Service manual
Contents
1. 3 DIAGRAMS 3 1 Wiring diagram Electric supply External controls Three way Pump Fan Ignition Flame detection terminal block terminal block diverter valve electrodes electrode SEN Air pressure Primary circuit sensor pressure switch 3 3 2 1 bkbubn gt bk bk gnye bu bn gnye bk P rd bn gnyebu h r P ye bk 2 gy bu bk bn 3 I bn bn bu bk bu bk bn bu bk bk O ER XS X15 rd n u nas gy bu bu a 22 4 ami J bk rd gt rd o 2 L X13 X10 S St Hi wg O gn wh L SB1 bk LD1 LDe LD4 EA Fal P1 Pe D O bk bk wh bu KI 5V gt d rd LY sU a E l 0UT Le who gn D h w temperature D h w Modulating Combustion Safety Flue C h temperature Time switch probe NTC flowmeter gas valve chamber thermostat probe NTC probe NTC over heat bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow Figure 3 1 DIAGRAMS 3 2 Functional flow diagrams General layout Electronic control p c2. 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Figure 20 1 If the temperature of the combustion products circuit reaches the limit temperature the Flue temperature probe NTC reduces the gas flow rate to the burner The temperature of the combustion products should decrease to a safe value temperature lt gt lt gt I D lt lt Figure 20 2 In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler opera tion It is therefore allowed the use of plastic materials for the flue outlet pipes and bends The use of kits different from the original isn t however al lowed since the flue pipes are integral parts of the boiler If not the electronic control p c b attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp A B a x o KE Figure 20 3 20 2 Checks Overheat temperature value 1 Set the temperature control knobs to their max position and run the boiler in d h w and c h 2 Allow the boiler to reach its max
3. Figure 5 3 8 Loosen the connection L and move the pipe M downwards freeing it from the connection of the primary het exchanger 9 Remove the clip N 10 Loosen the connection O 11 Free the pipe P from the connection of the condensing heat exchanger lift and rotate it towards right 12 Remove the heat exchanger by sliding it forwards 13 Reassemble the boiler carrying out the removal operations in reverse order Fit the clip with the arrow pointing upwards as illustrated in Figure 5 3 ON IMPORTANT do not force the connection G when tighting it 5 3 Cleaning Ifthere are deposits of soot or dirt between the blades of the heat exchanger clean with a brush or non metallic bristle brush In any case avoid any actions that can damage the protective varnish with which the exchanger has been covered above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual T Warning After cleaning or replacement as detailed 212 CONDENSING HEAT EXCHANGER 6 CONDENSING HEAT EXCHANGER 6 1 Function The return water flows through the condensing heat exchanger A in Figure 6 1 and Figure 6 2 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water circuit allowing an extra gain of useful
4. Figure 21 1 If the drain pipe is plugged or in any case in which the conden sate isn t correctly evacuated the condensate level rises filling the trap and reaching the condensing heat exchanger When the condensate reaches the lower part of the exchanger obstructs the exhaust gas flow and the boiler stops no signal from the air pressure sensor 21 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Remove the front and right case panels Disconnect the trap from the draining pipe Using pliers remove the spring B moving it upwards Disconnect the rubber pipe C Unscrew the nut D and lower the trap Disconnect the wirings from the trap Reassemble carrying out the removal operations in reverse order NO OQ GQ N SJ Se a O O O O O Figure 21 2 RS SHORT SPARE PARTS LIST 22 SHORT SPARE PARTS LIST Key G C part no Description Q ty GC el 1 173 148 Burner mod M296 24SM C 1 KI1004 102 Polidoro 173 149 Burner mod M296 28SM C 1 KI1004 147 2 H74 599 Injectors for natural gas mod M296 24SM C 12 BI1213 109 Polidoro Injectors for natural gas mod M296 28SM C 14 169 070 Injectors for LPG mod M296 24SM C 12
5. 6 n oll CS zE ke J Figure 11 1 By means of an electric command given to the on off operators the passage of the gas through the Modulating gas valve can be opened or closed By means of an electric command given to the modulation opera tor the pressure can be varied and therefore the gas flow rate to the burner modulation The modulation operator has mechani cal components which allow the adjustment of the minimum and maximum pressure exiting the valve 11 2 Nomenclature of the parts Figure 11 2 Minimum gas pressure adjustment Maximum gas pressure adjustment Modulation operator s electric connectors On off operators electric connector On off operators Gas valve inlet pressure test point Gas valve outlet pressure test point Modulation operator 0 Jo o P Go N Figure 11 2 11 3 Adjustment For the pressure values refer to the Technical data section of the User manual and Installation instructions Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the case panels and the sealed chamber lid section Body panels page 5 2 Open the gas valve inlet pressure test point 6 in Figure 11 2 at the valve input connect a suitable pressure gauge and check the gas pressure of the supply network 3 Remove the gauge and close the pressure test point 6 4 Op
6. Figure 8 1 8 2 Checks Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Check that the pump is not seized and that the movement of the rotor is not subject to mechanical impediments With the boiler off remove the front panel Remove the air re lease plug of the pump and turn the rotor with a screwdriver Check the electrical continuity With the boiler off remove the front panel and disconnect the connector B Figure 8 4 Measure the electrical resistance between the pump supply con nections Electrical resistance of the windings at ambient temperature must be about 213 Q coil 1 and 480 Q coil 2 Figure 8 2 Check the absence of starting defects With the boiler off remove the front case panel Remove the air release plug from the pump Start the boiler and with a screwdriver turn the rotor in the direction of the arrow If there is a defect in starting the rotor will begin to turn normally only starting it manually Check that the impeller is integral with the rotor With the boiler off remove the front and right hand side case pan els lower the control panel and empty the primary circuit Remove the pump head by undoing the screws which hold it to the pump body and check that the impeller is firmly joined to the rotor Figure 8 2 8 3 Removal pump Warning isolate the boiler from th
7. 13 OT e ie Tele NEE 13 Ee EEN 13 6 3 CISMA wae u u ME ENEE AR EE 14 7 D H W HEAT EXCHANGER 15 Z AFUNCUON rb u Seege 15 Y 2 Removal yengen paoata o Sah alak CS 15 8 PUMP e ENEE a saa EE ama gam aga 16 T FUNCION uya SEAN Ae kanan a aa 16 82 CHECKS ui a E N EE RA ER 16 8 3 Removal PUMP ces ira tus uas deet qas EEN ER 16 8 4 Removal electrical capacitor 17 9 THREE WAY DIVERTER VALVE 18 Sc FUNCION Ze a te SSC ee De EEA 18 92 Checker rce susu susu ae eee ds pd See AE 18 93 Removal of the electric actuator 18 94 Removal of the tree way diverter valve 19 9 5 Removal of the diverter group 19 10 ELECTRONIC CONTROL IGNITION P C B 20 10 4 FUNCION bed a ee 20 10 2 Selection and adjustment devices 20 10 3 Checking the temperature oo o o o 21 10 4 Operation lightS o o ooooooooomoo 22 10 5 Setting the boiler control function modes 22 10 6 Useful output setting 22 10 7 Reignition frequency setting 23 10 8 Ignition gas pressure adjustment 24 10 9 Setting the d h w flowmeter operation mode 24 10 10 CHECKS e 2 laa 25 10 11 Removal of the electronic control p c b 25 10 12 Thermal control in the el lee EE 27 10 13 Thermal control in the lte EE 27 10 14 Ignition and control sequence 28
8. Function control C h temperature adjustment D h w temperature adjustment Boiler reset button control panel fascia From other boiler devices C h temperature probe NTC D h w temperature probe NTC D h w flow switch Primary circuit pressure switch Air pressure sensor Flue temperature probe NTC Safety thermostat Flame detection electrode Room thermostat if fitted Time switch Outlet command Pump Three way diverter valve On off operators gas valve Modulation operator gas valve Fan Ignition electrodes Appliance operation lights Lock out signal lamp control panel fascia Figure 10 1 The fundamental function of the Electronic control ignition p c b is that of controlling the boiler in relation to the external needs i e heating the dwelling or heating the water for d h w use and operating in order to keep the temperature of the hydraulic cir cuits constant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Electronic control ignition p c b receives inlet information coming from the boiler the sensors or from the outside knobs room thermostat etc processes it and conse quently acts with outlet commands on other components of the boiler Figure 10 1 The Electronic control ignition p c b is also a full sequence igni tion device and does a sequence of operations ignition cycle which lead to the ignition of t
