Service manual
Contents
1. G Figure 6 1 The schematic structure is shown in Figure 6 2 V A V Primary hydraulic circuit Domestic hot water circuit Figure 6 2 6 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 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 Allen key screws B in Figure 6 3 which hold the exchanger to the brass group 4 Remove the electric actuator following the instructions in sec tion Removal of the electric actuator page 15 Figure 6 3 5 Remove the pump following the instructions in section Re moval page 14 6 Completely unscrew the Allen key screws C Figure 6 4 which hold the exchanger to the plastic groups Figure 6 4 7 Move the exchanger towards the rear of the boiler and extract it to the left Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order EA Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities Warning When reassembling the exchanger be sure A to put the off center location securing pin indicated in Figure 6 5 towards the left2. il ZI ny n ja PB ls n Ji X X A A c h c h d h w d h w return flow inlet outlet Figure 15 2 15 2 Checks Temperature resistance relationship Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Disconnect the cable from the Temperature probe Measure the temperature of the pipe near the Temperature probe and check the electrical resistance according to the graph in Fig ure 15 1 15 3 Removal of the c h Temperature probe Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels and the sealed chamber lid 2 Empty the primary circuit of the boiler 3 Remove the electric connector C and unscrew the c h tem perature probe A Figure 15 3 4 Reassemble the c h temperature probe carrying out the re moval operations in reverse order C Y Figure 15 3 15 4 Removal of the d h w Temperature probe Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove the front panel of the case 2 Empty the d h w circuit of the boiler 3 Remove the electric connector D and unscrew the d h w temperature probe B Figure 15 3 4 Reassemble the d h w temperature probe carrying
3. A B Figure 5 1 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water circuit allowing an extra gain of useful heat The condensed vapour is then drained through the condensate trap B and the draining pipe C 5 2 Removal Warning isolate the boiler from the mains electricity A supply before removing any covering or component 1 Disconnect the flue system from the boiler 2 Remove the fan group rubber pipe gas pipe following the instructions from 1 to 6 in section Removal of the Air box and the Fan page 35 3 Disconnect the detection electrode connector D the ignition electrodes connector E and the earth wire F Disconnect the fan connector G by pressing the plastic hook placed on the side of the connector Figure 5 2 Unscrew the nuts H Figure 5 2 Remove the fan burner group I Empty the primary circuit of the boiler Remove the clips J Figure 5 2 Loosen the connection K and slightly move the pipe L up wards turn it towards left Figure 5 2 and then move the pipe downwards freeing it from the Condensing heat exchanger 10 Loosen the connection M and slightly move the pipe N up wards turn it towards left Figure 5 2 and then move the pipe downwards freeing it from the Condensing heat exchanger O 0 N O Oi Figure 5 3 11 Using pliers remove the spring O moving it downwards and disconnect the rubber pipe
4. 27 PRIMARY CIRCUIT FLOW SWITCH 12 PRIMARY CIRCUIT FLOW SWITCH 12 1 Function The Primary circuit flow switch A in Figure 12 1 function is to detect water flow rate through the primary hydraulic circuit of the boiler Figure 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 cir cuit 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 within 20 seconds the control board will indicate that a fault condition see section Operation lights page 19 has occurred 12 2 Checks Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Mechanical function Remove the front panel of the case Start and stop the boiler either in d h w or c h mode Looking through the switch box verify the position of the lever C referring to Figure 12 2 NS Boiler OFF C Boiler ON Figure 12 2 Electrical check It is possible to verify the general operation of the switch by measuring the electric resistance between the contacts D and N O of the switch 1 Remove the switch as explained in section Remo
5. bring the base of the panels away from the boiler and lift them freeing them from the top hooks Figure 2 3 Bottom view of the boiler 2 3 Control panel Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent To gain access to the parts located inside the control panel pro ceed as follows 1 Remove the front panel of the case 2 Loosen the screws C and D Figure 2 3 3 Remove the screws B 4 Move the lower part of the side panels as indicated in Figure 2 4 and pull the control panel When completely pulled out the panel can rotate 45 down wards to facilitate the service operations on the internal parts Figure 2 4 5 Remove the screws E and remove the service panel Figure 2 5 na GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 6 Remove the screws F and remove the control panel lid Fig 2 Remove the front and right panels of the boiler ure 2 5 3 Open the drain tap J Figure 2 8 until the boiler is completely emptied Figure 2 5 2 4 Access to the sealed chamber Figure 2 8 4 To help the draining of the primary circuit loose the condens ing heat exchanger air purger valve K Figure 2 9 Figure 2 6 To gain access to the parts contained in the sealed chamber it is necessary to remove the lid of the sealed chamber For this pur Figure 2 9 pose remove the front and side p
6. Air hose relief valve may Automatic Diverter valve i d s air purger Lo valve Codensate J NEN D hw Flow trap y Switch C h temp p RES Pump probe v Gas valve Main circuit i flow switch V 7 K Control D h w temp panel probe Figure 1 1 1 2 Hydraulic diagram Central heating c h operation gt dre 2 C h water flow C h water return Figure 1 2 Expansion vessel Condensate D h w heat exchanger Domestic hot water d h w operation gt dfe SY i SN P j D h w D h w inlet outlet GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 GENERAL ACCESS AND EMPTYING HYDRAU LIC CIRCUITS 2 1 Nomenclature DX 2 Ll Da 5 Figure 2 1 Right side panel Front panel Control panel lid Control panel cover Service panel Left side panel oa hwnd 2 2 Body panels Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent For the most part of the check and maintenance operations it is necessary to remove one or more panels of the case The side panels can be removed only after the removal of the front panel To remove the front panel remove screws A Figure 2 2 lift the panel and remove it Figure 2 2 To remove the side panels loosen the screws C and D Figure 2 3
7. 10 1 A 1 Remove allthe case panels and the sealed chamber lid see section General access and emptying hydraulic circuits page 5 2 Disconnect the four connectors A 3 Unscrew the screws B and remove the Transformer C by slid ing it forward 4 Reassemble the Transformer carrying out the removal opera tions in the reverse order Warning isolate the boiler from the mains electricity supply before removing any covering or component After reassembling ensure the wires are correctly connect ed see Figure 10 2 clamp for fitting the transformer smaller larger connector connector r a W larger A connector connector Figure 10 2 10 2 Check the transformer Warning isolate the boiler from the mains electricity A supply before removing any covering or component 1 Remove the Transformer see section Removal page 24 2 Measure the electrical resistance of the primary and second ary windings The primary should have a resistance approx 35 ohm and the secondary approx 1 4 ohm 24 GAS VALVE 11 GAS VALVE 11 3 Adjustment Warning isolate the boiler from the mains electrici 11 1 Function ty supply before removing any covering or compo The gas valve A in Figure 11 1 controls the gas inflow to the boiler nent burner Check the supply pressure before making any adjustment to the gas valve MAA 1 Close the gas inlet valve 2 Remove the front panel of the c
