temperature, no modulation in any circumstancesAt 29 0 l t t d 10 d th h t h d l ti

.

Fig. 2.0

DIS

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RES

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REDLED1

RED

REDLED2

Run

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sing

poo

l tem

pera

ture

to 2

8°C

Up

to te

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ratu

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ater

pre

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GENIE C, S & DUAL - FAULT FINDING

GENIE C, S & DUAL - FAULT FINDING

DIS

PLAY

LOC

K /

RES

ET

GREEN

YELLOW

REDLED1

RED

REDLED2

FRO

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PAN

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YES

YES

YES

YES

NO NO

YES

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Is w

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?V

1 =

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GENIE C, S & DUAL - SPARES

SPMBC009100C Flow Overheat Stat

SPMBG055 80C Flow Control Stat

SPMBC011Flow Sensor

Genie S

SPMBG057Pool Thermostat PCB

SPMBG008Condensate Pressure Switch

SPMBG054Relay

SPCOH2/003Pressure Gauge

GENIE C, S & DUAL - SPARES

Item Mfg’ Part Number Supplier Part No Primary Heat Exchanger (Genie35) M2136 SPMBG001 Primary Heat Exchanger (Genie 50) M2139 SPMBG002Secondary Heat Exchanger (Bowman) M2745 SPMBG053Propane Orifi ce (Genie 35) M2150 SPMBG014Propane Orifi ce (Genie 50) M2151 SPMBG015 Combustion Fan M2138 SPMBG003 Gas Valve M2140 SPMBG004Ignition Control (Honeywell) M2141 SPMBG005Pool Thermostat PCB M2746 SPMBG057 Heat Exchanger Door Seal M2995 -Relay M2688 SPMBG054Pressure Gauge M4240 SPCOH2/003Water Pressure Switch 651284 SPCOH2/014 HT Lead M2142 SPMBG006Condensate Syphon M2143 SPMBG007Condensate Pressure Switch M2144 SPMBG008Spark & Sense Electrode M2146 SPMBG010 Flue High Limit Thermostat M2875 SPMBG060Flow Control Thermostat M2667 SPMBG055Flow High Limit Thermostat M0868 SPMBC009 Flow Sensor (Genie C) M2149 SPMBG013Flow Sensor (Genie S) M3338 SPMBC011 Pool Temperature Sensor M2798 SPCOH2/002Genie Pump M2683 SPMBG056Expansion Vessel M3369 SPCOH103

Genie CVBC Honeywell Controller error codes

Several checks are included to protect the boiler and its environment. Some checks are made even when there is no demand for heat and will lead to “gas” lockout, which can only be cleared when the fault is recti-fi ed. This includes the High Limit thermostats (in the fl ue and on the primary fl ow pipe) and the electrical connection to the gas valve coils.

Other “gas” lockouts will occur during the heating operation of the unit and in the case of some lockout and blocking conditions the fan may still operate depending on the parameter option fan On/Off during error.

Complete list of errors is given as following:

External Lock out conditions: Internal lock out conditions:01 Flame lockout after several ignition trials 10 EEPROM (I2C) com error02 False Flame Lockout. 20 IO Error03 High Limit error 21 ADC test HUP05 Fan Tacho Signal error 22 ADC test LUP08 Flame circuit error

Blocking condition codes:09 Valve driver circuit error34 Low mains voltage35 Mains Frequency error36 Mains difference errorxx Other faults

External Lock out condition codes

FAULT 1 = Lock out signal after no fl ame and/or all ignition attempts have completed. This error condition is stopping the boiler and to get to the normal operation again, a manual reset is required.

FAULT 2 = False Flame error - when a fl ame current is detected in when there should be no fl ame present (i.e. when the gas valve is closed).

FAULT 3 = High limit error – if one or both of the two High Limit sensors detects a temperature of more then 105�C or if Hi limit sensors or wiring is open circuit an error 3 will be generated.

FAULT 5 = Fan Tacho Error – The measured fan speed is not within 900 RPM of therequested fan speed after 20 seconds. Connections or fan is open circuit.

FAULT 8 = Flame circuit error - during normal operation of the ignition controller, the fl ame circuit is regu-larly checked. This check compares actual to predicted behaviour patterns and will result in error 8 if the actual readings fall outside the predicted.

Internal Lock out condition codes

FAULT 10 = EEprom communication error. Non correct behaviour of the I2C protocol caused this error to happen. EEPROM is not accessible. Fault with communications port on the controller itself. Replace Hon-eywell controller if this fault persists.

FAULT 20 = IO error. Internal check of valve command and the signal feedback. The high limit circuit signal is also checked. If the feedback signals are not aligned with commands for more than 3.5s, then a lockout occurs.

