Service manual - boiler,burner and fire service and
Contents
1. Flame detection electrode Condensate trap External controls Electric supply Flue Safety Fan Air pressigaition terminal block terminal block thermostat thermostat switotlectrodes bu br br br NI 22 C 555 gnye F 2 e J BN bk 45 TE C bu H Gei e 5 Ile GIE BFE iM o GE HESE l gt x A Electronic lt 52 L ttre et b control p c b ek bu S C te 09 f bk Tipp ei JUI Full sequence ignition device M d __ _ _ d ce 2 rd wh 7 rd bk bk bu bk DHW temperature DHW flow Primary circuit CH temperature probe NTC switch flow switch probe NTC Three way Pad diverter valve Pump bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow Modulating gas valve Time switch Diagrams Wiring diagram M96 28SR Wiring diagram for boiler equiped with full2. E 00 L A 230 o 230 JL o EE Ww Modulating Gas valve Safety thermostat Fan 230 Air pressure Switch Electronic control p c b 230 230 230 3 way diverter valve Pump Full sequence Ignition device Electronic control p c b Diagrams Diagrams for boiler equiped with full sequence ignition device type Honeywell FPLD Electrical voltages with burner on gt during c h or d h w operation only during c h operation only during d h w operation c gt S
3. Fig 10 Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the case panels and the sealed chamber lid see section 2 2 Empty the primary circuit of the boiler 3 Remove the combustion chamber lid B by un screwing the screws C and removing the clamp D Fig 11 4 Remove the screws E and the plate F 5 Loosen the connection G and slightly move the pipe H upwards 6 Remove the clip and the safety thermostat J It is not necessary to disconnect it from the wiring 7 Loosen the connection K and move the pipe L downwards freeing it from the connection of the primary het exchanger 8 Remove the clip M 9 Move the pipe N upwards freeing it from the con nection and rotate towards right 10 Remove the heat exchanger by sliding it for wards 11 Reassemble the boiler carrying out the removal operations in reverse order Fit the clip with the arrow pointing upwards as illustrated in Fig 11 IMPORTANT do not force the connection when tighting it Cleaning If there are deposits of soot or dirt between the blades of the heat exchanger clean with a brush or non me tallic bristle brush In any case avoid any actions that can damage the pro tective varnish with which the exchanger has been
4. 38 20 Safety thermostat 39 20 1 cere pex ed Deque ei re 39 20 2 Ghecks ed A 39 20 3 39 21 Flue thermostat 40 21 1 FUNCION eee itl p itte eb ie 40 21 2 40 21 3 Removal L Sha Sees 40 22 Condensate trap 41 22 1 41 222 41 23 Short spare parts list 42 1 information Overall View Flue thermostat Air pressure Switch Condensing _ heat exchanger Main heat exchanger Combustion S afety chamber S thermostat Burner gt Ignition ES E BU LELES Detection COCCI Automatic electrode air release Diverter valve 5 valve Main circuit flow switch Condensate D h w temp trap probe E Y i Pump Control Il panel Hydraulic diagram Central heating c h operation smd water return C h water flow Expansion vessel D h w heat exchanger Domestic hot water d h w operation uu D h w inlet D h w outlet 2 General access and emptying hydraulic circuits EX Nomenclature Right side panel Front panel Contr
5. Fig 86 41 23 Short spare parts list Key Description Q ty Manufac Manufacturer s reference turer part no 148 Burner mod M96 24SM KI1004 102 Polidoro 149 Burner mod M96 28SM 1004 147 169 069 Injectors for natural gas uod M96 24SM 1064 505 Polidoro Injectors for natural gas 1 mod M96 28SM 9 2858 E01 156 Injectors for LPG mod M96 24SM 1003 509 Injectors for LPG 14 mod M96 28SM 9 2858 eez emaninwse O ooo ESO Je mod M96 28SM M96 28SR fa paneas p pe ad 6 26ST mee We 129 Gas vave ____________ RE SIT 845 Sigma 169 127 ere pressure switch 880 74 1267 103 Yamatake Honeywell C6065 mod M96 24SW SIT 380 alternative Jm pressure switch 1 38 1 25 de 1376 104 Yamatake Honeywell C6065 mod M96 28SM M96 28SR SIT 380 alternative mE 013 81131 100 Watts J alternative 9 E83 178 Combustion chamber side Combustion chambersidepanels o a get 81326 100 8 180 Combustion Ped rear panel 811326 107 mod 9 245 E83 181 Combustion amis rear Se 1326 108 mod M96 28SM 96 285 E83 196 Combustion ee front 28 1406 103 mod 9 245 E83 197 Combustion ami front Ge 811406 104 mod M96 28SM
6. ES NI Fig 68 Checks Check of the fan NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the connectors D Fig 69 and measure the electrical resistance of the motor that has to be about 43 M96 24SM 25 M96 28SM 9 2858 at ambient temperature Fig 69 Check of the Air pressure switch operation NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the wires and check the electrical re sistance between the connections of the Air pres sure switch Refer to the Fig 70a or b in accordance with the type of air pressure switch used Between or3 and N O or 2 the contact must be open Between or 1 the contact must be closed electrical resistance zero 3 Connect the black wire COM or 3 and the brown wire N C or 1 4 Run the boiler the Fan must run and check the the electric resistance between COM or 3 and N O or 2 Between COM or 3 and N O or 2 the contact must be closed electrical resistance zero 35 Fan and Air pressure switch NN Fig
7. E ae gt 4 fa gnye Gem gnye e 1 m ui PET Condensate d 3 nk trap bu o EY bu e 9 R9 bn e rd 5 EN g d gt xe UM b gt x fo Electronic S MS et bn 5 control p c b 26258 er bu e bk s I Dom bu bk k ell rd 0 U Full sequence ignition device bk bu Dh D h w temperature D h w flow Primary circuit Ch temperature v probe NTC switch flow switch probe NTC Modulating x ew gas Three way Pump diverter valve bn brown bu blue bk black wh white rd red gy SC Pow Time switch vt violet og orange gnye green yellow Diagrams Wiring diagram for boiler equiped with full sequence ignition device type Honeywell FPLD
8. o JC 230 QO ll as SD Hung 230 230 E JoL Modulating Gas valve 0 Safety thermostat Fan 230 Air Sp pressure switch Electronic EE control p c b 230 10 3 way diverter valve Pump Full sequence Ignition device Electronic control p c b w y p uo wo UO HOUS e JO 1461 eu Wo uo Joo0 941 eure j eui JO uon uo Dag j useu qou juewjsnipe duet wu p eui Buluan e1njeeduue MUP 1 useop 941 US Op ueJ epoul wp JO uo ui Jeuye 1461 1 useop 941 Sum ue epoul wp JO uo ui Jee 1461 1 eu IIRS ue4 340 1961 epouJ AUDIO UD JOYE peys JOU seop eu ureDe S90 eu pue enunuoo uoniuBi eui uo 941 y sueis Je ioq eui usnd 1959 au Bursseud Ag ureBe s20 Jejoq pue enunuoo syseds uoniufi UO eu eu sueis eui usnd 1959 au Bursseud Ag eee Ho uo TUM _ TOR pgoeuoo pue uo suum
9. Removal of the electric actuator 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 24 3 Remove the fixing spring D and remove the actuator E Reassemble the actuator carrying out the re moval operations in the reverse order When reassembling the actuator refer to Fig 22 or to the wiring diagram in section NO TAG for the correct wiring connection 17 Three way valve U Fig 24 FEN Removal of the diverter group and its internal parts 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 9 3 4 Remove the fixing spring F Fig 25 and remove the primary circuit flow switch G 5 Disconnect both c h and d h w temperature probe respectively H and 6 Unscrew the connector J the c h flow connector and the d h w outlet connector Fig 25 7 Remove the d h w heat exchanger see section 7 2 8 Remove the fork and move away the pipe L Fig 26 18 9 Unscrew the screw M and remove the diverter group Fig 26 10 Rear view of the boiler Refer to the exploded view in Fig 27 to remove the internal parts of the three way diverter valve Fi
