Biasi Activ A 25S User manual

Wall hung, fanflue, roomsealed, high efficiency gas boiler

Service manual

ActivA Plus

Models

Activ A Plus 30C

Activ A Plus 35C

Activ A Plus 16S

Activ A Plus 25S

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.

- 3 -

TABLE OF CONTENTS

1

OVERALL INFORMATION..........................4

1.1 Overall View .....................................4

1.2 Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 GENERAL ACCESS AND EMPTYING HYDRAULIC CIR-

CUITS ..........................................5

2.1 Nomenclature ....................................5

2.2 Case panels......................................5

2.3 Control panel .....................................6

2.4 Main electronic p.c.b. box ...........................6

2.5 Emptying the primary circuit .........................7

2.6 Emptying the d.h.w. circuit...........................7

3 DIAGRAMS .....................................8

3.1 Wiring diagram Activ A Plus 30C - Activ A Plus 35C .......8

3.2 Wiring diagram Activ A Plus 16S - Activ A Plus 25S .......9

3.3 Circuit voltages ..................................10

4 FAULT FINDING.................................11

4.1 Display diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 CONDENSING HEAT EXCHANGER.................14

5.1 Function........................................14

5.2 Removal .......................................14

5.3 Cleaning .......................................15

6 D.H.W. HEAT EXCHANGER .......................16

6.1 Function........................................16

6.2 Removal .......................................16

7 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

7.1 Function........................................17

7.2 Checks.........................................17

7.3 Removal pump ..................................18

7.4 Removal electrical capacitor . . . . . . . . . . . . . . . . . . . . . . . . 18

8 THREE WAY DIVERTER VALVE ....................19

8.1 Function........................................19

8.2 Checks.........................................19

8.3 Removal of the electric actuator .....................19

8.4 Removal of the three way diverter valve ...............20

8.5 Removal of the diverter group .......................20

9 MAIN ELECTRONIC CONTROL/IGNITION P.C.B. ......21

9.1 Function........................................21

9.2 Selection and adjustment devices....................21

9.3 Checking the temperature ..........................22

9.4 Setting the boiler control function modes ..............23

9.5 Checks.........................................26

9.6 Removal of the electronic control p.c.b ................26

9.7 Thermal control in the mode ....................27

9.8 Thermal control in the mode.....................28

10 CONTROL PANEL ELECTRONIC P.C.B. .............29

10.1 Function........................................29

10.2 Normaly information ..............................29

10.3 Info modality ....................................31

10.4 Function modes setting modality.....................31

10.5 Removal of the control panel electronic p.c.b . . . . . . . . . . . 31

10.6 Removal of the interface electronic p.c.b ..............31

11 GAS VALVE ....................................33

11.1 Function........................................33

11.2 Description of the parts - (Figure 11.2) ................33

11.3 Adjustment......................................33

11.4 Checks.........................................35

11.5 Removal of the gas valve ..........................36

12 PRIMARY CIRCUIT FLOW SWITCH .................37

12.1 Function........................................37

12.2 Checks.........................................37

12.3 Removal .......................................37

13 EXPANSION VESSEL AND PRESSURE GAUGE ......38

13.1 Function........................................38

13.2 Checks.........................................38

13.3 Removal of the expansion vessel ....................38

14 D.H.W. FLOW SWITCH, FILTER AND FLOW LIMITER ..39

14.1 Function........................................39

14.2 Description and location of parts - (Figure 14.2) .........39

14.3 Removal of the sensor.............................39

14.4 Checks.........................................39

14.5 Removaloftheowswitchgroupandd.h.w.circuitlter ..40

14.6 Flow limiter .....................................40

15 TEMPERATURE PROBE..........................41

15.1 Function........................................41

15.2 Checks.........................................41

15.3 Removal of the c.h. Temperature probes ..............41

15.4 Removal of the d.h.w. Temperature probes.............42

