Certikin Genie S, Genie C, Genie Dual, MB055, MB105 Training

BOILERS LIMITED

Training notes for the following Certikin pool heaters:

Genie S
Genie C

Genie Dual

MB055 - MB405

COH110 - COH280

December 2011

Page 2

CONTENTS

Genie C Wiring 3

Genie C Schematic 4

Genie S Wiring 5

Genie S Schematic 6

Genie Dual Wiring 7

Genie Dual Schematic 8

Genie C & S Setup & Service Modes 9

Genie Dual Setup & Service Modes 11

Genie C & S Engineering Modes 13

Genie C, S & Dual Fault Guide 15

Genie C, S & Dual Parts Identifi cation 18

Genie C, S & Dual Microcom Software 20

MB 055, 105 & 155 Wiring 22

MB 185, 265 & 405 Wiring 24

MB 055, 105 & 155 Troubleshooting 26

MB 185, 265 & 405 Troubleshooting 28

MB All Models Control Panel Lights 30

COH 100 - 275 Mk1 Wiring 31

COH 100 - 275 Mk1 Parts Identifi cation 32

COH 110 - 280 Mk2 Wiring 34

COH 110 - 280 Mk2 Electrical Parts Idenifi cation 35

COH 110 - 280 Flueing options 37

Oil Nozzle Sizing 38

Networking 39

Useful Multimeter Values 41

Page 3

GENIE C - WIRING

123456

78

9101112

131415

1617181920

21

22

ON /OFF
SWITCH

W ITH TH E R MA L FU S E

TR A NS FO RME R

24 V

Y

3 A mps

POOL SENSOR

Po ol Th ermosta t

COND ENS ATE PS

FLOW SENSOR

EXCHANGER SE NSOR

2B2C

230 V

Y

60 C

X1.1

X1.3

X1.5

X1.8

X1.10

FA N

Br

B

X12.1

X12.8

X1 2.16

X12.3

X1 2.12

Hi Li mit

X12.4

X1 2.14

X12.5

W

X1 2.11

Y

910 ohm s

X1 2.13

Bk

B

1%

240v 3 Wi re

X12.2

X1 2.10

X1.7

X1.9

X1.2

Flue

230V /50Hz

L

N

SL

LINK: R emove if seperat e

swi tched live provided

WATER PRESSU RE SWITCH

Gy

P

P

Gy

Gy

Bk

Or

V

P

R/B

R/B

Gy /B k

P

V

Or

Gy

V

B

Br

G/ Y

Br

B

Br

B

B

YY

Bk

Br

Br

Bk

R

Gy

R

Bk

W

W

G

G

Gy /B k

Bk

Bk

W

V

Gy

HE AT DEMAN D

LO CK O UT ALA R M

FA N 23 0v

L

N

N

FA N TA C H O

RE SE T +v e

HI LIMIT

HI LIMIT

FA N P W M

MO DU LATION +ve

RE SE T -ve

FA N +v e

FA N -v e

MO DU LATION -ve

Gy /B k

Br

B

2D

Bk Bl ack

B Bl ue

Gy Grey
Gy/Bk Grey/Bl ack

Br B rown

P Pink

V Violet

Y Yellow

R/ B R ed/B l ue

Or Or ange

W White

G/ Y G reen/Y el low

R Re d

Control Stat

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

Tf

Th

Tfl

Tc

Pw

Tp

Page 5

GENIE S - WIRING

123456

78

9101112

13

14151617181920

21

22

ON/OFF
SWITCH

W I TH TH E R M A L FU S E

TRANSFORMER

Y

3 A mps

POOL SENSOR

P o ol T hermo st at

CONDENSATE PS

FLOW SENSOR

EXCHANGER SENSOR

2B2C

Y

8 0C Cont rol Stat

X1.1

X1.3

X1.5

X1.8

X1.10

FA N

GyB k

B

X12.1

X12.8

X12.16

X12.3

X 1 2.12

Hi Limit

X12.4

X 1 2.14

X12.5

Or

X 1 2.11

Y

910 ohms

X 1 2.13

Bk

B

1%

X12.2

X 1 2.10

X1.7

X1.9

X1.2

Flue

230V/50Hz

L
N

SL

LINK: Remove if seperate