9. Run the boiler in c h mode do not open any d h w tap F Figure 10 15 5 Keep pressed the reset button D for about 10 seconds until the lock out signal lamp E blinks 6 The lamps F should give the indication as in Figure 10 16 If not press the reset button repeatedly to obtain it O O Where O Lamp OFF LI 00 000 O Lamp on Figure 10 16 7 Keep pressed the reset button D for about 5 seconds until the lock out signal lamp E is switched OFF The boiler runs in c h mode and the lamps F give the indica tion as in Figure 10 17 ve O O 20 Were Lamp OFF vu Flashing lamp alone L U0 000 O or simultaneously with an other lamp Figure 10 17 8 Rotate the knob B on a position corresponding to an ade quate ignition pressure Refer to the value indicated in the tables of the User Installa tion manual Technical information section Gas pressures at the burner table By rotating clockwise the pressure increases 9 Make a note of the position of the knob B 10 Turn the boiler OFF and ON positioning the function selector knob A as indicated in Figure 10 18 Figure 10 18 11 Keep pressed the reset button D for about 10 seconds until the lock out signal lamp E blinks 12 Press the reset button D repeatedly 4 times until the lamps F give the indication as in Figure 10 19 ignition pressure ad justment mode O wiere Lamp OFF O DD 000 ampon Figure 10 19 13 Turn the kno
10. KI1064 506 Injectors for LPG mod M296 28SM C 14 3 E83 121 Expansion vessel mod M296 24SM C M296 28SM C 1 BI1172 103 CIMM 6 litres 4 H20 984 Main heat exchanger mod M296 24SM C 1 Bl1262 101 H20 985 Main heat exchanger mod M296 28SM C 1 BI1262 102 5 H74 578 Fan mod M296 24SM C 1 BI1536 105 Fime H74 604 Fan mod M296 285M C 1 BI1536 113 Fime 6 H03 746 Gas valve 1 BI1093 105 Sit 845 7 H74 576 Air pressure sensor 1 BI1536 103 HUBA 0 3 mbar 8 H50 189 Safety valve 1 BI1181 100 Watts 9 E83 178 Combustion chamber side panels 2 BI1326 100 10 E83 180 Combustion chamber rear panel mod M296 24SM C 1 BI1326 107 E83 181 Combustion chamber rear panel mod M296 28SM C 1 BI1326 108 11 H74 591 Combustion chamber front panel mod M296 24SM C 1 BI1536 110 H74 592 Combustion chamber front panel mod M296 28SM C 1 BI1536 111 12 Electronic regulation p c b 1 BI2015 105 Bertelli 8 Partners 13 E01 204 D h w heat exchanger M296 24SM C 1 BI1001 101 E01 205 D h w heat exchanger M296 28SM C 1 BI1001 102 14 Pump 1 BI1552 100 WILO INTNFSL12 6 HEP 1 12 15 H74 545 Primary circuit pressure switch 1 Bl1351 118 16 169 010 D h w flowmeter 1 BI1441 104 17 H74 535 Three way diverter valve electric actuator 1 BI1431 100 18 E83 101 Overheat thermostat 1 BI1172 105 ELTH type 261 19 H74 589 Flue temperature probe NTC 1 BI1536 104 20 H44 170 Fuse 3 15 AF 2 BI1295 108 21 169 016 Temperature probe d h w ci
11. LL Liu Gas gun EE dale 37 17 FAN AND AIR PRESSURE SENSOR 38 17 4 Epos bb iii uN 38 he CHECKS EE 38 17 3 Removal of the Fan 2 2 205 39 17 4 Removal of the Air pressure sensor 39 18 IGNITION AND DETECTION ELECTRODES 40 18 11 FUNCION Set iiss tn um p Ree os eee ete 40 18 2 Ch CKS cocacola Seb ord Heb deen deeg Ach ER re A 40 18 3 REMOVAL ee cniin ea eer ds Eada ete eed aq 40 19 SAFETY THERMOSTAT 41 19 1 FUNCION us u Sg d die hapus Festa u 41 19 2 e RAS 41 19 3 Removal Red EE E Sas Rothe ae Ee ed 41 20 FLUE TEMPERATURE PROBE NTC 42 201 FUNCION vecs rra ridad 42 EE 42 20 3 REMOVA S uv ba u u usss uama aan aaa eid 42 21 CONDENSATE TRAP 43 21 1 FUNCION oi dr E E E 43 KL CES 43 22 SHORT SPARE PARTS LIST 44 OVERALL INFORMATION 1 OVERALL INFORMATION 1 1 Overall View Airpressur sensor Flue temperature probe NTC Condensing Fan Ve AL heat exchanger Mainheat p A exchanger CE vessel Safet H ae Burner C h temp 1 probe ol Ignition IK 0 e rie FSSC Detection lt ch Automatic electrode A RE air release Combustion Y l j E heat AE H Condensate Primarycircuit i rap pressureswitch SE Va Dhu heat Divertervalve
12. SNA Jos dung JoBueyoxe yeay WU nouo wu yno yD den pue adid umep ayesuapuoy sadid on aul iddns seo Il aul iddns Jamog 1 joejeg pau dure eubis no 4907 LO c 6L CH EE 9 SL Stl lt l YLL DLOL Cp CH T y N s y921q ul ya ajou jenuew y JO UOIOee yoayo 0 syuauodwog 10 FAULT FINDING 9 p1 Jeu ayes MOY e Les ul Aressaoau J yBly 00 ayes mo 10 uBiu 00 inss id w u p sen ea Jadoud Jo jenuew uogejesu BU 0 JOJO l ss A uoisuedx out JO uonezunss id y 40949 siol9 uil Jo ssauueaj9 y JUu A 1 Mooq UODSIEISUL y uo UdAIH anjea y ULM y 1eduuoo pue e es Bas anjen seb ay JO jurod sa jeyno ay ye inss id sef unu uu ay YOOUD yeysouley AJayes ay jo uOpusalajul ay pue ynd urew ay yo Bugey eno ay asneo Pinos ssed Aq powwel y enueu uonelle1su osje ass Sun 1081109 sy Auen pue yno ay JO sseupunos 104 YOBUD 1 loq ay Aq OO paxons ou si seb 1sneux ey ans u pue sesueJeaj9 ass pajyezsul 199 1009 si peua any out yeu Aja suononu sqo jo 99u sqe pue sseupunos JO Y98049 19yy00q UOISIEISUL ayj uo UAD sanjen ay yum y aseduoo pue uorelado Duunp pue sa ye Joo 24 UM 9S ass SNA sef au jo ulod sa out ay ye Sinssaid seb ay yYOOYD S9AJBA doe jo uonisod au di
13. b low voltage section J1 1 Fuse 3 15 A PTC Transformer a L E J3 5 J3 4 SS Zen E C4 1 J3 3 Three wa diverter valve 312 f i v Pump J3 1 N J3 2 e E 1 J2 5 J2 4 Heat request on d h w J1 1 Fuse 3 15 A PTC L LINE N NEUTRAL ACTIVE CIRCUIT INACTIVE CIRCUIT Heat request on c h J1 1 Fuse 3 15 A PTC Lt Figure 3 2 Electronic control p c b low voltage section Transformer x Full sequence ignition device Electronic control p c b J3 3 low voltage section Transformer x Three way diverter valve Full sequence ignition device J3 3 Three way diverter valve re Full sequence ignition device a DIAGRAMS 3 3 Circuit voltages during c h or d h w operation Electrical voltages with burner on CC only during c h operation eS only during d h w operation Pump Supply network to s A 3 way CA Fan diverter valve Modulating 230 Gas valve 8 u be 230 230 Z aa UN a gt N vt Y 2 Air Safety pressure thermost
14. from the modulat ing operator and measure the electrical resistance of the coil lts electrical resistance value must be approx 80 Q Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector E Figure 11 5 Measure the electrical resistance between the connector pins of the on off operators as illustrated in Figure 11 4 _ SINN Upper on off operator approx 6400 Q Lower on off operator approx 920 Q at ambient temperature Figure 11 4 11 5 Removal of the on off operators coils Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Remove the front panel of the case Disconnect the connector E Figure 11 5 Unscrew the screw F and remove on off operator coils Reassemble the coils carrying out the removal operations in reverse order Q N Figure 11 5 11 6 Removal of the gas valve Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front panel of the case as explained in the sec tion Control panel page 5 of this manual 2 Disconnect the connectors D and E Figure 11 5 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve Unscrew the connectors G and remove the pipe H Remove the rubber pipe I Unscrew the screws J and remove the valve Reassemble the va
15. ignition device Figure 10 26 e 10 14 ELECTRONIC CONTROLIIGNITION P C B Ignition and control sequence YES Ignition request lock memorised g cancels lock NO Air pressure sensor YES at rest I starts fan NO Air pressure sensor NO at work Air pressure sensor YES ER at work beginning of wait period NO YES presence of flame YES Y starts ignition discharges opens gas valve beginning of ignition period end of ignition NO period NO YES flame presence closes gas valve stops fan interrupts ignition discharges memorizes lock turns on lock out light NO interrupts ignition discharges gas valve open reset push button YES pressed m YES flame presence NO closes gas valve gt safety thermostat or flue NO L YES Air pressure sensor at work Figure 10 27 28 temperature probe lock out NO YES si MODULATING GAS VALVE 11 MODULATING GAS VALVE 11 1 Function The Modulating gas valve Ain Figure 11 1 controls the gas inflow to the boiler burner
