Upload
others
View
14
Download
0
Embed Size (px)
Citation preview
BOILERS LIMITED
Training notes for the following Certikin pool heaters:
Genie SGenie C
Genie DualMB055 - MB405
COH110 - COH280
December 2011
Page 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
GENIE S - SCHEMATIC
TfTh
To
Tc
Tfl
PwTp
Tf = Overheat stat, Flue 100C
Th = Overheat stat, Heat exchanger 150C
To = Overheat stat Flow 100C
Tc = Limit temp control stat Flow 80C
Tfl = Temperature Sensor Flow
Tp = Temperature Sensor Pool
Pw = Pressure Switch Pool fl ow
Page 7
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
Page 8
GENIE DUAL - SCHEMATIC
Tf = Overheat stat, Flue 100C
Th = Overheat stat, Heat exchanger 150C
To = Overheat stat Flow 100C
Tc = Limit temp control stat Flow 80C
Tfl = Temperature Sensor Flow
Tp = Temperature Sensor Pool
Pw = Pressure Switch Pool fl ow
To
Tc
Tfl
PwTp
TfTh
Page 9
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.
Page 10
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
Page 11
GENIE DUAL - SETUP & SERVICE MODES
Page 12
GENIE DUAL - SETUP & SERVICE MODES
Page 13
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
Page 14
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
Page 15
DIS
PLAY
LOC
K /
RES
ET
GREEN
YELLOW
REDLED1
RED
REDLED2
Run
ning
, rai
sing
poo
l tem
pera
ture
to 2
8°C
Up
to te
mpe
ratu
re, 2
8°C
Insu
ffi ci
ent w
ater
pre
ssur
e. F
ilter
?, B
lock
age?
‘OH
2’ F
lue
gas
over
tem
pera
ture
. Allo
w to
co
ol th
en in
vest
igat
e in
Eng
inee
ring
Mod
e.
Res
et w
ith B
utto
n
‘GA
S’ G
as C
ontro
l Loc
kout
. Una
ble
to li
ght b
urne
r, re
set w
ith B
utto
n.
OR
Flu
e or
Wat
er S
tat t
rippe
d, re
set o
n st
at O
R F
an re
sist
or o
pen
cicu
it, in
vest
igat
e ca
use.
OR
Val
ve C
oils
faul
ty. S
ee “G
as” s
ectio
n
FRO
NT
PAN
ELO
N P
CB
EXPL
AN
ATIO
N
OFF
, no
mai
ns s
uppl
y or
faile
d po
wer
sup
ply
Flas
hing
‘HI’
Con
dens
ate
leve
l hig
h. B
lock
ed?
Cle
ar
obst
ruct
ion
and
allo
w c
ontro
l to
auto
rese
t .
‘SE
r’ al
tern
atin
g w
ith p
ool t
empe
ratu
re. S
erv-
ice
requ
ired,
wor
king
hou
rs h
as re
ache
d se
tpoi
nt.
GENIE C, S & DUAL - FAULT FINDING
Page 16
GENIE C, S & DUAL - FAULT FINDING
DIS
PLAY
LOC
K /
RES
ET
GREEN
YELLOW
REDLED1
RED
REDLED2
FRO
NT
PAN
ELO
N P
CB
EXPL
AN
ATIO
N
‘P’ a
ltern
atin
g w
ith ‘o
c’ =
Poo
l sen
sor o
pen
circ
uit O
R N
o ne
t-w
ork
dete
cted
if a
Mas
ter i
n a
mul
tiple
hea
ter i
nsta
llatio
n‘P
’ alte
rnat
ing
with
‘cc’
= P
ool s
enso
r sho
rt ci
rcui
t‘F
’ alte
rnat
ing
with
‘oc’
= H
eat E
xcha
nger
Fl
ow s
enso
r ope
n ci
rcui
t
‘H’ a
ltern
atin
g w
ith ‘o
c’ =
Hea
t Exc
hang
er
Com
bust
ion
sens
or o
pen
circ
uit
‘H’ a
ltern
atin
g w
ith ‘c
c’ =
Hea
t Exc
hang
er
Com
bust
ion
sens
or s
hort
circ
uit
‘F’ a
ltern
atin
g w
ith ‘c
c’ =
Hea
t Exc
hang
er
Flow
sen
sor s
hort
circ
uit
‘Err
’ alte
rnat
ing
with
‘4’ =
Poo
l pot
entio
met
er o
pen
circ
uit
‘Err
’ alte
rnat
ing
with
‘5’ =
Poo
l pot
entio
met
er s
hort
circ
uit
For a
ll of
the
abov
e. T
urn
off,
corr
ect p
robl
em a
nd tu
rn b
ack
on a
gain
and
the
disp
lay
and
oper
atio
n w
ill b
e no
rmal
.
