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Wall hung, fanflue, roomsealed, high efficiency gas boiler
Service manual
Inovia ERP
Models
Inovia 25C ERP
Inovia 30C ERP
Inovia 35C ERP
Inovia 25S ERP
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.
G.C. Appl. No.
47-583-38
47-583-39
47-583-40
41-583-30
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Table of Contents
Related Manuals for Biasi Inovia ERP Series
Summary of Contents for Biasi Inovia ERP Series
- Page 1 Wall hung, fanflue, roomsealed, high efficiency gas boiler Service manual Inovia ERP Models G.C. Appl. No. Inovia 25C ERP 47-583-38 Inovia 30C ERP 47-583-39 Inovia 35C ERP 47-583-40 Inovia 25S ERP 41-583-30 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...
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Page 3: Table Of Contents
Table of conTenTs 1 Overall infOrmatiOn . . . . . . . . . . . . . . . . . . . . . . . . . .4 12 primary circuit flOw switch . -
Page 4: Overall Information
OVERALL INFORMATION Overall infOrmatiOn 1 .1 Overall view Flue temperature probe NTC Condensing heat exchanger Safety thermostat Expansion Ighition vessel electrodes Detection electrode Pipe silencer Burner Airbox (air/gasmixer) Electronic controlbox Three way diverter valve D.h.w.heat Gas restrictor exchanger Condensate trap Main circuit pressure switch C.h. -
Page 5: General Access And Emptying Hydraulic Cir
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS General access and emptyinG Pull the lower part of the front panel and lift it upwards (Figure hydraulic circuits 2.3). 2 .1 nomenclature figure 2 .3 To remove the side panels loosen the screws B (Figure 2.2) and C (Figure 2.3). -
Page 6: Control Panel
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS 2 .3 control panel terminal block lid removal 2 To remove the terminal block lid F (Figure 2.7), free the front warning: isolate the boiler from the mains electrici- hooks. ty supply before removing any covering or compo- nent . -
Page 7: Emptying The Primary Circuit
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS figure 2 .9 figure 2 .12 2 .5 emptying the primary circuit 2 .6 emptying the d .h .w . circuit 1 Close the c.h. circuit flow and return cocks G (Figure 2.10). 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. -
Page 8: Diagrams
DIAGRAMS diaGrams 3 .1 wiring diagram inovia 25c erp - inovia 30c erp - inovia 35c erp Three way Gas valve diverter valve Flame detection Ignition electrode electrodes Pump gnye gnye C.h. temperature probe NTC return Flue temp. probe NTC Safety thermal fuse D.h.w. -
Page 9: Wiring Diagram Inovia 25S Erp
DIAGRAMS 3 .2 wiring diagram inovia 25s erp Three way Gas valve diverter valve Flame detection Ignition electrode electrodes Pump gnye gnye C.h. temperature probe NTC return Flue temp. probe NTC thermal fuse Primary circuit pressure switch gnye C.h. temperature probe NTC Safety thermostat... -
Page 10: Circuit Voltages
DIAGRAMS 3 .3 circuit voltages during c.h. or d.h.w. operation Electrical voltages with burner on only during c.h. operation only during d.h.w. operation 3 way D.h.w. diverter valve Flow switch Gas valve Safety Supply network Main circuit thermostat pressure switch figure 3 .3 - 10 -... -
Page 11: Fault Finding
FAult Finding fault findinG - 11 -... - Page 12 FAult Finding - 12 -...
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Page 13: Display Diagnostic
FAult Finding 4 .1 display diagnostic The display indications provide help in the diagnosis of fault find- ing. 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... -
Page 14: Condensing Heat Exchanger
Condensing heat exChanger cOndensinG heat exchanGer 5 .1 function The Condensing heat exchanger A in (Figure 5.1) has the func- tion of transferring heat produced from combustion of the gas and from the flue exhausted gas to the water circulating in it. 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. -
Page 15: Cleaning
Condensing heat exChanger disconnect the rubber pipe P (Figure 5.3). 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. -
Page 16: D .H .W . Heat Exchanger
D.h.w. heat exchanger 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 .3 7 Move the exchanger towards the rear of the boiler and extract it to the left. -
Page 17: Pump
PUMP pump 7 .2 removal pump 7 .1 function warning: isolate the boiler from the mains electrici- The pump A in Figure 7.1 and Figure 7.2 has the function of mak- ty supply before removing any covering or compo- ing the water in the main circuit circulate through the main con- nent . -
Page 18: Three Way Diverter Valve
Three way diverTer valve 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. -
Page 19: Removal Of The Three Way Diverter Valve
Three way diverTer valve 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 20: Main Electronic Control/Ignition P.c.b
MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. main electrOnic cOntrOl/iGnitiOn The fundamental function of the Main electronic control/ignition p .c .b . 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. 9 .1 function use) and operating in order to keep the temperature of the hy- draulic circuits constant. -
Page 21: Checking The Temperature
MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. figure 9 .2 1 Connector - ignition electrode. 2 Connector - flame detection electrode 3 Connector - controler fan 4 Connector - flue temperature probe NTC 5 Connector - d.h.w. temperature probe NTC, d.h.w. flow switch and external temperature probe (optional) 6 Connector - Primary circuit pressure switch 7 Connector - safety thermostat and c.h. temperature probe figure 9 .3 8 Connector - remote control (optional) 9 Connector - display and function control / c.h. / d.h.w. tem-... -
Page 22: Setting The Boiler Control Function Modes
MAIN ElEctroNIc coNtrol/IgNItIoN p.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. - Page 23 MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. important: at the end of the setting operation it is important to fill/update the table in the installation manual see chapter cOmmissiOninG section: setting record . parameter values (set) Boiler type (to be up- p 01 00 = No power Er 99 dated with the complete 35 = Inovia 25C ERP...