10. Wall hung fan flue room sealed high efficiency gas boiler Service manual RIVA COMPACT HE Models G C Appl No M96 24SM C 47 970 23 M96 28SM C 47 970 24 M96 28SR C 41 970 12 Leave this manual adjacent to the gas meter RECOMMENDED This product has an energy rating B on a scale of A to G For more information see www boilers org uk This is a certification mark A BIASI Table of contents 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 11 11 1 11 2 11 3 11 4 Overall information 1 Overall View 1 Hydraulic diagram 1 General access and emptying hydraulic circuits 2 Nomenclature 2 Body panels 2 Control panel 2 Access to the sealed chamber 3 Emptying the primary circuit 3 Emptying the d h w circuit 3 Diagrams 4 Wiring diagram M96 24SM M96 28SM 4 Wiring diagram M96 28SR 6 Functional flow diagrams 8 Circuit voltages 9 Fault finding 11 Primary heat exchanger 13 FUNCUOM METH 13 REMOVAL i oe 13 Cleaning iacu epe ce ee ors 13 Condensing heat exchanger 14 Functions mo see ome eMe RANGE 14 Removal iiie ROPA ae Due 14 D
11. gnye green yellow Diagrams Functional flow diagrams General layout J1 1 Fuse 1 6A T PTC Electronic control p c b low voltage section Transformer PA gt A Heat request on d h w J1 1 Fuse 1 6A T PTC L LINE N NEUTRAL ACTIVE CIRCUIT INACTIVE CIRCUIT Heat request on c h J1 1 Fuse 1 6A T PTC low voltage section Transformer 2 J3 5 m 1 J3 4 1 M CS eg Three way diverter valve 01 2 Ka N ted 43 1 fex J8 2 uc J2 5 J2 4 H H G D Full sequence ignition device Electronic control p c b low voltage section Transformer 2 M J3 3 Three way diverter valve Full sequence ignition device Electronic control p c b J3 3 Three way diverter valve Full sequence ignition device Circuit voltages Diagrams Diagrams for boiler equiped with full sequence ignition device type Bertelli amp Partners FM30 Electrical voltages with burner on during c h or d h w operation only during c h operation only during d h w operation Supply network
12. Fig 28 ER Selection and adjustment devices On the Electronic control p c b several selection ad justment and protection devices are located Fig 29 Some of these devices are directly accessible by the user function control temperature adjustment poten tiometers etc others are accessible by removing the service panel or the control panel lid Fig 29 J3 connector J2 connector Lock out signal lamp Boiler reset button Function control C h temperature adjustment D h w temperature adjustment Appliance operation lights Dip switch selectors Setting jumpers 10 Ignition gas pressure adjustment ACC 11 J1 connector 12 Fuse1 6AT Checking the temperature The Electronic control p c b makes it possible to separ ately adjust the c h water flow temperature and d h w outlet temperature The temperature of the water is converted into an elec tric signal by means of temperature probes The user setting the desired temperature with the con trol panel knobs operates the variable elements 5 and 6 in Fig 29 of the electronic control p c b DJ OO PS OM A 19 Electronic control p c b If the power requested is lower than 4096 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 higher then the burner is switched ON at maximum power and will control by modu
13. Start the boiler and with a screwdriver turn the rotor in the direc tion of the arrow If there is a defect in starting the rotor will begin to turn normally only starting it manually 16 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 Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Remove the front and right hand side case panels Empty the primary circuit of the boiler Extract and lower the control panel Disconnect the connector B Fig 19 Loosen the connection C remove the fork D and the pipe E H Tee _ CN X EE y gt D Fig 19 6 Remove the fork F Fig 20 and the connection of the capillary pipe of the pressure gauge 7 Remove the locking plate G Completely loosen the connection H 9 Unscrew the two screws that hold the pump the frame and remove the pump SS S Us A Fig 20 Reassemble the pump carrying out the removal oper ations in the reverse order When reassembling the pump check the correct locatio
14. Fig 48 3 Unscrew the screw and remove on off oper ator coils 4 Reassemble the coils carrying out the removal operations in reverse order U E E Fig 48 28 ER Removal of the gas valve NN 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 connectors B and C Fig 49 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve 4 Unscrew the connectors F and remove the pipe G 5 Unscrew the screws H and remove the valve 6 Reassemble the valve carrying out the removal operations in reverse order 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 Fig 49 13 Primary circuit flow switch ESN Function The Primary circuit flow switch A in Fig 50 function is Boiler OFF B Boiler ON to detect water flowrate through the primary hydraulic circuit of the boi
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16. by mode or during the normal operation of the boiler The following table gives the relationship between the lamp indication and its meaning Electronic control p c b Boiler in stand by condition function control in o position Anti freeze system active Boiler ON condition function control in ag or position 1 second ON 1 second OFF With the boiler switched ON all the lamps 7 in Fig 29 are activated Thefollowing table gives the relationship between each of the possible lamp combinations and their meaning Normally operating boiler ARS see the previous table for details D h w operation AE Excessive temperature on primary circuit O O Faulty c h temperature probe NTC Faulty d h w temperature probe NTC ANS e Faulty primary circuit 2 no water or absence of flow Lack of burner ignition no ignition signal from dc o O the full seqence ignition device Ignition gas pressure adjustment Minimum gas pressure adjustment Lack of power supply or fauly electronic control p c b Fauly electronic control p c b Lamp Lamp OFF ON Flashing lamp alone or simultaneously with an other lamp Flashing lamp alternate with another lamp These conditions are normal only for a short time when the power supply is applied to the boiler If permanent they indicate a faulty p c b IDE Dip switch selectors The function select
17. cov ered 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 13 6 Condensing heat exchanger ES Function Thereturn water flows through the condensing heat ex changer A in Fig 12 and Fig 13 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 A Fig 12 ER Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the case panels and the sealed chamber lid see section 2 2 Empty the primary circuit of the boiler 3 Remove the fan D in Fig 13 see section 18 3 and the air pressure switch E see section 18 5 4 Remove the flue thermostat F see section 21 3 5 Completely loosen the connection G and slightly move the pipe upwards 6 Remove the clip and move the pipe J down wards freeing it from the connection then turn it towards right 7 Using pliers remove the spring K moving it down wards and disconnect the rubber pipe L 8 Remove the bracket M by unscrewing the screws that hold it on the frame 9 Rotate the exchanger as indicated by the arrow and remove it t
