SERVICE MANUAL for CARDRONA MONACO Series 2 PICCOLO SOFIA MADRID GAS FIRES TO BE USED ONLY BY AUTHORISED PERSONNEL Part No 591402
CONTENTS TROUBLESHOOTING A. Ba. Bb. C. D. E. F. G. H. I. Page Pilot will not light after repeated attempts........................................................... 2 EIS fire won’t light after repeated attempts ........................................................ 3 ECS II fire won’t light after repeated attempts.................................................... 4 Spark OK, but pilot won’t light (not ECS II or EIS)...........................................
A — PILOT WILL NOT LIGHT AFTER REPEATED ATTEMPTS YES Is it an EIS or an ECS II model? EIS, EIS,go goto toBa: Ba:ECS ECSII,II,go goto toBb Bb NO Has it Battery battery ignition? YES Is Isthere thereaaspark sparkat at NO the theigniter? igniter? Replace battery, check battery contacts NO YES NO 1 Does the Piezo 'click'? Wiring OK Go to A3 NO YES Go to A3 Spark? Check switch wiring Switch OK Check switch at valve 52 Replace Replace Piezo, Piezo, gogo to to A1A1 YES 6 3 Is Is there there aa s
Ba — EIS FIRE WON'T LIGHT AFTER REPEATED ATTEMPTS Note: These fires have no standing pilot. The burner lights each time the heat is called for. When operating correctly, the spark ceases as soon as the main burner flame is established. FIRST:Check that the mains power supply and the gas supply are valid and that any gas valves are open. 1 2 Turn on the flame switch on the side of the fascia Fit jumper wire across thermostat terminals.
Bb — ECS II FIRE WON'T LIGHT AFTER REPEATED ATTEMPTS Note: These fires have no standing pilot. The burner lights each time the heat is called for. When operating correctly, the spark ceases as soon as the main burner flame is established. FIRST:Check that the mains power supply and the gas supply are valid and that any gas valves are open. 1 2 Press the ON/OFF button on the remote until MANUAL, AUTO, or PROG is showing.
C — SPARK OK BUT PILOT WON'T LIGHT (Not ECS II or EIS) FIRST :• Check that all shut-off valves in the gas supply are open. • For LPG models, check for gas in the bottle and open the bottle valve. • Check for a gas smell near the pilot, and wait for it to disperse before starting this procedure. 1 Press control down in 'Pilot' position and hold match flame at pilot Pilot Ignites YES 5 Wait several YES 8 Purge air from system until pilot ignites.
D — PILOT LIGHTS BUT WILL NOT REMAIN ALIGHT (Not ECS) Disconnect the valve control rod (and adaptor if fitted), and operate the valve directly.
E — STD HEATERS, PILOT ALIGHT BUT BURNER WILL NOT LIGHT WITHIN TEN SECONDS FIRST :• For an LPG heater, check that there is ample gas in the bottle. • For a Thermostat heater, verify that the sensor is not warmer than the temperature set-point.
F — THERMOSTAT HEATERS. MAIN BURNER WILL NOT LIGHT WITHIN 30 SECONDS. ON HEATERS FITTED WITH PILOT LIGHTS, THE PILOT MUST BE ALIGHT BEFORE THE THERMOSTAT CAN TURN ON THE FIRE. NOTE: When hand-held remote thermostats are set to MANUAL, they do not operate as thermostats but give direct control.
G — THERMOSTAT HEATERS. ERRATIC OPERATION ROOM TEMPERATURE FLUCTUATES TOO WIDELY Ensure that the wall thermostat or the temperature sensor in the hand unit is exposed to free-flowing room air but not in draughts or too close to windows. HEATER CYCLES ON AND OFF TOO FREQUENTLY Move the hand unit or the wall thermostat further away from the heater, ensuring that it is exposed to free-flowing room air but not in draughts or near windows.
