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1. J3 3 Three way diverter valve J1 2 Full sequence ignition device Diagrams EEN Circuit voltages during c h or d h w operation Electrical voltages with burner on C gt only during c h operation GO only during d h w operation Pump N 3 way 8 Fan diverter valve Modulating 4 Gas valve q Supply network 230 230 K3 K4 f K2 X4 Q Q LD3 LD2 LD1 LD4 SB1 Air a afety switch thermostat pressure uonouni m y p uo uonle19do BLUON yO UO lIUA HOUS e 104 s1yBi lloq ayl y 9 uo ppoaJlo9 s do Jajloq ayl awe ey JO uonelnpoui ay UO y 1 usey qouy juewjsnipe dwa m y p ay Buin a1njeladuea M Y P ay Ionuoo 1 us op Jejloq ay 1 uin1 US9Op UR pouu M y p JO y 9 Ul Jeyye 1461 1 Useop aunq ay suJn Ue pouu M y p JO y 9 Ul JOULE 1461 1 Useop aunq ay Ins Uey 440 s1uB1 uoyesedo au IIV apou m y p JO y o ul JOYE Hes JOU seop Ja loq ay urebe SOO Ja 1oq ay pue nunuoo syieds uoniuBi y uo s1yBi seumq ay ay9 9 uoniuB ay suls Jajroq y uopnq ysnd 18s 1 ayy Hussard Ag ureBe sy90
2. Fig 10 ERIN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the case panels and the sealed chamber lid see section 2 2 Empty the primary circuit of the boiler 3 Remove the combustion chamber lid B by un screwing the screws C and removing the clamp D Fig 11 4 Remove the screws E and the plate F 5 Loosen the connection G and slightly move the pipe H upwards 6 Remove the clip and the safety thermostat J It 7 Loosen the connection K and move the pipe L downwards freeing it from the connection of the primary het exchanger 8 Remove the clip M 9 Move the pipe N upwards freeing it from the con nection and rotate towards right 10 Remove the heat exchanger by sliding it for wards 11 Reassemble the boiler carrying out the removal operations in reverse order Fit the clip with the arrow pointing upwards as illustrated in Fig 11 IMPORTANT do not force the connection G when tighting it EEE Cleaning If there are deposits of soot or dirt between the blades of the heat exchanger clean with a brush or non me tallic bristle brush In any case avoid any actions that can damage the pro tective varnish with which the exchanger has been cov ered Warning After cleaning or replacement as detailed above if it deemed necessa
3. Fig 7 bottom view of the boiler 2 Remove the front and right panels of the boiler 3 Open the drain tap Fig 8 until the boiler is com pletely emptied 4 Close drain tap again once the emptying has been completed 2 pQ FI VOD FAN Fig 8 e PON Emptying the d h w circuit 5 Close the d c w inlet cock J Fig 7 6 Open one or more hot water taps until the boiler has been completely emptied 3 Diagrams EXI Wiring diagram Electric supply External controls Three way Pump Fan Primary circuit Air pressure Ignition Flame detection terminal block terminal block diverter valve Se flow switch switch electrodes electrode L N 1 M p s E se BER a D D bk gy A J a 53 53 jJ saa 553 E i I Le i mal alle O gt x x1 a a rrr HEERA F2 FA KT k3 K4 X5 A O e K2 tani L bn bu bu ae eH a bk pa wn Li
4. 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 supplies the fan and checks its functioning by means of the signal coming from the air pressure switch The Electronic control ignition p c b has a safety func tion and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler The Electronic control ignition p c b can lock the func tioning of the boiler lock state and stop its functioning up to the resetting intervention The lock is signalled by the lighting of the lock out signal lamp and the device can be reset only by using the boiler reset button placed on the control panel fascia Some components which are connected to the device can activate the lock state The causes of a lock state could be The intervention of the safety thermostat over heat of the primary circuit The intervention of the flue temperature probe overheat of the combustion products A fault on gas supply Faulty ignition faulty ignition electrodes their wir ing or connection Faulty flame detection faulty detection electrode its wiring or connection Faulty condensate drainage Gas injectors blocked Faulty modulation gas valve faulty on off oper ators
5. Wall hung fan flue room sealed high efficiency gas boiler Service manual GARDA HE Models G C Appl No M96 24SM B2 47 583 03A M96 28SM B2 47 583 04A GARDA HE SILVER Models G C Appl No M96 24SM D2 47 583 03B M96 28SM D2 47 583 04B Leave this manual adjacent to the gas meter Table of contents mb N gt 10 11 10 12 Overall information 1 Overall View 1 Hydraulic diagram 1 General access and emptying hydraulic circuits 2 Nomenclature 2 Body panels 2 Control panel 2 Access to the sealed chamber 3 Emptying the primary circuit 3 Emptying the d h w circuit 3 Diagrams 4 Wiring diagram 4 Functional flow diagrams 5 Circuit voltages 6 Fault finding 7 Primary heat exchanger 9 FUNCION O T yT yT eek Bee nas 9 Removal cy gu yy EEEE iets 9 Cleaning s US Tau See 9 Condensing heat exchanger 10 FUNCUON ii as 10 REMOVA Na es 10 D h w heat exchanger 11 FUNCION ir ppp Suk Sus 11 Removal asus a l fea eee 11 PUMP siete y uy uya ua suy quy a 12 FUNCHON S44 teen Es 12 Checks iyini a pa a aasan ees 12 Removal css uy p i awu chha ss 12
6. i Fig 65 30 KEEN Removal Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels 2 Empty the primary circuit of the boiler 3 Remove the diverter group as described in the section 9 4 of this manual 4 Unscrew the connector B and remove the by pass valve C Fig 66 Fig 66 5 Reassemble the by pass valve as illustrated in Fig 66 reversing the order of removal 17 Fan venturi device and Air pressure switch Function The function ofthe FanA Fig 67 and Fig 68 is to force the products of combustion through the condensing heat exchanger to the outside air via the flue system The Fan is supplied by the full sequence ignition device at the beginning of the ignition cycle Its correct functioning is controlled by means of a sys tem incorporating a built in venturi device B in Fig 73 and an Air pressure switch C Fig 67 and Fig 68 A lt ry y G El a HU Al g Ge C 1 ONS Fig 67 Checks 4 Check of the fa
7. 1 loq ay pue nunuoo syJeds uol Iu ay uo 1461 1Lus op JaUING ay ay9 9 uoniuB ay suls Jajloq y uopnq ysnd 18s 1 ayy Hussard Ag Apoa 100 sayesado pue uo SUIN 18 10q ay uopnq ysnd jase y Buiss id Ag ebneb inss iq 9ssaa uoisuedxg siolo ul e sow19uy jejes IB poxno l uono l q poxo uou pau dw peusis jno yo07 t joajeg E E E Cs jas s Ae E A ESA T EI ERA E Cp E A EL TA A O O a e EA EA AA o s EEN C m IP O A E O O E po sara de IE O e o Pe C MAPA A Pre Je a o o 1 EA C A le o AAA O e el sa Cia A j TA A A EA AA EA E EEE j ee 2 l je l Ea Se U C C s ro AE EA S C TASA A E ARA ETE Uu ee AA E A AL Al a LA EA CARA E e O au Ajddns Jamogy v N a sjexoeJq Ul J 1 ajou jenueu y jo uono s E ws jJ j T L TEL levi ile sar Leet 2 voz z6Ll z 84 zzi or zs Sv y y 0 slu uoduioo Bulpuyynej 9 t L ayw ayes MO e LES ul 1essegau J uBIu 00 ayes mo Jo uBiu ool aunsseud w u p san ea 1 do1d Jo jenuew uonelj e su OU 0 Jajey SS A uolsuedx ay JO uonezunss id ay 42949 s10 9 fu Jo ss uue o y AOA 1eyy0O0q uonelielsu ay uo UaAIB anjea y ULM y aseduoso pue g 429S Bas anjen seb QU JO JULIO 158 jano ay ye arnssaud sef unu ur 24 Y02949 ye soueyj jejes ay jo uonlu AJ lui ay pue NIO urew y j
