Service Manual
Contents
1. Service Manua Compact 3000 92x 93x 94x lt FOREWORD This service handbook is intended to assist with servicing and fault finding in caravans and motor caravans equipped with the Alde Compact 3000 92x 94x The handbook may also be of assistance in ordering spare parts It also provides general information on how Alde central heating systems are designed and how they operate When servicing components designed for LPG and 230 volts national safety regulations must be adhered to After the boiler has been serviced the service record must always be completed Alde International Systems AB Service department NB We reserve the right to make changes after this handbook has been printed CONTENTS Page Chap 3 1 0 About the Alde central heating system 1 1 of the heating system 2 0 About the Compact 3000 Technical data 3 0 Fault finding 3 1 The electrical heating cartridge does not Work P 3 2 The LPG boiler do not start 7 3 2 1 The LPG boiler shuts down on start up 7 3 2 2 No ignition spark 8 3 2 3 Ignition spark is generated but the boiler does not start 8 3 3 The LPG boiler starts but goes out after approx 10 seconds 9 3 4 TheLPOG boiler starts and switches off at short intervals 9 35 Noisy fan 9 36 Noisy burner 9 3 7 Unstable or violent ignition 9 3 8 Other technical information 10 4 0 Replacing components 10 4 1 Replacing the printed circuit bo2. Check that the intake exhaust hoses are at least 2 metres long and that they are undamaged and correctly fitted at the boiler and flue if a wall flue is fitted 0 7 1 5 Check that the flue is free from objects that may obstruct the air circulation Check that the gas pressure to the boiler is correct 28 50 mbar Where the ignition is unstable remove the soft start valve and test start the boiler The start should now be stable but with a more violent ignition than normal Replace with a new soft start valve or clean the old one and carry out another test start Unscrew the nozzle and check that it is marked 230 Detach the ignition cable from the electronic ignition unit and start the boiler A clicking sound should be heard from the electronic ignition unit with a frequency of at least 2 Hz at 12 volts two clicks per second If the frequency is too low the ignition electronics must be replaced Check that the ignition cable is intact and that there are no short circuits along the cable Remove the burner and check that the spark electrode is correctly fitted see fig 6 and undamaged Replace adjust if necessary Using a leakage tester for example check that no gas is passing through the boiler when it is switched off If a leak is discovered check that all gas connections are tight If there is no noticeable external leakage replace the solenoid valve 3 8 OTHER TECHNICAL INFORM
3. Resetting time too short The pressure switch does not cut out Fault in electronic ignition unit Faulty wiring Faulty printed circuit board Action Reset the electronic ignition unit by switching off the boiler on the control panel the red LED goes out and wait at least 30 seconds before attempting a restart Check that the pressure switch cuts out There should be 12 V on the white cable connection no 1 on the pressure switch fig 4 A If there is no voltage replace the pres sure switch Replace the electronic ignition unit Check that the wiring connections are intact and correctly fitted Replace the printed circuit board with a new one 3 2 2 NO IGNITION SPARK Cause Check that the changeover switches on the control panel are in the correct positions see the boiler operating instructions The 12 V fuse has blown The overheating protection device has tripped The red LED on the control panel is lit shut down No or low voltage on the boiler lt 12 V The operating thermostat is broken damaged The pressure generated by the fan is too low The pressure switch does not come on The printed circuit board is damaged Faulty electronic ignition unit Faulty wiring Action Check that the 12 V fuse see fig 1A is intact Reset the electronics by switching off the boiler on the control panel the red LED light goes out and wait approx 20 30 seconds be
4. 6 4 WIRING DIAGRAM WITH CONTROL PANEL 3000 565 WITH AUXILIARY FUNCTIONS e CO omg Vo reen ned iude d V i ZO reng ie E i mm Fara cundo at suc bs p fire How s n gt arab wide Dy e P poly Hat Ee sil mredi once cord ri Fe beier S e Fi Beie tap on me an mra i Bh Pie Iesel Lock an He fet eed ef he Bee PL h i Dn Um oroz mds ep ar teg Bt urs beng 2 ee GK e E Ss ert Jee 1 aui l urmx a Fra cE hu E E Ba Tires gr m 2 4 eko ine Bars Da eech eg En don We 20 6 5 CIRCUIT DIAGRAM 12V AND 230 V si iul stel yet n d he DBL d db d hen DOES rg Bde Edu 3 Operoting thermostat fin immersion pipe Pressure switch Greenyellow Sensor 123456 TH Spark electrode 3000 92X 011017 bas vnlve 6 6 FLOW CHART 230 V 230 V 2kw alt 3kw 230 V 3kw R phase or 0 R phase or 0 Connection to Connection to 230 V mains voltage 230 V mains voltage R phase or 0 with RKK 3x1 5 mm R phase or 0 with RKK 3x15 mm fuse 10 alt 16A fuse 10 alt 16 elny Relay R Relay 2 Relay R R die 7 R Rel iControl voltage Control voltage Js Control voltage fv D 12V OC t 2 log Na DC IEN Controt voltage 112 DC D Control vo
