Service manual - free boiler manuals
Contents
1. 5 X x1 CH PTA E F2 F1 La Ki X5 A x2 Lee neo 5 bn gt es d E x4 bk ES wh 11 N 5 8 8 amp EEE KE J gy G xt O ES SE z 0 G E J P4 f D ji LD3 LD2 1 1 SE 4 TTE s a wh bk M wh S S bu V V bk M wh Remote control D h w flow C h temperature Modulating Safety Flue D h w temperature Time switch terminal block switch probe NTC gas valve thermostat temperature probe NTC probe NTC LE bn brown bu blue bk black wh white rd red grey gn green ye yellow vt violet og orange gnye green yellow alternative yellow Diagrams EF Wiring diagram M96 28SR M96 32SR Electric supply External controls Pump Fan Primary circuit Air pressure lgnition Flame detection terminal block terminal block Se flow switch switch electrodes electrode LON 32. Fig 10 EFI 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 Fig 11 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 G 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 cov ere
3. Fig 64 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 65 3 Squeeze the tabs O to release the temperature pressure gauge P and remove it 4 Re assemble the parts in reverse order of re moval Fig 65 14 D h w flow switch filter Function The d h w flow switch A in Fig 66 is a device that gen erates an electrical signal when hot water is drawn s HE Fig 66 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 5 Fig 66 is dragged up wards and the magnet in it getting closer to the sensor 8 closes the electric contact Fig 67 Description and location of parts Fig 68 1 Flow switch plug 2 O ring Flow limiter optional for M96 28SM M96 32SM Body Float Filter Sensor holder spring oO 8 Sensor SS AS Fig 68 Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Sensor operation Remove the front panel of
4. 58 5 m H ai rer NAE x1 F2 F1 Ki X5 x2 _ n crus Peake pui Du X4 bk SC wn 11 5 3 8 Jj eke S E Bx 2 n bk TA xt E 1 C a f F E lt LD3 102 LD1 P4 E D4 SB1 7 P5 H st bk 4 wh 5 22 M bk wh C h temperature Modulating Safety Flue probe NTC gas valve thermostat NIC probe E bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet orange gnye green yellow alternative yellow Diagrams Functional flow diagrams General layout Electronic control p c b low voltage section Transformer i d J1 1 Fuse 3 15 A PTC A J3 5 1 J3 4 M J3 3 Three way diverter valve J 2 Pump Heat request on d h w J1 1 Fuse 3 15 A PTC L LINE N NEUTRAL ACTIVE CIRCUIT INACTIVE CIRCUIT Heat request on c h J1 1 Fuse 3 15 A PTC low voltage section Transformer Da Full sequence ignition device Electronic control p c b low voltage section Transformer Da Three way diverter valve J 2
5. pue ajqeo Ajddns jo AjuDeiur eui Ae N ennau pue 1 au 10 peu L rot uonoes ees 51461 uone aoueldde uoneoripuri jeondo y WO1 Osje peurejqo eq ueo njesf SON HO s jejioq eu ueuw j9jes eui SALA JejeM y o uo INP Ajayes ay SALA ayes MO 100d ye SureuJeJ eui einsseid seb y nq poeuoo seyesedo eu Jeioq ASION 1994109U epou uo poe4100 sejejedo 1jejioq 941 yeay seop uJejs s y o ay pue 9 67 seuoeei PNI eu jo ay y o uo Wwu p yo e Buunp y o y wy p Ajddns jou seop 941 1no 3201 t Daa sedid an Ajddns seo eui A ddns 160g sieyoeJq eyou Jenuew ay jo uonoeg e Y 5 Primary heat exchanger EXI Function The primary heat exchanger A in Fig 9 has the function of transferring heat produced from combustion of the gas tothe water circulating in it s i Fig 9 The hydraulic circuit is composed of 8 elliptical pipes connected in parallel Fig 10
6. Full sequence ignition device Electronic control p c b J3 3 Three way diverter valve 01 2 Full sequence ignition device Diagrams EX Circuit voltages during c h or d h w operation Electrical voltages with burner on only during c h operation only during d h w operation Pump Fan 230 3 diverter valve pum Modulating Gas valve x 230 230 230 K3 K4 LD3 LD2 LD1 P4 ex RICE P5 Ky Air es afety Switch thermostat pressure W u p uo wo UO HOUS e 104 1460 Joo eu Wo uo sejejedo 941 ay JO ay uo 09 1529 qou due wup eui Buruan eanejedujej N Wp eui o3uoo 1 useop 941 un ueJ epoul UD JO Ul Jeuye 161 1 Useop eu Sum ue epoul wp 10 ui Jeuye 161 1 Useop eu Ins 440 91961 uonejedo au muy p JO y o Ul Jeuyie Hes JOU SBOP eu ureBe SOO
7. beginning of wait period presence of flame YES starts ignition discharges opens gas valve beginning of ignition period NO end of ignition flame presence YES YES closes gas valve stops fan interrupts ignition discharges period memorizes lock turns on lock out light A interrupts ignition discharges gas valve open NO reset push button YES pressed r YES flame presence NO Safety thermostat ER opens the circuit YES L YES Air pressure switch at NO work Fig 52 24 11 Modulating gas valve URBI Function The Modulating gas valve A in Fig 53 controls the gas inflow to the boiler burner s Ir n Fig 53 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 RER Nomenclature of the parts Fig 54 Minimum gas pressure adjustment Maximum gas pressure adjustment Modulation operator s electric connectors On off operators electric connector On off operators Gas valve inl
8. ep hen 12 Pump 13 Euniction see eel oa dea 13 Checks POR Ee es 13 Removal 13 Three way diverter valve 14 Function x su las adds des 14 Checks 14 Removal of the electric actuator 14 Removal of the diverter group and its internal parts 15 Electronic control ignition p c b 16 elle e 16 Selection and adjustment devices 16 Checking the temperature 17 Operation lights 18 Setting the boiler control function modes 18 Reignition frequency setting 19 Combi C H only mode setting 19 Ignition gas pressure adjustment 20 Checks 21 Removal of the electronic control p c b 21 Thermal control in the Je mode 23 Thermal control in the ue mode 23 Ignition and control sequence 24 11 1 16 1 16 2 17 17 1 17 2 17 8 17 5 18 18 1 182 18 3 19 19 1 19 2 19 3 20 20 1 20 3 21 21 1 21 2 22 Modulating gas valve 25 FUNCHON wee awe nee ewes 25 Nomenclature of the parts 25 Adjustment 25 deerat eoa de 26 Removal of the gas valve 26 Primary circuit flow switch 27 FUNCTION Sete teehee des GS
