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Installation Instructions Type C Boilers G.C.N: 41-116-01 47-116-08 47-116-09 47-116-13 LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Country of destination: GB
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2 B004 TABLE OF CONTENTS 1. GENERAL INFORMATION 1.1 General Instructions 1.2 Technical Information 1.3 Overall View 2. INSTALLATION 2.1 Reference Standards 2.2 Siting the Appliance 2.3 Overall Dimensions 2.4 Clearances 2.5 Mounting the Appliance 2.6 Electrical Connection 2.7 Gas Connection 2.8 Water Connections 2.9 Flue Connection 2.10 Room Thermostat Connection 2.11 Electrical/System Diagrams 2.12 Water Circuit Diagrams 3. COMMISSIONING 3.1 Initial Preparation 3.2 Removing the Casing 3.3 Control Panel 3.4 Initial Start-up 3.5 Operational Adjustments 3.6 Combustion Analysis 3.7 Fume Discharge Monitoring 3.8 Boiler Safety Systems 3.9 Draining the System 4. GAS ADJUSTMENTS - Gas Adjustment Table 4.1 Changing the Type of Gas 5. MAINTENANCE 6. MISCELLANEOUS 6.1 Wiring Diagram for Two Heating Zones 6.2 Wiring Diagram for Connection to Ariston Unvented Cylinder
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3 B004 This manual is an integral and essential part of the product. It should be kept with the appliance so that it can be consulted by the user and our authorised personnel. Please carefully read the instructions and notices about the unit contained in this manual, as they provide important information regarding the safe installation, use and maintenance of the product. For operating instructions please consult the separate User’s Manual. Read the instructions and recommendations in these Installation Instructions carefully to ensure proper installation, use and maintenance of the appliance. Keep this manual in a safe place. You may need it for your own reference while our Servicing Centre technicians or your installer may need to consult it in the future. This is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.). This appliance must be used only for the purpose for which it is designed. The manufacturer declines all liability for damage caused by improper or negligent use. No asbestos or other hazardous materials have been used in the fabrication of this product. Before connecting the appliance, check that the information shown on the data plate and the table on pages 4-5 comply with the electric, water and gas mains of the property.You will find the data plate on the reverse of the control panel. The gas with which this appliance operates is also shown on the label at the bottom of the boiler. Do not install this appliance in a damp environment or close to equipment which spray water or other liquids. Do not place objects on the appliance. Do not allow children or inexperienced persons to use the appliance without supervision. If you smell gas in the room, do not turn on light switches, use the telephone or any other object which might cause sparks. Open doors and windows immediately to ventilate the room. Shut the gas mains tap (on the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately. If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve. Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the appliance or carriyng out maintenance. In the case of faults or failure, switch off the appliance and turn off the gas tap. Do not tamper with the appliance. For repairs, call your local Authorised Servicing Centre and request the use of original spare parts. For in-guarantee repairs contact MTS (GB) Limited Check the following at least once a year: 1 - Check the seal of water connections, replacing the gaskets if necessary. 2 - Check the seal of the gas connections, replacing the gaskets if necessary. 1. GENERAL INFORMATION User’s Manual 1.1 General Information
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4 B004 23 MFFI 27 MFFI 27 RFFI SYSTEM 30 MFFI CE Certification Heat Input max/min kW 25.6/11.0 29.8/12.0 29.8/12.0 33.0/12.0 Heat Output max/min kW 23.1/9.2 27.3/10.1 27.3/10.1 30.3/10.2 Efficiency of Nominal Heat Input % 90.2 91.6 91.6 92.0 Efficiency at 30% of Nominal Heat Input % 87.8 88.3 88.3 88.6 Heat Loss to the Casing (³T=50°C) % 1.2 1.3 1.3 1.4 Flue Heat Loss with Burner Operating % 8.6 7.1 7.1 6.6 Flue Heat Loss with Burner Off % 0.4 0.4 0.4 0.4 Maximum Discharge of Fumes (G20-G25) Kg/h 59 62 62 61 Residual Discharge Head mbar 1.15 1.4 1.4 1.4 Consumption at Nominal Capacity (G20-G25) m3/h 2.72/3.32 3.16/3.86 3.16/3.86 3.49/4.05 Gas Consumption after 10 Minutes* m3 0.32/0.39 0.37/0.45 0.37/0.45 0.41/0.47 (15°C, 1013 mbar) (G30-G31) Kg/h 2.02/2.00 2.35/2.32 2.35/2.32 2.60/2.57 Temp. of exhaust fumes at