Service manual
Contents
1. 2 at FEBRE x AAA I L ai mme Al t ME ME 1 hl Ui J a 3 n Fig 11 1 By means of an electric command given to the on off operators the passage ofthe gas through the Gas valve can be opened or closed HEJ Description of the parts Fig 11 2 L Fig 11 2 1 Maximum gas pressure adjustment 2 Minimum gas pressure adjustment 3 On off operators 4 On off operators electric connector 5 Gas valve inlet pressure test point HEN Adjustment NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Check the supply pressure before making any ad justment to the gas valve 1 Close the gas inlet valve 2 Remove the front panel of the case and lower the control panel see sections 2 2 and 2 3 3 Loosen the internal screw on the Inlet Pressure Test Point 5 Fig 11 2 of the Gas valve and con nect a pressure gauge using a suitable hose 4 Open the gas inlet valve 5 Turn on the electricity supply to the boiler switch ing on the fused spur isolation switch 6 Setthe boiler in c h d h w function as illustrated in Fig 11 3 AL O foe 7 Open at least one hot water tap fully 8 Read the inlet pressure value and ensure that it is within the li2. SW version BC burner control SW version MB main board Tab 10 1 Fan speedy the value has to be x 100 4400 rpm KEN Function modes setting modality Itis possible to selectthe various boiler control function modes hereafter named parameters by using the keys of the control panel p c b During the function modes setting the boiler does not operate To get in function modes setting modality see section 9 4 ID EN Removal of the control panel electronic p c b NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the body panels see section 2 2 2 Gain access to the parts located inside the Con trol panel electronic p c b as explained in the section 2 3 of this manual 3 Remove all the wiring A connected to the Control panel electronic p c b Fig 10 3 25 Control panel electronic p c b Fig 10 3 26 Unscrew the screws B Delicately flex the hooks C in the directions indi cated Fig 10 3 in order to release the circuit from the box Remove the Control panel electronic p c b Reassemble the Control panel electronic p c b carrying out the removal operations in the reverse order 11 Gas valve URN Function The Gas valve A in Fig 11 1 controls the gas inflow to the boiler burner
3. Wall hung fan flue room sealed high efficiency gas boiler Service manual ActivA Models Activ A 25C Activ A 30C Activ A 35C Activ A 18S Activ A 25S Activ A 30S Leave this manual adjacent to the gas meter recommended G C Appl No 47 583 21 47 583 22 47 583 23 41 583 11 41 583 12 41 583 13 Table of contents h n 10 1 10 2 10 3 10 4 Overall information 1 Overall View 1 Hydraulic diagram 1 General access and emptying hydraulic circuits l ieee Re eee T xS Nomenclature 2 Body panels sseesssss 2 Control panel 2 Main electronic p c b box 3 Emptying the primary circuit 3 Emptying the d h w circuit 4 Diagrams 5 Wiring diagram Activ A 25C Activ A 30C Activ A 35C 5 Wiring diagram Activ A 18S Activ A 25S Activ A 308 6 Circuit voltages 7 Fault finding 8 Display diagnostic 10 Condensing heat exchanger 11 Function ea ix Mene 11 Removal orae ua yuyaq uy ees 11 Cleaning 12 D h w heat exchanger 13 Function oe rixa enun 13 Removal s aran eae a ep epe aes 13 PUM Ps ua 14 Function uo care bite pe baad 14 Checks sec Mea cal eet
4. D h w temperature reduce key E D h w temperature increase key F Display The Control panel electronic p c b can give to the ser vice 3 levels of informations O Normally information see the installation manual chapter APPLIANCE DESCRIPTION section LCD general features O Info modality O Function modes setting modality EDEN info modality The INFO mode allows the display of some information on the boiler functioning status In case of malfunction ing of the boiler it may be useful to communicate such information to the Authorised Service Centre Engineer so that the causes can be understood In order to access the INFO mode press keys A and C Fig 10 1 at the same time until the letter di appears on the display that alternates with a code Fig 10 2 S1 s 17 la B I Lt N V l J YN AMAN Fig 10 2 To scroll the values press B reduce and A increase keys Fig 10 1 In order to exit the INFO mode hold keys A and C Fig 10 1 pressed at the same time The following table gives details of each parameter and the possible value that can be show External temperature C if fitted K value external probe dia gram the value is x 10 Offset Transaltion of K diagram 15 C C h temperature C calcu lated by external sensor C h flow temperature C 6 78 C h return temperature C if fitted D h w temperature C Flue temperature C 8 67
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6. carrying out the removal operation in reverse or der KEEN Removal of the burner NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the air box and the fan see section 17 2 2 Unscrew the screws Fig 18 1 and remove the fan burner duct A 3 Remove the burner by sliding it forward locating tab burner gasket Fig 18 3 4 Assemble the burner carrying out the removal operation in reverse order Ensure the burner is correctly located by lining up the locating tab Fig 18 3 Before reassembling ensure the burner gasket is correctly located Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual REX Checks Check the position of the electrode edges NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the ignition electrodes see section 18 2 2 Check for the correct distance between the me tallic edges of the ignition electrode see Fig 18 4 39 Ignition and detection electrodes earth electrode Check the connection wires Ignition electrode Fig 18 4 40 19 Safety thermostat KAN Function The safety thermostat A in Fig 19 1 is a device that senses the temperature of the primary circuit water wh
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8. 9 i l28 2 2 3 38 8 28 s o s 8 S ls 8 2 8 l amp 8 2 5 3 ale 5 D lt S 2 s S 5 2 o 8 S 5 2 Q o t amp 5 o 2 3 188 3 12 S S 9 ele S 3 2 5 gt 3 s lt 8 ele 88 al8 lala 3 3 le 8 S amp 8g g 3 5 gt o o o olo 17 gt s o 5 I o a o o o S S o j gt gt o S o c 9 o o 3 o o g 5 2 2 a e x 5 Z o 3 o 3 o o a 9 e ES lo 313 m x 2 S 5 S 3 o e o S lo jeq 2 r g 2 U siexoeJq ul 184 eyou _ rO0Oc c 6L c 6L vel ZL 9L SL Svi c ctv LL OL S6 vi c8 c2 9 S E Lic enueu ay jo uonoes yooyd 0 sjueuoduuo2 EXI Display diagnostic An help forthe fault finding may be given by the display indications The display on the control panel gives many informa tion Only the indications useful for the fault finding are here described The following table gives the relationship between the indications of error of the display and their meaning Er 01 RESET Lack of burner Lack of burner ignition Er 02 RESET ESTE thermostat lockout Er 03 RESET Other faults Faulty primary circuit no water or Fros absence of flow Er 05 Faulty fan control system Faulty c h temperature probe Er 06 c NTC Faulty d h w temperature probe Er 07 c NTC Faulty external temperature probe Er 08 NTC i fitted Faulty flue temperatu