‘Err
’ alte
rnat
ing
with
‘6’ =
Hea
ting
pot
entio
met
er s
hort
circ
uit
‘Err
’ alte
rnat
ing
with
‘7’ =
Hea
ting
pote
ntio
met
er s
hort
circ
uit
Page 17
Faul
t will
not
cle
ar
Rep
lace
C
VB
C
on
gas
valv
e. C
heck
for
be
nt
pins
. Fa
ult
will
se
lf cl
ear
Faul
t cle
ars
briefl y
(for
1 s
ec)
Faul
t cle
ars
Briefl y
(for
20
sec)
YES
YES
YES
YES
NO NO
YES
NO
Is w
iring
and
con
-ne
ctio
ns b
etw
een
CV
BC
and
fan
OK
?
YES
NO
YES
YES
YES
YE
S
NO
Is g
as b
eing
re-
leas
ed b
y th
e ga
s va
lve? YE
S
NO
Che
ck
wiri
ng /
Rep
lace
gas
va
lve
Sus
pect
C
VB
C
to b
e at
faul
t
NO
Rep
lace
G
as
valv
e. F
ault
will
sel
f cl
ear
Is C
VB
C s
eate
d on
ga
s va
lve
co
rre
ctl
y?
Is c
ontin
uity
of g
as
valv
e co
ils
OK
?V
1 =
2.8kΩ
V2
=1.6
kΩ
Are
th
ere
any
faul
ts in
the
wir-
ing
or
conn
ec-
tors
?
Rec
tify
faul
t. Fa
ult
will
sel
f cle
ar
Sus
pect
C
VB
C
to b
e at
faul
tR
epla
ce C
VB
C
NB
- A
faul
t inv
olvi
ng th
e G
as v
alve
circ
uit w
ill
occu
r eve
n if
ther
e is
no
heat
ing
dem
and.
Res
et
appl
ianc
e w
hen
ther
e is
no
heat
dem
and
to id
en-
tify
a fa
ult o
f thi
s na
ture
. Onc
e co
rrec
ted,
ther
e is
no
nee
d to
use
the
rese
t but
ton,
as
the
faul
t will
se
lf cl
ear.
Hav
e ei
ther
th
e F
lue
gas
or
Wat
er fl
ow te
m-
pera
ture
s be
en
exce
eded
?
With
mai
n po
wer
of
f pus
h th
e re
d re
set b
utto
ns o
n th
e Fl
ue a
nd F
low
lim
it de
vice
s.
YES
NO
T CL
EARE
D
Inve
stig
ate
caus
e of
ove
rhea
ting.
Are
ove
rhea
t lim
it de
vice
s w
orki
ng c
or-
rect
ly?
Che
ck li
mit
devi
ces
are
not
op
en c
ircui
t. R
epla
ce fa
ulty
lim
it de
vice
s.
NO
T CL
EARE
D
NO
T CL
EARE
D
Are
con
nec-
tors
and
wiri
ng
betw
een
the
CV
BC
and
lim
it de
vice
s O
K?
Rep
lace
faul
ty w
iring
as
nec
essa
ryE
nsur
e w
iring
at
the
conn
ectio
ns
to th
e C
VB
C a
re
in g
ood
cond
ition
.