nominal capacity (G20-G25) °C 137 128 128 135 CO2 Content % 5.8 6.6 6.6 7.5 O2 Content % 9.2 8.0 8.0 8.0 CO Content ppm 32 34 34 49 Minimum Ambient Temperature °C +5 +5 +5 +5 Head Loss on Water Side (max) (³T=20°C) mbar 200 200 200 200 Residual Head of System bar 0.25 0.25 0.25 0.25 Heating Temperature max/min °C 82/42 82/42 82/42 82/42 Domestic Hot Water Temperature max/min °C 56/36 56/36 --- 56/36 D.H.W. Flow Rate ³T=35°C l/min 9.5 11.2 --- 12.3 D.H.W. Flow Rate ³T=35°C gal/min 2.1 2.5 --- 2.7 D.H.W. Flow Minimum Rate l/min 2.6 2.6 --- 2.6 Pressure of Domestic Hot Water max/min bar 6/0.2 6/0.2 --- 6/.02 Expansion Vessel Capacity l 7 7 7 7 Expansion Vessel Pre-load Pressure bar 1 1 1 1 Maximum Water Content in System l 145 145 145 145 Maximum Heating Pressure bar 3 3 3 3 Nominal Pressure Natural Gas (G20-G25) mbar 20-25 20-25 20-25 20-25 Liquid Gas (G30-G31) mbar 30-37 30-37 30-37 30-37 Electrical Supply V/Hz 230 / 50 230 / 50 230 / 50 230 / 560 Power Consumption W 150 190 190 190 Protection Grade of Electrical System IP X4D X4D X4D X4D Internal Fuse Rating FAST 2 AT FAST 2 AT FAST 2 AT FAST 2 AT Weight Kg 47 47 46.5 47 G.C. Number 47-116-08 47-116-09 41-116-01 47-116-13 1.2 Technical Information 3 - Check the general condition of the appliance and of the combustion chamber visually. 4 - Visual check of the combustion: clean burners if necessary. 5 - With reference to point 3, dismantle and clean the combustion chamber if necessary. 6 - With reference to point 4, dismantle and clean the injectors if necessary. 7 - Visual check of the primary heat exchanger: - check for overheating of the exchangers fins; - clean the exhaust side of the exchanger and fan if necessary. 8 - Regulate the gas pressure, ignition pressure, partial flame, maximum flame. 9 - Check proper operation of the heating safety system: - maximum safety temperature; - maximum safety pressure. 10 - Check the proper operation of the gas safety system: - gas or flame safety device; - gas valve safety device. 11 - Check that the electrical connections have been made in compliance with the instructions shown in the Installation Instructions. 12 - Check the efficiency of the hot water supply (flow and temperature). 13 - Check general operation of the appliance. 14 - Check the exhaust system for the combustion products. *Calculated at 70% maximum output
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5 B004 GENUS 23/27/30 MFFI Legend: 1. Flue Connector 2. Combustion Chamber Hood 3. Main Heat Exchanger 4. Combustion Chamber Insulation Panel 5. Burner 6. Expansion Vessel 7. Overheat Thermostat 8. Spark Generator 9. Diverter Valve (MFFI) Motorised Valve (RFFI) 10. Main Circuit Temperature Probe 11. Main Circuit Flow Switch 12. Domestic Hot Water Temperature Probe 13. Diverter Valve Microswitch 14. Filter Seat 15. Drain Valve 16. Secondary Heat Exchanger 17. Safety Valve (3 bar) 18. Circulation Pump with Automatic Air Release Valve 19. Gas Valve 20. Detection Electrodes 21. Ignition Electrodes 22. Fan 23. Venturi 24. Air Pressure Switch GENUS 27 RFFI SYSTEM Fig. 1.1 1.3 Overall View
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6 B004 The technical information and instructions provided herein below are intended for the installer so that the unit may be installed correctly and safely. The installation and initial startup of the boiler must be by a CORGI Approved Installer in compliance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI. This appliance must be installed by a competent installer in accordance with the current Gas Safety (installation & use) Regulations The installation of this appliance must be in accordance with the relevant requirements of the current Gas Safety (installation & use) Regulations, the Local Building Regulations, the current I.E.E. Wiring Regulations, the byelaws of the local water authority, and in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635 “Electricity at work regs. 1989”. Installation should also comply with the following British Standard Codes of Practice: The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combined appliance in a room containing a bath or shower. Where a room-sealed appliance is installed in a room containing a bath or shower the boiler and any electrical switch or appliance control, utilising mains electricity should be situated so that it cannot be touched by a person using the bath or shower. The location must permit adequate space for servicing and air circulation around the appliance as indicated in paragraph 2.4. The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary. BS 6798-1987 gives detailed guidance on this aspect. A compartment used to enclose the appliance must be designed specifically for this purpose. No specific ventilation requirements are needed for an installation within a cupboard This appliance is not suitable for outdoor installation. The type C appliances (in which the combustion circuit, air vent intake and combustion chamber are air-tight with respect to the room in which the appliance is installed) can be installed in any type of room. There are no limitations with respect to ventilation and the volume of the room itself. The boiler must be installed on a solid, permanent wall to prevent access to the electrical parts (when live) through the aperture on the back frame. 