5. 3000 25 9 0 Spare parts 26 9 0 Spare parts Roof vent Window Air intake Radiator The radiators which are fitted along the outer walls heat up the air which rises and warms the walls and furniture As the warm air rises it forms an air barrier which keeps the cold away from the windows The temperature inside the caravan is controlled by a 12 volt thermostat on the control panel 1 1 MAINTAINING THE HEATING SYSTEM Check the heating system s fluid level regularly in the expansion vessel The level should be approximately 10 mm above the min mark when the system is cold The heating system should be filled with a mixture of water and glycol For preference use high quality pre mixed glycol with inhibitor intended for use in aluminium heating systems If using concentrated glycol the mixture should consist of 60 water and 40 glycol If the heating system will be exposed to temperatures below 25 C the glycol content must be increased but not to more than 50 Any vessels used in handling the liquid must be spotlessly clean and the pipes in the heating system must be free of contamination This will prevent the growth of bacteria in the system The glycol mixture should be changed every second year since its ability to protect against corrosion for example will deteriorate The glycol content should be checked before topping up with new liquid This will ensure that the concentration of glycol in
6. Check that a clicking sound can be heard from the sole noid valves Check the valves one at a time by removing the flat pin contacts Replace if there is a fault Remove the soft start valve see the exploded diagram and attempt to restart If the boiler now ignites the soft start valve must be changed NB The boiler ignites a little harder without the soft start valve Remove the burner and check that the spark electrode is intact and correctly fitted see fig 6 Replace if neces sary Remove the nozzle and blow the nozzle and gas pipe clean Check the wiring contact points again Check that the exhaust cowl and the intake exhaust hoses are free from objects that may obstruct the air supply Flame sensor Fig 6 Spark electrode 2 5 3 5 mm Flame SIE Sensor electrode 3 3 THE LPG BOILER STARTS BUT GOES OUT AFTER APPROX 10 SECONDS RED LED COMES ON Cause The flame sensor cable is damaged Faulty electronic ignition unit Sensor damaged or incorrectly positioned Action Check that the flame sensor cable is intact and correctly connected The only way to check whether the electronic ignition unit is working is to change it and then check that the boiler is operating properly Remove the burner and check that the flame sensor is intact and correctly fitted see fig 6 Replace the flame sensor if necessary 3 4 THE LPG BOILER STARTS AND SWITCHES OFF AT SHORT IN
7. Is the fan working Voltage 8 8 9 2 V Current 0 4 0 6 A Pressure switch blue cable Voltage fan 8 8 9 2 V Fan Pressure switch white cable Circuit card Re 5 Panel 9 0 SPARE PARTS 1 3000 452 2 3000 409 Fan complete 9 V for 3000 92x 93x Fan complete 9 V for 3000 94x Packed in cardboard box with Allen key for impeller 1 3000 289 2 3000 168 Solenoid compl inc soft start valve Soft start valve 3000 516 Burner set including throttle plate Replaces earlier models 3000 385 3000 408 and 3000 444 25 3000 407 Ignition kit incl spark electrode flame sensor cable grommet and gasket for all models 9 0 SPARE PARTS 1 3000 333 Printed circuit board 92x 94x with 3 kW 1 3000 365 heating cartridge 2 3000 334 Printed circuit board 92x 94x with 2 kW 2 3000 362 heating cartridge Operating thermostat Imit including retaining clip Overheating protection device Imit compl 1 3000 127 SIT pressure switch 1 3000 256 2 3000 157 Electronic ignition unit 2 3000 250 3 3000 471 Hose nipple with in built non return valve 3 3000 315 4 3000 290 Pressure release valve 26 Electrical heating cartridge 1 kW Electrical heating cartridge 2 kW Electrical heating cartridge 3 kW Alde International Systems Wrangels all 90 Box 11066 S 291 11 Farlov Sweden Tel 46 0 44 71270 Fax 46 0 44 718 48 www a
8. fig 7 A and brown R fig 7 B cables at the cable ports on the printed circuit board and remove the blue N fig 7 C brown R fig 7 D and red R fig 7 G cables from the electrical heating cartridge 3 Detach the white 15 point connection block fig 7 E from the printed circuit board 4 Remove the screw behind the connection block fig 7H 5 Remove the printed circuit board by pressing together the hooks on the 5 plastic spacers fig 7 F and pulling out the circuit board 6 Push the new board firmly into the spacers and connect the cables as shown in fig 7 7 Refit the service door and cover and test run the electrical heating cartridge Fig 7 10 4 2 REPLACING FAN 1 2 3 Remove the cover and the service panel from the boiler Disconnect the positive red fig 8 A and negative black fig 8 B cables on the fan motor Unscrew the plastic housing from the motor 2 screws fig 8 NB On boilers with wall flues 94x item 3 shall be ignored Unscrew the 4 plate screws fig 9 C securing the fan to the fan housing Tilting the fan towards the boiler body lift it upwards out of the fan housing see fig 10 Fit the new fan by following these instructions in reverse NB Take care not to damage the impeller when fitting the fan Fit the service panel and lid and test run the boiler NB a small number of boilers the gas pipe is fitted in such
