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Tuesday, June 25, 2024

Diagnosing and Repairing/Fixing a Vulcan CX90 Central Heating System, Random Stuff, and More

- we've entered the colder months in my part of the world recently but when I tried to turn my central heating system back on this year it decided not to work. This is how I managed to diagnose and fix it. The pilot flame was working as well as the fan (you can isolate this by switches on the actual outdoor unit itself) so I went to look at the thermostat/controller board. There is a knob which controls the temperature level for the central heating system. Occasionally, the light for it would flash (rather than stay on) which meant something regarding that was faulty. I obviously thought about calling a repairman but it was pretty late at night (so unlikely that anyone would be available) so I decided to see what I could figure out myself before I asked for quotes over the next few days for a repair/service. I looked around for a new thermostat/controller board but the system was so old that there were no parts, repair people didn't actually know much about it because the wiring was unlike what is used in modern systems, those that did have spare controllers wanted to charge crazy prices (~$350-$700) for them (this is ridiculous because entire cooling/heating systems can be had for not much more than that brand new), turnaround times for component level repair people was ~1-2wks with quotes of ~$200 for repair (ironically, I even told them what the problem was but they still wanted to charge me that), etc...
vulcan cx90 thermostat thermistor replacement
https://www.modulerepair.com.au/search/?category_reference_id=36
VULCAN CX90 GAS HEATER CONTROLLER
PART NO: 2120807B
ALTERNATE PART:
OUR PART NUMBER IS 2120807B. MAY ALSO BE KNOWN AS OR SUITABLE FOR THE FOLLOWING:
CX90
https://www.modulerepair.com.au/product-details/1434/vulcan-cx90-gas-heater-controller
https://www.servicecentral.com.au/heating/replace-hard-wired-thermostat-on-vulcan-cx90-ducted-heating-system/340978/
https://www.facebook.com/marketplace/item/927021837701780/
- I decided to tear down the thermostat/controller to see whether I could see anything wrong. The good thing is that a simple multimeter can help to diagnose and help fix a lot of stuff. You can test a lot of parts in-situ withou having to remove them. What bugged me is that the potentiometer/temperature control knob seemed to be fine but the circuit to it obviously didn't seem to be working properly. All resistors, diodes, capacitors seemed to be fine but there seemed to be some oxidisation in one part of the board which I cleaned up with Isopropyl Alchohol and some cotton buds. I then decided to disconnect the thermistor (there's two sets of cables which plug into the main PCB. One of them is for the thermistor/temperature sensor while the rest is for all other cables which means that doing this is very easy) from the controller and the heating system seemed to turn on fine but I had no control over the final temperature
how to measure thermistor with multimeter
http://www.learningaboutelectronics.com/Articles/How-to-test-a-thermistor.php
https://www.hldxsensor.com/article/a-beginners-guide-test-ntc-thermistor.html
How to Test Thermistor with Multimeter । Temperature Sensor Testing । PTC & NTC Thermistor Test.
https://www.youtube.com/watch?v=dZEKcFyzacc
https://www.youtube.com/@industrialsolutions8138
how to test components using multimeter
https://www.onepointesolutions.com/blog/how-to-test-electrical-components-with-a-multimeter/
https://www.ifixit.com/Guide/How+To+Use+A+Multimeter/25632
- I decided to disconnect the thermistor and swap it out for a variable resistor disc (I never sought out to buy this thing but it's become very useful. It was part of a bag of other stuff a local electronics store was trying to get rid of for $10) and try different settings to see what happened. Anything above 22K+ Ohm and the heating system turned itself on, anything below that and it would turn off. This actually makes sense because when it's colder the resistance in a thermistor is likely higher which means that it basically acts as gate/switch to control how when to turn the heater on and/off. It basically confirmed my suspicion that my entire central heating system was brought down by a single thermistor/sensor that cost ~$1-2
https://www.jaycar.com.au/resistance-wheel/p/RR0700
https://www.altronics.com.au/p/k7515-resistance-1r-10m-decade-box-kit/
