Service manual
Contents
1. Fig 5 1 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water cir cuit allowing an extra gain of useful heat The condensed vapour is then drained through the condensate trap B and the draining pipe C ERP Removal Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Disconnect the flue system from the boiler 2 Remove the air box following the instructions from 1 to 7 in section 17 2 3 Disconnect the detection electrode connector D the ignition electrodes connector E and the earth wire 4 Disconnect the fan connector G by pressing the plastic hook placed on the rear side of the con nector Fig 5 3 5 Unscrew the nuts H Fig 5 2 6 Remove the fan burner group 7 Empty the primary circuit of the boiler Fig 5 3 8 Disconnect the C h temperature probe J and the flue temperature probe connector K Fig 5 4 9 Condensing heat exchanger Fig 5 4 9 Using pliers remove the spring L moving it down wards and disconnect the rubber pipe M Fig 5 4 10 Remove the clips N Fig 5 6 11 Completely loosen the connection and slightly move the pipe P upwards then turn it towards right Fig 5 5 12 Completely loosen the connection and move the pipe R downwards Fig 5 52. ay wy p Ajddns seop 941 lt 90 0 0 2 2 151512 8 2 5 5 515 515 5 22 8 121515 18 15 2151815186 9 5 5 D ola 5 9 2 25 12 _ slo 5 5 2 6 amp 2 8 518 5 8 2 2 lt 12 3 3 lt 5 9 lt SIS 5 5 S lt 8 gt 212 lt 5 9 lt 0 15 5 5 aa al o 5 amp S alslea oe 2 5 3 5 3 o 5 Oo ols D 5 g 2 o 5 3 7 gt 3 a o t 5 2 2 2 2 1 siexoeJq 10 LOz lt 6L 3 6L 8 8 88 ZL Ob 9 EL 8 6 8 27119 Eke 2 OL Jenuew ay jo 499y9 sjuauoduoo 5 Condensing heat exchanger EXI Function The Condensing heat exchanger A in Fig 5 1 has the function of transferring heat produced from combus tion of the gas and from the flue exhausted gas to the water circulating in it e a
3. 13 Free the pipes R and P from the connection of the Condensing heat exchanger Fig 5 6 Fig 5 6 14 Unscrew the screws S and remove the clamps Fig 5 4 15 Unscrew the screws and remove the support U Fig 5 6 16 Remove the Condensing heat exchanger by levering it and sliding it forwards 17 Reassemble the Condensing heat exchanger carrying out the removal operations in reverse order EEN Cleaning Ifthere are deposits of dirt on the coil of the Condensing heat exchanger clean with a bristle paintbrush and re move the dust with a hoover Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 10 6 D h w heat exchanger Removal Functi NA Warning isolate the boiler from the mains 61 uncHon electricity supply before removing any The d h w heat exchanger A in Fig 6 1 and Fig 6 3 al covering or component lows the instantaneous transfer of heat the primary 1 Remove the front and right hand side panels of hydraulic circuit to the water destined for d h w use the case 2 Empty the primary circuit and the d h w circuit of the boiler HN 3 Completely unscrew the two Allen key screws B Fig 6 3 which hold the exchanger to the brass groups Fig 6 3 4 Move the exchanger towards the rear
4. The result of such a comparison operates the fan speed thus regulating the gas flow rate and consequently changing the useful output of the boiler ayy pi ref pz VV iT AA E N 2 Fig 9 3 When the boiler functions in d h w Fig 9 4 the signal coming from the d h w temperature probe is compared Electronic control ignition p c b with the signal given by the control panel through the adjustment made by the user knob Y E E aS AS PTA vy L AE Fig 9 4 Normally the result of the comparison between these two signals directly operates the fan speed adjusting the useful output generated in order to stabilize the temperature of the exiting water If during the d h w mode operation the temperature of the primary circuit goes over 90 C the useful output is automatically reduced so that the primary circuit can not reach excessive temperatures The control sequences in function and in func tion are illustrated in detail in sections 9 10 and 9 11 EX Operation lights The Electronic control ignition p c b is provided with three lamps L E D indicators 18 in Fig 9 2 that give optical information during the operation of the boiler The green lamp on the left gives information whether the
5. _ j ee Safety Transformer Fan Main circuit thermostat pressure switch m y p UO ELON UO HOUS e 10 516 191109 941 s do SUL awel ey JO ay UO y 1 usey qouy juewjsnipe dwa m y p Buin M Y P ey O4JUOD 1 Jejloq 941 US9OP Ue M y p JO Ul JOULE 1461 1 Useop 291 Uey M y p JO Ul JOYE 1961 1 Useop 241 195 440 1961 m y p JO y o Hes JOU seop 941 sy90 ay pue uo s1y61 94 y syeys 5 19592 ayy Hussard Ag ureBe ay pue uo 1461 1 94 syeys 5 19592 au Buissald Ag 330 109 pue UO ey E 5 19592 ayy Buissald Ag ao m nlololola ola w o U 0 2 215 5 5 2 5 2 2 5 5 gt 5 5 gt 8 lz 2158 gt S I 2 8 8 S 53 S35lel 8 2 2 S 5
6. 1 N D 9 4 Kohm rd red Open circuit bk black x 5 wh 2 2 gt g gt Fig 8 2 D h w mode B Spindle B visible e 1 N Open circuit rd red 9 4 Kohm bk black gt wh white gt Fig 8 3 mode EE 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 8 4 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 8 2 or to the wiring diagram in section NO TAG for the correct wiring connection 13 Three way diverter valve J 9 Unscrew the screw L and remove the diverter group e Fig 8 4 EX Removal of the diverter group and its internal parts Fig 8 6 Rear view of the boiler Remove the front and both side case panels 10 Refer to the exploded view in Fig 8 7 to remove the internal parts of the three way diverter valve 2 Empty the primary circuit and the d h w circuit of the boiler 3 Remove the el
7. 23 Short spare parts list 44 Key G C part no Manufac Manufacturer s reference turer part no 1 Burner mod M110 24SM 3 Condensing heat exchanger mod M110 24SM Condensing heat exchanger mod 1282 102 M110 32SM 6 Safety valve 1 BI1131 100 Watts Orkly alternative 7 Electronic regulation p c b mod M110 24SM 1 1805 103 Bertelli amp Partners Electronic regulation p c b 110 325 BI1805 101 s fenaa 0 965 NES 13 E83 086 Three way diverter electric actuator 1 1101 102 Elbi 14 E83 101 Overheat thermostat 1 1172 105 ELTH type 261 15 Flue temperature probe 50 wt _ _ __ _ E 18 164 026 Temperature probe main or D h w circuit 2 B10011417 E 2 RETO ESET Temperature pressure gauge Part Short spare parts list 45 17962 1252 2 1207 48A4 UK Biasi UK Ltd Newman Park Western Way Wednesbury WS10 7BJ Sales Tel No 0121 506 1340 Sales Fax No 0121 506 1360 Service Tel No 0121 506 1350 Service Fax No 0121 506 1370 www biasi co uk