16. lamps F give the indi cation as in Figure 10 10 useful output second step O Where O Lamp OFF O 00 00 ampon Figure 10 10 At this step it is possible to visualize the current setting by keep ing the reset button D pressed for more than 5 seconds The lamps F will flash a number of times corresponding to the setting Figure 10 11 once for M296 24SM C and M296 28SM C M296 24SM C _ M296 28SM C a 7 flashes B Setting No Figure 10 11 12 To change the setting turn the knob B on a position corre sponding to the boiler model Figure 10 11 By turning the knob B the lock out signal lamp E blinks quick ly 2 per seconds indicating that the setting has changed and must be memorised 13 To memorize the setting keep pressed the reset button D for about 5 seconds until the lights F briefly blinks simultane ously 14 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A 10 7 Reignition frequency setting It is possible to select the minimum time that must pass between two ignitions of the burner in c h function mode 1 Turn the boiler ON positioning the function selector knob A as indicated in Figure 10 12 vom ta d d B A D E F Figure 10 12 2 Keep pressed the reset button D for about 10 seconds until the lock out signal lamp E blinks 3 Thelamps F should give the indication as in Figure 10 13 r
17. parts located inside the control panel pro ceed as follows 1 Remove the front panel of the case 2 Loosen the screws B and C Figure 2 3 3 Remove the screws D 4 Move the lower part of the side panels as indicated in Figure 2 4 and pull the control panel When completely pulled out the panel can rotate 45 down wards to facilitate the service operations on the internal parts GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 5 Emptying the primary circuit 1 Close the c h circuit flow and return cocks 2 Remove the front and right panels of the boiler 3 Open the drain tap Figure 2 7 until the boiler is completely emptied 4 Close drain tap again once the emptying has been complet ed Figure 2 4 5 Remove the screws E and remove the service panel Figure 2 5 6 To gain access to the electronic regulation PCB remove the screws F and remove the control panel lid Figure 2 5 Figure 2 7 2 6 Emptying the d h w circuit 5 Close the d c w inlet cock 6 Open one or more hot water taps until the boiler has been completely emptied Figure 2 6 To gain access to the parts contained in the sealed chamber it is necessary to remove the lid of the sealed chamber For this pur pose remove the front and side panels of the case remove the screws G as indicated in Figure 2 6 and remove the lid 6 DIAGRAMS
18. 11 MODULATING GAS VALVE 29 14 1 FUNCION oz S sat asi era 29 11 2 Nomenclature of the parts 29 E We dn EE 29 44 4 e ENEE 30 11 5 Removal of the on off operators coils 30 11 6 Removal of the gas valve 30 12 PRIMARY CIRCUIT PRESSURE SWITCH 31 12 1 FUNCION estara eek ee Sede oth da 31 122 CHECKS si dc wi ea aed pee ee 31 123 REMOVA EE EN 13 EXPANSION VESSEL AND TEMPERATURE PRES SURE GAUGE areire aaa i E 32 1S GL TEE 32 13 2 CHECKS 2 03 0 ene deg Are ege Zeie NEEN ees 32 13 3 Removal of the expansion vessel 32 13 4 Removal of the temperature pressure gauge 32 14 D H W FLOWMETER FILTER AND FLOW LIMITER 33 TAT FUNCION y yy Wad eases QS ge Saeed esa isis 33 14 2 Description and location of parts Figure 14 2 33 14 3 Removal of the sensor 33 14 4 CHECKS ek ee ea 33 14 5 Removal of the flow switch group and d h w circuit MMs z u S anys ssp Sond SNS Sank Sedat Da ara ao au Su eres 33 14 6 FloWillMitSr su EELER E E Lula sia 34 15 TEMPERATURE PROBE 35 15 1 FUNCION 220 32 Ee ea Ba ey eee ee 35 15 2 CHECKS 05 04 terae be yee Slee Eee ee ea eee 35 15 3 Removal of the c h temperature probe 35 15 4 Removal of the d h w temperature probe 35 16 BY PASS VALVE 37 16 1 FUNCION tnd cnn drier dite ees eee 37 16 2 REMOVAL ute L
19. 18 2 3 Check the integrity of the detection electrode and ensure that its metallic edge is correctly placed over the ramp of the burner Check the connection wires Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Check for the integrity of the insulation of wires which con nect the electrodes to the ignition device 18 3 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Disconnect the electrode wires from the full sequence ignition device 3 Remove the plate E see Figure 5 3 on page 12 4 Remove the burner by unscrewing the four screws placed at the right and left sides of the burner 5 Unscrew the screws A Figure 18 3 which hold the elec trodes to the burner Figure 18 3 6 Extract the electrodes from the burner 7 Assemble the electrodes carrying out the removal operation in reverse order Refer to Figure 18 1 in order to recognise the electrodes and to correctly connect the wiring Note the metallic edge of the detection electrode is longer than the one of the ignition electrodes above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installa
20. D H W FLOWMETER FILTER AND FLOW LIM ITER 14 1 Function The d h w flowmeter A in Figure 14 1 is a device that generates an electrical signal when hot water is drawn SS u m PU 5 Wu N ei Ly H raat bel t A A X X Figure 14 1 When the flow rate through the d h w circuit reaches about 2 5 litres min the sensor closes the electric contact that switches the boiler d h w operation ON 14 2 Description and location of parts Figure 14 2 Figure 14 2 Flow switch plug O ring Flow limiter optional accessory Body with flow meter turbine Filter OO P O N 14 3 Removal of the sensor Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent O O Figure 14 3 1 Remove the front panel of the case 2 Disconnect the connectors B and remove the sensor holder C Figure 14 3 3 Remove the sensor 14 4 Checks Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Y Sensor operation 0 32 Hz without flow rate 33 200 Hz witht flow rate wh white bu blue rd red Figure 14 4 Remove t
21. EAT EXCHANGER 5 1 Function The primary heat exchanger A in Figure 5 1 has the function of transferring heat produced from combustion of the gas to the water circulating in it I A ale me AS g Le i J k 0 4 Du 1 L 5 W d H RW It m Figure 5 1 The hydraulic circuit is composed of 8 elliptical pipes connected in parallel Figure 5 2 Figure 5 2 5 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the case panels and the sealed chamber lid section Body panels page 5 2 Empty the primary circuit of the boiler 3 Remove the combustion chamber lid B by unscrewing the screws C Figure 5 3 4 Remove the screws D and the plate E 5 Remove the clip F 6 Loosen the connection G and slightly move the pipe H up wards 7 Remove the clip and the safety thermostat J and the c h temperature probe K It is not necessary to disconnect it from the wiring
22. FF Lamp ON SC Flashing lamp alone or simultaneously nes with another lamp Ba d Flashing lamp alternate with another lamp These conditions are normal only for a short time when the power supply is applied to the boiler If permanent they indicate a faulty p c b LI DD M0 yN Normally operating boiler e es see the previous table for details CO O O C h operation O GQ D h w operation O IO O Frost protect operation D h w operation O O oe P Excessive temperature on primary circuit O SC SC Faulty c h temperature probe NTC O O Faulty d h w temperature probe NTC O O Faulty flue temperature probe NTC y Faulty primary circuit O O O no water or low c h pressure ZAK Zb Faulty primary circuit DEDO absence of flow 10 5 Setting the boiler control function modes It is possible to select the various boiler control function modes by using the function selector knob A and the D h w temperature control knob B Figure 10 5 During the function modes setting the boiler does not operate SEEN T A B A D E Figure 10 5 10 6 Useful output setting To set the useful output proceed as follows 1 Remove the front panel of the case 2 Take off the lid of the sealed chamber 3 Switch on the appliance at the mains isolating spur 4 T
23. IH ampon Figure 10 21 At this step it is possible to visualize the current setting by keep ing the reset button D pressed for more than 5 seconds The lamps F will flash a number of times corresponding to the setting Figure 10 22 5 Change the setting by turning the knob B on the position cor responding to the desired setting Figure 10 22 By turning the knob B the lock out signal lamp E blinks quick ly 2 per seconds indicating that the setting has changed and must be memorised 6 To memorize the setting keep pressed the reset button D for about 5 seconds until the lights F briefly blinks simultane ously D H W FLOWMETER S 7 flashes VW a d Se l Setting No At this step it is possible to visualize the current setting by keep ing the reset button D pressed for more than 5 seconds The lamps F will flash a number of times corresponding to the setting of Figure 10 22 that must be seven times Figure 10 22 7 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A checking the ignition pressure and that the burner lights up uniformly In any case the boiler automatically resets to its normal operation after 10 minutes 10 10 Checks Check that the fuses are complete If the Electronic control ignition p c b does not supply any de vice pump fan etc check that the fuses 14 Figure 10 2 are complete If a fuse has blown replace it