9. M96 32SM Pump Primary circuit flow switch D h w flow switch Main flow switch membrane Three way diverter valve electric actuator Overheat thermostat Flue temperature probe NTC Fuse 3 15 AF Temperature probe main or d h w circuit Ignition electrode left Ignition electrode right Detection electrode Q ty 12 14 12 14 hl a Manufac turer part no KI1004 102 KI1004 147 1064 505 BI1003 509 81172 103 81262 101 81262 102 81262 130 81406 100 81406 101 81243 100 267 103 81376 104 81181 100 81326 100 81326 107 81326 108 81406 118 81406 119 81715 105 81001 101 81001 102 81911 103 81011 505 1042 107 81011 103 1101 102 81172 105 Bl1342 100 Bl1295 108 Bl1001 117 Bl1123 101 Bl1123 103 Bl1123 102 Manufacturer s reference Polidoro Polidoro CIMM 6 litres Honeywell Yamatake Honeywell C6065 SIT 380 alternative Yamatake Honeywell C6065 SIT 380 alternative Bertelli amp Partners Elbi ELTH type 261 Short spare parts list MIT 1475 108 1262 122 E83 145 Temperature H07 112 Recuperator 41 17962 1402 0 2407 4444 UK Biasi UK Ltd Newman Park Western Way Wednesbury WS10 7BJ Sales Tel No 0121 506 1340 Sales Fax No 0121 506 1360 Service Tel No 0121 506 1350 Service Fax No 0121 506 1370 www
10. Wall hung fan flue room sealed high efficiency gas boiler Service manual Models M96 24SM P M96 28SM P M96 32SM P M96 28SR P M96 32SR P G C Appl No 47 583 08 47 583 09 47 583 10 41 583 05 41 583 06 Leave this manual adjacent to the gas meter PARVA HE Table of contents bh 10 9 10 10 10 11 10 12 10 13 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 ii ii es 4 Wiring diagram 96 245 M96 28SM M96 32SM 4 Wiring diagram M96 28SR 9 3258 5 Functional flow diagrams 6 Circuit voltages 7 Fault finding 8 Primary heat exchanger 10 FONCION ue DEAS 10 Removal a 10 Cleaning 10 Condensing heat exchanger 11 FUNCION concisa aa aa ee 11 Removal elec epe pag es 11 D h w heat exchanger 12 FUNCION ri 12 Removal
11. ay pue enunuoo uoniuDi eui jeuunq 941 ejo o uoniuBi eui sueis 99 usnd 1959 ay Bursseud Ag ureBe Jejioq ey pue enunuoo syseds uon ay 1 useop eu ejo o uoniuDi eui sueis y usnd 1959 ay Bursseud Ag 100 sayesado pue uo suuni ay 1959 ay Bursseud Ag t Daa 2 BL E AL AE A en ew ow O A _ mM w A 0 nce Lc A o cH cL 1 E E mee Lip sh p E er ses 1 1 7 gt _ Fear LO ee a A po o SCT E qn on E RE iN 15 AE AAA js Ls E Ma O A E n SA EA gp m EL Rare O AE E o AE pm e ei E Pe gt zz E er A III EE EL csl eyou Jenuew y jo uonoes l Svi cci 6 0 y y 0 N pu quur c N t o 9 tL eu ejes e ues ui 00 ayes yBiy 00 eunsseJd wu p senjeA 104 jenueuu uonejeisur y 0 uoisuedxe ay jo uonezunsseJd eui 40849 S103oefui jo sseuueejo eui AOA
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13. H20 984 H20 985 H21 048 H21 049 169 127 H08 605 E83 178 E83 180 E83 181 E01 204 E01 205 E00 684 E00 688 E83 086 E83 101 164 026 E83 127 E83 126 E83 122 Description Burner mod 96 245 Burner mod 9 285 M96 28SR M96 32SM M96 32SR Injectors for natural gas mod M96 24SM Injectors for natural gas mod 9 285 M96 28SR M96 32SM M96 32SR Injectors for LPG mod M96 24SM Injectors for LPG mod M96 28SM M96 32SM M96 32SR Expansion vessel Main heat exchanger mod M96 24SM Main heat exchanger mod M96 28SM M96 28SR Main heat exchanger mod M96 32SM M96 32SR Fan mod M96 24SM Fan mod M96 28SM M96 28SR M96 32SM M96 32SR Gas valve Air pressure switch 0 88 0 74 mbar mod M96 24SM M96 32SM M96 32SR Air pressure switch 1 38 1 25 mbar mod M96 28SM 96 285 Safety valve Combustion chamber side panels Combustion chamber rear panel mod M96 24SM Combustion chamber rear panel mod M96 28SM M96 28SR M96 32SM M96 32SR Combustion chamber front panel mod M96 24SM Combustion chamber front panel mod M96 28SM M96 28SR M96 32SM M96 32SR Electronic regulation p c b D h w heat exchanger M96 24SM D h w heat exchanger 96 285
14. Tochange the setting turn the knob B on a posi tion corresponding to the boiler model Fig 41 20 12 To memorize the setting keep pressed the reset button C for about 5 seconds until the lights E briefly blinks simultaneously At this point only the right green light flashes 13 Toreset the boiler to the normal operation turn it OFF and ON by the function selector knob A ITE ignition gas pressure adjustment 1 Turn the boiler OFF 2 Remove the front panel of the case 3 Open the gas valve outlet pressure test point 7 see section 11 2 and connect the gauge 4 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks 5 The lamps E should give the indication as in Fig 44 If not press the reset button repeatedly to obtain it O O wiere Lamp OFF 1 11 11 o Lamp ON Fig 44 6 Keep pressed the reset button C for about 5 sec onds until the lock out signal lamp D is switched OFF The boiler runs in c h mode and the lamps E give the indication as in Fig 45 uly IX O O Where Lamp OFF Flashing lamp alone 1 D 11 or simultaneously with an other lamp Fig 45 7 Rotate the knob B on a position corresponding to an adequate ignition pressure Refer to the value indicated in the tables of the User Installation manual Technical information section Gas pressures at the burner table By rotating clockwise the pressure increase
