Atag i Series Manual

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ATAG i Series Boiler Fault Finding 02/10/23.

(All models and generations).

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Summary of Contents for Atag i Series

Page 1 ATAG i Series Boiler Fault Finding 02/10/23. (All models and generations).
Page 2 Contents Generation boiler Page 2 Generation boiler Page 20 Generation boiler Page 41 Wilo Pump LED’s Page 66 Sensor resistances Page 67 Expansion vessel servicing Page 68 P a g e...
Page 3 ATAG i Series 1st generation boiler fault finding. Fault codes or error: Fault Fault Fault Other Spanner symbol Pump constantly running. Blank display screen Boiler heating – no demand & One Connected. Error code on ONE Controller: Code 002 / Random fault codes on One Controller.
Page 4 10 Description: Outside sensor error Cause: Outside sensor not present, short-circuited, broken or values outside specifications. 1. If using ATAG One with internet weather: • Check Wi-Fi signal & re-connect if required. 2. If internet weather is not being used, check if outdoor sensor is in use with boiler.
Page 5 40 Description: Return sensor error Cause: The return sensor T2 value out of range. 1. Check full T2 wiring harness and connectors for signs of damage, corrosion, or loose contact. 2. Use a multimeter to check T2 sensor resistances are in line with the return temperatures. •...
Page 6 61 Description: Bus communication error Cause: No signal from One controller (contact open). 1. Turn off the power at fused spur, wait 5 seconds and re-establish power. If connection fails to establish, follow on from point 2. 2. Perform a factory reset on the controller by removing the controller from the wall. Then use a pen or small screwdriver and press the reset button on the rear of the controller.
Page 7 • You can force the pump by removing PWM cable at the pump to allow the 230v cable to power the pump at full speed. • To do this, ensure safe electrical isolation and then use a 4mm electrical screwdriver to push down the clip below the PWM connector and gently pull the connector out.
Page 8 4. Ensure all air is vented out of the boiler and system. 5. On combi’s, the diverter valve operation may be faulty, check as follows: • Safely isolate boiler from electrics. • Remove the motor from the three-way valve and see if the cartridge moves up and down. •...
Page 9 11. In the case of a combi, check the plate heat exchanger is not blocked. Check for Voltage at the pump. You can force the pump: • By removing PWM cable to allow 230v cable to power pump at full speed. •...
Page 10 118 Description: Water pressure too low (<0.8 bar to 0.5 bar) or no pump kick detected. Cause: Insufficient water pressure in system, blockage in boiler, pump not operating or water pressure sensor faulty. 1. Check analogue and digital pressure readouts match. If these do not match add pressure to the system and check gauges read new pressure.
Page 11 128 Description: Ionisation current too low. Cause: Ionisation level too low at max fan speed/RPM. 1. Check condensate pipe is clear of blockages and is running freely. Clear as required. 2. Check 230v at gas valve, connections 1 & 3. a.
Page 12 129 Description: Fan error. Cause: Fan does not start up. Ensure safe electrical isolation and remove the PWM cable at the fan (4 wire connector). Re-establish power to the boiler and the fan should run at full speed. 2. If fan does not run, check for 230v from the PCB connector X11, pins 1 & 2. If no voltage, replace PCB. If 230v present and fan did not run with PWM removed, replace fan.
Page 13 a. If the voltage is correct, move to step 8. b. If voltage is incorrect at the ignition transformer, check the PCB is sending 230v to the ignition transformer from connector X12, pins 3 & 4. Replace PCB if there is no voltage. c.
Page 14 If iR boiler, pump has started and flow switch has made, then the flow has dropped out causing the flow switch to connection to break. Usually, system related. 1. Check the pump for air and vent the system if required. •...
Page 15 4. On combi’s, the diverter valve operation may be faulty, check as follows: • Safely isolate boiler from electrics. • Remove the motor from the three-way valve and see if the cartridge moves up and down. • If this doesn't move smoothly and seems to be sticking, replace the cartridge. 5.