8. 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 13 2 and remove the expansion vessel from the top of the boiler y U o Let Fig 13 2 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 13 3 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 13 3 14 D h w flow switch filter and flow limiter EAN Function The d h w flow switch A in Fig 14 1 is a device that generates an electrical signal when hot water is drawn aj I Fig 14 1 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 6 Fig 14 3 is drawn to wards the right The resulting m
9. Wall hung fan flue room sealed high efficiency gas boiler Service manual GARDA PLUS HE Models G C Appl No M110 24SM E 47 970 31 110 325 47 970 32 Leave this manual adjacent to the gas meter recommended Table of contents 1 1 1 1 2 N 9 10 9 11 10 10 1 10 2 11 11 1 11 2 11 3 11 4 11 5 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 4 Diagrams 5 Wiring diagram 5 Circuit voltages 6 Fault finding elect 7 Condensing heat exchanger 9 FUNCION en tame 9 Removal 9 CIE ANING nse patents 10 D h w heat exchanger 11 aed 11 Removal 11 PUMP eee 12 4 ceca jos Secale 12 CHECKS 12 Removal 12 Three way diverter valve 13 FUNCION 5 fascias cen tees 13 CHECKS iia ha ENA 13 Remo
10. 2 5 Q Q 5 m lt D 9 3 2 5 151813 2 2 5 lz 2 5 9 5 E g 7 o lt E 2 8 5 ss 5 2 a 5 D 5 2 5 D o 3 gt z 5 5 2 2 lt 2 a 1 2 19942 2 2 2 1 10 LOc c 6L lt 6L 88L 8811 ZL 9L 9 8 6 8 27419 bboy 10 ay jo sjuauoduoo Z app Burpuy yney indu ay yoea 6 9 1 aye e yes ul 00 aye mo 8 Jo jenuew QU 0 Jajey BU jo y Z au JO e s 5141 59526 an au anjea 209 au YezAyeue ay Huis 9 jejes y jo ay pue ayy Bunesy Jano ay ssed q pauwely osje a
11. 38 Removal of the spark generator 38 wane ote 38 Safety thermostat 40 FUNCION aio aa ies 40 CHECKS dd cd os dd oes 40 Removal serte cd e tho etter cated ah 40 Flue temperature probe NTC 41 FUNCION do di ree ahha ets 41 REMOVAL See 41 Check eee cet tet o Ls 41 Condensate trap 42 UNCON tas 42 Removal sner erua we 42 External temperature probe optional 43 FUNCION ridad 43 CheckSr oat a 43 Short spare parts list 44 1 information Overall View Flue temperature probe NTC EX C h temp Condensing heat exchanger H a q Safety Burner thermostat Expansion vessel Ignition electrodes SM J Detection Spark h 114 electrode Generator ee j Transformer Air restrictor Gas restrictor Fan fq Automatic y air release Diverter valve y valve D h w Flow DN Switch 1 r 1 Condensate Main circuit MA e flow switch 1 A D h w temp a 2 D h w gt Control ca panel heat exchanger Hydraulic diagram Central heating c h operation C h C h D h w D h w water return water flow inlet outle
12. spark generator When the fan turns but burner does not light a poss ible cause is a faulty spark generator and it is advisable to replace it to locate the fault Check the position of the electrode edges NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the ignition electrodes see section 18 2 2 Check for the correct distance between the me tallic edges of the ignition electrode see Fig 18 10 Ignition and detection electrodes 4mm Fig 18 10 Check the connection wires Nx 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 Check for the integrity of the insulation of wires which connect the electrodes to the spark gener ator and to the control ignition p c b Warning Insulation panels material handling care Mineral fibres are used in this appliance for the insula tion panels of the combustion chamber Excessive exposure to these materials may cause tem porary irritation to eyes skin and respiratory tract Known hazards Some people can suffer reddening and itching of the skin Fibre entry into the eye will cause foreign body irritation which can cause severe irritation to people wearing contact lenses Irritation to respiratory tract Precautio
13. 27 Removals cia ees 27 Expansion vessel and temperature pressure gauge 28 FUNCION ts hex 28 A 28 Removal of the expansion vessel 28 Removal of temperature pressure gauge 28 D h w flow switch filter and flow limiter 29 Function 29 Description and location of parts 29 CHECKS vaticano 29 Removal of the flow switch sensor 29 Removal of the flow switch group and d h w circuit filter 29 Flow limiter 30 Temperature probe 31 Function iat 31 CHECKS adios 31 Removal of the c h Temperature probe 31 Removal of the d h w Temperature probe 31 By pass valve 33 nada 33 Removal ae ied 33 Fan and Air 34 FUNCION at ete RA ne 34 Removal of the fan group 34 Removal of the Air box 35 Removal of the Fan 35 Ignition and detection electrodes burner and spark generator 36 FUNCION wants 36 Removal of the Ignition and detection electrodes Roading see Ae 36 Removal of the burner 36 Removal of the front insulation panel 37 Removal of the rear insulation 37 Removal of the flue hood
14. 4 of this manual has occurred Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Y Mechanical function bh 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 Boiler OFF B Fig 12 2 Boiler ON Y Electrical check Itis possible to verify the general operation of the switch by measuring the electric resistance between the con tacts C and N O of the switch 1 Remove the switch as explained in section 12 3 2 Measure the electrical resistance between the tabs marked and N O Fig 12 3 The contact must be normally open 3 Operate the switch by hand and verify that the contact is now closed C X do not use Fig 12 3 PEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Removal of the switch Remove the front panel of the case Remove the fork C Fig 12 4 Open the box and disconnect the switch Re assemble the parts in reverse order of re moval Refer to Fig 12 3 for the correct wiring connectors on the switch gt 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 2 Remove the fork C that holds the micro swit
15. Fig 11 4 The appliance operation light on the left will flash every 4 seconds hog pa E F B D Gas valve 15 Keep pressed the reset button C for about 10 seconds Fig 11 4 until the lock out signal lamp D blinks 16 The lamps E should give the indication as in Fig 11 5 O Where Lamp OFF 00m Fig 11 5 17 Release and keep the reset button pressed for 18 more than 5 seconds until the lock out signal lamp D is switched off The boiler will now go through an ignition se quence and the burner will light Open at least one hot water tap fully Adjusting minimum gas valve setting 19 Set the knob F to the minimum position as illus trated in Fig 11 6 a fs 3 y Y E 1 4 2 8 AA J lt A PQ 20 im AA B D Fig 11 6 20 Allow the analyser to give a stable reading 21 Read the COs value It should be 9 0 To adjust the value remove the brass plug by unscrewing it and rotate the plastic screw 1 Fig 11 2 by rotating it clockwise the in creases Checking the maximum gas valve setting 22 Setthe knob F to the maximum position as illus trated in Fig 11 7 ata E 1323 2 8 AA P J lt A OQ ONE a aw B D Fig 11 7 23 Allow the analyser to give a stable reading 24 Read the value It should be between 9 0 and 9 8 25 Switch off the boiler and turn off the hot wate