9. Fig 12 1 This device is connected to the main electronic control p c b and if it does not activate the control board will indicate that a fault condition see section 4 1 of this manual has occurred EEN Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Electrical check Itis possibleto verify the general operation of the switch by measuring the electric resistance between the con tacts C and N O of the switch 1 Measure the electrical resistance between the tabs marked C and N O Fig 12 2 The contact must close resistance zero with c h pressure of 0 35 bar or higher 30 N O Y NY a P x Nuit ENS iN U i al Fig 12 2 PEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 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 fixing spring B Fig 12 3 and re move the primary circuit pressure switch A 3 Disconnect the connectors C Fig 12 3 Fig 12 3 4 Reassemble the primary circuit pressure switch in reverse order of removal E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Auth
10. NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front case panel 2 Disconnect the connectors C Fig 8 4 3 Remove the fixing spring D and remove the actuator B Reassemble the actuator carrying out the re moval operations in the reverse order When reassembling the actuator refer to Fig 8 2 or to the wiring diagram in section 8 2 for the cor rect wiring connection Three way diverter valve Fig 8 4 EX 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 see section 8 3 4 Remove the fixing spring E Fig 8 5 5 Remove the tree way diverter valve F by levering with a screwdriver in as shown in Fig 8 5 Fig 8 5 Reassemble the tree way diverter valve carrying outthe removal operations in the reverse order E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities Attention When reassembling the tree way diverter valve be sure that the tree way diverter is correctly oriented by matching the reference G with the notch of the water group Fig 8 5 EXE Removal of the diverter group 1 Remove the front and both side case panels 2 Empty the primary circuit and the d h w circuit of
11. Remove the front panel of the case Terminal block lid removal 2 To remove the terminal block lid E Fig 2 6 free the front hooks Fig 2 6 3 Slightly rotate the lid as indicated by the curved arrow and free the rear hooks 4 Remove the lid Main electronic p c b lid removal To get access to the main electronic p c b 5 Pull the box that contains the electronic p c b and rotate it Fig 2 7 General access and emptying hydraulic circuits Fig 2 7 6 Remove the terminal block lid E Fig 2 6 7 Free the hooks placed on the three sides indi cated and rotate the lid towards left Fig 2 8 Fig 2 8 PU Emptying the primary circuit 1 Close the c h circuit flow and return cocks F Fig 2 9 Fig 2 9 bottom view of the boiler 2 Remove the front and right panels of the boiler 3 Open the drain tap G Fig 2 10 combi or Fig 2 11 only c h until the boiler is completely emptied 4 Close drain tap once the emptying has been completed 3 General access and emptying hydraulic circuits CLOSED Fig 2 11 PON Emptying the d h w circuit 5 Close the d c w inlet cock H Fig 2 9 6 Open one or more hot water taps until the boiler Fig 2 10 has been completely emptied 3 Diagrams EXI Wiring diagram Activ A 25C Activ A 30C Activ A 35C Three way Gas valve Fan Condensate di
12. leftwards Reassemble the d h w heat exchanger carrying outthe removal operations in the reverse order E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities Attention When reassembling the exchanger be sure to put the off centre location securing pin indi cated in Fig 6 4 towards the left side of the boiler Fig 6 4 13 7 Pump Function The pumpA in Fig 7 1 and Fig 7 3 has the function of making the water in the main circuit circulate through the main 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 J 2 J XEM faa lt P m Ln Fig 7 1 Checks Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm Check that the pump is not seized and that the movement of the rotor is not subject to mechanical im pediments With the boiler off remove the front panel Remove the air release plug of the pu
13. p c b box Left side panel PRI Body panels NN Warning isolate the boiler from the mains electricity supply before removing any covering or component a C0 nm For the most part of the check and maintenance oper ations 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 loosen screws A Fig 2 2 Fig 2 2 bottom view of the boiler Pull the lower part of the front panel and lift it upwards Fig 2 3 2 Fig 2 3 To remove the side panels loosen the screws B Fig 2 2 and C Fig 2 3 Pull the side panels towards the outside PEN Contro panel NN Warning isolate the boiler from the mains electricity supply before removing any covering or component To gain access to the parts located inside the control panel proceed as follows 1 Remove the front panel of the case 2 To open the control panel by leverig with a screw driver in as shown in Fig 2 4 Fig 2 4 3 To access to the parts located inside the control panel to free the hook D Fig 2 4 and turn it as shown in Fig 2 5 Fig 2 5 EX Nain electronic p c b box Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component To gain access to the parts located into main electronic p c b box proceed as follows 1
14. the boiler 3 Remove the electric actuator see section 8 3 4 Remove the fixing spring H Fig 8 6 and remove the primary circuit pressure switch Fig 8 6 5 Disconnect d h w temperature probe respect ively J Fig 8 7 lg Fig 8 7 6 Unscrew the connector K Fig 8 6 the c h flow connector and the d h w outlet connector 7 Remove the d h w heat exchanger see section 6 2 8 Remove the fork L and move away the pipe M Fig 8 6 9 Unscrew the screws N and remove the diverter group Fig 8 6 10 Reassemble the diverter group carrying out the removal operations in the reverse order E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities 17 9 Main electronic control ignition p c b EXI Function Fig 9 1 18 Inlet Information On the Main electronic control ignition PCD Function control C h temperature adjustment D h w temperature adjustment Boiler reset button control panel electronic p c b From other boiler devices C h temperature probe NTC D h w temperature probe NTC D h w flow switch Primary circuit pressure switch Flue temperature probe NTC Safety thermostat Flame detection electrode Room thermostat if fitted Time switch if fitted Outlet command Pump Three way diverter valve Gas valve Fan Igni
