Luna 3 Comfort Troubleshooting Guide For Technical Assistance Call: (800)461-4657 June 2008 i Text Box: WARNING! THIS DOCUMENT IS INTENDED ONLY AS AN EDUCATIONAL TOOL This Troubleshooting Guide, and the instructions and suggestions within are intended solely as an educational tool assisting completely qualified Gas Appliance Mechanics who have WARNING! THIS DOCUMENT IS INTENDED ONLY AS AN EDUCATIONAL TOOLThis Troubleshooting Guide,and the instructions and suggestions within are intended solely as an educational tool assisting completely qualified Gas Appliance Mechanics who have successfully completed the BaxiInstallation Certification Program. Use of the information herein for the purposes of onsite appliance correction by untrained personnel may cause extremely dangerous conditions, and may void the manufacturer’s warranty. Marathon International assumes absolutely no liability in the execution of the training suggestions in this document. Should you experience problems or complications beyond your realm of training, please contact Marathon International for further instructions. Resetting The Boiler ii There are two types of errors that can be found on the controller: Fault and Block. Press the OKbutton on the controller to reset the boiler. The display showsthe writing followed by the >>>OK writing. Fault: If a fault occurs, the display shows symbols flashing with the writing . The fault is identified by the error code followed by the letter“E”and is not resettableunless the problem is corrected. Block: If a block occurs, the display shows the symbols flashing together with the and <>>>OK> symbols alternating. The block fault is identified by an error code (see the table below) followed by the letter “E”. Increase DHW max. temperature Reduce DHW max. temperature On/off Winter Summer selection Comfort/economy selection Automatic/manual/ Of/reset Real/Set room temperature display Reduce room temperature Increase room temperature Temporary Special function Setting (i.e. holidays, presence, shower setting) Selection of INFO mode / Programming mode iii CONTROLLER These buttons operate accordingly when in the standard operation mode. The buttons may have different functions depending on operation, and the programming mode. CONTROLLERFUNCTIONS iv Types of Functions•Normal functioning (RUN) This level is what appears on the controller during normal operation. •User programming (PROGR) This level allows the user to set the clock, the date, temperature setpointsand time programs. •Advanced information (INFO) This level allows the installer to set a group of advanced parameters and obtain a sequence of advanced information on the system functioning. The programming functions operate as follows: 1.To change from RUNto PROGRshortly press the IP button (on the display you should see the running inscription ) for two seconds then the time will appear. 2.To change fromRUN to INFO press the IPbutton for 3 seconds (you should see the running inscription ) appear. 3.To return from PROGRor INFOto RUNshortly press the IPbutton (you will see the running inscription ) for two seconds and the screen will go back to normal. INFO MODE AND ADVANCED SETTINGS v •“HW O>”DHW inlet or storage tank temperature. •“HW S^”Set-point water sanitary inlet. Value set up with buttons +/- •“HW MX”Maximum setpointsanitary circuit (max. setting value) •“HW Mn”Minimum setpointsanitary circuit (min. setting value) DHW CIRCUIT•“CH Sl”Maximum setpointheating circuit, setting value with buttons +/-. Notice: by pushing the comfort button it is possible to change the temp. value from °C to °F. •“EXT°c”External temperature (with external connecting probe). •“CH O>”Temperature water heating inlet pipe. •“CH S^”Set-point water heating circuit. •“CH MX”Maximum setpointheating circuit (max. setting value). •“CH MN”Minimum setpointheating circuit (min. setting value). HEATING CIRCUITTo enter the Information and Advanced Setting modes it is necessary to press the IP button for at least 3 seconds; the running words “INFO”should appear. Once the running words appear, press the OKbutton to scroll through the parameters; when the big numbers are blinking it is possible to modify the value using buttons +/-. vi ADVANCED INFORMATION•“PWR %”Power level/flame modulation (in %). •“P BAR”Water pressure heating circuit (in bar). •“F l/M”Water flow outlet sanitary circuit (in liters/min). Advanced FunctionsTo setting the boiler’s parameters: 1.Press the IPbutton for at least 3 seconds2.Hold the button and press thebuttonWhen the function is active on the display the F01will appear and the value of the selected parameter. 