15. 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 59 Fig 60 PEN Removal NN Warning isolate the boiler from the mains tacts C and N O of the switch Remove the switch as explained in section 12 3 Measure the electrical resistance between the tabs marked C and N O Fig 60 The contact must be normally open Operate the switch by hand and verify that the contact is now closed No X do not use electricity supply before removing any covering or component Removal of the switch Remove the front panel of the case Remove the fork C Fig 61 Open the box and disconnect the switch Re assemble the parts in reverse order of re moval Refer to Fig 60 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 61 Ee Fig 61 Unscrew the four screws E see Fig 62 open the hydraulic operator and remove the membrane F 27 Primary ci
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17. but allow its igni tion when the cause of the intervention has stopped Fig 52 shows the sequence of the operations that are carried out at the start of every ignition cycle and during normal functioning Selection and adjustment devices On the Electronic control ignition p c b several selec tion adjustment and protection devices are located Fig 29 Electronic control ignition p c b 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 1 x1 connector 2 x6 connector 3 x7 connector 4 x4 connector 5 x2 connector 6 Lock out signal lamp 7 Boiler reset button 8 Function control C h temperature adjustment 9 D h w temperature adjustment 10 Appliance operation lights 11 Fuse3 15AF Checking the temperature The Electronic control ignition p c b makes it possible to separately 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 8 and 9 in Fig 29 of the electronic control p c b If the power requested is lower than 40 of the maxi mum power output then control is achieved by switch ing ON the burner at minimum power then sw
18. fail ure Lock sequence Start the boiler until the burner is ignited With the burner firing interrupt the gas supply The Electronic control ignition p c b must carry out three complete ignition cycles and then after about 3 min utes goes to lock out state By turning the boiler on and off by means of the function switch the device must not unlock and the burner must not turn on 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 PAT Removal of the electronic control p c b NN Warning isolate the boiler from the mains electricity supply before removing any covering or component When replacing the Electronic control ignition p c b itis advisable to go through the setting modes of the boiler 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 ignition p c b To disconnect the connectors x1 x6 and x7 1 2 and 3 in Fig 29 delicately flex the hook present on one side of each socket To disconnet the connectors x4 and x2 4 and 5 in Fig 29 press delicately the hook present on one side of each connector 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 ar row
19. 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 Air pressure switch 3 Remove the pipe from the Air pressure switch 4 Unscrew the screws which hold the Air pressure switch to the frame 5 Assemble the Air pressure switch carrying out the removal operations in reverse sequence Warning to correctly connect the Air pressure switch refer to Fig 79 and Fig 76a or Fig 76b for the correct wiring 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 35 18 Ignition and detection electrodes 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 Male Fig 81 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
20. 27 Checks cad re e et eh 27 Removal 27 Expansion vessel and temperature pressure gauge 28 FUNCION 42 4 xcii Rer Ee Dehn 28 CHECKS heu on 28 Removal of the expansion vessel 28 Removal of the temperature pressure gauge e Re ym IR ERE e 28 D h w flow switch filter 29 ee rives OY E 29 Description and location of parts 29 Checks 29 Removal of the sensor 29 Removal of the flow switch group and d h w circuit filter 29 Flow limiter 30 Temperature probe 31 FUNCTION Soin tinea 31 CHECKS usa re e re Ra 31 Removal 31 By pass valve 32 FUNCION ore tents 32 Removal nse 32 Fan venturi device and Air pressure switch 33 FUNGON oe Praca aedi unas 33 GheckS dass veg ree ead ees 33 Removal of the Fan 34 Inspection and removal of venturi device 34 Removal of the Air pressure switch 35 Ignition and detection electrodes 36 FUNCION s ues ier dela EE 36 GHeCKS re e E TERDUM EID CREW 36 Removal 36 Safety thermostat 37 FUNCION EE 37 CHECKS 37 Remo
21. 38 boiler mode 19 Electronic control ignition p c b e wiere Lamp OFF mm oso Fig 38 At this step it is possible to visualize the current setting by keeping the reset button C pressed for more than 5 seconds The lamps E will flash a number of times corresponding to the setting Fig 39 M96 288R M96 32SR M96 24SM wai 4 flashes 96 285 SE 5 96 325 1 flash Fig 39 7 To change the setting turn the knob B on a posi tion corresponding to the boiler models Fig 39 By turning the knob B the lock out signal lamp D blinks quickly 2 per seconds indicating that the setting has changed and must be memo rised 8 To memorize the setting keep pressed the reset button C for about 5 seconds until the lights E briefly blinks simultaneously 9 Press the reset button C once until the lamps E give the indication as in Fig 40 boiler mode O O Where Lamp OFF DOM Fig 40 It s now possible to check the current setting by pres sing reset button C for more than 5 seconds The three lamps E will flash a number of times corresponding to the setting as in Fig 41 once for the combination and four times for system boilers At this point only the right green light flashes Fig 41 10 the water control to minimum Lock out lamp blinks 2 per second indicating the setting has changed 11