2. INSTALLATION 2.1 Reference Standards 2.2 Siting the Appliance Low pressure pipes BS 6891 1988 Boilers of rated input not exceeding 60 kW BS 6798 1987 Forced circulation hot water system BS 5449 1990 Installation of gas hot water supplies for domestic purposes ( 2nd family gases) BS 5546 1990 Flues BS 5440-1 1990 Air supply BS 5440-2 1989
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7 B004 Legend: A = Central Heating Flow (3/4”) B = Domestic Hot Water Outlet (1/2”) C = Gas Inlet (3/4”) D = Domestic Cold Water Inlet (1/2”) E = Central Heating Return (3/4”) F = Cylinder Flow (3/4”) G = Cylinder Return (3/4”) 2.3 Overall Dimensions 890 385 (A-B-D-E) (C) 465 99 99 132 67 65 85 155 208 30 49 (F - G) (A - D - E) (C) AF C DGE GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM In order to allow for access to the interior of the boiler for maintenance purposes, the boiler must be installed in compliance with the clearance requirements indicated in the diagram below. 400 300 450 60 60 110 197 160 2.4 Clearances min30-max350 GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM Fig. 2.1 Fig. 2.2
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8 B004 Fasten the boiler in place using the template and anchors supplied with the unit. It is highly recommended that a spirit level be used to position the boiler so that it is perfectly level. For additional information, please consult the instructions contained in the connection kit and the flue kit. For safety purposes, have a competent person carefully check the electrical system in the property, as the manufacturer will not be held liable for damage caused by the failure to earth the appliance properly or by anomalies in the supply of power. Make sure that the residential electrical system is adequate for the maximum power absorbed by the unit, which is indicated on the rating plate. In addition, check that the section of cabling is appropriate for the power absorbed by the boiler. The boiler operates with alternating current, as indicated in the technical data table (1.2), where the maximum absorbed power is also indicated. Make sure that the connections for the neutral and live wires correspond to the indications in the diagram. The appliance electrical connections are situated on the reverse of the control panel (see the servicing manual for further information) 2.5 Mounting the Appliance 2.6 Electrical Connection Important! In the event that the power supply cord must be changed, replace it with one with the same specifications. Make the connections to the terminal board located within the control panel, as follows: - The yellow-green wire should be connected to the terminal marked with the earth symbol; make sure to re-use the ferrule mounted on the other supply cord; - The blue wire should be connected to the terminal marked “N”; - The brown wire should be connected to the terminal marked “L”. Note: The diagrams for the electrical system are indicated in section 2.11. Warning, this appliance must be earthed. External wiring to the appliance must be carried out by a qualified technician and be in accordance with the current I.E.E. Regulations and applicable local regulations. The Genus range of boilers are supplied for connection to a 230 V~ 50 Hz supply. The supply must be fused at 3 A. The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance, by the use of a fused double pole isolator having a contact separation of at least 3 mm in all poles or alternatively, by means of a 3 A fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363. The point of connection to the Electricity supply must be readily accessible and adjacent to the appliance unless the appliance is installed in a bathroom when this must be sited outside the bathroom. Fig. 2.3 2.7 Gas Connection The local gas supplier contractor connects the gas meter to the service pipe. If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time. Pipe work must be of an adequate size. Pipes of a smaller size than the boiler inlet connection should not be used.