18. h w heat exchanger 15 Eunctlon MD LS SE 15 Removal ore uve 15 eol und cues 16 FUGON 16 L O REENEN 16 Removal 16 Three way diverter valve 17 F nctlofi sor cec lex eT Ine 17 GRECKS gt oru der iita 17 Removal of the electric actuator 17 Removal of the diverter group and its internal parts 18 Electronic control p c b 19 Eunctlon ence tbe nete 19 Selection and adjustment devices 19 Checking the temperature 19 Operation lights 20 Dip switch selectors 21 Settings emer es 22 Ignition gas pressure adjustment 22 GREGCKS kar en 22 Removal of the electronic control p c b 22 Thermal control in the EH mode 24 Thermal control in the 24 Full sequence ignition device 25 Functions evtl D EE 25 Check852 oa foe ixe i AT Ier 25 Removal 25 Ignition and control sequence 26 12 Modulating gas valve 27 12 1 Function oe vee rem 27 12 2 Nomenclature of the parts Fig 46 27 12 9 Adjustment 27 124 Checker Se wae a See 28 125 Removal of the on off operators coils 28 12 6 Removal of the gas valve 28 13 Primary circuit flow swi
19. sequence ignition device type Bertelli amp Partners FM30 External controls Electric supply Flue Safety Fan Air pressure Ignition Flame detection terminal block terminal block thermostat thermostat switch electrodes electrode V a cb bu br Y LLI 285 NC bk ry 5 EE br br 5292 312 1 000 ae i 9 Li E coo gnye S A V Je J Condensate m S ve 9 rd acaao E cR xe a ali ML BE 225 Je Electronic 9 uim 522 pn o control p c b e bu S bn 5 1 m el bu bk et U Full sequence ignition device d d S lt JEE rd bk Ne bk gnye Primary circuit Ch temperature flow switch probe NTC Modulating gas valve Pump bn brown bu blue bk black wh white red gy grey gn green ye yellow vt violet orange gnye green yellow Diagrams
20. seyesado Joo 941 Jeioq ASION 1994109U epoul wup uo poeu100 1e ioq 941 yeoy jou wajsAs u o 991 0 62 eus JO euymejeduue u o uo ww Up Buunp u o uoneJedo y Ajddns jou saop 941 510108 98 uonounJ q o d esn4 poi 1no 3201 q o d q o d 1 Jk eouenbes 08 E mee uonoejeq uous U91IMS ainsseid pue eqoud due wug D 2100 Jenuew y jo uonoeg E _ n a III D ka Ed o 2 lt 5 o lt LN S lt 3 D lt 5 E ssed g 8 01 epe m sjueuoduuo2 5 Primary heat exchanger ES Function The primary heat exchanger A in Fig 9 has the function of transferring heat produced from combustion of the gas to the water circulating in it s SS Fig 9 The hydraulic circuit is composed of 8 elliptical pipes connected in parallel Fig 10
21. that hold the Electronic control p c b on to the control panel 5 Remove it by lifting its rear edge and freeing it from any of the wiring 6 Re assemble the Electronic control p c b fol lowing the removal procedures in the reverse order Important When re assembling the Electronic control p c b Electronic control p c b Fit the p c b into the control panel by first insert ing the front lower edge under the control knob shafts Lower the rear edge and ensure that no wiring is trapped beneath Insert the spindles in the control panel knobs un till the notch A Fig 40 reaches the potentio meter edge It is not necessary to force them in the knob While tightening the screws that fix the Electronic control p c b on the control panel keep the p c b towards the control panel fascia making sure of the contact between the boiler reset but ton B and the tab C Fig 40 Fig 40 Attention After installing the Electronic control p c b 10 11 12 Make sure the c h and d h w A tem perature adjustment knobs can move freely for the complete range If not remove the spindle again as described at step 3 turn the knob half a turn and re insert the spindle Make sure that the settings comply with the in dications given in section 10 6 Operate the boiler and close the gas inlet cock so that the boiler goes into the safety lock out state Verify the correct operation of the boiler r
22. 63 On the boiler there are two Temperature probes One on the output of the primary heat exchanger c h Tem perature probe A in Fig 64 and Fig 65 oneon the out put of the d h w heat exchanger d h w Temperature probe B in Fig 64 and Fig 65 7 c h c h d h w d h w return flow inlet outlet Fig 64 Checks Temperature resistance relationship 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 brass group where the Temperature probe is located and check the electrical resistance according to the graph in Fig 63 Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 To remove the Temperature probes remove the front panel of the case 2 To remove the c h Temperature probe empty the primary circuit of the boiler To remove the d h w Temperature probe empty the d h w circuit of the boiler 3 Remove the electric connector of the Tempera ture probe and unscrew it 4 Reassemble the Temperature probe carrying out the removal operations in reverse order 33 17 By pass valve Removal Function w Warning isolate the boiler from the mains The By pass valve A in Fig 66 is located between the electricity supply before removing any c h water fl
23. 70a H connection ees P connection Fig 70b Lk Check of the venturi device This test must be carried out with the sealed chamber closed 1 Remove the caps of the pressure test points lo cated on the top of the boiler and connect a differ ential pressure gauge Fig 71 Removal of the Fan Warning isolate the boiler from the mains electricity supply before removing any covering or component Remove all the case panels the sealed chamber lid and the combustion chamber lid Disconnect the connectors D and the earth con nection E Fig 69 Disconnect the pipe which connect the venturi device to the Air pressure switch Unscrew the screw F and remove the bracket G Fig 72 2 Switch on the boiler Warn Warn Fig 73 Fig 71 3 Compare the value on the gauge with the follow ing minimum values 80 0 8 mbar M96 24SM 110 Pa 1 1 mbar M96 28SM M96 28SR 36 Remove the Fan by sliding it towards left se the arrow in Fig 72 Assemble the fan carrying out the removal oper ations in reverse sequence ing Re assembling the fan ensure that the hooks around the inlet port of the fan hung correctly on the flue hood ing to correctly connect the venturi device to the Air pressure switch refer to Fig 73 Warning After cleaning or replacement as detailed above if it deemed necessary
24. 96 285 Electronic Electronic regulation p c b p c b GE 811605 100 ees 142 Full sequence ignition device 811305 101 n amp Partners FM30 Honeywell FPLD alternative X Eoo Dhw heat echange WZS 1 _ 206 Dh heat exchanger M96285 1 enore o emp mesi Em om Dhwiowswun EE lee Jeroen remm Jee eege mme ruse GAT 164 026 Temperature probe ain or dhw een one sce a eler leen ionien seeroete p CS lee n Al a el 42 Short spare parts list 43 17962 1114 0 3704 48A4 UK Biasi U K Ltd Unit 31 33 Planetary Road Industrial Estate Neachells Lane Willenhall Wolverhampton WV 13 3XB Technical helpline 01902 304 400 Web site www biasi co uk