GENIE C, S & DUAL - MICROCOM SOFWARE

FAULT 21 = ADC Internal test on HUP processor. Test measures mains voltage. If the min. and max. values of this mains sine wave are not correct for more than 5 sec. then this error code is shown.

FAULT 22 = ADC Internal test on LUP processor. Basically the processor manipulates periodi-cally power inputs in defi ned way for very short time (milliseconds) (e.g. grounding and checking if value follows the manipulation and there is no change on other power input channels at the same time (e.g. shorts). There is also a check if reference voltage is within defi ned tolerance. If there is an issue detected for more than 3.5 seconds, then this error is shown.

Blocking codes

The boiler controller also recognises that faults can occur which are temporary in nature and will normally be resolved after a short while. This will result in a “gas” lockout, but will clear itself once the error condition is resolved. There is no requirement to manually reset the device. This type of error will be written into the history data. The meaning of the codes is as follows:

FAULT 9 = Valve circuit error - during normal operation of the ignition controller, the valve circuit is regularly checked. This check compares actual to predicted behaviour patterns and will re-sult in error 8 if the actual readings fall outside the predicted. Valve coils may be open circuit or shorted. Controller may not be making good contact with the valve pins. The “gas” error will clear when the fault is no longer detected.

FAULT 34 = Low Mains voltage (less than 185VAC) will trigger this error if it is detected for more than 10 seconds. When normal voltage is restored (190-250VAC), the “gas” error will self clear and the heater will resume normal operation.

FAULT 35 = Mains frequency has more than +/- 5% tolerance. When the frequency is within tolerance again, the error will be resolved. Same rules as fault 34, but supply frequency must be in the range 47.5 – 52.5Hz

FAULT 36 = Mains voltage measured on low and high voltage side differ too much. Probably an internal hardware cause. If measured voltages within tolerance again, error will be resolved.

XX OTHER FAULT CODES = any other codes in error history indicate faults internal to the CVBC controller. No corrective action can be performed to prevent these faults occurring, except to replace the controller if the fault is persistent. Current spikes and poor electricity supply can cause internal memory errors, which are normally reset by switching power to the unit off and then on again.

GENIE C, S & DUAL - MICROCOM SOFWARE

MB 055, 105 & 155 - WIRING

ROBERTSHAW IGNITION DEVICE

MB 055, 105 & 155 - WIRING

KEY

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MB 185, 265 & 405 - WIRING

MB 185, 265 & 405 - WIRING

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ROBERTSHAW IGNITION DEVICE

MB 055, 105 & 155 - TROUBLESHOOTING

055, 105 & 155 ModelsELECTRICAL TROUBLESHOOTING

START

SET THERMOSTAT TO CALL FOR HEAT

DOES THE DIAGNOSTIC

LED STAY ON?

YES

AFTER PREPURGEIS THERE SPARK

AT THE PILOT ASSEMBLY?

YES

PILOT BURNERLIGHTS

YES

SPARK STOPS WHENPILOT IS LIT

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTILCALL FOR HEAT ENDS

YES

CALL FOR HEAT OVERSYSTEM SHUTS OFF

YES

END TROUBLESHOOTING

NO

NO

NO

NO

NO

CHECK LINE VOLTAGE POWER. CONFIRM TRANSFORMER OUTPUT, LIMIT CONTROLLERS, THERMOSTAT AND WIRING. ALSO, INDUCED DRAFT FAN AND AIR PROVING SWITCH ON INDUCED DRAFT SYSTEMS.

CHECK IGNITION CABLE, GROUND WIRING, PILOT ASSEMBLY INSULATOR AND GAP. CHECK CABLE FOR SIGNS OF MELTING.

CHECK VALVE, VALVE WIRING, GAS SHUT OFF VALVES.

CHECK FLAME SENSE WIRE AND GROUNDWIRE. CHECK PILOT FLAME COVERS SENSE ROD. CLEAN SENSE ROD.

CHECK VALVE, VALVE WIRING.

CHECK LIMITS AND CIRCULATION FAN. CHECKCONTINUITY OF SENSOR CABLE AND GROUNDWIRE. POOR GROUNDING MAY CAUSE OCCASIONAL SHUTDOWNS. CHECK FOR EXCESSIVEHEAT AT FLAME SENSOR INSULATOR.

CHECK THERMOSTATCHECK VALVE

CHECK FOR 25VACNOMINAL AT TH & TR

TERMINALS

YES

REPLACE CONTROL

IS THERE ANY AUDIBLE SPARK

NOISE @ 5 SPARKS/SEC?