Page 16 180 Description: Boiler is in chimney sweep (service) mode. Cause: No fault. Chimney sweep will run for 15 minutes and clear. If doing this constantly, replace PCB. 181 Description: Boiler coming out of chimney sweep (service) mode. Cause: No fault. This code shows when boiler comes out of chimney sweep mode. If doing this constantly, replace PCB.
Page 17 Check for Voltage at the pump: • You can force the pump by removing the PWM cable to allow 230v cable to power pump at full speed. • If pump does not run via above test check, check 230v across PCB connectors X9, pin 1, and X10 pin 2.
Page 18 Error code on One Controller 002/003. Cause: No fault - These codes show the boiler is in chimney sweep mode (service mode), the same as codes 180 & 181. Random fault codes on One Controller. Cause: Faulty battery or controller. 1.
Page 19 18 | P a g e...
Page 20 19 | P a g e...
Page 21 ATAG i Series 2nd generation boiler fault finding. Fault codes or error: 1 Fault 1 Fault 2 Fault 3 Fault 4 Fault 5 Fault 6 Fault 7 Fault Other 411 to 701 to Heat Generation Lock 711 to Blank screen...
Page 22 1P1, 1P2, 1P3, 101, 102, 103, 104, 105, 106, 107 Fault codes. The fault code explanations for all the above fault codes are below, with the fault-finding guidance on page 22. 1P1 Description: Flow check 1 error Cause: Change in the supply temperature between 7°C and 15°C degrees in 1 second. A rapid increase of the supply temperature can mean that the water flow over the boiler is falling sharply and can be an indication of overheating.
Page 23 1P1, 1P2, 1P3, 101, 103, 104, 105, 106, 107 Fault codes. 1. Check the last 10 faults in the technical area for other pump or flow related faults to aid in diagnosis. 2. Check the system for an external heat source such as solar which may affect the return temperature. 3.
Page 24 1P4 Description: System pressure low. Cause: system pressure is below 1 bar; boiler continues to operate at a system pressure between 0.7 and 1 bar with a warning in the display. 1. Check pressure loss patterns with the consumer and if any work has been carried out on the system or boiler.
Page 25 4. Check the pump for air and vent the system if required. • Use the boiler air purge to assist by turning off the power at the fused spur for 5 seconds and then re-establish the power. 5. Check auto air vent is operating correctly and not contaminated with sludge. 6.
Page 26 102 Description: Pressure sensor defective Cause: Pressure sensor outside the expected resistance value, open or short circuit. 1. Use a multimeter to check the wiring harness to the water pressure sensor for continuity from PCB connector CN12, pins 6, 7 & 8, whilst checking connectors are tight and free from damage or corrosion. •...
Page 27 9. If no obvious leaks are found, isolate boiler from system and leave on test. • *Note* system must be cold, and pressure set to approx. 1.5 bar before isolating valves from boiler to system. • The time required for this test will depend on patterns and amount of pressure loss. (i.e., every 2 days etc.).
Page 28 3. If error 112 remains after the above has been checked, replace PCB. 114 Description: Outside sensor absent Cause: Outside sensor not present, short-circuited, broken or values outside specifications. 1. If using ATAG One Zone with internet weather: • Check Wi-Fi signal & re-connect if required.
Page 29 118 Description: Flow and return probe plausibility checks failed. Cause: Incorrect flow and return sensor readings, usually where the flow and returns are reversed. 1. Check system design and alter as required. 2. Use customer information menu or parameter 8.3 to check flow and return temperatures. 3.
Page 30 • By removing PWM cable at the pump to allow the 230v cable to power the pump at full speed. To do this, ensure safe electrical isolation and then use a 4mm electrical screwdriver to push down the clip below the PWM connector and gently pull the connector out. Re-establish power to the boiler and the pump should run at full speed.