sw itched li ve provided

WATER PRESSURE SWITCH

Gy

P

Bk

Or

V

P

R/B

Gy/Bk

Gy

V

G/Y

Br

B

B

R

R

Br

Bk

R

Gy

R

Bk

W

W

G

G

Br

Bk

Bk

Or

V

P

HEAT DEM AND

LOCKOUT ALARM

FAN 230v

L

N

N

FAN TACHO

RESET +ve

HI L IMI T

HI L IMI T

FAN PWM

MODULATION +ve

RESET -ve

FAN +ve

FAN -ve

R/B

Gy/Bk

Y

2D

Bk Black

B Blue

Gy Grey

Gy/Bk Grey/B lack

Br Brown

P Pink

V Violet

Y Yellow

R/B Red/Blue

Or Orange

W White

G/Y Green/Yellow

R Red

G Green

P

Gy

P

V

MODULATION -v e

G/Y

PUMP

B

PUMP RELAY

GyB k

B

Br

Br

Br

Hi Limit

Water

Gy

PUMP PRIMER

24 V

Br

Bk

BBr

Y

Br BrB

BBr

Br

Y

Or

Gy

IG N IT IO N

CONTROL

Page 6

GENIE S - SCHEMATIC

Tf

Th

To

Tc

Tfl

Pw

Tp

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

NC

N

L

PL DM D

HT G DM D

HT R P M P

3P VL V

NC

BU RNER

LKOUT

NC

RESET

MODULATION

COM B ' SE NSOR

+

+--

SE NSOR RT N

B' SENSOR

PL SENSOR

PRESS URE

COND' HI

W

Or

R

B
Br

Gr

V

P

Bk Bl a ck

Bl ue
Br own
Gr e y

Orang e
Pi nk
Re d
Violet

White

KE Y

Y Ye llow

Flow s ensor

Pool s ens or

Co mb ustion s ensor

Co ndensa te

Level Switch

NC

Pool d emand

He ating d emand

E

N

Perma nent Liv e

>

>

>>>

Fac t ory F it t ed Link

Rem ove when se perat e

swit che d liv e sup plied

He ater pum p

E

N

E

N

3 Po rt Val v e

Co ntro l Stat

X1 .1

X1 .3

X1 .5

X1 .8

X1 .1 0

FAN

Gy B k

B

X1 2. 1

X1 2. 8

X1 2. 1 6

X1 2. 3

X1 2. 1 2

Hi L i m it

X1 2. 4

X1 2. 1 4

X1 2. 5

Or

X1 2. 1 1

Y

910 ohm s

X1 2. 1 3

Bk

B

1%

X1 2. 2

X1 2. 1 0

X1 .7

X1 .9

X1 .2

Flue

Gy

V

R

G

W

G

Br

Bk

Bk

Or

V

P

HEAT DEMAND

LO CKOUT ALARM

FAN 230v

L

N

N

FAN TACHO

RESET +ve

HI LIMIT

HI LIMIT

FAN PWM

MO DULATIO N +ve

RESET - ve

FAN +ve

FAN -ve

MO DULATIO N -ve

Hi L i m it

Wat er

Gy

IG NITION
CONTROL

10 0609

Pr es s ure Swit ch

W

G

R
P

Gy

Bk

Br

B

P

R

B

Gy

BrBkG/ Y

BGy

Bk

G
Y

R

Gy / B k

R/ B

P

P

Or V

Gy

V

Or

G Green

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

Pw

Tp

Tf

Th

Page 9

Lock/Reset

Button

On / Off

Switch

Temperature

Display

Pool Temperature

Control 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, POLAR­ITY AND RESISTANCE TO EARTH ARE MADE. ALL WORK CARRIED OUT SHOULD FOLLOW GUIDELINES
LAID DOWN BY THE I.E.E.

Operation

The 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 Exchanger

2. 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 & Lockouts

The Pool Thermostat Control indicates the actual and set temperature of the pool and also displays all the lock­outs. The next pages detail the fault conditions, the indicators, the display and the actions required.