25. Wiring diagram for boiler equiped with full sequence ignition device type Honeywell FPLD External controls Electric supply Flue Safety Fan Air pressigaition Flame detection terminal block terminal block thermostat thermostat switatlectrodes electrode V bu br 222 br 4 br 521 600 3122 71 000 Ne 22 C EL ooo gnye E 5 1 1 V Ie 2 E Condensate E E trap d 5 rd 9 m o e comm EE P EK zag Electronic 9 5952 on control p c b e bu bu S ele bn E S EE m le bu bu n bn 9 JUI Full sequence x P ignition device d SEI d Sle rd bk bk Primary circuit temperature flow switch probe NTC Modulating Pump gas valve bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet orange
26. ansion vessel and con nect a suitable air pressure gauge Fig 55 3 Check the pre load pressure and refer to the section Expansion vessel in the User manual and installation instructions for the correct value Removal of the expansion vessel If there is at least 400 mm clearance above the boiler and the rear exit flue can be easily removed the expan sion vessel can be changed without removing the boiler 30 NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front and left hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit 2 Completely unscrew the connection K the lock nut L Fig 56 and remove the expansion vessel from the top of the boiler U Fig 56 3 Re assemble the parts in reverse order of re moval Removal of the temperature pressure gauge 1 Remove the front and right hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit 2 Remove the fork M and the probe holder spring N Fig 57 3 Squeeze the tabs to release the temperature pressure gauge P and remove it 4 Re assemble the parts in reverse order of re moval 90 Fig 57 15 D h w flow switch filter an
27. are carried out at the start of every ignition cycle and during normal functioning Checks Lock sequence Start the boiler until the burner is ignited O O With the burner firing interrupt the gas supply The Full sequence ignition device must carry out a complete ignition cycle and then stop By turning the boiler on and off by means of the function switch the device must not unlock and the burner must not turn on Lk Fanfunctioning device With the boiler operating and the burner on open the negative pressure test point of the Venturi device At the moment of opening the burner must turn off Removal NA Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Gain access to the parts located inside the con trol panel as explained in the section 2 3 of this manual 2 Remove all the wiring connected to the Full se quence ignition device To disconnect the connectors A delicately flex the hook present on one side of each socket Fig 43 3 Unscrew the two screws B that hold the Full se quence ignition device on the panel and remove the component 4 Re assemble the Full sequence ignition device following the removal procedures in the reverse order 25 Full sequence ignition device onion and control sequence supply from the electronic control circuit YES lock memori
28. ary heat ex changer and remove it o 9 n a Fig 80 5 Reassemble the overheat thermostat carrying out the operations in reverse order 6 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 39 21 Flue thermostat ARH Function The Flue thermostat A in Fig 81 and Fig 82 senses the temperature of the combustion products that flow through the condensing heat exchanger A SCH SE seg Fig 81 In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler operation It is therefore allowed the use of plastic materials for the flue outlet pipes and bends The use of kits different from the original isn t how ever allowed since the flue pipes are integral parts of the boiler If the temperature of the combustion products circuit reaches the limit temperature the Flue thermostat opens the electric circuit that supplies the on off oper ators 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 The Flue ther
29. back to the normal position ON ON 1 OFF 0 gas pressure calibration Normal Fig 34 Selector 4 This allows you to select the minimum time that must pass between two ignitions of the burner in c h func tion 3 min ON 1 lg d OFF 0 30 sec Fig 35 21 Electronic control p c b Settings Two setting jumpers are fitted on the Electronic control p c b Refer to Fig 36 for the position of the jumpers when the Electronic control p c b is fitted on a M96 24SM or M96 28SM boiler Refer to Fig 37 when the Electronic control p c b is fitted on M96 28SR boiler The numbers refer to the marking printed on the circuit board 123456789 Fig 36 123456789 Fig 37 The device N indicated in Fig 38 and marked RISC on the Electronic control p c b must be set fully counter clockwise Fig 38 Ignition gas pressure adjustment By using the device 10 Fig 29 marked ACC on the Electronic control p c b it is possible to adjust the gas pressure at the injectors in the ignition phase This pressure is maintained at the injectors until ignition occurs ionization signal from the full sequence ignition device To carry out the adjustment move the function selector 3 to the OFF position Fig 34 and use the adjustment device 10 ACC Adjustthe gas pressure atthe injectors tothe value indi cated in t
30. d and verify that the contact is now closed X electricity supply before removing any covering or component Removal of the switch Remove the front panel of the case Remove the fork C Fig 53 Open the box and disconnect the switch Re assemble the parts in reverse order of re moval Refer to Fig 52 for the correct wiring con nectors on the switch Removal of the membrane Remove the front and right hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit Remove the fork C that holds the micro switch housing D Fig 53 TTE Fig 53 V Unscrew the four screws E see Fig 54 open the hydraulic operator and remove the membrane F 29 Primary circuit flow switch Fig 54 4 Reassemble the parts in reverse order of removal When assembling the membrane ensure that its concave side faces towards the actuator plate G and the reference indicated aligns with the seat H see Fig 54 14 Expansion vessel and temperature pressure gauge Function The Expansion vessel in Fig 50 function is to allow for the volume expansion of the c h circuit water due to the temperature rise Checks 1 Turn off the flow and return isolation valves and empty the primary circuit of the boiler 2 Remove the protective cap J Fig 55 from the valve on the top of the exp
31. d checks its functioning by means ofthe signal coming from the air pressure Switch The Full sequence ignition device is supplied by the electronic control p c b when the ignition of the burner is requested The Full sequence ignition device has a safety function and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler The Full sequence ignition device can lock the function ing of the boiler lock state and stop its functioning up to the resetting intervention The lock is signalled by the lighting of the lock out signal lamp and the device be reset only by using the boiler reset button placed on the control panel fascia Some components which are connected to the device can activate the lock state The causes of a lock state could be intervention of the safety thermostat over heat of the primary circuit 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 Gas injectors blocked Faulty modulation gas valve faulty on off oper ators or not electrically supplied Faulty Full sequence ignition device Other components like the air pressure switch can tem porarily stop the ignition of the burner but allow its igni tion when the cause of the intervention has stopped Fig 44 shows the sequence of the operations that