8. A 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 from the con trol p c b the electrode swire and the earth wire coming from the ignition electrodes Figure 18 8 spark generator connector Figure 18 8 3 Unscrew the screws O and remove the spark generator 4 Assemble the spark generator carrying out the removal opera tion in reverse order When reassembling the spark generator be sure to connect correctly the wires 18 7 Checks Check of the spark generator Warning isolate the boiler from the mains electricity A supply before removing any covering or component There is not a significant way to verify the integrity of the spark gen erator When the fan turns but the burner does not light a possible cause is a faulty spark generator and it is advisable to replace it to locate the fault Check the position of the electrode edges Warning isolate the boiler from the mains electricity AN supply before removing any covering or component 1 Remove the ignition electrodes see section Removal of the Ig nition and detection electrodes page 36 2 Check for the correct distance between the metallic edges of the ignition electrode see Figure 18 9 Figure 18 10 3 5 mm earth electrode Ignition electrode Figure 18 9 Check the connection wires Warning isolate the boiler from the mains ele
9. By turning the knob 8 the lock out signal lamp 10 blinks quick ly 2 per seconds indicating that the setting has changed and must be memorised O00 DNN o Figure 9 12 Delay minutes Setting No 5 To memorize the setting keep pressed the reset button 9 for about 5 seconds until the lights 11 briefly blinks simultaneously 6 Toreset the boiler to the normal operation turn it OFF and ON by the function selector knob 7 In any case the boiler automatically resets to its normal operation after 10 minutes Factory setting 3 minutes 9 8 Checks M 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 2 and 3 Figure 9 2 are complete If a fuse has blown replace it with one that has the same charac teristics after having identified the reason for failure M 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 cy cles and then after about 3 minutes 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 9 9 Removal of the electronic control p c b Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent When replacing the Electronic control ignitio
10. C B Normally the result of the comparison between these two signals directly operates the fan speed adjusting the useful output gen erated in order to stabilize the temperature of the exiting water If during the d h w mode operation the temperature of the pri mary circuit goes over 90 C the useful output is automatically reduced so that the primary circuit cannot reach excessive tem peratures The control sequences in function and in e function are illustrated in detail in sections 9 10 and 9 11page 23 9 4 Operation lights The Electronic control ignition p c b is provided with three lamps L E D indicators 20 in Figure 9 2 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 lamps in dication and their meaning CE OE Or Boiler in stand by condition function control in position A short pulse every 4 seconds Anti freeze system active Boiler ON condition function control in or position xx xx x ILI LI L 1 second ON 1second OFF With the boiler switched ON 3 or 3 all the lamps 20 in Fig ure 9 2 are activated The following table gives the relationship between each of the possible lamp combinations and their meaning LI DD M0 Dd Normally operating
11. F uoneinpouj 9 uo3u pouui my p uo poeuco sejeJedo 19 10g eu Je9U jou seop Wa shs u o ay pue 235306 Seuoeej PND UIE oO gu ay Jo eunje1eduue BU epoul y o uo WU p yo Buiweip e Buunp u A epouiJ y o ui uonejedo JejnBay dej ay wo 19 em poo NWp Ajddns jou s op 19 10g eu p a v I SIS ese eye SF 2152 Eley El ele ele sie ele ei zl 2 23 3 B S 9S sis ie S s 2 2 mg la 8lazls2 3 2 s 2 9 8 l8 eo 2 s 9e 3 o a S 3 e 2 8 S ma S o S gt lo a o0l3 S 3 I a lt o 3 eR o o n o 3 Ga o 2 m o D o Q D o o E S o m o 3 O gt x 5 p o 3 c o c o o m S 3 lt 8 v 3 E 2 8 3 e 8 5 2 8s8 2 5SiIs 2 3 5 2 lel 3 lt 3 0 c 5 s S o z sj 2zl lo5 S P olal g a lt amp o o a 8g8 3 9 0o gt 3 3 s 5 E o 3 3 8lgio s a MEE o o E a o A 3 a o o 8 z 5 o m o o z S o E 1 5 paje g OVIL ON 2 r e sjayoe q u eJ eyou 026726 Z9 Z 8L ZL OL TSI StLITTLIPIL 66 c8 c1 9 LIT gt lt OL lt enueu ay jo uollb S xoeuo 0 slu uoduloo CONDENSING HEAT EXCHANGER 5 CONDENSING HEAT EXCHANGER 5 1 Function The Condensing heat exchanger A in Figure 5 1 has the function of transferring heat produced from combustion of the gas and from the flue exhausted gas to the water circulating in it a2 AY
12. P Figure 5 3 12 Unscrew the screws O and remove the clamps Figure 5 3 13 Disconnect the two connectors R by pressing the plastic hook placed on the side of the connector Figure 5 3 11 CONDENSING HEAT EXCHANGER 14 Remove the Condensing heat exchanger by levering it and sliding it forwards 15 Reassemble the Condensing heat exchanger carrying out the removal operations in reverse order Ensure to tighten the nuts H Figure 5 2 firmly 5 3 Cleaning If there are deposits of dirt on the coil of the Condensing heat exchanger clean with a bristle paintbrush and remove the dust with a hoover Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a com bustion analysis as detailed in chapter 11 3 section 11 Figure 5 4 Caution After any periodical servicing or disturbance the combustion chamber silicon seal S Figure 5 4 must be fully inspected and replaced at the discretion of the service engineer After any disturbance to the chamber door seal the appliance must undergo a full analytical combustion performance check 12 D H W HEAT EXCHANGER 6 D H W HEAT EXCHANGER 6 1 Function The d h w heat exchanger A in Figure 6 1 and Figure 6 3 allows the instantaneous transfer of heat from the primary hydraulic cir cuit to the water destined for d h w use nsncrZ o d
13. W HEAT EXCHANGER 13 6 1 FUNCION aorta s main sach pret tens 13 6 2 Removal 22 aeree Ra uet pps i 13 TO PUMP u uma sua a wax TAAN ieee 14 7 1 FUNCION acatar E 14 1 2 GIG COMMENT O Gaga m 14 7 3 Removal sare arca aaa pillas 14 8 THREE WAY DIVERTER VALVE 15 8 1 FUNCION aitor dre 15 8 2 2 C 15 8 3 Removal of the electric actuator 15 8 4 Removal of the diverter group and its internal parts 16 9 ELECTRONIC CONTROL IGNITION P C B 17 9 1 FUNCION RP 17 9 2 Selection and adjustment devices 17 9 3 Checking the temperature 18 94 Operation lights 2e cam ee ha eae 19 9 5 Setting the boiler control function modes 19 9 6 X Adjustment of maximum useful output in c h mode 19 9 7 Reignition frequency setting 20 9 8 CHECKS Rm 20 9 9 Removal of the electronic control p c b 20 9 10 Thermal control in the 8 amp mode nece 22 9 11 Thermal control in the Gk MOJO AH 23 10 TRANSFORMER 24 10 1 Removal lt cocino el koa ta be e bands 24 10 2 Check the transformer u uuu usasqa a Q co 24 11 GAS VALVE iiss cede een EAR EH mnsa aga 25 11 4 Function sau us den sus usus pusha puqu a 25 11 2 Nomenclature of the parfs 25 11 3 Adjustment sde ii doe oa oo 25 IA Checks odio ia oe 2