- parts for this system are difficult to come by locally. It often feels like you can get everything except for the part that you really need locally nowadays in repair jobs. I guess that's why a lot of repair people ask people to wait while parts come in or until external expertise is brought in? Many repairers seem to just replace or retrofit new thermostats when they have failed? Unlike car scrap yards and general repair workshops (such as for bicycles, mowers, cars, electronics, musical instruments, etc...) there doesn't seem to be many of the equivalent locally in the central heating/cooling world that I can see? My guess is that technology has moved so far ahead and prices of new systems dropped so low that it makes no sense to maintain older systems so most people just replace them if they have a problem
How to Upgrade to a Smart Thermostat without Changing the Wiring | Ask This Old House
https://www.youtube.com/watch?v=eAesY_G7AEQ
https://www.youtube.com/@thisoldhouse
central heating thermostat scrapyard
Replacing thermostat on old gas central heating
https://forums.whirlpool.net.au/archive/2633421
thermistor melbourne
https://au.mouser.com/ProductDetail/EPCOS-TDK/B57164K0682J000?qs=E%2F3ZYvLbbh%2F3FcCfkyCoLA%3D%3D&mgh=1&vip=1&utm_id=17753636782&gad_source=1
https://aurarum.com.au/?s=thermistor&post_type=product&dgwt_wcas=1
https://au.mouser.com/c/passive-components/thermistors-ptc/
https://au.element14.com/c/circuit-protection/thermistors/temperature-sensing-compensation-ntc-thermistors
electronics specialists thermistor
thermistor melbourne
https://au.rs-online.com/web/c/automation-control-gear/sensors/thermistors/
https://www.altronics.com.au/search/all/?sr=thermistor
https://au.mouser.com/c/circuit-protection/thermistors/
thermistor pack
100 Pcs 10 Values NTC-MF58 Thermistor 1K 2K 5K 10K 20K 50K 100K 200K 500K 1M
https://www.ebay.com.au/itm/373933489359
Thermal Resistors NTC Thermistor MF52 1K 2K 3K 4.7K 5K 10K 20K 47K 50K 100K ohms
https://www.ebay.com.au/itm/296469274354
100 Pcs 10 Values Thermistor Temperature 1K 2K 4.7K 5K 10K 20K 47K 50K 100K
https://www.ebay.com.au/itm/305607875998
- it's almost impossible to get the specifications of a lot of these things (since they're so old). I used charts of what is reasonable to try and guess what the correct rating were. Then I double checked with at least two other people to see what the ratings/specifications were off of currently functional systems. Triple checked by having someone else measure the specifications of the faulty thermistor as well. It seems to be ~22K Ohm. Not easy to find locally unless you find someone who specialises in antique electronics. Available from overseas/China though
https://www.jaycar.com.au/search?text=thermistor
what thermister rating is normally used in thermostats
https://www.teamwavelength.com/thermistor-basics/
https://electronics.stackexchange.com/questions/596723/identify-temperature-sensor-in-thermostat
mf58 vs mf52 thermistor
thermistor
https://reprap.org/forum/read.php?1,828786
https://www.jaycar.com.au/search?text=thermistor
Thermistor, abbreviated for THERMally sensitive resiSTOR.
PTC, abbreviated for Positive Temperature Coefficient.
NTC, abbreviated for Negative Temperature Coefficient.
PTC thermistors resistance increases with temperature rising.
NTC thermistors resistance decreases with temperature rising.
PTC thermistors are made of doped polycrystalline ceramic on the basis of barium titanate, major material BaTio3.
NTC thermistor are made of polycrystalline mixed oxide ceramics, major material is Mn, Ni, Cu.
PTC thermistors are mainly applied in overcurrent overload and short circuit protection , telecom protection, temperature sensing, temperature protection, motor sensing protection,motor starting, lighting soft switching time delay, self-regulation constant heating, etc.
NTC thermistors are mainly applied in inrush current limiting surge suppressing, temperature sensing measurement, temperature compensation, temperature control, etc.
https://amwei.com/ptc-ntc-thermistor-comparison/
- some of the schematics and pin outs don't actually make sense unless you understand how old this system actually is. Unlike modern environmental control systems it can't do both heat and cooling at the same time. It can either blow air/fan or blow heat (like personal electric heaters). What I didn't realise is how simple/basic thermostats are. You basically have a some electricity going into the thermostat, an on/off switch, and if there is automated timing or temperature/climate control it's handled a thermistor and periodic on/off sequences to maintain temperature range often on circuitry that's entirely on the thermostat controller PCB
vulcan cx 90 central heater release year australia
Climate Technologies handle Vulcan/Bonaire products, but good luck with that, their support is well known in the trade to be piss poor. I'd be trying independents that specialise in HVAC repairs and maintenance.