Page 31 Check flow and return pipes not reversed. 12. Check system for blockages and remove. 13. Remove flow switch and check continuity when making and breaking the switch manually. Replace flow switch as required. 14. Use a multimeter to check the wiring harness to the flow switch for continuity from PCB connector CN12, pins 9 &...
Page 32 8. If changing the parameter does not work, carry out a factory reset on the PCB using parameter 2.8.0. If this does not work, replace the PCB. 205 Description: Solar water sensor defective. Cause: (Very unlikely to see) The values of solar sensor out of specification. (10k OHM sensor is used for solar). 1.
Page 33 303 Description: PCB Error Cause: The PCB has a software or hardware error. 1. Check boiler polarity and voltages are correct. 2. Check boiler is properly earthed using an earth loop impedance tester. 3. Check all connectors on the PCB for loose or broken contacts. Replace as required. 4.
Page 34 411 to 416 Description: Faulty Room Sensor Cause: The ATAG One Zone or Cubes for the specified zone are incorrectly set or faulty. The zones are highlighted via the 3 number of the fault code i.e., 411 is zone 1, 412 is zone 2 and so on up to zone 6, 416.
Page 35 5P1, 5P2, 5P3, 5P6, 501 & 504 Fault codes. The fault code explanations for all the above fault codes are below, with the fault-finding guidance directly after and on the next page. 5P1 Description: 1st ignition attempt error Cause: No flame detection on the 1st ignition attempt. No ionisation >0.8 μA detected on first start attempt. 2 launch is successful.
Page 36 b. If under pressure at the boiler, investigate secondary isolation valves, pipe sizing or shale/debris, etc. in gas pipe. 4. If the working pressure is correct, check the following: 5. Check ionisation current is between 0.8μA & 4μA using the customer information menu or parameter 8.7.5. 6.
Page 37 612 Description: Fan Failure Cause: Fan speed outside the expected range. 1. If the boiler can be reset, check the fan speed via the customer information menu or via parameter 8.2.2. The fan speeds and approximate resistances are below: 2. Check fan resistances and replace fan if not within limits below: 3.
Page 38 701 to 706 Description Zone Flow temperature sensor fault. Cause: The flow sensor on the specified zone is faulty. The individual zones faults are identified as 701 for zone 1, 702 for zone 2, and so on up to zone 6, 706. 1.
Page 39 723 Description Zone 3 overheating. Cause: The Zone Manager ST3 overheat thermostat has overheated. **Note** if 2 zone managers have been used together, the fault may be in either zone manager and is not individually defined. 1. Check the link and its connection to the "ST3" terminal block on the module. 2.
Page 40 Bus address collision. Cause: ATAG controls incorrectly wired or wrong zone assigned. 1. Ensure wires from the ATAG Zone Managers and Cube controls match the boiler B & T BUS connectors. (The One Zone is not polarity sensitive). 2. Ensure the ATAG controls are set to the correct zone.
Page 41 Pump constantly running. Cause: Frost protection active or pump PWM fault. Sometimes linked with 109 & 140 fault codes, if so PWM fault. 1. If a frost symbol is present in the boiler display, follow from point 2. If there is no frost symbol on the display, follow from point 3.
Page 42 ATAG i Series 3rd generation boiler fault finding. Fault codes or error: 1 Fault 1 Fault 2 Fault 3 Fault 4 Fault 5 Fault 6 Fault 7 Fault Other 411 to Heat Generation 701 to Lock Blank screen 711 to...
Page 43 1P1, 1P2, 1P3, 101, 102, 103, 104, 105, 106, 107 Fault codes. The fault code explanations for all the above fault codes are below, with the fault-finding guidance on page 43. 1P1 Description: Flow check 1 error Cause: Change in the supply temperature between 7°C and 15°C degrees in 1 second. A rapid increase of the supply temperature can mean that the water flow over the boiler is falling sharply and can be an indication of overheating.
