Thermecon s90/120 lockout fault

[Oddbod]

Bit of a thread resurrection!

Well we had one more go and couldn't find the fault so in the end I build an auto-lockout-reset gadget out of a linear actuator and a little micro-controller. It tries three resets before giving up.

It does look a little bit like the sort of thing you'd find in one of those shops in Soho, but hey it works.

The bad (good?) news is that the boiler has gradually started to lockout more often - to the point where it now does it regularly. I'm hoping this means that we have a better chance of finding the problem.

So any oil boiler engineer out there in the Reading/Newbury/Basingstoke fancy a challenge? (Or a laugh at a slow moving electric ***** - no, not me, the reset mechanism!). Full fee and as much tea/coffee/biscuits as you want. Located Tadley.

 

[Bunker]

Im in Newbury but Tadley is a bit far for an intermittent fault. Give James Mead a call, he's in Brimpton.

"RPS OFTEC Oil Boiler Replacement Breakdown Servicing Maintainance Tank Replacement content="RPS OFTEC Oil Boiler Replacement Breakdown Servicing Maintainance Tank Replacement Berkshire Hampshire, Heating, Plumbing Berkshire Hampshire, Heating, Plumb

James is an excellent engineer.

Good luck.

 

[OilBoy]

My breath has never been so baited, how did this lock out problem work out?

 

[Bunker]

James did tell me, think it was a blocked filter. This is the device

 

[OilBoy]

Wow, that's a great invention. Better get a patent on that quick smart :aureola:

 

[Oddbod]

Yep, James is still on the case! A new motor to be fitted and all sorts of oil unions to be tightened.

It's not yet 100% reliable and the auto reset device still kicks in from time to time, but it is soooo much better.

If we can get another year or two from it we'll ask James to fit something decent.

I'll post a picture of the other end of the reset device, with the electronics, tonight.

Thanks all

 

[Oddbod]

Here is photo of the other end


I had the bits lying around, but it would probably cost about £80 if I had to buy it all. It took about3 hours to make. The reset arm is a linear actuator from a lawnmower cutting deck height adjuster. It gets connected to 12v DC by the electronics. It moves forwards or backwards depending on the polarity.


The electronic gubbins is based on an Arduino micro controller. The black tube contains a neon indicator connected in parallel to the lock out light. (It’s 240v but very low current so not dangerous). The other end of the tube contains a5v light sensor that tells the micro controller if the lockout is on or off. The blue relays are connected as an H-bridge (basically a polarity flipper) and allow the micro controller to drive the actuator in either director. The little display just reports what the thing is up to – number of retrys, time before the next attempt etc etc. Finally the whole thing is driven by an old laptop power supply. The actuator needs about 1A at 12v.


When the software detects a lockout it waits 60 seconds and pushes the reset button. It tries this three times and then waits for an hour before trying another three times.It’ll do this forever if the reset light stays on. If it fails to start from cold three goes are usually enough. If it fails when hot an hour is usually enough to let it cool down to the point where it will restart.


I know it’s something Heath Robinson would be proud of, and I’m sure Thermecon would be having kittens if they knew about it, but until Bunker recommended James it was this or freeze!


Hopefully I’ll never have to make aMkII.


In the unlikely event that anyone is daft enough to want to know any more, ask away.

 

[lame plumber]

omg.................

 

[Oddbod]

You forgot the 'f'!

 

[Millsy 82]

Here is photo of the other end
View attachment 21231

I had the bits lying around, but it would probably cost about £80 if I had to buy it all. It took about3 hours to make. The reset arm is a linear actuator from a lawnmower cutting deck height adjuster. It gets connected to 12v DC by the electronics. It moves forwards or backwards depending on the polarity.


The electronic gubbins is based on an Arduino micro controller. The black tube contains a neon indicator connected in parallel to the lock out light. (It’s 240v but very low current so not dangerous). The other end of the tube contains a5v light sensor that tells the micro controller if the lockout is on or off. The blue relays are connected as an H-bridge (basically a polarity flipper) and allow the micro controller to drive the actuator in either director. The little display just reports what the thing is up to – number of retrys, time before the next attempt etc etc. Finally the whole thing is driven by an old laptop power supply. The actuator needs about 1A at 12v.


When the software detects a lockout it waits 60 seconds and pushes the reset button. It tries this three times and then waits for an hour before trying another three times.It’ll do this forever if the reset light stays on. If it fails to start from cold three goes are usually enough. If it fails when hot an hour is usually enough to let it cool down to the point where it will restart.


I know it’s something Heath Robinson would be proud of, and I’m sure Thermecon would be having kittens if they knew about it, but until Bunker recommended James it was this or freeze!


Hopefully I’ll never have to make aMkII.


In the unlikely event that anyone is daft enough to want to know any more, ask away.

Would it not of been better to spend the 3 hours finding and repairing the fault? I'm kind of guessing that is also at your home and not in someone's utility for them to trip over lol.

 

[oz-plumber]

I am intrigued...totally intrigued....as to why you called yourself...

'Oddbod'

As for the MK11 - Jaguar made one and it was very popular - probably their most recognized car.

As for asking more question being 'unlikely', I don't think it is a matter of us not being interested, its a matter of us not knowing what to ask.

You should take up lodgings, I'm sure you could be of assistance to many people on here.

Oz

 

[OilBoy]

Wow, what a great idea and know how. Respect

 

[Oddbod]

Millsy 82. Yep, it would have been infinitely better to spend 3 hours fixing the bleedin' thing. Unfortunately I'm just an ordinary punter, not a heating engineer.

Originally the idea was just to have the boiler serviced.

"I know", I thought, "I will use this new fangled interweb thing and find an engineer of repute and good standing. I will ply him with tea, biscuits and the odd florin from my hoard and I will be warm for another year."

The engineer duly arrived, drank my tea, ate my biscuits, took my florin and left me a boiler that locked out every couple of days. He came back couple of days later and repeated the process. Strangely he then stopped taking my calls.

"This is dashed unfortunate" thought I. "Let us find another engineer". So I did, and the story repeated.

In desperation I resolved to voyage - virtually - to the place where the soothsayers, shamans and gurus of boilers dwell - ukplumbersforum. There I will request audience and they shall advise me well.

And so they did. "'It's setup, over aired, its a thermecon, get a good engineer" they said.

And so I did, and so the story repeated.

By this time I was bloody cold, down £200 and 6 half days off work, had three engineers who wouldn't talk to me and was remembering Churchills maxim that stupidity is repeating the same thing and expecting a different outcome.

At this point a thought crossed my mind - not a long journey I confess. Why not build an auto-reset device and wait 'till the thing really does break. Surely then someone can fix it.

So since I used to design and build medical robotic instruments for a living thats what I did. It cost less than a 4th engineer, took less time and kept me going for a year.

(BTW if you are ever diagnosed by an "amerlite" machine ask for a second opinion - I helped design it).


OZ Plumber - When I was a spotty pubescent oik I decided that a mullet would turn me into a babe magnet. Unfortunately my sister decided it made me look more like oddbod from Carry on Screaming and it kinda stuck. In hindsight she was probably right. Me and my mullet did pull the odd babe, but probably more out of sympathy or morbid curiosity on their part.

Oilboy, thanks, but personally I admire you guys - and indeed all engineers of whatever ilk who keep odd bits of junk running year after year.

 

[Bunker]

Well its great to have a bit of colour in the forum, amazing work Oddball, a mate of mine is often tinkering with Arduinos - the sort of mate who often offers to 'draw me a diagram' (sharp exit stage left).
Thank God for you brainboxes, especially those with a sense of humour.

 

[Lou]

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