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1. O lef cl A PU c h c h d h w d h w return flow inlet outlet Figure 15 2 15 2 Checks Temperature resistance relationship Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo S nent Disconnect the cable from the Temperature probe Measure the temperature of the pipes F and H only c h Tem perature probe where the Temperature probes are located and check the electrical resistance according to the graph in Figure 15 1 15 3 Removal of the c h Temperature probes 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 Empty the primary circuit of the boiler 3 Remove the electric connector G and E and unscrew the c h Temperature probes A and B Figure 15 3 4 Reassemble the c h Temperature probes carrying out the re moval operations in reverse order Figure 15 3 15 4 Removal of the d h w Temperature probes Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Removal of the d h w Outlet Temperature probe 1 Remove the front panel of the case and lower the control 44 TEMPERATURE PROBE panel Empty the d h w circuit of the boiler Remove the electric connector Figure 15 4 Remove the fork J and pull the d
2. Ht A IL e gt ej Lt I YE H E J mM UN i Figure 12 1 U 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 condi tion see section 4 1 of this manual 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 bk and wh of the switch 1 Measure the electrical resistance between the tabs bk and wh Figure 12 2 The contact must close resistance zero with c h pressure of 0 35 bar or higher bk The contact close resistance zero bk with c h pressure of 0 35 bar or higher bk black rd red Figure 12 2 12 3Removal 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 turn off the flow and return isolation valves and empty the primary circuit 2 Remove the fixing spring D Figure 12 3 and remove the pri mary circuit pressure switch C 3 Disconnect the connectors E Figure 12 3 Figure 12 3 4 Reassemb
3. A l Figure 21 1 If the drain pipe becomes blocked or condensate cannot drain the condensate level it the trap rises until it reaches the screw at tached to the flame detection electrode this will cause the boiler lock outt 21 2 Check the cleanness of the trap Unscrew the plug B on the bottom of the trap A and remove dirt eventually deposit Figure 21 2 21 3Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Remove the front and right case panels 2 Unscrew the threaded locking ring B and remove the flexible pipe C Figure 21 2 3 Using pliers remove the spring D moving it upwards 4 Unscrew the screw E and remove the trap A from the pipe F 5 Reassemble carrying out the removal operations in reverse order EII Figure 21 2 54 SHORT SPARE PARTS LIST 22 SHORT SPARE PARTS LIST Key G C part no Description Q ty c um e s 1 Burner mod Activ A Plus 25C Activ A Plus 25S Activ A Plus 16S 1 BI1293 100 Burner mod Activ A Plus 30C Activ A Plus 35C 1 BI1293 101 2 Expansion vessel 1 BI1462 100 3 H58 660 Condensing heat exchanger 1 BI1432 101 mod Activ A Plus 30C Activ A Plus 35C H58 659 Condensing heat exchanger 1 BI1432 100 mod Activ A Plus 25C Activ A Plus 25S Activ A
4. 52 OVERALL INFORMATION 1 OVERALL INFORMATION 1 1 Overall View Flue temperature probe NTC Condensing heat exchanger Safety thermostat Ighition electrodes Detection electrode Burner Fan Electronic controlbox Three way diverter valve Gas restrictor Main circuit pressure switch ATA FEO LO 4 e i Electric actuator diverter valve D h w D h w temperature probe Gas valve flow switch Figure 1 1 1 2 Hydraulic diagram Central heating c h operation gt d cn V CHi water return Ch water flow Figure 1 2 Expansion vessel Pipe silencer Airbox air gasmixer D h w heat L exchanger Condensate trap C h pressure Q relief valve Automatic air purger valve Control panel Pump Domestic hot water d h w operation D h w D h w inlet outlet 24 GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 GENERAL ACCESS AND EMPTYING HYDRAUL
5. 14 5 1 FUNGON egere nra ri Ee Eee eer reed ons 14 5 2 REMOVAL P rnm 14 5 9 Cleaning oo verbo I db es bpm mede aded qued 15 6 D H W HEAT EXCHANGER 16 6 1 FUNCION TC PH 16 6 2 Removal caiste ge eR e SP pato 16 T PUMP ata ota so is e s as 17 7 1 FUNCION PER 17 1 2 Checks e ayaka RR huqqq a Rs 17 1 3 Removal pump lt a spa pay Ve e Gels dp ERR PR 18 7 4 Removal electrical capacitor 18 8 THREE WAY DIVERTER VALVE 19 8 1 FUNCION MET T E 19 08 2 CHECKS 5h sacer Pee lodos 19 8 3 Removal of the electric actuator 19 8 4 Removal of the three way diverter valve 20 8 5 Removal of the diverter group 20 9 MAIN ELECTRONIC CONTROL IGNITION P C B 21 9 1 FUNCION cuocere t bee nae seeped doers bar be male 21 9 2 Selection and adjustment devices 21 9 3 Checking the temperature 22 9 4 Setting the boiler control function modes 23 9 5 Checks roe eProps PV mE deep 26 9 6 Removal of the electronic control p c b 26 97 Thermal control in the x Md uu 30e gya did 27 9 8 Thermal control in the MODS orn L uya ama Rd 28 10 CONTROL PANEL ELECTRONIC P C B 29 10 1 FuDGtfi n ua ya gt phate Ade gt bigs px eee See 29 10 2 Normaly information 0 eee 29 10 3 Info modality e RR bears cede Gabbe ge 31 1
6. Figure 16 1 16 2Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove allthe 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 2 Figure 16 2 4 Reassemble the by pass valve as illustrated in Figure 16 2 reversing the order of removal um 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 sure that it is correctly oriented by matching the reference C with the notch D of the water group Figure 16 3 Figure 16 3 2436 FAN AND AIR BOX 17 FANAND AIR BOX 17 1 Function The function of the Fan A Figure 17 1 is to force the mixture 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 gas mixture and consequently the input power of the boiler is proportional to the speed of the fan that is controlled by the electronic control p c b S S IL e i q Li I I pil E a P
7. To adjust the CO value rotate screw B Figure 11 2 by rotat ing it clockwise the CO decreases 29 Press keys G H Figure 11 5 at the same time again to exit the chimney sweep mode and return to the previously set boiler status Figure 11 11 C h d h w function Figure 11 11 30 Switch off the boiler and turn off the hot water tap s 31 Close the air flue sampling points 32 After adjustment fit the protective brass plug C Figure 11 2 Important after the gas pressure checks and any adjust ment operations all of the test points must be sealed 11 4 Checks Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector E Figure 11 2 Measure the electrical resistance between the connector pins of the on off operators as illustrated in Figure 11 12 Zub e NS XxX Upper on off operator approx 6400 O Lower on off operator approx 920 O at ambient temperature Figure 11 12 11 5 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 2 3 of this manual 2 Disconnect the connector J Figure 11 13 35 GAS VALVE Warning After cleaning or repla
8. b ij Lm Figure 17 1 17 2 Removal of the Air box and the Fan Warning isolate the boiler from the mains electricity A supply before removing any covering or component 1 Turn off the gas supply 2 Remove all the case panels see section 2 UESY T NANS Us Zi Figure 17 2 Disconnect the air manifold C Figure 17 2 Disconnect the rubber pipe D Unscrew the gas connector E Remove the fixing fork F and remove the gas pipe G Disconnect the connector H AN O Q C 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 Figure 17 3 Figure 17 3 12 Assemble the Fan and the Air box carrying out the removal op erations in reverse sequence Before reassembling ensure the fan gasket Figure 17 2 is cor rectly 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 cir cuit check all the connections for gas leaks Warning After cleaning or replacement as detailed above it is deemed necessary to undertake a combus tion analysis as detailed in section 11 3 44 IGNITION AND DETECTION ELECTRODES 18 IGNITION DETECTION ELECTRODES AND BUR