22. B and the plate C Fig 85 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 85 3 Disconnect the wiring D detail in Fig 86 4 Remove the spring E which holds the overheat thermostat on the pipe of the primary heat ex changer and remove it D Fig 86 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 37 20 Flue temperature probe NTC Function The Flue temperature probe NTC A in Fig 87 and Fig 88 senses the temperature of the combustion products that flow through the condensing heat ex changer A Fig 87 If the temperature of the combustion products circuit reaches the limit temperature the Flue temperature probe NTC red
23. 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 DEN Setting the boiler control function modes It is possible to select the various boiler control function modes by using the function selector knob A and the D h w temperature control knob B Fig 32 On models M96 28SR and M96 32SR the knob B is used just for boiler setting and doesn t affect the boiler functions during the normal operation During the function modes setting the boiler does not operate A A Je E B Fig 32 IT Reignition frequency setting It is possible to select the minimum time that must pass between two ignitions of the burner in c h function mode 1 Turn the boiler ON positioning the function selec tor knob A as indicated in Fig 33 2 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks 3 The lamps E should give the indication as in Fig 34 reignition frequency If not press the reset button repeatedly to obtain it O O wiere Lamp OFF DOM oso Fig 34 At this step it is possible to visualize the current setting by keeping the reset button C pressed for more than 5 seconds The lamps E will flash a number of times corresponding to the setting Fig 35 4 To ch
24. ange the setting turn the knob B on a posi tion corresponding to the desidered delay By turning the knob B the lock out signal lamp D blinks quickly 2 per seconds indicating that the setting has changed and must be memo rised Electronic control ignition p c b 3 5 1 2 4 WER 3 S 7 2 8 0 a _ 81 2 50 Delay minutes 000 Setting Fig 35 5 memorize the setting keep pressed the reset button C for about 5 seconds until the lights E briefly blinks simultaneously 6 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A In any case the boiler automatically resets to its nor mal operation after 10 minutes Factory setting 3minutes Combi C H only mode setting Two different options are available on the Electronic control ignition p c b and proper setting must be done after a replacement of the p c b 1 Remove the front panel of the case 2 Turn ON the power supply Lamps E give the in dication as in Fig 36 20 XD where Lamp OFF Fig 36 3 Position the function selector A as in Fig 37 and disconnect the C h temperature probe 4 Keep pressed the reset button C for about 10 sec onds Fig 37 until the lock out signal lamp D blinks 5 Connect the c h temperature probe BS PPP GES AER jm Dei B E Fig 37 6 Press the reset button C repeatedly 2 times until the lamps E give the indication as in Fig
25. 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 H Fig 57 12 Primary circuit flow switch Function The Primary circuit flow switch A in Fig 58 function is Boiler OFF B Boiler ON to detect water flowrate through the primary hydraulic circuit of the boiler Fig 59 Electrical check It is possible to verify the general operation of the switch by measuring the electric resistance between the con 1 2 Fig 58 This hydraulic membrane operated electrical micro switch device will control the functioning of the ignition control circuit providing there is an adequate quantity and flow of water in the primary circuit Any failure of the pump or obstructions in the primary circuit whilst in either c h or d h w modes will not allow the device to dd operate ko This device is connected to the electronic control p c b andif afterthe 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
26. d 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 is not necessary to disconnect it from the wiring 10 6 Condensing heat exchanger EX Function The return 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 mW Fig 12 E 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 17 3 and the air pressure switch E see section 17 5 4 Remove the flue temperature probe NTC F see section 20 3 5 Completely loosen the connection G and slightly move the pipe H 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 by unscrewing the screws that hold it on the frame 9 Ro
27. e 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 Temperatu re probe and unscrew it 4 Reassemble the Temperature probe carrying out the removal operations in reverse order Q Gd 31 16 By pass Function The By pass valve in Fig 72 is located between the c h water flow and return and its function is that of guar anteeing a minimum flow across the primary heat ex changer ifthe circulation across the c h system is com pletely closed The By pass valve is fitted on the rear side of the div erter group A Fig 72 ERR Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels 2 Empty the primary circuit of the boiler 3 Remove the 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 73 Fig 73 5 Reassemble the by pass valve as illustrated in Fig 73 reversing the order of removal 32 17 Fan venturi device and Air pressure switch Function The function ofthe FanA Fig 74 and Fig 75 is to force the products of combustion through the co