14. boiler 20 O see the previous table for details CO OX C h operation O O IQ D h w operation QE O O Frost protect operation X D h w operation O O Cx Excessive temperature on primary circuit Q O Xx Faulty c h temperature probe NTC Q xx O Faulty d h w temperature probe NTC MV Faulty primary circuit Cx e o no water or absence of flow xXx O O Lack of burner ignition eo Cx X Safety thermostat lock out i O O Faulty fan control system TA LI DU M O O C Flue temperature probe NTC lock out O O E Open flue temperature probe NTC Faulty external temperature probe NTC Ole vty STN vty STN A TA Flame detection error Lack of power supply or faulty electronic control p c b o o e o e o Faulty Electronic control ignition p c b Lamp OFF e O Lamp ON Flashing lamp alone or simultaneously with another lamp ISP TN JN 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 Drs Flashing lamp alternate with another lamp 9 5 Setting the boiler control function modes It is possible to select the various boiler control function modes by using the function selector knob 7 and the D h w temperature control knob 8 Figure 9 5 During the function modes setting the boiler does not
15. side of the boiler Figure 6 5 ND PUMP 7 PUMP 7 1 Function The pump A in Figure 7 1 and Figure 7 2 has the function of mak ing the water in the main circuit circulate through the main con densing heat exchanger and therefore through the c h system during the c h function or through the secondary heat exchang er during the d h w function Figure 7 1 7 2 Checks Warning isolate the boiler from the mains electricity A supply before removing any covering or component M Check that the pump is not seized and that the movement of the rotor is not subject to mechanical impediments With the boiler off remove the front panel Remove the air re lease plug of the pump and turn the rotor with a screwdriver Check the electrical continuity With the boiler off remove the front panel and disconnect the connector B Figure 7 2 Measure the electrical resistance between the pump supply con nections Electrical resistance of the windings at ambient temperature must be about 230 Q Y Check the absence of starting defects With the boiler off remove the front case panel Remove the air release plug from the pump Start the boiler and with a screwdriver turn th
16. the CO value It should be between 9 0 and 9 8 natural gas G20 or between 10 0 and 11 0 LPG G31 To adjust the CO value remove the brass plug by unscrewing it and rotate the Allen key screw 4 mm C Figure 11 2 by rotating it clockwise the CO increases Checking the maximum gas valve setting 22 Set the knob 8 to the maximum position as illustrated in Fig ure 11 4 23 Allow the analyser to give a stable reading 24 Read the CO value It should be between 9 0 and 9 8 natural gas G20 or between 10 0 and 11 0 LPG G31 To adjust the CO value rotate screw B Figure 11 2 by rotating it clockwise the CO decreases 25 Switch off the boiler and turn off the hot water tap s 26 Close the air flue sampling points 27 After adjustment fit the protective brass plug C Figure 11 2 Important after the gas pressure checks and any adjust ment operations all of the test points must be sealed 11 4 Checks Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Check the on off operators coils Remove the front panel of the case Disconnect the electrical connector E Figure 11 2 Measure the electrical resistance between the connector pins of the on off operators as illustrated in Figure 11 7 Zn AN Upper on off operator approx 6400 O Lower on off operator E approx 920 O at ambient temperature Figure 11 7 11 5 Removal
17. the air gas mixture and consequently the input power of the boiler is proportional to the speed of the fan that is controlled by the electronic control p c b d E 9 Figure 17 1 17 2 Removal of the Air box and the Fan Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent Turn off the gas supply 2 Remove all the case panels and the sealed chamber lid see section General access and emptying hydraulic circuits page 5 Figure 17 2 3 Disconnect the air manifold C Figure 17 2 by pulling it Fan gasket Figure 17 3 4 Disconnect the rubber pipe G Figure 17 3 Figure 17 4 5 Unscrew the gas connector M Figure 17 4 6 Remove the fixing fork H and remove the gas pipe I Figure 17 3 7 Loosen without removing the screw J 8 Remove the screws K and the air box L Leave the air box with the air manifold clamped to the water pipe 9 Disconnect the fan connector K by pressing the plastic hook placed on the side of the connector Figure 17 2 10 Unscrew the screws D Figure 17 2 11 Remove the fan E 12 Assemble the Fan and the Air box carrying out the removal operations in reverse sequence B
18. the p c b is handled with care and held at the edges and with clean dry hands 8 Fitthe p c b into the control panel by first inserting the front lower 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 notch A Figure 9 14 reaches the potentiometer edge It is not neces sary to force them in the knob 10 While tightening the screws that fix the Electronic control igni tion p c b on the control panel keep the p c b towards the control panel fascia making sure of the contact between the boiler reset button B and the tab C Figure 9 14 Figure 9 14 Attention After installing the Electronic control ignition p c b 11 Make sure the c h 81MK and d h w BEA temperature ad justment 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 12 Make sure that the settings comply with the indications given in section Setting the boiler control function modes page 19 13 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 button by pressing and releasing it above if it deemed necessary to undertake a com bustion analysis as detailed in section Removal page 28 T Warning After cleaning or replacement a
19. 000281 da ain e a is TAS 36 18 2 Removal of the Ignition and detection electrodes 36 18 3 Removal of the burner 36 18 4 Removal of the front insulation panel 37 18 5 Removal of the rear insulation 37 18 6 Removal of the spark generator 38 18 7 Checks cos reo a span a Ad Santee eda 38 19 SAFETY THERMOSTAT 39 19 14 FUNCION iic sl nayan A Y Eis 39 19 2 CHECKS seb Sisco vehe Rer ente a RUE 39 19 3 Removal 5 hien ER eet han eee d Rx 39 20 FLUE TEMPERATURE PROBE NTC AND SAFETY THER MAL FUSE 2522s ee indole d 40 20 1 IF lictiom is cae ecce Mes aes en E do epe d eed 40 20 2 Removal os inicia d ca aces dee m tono Ere ido dg 40 20 3 GHECKS ici vise a bp vo nee med eade d 40 21 CONDENSATE TRAP 41 21 1 TEU CHOM catala lata tdt 41 21 2 Check the cleanness of the trap 41 210 Rermovalku au incas pe 41 22 SHORT SPARE PARTS LIST 42 OVERALL INFORMATION 1 OVERALL INFORMATION 1 1 Overall View Flue temperature probe NTC Z Safety thermal a fuse Condensing heat dii p exchanger air 4 Condensing purger valve E heat exchanger ens AN W Ignition in mt electrodes Detection b electrode Jl AM Spark LY Generator da ransformer Safety thermostat Rem Gas restrictor S A x Fan C h pressure
20. 2SM 5 8 19 789 8 2 27 977 9 0 30 707 12 4 42 307 12 2 41 625 16 5 56 296 15 5 52 884 20 7 70 626 18 7 63 802 24 8 84 614 3 Knob position 21 9 74 720 29 0 98 944 25 1 85 638 33 1 112 933 Figure 9 9 5 To memorize the setting keep pressed the reset button 9 for about 5 seconds until the lights 11 briefly blinks simultaneously 6 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob 7 In any case the boiler automatically resets to its normal operation after 10 minutes 9 7 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 selector knob 7 as indicated in Figure 9 10 Figure 9 10 2 Keep pressed the reset button 9 for about 10 seconds until the lock out signal lamp 10 blinks 3 The lamps 11 should give the indication as in Figure 9 11 reignition frequency If not press the reset button repeat edly to obtain it O O were O Lamp OFF LJ 00 000 O Lamp on Figure 9 11 At this step it is possible to visualize the current setting by keep ing the reset button 9 pressed for more than 5 seconds The lamps will flash a number of times corresponding to the setting Figure 9 12 4 To change the setting turn the knob 8 on a position corre sponding to the desired delay