1. CARDRONA & MONACO S2 ASSY AND DIS-ASSEMBLY 1.1 REMOVING THE GLASS 1. 2. 3. 4. 5. 6. 7. 8. 9. 1.2 Do this only while the heater is standing upright. Remove the louvre assembly by lifting it up about 5mm and pulling it carefully toward you. Remove the dress guard if fitted. For the Cardrona, first remove the front panel (below the glass). Do this by removing the two retaining plates underneath the front panel, and then lifting its rear corners off their support posts.
4. 5. 6. 7. 8. 9. 10. 1.2.2 1. 2. 3. 1.2.3 1. 2. 3. 4. 5. 1.2.4 1. 2. 3. 4. For safety, strap the glasses together with a piece of adhesive tape at each top corner to prevent them from falling out while the top trim is being fitted. Slide the top trim into position under its guides and replace the two horizontal retaining screws. Before tightening the screws, ensure that the three glass pieces are seated snugly against the top glass tape to prevent any leakage. Do not over-tighten the screws.
1.3 DISCONNECTING THE FLUE 1. 2. 3. 4. 5. 6. 7. 1.4 Shut off the gas supply at the valve behind the heater. Remove the access panel on the rear of the cabinet. Disconnect the gas line at the heater. Lift the flue sleeve about 75mm and support it with a wooden block. Slacken any flue clamp and lift the flue while moving the heater from beneath it. Slide the heater away from the wall, supporting the flue and trim on a suitable spacer. Keep the heater upright at all times to avoid displacing the logs.
1.6.4 1. 2. 3. 1.6.5 1. 2. 1.6.6 1. 1.7 REPLACING THE SIDE ACCESS PANEL Fit the holes in the top flange of the panel over the top locating pins. Pushing upward, swing the bottom of the panel in until the screw holes align. Replace the two screws. Do not overtighten. REMOVING THE PIEZO/FAN SWITCH ACCESS PANEL (Not ECS II ) Remove the screws securing the panel to the top rear of the cabinet. Lift the panel clear.
1.8 REMOVING AND REPLACING THE PILOT ASSEMBLY NOTE: EIS and ECS models have no pilot. The pilots fitted to the other models have top loading jets, so the jet can be removed without removing the pilot assembly. Pilot assembly removal should be rare. 1. Remove the burner, following steps 1 – 6 in Section 1.7. 2. Disconnect the Piezo wire, (the thermopile and thermocouple, if fitted) and the gas pipe to the pilot. 3. Withdraw the screws fixing the pilot assembly to the burner tray. 4.
1.11.2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1.11.3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. ACC MODELS Turn off the gas supply. Remove the access panels. See Section 1.6.1 and 1.6.3. Disconnect the gas pipe at the inlet to the control valve. See Drawing No 9 & 10. At the control valve, disconnect the pipes to the burner and the pilot. Disconnect the thermocouple connection to the control valve. Also disconnect the thermopile connection to the control valve. Disconnect the thermostat wires (if any).
2. PICCOLO, SOFIA & MADRID ASSY & DIS-ASSEMBLY 2.1 REMOVING AND REPLACING THE MADRID GLASS 1. 2. 3. 4. 5. 6. 2.2 Remove the top louvre assembly by lifting upward, then outward to clear the mounting pins. Release the bottom grille retaining screw by turning it one quarter of a turn anticlockwise. Swing the bottom of the grille out slightly, then lift it up off its mounting pins. If a dress guard is fitted, release it by springing out the clips which hook behind the vertical sides of the glass frame.
2. 3. 2.3.2 1. Confirm correct engagement by pulling forward gently on the top of the louvre assembly. To fit a bottom louvre assembly, fit it as for a top assembly, but make sure the retainins screw at the bottom engages with its clip and then push in on the head of the screw until it ‘clicks’. DRESS GUARDS (IF REQUIRED) Madrid: The guard is retained simply by clipping its retaining lugs between the glass and the steel frame at each side of the curved glass. Piccolo and Sofia: 1. 2. 3. 4. 2.
2.5 REMOVING AND REPLACING THE PILOT ASSEMBLY NOTE: EIS models have no pilot. The pilots fitted to the Piccolo have top loading jets, so the jet can be removed without removing the pilot assembly. Pilot assembly removal should be rare. 1. Remove the burner, following steps 1 – 6 in Section 2.4. 2. Disconnect the Piezo wire, (the thermopile and thermocouple, if fitted) and the gas pipe to the pilot. 3. Withdraw the screws fixing the pilot assembly to the burner tray. 4.
