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Wall hung, fanflue, roomsealed, high efficiency gas boiler
Service manual
ActivA Plus
Models
Activ A Plus 25C
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.
G.C. Appl. No.
47-583-28
47-583-26
47-583-27
41-583-20
41-583-21
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Summary of Contents for Biasi ActivA Plus
- Page 1 Wall hung, fanflue, roomsealed, high efficiency gas boiler Service manual ActivA Plus Models G.C. Appl. No. Activ A Plus 25C 47-583-28 Activ A Plus 30C 47-583-26 Activ A Plus 35C 47-583-27 Activ A Plus 16S 41-583-20 Activ A Plus 25S...
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Page 3: Table Of Contents
TABLE OF CONTENTS 1 OVERALL INFORMATION......4 12 PRIMARY CIRCUIT FLOW SWITCH ....37 Overall View . -
Page 4: Overall Information
OVERALL INFORMATION OVERALL INFORMATION 1.1 Overall View Flue temperature probe NTC Condensing heat exchanger Safety thermostat Expansion vessel Ighition electrodes Detection electrode Pipe silencer Burner Airbox (air/gasmixer) Electronic controlbox Three way diverter valve D.h.w.heat exchanger Gas restrictor Condensate trap Main circuit pressure switch C.h. -
Page 5: General Access And Emptying Hydraulic Circuits
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 &ORVH WKH FK FLUFXLW ÀRZ DQG UHWXUQ FRFNV * )LJXUH 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 Activ A Plus 25C - Activ A Plus 30C - Activ A Plus 35C 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... -
Page 9: Wiring Diagram Activ A Plus 16S - Activ A Plus 25S
DIAGRAMS 3.2 Wiring diagram Activ A Plus 16S - Activ A Plus 25S 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. -
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 7KH GLVSOD\ LQGLFDWLRQV SURYLGH KHOS LQ WKH GLDJQRVLV RI IDXOW ¿QG- 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... -
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 DQG IURP WKH ÀXH H[KDXVWHG JDV WR WKH ZDWHU FLUFXODWLQJ LQ LW Figure 5.1 By reducing the combustion products temperature, the latent heat of the vapour is transferred to the water circuit, allowing an... -
Page 15: Cleaning
CONDENSING HEAT EXCHANGER 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 ¿UPO\ 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... -
Page 16: 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 7.1 Function The pump A in Figure 7.1 and Figure 7.3 has the function of mak- ing the water in the main circuit circulate through the main con- densing heat exchanger and therefore through the c.h. system (during the c.h. function) or through the secondary heat exchang- er (during the d.h.w. -
Page 18: Removal Pump
PUMP 7.3 Removal pump 7.4 Removal electrical capacitor Warning: isolate the boiler from the mains electricity Warning: isolate the boiler from the mains electricity supply before removing any covering or component. supply before removing any covering or component. 1 Remove the front and right hand side case panels. 1 Remove the front and right hand side case panels. -
Page 19: 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 20: 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 21: 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 22: Checking The Temperature
MAIN ELECTRONIC CONTROL/IGNITION P.C.B. Figure 9.2 1 Connector - ignition electrode. 2 &RQQHFWRU ÀDPH GHWHFWLRQ HOHFWURGH 3 Connector - controler fan 4 &RQQHFWRU ÀXH WHPSHUDWXUH SUREH 17& 5 &RQQHFWRU GKZ WHPSHUDWXUH SUREH 17& GKZ ÀRZ VZLWFK and external temperature probe (optional) 6 Connector - Primary circuit pressure switch 7 Connector - safety thermostat and c.h. -
Page 23: 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 24 MAIN ELECTRONIC CONTROL/IGNITION P.C.B. Important: at the end of the setting operation it is important WR ¿OOXSGDWH WKH WDEOH LQ WKH LQVWDOODWLRQ PDQXDO VHH FKDSWHU COMMISSIONING section: Setting record. PARAMETER VALUES (SET) Boiler type (to be up- P 01 00 = No power Er 99 dated with the complete 35 = Activ A Plus 25C range)
- Page 25 MAIN ELECTRONIC CONTROL/IGNITION P.C.B. PARAMETER VALUES (SET) PARAMETER VALUES (SET) Chimney sweep function P 09 00 = No chimney sweep Presence of domestic P 29 00 = No NTC probe fun (factory set) cold water temp. 01 = Yes NTC probe 01 = D.h.w.
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Page 26: 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. ,I WKH 0DLQ HOHFWURQLF FRQWUROLJQLWLRQ SFE GRHV QRW VXSSO\ DQ\ device (pump, fan, etc.) check that the fuses 10 (Figure 9.2) are Important complete. -
Page 27: Thermal Control In The Mode
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 28: Thermal Control In The 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 29: Control Panel Electronic P.c.b
CONTROL PANEL ELECTRONIC P.C.B. Indicate the status of the scheduling re- 10 CONTROL PANEL ELECTRONIC P.C.B. 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 30 CONTROL PANEL ELECTRONIC P.C.B. FUNCTION Constantly illuminated: boiler antifreeze Boiler Stand-By, hyphens are turned on in active sequence to simulate running (antifreeze Antifrostat protection activated) Constantly illuminated: (system anti- freeze active In the case of incorrect pressure the value is YLVXDOLVHG ZLWK D ÀDVKLQJ V\PERO SIGNAL DISPLAYED BY THE LCD When pressure is achieved the symbol re-...