24. Wall hung fanflue roomsealed high efficiency gas boiler Service manual Riva Plus HE Models G C Appl No M296 24SM C 47 583 24 COMBI BOILER M296 28SM C 47 583 25 COMBI BOILER Leave this manual adjacent to the gas meter Warning Service repairs must be carried out only by a qualified Gas Safety Registered Engineer who will be responsible for the current Regulations for gas appliances Note After servicing complete the relevant Service Interval Record section of the Benchmark Checklist of the user and installation manual ABIASI TABLE OF CONTENTS 1 OVERALL INFORMATION 4 1 1 Overall VIEW ur sq u eee bie Q Cw wa a eee 4 1 2 Hydraulic dagram u u u u res pupusa pss ispa 4 2 GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS a sum aqa a s au aa suka 5 2 1 Nomenclature E is ee pupu de aq 5 2 2 Body panels 232 uu u suu apuyay E e 5 23 Controlpangl EN EN ie tia deed dd e 5 2 4 Access to the sealed chamber 6 2 5 Emptying the primary circuit 6 2 6 Emptying the d h w circuit 6 3 DIAGRAMS 7 31 Wining diagram escam d AE ON 7 3 2 Functional flow diagrams 8 3 3 ee e le TEE 9 4 FAULT FINDING 10 5 PRIMARY HEAT EXCHANGER 12 9 1 FUNCION er usss peeved Sage e A 12 Nu EE 12 O23 CIGANING EE 12 6 CONDENSING HEAT EXCHANGER
25. according to the graph in Figure 15 1 15 3 Removal of the c h temperature probe Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels and the sealed chamber lid A Figure 15 3 2 Remove the electric connector D and remove the c h Tem perature probe A Figure 15 3 3 Reassemble the c h temperature probe carrying out the re moval operations in reverse order 15 4 Removal of the d h w temperature probe Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Figure 15 4 1 Remove the front panel of the case 2 Empty the d h w circuit of the boiler 3 Remove the fixing spring E Figure 15 4 35 TEMPERATURE PROBE 4 Remove the electric connector F and unscrew the d h w Temperature probe B Figure 15 4 5 Reassemble the d h w temperature probe carrying out the removal operations in reverse order Cr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities 36 BY PASS VALVE 16 BY PASS VALVE 16 1 Function The By pass valve A in Figure 16 1 is located between the c h water flow and return and its function is that of guaranteeing a minimum flow across the primary heat exchanger if the circula tion across the c h syst
26. at sensor Figure 3 3 FAULT FINDING FAULT FINDING 4 uonouni W u p uo uonej do ELON y o UO ai HOUS e Jo SUD J lloq UL uo uo ll98Jiuo2 sejejado 1 l loq ay oU OU JO uonmelnpoui ay UO y 1 usey qouy juauisn pe due wup ay Buin aunyesaduue UD au O4JUOD 1Llus op Jaejioq ay uny 1 us op UE pouu UD JO y 9 Ul ayya 1461 1 Useop JaUING ay Sum UE pouu UD JO U2 Ul ayya ID 1 Useop JeUING ay Ins ueq 440 SluBIl uonesado out IIV pow w y p JO y o ul Jeyue WEIS JOU s op J l ioq ayl 330 ureBe SOO 1 lloq ay pue anunuoo syeds uonliuB y uo Sub 4aUING oul S uoniuBi y suls Jaj1oq 2U uopnq ysnd 18s81 ay Buiss id Ag ureBe sy90 1 Jloq ay pue anunuos syseds uon 1UBI ay uo 1461 Luseop unq oul S uoniuBi y suls Jaj1oq 24 uolng ysnd jasa ay Buissald Ag e Apoa 109 sayesado pue uo suni eo ay uopnq ysnd 18s81 y Buiss id Ag NO BneB inss iq ana es I8ss A uoisuedxg siolo ul ON eqold an y Jelsouuj u1 jejes Il poxno l uono l q ponmno uoniuB ue4 Josuas inss id Ay anun ssed Ag aqoid duet wug aqoid duet novo UEN et Mud YOUMS aunsseid WOU VIEJA doyesodo Bunenpoul saen sed IB suoyesodo JJo uo SAJLA seg sBumes Ja 0g qo d 91101993 q o d 91U0 19913 sesny YOUMS Mol Wu
27. b B to the minimum fully counterclockwise and then on the position corresponding to the position obtained on step 8 By turning the knob B the lock out signal lamp E blinks quick ly 2 per second indicating that the setting has changed and must be memorised 14 To memorize the setting keep pressed the reset button D for about 5 seconds until the lights F briefly blinks simultane ously 15 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A checking the ignition pressure and that the burner lights up uniformly In any case the boiler automatically resets to its normal operation after 10 minutes 10 9 Setting the d h w flowmeter operation mode When replacing the Electronic control ignition p c b it must be set for the correct operation of the d h w flowmeter Note the Electronic control ignition p c b spare part is fattory set on mode 1 For all the models covered by this manual 1 Turn the boiler ON positioning the function selector knob A as indicated in Figure 10 20 2 Turn knob B as indicated in Figure 10 20 24 ELECTRONIC CONTROLIIGNITION P C B F A D E Figure 10 20 3 Keep pressed the reset button D for about 10 seconds until the lock out signal lamp E blinks 4 Press the reset button D repeatedly 4 times until the lamps F give the indication as in Figure 10 21 setting the d h w flowmeter mode operation O wiere O Lamp OFF O DD
28. bar M296 24SM C 155 Pa 1 55 mbar M296 28SM C 7 With values less than 64 Pa 0 64 mbar M296 24SM C 82 Pa 0 82 mbar M296 28SM C The ignition is not allowed and appropriate fault indication is given see section 10 4 38 FAN AND AIR PRESSURE SENSOR 17 3 Removal of the Fan Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Pressure point P2 Remove all the case panels and the sealed chamber lid 2 Disconnect the connectors C and the earth connection D Figure 17 4 3 Disconnect the pipe E by the pressure test point F Figure 17 4 4 Unscrew the screw G and remove the bracket H Figure 17 4 Figure 17 5 Warning After cleaning or replacement as detailed A above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual j Figure 17 4 5 Remove the Fan by sliding it towards left se the arrow in Figure 17 4 6 Assemble the fan carrying out the removal operations in re verse sequence Warning Re assembling the fan ensure that the hooks around the inlet port of the fan hung correct A ly on the flue hood Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 17 4 Removal of the A
29. beginning of the ignition cycle Its correct functioning is controlled by means of an Air pressure sensor B Figure 17 1 and Figure 17 2 m i D lt P lt P lt lt lt Figure 17 1 17 2 Checks LZ Check of the fan Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the connectors C Figure 17 2 and measure the electrical resistance of the motor that has to be about 43 Q M296 24SM C 25 Q M296 28SM C at ambient temperature Figure 17 2 Check of the Air pressure sensor operation This test must be carried out with the sealed chamber closed 1 Remove the caps of the pressure test points located on the top of the boiler and connect a differential pressure gauge Figure 17 3 2 Switch on the boiler Figure 17 3 3 Run the boiler at minimum by disconnecting the gas valve modulation operator 4 Compare the value on the gauge with the following 75 Pa 0 75 mbar M296 24SM C 92 Pa 0 92 mbar M296 28SM C 5 Run the boiler at maximum connect the modulation opera tor 6 Compare the value on the gauge with the following 125 Pa 1 25 m
30. d Ajddns sef ay jo ssauzyBn y Ga z r uono uuo2o enau pue oul Jo yuejod ay yO9YD Soen Ieu1 1x pue Bnid ajqeo Ajddns Jo Abazu oun A N Ienn u pue q au u w q A0EZ 10 YOUN e rot uono s s ef uone 1 do aoueldde ay Aq usalb uonesipul jeondo ay w014 Osje paule qo aq ues uonguuioju InJj sn SON yO SI 1 ioq ay uaym SEA ajes au Wo4 SALA Jam y o uo uonei do Bu INP SAJEA Ajayes ay WO SALA JSJEM SEI WOU WUD MOT aunyes9dwd AWUD 100d uinuuuluu ye sureula 1 uinq ay 0 anssald seb zl eg ge Se II g OLN 8qoid an JOSUas inss id 1y le SE 25 Aa II ponxo uoniuB E D gt e TI 0 D n 172 E kd Q D E Q o N yeysowueuy Ajeyes E apo joaje uono l q N Ka LO N YOUMS nss 1d WOU UNEN N LO suoyesodo JJO uo snena seg 10jesado BuneInpouu snena ser q o9 d 9140 1199 3 Do EIC Jk T JaBueyoxe jesy my q ees ll N 1J lloq ASION uonejnpou 19 uoou j po w u p uo o 1109 seyeiado 1 lioq oul yeoy jou s op uu ls s y o ay pue 9 94 Seyoeal 4ND UleLU out jo n adw ay apou UD UO wuy p yo Bulmeip e Buunp u A apou y o u uone1 do JejnBay de ay wo Jayem poo wy p Ajddns jou saop Jajiog ay pe dure jeus no 4907 t oa aul iddns seo siexoelq ul J 1 lou enueu y jo Ondas siie PRIMARY HEAT EXCHANGER 5 PRIMARY H