28. ealed 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 76 in accordance with the type of air pressure switch used Between or 3 and or 2 the contact must be open Between COM or 3 and N C or 1 the contact must be closed electrical resistance zero 3 Connect the grey wire COM or 3 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 Fig 76 Check of the venturi device This test must be carried out with the sealed chamber closed 33 Fan and Air pressure switch 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 77 2 Switch on the boiler Fig 77 3 Compare the value on the gauge with the follow ing minimum values 80 Pa 0 8 mbar M96 24SM 110 Pa 1 1 mbar M96 28SM M96 32SM Removal 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 the sealed chamber lid and the combustion chamber lid 2 Disconnect the connectors D and the earth con nection E Fig 75 3 Disconnect the pipe which connect the venturi device to the Air p
29. ecks the presence of the flame during the entire period in which it is activated supplies the fan and checks its functioning by means of the signal coming from the air pressure switch The Electronic control ignition p c b has a safety func tion and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler The Electronic control ignition p c b can lock the func tioning of the boiler lock state and stop its functioning up to the resetting intervention The lock is signalled by the lighting of the lock out signal lamp and the device can be reset only by using the boiler reset button placed on the control panel fascia Some components which are connected to the device can activate the lock state The causes of a lock state could be O intervention of the safety thermostat over heat of the primary circuit The intervention of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wir ing or connection Faulty flame detection faulty detection electrode its wiring or connection Faulty condensate drainage Gas injectors blocked Faulty modulation gas valve faulty on off oper ators or not electrically supplied Faulty Electronic control ignition p c b Q DOS OUO Other components like the air pressure switch can tem porarily stop the ignition of the burner
30. efore 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 2 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 Fig 3 bottom view of the boiler PES 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 Remove the front panel of the case 2 Loosen the screws B and C Fig 3 3 Remove the screws D 4 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 Fig 5 Remove the screws E and remove the service panel Fig 5 To gain access to the electronic regulation PCB remove the screws F and remove the control pan el lid Fig 5 General access and emptying hydraulic circuits To gain access to the parts contained in the sealed chamber it is necessary t
31. emove 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 9 2 for the cor rect wiring connection Three way diverter valve 9 Unscrew the screw and remove the diverter 9 5 group Fig 24 EX Removal of the diverter group and its internal parts Fig 26 Rear view of the boiler 1 Remove the front and both side case panels 10 Refer to the exploded view Fig 27 to remove 2 Empty the primary circuit and the d h w circuit of the internal parts of the three way diverter valve 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 bw heat exchanger see section 7 2 Fig 27 8 Remove the fork K and move away the pipe L 11 Reassemble the diverter group carrying out the Fig 26 removal operations in the reverse order 15 10 Electronic control ignition p c b Function Fig 28 16 Inlet Information On the Electronic control ignition p c b F
32. erify the correct operation of the boiler reset 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 Electronic control ignition p c b Thermal control in the 8 mode Switch in the s amp function mode See functioning with the function control in the mode lt YES sec 10 12 NO Is primary circuit temperature higher than that selected YES NO Request for heat from room thermostat B _ Circulator off Starts the circulator Operates motorised valve Operates motorised valve Ignition device off Supplies the ignition device Fig 50 Thermal control in the mode Switch in the B function mode m YES Circulator off NO gt Ignition device off Circulator on 15 domestic hot water outlet temperature lower than that required YES NO Supplies the ignition device Ignition device off Fig 51 23 Electronic control ignition p c b gnition and control sequence YES Ignition request lock memorised NO Air pressure switch at rest g cancels lock YES Y NO NO NO Air pressure switch at work Air pressure switch at work YES gt lt
33. et pressure test point Gas valve outlet pressure test point Modulation operator AN Oa PS Go Fig 54 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 54 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 7 in Fig 54 and connect the gauge 5 Remove the protection cap B Fig 55 from the mechanical pressure adjustment components levering with a flat screwdriver in the slots C 25 Modulating gas valve 6 Start the boiler at its maximum power Operate the boiler in d h w mode or ensure that the boiler is not range rated if the testis carried out in c h mode 7 Rotate the maximum gas pressure adjustment 2 in Fig 54 until you obtain the required pressure by rotating clockwise the pressure increases 8 Turn the boiler off and disconnect one of the two connectors 3 in Fig 54 9 Start the boiler and rotate the minimum gas pres sure adjustment 1 in Fig 54 until you obtain the required pressure by rotating clockwise the pressure increases 10 Turnthe boiler off and re connect the wire to the modulating operator 11 Start the boiler and check again the maxim
34. for the correct distance between the me tallic edges of the ignition electrodes see Fig 82 4mm cs Ignition lt 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 the 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 85 on page 37 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 83 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 81 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 Warn