21. 6 11 5 Removal of the gas valve 26 12 PRIMARY CIRCUIT FLOW SWITCH 28 124 function ici ee e ie E a 28 122 CHECKS Ee 28 128 Removal 1 22 ci iii A e 28 13 EXPANSION VESSEL AND TEMPERATURE PRESSURE GAUGE idu us are EAN N i oe RARE a 30 NSl Dele ER T CERERI TETTE dci dad 30 EPA A O 30 13 3 Removal of the expansion vessel 30 13 4 Removal of the temperature pressure gauge 30 14 D H W FLOW SWITCH FILTER AND FLOW LIMITER 31 14 1 FUNCION ERE 31 14 2 Nomenclature and location of partS 31 14 3 o MEC 34 14 4 Removal ofthe sensor 31 14 5 Removal of the flow switch group and d h w circuit filter 31 146 Flow limiter s oossoo RR 32 15 TEMPERATURE PROBE 33 15 1 FUNCHOMNG L2 Cta LEID Quen t a Ree eae 33 15 2 CHECKS oc dod RE Dre Pe e ede xe eg 33 15 3 Removal of the c h Temperature probe 33 15 4 Removal of the d h w Temperature probe 33 16 BY PASS VALVE RR RR rated awe rane 34 16 4 FUNCION cs aa i bi ay td isa aswa eae ae us 34 162 Removal 4 RM e uama eae ua a 34 17 FAN AND AIR BOX 35 IZA FUNCION ty cerdos eR a geh e e EU ee 35 17 2 Removal of the Air box and the Fan 35 18 IGNITION AND DETECTION ELECTRODES BURNER AND SPARK GENERATOR 36 18 1 FUNCION 2
22. Fan gy bu blue bk black Ignition Flame detection h white lectrode gy aerd electrodes elec Flue Safet gy grey M temperature thermostat gn green probe NTC Time switch ye yellow vt violet 4 og orange wh gnye green yellow rdwh red white Safety thermal fuse Figure 3 1 DIAGRAMS 3 2 Circuit voltages during c h or d h w operation Electrical voltages with burner on C only during c h operation O only during d h w operation H Pump 3 S way D h w diverter valve Flow switch gt Gas valve Supply network amp N o e N x xP s Jo X11 X10 x7 X17 2 Fa K2 e o x3 X16 a T3 E 2 X15 N raul S X23 S X6 a x x2 X24 i P6 P3 LD4 a LEE O o i q N Y Safety Transformer Fan Main circuit thermostat pressure switch Figure 3 2 FAULT FINDING FAULT FINDING 4 uonouni w u p uo uone1j do eLLION 9 Wo UO eJIuM POUS e JO SIUPI
23. Jejioq eu Uo uo p9e4100 sejeJedo 19 10g eu euJej BU JO uone npoui ay UO 158 JJ8 usey Jour jueunsn pe duu m y p ay Buluan eanje1eduje N Wp ay lonuoo 1 us op 19 10g eu L UI j useop ue epou Wu p 10 Wo Ul Jayye JUDI j useop jeuunq eu L suin Uey epoui Wu p 10 Wo Ul Jayye JUDI j useop jeuunq eu L Ins uey 340 siufi uonejedo y iv Pow A u p JO y o ul JOULE yej s JOU seop 19 10g ay ureBe syoo Jajiog ay pue uo s3yB1 jeuung eu L ejoKo uoniuBi ay suejs 1e oq eui uognq usnd jasa ay Bursseud Ag ureBe sy90 Jejoq ay pue uo 3461 usaop jeuunq eu ay9 9 uoniuBi ay suejs 19 10g eui uognq usnd jasa ay Bursseud Ag Ape 109 sejeJedo pue UO suun Je ioq ay uognq usnd jasa ay Bursseud Ag RII ELEP t pajeq mua 1 SS IS manek N N L l L T sammal a L ma n men O S TL T vammaa m RR to ssa ll uma 1 x L TL T T T x m 11 T mel L T T T N cs fe m x 9 2 o o 5 lt o n n y ye souu u Ajejes sjox9e 1q UI ya ejou lt enueu ay jo uonoas SN oo N N B ero w ju 281 ZL Ob CSL GVlLiccliv bt yoayo 0 sjueuodulo2 L OZ 2 sa ja e pj E masm m ja ja ja E we a j vi o o x o e lt 5 5 Q lt o c O o A 181 FAULT FINDING u
24. N VESSEL AND TEMPERATURE PRESSURE GAUGE 13 EXPANSION VESSEL AND TEMPERATURE PRESSURE GAUGE 13 1 Function The Expansion vessel B in Figure 12 1 function is to allow for the volume expansion of the c h circuit water due to the tem perature rise 13 2 Checks 1 Turn off the flow and return isolation valves and empty the primary circuit of the boiler 2 Remove the protective cap K Figure 13 1 from the valve on the top of the expansion vessel and connect a suitable air pressure gauge Figure 13 1 Rear view of the boiler 3 Check the pre load pressure and refer to the section Expan sion vessel in the User manual and installation instructions for the correct value 13 3 Removal of the expansion vessel If there is at least 400 mm clearance above the boiler and the rear exit flue can be easily removed the expansion vessel can be changed without removing the boiler Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 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 L the locknut M Figure 13 2 and remove the expansion vessel from the top of the boiler 30 Figure 13 2 3 Re assemble the parts in reverse order of removal 13 4 Removal of the temperature pressure gauge 1 Remove the front and right hand side panels of the case t
25. Wall hung fanflue roomsealed high efficiency gas boiler Service manual GARDA PLUS HE Models G C Appl No M110B 24SM E 4T 583 13 M110B 32SM E 47 583 14 Leave this manual adjacent to the gas meter Warning Service repairs must be carried out only by a qualified Gas Safety Registered Engineer who will be responsible for the current Regulations for gas appliances Note After servicing complete the relevant Service Interval Record section of the Benchmark Checklist of the user and installation manual ABIASI TABLE OF CONTENTS 1 OVERALL INFORMATION 4 14 Overall VIEW nessspik as hls 4 1 2 Hydraulic diagram s usa o gee mmn 4 2 GENERAL ACCESS AND EMPTYING HYDRAULIC CIR GUITS Lugu Sisaqa squa as a Rame qoa name Saa a wade 5 24 Nomenclature 5 2 2 Body Panels AM meu esee rosae E E etos sea 5 2 3 Control panela e omncs Coa Susan sata ds 5 2 4 Access to the sealed chamber 6 2 5 Emptying the primary circuit 6 2 6 Emptying the d h w circuit llle 6 3 DIAGRAMS i A RR e KON wade 7 3 1 Wiring diagram M110B 24SM M110B 32SM 7 3 2 Circuit voltages 2 lle mnm Rem Rte ena 8 4 FAULTFINDING 9 5 CONDENSING HEAT EXCHANGER 11 5 1 FUNCION EDD 11 5 2 Removal 1 saa at lod 11 5 3 O uu u uy apus yau ERE FRE Rd VES 12 6 D H
26. anels of the case remove the Screws G as indicated in Figure 2 6 and remove the lid Attention some water could remain in the condensing heat exchanger 2 5 Emptying the primary circuit 5 Close drain tap once the emptying has been completed 1 Close the c h circuit flow and return cocks H Figure 2 7 2 6 Emptying the d h w circuit 1 Close the d c w inlet cock I Figure 2 7 2 Open one or more hot water taps until the boiler has been completely emptied Figure 2 7 Bottom view of the boiler 6 DIAGRAMS 3 DIAGRAMS 3 1 Wiring diagram M110B 24SM M110B 32SMI Electric supply Three wa terminal block dive ci vale e LON C h temperature External controls probe NTC terminal block x M N 3 Gas valve bngnyebu 3 2 1 Pump nec D h w flow switch bn bu X10 EN oKuB sAub c bu bn bu bn ae Em lt bu Je x24 p 1 wh P6 bn bn bu bu bn bu ij 3 NITA Po 38 OM ES 9 rd U m a Transformer Primary circuit 230V 24V og wh bk flow switch gy wh bn brown
27. ase and lower the control panel see sections Body panels and Control panel page 5 3 Loosen the internal screw on the Inlet Pressure Test Point F Figure 11 2 of the Gas valve and connect a pressure gauge using a suitable hose 4 Open the gas inlet valve 5 Turn on the electricity supply to the boiler switching 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 Figure 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 in stallation manual If it does not comply with the required pres sure 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 n ccn N Figure 11 1 water tap 10 Disconnect the pressure gauge and close the Inlet Pressure By means of an electric command given to the on off operators Test Point F Figure 11 2 the passage of the gas through the Gas valve can be opened or closed Gas valve adjustment The person carrying out a combustion measurement A should have been assessed as competent in the use of 11 2 Nomenclature of the parts a flue gas analyser and the interpretation of the re Figure 11 2 sults The flue gas analyser used should be one meet B Maximum gas pressure adjustment ing the re
28. ctricity A supply before removing any covering or component Figure 18 10 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 generator and to the control ignition p c b Warning Insulation panels material handling care Mineral fibres are used in this appliance for the insulation panels of the combustion chamber Excessive exposure to these materials may cause temporary irrita tion 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 Precautions 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 gen eral 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 38 SAFETY THERMOSTAT 19 SAFETY THERMOSTAT 19 1 Function The safety thermostat A in Figure 19 1 is a device that senses the temperature of the primary circuit water which flows in the outlet pip