Don't call in your average plumber, many of them don't have the expertise and experience to cover this, it will be hit and miss.
Vulcan ducted gas heater not working
https://forums.whirlpool.net.au/archive/2650469
vulcan central heating schematics
https://diy.stackexchange.com/questions/184510/c-wire-for-a-vulcan-gas-central-heater-for-nest-thermostat-e
Thermostat Wiring Explained!
https://www.youtube.com/watch?v=b0CuS2gNzYQ
https://www.youtube.com/@BenjaminSahlstrom
Central Heating Electrical Wiring - Part 3 - Y Plan
https://www.youtube.com/watch?v=B7eAiiKUk2Y
https://www.youtube.com/@jwflame
Central Heating Electrical Wiring - Part 2 - S Plan
https://www.youtube.com/watch?v=V9rN5D-wQIc
https://www.youtube.com/@jwflame
HOW TO WIRE A CENTRAL HEATING SYSTEM FROM SCRATCH - S PLAN
https://www.youtube.com/watch?v=kpEdtQiCydo
https://www.youtube.com/@plumberparts
Y plan heating system wiring explained Honeywell edition
https://www.youtube.com/watch?v=3Pg_wraofvs
https://www.youtube.com/@boilerstobathrooms6267
Training Videos. How to Wire Heating Systems
https://www.youtube.com/playlist?list=PLSdnRlSp7Cp6tVsz9ar1N5L2J2sb8wL0P
https://www.youtube.com/@HeatingGeek
central heating wiring plan 1990s
https://flameport.com/electric/central_heating/heating_wiring_S_plan.cs4
https://flameport.com/electric/central_heating/room_thermostat.cs4
- there have been some people who have converted the old wiring system and created new interfaces for it to new themostats which means you don't have to spend thousands on a new central heating/cooling system but you get a lot of the benefits of modern control systems such as better control and alternative interfaces. There seem to be 12V, 24V, mains voltage, powered, and battery powered thermostats out there now but the core functions and wiring are very similar
VulcanConversion 7 - Small 3.zip
https://drive.google.com/file/d/1aCsWrfeiEjxfsiaSJfNHKeEY_XceiRJX/view?usp=sharing
convert vulcna cx90 to wifi thermostat
Vulcan CX90- 31 gas heater
https://forums.whirlpool.net.au/archive/2710023
https://www.energyfieldtheory.com/about
https://au.linkedin.com/in/declan-traill-0437b29
https://x.com/engyfieldtheory?lang=en
are ducted heating thermostats universal
https://ozthermostats.com.au/
- when I did a little big of digging around, I found out that Vulcan seemed to have stopped making ducted heating systems decades ago. It still makes water heaters though. It's owned by Rheem which is in turn owned by Paloma. If this is the case it explains a lot about why there aren't too many people who know much about these systems and how to repeair them anymore. Suprisingly, I wasn't actually able to find much online documentation regarding this online which isn't usually the case unless it's really old
Rheem Manufacturing Company is an American privately held manufacturer that produces residential and commercial water heaters and boilers, as well as heating, ventilating and air conditioning (HVAC) equipment. The company also produces and sells products under the Ruud brand name. It is an independent subsidiary of Paloma Industries[2].What became Rheem started in 1925 as a supplier of packaging to the petroleum industry, and is currently headquartered in Atlanta, Georgia in the United States. The company is one of the largest manufacturers of both water heating and HVAC equipment in the United States, and also produces and markets products in Argentina, Armenia, Australia, Bahrain, China, Chile,[3] Brazil, Canada, Iraq, Kuwait, Mexico,[4] New Zealand, PerĂº,[5] Oman, Qatar, Saudi Arabia, Singapore, UAE, and Ukraine.[6]
https://en.wikipedia.org/wiki/Rheem_Manufacturing_Company
https://www.rheem.com.au/
https://en.wikipedia.org/wiki/Paloma
https://www.palomaglobal.com/
vulcan heating
https://www.vulcan.com.au/
Vulcan Ducted Gas Heating Repairs Melbourne
Vulcan no longer makes ducted gas heating. If you still have a Vulcan ducted gas heater it is likely to be more than 20 years old. Due to the age of all Vulcan ducted gas heaters they need to be serviced on a regular basis. This is to make sure there are no fire or carbon monoxide risks when they are used.