NO

REPLACE CONTROL

NO NO

NOYES

WARNINGHIGH VOLTAGE

For qualified Technicians ONLY

*NOTE: This heater is equipped with an ignition module that shuts off pilot gas if pilot fails to light after the third attempt. This is iden tified by the LED flashing on the ignition module. To reset, in terrupt power to heater.

*

MB 055, 105 & 155 - TROUBLESHOOTINGELECTRICAL TROUBLESHOOTING055, 105 & 155 Models If the pool/spa water is too cold, troubleshoot the system as follows:

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.Check transformer, 230 V supply, correct as necessary.If 230 V side of transformer is open circuit, check combus-tion chamber for heat leaksCheck 3 Amp fuse.

TEMPERATURE 40°C-40.5° C.Control ok.

RESISTANCE 0 OHMS (SHORT CIRCUIT)Check system for shorted wires or open circuits.Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCEDON'T MATCH.Replace sensor. Reconnect all leads and check out system.

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V. Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE ABOVE 42°CDisconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS.Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT.Disconnect potentiometer leads from circuit board.Measure resistance with ohmmeter. If resistance is: 0-100 ohms at minimum setting: 9k to 11k at maximum setting, replace circuit board. Above 11k ohms, replace potentiometer. 0 ohms (short circuit), replace potentiometer. Reconnect all leads and check out system.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.Check transformer, 230 V supply, correct as necessary.If 230 V side of transformer is open circuit, check combus-tion chamber for heat leaksCheck 3 Amp fuse.

TEMPERATURE 40°C-40.5° CControl ok.

RESISTANCE ABOVE 15k OHMS (OPENCIRCUIT) OR SHORT CIRCUIT.Fix loose or broken wires. Replace sensor ifnecessary.

MEASURED AND ESTIMATED RESISTANCEDON'T MATCH.Replace sensor. Reconnect all leads and check out system.

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V. Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE BELOW 40°CDisconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS.Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT.Disconnect potentiometer leads from circuit board.Measure resistance with ohmmeter. If resistance is: 0-100 ohms at minimum setting; 9k to 11k at maximum setting, replace circuit board. Above 11k ohms but less than 15 k ohms, replace potentiometer. Above 15k ohms, fix loose or broken wires; replace potentiometer if necessary. Reconnect all leads and check out system.

If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

Temperature (deg C) 16°C 20°C 21°C 25°C 30°C 31°C 35°C 40°C 41°C

(deg. F) 61 68 70 77 86 88 95 104 106

Resistance (k ohms) 14.9 12.5 11.9 10.0 8.1 7.7 6.5 5.3 5.1


• Check that All Manual Gas ValvesAre Open, Supply Tubing & GasPressure Good.

• Check "PV" Power Monitor OnBack of Control Board (24 VACFrom IID to Pilot Gas Valve). IfNo Power, Replace IID.

• Check for Gas to Pilot (CrackFitting on Gas Valve Pilot TubeConnection-Clear Tube/PilotOrifice as Necessary)

• Verify Pilot Rectification (Pilot On- Spark Off)

• Check "MV" Power Monitor onBack of heater Control Board(24 VAC from IID to Main GasValve) If No Power, Replace IID.

• If All Okay, Replace Gas Valve.

YES

Sensor "Fail"• Inspect Thermister, wires, and connector at Terminal P1.• Using andOhmmeter, measure resistance from Red (ST) to

Back (Com) and Red (SR) to Black (Com), if not within 5% ofeach other replace Thermister.

• Check resistance value of Thermister. Reference to chart below.Replace Thermister in not within 10% of values shown.

• If all okay, replace heater Control Board.

SENSOR RESISTANCE AT VARIOUS TEMPERATURES TEMP°C DEGREES 22 27 33 39 44 50 55 59 Resistance (K ) 26.11 19.90 15.31 11.88 9.30 7.33 5.83 5.10 If All Okay, Replace heater Control Board

OVERTEMP "FAIL"Fail May indicate temporary residual

heat in heat exchanger. Reset & repeat. If problem continues, call service agent

- OR -Fail May indicate failure of heater

Control Board. If power to heater must be interrupted to reset, replace heater Control Board.

YES

• Check for "Fail" of Limit/Switch LEDLights on back of heater Control Board.Identify and Verify Fault. Replace Switch/Control as Necessary.

• Check for "Fail" of "Overtemp" or"Sensor" LED Lights on Back ofheater Control Board.

"Sensor" Fail "ON" / "Overtemp" Fail "ON"

YES

Temporary Condition mayhave caused problem.Does Heater Now OperateNormally?