8. 2 lift the panel and remove it 2 Fig 2 To remove the side panels loosen the screws B and C Fig 3 bring the base of the panels away from the boiler and lift them freeing them from the top hooks Fig 3 bottom view of the boiler PEN 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 3 3 Remove the screws D 4 Move the lower part of the side panels as indi cated in Fig 4 and pull the control panel When completely pulled out the panel can rotate 45 downwards to facilitate the service oper ations on the internal parts 5 Remove the screws E and remove the service panel Fig 5 6 To gain access to the electronic regulation PCB remove the screws F and remove the control pan el lid Fig 5 Fig 5 General access and emptying hydraulic circuits To gain access to the parts contained in the sealed chamber it is necessary to remove the lid of the sealed chamber For this purpose remove the front and side panels of the case remove the screws G as indicated in Fig 6 and remove the lid PJ Emptying the primary circuit 1 Close the c h circuit flow and return cocks H Fig 7
9. put of the d h w heat exchanger d h w Temperature probe B in Fig 63 and Fig 64 Z s c h c h d h w d h w return flow inlet outlet Fig 63 KEY Checks Temperature resistance relationship NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Disconnect the cable from the Temperature probe Measure the temperature of the brass group where the Temperature probe is located and check the electrical resistance according to the graph in Fig 62 KEEN Removal Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 To remove the Temperature probes remove the front panel of the case 2 To remove the c h Temperature probe empty the primary circuit of the boiler To remove the d h w Temperature probe empty the d h w circuit of the boiler 3 Remove the electric connector of the Tempera ture probe and unscrew it 4 Reassemble the Temperature probe carrying out the removal operations in reverse order 29 16 By pass valve HAH Function The By pass valve A in Fig 65 is located between the c h water flow and return and its function is that of guar anteeing a minimum flow across the primary heat ex changer if the circulation across the c h system is com pletely closed The By pass valve is fitted on the rear side of the div erter group
10. 1 e 1 25 mbar BI1376 104 Yamatake Honeywell C6065 mod M96 28SM SIT 380 alternative 8 E83 013 9 E83 178 10 E83 180 E83 181 Combustion chamber rear panel mod M96 28SM M96 32SM Combustion chamber front panel mod M96 28SM M96 32SM 38 i en EXT es 1 BI1406 101 KI1267 103 Yamatake Honeywell C6065 SIT 380 alternative Safety valve Bl1131 100 Watts Orkly alternative Combustion chamber side panels BI1326 100 Combustion chamber rear panel 1 BI1326 107 mod M96 24SM Bl1326 108 11 Combustion chamber front panel 1 BI1406 118 mod M96 24SM BI1406 119 z 13 E01 204 D h w heat exchanger M96 24SM E01 205 D h w heat exchanger M96 28SM BI1001 102 M96 32SM EMS i 17 E00 688 Main flow switch membrane Ta E6606 a 23 E83 127 Ignition electrode left 25 885 122 Detection decode 5162 27 orme Short spare parts list 39 17962 1231 4 0907 44A4 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
11. N s alal l E HE TDS a E gy Es gy A A xa e O ae r A apt q 5 E R F 2 P4 D4 a LD3 Le E e P5 i J 1 4 3 wh bk N wh a N t bu bk wh Vg ira Remote control D h w flow C h temperature Modulating _ Safety Flue D h w temperature Time switch terminal block switch probe NTC gas valve thermostat temperature probe NTC probe NTC bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow alternative yellow Diagrams EF Functional flow diagrams General layout J1 1 Fuse 3 15 A PTC Electronic control p c b low voltage section Transformer x L gt D A J3 5 q J3 4 x J3 3 Three way diverter valve y1 2 N Pump Heat request on d h w J1 1 Fuse 3 15 A PTC L LINE N NEUTRAL ACTIVE CIRCUIT INACTIVE CIRCUIT Heat request on c h J1 1 Fuse 3 15 A PTC CANONA low voltage section Transformer x J2 5 J2 4 C Full sequence ignition device Electronic control p c b low voltage section Transformer x Three way diverter valve y1 2 Full sequence ignition device Electronic control p c b
12. control sequences in function and in func tion are illustrated in detailin sections 10 10 and 10 11 TEN Operation lights The Electronic control ignition p c b is provided with three lamps L E D indicators 10 in Fig 29 that give optical information during the operation of the boiler The green lamp on the left gives information whether the boiler is in stand by mode or during the normal operation of the boiler The following table gives the relationship between the lamp indication and its meaning Boiler in stand by condition function control in position Anti freeze system active Boiler ON condition function control in 388 or position 1 second ON 1 second OFF With the boiler switched ON ea or allthe lamps 10 in Fig 29 are activated The following table gives the relationship between each of the possible lamp combinations and their meaning Normally operating boiler BO O O see the previous table for details Om ro ie so apa on primary circuit OT O O O Faulty flue temperature probe NTC Faulty primary circuit no water or absence of flow Lack of power supply or fauly electronic control p c b eoo o Faulty Electronic control ignition p c b Lamp Lamp OFF ON Flashing lamp alone or simultaneously with an other lamp Flashing lamp alternate with another lamp These conditions are normal only for a short time when the power supply is
13. in Fig 29 of the electronic control p c b If the power requested is lower than 40 of the maxi mum power output then control is achieved by switch ing ON the burner at minimum power then 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 30 the signal coming from the c h temperature probe is compared to the sig nal given by the control panel through the adjustment made by the user knob 81m The result of such a comparison operates the modulation of the gas valve consequently changing the useful output of the boiler 0 Y O OI GQ NN co 16 When the boiler functions in d h w Fig 31 the signal coming fromthe d h w temperature probe is compared with the signal given by the control panel through the adjustment made by the user knob Electronic controllignition p c b Normally the result of the comparison between these two signals directly operates the adjustment elements ofthe gas valve modulation device adjusting the useful output generated in order to stabilize the temperature of the exiting water If during the d h w mode operation the temperature of the primary circuit goes over 75 C the useful output is automatically reduced so that the primary circuit can not reach excessive temperatures The