4. Before re-fitting the fascia, make sure the looms are connected to the switches correctly. BLUE FIRE: BLACK OFF ON BLACK YELLOW VIOLET BLACK RED 2.9 FIRE: HIGH LOW FAN: HIGH OFF LOW ACCESSING THE FAN 1. 2. 3. 4. 5. 6. 7. 8. Un-plug the lead from the mains supply. Remove the glass. See 2.1 and 2.2. Remove the logs and embers. Remove the screws holding the rear access panel to the inside of the back of the firebox.
3. SERVICE ADJUSTMENTS 3.1 GAS PRESSURE ADJUSTMENT — CARDRONA and MONACO S2 All pressure adjustments must be made while the heater is operating. Part or all of the right hand side panel of the cabinet may be removed to gain access to the gas valve. See ACCESS POINTS on page 11. GAS PRESSURES kPa ECS II ACC STD NG ULPG PROP NG ULPG PROP NG ULPG PROP High Pressure 0.9 2.0 2.0 0.85 2.2 2.2 0.85 2.2 2.2 Turndown Pressure 0.35 0.5 0.5 0.43 1.36 1.36 0.23 0.7 0.7 3.1.1 1. 2.
3.1.3 1. 2. 3. 4. 3.2 ECS II MODELS. These also have a pressure regulator in the control valve. The outlet pressure test point is on the top of the control valve and is the one furthest from the gas inlet connection. There are two pressure settings to adjust, high and turndown. Access to the adjusters is gained by first removing the heat shield above the valve and then removing the protective transparent cap at the top of the control valve modulating coil.
3. 4. 3.3 To set the turndown pressure, set the switch on the side of the fascia to LOW, and adjust the turndown pressure to the figure in the Table by rotating the central Phillips head screw, taking care not to shift the position of the already adjusted 10mm hex. nut. Screw in to increase the pressure. Be careful to use the correct screwdriver when making this adjustment as the head of the turndown pressure adjusting screw is easily damaged.
4 CONVERSION 4.1 CONVERTING CARDRONA STD and ACC FIRES 1. Remove the glass, logs, embers and burner. See section 1. 2. Remove the pilot jet (See 1.9) and fit the new pilot jet. (0.51 for NG, or 0.35 for ULPG and PROP). 3. Remove main jet (injector) from the elbow at the right end of the burner tray, and fit the new jet in its place. (2.96 for NG, or 1.8 for ULPG and PROP). Note.
6. 7. 8. 9. 4.3 Connect the gas supply and check all new joints for gas leaks. Adjust the high and turndown gas pressures as detailed in section 3. The pressures are:GAS PRESSURES - kPa NG ULPG PROP High Pressure 0.85 2.2 2.2 Turndown Pressure 0.43 1.36 1.36 Replace the side and rear access panels. Carry out a full test firing procedure as described in the installing and operating manual. CONVERTING MONACO S2 ECS II FIRES 1. 2. 3. 4. 5. 6. 7. 8. 4.
5. 6. 7. 8. 4.4 Connect the gas supply and check all new joints for gas leaks. Adjust the high and turndown gas pressures as detailed in section 3.2.1. The correct pressures are:GAS PRESSURES - kPa NG ULPG PROP High Pressure 0.75 2.1 2.1 Turndown Pressure 0.30 0.9 0.9 Replace the louvre assemblies. Carry out a full test firing procedure as described in the installing and operating manual. CONVERTING SOFIA and MADRID EIS FIRES 1. 2. 3. 4. 5. 6. 7. Remove the glass, logs, embers and burner.
6. ECS II INFORMATION 6.1 BASIC DESCRIPTION – MONACO S2 ECS II The main components are:The HANDPIECE. This is a battery powered radio frequency hand held remote control which gives complete control over all the functions of the heater. It can operate in three modes — MANUAL, AUTO and PROGRAM. In the MANUAL mode there is no thermostatic operation as the flame height and fan speed are selected as desired by the operator.