16. loosen the connection H 9 Unscrew the two screws that hold the pump on the frame and remove the pump Fig 7 3 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 8 Three way diverter valve EXI Function The diverter valve A Fig 8 1 has the function of mod ifying the hydraulic circuit of the boiler by means of an electric command given 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 LJ MEAR Fig 8 1 EF Checks Mm the electrical continuity Fig 8 2 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 8 3 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 RO
17. of starting defects With the boiler off remove the front case panel Remove the air release plug from the pump Start the boiler and with a screwdriver turn the rotor in the direc tion ofthe arrow Ifthere is a defect in starting the rotor will begin to turn normally only starting it manually 12 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 7 2 Loosen the connection C remove the fork D and the pipe E y U Edi Fig 7 2 6 Remove the fork F Fig 7 3 and the connection of the capillary pipe of the pressure gauge 7 Remove the locking plate 8 Completely
18. Fig 2 4 5 Remove the screws E and remove the service panel Fig 2 5 If the external temperature probe optional is fitted fol low the steps 6 to 9 6 Remove the screws F and remove external tem perature probe lid Fig 2 5 7 With the help of a screwdriver disconnect the ter minal block G Fig 2 6 8 Remove the clamp H that holds the cable Fig 2 6 General access and emptying hydraulic circuits 9 Pass the terminal block connected to the boiler through the hole of the control panel lid Fig 2 7 Fig 2 7 10 Remove the screws and remove the control pan el lid Fig 2 5 EXI Access to the sealed chamber Fig 2 8 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 J as indicated in Fig 2 8 and remove the lid Emptying the primary circuit 1 Close the c h circuit flow and return cocks K Fig 2 9 General access and emptying hydraulic circuits Attention some water could remain in the condens ing heat exchanger 5 Close drain tap once the emptying has been completed Fig 2 9 bottom view of the boiler 2 Remove the front and right panels of the boiler 3 Open the drain tap L Fig 2 11 until the boiler is completely emptied 4 To help the draining of the pr
19. agnetic field of ring 5 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 of the sensor is also indicated by means ofthe lamp B placed on the sensor body Fig 14 2 Description and location of parts Fig 14 3 Flow switch sensor Body O ring Spring Magnetic ring aor WD Float Threaded ring Flow limiter M110 28SM optional accessory Filter O Spring seat gt ON o Fig 14 3 Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm switch sensor operation 1 Remove the front panel of the case 2 Switch on the boiler and open a d h w tap The lamp B Fig 14 2 placed on the sensor body is switched on when the flow rate reaches about 2 5 litres min ZEN 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 the connector C Fig 14 2 and re move the sensor by delicately levering down wards with a screwdriver TEN Removal of the flow switch group and d h w circuit filter NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case and empty the d h w circuit 2 Remo
20. boiler is in stand by mode or during the normal operation of the boiler The following table gives the relationship between the lamps indication and their meaning Boiler in stand by condition function control in position Anti freeze system active Boiler ON condition function control i in 3 3 position 1 second ON 1 second OFF With the boiler switched ON ea or 8 all the lamps 18 in Fig 9 2 are activated The following table gives the relationship between each of the possible lamp combinations and their meaning SE Normally operating boiler Q O see the previous table for details O y D h w operation O ES Excessive temperature on primary circuit O O Faulty c h temperature probe Faulty d h w temperature probe NTC Faulty flue temperature probe NTC XP Faulty external temperature probe Faulty primary circuit O no water or absence of flow 8 2 See _ Lack of power supply faulty electronic control p c b Faulty Electronic p c b Flashing lamp alone or simultaneously with an other lamp Lamp Lamp OFF ON 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 Electronic control ignition p c b Setting the boiler control function modes Itis possible t
21. cating that the setting has changed and must be memo rised 18 Knob position Maximum useful output in c h mode non condensing kW BTU h 110 245 110 325 5 8 19 788 10 6 36 165 10 3 35 142 13 2 45 036 16 7 56 977 21 0 71 648 SE Tab 9 1 5 To 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 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 9 8 A Fig 9 8 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 9 9 reignition frequency If not press the reset button repeatedly to obtain it 000 Where Lamp OFF DMM Ao Fig 9 9 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 will flash a number of times corre sponding to the setting Fig 9 10 4 To change the setting turn the knob B on a posi tion corresponding to the desired delay B
22. ce of the flame Fig 18 1 The burner E is fitted on the rear of the fan burner group A 36 Fig 18 2 KEEN Removal of the Ignition and detection electrodes NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid see section 2 2 Disconnect the ignition electrodes connector F and the earth wire G from the spark generator Fig 18 1 and disconnect the detection elec trode connector H 3 Unscrew the screws and remove the ignition electrodes B and the detection electrode D Fig 18 1 4 Assemble the Ignition and detection electrodes carrying out the removal operation in reverse or der When reassembling the ignition electrodes be sure to connect correctly the wires to the spark genera tor see Fig 18 3 ger Fy ee earth wire ignition electrodes wire Be Fig 18 3 KEEN Removal of the burner NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Ignition and detection electrodes 1 Remove the fan group see section 17 2 2 Remove the burner by sliding it forward burner gasket locating tab Fig 18 4 3 Assemble the burner carrying out the removal operation in reverse order Ensure the burner is correctly located by lining up the locating tab Fig 18 4 Before reassembling ensure the burner gask