29. d M110B 24SM 1 BI1955 100 Bertelli amp Partners H58 718 Electronic regulation p c b mod M110B 32SM 1 BI1955 101 8 H22 543 D h w heat exchanger M110B 24SM 1 BI1181 122 E01 205 D h w heat exchanger M110B 32SM 1 BI1001 102 9 H58 670 Pump 1 BI1911 103 10 H32 555 Primary circuit flow switch 1 Bl1251 501 11 169 010 D h w flow switch 1 KI1042 107 12 E00 688 Main flow switch membrane 1 BI1011 103 13 E83 086 Three way diverter valve electric actuator 1 BI1101 102 Elbi 14 E83 101 Overheat thermostat 1 BI1172 105 ELTH type 261 15 H58 661 Flue temperature probe NTC 1 BI1432 102 16 H44 170 Fuse 3 15 AF 2 BI1295 108 17 H58 716 Fuse 400 mAT 1 BI1665 104 18 1164 026 Temperature probe main or D h w circuit 2 KI1001 117 19 H58 709 Detection electrode 1 BI1293 103 20 H58 680 Ignition electrode 1 BI1293 102 21 E83 145 Temperature pressure gauge 1 BI1475 108 IMIT 42 SHORT SPARE PARTS LIST j ca ex J I N N j a y J Vi LLL Ih x E e N P N dn 4 x AT Ki Ea j Figure 22 1 LIKA NT EU I IU ANI A 17962 1455 0 0412 4444 UK Biasi UK Ltd Commercial Road Leamore Enterprise Park WALSALL WS2 7NQ Sales Tel 01922 714600 Tech Service Tel 01922 714636 www biasi co uk
30. d Figure 9 16 show the sequence of the opera tions that are carried out at the start of every ignition cycle and during normal functioning 9 2 Selection and adjustment devices On the Electronic control ignition p c b several selection adjust ment and protection devices are located Figure 9 2 Some of these devices are directly accessible by the user func tion control temperature adjustment potentiometers etc others like the fuses are accessible by removing the service panel sA ELECTRONIC CONTROLIIGNITION P C B 20 Figure 9 2 19 18 1716 15 14 1 x7 x16 connector electric supply terminal block and exter nal controls terminal block Fuse F1 F23 15 AF Fuse F3 400 mAT x15 connector flame detection electrode x12 connector pump and 3 way diverter valve x17 connector gas valve x14 connector external temperature probe optional x9 connector safety thermostat flue temperature probe NTC c h temperature probe NTC 9 x11 connector d h w temperature probe 10 x10 connector d h w flow switch 11 x13 connector remote control optional 12 x2 connector timer 13 Lock out signal lamp 14 Boiler reset button 15 Function control C h temperature adjustment 16 x22 connector fan 17 x6 connector spark generator 18 D h w temperature adjustment 19 x5 x24 connector transformer 20 Appliance operation lights 0 4 0 0 ON 9 3 Checking the temperature The Electronic cont
31. d c h 2 Allow the boiler to reach its maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain a temperature below that of the Flue temperature probe NTC and no overheat intervention should occur 4 Temperature resistance relationship 1 Remove the Flue temperature probe NTC section Removal page 40 2 Measure the Flue temperature probe NTC electrical resistance at the ambient temperature and check it according to the graph in Figure 20 4 Q 12500 12000 11500 11000 10500 10000 o 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Figure 20 4 40 CONDENSATE TRAP 21 CONDENSATE TRAP 21 1 Function The condensate trap A in Figure 21 1 and Figure 21 2 allows the discharge of the condensate via the condensate drain pipe avoiding in the mean time the escape of combustion products A plastic ball closes the trap outlet in case that the trap is empty 1 N y g j m a c HZ 1 a ji S H El lt lt D lt A A X Figure 21 1 If the drain pipe becomes blocked or condensate cannot drain the co
32. e of the condensing heat exchanger If the temperature control system of the boiler fails and the tem perature of the primary circuit reaches a dangerous temperature the safety thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp Figure 19 1 19 2 Checks YM 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 Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent J Electrical function 1 Remove all the case panels and the lid of the sealed cham ber 2 Disconnect the safety thermostat and check its electrical function Normally no intervention the contact must be closed electrical resistance zero Q 19 3 Removal Warning isolate the boiler from the mains electric
33. e rotor in the direction of the arrow If there is a defect in starting the rotor will begin to turn normally only starting it manually Check that the impeller is integral with the rotor With the boiler off remove the front and right hand side case pan els lower the control panel and empty the primary circuit Remove the pump head by undoing the screws which hold it to the pump body and check that the impeller is firmly joined to the rotor 7 3 Removal Warning isolate the boiler from the mains electricity A 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 Figure 7 2 Loosen the connection C and pull up and turn to the left the pipe D Q Q N Figure 7 2 6 Remove the locking plate E 7 Unscrew the two screws F that hold the pump on the frame and remove the pump Reassemble the pump carrying out the removal operations in the reverse order When reassembling the pump check the correct location of the O ring gasket in the inlet port of the pump that seals the connection between the pump and the plastic group 14 THREE WAY DIVERTER VALVE 8 THREE WAY DIVERTER VALVE 8 4 Function The diverter valve A Figure 8 1 has the function of modifying the hydraulic circuit of the boiler by means of an electric command given by the el
34. ectronic control p c b in order to send the water that exits the primary heat exchanger towards the c h system or towards the d h w heat exchanger L dl lt NS N Figure 8 1 8 2 Checks A Warning check the electrical continuity Figure 8 2 indicates the relationship between the electric com mand coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in d h w mode Figure 8 3 indicates the relationship between the electric com mand coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in c h mode In both figures the relationship between the position of the actua tor and the resistance of the motor windings the motor must be disconnected from the wiring is also given Spindle B not visible 9 4 Kohm rd red Open circuit bk black p wh white FC gt g gt No Figure 8 2 D h w mode Spindle B visible Bo Open circuit rd red 9 4 Kohm bk black S xv i a 2 wh white gt gt o 8 Figure 8 3 C h mode 8 3 Removal of the electric actuator Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove the front case panel 2 Disconnect the connectors C Figure 8 4 3 Remove the fixing spring D and remove the actuator E Reassemble the act
35. efore reassembling ensure the fan gasket Figure 17 3 is correctly mounted Warning After cleaning or replacement as detailed A above it is deemed necessary to undertake a com bustion analysis as detailed in section Adjust ment page 25 35 IGNITION AND DETECTION ELECTRODES 18 IGNITION AND DETECTION ELECTRODES BURN ER AND SPARK GENERATOR 18 1 Function Three electrodes are fitted on the fan burner group Two of them fitted on the right side of the fan burner group A are the ignition electrodes B and are connected to the spark generator C On the left side is the detection electrode D and it detects the pres ence of the flame Figure 18 1 The burner K is fitted on the rear of the fan burner group A ttt Tamma Kummun Figure 18 2 18 2 Removal of the Ignition and detection electrodes Warning isolate the boiler from the mains electricity A supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid see section General access and emptying hydraulic circuits page 5 2 Disconnect the ignition electrodes connector E and the earth wire F from the spark generator C Figure 18 1 and disconnect the detection electrode connector G 3 Unscrew the screws H and remove the ignition electrodes B and the detection electrode D Figure 18 1 4 Assemble the Ignition and detection electrodes carrying o
