Baxi Luna 3 Comfort User manual

Luna 3 Comfort
Troubleshooting Guide
For Technical Assistance Call: [phone]
June 2008

WARNING!
THIS DOCUMENT IS INTENDED ONLY AS AN
EDUCATIONAL TOOL
This Troubleshooting Guide, and the instructions and suggestions within are
intended solely as an educational tool assisting completely qualified Gas
Appliance Mechanics who have successfully completed the Baxi Installation
Certification Program.
Use of the information herein for the purposes of onsite appliance correction by
untrained personnel may cause extremely dangerous conditions, and may void
the manufacturer’s warranty.
Marathon International assumes absolutely no liability in the execution of the
training suggestions in this document. Should you experience problems or
complications beyond your realm of training, please contact Marathon
International for further instructions.
i

Resetting The Boiler
ii
There are two types of errors that can be found on the controller:
Fault and Block.
Fault:
If a fault occurs, the display shows symbols flashing with the writing <ERROR>.
The fault is identified by the error code followed by the letter “E” and is not resettable
unless the problem is corrected.
Block:
If a block occurs, the display shows the symbols flashing together with the <ERROR> and
<>>>OK> symbols alternating.
The block fault is identified by an error code (see the table below) followed by the letter “E”.
Press the OK button on the controller to reset the boiler. The display shows the
<RESET> writing followed by the >>>OK writing.

Increase
DHW max.
temperature
Reduce
DHW max.
temperature
On/off
Winter
Summer
selection
Comfort/economy
selection Automatic/manual/
Off/reset
Real/Set
room
temperature
display
Reduce
room
temperature
Increase
room
temperature
Temporary
Special function
Setting
(i.e. holidays,
presence,
shower setting)
Selection of
INFO mode /
Programming
mode
CONTROLLER
These buttons operate
accordingly when in the standard
operation mode. The buttons may
have different functions
depending on operation, and the
programming mode.
iii

CONTROLLER
FUNCTIONS
Types of Functions
• Normal functioning (RUN)
This level is what appears on the controller during normal operation.
• User programming (PROGR)
This level allows the user to set the clock, the date, temperature setpoints and time
programs.
• Advanced information (INFO)
This level allows the installer to set a group of advanced parameters and obtain a
sequence of advanced information on the system functioning.
The programming functions operate as follows:
1. To change from RUN to PROGR shortly press the IP button (on the display you should see the running inscription
<PROGR>) for two seconds then the time will appear.
2. To change from RUN to INFO press the IP button for 3 seconds (you should see the running inscription <INFO>)
appear.
3. To return from PROGR or INFO to RUN shortly press the IP button (you will see the running inscription < RUN>) for
two seconds and the screen will go back to normal.
iv

INFO MODE AND ADVANCED SETTINGS
• “HW O>” DHW inlet or storage tank temperature.
• “HW S^” Set-point water sanitary inlet. Value set up with buttons +/-
• “HW MX” Maximum setpoint sanitary circuit (max. setting value)
• “HW Mn” Minimum setpoint sanitary circuit (min. setting value)
DHW CIRCUIT
• “CH Sl” Maximum setpoint heating circuit, setting value with buttons +/- .
Notice: by pushing the comfort button it is possible to change the temp. value from °C to °F.
• “EXT°c” External temperature (with external connecting probe).
• “CH O>” Temperature water heating inlet pipe.
• “CH S^” Set-point water heating circuit.
• “CH MX” Maximum setpoint heating circuit (max. setting value).
• “CH MN” Minimum setpoint heating circuit (min. setting value).
HEATING CIRCUIT
To enter the Information and Advanced Setting modes it is necessary to press the IP button for at
least 3 seconds; the running words “INFO” should appear.
Once the running words appear, press the OK button to scroll through the parameters; when the
big numbers are blinking it is possible to modify the value using buttons +/- .
v