9. O O O bn brown gn green O L I bib s bu 7 blue ye yellow bk black vt violet wh white og 7 orange rd 7 red gnye green yellow gy grey rdwh red white Figure 3 2 DIAGRAMS 3 3 Circuit voltages during c h or d h w operation Electrical voltages with burner on C only during c h operation only during d h w operation 3 way diverter valve D h w Gas valve Flow switch 230 230 0 OT e y i 6 a a a L ep gt y o M e gt ap D it iu ES o q a paa s Supply network Fan Main circuit Safety thermostat pressure switch Figure 3 3 10 FAULT FINDING 4 FAULT FINDING Components to check e rs Pel T E mesas le OEA EM ees TT III Pel mesa ome s eje j el sss AA A o JOJO11JS9J Sec N mou res lol TTT TT tT sawara tt fel co j sessa AAA tt suem el tt tt sn ee sasi e masu e j ewmvol TT TTT TTT l yy N samsons e TA oe SS fir E
10. A 8A Sec ia sss Sms ET EET 3 mau fel fel odmeme sens TT TT tT emma TTT TET TT tT E ES CEE we e OA EE p jsuapreoususuepuo e e hasa TTT TT EE EE ET 1 ig gt meu e cerpecdduen mole fel wu ee use ttt enimse Ltt b ijj 1n0 390 souel ddy 43 Sejeoipur Aejdsiq Section of the manual note ref in brackets E20 s FAULT FINDING ui lessa9au y uBiu 00 aye mo 10 uBiu oo eunsseud wu p y 0 JaJay ss A uolsuedx ay JO uonezunssaJd ay y99uO s seB any ay jo anjea OO au 39ayo ez jeue n ay Buisn indu yeay eujuou y uoeejjuseopJeloqeu 6 9 y1 say ejes MOY e ues senjeA 1 do1d 104 jenuew uone jejsul Bumes enen seb ay 10 an ea aouasajas e sI upea siu je1souueu jojes y jo uonueAJ9jul ay pue yN ule ay JO Bunesy Jano ay esneo p nos ssed Aq powwel y Jenueui uonej ejsur osje ees Buy 198 109 Sy AJA pue yno ay jo sseupunos JO YOOYD Je loq ay Aq xoeq peyons jou si seb jsneuxe yeu ens ue pue seoueJeej ees pej ejsul AnoeJioo si jeur SN ay yeu Aja suononujsqo Jo eouesqe pue sseupunos J0J Y99049 ss uluBn seb 10 de uonejosi pue edid Ajddns sef ay yoouD uonoeuuoo ejneu pue aul jo juejod ay 490949 sesnj euJajxa pue Bnid ejqeo Ajddns jo AjuBejur
11. a E Ul Y Nos un L cp S E Figure 9 9 5 To exit from setting without modifing the set press the keys A or C till the visualization of parameter P 01 show ing the lighting value before the setting Figure 9 10 2935 MAIN ELECTRONIC CONTROLIIGNITION P C B Important at the end of the setting operation it is important 1 Va to fill update the table in the installation manual see chapter Go CM COMMISSIONING section Setting record yii E PARAMETER LCD fel 19 Boiler type to be up 00 No power Er 99 oe dated with the complete 35 Activ A Plus 25C A range 36 Activ A Plus 30C 37 Activ A Plus 35C 40 Activ A Plus 16S 41 Activ A Plus 25S C Type of water sensors C h d h w Figure 9 10 6 In order to pass from a parameter to another press c h set keys A or C at the same time until P 02 are displayed on the display indicating the entry in the parameter 02 and the value of parameter Figure 9 11 lt 2 apt E SINS LAWS NETS Pump speed P 03 A s 02 A Self regulat Zone valve setting P 04 00 No factory set Room Thermostat 01 Z1 with R T Z2 Remote Control with R C
12. Max c h flow temperature Figure 9 11 02 Z1 with R T Z2 with R C Min c h 7 Repeat the previous steps in order to display the parameter s flow temperature setting or to switch to the following Gas type P 05 00 G20 Natural 01 G25 02 coo seo 03 04 G30 Butane 05 G31 Propane Not used P 06 C h flow max P 07 85 45 factory set 85 C o Y R temperature C Factory parameters P 08 00 No reset Figure 9 12 reset 04 All parameters return to factory set To resetthe boiler to the normal operation press the key B Figure with the exclusion of 9 5 for 10 second or turn off the electricity supply to the boiler P 01 and P 05 39 All parameters return to factory set included Pr 01 and Pr 05 24 MAIN ELECTRONIC CONTROLIIGNITION P C B PARAMETER Chimney sweep function VALUES SET 00 No chimney sweep fun factory set 01 D h w low power sweep test 02 C h low power sweep test 03 C h max power sweep test 04 D h w max power sweep test C h reignition frequency C h pump post circu lation 00 99 0 600 sec factory set 30 3 minutes 00 99 0 600 sec factory set 10 1 minute Max useful output in c h mode 00 99 0 100 factory set according to P 01 C h pump working type Ignition power 00 Depends on room thermostat factory set 04 Always running 00 99 0 100 factory set Natural gas G
13. 2 Disconnect the safety thermostat and check its electrical function Normally no intervention the contact must be closed electrical resistance zero Q 19 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 2 Disconnect the wiring B detail in Figure 19 2 3 Unscrew the screws C and remove the overheat thermostat Figure 19 2 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 above if it deemed necessary to undertake a com i Warning After cleaning or replacement as detailed bustion analysis as detailed in section 11 3 48 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE 20 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE 20 1 Function The Flue temperature probe NTC A in Figure 20 1 and Figure 20 2 senses the temperature of the combustion products that flow through the condensing heat exchanger 5 Figure 20 1 If the temperature of the combustion products circuit reaches the limit temperature the Flue temperature probe NTC reduces the gas
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15. b Figure 9 13 6 Re assemble the Main electronic control ignition p c b fol lowing the removal procedures in the reverse order Important When re assembling the Main electronic control ignition p c b 7 Itis not necessary to utilise static protections but it is advis able to ensure that the pcb is handled with care and held at the edges andwith 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 it is deemed necessary to undertake a com bustion analysis as detailed in section 11 3 26 MAIN ELECTRONIC CONTROLIIGNITION P C B 9 7 Thermal control in the 3 mode Switch in the e function mode Taking water from the domestic ho water circuit m YES circulator on NO circulator off fan still x YES M Is primary circuit temperature higher than that selected Main circuit pressure a ES switch consense YES NO stop circulator 3min NO YES lock memorised starts fan checks fan rpm Is fan rom exact NO 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
16. be fully inspected and replaced at the discretion of the service engineer After any disturbance to the chamber door seal the appliance must undergo a full analytical combustion performance check 18 5 Removal of the rear insulation See warning note at the end of this chapter before to remove this part Attention Cover the inner of the condensing heat exchanger to avoid that dirt and debris fall in the coil 1 Dothe operations of section Removal of the burner page 45 from step 1 to step 3 2 Unscrew the screw K remove the washer L and the rear in sulation M Figure 18 6 Figure 18 6 18 6 Checks Check of the spark generator Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent There is not a significant way to verify the integrity of the spark generator When the fan turns but the burner does not light a possible cause is a faulty spark generator and it is advisable to replace it to locate the fault Check the position of the electrode edges Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the ignition electrodes see section Removal of the Ignition and detection electrodes page 45 2 Check for the correct distance between the metallic edges of the ignition electrode see Figure 18 7 Figure 18 8 46 IGNITION AND DETECTION ELECTRODES 3 5 mm earth ele
17. boiler from the mains electricity supply before removing any covering or component supply before removing any covering or component Remove the front and right hand side case panels 1 Remove the front and right hand side case panels 2 Empty the primary circuit of the boiler 2 Disconnect the connector B Figure 7 3 following the indica 3 Disconnect the connector B Figure 7 3 following the indica tions given on the connector box tions given on the connector box 3 Remove the connector K of the cover box by levering with a 4 Disconnect the earth connector C screwdriver in as shown in Figure 7 4 08 2342 ALINE so so or Figure 7 4 4 Remove the capacitor connection block L freeing it from the hook M and pulling it as indicated by the arrow Figure 7 5 Figure 7 3 5 Loosen the connection G and pull up and turn to the left the pipe H 6 Remove the fork F loosen the connection J and remove the pipe l 7 Remove the locking plate D Unscrew the two screws E that hold the pump on the frame and remove the pump Figure 7 5 Reassemble the pump carrying out the removal operations 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 18 THREE WAY DIVERTER VALVE 8 THREE WAY DIVERTER VALVE 8 1 Function The diverter valve A Figure 8 1 has t