15. 1 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 a E A E 22 y A Fig 21 1 If the drain pipe is plugged or in any case in which the condensate isn t correctly evacuated the condensate level in the trap rises till it reaches a screw that is in con tact with the flame detection circuit thus causing the boiler lock out AEJ Check the cleanness of the trap Unscrew the plug B on the bottom of the trap A and re move dirt eventually deposit Fig 21 2 BEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front and right case panels 2 Unscrew the threaded locking ring C and remove the flexible pipe D Fig 21 2 3 Disconnect the electric connector E 4 Using pliers remove the spring F moving it up wards 5 Remove the trap A from the pipe G Reassemble carrying out the removal operations in reverse order Fig 21 2 43 22 Short spare parts list 44 turer part no 1 Burner mod Activ A 25C Activ A 18S Burner mod Activ A 30C Activ A 35C BI1313 101 Activ A 25S Activ A 30S 2 Expansion vessel Bl1462 100 3 Condensing heat exchanger mod Activ A 25C Activ A 18S Condensing heat e
16. 14 Removal pump 14 Removal electrical capacitor 15 Three way diverter valve 16 PUN CHOM eo 16 Ghiecks ers Meiers at ERR 16 Removal of the electric actuator 16 Removal of the tree way diverter valve 17 Removal of the diverter group 17 Main electronic control ignition p c b 18 Function sone rp eR ELM ER 18 Selection and adjustment devices 18 Checking the temperature 19 Setting the boiler control function modes 20 CHECKS cede asi 22 Removal of the electronic control p c b 22 Thermal control in the 2 amp mode 23 Thermal control in the gt mode 24 Control panel electronic p c b 25 FUNCION c suc up ume IER e 25 Info modality uu aula p AQ aq us 25 Function modes setting modality 25 Removal of the control panel electr p c b 25 11 11 1 11 3 11 4 11 5 12 12 1 12 2 12 3 13 13 1 13 2 13 3 13 4 14 14 1 14 2 14 3 14 4 14 5 14 6 15 15 1 15 2 15 3 15 4 16 16 1 16 2 17 17 1 17 2 18 18 1 18 2 18 3 18 4 19 19 1 19 2 19 3 20 20 1 20 2 20 3 21 21 1 21 3 22 Gas valve 27 Function 2 2 L L pa eee a ua 27 Description of the parts 27 AdJ stment ssa eee seer eda es 27 CheckS icri Sea ee ea 29 Removal of the gas valve 29 Primary circuit flow switch 30 FUNCION eee ot
17. 3 10 9 Activ A 25C Activ A 30C Activ A 35C Activ A 18S To adjust the COs value rotate screw 1 Fig 11 2 by rotating it clockwise the CO 96 decreases 23 Presskeys A B C Fig 11 5 atthe same time again to exit the chimney sweep mode and re turn to the previously set boiler status Fig 11 10 ALI E F Ja i 24 Switch off the boiler and turn off the hot water tap s 25 Close the air flue sampling points 26 After adjustment fit the protective brass plug 2 Fig 11 2 Important after the gas pressure checks and any adjustment operations all of the test points must be sealed BEEN Checks Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component Activ A 25S Activ A 30S Tab 11 2 C h d h w function Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector 4 Fig 11 2 Measure the electrical resistance between the connector pins of the on off operators as illus trated in Fig 11 11 N N ON OFF Operator approx 6 400 Q ON OFF Operator approx 920 Q at ambient temperature Fig 11 11 HEN Removal of the gas valve Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case as explained in the section 2 3 of this manual 2 Disconnect the conne
18. 42 FUNCION Es lr 42 Removal ici a 42 CHECKS cioe dune ca 42 Condensate trap 43 FUrietl nc eve ies 43 Check the cleanness of the trap 43 Removal 43 Short spare parts list 44 1 Overall information IB Overall View Flue temperature probe NTC Safet lt Ds Expansi afety gt SA xpansion thermostat NN gt In vessel bod Z Z G es temperature Condensing S probe heat exchanger d RNA LE Y ASS Ighition of ee electrodes Detection electrode Burner Pipe silencer Condensate trap Fan a C h pressure relief valve Air box air gas mixer Automatic air Electronic purger valve control box D h w flow Switch Pump Control panel Gas restrictor Electric actuator D h w heat exchanger diverter valve Pressure Main circuit gauge pressure switch D h w temperature By pass probe valve Gas valve Three way diverter valve IENB Hydraulic diagram Central heating c h operation ce lt s Domestic hot water d h w operation A E s 6 6 U Z VA C h C h D h w D h w inlet outlet water return water flow 2 General access and emptying hydraulic circuits EXI Nomenclature Fig 2 1 1 Right side panel Front panel Control panel Main electronic
19. 5 2 firmly EEN Cleaning If there are deposits of dirt between the fins of the Con densing heat exchanger clean with a bristle paintbrush and remove the dust with a hoover Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 6 D h w heat exchanger EX Function The d h w heat exchanger A in Fig 6 1 and Fig 6 3 al lows the instantaneous transfer of heat from the primary hydraulic circuit to the water destined for d h w use J f TNA NM iS Fig 6 1 The schematic structure is shown in Fig 6 2 A Y A V Primary hydraulic circuit Domestic hot water circuit Fig 6 2 EY Removal Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the panels of the case 2 Empty the primary circuit and the d h w circuit of the boiler 3 Remove the control panel following the instruc tions from 3 in section 2 3 4 Remove main electronic p c b box following the instructions from 5 in section 2 4 5 Remove the pump following the instructions in section 7 3 6 Completely unscrew the Allen key screws B Fig 6 3 which hold the exchanger to the plastic groups Fig 6 3 7 Move the exchanger towards the rear of the boiler and extract it
20. IT VALUES Boiler type to be up 00 No power Er 99 dated with the com 01 Activ A 25C plete range 02 Activ A 30C 03 Activ A 35C 06 Activ A 18S 08 Activ A 25S 09 Activ A 30S IEC mu awe o Nusa a Gas type 00 G20 Natural 05 G31 Propane C h flow max Pr07 85 45 factory set temperature C 85 C Factory parameters Pr 08 00 No reset reset 04 All parameters return to factory set with the exclusion of Pr 01 and Pr 05 39 All parameters return to factory set included Pr 01 and Pr 05 Main electronic control ignition p c b PARAMETER DIGIT VALUES 00 No chimney sweep fun factory set Chimney function sweep 01 Low power sweep test 04 C h power sweep test 07 D h w power sweep test 00 99 0600 sec factory set 30 3 minutes 00 99 0 600 sec factory set 10 1 minute 00 99 0 100 factory set 74 Activ A 25C 79 Activ A 30C 86 Activ A 35C 99 Activ A 18S 99 Activ A 25S 99 Activ A 30S 00 Depends on room thermostat factory set 04 Always running 00 99 0 100 factory set Natural gas G20 20 Activ A 25C 30 Activ A 30C 26 Activ A 35C 32 ActivA 18S 38 Activ A 25S 30 Activ A 30S Propane G31 31 Activ A 25C 30 Activ A 30C 26 Activ A 35C 49 ActivA 18S 37 Activ A 25S 31 Activ A 30S 01 0 1 60 6 0 K value fact
21. alyser to give a stable reading 18 Read the CO value 28 It should be between Type gas CO 9 ducis Activ A 25C Activ A 30C Activ A 35C Activ A 25S Activ A 30S Activ A 18S value Natural G20 8 6 9 2 Propane G31 9 5 10 1 Natural G20 8 6 9 2 Propane G31 9 7 10 3 Tab 11 1 To adjust the CO value remove the brass plug by un screwing it and rotate the Allen key screw g 4 mm 2 Fig 11 2 by rotating it clockwise the CO in creases Checking the maximum gas valve setting 19 Press key A to vary the output in chimney sweep mode when the display shows the letters cP that alternate with the heating water temperature value e g 60 the chimney sweep function is at maximum output in heating mode Fig 11 8 1112 1 1 faa r1 N L V lt a 4 AY Sl gt _ LILI 2529 2492 Fig 11 8 20 Press further key A to vary again the output in chimney sweep mode when the display shows the letters dP that alternate with the heating water temperature value e g 60 the chimney sweep function is at maximum output in domestic hot water mode Fig 11 9 AMY A 412 NET a M Li NN y C lt Y D EN TS D 299 2492 Fig 11 9 21 Allow the analyser to give a stable reading 22 Read the COs value It should be between Gas valve Type gas CO value range Natural G20 9 3 9 9 Propane G31 10