14. position and run the boiler in d h w and c h 2 Allow the boiler to reach its maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain a temperature below that of the Flue temperature probe NTC and no overheat intervention should occur EXE Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the wires from the Flue temperature probe NTC 3 Unscrew and remove the thermostat probe B Fig 81 from the condensing heat exchanger 4 Assemble the Flue temperature probe NTC carry ing out the removal operations in reverse se quence 21 Condensate trap ARN Function The condensate trap A in Fig 82 and Fig 84 allows the discharge of the condensate via the condensate drain pipe avoiding in the mean time the escape of combus tion products A plastic ball closes the trap outlet in case that the trap is empty Fig 82 The condensate trap is provided with two electrodes The electrode B is connected to the ground circuit the electrode C is connected to the flame detecting elec trode Fig 83 Fig 83 Ifthe drain pipe is plugged or in any case in which the condensate isn t correctly evacuated the condensate level in the trap rises putting in contact the electrodes thus causing the boiler lock out AE
15. J Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 5 Remove the front and right case panels Disconnect the trap from the draining pipe 7 Using pliers remove the spring D moving it up wards 8 Remove the spring E and lower the trap 9 Disconnect the wirings from the trap 10 Reassemble carrying out the removal operations in reverse order o Fig 84 37 22 Short spare parts list Key G C part no Description 1 173 148 Burner mod M96 24SM Q ty Manufac Manufacturer s reference turer part no J i ss KI1004 102 Polidoro 173 149 Burner mod M96 28SM M96 32SM KI1004 147 2 169 069 Injectors for natural gas mod M96 24SM KI1064 505 Polidoro Injectors for natural gas 14 mod M96 28SM M96 32SM L E01 156 Injectors for LPG mod M96 24SM F BI1003 509 Injectors for LPG mod M96 28SM M96 32SM 3 E83 121 Expansion vessel BI1172 103 CIMM 6 litres 4 H20 984 Main heat exchanger mod M96 24SM H20 985 Main heat exchanger mod M96 28SM Main heat exchanger mod M96 32SM 1 BI1262 101 1 BI1262 102 BI1262 130 7 BI1406 100 5 H21 048 Fan mod M96 24SM H21 049 Fan mod M96 28SM M96 32SM 6 Gas valve 7 169 127 Air pressure switch 0 88 0 74 Hie mod M96 24SM M96 32SM HO8 605 Air pressure switch
16. NO lower than that required Supplies the ignition device Ignition device off Fig 44 21 Electronic controllignition p c b XP onition and control sequence Ignition request YES lock memorised NO NO Air pressure switch at YES rest Y NO Air pressure switch at YES work Y beginning of wait period NO presence of flame YES L NO Air pressure switch at work YES starts ignition discharges opens gas valve beginning of ignition period NO flame presence YES closes gas valve d of igniti stops fan L NO ene o ae lon interrupts ignition discharges peroo memorizes lock turns on lock out light interrupts ignition discharges gas valve open NO reset push button YES pressed A YES flame presence NO gt Safety thermostat NO opens the circuit YES L YES Air pressure switch at NO work Fig 45 22 11 Modulating gas valve HA Function The Modulating gas valve A in Fig 46 controls the gas inflow to the boiler burner AS Fig 46 By means of an electric command given to the on off operators the passage ofthe gas through the Modula ting gas valve can be opened or closed By means of an electric command given to the modula tion operator the pressure can be varied and therefore the gas flow rate to the burner modulation The mo dulation op
17. Three way diverter valve 13 FRUNCHON sect ee es 13 Checks anes eee a 13 Removal of the electric actuator 13 Removal of the diverter group and its internal parts 14 Electronic control ignition p c b 15 FUNCION I u yb saa aaa 15 Selection and adjustment devices 15 Checking the temperature 16 Operation lights 17 Setting the boiler control function modes 17 Reignition frequency setting 18 Ignition gas pressure adjustment 18 Checks aus oca cayu oraya sauna u 19 Removal of the electronic control p c b 19 Thermal control in the 8 mode 21 Thermal control in the BE mode 21 Ignition and control sequence 22 11 11 1 11 2 11 4 11 5 12 12 1 12 3 13 13 1 13 2 13 3 13 4 26 14 14 1 14 2 14 3 14 4 14 5 14 6 15 15 1 15 3 16 16 1 16 2 17 17 1 17 2 17 4 17 5 18 18 1 18 2 18 3 19 19 1 19 2 19 3 20 20 1 20 2 20 3 21 21 1 21 2 22 Modulating gas valve 23 FUNCHOR Ate be fon eh eee a 23 Nomenclature of the parts 23 Adjustment u l usa yuaya aus eee ee 23 Checks fune cosa 1 aaa aap awan ele 24 Removal of the gas valve 24 Primary circuit flow switch 25 FUNCION 30 26 c 20 eek tie Esa eek Ge 25 Checks uay sy eileen ears 25 Removal euena a idee se uki Qu pens 25 Expansion vessel and t
18. 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 Mm 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 EEN Removal Ns Warning isolate the boiler from the mains electricity supply before removing any covering or component Remove the front and right hand side case panels Empty the primary circuit of the boiler Extract and lower the control panel Disconnect the connector B Fig 19 Loosen the connection C remove the fork D and the pipe E j V O AK o O O AA 3 OI Q NN gt O m Fig 19 6 Remove the fork F Fig 20 and the connection of the capillary pipe of the pressure gauge 7 Remove the locking plate G 8 Completely loosen the connection H 9 Unscrew the two screws that hold the pump on the frame and remove the pump Fig 20 Reassemble the pump carrying out the removal oper ations in the reverse order When reassembling the pump check the correct location of the O ring gasket in the inlet port of the pump th
19. ained in the section 2 3 of this manual 2 Disconnect the connectors D and E Fig 50 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve 4 Unscrew the connectors F and remove the pipe G 5 Unscrew the screws H and remove the valve 6 Reassemble the valve carrying out the removal operations in reverse order After any service operation on the components of the gas circuit check all the connections for gas leaks Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Fig 50 12 Primary circuit flow switch EAN Function The Primary circuit flow switch A in Fig 51 function is Boiler OFF B Boil N to detect water flowrate through the primary hydraulic es oiler O circuit of the boiler Fig 52 rm Electrical check 1 2 Fig 51 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 ofthe pump or obstructions in the primary circuit whilst in either c h or d h w modes will not allow the device to la operate O N N This device is connected t