Page 44 Cause the return water temperature to rise. The sensor measures T2 – T1 > 35K (with burner on). 1P1, 1P2, 1P3, 101, 103, 104, 105, 106, 107 Fault codes. 1. Check the last 10 faults in the technical area for other pump or flow related faults to aid in diagnosis. 2.
Page 45 *Note * If plastic pipes are used, they must be barrier pipes & UFH must comply with DIN4726-4729. If this is not the case, system separation must be provided as these pipes are porous & will allow air into the system. 1P4 Description: System pressure low.
Page 46 3. Check DC voltage from pressure sensor back to the PCB on connector CN12, pins 7&8. The voltage should be as per the table below. Clean or replace the sensor as required. 4. Check the pump for air and vent the system if required. •...
Page 47 102 Description: Pressure sensor defective Cause: Pressure sensor outside the expected resistance value, open or short circuit. 1. Use a multimeter to check the wiring harness to the water pressure sensor for continuity from PCB connector CN12, pins 6, 7 & 8, whilst checking connectors are tight and free from damage or corrosion. •...
Page 48 • Check expansion vessel not leaking, replace as required. • If the expansion vessel is of adequate size for the property, is not leaking and has been fully serviced but not holding pressure, replace the expansion vessel. 9. If no obvious leaks are found, isolate boiler from system and leave on test. •...
Page 49 3. If error 112 remains after the above has been checked, replace PCB. 114 Description: Outside sensor absent Cause: Outside sensor not present, short-circuited, broken or values outside specifications. 1. If using ATAG One Zone with internet weather: • Check Wi-Fi signal & re-connect if required.
Page 50 118 Description: Flow and return probe plausibility checks failed. Cause: Incorrect flow and return sensor readings, usually where the flow and returns are reversed. 1. Check system design and alter as required. 2. Use customer information menu or parameter 8.3 to check flow and return temperatures. 3.
Page 51 • If this does not help, follow the next steps. 8. Check the operation and voltage of the pump with a demand. You can force the pump 'on' via 2 methods: • Preferred and safest method by using the manual settings in parameter menu 2. Set parameter 2.6.0 to 1 = Manual mode On, and 2.6.1 to 1 pump control 'On'.
Page 52 • Check the resistance of the pump which should be approximately 150 Ohms. • Replace pump as required. 6. Check bypass is of suitable size to function correctly on pump overrun. 7. Check system configuration of open vent and cold feed pipework is correct.
Page 53 9. If the above DC voltages are correct are correct, replace the pump. 10. If the voltages are incorrect, replace the PCB. 143 Description: Pump feedback abnormal running. Cause: High power consumption on the pump leading to pump overheating. PWM > 77.5% and < 82.5% and the pump led flashes green/red.
Page 54 144 Description: Pump feedback abnormal stop. Cause: High power consumption on the pump leading to pump overheating. PWM > 82.5% and < 92.5% and the pump led flashes red. 1. Where possible, use the customer information menu to check the pump PWM % and the pump flow rate. 2.
Page 55 145 Description: Pump feedback failure. Cause: No circulation/the pump impeller is stuck or full of debris/sludge. Because of this the power consumption is high, leading to the pump overheating. PWM > 92.5% and < 97.5% and the pump led is constant red. 1.
Page 56 6. If after changing the sensor, the fault does not clear, carry out a factory reset on the PCB using parameter 2.8. If this does not work, replace the PCB. 7. If no sensor is fitted to the boiler, check parameter 2.2.8 and change the setting if required. Restart the boiler from the power supply.
Page 57 303 Description: PCB Error Cause: The PCB has a software or hardware error. 1. Check boiler polarity and voltages are correct. 2. Check boiler is properly earthed using an earth loop impedance tester. 3. Check all connectors on the PCB for loose or broken contacts. Replace as required. 4.
Page 58 7. If intermittent and all other checks OK, replace the PCB. 411 to 416 Description: Faulty Room Sensor Cause: The ATAG One Zone or Cubes for the specified zone are incorrectly set or faulty. The zones are highlighted via the 3 number of the fault code i.e., 411 is zone 1, 412 is zone 2 and so on up to zone 6, 416.