User Setup Mode

Turn 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 Mode

This 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 tem­peratures 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 ° C
2 Maximum temperature 32 °C (90 °F) 41 °C ( 106 °F) PL or SPA
3 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 MODE

Genie Pool Thermostat, Engineering Mode

Background

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

Engineering Mode

Turn the Heater OFF with the Panel Switch
Remove 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

Parameters

NB. The following explanation uses Centigrade, if the control is setup for Fahrenheit the values will be
the 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 the
button whilst one of the temperatures is displayed will ‘lock/unlock’ it on the display for
continuous observation.

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

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

Example: Default settings, 1 and 12. Required Pool temperature 30C.

At 28.9 pool temperature, no modulation in any circumstances
At 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

Background

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

Engineering Mode

Turn the Heater OFF with the Panel Switch
Remove 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

Parameters

NB. The following explanation uses Centigrade, if the control is setup for Fahrenheit the values will be
the 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 the
button whilst one of the temperatures is displayed will ‘lock/unlock’ it on the display for
continuous observation.

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

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

Example: Default settings, 1 and 12. Required Pool temperature 30C.

At 28.9 pool temperature, no modulation in any circumstances

.

Fig. 2.0

Page 15

DISPLAY

LOCK / RESET

GREEN

YELLOW

RED
LED1

RED

RED
LED2

Running, raising pool temperature to 28°C

Up to temperature, 28°C

Insuffi cient water pressure. Filter?, Blockage?

‘OH2’ Flue gas over temperature. Allow to

cool then investigate in Engineering Mode.

Reset with Button

‘GAS’ Gas Control Lockout. Unable to light burner, reset with Button.

OR Flue or Water Stat tripped, reset on stat OR Fan resistor open

cicuit, investigate cause. OR Valve Coils faulty. See “Gas” section

FRONT PANEL

ON PCB

EXPLANATION

OFF, no mains supply or failed power supply

Flashing

‘HI’ Condensate level high. Blocked? Clear

obstruction and allow control to auto reset .

‘SEr’ alternating with pool temperature. Serv-

ice required, working hours has reached

setpoint.

GENIE C, S & DUAL - FAULT FINDING

Page 16

GENIE C, S & DUAL - FAULT FINDING

DISPLAY

LOCK / RESET

GREEN

YELLOW

RED
LED1

RED

RED
LED2

FRONT PANEL ON PCB

EXPLANATION

‘P’ alternating with ‘oc’ = Pool sensor open circuit OR No net-

work detected if a Master in a multiple heater installation

‘P’ alternating with ‘cc’ = Pool sensor short circuit

‘F’ alternating with ‘oc’ = Heat Exchanger

Flow sensor open circuit

‘H’ alternating with ‘oc’ = Heat Exchanger

Combustion sensor open circuit

‘H’ alternating with ‘cc’ = Heat Exchanger

Combustion sensor short circuit

‘F’ alternating with ‘cc’ = Heat Exchanger

Flow sensor short circuit

‘Err’ alternating with ‘4’ = Pool potentiometer open circuit

‘Err’ alternating with ‘5’ = Pool potentiometer short circuit

For all of the above. Turn off, correct problem and turn back

on again and the display and operation will be normal.

‘Err’ alternating with ‘6’ = Heating potentiometer short circuit

‘Err’ alternating with ‘7’ = Heating potentiometer short circuit

Page 17

Fault will not clear

Replace CVBC on

gas valve. Check for

bent pins. Fault will

self clear

Fault clears briefl y (for 1 sec)

Fault clears Briefl y (for 20 sec)

YES

YES

YES

YES

NO

NO

YES

NO

Is wiring and con-

nections between

CVBC and fan OK?

YES

NO

YES

YES

YES

YES

NO

Is gas being re-

leased by the gas

valve?

YES

NO

Check

wiring /

Replace gas

valve

Suspect CVBC

to be at fault

NO

Replace Gas

valve. Fault will self

clear

Is CVBC seated

on gas valve

correctly?

Is continuity of gas

valve coils OK?

V1 = 2.8kΩ

V2 =1.6kΩ

Are there any

faults in the wir-

ing or connec-

tors?

Rectify fault. Fault

will self clear

Suspect CVBC

to be at fault

Replace CVBC

NB - A fault involving the Gas valve circuit will

occur even if there is no heating demand. Reset

appliance when there is no heat demand to iden-

tify a fault of this nature. Once corrected, there is

no need to use the reset button, as the fault will

self clear.