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9 B004 2.8 Water Connections Legend A = Central Heating Flow B = Domestic Hot Water Outlet C = Gas Inlet D = Domestic Cold Water Inlet E = Central Heating Return F = Cylinder Flow G = Cylinder Return I = Safety Valve Central Heating Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance. Pipe Work: Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing should be either with capillary soldered or compression fittings. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps. The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air. Except where providing useful heat, pipes should be insulated to prevent heat loss and avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors. By-pass: The appliance includes an automatic by-pass valve, which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system, due to the closing of thermostatic valves or cock-type valves within the system. System Design: This boiler is suitable only for sealed systems. Drain Cocks: These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15mm nominal size and manufactured in accordance with BS 2870:1980. Safety Valve Discharge: The discharge should terminate facing downwards on the exterior of the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, but in an easily visible position, and not cause damage to electrical components and wiring. The discharge must not be over an entrance or a window or any other type of public access. A C B D E I A C G D E I F GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM View of the Boiler Connections Fig. 2.4 Fig. 2.5 Fitting the connection kit to the Genus 27 RFFI System only. It will be noted that the kit has two connections not required for this boiler i.e. the domestic cold inlet “E” and the domestic hot water outlet “B” (see fig. 2.4). Although the cold water main supply must be connected to the isolation valve for the purpose of operating the filling- loop, the isolation valve is NOT connected to the boiler and should be left in the OFF position. The D.H.W. outlet is capped-off on the boiler, therefore not requiring the isolation valve to be used. The Genus 27 RFFI System has 2 x 3/4" B.S.P. male threads for the cylinder flow and return. It is recommended that 2 x 22mm x 3/4" female iron fittings (not supplied) be used on these connections (using P.T.F.E. tape), before the boiler is mounted on the wall.
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10 B004 Residual Head of the Boiler 27/30 kW 23 kW Air Release Points: These must be fitted at all high points where air naturally collects and must be sited to facilitate complete filling of the system. The appliance has an integral sealed expansion vessel to accommodate the increase of water value when the system is heated. It can accept up to 7 l (1.5 gal) of expansion water. If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity. Mains Water Feed - Central Heating: There must be no direct connection to the mains water supply even through a non-return valve, without the approval of the Local Water Authority. Filling: A temporary method for initially filling the system and replacing lost water during servicing and initial filling (in accordance with Water Supply Byelaw 14), is provided as an intergal part of the connection kit (see fig. 2.5). The flexible hose must be removed once the system has been filled. The D.H.W. inlet valve on the connection kit has two postions, one for winter and one for the summer. This enables the flow-rate through the appliance to be adjusted so that a sensible D.H.W. temperature may be achieved throughout the year. Domestic Water The domestic water must be in accordance with the relevant recommendation of BS 5546:1990. Copper tubing to BS EN 1057:1996 is recommended for water carrying pipe work and must be used for pipe work carrying drinking water. 2.9 Flue Connections Flue System The provision for satisfactory flue termination must be made as described in BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outdoor air. The terminal must not discharge into another room or space such as an outhouse or lean-to. It is important that the position of the terminal allows a free passage of air across it at all times. The terminal should be located with due regard for the damage or discolouration that might occur on buildings in the vicinity. In cold or humid weather water vapour may condense on leaving the flue terminal. The effect of such “steaming” must be considered. If the terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be fitted. When ordering a terminal guard, quote the appliance model number.