16 BY-PASS VALVE ................................43

16.1 Function........................................43

16.2 Removal .......................................43

17 FAN AND AIR BOX ..............................44

17.1 Function........................................44

17.2 Removal of the Air box and the Fan ..................44

18 IGNITION, DETECTION ELECTRODES AND BURNER .45

18.1 Function........................................45

18.2 Removal of the Ignition and detection electrodes . . . . . . . . 45

18.3 Removal of the burner.............................45

18.4 Removal of the front insulation panel .................46

18.5 Removal of the rear insulation.......................46

18.6 Checks.........................................46

19 SAFETY THERMOSTAT ..........................48

19.1 Function........................................48

19.2 Checks.........................................48

19.3 Removal .......................................48

20 FLUE TEMPERATURE PROBE NTC AND SAFETY THER-

MAL FUSE .....................................49

20.1 Function........................................49

20.2 Removal .......................................49

20.3 Checks.........................................49

21 CONDENSATE TRAP ............................51

21.1 Function........................................51

21.2 Check the cleanness of the trap .....................51

21.3 Removal .......................................51

22 SHORT SPARE PARTS LIST ......................52

- 4 -

OVERALL INFORMATION

1 OVERALL INFORMATION

1.1 Overall View

Figure 1.1

Pump

Gasvalve

Gas restrictor

Flue temperature

probeNTC

Condensing

heat exchanger

Detection

electrode

Burner

Fan

Electronic controlbox

Three way diverter valve

Ighition

electrodes

Expansion

vessel

Condensate

trap

C.h. pressure

relief valve

D.h.w.heat

exchanger

Automatic air

purger valve

Control

panel

Electric actuator

diverter valve

D.h.w. temperature probe

Airbox

(air/gasmixer)

Main circuit

pressure switch

D.h.w.

flow switch

Pipe silencer

Safety

thermostat

1.2 Hydraulic diagram

Figure 1.2

Centralheating (c.h.) operation

Domestic hotwater (d.h.w.) operation

D.h.w.

inlet

D.h.w.

outlet

C.h.

waterflow

C.h.

water return

- 5 -

GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS

2 GENERAL ACCESS AND EMPTYING

HYDRAULIC CIRCUITS

2.1 Nomenclature

Figure 2.1

1

2

3

4

5

1 Right side panel

2 Front panel

3 Control panel

4 Main electronic p.c.b. box

5 Left side panel

2.2 Case panels

Warning: isolate the boiler from the mains electrici-

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 loosen screws A (Figure 2.2), lift the

panel and remove it.

Figure 2.2

A

B

- bottom view of the boiler

Pull the lower part of the front panel and lift it upwards (Figure

2.3).

Figure 2.3

C

To remove the side panels loosen the screws B (Figure 2.2) and

C (Figure 2.3).

Pull the side panels towards the outside.

To Fit the case panels

Fit the side case panels.

Warning: Fit the front panel hooking it on the upper

side.

Push the spring towards the internal side of the boiler and simul-

taneously push the front case panel until it is completely hold in

place (Figure 2.4 step 1, 2).

Repeat the same operation on the opposite side of the front pa-

nel (Figure 2.4 step 3, 4).

Ensurethatthefrontpaneledgeisclose-ttingtothesidepanels.

Lock in place the panel with the appropriate screws.

Figure 2.4

1

3

2

4

- 6 -

GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS

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 Unscrew the screws D and E (Figure 2.5).

3 Free the hooks indicated and rotate the lid towards left.

Figure 2.5

Rotate

D

E

4 To access to the parts located behind the control panel turn it

as shown in Figure 2.6.

Figure 2.6

2.4 Main electronic p.c.b. box

Warning: isolate the boiler from the mains electrici-

ty supply before removing any covering or compo-

nent.

To gain access to the parts located intomain electronic p.c.b. box

proceed as follows:

1 Remove the front panel of the case.

Terminal block lid removal

2 To remove the terminal block lid F (Figure 2.7), free the front

hooks.

Figure 2.7

F

3 Slightly rotate the lid as indicated by the curved arrow and

free the rear hooks.

4 Remove the lid.

Main electronic p.c.b. lid removal

To get access to the main electronic p.c.b.:

5 Pull the box that contains the electronic p.c.b. and rotate it

(Figure 2.8).

Figure 2.8

- 7 -

GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS

6 Remove the terminal block lid F (Figure 2.7).

7 Free the hooks placed on the three sides indicated and rotate

the lid towards left (Figure 2.9).