Have either

the Flue gas or

Water fl ow tem-

peratures been

exceeded?

With main power

off push the red

reset buttons on

the Flue and Flow

limit devices.

YES

NOT CLEARED

Investigate cause

of overheating.

Are overheat

limit devices

working cor-

rectly?

Check limit

devices are not

open circuit.

Replace faulty limit

devices.

NOT CLEARED

NOT CLEARED

Are connec-

tors and wiring

between the

CVBC and limit

devices OK?

Replace faulty wiring

as necessary

Ensure wiring at

the connections

to the CVBC are

in good condition.

Suspect CVBC

to be at fault

Replace CVBC

Fan runs throughout Fan does not run

Does appliance reach

ignition stage (can you

hear the spark)?

Does gas ignition take

place (seen through sight

glass) but only for 10

secs?

Is appliance earth-

ing, the condition and

connection of electrode

and lead OK?

Replace faulty parts

Replace CVBC

Replace fan

NB - A fault involving the high limit circuit will occur even if

there is no heating demand. Reset appliance when there is no

heat demand to identify a fault of this nature. Once corrected,

the reset button will need to be pushed, as this fault will not self

clear.

NB - A fault involving the fan circuit or ignition circuit can

only occur if there is a heat demand. Once corrected, the

reset button will need to be pushed, as this fault will not self

clear.

NB - A fault in the ionisation circuit will be identifyable when

the ignition cycle is repeated 5 times.

?

?

Page 18

GENIE C, S & DUAL - SPARES

SPMBC009
100C Flow Overheat Stat

SPMBG055
80C Flow Control Stat

SPMBC011
Flow Sensor

Genie S

SPMBG057
Pool Thermostat PCB

SPMBG008
Condensate Pressure Switch

SPMBG054
Relay

SPCOH2/003
Pressure 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 SPMBG002

Secondary Heat Exchanger (Bowman) M2745 SPMBG053

Propane Orifi ce (Genie 35) M2150 SPMBG014

Propane Orifi ce (Genie 50) M2151 SPMBG015

Combustion Fan M2138 SPMBG003

Gas Valve M2140 SPMBG004

Ignition Control (Honeywell) M2141 SPMBG005

Pool Thermostat PCB M2746 SPMBG057

Heat Exchanger Door Seal M2995 -

Relay M2688 SPMBG054

Pressure Gauge M4240 SPCOH2/003

Water Pressure Switch 651284 SPCOH2/014

HT Lead M2142 SPMBG006

Condensate Syphon M2143 SPMBG007

Condensate Pressure Switch M2144 SPMBG008

Spark & Sense Electrode M2146 SPMBG010

Flue High Limit Thermostat M2875 SPMBG060

Flow Control Thermostat M2667 SPMBG055

Flow High Limit Thermostat M0868 SPMBC009

Flow Sensor (Genie C) M2149 SPMBG013

Flow Sensor (Genie S) M3338 SPMBC011

Pool Temperature Sensor M2798 SPCOH2/002

Genie Pump M2683 SPMBG056

Expansion 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 recti­fi 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 error
02 False Flame Lockout. 20 IO Error
03 High Limit error 21 ADC test HUP
05 Fan Tacho Signal error 22 ADC test LUP
08 Flame circuit error

Blocking condition codes:

09 Valve driver circuit error
34 Low mains voltage
35 Mains Frequency error
36 Mains difference error
xx 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 the
requested 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 Hon­eywell 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 periodi­cally 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 re­sult 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- BLACK