- Page 24 MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. parameter values (set) parameter values (set) Chimney sweep function p 09 00 = No chimney sweep C.h. minimum setpoint p 27 25÷45 (factory set 25 °C) fun (factory set) Maintenance intervals p 28 00 ÷ 48 (= months) 01 = D.h.w.
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Page 25: Checks
MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. 9 .5 checks 6 Re-assemble the Main electronic control/ignition p.c.b. fol- Check that the fuses are complete lowing the removal procedures in the reverse order. If the Main electronic control/ignition p.c.b. does not supply any device (pump, fan, etc.) check that the fuses 10 (Figure 9.2) are important complete. -
Page 26: Thermal Control In The
MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. 9 .7 thermal control in the mode Switch in the function mode Taking circulator off water from the domestic hot circulator on fan still water circuit? Is primary circuit Main circuit pressure stop circulator (3min) temperature higher than that switch consense? selected? lock memorised? -
Page 27: Mode
MAIN ElEctroNIc coNtrol/IgNItIoN p.c.b. 9 .8 thermal control in the mode Switch in the function mode See functioning with the function Taking Request for heat from control in the mode water from the domestic hot room thermostat? water circuit? (sec. 9.7) circulator off fan still circulator on... -
Page 28: Control Panel Electronic P.c.b
Control panel eleCtroniC p.C.b. 10 cOntrOl panel electrOnic p .c .b . Indicate the status of the scheduling re- quest. Flashing: 10 .1 function comfort program in process; reduced program in process. The day of the week is displayed high- lighting the number with the following se- quence: 1=Mon…... -
Page 29: Signal Displayed By Lcd
Control panel eleCtroniC p.C.b. functiOn Constantly illuminated: boiler antifreeze active. Antifrostat In the case of incorrect pressure the value is Constantly illuminated: (system anti- visualised with a flashing symbol. freeze active. When pressure is achieved the symbol re- mains on for 15 s and then disappears. Flashing: siGnal displayed by the lcd high pressure > 2.8 bar ON, 2.6 bar OFF;... -
Page 30: Info Modality
Control panel eleCtroniC p.C.b. 10 .3 info modality 10 .5 removal of the control panel electronic p .c .b The INFO mode allows the display of some information on the boiler functioning status. In case of malfunctioning of the boiler, it may be useful to communicate such information to the Author- warning: isolate the boiler from the mains electrici- ised Service Centre Engineer so that the causes can be under-... - Page 31 Control panel eleCtroniC p.C.b. figure 10 .4 4 Unscrew the screws R and Q. 5 Remove the Interface electronic p.c.b. 6 Reassemble the Interface electronic p.c.b. carrying out the removal operations in the reverse order. - 31 -...
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Page 32: Gas Valve
gas valve 11 Gas valve 11 .3 adjustment 11 .1 function warning: isolate the boiler from the mains electrici- The gas valve A in Figure 11.1 controls the gas inflow to the boiler ty supply before removing any covering or compo- burner. nent . check the supply pressure before making any adjustment to the gas valve . - Page 33 gas valve 12 Turn on the boiler, switching on the fused spur isolation it and rotate the Allen key screw ø 4 mm (C - Figure 11.2) (by switch. rotating it clockwise the CO % increases). 13 Open the gas inlet valve. checking the maximum gas valve setting in heating mode 14 Turn on the boiler and operate for 2 minuets to pre-heat the 19 Press key G to vary the output in chimney sweep mode: when...