32. d flow limiter Function The d h w flow switch A in Fig 58 is a device that gener ates an electrical signal when hot water is drawn Fig 58 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 4 Fig 60 is drawn to wards the right The resulting magnetic field of ring 3 increases and re aches the flow switch sensor 1 The sensor generates an electrical signal that switches the boiler d h w operation ON The state ofthe sensor is also indicated by means ofthe lamp B placed on the sensor body Fig 59 IEEB Nomenclature and location of parts Fig 60 Flow switch sensor Plug Magnetic ring Float Spring Filter Body Spring seat Flow limiter M96 28SM optional accessory 0 Threaded ring OMAN OO P Go Fig 60 Checks Warning isolate the boiler from the mains electricity supply before removing any covering or component Flow switch sensor operation Remove the front panel of the case 2 Switch on the boiler and open a d h w tap The lamp B Fig 59 placed on the sensor body is Switched on when the flow rate reaches about 2 5 litres min Removal of the flow switch sensor NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case 2 Disconnect connector Fig 59 and remove the
33. d the Flue ther mostat to the frame 5 Assemble the Flue thermostat carrying out the re moval operations in reverse sequence Warning to correctly connect the Flue thermostat refer to Fig 83 and Fig 70a or Fig 70b for the cor rect wiring ox SES 29 Fig 83 22 Condensate trap EAN Function The condensate trap A in Fig 84 and Fig 86 allows the discharge of the condensate via the condensate drain pipe avoiding in the mean time the escape of combus tion products A plastic ball closes the trap outlet in case that the trap is empty Fig 84 The condensate trap is provided with two electrodes The electrode B is connected to the ground circuit the electrode C is connected to the flame detecting elec trode Fig 85 Fig 85 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 putting in contact the electrodes thus causing the boiler lock out EEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 6 Remove the front and right case panels 7 Disconnect the trap from the draining pipe 8 Using pliers remove the spring D moving it up wards 9 Remove the spring E and lower the trap 10 Disconnect the wirings from the trap 11 Reassemble carrying out the removal operations in reverse order
34. e electrodes to the ignition de vice Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Disconnect the electrode wires from the full se quence ignition device 3 Remove the plate C see Fig 79 on page 39 4 Remove the burner by unscrewing the four screws placed at the right and left sides of the burner 5 Unscrew the screws A Fig 77 which hold the electrodes to the burner 6 Extract the electrodes from the burner 7 Assemble the electrodes carrying out the removal operation in reverse order Refer to Fig 75 in order to recognise the elec trodes and to correctly connect the wiring Note the metallic edge of the detection electrode is longer than the one of the ignition electrodes 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 20 Safety thermostat Function The safety thermostat A in Fig 78 and Fig 79 is a de vice that senses the temperature of the primary circuit water which flows in the outlet pipe of the primary heat exchanger If the temperature control system of the boiler fails and the temperature of the primary circuit reaches a dan gerous temperature the safety thermosta
35. eset but ton by pressing and releasing it 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 23 Electronic control p c b Thermal control in the 242 mode Switch in the uk function mode See functioning with the function control in the ye mode lt YES NO sec 10 11 Is primary circuit temperature higher than that selected YES NO Request for heat from room thermostat _ Circulator off Starts the circulator Operates motorised valve Operates motorised valve Ignition device off Supplies the ignition device Fig 41 Thermal control in the 3 mode Switch in the JI function mode m YES Circulator off NO gt Ignition device off Y Circulator on Is domestic hot water outlet temperature lower than that required YES NO Supplies the ignition device Ignition device off Fig 42 24 11 Full sequence ignition device Function The Full sequence ignition device used on the boiler carries out the following fundamental functions O does a sequence of operations ignition cycle which lead to the ignition of the gas at the burner checks the presence of the flame during the en tire period in which it is activated O supplies the fan an
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37. g 27 11 Reassemble the diverter group carrying out the removal operations in the reverse order 10 Electronic control p c b Function Inlet Information On the Electronic control p c b Function control C h temperature adjustment D h w temperature adjustment Function dip switches Ignition gas pressure adjustment Boiler reset button control panel fascia From other boiler devices C h temperature probe NTC D h w temperature probe NTC D h w flow switch Primary circuit flow switch Room thermostat if fitted Time switch Flame presence signal from the full sequence ignition device Outlet command Pump Three way diverter valve Full sequence ignition device Modulation operator Appliance operation lights Lock out signal lamp control panel fascia Fig 28 The fundamental function of the Electronic control p c b is that of controlling the boiler in relation to the ex ternal 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 constant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Electronic control p c b receives inlet in formation coming from the boiler the sensors or from the outside knobs room thermostat etc processes it and consequently acts with outlet commands on other components of the boiler
38. he full sequence ignition device remove the screws F and remove the control panel lid Fig 5 General access and emplying hyaraulic circuits To gain access to the parts contained in the sealed chamber it is necessary to remove the lid of the sealed chamber For this purpose remove the front and side panels of the case remove the screws G as indicated in Fig 6 and remove the lid EX Emptying the primary circuit 1 Close the c h circuit flow and return cocks H Fig 7 Fig 7 bottom view of the boiler 2 Remove the front and right panels of the boiler 3 Open the drain tap Fig 8 until the boiler is com pletely emptied 4 Close drain tap again once the emptying has been completed Est 12 Fig 8 EX Emptying the d h w circuit 5 Close the d c w inlet cock J Fig 7 6 Open one or more hot water taps until the boiler has been completely emptied 3 Diagrams EAR Wiring diagram M96 24SM M96 28SM Wiring diagram for boiler equiped with full sequence ignition device type Bertelli amp Partners FM30 External controls Electric supply Flue Safety Fan Air pressure Ignition Flame detection terminal block terminal block thermostat thermostat switch electrodes electrode V fed cb bu iu br FA Re 411 235 NC bk Aen ER br br 528 312 1