BR- BROWN

R- RED

Y- YELLOW

G/Y- GREEN &

YELLOW

BL- BLUE

ABBEY IGNITION DEVICE

HI-LIMIT

RANCO

HI-LIMIT

MANUAL

RESET

PRESSURE

SWITCH

THERMAL

FUSE

N.O

COM

POT

SEN1

24V

SOLID STATE

THERMOSTAT

BK

BK

BK

BK

R

BK

GAS VALVE

3 AMP

FUSE

WITH THERMAL FUSE

TRANSFORMER

NON-REPLACEABLE

POTENTIOMETER

MANUAL

SWITCH

TEMP SENSOR

L

N

E

BK

BK

BK

BK

1

MV

PV/MV & AC NEUTRAL

AC 24 VOLTS

EARTH

PILOT

Led

10

BR

B

Y

Y

230 V

24 V

G/Y

Y

Y

Y

BK

G/Y

FAULT INDICATIONS

No of flashes between pauses

Reset by turning supply off, then on

MAIN VALVE FAILED

PILOT VALVE FAILED

FLAME DETECTION FAILED

FAILED TO LIGHT

1

13, 14 and 15

16, 17 and 18

5, 7 and 10

20/08/03

PV

Page 24

KEY

Bk- BLACK

Br- BROWN

R- RED

Y- YELLOW

G/Y- GREEN &

YELLOW

Bl- BLUE

Or- ORANGE

V - VIOLET

Gy - GREY

ABBEY IGNITION DEVICE

1
2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1718

19

20

21
22

23

24

HI-LIMIT

RANCO

HI-LIMIT

MANUAL

RESET

PRESSURE

SWITCH

THERMAL

FUSE

MANUAL

SWITCH

TEMP SENSOR

FAULT INDICATIONS

No of flashes between pauses

Reset by turning supply off, then on

MAIN VALVE FAILED

PILOT VALVE FAILED

FLAME DETECTION FAILED

FAILED TO LIGHT

1

13, 14 and 15

16, 17 and 18

5, 7 and 10

WITH THERMAL FUSE

TRANSFORMER

L

N

E

BR

B

230 V

24 V

G/Y

1

MV

PV/MV & AC NEUTRAL

AC 24 VOLTS

EARTH

PILOT

Led

10

G/Y

20/02/04

PV

GAS VALVE

Gy

B

B

Br

Or

Or

R

W

V

P

Y

Bk

Bk

Bk

Y

R

Or

MB 185, 265 & 405 - WIRING

Page 25

MB 185, 265 & 405 - WIRING

HI- LIMIT

RANCO MANUAL

HI- LIMIT RE SET

PR ESS U R E

SW IT C H

TH ERMAL

FU SE

MAN U AL

SWI TC H

TEMP SENSO R

WITH THERMAL FUSE

TR ANSFO RMER

L

NE

Br

B

230 V

24 V

G/Y

PIL O T

G/Y

GAS VAL VE

Gy

B

B

Br

Or

Or

RWV

P

Y

Bk

Bk

Or

ROBERTSHAW FAULT INDICATIONS

Reset by turning suppl y off, then on

OK, WORKING

FAIL ED TO LIGHT PILOT

FAILED IN TERN AL CHECK

OFF or

OFF

ON

FLASHIN G

1/01/07

GND

PV / MV

MV

PV

TH 2 4

TR G N D

Y

Led

R

Bk

Y

G/Y

Y

Y

3 Amps

12345

678910

1112

13141516

171819

20

21

22

Pool Thermostat

2B2C2D

ROBERTSHAW IGNITION DEVICE

Page 26

MB 055, 105 & 155 - TROUBLESHOOTING

055, 105 & 155 Models

ELECTRICAL TROUBLESHOOTING

START

SET THERMOSTAT

TO CALL FOR HEAT

DOES THE

DIAGNOSTIC

LED STAY ON?

YES

AFTER PREPURGE

IS THERE SPARK

AT THE PILOT

ASSEMBLY?

YES

PILOT BURNER

LIGHTS

YES

SPARK STOPS WHEN

PILOT IS LIT

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

CALL FOR HEAT OVER

SYSTEM 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 GROUND
WIRE. CHECK PILOT FLAME COVERS SENSE
ROD. CLEAN SENSE ROD.

CHECK VALVE, VALVE WIRING.

CHECK LIMITS AND CIRCULATION FAN. CHECK
CONTINUITY OF SENSOR CABLE AND GROUND
WIRE. POOR GROUNDING MAY CAUSE
OCCASIONAL SHUTDOWNS. CHECK FOR EXCESSIVE
HEAT AT FLAME SENSOR INSULATOR.