Figure 2.9

2.5 Emptying the primary circuit

1 Closethec.h.circuitowandreturncocksG(Figure2.10).

Figure 2.10

G H

2 Remove the front and right panels of the boiler.

3 Open the drain tap I (Figure 2.11 combi or Figure 2.12 only

c.h.) until the boiler is completely emptied.

4 To help the draining of the primary circuit loose the condens-

ing heat exchanger air purger valve.

Figure 2.11

OPEN

CLOSED

I

Figure 2.12

I

2.6 Emptying the d.h.w. circuit

1 Close the d.c.w. inlet cock H (Figure 2.10).

2 Open one or more hot water taps until the boiler has been

completely emptied.

- 8 -

DIAGRAMS

3 DIAGRAMS

3.1 Wiring diagram Activ A Plus 30C - Activ A Plus 35C

Figure 3.1

bk

bu

bn

bu

bk

1

2

3

L

N

M

~

1

2

3

1

3

4

t

M

~

t

Safety

OUT

GND

5V

OUT

GND

5V

bn =brown

bu =blue

bk =black

wh =white

rd =red

gy =grey

gn =green

ye =yellow

vt =violet

og =orange

gnye =green/yellow

rdwh =red/white

gnye

bn

rd

bk

bu

rd

br

bk

bu

gnye

bu

bn

bu

bn

gy

bk

bu

rd rd

bu

bk

bu

bn

gnye

whwh

gy

wh

bu

bn

bu

bn

br

bu

og

gnye

bu

bn

bu

bn

gnye

ye

bk

ye

wh

bk

rd

bk

wh

t

wh

bk

rd

bu

bk

wh

rd

wh

rd

bu

rd

wh

bk

diverter valve

Threeway

Pump

Gasvalve Fan

Ignition

electrodes

Flamedetection

electrode

Flue temp.

probeNTC

C.h. temperature

probeNTC

thermalfuse

return

C.h. temperature

probeNTC

flow

D.h.w. outlet

probeNTC

temperature

D.h.w. inlet

probeNTC

temperature

D.h.w. flow

switch

pressure switch

Primarycircuit

Safety

thermostat

- 9 -

DIAGRAMS

3.2 Wiring diagram Activ A Plus 16S - Activ A Plus 25S

Figure 3.2

bk

bu

bn

bu

bk

1

2

3

L

N

M

~

1

2

3

1

3

4

t

M

~

t

OUT

GND

5V

bn =brown

bu =blue

bk =black

wh =white

rd =red

gy =grey

gn =green

ye =yellow

vt =violet

og =orange

gnye =green/yellow

rdwh =red/white

gnye

bn

rd

bk

bu

rd

br

bk

bu

gnye

bu

bn

bu

bn

gy

bk

bu

rd rd

bu

bk

bu

bn

gnye

whwh

gy

wh

bu

bn

bu

bn

br

bu

og

gnye

bu

bn

bu

bn

gnye

ye

bk

ye

wh

bk

rd

bk

wh

bk

rd

bu

bk

wh

rd

wh

bk

diverter valve

Threeway

Pump

Gasvalve Fan

Ignition

electrodes

Flamedetection

electrode

Flue temp.

probeNTC

C.h. temperature

probeNTC

thermalfuse

return

C.h. temperature

probeNTC

flow

pressure switch

Primarycircuit

Safety

thermostat

- 10 -

DIAGRAMS

3.3 Circuit voltages

Figure 3.3

230~

Electrical voltages with burner on

during c.h. or d.h.w. operation

only during c.h. operation

only during d.h.w. operation

230~

Safety

thermostat

1

Fan

0

Main circuitSupply network

230~ 0230~0

3way

diverter valve

230~

Gasvalve

33...200Hz

0...32 Hz

D.h.w.