39. he tables of the User Installation manual Technical information section Gas pressures at the burner table By rotating the device clockwise the pressure in creases 22 Check the regular ignition of the burner by turning the boiler on and off repeatedly After the adjustment operations bring the selector 3 back to the normal position ON IDE Checks Check that the fuse is complete If the Electronic control p c b does not supply any de vice pump fan etc check that the fuse 12 Fig 29 is complete If the fuse has blown replace it with one that has the same characteristics after having identified the reason for failure Check the setting jumpers position Two setting jumpers must be fitted on the Electronic control p c b as shown in Fig 36 Removal of the electronic control p c b Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Gain access to the parts located inside the con trol panel as explained in the section 2 3 of this manual 2 Remove all the wiring connected to the Electronic control p c b To disconnect the connectors J1 J2 and J3 11 2and 1 in Fig 29 delicately flex the hook present on one side of each socket 3 Remove the spindles of the c h and d h w tem perature adjustment knobs by delicately pulling them with pliers in the direction shown by the arrow in Fig 39 4 Unscrew the four screws
40. ight If not reverse the ring and repeat the previous operation 32 5 Fit the ring on the spindle of the float in the way that lights the lamp B 6 Isolate the boiler from the mains electricity supply and reassemble the parts following the removing sequence in reverse order Fig 62 Flow limiter The M96 24SM model is factory fitted with a 10 litre min flow limiter If on the M96 28SM model the flow rate of the d h w circuit is too high it is possible to limit it by installing a flow limiter The following sizes are available Nominal flow rate litres min To install the flow limiter 1 Remove the flow switch group as explained in the section 15 5 2 Unscrew the threaded ring 10 Fig 60 and re move it from the body 7 3 Install the flow limiter 9 putting its smaller diam eter side towards the threaded ring 4 Reassemble the group following the above se quence in reverse order 16 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 63 Q re 11500 11000 10500 10000 1000 soo Ts EE spe qoae p Sp 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 1009 Fig
41. lating to 40 of the maximum power output During the c h operation Fig 30 the signal coming from the c h temperature probe is compared to the sig nal given by the control panel through the adjustment made by the user knob The result of such a com parison operates the modulation of the gas valve consequently changing the useful output of the boiler Fig 30 When the boiler functions in d h w Fig 31 the signal coming from the d h w temperature probe is compared with the signal given by the control panel through the adjustment made by the user knob bes 20 Fig 31 Normally the result of the comparison between these two signals directly operates the adjustment elements ofthe gas valve modulation device adjusting the useful output generated in order to stabilize the temperature of the exiting water If during the d h w mode operation the temperature of the primary circuit goes over 75 the useful output is automatically reduced so that the primary circuit can not reach excessive temperatures The control sequences in z function and in 3 func tion are illustrated in detail in sections 10 10 and 10 11 Operation lights The Electronic control p c b is provided with three lamps L E D indicators 7 in Fig 29 that give optical in formation during the operation of the boiler The green lamp on the left gives information whether the boiler is in stand
42. ler Fig 51 Electrical check Itis possibleto verify the general operation of the switch by measuring the electric resistance between the con 1 2 1 Fig 50 2 This hydraulic membrane operated electrical micro 3 switch device will control the functioning of the ignition 4 control circuit providing there is an adequate quantity and flow of water in the primary circuit Any failure ofthe pump or obstructions in the primary circuit whilst in either c h or d h w modes will not allow the device to E ch This device is connected to the electronic control p c b and if after the pump operates it does not activate with in 20 seconds the control board will indicate that a fault 2 condition see section 10 4 of this manual has oc curred Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Mechanical function ech Remove the front panel of the case 2 Start and stop the boiler either in d h w or c h mode 3 Looking through the switch box verify the position 3 of the shaft B referring to Fig 51 Fig 52 ERR Removal NN Warning isolate the boiler from the mains tacts C and N O of the switch Remove the switch as explained in section 13 3 Measure the electrical resistance between the tabs marked C and N O Fig 52 The contact must be normally open Operate the switch by han
43. ment On off operators Maximum gas pressure adjustment On off operators electric connector Gas valve inlet pressure test point Modulation operator N O A Gas valve outlet pressure test point Fig 46 EEN Adjustment NN Warning isolate the boiler from the mains electricity supply before covering or component removing any Remove the front panel of the case 2 Open the gas valve inlet pressure test point 6 in Fig 46 at the valve input connect a suitable pressure gauge and check the gas pressure of the supply network 3 Remove the gauge and close the pressure test point 6 4 Open the gas valve outlet pressure test point 8 in Fig 46 and connect the gauge 5 Remove the protection cap from the mechanical pressure adjustment components 6 Start the boiler at its maximum power Operate the boiler in d h w mode or ensure that the boiler is not range rated ifthe testis carried out in c h mode 7 Rotate the maximum gas pressure adjustment 4 in Fig 46 until you obtain the required pressure by rotating clockwise the pressure increases 8 Disconnect one of the two connectors 1 in Fig 46 or alternatively remove the service panel as explained in the section 2 3 of this manual and set the dip switch selector 1 see section 10 5 to the OFF position 9 Rotate the minimum gas pressure adjustment 2 in Fig 46 until you obtain the required pressure by rotating clockwise the
