Professional Documents
Culture Documents
Notice to purchasers:
This "Boiler Fault Finder" is solely intended by way of a guide only and
is paramount, for all users to exercise skill and above all, safe
judgement at all times when making use of it.
By using this "Boiler Fault Finder", each and every user by doing so,
agrees to accept full responsibility for their own actions and therefore
agrees to indemnify and hold harmless all participants and
contributors of this particular "Boiler Fault Finder", from any and all
liabilities arising out of or in connection with such use. Any and all such
liability is disclaimed.
Contents
System Component Testing .................................................................................9
Pumps..............................................................................................................9
Reasons a pump will fail to start:.................................................................9
Burnt out motor windings ...........................................................................9
Rotor shaft seized ......................................................................................10
Worn out bearings .....................................................................................10
Fans ...............................................................................................................11
Reasons a fan will fail to start: ...................................................................11
Burnt Out Motor Windings ........................................................................11
Worn Out Bearings ....................................................................................11
Air Rotor Jammed ......................................................................................11
Fan Speed Control Resistor........................................................................12
Reasons a resistor will fail to start: ............................................................12
To test a fan speed resistor: ......................................................................12
Temperature Sensors / Thermistors ..............................................................13
Reasons to affect a thermistor: .................................................................13
Two types of thermistor: ...........................................................................13
Typical Sequence: ......................................................................................13
To Test a Thermistor:.................................................................................13
Graphs Representing resistance versus temperature ................................15
Potentiometers .............................................................................................16
To Test a Potentiometer (three pin connector): ........................................17
To Test a Potentiometer (two pin connector): ..........................................18
Alternative test (where manufacturers resistance readings are known -
example): ...................................................................................................18
Thermostats (liquid expansion / vapour pressure type/ Over heat cut out) .21
Note:
A good indication when 3 amp fuses and or quick - blow glass type fuses
repeatedly fail is when the motor windings have burnt out.
When 240V is present at the pump terminals and the rotor shaft is free moving
(anti-clockwise), but still refusing to mechanically spin, then you know the
motor windings have burnt out. (This is due to the rotor shaft seizing at some
point and causing the pump motor windings to overheat).
If water severely escapes, bearings are worn out (new pump needed)
If a small amount escapes, this is to be expected and is quite normal.
Fans
Reasons a fan will fail to start:
No 240V supplying (L) & (N) terminals
Burnt out motor windings
Worn out bearings
Air rotor jammed (on fan casing)
impeller heavy with foreign matter accumulation
Faulty fan speed control resistor (if fitted)
The resistors are enclosed within a metal casing with a heat sink connected to
it, which then connects to the boiler chassis to dissipate the heat quickly.
Because of the heat sink absorbing the high temperature rise, it prevents
damage to the enclosed resistor.
Test Outcome
No resistance/infinity faulty
Resistance reading (may vary) ok
A bad connection will increase resistance and as a result may drop the fan
speed performance, which in turn, may affect the air pressure switch resulting
in no combustion.
NTC Thermistor
Shows a decrease of electrical resistance when the system water increases in
temperature and shows an increase of electrical resistance when the system
water decreases in temperature.
PTC Thermistor
Shows an increase of electrical resistance when the system water increases in
temperature and shows a decrease of electrical resistance when the system
water decreases in temperature.
Typical Sequence:
As the system water increases in temperature, the resistance of the NTC
thermistor, decreases, and the potentiometer at the p.c.b then varies the
voltage to the modureg on the gas valve, which in turn, modulates the burner
accordingly, to match the demand for the heat load.
To Test a Thermistor:
Electrically isolate boiler / system controls
Ascertain system water temperature (near to thermistor) by using a
thermal laser or clamp on thermal sensor
Remove thermistor wires (at the p.c.b end) to prevent stray resistances
from the p.c.b itself
Set multimeter on ohms scale for resistance readings
Test Outcome
Closed circuit of less than 1 ohm faulty
No resistance/infinity faulty
PTC thermistor
Potentiometers
Potentiometers (potential dividers) are a variable resistor which, depending on
the function it is used for, can be adjusted either by the end user (electronic
thermostat knob on front fascia numbered 1-6 providing the set point, which
could be between 54 degrees C and 82 degrees C), or by the engineer for
onsite technical adjustments (within the inner face of the printed circuit board
to adjust fan speeds, gas pressures / range rating, maximum operational
temperatures, service mode and time delay periods).
Potentiometers work by introducing a voltage across a fixed top and bottom
connection on a metallic plate or coil of wire. A third connection, called the
wiper connection, is positioned between the top and bottom connections and
attached to a rotating shaft.
The wiper rotates along the length of the plate or coil. If the wiper is positioned
close to the top connection, almost all of the supply voltage is available at this
connection. As the rotating shaft is turned, the voltage supplied to the wiper is
moved from the top connection.
A small measured direct current (DC) is passed from the printed circuit board
into the potentiometers top connection. This current travels along the metallic
plate or wire coil and returns to the printed circuit board via the bottom
connection. The wiper connection voltage is governed by its position in relation
to the top and bottom connection.
The values of the top and wiper connections are then compared by the printed
circuit board. The difference between these two voltages is then interpreted by
the printed circuit board and used to determine the required temperature.
Rotating the potentiometers control dial will not change the information to the
printed circuit board, symptoms such as no heating, boiler shutting down at
low temperatures or overheating are signs of failure.