18. flow rate to the burner The temperature of the combustion products should decrease to a safe value temperature In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler opera tion 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 parts of the boiler Figure 20 2 A Safety thermal fuse B in Figure 20 1 Figure 20 2 is also con nected in series with the Flue temperature probe NTC and acts as a safety device in extreme case of incorrect operation of the Flue temperature control system Reaching the breakdown temperature it opens the circuit and locks out the boiler In case of intervention of this safety device the heat exchanger part shown in Figure 20 3 may be damaged and must be replaced Figure 20 3 20 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove all the case panels 2 Disconnect the connector C from the Flue temperature probe NTC by pressing the plastic hook placed on the side of the connector 3 Unscrew and remove the flue temperature probe A Figure 20 2 from the condensing heat exchanger 4 Assemble the Flue temperature probe NTC carrying out the removal operations in reverse sequence 20 3 Checks Ov
19. gas valve stops fan YES interrupts ignition discharges memorizes lock display show lock out End of ignition period reset key pressed Is fan rpm NO YES gt Safety thermostat or flue temperature probe lock out YES flame presence YES Figure 9 14 s27 MAIN ELECTRONIC CONTROLIIGNITION P C B 9 8 Thermal control in the se mode Switch in the ap function mode See functioning with the function Taking control in the JE mode YES water from the domestic ho water circuit Request for heat from room thermostat NO NO sec 9 7 circulator off fan still YES circulator on 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 NO 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 press
20. heat ing water temperature value e g 78 the chimney sweep function is at maximum output in heating mode Figure 11 9 Figure 11 9 23 Allow the analyser to give a stable reading 24 Read the CO2 value It should be between 34 GAS VALVE Type gas Natural G20 Propane G31 Natural G20 Propane G31 Natural G20 Propane G31 CO value range 9 2 9 8 9 9 10 8 9 2 9 8 9 9 10 8 9 0 9 8 9 9 10 8 Activ A Plus 25C Activ A Plus 30C Activ A Plus 35C Activ A Plus 16S Activ A Plus 25S To adjust the CO value rotate screw B Figure 11 2 by rotat ing it clockwise the CO decreases Checking the maximum gas valve setting in domestic hot water mode 25 Press further key G to vary again the output in chimney sweep mode when the display shows the letters dP that al ternate with the heating water temperature value e g 60 the chimney sweep function is at maximum output in domestic hot water mode Figure 11 10 Figure 11 10 26 Open at least one hot water tap fully 27 Allow the analyser to give a stable reading 28 Read the CO2 value It should be between Model Type gas Natural G20 Propane G31 Natural G20 Propane G31 Natural G20 Propane G31 CO value range 9 3 9 9 10 0 10 9 9 2 9 8 9 9 10 8 9 3 9 9 10 0 10 9 Activ A Plus 25C Activ A Plus 30C Activ A Plus 35C
21. panel following the instructions from 4 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 in Figure 6 3 which hold the exchanger to the plastic groups Figure 6 3 7 Move the exchanger towards the rear of the boiler and extract it to the left Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order Cyr 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 to put the off center location securing pin indicated i Warning When reassembling the exchanger be sure in Figure 6 4 towards the left side of the boiler Figure 6 4 16 PUMP 7 PUMP 7 1 Function The pump Ain Figure 7 1 and Figure 7 3 has the function of mak ing the water in the main circuit circulate through the main con densing heat exchanger and therefore through the c h system during the c h function or through the secondary heat exchang er during the d h w function Figure 7 1 7 2 Che
22. sign probe connected bar psi my m Indicated boiler pressure I Constantly illuminated boiler power de layed by inhibitor AFCT or other events INFO menu input enabled Constantly illuminated remote control connected Flashing request from remote control in process Constantly illuminated pump active The icon remains on for post circulation 29 CONTROL PANEL ELECTRONIC P C B xE Constantly illuminated boiler antifreeze active LCD FUNCTION AF Dk Antifrostat Constantly freeze active illuminated system anti Boiler Stand By hyphens are turned on in sequence to simulate running antifreeze protection activated SIGNAL DISPLAYED BY THE LCD LCD FUNCTION E01 RESET Lack of burner ignition on safety lockout E02 RESET Safety thermostat intervention lockout E03 RESET General lockout E04 x Little pressure in the system or pressure transducer disconnected E05 x Faulty fan control system Mc bar E06 x Faulty c h temp probe NTC1 or NTC2 E07 x Faulty d h w temp probe NTC E08 x Faulty external temp probe NTC with K set E09 x Faulty flue temp probe NTC if present E13 E10 RESET Flue probe intervention lockout if present ER LII Flame detection error An flasching error I 4 flashing number l E12 x Failure return NTC pro
23. the function ing of the boiler lock state and stop its functioning up to the resetting intervention The lock out is signalled on the display of the printed circuit board 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 acti vate the lock state The causes of a lock state could be 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 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 Figure 9 14 and Figure 9 15 show the sequence of the opera tions that are carried out at the start of every ignition cycle and during normal functioning 9 2 Selection and adjustment devices On the Main electronic control ignition p c b several selection adjustment and protection devices are located Figure 9 2 Some of these devices are d
24. wwg yno y 2 den pue edid ureup puoo sedid n j eui Ajddns seo eui Ajddns 1amog 4 3no 390 eoueijddy T pajeq 2 lrozlzelizer ter 2L or cS GVLICCLIV LL OL S6 Evl csgcl 9 v Ve z U sjey9eJq ul ya ejou lt Jenuew ay jo uon9as 39 u2 0 slu uoduijoo FAULT FINDING 4 1 Display diagnostic The display indications provide help in the diagnosis of fault find ing The control panel display gives other information for the user The following table gives fault code error and the reson for the fault E01 RESET Lack of burner ignition on safety lockout E02 RESET Safety thermostat intervention lockout E03 RESET General lockout E04 Y Little pressure in the system or pressure transducer disconnected E05 Y Faulty fan control system E06 Y Faulty c h temp probe NTC1 or NTC2 E07 4 Faulty d h w temp probe NTC E08 4 Faulty external temp probe NTC with K set E09 Y Faulty flue temp probe NTC if present E10 RESET Flue probe intervention lockout if present Flame detection error An flasching error flashing number Failure return NTC probe AT delivery return gt 40K if foreseen E14 RESET Faulty pump or primary temperature above 105 C E14 Absence of flow from temperature gradient gt 2K s E19 4 Faulty d
25. 0 4 Function modes setting modality 31 10 5 Removal of the control panel electronic p c b 31 10 6 Removal of the interface electronic p c b 31 11 GAS VALVE cuna io bled ad ERE ETE deed 33 11 4 IFODGUDD a 2 inh pete ee ae sae Sue Spine S SY Gears 33 11 2 Description of the parts Figure 11 2 33 44 3 Adjustment toria ia en ens rente ons 33 11 4 Checks oso hune Eutr hpLE Reda pasos 35 11 5 Removal of the gas valve 35 12 PRIMARY CIRCUIT FLOW SWITCH 37 12 1 AEUDOLOD c dr hen eoe pr ete tos Rn Rm rie ex ton ds 37 12 2 CHECKS sc eh hp PROPOSED EE qasaq 37 12 3 Removals ener Ite uapa maya Ege deve 37 13 EXPANSION VESSEL AND PRESSURE GAUGE 38 19 4 FUNCION S asss ae ia Snares epe PER S 38 13 2 Checks z u uqu bebo zd Beh e o na Yapa d a 38 13 3 Removal of the expansion vessel 38 14 D H W FLOW SWITCH FILTER AND FLOW LIMITER 39 14 1 FUNCION aut Eder npe ean rind 39 14 2 Description and location of parts Figure 14 2 39 14 3 Removal of the sensor 39 14 4 CheCkKS uy r mua asas chs e t aqata A Bard asa Tope 39 14 5 Removal of the flow switch group and d h w circuit filter 40 14 6 Flow limiter soso hr Rer ERU TE eee DER S ES 40 15 TEMPERATURE PROBE 41 154 FUNCION Lu uu ara e bs 41 192 ENS ra vaio SE 41 15 3 Rem