35. g 14 Attention When reassembling the exchanger be sure to put the off center location securing pin indi cated in Fig 17 towards the left side of the boiler The schematic structure is shown in Fig 15 A Y A Primary hydraulic circuit Domestic hot water circuit Fig 15 Fig 17 12 8 EXI 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 s 1 Fig 18 EX 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 Mm Check the absence of starting defects With the boiler off remove the front case panel Remove the air release p
36. in Fig 29 that give optical information during the operation of the boiler The green lamp on the left gives information whether the boiler is in stand by mode or during the normal operation of the boiler The following table gives the relationship between the lamp indication and its meaning 18 Boiler in stand by condition function control in position Anti freeze system active Boiler ON condition function control EZ or position 1 second ON 1 second OFF With the boiler switched ON ER all the lamps 10 in Fig 29 are activated The following table gives the relationship between each of the possible lamp combinations and their meaning DC Normally operating boiler O see the previous table for details 4 D h w operation O O O Excessive temperature on primary circuit O SCH DE Faulty c h temperature probe NTC Faulty d h w temperature probe NTC Faulty flue temperature probe Faulty primary circuit water absence of flow 20 20 O Faulty air pressure switch MA SX Lack of burner ignition no ignition signal from O O the full seqence ignition device O Ce z O Safety thermostat lock out Flue temperature probe NTC lock out Lack of power supply or fauly electronic control p c b Faulty Electronic control ignition p c b O E Lamp Lamp OFF ON Flashing lamp alone or simultaneously with an other lamp
37. ing 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 82 36 19 Safety thermostat Function The safety thermostat A in Fig 84 and Fig 85 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 thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device at tempts to light the burner and at the end locks the boiler and lights the lock out signal lamp Fig 84 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 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
38. ircuit 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 dl Fig 21 EX 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 14 Spindle B not visible AC 1 eo 1 N D 9 4 Kohm bn brown Open circuit bu blue e bk black gt g gt alo Fig 22 D h w mode B K visible e Ra y Open circuit bn brown 9 4 Kohm bu blue Dn We 42 bk black 4 gt 9 Fig 23 mode 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 R
39. itching 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 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 jtm The result of such a comparison operates the modulation of the gas valve consequently changing the useful output of the boiler 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 17 Electronic control ignition p c b 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 C the useful output is automatically reduced so that the primary circuit can not reach excessive temperatures The control sequences in function and in func tion are illustrated in detail in sections 10 11 and 10 12 Operation lights The Electronic control ignition p c b is provided with three lamps L E D indicators 10
40. lained in the able section 14 5 Nominal flow rate litres min 2 Remove the flow switch plug 1 from the 4 3 Fit the flow limiter in the plug E CES fee 4 Reassemble the group following the above se 30 15 Temperature probe Function The Temperature probe has the function of converting the temperature of the water in the hydraulic circuit where it is installed into an electrical signal resistance The relation between temperature and electrical resis tance is stated in Fig 69 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 69 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 70 and Fig 71 one on the out put of the d h w heat exchanger d h w Temperature probe B in Fig 70 and Fig 71 74 7 c h c h d h w d h w return flow inlet outlet Fig 70 Checks Lk 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 69 EEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 To remov
41. lug from the pump 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 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 EE 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 and pull up and turn to the left the pipe D aR OND bp Fig 19 6 Remove the locking plate E Fig 20 7 Unscrew the two screws F that hold the pump on the frame and remove the pump Fig 20 Reassemble the pump carrying out the removal oper ations in the reverse order When reassembling the pump check the correct location of the O ring gasket in the inlet port of the pump that seals the connection between the pump and the brass group 13 9 Three way diverter EXI Function The diverter valve A Fig 21 has the function of modify ing the hydraulic c
42. ndensing 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 in Fig 80 and an Air pressure switch C Fig 74 and Fig 75 A 0 4 E Y GU d a D B HEW 08 1 t Ts A Fig 74 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 75 and measure the electrical resistance of the motor that has to be about 43 M96 24SM 25 M96 28SM M96 32SM at ambient temperature Fig 75 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 s