36. guirements of BS7927 or BS EN50379 3 and C Minimum gas pressure adjustment be calibrated in accordance with the analyser manu D On off operators facturers requirements and have a current calibration E On off operators electric connector certificate F Gas valve inlet pressure test point j 11 Fit the probe of the flue analyser in the flue exhaust sampling point located on the exhaust pipes of the boiler Figure 11 3 air sampling flue exhaust points sampling points Figure 11 2 Figure 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 8 as indicated in Figure 11 4 The ap pliance operation light on the left will flash every 4 seconds 25 GAS VALVE Figure 11 4 15 Keep pressed the reset button 9 for about 10 seconds Figure 11 4 until the lock out signal lamp 10 blinks 16 The lamps 11 should give the indication as in Figure 11 5 e O C Where C Lamp OFF O00 00 O Lamon Figure 11 5 17 Release and keep the reset button 9 pressed for more than 5 seconds until the lock out signal lamp 10 is switched off The boiler will now go through an ignition sequence and the burner will light 18 Open at least one hot water tap fully Adjusting minimum gas valve setting 19 Set the knob 8 to the minimum position as illustrated in Figure 11 6 Figure 11 6 20 Allow the analyser to give a stable reading 21 Read
37. he electrical resistance at 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 O 14 4 Removal of the sensor Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front panel of the case 2 Disconnect the connectors B and remove the sensor holder spring 7 Figure 14 2 Figure 14 3 3 Remove the sensor 14 5 Removal of the flow switch group and d h w circuit filter Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front panel of the case and empty the d h w circuit 2 Remove the sensor see section Removal of the sensor page 31 3 Remove the fork D and pull up the flow switch plug 1 Figure 14 2 Figure 14 3 with the help of a screwdriver 4 To remove the filter from the flow switch group separate the filter 6 from the body 4 Figure 14 3 by levering it 5 Reassemble the parts following the removing sequence in reverse order 31 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 6 Flow limiter The M110B 24SM model is factory fitted with a 10 litre min flow limiter If on the M110B 32SM model the flow rate of the d h w circuit is too high it is possible to limit it by installing a flow limiter The following sizes are available N
38. i ty supply before removing any covering or compo nent 1 Remove all the case panels and the lid of the sealed cham ber 2 Disconnect the wiring B detail in Figure 19 2 3 Unscrew the screws C which hold the overheat thermostat on the pipe of the condensing heat exchanger and remove it Figure 19 2 4 Reassemble the overheat thermostat carrying out the opera tions in reverse order 5 Apply an adequate quantity of heat conducting compound between the pipe and the thermostat above if it deemed necessary to undertake a com bustion analysis as detailed in section Adjust ment page 25 T Warning After cleaning or replacement as detailed 39 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE 20 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE 20 1 Function The Flue temperature probe NTC A in Figure 20 1 and Figure 20 2 senses the temperature of the combustion products that flow through the condensing heat exchanger Figure 20 1 Ifthe temperature of the combustion products circuit reaches the limit temperature the Flue temperature probe NTC reduces the gas flow rate to the burner The temperature of the combustion products should decrease to a safe value temperature In the ca
39. lead to the ignition of the gas at the burner It checks the presence of the flame during the entire period in which it is activated and supplies the fan regulating its speed The Electronic control ignition p c b has a safety function and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler The Electronic control ignition p c b can lock the functioning 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 acti vate the lock state The causes of a lock state could be The intervention of the safety thermostat overheat of the pri mary circuit The intervention of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wiring or connection Faulty flame detection faulty detection electrode its wiring or connection Faulty condensate drainage Faulty gas valve faulty on off operators or not electrically supplied Faulty Electronic control ignition p c b Other components like the primary circuit flow switch can tempo rarily stop the ignition of the burner but allow its ignition when the cause of the intervention has stopped Figure 9 15 an
40. n p c b it is ad visable to go through the setting modes of the boiler here described in sections 9 5 to 9 7 20 ELECTRONIC CONTROLIIGNITION P C B The spare electronic control ignition p c b is set for natural gas If the boiler is fed with different gas type go through the Gas conversion operations described in the Installation manual If an external temperature probe optional is fitted the coef ficient K has also to be set as described in the Commission ing chapter of the installation manual 1 Gain access to the parts located inside the control panel as explained in the section Control panel page 5 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 temperature ad justment knobs by delicately pulling them with pliers in the direction shown by the arrow in Figure 9 13 DES ok s Figure 9 13 4 Unscrew the four screws that hold the Electronic control igni tion 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 reverse order Important When re assembling the Electronic control ignition p c b 7 Itis not necessary to utilise static protections but it is advis able to ensure that
41. n panel See warning note at the end of this chapter before to remove this part 1 Remove the Ignition and detection electrodes see section Re moval of the Ignition and detection electrodes page 36 2 Remove the burner see section Removal of the burner page 36 3 Remove the front insulation panel Figure 18 6 4 Assemble the new front insulation carrying out the removal op eration in reverse order When fitting the new panel ensure that the electrodes holes coincide with the holes of the combustion chamber g front insulation Figure 18 6 Caution After any periodical servicing or disturbance the combustion cham ber silicon seal Figure 18 6 must be fully inspected and replaced at the discretion of the service engineer After any disturbance to the chamber door seal the appliance must undergo a full analytical combustion performance check 18 5 Removal of the rear insulation See warning note at the end of this chapter before to remove this part Attention Cover the inner of the condensing heat ex A changer to avoid that dirt and debris fall in the coil 1 Do the operations of section Removal of the burner page 36 from step 1 to step 3 2 Unscrew the screw L remove the washer M and the rear insula tion N Figure 18 7 Figure 18 7 237 IGNITION AND DETECTION ELECTRODES 18 6 Removal of the spark generator Warning isolate the boiler from the mains electricity