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Page 31: 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- ty supply before removing any covering or compo-... - Page 32 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. - 32 -...
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Page 33: 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 FRQWUROV WKH JDV LQÀRZ WR WKH ERLOHU ty supply before removing any covering or compo- burner. nent. - Page 34 GAS VALVE 12 Turn on the boiler, switching on the fused spur isolation Checking the minimum gas valve setting in heating mode switch. 19 Press key G to vary the output in chimney sweep mode: when the display shows the letters hP that alternate with the heat- 13 Open the gas inlet valve.
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Page 35: Checks
GAS VALVE Model Type gas % value (range) C.h. / d.h.w. function Activ A Plus 25C Natural (G20) 9,2 - 9,8 Activ A Plus 30C Propane (G31) 9,9 - 10,8 Activ A Plus 35C Natural (G20) 9,2 - 9,8 Activ A Plus 16S Propane (G31) 9,9 - 10,8 Natural (G20) - Page 36 GAS VALVE Warning: After cleaning or replacement as detailed above, it is deemed necessary to undertake a com- bustion analysis as detailed in section 11.3. Figure 11.13 3 Turn off the gas supply and disconnect the gas isolation cock connector from the inlet port of the gas valve. 4 Using pliers, remove the spring L and the rubber pipe M (Fig- ure 11.13).
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Page 37: Primary Circuit Flow Switch
PRIMARY CIRCUIT FLOW SWITCH 12 PRIMARY CIRCUIT FLOW SWITCH 12.1 Function 7KH 3ULPDU\ FLUFXLW ÀRZ VZLWFK 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 38: 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 39: 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 7KH GKZ ÀRZ VZLWFK 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 40: 5Hprydo Ri Wkh Àrz Vzlwfk Jurxs Dqg GKZ Flufxlw ¿Owhu
D.H.W. FLOW SWITCH, FILTER AND FLOW LIMITER 14.5 5HPRYDO RI WKH ÀRZ VZLWFK JURXS DQG GKZ FLUFXLW ¿OWHU 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 DQG SXOO XS WKH ÀRZ VZLWFK SOXJ ( )LJXUH 14.3) with the help of a screwdriver. -
Page 41: 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 42 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 43: 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 44: 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 6 5HPRYH WKH ¿[LQJ IRUN ) DQG UHPRYH WKH JDV SLSH * The function of the Fan A (Figure 17.1) is to force the mixture of air and gas into the burner. -
Page 45: 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- 7KUHH HOHFWURGHV DUH ¿WWHG RQ WKH IDQEXUQHU JURXS ty supply before removing any covering or compo- 7ZR RI WKHP ¿WWHG RQ WKH ULJKW VLGH RI WKH IDQEXUQHU JURXS A, are nent. -
Page 46: Removal Of The Front Insulation Panel
IGNITION AND DETECTION ELECTRODES must undergo a full analytical combustion performance check. burner gasket Air--- gas duct gasket 18.5 Removal of the rear insulation See warning note at the end of this chapter before to remove this part. Attention: Cover the inner of the condensing heat exchanger to avoid that dirt and debris fall in the coil. - Page 47 IGNITION AND DETECTION ELECTRODES In general, normal handling and use will not present high risk, fol- 3,5 mm low good hygiene practices, wash hands before, touching eyes, consuming food, drinking or using the toilet. First aid - Medical attention must be sought following eye contact or prolonged reddening of the skin.
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Page 48: 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- WKH WHPSHUDWXUH RI WKH SULPDU\ FLUFXLW ZDWHU ZKLFK ÀRZV LQ WKH nent. -
Page 49: Flue Temperature Probe Ntc And Safety Thermal Fuse
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 50 FLUE TEMPERATURE PROBE NTC AND SAFETY THERMAL FUSE Ω 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 - 50 -...
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Page 51: 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. ty supply before removing any covering or compo- A plastic ball closes the trap outlet in case that the trap is empty. -
Page 52: 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. Activ A Plus 25C, Activ A Plus 25S, Activ A Plus 16S) 1 BI1293 100 Burner (mod. Activ A Plus 30C, Activ A Plus 35C) BI1293 101 Expansion vessel BI1462 100... - Page 53 SHORT SPARE PARTS LIST Figure 22.1 - 53 -...
- Page 54 NOTE - 54 -...
- Page 56 *1796221010* 17962.2101.0 5111 56A4 Biasi UK Ltd Commercial Road Leamore Enterprise Park WALSALL WS2 7NQ Sales Tel. 01922 714600 Tech. Service Tel. 01922 714636 www.biasi.co.uk...
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