9. old heating cartridge was Then fit the new heating cartridge Before fitting Fig 22 it check the direction of the T screw push the heating cartridge in and turn the T screw a quarter turn Then pull the nut so that the T screw comes into the correct position the screw should be at the same height as the cable connections Tighten to 4 Nm Check that the T screw projects 15 18 mm from the nut otherwise there is a risk that the T screw is not in the right position 14 4 8 REPLACING THE OPERATING THERMOSTAT 1 Remove the cover on the boiler 2 Remove the locking clip fig 24 A Remove the split pin fig 24 B on the immersion pipe Remove the overhea ting protection device sensor first fig 25 and then the operating thermostat sensor fig 26 A 3 Unscrew the two screws which secure the operating thermostat fig 27 A to the fastening plate and remove the cables from the flat pin connections 4 Transfer the contact spring fig 26 B to the new opera ting thermostat The spring must be fitted with the rear end of the bulb uppermost so that it pushes the sensor downwards into the immersion pipe 5 First insert the operating thermostat sensor all the way to the very end of the immersion pipe Then insert the overheating protection device sensor as far as possible Fit the split pin on the immersion pipe 6 Attach the operating thermostat to the service panel NB Use the original screws only and connect the cab
10. the new inlet plate and then put back the old one two screws 12 Remount the fan in reverse order NB Take care that the impeller does not get damaged during fitting Check that the fan does not make an unpleasant noise 13 With the boiler operating check the system and con nections for any leaks using a leak detector spray Once this is done fit the end plate and cover 4 4 REPLACING THE SPARK ELECTRODE When replacing the spark electrode also replace the flame sensor 1 Detach the burner as per instructions in 4 3 2 Remove the nut fig 13 A and pull the spark electrode fig 16 B straight backwards 3 Fit the new spark electrode and secure it Check that the distance between the tip of the spark electrode and the mesh cover of the burner is 2 5 3 5 mm and that the spark electrode is correctly positioned see fig 6 4 Fit the burner in accordance with instructions and test start the boiler 4 5 REPLACING THE FLAME SENSOR When replacing the flame sensor also replace the spark electrode 1 Detach the burner in accordance with 4 3 2 Remove the nut fig 13 C and pull the flame sensor fig 13 D straight backwards 3 Fit the new flame sensor ensuring that the tip of the flame sensor is positioned above the burner in accor dance with fig 6 Secure the flame sensor 4 Fit the burner in accordance with instructions and test start the boiler Fig 13 Aide 4 6 REPLACING THE SOLENOID VALVE For b
11. 132 3000 231 3000 232 3000 157 7410 325 3000 286 2762 125 3000 351 3000 131 3000 261 3000 330 3000 333 3000 334 3000 367 3000 184 3000 327 4071 011 3000 460 3000 251 2959 120 3000 290 3000 143 3000 166 Ignition kit compl Burner compl SIT pressure switch Overheating protection device compl Operating thermostat compl Casing Insulation Front end plate Grommet Plastic spacer Electronic ignition unit Self tapping screw 2 9x25 Mains supply cable Cable clamp Service panel Rear end plate Insulation Printed circuit board for 921 Printed circuit board for 3 kW heating cartridge Printed circuit board for 2 kW heating cartridge Wiring loom for 230 V Wiring loom opring Retaining clip Boiler body compl Insulation T piece Pressure relief valve Pipe Fuse 2A 8 0 GUIDE FOR FAULT FINDING ON COMPACT 3000 Neither electricity nor gas working Is the pump working Overheating Fuse protection 2A Thermostat Circuit card Thermal fuse 88 C Circuit card Re 7 Panel Panel Guide for faultfinding on Compact 3000 Only gas not working Only electricity not working Voltage 230 V Circuit card Re 2 3 4 Panel Red light emitting diode lit Is the fan working Pressure switch does not return Ignition electronics click in gas valve ignition spark Sparking plug Sensor pin Gas supply 24
12. 17 6 3 WIRING DIAGRAM WITH CONTROL PANEL 3000 465 WITH AUXILIARY FUNCTIONS Current 12 OC from battery KZ only s 12V OC fro rectifier mss lemote control of bailer 7 Timer tfipn sFondorqn oF tier ES Separate panel 52 arate relay for e tl Night time reducer ILL lt 230 circwatian puma 1 Be D 230v inon s tondar P214 Ds mn d A T Roo bia revl SS ER en 5 Laip 1 2 Pis P25 Vi pu 7 o t tw lexternat sensor non standard res 2A L F2 216 P26 Bic Fusible cut out e e BT P10 14 Re 6 without pump aw temp amp thw 4 Overhegtin pump Low temp f d protection Device lt oh Jp immersion pipe 1 bk F er 202 10 15 c b H yke 6 D amp KI Reduce voltage drop Pt short circuit fan 3 ol Operating thermostat in immersion pipet Re 2 i _ 0 NAVAS EA Am 9 I D We T 20 Ste 2 03 8 Exclusive 03 at 3kw Ba Fon PO 10 AD PES Voltage stabilisation I1 2 Safety connector pressure switch Spork electrode Sensor ES 5 82 pog 1 P10 8 TE D Bas 08 MARK v P40 5 12 4 fos valve Electronic ignition circuitry p 3000 465 B 011017 19