44. mostat is a push button reset type This allows to recognise if the lock out has been due to its intervention or to another different cause flame failure main circuit overheating etc The reset push button is located on the top of the boiler under a protective cap B in Fig 82 and can be re ached by unscrewing the cap The intervention of the Flue thermostat may be caused by a defective operation of the device but more probably is due to a poor heat exchange and therefore to a low efficiency of the boiler In this case the cleaness of main and condensing heat exchangers is recommended 40 E R _ vod Un ol Fig 82 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 thermostat and no overheat intervention should occur HEB 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 sealed chamber lid 2 Disconnect the wires from the Flue thermostat 3 Unscrew and remove the thermostat probe C Fig 82 from the condensing heat exchanger 4 Unscrew the screws D which hol
45. n of the O ring gasket in the inlet port of the pump that seals the connection between the pump and the brass group 9 Three way diverter valve Function The diverter valve Fig 21 has the function of modify ing 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 ex changer towards the c h system or towards the d h w heat exchanger Fig 21 FEN Checks Check the electrical continuity Fig 22 indicates the relationship between the electric command 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 Fig 23 indicates the relationship between the electric command 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 actuator and the resistance of the motor windings the motor must be disconnected from the wiring is also given Spindle B not visible e 9 4 bn brown Open circuit bu blue E bk black 2 2 gt Q gt amp Spindle B visible Bo Open circuit bn brown 9 4 Kohm bu blue AU ger a 2 a bk black gt Ei amp Fig 23 mode
46. ol panel lid 1 2 3 4 Control panel cover 5 Service panel 6 Left side panel Body panels NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 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 remove screws A Fig 2 lift the panel and remove it Fig 2 To remove the side panels loosen the screws B and C Fig 3 bring the base of the panels away from the boiler and lift them freeing them from the top hooks VS Fig 3 bottom view of the boiler 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 Loosen the screws B and C Fig 3 Remove the screws D Move the lower part of the side panels as indi cated in Fig 4 and pull the control panel When completely pulled out the panel can rotate 45 downwards to facilitate the service oper ations on the internal parts amp Go Fig 5 Fig 6 Remove the screws E and remove the service panel Fig 5 To gain access to the electronic regulation PCB and t
47. ors 8 Fig 29 and Fig 32 are micro switches with which it is possible to select the various boiler control function modes In Fig 32 the selectors are illustrated in the configur ation in which the boiler is set in the factory natural gas boiler Minimum gas pressure adjustment Gas conversion Ignition gas pressure adjustment Reignition frequency 1 12 13 4 IN 0 8 Fig 32 Selector 1 This forces the boiler to operate at the minimum gas pressure in order to allow the adjustment of the mini mum gas pressure at the burner on the modulation op erator of the gas valve After any adjustment operation the selector has to be brought back to the normal position ON Selector 2 This selects the boiler functions on the basis of the type of gas used It allows the selection of the maximum supply current given to the modulator device To set selector 2 correctly follow the table in Fig 33 Gas supply Position of selector Approx Max current through the modu lator device Natural gas 120 mA L PG 165 mA Fig 33 Selector This forces the functioning of the boiler in order to allow the optimal gas pressure at the burner to be adjusted during the ignition phase The adjustment see section 10 7 is done by means of the potentiometer 10 marked ACC Fig 29 on page 19 After the adjustment operations bring the selector
48. ow and return and its function is that of guar covering or component anteeing a minimum flow across the primary heat ex changer ifthe circulation across the c h system is com 1 Remove all the case panels pletely closed 2 Empty the primary circuit of the boiler The By pass valve is fitted on the rear side of the div erter group Remove the diverter group as described in the section 9 4 of this manual 4 Unscrew the connector B and remove the by pass valve C Fig 67 Fig 67 5 Reassemble the by pass valve as illustrated in Fig 66 Fig 67 reversing the order of removal 34 18 Fan venturi device and Air pressure switch Function The function of the Fan Fig 68 and Fig 69 is to force the products of combustion trough the condensing heat exchanger to the outside air via the flue system The Fan is supplied by the full sequence ignition device at the beginning of the ignition cycle Its correct functioning is controlled by means of a sys tem incorporating a built in venturi device B Fig 74 and an Air pressure switch C Fig 68 and Fig 69 A PE
49. owards the front of the boiler 10 Remove the clip N and the pipe H O DN Fig 13 11 Reassemble the exchanger carrying out the re moval operations in reverse order After reassembling ensure that the fan exchanger and exchanger elbow gaskets are correctly mounted and ensure a good sealing 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 14 7 D h w heat exchanger Removal Function NN Warning isolate the boiler from the mains electricity supply before removing any The d h w heat exchanger A in Fig 14 and Fig 16 al covering or component lows the instantaneous transfer of heatfrom the primary hydraulic circuit to the water destined for d h w use ch Remove the front and right hand side panels of the case t Ee 2 Empty the primary circuit and the d h w circuit of the boiler 3 Completely unscrew the two Allen key screws B Fig 16 which hold the exchanger to the brass groups 4 Move the exchanger towards the rear of the boiler and extract it Reassemble the d h w heat exchanger carrying out the SE removal operations in the reverse order ig 14 Attention When reassembling the exchanger be sure to put the off cen
50. pressure increases 10 the boiler off and re connect the wire to the modulating operator or set the dip switch se lector 1 back to the ON position 11 Start the boiler and check again the maximum gas pressure setting 12 Turn the boiler off and disconnect the gauge Important after the gas pressure checks and any adjustment operations all of the test points must be sealed 27 Modulating gas valve EZB Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Lk Check the modulation operator coil Remove the front panel of the case Disconnect the connectors B Fig 49 from the modulating operator and measure the electrical resistance of the coil Its electrical resistance value must be approx 80 2 Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector C Fig 49 Measure the electrical resistance between the connector pins of the on off operators as illus trated in Fig 47 on Upper on off operator approx 6 400 Q Lower on off operator approx 920 Q at ambient temperature Fig 47 Removal of the on off operators coils NN 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 connector D