NO

YES

Interrupt Power toHeater. Wait 10Seconds, Re-applyPower (to ResetPoly Fuse) Green"Call For Heat "On?

NO

Heater Sparks ?

YES

NO (OrFlashesOn-Off)

NO

NO ( Or Flashes On-Off)

NO

HEATER WILL NOT FIRE

08-08-01

START

"Green" Power Light "ON"

YES

"Green" Call-For-HeatLight "ON"

YES

"Red" Service Light "ON"

YES

"Red" Pressure/Hi-LimitLight"ON"

YES

• Check for "Fail" Pressure or HighLimit. Lights on Back of heaterControl Board.Verify Proper Water Flow/Pressure.Identify and ReplaceFaulty Limit/Switch as Necessary.

If All Okay, Replace heater Control Board

• Check for 230 V Power to Transformer(Circuit Breaker,Time Clock, Wire Connections)

• Check for Fireman Switch/Remote ThermostatOperation (Red Jumper Wire from TP4 to TP5)Bypass If Necessary.

• Check for 24 VAC from TP6 to TP7(Transformer Output) If No Power, ReplaceTransformer.

• Check Combustion chamber for heat leaks

• Check Fuse F1 on Back of heater Control Board.If Fuse is Open, Replace with Auto Reset Poly Fuse,Proceed.

• Check Toggle Switch for "Pool" or "Spa" Selec-tion. Set Temperature Control Knob toMaximum (Counter-Clockwise)

• Check Water Temperature - Must be Less than40°C ( Maximum Call-For Heat)

• Check Pool/Spa Selector switch and wiring toterminal TP2 and TP3.

Is Green "Call For Heat" And/Or Red "Service"Light On?

NO

NO


Probable Component or Wire Short to Ground.• Interrupt power to heater.• Remove Molex Connectors P1, P2, P3 and

P4 on heater Control Board• Re-Apply Power to Heater, Does "Power"

and "Service" Light Stay On?Replace heaterControl Board

• Check for 24 VAC Power to IID - (24 V to24V GND Terminals on IID). If No Power,Replace heater Control Board, or wireharness to IID.

• Check for Spark at IID Spark Terminal(Remove Hi-Tension Lead from IID Module-Position end near spark terminal. Turn controlon. If spark jumps to wire, check Hi-Tensionwire, insulators, ceramic ignitor and gap. If nospark jumps to wire, replace IID Module.

NO

YES

NO

NO

NO

ReplaceTemp Sensor

Check for properwire connectionson IID module. Ifokay, replaceIID module.

NO

• Remove Molex Connector PlugP2 on heater Control Board.

• With OHM Meter, check forcontinuity from each pin in plugto ground (cabinet)

• If continuity exits trace to wire/ com-ponent; repair or replace asnecessary.

• Re-check door clearance toterminals on gas valve.

• Trace wires to gas valve. Inspectfor proper connection on valve.

• If connections okay, replace gasvalve.

• Reconnect temp. sensor plugat connector P1

Does "Power" and "Service"light stay on? (Front Panel)

YES

Verify "Call For Heat" light(Front Panel)

• Reconnect safety circuitplug at connector P2.Does "Power" and"Service"light stay on? (Front Panel)

YES

• Reconnect IID Module plugat connector P3Does "Power" and "Call forHeat" Light stay on? (FrontPanel)

YES

• Place cabinet door onheater. Check for adequateclearance from door toterminals on gas valve.Remove door, correct ifnecessary.

• Reconnect gas valve plugP4 on heater ControlBoard

Does "Power" and "Call forHeat" Light stay on?

YES

Heater should operatenormally. If not, refer to start.

MB ALL MODELS - CONTROL PANEL LIGHTS

Control Panel Lights

COH 100 - 275 MK1 OIL - WIRING

ELECTRICAL ASSEMBLY - All Models (Wires not shown for clarity)