Flow switch

pressure switch

- 11 -

FAULT FINDING

Components to check

Sectionofthe manual →

(noteref.inbrackets)

---

(1)

---

(2)

---

(3)

21.1 ---

(4)

5

6

7.2

8.2

14.3

9.5

10 11.4 12.2

14.5 15.2

16

17

18.4

19.2 19.2

20.1

---

(7)

---

Appliancelock--- out(*)

Defect

↓

Powersupplyline

Gassupplyline

Flue pipes

Cond.drain pipe andtrap

C.h. circuit

D.h.w. circuit

Condensing heat exchanger

D.h.w. heat exchanger

Pump

Diverter valve

D.h.w. flow switch

Fuses(Electronic p.c.b.)

Mainelectronicp.c.b.

Boiler settings

Controlpanel electr.p.c.b.

Gasvalve

Maincircuit pressure switch

D.h.w. filter

Maincircuit temp.probe

D.h.w. temp.probe

By---passvalve

Fan/airrestrictor

Ignition electrode

Detectionelectrode

Safety thermostat

Gasrestrictor

Flue temp.probe NTC

Expansionvessel

Safety valve

Pressure gauge

External temp.probe

E01

 



E02

 



E03



E04



E05



E06



E07



E08



s”E”

E09

 

c

ate

s

E10

 

indi

c

E11

E12

E13



p

layi

E14

E20



Disp

4 FAULT FINDING

- 12 -

FAULT FINDING

Components to check

Sectionofthe manual →

(noteref.inbrackets)

--------

--

(7)

2.912.911.0218.4617115.24.112.215.41109.514.32.72.865---

(4)

21.1---

(3)

---

(2)

---

(1)

Appliancelock--- out(*)

External temp.probe

Pressure gauge

Safety valve

Expansionvessel

Flue temp.probe NTC

Gasrestrictor

Safety thermostat

Detectionelectrode

Ignitionelectrode

Fan/airrestrictor

By---passvalve

D.h.w. temp.probe

Main circuittemp. probe

D.h.w. filter

Main circuitpressure switch

Gasvalve

Controlpanel electr.p.c.b.

Boiler settings

Main electronic p.c.b.

Fuses(Electronic p.c.b.)

D.h.w. flow switch

Diverter valve

Pump

D.h.w. heat exchanger

Condensing heat exchanger

D.h.w. circuit

C.h. circuit

Cond.drain pipe andtrap

Flue pipes

Gassupplyline

Powersupplyline

Defect

↓

Theboiler does notstart either in

c/hord.h.w.mod e.

Thecontrol paneldisplay OFF

Fanstill.



Theboiler does notsupplyd.h.w.

(cold waterfromthe tap).

Regularoperation in c/hmodeeven

during adrawing offd.h.w.

  

d

isplay

On c/hmodethe temperatureof

themaincircuit reaches90Cand

thec/h system does notheat.

Theboileroperates correctly on

d.h.w. mode.

  

on di

Incorrectmodulation

   

t

ion

o

Noisybolier

 



  

d

icati

Poor c.h. /d.h.w.temperature

(9)

    

”Er” ind

Poor d.h.w. temperature. Regular

operationinc/h mode.

  

(8)



No ”

Lowd.h.w.flowrate



 

---

Waterleaks from thesafetyvalve

during operationonc/h

     

---

Waterleaks from thesafetyvalve

when theboilerisoff.

  

*Lockout is indicatedas“E ”onthe display.

Note

Useful informatio ncan be obtained also from the

opticalindicationgiven by theappliance display

(see section4.1).

1Check for230V~between line (L)and neutral(N)

Ve rify theintegrity of su pply cable, plug andexternalfuses.

Checkthe polarity of line and neutralconnection

2Check thegas supply pipe andisolation tapfor gastightness.

3Check forsoundness and absenceofobstructions. Verify that

theflueterminal is correctly installed(seeclearances) anden-

sure that exhaustgas is notsuckedbackbythe boiler.

4Check forsoundness of thecircuit andverif yits correct filling

(see also installation manual).

5Ajammed by---passcould causethe over --- heatingofthe main

circuitand theinterventionofthe safety thermostat.

6Using theflu eanalyzer, checkthe CO

2

value of theflue gases.

This readingisareferencevalue forthe gasvalve setting.

7Check thepressurization of theexpansion vessel.Refer to the

installation manual forpropervalues.

8d.h.w.pressure toohighorflowratetoo high.Ifnecessary in-

sert aflowratelimiter (14.6).