Test Outcome
Switch to ON position but no more ok
further 1 ohm
Slowly turn potentiometer to FULL ON ok
position where the resistance reading
decreases proportionally to 0 ohms
No variation when rotated faulty
Test Outcome
Turn potentiometer to fully OFF ok
position 0 ohms
Slowly turn potentiometer to FULL ON ok
position where the resistance reading
Test Outcome
increases proportionally to 1 ohm
Off position again should read 0 ohms ok
Test Outcome
Turn potentiometer to ON position ok
continuity
No continuity faulty
Alternative test
(where manufacturers resistance readings are known -
example):
Thermostats
(liquid expansion / vapour pressure type/
Over heat cut out)
Liquid expansion / vapour pressure
Reasons to affect a liquid / vapour expansion type thermostat:
The unit consists of a remote phial (located within or very near to heat
exchanger) and a capillary tube that joins it to the bellows chamber. Within the
phial is a volatile fluid having a rapid expansion rate.
As the phial heats up, the fluid expands, in some cases changing to a vapour,
and passes through the small capillary tube to fill the bellows.
The bellows in turn, increases in size to take up this expansion and in so doing,
breaks the electrical circuit and extinguishes the pilot and / or main burner.
On cooling, the volatile fluid contracts and is forced back by the pressure of a
spring acting on the bellows, through the capillary tube to the phial and
remaking the electrical circuit once more to relight the pilot and / or main
burner.
Test Outcome
Closed circuit of less than 1 ohm ok
No resistance/infinity faulty
Continuity ok
Test Outcome
Closed circuit of less than 1 ohm faulty
No resistance/infinity ok
No continuity ok
240V AC = faulty
The control thermostat may rest in a Normally Open (NO) position of this type.
On some control thermostats, the manufacturer may need to be consulted in
order to identify the relevant terminal connections for correct operation.
These thermally activated control devices may interrupt the electricity supply
to a gas solenoid valve extinguishing the pilot and/or main burner, signalled by
the printed circuit board. The overheat cut out thermostat must be manually
reset to prevent further boiler cycling whilst a fault may be present (overheat
lockout).
To test an over heat cut out thermostat (when not at trip point):
Test Outcome
Continuity across ok
terminals
No continuity faulty
across terminals
Test Outcome
Continuity across ok
terminals
No continuity faulty
across terminals
The pressure differential created by the fan is transmitted via the pressure
hoses and creates a difference in pressure on top and bottom of the
diaphragm, this in turn, pushes the diaphragm and an attached pin and lever.
When the diaphragm has fully reached its proved air flow position, the pin and
lever operate a micro switch, sending a signal to the printed circuit board to
commence ignition sequence (by either a 2 or 3 wire configuration).
When the fan has stopped, a force (usually a spring or gravity) returns the
diaphragm to its rest/no air flow position.
2 wire configuration:
C Common
NC Normally closed
3 Wire configurations:
C Common:
Printed circuit board signal (voltage) to the air pressure switch
When the fan operates effectively and air is proved at the air pressure switch,
the micro switch moves to the proved air flow position NO terminal.
Open circuit (infinity) across both terminals = ok (switch in rest / no air flow
position)
Note: Some appliances will give you very little time to check a proved air flow
ensure the fan is at high speed for this check.
Test Outcome
Continuity ok (switch in proved air flow position)
Closed circuit of less than 1 ohm ok (switch in proved air flow position)
Should an open circuit (infinity) reading be present, it does not prove a fault
with the switch itself, but could be fan, venturi, blockages, hose problems etc
needs - further investigation.
Electrically isolate boiler - Replace both wires back onto their respective
terminals - Restore power once more
Note: Some appliances will give you very little time to check a proved air flow
ensure the fan is at high speed for this check.
Test Outcome
Continuity ok (switch in proved air flow position)
Closed circuit of less than 1 ohm ok (switch in proved air flow position)
Should an open circuit (infinity) reading be present, it does not prove a fault
with the switch itself, but could be fan, venturi, blockages, hose problems etc
(needs further investigation). Electrically isolate boiler replace both wires back
onto their respective terminals and restore power once more.
Where an air pressure switch is not present, purposely designed thermistors are
used to measure the differential temperatures of the flue/air ducts, which are
then transmitted to the printed circuit board for correct operation.
Some boilers use a low DC voltage, whereas others use a 240 V AC voltage.
(Remember - the input will appear as an output, unless a fault is present).
Some air pressure switches use a push (positive) pressure on the diaphragm to
make the micro switch, whereas others will use a pull (negative) pressure on
the diaphragm to make the micro switch. The operation depends on the
position of the return force (spring or gravity) when the fan is at rest.
A demand for domestic hot water will either activate a turbine arrangement, a
paddle / wheel arrangement or a rubber diaphragm arrangement, all of which
communicating to a micro switch assembly, transmitting a signal to the printed
circuit board for correct operation.
A demand for central heating will activate the pump and a rubber diaphragm /
spindle arrangement communicates to a micro switch assembly above,
transmitting a signal to the printed circuit board for correct operation.
Test Outcome
Continuity between C and NC ok
Continuity between C and NO faulty
The low water pressure switch receives 230V AC from the printed circuit board
via the (C) and upon adequate system pressure being applied (0.5 bar and
above typically) the switch will then return 230V AC back to the printed circuit
board via the (NO).
The switch when new or when there is inadequate system pressure applied,
will rest in the (NC) position, and only upon there being adequate system
pressure again, will it switch over to the (NO) position.
Not all boilers incorporate these switches to detect a low water system
pressure, but instead rely just on the high limit thermostat to protect the main
heat exchanger.
