No fault registering but no hot water?!

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No fault registering but no hot water?!

Post  Carney on Tue Oct 09, 2012 11:02 am

I seem to have a huge problem!
I have a Gledhill Pulsacoil 'A' Class APA4140, serial number: 0751014053. This unit has been in my home since it was built 4 years ago and over the last 3 months has developed this fault.
It seems as though the pump is constantly running but isn't producing any hot water.
On the front control panel there isn't even a flashing red light to indicate there's a problem.
The front of the unit has been removed to gain access to the appliance control board. The 2 digit display, according to the instruction booklet tells me that on the digital display 2, i have 'on peak supply present', 'S5 sensor (bottom) calling', and 'off peak supply present. The little light in the corner is flashing on its own stating the system is running normal
Display1 states 'off peak heater on' and 'DHW pump on'. The little light in the corner of this display is not flashing at all!
When S2 is first pressed i get a flashing S1 then 30, if i press S2 again i get S1 then 70, pressed again, C0 then 44, pressed again, a lower case c0 then 44.
I've had the fuses checked in the wall mounted sockets, the relays click (presume they're ok if they're clicking), the on & off peak immersion heaters checked, the pump checked & bled, disconnected the temperature sensor, cold water sensor and reconnected. Doing this did make it alarm out indicating a fault but still no joy obtaining hot water.
Cistern above it has never ran low and is still at the correct level.
I've left it hours upon end in hope of having hot water but never any luck.
The off peak boost button has never worked but really cant see that being the issue.
I'm not quite sure what else to do!
I'm no plumber or electrician so would appreciate some suggestions or someway to rectify this problem without the extortionate costs of ringing Gledhill themselves or calling out a plumber if it's something i can resolve myself.
Please help!

many thanks, Lee

Carney

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Re: No fault registering but no hot water?!

Post  mike on Tue Oct 09, 2012 5:39 pm

Well Lee,
Have you the manual?
If not down load one for free at Gledhill's website.
You have some fault codes showing up.
Read a bit more and see what you can find.
Mike

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Re: No fault registering but no hot water?!

Post  Carney on Wed Oct 10, 2012 1:46 pm

Hi Mike,
Thanks for the reply
Yes, i do have a copy of the manual & apologize for not stating it previously.
I've had a read through and on page 24 where the fault codes are, from what i can assume the problem is code 44 'S2 overheat 2 open'.
I'm not going to act as though i know exactly what this means because i don't!
Would i be right in thinking that it might be the overheat thermostat on the circuit board (big blue box) or the common fault of the 2 large relays situated to the left of the circuit board?



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Re: No fault registering but no hot water?!

Post  mike on Wed Oct 10, 2012 2:21 pm

No it is the overheat sensor.
Look at the beginning of the book ref sensors
Mike

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Re: No fault registering but no hot water?!

Post  Carney on Wed Oct 10, 2012 2:46 pm

Something as simple as the S1/S2 thermistor?

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Re: No fault registering but no hot water?!

Post  mike on Wed Oct 10, 2012 3:13 pm

Well 44 is the over heat sensor.
So a starting point.
Is it the sensor?
Or why has it worked?
Mike

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Re: No fault registering but no hot water?!

Post  mike on Wed Oct 10, 2012 3:14 pm

If it was older I would renew all those 3 sensors on the left hand side.
Mike

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Re: No fault registering but no hot water?!

Post  Carney on Wed Oct 10, 2012 3:48 pm

Well according to the manual, the top sensor would theoretically kick in if the middle or bottom sensor were to fail when becoming overheated.
I had checked the off & on peak immersion heaters for there resistance and voltage this evening. the off peak being 18.9 ohms & 240v, the on peak 19.4 ohms & at 8.4v.
I haven't a clue about these things but surely if the voltage rating was pretty much non exsistant for the on peak, that would mean S6 would need replacing right?

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Re: No fault registering but no hot water?!

Post  mike on Wed Oct 10, 2012 4:05 pm

Well that sensor code 44 is open.
So the sensor is faulty.
It is nothing about the heaters.
It is the sensor.
Could be 1 of the 5 relays but normally a different fault code would appear.
And that code does not tell you which relay.
Now were you in the cupboard when the failure happened?
And one more thing to remember that the fault code could be an old one.
The ACB hold them until 16 fault codes then they get dropped off.
So when I have any unit which gives me a code I try to remember to write inside the unit the code the fault and the date.
Not easy working on these units at times.
And I do them every day.
S6 would be 43 or 51 fault codes.
Let me know how you get on.
Mike


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Re: No fault registering but no hot water?!

Post  Carney on Wed Oct 10, 2012 4:29 pm

No, i wasn't in the cupboard when the failure happened but i've checked all of the fault code indicator block & lock outs and the fault code 44 has only occurred the once in both if that makes any sense?

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Re: No fault registering but no hot water?!

Post  mike on Wed Oct 10, 2012 4:39 pm

You say the DHW pump is running all the time.
Is the unit hot?
If it is not hot then then DHW pump will run to find some heat.
If the unit is hot and the pump is running then it could be sensor trouble. FAULT codes do not always tell you or show.
Or the Main ACB has gone down.
Try switching the unit off for a few minute then on. This can re boot them.
!; check water level 1st.
2; Is the unit hot.
3; You can always connect a temporary supply to the off peak heater.
4; The sensors all go to the ACB. The ACB is the brain which control temperature and the pump etc etc.
So if the unit is hot and all the signal are there.
Then ACB
Mike

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Re: No fault registering but no hot water?!

Post  Carney on Thu Oct 11, 2012 12:33 pm

hi mike
bit of an update today as i've just been tinkering!
I've swapped around the on & off peak relays. i also disconnected and reconnected the plug that has J3 next to it, the same to S1/S2, S3, S4, S5 & S6 whilst being switched on and doing this threw up a few codes.
I then switched unit off and waited a few minutes then switched it on to view the fault codes.
In the lock out fault codes i now have 23 and in the block out codes i called up code 44 (S2 overheat 2 open) again but also 37 (S1 overheat 1 open).
Strangely though, the unit is warming up, the dhw pump has switched off and it's sounds like its normal working status!
I'm not moaning but i feel it won't be long before i'm here asking the same questions again.
Do you have any idea as to what's going on?

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