22. and pull up and turn to the left the pipe E Pump Fig 7 4 6 C H only model remove the fork F loosen the connection G and remove the pipe H Fig 7 4 7 C H only model remove the fork and remove the pressure gauge pipe J Fig 7 4 8 Remove the locking plate K Fig 7 3 Fig 7 4 9 Unscrew the two screws L that hold the pump on the frame and remove the pump Reassemble the pump carrying out the removal oper ations in the 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 plastic group Removal electrical capacitor Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front and right hand side case pan els 2 Disconnect the connector B Fig 7 3 following the indications given on the connector box 3 Remove the connector M of the cover box by levering with a screwdriver in as shown in Fig 7 5 03323H3 ALITONE gp so or IO ierozsr Fig 7 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 Fig 7 6 15 8 Three way diverter valve EXI Function The diverter valve A Fig 8 1 has the function of mod ifying the hydraulic circuit of the boiler by means of an electric command given b
23. as mixture and consequently the input power ofthe boiler is proportionalto the speed of the fan that is controlled by the electronic control p c b LN f SN T HIN i Sd Z Y n Fig 17 1 Removal of the Fan and the Air box NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Turn off the gas supply 2 Remove all the case panels see section 2 Fig 17 2 3 Disconnect the air manifold from pipe C by open ing the strip Fig 17 2 38 4 Disconnect the rubber pipe D 5 Unscrew the gas connector E 6 Remove the fixing fork F and remove the gas pipe G 7 Disconnect the connector H 8 Disconnect the fan connector by pressing the plastic hook placed on the side of the connector 9 Unscrew the screws J 10 Remove the fan A with the air box B 11 Remove the screws K and the air box B Fig 17 3 Fig 17 3 12 Openthestrip L by sliding the edges with the help of a screwdriver and remove the Air box Fig 17 4 Fig 17 4 13 Assemble the Fan and the Air box carrying out the removal operations in reverse sequence Before reassembling ensure the fan gasket F
24. case 2 Disconnect the connectors B and remove the sensor holder spring C Fig 14 2 3 Remove the sensor TEN Removal of the flow switch group and d h w circuit filter NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel ofthe case and emptythe d h w circuit 2 Remove the sensor see section 14 4 3 Remove the fork D and pull up the flow switch plug 1 with the help of a screwdriver 4 To remove the filter from the flow switch group separate the filter 6 from the body 4 Fig 14 3 by levering it 5 Reassemble the parts following the removing se quence in reverse order 33 D h w flow switch filtrer and flow limiter MON Flow limiter The Activ A 25C model is factory fitted with a 10 litres min flow limiter The Activ A 30C model is factory fitted with a 12 litres min flow limiter The Activ A 35C model is factory fitted with a 14 litres min flow limiter The following sizes are available If the flow rate of the d h w circuit is still too high it is possible to limit it by replacing the flow limiter The fol lowing sizes are available Nominal flow rate litres min T Re 34 To install the flow limiter 1 Remove the flow switch group as explained in the section 14 5 2 Separate the flow switch plug 1 from the body 4 levering with a screwdriver one of the two hooks Fig 14 4 3 Insert the f
25. ctor D Fig 11 12 Fig 11 12 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port ofthe gas valve 4 Using pliers remove the spring E and the rubber pipe F Fig 11 12 5 Unscrew the connector G Fig 11 12 remove the fixing fork H and remove the pipe I 6 Unscrew the screws J and remove the valve Fig 11 12 7 Reassemble the valve carrying out the removal operations in reverse order Warning Be careful not to damage the OR AN gasket of the gas pipe when inserting the pipe in the air box air gas mixer Before to fit a new valve it is advisable to pre set it as follows 8 Remove the brass plug and turn the plastic screw inside it fully clockwise until it stops Do not over tight 9 Turn it counter clockwise 2 and 3 4 turns 10 Adjust the gas valve using the flue analyser as de scribed in section 11 3 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 above it is deemed necessary to undertake a combustion analysis as detailed in chapter 11 3 section 11 29 12 Primary circuit flow switch EAH Function The Primary circuit flow switch A in Fig 12 1 function is to check the presence of water in the primary hy draulic circuit and that the pressure is above the mini mum
26. e a eck ale 30 GREGCKS Lct sa aaa A hs 30 Removal rieni 22 en ea tia dle 30 Expansion vessel and pressure gauge 30 FUNCION td 30 CREEK ua riada ias ide Ires 30 Removal of the expansion vessel 31 Removal of the pressure gauge 31 D h w flow switch filter and flow limiter 33 FUNCHON uos me ep ELS 33 Description and location of parts 33 CHECKS x ree e xev 33 Removal of the sensor 33 Remowval of the flow switch group and d h w circuit filler 33 Flow limiter 34 Temperature probe 35 FUNCION s pato ates artes eins ie Lo epus 35 CHECKS aia cis veda de bias 35 Removal of the c h Temperature probe 35 Removal of the d h w Temperature probe 35 By pass valve 37 Function 2 u LA eee eee aia aod 37 Removal ueeeseesss 37 Fan and Air box 38 Function es retos deudas tcd Uit c 38 Removal of the Fan and the Air box 38 Ignition and detection electrodes and burner 39 FUNCION ina ede ras uis 39 Removal of the Ignition and detection electrodes 39 Removal of the burner 39 Checks uet ed etd er ratio 39 Safety thermostat 41 Function ome a 41 CHECKS ues da hri Rx Dadas 41 Removal scusato rakera a aana i 41 Flue temperature probe NTC and Safety thermal fuse
27. e probe Fig 15 4 36 16 By pass valve HAN Function The By pass valve A in Fig 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 circulation across the c h system is completely closed The By pass valve is fitted on the rear side of the div erter group p ait yy gt Fig 16 1 KEEN Removal Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 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 Fig 16 2 Fig 16 2 4 Reassemble the by pass valve as illustrated in Fig 16 2 reversing the order of removal E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities Attention When reassembling the By pass valve be sure that it is correctly oriented by matching the reference C with the notch D of the water group Fig 16 3 Fig 16 3 37 17 Fanand Air box Function The function of the Fan A Fig 17 1 is to force the mix ture of air and gas into the burner The function of the Air box B is to mix the gas and the air in the right proportion The flow rate of the air g