51. rtake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 37 19 Ignition and detection electrodes ERR Function Three electrodes are fitted on the burner Two of them are the ignition electrodes and are fitted near the front part of the burner The ignition sparks take place be tween their metallic edges over the central ramp of the burner during the ignition sequence The third electrode is the detection electrode and it de tects the presence of the flame Detection Ignition 1 E Male Fig 75 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 all the case panels the sealed chamber lid and the combustion chamber lid 2 Check for the correct distance between the me tallic edges of the ignition electrodes see Fig 76 MN Ignition A Fig 76 38 3 Check the integrity of the detection electrode and ensure that its metallic edge is correctly placed over the ramp of the burner Check the connection wires NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Check for the integrity of the insulation of wires which connect th
52. sed NO cancels tock J NO Air pressure switch at YES rest NO Air pressure switch at YES gt lt work beginning of wait period NO presence of flame YES NO Air pressure switch at work YES starts ignition discharges opens gas valve beginning of ignition period NO flame presence YES end of ignition closes gas valve stops fan interrupts ignition discharges period memorizes lock turns on lock out light interrupts ignition discharges gas valve open NO reset push button YES pressed r YES flame presence NO Safety thermostat No opens the circuit A L YES Air pressure switch at NO work Fig 44 26 12 Modulating gas valve EAN Function The Modulating gas valve A in Fig 45 controls the gas inflow to the boiler burner Fig 45 By means of an electric command given to the on off operators the passage of the gas through the Modula ting gas valve can be opened or closed By means of an electric command given to the modula tion operator the pressure can be varied and therefore the gas flow rate to the burner modulation The mo dulation operator has mechanical components which allow the adjustment of the minimum and maximum pressure exiting the valve ERR Nomenclature of the parts Fig 46 1 Modulation operator s electric connectors Minimum gas pressure adjust
53. sensor by pulling it towards the front of the boiler the sensor is held in place by means of a spring Removal of the flow switch group and d h w circuit filter Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel ofthe case and empty the d h w circuit 31 D h w flow switch filter and flow limiter 2 Remove the flow switch sensor see section 15 4 3 Remove the gas valve see section 12 6 4 Unscrew the plug 2 Fig 60 and extract the flow switch group 5 To remove the filter from the flow switch group separate the body 7 from the plug 2 Fig 60 by unscrewing it 6 Reassemble the parts following the removing se quence in reverse order Attention the ring 3 Fig 60 has a magnetic polarity and must be correctly coupled with the spindle of the float 4 To determine the correct orientation ofthe ring proceed as follows 1 Setthe function selector of the boiler in stand by mode Fig 61 GER Dom Fig 61 2 Restore the mains electricity supply to the boiler Waring ensure that all the electric parts and wirings are dry and do not touch other not mentioned electric parts during the following operations 3 Hold the flow switch sensor 1 and bring the ring in touch with the sensor as illustrated in Fig 62 4 Observe the lamp B placed on the sensor body that should l
54. t 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 Fig 78 BER 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 ofthe safety thermostat and no overheat intervention should occur NN 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 Remove the screws B and the plate C Fig 79 3 Disconnect the safety thermostat and check its electrical function Normally no intervention the ech contact must be closed electrical resistance zero 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 sealed chamber 2 Remove the screw B and the plate C Fig 79 3 Disconnect the wiring D detail in Fig 80 4 Remove the spring E which holds the overheat thermostat on the pipe of the prim
55. tch 29 13 1 BURGCUOM ertet 29 13 2 Checks 29 13 8 29 14 Expansion vessel and temperature pressure gauge 30 14 1 Function orm IE pue 30 14 2 Checks eee 30 14 8 Removal of the expansion vessel 30 14 4 Removal of the temperature pressure gauge 30 15 D h w flow switch filter and flow limiter 31 15 1 Function 31 15 2 Nomenclature and location of parts 31 15 3 GHECKS svo bete le Rb a 31 15 4 Removal of the flow switch sensor 31 15 5 Removal of the flow switch group and d h w circuit fill r solere RR 31 156 Flow 32 16 Temperature probe 33 16 1 ett prete i e 33 16 2 Checks sese ae ale armor eir dot 33 163 33 17 By pass valve 34 17 1 Function 34 17 2 34 18 Fan venturi device and air pressure SWITCH s nd ull od 35 SPUBBUOD EE 35 18 2 lt GHECKS oda VERA 35 18 3 Removal ofthe Fan 36 18 4 Inspection and removal of venturi device 37 18 5 Removal of the Air pressure switch 37 19 Ignition and detection electrodes 38 19 1 Function n i E pe eic at ees 38 19 2 e EEN 38 19 3
56. ter location securing pin indi cated in Fig 17 towards the left side of the boiler The schematic structure is shown in Fig 15 A V A mmm Primary hydraulic circuit Domestic hot water circuit Fig 15 Fig 17 15 8 Function The pump A in Fig 18 and Fig 19 has the function of making the water in the main circuit circulate through the main heat exchanger the condensing heat ex changer and therefore through the c h system during the c h function or through the secondary heat ex changer during the d h w function J 2 EE EE CES L Fig 18 Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Lk 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 pump 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 20 Measure the electrical resistance between the pump supply connections Electrical resistance of the windings at ambient tem perature must be about 230 Q Check the absence of starting defects With the boiler off remove the front case panel Remove the air release plug from the pump
57. to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Fan and Air pressure switch Inspection and removal of the venturi NN Fig 74 device Warning isolate the boiler from the mains electricity supply before removing any covering or component Remove the fan section 18 3 Remove the venturi device by unscrewing the screw H Inspect the venturi device B and the connection pipe Ensure they are clean Re assemble the parts in reverse order of re moval 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 KEEN Removal of the Air pressure switch NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Remove all the case panels and the sealed chamber lid Disconnect the wires from the Air pressure switch Remove the pipe from the Air pressure switch Unscrew the screws which hold the Air pressure switch to the frame Assemble the Air pressure switch carrying out the removal operations in reverse sequence Warning to correctly connect the Air pressure switch refer to Fig 73 and Fig 70a or Fig 70b for the correct wiring Warning After cleaning or replacement as detailed above if it deemed necessary to unde
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