10-12-01

Item Description 100 175 210 275

1 High Limit Stat EL 00215 EL 00215 EL 00215 206892

2 Control Thermostat EL 0230 EL 0230 EL 0230 206896

3 On/Off Switch AH0050 AH0050 AH0050 AH0050

4 Pressure Gauge M0448 M0448 M0448 M0448

5 Potentiometer 600961 600961 600961 600961

6 Pool Temperature Sensor 600962 600962 600962 600962

7 Transformer M650531 M650531 M650531 M650531

8 Neon Red (2 Plc’s) AH0053 AH0053 AH0053 AH0053

9 Neon Amber AH0052 AH0052 AH0052 AH0052

10 Neon Green AH0133 AH0133 AH0133 AH0133

11 Thermostat Control (Solid State) 600960 600960 600960 600960

12 Relay M3363 M3363 M3363 M3363

- Control Knob (2 Plc’s) not shown M3224 M3224 M3224 M3224

6

3

4

7

8

8

9

10

5

2

1

11

12

COH 100 - 275 MK1 OIL - PARTS IDENTIFICATION

Item Description 100 175 210 275

1 Heat Exchanger SBECO 90 SBQF 150 SB 135/175 209451

2 Top 1st Baffl e HE 37031C HE 23031C SPCOH219 2 off 209282

3 2nd Baffl e HE 37031C HE 23042C SPCOH218 2 off 209280

4 3rd Baffl e SPCOH104 HE 23043C SPCOH218 2 off 209280

5 4th Baffl e - HE 23044C SPCOH217 2 off 209280

6 5th Baffl e - HE 23046C 2 off 209280

7 Combustion Chamber Base Insulation IN 14303 IN 14403 IN14403

8 Inspection Cover complete HE 37318C HE 23318C HE14418C

9 Inspection Cover Insulation N 14202 IN 23301

10 Base Tray PN 37201C PN 31301C PN14401C

11 Grommet RP 00610 RP 00610 RP 00610 RP 00610

12 Heat Exchanger Insulation Set IN 37300C IN 26300C IN02301C

14 Flueway Insulation Ceraboard (pair) IN 14401

15 Door Panel M3341 M3437 M3437 M3977

17 Rear Casing Panel M3344 M3436 M3657 M3976

18 Left side Casing Panel M3342 M3432 M3451 M3975

19 Right side Casing Panel M3343 M3433 M3450 M3984

20 Top Casing Panel Front M3407 M3440 M3440 M3980

21 Top Casing Panel Rear M3347 M3438 M3438 N/A

Casing Blanking Panel M3469 M3453 M3453 M3982

27 Gasket RP 03002 RP 03002 RP 03002 208799

28 Burner Complete 443T58 459T55 464T55 221410

Automatic Air Vent 6166 6166 6166 6166

Safety Valve M0480 M0480 M0480 M0480

Bulkhead Valve M0619 M0619 M0619 M0619

Expansion Vessel M3369 M3369 M3369 M3369

Secondary Heat Exchanger M3380 M3381 M3381 M4034

(SPCOH1HE) (SPCOH2HE) (SPCOH2HE) (SPCOH3HE)

Pressure Switch 650634 650634 650634 650634


COH 110 - 280 MK2 OIL - WIRING

ELECTRICAL ASSEMBLY - All Models

Item Description All Models 1 High Limit Stat SPCOH015

2 Control Board SPCOH2/001

3 Boiler & Pool Temperature Sensor SPCOH2/002

4 Pressure Gauge SPCOH2/003

5 Control Knob (2 Places, not shown) SPMB3411

6 Stop Ring (not shown) SPMB515

7 Bypass valve (not shown) SPCOH034

8 Reset grommet (not shown) SPCOH2/007

9 Bypass Sensor (not shown) SPCOH2/004

1 2 4

3

9:2 ACCESSORIES 110 180 220 280 Standard Horizontal Balanced Flue Kit SPCOHBF1 SPCOHBF2 SPCOHBF3

Extended Horizontal Balanced Flue Kit SPCOHBF1L SPCOHBF2L uses extensions

Terminal Guard SPCOHTG1 SPCOHTG2 Outdoor Vertical Kit SPCOHBFOV10 SPCOHBFOV11 PCOHBFOV3

Vertical Balanced Flue Adapter & Terminal SPCOHBFIV1 SPCOHBFIV2 SPCOHB-FIV3 Short Vertical Balanced Flue Extension SPCOHBFV15E SPCOHBFV25E

Long Vertical Balanced Flue Extension SPCOHBFV11E SPCOHBFC21E


.

Item Description 110 180 220 280 1 Heat Exchanger HE 26451C HE 14551C HE 47651C HE 51351C