Some switches are only a two wire connection only (there is not a NC
connection).
Test Outcome
Measuring between C and NC - No ok
resistance/infinity
Measuring between C and NC closed faulty
circuit of less than 1 ohm
Test Outcome
Continuity between C and NO ok
Continuity between C and NC faulty
Test Outcome
Measuring between C and NC - closed ok
circuit of less than 1 ohm
Measuring between C and NC - No faulty
resistance/infinity
Test Outcome
Continuity between C and NC ok
Continuity between C and NO faulty
Solenoids
Reasons a solenoid will fail to operate:
As voltage is applied to the coil, the armature is drawn into the solenoid valve
body, allowing gas to flow through the main gas valve which is proportional to
the current applied.
Typically, the pilot solenoid and main solenoids are 230V AC and the
modulating solenoid approx. 24V DC, but manufacturer instructions/data must
always be checked.
To test a solenoid:
Test Outcome
No resistance/infinity faulty
Less than 1 Ohm faulty
Modureg coil resistance 45 +Ohms ok
approx*
*(This will vary depending on manufacturer and type of solenoid. Some modern
two stage safety solenoids may be 165 + ohms)
Modureg adjustments
(early production boilers)
Maximum adjustment:
Minimum adjustment:
Modureg adjustments
(later production models)
On moduregs where the minimum and maximum adjustment nuts are
enclosed behind a plastic cover, always check with manufacturer instructions
first before making any adjustments.
For most boilers, the large nut is for maximum pressure and the small nut is for
minimum pressure, however, there are some boilers which are arranged
opposite to this (large nut is minimum and small nut is maximum).
In order to adjust the maximum pressure, call for a demand via fully opening a
hot tap and turn the large nut clockwise to increase whilst at the same time,
holding the minimum screw still.
In order to adjust minimum pressure, remove one of the wires from the
modureg coil terminals (this automatically drops the pressure down to low
rate) and turn the small screw clockwise to increase (the large nut will not
freely move so no need to hold during this adjustment).
These devices are energised or de energised to control the on/off of pump and
boiler (calling from the cylinder thermostat or room thermostat).
Two port valves are either in the open or closed position via the internal ball
(shoe or paddle).
3 port diverter valves (hot water priority valves) control one circuit only; not
both, (hot water or heating). Once the hot water cylinder thermostat is
satisfied, the central heating port will open.
This is why blocker valves (an additional two port zone valve) must be
installed after port B on a mid position valve when installed on an unvented
hot water cylinder system, to prevent the stored water from overheating / over
pressurising.
Should the synchronous motor burn out, it is possible to replace the motor,
however, if the end switch fails, a complete actuator must be replaced.
The manual override lever should only be used for draining and refilling
purposes and not as a solution to heat the hot water and/or central heating, in
case of the actuator failing.
Warning:
Some very old actuator heads require the system to be drained first, before
separating from the brass valve body.
Experience has shown that actuator covers not having a raised pip (reversed
dimple) on top of the cover, are the type which will leak if separated from the
brass body, prior to draining.
Manually override lever to open position and call for a demand via room or
cylinder thermostat (with timer or programmer calling).
Should boiler / pump not respond, the auxiliary switch may be faulty (new
actuator needed)
Manually override lever to open position and call for a demand via room or
cylinder thermostat (with timer or programmer calling).
Should boiler / pump respond, the syncron motor will be faulty (new motor
needed)
The motor windings can overheat and break, which is a common fault when
motorised valves fail to operate.
Test Outcome
Approx. 2.4K ohms ok (resistance will vary depending on
manufacturer)
No resistance / Infinity faulty
Purposely designed insulated wire crimps are easily obtained and must be used
to reconnect the broken wires safely.
When replacing faulty syncron motors, the two factory fitted wires do vary in
colour (orange, blue and white), however, this will not matter as long as it fits
onto the actuator head, designed for this purpose.
Heating mode:
If this functional check proves to be correct, the problem is not the motorised
valve, but elsewhere in the circuit possibly cylinder stat or room stat.
If the motor fails to rotate with live applied to the brown wire and neutral
applied to the blue wire (brown wire connects to T3 on room stat calling, and
the blue wire connects to T2 on room stat satisfied) then the motor has failed
to operate
Note: When the valve stops, the valve remains fully open as long as live is
applied to the brown wire - The valve closes under spring return when live is
removed from the brown wire - The valve may also be faulty if:
The orange wire only becomes live after the valve has fully opened (grey wire
must also be live)
(Orange connects to L on the pump and boiler only and grey wire connects to L
terminal on time controller and L terminal on fused spur).
If the boiler and pump continues to run when the cylinder stat and or room
stat is satisfied when the time controller is in the OFF position.
Sequence of operation:
(2 port valve Honeywell V4043H)
There are five wires to the valve: brown (live to syncron motor), orange
(switched live to supply power to pump and boiler), grey (permanent live to
the micro switch), blue (neutral to syncron motor) and green/yellow (earth).
When there is a call for heat (via room stat or cylinder stat), power is sent
down the brown wire which starts the motor. When the valve is open, a micro
switch is made via a cam and power is then sent to the boiler and pump via the
orange wire (switched live).
Power is constantly provided to the motor via the brown wire, keeping the
valve open, as long as there is a call for heat. Once the call for heat is satisfied,
power comes off the brown, causing the motor to be de-energised.
A spring then returns the valve to the closed position, closing the micro switch
and disconnecting power to the orange wire, switching off the hot water or
heating zone respectively.