42. ndensate level it the trap rises until it reaches the screw at tached to the flame detection electrode this will cause the boiler lock out 21 2 Check the cleanness of the trap Unscrew the plug on the bottom of the trap and remove dirt even tually deposit 21 3 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove the front and left case panels 2 Disconnect the trap from the draining pipe 3 Using pliers remove the spring B moving it upwards and re move the flexible pipe C 4 Unscrew the screw D and remove the trap 5 Unscrew the lock nut E and separate the trap from its bracket 6 Reassemble carrying out the removal operations in reverse order Figure 21 2 44 SHORT SPARE PARTS LIST 22 SHORT SPARE PARTS LIST Key G C part no Description Q ty E SI 1 H58 688 Burner mod M110B 24SM 1 BI1293 100 H58 689 Burner mod M110B 32SM 1 BI1293 101 2 E94 576 Expansion vessel 1 BI1182 105 CIMM 7 litres 3 H58 659 Condensing heat exchanger mod M110B 24SM 1 BI1432 100 H58 660 Condensing heat exchanger mod M110B 32SM 1 BI1432 101 4 H58 702 Fan 1 BI1293 105 EBM RG128 24V 54W 5 H58 694 Gas valve 1 BI1293 104 SIT 848 Sigma 6 H50 189 Safety valve 1 BI1181 100 Watts Orkly alternative 7 H58 717 Electronic regulation p c b mo
43. of the gas valve Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent 1 Remove the front panel of the case as explained in the sec tion Control panel page 5 and the sealed chamber lid 2 Remove the screw G and disconnect the connector H Figure 11 8 Figure 11 8 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve 4 Using pliers remove the spring and the rubber pipe J Fig ure 11 8 5 Unscrew the connector K Figure 11 8 remove the fixing fork L and remove the pipe M Figure 11 9 LOG GAS VALVE Figure 11 9 6 Unscrew the screws N and remove the valve Figure 11 10 7 Reassemble the valve carrying out the removal operations in reverse order Figure 11 10 Before fitting a new gas valve it is advisable to pre set it as hereafter explained 8 Remove the brass plug and turn the plastic screw inside it fully clockwise until it stops Do not over tight 9 Turn it counter clockwise 2 and 3 4 turns 10 Adjust the gas valve using the flue analyser as described in section Adjustment page 25 After any service operation on the components of the gas circuit check all the connections for gas leaks above it is deemed necessary to undertake a com bustion analysis as detailed in section Adjust ment page 25 1 Warning After cleaning or replacement as detailed
44. ominal flow rate litres min Colour 10 Blue 12 Red 14 Pink To install the flow limiter 1 Remove the flow switch group as explained in the section Removal of the flow switch group and d h w circuit filter page 31 2 Separate the flow switch plug 1 from the body 4 Figure 14 4 levering with a screwdriver one of the two hooks Figure 14 4 3 Insert the flow limiter 3 as shown in Figure 14 3 4 Reassemble the group following the above sequence in re verse order 32 TEMPERATURE PROBE 15 TEMPERATURE PROBE 15 1 Function The Temperature probe has the function of converting the tem perature of the water in the hydraulic circuit where it is installed into an electrical signal resistance The relation between temperature and electrical resistance is stated in Figure 15 1 Q 12500 12000 11500 11000 10500 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Figure 15 1 On the boiler there are two Temperature probes One on the out put of the primary heat exchanger c h Temperature probe A in Figure 15 2 and Figure 15 3 one on the output of the d h w heat exchanger d h w Temperature probe B in Figure 15 2 E
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46. operate at 2 7 11 8 7 Figure 9 5 00000 9 6 Adjustment of maximum useful output in 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 maxi mum 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 selector knob 7 as indicated in Figure 9 6 Figure 9 6 2 Keep pressed the reset button 9 for about 10 seconds until the lock out signal lamp 10 blinks 3 The lamps 11 should give the indication as in Figure 9 7 maximum c h useful output adjustment If not press the reset button repeatedly to obtain it 19 ELECTRONIC CONTROLIIGNITION P C B eoe O O wee O Lamp OFF LJ 00 000 O Lamp on Figure 9 7 At this step it is possible to visualize the current setting by keep ing the reset button 9 pressed for more than 5 seconds The lamps will flash a number of times corresponding to the setting Figure 9 8 and Figure 9 9 4 To change the setting turn the knob 8 on a position corre sponding to the desired maximum useful output Figure 9 8 and Figure 9 9 By turning the knob 8 the lock out signal lamp 10 blinks quickly 2 per seconds indicating that the set ting has changed and must be memorised Maximum useful output in c h mode non condensing kW BTU h M110B 24SM M110B 3
47. out the removal operations in reverse order CA Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities 33 BY PASS VALVE 16 BY PASS VALVE 16 1 Function The By pass valve A in Figure 16 1 is located between the c h water flow and return and its function is that of guaranteeing a minimum flow across the primary heat exchanger if the circula tion across the c h system is completely closed The By pass valve is fitted on the rear side of the diverter group L dl lt gt N Figure 16 1 16 2 Removal Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent k Remove all the case panels 2 Empty the primary circuit of the boiler 3 Remove the diverter group as described in the section Re moval of the diverter group and its internal parts page 16 4 Unscrew the connector B and remove the by pass valve C Figure 16 2 Figure 16 2 4 Reassemble the by pass valve as illustrated in Figure 16 2 reversing the order of removal 34 FAN AND AIR BOX 17 FANAND AIR BOX 17 1 Function The function of the Fan A Figure 17 1 is to force the mixture of air and gas into the burner The function of the Air box B is to mix the gas and the air in the right proportion The flow rate of
48. rol ignition p c b makes it possible to sepa rately adjust the c h water flow temperature and d h w outlet temperature The temperature of the water is converted into an electric signal by means of temperature probes The user setting the desired temperature with the control panel knobs operates the variable elements 15 and 18 in Figure 9 2 of the electronic control p c b If the power requested is lower than 40 of the maximum power output then control is achieved by switching 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 4096 of the maximum power output During the c h operation Figure 9 3 the signal coming from the c h temperature probe is compared to the signal given by the control panel through the adjustment made by the user knob 8mm 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 When the boiler functions in d h w Figure 9 4 the signal com ing from the d h w temperature probe is compared with the sig nal given by the control panel through the adjustment made by the user knob BEA Figure 9 4 18 ELECTRONIC CONTROLIIGNITION P
49. s detailed 24 ELECTRONIC CONTROLIIGNITION P C B 9 10 Thermal control in the mode Switch in the E function mode Taking water from the domestic ho water circuit YES gt circulator on NO circulator off fan still 6 YES J stop circulator 3min Is primary circuit NO Operation lights temperature higher than that selected Main circuit pressure switch consense L YES YES Oe O N NO YES NO lock memorised L cancels lock starts fan checks fan rpm Operation lights ls f S NO s lamp YES X temperature higher than 110 C NO 0 0 o exact 1 turns on lock out light YES Le Opeartion lights Q E beginning of wait period A 1 A YES flame presence End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve YES stops fan interrupts ignition discharges memorizes lock turns on lock out light End of ignition period NO reset push button pressed Is fan rpm NO YES gt Safety thermostat or flue temperature probe lock out YES Figure 9 15 2225 ELECTRONIC CONTROLIIGNITION P C B 9 11 Thermal control in the B mode S