3.Use +/-for scrolling through the parameters; 4.Use +/-for changing parameter values; 5.The new value is automatically saved after 3 seconds; 6.Press the IPbutton to exit. vii Advanced Functions viii Text Box: Advanced Functions Advanced Functions Anomalies ix Text Box: The electronic PCB for the LUNA 3 Comfort is able to memorize the last 10 anomalies which have occurred. Every anomaly has a counter which increases only if the same anomaly is consecutive; the same mistake non-consecutively is recognized as new The electronic PCB for the LUNA 3 Comfort is able to memorize the last 10 anomalies which have occurred. Every anomaly has a counter which increases only if the same anomaly is consecutive; the same mistake non-consecutively is recognized as new. To see all the information of every single anomaly you have, go to the Advanced Functions and run down the list of parameters toF32. Parameters F32 to F38 refer to volatile anomalies which means mistakes with no necessity to Reset (for example DHW probe mistake); parameters from F39 to F41 refer to anomalies that need to be Reset (e.g. safety thermostat). Mistakes without resetF32F33F34F35F36F37F38Mistakes with resetF39F40F41 Text Box: By using the OK button at each of these parameters you can read: ANOMALY CONSECUTIVE NUMBER (F32 is the last one that occurred so it has a 00 value) ANOMALY CODE (xxE – for example 06E, DHW NTC failure) CONSECUTIVE EVENTS FOR THE SAME ANOMALY By using the OKbutton at each of these parameters you can read: 1.ANOMALY CONSECUTIVE NUMBER (F32 is the last one that occurred soit has a 00 value) 2.ANOMALY CODE (xxE–for example 06E, DHW NTC failure) 3.CONSECUTIVE EVENTS FOR THE SAME ANOMALY4.TIME (days) PASSED FROM THE SIGNALLING (00 means “today”) 5.SYSTEM STATUS6.SYSTEM PHASE7.CENTRAL HEATING DELIVERY TEMPERATURE WHEN THE ANOMALY OCCURREDBy using this information you can keep a SERVICE CHART for the boiler. Anomalies diagnostic x Text Box: The system condition (STATUS) identifies the working method in which the boiler is at the moment of the anomaly: 00 Stand-by 01 Sanitary active 02 Calibration function 03 Heating active 04 Pre-heating active 05 Anti-freezing heating 06 Anti- stem condition(STATUS) identifies the working method in which the boiler is at the moment of the anomaly: nitary activealibration functioneating activee-heating activengrculationrculation for over temperaturestem phaseidentifies in which particular function the boiler is at the moment of the anomaly: e-ventilationation between first and second ignition attemptition attemptngoppageion attemptation between second and third ignition attempt d ignition attempt t-ventilationation for over temperature Error CodeDescriptionSolution01EBurner LockoutNo Spark: Check ground and polarity back to the circuit breakerEnsure the boiler is on a dedicated circuitCheck for 120 V going to the spark generatorIf there is voltage to the spark generator change the spark generatorIf there is no voltage to the spark generator change the main control boardNo Flame: Ensure that all gas shutoffs are open and that adequate working gas pressure is coming to the unit. 7 in. w.c. for NG and 11 in. w.c. for LPNote: These pressures must be maintained while the unit is operatingCheck for 120 V going to coils 1 and 2 on the gas valveIf there is voltage to the gas valve replace the gas valveIf there is no voltage to the gas valve replace the main control boardFlame Sensor is not sensingCheck polarity and ground from the boiler back to the circuit breakerCheck for 3-5 micro amps going to the boardIf you do not have 3-5 micro amps try cleaning the flame sensor Note: Do not clean the flame sensor using sandpaper as it may damage the protective coating. Flame Sensor is DirtyCheck your venting to ensure you are not recycling products of combustionMake sure you have the proper orifices in the unit and the controller is set to the correct type of gas. Weak SparkMake sure you have 3-5 sparks per second and the boiler is groundedMake sure the spark generator ground is fastened tightly to the mounting bracketIf a weak spark persists follow the procedure outlined in the "No Spark" section Error CodeDescriptionSolution02EHighlimit Safety ThermostatCheck pump to make sure it is running and not ceased. Check for restrictionsMake sure that all air is purged from the systemTake an ohm reading on the high limit sensor (0O indicates the sensor is closed, OL indicates the sensor is open) If an E110 error code persists change the high limit sensor. 03EFan/ Flue FaultEnsure the venting is within the maximum venting length requirementsCheck for obstructions in the venting and terminationCheck gas pressure on the inlet test port of the gas valve and make certain there is less than 14" w.c. Check for 120 V going to the fanIf there is 120V going to the fan and it does not turn on, replace the fan. If there is no voltage to the fan replace the main control boardCheck the flue venturi for any obstructions or meltingEnsure that there are no loose wires and that the pressure switch is opening and closing properlyCheck the silicone tubes coming from the air pressure switch for kinks, melting and holes, make sure that the low pressure opening at the back of the unit is not blocked. 