26. 20 20 Activ A Plus 25C 31 Activ A Plus 30C 25 Activ A Plus 35C 30 Activ A Plus 16S 37 Activ A Plus 25S Ignition power LPG Propane G31 26 Activ A Plus 25C 37 Activ A Plus 30C 31 Activ A Plus 35C 36 ActivA Plus 16S 43 Activ A Plus 25S K value external probe diagram 00 Off factory set 01 0 1 60 6 0 K value Min useful output c h D h w burner turn off function 00 99 0965 100 factory set 00 0 00 Burner off at fixed d h w 65 C factory set 01 Burner off at set point 5 C NTC on the c h return 00 Probe not present 01 Probe present Not used P 19 Not used P 20 Not used P 21 Not used P 22 Not used P 23 Not used P 24 Not used P 25 Not used P 26 C h minimum setpoint P 27 25 45 factory set 25 C Maintenance intervals P 28 00 48 months factory set 12 months PARAMETER LCD Presence of domestic cold water temp probe or set of inlet cold water with solar control VALUES SET 00 No NTC probe 01 Yes NTC probe 04 45 C temp NTC inlet probe with solar control 05 0 5 bar 15 1 5 bar factory set 10 1 bar Correct pressure c h system Tab 9 1 25 MAIN ELECTRONIC CONTROLIIGNITION P C B 9 5 Checks Check that the fuses are complete If the Main electronic control ignition p c b does not supply any device pump fan etc
27. 8 1 and remove the Air gas duct lid 5 Remove the burner by sliding it forward burner gasket locating tab Figure 18 3 6 Assemble the burner carrying out the removal operation in reverse order Ensure the burner is correctly located by lining up the locating tab Figure 18 3 45 IGNITION AND DETECTION ELECTRODES burner gasket Air gas duct gasket Figure 18 4 Before reassembling ensure the burner gasket is correctly located Warning After cleaning or replacement as detailed above it is deemed necessary to undertake a com bustion analysis as detailed in section Adjust ment page 33 18 4Removal of the front insulation panel See warning note at the end of this chapter before to remove this part 1 Remove the Ignition and detection electrodes see section Removal of the Ignition and detection electrodes page 45 2 Remove the burner see section Removal of the burner page 45 3 Remove the front insulation panel Figure 18 5 4 Assemble the new front insulation carrying out the removal operation in reverse order When fitting the new panel ensure that the electrodes holes coincide with the holes of the com bustion chamber 0 front insulation Siliconic gasket Figure 18 5 Caution After any periodical servicing or disturbance the combustion chamber silicon seal Figure 18 5 must
28. EE C h temperature probe NTC return Flue temp probe NTC Safety thermal fuse D h w outlet temperature probe NTC D h w flow switch Primary circuit pressure switch C h temperature probe NTC flow Safety thermostat D h w inlet temperature probe NTC O O O OPD E O O hl 8 DIAGRAMS 3 2 Wiring diagram Activ A Plus 16S Activ A Plus 25S Three way diverter valve Gas valve Fan Flame detection Ignition electrode electrodes C h temperature t probe NTC Y 36 Wh return Flue temp probe NTC D i 12 x A thermal fuse gt m Met v Primary circuit bk GND pressure switch s U ml our bu C h temperature probe NTC bu flow bk Safety SS l G N thermostat L A bk ess la ele a 4
29. EIE Delayed burner ignition for setting the sys l l tem the hourglass symbol turns on aaa 12 7 Boiler in chimney sweep in function 2 The activation of the chimney sweep occurs Ki configuring the parameter PO9 01 and is LI visualized E i2 LP minimum dhw hP minimum heating e u CP maximum heating dP maximum dhw The transition occurs with keys A increase and B decrease dhw temperature The writing on the display alternates E99 x Boiler not configured L 01 Primary circuit temp limit during D h w op eration 30 CONTROL PANEL ELECTRONIC P C B 10 3 Info modality The INFO mode allows the display of some information on the boiler functioning status In case of malfunctioning of the boiler it may be useful to communicate such information to the Author ised Service Centre Engineer so that the causes can be under stood In order to access the INFO mode press keys A Figure 10 1 the index J00 and the value of the parameter appear on the display Figure 10 2 Figure 10 2 To scroll the values press B reduce and A increase keys Fig ure 10 1 In order to exit the INFO mode hold keys A and C Fig ure 10 1 pressed at the same time The following table gives de tails of each parameter and the possible value that can be show Value visualised Index Primary circui
30. Function The safety thermostat A in Figure 19 1 is a device that senses the temperature of the primary circuit water which flows in the outlet pipe of the condensing heat exchanger If the temperature control system of the boiler fails and the tem 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 on the display A d 3 A BEA 3 N H ic 2 e Y Figure 19 1 A 19 2 Checks Overheat temperature value 1 Runthe boiler and set the temperature at maximum by press ing the appropriate key 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
31. IC CIRCUITS 2 1 Nomenclature Figure 2 1 Right side panel Front panel Control panel Main electronic p c b box Left side panel ah wh 2 2 2 Case panels Warning isolate the boiler from the mains electrici 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 loosen screws A Figure 2 2 lift the panel and remove it Figure 2 2 Bottom view of the boiler Pull the lower part of the front panel and lift it upwards Figure 2 3 Figure 2 3 To remove the side panels loosen the screws B Figure 2 2 and C Figure 2 3 Pull the side panels towards the outside To Fit the case panels Fit the side case panels Warning Fit the front panel hooking it on the upper A side Push the spring towards the internal side of the boiler and simul taneously push the front case panel until it is completely hold in place Figure 2 4 step 1 2 Repeat the same operation on the opposite side of the front pan el Figure 2 4 step 3 4 Ensure that the front panel edge is close fitting to the side panels Lock in place the panel with the appropriate screws Figure 2 4 GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 3 Control panel Warning isolate the boiler f
32. If during the d h w mode operation the temperature of the pri mary circuit goes over 90 C the useful output is automatically reduced so that the primary circuit cannot reach excessive tem peratures The control sequences in function a and 3 in function are illustrated in detail in sections 9 7 and 9 8 9 4 Setting the boiler control function modes It is possible to select the various boiler control function modes hereafter named parameters by using the keys of the control panel p c b amp amp JO Figure 9 5 1 To enter in the parameters setting mode press contemporary the 3 keys A B C Figure 9 5 for 10 seconds at the same time until P01 are displayed on the display indicating the en try in the parameter 01 and the value of parameter Figure 9 5 Figure 9 6 J a gt E JL ri n r Figure 9 6 2 To change the parameters press c h set keys D or E Figure 9 7 see also Tab 9 1 Figure 9 7 3 To memorize the setting press the key B Figure 9 8 amp amp JO Figure 9 8 4 The setting is confirmed by the visualization of OK and then the display shows the value of changed parameter Figure 9 9 a x lt a
33. Inlet Pressure Test Point F Figure 11 2 Gas valve adjustment The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the re sults The flue gas analyser used should be one meet ing the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manu facturers requirements and have a current calibration certificate 11 Fit the probe of the flue analyser in the flue exhaust sampling point located on the exhaust pipes of the boiler Figure 11 4 flue exhaust sampling point air intake sampling point Figure 11 4 33 GAS VALVE 12 Turn on the boiler switching on the fused spur isolation switch 13 Open the gas inlet valve 14 Turn on the boiler and operate for 2 minuets to pre heat the flue before commencing any adjustments Figure 11 5 15 To enter in the parameters setting mode press contemporary the 3 keys G H Figure 11 5 for 10 second until the dis play shows Figure 11 6 Figure 11 6 Checking the minimum gas valve setting in domestic hot water mode 16 Press keys G and H Figure 11 5 at the same time until the display shows the letters LP that alternate with the heating water temperature value e g 45 indicating the activation of the chimney sweep function at minimum output F