Note: If using a 28m/m V4043H1106 zone valve on either hot water or heating
circuits (S plan configuration only), the white wire is not needed and must be
made electrically safe (cut back tight to black fly lead no power will be on this
wire).
There are five wires to the valve: white (from room thermostat calling for
demand), orange (from cylinder thermostat calling for demand and switched
live to supply power to pump and boiler), grey (from cylinder thermostat
satisfied and H/W OFF of programmer blue (neutral to syncron motor) and
green/yellow (earth).
Always check the wiring, all the links are in place and that 240V on L and N is
present on the back plate before suspecting a faulty programmer.
If Live does not appear on HTG ON terminal when HTG only is selected
(continuous or timed) Y plan and S plan (refer to diagrams)
Live does not appear on HW OFF terminal when HW is off on
programmer
Y plan (refer to diagram)
Live does not appear on HW ON terminal when HW only is selected
(continuous or timed) Y plan and S plan (refer to diagrams)
Note: When a single channel time switch is on and calling for a demand but the
motorised valve is not moving on the lever to switch on the boiler, then try
linking the C (common) and ON (calling) connections together on programmer
back plate. (Always isolate electrical power supply and remove fuse prior to
this).
Should the zone valve motor across, then the programmer switching contacts
are faulty.
Should the zone valve remain the same, then further investigation is needed
(syncron motor windings maybe burnt out or a seized valve spindle).
These devices are energised or de energised (via the printed circuit board) to
operate a motorised axle/spindle. The movement of the motorised spindle
communicates with the diverter valve via a bobbin assembly, controlling the
path of heated primary water, either to the secondary plate exchanger or to
the central heating circuit.
Lead:
Set multimeter to correct voltage scale and check at connections
Test Result
Central heating on: 240Vac between connections 1 and 2
25Vac-35Vac between connections 2
and 3
Hot water on: 240Vac between connections 2 and 3
25Vac-35Vac between 1 and 2
Incorrect voltages maybe faulty printed circuit board or lead needs further
investigating. Correct voltages but motor axle not moving replace motorised
valve head
Diverter valves
Reasons a diverter valve will fail to move
These devices, depending on the demand, controls the path of heated primary
water either to the secondary heat exchanger (plate exchanger) or through to
the central heating circuit.
Diverter valves normally rest in central heating mode so it can dump excess
heat on the central heating circuit.
Note: Should correct voltages be present at respective connections, but still not
functioning correctly on a hot water or central heating demand, then the
diverter valve may need replacing.
On a hot water demand with the hot water temperature remaining cold but a
temperature rise through the central heating flow pipe, the diverter valve will
be stuck in the central heating mode.
On a hot water demand with the hot water temperature remaining warm not
hot, with a temperature rise through the central heating flow pipe, the diverter
valve will be letting by.
Room thermostats
Reasons a room thermostat will fail to start
Should only one pair of wires be live when at maximum and minimum settings,
then the room thermostat is faulty.
Others however, will be terminal 1 for C, terminal 3 for demand and terminal 2
for satisfied. (Generally there will be a small switching diagram inside the outer
casing of room thermostats for guidance purposes).
Common terminal:
The live in terminal from the central heating on terminal of the
programmer in most cases.
Demand terminal:
This contact will be made to the common when the thermostat is calling or
demanding heat.
Satisfied terminal:
This contact will be made to the common when the thermostat has reached
the required temperature or is satisfied.
Cylinder thermostats
Reasons a cylinder thermostat will fail to start
The cylinder thermostat upon calling for heat turns on the boiler and/or
energises a motorised valve.
Common terminal:
The live in terminal from the hot water on terminal of the programmer in
most cases.
Demand terminal:
This contact will be made to the common when the thermostat is calling or
demanding heat.
Satisfied terminal:
This contact will be made to the common when the thermostat has reached
the required temperature or is satisfied.
Closed position (calling for heat) = 240V between common terminal (3) and
calling terminal (1).
Stat is faulty if terminal (1) does not become live when calling
Open position (satisfied) = 240V between common terminal (3) and satisfied
terminal (2).
Stat is faulty if terminal (2) does not become live when satisfied
Some models maybe marked C, NC and NO where NC is calling and NO is
satisfied.
Other models may be pre-wired where red is C, black is calling (NC) and yellow
is satisfied (NO).
Note: The Common, demand and satisfied terminals do vary on some cylinder
thermostats, depending on make and model, where some will be terminal 3 for
C, terminal 1 for demand and terminal 2 for satisfied.
Others however, will be terminal 1 for C, terminal 3 for demand and terminal 2
for satisfied. (Generally there will be a small switching diagram inside the outer
casing of room thermostats for guidance purposes).
Spark electrode(s)
Reasons spark electrode(s) will fail to start
Where this may be the case, always check the spark generator first for correct
voltage readings (if possible, as not all boilers have remote spark generators,
instead they are permanently fixed on the main p.c.b., where a new board will
be required in this instance).
No sparking occurs
Note: If the gasket between the electrode base and the burner assembly
appears to be worn / damaged when removing the electrodes for
inspection, then both the gas supply and the electrical power supply must
be isolated to prevent use this would be AN IMMEDIATELY DANGEROUS
SITUATION as products of combustion may enter the room.
Note: not all models incorporate a diverter valve and plate to plate
heat exchanger, but instead utilise a twin pass main heat exchanger
Please note: The above sequence of operation for both hot water and central
heating are not identical for every boiler out there, however, the sequence of
events will not progress any further forward, if there are no feedback signals or if
they are incorrect.