13. ATION The electronic ignition unit may emit a slight high fre quency sound during operation Boiler models 3000 92x and 3000 93x are intended only for roof flues Boiler model 3000 94x is intended only for wall flues Boilers with manuf no 10921 and higher have circuit board rev C which means that the fan does not start if the pressure switch is on and there is a new voltage stabilisation which handles lower voltages 10 V Boilers with manuf no 7536 and lower may have a fault in the fan that causes a whistling sound If there is a resonant noise on boiler model 3000 94x insulate the exhaust hose with insulation hose art no 1900 233 If the fuse F2 has blown the boiler should not be repai red but should be replaced with a new boiler Insulate the outer pin on the solenoid valve so that it cannot come into contact with the end plate If this should happen the electronics box short circuits and must be replaced n order to simplify operation and maintenance fitting automatic air bleeders on the installation can be recommended Aide 4 0 REPLACING COMPONENTS Always switch off 12 V DC and 230 V power supply and turn the main gas cock to off position before starting any servicing The seals marked in red must NOT be broken unless special permission has been obtained from Alde 4 1 REPLACING THE PRINTED CIRCUIT BOARD Remove the cover and service panel on the boiler 2 Detach the blue N
14. RIDGE DOES NOT WORK Cause Check that the changeover switches on the control panel are in the correct positions See operating instruction for boiler The 12 V fuse has blown No or low voltage to the boiler lt 12 V 230 volt not connected The overheating protection device has been triggered The thermostat is broken damaged Damaged printed circuit board Damaged electrical heating cartridge Faulty wiring or wire connections Action During faultfinding the hot water switch must be in the ON position and the power plug switched to 2 or 3 kW on the control panel Check that the 12 V fuse see fig 1 A is intact Measure the input voltage It must be no lower than 10 8 V Check that the 230 volt cable is connected and that the vehicle is connected to a 230 volt outlet Check that the overheating protection device has not tripped If necessary reset by first unscrewing the black protective cap then pressing down the reset button see fig 1 B When the overheating protection device has been reset there must be a 12 volt input on one flat pin terminal and 12 volt output on the other see fig 2 A otherwise it is defective and must be replaced If the overheating protection device has tripped it cannot be reset until the boiler has cooled 10 20 C Before the boiler is restarted check that it has been bled thoroughly Check that the operating thermostat is turned to the maxim
15. TERVALS Cause Voltage to boiler too low lt 12 V Poor contact point in the wiring earth fault Pressure switch damaged or incorrectly connected Ignition unstable Flue blocked Action Measure incoming voltage It must be no lower than 10 8 V Check the wiring connections particularly the earth con nections Check that both hoses between the pressure switch and the fan housing are connected see fig 5 Replace the pressure switch f the problem persists please refer to Unstable or vio lent ignition Check that the exhaust cowl and the intake exhaust hoses are free from objects that may obstruct the air supply 3 5 NOISY FAN Cause The fan motor is damaged worn Impeller out of balance Impeller touches fan housing Action Remove the fan and check whether the impeller has touched the fan housing wear marks on the fan hou sing necessary adjust the fan housing axially Replace the fan 3 6 NOISY BURNER Cause Whistling sound from the burner on 92x 93x Change to burner 3000 516 3 UNSTABLE OR VIOLENT IGNITION Cause The exhaust intake hoses are too short The exhaust intake hoses are damaged or loose The exhaust cowl is blocked Incorrect gas pressure Blocked or faulty soft start valve Faulty nozzle Low spark frequency The pressure switch does not shut off or has stuck The solenoid valves are leaky Action
16. a way that the fan cannot be extracted without first removing the gas pipe Do not forget to check that the seal is tight Fig 9 4 3 REPLACING THE BURNER Applies to boiler models 3000 927 and later If the burner is replaced burner 3000 516 should be installed 1 Remove the cover and end plate from the boiler 2 Detach the spark electrode and sensor cables from the electronic ignition unit 3 Using two spanners unscrew the nut on the gas pipe fig 11 A between the burner and the solenoid valve fig 11 B 4 Remove the end plate with burner by slackening the screws fig 11 C on the burner housing 5 Pull the end plate with burner straight out of the burner housing fig 12 6 Fit the new burner insert it straight in and secure it via the end plate in the burner housing fig 11 C 7 Secure the gas pipe to the solenoid valve fig 11 and to the burner fig 11 A Remember to check that the cones are correctly fitted to the pipes Using two span ners tighten the nuts on the gas pipe to 7 9 Nm fig 11 8 Fit the ignition spark and flame sensor cables to the electronic ignition unit Fig 11 Aide NB Items 9 12 shall be ignored on boilers with manu facturing no 3000 9xx B and on boilers where burner 3000 516 is installed 9 Adjust the pressure switch screw 1 2 turn clockwise 10 Remove the as in item 4 2 and the under the inlet plate under impeller by removing the two screws 11 Install