34. NER 18 1Function 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 detects the presence of the flame Figure 18 1 The burner J is fitted on the rear of the fan burner group A E naa hi LI Ty Figure 18 2 18 2 Removal of the Ignition and detection elec trodes Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove all the case panels see section 2 2 Disconnect the ignition electrodes connector D and the earth wire E Figure 18 1 and disconnect the detection electrode connector F 3 Unscrew the screws G and remove the ignition electrodes B and the detection electrode C 4 Assemble the Ignition and detection electrodes carrying out the removal operation in reverse order 18 3 Removal of the burner Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the air box and the fan see section Removal of the Air box and the Fan page 44 2 Remove the Ignition and detection electrodes see section Removal of the Ignition and detection electrodes page 45 3 Unscrew the screws H Figure 18 1 and remove the cover of the combustion chamber 4 Unscrew the screws Figure 1
35. Plus 16S 4 Fan 1 BI1313 102 5 Gas valve 1 BI1313 103 SIT 848 Sigma 0848135 6 E83 013 Safety valve 1 Bl1441 116 Watts mod Activ A Plus 25C Activ A Plus 30C Activ A Plus 35C Safety valve mod Activ A Plus 25S Activ A Plus 16S 1 BI1131 100 Watts 7 Main Electronic control ignition p c b 1 BI2035 100 8 Auxiliary p c b 1 BI2035 120 9 Control panel electronic p c b 1 BI2035 119 10 E01 204 D h w heat exchanger mod Activ A Plus 25C 1 BI1001 101 E01 205 D h w heat exchanger mod Activ A Plus 30C Activ A Plus 35C 1 BI1001 102 11 Pump 1 BI1552 104 Wilo INTNFSL12 6 HE 1 12 12 H74 553 Temperature probe main circuit 2 BI1442 106 13 D h w flow switch 1 BI1441 501 14 D h w flow sensor 1 Bl1441 104 15 Primary circuit pressure switch 1 BI1431 101 16 Three way diverter valve electric actuator 1 BI1431 100 17 H74 550 Condensate trap 1 BI1442 104 18 E83 101 Overheat thermostat 1 BI1172 105 ELTH type 261 19 H58 661 Flue temperature probe NTC 1 BI1432 102 20 E23 792 Fuse 2 AF 250VAC 5x20 3 BI1165 112 21 1169 016 Temperature probe D h w circuit 2 KI1042 501 22 H58 709 Detection electrode 1 BI1293 103 23 Ignition electrode 1 BI1363 103 52 SHORT SPARE PARTS LIST Figure 22 1 53 NOTE 54 17962 2101 0 5111 56A4 UK Biasi UK Ltd Commercial Road Leamore Enterprise Park
36. Wall hung fanflue roomsealed high efficiency gas boiler Service manual ActivA Plus Models G C Appl No Activ A Plus 25C 47 583 28 Activ A Plus 30C 47 583 26 Activ A Plus 35C 47 583 27 Activ A Plus 16S 41 583 20 Activ A Plus 25S 41 583 21 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 ABIASI TABLE OF CONTENTS 1 OVERALL INFORMATION 4 1 1 OVerallVIeW ataca m Na a waya msaada gs 4 1 2 Hydraulic diagram u s usu a tes 4 2 GENERAL ACCESS AND EMPTYING HYDRAULIC CIR CUTS co sentient oats cate tet aoe ee ners aed 5 2 1 Nomenclature sic emm ett he ee 5 2 2 Case panels u niss Nba dy riu Lea dos lee td dede 5 23 Control panel eR ERR ER Roten 6 2 4 Main electronic p c b box 6 2 5 Emptying the primary circuit ooooocoooocooo 7 2 6 Emptying the d h w CirCuit ooooooooooooooo 7 3 DIAGRAMS 8 3 1 Wiring diagram Activ A Plus 25C Activ A Plus 30C Activ APIS 3D Coronda avere yaka ala 8 3 2 Wiring diagram Activ A Plus 16S Activ A Plus 25S 9 33 Circuit voltages 24 2 cite meh EE RE ARCA 10 4 FAULT FINDING eseeeeeeeenneene 11 4 1 Display diagnose l a urbe Ee donatis 13 5 CONDENSING HEAT EXCHANGER
37. assage of the gas through the Gas valve can be opened or closed 11 2 Description of the parts Figure 11 2 Maximum gas pressure adjustment Minimum gas pressure adjustment On off operators On off operators electric connector Gas valve inlet pressure test point mmoou Figure 11 2 11 3 Adjustment Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Check the supply pressure before making any adjustment to the gas valve 1 2 Close the gas inlet valve Remove the front panel of the case and lower the control panel see sections 2 2 and 2 3 Loosen the internal screw on the Inlet Pressure Test Point F Figure 11 2 of the Gas valve and connect a pressure gauge using a suitable hose Open the gas inlet valve Turn on the electricity supply to the boiler switching on the fused spur isolation switch 6 Set the boiler in c h d h w function as illustrated in Figure 11 3 C h d h w function Figure 11 3 7 Open atleast one hot water tap fully 8 Read the inlet pressure value and ensure that it is within the limits 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 off the boiler close the gas inlet valve and close the 10 water tap Disconnect the pressure gauge and close the
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39. be DT delivery return gt 40K if foreseen E14 RESET Faulty pump or primary temperature above 105 C E14 x Absence of flow from temperature gradient gt 2K s E19 Faulty d h w temp probe inlet if present E20 RESET Lockout EVG E21 RESET Lockout EVG E22 RESET Lockout EVG E23 RESET Lockout EVG E24 RESET Abnormal combustion ignition lock E25 RESET Abnormal combustion operation lock E69 x Wiring error lockout SN In the case of incorrect pressure the value is l visualised with a flashing symbol L Ll When pressure is achieved the symbol re d b mains on for 15 s and then disappears N bar Flashing high pressure gt 2 8 bar ON 2 6 bar OFF LI intermediate pressure LI l 0 15 lt P lt Pon rising f de 0 15 lt P lt Pon 0 2 decreasing bar pressure critical ul I 0 00 lt P lt 0 15 bar Li riri LA LEE E Pump activated for the post circulation phase Po flashing temperature flashing a I1 1 1 LLL Boiler in anti freeze phase bP flashing temperature flashing arse gt i LIL Boiler on demand for d h w power of The d h w temperature is displayed o 12 AS H k Boiler requesting heating power and remote control connected g 12 E Ltr Setch I ELI all other symbols are disabled SEE S LIP Set D hw LS all other symbols are disabled x Se ZW Li
40. bn bk black gt bu blue ol gt bn brown alo Figure 8 3 C h mode 8 3 Removal of the electric actuator Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front case panel 2 Disconnect the connectors C Figure 8 4 3 Remove the fixing spring D and remove the actuator E Reassemble the actuator carrying out the removal operations in the reverse order When reassembling the actuator refer to Figure 8 3 or to the wiring diagram in section 3 for the correct wiring connection 19 THREE WAY DIVERTER VALVE Figure 8 4 8 4 Removal of the three 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 Removal of the electric actuator page 19 4 Remove the fixing spring F Figure 8 5 5 Remove the three way diverter valve G by levering with a screwdriver in as shown in Figure 8 5 Figure 8 5 Reassemble the three way diverter valve carrying out the remov al operations in the reverse order Cyr 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 three way diverter valve be sure that the three way diverter is correctly oriented by matching the
41. cement as detailed A above it is deemed necessary to undertake a com bustion analysis as detailed in section 11 3 Figure 11 13 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve 4 Using pliers remove the spring L and the rubber pipe M Fig ure 11 13 5 Unscrew the connector N remove the fixing fork O and re move the pipe P Unscrew the screws K and remove the valve 7 Reassemble the valve carrying out the removal operations in reverse order Warning Be careful not to damage the OR gasket of A the gas pipe when inserting the pipe in the air box air gas mixer Before fitting a new valve it is advisable to preset it as fol lows 8 Remove the brass plug and turn the plastic screw inside it fully clockwise until it stops Do not overtight 9 Turn it counter clockwise 2 and 3 4 turns 10 Adjust the gas valve using the flue analyser as described in section 11 3 After any service operation on the components of the gas circuit check all the connections for gas leaks 36 PRIMARY CIRCUIT FLOW SWITCH 12 PRIMARY CIRCUIT FLOW SWITCH 12 1 Function The Primary circuit flow switch A in Figure 12 1 function is to check the presence of water in the primary hydraulic circuit and that the pressure is above the minimum