Electrically isolate power supply at fused spur switch and remove fuse
(Always ensure the boiler is fused at 3 amps on completion of work)
Set multimeter to correct voltage scale (above 240V AC) and check L
and N at the boiler terminal block
This should read zero volts, the boiler is now safe to work on.
The resistance reading must be no more than 1 ohm and whenever the
resistance reading proves to be more than 1 ohm, there is a fault present and
must be traced and rectified before proceeding any further. Check all the earth
wires for continuity and check all connections are secure.
Should the resistance reading move, there is a dead short and a fault is
present. Where the boiler supply is connected to a fused double pole switch, it
should be isolated at the ring main supply end, to eliminate any possible,
further faults present on the circuit. (This is why a 3 pin plug is a much better
option as a double pole spur can cause further problems).
There are six internal boiler components to check and the L and N connections
for each component must be removed individually and then the L and N at the
3 pin plug top or at the boiler terminal block must be measured again.
Pump
Fan
Gas valve
Diverter valve
Circuit board
Internal wiring loom (visual observation only)
With the boiler switches, time switches and thermostats on and the
multimeter set on ohms scale, the resistance reading between L and E should
read no other than O L ( infinity ) and if so, there is a fault .
Connect boiler to power supply via 3 pin plug top or inserting 3 amp
fuse into switch
Ensure boiler is on but with all controls off, so there is no demand
Set multimeter to correct voltage scale on V AC
Firstly put the black lead from multi meter to the E terminal block on
the boiler and secondly the red lead from multi meter to the N
terminal block on the boiler this should read 0V AC, but up to 15V AC
is ok
Note: Should a reading be greater than 15V AC, this indicates a fault is present
within the house wiring, but the polarity at the fused switch should first be
checked, prior to calling an (NICEIC) approved electrician.
240 V TEST
Connect boiler to power supply via 3 pin plug top or inserting 3 amp
fuse into switch
Ensure boiler is on but with all controls off, so there is no demand
Set multimeter to correct voltage scale on V AC
Firstly put the black lead from multi meter to the E terminal block on
the boiler then secondly the red lead from multi meter to the L
terminal block on the boiler - this should read approx. 240V AC
240 V TEST
Noisy pump
Noisy fan
Explosive ignition
Noisy solenoid
Radiators warm up when no hot tap is open and the timer is in the off
position (timer working correctly)
air pressure switch hoses loose check ports and firmly fix
split / kinked hoses remove kink / replace hose
water in hoses (condensation) dry hoses / replace hoses
reversed pressure connections (hoses correctly connect hoses
wrong way around)
split/punctured air pressure switch replace air pressure switch
diaphragm
damaged combustion chamber seals replace entire seal
cracked pilot window or damaged seal replace glass / seal
faulty air pressure micro switch replace air pressure switch
flue / airway ducts blocked at terminal clear restrictions/blockages
faulty fan (not at full capacity) check/ lubricate bearings
clear debris build up
blocked / melted venturi
replace fan assembly
ignition electrodes cracked check / replace electrodes
ignition wiring harness damaged / loose check wiring / connections
faulty spark generator on p.c.b. replace p.c.b.
ignition electrodes gap too far apart check gap (as per manufacturers
instructions)
Therefore, the fault can only be at the diverter valve, micro switch, flow switch,
central heating thermistor, high limit cut out thermostat, printed circuit board
and external controls (room thermostat and timer).
Therefore, the fault can only be at the diverter valve, micro switch, flow switch,
domestic hot water thermistor, high limit cut-out thermostat, domestic hot
water heat exchanger and printed circuit board.
No Central Heating
split diaphragm on flow switch (pin not moving)
faulty micro switch (burnt out contacts)
faulty motorised valve head (burnt out windings)
diverter valve (faulty wax capsule or bobbin assembly)
faulty programmer (faulty switching contacts)
faulty room thermostat stuck in the open (satisfied) position
faulty zone valve (seized, burnt motor, end switch)
faulty mid-position valve (seized at port A)
severely blocked heat exchanger (scale and sludge)
faulty printed circuit board (central heating side)
faulty thermistor (open circuit / infinity)
faulty high limit cut out thermostat (open circuit / infinity)
faulty pump (not at full capacity)
Top tips
It sometimes pays to test the air pressure hoses with (LDF) Leak
detection fluid, when encountering ignition problems. (Hoses maybe
split or have loose connections).
When the automatic air vent on the boiler shows signs of severe
leakage through the threaded bleed cap, it is not always a fault with
the air vent itself, despite the fact of sludge being present within the
system water.
Check the pressure charge at the expansion vessel, as the air vent is a
much weaker component than most under pressure and releases the
build up which the vessel should be taking up, but cant due to a loss in
air.
Always isolate boiler at flow and return valves and depressurise via the
pump vent cap (using an absorbent towel or similar), never the
pressure relief valve as this may encounter debris on the seat and then
drip constantly. Better still, utilise the drain off valve connected to the
hydraulic block (where fitted). Pre-charge vessel as shown on data
badge (typically between 0.5 1.0 bar) and re-pressurise boiler via
filling loop.
Open isolation valves (these may start to leak) and monitor pressure
gauge and air vent.
Should water maintain leaking from air vent, then a direct replacement
in necessary, however, should the pressure gauge remain under 2.5 bar
(when hot) with no leaks, then the air vent is ok.
Faults can only then rest with (diverter valve being seized/sticking,
faulty primary flow switch and/or micro switch, faulty primary
thermistor or p.c.b). The same process applies for a hot water fault!