Page 59 5P1, 5P2, 5P3, 5P6, 501 & 504 Fault codes. The fault code explanations for all the above fault codes are below, with the fault-finding guidance directly after. 5P1 Description: 1st ignition attempt error Cause: No flame detection on the 1st ignition attempt. No ionisation >0.8 μA detected on first start attempt. 2 launch is successful.
Page 60 3. Check the working pressure at the P1 test point of the gas valve with all gas appliances in the house fully on. The WP must be no less than 4mb under that of the WP at the gas meter for NG or 2.5mb for LPG. a.
Page 61 612 Description: Fan Failure Cause: Fan speed outside the expected range. 1. If the boiler can be reset, check the fan speed via the customer information menu or via parameter 8.2.2. The fan speeds and approximate resistances are below: 2. Check fan resistances and replace fan if not within limits below: 3.
Page 62 7P1 Description Pump error: low flow rate. Cause: This is not visible on the display screen and is only shown in the Faults section of the technical area with Pump Active is normally displayed on the screen. The flow control technology and pump feedback has detected insufficient flow around the system.
Page 63 711 to 716 Description Zone Return temperature sensor fault. Cause: The return sensor on the specified zone is faulty. The individual zones faults are identified as 711 for zone 1, 712 for zone 2, and so on up to zone 6, 716. 1.
Page 64 750 Description ZM undefined hydraulic scheme Cause: Issue with the zone manager hydraulic settings. The zone manager(s) need defined. Use parameter 7.2.0 for zone manager 1 and parameter 7.5.0 for zone manager 2. Use the guide below to set correctly. 0 = Not defined - DO NOT USE.
Page 65 Bus address collision. Cause: ATAG controls incorrectly wired or wrong zone assigned. 1. Ensure wires from the ATAG Zone Managers and Cube controls match the boiler B & T BUS connectors. (The One Zone is not polarity sensitive). 2. Ensure the ATAG controls are set to the correct zone.
Page 66 3. 61% load the voltage is +/- 1.9VDC. 4. 100% load the voltage is +/- 0.24VDC. d. If the voltages are incorrect, replace the PCB. e. If the voltages are correct, replace the pump. 65 | P a g e...
Page 67 Pump LED’s Description of WILO Para 15/7-60/IPWM1 pump operational LED’s. LED is green, pump in normal function, PWM between 5% and 85%. The green LED is flashing, pump in standby mode, PWM between 93% and 100%. LED is Green/Red flashing, warning pump has a failure. If not solved, then it will start flashing RED. LED is Red, pump has a failure.
Page 68 RESISTANCE TABLE SENSORS Outside Sensor Flow Sensor, Return Sensor, DHW Sensor NTC 1k (25°C) NTC 10k (25°C) Temperature (°C) Resistance (KΩ) Temperature (°C) Resistance (KΩ) 4.574 55.047 4.358 32.555 4.152 19.873 3.958 18.069 3.774 16.447 3.600 14.988 3.435 13.674 3.279 12.488 3.131 11.417...
Page 69 The water can easily be removed to avoid unnecessary replacements and return the vessel to factory condition thus improving performance. To correctly service the ATAG expansion vessel, follow the below instructions: 1. Remove the system pressure via a drain point (not PRV). Remove the diverter valve actuator on a combi before doing this to ensure boiler is fully drained.
Page 70 4. Repressurise boiler to 1 bar via filling loop to remove the condense water (around 0.5Ltr) from the vessel * 5. When condense has stopped flowing, drain boiler via a drain point. Leave drain point open and remove tube. 6. Fit new Schrader core and recharge the restored vessel as per the manufacturer’s instructions and above guidance (normally 0.5 bar for most installations).
Page 71 Zone manager & Zone Manager Light LED’s 70 | P a g e...

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