23. ch housing D Fig 12 4 _ of the shaft B referring to Fig 12 2 Fig 12 4 27 Primary circuit flow switch 3 Unscrew the four screws E see Fig 12 5 open the hydraulic operator and remove the mem brane F Fig 12 5 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 12 5 13 Expansion vessel and temperature pressure gauge Function The Expansion vessel in Fig 12 1 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 13 1 from the valve on the top of the expansion vessel and con nect a suitable air pressure gauge Fig 13 1 3 Check the pre load pressure and refer to the section Expansion vessel in the User manual and installation instructions for the correct value KEEN 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 28 sion vessel can be changed without removing the boiler NN Warning isolate the boiler from the mains electricity supply before removing any covering or component _
24. d 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 bh 40 2 Disconnect the safety thermostat and check its electrical function Normally no intervention the contact must be closed electrical resistance zero Q KEEN Removal Nx 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 Disconnect the wiring B detail in Fig 19 2 3 Unscrew the screws C which hold the overheat thermostat on the pipe ofthe condensing heat ex changer and remove it Fig 19 2 4 Reassemble the overheat thermostat carrying out the operations in reverse order 5 Apply an adequate quantity of heat conducting compound between the pipe and the thermostat Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 20 Flue temperature probe NTC Function The Flue temperature probe NTC A in Fig 20 1 and Fig 20 2 senses the temperature of the combustion products that flow through the condensing heat ex changer Fig 20 1 If the tempera
25. der A B Fig 21 2 22 External temperature probe optional EAN Function The External temperature probe if fitted allows to ad just automatically the temperature of the c h flow with reference to the external temperature The relationship between the external temperature and the c h flow temperature is represented by the coeffi cient K Fig 22 1 that can be set between 0 and 6 More details concerning the coefficient K and the set ting procedure are given in the Commissioning section of the installation manual The coefficient K is factory set 0 that is the setting for the operation with no external temperature probe fitted C h flow temperature C 80 70 60 50 40 30 20 15 10 5 0 5 10 15 20 25 External temperature Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Disconnect the cable from the External temperature probe Measure the external temperature where the External temperature probe is located and check the electrical resistance according to the graph in Fig 22 2 L_ 2500 INT 20 TAX 7 fT 1500 ft ft ft TT so ft tT 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 22 2 43
26. e boiler should maintain a temperature below that of the Flue temperature probe NTC and no overheat intervention should occur Temperature resistance relationship Remove the Flue temperature probe NTC see section 20 2 2 Measure the Flue temperature probe NTC electri cal resistance at the ambient temperature and check it according to the graph in Fig 20 3 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 20 3 41 21 Condensate trap Function The condensate trap A in Fig 21 1 and Fig 21 2 allows the discharge of the condensate via the condensate drain pipe avoiding in the mean time the escape of combustion products A plastic ball closes the trap outlet in case that the trap is empty ic Fig 21 1 If the drain pipe is plugged or in any case in which the condensate isn t correctly evacuated the condensate 42 level in the trap rises till it reaches thus causing the boiler lock out Removal Ns Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front and right case panels 2 Remove the motor of three way diverter valve see section 8 4 3 Disconnect the trap from the draining pipe 4 Using pliers remove the spring B moving it up wards 5 Unscrew the lock nut and lower the trap 6 Reassemble carrying out the removal operations in reverse or
27. e order 37 Ignition and detection electrodes Removal of the flue hood 1 Remove the condensing heat exchanger see section 5 2 Fig 18 7 2 Using pliers remove the spring O moving it downwards and disconnect the rubber pipe P Fig 18 7 3 Remove the screws Q and remove the flue hood R 4 Assemble the flue hood carrying out the removal operation in reverse order Flue hood Fig 18 8 38 Before reassembling ensure that the flue hood gasket is correctly mounted Fig 18 8 Removal of the spark generator Ns 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 spark generator connector coming fromthe control p c b the electrodes wire and the earth wire coming from the ignition elec trodes Fig 18 9 ignition electrodes wire A 7 8 connector earth wire 5 Fig 18 9 3 Unscrew the screws S and remove the spark gen erator 4 Assemble the spark generator carrying out the re moval operation in reverse order When reassembling the spark generator be sure to connect correctly the wires Checks Mm Check of the spark generator Warning isolate the boiler from the mains electricity supply before removing any covering or component There is nota significant way to verify the integrity ofthe
28. ectric actuator see section 8 3 4 Remove the fixing spring F Fig 8 5 and remove the primary circuit flow switch G 5 Disconnect d h w temperature probe 6 Unscrew the connector the c h flow connector and the d h w outlet connector Fig 8 5 7 Remove the d h w heat exchanger see section 6 2 Fig 8 7 8 Remove the fork J and move away the pipe K 11 Reassemble the diverter group carrying out the Fig 8 6 removal operations in the reverse order 14 9 Electronic control ignition p c b EXI Function Fig 9 1 Inlet Information On the Electronic control ignition p C b Function control C h temperature adjustment D h w temperature adjustment Boiler reset button control panel fascia From other boiler devices C h temperature probe NTC D h w temperature probe NTC D h w flow switch Primary circuit flow switch Flue temperature probe NTC Safety thermostat Flame detection electrode Room thermostat if fitted External temperature probe if fitted Time switch Outlet command Pump Three way diverter valve Gas valve Fan Ignition electrodes Appliance operation lights Lock out signal lamp control panel fascia The fundamental function ofthe 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 ord