2 1st Baffl e HE 51031C HE 23041C 2 off HE14034C 1 off HE47061

3 2nd Baffl e 2 off unless stated HE 51032C HE 23042C HE14035C 3 off HE47062C

4 3rd Baffl e 2 off unless stated HE 51033C HE 23043C HE14036C 3 off HE47063C

5 4th Baffl e 2 off unless stated _ HE 23044C _ 3 off HE47063C

6 5th Baffl e 2 off unless stated _ HE 23046C _ 3 off HE47067

7 Combustion Chamber Base Insulation 2 x IN51303 2 x IN14403 2 x IN14403 3 x IN47603

8 Inspection Cover complete HE 37318C HE 14418C HE14418C HE47618C

9 Inspection Cover Insulation IN37301 IN14402 IN14402 IN47602

10 Base Tray PN37331C PN31301C PN31301C PN47501C

11 Grommet RP00610 RP00610 RP00610 RP00610

12 Heat Exchanger Insulation Set IN37350C IN26350C IN26350C IN47500C

14 Flueway Insulation Ceraboard (pair) _ IN14401 IN14401 _

15 Door Panel M4436 M4542 M4542 M4494

17 Rear Casing Panel M4437 M4543 M4543 M4492

18 Left side Casing Panel M4435 M4538 M4538 M4488

19 Right side Casing Panel M4438 M4544 M4544 M4491

20 Top Casing Panel Front (Assy.) M4586 M4548 M4548 M4504

21 Top Casing Panel Rear M4584 M4559 M4545 M4500

Rear/Side Casing Blanking Panel M4589 M4557 M4557 M4505

Top Panel Blanking Panel M4561 M4561 M4560 M4506

27 Burner Gasket RP03001 RP03002 RP03002 RP03002

28 Burner Complete 3744363 3745960 3746457 3748960

Automatic Air Vent 6166 6166 6166 6166

Safety Valve SPCOH012 SPCOH012 SPCOH012 SPCOH012

Bulkhead Valve M0619 M0619 M0619 M0619

Expansion Vessel SPCOH103 SPCOH103 SPCOH103 SPCOH103

Secondary Heat Exchanger M4477 M4374 M4374 M4374

Pressure Switch (Plastic thread) SPCOH02/014 SPCOH02/014 SPCOH02/014 SPCOH02/04

Seal Ring Flue, Green, 60mm SPCOHBF04 SPCOHBF04 _ _

Seal Ring Air, Brown, 100mm SPCOHBF05 SPCOHBF05 _ _

Seal Ring, Flue, Black, 2x lip, 120mm _ _ SPCOHBF07 SPCOHBF07

Seal Ring Air, Black, 1x lip, 170mm _ _ SPCOHBF08 SPCOHBF08

Gasket, Low Level Terminal SPCOHBF01 SPCOHBF02 SPCOHBF02 _

Gasket, 170 x 170 mm SPCOHBF03 SPCOHBF03 _ _

Gasket 195 x 195 mm _ _ SPCOHBF06 SPCOHBF06

Gasket, 185 x 185 mm _ _ SPCOHBF09 SPCOHBF09

Nozzle Kerosine BS11106 BS11110 BS11112 BS11114

Nozzle Gas Oil SPCOH2/009 SPCOH2 SPCOH26 SPCOH2/012

Pump UPS 25-60 M0623 M0623 M0623

Pump UPS 25-55 M4024


Model Kit Number

110 SPCOHBFOV10

180 SPCOHBFOV11

220 SPCOHBFOV11

280 SPCOHBFOV3

Model L, Length range mm Part No Description

Rear Right Left

110 254 - 457 254 - 457 X SPCOHBF1 Standard 110 Balanced Flue Kit

110 457 - 864 457 - 864 500 - 864 SPCOHBF1L Long 110 Balanced Flue Kit

180 & 220 254 - 457 254 - 457 X SPCOHBF2 Standard 180/220 Balanced Flue Kit

180 & 220 457 - 864 457 - 864 500 - 864 SPCOHBF2L Long 180/220 Balanced Flue Kit

280 214 - 414 110 - 310 X SPCOHBF3 280 Standard Flue Kit 280 674 - 874 570 - 770 1175 - 1375 Plus SPCOHBFV25E 280 Short Extension

280 1084 - 1284 980 - 1180 1585 - 1785 Plus SPCOHBFV21E 280 Long Extension

mm 110 180 220

280 A 785 908 908 1320

B 142 180 180 230

C 175 200 200 225

Model Adjustment Flue Kit Short Extension Long Extension

110 590 SPCOHBFIV1 SPCOHBFV15E (500 mm) SPCOHBFV11E (1000 mm)




Measure the height from the fl oor to the outside of the roof (H). MAXIMUM H = 6000mm. Subtract the Adjustment fi gure in the Table above, this takes into account all other dimensions including the 600mm required above the roof. The length of Extensions must be equal or greater than this fi gure. Example for a Model 110. H = 3000mm; Extension Length = 3000 - 590 = 2410 = 2 x SPCOHBFV11E (2 x 1000mm) plus 1 x SPCOHBFV15E (1 x 500mm).