31. e ignition frequency If not press the reset button repeatedly to obtain it O O were Lamp OFF LI 00 000 O Lamp on Figure 10 13 At this step it is possible to visualize the current setting by keep ing the reset button D pressed for more than 5 seconds The lamps F will flash a number of times corresponding to the setting Figure 10 14 4 To change the setting turn the knob B on a position corre sponding to the desired delay 2903 s ELECTRONIC CONTROLIIGNITION P C B By turning the knob B the lock out signal lamp E blinks quick ly 2 per seconds indicating that the setting has changed and must be memorised com Zei B Delay minutes Setting No Figure 10 14 5 To memorize the setting keep pressed the reset button D for about 5 seconds until the lights F briefly blinks simultane ously 6 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A In any case the boiler automatically resets to its normal operation after 10 minutes Factory setting 3 minutes 10 8 Ignition gas pressure adjustment 1 Turn the boiler OFF 2 Remove the front panel of the case 3 Open the gas valve outlet pressure test point 7 see section 11 2 and connect the gauge 4 Turn the boiler ON positioning the function selector knob A as indicated in Figure 10 15 and ensure that the timer se lector switch and room thermostat if fitted are set to heat demand
32. e exchanger carrying out the removal opera tions in reverse order Crs Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities After reassembling ensure that the fan exchanger and ex changer elbow gaskets are correctly mounted and ensure a good sealing above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual T Warning After cleaning or replacement as detailed EE CONDENSING HEAT EXCHANGER 6 3 Cleaning 1 Using pliers remove the spring L moving it to wards right and disconnect the rubber pipe M Figure 6 3 2 Unscrewing the screws N Figure 6 3 3 Remove the condensing heat exchange lid O Figure 6 3 moving towards the front of the boiler If there are deposits of soot or dirt on the exchanger lid clean with a brush or non metallic bristle brush ll ME SP SS 1 _ F J N AN D d Ee 7 Senf O I st Figure 6 3 4 Reassemble the exchanger carrying out the removal opera tions in reverse order Cys Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact wit
33. e mains electrici A ty supply before removing any covering or compo nent 1 Remove the case panels and the sealed chamber lid section Body panels page 5 2 Empty the primary circuit of the boiler 3 Disconnect the connector B Figure 8 4 following the indica tions given on the connector box 4 Disconnect the earth connector T Figure 8 4 5 Loosen the connection D Figure 8 3 and pull up and turn to the left the pipe E 6 Remove the locking plate F Figure 8 4 16 PUMP 8 4 Removal electrical capacitor Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo mei c nent Remove the front and right hand side case panels 2 Disconnect the connector B Figure 8 4 following the indica tions given on the connector box E E 3 Remove the connector M of the cover box by levering with a m screwdriver in as shown in Figure 8 5 3 D s E 1 3 O 15 o G Q3NDSHD ALI ING a eg ep er Zb Me 10 crozar Ee r aru Figure 8 3 Figure 8 5 4 Remove the capacitor connection block N freeing it from the hook O and pulling it as indicated by the arrow Fig 7 6 Figure 8 4 7 Unscrew the two screws G that hold the pump on the frame and remove the pump Reassemble the pump carrying out the removal operation
34. e resistance of the motor windings the motor must be disconnected from the wiring is also given 18 B Spindle visible 9 4 Kohm Open circuit bn bu bk bk black gt bu blue le bn brown bal S N Figure 9 2 D h w mode B Spindle not visible Open circuit 9 4 Kohm bn bu bk bk black gt bu blue 9 gt bn brown DIE Figure 9 3 C h mode 9 3 Removal of the electric actuator A Warning isolate the boiler from the mains electric ity supply before removing any covering or compo nent 1 Remove the front case panel 2 Disconnect the connectors C Figure 9 4 3 Remove the fixing spring D and remove the actuator B Reassemble the actuator carrying out the removal operations in the reverse order When reassembling the actuator refer to Figure 9 2 or to the wiring diagram in section Checks page 18 for the correct wiring connection THREE WAY DIVERTER VALVE Figure 9 4 9 4 Removal of the tree way diverter valve 1 Remove the front and both side case panels 2 Empty the primary circuit and the d h w circuit of the boiler 3 Remove the electric actuator section Removal of the elec tric actuator page 18 4 Remove the fixing spring E Figure 9 5 5 Remove the tree way diverter valve F by levering with a screwdriver in as shown in Figure 9 5 Figure 9 5 Reassemble the tree way diverter valve carrying out the removal operations in the reverse order C
35. e spindle 11 Operate the boiler and close the gas inlet cock so that the boiler goes into the safety lock out state Verify the correct operation of the boiler reset button by pressing and releasing it Warning After cleaning or replacement as detailed A above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual LOG ELECTRONIC CONTROLIIGNITION P C B 10 12 Thermal control in the mode Switch in the function mode See functioning with the function control in the 3 mode lt YES sec 10 13 water from the domestic hot NO Is primary circuit temperature higher than that selected YES NO Request for heat from room thermostat Se _ Circulator off Starts the circulator Operates motorised valve Operates motorised valve Ignition device off Supplies the ignition device Figure 10 25 10 13 Thermal control in the 3 mode Switch in the function mode See functioning with the function control in the 3 mode lt YES sec 10 13 water from the domestic hot NO Is primary circuit temperature higher than that selected YES NO Request for heat from room thermostat _ Circulator off Starts the circulator Operates motorised valve Operates motorised valve Ignition device off Supplies the
36. em is completely closed The By pass valve is inside of the diverter group 5 j s W ol La TE HS BN j Figure 16 1 16 2 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels 2 Empty the primary circuit of the boiler 3 Remove the locking plate B and pull up the by pass valve A Figure 16 3 Figure 16 2 4 Reassemble the by pass valve as illustrated in Figure 16 2 reversing the order of removal Cr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities Attention when reassembling the By pass valve be A sure that it is correctly oriented by matching the ref erence C with the notch D of the water group Figure 16 3 A Figure 16 3 KS FAN AND AIR PRESSURE SENSOR 17 FANAND AIR PRESSURE SENSOR 17 1 Function The function of the Fan A Figure 17 1 and Figure 17 2 is to force the products of combustion through the condensing heat exchanger to the outside air via the flue system The Fan is supplied by the full sequence ignition device at the
37. emperature ad justment knobs by delicately pulling them with pliers in the direction shown by the arrows in Figure 10 23 Figure 10 23 4 Unscrew the four screws that hold the Electronic control igni tion p c b on to the control panel 5 Remove it by lifting its rear edge and freeing it from any of the wiring 6 Re assemble the Electronic control ignition p c b following the removal procedures in the reverse order 25 ELECTRONIC CONTROLIIGNITION P C B Important When re assembling the Electronic control ignition p c b 7 Fitthe p c b into the control panel by first inserting the front lower edge under the control knob shafts Lower the rear edge and ensure that no wiring is trapped beneath 8 Insert the spindles in the control panel knobs until the notch A Figure 10 24 reaches the potentiometer edge It is not necessary to force them in the knob 9 While tightening the screws that fix the Electronic control igni tion p c b on the control panel keep the p c b towards the control panel fascia making sure of the contact between the boiler reset button B and the tab C Figure 10 24 o Ce ks kr kr e Figure 10 24 Attention After installing the Electronic control ignition p c b 10 Make sure the c h Gm and d h w GA temperature ad justment knobs can move freely for the complete range If not remove the spindle again as described at step 3 turn the knob half a turn and re insert th