20. and the combustion chamber lid 2 Disconnect the electrode wires from the full se quence ignition device 3 Remove the plate C see Fig 78 on page 35 4 Remove the burner by unscrewing the four screws placed at the right and left sides of the burner 5 Unscrew the screws A Fig 76 which hold the electrodes to the burner 6 Extract the electrodes from the burner 7 Assemble the electrodes carrying out the removal operation in reverse order Refer to Fig 74 in order to recognise the elec trodes and to correctly connect the wiring Note the metallic edge of the detection electrode is longer than the one of the ignition electrodes Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 19 Safety thermostat EAN Function The safety thermostat A in Fig 77 and Fig 78 is a de vice that senses the temperature of the primary circuit water which flows in the outlet pipe of the primary heat exchanger If the temperature control system of the boiler fails and the temperature of the primary circuit reaches a dan gerous temperature the safety thermostat opens the electric circuit that supplies the on off operators of the gas valve Consequently the full sequence ignition device at tempts to light the burner and at the end locks the boiler and lights the lock out si
21. applied to the boiler If permanent they indicate a faulty p c b DEN Setting the boiler control function modes It is possible to select the various boiler control function modes by using the function selector knob A and the D h w temperature control knob B Fig 32 During the function modes setting the boiler does not operate t E B A C D Fig 32 Gg A NEN 9 a 17 Electronic controllignition p c b MON Reignition frequency setting Itis possible to select the minimum time that must pass between two ignitions of the burner in c h function mode 1 Turn the boiler ON positioning the function selec tor knob A as indicated in Fig 33 a fis wii SEW Pe gt AMOO m za E B A C D Fig 33 2 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks 3 The lamps E should give the indication as in Fig 34 reignition frequency If not press the reset button repeatedly to obtain it O O were O Lamp OFF 00m Ao Fig 34 At this step it is possible to visualize the current setting by keeping the reset button C pressed for more than 5 seconds The lamps E will flash a number of times corresponding to the setting Fig 35 4 To change the setting turn the knob B on a posi tion corresponding to the desidered delay By turning the knob B the lock out signal lamp D blinks quickly 2 per seconds indicating that
22. at seals the connection between the pump and the brass group 9 Three way diverter valve EXI Function The diverter valve A Fig 21 has the function of modify ing the hydraulic circuit of the boiler by means of an electric command given by the electronic control p c b in order to send the water that exits the primary heat ex changer towards the c h system or towards the d h w heat exchanger et Fig 21 EX Checks Mm Check the electrical continuity Fig 22 indicates the relationship between the electric command coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in d h w mode Fig 23 indicates the relationship between the electric command coming from the electronic control p c b and the position of the actuator B brass spindle when the boiler operates in c h mode In both figures the relationship between the position of the actuator and the resistance of the motor windings the motor must be disconnected from the wiring is also given Spindle B not visible NE o N p 9 4 Kohm bn brown Open circuit bu blue eo oe a a bk black gt o ise N Fig 22 D h w mode gt o B Se Spindle B visible b I a N n Open circuit bn brown 9 4 Kohm bu blue ion gan eS a a Es a bk black gt o oll Fig 23 C h mode EEN Removal o
23. burner Two of them are the ignition electrodes and are fitted near the front part of the burner The ignition sparks take place be tween their metallic edges over the central ramp of the burner during the ignition sequence The third electrode is the detection electrode and it de tects the presence of the flame i Detection Igntion Male Fig 74 EEJ Checks Mm Check the position of the electrode edges NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Check for the correct distance between the me tallic edges of the ignition electrodes see Fig 75 4mm Ignition lt Fig 75 34 3 Check the integrity ofthe detection electrode and ensure that its metallic edge is correctly placed over the ramp of the burner 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 the sealed chamber lid and the combustion chamber lid 2 Check for the integrity of the insulation of wires which connect the electrodes to the ignition de vice KEEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels the sealed chamber lid
24. e and that the burner lights up uniformly In any case the boiler automatically resets to its normal operation after 10 minutes MEN Checks Mm Check that the fuses are complete If the Electronic control ignition p c b does not supply any device pump fan etc check that the fuses 11 Fig 29 are complete If a fuse has blown replace it with one that has the same characteristics after having identified the reason for fail ure Mm Lock sequence Start the boiler until the burner is ignited With the burner firing interrupt the gas supply The Electronic control ignition p c b must carry out three complete ignition cycles and then after about 3 min utes goes to lock out state By turning the boiler on and off by means of the function switch the device must not unlock and the burner must not turn on Y Fan functioning device With the boiler operating and the burner on open the negative pressure test point of the Venturi device At the moment of opening the burner must turn off PEN Removal of the electronic control p c b NN Warning isolate the boiler from the mains electricity supply before removing any covering or component When replacing the Electronic control ignition p c b itis advisable to go through the setting modes of the boiler 1 Gain access to the parts located inside the con trol panel as explained in the section 2 3 of this manual 2 Remove all the wiring connected to the Electronic c
25. e sensor is also indicated by means ofthe lamp B placed on the sensor body ZEN Nomenclature and location of parts Fig 61 Flow switch sensor Body O ring Spring Magnetic ring Float Threaded ring Flow limiter M96 28SM M96 32SM op tional accessory Filter 10 Spring seat AN Oa GQ N co Fig 61 KEN Checks NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm Flow 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 60 placed on the sensor body is switched on when the flow rate reaches about 2 5 litres min KEN 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 60 and remove the sensor by delicately livering downwards with a screwdriver 27 D h w flow switch filter and flow limiter 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 Remove the flow switch sensor see section 14 4 3 Unscrew the body 2 Fig 61 and extract the flow switch group 4 To remove the filter from the