OUTDOOR FLUE KITS

HORIZONTAL BALANCED FLUE

Flat or Pitched RoofVERTICAL BALANCED FLUE

CRAVAT(SUPPLIED)

FLASHING(NOT SUPPLIED)

SIDE VIEW

GAS OIL CONVERSION COMPONENTS

CALCULATIONS

Model Nozzle Pre-Heater Flame Ring Bottom Baffl e

110 SPCOH2/009 SPCOH2/008 Not Required As Supplied

180 SPCOH2/010 SPCOH001 Not Required As Supplied

220 SPCOH2/011 Not Required Not Required As Supplied

280 Not Available

B

B

PLAN VIEW

REAR

LEFT RIGHTL

L

L

B

C

by a

min

imum

60

mm

All j

oint

s ov

erla

p

Service clearance

A

Allow 10mm clearance around flue to brickwork

A (2

80 O

nly)

COH 110 - 280 OIL MK2 - FLUEING OPTIONS

OIL NOZZLES - SIZING

Nozzle sizes 60W (Class C2 Kerosine)

COH Model 100/110 175/180 210/220 275/280Nozzle fi tted (GPH) 0.75/0.85 1.35 1.75 2.25 PSI 138/105 120 100 100/110

Nozzle sizes 60W (Class D Gas Oil)

COH Model 100/110 175/180 210/220 NANozzle fi tted (GPH) 0.75 1.1 1.25 NA PSI 105 135 150 NA

GPH 125 145 175 200 2500.40 0.45 0.48 0.53 0.57 0.690.45 0.50 0.54 0.60 0.64 0.780.50 0.56 0.60 0.66 0.71 0.870.55 0.62 0.66 0.73 0.78 0.950.60 0.67 0.72 0.79 0.85 1.040.65 0.73 0.78 0.86 0.92 1.130.75 0.84 0.90 0.99 1.06 1.300.85 0.95 1.02 1.12 1.20 1.470.90 1.01 1.08 1.19 1.27 1.561.00 1.12 1.20 1.32 1.41 1.731.10 1.23 1.32 1.46 1.56 1.911.20 1.34 1.45 1.59 1.70 2.081.25 1.40 1.51 1.65 1.77 2.171.35 1.51 1.63 1.79 1.91 2.341.50 1.68 1.81 1.98 2.12 2.601.65 1.84 1.99 2.18 2.33 2.861.75 1.96 2.11 2.32 2.47 3.032.00 2.24 2.41 2.65 2.83 3.462.25 2.52 2.71 2.98 3.18 3.902.50 2.80 3.01 3.31 3.54 4.33

Oil Nozzles - Approximate capacities at Various Pressures

RatedFlow at 100 PSI

U.S. Gallons per Hour

Pressure PSI

What is networking?

You get this type of control if there is a network containing a master and at least one available slave, otherwise you will get stand-alone control. The output power is modulated by switching boilers on or off.

One of the boilers is a ‘master’, the others are ‘slaves’. The master shares the work between itself and the slaves. The network can contain any Genie C, Genie S, Genie Dual and OIL type heaters.

Fitting the Network adapter

The network adapter fi ts on the left hand side of the pool thermostat PCB. Carefully fi t the board so that the 6 pins on control board pass through the underside of the adapter, and push it home so that the three plastic locking pillars snap into place. Use the supplied leads to daisy chain the heaters together by plugging them in to the network adapters. You must then fi ll the 2 remaining sockets with terminators. There are 2 types of terminator, you should use one of each. When you have fi nished all the sockets should be fi lled.

Setting up the network

Decide which heater is to be the master and connect the Pool sensor to it. It knows it is the master because it has a network and a pool sensor. Do not connect a pool sensor to any of the slaves. They know that they are slaves because they have a network but no pool sensor.

If you incorrectly connect pool sensors to more than one unit, the system will behave erratically; boilers may switch on and off at random. You can tell it is connected incorrectly because more than one unit will display the temperature. You operate the master in exactly the same way as a stand-alone system. A master with no slaves or no network is a stand-alone system.

If a master has a fault indicated on its LEDs, it is no longer available to heat the pool, but will continue to share the load with slaves that are OK.

Space heating is an individual, not networked activity. The master and each slave can each have their own space heating loop. For example one might heat radiators, another might heat a hot water cylinder.

On the master, space heating works as in a stand-alone system, it does space heating on de-mand unless pool demand takes priority.

When space heating has priority and the master is doing space heating, it can still command slaves to heat the pool. Switching the pool pot on will make a slave available for pool heating. When available it will display “---”.

Understanding the Operation of networking system

If the “---” display turns into a moving pattern “- “, “-- “, “ -”, “ --” then it means that the slave is available for pool heating but has not yet established communication to the master. This may happen for a few seconds after you switch it on. If it continues check the network cables and check that the master is working. Check that only one boiler has a pool thermistor - only this one will display the temperature.