Always oversize the remotely fitted vessel if not sure and purge the
system water from the abrasive particulates (iron oxide), by way of
flushing with good quality chemical cleanser and inhibitor. (Heavy
corrosion build up may have been the reason why the rubber
diaphragm perished).
Always photograph and manually log / record the boiler gas council
(GC) number and serial number when working on boilers which needs
attention to parts - if possible. (Manufacturers have the right to change
their internal component design at time of mass production, without
you even knowing).
This will be hassle when the wrong part turns up, leaving you the
embarrassment, but more importantly, your customer without a
working boiler for longer periods not good for promoting your
professional and reliable services.
When sparking occurs but no ignition takes place (flow switches, air
pressure switch, thermistors, fan, diverter valve, high limit cut out stat
and pump all being ok). The fault can only then rest with the gas
valve or p.c.b).
These can be seen on top of boiler casing, below the boiler casing or
within the boiler clamped onto pipes, where the button will be raised
and you will be able to press down to reset (closed circuit).
When the diverter valve is in its rest position, it leaves the central
heating port open, and when the domestic hot water micro switch is
stuck in the NC position (calling for a demand), the boiler thinks a hot
water draw off has occurred, but due to the pressure differential flow
switch (attached on top of the diverter valve) not actually moving the
spindle / diverter assembly within, the boiler fires up and heats the
radiator circuit due to the open port in its rest position.
Black test lead always goes into COM terminal on multimeter (first).
Red test lead always goes into V or ACV or V~ terminal on multimeter
(second).
Always select voltage range above 240 as less than this will read off the scale
when measuring for mains voltage and never rotate the dial while the meter is
connected to a circuit you may rotate it through a current range, short
circuiting the probes and damaging either the meter or the circuit.
The resistance readings in motor windings will vary (pumps, fans, solenoids,
transformers).
When measuring closed switches (micro switches, overheat cut out stats) a
reading of zero resistance (closed circuit / continuity) = ok.
When measuring open switches (micro switches, overheat cut out stats) a
reading of infinity / OL (open circuit / no continuity) = ok.
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When measuring in volts AC the black test lead must first be connected to E or
N connections and then secondly the red test lead be connected to the L
connection, which then completes the circuit.
All electrical test equipment used should be suitable for the electrical tests
being carried out and any leads / probes to be inspected before use to ensure
it is safe.
Respect the circuitry you are working on - If you touch exposed metal, or cause
a short circuit, or connect to high voltage, you may expose yourself to a serious
hazard.
The main ranges typically used are AC, DC and continuity keep it simple rule!
The gas operative should ensure they have sufficient knowledge of the test
equipment capabilities and functions so as to be able to conduct electrical
testing in a safe manner.
Carry out a visual risk assessment of the gas installation pipe work, gas
meter / box and any sealing, other appliances, system controls and any
ventilation provisions needed.
Inspect heat exchanger connections for signs of any leakage and brush
clean the waterways using correct grade heat exchanger brush and
hoover.
Inspect fan assembly and clean off any dirt / debris accumulation using
a soft brush, can of compressed air and hoover. (The fan may need to
be removed when there is heavy accumulation present, as it can
imbalance the impellor always handle with care!).
Undertake necessary flue flow continuity test / spillage test (open flue
appliance only).
Check minimum and maximum gas setting pressures (if possible) and
inlet working pressure.
Vent system to remove any trapped hydrogen gas / air build up.
(Hydrogen gas is a by product of electrolytic corrosion FLAMMABLE!).
Attach service sticker to appliance showing next due service date and
contact details (remember, the property may change hands but if not,
it will be another satisfied customer).
Ensure property has been left clean and tidy and as you found it.
Finally, discuss with the customer any possible energy efficient system
improvements you think they could benefit from, by adding onto their
existing system. Always look at it as your responsibility to raise their
awareness in these matters as it can only maintain a positive and
professional relationship, which should lead to more work.
Background:
When natural gas burns, it produces considerable quantities of water and this
is vaporised in the combustion process (converted to steam). This process
absorbs quite a lot of energy (heat), in fact, approximately 14% of the heat
produced by burning the gas is required to boil off the water this heat is
commonly known as latent heat, as it causes a change of state from liquid to
gas (steam).
Question:
So why do we need to get the return water temperature less than 55 degrees C
in order to maximise condensing operation?
Answer:
The design of a condensing boiler enables a lot of this latent heat to be
recovered by condensing the steam in the flue gases back to water
(condensate), but this can only be achieved by getting the return water
temperature down to 54 degrees C the dew point of gases.
At this temperature, the water vapour in the flue gases will start to condense
onto the heat exchanger and give up its latent heat. This heat, plus the sensible
heat recovered through cooling the flue gases, can amount to around 12% of
the heat that would have otherwise been lost.
Reducing the return water temperature still further will recover even more
latent heat.
Whilst commissioning your boiler replacement, you may have heard the boiler
condensing through the plastic pipe leading to the drain within only minutes of
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With underfloor heating, where lower flow water temperatures can be used at
the manifolds, weather compensation controller settings can be changed so
that the maximum water temperature is 66 degrees C when the outside
temperature is say - 2 degrees C. Changes in the external temperature alter
the temperature of the flow, lowering it if the outside temperature rises and
increases it if it drops.
The constant monitoring of the external climate means the boiler is able to
operate efficiently at the minimum required temperature and condense for
longer. With outside weather compensation controls, there is always a
provision for running at maximum boiler flow temperature for domestic hot
water heating, and this should be on a priority basis.