43. o 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 PJ 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 Fig 8 PIS 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 EXI Wiring diagram M96 24SM M96 28SM M96 32SM Electric supply External controls Three way Pump Fan Primary circuit Air pressure Ignition Flame detection terminal block terminal block diverter valve S flow switch switch electrodes electrode L N e 1 M D 3 2 1 2 esx o trap Se jee bk bn bu bn bu bn bu gny bu bu y bk bk gnye gnye B N c c Q Q E J B EU a s H a
44. probe NTC carry ing out the removal operations in reverse se quence 21 Condensate trap RR Function The condensate trap A in Fig 89 and Fig 91 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 89 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 90 Fig 90 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 HEB Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 5 Remove the front and right case panels Disconnect the trap from the draining pipe 7 Using pliers remove the spring D moving it up wards 8 Remove the spring E and lower the trap 9 Disconnect the wirings from the trap 10 Reassemble carrying out the removal operations in reverse order Fig 91 39 22 Short spare parts list Key 1 11 12 18 14 15 16 17 18 19 20 21 22 23 24 25 40 G C part no 173 148 173 149 169 069 E01 156 E83 121
45. rcuit flow switch Fig 62 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 62 13 Expansion vessel and temperature pressure gauge Function The Expansion vessel in Fig 58 function is to allow for the volume expansion of the c h circuit water due to the temperature rise em Checks Turn off the flow and return isolation valves and empty the primary circuit of the boiler 2 Remove the protective cap J Fig 63 from the valve on the top of the expansion vessel and con nect a suitable air pressure gauge Fig 63 3 Check the pre load pressure and refer to the section Expansion vessel in the User manual and installation instructions for the correct value EEN 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 28 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 64 and remove the expansion vessel from the top of the boiler H
46. ressure switch 4 Unscrew the screw F and remove the bracket G Fig 78 34 Fig 78 5 Remove the Fan by sliding it towards left se the arrow in Fig 78 6 Assemble the fan carrying out the removal oper ations in reverse sequence Warning Re assembling the fan ensure that the hooks around the inlet port of the fan hung correctly on the flue hood Warning to correctly connect the venturi device to the Air pressure switch refer to Fig 79 Fig 79 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 Inspection and removal of the venturi device NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the fan section 17 3 2 Remove the venturi device by unscrewing the screw H Fan and Air pressure switch 3 4 Fig 80 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 Removal of the Air pressure switch NN Warning isolate the boiler
47. s 8 Make a note of the position of the knob B Electronic control ignition p c b 9 Turn the boiler OFF and ON positioning the func tion selector knob A as indicated in Fig 46 10 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks 11 Press the reset button C repeatedly 4 times until the lamps E give the indication as in Fig 47 igni tion pressure adjustment mode O Q wiere O Lamp OFF DOM oso Fig 47 12 Turn the knob B to the minimum fully counter clockwise and then on the position correspon ding to the position obtained on step 7 By turning the knob B the lock out signal lamp D blinks quickly 2 per second indicating that the setting has changed and must be memorised 13 memorize the setting keep pressed the reset button C for about 5 seconds until the lights E briefly blinks simultaneously 14 Toreset the boiler to the normal operation turn it OFF and ON by the function selector knob A checking the ignition pressure and that the burner lights up uniformly In any case the boiler automatically resets to its normal operation after 10 minutes ER Checks Check that the fuses are complete If the Electronic control ignition p c b does not supply any device pump fan etc check that the fuses 11 Fig 29 are complete If afuse has blown replace it with one that has the same characteristics after having identified the reason for
48. s in Fig 48 4 Unscrew the four screws that hold the Electronic control ignition p c b on to the control panel 5 Remove it by lifting its rear edge and freeing it from any of the wiring 6 Re assemble the Electronic control ignition p c b following the removal procedures in the re verse order Important When re assembling the Electronic control ignition p c b 7 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 8 Insert the spindles in the control panel knobs un till the notch A Fig 49 reaches the potentio meter edge It is not necessary to force them in the knob 21 Electronic control ignition p c b 9 22 While tightening the screws that fix the Electronic control ignition p c b on the control panel keep the p c b towards the control panel fascia mak ing sure of the contact between the boiler reset button B and the tab C Fig 49 Pu Attention After installing the Electronic control ignition p c b 10 Make sure the c h 8m and d h w BE tem 11 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 Operate the boiler and close the gas inlet cock so that the boiler goes into the safety lock out state V