38. en the gas valve outlet pressure test point 7 in Figure 11 2 and connect the gauge Figure 11 3 29 MODULATING GAS VALVE 5 Remove the protection cap B Figure 11 3 from the me chanical pressure adjustment components levering with a flat screwdriver in the slots C 6 Start the boiler at its maximum power Operate the boiler in d h w mode or ensure that the boiler is not range rated if the test is carried out in c h mode 7 Rotate the maximum gas pressure adjustment 2 in Figure 11 2 until you obtain the required pressure by rotating clock wise the pressure increases 8 Turn the boiler off and disconnect one of the two connectors 3 in Figure 11 2 9 Start the boiler and rotate the minimum gas pressure adjust ment 1 in Figure 11 2 until you obtain the required pressure by rotating clockwise the pressure increases 10 Turn the boiler off and re connect the wire to the modulating operator 11 Start the boiler and check again the maximum gas pressure setting 12 Turn the boiler off and disconnect the gauge Important after the gas pressure checks and any adjust ment operations all of the test points must be sealed and replace the adjustment protection cap 11 4 Checks Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Check the modulation operator coil 1 Remove the front panel of the case 2 Disconnect the connectors D Figure 11 5
39. h foods and approved by the local water Au thorities above if it deemed necessary to undertake a com T Warning After cleaning or replacement as detailed bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 14 D H W HEAT EXCHANGER 7 D H W HEAT EXCHANGER 7 1 Function The d h w heat exchanger A in Figure 7 1 and Fig 4 allows the instantaneous transfer of heat from the primary hydraulic circuit to the water destined for d h w use m d NG os Ny y A Hl t J 1 H EY ei dk ly ga M 4 k mr x A A A A Figure 7 1 The schematic structure is shown in Figure 7 2 A V A V m Primary hydraulic circuit Domestic hot water circuit Figure 7 2 7 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front and right hand side panels of the case 2 Empty the primary circuit and the d h w circuit of the boiler 3 Remove the pump B in Figure 7 3 see section Removal pump page 16 4 Remove the clip C and remove the primary circuit pressure switch D by lifting it upwards It is not necessary to disconnect it fro
40. he front panel of the case Don t disconnect the connectors B 3 Measure the electrical frequency at the leads of the sensor Without flow rate the electrical frequency must be 0 32Hz With flow rate the electrical frequency must be 33 200Hz N 14 5 Removal of the flow switch group and d h w cir cuit filter Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 33 D H W FLOW SWITCH FILTER AND FLOW LIMITER 1 Remove the front panel of the case and empty the d h w cir cuit 2 Remove the fork D and pull up the flow switch plug E Figure 14 3 with the help of a screwdriver A To remove the body 4 with the filter from the flow switch group rotate the flow switch plug 1 Figure 14 5 4 Reassemble the parts following the removing sequence in reverse order 14 6 Flow limiter The M296 24SM C model is factory fitted with a 10 litres min flow limiter white To install the flow limiter 1 Remove the flow switch group as explained in the section 14 5 2 Rotate the flow switch plug 1 to separate it from the body 4 Figure 14 5 rotate e et amp Figure 14 5 1 Insertthe flow limiter 3 as shown in Figure 14 5 2 Reassemble the group following the above sequence in re verse order 34 TEMPERATURE PROBE 15 TEMPERATURE PROBE 15 1 Function The Temperature probe has the function of converting the tem perature of t
41. he gas at the burner It checks the presence of the flame during the entire period in which it is activated supplies the fan and checks its functioning by means of the signal coming from the air pressure sensor The Electronic control ignition p c b has a safety function and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler The Electronic control ignition p c b can lock the functioning of the boiler lock state and stop its functioning up to the resetting intervention The lock is signalled by the lighting of the lock out signal lamp and the device can be reset only by using the boiler reset button placed on the control panel fascia Some components which are connected to the device can acti vate the lock state The causes of a lock state could be e The intervention of the safety thermostat overheat of the pri mary circuit The intervention of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wiring or con nection Faulty flame detection faulty detection electrode its wiring or connection Gas injectors blocked Faulty modulation gas valve faulty on off operators or not elec trically supplied Faulty Electronic control ignition p c b Other components like the air pressure sensor can temporar ily stop the ignition of the burner but allow its ignition when the cause of the
42. he water in the hydraulic circuit where it is installed into an electrical signal resistance The relation between temperature and electrical resistance is stated in Figure 15 1 Q 12500 12000 11500 11000 10500 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Figure 15 1 On the boiler there are two Temperature probes One on the out put of the primary heat exchanger c h temperature probe A in Figure 15 2 and Figure 15 3 one on the output of the d h w heat exchanger d h w temperature probe B in Figure 15 2 and Fig ure 15 4 mt ch ch er ea Sa return flow inlet outlet Figure 15 2 15 2 Checks Sensor operation Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Disconnect the cable from the Temperature probe Measure the temperature of the pipe C where the Temper ature probe is located and check the electrical resistance
43. heat The condensed vapour is then drained through the condensate trap B and the draining pipe C gt lt D lt Pq D lt Figure 6 1 6 2 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove the case panels and the sealed chamber lid section Body panels page 5 2 Empty the primary circuit of the boiler 3 Remove the fan D in Figure 6 2 see section Removal of the Fan page 39 4 Disconnect the connectors of the flue temperature probe NTC E Remove the clip F 6 Completely loosen the connection G and slightly move the pipe H upwards 7 Remove the clip I Loosen the connection J 9 Free the pipe K from the connection of the condensing heat exchanger lift and rotate it towards right 10 Using pliers remove the spring L moving it to wards right and disconnect the rubber pipe M 11 Rotate the exchanger as indicated by the arrow and remove it towards the front of the boiler al CO NM SS _ im o I iii Figure 6 2 12 Reassemble th
44. hing ON the burner at minimum power then switching OFF ON OFF function If the power requested is higher then the burner is switched ON at maximum power and will control by modulating to 40 of the maximum power output During the c h operation Figure 10 3 the signal coming from the c h temperature probe is compared to the signal given by the control panel through the adjustment made by the user knob 8 1 The result of such a comparison operates the modulation of the gas valve consequently changing the useful output of the boiler Figure 10 3 When the boiler functions in d h w Figure 10 4 the signal com ing from the d h w temperature probe is compared with the sig nal given by the control panel through the adjustment made by the user knob BEA SCH t ES IS ane KEE vv vv 1 bee J J SY ES R RR Figure 10 4 2 li ELECTRONIC CONTROLIIGNITION P C B Normally the result of the comparison between these two sig nals directly operates the adjustment elements of the gas valve modulation device adjusting the useful output generated in order to stabilize the temperature of the exiting water If during the d h w mode operation the temperature of the pri mary circuit goes over 75 C the useful output is automatically reduced so that the primary circuit cannot reach excessive tem peratures The cont
45. imum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain a temperature below that of the Flue temperature probe NTC and no overheat intervention should occur M Temperature resistance relationship Remove the probe see section Removal page 42 to have it at room temperature 2 The electric resistance of the Flue temperature probe NTC at room temperature of 20 C must be of approximately 12000 Q 3 For other temperatures of the probe check the electrical re sistance according to the graph Figure 20 1 20 3 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the wires B from the Flue temperature probe NTC Figure 20 3 3 Unscrew and remove the thermostat probe A Figure 20 3 from the condensing heat exchanger 4 Assemble the Flue temperature probe NTC carrying out the removal operations in reverse sequence 42 CONDENSATE TRAP 21 CONDENSATE TRAP 21 1 Function The condensate trap A in Figure 21 1 and Figure 21 2 allows the discharge of the condensate via the condensate drain pipe avoiding in the mean time the escape of combustion products A plastic ball closes the trap outlet in case that the trap is empty