Sus
pect
C
VB
C
to b
e at
faul
tR
epla
ce C
VB
C
Fan
runs
thro
ugho
utFa
n do
es n
ot ru
n
Doe
s ap
plia
nce
reac
h ig
nitio
n st
age
(can
you
he
ar th
e sp
ark)
?
Doe
s ga
s ig
nitio
n ta
ke
plac
e (s
een
thro
ugh
sigh
t gl
ass)
but
onl
y fo
r 10
secs
?
Is a
pplia
nce
earth
-in
g, th
e co
nditi
on a
nd
conn
ectio
n of
ele
ctro
de
and
lead
OK
?
Rep
lace
faul
ty p
arts
Rep
lace
CV
BC
Rep
lace
fan
NB
- A
faul
t inv
olvi
ng th
e hi
gh li
mit
circ
uit w
ill o
ccur
eve
n if
ther
e is
no
heat
ing
dem
and.
Res
et a
pplia
nce
whe
n th
ere
is n
o he
at d
eman
d to
iden
tify
a fa
ult o
f thi
s na
ture
. Onc
e co
rrec
ted,
th
e re
set b
utto
n w
ill n
eed
to b
e pu
shed
, as
this
faul
t will
not
sel
f cl
ear.
NB
- A
faul
t inv
olvi
ng th
e fa
n ci
rcui
t or i
gniti
on c
ircui
t can
on
ly o
ccur
if th
ere
is a
hea
t dem
and.
Onc
e co
rrec
ted,
the
rese
t but
ton
will
nee
d to
be
push
ed, a
s th
is fa
ult w
ill n
ot s
elf
clea
r.
NB
- A
faul
t in
the
ioni
satio
n ci
rcui
t will
be
iden
tifya
ble
whe
n th
e ig
nitio
n cy
cle
is re
peat
ed 5
tim
es.
? ?
Page 18
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
Page 19
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
Page 20
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
Page 21
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
Page 22
MB 055, 105 & 155 - WIRING
ROBERTSHAW IGNITION DEVICE
Page 23
MB 055, 105 & 155 - WIRING
KEY
BK
-
BLA
CK
BR
- B
RO
WN
R-
R
ED
Y-
Y
ELL
OW
G/Y
- GR
EE
N &
YE
LLO
WB
L-
BLU
E
ABBEY IGNITION DEVICE
HI-L
IMIT
RA
NC
OH
I-LIM
IT
MAN
UAL
RES
ET
PRES
SUR
ESW
ITC
HTH
ERM
ALFU
SE
N.O
CO
M
POT
SEN
1
24V
SO
LID
STA
TETH
ERM
OST
ATB
K
BKBK BKR
BK
GA
S V
ALV
E
3 AM
P
FUSE
WIT
H T
HER
MAL
FU
SE
TRAN
SFO
RM
ER
NO
N-R
EPLA
CEA
BLE
POTE
NTI
OM
ETER
MAN
UAL
SWIT
CH
TEM
P SE
NSO
R
LN
E
BK
BKBK
BK
1
MV
PV/M
V &
AC N
EUTR
AL
AC
24
VO
LTS
EAR
TH
PIL
OT
Led
10
BRB
Y
Y
230
V
24 VG
/Y
Y
Y Y
BK
G/Y
FAU
LT IN
DIC
ATIO
NS
No
of fl
ashe
s be
twee
n pa
uses
Res
et b
y tu
rnin
g su
pply
off,
then
on
MAI
N V
ALVE
FAI
LED
PIL
OT
VA
LVE
FA
ILE
D
FLA
ME
DE
TEC
TIO
N F
AIL
ED
FAIL
ED
TO
LIG
HT
1
13, 1
4 an
d 15
16, 1
7 an
d 18
5, 7
and
10
20/0
8/03
PV
Page 24
KEY
Bk-
B
LAC
KB
r-
B
RO
WN
R-
R
ED
Y-
Y
ELL
OW
G/Y
- GR
EE
N &
YE
LLO
WB
l-
BLU
EO
r-
OR
AN
GE
V -
V
IOLE
TG
y -
GR
EY
ABBEY IGNITION DEVICE
12
34
56
78
910
1112
1314
1516
1718
1920
2122
2324
HI-L
IMIT
RAN
CO
HI-L
IMIT
MAN
UAL
RESE
T
PRES
SUR
ESW
ITC
H
THER
MAL
FUSE
MAN
UAL
SWIT
CH
TEM
P SE
NSO
R
FAU
LT IN
DIC
ATIO
NS
No
of fl
ashe
s be
twee
n pa
uses
Res
et b
y tu
rnin