17. ard 10 4 2 Replacing fan 1 0 ABOUT THE ALDE CENTRAL HEATING SYSTEM The central heating system uses two or three heat sources LPG boiler and a 230 volt electrical heating cartridge as well as an externally fitted heat exchanger for motor caravans The LPG boiler heating cartridge heats up a liquid mixture consisting of water 60 and glycol 40 With the aid of a 12 volt circulation pump which is located in an expansion vessel the warm glycol water mixture is circulated round the system through pipes and radiators Flue Radiator LPG boiler Compact 3000 Heat exchanger 2968 11 4 3 Replacing a burner new model 11 4 4 Replacing the spark electrode 11 4 5 Replacing the flame sensor 12 46 Replacing the solenoid valve 13 4 7 1 Replacing a 1 kW heating cartridge 14 4 7 2 Replacing a 2 kW heating cartridge 15 4 8 Replacing the operating thermostat 15 4 9 Replacing the overheating protection device 16 4 10 Replacing the pressure switch 16 5 0 Safety check 17 6 0 Wiring diagram with control panel 3000 266 18 6 1 Wiring diagram with control panel 3000 380 19 6 2 Wiring diagram for 3000 465 19 6 3 Wiring diagram for 3000 465 with auxiliay functions 20 6 4 Wiring diagram for 3000 565 with auxiliay functions 21 6 5 Circuit diagram 12 V and 230 V 21 6 6 Flow chart 230 V 22 7 0 Exploded diagram 23 7 1 Article numbers for exploded diagram 24 8 0 Faultfinding Compact
18. derneath with a screw Fit the new solenoid valve by following the instructions in reverse order Using two spanners tighten the nut on the incoming gas pipe to 25 30 Nm and the gas pipe to the burner to 7 9 Nm Remember to check that the bevels are cor rectly fitted to the pipes With the boiler operating check the system and connections for any leaks using a leak detector spray Fit the end plate and cover 4 7 1 REPLACING THE 1 KW HEATING aoa P WN CARTRIDGE Switch off 230 V power supply Drain the glycol mixture from the heating system Remove the cover and end plate Remove the fan in accordance with 4 2 Remove the cables from the heating cartridge Slacken the nut in the centre of the electrical heating cartridge electrode fig 17 Give the t screw on the heating cartridge a one quarter turn fig 18 Extract the heating cartridge by pulling straight back wards fig 19 Clean around the edges where the old heating cartridge has been located 10 Then fit the new heating cartridge give the t screw a one quarter turn and tighten the nut NB Before fitting the heating cartridge check the direc tion in which to turn the t screw Fig 17 13 Aide NB Check that the rubber plug is fully inserted and push the lower edge of the heating cartridge while tigh tening the nut Tighten the nut to 4 Nm 11 Connect the cables according to fig 20 A brown B b
19. e Check whether the pipes and radiators all around the caravan are warm If air still remains in the system try the following The LPG must be switched on and the circulation pump switched off Lower the front of the caravan as far as possible using the jockey wheel Leave it in this position for several minutes to allow any air to rise to the highest point in the system Open the bleeder screw at the highest point and keep it open until all the air has escaped Raise the front of the caravan as high as possible using the jockey wheel and repeat the process Return the caravan to a horizontal position and start the circulation pump Check that the heat is circulating all around the caravan When bleeding a bogey wagon or a motor caravan it is easier to park on a steep slope or raise the vehicle using a jack 2 0 ABOUT THE COMPACT 3000 The set up of the boiler The boiler consists of three eccentrically fitted pipes The innermost pipe is a heat exchanger made from extruded aluminium This is surrounded by a water jacket containing a 40 glycol mixture which is the fluid for the heating system The fresh water heater is located outside the water jacket The two outer pipes as well as their ends and connections are made from stainless steel The heat exchanger is divided into two semi circular parts by a u shaped baffle plate The burner is located in the upper semi circle the combustion chamber The baffle plate leads the flue gase