...
Due to the age of all Vulcan ducted gas heaters it is even more important to get them serviced on a regular basis. This is to make sure you and your family are safe during Melbourne's cold winter months.
In addition, it is important to know when it is best to replace your Vulcan model. The main reasons they will need to be replaced are safety or efficiency issues.
With the cost of gas being as high as it is, our trained technicians can make recommendations about whether it is time to replace your ducted gas heater. Alternatively, they will let you know or whether it can be serviced and continue working for some time to come.
https://hrheatingandcooling.com.au/vulcan-ducted-gas-heating-repairs/
https://melbourneheatingandcooling.com.au/brand/vulcan/
https://www.metropolitanheatingandcooling.com.au/brands/vulcan/
vulcan model-cx901 thermostat
We replaced a similar Vulcan system a few years ago with a newer 4 star Brivis (they were on special). When the guy came out to quote he said it was the oldest Vulcan he had seen (around 24 years). The house was pretty small (around 18 squares) . Be aware that you may need to upgrade/replace your ducting if it's very old. You might be getting lots of heat loss from breaks in the ducts and it's also possible the ducting is undersized for newer heaters.
I did note that I had to turn down the fan speed as almost all the new heaters are far more powerful than the old one. There wasn't much change in gas bill – definitely lower, but not excessively so. Maybe around 10-20%. What was better was the house got warmer much faster and the unit runs for much less time.
The whole turnaround cost was around $3K, which was unit replacement plus complete ducting replacement. We did however have good (easy) access under the house.
...
Donnie Darko writes...
Be aware that you may need to upgrade/replace your ducting
I replaced a really old Vulcan some years ago (I had already rebuilt it once by dismantling it and fitting a new heat exchanger). We had the old solid box ducting and I was told it wouldn't suit the new unit so had to rip all that out and replace it. Not a fun job.
I keep a spreadsheet of my gas bills. It's hard to tell how much less gas we use because it depends on how severe the winter is, but I'd agree with Donnie and say around 10-20% would be roughly right. But note I am also gradually fixing up other areas like better door seals and adding double glazing so that would also contribute.
Bottom line is don't expect a huge change in your bill.
Edit. One thing you will probably get is a better controller. The old Vulcan had a thermostat that involved a tilting glass tube with contacts at one end and a blob of mercury to make the connection. With the new one I can program it to come on 20mins before I get up. Wonderful!
Is it worth replacing Vulcan Heating System?
https://forums.whirlpool.net.au/archive/3n1j1r8w
- for the moment, my home central heating system will remain off until the required part/s can be acquired (will use personal heaters for time being). The only question I have is whether I can get part/s for a reasonable price and in a decent timeframe? I've also thought about building an interface for myself (via a small lower power computer such as Arduino, Raspberry Pi, Intel NUC, or super simple home control system which already handle 12V/24V devices which seems common to camping and car based gear, etc...), retrofitting a newer thermostat, just buying a working thermostat from somewhere, getting an entirely new central heating system,  etc... as well but realistically I just want something that is safe and reliable
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Random Quotes:
- Because foreign media firms can operate in China only with a local partner, Warner joined with China Audio Video, a publishing house affiliated with the Ministry of Culture, two years ago.
Mr Vaughan, managing director of the joint venture, estimates the Chinese DVD market is 2.5 billion to 3 billion discs sold a year.
"This shows that Chinese consumers love to watch movies," he said. Warner's target is the estimated 550 million urban Chinese, 80 per cent of whom own a DVD player.
A study commissioned by the Motion Picture Association of America last year estimated that 90 per cent of the movie market share in China was lost to piracy, and the cost to the big Hollywood studios of piracy worldwide last year was more than $US7 billion ($7 billion).
Most ordinary Chinese buy pirated DVDs from street vendors for five to six yuan (80 cents to $1) in the big cities such as Beijing and Shanghai. Foreigners also flock to various permanent shops and stalls that offer a far wider range but at higher prices, usually 10 yuan per disc.
