BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

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BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  octane83 on Thu Jan 19, 2017 3:05 pm

Hi all, sorry for the long post but please bear with me.
I've scoured the topics on this forum to see if anyone has the same issues but have so far been unsuccessful. I'd appreciate some help as this problem is literally giving me sleepless nights!

System is a Gloworm 50ff coupled to a Boilermate 2000.

Issue 1 (fixed): LEDs 1, 2 and 3 randomly came ON (even when there was no CH demand and store was upto temp). This was fixed with a new ACB on the Boilermate 2000.
Issue 2 (fixed): PHE return sensor error, fixed with a new sensor
Issue 3 (partially fixed): LEDs 1 and 2 remain ON thereby demanding heat from the Gloworm 50ff boiler. The boiler was firing but not delivering water at a high enough temperature causing the desired store temps to not be met. This was investigated by checking temps of feed and return from boiler. The problem seems to have been fixed by replacement of the thermistor in the boiler, now the store temps are satisfied (around 72-76degC).

Issue 4 (NOT FIXED): This is the major issue and is driving me insane. There are 2 parts to this problem:
PART1: LEDs 1 and 2 remain ON irrespective of whether the store temp has been met, Store Temp Bar on LCD display is lit. Therefore BM2000 continues to call for heat and the boiler pump continues to run for hours on end. Eventually the store temp will fall below the lower set value, but the boiler does not fire, even though BM2000 continues to call for heat.
However if the room thermostat is set to a high enough demand, the boiler will fire (all of this time the LEDs 1 and 2 remain ON).

PART2: After several hours of running (5 hours this evening!), the boiler pump will eventually turn off, along with the call for heat. I suspect this is coincident with when the desired store temp range moves to a lower range i.e from 71-75degC desired the range shifts to 61-69degC, but the actual store temp is 75degC and this seems to cause the pumps and the call for heat to switch off. HOWEVER, Store Temp Bar is STILL lit on the LCD (indicating the store is not upto temp, even though it clearly is).
At some point during the night (usually around 3am) the store temp falls low enough for BM2000 to call for heat and start the boiler pump, this time the boiler fires, delivers heat and turns off after a while but the call for heat remains, alongwith boiler pump and does so for the next 2 hours atleast and so the whole cycle begins again............

The ACB has been replaced (twice) as it was thought that the first ACB may have been faulty (even though it was brand new).

I could really do with some help on this matter as every single boiler technician I have spoken to seems to be clueless about this unit and I've spent a small fortune getting it to this point! I'm now completely lost and don't know what to do.

Many thanks and sorry for the long post.

octane83

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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  mike on Sat Jan 21, 2017 11:06 am

Is the boiler a Micron?

Have you checked the fault codes on the BM 2000?
Store sensor?

I presume the boiler is on MAX
Is the boiler putting out 80c?
Is 80c reaching the unit?

I presume you have the jumpers on the ACB (1,3 & 4) ?

Have you tried re installing the ACB to the unit / boiler?

Mike

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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  octane83 on Mon Feb 13, 2017 6:27 am

Hi Mike apologies for the late response life got in the way! I still have the prpblem (been home all day and the pump has been running continuously today.

Have you checked the fault codes on the BM 2000?
There are no fault codes on the BM2000, there was one earlier for the PHE ensor but that has been replaced and the fault has gone.

Store sensor?
There is no fault relating to the store sensor thats showing on the BM2000 lcd screen

I presume the boiler is on MAX
Yes

Is the boiler putting out 80c?
Yes

Is 80c reaching the unit?
Yes

I presume you have the jumpers on the ACB (1,3 & 4) ?
Yes

Have you tried re installing the ACB to the unit / boiler?
Yes, twice and the board has been changed twice




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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  mike on Tue Feb 14, 2017 2:37 pm

Right
The bars / led display.

Example;

Put heating on timer / room stat
It will show on the display.
But if below 60c heating pump will not run.
It is showing an indication that it is on.

Hard with out seeing it.
Is the boiler a MICRON?

Sometimes the flow and return from the boiler to the unit can be part blocked.
Or even the left hand side of the BM can be blocked.
Email me and I will send you pictures of a BM opened up / exposed.

Mike

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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  octane83 on Thu Feb 16, 2017 1:39 pm

Hi Mike yes the boiler is a Gloworm MICRON 50ff

The store DOES get upto temp, originally the boiler output was quite weak at around 60degC and the store would never get to the requested set point. The boiler thermostat was replaced and this cured the issue.

The problem now is that the boiler pump almost never stops running.

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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

Post  mike on Thu Feb 16, 2017 3:11 pm

Well you need to get the unit up to temperature.
Check the codes etc.
You can read the temp setting on the ACB
Watch it rising up.

Check with a meter or test leads.

1 Has the boiler pump got a supply / voltage?

2 Has the boiler switched live (at the unit) giving a voltage reading.

Can you go through the fault codes ok?

Mike
MGC/H2O

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GT155 PCB Operation (simulated)

Post  mmartin on Tue Feb 21, 2017 3:05 am

Hi I this link is to a youtube video showing the basic operation of the GT155 pcb on a boilermate 2000 setup it might help you shed some light on what is or is not happening. As you know by pressing SW2 once you will see the store temperature and you can manipulate this by using a hair dryer or similar to artificially warm the store sensor once it is out of its pocket. This might aid diagnosis as you can make changes without waiting for the boiler to warm/cool etc. Once the store has reached the target temp. the boiler should switch off and after a few minutes of overrun (to remove residual heat from the boiler) the pump should stop (the store temp must stay in the target figure otherwise if it drops the boiler sill switch back on again). If artificially manipulating the store sensor it would probably be a good idea to temporarily turn the boiler off and just use the green LED's to see what is happening. Hope you get it sorted.

https://www.youtube.com/watch?v=EaRdpx5LFd4

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Re: BoilerMate 2000 calling for heat, boiler pump running all night, ACBs replaced twice!

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