CHECK THERMOSTAT
CHECK VALVE

CHECK FOR 25VAC

NOMINAL AT TH & TR

TERMINALS

YES

REPLACE CONTROL

IS THERE ANY

AUDIBLE SPARK

NOISE @ 5 SPARKS/

SEC?

NO

REPLACE CONTROL

NO

NO

NO

YES

WARNING

HIGH 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 - TROUBLESHOOTING

ELECTRICAL TROUBLESHOOTING

055, 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 combus­tion chamber for heat leaks

Check 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 RESISTANCE
DON'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°C
Disconnect 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 combus­tion chamber for heat leaks

Check 3 Amp fuse.

TEMPERATURE 40°C-40.5° C
Control ok.

RESISTANCE ABOVE 15k OHMS (OPEN
CIRCUIT) OR SHORT CIRCUIT.
Fix loose or broken wires. Replace sensor if
necessary.

MEASURED AND ESTIMATED RESISTANCE
DON'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°C
Disconnect 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 Valves
Are Open, Supply Tubing & Gas
Pressure Good.

• Check "PV" Power Monitor On
Back of Control Board (24 VAC
From IID to Pilot Gas Valve). If
No Power, Replace IID.

• Check for Gas to Pilot (Crack
Fitting on Gas Valve Pilot Tube
Connection-Clear Tube/Pilot
Orifice as Necessary)

• Verify Pilot Rectification (Pilot On

- Spark Off)

• Check "MV" Power Monitor on
Back of heater Control Board
(24 VAC from IID to Main Gas
Valve) 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% of
each 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 LED
Lights 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 of
heater Control Board.

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

YES

Temporary Condition may
have caused problem.
Does Heater Now Operate
Normally?

NO

YES

Interrupt Power to
Heater. Wait 10
Seconds, Re-apply
Power (to Reset
Poly Fuse) Green
"Call For Heat "On?

NO

Heater Sparks ?

YES

NO (Or
Flashes
On-Off)

NO

NO ( Or Flashes On-Off)

NO

HEATER WILL NOT FIRE

08-08-01

START

"Green" Power Light "ON"

YES

"Green" Call-For-Heat
Light "ON"

YES

"Red" Service Light "ON"

YES

"Red" Pressure/Hi-Limit
Light"ON"

YES

• Check for "Fail" Pressure or High
Limit. Lights on Back of heater
Control Board.
Verify Proper Water Flow/
Pressure.Identify and Replace
Faulty 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 Thermostat
Operation (Red Jumper Wire from TP4 to TP5)
Bypass If Necessary.

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

• 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" Selec­tion. Set Temperature Control Knob to
Maximum (Counter-Clockwise)

• Check Water Temperature - Must be Less than
40°C ( Maximum Call-For Heat)

• Check Pool/Spa Selector switch and wiring to
terminal 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 heater
Control Board

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

• Check for Spark at IID Spark Terminal
(Remove Hi-Tension Lead from IID Module­Position end near spark terminal. Turn control
on. If spark jumps to wire, check Hi-Tension
wire, insulators, ceramic ignitor and gap. If no
spark jumps to wire, replace IID Module.

NO

YES

NO

NO

NO

Replace
Temp Sensor

Check for proper
wire connections
on IID module. If
okay, replace
IID module.

NO

• Remove Molex Connector Plug
P2 on heater Control Board.

• With OHM Meter, check for
continuity from each pin in plug
to ground (cabinet)

• If continuity exits trace to wire/ com­ponent; repair or replace as
necessary.

• Re-check door clearance to
terminals on gas valve.

• Trace wires to gas valve. Inspect
for proper connection on valve.

• If connections okay, replace gas
valve.

• Reconnect temp. sensor plug
at connector P1

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

YES

Verify "Call For Heat" light
(Front Panel)

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

YES

• Reconnect IID Module plug
at connector P3
Does "Power" and "Call for
Heat" Light stay on? (Front
Panel)

YES

• Place cabinet door on
heater. Check for adequate
clearance from door to
terminals on gas valve.
Remove door, correct if
necessary.

• Reconnect gas valve plug
P4 on heater Control
Board

Does "Power" and "Call for
Heat" Light stay on?