The optimum efficiency level that many newly installed condensing boilers can
achieve is not being fully recognised. Domestic heating accounts for around
14% of the UK`s CO2 emissions, the installation of intelligent weather
compensation controls could help to reduce it by almost a quarter.
Identify the difference between room temperature required and the mean
radiator water temperature, which determines the rate at which heat from the
water can be transferred to the room. This determines the value of the Delta T
factor which is used to adjust the rated output of the radiator from the
manufacturers catalogue rating.
Delta T factors for radiator- to- room temperature differences (figures may
vary slightly depending on manufacturer):
Example:
Heat emission required: 2000 Watts (2 KW)
1. Temperature difference
60 20 = 40 degrees C
Mini programmer
The hot water mode can be switched on without the heating mode, but in
order to switch on just the central heating, the hot water will also
simultaneously come on with it. (This will be common on gravity hot water
systems with fully pumped heating).
The temperature of the domestic hot water can reach very high temperatures
in this arrangement, as whilst the heating is on, gravity convection currents
take place and cycles until heating is satisfied via room thermostat or more
commonly the boiler thermostat.
Should a temperature rise occur within the radiators during the summer
months whilst on hot water mode only, then the anti-gravity valve (fitted on
central heating flow pipe) may be faulty letting-by.
Full programmer
The hot water mode and heating mode can be switched on totally
independent from one another or both modes can be on at the same time.
(This will be common on fully pumped systems).
Some two channel programmers will share the time base (common time base)
which means both hot water and heating must share the same on/off periods.
The following compatibility guides are a quick and easy reference tool to
upgrade and replace existing programmers and time switches to Drayton
models, indicating the respective time base (24 hour, 5/2 day or 7 day) and
respective terminal comparisons (E, N, L, H/W ON/OFF, C/H ON/OFF).
Simply look through the existing makes and models within the faulty
programmer sections or within the faulty time switch sections and the "Boiler
Fault Finder" will show all recommended Drayton replacements.
Then simply look through the programmer or time switch terminal comparison
tables to ascertain the necessary back plate wiring conversion.
You may find the existing faulty programmer or time switch model has been
discontinued, however, by using this guide, it will indicate the suitable
replacement.
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP522 (Electronic, independent H/W & C/H)
LP522 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
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Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
Suitable replacements for above: LP722 (Electronic, independent H/W & C/H)
LP722 SI (Electronic, independent H/W & C/H)
ACL MP(TOWERCHRON) 2 1
FP (TOWERCHRON) 2 1 8 11 6 10
400,600 (NO CONNECTION TO
Switchmaster N L 4 3 1
TERM.4 ON 600)
Drayton 805,900,900I N L 4 2 3 1
British Gas EMP2, UP1 N L 1 2 3 4
Danfoss CP15,CP715,FP15,FP715,CP71
N L 1 2 3 4
Randall 5SI, FP715SI
3020P,3060 E 7 6 4 2
4033(LINK 1-6) E 7 6 5 4 3 2
102,102E,102E5,102E7(LINK6-
E 5 6 1 2
3)
701(LINK L-5 AND 5-6) E N L 3 1
702(LINK L-5 AND 5-6) E N L 4 2 3 1
922,972 (LINK L-2 AND 2-5) E N L 1 4 3 6
SET2,SET2E,SET3E,SET3M,FP9
E N L 3 6 1 4
75,
SET5 (LINK L-2 AND 2-5) N L 7 4 6 3
C/
H/ H/ C/
H
Make Model E N L W W H
OF
OFF ON ON
F
Drayton LP112,LP241, LP522,
N L 1 2 3 4
lifestyle LP722,LP241 SI,
LP522 SI, LP722 SI
Drayton SM2 N L 1 2 3 4
The following makes and models need to be cross referenced to the above for wiring
comparisons
(Some of the following existing models may be discontinued but replace with the above
models)
C
O O
Make Model E L M N OFF SPARE
Drayton LP111,LP711,LP111SI,L
lifestyle P711SI N L 1 3 2 4
Drayton SM1 N L 1 3 2 4
The following makes and models need to be cross referenced to the above for
wiring comparisons
(Some of the following existing models may be discontinued but replace with the
above models)
ACL TC (TOWERCHRON) 2 1 4 7
Switchmaster 300,980 N L 4 1
Drayton TEMPUS 1 AND 2 N L 1 3 2 4
British Gas EMT2, N L 1 3 2 4
UT1 N L 1 3 2 4
Danfoss
Randall TS15,75 E N L 1 4 2 5&6
TS715,TS715SI N L 1 4 2 3
TS975 E N L 5 4 6 1,2,3
SET1, SET1E E N L 5 4 6
SET4 E N L 5 4 6
103,103E,103E5,103E7 4 5 6 3 1 2
911,971 E N L 5 6 4 2
Honeywell ST6100A,ST6100C,ST61
00S,ST9100A,ST9100S N L 1 4 2
ST7000B N L 1 2 3 4
C
O O
Make Model E L M N OFF SPARE
Drayton LP111,LP711,LP111SI,L
lifestyle P711SI N L 1 3 2 4
Drayton SM1 N L 1 3 2 4
The following makes and models need to be cross referenced to the above for
wiring comparisons
(Some of the following existing models may be discontinued but replace with the
above models)
Horstmann CENTAUR SC1,SC7 L 3 2
CHANNEL PLUS H17XL,
H11XL E N L 4 6
CENTAUR PLUS
C11,C17 N L 2 4 3
EMERALD423,PEARL
AUTO N L 2 4 3
517,CORONET,H11,H1
7 E N L 3 4
MICROTIMER (LINK L-5
Myson AND 5-8) E N L 5 4 6
MEP1C N L 3 4 2
Potterton EP4000,4001,4002,500
Myson 2 N L 5 4 2
Siemens / RWB3, N L 4 3
Landis & RWB27,RWB30,RWB50
Staefa ,100,152,170 N L 2 4 3
RWB7 E N L 2 4 3
Sunvic SELECT 107 N L 1 3 2 4
SP20,SP35 N L 3 5 4 5
Chrysotile (white)
Amosite (brown)
Crocidolite (blue)
Asbestos fibres enter the body through breathing, via the nose and mouth.