46. intervention has stopped Figure 10 27 shows the sequence of the operations that are car ried out at the start of every ignition cycle and during normal functioning 10 2 Selection and adjustment devices On the Electronic control ignition p c b several selection adjust ment and protection devices are located Figure 10 2 Some of these devices are directly accessible by the user func tion control temperature adjustment potentiometers etc others are accessible by removing the service panel or the control panel lid 20 ELECTRONIC CONTROLIIGNITION P C B Figure 10 2 1 vi connector 2 x6 connector 3 x7 connector 4 x4 connector 5 x2 connector 6 x15 connector 7 x11 connector 8 Lock out signal lamp 9 Boiler reset button 10 Function control C h temperature adjustment 11 D h w temperature adjustment 12 Appliance operation lights 13 x8 connector 14 Fuse 3 15 A F 10 3 Checking the temperature The Electronic control ignition p c b makes it possible to sepa rately adjust the c h water flow temperature and d h w outlet temperature The temperature of the water is converted into an electric signal by means of temperature probes The user setting the desired temperature with the control panel knobs operates the variable elements 10 and 11 in Figure 10 2 of the electronic control p c b l f the power requested is lower than 40 of the maximum power output then control is achieved by switc
47. ir pressure sensor Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Remove all the case panels and the sealed chamber lid Disconnect the wires from the Air pressure sensor Remove the pipe J from the Air pressure sensor Unscrew the screws which hold the Air pressure sensor to the frame 5 Assemble the Air pressure sensor carrying out the removal operations in reverse sequence Q N Warning to correctly connect the Air pressure sen A sor refer to Figure 17 5 39 IGNITION AND DETECTION ELECTRODES 18 IGNITION AND DETECTION ELECTRODES 18 1 Function Three electrodes are fitted on the burner Two of them are the ignition electrodes and are fitted near the front part of the burner The ignition sparks take place between their metallic edges over the central ramp of the burner during the ignition sequence The third electrode is the detection electrode and it detects the presence of the flame Detection Male Figure 18 1 18 2 Checks Check the position of the electrode edges Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Check for the correct distance between the metallic edges of the ignition electrodes see Figure 18 2 4mm Ignition si ch I Figure
48. le to be in con This device is connected to the electronic control p c b and if it tact with foods and approved by the local water Au does not activate the control board will indicate that a fault condi thorities tion see section Operation lights page 22 has occurred 12 2 Checks Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Electrical check It is possible to verify the general operation of the switch by measuring the electric resistance between the contacts C and N O of the switch 1 Measure the electrical resistance between the tabs marked C and N O Figure 12 2 The contact must close resistance zero with c h pressure of 0 35 bar or higher N O 0 7 Figure 12 2 Ne EXPANSION VESSEL AND TEMPERATURE PRESSURE GAUGE 13 EXPANSION VESSEL AND TEMPERATURE PRESSURE GAUGE 13 1 Function The Expansion vessel D in Figure 12 1 function is to allow for the volume expansion of the c h circuit water due to the tem perature rise 13 2 Checks 1 Turn off the flow and return isolation valves and empty the primary circuit of the boiler 2 Remove the protective cap E Figure 13 1 from the valve on the top of the expansion vessel and connect a suitable air pressure gauge Figure 13 1 Rear view of the boiler 3 Check the pre load pressure and refer to the section Expan si
49. lt JA i 2 exchanger GER Pump AS wW Control Gasvalve panel Figure 1 1 1 2 Hydraulic diagram Central heating c h operation heemesch A NA C h C h waterreturn Figure 1 2 waterflow Domestic hot water d h w operation L lt t A D h w inlet y D h w outlet GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 1 Nomenclature T Figure 2 1 Right side panel Front panel Control panel lid Control panel cover Service panel Left side panel oa hwnd 2 2 Body panels Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent For the most part of the check and maintenance operations it is necessary to remove one or more panels of the case The side panels can be removed only after the removal of the front panel To remove the front panel remove screws A Figure 2 2 lift the panel and remove it Figure 2 2 To remove the side panels loosen the screws B and C Figure 2 3 bring the base of the panels away from the boiler and lift them freeing them from the top hooks Figure 2 3 bottom view of the boiler 2 3 Control panel Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent To gain access to the
50. lve carrying out the removal operations in reverse order wo NO Q After any service operation on the components of the gas circuit check all the connections for gas leaks Warning After cleaning or replacement as detailed A above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 30 PRIMARY CIRCUIT PRESSURE SWITCH 12 PRIMARY CIRCUIT PRESSURE SWITCH 12 3 Removal Warning isolate the boiler from the mains electrici 12 1 Function ty supply before removing any covering or compo The Primary circuit pressure switch A in Figure 12 1 function nent is to check the presence of water in the primary hydraulic circuit and that the pressure is above the minimum 1 Remove the front and right hand side panels of the case turn off the flow and return isolation valves and empty the primary SCH circuit SE 2 Remove the fixing spring B Figure 12 3 and remove the pri mary circuit pressure switch A 3 Disconnect the connectors Figure 12 3 4 4 Reassemble the primary circuit pressure switch in reverse order of removal A d Figure 12 1 f Cyr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatib
51. m the wiring 5 Remove the clip E and remove the electric actuator F by pull ing it It is not necessary to disconnect it from the wiring SS U E Wh W Figure 7 3 6 Completely unscrew the two Allen key screws G Figure 7 4 which hold the exchanger to the plastic groups o Figure 7 4 7 Move the exchanger towards the rear of the boiler and extract it Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order EA Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities sure to put the off center location securing pin indi T Warning When reassembling the exchanger be cated in Figure 7 5 towards the left side of the boiler Figure 7 5 15 PUMP 8 PUMP 8 1 Function The pump A in Figure 8 1 and Figure 8 4 has the function of making the water in the main circuit circulate through the main heat exchanger the condensing heat exchanger and therefore through the c h system during the c h function or through the secondary heat exchanger during the d h w function m E ik J al L m gt a 7 L
52. on vessel in the User manual and installation instructions for the correct value 13 3 Removal of the expansion vessel If there is at least 400 mm clearance above the boiler and the rear exit flue can be easily removed the expansion vessel can be changed without removing the boiler Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove the front and left hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit 2 Completely unscrew the connection F the locknut G Figure 13 2 and remove the expansion vessel from the top of the boiler AS 0 Figure 13 2 3 Re assemble the parts in reverse order of removal 13 4 Removal of the temperature pressure gauge 1 Remove the front and right hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit 2 Remove the fork H and the probe holder spring Figure 13 3 3 Squeeze the tabs J to release the temperature pressure gauge K and remove it 4 Re assemble the parts in reverse order of removal pp pu gt e E H SE e 06 e D ee e la py o E E la O Se 2 80 Figure 13 3 32 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14
53. rcuit 1 KI1042 501 22 H74 553 Temperature probe main circuit 1 BI1442 106 23 E83 127 Ignition electrode left 1 BI1123 101 mod M296 24SM C M296 28SM C 24 E83 126 Ignition electrode right 1 BI1123 103 mod M296 24SM C M296 28SM C 25 E83 122 Detection electrode mod M296 24SM C M296 28SM C 1 BI1123 102 26 E83 145 Temperature pressure gauge 1 BI1475 108 IMIT 27 Recuperator 1 Bl1442 121 44 SHORT SPARE PARTS LIST SA Y Ay 4 Figure 22 1 45 NOTE 46 17962 1549 5 0312 48A4 UK 2102 10 91 Biasi UK Ltd Commercial Road Leamore Enterprise Park WALSALL WS2 7NQ Sales Tel 01922 714600 Tech Service Tel 01922 714636 www biasi co uk