26. emoval operations in the reverse order 14 10 Electronic control ignition p c b HAN Function Fig 28 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 Air pressure switch Flue temperature probe NTC Safety thermostat Flame detection electrode Room thermostat if fitted Time switch Outlet command Pump Three way diverter valve On off operators gas valve Modulation operator gas valve Fan Ignition electrodes Appliance operation lights Lock out signal lamp control panel fascia The fundamental function of the Electronic control igni tion p c b is that of controlling the boiler in relation to the external needs i e heating the dwelling or heating the water for d h w use and operating in order to keep the temperature of the hydraulic circuits constant This is obviously possible within the useful power and maximum working temperature limits foreseen Generally the Electronic control ignition p c b receives inlet information coming from the boiler the sensors or from the outside knobs room thermostat etc pro cesses it and consequently acts with outlet commands on other components of the boiler Fig 28
27. emperature pressure gauge 26 FUNCION Z u ised cae tado nes 26 Checks e 2 sayaq awa aq Suay ayunaq 26 Removal of the expansion vessel 26 Removal of the temperature pressure gauge D h w flow switch filter and flow limiter 27 FUNCHON 2 ges t s oe ti t h aaa 27 Nomenclature and location of parts 27 CheckS 2 datada ica 27 Removal of the flow switch sensor 27 Removal of the flow switch group and d h w circuit filter 28 Flow limiter 28 Temperature probe 29 Function ass 29 CHECKE ia ma aaa naci 29 Removal senori et uean ea ae 29 By pass valve 30 FUNCION soriano ateq usia AS 30 Removal 30 Fan venturi device and Air pressure switch 31 FUNCHON sotana ba 31 CHECKS tan aku pusa E ES 31 Removal of the Fan 32 Inspection and removal of venturi device 32 Removal of the Air pressure switch 33 Ignition and detection electrodes 34 FUNCION aa mu m Z tog ee aes 34 CHECKS iia dees can ua as aus 34 Removal 34 Safety thermostat 35 FUNCION aeien ends meth ays ate eee 35 Checker itd chy ads espera donb aks aed 35 Removal uuu cece eee eee ees 35 Flue temperature probe NTC 36 FUNCTION z Sun tice toe te hee kes 36 CHECKS suysu as dace caves Heda kaa 36 Removal ona td p 36 Condensate t
28. erator has mechanical components which allow the adjustment of the minimum and maximum pressure exiting the valve KIA Nomenclature of the parts Fig 47 Minimum gas pressure adjustment Maximum gas pressure adjustment Modulation operator s electric connectors On off operators electric connector On off operators Gas valve inlet pressure test point Gas valve outlet pressure test point Modulation operator ON Oa G NN Fig 47 HEN Adjustment NN Warning isolate the boiler from the mains electricity supply before covering or component removing any 1 Remove the front panel of the case 2 Open the gas valve inlet pressure test point 6 in Fig 47 at the valve input connect a suitable pressure gauge and check the gas pressure of the supply network 3 Remove the gauge and close the pressure test point 6 4 Open the gas valve outlet pressure test point 7 in Fig 47 and connect the gauge 5 Remove the protection cap B Fig 48 from the mechanical pressure adjustment components levering with a flat screwdriver in the slots C 23 Modulating gas valve 6 Start the boiler at its maximum power Operate the boiler in d h w mode or ensure that the boiler is not range rated if the testis carried out in c h mode 7 Rotate the maximum gas pressure adjustment 2 in Fig 47 until you obtain the required pressure by rotating clockwise the pressure increases 8 Turn the boiler off and disconnect one of t
29. f the boiler 10 Remove the clip N and the pipe H _ d E aI PW I Y WA Fig 13 11 Reassemble the exchanger carrying out the re moval operations in reverse order After reassembling ensure that the fan exchanger and exchanger elbow gaskets are correctly mounted and ensure a good sealing Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 7 D h w heat exchanger Removal Function Nx Warning isolate the boiler from the mains electricity supply before removing any The d h w heat exchanger A in Fig 14 and Fig 16 al covering or component lows the instantaneous transfer of heat from the primary hydraulic circuit to the water destined for d h w use _ Remove the front and right hand side panels of the case z gt gt e 2 Empty the primary circuit and the d h w circuit of the boiler 3 Completely unscrew the two Allen key screws B Fig 16 which hold the exchanger to the brass groups Fig 16 4 Move the exchanger towards the rear of the boiler and extract it Reassemble the d h w heat exchanger carrying out the removal operations in the reverse order Fig 14 i Attention When reassembling the e
30. f the electric actuator Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front case panel 2 Disconnect the connectors C Fig 24 3 Remove the fixing spring D and remove the actuator E Reassemble the actuator carrying out the re moval operations in the reverse order When reassembling the actuator refer to Fig 22 or to the wiring diagram in section 9 2 for the cor rect wiring connection 13 Three way diverter valve ms 9 Unscrew the screw M and remove the diverter 9 group Fig 24 EX Removal of the diverter group and its internal parts Fig 26 Rear view of the boiler 1 Remove the front and both side case panels 10 Refer to the exploded view in Fig 27 to remove 2 Empty the primary circuit and the d h w circuit of the internal parts of the three way diverter valve the boiler 3 Remove the electric actuator see section 9 3 4 Remove the fixing spring F Fig 25 and remove the primary circuit flow switch G 5 Disconnect both c h and d h w temperature probe respectively H and 6 Unscrew the connector J the c h flow connector and the d h w outlet connector Fig 25 7 Remove the d h w heat exchanger see section 7 2 Fig 27 8 Remove the fork K and move away the pipe L 11 Reassemble the diverter group carrying out the Fig 26 r