But Chinese can now buy a genuine Warner Bros or Universal movie from as little as 15 yuan. Deluxe editions retail for up to 45 yuan from an increasing number of official outlets.
Hollywood's failure to profit in China is not just a result of DVD piracy. China does not have many cinemas and the Government permits only 20 foreign films a year to be released in those outlets.
Other Hollywood studios are talking about joining Warner Bros, a move Mr Vaughan said his company would welcome. "Our competitors are the pirates," he said.
News Corporation's 20th Century Fox announced a deal with a Chinese distributor late last year to introduce cheaper genuine DVDs and improve availability from its library, but other details were not forthcoming.
https://www.smh.com.au/world/hollywood-takes-on-chinese-fake-dvds-20070127-gdpc76.html
- A Mexican official has announced that 2020 saw the most murders of journalists in 10 years, with 19 killed. The figure suggests that homicide numbers remain out of control in parts of the country.
...
Mexico is often ranked one of the worst countries in the world to be a journalist. According to the Committee for Protection of Journalists (CPJ), an advocacy group, media professionals are often targeted when their work upsets criminal gangs or corrupt officials.
The most dangerous states for journalists since Lopez Obrador took office have been Sonora, Guerrero, Veracruz and Michoacan, according to the government's figures.
The failure of authorities to punish perpetrators of murders is regularly cited as a factor behind the violence, and Encinas said only 5% of the murders against journalists committed under the current administration had led to criminal sentencing.
https://www.dw.com/en/journalist-killings-in-mexico-worst-in-a-decade/a-55728646
- Google is bringing its political ad reporting to Australia — and for the first time, we will see how much money parties and other groups spend to target us with ads on its search engine, YouTube, and elsewhere in its network.
This change will bring more transparency to how parties run their online campaigns, including how much is spent on ads targeting certain groups of voters.
A Google spokesman has confirmed the system, which the US has had since 2018, will be running in Australia "early next year".
Political communication experts have welcomed the news, saying they expect the system will be an important resource for journalists, academics and other interested parties.
Andrea Carson, an expert on political communication at La Trobe University, said Google's transparency website was "long overdue", adding that she could not wait to learn how much parties were spending online.
https://www.abc.net.au/news/science/2020-11-25/google-political-ad-transparency-reporting-coming-to-australia/12914734
- The economist Yanis Varoufakis has called for a one-day boycott of Amazon on Black Friday as trade unionists, environmental activists, privacy campaigners and tax justice advocates plan coordinated actions against the company's sites and supply chain.
Amazon's success during the coronavirus pandemic – at one point the company was reported to be making sales of $11,000 (£8,200) a second – has vastly inflated its share price, increasing the personal wealth of its chief executive, Jeff Bezos, already the world's richest man, by $70bn. Bloomberg estimates his current wealth to be $187bn.
In an online video, Varoufakis asks viewers "not even to visit" Amazon's website on Black Friday – the retail industry's most profitable day of the year – which falls on 27 November this year.
"By boycotting Amazon you will be adding your strength to an international coalition of workers and activists," he said. "Amazon is not a mere company. It is not merely a monopolistic mega-firm. It is far more, and far worse, than that. It is the pillar of a new techno-feudalism."
Under a banner of "make Amazon pay", Friday's actions are intended as the start of a campaign against the retailer's record on workers' rights, environmental impact, tax avoidance, work with police and immigration authorities, and what activists say are invasions of privacy via its growing range of internet-connected devices.
The campaign is co-convened by Progressive International, a global initiative bringing together progressive leftwing groups, politicians and intellectuals, including Varoufakis, Prof Noam Chomsky and Bernie Sanders, and UNI Global, a trade union federation representing 20 million workers including the UK's GMB union.
Casper Gelderblom, Progressive International's campaign lead said: "Trillion-dollar corporations like Amazon have too much power and are too large for a single government, trade union or organisation to rein in. That's why workers, citizens and activists are coming together across borders and issues to take the power back."