ADVANCED INFORMATION
• “PWR %” Power level/flame modulation (in %).
• “P BAR” Water pressure heating circuit (in bar).
• “F l/M” Water flow outlet sanitary circuit (in liters/min).
Advanced Functions
To setting the boiler’s parameters:
1. Press the IP button for at least 3 seconds
2. Hold the button and press the button
When the function is active on the display the F01 will appear and the value of the selected parameter.
3. Use +/- for scrolling through the parameters;
4. Use +/- for changing parameter values;
5. The new value is automatically saved after 3 seconds;
6. Press the IP button to exit.
vi

Advanced Functions
Default Value
Parameter
Number Description 310 Fi 1.310 Fi
1 Type of Boiler
10= Sealed Chamber 20= Atmospheric Chamber
2TypeofGas
00 = Natural Gas 01 = LPG
3 Hydraulic System
00 = Instantaneous Appliance
05 = Appliance with External Water Tank
08 = Heating Only Appliacnce
4 Programmable Relay 1 Setting
2 = Zone System (See Service Instructions)
5 Programmable Realy 2 Setting
13 = Cool Function (See Service Instructions)
6 External Sensor Programmable Input Setting
(See Service Instructions)
7 to 9 Manufacturer Information 0
10 Controller Installation
00 = Wall Mounted
01 = Not Used
02 =Boiler Front Panel Mounted
11 to 12 Manufacturer Information 0
13 CH max. Heating Output (0-100%) 100
0
0
4
2
08
0
10
vii

Advanced Functions
Default Value
Parameter
Number Description 310 Fi 1.310 Fi
14 D.H.W. max. Heating Output (0-100%) 100
15 CH min. Heating Output (0-100%) 0
16 Maximum Temperature Setpoint Setting
00 = 85ºC 01 = 45ºC
17 Pump Overrun Time
01 - 240 minutes
18 Minimum Burner Pause Time
(01-10 minutes( - 00 = 10 seconds
19 Manufacturer Information 7
20 Manufacturer Information 0
21 Anti-Legionella Function
00 = Disabled 01 = Enabled
22 Manufacturer Information 0
23 Maximum D.H.W. Setpoint 60
24 Manufacturer Information 35
25 Lack of Water Safety Device 0
26 to 29 Manufactuerer Information (Read Only Parameters – –
30 Manufacturer Information 10
31 Manufacturer Information 30
32 to 41 Diagnostics (See Service Instructions) – –
0
3
3
0
viii

Anomalies
The electronic PCB for the LUNA 3 Comfort is able to memorize the last 10 anomalies which have occurred.
Every anomaly has a counter which increases only if the same anomaly is consecutive; the same mistake non-consecutively is recognized as
new.
To see all the information of every single anomaly you have, go to the Advanced Functions and run down the list of parameters to F32.
Parameters F32 to F38 refer to volatile anomalies which means mistakes with no necessity to Reset (for example DHW probe mistake);
parameters from F39 to F41 refer to anomalies that need to be Reset (e.g. safety thermostat).
Mistakes
without
reset
F32
F33
F34
F35
F36
F37
F38
Mistakes
with
reset
F39
F40
F41
By using the OK button at each of these parameters you can read:
1. ANOMALY CONSECUTIVE NUMBER (F32 is the last one that occurred so it has a 00 value)
2. ANOMALY CODE (xxE – for example 06E, DHW NTC failure)
3. CONSECUTIVE EVENTS FOR THE SAME ANOMALY
4. TIME (days) PASSED FROM THE SIGNALLING (00 means “today”)
5. SYSTEM STATUS
6. SYSTEM PHASE
7. CENTRAL HEATING DELIVERY TEMPERATURE WHEN THE ANOMALY OCCURRED
By using this information you can keep a SERVICE CHART for the boiler.
ix

The system condition (STATUS) identifies the working method in which the boiler is at the moment of the anomaly:
00 Stand-by
01 Sanitary active
02 Calibration function
03 Heating active
04 Pre-heating active
05 Anti-freezing heating
06 Anti-freezing DHW
07 Post-circulation
08 Circulation for over temperature
The system phase identifies in which particular function the boiler is at the moment of the anomaly:
00 Stand-by
01 Pre-ventilation
03 Ventilation between first and second ignition attempt
04 First ignition attempt
05 Active operating
06 Stoppage
08 Second ignition attempt
11 Ventilation between second and third ignition attempt
14 Third ignition attempt
15 Post-ventilation
16 Ventilation for over temperature
Anomalies diagnostic
x