42. check that the fuses 10 Figure 9 2 are complete If a fuse has blown replace it with one that has the same charac teristics after having identified the reason for failure Y Lock sequence Start the boiler until the burner is ignited With the burner firing interrupt the gas supply The Main elec tronic control ignition 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 9 6 Removal of the electronic control p c b Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent When replacing the Main electronic control ignition p c b all parameters must be correctly checked adjusted accord ingly with the values noted in table in the installation manual see chapter COMMISSIONING section Setting record for information on parameters see also section 9 4 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 electronic con trol ignition p c b 4 Delicately flex the hooks F in the directions indicated Figure 9 13 in order to release the circuit from the box 5 Remove the Main electronic control ignition p c
43. cks Warning isolate the boiler from the mains electricity A supply before removing any covering or component 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 7 3 Measure the electrical resistance between the pump supply con nections Figure 7 2 Electrical resistance of the windings at ambient temperature must be RESISTANCE Y 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 Y 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 a Ss PUMP 7 3 Removal pump 7 4 Removal electrical capacitor Warning isolate the boiler from the mains electricity Warning isolate the
44. ctrode Ignition electrode Figure 18 7 Check the connection wires ty supply before removing any covering or compo Warning isolate the boiler from the mains electrici nent Figure 18 8 1 Remove all the case panels and the sealed chamber lid 2 Check for the integrity of the insulation of wires which con nect the electrodes to the spark generator and to the control ignition p c b Warning Insulation panels material handling care Mineral fibres are used in this appliance for the insulation panels of the combustion chamber Excessive exposure to these materials may cause temporary ir ritation to eyes skin and respiratory tract Known hazards Some people can suffer reddening and itching of the skin Fibre entry into the eye will cause foreign body irrita tion which can cause severe irritation to people wearing contact lenses Irritation to respiratory tract Precautions Dust goggles will protect eyes People with a histo ry of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present high risk fol low good hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First aid Medical attention must be sought following eye contact or prolonged reddening of the skin 47 SAFETY THERMOSTAT 19 SAFETY THERMOSTAT 19 1
45. ed Is fan rpm NO YES gt Safety thermostat or flue temperature probe lock out Figure 9 15 28 CONTROL PANEL ELECTRONIC P C B 10 CONTROL PANEL ELECTRONIC P C B 10 1Function Figure 10 1 Display Reset Key Access to function Clock key used to Date setting and t heating flow timer c rommocoou The Control panel electronic p c b can give to the service 3 lev els of informations C h temperature increase key C h temperature reduce key Reset Stand by Winter Summer key D h w temperature reduce key D h w temperature increase key 3 star preheating function key menu key access the clock functions Time Day he timer 3 star preheating function and Normally information Info modality Function modes setting modality 10 2 Normaly information KE A Y Indicate the status of the scheduling re quest Flashing vig 9 comfort program in process reduced program in process 1234567 The day of the week is displayed high lighting the number with the following se quence 1 Mon 7 Sun Constantly illuminated d h w function enabled Flashing d h w function enabled vig 70 2 Aya Flashing solar circuit pump in operation Solar integration at the time of d h w with drawal is indicated by the lighting of the bars SV v
46. er 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 9 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 key AM The result of such a comparison operates the fan speed thus regulating the gas flow rate and consequently chang ing the useful output of the boiler lt lt t 55 m TRA I Figure 9 3 When the boiler functions in d h w Figure 9 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 key A P V Figure 9 4 22 MAIN ELECTRONIC CONTROLIIGNITION P C B Normally the result of the comparison between these two signals directly operates the fan speed adjusting the useful output gen erated in order to stabilize the temperature of the exiting water
47. erheat temperature value 1 Setthe 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 Measure the Flue temperature probe NTC electrical resist ance at the ambient temperature and check it according to the graph in Figure 20 4 49 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE 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 500 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Figure 20 4 50 CONDENSATE TRAP 21 CONDENSATE TRAP 21 1Function 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
48. ersions the bars indicate the value of the temperature of the solar storage range 40 80 C Constantly illuminated heating request from zone 1 and or zone 2 Flashing heating function in progress Constantly illuminated delivery probe and or return probe The ignition of the key the arrow M and the month 1 or 2 indicates the next due date for maintenance The flashing of the symbol the arrow M and 0 indicates that the maintenance pe riod has expired Temperature measurement unit Constantly illuminated 3 star preheating function active Flashing 3 star preheating function in process Flashing down before flame detection Constantly illuminated flame present and modulation level Constantly illuminated lockout error The boiler can be restarted by the user by pressing the reset button Y V BIS All symbols represented with lines that surround them indicate that the symbol is flashing Non resettable error if Constantly illuminated chimney sweep function enabled AM D Pw Constantly illuminated the presence of this symbol during normal operation indi cates that the heating or preheating timer has been set Flashing this indicates that the clock has not yet been set by the user ct The back lighting has to be flashing K Constantly illuminated set value Al Constantly illuminated temperature is a r1 displayed without decimals but with a Jy
49. fitted Time switch if fitted Outlet command Pump Three way diverter valve Gas valve Fan Ignition electrodes Display indicates Er control panel electronic p c b Figure 9 1 The fundamental function of the Main 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 hy draulic circuits constant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Main electronic control ignition p c b receives in let information coming from the boiler the sensors or from the outside printed circuit board p c b room thermostat etc pro cesses it and consequently acts with outlet commands on other components of the boiler Figure 9 1 The Main electronic control ignition p c b is also a full sequence ignition device and does a sequence of operations ignition cy cle 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 regulating its speed The Main electronic control ignition p c b has a safety function and any incorrect interventions or tampering can result in condi tions of dangerous functioning of the boiler The Main electronic control ignition p c b can lock