20. entry 3000 380 011017 P2 8 F1 Fuse 2A Pump 12 V A P92 QW Re 1 F2 S Bic Fusible cut out DA 87 C 01 de ER verheatin q Re 6 without pump low temp amp Ikw protection device in immersion pipe SA Ir EE Sei 75 P10 2 P10 15 21 gt Dd GE Reduce voltage drop E 3 z E AA short circuit fan P10 1 Operating thermostat in immersion pipe j Re 2 NE A Step 1 Re Step 2 AY A Safety connector pressure switch Spark electrode Sensor St C 6 Gas valve a 2 bk Electronic ignition circuitry RAE 3000 380 011017 18 6 2 WIRING DIAGRAM WITH CONTROL PANEL 3000 465 F Fuse 2 F2 Pi P26 int cut out 2 ooa PIG 14 Re 6 Without pump low temp amp ku 2 verhientin pump A ii protection device j VN top Jm immersion pipel h NE a P 210 15 e D Reduce voltage drop A short circuit fan 201 p03 m Pe Operating thermostat Voltage stabilisation Ch ue Pressure Switch safety connector pressure switch Spark elecirode PO a 3 82 Sensor Re 5 Tt e 7 2 1 pop D eg P13 p PQ 08 EI w eos 245 Gas valve ANAS aes Electronic ignition circuitry 3000 465 0110
21. fore attempting to restart If the red LED comes on again please refer to section 3 2 1 The LPG boiler shuts down on start up Check the incoming voltage is must be no lower than 10 8 V Check that the overheating protection device has not trip ped If necessary reset by first unscrewing the black pro tective cap then pressing the reset button see fig 1 B When the overheating protection device has been reset there should be a 12 volt input on one flat pin connector and a 12 volt output on the other see fig 2 A otherwise it is defective and must be replaced The overheating protection is broken if there is 12 volt on only one cable NB If the overheating protection device has tripped it cannot be reset until the boiler has cooled by 10 20 C Before the boiler is restarted check that it has been bled thoroughly Check that the operating thermostat is turned to the maxi mum clockwise position see fig 1 C continue page 8 Fig 4 Fig 5 1 Hose fitting on press cast burner housing shiny smooth surface Fig 5 2 Hose fitting on sand cast burner housing dull rough surface Check that there is voltage 12 V on flat pin terminal 12 grey cable low temperature and terminal 22 blue cable high temperature see fig 2 If there is no voltage on terminals 12 and 22 but there is voltage on terminal 11 red cable the operating thermostat must be repla ced C
22. heck that the hoses fig 5 1 or 5 2 between the fan housing and pressure switch are intact and correctly fitted Check that the voltage to the fan is at least 9 volts 0 2 and that no abnormal noise can be heard At 9 volts the current consumption shall be approx 0 4 0 6 A In the event of a fault change the fan Check that the pressure switch is making a clicking noise 2 5 seconds after the fan has started or check that there is voltage on the flat pin terminal of the blue cable con nection no 2 see fig 4 B If the fan does not start check that there is 12V in both the red and white cables If there is 12V only in the red cable the pressure switch should be replaced Check that the wiring connections are intact and are cor rectly fitted Replace the electronic ignition unit If this has no effect replace the printed circuit board 3 2 3 IGNITION SPARK IS GENERATED BUT THE BOILER DOES NOT START Cause Noor poor gas supply No or faulty spark on the spark electrode The solenoid valves do not open Faulty soft start valve Faulty electronic ignition unit Nozzle blocked Faulty wiring Flue blocked Action Check that the gas pressure to the boiler is correct 28 50 mbar Check that the ignition cable is intact and that there are no short circuits along the cable Check when starting that voltage is being supplied to the solenoid valves If not replace the electronic ignition unit
23. lde se info alde se Service 3000 Rev 921 GB
24. les in accordance with fig 2 blue grey and two red 7 Fit the cover and test run the boiler Fig 24 15 4 9 REPLACING THE OVERHEATING PROTECTION DEVICE 1 Remove the cover on the boiler 2 Remove the locking clip fig 24 A Remove the split pin fig 24 B on the immersion pipe and take out the sensor fig 25 3 Remove the black plastic cap and unscrew the nut fig 27 B which holds the overheating protection device to the service panel Release the cables fig 2 A from the flat pin contacts and change the overheating prote tion device 4 Fit the new overheating protection device by following the instructions in reverse order Test run the boiler 4 10 REPLACING THE PRESSURE SWITCH 1 2 3 Remove the cover and end plate from the boiler Detach the blue white and red cables on the pressure switch Push back the metal securing plate and pull out the pressure switch fig 28 A Detach the rubber hoses fig 28 B from the pressure switch do not pull the hoses unscrew them Refit the hoses to the new pressure switch before pushing it into place Fasten the pressure switch and fit the cables to the flat pin contacts in accordance with fig 28 Fit the cover and end plate to the boiler Test start the boiler Fig 28 16 5 0 SAFETY CHECK The safety check must be carried out after every service Check That the intake exhaust hoses and flue are