CONNECTOR CONNECTORS LOW MED HIGH IGN E WHITE BLUE RED BLACK GREEN WHITE BLUE RED BLACK GRN/YEL WHITE BLUE RED BLACK GRN/YEL FAN EARTH (Fan Box) FAN BOX CONTROL BOX ECS II FAN LOOM WIRING 7. EIS INFORMATION 7.1 BASIC DESCRIPTION The EIS system is an Electronic Ignition System which lights the fire each time heat is required. There is no pilot light, so economies in gas consumption can be significant. The basic system is illustrated below.
The THERMOSTAT should be mounted on a wall not too close to the heater, preferably not an external wall which might give misleading room temperature information. REMOVING THE CONTROL BOX.To remove the control box, extract the six pin fan plug at the rear corner and the nine pin plug on the front of the box, withdraw one screw securing the front of the box to the side of the firebox cabinet, pull the box toward you about 15 mm to disengage it from the clip at its rear end.
2. Switch the HI / LO switch on the fascia to HI. Check for 230 volts across 2 & 3 (or 5 & 6) in the control box. If dead, check the 5 - core loom and its connections between the control box and the switch cluster. If the voltage at 2 & 3 is OK, and the modulator coil resistance is correct, the modulator lead from the control box to the modulator coil is faulty. NINE PIN CONNECTOR SIX PIN CONNECTOR Fan loom Red Red Red White White Violet Brown Brown Y/Gn Y/Gn 8 7 2 4 14 10 Brown (6.
FURTHER WIRING DIAGRAMS FAN LOOM - Part No 590407 COVERS BLUE BLUE BROWN BROWN YEL/GN GREEN CONNECTORS WHITE BLUE BROWN BLACK GREEN EARTH POST (Cabinet) MAINS LEAD Part No 588068 FAN EARTH POST (Rear Panel) PICCOLO FAN WIRING DIAGRAM SWITCH CONNECTORS BROWN SIX PIN PLUG AND SOCKET ORANGE BRN BLUE CONNECTORS ORANGE RED BLUE WHITE RED BLUE GN/YEL GN/YEL BROWN WHITE BLUE BLACK GREEN FAN EARTH POST FAN ADAPTOR LOOM 590227 SWITCH LOOM 590226 MAINS LEAD 588068 FAN 586174 PICCOLO FAN W
DRAWING 1 IGNITER ASSEMBLIES USED ON: CARDRONA STD, ACC MONACO S2 ACC PICCOLO from March 2004, with no Thermopile bulb. USED ON EARLY PICCOLOS G.
DRAWING 2 GAS VALVES EIS MODELS USE A SIT 843 VALVE, SIMILAR IN APPEARANCE TO SIT 845 (Black Modulating coil — approx. 18.5k ) USED ON CARDRONA ACC THE SIT 845 VALVE FITTED WITH MODULE 0537402 IS USED ON PILOTLESS FIRES. THE SIT 845 VALVE FITTED WITH MODULE O537201 IS USED ON FIRES WITH PILOTS G.Fire Service Manual 32 (Blue Modulating coil — approx.
DRAWING 3 TESTING FOR PILOT GAS FLOW LIGHT A MATCH AND ALLOW GAS TO FLOW TO PILOT DO NOT LIGHT A MATCH IF YOU SMELL GAS MATCH ‘BLOWS’ BUT PILOT DOES NOT LIGHT MATCH ‘STANDS TALL’ G.
DRAWING 4 LOG POSITIONING & EMBER PLACEMENT LOG IDENTIFICATION: Rear Log: Mounting centres 340mm Left Centre Log: Mtg. crs. 115mm Left Front Log: Mtg. crs 93mm Right Lower Log: Mtg.crs 122mm Right Upper Log length: 245mm Centre Log length: 255mm CARDRONA & MONACO FITTING THE LOGS Fit the first four logs on their mounting posts in the following order:1. The Rear Log 2. The Left Centre Log 3. The Left Front Log. 4.
G.
G.
G.
G.
G.
G.