49. tate the exchanger as indicated by the arrow and remove it towards the front of the boiler 10 Remove the clip N and the pipe H f lle Hw Fig 13 11 Reassemble the exchanger carrying out the re moval operations in reverse order After reassembling ensure that the 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 11 D h w heat exchanger Removal Function Nx 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 heat from the primary hydraulic circuit to the water destined for d h w use 1 Remove the front and right hand side panels of the case 2 Empty the primary circuit and the d h w circuit of the boiler 3 Completely unscrew the two Allen key screws B Fig 16 which hold the exchanger to the brass groups Fig 16 4 Move the exchanger towards the rear ofthe boiler and extract it Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order i
50. the case Disconnect the connectors B and measure the electrical resistance between the leads of the sensor Without water being drawn the contact must be open By opening a hot water tap the contact must be close electrical resistance zero Removal of the sensor NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case 2 Disconnect the connectors C and remove the sensor holder spring 7 Fig 67 3 Remove the sensor Removal of the flow switch group and d h w circuit filter N NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case and empty the d h w circuit 2 Remove the fork D and pull up the flow switch plug 1 with the help of a screwdriver 3 To remove the filter from the flow switch group separate the filter 6 from the body 4 Fig 68 by levering it 4 Reassemble the parts following the removing se quence in reverse order Flow limiter The M96 24SM model is factory fitted with a 10 litre min flow limiter 29 D h w flow switch filter If on the M96 28SM and M96 32SM model the flow To install the flow limiter 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 avail 1 Remove the flow switch group as exp
51. uces the gas flow rate to the burner The temperature of the combustion products should de crease to a safe value temperature In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler operation 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 not the electronic control p c b attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp 38 Fig 88 BER Checks temperature value 1 Set the temperature control knobs to their max position and run the boiler in d h w and c h 2 Allow the boiler to reach its maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain atemperature below that of the Flue temperature probe NTC and no overheat intervention should EXE 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 temperature probe NTC 3 Unscrew and remove the thermostat probe B Fig 88 from the condensing heat exchanger 4 Assemble the Flue temperature
52. um 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 and replace the adjustment protection cap RER 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 2 Disconnect the connectors D Fig 57 from the modulating operator and measure the electrical resistance of the coil Its electrical resistance value must be approx 114 2 Lk Check the on off operators coils Remove the front panel of the case 2 Disconnect the electrical connector E Fig 57 ech 26 3 Measure the electrical resistance between the connector pins of the on off operators as illus trated in Fig 56 On off operator approx 4 180 Q at ambient temperature Fig 56 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 D and E Fig 57 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
53. unction control C h temperature adjustment D h w temperature adjustment Boiler reset button control panel fascia From other boiler devices C h temperature probe NTC D h w temperature probe NTC D h w flow switch Primary circuit flow switch Air pressure switch Flue temperature probe NTC Safety thermostat Flame detection electrode Room thermostat if fitted Time switch Outlet command Pump Three way diverter valve On off operators gas valve Modulation operator gas valve Fan Ignition electrodes Appliance operation lights Lock out signal lamp control panel fascia The fundamental function of the Electronic control igni tion p c b is that of controlling the boiler in relation to the external needs i e heating the dwelling or heating the water for d h w use and operating in order to keep the temperature of the hydraulic circuits constant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Electronic control ignition p c b receives inlet information coming from the boiler the sensors or from the outside knobs room thermostat etc pro cesses it and consequently acts with outlet commands on other components of the boiler Fig 28 The Electronic control ignition p c b is also a full se quence ignition device and does a sequence of oper ations ignition cycle which lead to the ignition of the gas at the burner It ch
54. val 37 Flue temperature probe 38 Function cmn bx EEN 38 CHECKS d oes pendere etate ee es 38 Removal veiut E bees 38 Condensate trap 39 UE uie ope tet da as ee eee ating 39 Removal 39 Short spare parts list 40 1 information Overall View Flue thermostat Air pressure Condensing trap Gas m 4 Pump Control AN panel Hydraulic diagram Fan heat exchanger s Expansion vessel Main heat exchanger Combustion Safety chamber thermostat Burner Ignition WWW e __ j Detection 1 Automatic electrode air release 3 Box D h w probe heat exchanger Main circuit N flow switch gt i E D h w temp 5 Condensate Central heating c h operation Domestic hot water d h w operation sr I D h w D h w water return water flow inlet outlet 2 General access and emptying hydraulic circuits PX Nomenclature Fig 1 1 Right side panel Front panel Control panel lid Control panel cover Service panel Oo a 25 ND Left side panel EEJ Body panels NN Warning isolate the boiler from the mains electricity supply b
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