28. ent etc others like the fuses are accessible by removing the main electronic p c b lid Fig 9 2 1 Connector ignition electrode 2 Connector flame detection electrode 3 Connector controler fan 4 Connector flue temperature probe NTC 5 Connector d h w temperature probe NTC d h w flow switch and external temperature probe optional 6 Connector Primary circuit pressure switch 7 Connector safety thermostat and c h tempera ture probe NTC 8 Connector remote control optional 9 Connector display and function control c h d h w temperature adjustment control panel p c b 10 FuseF1 F22AF 11 Connector electric supply Main electronic con trol ignition p c b 12 Connector 3way diverter valve 13 Connector electric supply control panel p c b 14 Connector gas valve pump and fan EEN Checking the temperature The Main electronic control ignition p c b makes it possible to separately adjust the c h water flow tem perature and d h w outlet temperature The temperature ofthe water is converted into an elec tric signal by means of temperature probes The user setting the desired temperature with the con trol panel p c b key lt A PPS Or AY If the power requested is lower than 40 of the maxi mum power output then control is achieved by switch ing ON the burner at minimum power then switching OFF ON OFF function If the power requested is
29. ese function mode See functioning with the function Taking control in thes mode lt YES water from the domestic ho water circuit Request for heat from room thermostat NO NO sec 9 7 circulator off fan still circulator on YES Is primary circuit temperature higher than that selected Main circuit pressure Switch consense YES YES NO gt stop circulator 3min NO YES NO lock memorised L cancels lock starts fan checks fan rpm Is fan rpm exact temperature higher than 110 C NO NO l YES 1 beginning of wait period YES flame presence End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve YES I stops fan interrupts ignition discharges memorizes lock display show lock out End of ignition period L NO reset key pedal NO pressed YES d exact Safety thermostat or flue A NO temperature probe lock out YES flame presence NO gt Fig 9 14 24 10 Control panel electronic p c b HAN Function E E A n gp Lo o xi Ej A Fig 10 1 A C h temperature increase key B C h temperature reduce key C Reset Stand by Winter Summer key D
30. ge L and remove it 31 Primary circuit flow switch 4 Re assemble the parts in reverse order of re moval Fig 13 5 32 14 D h w flow switch filter and flow limiter EAN Function The d h w flow switch A in Fig 14 1 is a device that generates an electrical signal when hot water is drawn A nifa ii Fig 14 1 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 5 Fig 14 3 is dragged upwards and the magnetic in it getting closer to the sensor 8 closes the electric contact Fig 14 2 KEYS Description and location of parts Fig 14 3 1 Flow switch plug 2 O ring 3 Flow limiter Activ A 30C Activ A 35C optional ac cessory 4 Body 5 Float 6 Filter 7 Sensor holder spring 8 Sensor 2 CEA wo 3 e gsx Fig 14 3 PEN Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Sensor operation 1 Remove the front panel of the case 2 Measure the electrical resistance at the leads of the sensor Without water being drawn the con tact must be open By opening a hot water tap the contact must be close electrical resistance zero Q ZEN Removal of the sensor NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the
31. hermostat h AE bk V a M A bk E J a J Remote External temp probe terminal block Electric supply terminal block L Room thermostat_ 3 ye Frostat terminal block B 1 wh IIA Time switch option T bn brown gn green bu blue ye yellow bk black vt violet wh white og orange rd red gnye green yellow gy grey rdwh red white Diagrams EEJ Circuit voltages during c h or d h w operation Electrical voltages with burner on C 2 only during c h operation Ql only during d h w operation P 3 way TA diverter valve D h w Gas valve Flow switch ra a A 230 230 230 0 aud UU ap am am paes a em yz t zs au us ML mL v e it i d q d o q a o AA Supply network Fan Main circuit Safety thermostat pressure switch 16 17 18 4 19 2 19 2 20 1 15 2 10 11 4 12 2 14 5 Components to check 6 7 2 8 2 14 3 9 5 5 21 1 Fault finding Section of the manual gt note ref in brackets 214 eqoud duu eula x3 oDneD eunsseJg ane jejes
32. higher then the burner is switched ON at maximum power and will control by modulating to 4096 of the maximum power output During the c h operation Fig 9 3 the signal coming from the c h temperature probe is compared to the sig nal given by the control panel p c b through the adjust ment made by the user key AA ISZ The result of such a comparison operates the fan speed thus regu lating the gas flow rate and consequently changing the useful output of the boiler J A zl a x an VV AA m WERE it Y Fig 9 3 When the boiler functions in d h w Fig 9 4 the signal coming fromthe d h w temperature probe is compared with the signal given by the control panel through the adjustment made by the user key A PY 19 Main electronic control ignition p c b MEN m AA J S n r VV NMV W A AA AA e AE K X Fig 9 4 Normally the result of the comparison between these two signals directly operates the fan speed 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 primary circuit goes over 90 C the useful output is automatically reduced so that the primary circuit can not reach excessive temperatures The control sequences in T function and in 3 fu
33. hip NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Disconnect the cable from the Temperature probe Measure the temperature of the pipe C only c h Tem perature probe where the Temperature probe is lo cated and check the electrical resistance according to the graph in Fig 15 1 KEEN Removal of the c h Temperature probe NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels 2 Empty the primary circuit of the boiler 3 Remove the electric connector D and remove the c h Temperature probe A Fig 15 3 4 Reassemble the c h Temperature probe carrying out the removal operations in reverse order Fig 15 3 EEE Removal of the d h w Temperature probe NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case and lower the control panel 2 Empty the d h w circuit of the boiler 3 Remove the electric connector E 4 Remove the fork F and pull the d h w Tempera ture probe B Fig 15 4 5 Reassemble the d h w Temperature probe carry ing out the removal operations in reverse order E Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities 35 Temperatur