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Page 34: Checks
gas valve To adjust the CO % value rotate screw (B - Figure 11.2) (by rotat- ing it clockwise the CO % decreases). 24 Press keys G - H - I (Figure 11.5) at the same time again to exit the ”chimney sweep mode” and return to the previously set boiler status (Figure 11.10) C.h. -
Page 35: Primary Circuit Flow Switch
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 check the presence of water in the primary hydraulic circuit and that the pressure is above the minimum. The contact close (resistance zero) with c.h. -
Page 36: Expansion Vessel And Pressure Gauge
Expansion vEssEl and prEssurE gaugE 13 expansiOn vessel and pressure 13 .3 removal of the expansion vessel GauGe warning: isolate the boiler from the mains electrici- 13 .1 function ty supply before removing any covering or compo- The Expansion vessel (A in Figure 13.1 function is to allow for the nent . -
Page 37: 14 D .H .W . Flow Switch, Filter And Flow Limiter
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. figure 14 .3 1 Remove the front panel of the case. -
Page 38: Removal Of The Flow Switch Group And D.h.w. Circuit Filter
D.h.w. flow switch, filter anD flow limiter 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 . Remove the front panel of the case and empty the d.h.w. circuit. 2 Remove the fork D and pull up the flow switch plug E (Figure 14.3) with the help of a screwdriver. -
Page 39: Temperature Probe
TemperaTure probe 15 temperature prObe 15 .2 checks 15 .1 function Temperature-resistance relationship The Temperature probe has the function of converting the tem- perature of the water in the hydraulic circuit where it is installed warning: isolate the boiler from the mains electrici- into an electrical signal (resistance). - Page 40 TemperaTure probe panel. 2 Empty the d.h.w circuit of the boiler. 3 Remove the electric connector I (Figure 15.4) 4 Remove the fork J and pull the d.h.w. Temperature probe C. 5 Reassemble the d.h.w. Temperature probe carrying out the removal operations in reverse order.
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Page 41: By-Pass Valve
By-pass valve 16 by-pass valve warning: to lubricate the O-ring gaskets exclusively use a silicone base grease compatible to be in con- 16 .1 function tact with foods and approved by the local water au- The By-pass valve A in Figure 16.1 is located between the c.h. thorities . -
Page 42: Fan And Air Box
Fan and air box 3 Disconnect the air manifold C (Figure 17.2). 17 fan and air bOx 4 Disconnect the rubber pipe D. 5 Unscrew the gas connector E. 17 .1 function The function of the Fan A (Figure 17.1) is to force the mixture of air 6 Remove the fixing fork F and remove the gas pipe G. -
Page 43: Ignition, Detection Electrodes And Burner
IgnItIon and detectIon electrodes 18 iGnitiOn, detectiOn electrOdes 18 .2 removal of the ignition and detection elec- and burner trodes 18 .1 function warning: isolate the boiler from the mains electrici- Three electrodes are fitted on the fan-burner group. ty supply before removing any covering or compo- Two of them, fitted on the right side of the fan-burner group A, are nent . -
Page 44: Removal Of The Front Insulation Panel
IgnItIon and detectIon electrodes After any disturbance to the chamber door seal the appiance burner gasket must undergo a full analytical combustion performance check. Air--- gas duct gasket figure 18 .6 figure 18 .4 before reassembling ensure the burner gasket is correctly 18 .5 removal of the rear insulation located . -
Page 45: Ignition And Detection Electrodes
IgnItIon and detectIon electrodes replace it to locate the fault. warning - insulation panels material handling care Check the position of the electrode edges Mineral fibres are used in this appliance for the insulation panels of the combustion chamber warning: isolate the boiler from the mains electrici- Excessive exposure to these materials may cause temporary ir- ty supply before removing any covering or compo- ritation to eyes, skin and respiratory tract. -
Page 46: Safety Thermostat
Safety thermoStat 19 safety thermOstat 19 .3 removal 19 .1 function warning: isolate the boiler from the mains electrici- The safety thermostat A in Figure 19.1 is a device that senses ty supply before removing any covering or compo- the temperature of the primary circuit water which flows in the nent . -
Page 47: Flue Temperature Probe Ntc And Safety Ther
Flue temperature probe NtC aNd SaFety thermal FuSe 20 flue temperature prObe ntc and Reaching the breakdown temperature it opens the circuit and safety thermal fuse locks out the boiler. In case of intervention of this safety device the heat exchanger (part 20 .1 function shown in Figure 20.3) may be damaged and must be replaced. - Page 48 Flue temperature probe NtC aNd SaFety thermal FuSe 12500 12000 11500 11000 10500 10000 9500 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 °C 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 figure 20 .4 - 48 -...
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Page 49: Condensate Trap
Condensate trap 21 cOndensate trap 21 .1 function 21 .3 removal The condensate trap A in Figure 21.1 and Figure 21.2 allows the discharge of the condensate via the condensate drain pipe warning: isolate the boiler from the mains electrici- avoiding in the mean time the escape of combustion products. -
Page 50: Short Spare Parts List
Short Spare partS liSt 22 shOrt spare parts list manufacturer manufacturer’s Key G .c . part no . description Q .ty part no . reference Burner (mod. Inovia 25C ERP, Inovia 25S ERP) BI1293 100 Burner (mod. Inovia 30C ERP, Inovia 35C ERP) BI1293 101 Expansion vessel BI1462 100... - Page 51 Short Spare partS liSt figure 22 .1 - 51 -...
- Page 52 *1796221972* 17962.2197.2 3115 52A4 Biasi UK Ltd Commercial Road Leamore Enterprise Park WALSALL WS2 7NQ Sales Tel. 01922 714600 Tech. Service Tel. 01922 714636 www.biasi.co.uk...