They cannot enter the body through the skin or via food and drink as this will
pass through.
Disease is caused by tiny fibres of asbestos passing into the lungs where they
can stay for many years. Small but repeated exposure on different jobs over
time can lead to the development of an asbestos-related disease, which can
take anything from 15 to 60 years to develop.
The following list has been compiled to aid you and minimise the risk from
exposure, however, the list cannot be considered to be definitive, and any
material you do suspect as asbestos should be treated as such. There may be
other appliances containing asbestos materials that do not appear on the list.
Specialist advice should be sought from the manufacturer prior to commencing
any work and where necessary, specialist licensed asbestos removal
companies used.
Caradon concord
Ideal companion 44-392-21 G, R
Mexico
Super CF 100 41-407-46 MF
Mexico
Super CF 125 41-407-48 MF
Mexico
Super CF 140 41-421-39 MF
Mexico
Super CF30/40 41-415-26 MF
Mexico
Super CF30/40 41-415-05 MF
Mexico
Super CF40 41-407-20 MF
Mexico
Super 40/50 41-421-49 MF
Mexico
Super CF40/60 41-415-27 MF
Mexico
Super CF40/60 41-415-06 MF
Mexico
Super CF50/60 41-421-50 MF
Notches and holes in simply supported floor joists should be cut no deeper
than 1/8 of the depth of the joist. They should not be cut closer to the support
than 0.07 times the span, nor further away than 0.25 (1/4) of the span.
0.25 x L
Depth (D)
Max depth of
notch = D/8
0.07 x L
Rules for joist depth up to
250mm. For deeper joists
assume D = 250mm Notches should
be in this zone
Maximum diameter of a
hole = 0.25 x D
Neutral axis
of joist
Not less than 3 diameters
apart centre to centre
Drilled holes should be no greater in diameter than of the depth of the joist.
They should be drilled on a neutral axis and should not be less than three
diameters apart, measured from centre to centre. Drilled holes should be
located in the area between 0.25 and 0.4 times the span of the joist from the
support.
Engineering joists
Buildings that incorporate timber I joists (engineering joists) allow for more
flexible drilling of holes for pipework. I joists incorporate 38mm knockouts
(dependent upon the manufacturer), and also allow for larger holes to be
drilled through the joists. The same rule applies when drilling through I joists as
for drilling traditional joists where horizontal measurements between holes
are concerned.
However, as the strength of I joists is in the flange, these joists are not suitable
for notching, as notching the flange will damage the structure of the joist,
which will have a detrimental effect on its strength. The size and positioning of
holes drilled through I joists must be in accordance with the diagram shown
below.
Web
Flange
Therefore, notching may occur between 210mm and 750mm from the
supporting wall, and notches should be no deeper than 18.75mm.
Therefore, holes can be drilled at the neutral axis between 750mm and
1200mm from the supporting wall. The maximum hole diameter should not
exceed 37.5mm and holes should not be located less than three diameters
apart (centre to centre), meaning 37.5mm holes should be separated
Hand tools
Small adjustable spanners
Pump pliers (small, medium and large)
1000V rated electrical screwdriver set
1000V rated electrical nose pliers
Selection of TORX head bits & holder
Microbore pipe bender
Adjustable pipe cutter
Soldering equipment
Pair of earth continuity bonding leads
Hydraulic pressure vessel hand pump
Digital pressure vessel checker
Stopwatch
Telescopic inspection mirror
Telescopic magnet
Electronic combustion gas
Analyser & printer
Differential digital manometer
Differential digital thermometer
Water flow rate weir gauge
Electronic gas leak detector
Digital multimeter with fused leads
Battery powered volt stick
Selection of heat exchanger brushes
Smoke match holder
Very soft paint brushes (1 and 2)
Telescopic inspection camera
Infra red temperature gun
Consumables
Purimachos FJC non setting compound
Strikes smoke matches
Hayes orange smoke pellets
abrasive cleaning strips
ROCOL gas seal compound
ROCOL LDF (leak detection fluid)
ROCOL air dusting cans
PTFE tape (gas & non-gas types)
Gas ON/OFF identification tape
ROCOL gas tap lubricant
heat conductive paste
Hoover bags
PRS 10 approved closure tape
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Forms / Labels
CP1 (gas safety record)
CP14 (warning / advice
CP3 (chimney/flue/fireplace & hearth pad)
NEED WHEN CARRYING OUT SERVICE AND REPAIR WORK WITHIN THE FIELD.
THIS LIST HAS BEEN COMPILED TO ASSIST THOSE WHO ARE NOT AS
EXPERIENCED AS OTHERS AND MAY NOT SEE THESE ITEMS AS SO OBVIOUS.