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TERMINAL POSITION mm A - Directly below an open window or other opening 300 B - Below gutters, solid pipes or drain pipes 75 C - Below eaves 200 D - Below balconies or car-port roof 200 E - From vertical drain pipes and soil pipes 75 F - From internal or external corners 300 G - Above ground or below balcony level 300 H - From a surface facing a terminal 600 I - From a terminal facing a terminal 1200 J - From an opening in the car port (e.g. door, window) into dwelling 1200 K - Vertically from a terminal in the same wall 1500 L - Horizontally from a terminal in the same wall 300 11 B004 A BC D E F G J K HI L G F Fig. 2.6 Ø 60/100 mm The boiler is designed to be connected to a coaxial flue discharge system. Fig. 2.7 A suitable terminal guard is available from: TOWER FLUE COMPONENTS Morley Road Tonbridge Kent TN9 1RA The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig. 2.6
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12 B004 A Ø 80 mm Ø 80 mm In addition, it is also possible to use a split system by fitting a special adapter to the flue discharge collar and using one of the apertures for the air vent intake located on the top part of the combustion chamber (A). A A Fig. 2.8 This procedure must be done as follows: 1 - Remove the air vent intake you want to use, in the area indicated in Fig. 2.9, by breaking the perforated ring. 2 - Use a tool to grasp the lid and remove it completely. 3 - Clean any burrs or sharp edges with a knife or an appropriate tool. A Fig. 2.9 Fig. 2.10
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13 B004 In Fig. 2.11 below, several different types of flue systems are shown. For additional information regarding the flue accessories, please consult the Flue Pipe Accessories manual. Fig. 2.11
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14 B004 In calculating the lengths of the pipes, the maximum length must also take into consideration the values for the exhaust/air intake end terminals, as well as 90° elbows for coaxial systems. The C52 types must comply with the following requirements: 1. The discharge/intake vent pipes must have the same diameter of ø 80 mm. 2. The maximum combined flue length is 17 m for Models Genus 23/27 MFFI/RFFI and 15 m for Model Genus 30 MFFI. In this case the minimum length for the air intake pipe is 1 meter; the maximum length of vertical exhaust pipe must be a maximum of 12 m. 3. If an elbow is inserted into the discharge/ventilation system, the calculation of the overall extension must take into consideration the values for each curve, as indicated in the table. 4. The exhaust pipe must extend at least 0.5 m above the ridge of the roof if it is located on a side other than that for the air intake (this is not obligatory if the exhaust and air intake pipes are located on the same side of the building). 4 m 4 m 4 m 3 m 3 m 3 m Maximum Extension Exhaust/Air 23 kW - 27 kW 30kW Exhaust Type Diameter of Pipes (mm) Use of Restrictor on Discharge Side 42 mm 45 mm 23kW 27 kW 30 kW Risk of Condensation Forming 23kW 27 kW 30 kW C12 (xx) C32 (xx) C42 (xx) C12 (xy) C32 (xy) C42 (xy) C52 (xy) Coaxial Systems Twin Pipe Systems 23 kW 54 m 54 m 54 m 17 m 27 kW 46 m 46 m 46 m 17 m 30 kW 50 m 50 m 50 m 15 m ø 60/100 ø 60/100 ø 60/100 ø 80 ø 80 ø 80 ø 80 L * < 0.5 m L * < 0.5 m L * < 0.5 m L < 7 m L < 7 m L < 7 m L < 7 m L * < 0.5 m L * < 0.5 m L * < 0.5 m L < 5 m L < 5 m L < 5 m L < 5 m L * < 0.5 m L * < 0.5 m L * < 0.5 m L < 7.5 m L < 7.5 m L < 7.5 m L < 7.5 m L > 4.9 m L > 4.9 m L > 4.9 m L > 4.9 m L > 6.5 m L > 6.5 m L > 6.5 m L < 5.3 m L > 4.5 m L > 4.5 m L > 4.5 m L > 4.5 m (*) L = Length of Piping