50. from the body 4 Figure 14 5 rotate 2 fa a aon 1 Figure 14 5 3 Insert the flow limiter 3 as shown in Figure 14 5 4 Reassemble the group following the above sequence in re verse order 40 TEMPERATURE PROBE 15 TEMPERATURE PROBE 15 1 Function The Temperature probe has the function of converting the tem perature of the 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 four Temperature probes Two on the in put output of the primary condensing heat exchanger c h Tem perature probe A and B in Figure 15 2 and Figure 15 3 two on the input output of the d h w heat exchanger d h w Tempera ture probe C and D in Figure 15 2 Figure 15 4 and Figure 15 5 H N _ JI 7 Ce T amr l D t M a E Eo
51. g 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 com bustion analysis as detailed in chapter 11 3 section 11 Figure 5 4 Caution After any periodical servicing or disturbance the combustion chamber silicon seal S Figure 5 4 must be fully inspected and replaced at the discretion of the service engineer After any disturbance to the chamber door seal the appliance must undergo a full analytical combustion performance check D H W HEAT EXCHANGER 6 D H W HEAT EXCHANGER 6 1 Function The d h w heat exchanger A in Figure 6 1 and Figure 6 3 allows the instantaneous transfer of heat from the primary hydraulic cir cuit to the water destined for d h w use Figure 6 1 The schematic structure is shown in Figure 6 2 A V A V Primary hydraulic circuit Domestic hot water circuit Figure 6 2 6 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Remove the panels of the case 2 Empty the primary circuit and the d h w circuit of the boiler 3 Remove the control
52. h w Temperature probe C Reassemble the d h w Temperature probe carrying out the removal operations in reverse order Q ON Cyr 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 Figure 15 4 Removal of the d h w Intlet Temperature probe 6 Remove the front panel of the case and lower the control panel 7 Empty the d h w circuit of the boiler 8 Remove the electric connector K Figure 15 5 9 Remove the fork L and pull the d h w Temperature probe D 10 Reassemble the d h w Temperature probe carrying out the removal operations in 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 Cf r Figure 15 5 42 BY PASS VALVE 16 BY PASS VALVE 16 1Function 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 system is completely closed The By pass valve is fitted on the rear side of the diverter group 5 De t
53. h w temp probe inlet if present E20 RESET E21 RESET Lockout EVG Lockout EVG E22 RESET Lockout EVG E23 RESET Lockout EVG E24 RESET Abnormal combustion ignition lock E25 RESET Abnormal combustion operation lock E69 Y Wiring error lockout E99 Y Boiler not configured L01 Primary circuit temp limit during D h w op eration 13 CONDENSING HEAT EXCHANGER 5 CONDENSING HEAT EXCHANGER 5 1 Function The Condensing heat exchanger A in Figure 5 1 has the func tion of transferring heat produced from combustion of the gas and from the flue exhausted gas to the water circulating in it MAN gt Figure 5 1 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water circuit allowing an extra gain of useful heat The condensed vapour is then drained through the condensate trap B and the draining pipe C 5 2 Removal Warning isolate the boiler from the mains electricity A supply before removing any covering or component Disconnect the flue system from the boiler 2 Remove the fan group rubber pipe gas pipe following the instructions from 1 to 6 in sectio
54. he 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 d d Cc N t Y li SN E q Li A I H q E R Bag Ih Figure 8 1 8 2 Checks A Warning check the electrical continuity Figure 8 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 8 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 the resistance of the motor windings the motor must be disconnected from the wiring is also given B Spindle visible 123 9 4 Kohm Open circuit bk bu bn bk black gt bu blue gt bn brown SIN Figure 8 2 D h w mode B Spindle not visible DS Open circuit 9 4 Kohm bk bu
55. igure 11 7 2 El LI Al bar Figure 11 7 17 Allow the analyser to give a stable reading 18 Read the CO value It should be between Model Typegas CO value range Activ A Plus 25C Natural G20 Propane G31 Activ A Plus 30C Activ A Plus 35C To adjust the CO value remove the brass plug by unscrewing it and rotate the Allen key screw 4 mm C Figure 11 2 by rotating it clockwise the CO increases Checking the minimum gas valve setting in heating mode 19 Press key G to vary the output in chimney sweep mode when the display shows the letters hP that alternate with the heat ing water temperature value e g 32 the chimney sweep function is at minimum power during heating Figure 11 9 Figure 11 8 20 Allow the analyser to give a stable reading 21 Read the CO value It should be between Type gas Natural G20 Propane G31 Natural G20 Propane G31 Natural G20 Propane G31 CO value range Activ A Plus 25C Activ A Plus 30C Activ A Plus 35C Activ A Plus 16S Activ A Plus 25S To adjust the CO value remove the brass plug by unscrewing it and rotate the Allen key screw 2 4 mm C Figure 11 2 by rotating it clockwise the CO increases Checking the maximum gas valve setting in heating mode 22 Press key G to vary the output in chimney sweep mode when the display shows the letters cP that alternate with the
56. irectly accessible by the user func tion control temperature adjustment etc others like the fuses are accessible by removing the main electronic p c b lid 24 MAIN ELECTRONIC CONTROLIIGNITION P C B Connector ignition electrode Connector flame detection electrode 1 2 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 temperature probe NTC 8 Connector remote control optional 9 Connector display and function control c h d h w tem perature adjustment control panel p c b 10 Fuse F1 F2 2AF 11 Connector electric supply Main electronic control 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 9 3 Checking the temperature The Main electronic control ignition p c b makes it possible to separately adjust the c h water flow temperature and d h w out let 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 p c b key A FRY or AMI If the power requested is lower than 40 of the maximum power output then control is achieved by switching ON the burner at minimum pow
57. le 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 Authorities e EXPANSION VESSEL AND PRESSURE GAUGE 13 EXPANSION VESSEL AND PRESSURE GAUGE 13 1Function The Expansion vessel A in Figure 13 1 function is to allow for the volume expansion of the c h circuit water due to the temperature rise gt M WL Figure 13 1 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 B in Figure 13 2 from the valve on the top of the expansion vessel and connect a suitable air pressure gauge kesan a Figure 13 2 3 Check the pre load pressure and refer to the section Expan sion vessel in the User manual and installation instructions for the correct value 13 3 Removal of the expansion vessel 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 turn off the flow and return isolation valves and empty the primary ci
58. n Removal of the Air box and the Fan page 44 3 Disconnect the detection electrode connector D the ignition electrodes connector E and the earth wire F 4 Disconnect the fan connector G by pressing the plastic hook placed on the side of the connector Figure 5 2 Unscrew the nuts H Figure 5 2 Remove the fan burner group I Empty the primary circuit of the boiler Remove the clips J Figure 5 2 oo Y DH Loosen the connection K and slightly move the pipe L up wards turn it towards left Figure 5 2 and then move the pipe downwards freeing it from the Condensing heat exchanger Figure 5 2 10 Loosen the connection M and slightly move the pipe N up wards turn it towards left Figure 5 2 and then move the pipe downwards freeing it from the Condensing heat exchanger Figure 5 3 11 Using pliers remove the spring O moving it downwards and disconnect the rubber pipe P Figure 5 3 12 Unscrew the screws Q and remove the clamps Figure 5 3 13 Disconnect the two connectors R by pressing the plastic hook 14 CONDENSING HEAT EXCHANGER placed on the side of the connector Figure 5 3 14 Remove the Condensing heat exchanger by levering it and sliding it forwards 15 Reassemble the Condensing heat exchanger carrying out the removal operations in reverse order Ensure to tighten the nuts H Figure 5 2 firmly 5 3 Cleaning If there are deposits of dirt on the coil of the Condensin