34. ich flows in the outlet pipe ofthe condensing heat ex changer If the temperature control system of the boiler fails and the temperature of the primary circuit reaches a dan gerous temperature the safety thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device at tempts to light the burner and at the end locks the boiler and lights the lock out signal lamp J r MNT 6 Fig 19 1 EJ 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 maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain atemperature below that of the safety thermostat and no overheat intervention should occur Ns Warning isolate the boiler from the mains electricity supply before removing any covering or component Electrical function Remove all the case panels and the lid of the sealed chamber 2 Disconnect the safety thermostat and check its electrical function Normally no intervention the contact must be closed electrical resistance zero Q KEEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the lid of the
35. ig 17 2 is correctly mounted Warning Be careful not to damage the OR gasket of the gas pipe when inserting the pipe in the air box air gas mixer 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 above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 18 Ignition and detection electrodes and burner EAN Function Three electrodes are fitted on the fan burner group Two of them fitted on the right side of the fan burner group A are the ignition electrodes B On the left side is the detection electrode C and it de tects the presence of the flame Fig 18 1 The burner D is fitted on the rear of the fan burner group A Fig 18 2 KEEN Removal of the Ignition and detection electrodes NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels see section 2 2 Disconnect the ignition electrodes connector E and the earth wire F Fig 18 1 and disconnect the detection electrode connector G 3 Unscrew the screws H and remove the ignition electrodes B and the detection electrode C Fig 18 1 4 Assemble the Ignition and detection electrodes
36. l of the electronic control p c b NN Warning isolate the boiler from the mains electricity supply before removing any covering or component When replacing the Main electronic control ignition p c b all parameters must be correctly checked adjusted accordingly with the values noted in table in the installation manual see chapter COMMIS SIONING section Setting record for information on parameters see also section 9 4 1 Remove all the body panels see section 2 2 2 Gain access to the parts located inside the Main electronic p c b box as explained in the section 2 4 of this manual 3 Remove all the wiring connected to the Main elec tronic control ignition p c b 22 4 Delicately flex the hooks D in the directions indi cated Fig 9 12 in order to release the circuit from the box 5 Remove the Main electronic control ignition p c b Ja e Fig 9 12 6 Re assemble the Main electronic control igni tion p c b following the removal procedures in the reverse order Important When re assembling the Main electronic control igni tion p c b 7 It is not necessary to utilise static protections but it is advisable to ensure that the pcb is handled with care and held atthe edges and with clean dry hands Attention After installing the Main electronic control ignition p c b properly set the parameters Warning After cleaning or replacement as detailed above if it deemed necessary to
37. lled on the display of the control panel electronic p c b and can be reset only by using the boiler reset button placed on the control panel electronic p c b see section 10 1 Some components which are connected to the device can activate the lock state The causes of a lock state could be The intervention of the safety thermostat over heat of the primary circuit The intervention of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wir ing or connection Faulty flame detection faulty detection electrode its wiring or connection Faulty condensate drainage Faulty gas valve faulty on off operators or not electrically supplied Faulty Main electronic control ignition p c b Other components like the primary circuit pressure switch can temporarily stop the ignition of the burner but allow its ignition when the cause of the intervention has stopped Fig 9 13 and Fig 9 14 show the sequence ofthe oper ations that are carried out at the start of every ignition cycle and during normal functioning CENE Selection and adjustment devices On the Main electronic control ignition p c b several selection adjustment and protection devices are lo cated Fig 9 2 EE TO or HUC O O Main electronic control ignition p c b Some of these devices are directly accessible by the user function control temperature adjustm
38. low limiter 3 as shown in Fig 14 3 4 Reassemble the group following the above se quence in reverse order 15 Temperature probe HAH Function The Temperature probe has the function of converting the temperature of the water in the hydraulic circuit where itis installed into an electrical signal resistance The relation between temperature and electrical resis tance is stated in Fig 15 1 Q 12500 wooo _ LL LLLLLLI 11500 NER 11000 10500 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 15 1 On the boiler there are two Temperature probes One on the output of the primary condensing heat ex changer c h Temperature probe A in Fig 15 2 and Fig 15 3 one on the output of the d h w heat ex changer d h w Temperature probe B in Fig 15 2 and Fig 15 4 n Ex BERE das Ji r JA E c ied al th Qo 8 3 Mii oth gt P c h c h d h w d h w return flow inlet outlet Fig 15 2 KEY Checks Temperature resistance relations
39. mits given in the table Gas supply pressures of the user installation manual If it does not comply with the required pressure check the gas supply line and governor for faults and or correct adjustment 9 Switch offthe boiler close the gas inlet valve and close the water tap 10 Disconnect the pressure gauge and close the Inlet Pressure Test Point 5 Fig 11 2 Gas valve adjustment 11 Fitthe probe of the flue analyser in the flue ex haust sampling point located on the exhaust pipes of the boiler Fig 11 4 flue exhaust sampling point C h d h w function Fig 11 3 air intake sampling point Fig 11 4 12 Turn on the boiler switching on the fused spur isolation switch 13 Open the gas inlet valve 27 Gas valve Fig 11 5 14 To enter in the parameters setting mode press contemporary the 3 keys A B C Fig 11 5 for 10 second until the display shows Fig 11 6 At 124 A 412 C E N t oi a a P I YN AMAN NN Fig 11 6 Adjusting minimum gas valve setting 15 Press keys A and C Fig 11 5 at the same time until the display shows the letters LP that alter nate with the heating water temperature value 6 9 45 indicating the activation ofthe chimney sweep function at minimum output Fig 11 7 ATZA TY D EA ENE ap a 2 259 2492 Fig 11 7 16 Open at least one hot water tap fully 17 Allow the an