NETWORKING -

NETWORKING -

If the display is blank then it means that the slave is not available for pool heating. This can be because it has no power, because the pool pot is off, or because there is a fault indicated on its LEDs. While a heater is unavailable the heater removes itself from the network and load is shared between the remaining heaters.

The slave detects all error conditions except for the P-oc (pool thermistor open-circuit). If it dis-plays the P-oc error it means that the network has not been detected. Check the terminators and network cables.

The Pool LED may be off, fl ashing or on. It is off if the slave is unavailable for pool heating (see above) or if the master is not doing pool heating. It is fl ashing if the master is pool heating, but this slave is not currently needed because the pool is up to temperature. It is on if then the slave is heating the pool.

A slave may also be used for space heating, but this is an individual, not networked, activity. If it has a heating demand live input and the right hand pot is on, it will do space heating, and it will not be available for pool heating. Slaves always have heating priority regardless of their P-H pri-ority setting. The master shares pool heating between itself and all the slaves that are available for pool heating. For instance if the master decides that 50% heating is appropriate and there are 4 boilers (3 slaves + itself) then it will switch 2 heaters on. If 2 more become available (making 6) it will switch 3 on.

If a boiler has done pool heating for more than 6 hours longer than another boiler then it switched off and given lowest priority. Space heating is not counted since boilers that do space heating are doing this alone. Apart from this boilers are chosen essentially at random.

The effect is a kind of leap-frogging. For instance if there a 2 boilers and only one is needed. One will get 6 hours ahead, then the other one will start, but will run for 12 hours until it is 6 hours ahead.

Boilers remember how far ahead they are when they are switched off. The fl ow fault on the slave deserves special mention because a rather complicated sequence emerges as a result of other features of the system:

1. Slave is heating the pool normally (all relays on) 2. Slave see a fl ow fault. The burner goes off immediately. 3. After 10 seconds the yellow light comes on continuously and the heater pump is switch off,

which is the normal fl ow fault function. 4. The slave takes itself out of the network because it is no longer available for pool heating. 5. As a slave out of the network it has no demand. If therefore reverts to the normal no-demand

operation which is a run-on, and switches the heater pump back on. 6. After 3 minutes the run-on fi nishes and both pumps are switched off. Because the pool pump

is off the fl ow fault ends (the yellow light goes to fl ashing). 7. Since there is no fl ow fault the slave is available again for pool heating and adds it self back

into the network. 8. We go back to step 2 and the sequence repeats.

Though this is complicated it could be useful in understanding the behavour of networked heat-ers. The fl ow fault is shown and it retries every 3 minutes, so it recovers if the fault is cleared.

Model ItemTypical value Min value

Max Value

Genie (All Models)Fan 230V (Windings)

Resistance 2.4m 2.3m 2.9m

Gas Valve (Coil V1) Resistance 2.8k 2.6k 3.0k

Gas Valve (Coil V2) resistance 1.6k 1.3k 1.8k

Circulation Pump Currrent 0.514A 0.485A 0.565A

MB Rage (All Models)Gas Valve (Pilot Coil -

2 pin) Resistance 4.7 4.6 4.8

Gas Valve (Main Coil - 3 pin) Resistance 53.5 52.0 55.0

MBC100 & 100W

Fan 230V (Windings) 40.1 39.2 41.7Gas Valve (Coil V1) 3.74k 3.8k 4.0kGas Valve (Coil V2) 4.13k 3.9k 4.5k

MB Range (All Models)Circulation Pump

Currrent 0.525A 0.490A 0.595A

COH (All Models)Circulation Pump

Currrent 0.395A 0.365A 0.450A

COH 110 - 220Burner Fan Motor

Currrent 0.837A 0.825A 0.910ABurner Motor white wire AC return to

control box 51 VAC 50 VAC 53 VAC

Soleniod Wire (Blue and black) Resistance 0.1 0.0 1.5Soleniod Wire (Blue

and brown) Resistance 1.47k 1.3k 1.6k

COH 280Burner Fan Motor

Currrent 1.3A 1.15A 1.5ABurner Motor white wire AC return to

control box 51 VAC 50 VAC 53 VACSoleniod Wires

Resistance 100 95 105

( at ambient temperature of 18ºC)Useful Values

MULTIMETER VALVES

Malvern Boilers LtdSpring Lane North,

Malvern, WR14 1BWTel. +44 (0)1864 893777Fax. +44 (0)1864 893776www.malvernboilers.co.uk

BOILERS LIMITED - Calypso Ltd · 2014. 3. 7. · December 2011. Page 2 CONTENTS Genie C Wiring 3...

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