31. flow switch group separate the filter 9 from the threaded ring Fig 61 by levering it 5 Reassemble the parts following the removing se quence in reverse order MON Flow limiter The M96 24SM model is factory fitted with a 10 litre 28 min flow limiter Ifon the M96 28SM and M96 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 avail able Nominal flow rate litres min Colour 10 Yellow 12 Brown To install the threaded ring with the flow limiter 1 Remove the flow switch group as explained in the section 14 5 2 Remove the filter from the flow switch group 3 Unscrew the threaded ring 7 Fig 61 and re move it from the body 2 4 Reassemble the group following the above se quence in reverse order 15 Temperature probe HAN Function The Temperature probe has the function of converting the temperature of the water in the hydraulic circuit where it is installed into an electrical signal resistance The relation between temperature and electrical resis tance is stated in Fig 62 12000 11500 11000 AL V 10500 10000 AEE Q 12500 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 C Fig 62 On the boiler there are two Temperature probes One on the output of the primary heat exchanger c h Tem perature probe A in Fig 63 and Fig 64 one on the out
32. g 42 Attention 20 After installing the Electronic control ignition p c b 10 Make sure the c h 8 and d h w BE 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 11 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 controllignition p c b EXT Thermal control in the mode Switch in the function mode See functioning with the function control in these mode lt e YES sec 10 11 NO Is primary circuit temperature higher than that selected YES NO Request for heat from room thermostat hi _ Circulator off Starts the circulator Operates motorised valve Operates motorised valve Ignition device off Supplies the ignition device Fig 43 EXE Thermal control in the GX mode Switch in the 3 function mode YES Circulator off NO gt Ignition device off Y Circulator on Is domestic YES hot water outlet temperature
33. g any covering or component 1 Remove the front and left hand side panels of the case turn off the flow and return isolation valves and empty the primary circuit 2 Completely unscrew the connection K the lock nut L Fig 57 and remove the expansion vessel from the top of the boiler y Fig 57 3 Re assemble the parts in reverse order of re moval EEE 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 58 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 mals Fig 58 14 D h w flow switch filter and flow limiter EAN Function The d h w flow switch A in Fig 59 is a device that gener ates an electrical signal when hot water is drawn 0 Fig 59 When the flow rate through the d h w circuit reaches about 2 5 litres min the float 6 Fig 61 is drawn to wards the right The resulting magnetic 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 ofth
34. gnal lamp Fig 77 EEJ Checks 1 Overheat temperature value 1 Set the temperature control knobs to their max position and run the boiler in d h w and c h 2 Allow the boiler to reach its maximum operating temperature monitor the temperature gauge on the instrument panel The boiler should maintain a temperature below that of the safety thermostat and no overheat intervention should occur NN Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm Electrical function Remove all the case panels and the lid of the sealed chamber 2 Remove the screws B and the plate C Fig 78 3 Disconnect the safety thermostat and check its electrical function Normally no intervention the _ contact must be closed electrical resistance zero Q KEEN Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the lid of the sealed chamber 2 Remove the screw B and the plate C Fig 78 A Fig 78 3 Disconnect the wiring D detail in Fig 79 4 Remove the spring E which holds the overheat thermostat on the pipe of the primary heat ex changer and remove it 0 Fig 79 5 Reassemble the overheat thermostat carrying out the operations in reverse order 6 Apply a
35. he flow and return isolation valves and empty the primary circuit Remove the fork C that holds the micro switch housing D Fig 54 Fig 54 V Unscrew the four screws E see Fig 55 open the hydraulic operator and remove the membrane F 25 Primary circuit flow switch Fig 55 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 55 13 Expansion vessel and temperature pressure gauge EENI Function The Expansion vessel in Fig 51 function is to allow for the volume expansion of the c h circuit water due to the temperature rise KEPA 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 56 from the valve on the top ofthe expansion vessel and con nect a suitable air pressure gauge Fig 56 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 sion vessel can be changed without removing the boiler 26 NN Warning isolate the boiler from the mains electricity supply before removin
36. he two connectors 3 in Fig 47 9 Start the boiler and rotate the minimum gas pres sure adjustment 1 in Fig 47 until you obtain the required pressure by rotating clockwise the pressure increases 10 Turn the boiler off and re connect the wire to the modulating operator 11 Start the boiler and check again the maximum gas pressure setting 12 Turn the boiler off and disconnect the gauge Important after the gas pressure checks and any adjustment operations all of the test points must be sealed and replace the adjustment protection cap HN Checks Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component Mm Check the modulation operator coil Remove the front panel of the case 2 Disconnect the connectors D Fig 50 from the modulating operator and measure the electrical resistance of the coil lts electrical resistance value must be approx 114 Q m Check the on off operators coils Remove the front panel of the case 2 Disconnect the electrical connector E Fig 50 _ 24 3 Measure the electrical resistance between the connector pins of the on off operators as illus trated in Fig 49 On off operator approx 4 180 2 at ambient temperature Fig 49 HEN Removal of the gas valve NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the front panel of the case as expl
37. n NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the connectors D Fig 68 and measure the electrical resistance of the motor that has to be about 43 Q M96 24SM 25 Q M96 28SM M96 32SM at ambient temperature Fig 68 Mm Check of the Air pressure switch operation NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the wires and check the electrical re sistance between the connections of the Air pres sure switch Refer to the Fig 69 in accordance with the type of air pressure switch used Between COM or 3 and N O or 2 the contact must be open Between COM or 3 and N C or 1 the contact must be closed electrical resistance zero 3 Connect the grey wire COM or 3 4 Run the boiler the Fan must run and check the the electric resistance between COM or 3 and N O or 2 Between COM or 3 and N O or 2 the contact must be closed electrical resistance zero Fig 69 Check of the venturi device This test must be carried out with the sealed chamber closed 31 Fan and Air pressure switch 1 Remove the caps of the pressure test points lo cated on the top of the boile