YES

Heater should operate
normally. 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 ASSEMBL Y - 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 SPCOHB­FIV3
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 BS1111 0 BS 11112 BS 11114

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 Roof

VERTICAL 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

RIGHT

L

L

L

B

C

by a minimum 60 mm

All joints overlap

Service clearance

A

Allow 10mm clearance around flue to brickwork

A (280 Only)

COH 110 - 280 OIL MK2 - FLUEING OPTIONS

Page 38

OIL NOZZLES - SIZING

Nozzle sizes 60W (Class C2 Kerosine)

COH Model 100/110 175/180 210/220 275/280
Nozzle 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 NA
Nozzle fi tted (GPH) 0.75 1.1 1.25 NA
PSI 105 135 150 NA

GPH 125 145 175 200 250

0.40 0.45 0.48 0.53 0.57 0.69

0.45 0.50 0.54 0.60 0.64 0.78

0.50 0.56 0.60 0.66 0.71 0.87

0.55 0.62 0.66 0.73 0.78 0.95

0.60 0.67 0.72 0.79 0.85 1.04

0.65 0.73 0.78 0.86 0.92 1.13

0.75 0.84 0.90 0.99 1.06 1.30

0.85 0.95 1.02 1.12 1.20 1.47

0.90 1.01 1.08 1.19 1.27 1.56

1.00 1.12 1.20 1.32 1.41 1.73

1.10 1.23 1.32 1.46 1.56 1.91

1.20 1.34 1.45 1.59 1.70 2.08

1.25 1.40 1.51 1.65 1.77 2.17

1.35 1.51 1.63 1.79 1.91 2.34

1.50 1.68 1.81 1.98 2.12 2.60

1.65 1.84 1.99 2.18 2.33 2.86

1.75 1.96 2.11 2.32 2.47 3.03

2.00 2.24 2.41 2.65 2.83 3.46

2.25 2.52 2.71 2.98 3.18 3.90

2.50 2.80 3.01 3.31 3.54 4.33

Oil Nozzles - Approximate capacities at

Various Pressures

Rated

Flow 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 de­mand 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 dis­plays 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 pri­ority 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 heat­ers. The fl ow fault is shown and it retries every 3 minutes, so it recovers if the fault is cleared.

Page 41

Model Item

Typical

value Min value

Max

Value

Genie (All Models)

Fan 230V (Windings)

Resistance 2.4mȍ 2.3mȍ 2.9mȍ

Gas Valve (Coil V1)

Resistance 2.8kȍ 2.6kȍ 3.0kȍ

Gas Valve (Coil V2)

resistance 1.6kȍ 1.3kȍ 1.8kȍ

Circulation Pump

Currrent

0.514A 0.485A 0.565A

MB Rage (All Models)

Gas Valve (Pilot Coil -

2 pin) Resistance

4.7ȍ

4.6ȍ 4.8ȍ

Gas Valve (Main Coil -

3 pin) Resistance

53.5ȍ 52.0ȍ 55.0ȍ

MBC100 & 100W

Fan 230V (Windings)

40.1ȍ 39.2ȍ

41.7ȍ

Gas Valve (Coil V1)

3.74kȍ

3.8kȍ 4.0kȍ

Gas Valve (Coil V2)

4.13kȍ 3.9kȍ

4.5kȍ

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 - 220

Burner Fan Motor

Currrent

0.837A 0.825A 0.910A

Burner Motor white

wire AC return to

control box

51 VAC 50 VAC 53 VAC

Soleniod Wire (Blue

and black) Resistance 0.1ȍ 0.0ȍ 1.5ȍ

Soleniod Wire (Blue

and brown)
Resistance 1.47kȍ 1.3kȍ 1.6kȍ

COH 280

Burner Fan Motor

Currrent

1.3A 1.15A 1.5A

Burner Motor white

wire AC return to

control box

51 VAC 50 VAC 53 VAC

Soleniod Wires

Resistance 100 ȍ

95ȍ

105ȍ

(ȍ at ambient temperature of 18ºC)

Useful Values

MULTIMETER VALVES

Page 42

NOTES

NOTES

Malvern Boilers Ltd

Spring Lane North,

Malvern, WR14 1BW

Tel. [phone]

Fax. [phone]

www.malvernboilers.co.uk