05ECentral Heating NTC Sensor FaultTake an ohm reading of the CH NTC sensor using chart A. If the sensor is out of calibration, replace the sensor. If the sensor is working properly, replace the main control board. 06EDomestic Hot Water Fault NTC Sensor FaultTake an ohm reading of the DHW NTC sensor. If the NTC sensor is out of calibration replace the faulty sensor. Check for a resistor in terminals 5 and 6 on the M2 connector (Only for heating only boilers) If utilizing an indirect tank sensor, take an ohm reading using chart C. If the sensor is faulty replace it. If the sensor is working ensure function F03 is set to 08. (For heating only models only) If problem persists replace the main control boardNote: The DHW NTC sensor is in a wet well, shutoff the cold water inlet and open a hot water tap before replacing the sensor. Error CodeDescriptionSolution10ELow Water PressureEnsure all air is purged from the system and all shutoff valves are openCheck boiler and system for leaksEnsure the pressure in the expansion tank is 11.6 psiFill the system between 1 and 1.5 bar on the pressure gauge. If an 10E error code persists jump the leads on the low water cutoff. If the boiler fires up change the low water cutoff switch. Note: If the expansion tank is low on pressure pump it back up to 11.6 psi. If the expansion tank produces water at the Schrader valve change the expansion tank. 11EOutdoor Temperature Sensor FaultDisconnect the outdoor temperature sensor and take an ohm reading using chart B. If the sensor is out of calibration replace it. If the Sensor is working properly replace the main control board. 25EBoiler Max Temperature ExceededCheck the pump to ensure it is not ceasedCheck for restrictionsEnsure all air is purged from the system and all shutoff valves are open98EGas Valve Contact Relay/ Internal ErrorEnsure no water got on or into the gas valveIf error code persists check for 120 V going to the gas valve coils, if there is 120 V going to both coils replace the gas valve. If there is not 120 V going to the gas valve replace the main control board 99EControl Board Contact Relay. Internal ErrorEnsure that the boiler is operating on a dedicated circuit and is properly groundedCheck the polarityDisconnect all external controls and connect them back up one by one. If the error code comes back while connecting one of the controls check for faulty wiring and proper grounding of the control. Check the grounds on the internal pump, gas valve and fanCheck for water on the boardNo CodeDHW is not hot enoughMake sure the CH water is going through the plate heat exchanger and not into the CH loopIf it is going through the CH loop replace the paddles inside the diverter valve and clean the diverter valveClean the DHW plate heat exchangerCheck the DHW NTC sensorCheck your high fire gas setting using chart DEnsure you have adequate incoming gas pressures Error CodeDescriptionSolutionNo CodeBoiler Short Cycles/ Fluctuating Hot WaterCheck your low fire gas setting using chart DCheck to see if the modulating pin is brokenMake sure your heat load is adequate for the boilerMake sure your boiler is running on the proper type of gas. No CodeBoiler makes a Squealing NoiseCheck that there is no more than 25% of the system volume of glycol in the systemClean the diverter valveNo CodeBoiler makes a banging noisesEnsure there is no air in the systemMake sure the pump is movingMake sure there is no restrictions Chart ANTC SensorChart BOutdoor Temperature SensorChart CIndirect Tank SensorTemperature vs. Resistance Temperature vs. Resistance Temperature vs. Resistance Thermistor @ 25ºCThermistor @ 25ºCThermistor @ 25ºC ºFºCResistance (O)ºFºCResistance (O)ºFºCResistance (O) OpenOpen LoopOpenOpen LoopOpenOpen Loop32032,63032032,50532027,27941525,38041525,30841522,069501019,890501019,854501017,959591515,710591515,689591514,694682012,490682012,483682012,090772510,000772510,000772510,00086308,05786308,06086308,31395356,53195356,53795356,944104405,326104405,332104405,828113454,368113454,374113454,913122503,601122503,608122504,161131552,985131552,991131553,538140602,487140602,492140603,021149652,082149652,086149652,589158701,751158701,754158702,229176751,255176751,481176751,92519480917194801,257194801,66921285680212851,070212851,451Chart DGas PressuresHigh FireLow FireNatural Gas5.6" w.c.0.7" w.c. Propane9.8" w.c.1.3" w.c. Warning: The modulating pin should only be turned a quarter turn at a time to avoid damage. Avoid using magnetic screwdrivers on the modulating pin. In the event your gas pressures are not increasing when you are adjusting the modulating pin DO NOT continue to adjust the gas pressure as your incoming gas may be to low.