38. n 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 35 20 Fluetemperature probe NTC EA Function The Flue temperature probe NTC A in Fig 80 and Fig 81 senses the temperature of the combustion products that flow through the condensing heat ex changer A E lt E Y Fig 80 If the 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 de crease to a safe value temperature In the case that the temperature of the combustion products reaches a potentially dangerous value it stops the boiler operation It is therefore allowed the use of plastic materials for the flue outlet pipes and bends The use of kits different from the original isn t how ever allowed since the flue pipes are integral parts of the boiler If not the electronic control p c b attempts to light the burner and at the end locks the boiler and lights the lock out signal lamp 36 Fig 81 EQ Checks 1 Overheat temperature value 1 Set the temperature control knobs to their max
39. ns electricity supply before removing any covering or component 1 Remove the fan section 17 3 2 Remove the venturi device by unscrewing the screw H Fan and Air pressure switch 3 4 Fig 73 Inspect the venturi device B and the connection pipe Ensure they are clean Re assemble the parts in reverse order of re moval Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Removal of the Air pressure switch NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels and the sealed chamber lid 2 Disconnect the wires from the Air pressure switch 3 Remove the pipe from the Air pressure switch 4 Unscrew the screws which hold the Air pressure switch to the frame 5 Assemble the Air pressure switch carrying out the removal operations in reverse sequence Warning to correctly connect the Air pressure switch refer to Fig 72 and Fig 69a or Fig 69b for the correct wiring Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual 33 18 Ignition and detection electrodes HAN Function Three electrodes are fitted on the
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41. o the electronic control p c b and if after the pump operates it does not activate with in 20 seconds the control board will indicate that a fault 2 condition see section 10 4 of this manual has oc curred IEEJ Checks Nx Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Mechanical function Remove the front panel of the case 2 Start and stop the boiler either in d h w or c h mode 3 Looking through the switch box verify the position 3 of the shaft B referring to Fig 52 Fig 53 PEN Removal NN Warning isolate the boiler from the mains 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 Remove the switch as explained in section 12 3 Measure the electrical resistance between the tabs marked C and N O Fig 53 The contact must be normally open Operate the switch by hand and verify that the contact is now closed C No lt x do not use electricity supply before removing any covering or component Removal of the switch Remove the front panel of the case Remove the fork C Fig 54 Open the box and disconnect the switch Re assemble the parts in reverse order of re moval Refer to Fig 53 for the correct wiring con nectors on the switch Removal of the membrane Remove the front and right hand side panels of the case turn off t
42. ontrol ignition p c b To disconnect the connectors x1 x6 and x7 1 2 and 3 in Fig 29 delicately flex the hook present on one side of each socket To disconnet the connectors x4 and x2 4 and 5 in Fig 29 press delicately the hook present on one side of each connector 3 Remove the spindles of the c h and d h w tem perature adjustment knobs by delicately pulling them with pliers in the direction shown by the arrow in Fig 41 4 Unscrew the four screws that hold the Electronic control ignition p c b on to the control panel 5 Remove it by lifting its rear edge and freeing it from any of the wiring 6 Re assemble the Electronic control ignition p c b following the removal procedures in the re verse order Important When re assembling the Electronic control ignition p c b 7 Fit the p c b into the control panel by first insert ing the front lower edge under the control knob shafts Lower the rear edge and ensure that no wiring is trapped beneath 8 Insert the spindles in the control panel knobs un till the notch A Fig 42 reaches the potentio meter edge It is not necessary to force them in the knob 9 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 42 19 Electronic controllignition p c b Fi
43. or not electrically supplied Faulty Electronic control ignition p c b EG OY OA O O Other components like the air pressure switch can tem porarily stop the ignition of the burner but allow its igni tion when the cause of the intervention has stopped Fig 45 shows the sequence of the operations that are carried out at the start of every ignition cycle and during normal functioning YN Selection and adjustment devices On the Electronic control ignition p c b several selec tion adjustment and protection devices are located Fig 29 15 Electronic controllignition p c b Some of these devices are directly accessible by the user function control temperature adjustment poten tiometers etc others are accessible by removing the service panel or the control panel lid 10 9 8 7 6 Fig 29 x1 connector x6 connector x7 connector x4 connector x2 connector Lock out signal lamp Boiler reset button Function control C h temperature adjustment D h w temperature adjustment 10 Appliance operation lights 11 Fuse3 15AF EXE Checking the temperature The Electronic control ignition p c b makes it possible to separately adjust the c h water flow temperature and d h w outlet temperature The temperature of the water is converted into an elec tric signal by means of temperature probes The user setting the desired temperature with the con trol panel knobs operates the variable elements 8 and 9
44. poo m Hig wy p Ajddns jou saop Jajiog ay Di iO M S D2 YP orasysS T W U lt U Z3 O O uwW m 2 O0O Q Y U O O O m Q P s S slo 5 5S S 5 S 5 5 P 5 SS 8 B es 5 5 S PE 5 5 S 5 Ble ele sle 8 Fs ele Slolslolels 3 15 2 5 818 S s5 o0 lo 8 7 lola Slals s gt 8 alals Si 218 2 S 5 gt 2 lel3 3 3 5 2 os S 3ja S5 el2 lt 3 2 5 8 s s5 P 2 5 a s S 8 28 2 3 S Q lt o Do oO lt Est gt Lo 5 O l eles eis 2 ele ls Slslslelsleiels Je 3 2 2 Q 9 jo So o S o 3 13 1 2 5 o 3 2 5 lt o o on o a o oa 2 aj gt g 2 5 2 o b ollo ke c o o 2 a Q 7 gt gt 2 o o gt jo z o E a 3 D S al2l 3 D S 5 A o o A 0 o D 313 5 2 a 3 amp 3 D 3 1p jeq 8 2 r g 2 U sjoyoeJq ul J 1 lou U04 Z6L cst CLL 91 SL GVLigcl Vit 8 0L 36 os Z bho dl lt 7 enueu ay JO Ondas y y 0 sjuauoduoo 5 Primary heat exchanger EXI Function The primary heat exchanger A in Fig 9 has the function of transferring heat produced from combustion of the gas to the water circulating in it s AAA Fig 9 The hydraulic circuit is composed of 8 elliptical pipes comected in parallel Fig 10