9The boiler doesn’treach thenominal heat input.

- 13 -

FAULT FINDING

4.1 Display diagnostic

Thedisplayindicationsprovidehelpinthediagnosisoffaultn-

ding.

The control panel display gives other information for the user.

The following table gives fault code, error and the reson for the

fault.

E01 + RESET Lack of burner ignition on safety lockout

E02 + RESET Safety thermostat intervention lockout

E03 + RESET Generallockout

E04 +

Little pressure in the system or pressure

transducer disconnected

E05 +

Pressure switch anomaly (if present)

E06 +

Faulty c.h. temp. probe NTC1 or NTC2

E07 +

Faulty d.h.w. temp. probe NTC

E08 +

Faulty external temp. probe NTC (with K

set)

E09 +

Faultyuetemp.probeNTC(ifpresent)

E10 + RESET Flue probe intervention lockout (if present)

E11 + RESET Flame detection error

E12 +

Failure return NTC probe

E13 +

∆Tdelivery-return>40K(ifforeseen)

E14 + RESET Faulty pump or primary temperature above

105°C

E14 +

Absenceofowfromtemperaturegradient

(>2K/s)

E20 + RESET LockoutEVG

E21 + RESET LockoutEVG

E22 + RESET LockoutEVG

E23 + RESET LockoutEVG

E24 + RESET Abnormal combustion ignition lock

E25 + RESET Abnormal combustion operation lock

E69 +

Wiring error lockout

E99 +

Boilernotcongured

L01 Primary circuit temp. limit during D.h.w.

operation

- 14 -

CONDENSING HEAT EXCHANGER

5 CONDENSING HEAT EXCHANGER

5.1 Function

The Condensing heat exchanger A in (Figure 5.1) has the fun-

ction of transferring heat produced from combustion of the gas

andfromtheueexhaustedgastothewatercirculatinginit.

Figure 5.1

A

B

C

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

supply before removing any covering or component.

1 Disconnecttheue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 44.

3 Disconnect the detection electrode connector D, the ignition

electrodes connector E and the earth wire F.

4 Disconnect the fan connector G by pressing the plastic hook

placed on the side of the connector (Figure 5.2).

5 Unscrew the nuts H (Figure 5.2).

6 Remove the fan-burner group I.

7 Empty the primary circuit of the boiler.

8 Remove the clips J (Figure 5.2).

9 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.

Figure 5.2

D

E

F

G

H

I

J

K

L

M

N

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.

Figure 5.3

O

P

Q

R

11 Using pliers, remove the spring O moving it downwards and

disconnect the rubber pipe P (Figure 5.3).

- 15 -

CONDENSING HEAT EXCHANGER

12 Unscrew the screws Q 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).

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 rmly.

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

S

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.

- 16 -

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.

Figure 6.1

A

The schematic structure is shown in Figure 6.2.

Figure 6.2

Primaryhydraulic circuit

Domestic hotwater circuit

6.2 Removal

Warning: isolate the boiler from the mains electrici-

ty supply before removing any covering or compo-

nent.

1 Remove the panels of the case.

2 Empty the primary circuit and the d.h.w circuit of the boiler.

3 Remove the control panel following the instructions from 4 in

section 2.3.

4 Remove main electronic p.c.b. box following the instructions

from 5 in section 2.4.

5 Remove the pump following the instructions in section 7.3.

6 Completely unscrew the Allen key screws B in Figure 6.3

which hold the exchanger to the plastic groups.

Figure 6.3

B

A

B

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.

W

arning: to lubricate the O-ring gaskets exclusive-

ly use a silicone base grease compatible to be in

contact with foods and approved by the local water

Authorities.

Warning: When reassembling the exchanger be sure

to put the off center location/securing pin indicated

in Figure 6.4 towards the left side of the boiler.

Figure 6.4

- 17 -

PUMP

7 PUMP

7.1 Function

The pump A in Figure 7.1 and Figure 7.3 has the function of ma-

king 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 exchan-

ger (during the d.h.w. function).

Figure 7.1

A

7.2 Checks

Warning: isolate the boiler from the mains electricity

supply before removing any covering or component.