25. ltage d d d d Control voltage 12V DC 230V 3000 333 011017 21 7 0 EXPLODED DIAGRAM 22 7 1 LA 19 20 21 22 23 24 25 26 27 28 oe oe ARTICLE NUMBERS FOR EXLODED DIAGRAM 3000 133 2900 258 3000 195 3000 452 3000 409 3000 247 3000 372 3000 297 3000 324 2930 414 3000 196 3000 196 11 12 13 14 15 16 17 18 3000 196 3000 196 3000 138 3000 168 3000 289 3000 278 2737174 3000 256 3000 250 3000 315 3000 255 3000 240 3000 159 3000 528 3000 204 3000 213 3000 206 3000 501 3000 205 3000 383 2930 235 Metal cover Self tapping screw B6 x 9 5 Fan compl for 921 Fan compl for 92x and 93x Fan compl for 94x Insulation Double clip Rubber cap Double clip Sleeve Rubber hose L 190 mm Rubber hose L 55 mm Rubber hose L 330 mm Rubber hose L 110 mm Soft start valve Solenoid valve compl Gas pipe Screw M4x8 Electrical heating cartridge 1 kW Electrical heating cartridge 2 kW Electrical heating cartridge 3 kW Blind plug for electrical heating cartridge Plug Pipe Nozzle compl End plate Gasket Flame sensor Burner Spark electrode Nut Cable grommet 23 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 3000 407 3000 516 3000 127 3000 362 3000 365 3000 185 3000 246 3000
26. lue C yellow green Fit the cover and end plate Add glycol mixture Bleed and test run the boiler Fig 19 Aide 4 7 2 REPLACING THE 2 KW HEATING CARTRIDGE 1 Switch off 230 V power supply 10 Any angle bracket should not be fitted Fit the solenoid 2 Drain the glycol mixture from the heating system valve in accordance with the instructions Connect the 3 Remove the cover and end plate cables as shown fig 23 A brown B blue C yellow 4 Remove the burner together with the solenoid valve fig green D red Fit the cover and end plate Add glycol 21 Do not slacken the gas pipe this is in order to avoid mixture Bleed and test run the boiler having to check sealing 5 Remove the cables from the heating cartridge 6 Slacken the two plate screws and remove the sup porting angle bracket from the heating cartridge does not apply to boilers with serial numbers of 4445 or higher 7 Slacken the nut in the centre of the electrical heating cartridge electrode and unscrew it approximately 10 mm fig 22 8 Tap the nut lightly to release the rubber plug and extract the heating cartridge by pulling straight backward If there is a T screw on the heating cartridge the screw has a groove the nut must be unscrewed sufficiently for the T screw to be turned a quarter turn before the heating cartridge can be pulled out NB Leave the nut on the screw with several turns of thread in it 9 Clean round the edges where the
27. oilers with serial no from 04445 and upwards 1 Remove the cover and end plate on the boiler 2 Unfasten the cables black brown and yellow green on the solenoid valve fig 14 3 Using two spanners slacken the nuts on the incoming gas pipe fig 15 A and the gas pipe to the burner fig 15 B and remove the rubber cap from the soft start valve fig 14 D 4 Extract the solenoid valve fig 16 and fit the new one by following the instructions in reverse order 5 Using two spanners tighten the nut on the incoming gas pipe to 25 30 Nm and the gas pipe to the burner to 7 9 Nm With the boiler operating check the system and connections for any leaks using a leak detector spray 6 Fit the end plate and cover For boilers where the solenoid valve is fitted to the burner housing up to serial no 04444 1 Remove the cover and end plate on the boiler 2 Unfasten the cables black brown and yellow green on the solenoid valve fig 14 A C Using two spanners slacken the nuts on the incoming gas pipe fig 15 A and the gas pipe to the burner fig 15 B and remove the rubber cap from the soft start valve fig 14 D Detach the pressure switch hoses to and remove the insulation next to the burner housing Unscrew the two plate screws which fasten the gas valve angle bracket to the burner housing Extract the solenoid valve and transfer the angle bracket to the new solenoid valve attached un
28. s back into the lower part of the section which constitutes the convection part The burner unit is fitted on the end of the heat exchanger It consists of a combustion fan burner solenoid valve with built in relief valve and intake exhaust connections The exhaust gases escape through the inner tube and fresh air enters through the outer tube The exhaust fumes exit the vehicle via a hose and flue fitted either to the roof or to the wall Fresh air enters via the same flue balanced draft 2 or 3 electrical heating cartridges are fitted to the upper part of the water jacket The output of the cartridges is either 2x1 kW or 3x1 kW alt 2 1 kW depending on boiler model Thermostat box Overheating protection Fan Solenoid valve 2 1 TECHNICAL DATA Measurements Height Width Depth Boiler size 300 mm 345 mm 490 mm Rec Min install dimensions 310 mm 400 mm 550 mm Weight 6 5 kg Gas Gastryck 28 30 37 mbar 1 30 mbar 1 50 mbar Output Propane 5 2 kW Output Butane 6 0 kW Consumption Propane 380 g h Consumption Butane 430 g h Electronics When the room thermostat calls for heat i e the temperature in the vehicle is lower than the set room temperature the circulation pump starts The liquid in the heating system then starts circulating and cold liquid enters the boiler The boiler s operating thermostat senses that the temperature of the liquid is too low A signal is sen