A set of demands submitted to Amazon by Progressive International and signed by Oxfam, 350.org, Greenpeace and the Tax Justice Network, said: "Amazon warehouse workers risked their lives as essential workers, and only briefly received an increase in pay."
https://www.msn.com/en-gb/news/world/international-campaign-calls-for-boycott-of-amazon-on-black-friday/ar-BB1bopJV?MSCC=1603816099
- In my head, the awful puzzle pieces started to fall into place. One – the US has more prisoners per capita than any other country in the world. Two – these people are basically slaves, because they work for a pittance, while their services are sold by commercial companies at market prices. Three – so that they don't riot, they are transformed into obese monsters stuffed with hormones. Four – thanks to the hormone therapy, they are divided into women and half-men, so that they can be "happy" in same-sex couples. Those who are released from prison after serving long sentences will never be able to get a normal life. They will need the expensive pills they'll never be able to afford out there, so they will inevitably end up back here…
"Finney, my God, this is unspeakable!" I exhaled.
"I know, Maria, that's why I'm asking you to tell the world about this when you're out. The Lord made you famous. Nobody will listen to us. Who are we? We're just criminals, human scum despised by society."
"I promise you, Finney."
https://www.rt.com/russia/507910-maria-butina-prison-book-journal/
- Researchers are developing wheats capable of resisting a new strain of rust disease which risks huge losses to Australia's $6 billion annual grain crop.
Wheat stem rust can attack all above-ground parts of the plant, including the stem, leaves and inflorescence.
Infected wheat plants may also produce shrivelled grain, while an untreated infection could reduce grain yield by up to 90 per cent.
The new strain Ug99 (found in Uganda in 1999) is a virulent strain of wheat stem rust first detected in Africa and the Middle East that has overcome 17 out of 34 stem rust resistance genes found in wheat.
Around 30 per cent of current wheat varieties are susceptible to the Ug99 strain, and scientists are working to ensure Australian crops are protected against the disease.
Ug99 has not been detected in Australia, but an outbreak could cost the industry up to $1.4 billion over a decade, according to the CSIRO.
A previous major stem rust outbreak in Australia in 1973 affected crops across four states and cost the wheat industry between $1.8 billion and $2.7 billion (in 2014/15 dollars).
Desperate to avoid a Ug99 outbreak, scientists are working to develop wheats with a stronger and potentially more durable level of resistance by "stacking" five resistance genes together.
Researchers combined and inserted five different wheat resistance genes to make it much harder for rust pathogens to attack wheat successfully.
"Our approach is like putting five locks on a door - you're making it very difficult to get in," Lead CSIRO researcher Dr Mick Ayliffe said.
"Rigorous field testing showed that our gene stack approach provided complete protection against the rust pathogens we were targeting."
Dr Ayliffe said the approach could be used globally to protect crops.
"This promising gene stacking technology is a way we could rust-proof not only Australia but international crops as well," Dr Ayliffe said.
"It's a valuable insurance policy in case we face mutations in wheat rust with catastrophic virulence, with the ability to deploy long-lasting solutions to the field much sooner than we would have in the past."
Wheat provides around 20 per cent of the world's calorie intake, making crop protection vitally important for world food security, with cereal rusts also affecting barley, oats, rye and triticale crops.
Dr Ayliffe said the international study had targeted stem rust. Still, the same technology can breed against stripe and leaf rust diseases as well, and in different existing wheat varieties to add resistance.
Wheat rust can rapidly mutate, making it difficult for wheat breeders to respond quickly using conventional breeding.
The disease spreads from plant to plant by spores, which are small, light, and survive for several days.
In addition to being spread by wind, spores can easily attach to clothing, machinery and tools allowing movement and spread between farms and regions.
Adoption of this new in-built resistance technology would also be a valuable tool for integrated pest management, lowering the need for fungicides and increasing the durability of the management tools for farmers.
https://www.sheppnews.com.au/national-news/2021/01/05/2507235/scientists-develop-rust-resistant-wheat
- CSIRO-affiliated company Future Feed said it would use its Food Planet Prize winnings to create an international commercial fund to help First Nations communities generate income from cultivating and selling the seaweed.
https://www.msn.com/en-au/news/australia/australian-super-seaweed-supplement-to-reduce-cattle-gas-emissions-wins-1m-international-prize/ar-BB1c1utF?pfr=1

Saving Money (without Sacrificing), Random Stuff, and More

- use price matching when you can to get an extra discount. Note, a lot of companies advertise low prices just to get you through the door. ...