Baxi Luna 3 Comfort - Troubleshooting Guide 1
Error
Code Description Solution
01E Burner Lockout No Spark:
Check ground and polarity back to the circuit breaker
Ensure the boiler is on a dedicated circuit
Check for 120 V going to the spark generator
If there is voltage to the spark generator change the spark generator
If there is no voltage to the spark generator change the main control board
No Flame:
Ensure that all gas shutoffs are open and that adequate working gas
pressure is coming to the unit. 7 in. w.c. for NG and 11 in. w.c. for LP
Note: These pressures must be maintained while the unit is operating
Check for 120 V going to coils 1 and 2 on the gas valve
If there is voltage to the gas valve replace the gas valve
If there is no voltage to the gas valve replace the main control board
Flame Sensor is not sensing
Check polarity and ground from the boiler back to the circuit breaker
Check for 3-5 micro amps going to the board
If you do not have 3-5 micro amps try cleaning the flame sensor
Note: Do not clean the flame sensor using sandpaper as it may damage the
p
rotective coatin
g
.
Flame Sensor is Dirty
Check your venting to ensure you are not recycling products of combustion
Make sure you have the proper orifices in the unit and the controller is set to
the correct type of gas.
Weak Spark
Make sure you have 3-5 sparks per second and the boiler is grounded
Make sure the spark generator ground is fastened tightly to the mounting
bracket
If a weak spark persists follow the procedure outlined in the "No Spark"
section
Marathon International 2008

Baxi Luna 3 Comfort - Troubleshooting Guide 2
Error
Code Description Solution
02E Highlimit Safety Thermostat Check pump to make sure it is running and not ceased.
Check for restrictions
Make sure that all air is purged from the system
Take an ohm reading on the high limit sensor (0Ωindicates the sensor is closed, OL indicates the sensor is
open)
If an E110 error code persists change the high limit sensor.
03E Fan/ Flue Fault Ensure the venting is within the maximum venting length requirements
Check for obstructions in the venting and termination
Check gas pressure on the inlet test port of the gas valve and make certain there is less than 14" w.c.
Check for 120 V going to the fan
If there is 120V going to the fan and it does not turn on, replace the fan.
If there is no voltage to the fan replace the main control board
Check the flue venturi for any obstructions or melting
Ensure that there are no loose wires and that the pressure switch is opening and closing properly
Check the silicone tubes coming from the air pressure switch for kinks, melting and holes, make sure that the
low pressure opening at the back of the unit is not blocked.
05E Central Heating NTC Sensor
Fault
Take an ohm reading of the CH NTC sensor using chart A. If the sensor is out of calibration, replace the
sensor. If the sensor is workin
g
p
ro
p
erl
y
, re
p
lace the main control board.
06E Domestic Hot Water Fault NTC
Sensor Fault
Take an ohm reading of the DHW NTC sensor. If the NTC sensor is out of calibration replace the faulty
sensor.
Check for a resistor in terminals 5 and 6 on the M2 connector
(
Onl
y
for heatin
g
onl
y
boilers
)
If utilizing an indirect tank sensor, take an ohm reading using chart C. If the sensor is faulty replace it. If the
sensor is working ensure function F03 is set to 08. (For heating only models only)
If problem persists replace the main control board
Note: The DHW NTC sensor is in a wet well, shutoff the cold water inlet and open a hot water tap before
replacing the sensor.
Marathon International 2008