45. r and connect a differ ential pressure gauge Fig 70 2 Switch on the boiler Fig 70 3 Compare the value on the gauge with the follow ing minimum values 80 Pa 0 8 mbar M96 24SM 110 Pa 1 1 mbar M96 28SM and M96 32SM Removal of the Fan NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove all the case panels the sealed chamber lid and the combustion chamber lid 2 Disconnect the connectors D and the earth con nection E Fig 68 3 Disconnect the pipe which connect the venturi device to the Air pressure switch 4 Unscrew the screw F and remove the bracket G Fig 71 32 Fig 71 5 Remove the Fan by sliding it towards left se the arrow in Fig 71 6 Assemble the fan carrying out the removal oper ations in reverse sequence Warning Re assembling the fan ensure that the hooks around the inlet port of the fan hung correctly on the flue hood Warning to correctly connect the venturi device to the Air pressure switch refer to Fig 72 Fig 72 Warning After cleaning or replacement as detailed above if it deemed necessary to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual Inspection and removal of the venturi device Nx Warning isolate the boiler from the mai
46. rap 37 FUNCION noti a 37 Removal sieri rer ia a pais 37 Short spare parts list 38 1 Overall information Overall View Flue thermostat Air pressure s A switch as Condensing Fan A exchanger EW el Expansion vessel Main heat exchanger Combustion f F Safety chamber 7 thermostat Burner Ignition hh saa Detection ss Automatic electrode XE IF air release Diverter valve i valve D h w probe heat exchanger Main circuit gt BA flow switch 1 Condae _ oa D h w temp r trap Pa probe A PS Gas m 2 pumo Control panel Hydraulic diagram Central heating c h operation Domestic hot water d h w operation J MEA C h C h D h w D h w water return water flow inlet outlet 2 General access and emptying hydraulic circuits EXI Nomenclature Fig 1 1 Right side panel Front panel Control panel lid Control panel cover Service panel O a O N Left side panel PRI 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
47. re Lamp OFF Flashing lamp alone 1 11 11 O or simultaneously with an other lamp Fig 38 8 Rotate the knob B on a position corresponding to an adequate ignition pressure Refer to the value indicated in the tables of the User Installation manual Technical information section Gas pressures at the burner table By rotating clockwise the pressure increases Make a note of the position of the knob B 10 Turn the boiler OFF and ON positioning the func tion selector knob A as indicated in Fig 39 ais i SB i SW PT m MOQ fl za E B A C D Fig 39 11 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks Electronic controllignition p c b 12 Press the reset button C repeatedly 4 times until the lamps E give the indication as in Fig 40 igni tion pressure adjustment mode O were O Lamp OFF 00m avo Fig 40 13 Turn the knob B to the minimum fully counter clockwise and then on the position correspon ding to the position obtained on step 8 By turning the knob B the lock out signal lamp D blinks quickly 2 per second indicating that the setting has changed and must be memorised 14 To memorize the setting keep pressed the reset button C for about 5 seconds until the lights E briefly blinks simultaneously 15 To reset the boiler to the normal operation turn it OFF and ON by the function selector knob A checking the ignition pressur
48. ry to undertake a combustion analysis refer to the appropriate chapter Maintenance of the installation instructions manual is not necessary to disconnect it from the wiring 6 Condensing heat exchanger EX Function The return water flows through the condensing heat ex changer A in Fig 12 and Fig 13 By reducing the combustion products temperature the latent heat of the vapour is transferred to the water cir cuit allowing an extra gain of useful heat The condensed vapour is then drained through the condensate trap B and the draining pipe C NS Fig 12 GE Removal NN Warning isolate the boiler from the mains electricity supply before removing any covering or component 1 Remove the case panels and the sealed chamber lid see section 2 2 Empty the primary circuit of the boiler 3 Remove the fan D in Fig 13 see section 17 3 and the air pressure switch E see section 17 5 4 Remove the flue temperature probe NTC F see section 20 3 5 Completely loosen the connection G and slightly move the pipe H upwards 10 6 Remove the clip and move the pipe J down wards freeing it from the connection then turn it towards right 7 Using pliers remove the spring K moving it down wards and disconnect the rubber pipe L 8 Remove the bracket M by unscrewing the screws that hold it on the frame 9 Rotate the exchanger as indicated by the arrow and remove it towards the front o
49. the setting has changed and must be memo rised 4 3 5 1 2 4 112 4 J 8 7 2 6 0 de _ 81 2 OOO j A Delay minutes DAM Setting No Fig 35 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 3minutes Ignition gas pressure adjustment 1 Turn the boiler OFF 18 2 Remove the front panel of the case Open the gas valve outlet pressure test point 7 see section 11 2 and connect the gauge 4 Turn the boiler ON positioning the function selec tor knob A as indicated in Fig 36 and ensure that the timer selector switch and room thermostat if fitted are set to heat demand Run the boiler in c h mode do not open any d h w tap w Fig 36 5 Keep pressed the reset button C for about 10 sec onds until the lock out signal lamp D blinks 6 The lamps E should give the indication as in Fig 37 If not press the reset button repeatedly to obtain it O O were Lamp OFF 1 11 11 O Lamp ON Fig 37 7 Keep pressed the reset button C for about 5 sec onds until the lock out signal lamp D is switched OFF The boiler runs in c h mode and the lamps E give the indication as in Fig 38 vty O O S Whe
50. xchanger be The schematic structure is shown in Fig 15 sure to put the off center location securing pin indi cated in Fig 17 towards the left side of the boiler A V A V mam Primary hydraulic circuit Domestic hot water circuit Fig 15 Fig 17 11 8 Pump EXI Function The pump A in Fig 18 and Fig 19 has the function of making the water in the main circuit circulate through the main heat exchanger the condensing heat ex changer and therefore through the c h system during the c h function or through the secondary heat ex changer during the d h w function sy Fig 18 EX 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 20 Measure the electrical resistance between the pump supply connections Electrical resistance of the windings at ambient tem perature must be about 230 Q 4 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

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