40. mp and turn the rotor with a screwdriver Check the electrical continuity With the boiler off remove the front panel and discon nect the connector B Fig 7 3 Measure the electrical resistance between the pump supply connections Electrical resistance of the windings at ambient tem perature must be about 213 Q coil 1 and 480 Q coil 2 Fig 7 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 direc tion ofthe arrow Ifthere is a defect in starting the rotor will begin to turn normally only starting it manually 14 Mm Check that the impeller is integral with the rotor With the boiler off remove the front and right hand side case panels lower the control panel and empty the pri mary 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 Fig 7 2 Removal pump NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front and right hand side case pan els Empty the primary circuit of the boiler 3 Disconnect the connector B Fig 7 3 Fig 7 4 following the indications given on the connector box 4 Disconnect the earth connector C SS m 5 Loosen the connection D
41. nc tion are illustrated in detail in sections 9 7 and 9 8 EX Setting the boiler control function modes Itis possible to selectthe various boiler control function modes hereafter named parameters by using the keys of the control panel p c b Fig 9 5 1 To enter in the parameters setting mode press contemporary the 3 keys A B C Fig 9 5 for 10 second until the display shows Fig 9 6 20 Cr TY 1112 n Fig 9 6 2 To move trough the parameters press c h set keys A or C Fig 9 7 Fig 9 7 3 The display shows Fig 9 8 Au pa AC Pr A LU T LANN AANS LANN AANS v N 12M 1 ALTZA GEN SE Gy Li gt PI J 4 Lil LANN AANS LANN AM YNNN Fig 9 8 4 To modify the parameter press contemporary the keys A B Fig 9 9 Fig 9 9 5 To change the parameters press c h set keys A or C Fig 9 7 6 To memorize the setting press the key B Fig 9 10 Fig 9 10 7 To exit for setting without modifing the set press the keys B C Fig 9 11 Fig 9 11 To reset the boiler to the normal operation press con temporary the 3 keys A B C Fig 9 5 for 10 sec ond The following table gives details of each parameter and the possible value that can be set Important atthe end ofthe setting operation itis im portant to fill update the table in the installation manual see chapter COMMISSIONING section Set ting record PARAMETER DIG
42. orities 13 Expansion vessel and pressure gauge EAN Function The Expansion vessel D in Fig 12 1 function is to allow for the volume expansion of the c h circuit water due to the temperature rise REP Checks 1 Turn off the flow and return isolation valves and empty the primary circuit of the boiler Primary circuit flow switch 2 Remove the protective cap E Fig 13 1 from the 1 Remove the front and right hand side panels of valve on the top of the expansion vessel and con the case turn off the flow and return isolation nect a suitable air pressure gauge valves and empty the primary circuit 2 Completely unscrew the connection F the lock nut G Fig 13 2 3 Unscrew the screws H and remove the bracket Fig 13 2 4 Remove the expansion vessel from the front ofthe boiler 5 Re assemble the parts in reverse order of re moval Fig 13 1 3 Check the pre load pressure and refer to the section Expansion vessel in the User manual and installation instructions for the correct value REZ Removal of the pressure gauge 1 Remove the front and side panels of the case EEN Removal of the expansion vessel turn off the flow and return isolation valves and empty the primary circuit Nx Warning isolate the boiler from the mains d p i electricity supply before removing any 2 Remove the fork J Fig 13 3 covering or component Fig 13 4 C h only 3 Squeeze the tabs K to release the pressure gau
43. ory set 00 Off C h reignition fre quency C h pump post cir culation Max useful output in c h mode C h pump working type Ignition power K value external probe diagram D h w burner turn off Pr 17 00 Burner off at function fixed d h w 2 65 C factory set NTC on the c h re turn 01 Brurner off at set point 5 C 00 Probe not pres ent 01 Probe present 21 Main electronic control ignition p c b Piuse pu aue mz aue RN aue G aue E aue Pra awe G Nxuei 2 C h minimum set Pr 27 25 45 factory set point 25 C Tab 9 1 EX Checks Check that the fuses are complete If the Main electronic control ignition p c b does not supply any device pump fan etc check that the fuses 10 Fig 9 2 are complete If a fuse has blown replace it with one that has the same characteristics after having identified the reason for fail ure Mm Lock sequence Start the boiler until the burner is ignited With the burner firing interrupt the gas supply The Main electronic controllignition p c b must carry out four complete ignition cycles and then after about 4 minutes goes to lock out state Switch off and on the electricity supply to the boiler by means of the fused spur isolation switch the device must not unlock and the burner must not turn on EX Remova
44. ove the detection electrode connector Fig 5 2 9 Unscrew the screws and remove the ignition elec trodes connector J 10 Unscrew the screw and remove the overheat thermostat K 11 Disconnect the connector L by pressing the plas tic hook placed on the side of the connector 12 Disconnect the connector M Fig 5 2 13 Disconnect the fan connector N by pressing the plastic hook placed on the side of the connector Fig 5 3 Fig 5 3 14 Empty the primary circuit of the boiler 15 Remove the expansion vessel following the in structions in section 13 3 16 Remove the forks O Fig 5 2 17 Loosen the connection P and remove the pipe Q from the Condensing heat exchanger 11 Condensing heat exchanger 18 Loosen the connection R and remove the pipe S from the Condensing heat exchanger 19 Unscrew the screws T 20 Remove the fan burner group 12 21 22 23 24 25 Using pliers remove the spring U moving it down wards and disconnect the rubber pipe V Fig 5 4 Loosen the screws W Fig 5 4 Fig 5 2 Unscrew the screws X Fig 5 2 Remove the Condensing heat exchanger slightly move it upwards turn it frontwards freeing it from the below screws W Fig 5 4 Fig 5 2 and then extract it forwards Reassemble the Condensing heat exchanger carrying out the removal operations in reverse order Ensure to tight the screws T Fig
45. re probe LI Lockout flue temperature probe EAD RESET NTC Flue temperature gt 120 C Faulty primary circuit no water or absence of flow temperature in EL T4 crease gt 2K s the boiler can t restart for 10 minutes Faulty pump absence of water Er 14 RESET flow in the main circuit or primary temperature above 105 C Li 01 Primary circuit temperature limit during d h w operation 10 5 Condensing heat exchanger EXI Function The Condensing heat exchanger A in Fig 5 1 has the function of transferring heat produced from combus tion of the gas and from the flue exhausted gas to the water circulating in it dre eA Es B Fig 5 1 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water cir cuit allowing an extra gain of useful heat The condensed vapour is then drained through the condensate trap B and the draining pipe C ERP Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Turn off the gas supply 2 Remove all the case panels see section 2 3 Disconnect the flue system from the boiler 4 Disconnect the air manifold D Fig 5 2 by pulling it 5 Disconnect the rubber pipe E 6 Unscrew the gas connector F 7 Remove the fixing fork G and remove the gas pipe H 8 Unscrew the screws and rem