Baxi Luna 3 Comfort - Troubleshooting Guide 3
Error
Code Description Solution
10E Low Water Pressure Ensure all air is purged from the system and all shutoff valves are open
Check boiler and system for leaks
Ensure the pressure in the expansion tank is 11.6 psi
Fill the system between 1 and 1.5 bar on the pressure gauge.
If an 10E error code persists jump the leads on the low water cutoff. If the boiler fires up change the low
water cutoff switch.
Note: If the expansion tank is low on pressure pump it back up to 11.6 psi. If the expansion tank produces
water at the Schrader valve change the expansion tank.
11E Outdoor Temperature Sensor
Fault
Disconnect the outdoor temperature sensor and take an ohm reading using chart B. If the sensor is out of
calibration replace it.
If the Sensor is working properly replace the main control board.
25E Boiler Max Temperature
Exceeded
Check the pump to ensure it is not ceased
Check for restrictions
Ensure all air is purged from the system and all shutoff valves are open
98E Gas Valve Contact Relay/
Internal Error
Ensure no water got on or into the gas valve
If error code persists check for 120 V going to the gas valve coils, if there is 120 V going to both coils replace
the gas valve. If there is not 120 V going to the gas valve replace the main control board
99E Control Board Contact Relay.
Internal Error
Ensure that the boiler is operating on a dedicated circuit and is properly grounded
Check the polarity
Disconnect all external controls and connect them back up one by one. If the error code comes back while
connecting one of the controls check for faulty wiring and proper grounding of the control.
Check the grounds on the internal pump, gas valve and fan
Check for water on the board
No Code DHW is not hot enough Make sure the CH water is going through the plate heat exchanger and not into the CH loop
If it is going through the CH loop replace the paddles inside the diverter valve and clean the diverter valve
Clean the DHW plate heat exchanger
Check the DHW NTC sensor
Check your high fire gas setting using chart D
Ensure you have adequate incoming gas pressures
Marathon International 2008

Baxi Luna 3 Comfort - Troubleshooting Guide 4
Error
Code Description Solution
No Code Boiler Short Cycles/ Fluctuating
Hot Water
Check your low fire gas setting using chart D
Check to see if the modulating pin is broken
Make sure your heat load is adequate for the boiler
Make sure your boiler is running on the proper type of gas.
No Code Boiler makes a Squealing Noise Check that there is no more than 25% of the system volume of glycol in the system
Clean the diverter valve
No Code Boiler makes a banging noises Ensure there is no air in the system
Make sure the pump is moving
Make sure there is no restrictions
Marathon International 2008

Baxi Luna 3 Comfort - Troubleshooting Guide 5
Chart A NTC Sensor Chart B Outdoor Temperature Sensor Chart C Indirect Tank Sensor
Temperature vs. Resistance Temperature vs. Resistance Temperature vs. Resistance
Thermistor @ 25ºC Thermistor @ 25ºC Thermistor @ 25ºC
ºF ºC Resistance (Ω) ºF ºC Resistance (Ω) ºF ºC Resistance (Ω)
Open Open Loop Open Open Loop Open Open Loop
32 0 32,630 32 0 32,505 32 0 27,279
41 5 25,380 41 5 25,308 41 5 22,069
50 10 19,890 50 10 19,854 50 10 17,959
59 15 15,710 59 15 15,689 59 15 14,694
68 20 12,490 68 20 12,483 68 20 12,090
77 25 10,000 77 25 10,000 77 25 10,000
86 30 8,057 86 30 8,060 86 30 8,313
95 35 6,531 95 35 6,537 95 35 6,944
104 40 5,326 104 40 5,332 104 40 5,828
113 45 4,368 113 45 4,374 113 45 4,913
122 50 3,601 122 50 3,608 122 50 4,161
131 55 2,985 131 55 2,991 131 55 3,538
140 60 2,487 140 60 2,492 140 60 3,021
149 65 2,082 149 65 2,086 149 65 2,589
158 70 1,751 158 70 1,754 158 70 2,229
176 75 1,255 176 75 1,481 176 75 1,925
194 80 917 194 80 1,257 194 80 1,669
212 85 680 212 85 1,070 212 85 1,451
Chart D Gas Pressures
High Fire Low Fire
Natural
Gas 5.6" w.c. 0.7" w.c.
Propane 9.8" w.c. 1.3" w.c.
Warning: The modulating pin should only be turned a quarter turn at a time to avoid damage.
Avoid using magnetic screwdrivers on the modulating pin.
In the event your gas pressures are not increasing when you are adjusting the
modulating pin DO NOT continue to adjust the gas pressure as your incoming gas may
be to low.
Marathon International 2008