59. nic p c b Figure 10 3 Figure 10 3 4 Unscrew the screws L and K Remove the Control panel electronic p c b al 6 Reassemble the Control panel electronic p c b carrying out the removal operations in the reverse order 10 6Removal of the interface electronic p c b Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove all the body panels see section 2 2 2 Gain access to the parts located inside the Interface elec tronic p c b as explained in the section 2 3 of this manual 3 Remove all the wiring N S O e P connected to the Interface electronic p c b Figure 10 4 34 2 CONTROL PANEL ELECTRONIC P C B n gt EA Figure 10 4 Unscrew the screws R and Q Remove the nterface electronic p c b o0 Reassemble the nterface electronic p c b carrying out the removal operations in the reverse order ERA GAS VALVE 11 GAS VALVE 11 1 Function The gas valve Ain Figure 11 1 controls the gas inflow to the boiler burner an t J W amp 1 Le ee il E RA I s A Figure 11 1 By means of an electric command given to the on off operators the p
60. oval of the c h Temperature probes 41 15 4 Removal of the d h w Temperature probes 41 16 BY PASS VALVE 43 16 4 EUNCUON buitre ot Seas 43 16 2 Removal escindida ada eels 43 17 FAN AND AIR BOX 44 A FUNCION ctra a Sus D aa E EE 44 17 2 Removal of the Air box and the Fan 44 18 IGNITION DETECTION ELECTRODES AND BURNER 45 18 1 Fuhctio squa ed daa Seas 45 18 2 Removal of the Ignition and detection electrodes 45 18 3 Removal of the burn rf bemaak ennad deaa 45 18 4 Removal of the front insulation panel 46 18 5 Removal of the rear insulation 46 18 6 Checksum 46 19 SAFETY THERMOSTAT 48 19 1 f nctiOni uusha tetas tod hup tile a eden iain 48 19 2 Checks o don aa o BE Vege T SNR A Aging dpi 48 19 39 Removal 0 200 lucc nter Ru Loh wee ee as 48 20 FLUE TEMPERATURE PROBE NTC AND SAFETY THER MAL FUSE 1 0 ada rn um See Ai ES 49 20 1 FUNCION bi eet he uy pU EUR aes 49 20 2 Removal vnde a etitm qur sgh demas Wasa act EV RUN RE 49 2033 ClHOCKS z seo sh kerana Rupe ESO hee pred rd 49 21 CONDENSATE TRAP 51 21 1 FUNCION siai ien ri IARE RAMS bes 51 21 2 Check the cleanness of the trap 51 21 39 Removal 225 5 esa Laea dure na pe Rb gd a des 51 22 SHORT SPARE PARTS LIST
61. rcuit 2 Completely unscrew the connection C the locknut D Figure 13 3 3 Unscrew the screws E and remove the bracket F Figure 13 3 4 Remove the expansion vessel from the front of the boiler 5 Re assemble the parts in reverse order of removal Figure 13 3 38 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 1 Function The d h w flow switch A in Figure 14 1 is a device that generates an electrical signal when hot water is drawn gt d E TES Cc q Lt Hl A E ON k as Ka 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 2Description and location of parts Figure 14 2 1 Flow switch plug 2 O ring 3 Flow limiter Activ A 30C Activ A 35C optional accessory 4 Body with flow meter turbine 5 Filter P 2 3 Figure 14 2 14 3 Removal of the sensor Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Figure 14 3 1 Remove the front panel of the case 2 Disconnec
62. reference H with the notch of the water group Figure 8 5 8 5 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 the boiler 3 Remove the electric actuator section Removal of the elec tric actuator page 19 4 Remove the fixing spring Figure 8 6 and remove the pri mary circuit flow switch J Figure 8 7 6 Unscrew the connector L Figure 8 7 the c h flow connector and the d h w outlet connector 7 Remove the d h w heat exchanger see Removal page 16 8 Unscrew the screw M and remove the diverter group 9 Reassemble the diverter group carrying out the removal op erations in the reverse order Cy 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 20 MAIN ELECTRONIC CONTROLIIGNITION P C B 9 MAIN ELECTRONIC CONTROLIIGNITION P C B 9 1 Function Inlet Information On the Main electronic control ignition D C D Function control C h temperature adjustment D h w temperature adjustment Boiler reset button printed circuit board 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
63. rom the mains electrici ty supply before removing any covering or compo nent To gain access to the parts located inside the control panel pro ceed as follows 1 Remove the front panel of the case 2 Unscrew the screws D and E Figure 2 5 3 Free the hooks indicated and rotate the lid towards left Figure 2 5 4 Toaccess to the parts located behind the control panel turn it as shown in Figure 2 6 Figure 2 6 2 4 Main electronic p c b box Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent To gain access to the parts located into main electronic p c b box proceed as follows 1 Remove the front panel of the case Terminal block lid removal 2 Toremove the terminal block lid F Figure 2 7 free the front hooks Figure 2 7 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 Figure 2 8 Figure 2 8 6 Remove the terminal block lid F Figure 2 7 7 Free the hooks placed on the three sides indicated and rotate the lid towards left Figure 2 9 6 GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS Figure 2 9 Figure 2 12 2 5 Emptying the primary circuit 1 Close the c h circuit flo
64. t pressure JOO value External temperature J01 value K curve value configured in loco J02 value Offset climatic curve value J03 value AM set point with climatic curve avale Temperature NTC delivery J05 value Temperature NTC return J06 value Domestic set J07 value Temp Dhw inlet if foreseen J08 value Temp Dhw output J09 value Dhw capacity J10 value Flue temperature if foreseen J11 value Fan speed if foreseen J12 value Pressure transducer pressure if foreseen J13 value lonization value J14 value Number of months to maintenance J15 value ions E eli value HWCH Hardware code high J17 value HWCL Hardware code low J18 value SWCH Software code high J19 value SWCL Software code low J20 value 10 4Function modes setting modality It is possible to select the 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 10 5Removal of the control panel electronic p c b Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Remove all the body panels see section 2 2 2 Gainaccess to the parts located inside the Control panel elec tronic p c b as explained in the section 2 3 of this manual 3 Remove all the wiring M connected to the Control panel elec tro
65. t 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 ty supply before removing any covering or compo nent Sensor operation 0 32 Hz without flow rate 33 200 Hz witht flow rate wh white bu blue rd red Figure 14 4 1 Remove the front panel of the case 2 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 39 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 5Removal of the flow switch group and d h w circuit filter 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 and empty the d h w circuit 2 Remove the fork D and pull up the flow switch plug E Figure 14 3 with the help of a screwdriver 3 Toremove 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 Activ A 25C 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
66. w and return cocks G Figure 2 10 2 6 Emptying the d h w circuit 1 Close the d c w inlet cock H Figure 2 10 2 Open one or more hot water taps until the boiler has been completely emptied Figure 2 10 Remove the front and right panels of the boiler 3 Open the drain tap Figure 2 11 combi or Figure 2 12 only c h until the boiler is completely emptied 4 To help the draining of the primary circuit loose the condens ing heat exchanger air purger valve CLOSED Figure 2 11 DIAGRAMS 3 DIAGRAMS 3 1 Wiring diagram Activ A Plus 25C Activ A Plus 30C Activ A Plus 35C Three way Gas valve Fan diverter valve 2 Flame detection Ignition electrode bn brown bu blue bk black wh white rd red gy grey Figure 3 1 electrodes 5V GND wh OUT x bk d GND E A ou OUT wh bu Cn js bk gn green ye yellow vt violet og orange gnye green yellow rdwh red white bk

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