54. replacement as detailed above if it deemed necessary to undertake a com bustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Figure 19 1 19 2 Checks YM Overheat temperature value 1 Set the temperature control knobs to their max position and run the boiler in d h w and c h 2 Allow the boiler to reach its maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain a temperature below that of the safety thermostat and no overheat intervention should occur Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Electrical function 1 Remove all the case panels and the lid of the sealed cham ber 2 Disconnect the wiring B of the safety thermostat and check its electrical function Normally no intervention the contact must be closed electrical resistance zero Q 41 FLUE TEMPERATURE PROBE NTC 20 FLUE TEMPERATURE PROBE NTC 20 1 Function The Flue temperature probe NTC A in Figure 20 2 and Figure 20 3 senses the temperature of the combustion products that flow through the condensing heat exchanger The relation between temperature and electrical resistance is stated in Figure 20 1 Q 18500 18000 17500 17000 16500 16000 15500 15000 14500 14000 13500 13000
55. rol sequences in function and in function are illustrated in detail in sections 10 2 and 10 3 10 4 Operation lights The Electronic control ignition p c b is provided with three lamps L E D indicators 12 in Figure 10 2 that give optical information during the operation of the boiler The green lamp on the left gives information whether the boiler is in stand by mode or during the normal operation of the boiler The following table gives the relationship between the lamp indi cation and its meaning CE OE Or Boiler in stand by condition function control in di gt position A short pulse every 4 seconds Anti freeze system active res O Ee f D Boiler ON condition function control in or gt ort 1 second ON 1second OFF Pposition With the boiler switched ON 3 or GK all the lamps 12 in Figure 10 2 are activated The following table gives the relationship between each of the possible lamp combinations and their meaning LI DU M ule SR CC O Faulty air pressure sensor E yA Lack of burner ignition no ignition signal from O g no ig g A the full sequence ignition device SCH e Safety thermostat lock out O O Flue temperature probe NTC lock out vt Flame detection error Lack of power supply or fauly electronic O O X Flame detection error O O control p c b O O Lamp O
56. s in the Figure 8 6 reverse order When reassembling the pump check the correct location of the O ring gasket in the inlet port of the pump that seals the connection between the pump and the return water group 17 THREE WAY DIVERTER VALVE 9 THREE WAY DIVERTER VALVE 9 1 Function The diverter valve A Figure 9 1 has the function of modifying the hydraulic circuit of the boiler by means of an electric command given by the electronic control p c b in order to send the water that exits the primary heat exchanger towards the c h system or towards the d h w heat exchanger G eet Iess 228 Cc E Cl a 4 i mr X X A A Figure 9 1 9 2 Checks A Warning check the electrical continuity Figure 9 2 indicates the relationship between the electric com mand coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in d h w mode Figure 9 3 indicates the relationship between the electric com mand coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in c h mode In both figures the relationship between the position of the actua tor and th
57. tion instructions manual T Warning After cleaning or replacement as detailed 40 SAFETY THERMOSTAT 19 SAFETY THERMOSTAT 19 3 Removal Warning isolate the boiler from the mains electrici 19 1 Function ty supply before removing any covering or compo The safety thermostat A in Figure 19 1 and Figure 19 2 is a de nent vice that senses the temperature of the primary circuit water which flows in the outlet pipe of the primary heat exchanger 1 Remove all the case panels and the lid of the sealed cham If the temperature control system of the boiler fails and the tem ber perature of the primary circuit reaches a dangerous temperature the safety thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp Figure 19 2 2 Disconnect the wiring B Figure 19 2 3 Remove the spring C which holds the overheat thermostat on the pipe of the primary heat exchanger and remove it 4 Reassemble the overheat thermostat carrying out the opera tions in reverse order 5 Apply an adequate quantity of heat conducting compound between the pipe and the thermostat Warning After cleaning or
58. urn the boiler OFF positioning the function selector A as in dicated in Figure 10 6 Figure 10 6 5 Disconnect the electrical connectors C of the C h tempera ture probe NTC in Figure 10 7 22 ELECTRONIC CONTROLIIGNITION P C B Figure 10 7 6 Keep pressed the reset button D for about 10 seconds until the lock out signal lamp E blinks 7 Connect the electrical connectors C of the C h temperature probe NTC in Figure 10 7 8 Thelamps F should give the indication as in Figure 10 8 use ful output first step If not press the reset button repeatedly to obtain it O O were O Lamp OFF LI 00 000 O Lamp on Figure 10 8 At this step it is possible to visualize the current setting by keeping the reset button D pressed for more than 5 seconds The lamps F will flash a number of times corresponding to the setting Figure 10 9 once for M296 24SMI C and four times for M296 28SM C M296 28SM C 4 flashes M296 24SM C 1 flash Figure 10 9 9 To change the setting turn the knob B on a position corre sponding to the boiler models Figure 10 9 By turning the knob B the lock out signal lamp E blinks quickly 2 per sec onds indicating that the setting has changed and must be memorised 10 To memorize the setting keep pressed the reset button D for about 5 seconds until the lights F briefly blinks simultane ously 11 Press the reset button D once until the
59. with one that has the same charac teristics after having identified the reason for failure Lock sequence Start the boiler until the burner is ignited With the burner firing interrupt the gas supply The Electronic control ignition p c b must carry out three complete ignition cy cles and then after about 3 minutes goes to lock out state By turning the boiler on and off by means of the function switch the device must not unlock and the burner must not turn on Fan functioning device With the boiler operating and the burner on open the positive pressure test point of the Fan pressure connection devise After opening it the burner must turn off 10 11 Removal of the electronic control p c b Warning isolate the boiler from the mains electric ity supply before removing any covering or compo nent When replacing the Electronic control ignition p c b it is ad visable to go through the setting modes of the boiler 1 Gain access to the parts located inside the control panel as explained in the section Control panel page 5 of this manu al 2 Remove all the wiring connected to the Electronic control ignition p c b To disconnect the connectors x1 x6 and x7 1 2 and 3 in Figure 10 2 delicately flex the hook present on one side of each socket To disconnect the connectors x4 and x2 4 and 5 in Figure 10 2 press delicately the hook present on one side of each connector 3 Remove the spindles of the c h and d h w t
60. yr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities valve be sure that the tree way diverter is correctly oriented by matching the reference G with the notch of the water group Figure 9 5 T Warning When reassembling the tree way diverter 9 5 Removal of the diverter group Remove the front and both side case panels Empty the primary circuit and the d h w circuit of the boiler Remove the electric actuator section Removal of the elec tric actuator page 18 Remove the fixing spring H Figure 9 6 and remove the pri mary circuit pressure switch I Figure 9 6 5 Disconnect d h w temperature probe respectively J Figure 9 7 Figure 9 7 6 Unscrew the connector K Figure 9 6 the c h flow connector and the d h w outlet connector 7 Remove the d h w heat exchanger section Removal page 15 8 Unscrew the screws and remove the diverter group 9 Reassemble the diverter group carrying out the removal op erations in the reverse order Cr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities 19 ELECTRONIC CONTROLIIGNITION P C B 10 ELECTRONIC CONTROL IGNITION P C B 10 1 Function Inlet Information On the Electronic control ignition Tae A o NNAS
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