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 relea-

se 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 7.3).

Measure the electrical resistance between the pump supply con-

nections.

Figure 7.2

1

2

3

5

4

6

Electrical resistance of the windings (at ambient temperature)

must be:

COIL RESISTANCE

1 - 4 110Ω

1 - 6 215Ω

2 - 3 0Ω

2 - 5 230Ω

3 - 5 230Ω

4 - 6 110Ω

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 the 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 pa-

nels, 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rmlyjoinedtotherotor

- 18 -

PUMP

7.3 Removal pump

Warning: isolate the boiler from the mains electricity

supply before removing any covering or component.

1 Remove the front and right hand side case panels.

2 Empty the primary circuit of the boiler.

3 Disconnect the connector B (Figure 7.3) following the indica-

tions given on the connector box.

4 Disconnect the earth connector C.

Figure 7.3

B

A

C

D

E

F

G

H

I

J

5 LoosentheconnectionG,andpullupandturntotheleftthe

pipe H.

6 Remove the fork F, loosen the connection J and remove the

pipe I.

7 Remove the locking plate D.

8 Unscrew the two screws E 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.

7.4 Removal electrical capacitor

Warning: isolate the boiler from the mains electricity

supply before removing any covering or component.

1 Remove the front and right hand side case panels.

2 Disconnect the connector B (Figure 7.3) following the indica-

tions given on the connector box.

3 Remove the connector K of the cover box by levering with a

screwdriver in as shown in (Figure 7.4)

Figure 7.4

K

4 Remove the capacitor connection block L freeing it from the

hook M and pulling it as indicated by the arrow (Figure 7.5).

Figure 7.5

L M

- 19 -

THREE WAY DIVERTER VALVE

8 THREE WAY DIVERTER VALVE

8.1 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 electronic 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.

Figure 8.1

A

8.2 Checks

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gures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.

Figure 8.2

bk =black

Open circuit

9,4Kohm

3

bnbubk

21

bu =blue

bn =brown

230 V

0 V

B

Spindle visible

D.h.w. mode

Figure 8.3

bk =black

Open circuit

9,4Kohm

3

bnbubk

21

bu =blue

bn =brown

0 V

230 V

B

Spindle not visible

C.h. mode

8.3 Removal of the electric actuator

Warning: isolate the boiler from the mains electrici-

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xingspringDandremovetheactuatorE.

Reassemble the actuator carrying out the removal operations

in the reverse order.

When reassembling the actuator, refer to Figure 8.3 or to the

wiring diagram in section 3 for the correct wiring connection.

- 20 -

THREE WAY DIVERTER VALVE

Figure 8.4

C

D

E

8.4 Removal of the three way diverter valve

1 Remove the front and both side case panels.

2 Empty the primary circuit and the d.h.w circuit of the boiler.

3 Remove the electric actuator (see "Removal of the electric

actuator" page 19).

4 RemovethexingspringF(Figure8.5)

5 Remove the threewaydiverter valve G by levering with a

screwdriver in as shown in Figure 8.5.

Figure 8.5

F

G

H

Reassemble the three way diverter valve carrying out the remo-

val operations in the reverse order.

W

arning: 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.

Attention. When reassembling the three way diverter valve

be sure that the three way diverter is correctly oriented by

matching the reference H with the notch of the water group

Figure 8.5.

8.5 Removal of the diverter group

1 Remove the front and both side case panels.

2 Empty the primary circuit and the d.h.w circuit of the boiler.

3 Remove the electric actuator (section "Removal of the elec-

tric actuator" page 19).

4 RemovethexingspringI(Figure8.6)andremovethepri-

marycircuitowswitchJ.

Figure 8.6

I

J

5 Disconnect d.h.w. temperature probe K.

Figure 8.7

K

L

M

6 UnscrewtheconnectorL(Figure8.7),thec.h.owconnector

and the d.h.w. outlet connector.

7 Remove the d.h.w. heat exchanger (see "Removal" page

16).

8 Unscrew the screw M and remove the diverter group.

9 Reassemble the diverter group carrying out the removal op-

erations in the reverse order.

W

arning: 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.

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