46. s of the boiler Fig 20 2 42 ENE Removal Ns Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels Disconnect the connector B from the Flue tem perature probe NTC by pressing the plastic hook placed on the side of the connector 3 Unscrew and remove the flue temperature probe A Fig 20 2 from the condensing heat ex changer 4 Assemble the Flue temperature probe NTC carry ing out the removal operations in reverse se quence HEJ 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 maximum 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 Temperature resistance relationship 1 Remove the Flue temperature probe NTC see section 20 2 2 Measurethe Flue temperature probe NTC electri cal resistance at the ambient temperature and check it according to the graph in Fig 20 3 Q 12500 1200 LLL LLL LLL LLL LLL 150 KA LLL LLL LL LLL ft ft LLL 100 VL LLL LL LLL LL LLL 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 20 3 21 Condensate trap ARH Function The condensate trap A in Fig 21 1 and Fig 2
47. sealed chamber 2 Disconnect the wiring B detail in Fig 19 2 3 Unscrew the screws C and remove the overheat thermostat _ Fig 19 2 4 Reassemble the overheat thermostat carrying out the operations in reverse order 5 Apply an adequate quantity of heat conducting compound between the pipe and the thermostat Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 41 20 Flue temperature probe NTC and Safety thermal fuse EA Function The Flue temperature probe NTC A in Fig 20 1 and Fig 20 2 senses the temperature of the combustion products that flow through the condensing heat ex changer J f miifa Fig 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 de crease to a safe value temperature In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler operation lock out This allows the use of plastic materials for the flue outlet pipes and bends The use of kits different from the original isn t however allowed since the flue pipes are integral part
48. stat_ 3 ye z Frostat f 2 nm terminal block we J wh i i 1 wh og d J J ye Time switch option c J bn brown gn green bu blue ye yellow bk black vt violet wh white og orange rd red gnye green yellow gy grey rdwh red white Diagrams ERE Wiring diagram Activ A 18S Activ A 25S Activ A 30S Gas valve Fan Condensate trap Ignition Flame detection electrodes electrode Pump J Pa P pro J t Flue temp ik probe NTC C bu am bn e ae bul O gt aaa a e C DK aw COM bk la Fuse 2AF 250VAC om BK aa 5x20 Primary circuit 00 Tam bk pressure switch ge bk bk r v ap o bu eb i i NO o o bu N C h temperature a C O s probe NTC O Ye camp in 4 T bu eu o m bs _ bu Laa id E bk Safety bn Lam i t
49. tion electrodes Display indicates Er control panel electronic p c b The fundamental function of the Main electronic con trollignition p c b is that of controlling the boiler in rela tion 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 circuits con stant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Main electronic control ignition p c b re ceives inlet information coming from the boiler the sensors or from the outside control panel electronic p c b room thermostat etc processes it and conse quently acts with outlet commands on other compo nents of the boiler Fig 9 1 The Main electronic control ignition p c b is also a full sequence ignition device and does a sequence of oper ations ignition cycle which lead to the ignition of the gas at the burner It checks the presence of the flame during the entire period in which it is activated and supplies the fan regu lating its speed The Main 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 Main electronic control ignition p c b can lock the functioning of the boiler lock state and stop its func tioning up to the resetting intervention The lock out is signa
50. undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Main electronic control ignition p c b EXA Thermal control in the 3 mode Switch in the3 function mode NO circulator off fan still YES a Taking water from the domestic ho water circuit YES L circulator on Is primary circuit temperature higher than that selected Main circuit pressure Switch consense YES YES NO stop circulator 3min NO YES NO lock memorised L cancels lock starts fan checks fan rpm Is fan rpm exact NO temperature higher than 110 C NO l YES I Le beginning of wait period YES flame presence End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve YES stops fan interrupts ignition discharges memorizes lock display show lock out End of ignition period reset key Is fan rpm NO pressed YES Safety thermostat or flue E NO temperature probe lock out YES flame presence NO gt YES Fig 9 13 23 Main electronic control ignition p c b EXE Thermal control in the E mode Switch in th
51. verter valve trap Ignition Flame detection electrodes electrode 1 M Pump gt Mes 5 5 IN Ly gt 2 PI gy J wh Ls i X B prot ft Flue temp probe NTC bk E f rd D h w temp Ni i bei rd probe NTC bn e rd rd s _ bu bu e E ou D h w flow bn J switch a B ap N bk Lg COM NC bk la bk lam Fuse 2AF 250VAC Primary circuit 00 am an bk pressure switch ge bk bk ca alla M bk camp i E NO o QJ bu e au C h tem PON h perature V l bn am Vs probe NTC IVA m CX 2 a bu e d Aes bu fom Cal Safety n thermostat O gt x pk ox A bk E J 2 J bu bk Remote External temp probe amp terminal block Electric supply terminal block D nye s L bn 1 7 O O Room thermo
52. xchanger 1 Bl1462 102 mod Activ A 30C Activ A 35C Activ A 25S Activ A 30S 5 7 B2035 100 9 Hz2 548 Bet 122 E01 204 D h w heat exchanger BI1001 101 mod Activ A 30C Activ A 35C 10 Pump mod Activ A 25C Activ A 30C BI1462 103 Activ A 35C Pump mod Activ A 18S Activ A 25S BI1462 119 Activ A 30S n BIT442 108 E JENE 14 Three way diverter valve electric actuator 16 _ H58 66 15 1042 501 20 zi 22 Short spare parts list 45 LUE LLL d 17962 1825 1 2909 48A4 UK Biasi UK Ltd Newman Park Western Way Wednesbury WS10 7BJ Sales Tel No 0121 506 1340 Sales Fax No 0121 506 1360 Service Tel No 0121 506 1350 Service Fax No 0121 506 1370 www biasi co uk
53. y the electronic control p c b in order to send the water that exits the primary heat ex changer towards the c h system or towards the d h w heat exchanger Fig 8 1 EF Checks Check the electrical continuity Fig 8 2 indicates the relationship between the electric command coming from the electronic control p c b andthe position ofthe actuator B brass spindle when the boiler operates in d h w mode Fig 8 3 indicates the relationship between the electric command coming from the electronic control p c b and the position ofthe actuator B brass spindle when the boiler operates in c h mode In both figures the relationship between the position of the actuator and the resistance of the motor windings the motor must be disconnected from the wiring is also given 16 Spindle B visible Bc 9 4 Kohm Open circuit x 85 bk black bu blue bn brown gt gt o ol q Fig 8 2 D h w mode Spindle B not visible X Open circuit 9 4 Kohm x a 8 B bk black bu blue n brown Fa b bro o gt o 2 N Fig 8 3 C h mode EEN Removal of the electric actuator
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