g su
pply
off,
then
on
MAI
N V
ALVE
FAI
LED
PILO
T VA
LVE
FAIL
ED
FLAM
E D
ETEC
TIO
N F
AILE
D
FAIL
ED T
O L
IGH
T1
13, 1
4 an
d 15
16, 1
7 an
d 18
5, 7
and
10
WIT
H T
HER
MAL
FU
SE
TRAN
SFO
RM
ER
LN
E
BRB
230
V 24 V
G/Y
1
MV
PV/M
V &
AC N
EUTR
AL
AC 2
4 VO
LTS
EART
H
PIL
OT
Led
10
G/Y
20/0
2/04
PV
GAS
VAL
VE
Gy
B
B
BrO
rO
rR
WV
P
YBk Bk
BkY
R Or
MB 185, 265 & 405 - WIRING
Page 25
MB 185, 265 & 405 - WIRING
HI-
LIM
IT
RA
NC
O M
AN
UAL
HI-
LIM
ITR
ESE
T
PRES
SU
RE
SWIT
CH
THER
MA
LFU
SE
MAN
UAL
SWIT
CH
TEM
P SE
NSO
R
WIT
H T
HER
MAL
FU
SE
TRAN
SFO
RM
ER
LN
E
BrB
230
V
24 VG
/YPI
LO
TG
/YG
AS
VALV
E
Gy
B
B
BrO
rO
rR
WV
PY
Bk
BkO
r
RO
BER
TSH
AW
FAU
LT IN
DIC
ATIO
NS
Res
et b
y tu
rnin
g su
pply
off,
then
on
OK,
WO
RKI
NG
FAIL
ED T
O L
IGH
T PI
LOT
FAIL
ED IN
TER
NAL
CH
ECK
OFF
or
OFF ON
FLAS
HIN
G
1/01
/07
GN
DPV
/ MV
MV
PV TH 2
4
TR G
ND
Y
Led
R BkYG
/Y
Y
Y 3 A
mps
12
34
56
78
910
1112
1314
1516
1718
1920
21 22
Poo l Thermos tat
2B
2C
2D
ROBERTSHAW IGNITION DEVICE
Page 26
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.
*
Page 27
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
Page 28
MB 185, 265 & 405 - TROUBLESHOOTING
• 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
Page 29
MB 185, 265 & 405 - TROUBLESHOOTING
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.
Page 30
MB ALL MODELS - CONTROL PANEL LIGHTS
Control Panel Lights
Page 31
COH 100 - 275 MK1 OIL - WIRING
Page 32
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
Page 33
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 100 - 275 MK1 OIL - PARTS IDENTIFICATION
Page 34
COH 110 - 280 MK2 OIL - WIRING
Page 35
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
COH 110 - 280 MK2 OIL - PARTS IDENTIFICATION
Page 36
.
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
COH 110 - 280 MK2 OIL - PARTS IDENTIFICATION
Page 37
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)
180 730 SPCOHBFIV1 SPCOHBFV15E (500 mm) SPCOHBFV11E (1000 mm)
220 740 SPCOHBFIV2 SPCOHBFV25E (460 mm) SPCOHBFV21E (870 mm)
280 810 SPCOHBFIV3 SPCOHBFV25E (460 mm) SPCOHBFV21E (870 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
Page 38
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
Page 39
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 -
Page 40
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.
Page 41
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
Page 42
NOTES
NOTES
Malvern Boilers LtdSpring Lane North,
Malvern, WR14 1BWTel. +44 (0)1864 893777Fax. +44 (0)1864 893776www.malvernboilers.co.uk