50. se that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler opera tion lock out This allows the use of plastic materials for the flue outlet pipes and bends The use of kits different from the original isn t however allowed since the flue pipes are integral parts of the boiler Figure 20 2 A Safety thermal fuse B in Figure 20 1 Figure 20 2 is also con nected in series with the Flue temperature probe NTC and acts as a safety device in extreme case of incorrect operation of the Flue temperature control system Reaching the breakdown temperature it opens the circuit and locks out the boiler In case of intervention of this safety device the heat exchanger part shown in Figure 20 3 may be damaged and must be replaced Figure 20 3 20 2 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the connector C from the Flue temperature probe NTC by pressing the plastic hook placed on the side of the connector 3 Unscrew and remove the flue temperature probe A Figure 20 2 from the condensing heat exchanger 4 Assemble the Flue temperature probe NTC carrying out the removal operations in reverse seguence 20 3 Checks YM Overheat temperature value 1 Setthe temperature control knobs to their max position and run the boiler in d h w an
51. tion Figure 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 thermal fuse Safety thermostat Flame detection electrode Room thermostat 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 of the Electronic control ignition p c b is that of controlling the boiler in relation to the external needs i e heating the dwelling or heating the water for d h w use and operating in order to keep the temperature of the hydraulic cir cuits 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 processes it and conse quently acts with outlet commands on other components of the boiler Figure 9 1 The Electronic control ignition p c b is also a full sequence igni tion device and does a sequence of operations ignition cycle which
52. uator carrying out the removal operations in the reverse order When reassembling the actuator refer to Figure 8 2 or to the wiring diagram in section Checks page 15 for the correct wiring connection 15 THREE WAY DIVERTER VALVE Figure 8 4 8 4 Removal of the diverter group and its internal parts 1 Remove the front and both side case panels Empty the primary circuit and the d h w circuit of the boiler 3 Remove the electric actuator section Removal of the elec tric actuator page 15 4 Remove the fixing spring F Figure 8 5 and remove the pri mary circuit flow switch G 5 Disconnect both c h and d h w temperature probe respec tively H and l 6 Unscrew the connector J the c h flow connector and the Figure 8 7 d h w outlet connector 11 Reassemble the diverter group carrying out the removal op erations in the reverse order Cr Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities Figure 8 5 7 Remove the d h w heat exchanger see section Removal page 13 8 Remove the fork K and move away the pipe L Figure 8 6 9 Unscrew the screw M and remove the diverter group 10 Refer to the exploded view in Figure 8 7 to remove the inter nal parts of the three way diverter valve 16 ELECTRONIC CONTROLIIGNITION P C B 9 ELECTRONIC CONTROL IGNITION P C B 9 1 Func
53. urn off the flow and return isolation valves and empty the primary circuit 2 Remove the fork N and the probe holder spring O Figure 13 3 3 Squeeze the tabs P to release the temperature pressure gauge Q and remove it 4 Re assemble the parts in reverse order of removal Figure 13 3 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 D H W FLOW SWITCH FILTER AND FLOW LIMITER 14 1 Function The d h w flow switch A in Figure 14 1 is a device that generates an electrical signal when hot water is drawn 9 Figure 14 1 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 5 Figure 14 3 is dragged upwards and the magnet in it getting closer to the sensor 8 closes the electric contact that switches the boiler d h w operation ON p Figure 14 2 14 2 Nomenclature and location of parts Figure 14 3 Flow switch plug O ring Flow limiter optional for M96A 32SM Body Float Filter Sensor holder spring Sensor 0 4 00 ON p 4 A 8 I Figure 14 3 14 3 Checks Warning isolate the boiler from the mains electrici ty supply before removing any covering or compo nent JA Sensor operation 1 Remove the front panel of the case 2 Measure t
54. ut the removal operation in reverse order When reassembling the ignition electrodes be sure to connect correctly the wires to the spark generator Figure 18 3 A esa earth wire ignition electrodes wire nn I Figure 18 3 18 3 Removal of the burner Warning isolate the boiler from the mains electricity AN supply before removing any covering or component 1 Remove the air box and the fan see section Removal of the Air box and the Fan page 35 2 Remove the Ignition and detection electrodes see section Re moval of the Ignition and detection electrodes page 36 3 Unscrew the screws Figure 18 1 and remove the cover of the combustion chamber 4 Unscrew the screws J Figure 18 1 and remove the Air gas duct lid 5 Remove the burner by sliding it forward 36 IGNITION AND DETECTION ELECTRODES burner gasket locating tab Figure 18 4 6 Assemble the burner carrying out the removal operation in re verse order Ensure the burner is correctly located by lining up the locating tab Figure 18 4 burner gasket Air gas duct gasket Figure 18 5 Before reassembling ensure the burner gasket is correctly lo cated Warning After cleaning or replacement as detailed A above itis deemed necessary to undertake a combus tion analysis as detailed in section Adjustment page 25 18 4 Removal of the front insulatio
55. val page 28 2 Measure the electrical resistance between the tabs marked D and N O Figure 12 3 The contact must close resistance zero with c h pressure of 0 35 bar or higher D N O Ns do not use Figure 12 3 12 3 Removal Warning isolate the boiler from the mains electrici A ty supply before removing any covering or compo nent Removal of the switch Remove the front panel of the case Remove the fork E Figure 12 4 Open the box and disconnect the switch Re assemble the parts in reverse order of removal Refer to Figure 12 3 for the correct wiring connectors on the switch Q N 1 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 E that holds the micro switch housing F Figure 12 4 ES Figure 12 4 3 Unscrew the four screws G Figure 12 5 open the hydraulic operator and remove the membrane H Figure 12 5 4 Reassemble the parts in reverse order of removal 28 PRIMARY CIRCUIT FLOW SWITCH When assembling the membrane ensure that its concave side faces towards the actuator plate and the reference in dicated aligns with the seat J see Figure 12 5 EA Warning to lubricate the O ring gaskets exclusively use a silicone base grease compatible to be in con tact with foods and approved by the local water Au thorities 29 EXPANSIO
56. witch in the e function mode See functioning with the function Taking control in the Se mode lt YES water from the domestic ho water circuit Request for heat from room thermostat NO sec 9 11 circulator off fan still YES circulator on stop circulator 3min Operation lights Is primary circuit temperature higher than that selected Main circuit pressure switch consense YES YES O O TN NO YES NO lock memorised L cancels lock starts fan checks fan rpm Is fan rpm exact Opeartion lights NO NO temperature higher than 110 C 00 O rN 1 turns on lock out light YES Le Opeartion lights e o O beginning of wait period flame presence YES End of wait period NO starts ignition discharges Opens gas valve flame presence beginning of ignition period interrupts ignition discharges gas valve open fan runs closes gas valve YES stops fan interrupts ignition discharges memorizes lock turns on lock out light End of ignition period m NO Is fan rpm NO reset push button YES gt pressed Safety thermostat or flue TI gt NO NO temperature probe lock out YES ame presence X YES Figure 9 16 23 TRANSFORMER 10 TRANSFORMER 10 1 Removal Figure
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