29. t to switch on the fan When the pressure in the pressure switch is sufficiently high a signal is sent to the electronics box to generate an ignition spark and to open the solenoid valves to allow gas to enter the system Once the temperature in the vehicle has reached the temperature set on the room thermostat the circulation pump stops The operating thermostat senses that the liquid has reached the right temperature and the boiler is switched off When the temperature of the liquid has fallen a few degrees again the boiler restarts This ensures that there is always hot liquid available when the room thermostat calls for heat and that the fresh water in the boiler is always warm An electrical heater works in the same way but the signal from the thermostat is sent to the relays which start the electrical cartridges How the boiler works Water jacket glycol mixture Hot water jacket fresh water Electrical heating cartridges Pressure switch Burner Liquid volume Pressure Liquid volume glycol mix 4 1 liter Liquid volume fresh water 8 4 liter Max pressure heating system 0 5 bar Max pressure fresh water 3 0 bar 230 V Output electrical cartridge 2 KW 105041050 W Output electrical cartridge 3 KW 1050 1050 1050 W 12 V DC Current consumption 1 amp max incl circ pump Fuse 2 amp BE AWARE OF THE RISKS OF 230 V DURING ALL SERVICE WORK 3 0 FAULTFINDING Fig 1 3 1 THE ELECTRICAL HEATING CART
30. the mixture is not too high If the fluid level in the expansion tank falls for reasons other than evaporation check all joints drain cocks and bleeder screws to ensure that they are not leaking If the glycol water mixture leaks out rinse with water and wipe up Never allow the heating system to stand empty of glycol fluid Filling pump Art no 1900 811 Adding liquid Ensure that the vehicle is standing level and check that the bleeder screws and drain cocks are closed Release the plastic nut on the circulation pump located on the expansion vessel and lift out the pump Pour the glycol mixture slowly into the expansion vessel using a watering can When the system is being filled air pockets may form depending on how the pipe system has been installed A good indication that there is air in the system is when the heat only travels a few metres along the pipe from the boiler despite the fact that the circulation pump is operating To make refilling and bleeding easier we recommend using the Alde filling pump which quickly both fills and bleeds the system automatically Bleeding a caravan heating system manually The LPG boiler must be switched on and the circulation pump switched off Start by opening the bleeder screws please refer to the vehicle instruction book for their location Leave them open until liquid escapes through the spout at the air screw Switch on the circulation pump and let it run for a whil
31. tight and undamaged That the LPG pipes are tight Pressure test the system That the 230 V earth cable is connected That the safety valve on the water heater is not blocked That the heating system is filled with glycol mixture up to the mark on the expansion vessel 6 0 WIRING DIAGRAM WITH CONTROL PANEL 3000 266 Front of panel CO 0 0 Cable Rear of panet As seen from cable entry Coble no 12 B 3000 266 01101 Pump 12 F4 Fuse 2 21 oz P92 a F2 Bir Fusible cut out 98 Re 6 without pump low temp amp kw Overheatin protection oe NA in immersion pipel SA ME ST P102 Re 6 D Re 7 Reduce vottage dra M 21 22 pou CD ge drop P10 14 A 2 o short circuit fan P103 oC P10 1 Operating thermostat lin immersion pipe Re 2 _ 0 NM VS Re 3 Step 1 P212 P112 AAA ni a e PV 2 15 115 Voltage stabilisation Spark electrode gt 12 Safety connector pressure switch P211 P111 i Se d Gas valve Electronic ignition circuitry el 3000 266 011017 17 6 1 WIRING DIAGRAM WITH CONTROL PANEL 3000 380 Frant of panel Rear of panel OJ COMPACT 3000 5 seen from le
32. um clockwise position see fig 1 C Check that there is voltage 12 V on flat pin terminal 12 grey cable low temperature and terminal 22 blue cable high temperature see fig 2 If there is no voltage on terminals 12 and 22 but there is voltage on terminal 11 red cable the operating thermostat must be repla ced Check that there is voltage on pos 9 on the P1 printed circuit board see fig 3 If not the printed circuit board must be replaced Check that there is voltage on pos 12 and 15 on the P1 printed circuit board see fig 3 If not there is a fault in the wiring or on the control panel Check the resistance of the electrical heating cartridge approx 50 ohm for 1 kW and 25 ohm for 2 kW and the insulation to earth gt 1 Mohm In the event of a fault replace the cartridge Check that the wiring connections are intact and correctly fitted If none of the above measures solves the problem replace the printed circuit board The fault will lie in the control relays for 12 230 volts 3 2 THE LPG BOILER DOES START Initial check Disconnect the ignition cable from the electronics box and start the boiler The electronics box should make a clicking sound for about 10 seconds If you can hear the clicking continue to section 3 2 3 Ignition spark is gene rated but the boiler fails to start 3 2 1 THE LPG BOILER SHUTS DOWN ON START UP Red LED comes on immediately Cause
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