29. emperature probes One on the output of the primary condensing heat ex changer c h Temperature probe A in Fig 15 2 and Fig 15 4 one on the output of the d h w heat ex changer d h w Temperature probe B in Fig 15 2 and Fig 15 4 c h c h d h w return flow inlet outlet Fig 15 2 Checks Temperature resistance relationship Nx 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 ofthe brass group where the Temperature probe is located and check the electrical resistance according to the graph in Fig 15 1 Removal of the c h Temperature probe NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Empty the primary circuit of the boiler 3 Remove the electric connector and unscrew the c h Temperature probe Fig 15 3 4 Reassemble the c h Temperature probe carrying out the removal operations in reverse order Removal of the d h w Temperature probe NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case 2 Empty the d h w circuit of the boiler 3 Remove the electric connector and unscrew the d h w Temperature probe Fi
30. en Hs Ti gt o 2 E bu bn Xx wi X15 NI 5 X23 O 6 Fa O La E Ll EES IE bu bn bu bn 05 EA d AR X24 bn LD3 LD2 LI ES spi 104 Li gt it bn bn bu bu bn bu bul rd aH 1 55 DA 0 NO Transformer og rdwh Primary circuit 230V 24V gy Fan flow switch Ignition Flame detection electrodes electrode Flue Safety temperature thermostat bn brown probe NTC Time switch bu blue bk black wh white rd red gy grey gn green ye yellow vt violet orange gnye green yellow rdwh red white Diagrams ERIN Circuit voltages during c h or d h w operation Electrical voltages with burner on C gt only during c h operation only during d h w operation n l 9 3 way D h w diverter valve Flow switch Gas valve Supply network b g en 9 o N X12 X14 o O X11 X10 X7 X17 F2 Fi ka 2 5 x3 ao 5 el xis y X23 Ed Q X6 x1 TU N sg 4 i b g
31. er edge under the control knob shafts Lower the rear edge and ensure that no wiring is trapped beneath 9 Insert the spindles in the control panel knobs until the notchA Fig 9 12 reaches the potentiometer edge It is not necessary to force them in the knob 10 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 9 12 19 Electronic control ignition p c b Fig 9 12 Attention 20 After installing the Electronic control ignition p c b 11 12 13 Make sure the c h 8 and d h w 820 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 9 5 Operate the boiler and close the gas inlet cock so that the boiler goes into the safety lock out state Verify the correct operation of the boiler reset 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 EXT Thermal control in the mode Sw
32. er 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 orfromthe outside knobs room thermostat etc pro cesses it and consequently acts with outlet commands on other components of the boiler Fig 9 1 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 checks the presence of the flame during the entire period in which it is activated and supplies the fan regu lating its speed 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 interve
33. et is correctly located Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Removal of the front insulation panel See warning note at the end of this chapter before to remove this part 1 Remove the Ignition and detection electrodes see section 18 2 2 Do the operations of section 17 2 from step 1 to step 8 3 Unscrew the nuts J Fig 18 1 and remove the cover of the combustion chamber 4 Remove the front insulation panel Fig 18 5 5 Assemble the new front insulation carrying out the removal operation in reverse order When fitting the new panel ensure that the elec trodes holes coincide with the holes of the com bustion chamber front insulation Fig 18 5 ES Removal of the rear insulation See warning note at the end of this chapter before to remove this part Attention Cover the inner of the condensing heat exchanger to avoid that dirt and debris fall in the coil 1 Disconnect the Ignition and detection electrodes 2 Do the operations of section 17 2 from step 1 to step 8 3 Unscrew the nuts K Fig 18 1 and remove the cover of the combustion chamber 4 Unscrew the screw L remove the washer M and the rear insulation N Fig 18 6 Fig 18 6 5 Assemble the new rear insulation carrying out the removal operation in revers
34. fore removing any covering or component 24 Check the supply pressure before making any ad justment to the gas valve 1 Close the gas inlet valve 2 Remove the front panel of the case and lower the control panel see sections 2 2 and 2 3 3 Loosen the internal screw on the Inlet Pressure Test Point 4 Fig 11 2 of the Gas valve and con nect a pressure gauge using a suitable hose 4 Open the gas inlet valve 5 Turn on the electricity supply to the boiler switch ing on the fused spur isolation switch The appliance operation light on the left will flash every 4 seconds 6 Set the function knobs as illustrated in Fig 11 4 Open at least one hot water tap fully 8 Read the inlet pressure value and ensure that it is within the limits given in the table Gas supply pressures of the user installation manual If it does not comply with the required pressure check the gas supply line and governor for faults and or correct adjustment 9 Switch off the boiler close the gas inlet valve and close the water tap 10 Disconnect the pressure gauge and close the Inlet Pressure Test Point 4 Fig 11 2 N Gas valve adjustment 11 Fit the probe of the flue analyser in the flue ex haust sampling point located on the exhaust pipes of the boiler Fig 11 3 air flue exhaust Fig 11 3 12 Turn on the boiler switching on the fused spur isolation switch 13 Open the gas inlet valve 14 Set the function knob as indicated in
35. g 15 4 4 Reassemble the d h w Temperature probe ing out the removal operations in reverse order 31 Temperature probe as py SST q Fig 15 4 32 16 By pass valve Removal 116 1 Function NN Warning isolate the boiler from the mains electricity supply before removing any The By pass valve A in Fig 16 1 is located between covering or component the c h water flow and return and its function is that of guaranteeing a minimum flow across the primary heat 1 Remove all the case panels exchanger if the circulation across the c h system 15 pe completely closed 2 Empty the primary circuit of the boiler The By pass valve is fitted on the rear side of the div Remove the diverter group as described in the erter group section 8 4 of this manual 4 Unscrew the connector B and remove the by pass valve C Fig 16 2 I Fig 16 2 5 Reassemble the by pass valve as illustrated Fig 16 1 Fig 16 2 reversing the order of removal 33 17 Fan and Air box Function The function of the FanA Fig 17 1 is to force the mix ture of air and gas into the burner The function of the Air box B is to mix the gas and the air in the right proportion The flow rate of the air gas mixture and consequently the input power of the boiler is proportional to the speed of the fan that is controlled by the electronic cont
36. imary circuit loose the condensing heat exchanger air purger valve Fig 211 PON Emptying the d h w circuit 6 Close the d c w inlet cock N Fig 2 9 7 Open one or more hot water taps until the boiler has been completely emptied 3 Diagrams EXI Wiring diagram M110 24SM M110 32SM Electric supply Three way Ext i b terminal block diverter valve block P D h w temperature probe NTC LON C h temperature External controls 1fM prope NTO terminal block EN 3 Pump yl bu bn gnye bu 3 21 rd wN D h w flow bk switch bu a bu bk bn gnyej bu fn RM wh bn bn bu bn rd wh bk bu bn rd bk bk rd bu pe or eS EA 12 X11 X10 X7 A X17 E 22 FA 8 E J lt NA o 2 J bees o Y Soa Y wh wh a 4 lt F e 2 x16 Ab 5 wh wh
37. itch in function mode NO circulator off fan still YES 2 Taking water from the domestic ho water circuit circulator on YES stop circulator 3min Is primary circuit NO Operation lights temperature higher than that selected Main circuit pressure switch consense L YES YES O YES NO lock memorised cancels lock starts fan checks fan rpm Is fan rom exact Opeartion lights NO turns on lock out light Ye Opeartion lights e YES flame presence End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve stops fan interrupts ignition discharges memorizes lock turns on lock out light End of ignition period Is fan rpm NO reset push button YES pressed Safety thermostat or flue 1 5 NO NO temperature probe lock out YES ame Presence YES Fig 9 13 21 Electronic control ignition p c b EXE Thermal control in the mode Switch in the function mode See functioning with the function Taking control in lt YES water from the domestic ho water circuit Request for hea
38. le the Fan carrying out the removal oper ations in reverse sequence Before reassembling ensure the fan gasket is cor Fig 17 5 rectly mounted 10 Remove the fan group L by sliding it forwards 11 Assemble the fan group carrying out the removal Warning After cleaning or replacement as operations in reverse sequence detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 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 box Warning isolate the boiler from the mains electricity supply before removing any covering or component Carry out the operations 1 to 7 of section 17 2 Open the strip M by sliding the edges with the help of a screwdriver and remove the Air box I Assemble the Air box carrying out the removal operations in reverse sequence Fan gasket Fig 17 6 Fig 17 7 35 18 Ignition and detection electrodes burner and spark generator Function Three electrodes are fitted on the fan burner group Two of them fitted on the left side of the fan burner group A are the ignition electrodes B and are con nected to the spark generator C On the right side is the detection electrode D and it de tects the presen
39. ns Dust goggles will protect eyes People with a history of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present high risk follow good hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First aid Medical attention must be sought following eye contact or prolonged reddening of the skin 39 19 Safety thermostat Function The safety thermostat A in Fig 19 1 is a device that senses the temperature of the primary circuit water which flows in the outlet pipe of the condensing heat ex changer If the temperature control system of the boiler fails and the temperature of the primary circuit reaches a dan gerous temperature the safety thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device at tempts to light the burner and at the end locks the boiler and lights the lock out signal lamp Fig 19 1 EEJ 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 an
40. ntion of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wir ing or connection Faulty flame detection faulty detection electrode its wiring or connection Faulty condensate drainage Faulty gas valve faulty on off operators or not electrically supplied Faulty Electronic control ignition p c b Other components like the primary circuit flow switch can temporarily stop the ignition of the burner but allow its ignition when the cause of the intervention has stopped Fig 9 13 and Fig 9 14 show the sequence of the oper ations 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 9 2 Some of these devices are directly accessible by the user function control temperature adjustment poten 15 QO Or O DO Electronic control ignition p c b tiometers etc others like the fuses are accessible by removing the service panel 18 17 16 15 4 13 12 11 10 Fig 9 2 1 x7 connector electric supply terminal block and external controls terminal block Fuse F1 F23 15AF Fuse F3 400 mA T x12 connector pump and 3way diverter valve x17 connector gas valve x14 connector external temperature probe
41. o selectthe various boiler control function modes by using the function selector knob A and the D h w temperature control knob B Fig 9 5 During the function modes setting the boiler does not operate av is 219 5 Fig 9 5 SEN CG Adjustment of maximum useful output c h mode The following procedure allows the output of the boiler for c h to be limited to meet the system requirement Adjusting the maximum useful output in c h mode does not prevent the boiler firing at maximum rate for d h w production 1 Turn the boiler ON positioning the function selec tor knob A as indicated in Fig 9 6 POP Fig 9 6 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 9 7 maximum c h useful output adjust ment If not press the reset button repeatedly to obtain it Were Lamp OFF 1 11 11 O Lamp ON Fig 9 7 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 will flash a number of times corre sponding to the setting Tab 9 1 4 To change the setting turn the knob B on a posi tion corresponding to the desired maximum use ful output Tab 9 1 By turning the knob B the lock out signal lamp D blinks quickly 2 per seconds indi
42. of the boiler and extract it Fig 6 1 Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order Attention When reassembling the exchanger be sure to put the off centre location securing pin indi cated in Fig 6 4 towards the left side of the boiler The schematic structure is shown in Fig 6 2 A V Primary hydraulic circuit Domestic hot water circuit Fig 6 2 Fig 6 4 11 7 Function The pumpA in Fig 7 1 and Fig 7 2 has the function of making the water in the main circuit circulate through the main condensing heat exchanger and therefore through the c h system during the c h function or through the secondary heat exchanger during the d h w function Fig 7 1 Checks Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm Check that the pump is not seized and that the movement of the rotor is not subject to mechanical im pediments With the boiler off remove the front panel Remove the air release plug of the pump and turn the rotor with a screwdriver Mm Check the electrical continuity With the boiler off remove the front panel and discon nect the connector B Fig 7 3 Measure the electrical resistance between the pump supply connections Electrical resistance of the windings at ambient tem perature must be about 230 Q Check the absence
43. optional 7 x9 connector safety thermostat flue tempera ture probe NTC c h temperature probe NTC 8 x11 connector d h w temperature probe 9 x10 connector d h w flow switch 10 x2 connector timer 11 Lock out signal lamp 12 Boiler reset button 13 Function control C h temperature adjustment 14 x22 connector fan 15 x24 connector transformer 16 D h w temperature adjustment 17 5 connector transformer 18 Appliance operation lights 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 oak W DY 16 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 13 and 16 in Fig 9 2 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 switching OFF ON OFF function If the power requested is higher then the burner is switched ON at maximum power and will control by modulating to 40 of the maximum power output During the c h operation Fig 9 3 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
44. out the removal operations in reverse order Fig 11 10 Before to fit a new valve it is advisable to pre set it as hereafter explained 8 Remove the brass plug and turn the plastic screw 1 Fig 11 2 fully clockwise until it stops Do not overtight 9 Turn it counter clockwise 2 and 3 4 turns 26 10 Adjust the gas valve using the flue analyser as de scribed in section 11 3 After any service operation on the components of the gas circuit check all the connections for gas leaks Warning After cleaning or replacement as detailed above it is deemed necessary to undertake a combustion analysis as detailed in chapter 11 3 section 11 Fig 11 11 12 Primary circuit flow switch EAN Function The Primary circuit flow switch A in Fig 12 1 function is to detect water flow rate through the primary hy draulic circuit of the boiler Fig 12 1 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 operate 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 condition see section 9
45. r tap s 26 Close the air flue sampling points 27 After adjustment fit the protective brass plug 1 Fig 11 2 Important after the gas pressure checks and any adjustment operations all of the test points must be sealed Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector 3 Fig 11 2 Measure the electrical resistance between the connector pins of the on off operators as illus trated in Fig 11 8 ON OFF Operator approx 6 400 ON OFF Operator approx 920 Q at ambient temperature Fig 11 8 HEN Removal of the gas valve Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case as explained in the section 2 3 of this manual and the sealed chamber lid 2 Remove the screw G and disconnect the con nector H Fig 11 9 Fig 11 9 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port ofthe gas valve 4 Using pliers remove the spring and the rubber pipe J 5 Unscrew the connector K Fig 11 9 remove the fixing fork L and remove the pipe M Fig 11 10 25 Gas valve 6 Unscrew the screws N and remove the valve Fig 11 11 7 Reassemble the valve carrying
46. r carrying out the re moval operations in the reverse order After reassembling ensure the wires are correctly connected see Fig 10 2 larger larger connector connector clamp for fitting i m the transformer 9 1 y ul smaller smaller connector connector Fig 10 2 Check the transformer NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the Transformer see section 10 1 2 Measure the electrical resistance of the primary and secondary windings The primary should have a resistance approx 35 ohm and the secondary approx 1 4 ohm 23 11 Gas valve Function The Gas valve A in Fig 11 1 controls the gas inflow to the boiler burner Fig 11 1 By means of an electric command given to the on off operators the passage ofthe gas through the Gas valve can be opened or closed Description of the parts Fig 11 2 Minimum gas pressure adjustment On off operators On off operators electric connector Gas valve inlet pressure test point WD Fig 11 2 HEN Adjustment NN Warning isolate the boiler from the mains electricity supply be
47. rol p c b Fig 17 1 Removal of the fan group Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component Turn off the gas supply 2 Remove all the case panels and the sealed chamber lid see section 2 Fig 17 2 3 Disconnect the rubber pipe C Fig 17 2 34 Unscrew the gas connector D Fig 17 3 5 Remove the fixing fork E and remove the gas pipe F Fig 17 2 6 Loosen without removing the screw G Fig 17 3 7 Remove the screws H and the air box Leave the air box with the air hose clamped to the water pipe 8 Disconnect the fan connector J by pressing the plastic hook placed on the rear side of the con nector Fig 17 4 9 Unscrew the screws K Fig 17 5 Fig 17 4 Fan and Air box 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 Fan NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the fan group see section 17 2 2 Unscrew the screws N Fig 17 7 3 Assemb
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49. t 2 General access and emptying hydraulic circuits EXI Nomenclature Fig 2 1 1 Right side panel Front panel Control panel lid Control panel cover Service panel O a A ND 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 2 lift the panel and remove it 2 Fig 2 2 To remove the side panels loosen the screws B and C Fig 2 3 bring the base of the panels away from the boiler and lift them freeing them from the top hooks cy Fig 2 3 bottom view of the boiler Control panel NN Warning isolate the boiler from the mains electricity supply before removing any covering or component To gain access to the parts located inside the control panel proceed as follows 1 Remove the front panel of the case 2 Loosen the screws B and C Fig 2 3 3 Remove the screws D 4 Move the lower part of the side panels as indi cated in Fig 2 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
50. t from room thermostat NO circulator off fan still stop circulator 3min Operation lights Vly NO sec 9 10 YES circulator on Is primary circuit temperature higher than that selected Main circuit pressure switch consense YES YES YES NO lock memorised cancels lock Opeartion lights Is fan rom exact NO turns on lock out light lights beginning of wait period YES flame presence End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve stops fan interrupts ignition discharges memorizes lock turns on lock out light End of ignition period m NO Is fan rpm NO reset push button YES exact pressed Safety thermostat or flue 2 NO ANS temperature probe lock out YES flame presence Fig 9 14 22 10 Transformer HAN Removal Fig 10 1 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 see section 2 2 Disconnect the four connectors A 3 Unscrew the screws and remove the Transformer C by sliding it forward 4 Reassemble the Transforme
51. tricity supply before removing any covering or component When replacing the Electronic control ignition p c b it is advisable to go through the setting modes of the boiler here described in sections 9 5 to 9 7 If an external temperature probe optional is fitted the coefficient K has also to be set as described in the Commissioning chapter of the installation man ual 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 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 9 11 Fig 9 11 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 It is not necessary to utilise static protections but it is advisable to ensure that the pcb is handled with care and held at the edges and with clean dry hands 8 Fit the p c b into the control panel by first insert ing the front low
52. ture of the combustion products circuit reaches the limit temperature the Flue temperature probe NTC reduces the gas flow rate to the burner The temperature of the combustion products should de crease to a safe value temperature In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler operation 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 ignition p c b attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp Removal Nx 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 flue temperature probe A Fig 20 2 from the condensing heat ex changer 4 Assemble the Flue temperature probe NTC carry ing out the removal operations in reverse se quence 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 Th
53. val of the electric actuator 13 Removal of the diverter group and its internal 14 Electronic control ignition p c b 15 FUNCION wee aba aca 15 Selection and adjustment devices 15 Checking the temperature 16 Operation lights 17 Setting the boiler control function modes 18 Adjustment of maximum useful output coset dir Reignition frequency setting 18 A heed eee 19 Removal of the electronic control p c b 19 Thermal control in the BE mode 21 Thermal control in the mode 22 Transformer 23 Removal 23 Check the transformer 23 Gas 24 24 Description of the parts 24 Adjustment 24 ride areas 25 Removal of the gas valve 25 12 12 1 12 2 12 3 13 13 1 13 2 13 3 13 4 14 14 1 14 2 14 3 14 4 14 5 14 6 15 15 1 15 2 15 3 15 4 16 16 1 16 2 17 17 1 17 2 17 3 17 4 18 18 1 18 2 18 3 18 4 18 5 18 6 18 7 18 8 19 19 1 19 2 19 3 20 20 1 20 2 20 3 21 21 1 21 2 22 22 1 22 2 23 Primary circuit flow switch 27 FUNCION Secretar ae eed eae 27 A O
54. ve the flow switch sensor see section 14 4 29 D h w flow switch filter and flow limiter flow switch group q 10 Yellow 4 To remove the filter from the flow switch group separate the filter 9 from the threaded ring 12 Brown Pao eein l 5 Reassemble the parts following the removing se quence in reverse order To install the threaded ring with the flow limiter 1 Remove the flow switch group as explained in the Flow limiter section 14 5 The M110 24SM model is factory fitted with a 10 litre 2 Remove the filter from the flow switch group min flow limiter 3 Unscrew the threaded ring 7 Fig 14 3 and re If on the M110 32SM model the flow rate of the move it from the body 2 circuit is too high it is possible to limit it by installing a 4 Reassemble the group following the above se flow limiter The following sizes are available quence in reverse order 30 15 Temperature probe HAH Function The Temperature probe has the function of converting the temperature of the water in the hydraulic circuit where itis installed into an electrical signal resistance The relation between temperature and electrical resis tance 15 stated in Fig 15 1 Q 12500 12000 11500 11000 10500 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 15 1 On the boiler there are two T
55. y turning the knob 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 2 7 2 8 0 j _ 81 2 OOO Delay minutes 000 Setting Fig 9 10 5 To 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 3 minutes CEN Checks Mm Check that the fuses are complete Ifthe Electronic control ignition p c b does not supply any device pump fan etc check that the fuses 2 and 3 Fig 9 2 are complete If a fuse has blown replace it with one that has the same characteristics after having identified the reason for fail ure 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 four complete ignition cycles and then after about 4 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 EXI Removal of the electronic control p c b NN Warning isolate the boiler from the mains elec
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