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15 B004 4 Remove the grommet “E” shown in the photo 4, make a hole in it and pass the room thermostat wire through. 5 Remove the link located in the terminal block and connect the wire. 6 Replace the grommet and the terminal block to their original positions, close the cover on the grommet compartment and fasten the wire-clamp “D” in place. 7 If a remote time clock is to be fitted, disconnect the integral time clock plug from the P.C.B. 8 Using a volt-free switching time clock, connect the switching wires from the time clock following points 1-6 above. 9 If using a time clock and room thermostat, these must be connected in series as per points 1-8 above. Note: Only a two-wire type room thermostat can be used. For details on fitting the D.H.W. probe (Genus 27 RFFI only), please consult the separate instruction sheet supplied with the probe. An anti-frost device is built-in to the appliance’s electronic regulation system. 2.10 Room Thermostat Connection In order to perform this procedure, remove the boiler casing as indicated in section 3.2. Then proceed as follows: 1 Remove the two screws “A” in order to remove the cover, release the two clips “B” and lift and rotate down the control panel box. 2 Open the cover “C” on the left hand side of the compartment. 3 Insert the wire for the connection of the room thermostat into the cable clamp “D”, as indicated in photo 3. 1 2 A B 3 4 5 6 E D C D
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16 B004 2.11 Electrical Diagram Legend: AT = High Voltage P.C.B. BT = Low Voltage P.C.B. A = Remote Connector Kit B = Flame Failure L.E.D. C = Insufficient Water Pressure L.E.D. D = Water Temperature Indicator L.E.D.s E = Overheat Thermostat Warning L.E.D. F = System Reset Button G = Selector Knob for Operating Mode H = Domestic Hot Water Temp. Adjustment I = Central Heating Temp. Adjustment J = Wire Connector for Room Thermostat K = Connector for Total Check System L = Selector for Local/Remote Control M = Anti-cycling Device Adjustment for Heating N = Soft-light Adjustment O = Max Heating Temperature Adjustment P = Time Clock Connection Q = On/Off L.E.D. R = On/Off Switch S = Interface Wire for P.C.B.s T = Relay Motorised Valve U = Ignitor Relay V = Gas Valve Relay W = Fan Relay X = Circulation Pump Relay Y = Selector TCS2 Z = Link for Continuous Pump Run Aa = Adaptor (British Gas use only) A01 = Air Pressure Switch A02 = Fan A03 = Gas Valve A04 = Ignitor A05 = Motorised Valve A06 = Circulation Pump A07 = Flame Detector A08 = Earth Terminal A09 = Flame Detection Circuit A10 = Flame Indicator L.E.D. A11 = Transformer A12 = Filter B01 = Over Heat Thermostat B02 = External Thermostat B03 = Gas Valve Modulator B04 = D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only) B05 = Heating Sensor B06 = Pressure Switch for Heating Circuit B07 = Microswitch for Diverter Valve (MFFI models only) Colours Gry = Grey Rd = Red Bl = Blue Grn/Yll = Yellow/Green Wh = White Brn = Brown Blk = Black Wh/Rd = White/Red
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17 B004 Aa GENUS 23/27/30 MFFI Aa GENUS 27 RFFI SYSTEM
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18 B004 CN202 P GENUS 23/27/30 MFFI P GENUS 27 RFFI SYSTEM
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19 B004 GENUS 23/27/30 MFFI 2.12 Water Circuit Diagram Legend 1. Air Pressure Switch 2. Fan 3. Main Heat Exchanger 4. Burner 5. Electronic Ignitor and Electronic Flame Detector 6. Gas Valve 7. Overheat Thermostat 8. Heating Sensor 9. Diverter Valve (MFFI) Motorised Valve (RFFI) 10. Main Flow Switch Including Safety Pressure Switch for Primary Circuit 11. Automatic By-pass 12. Microswitch for Diverter Valve 13. Sensor for Domestic Hot Water 14. Secondary Heat Exchanger 15. Domestic Water Inlet Filter 16. Drain Valve 17. Safety Valve 18. Water Pressure Gauge 19. Circulation Pump with Automatic Air Valve 20. Expansion Vessel A. Central Heating Flow B. Domestic Hot Water Outlet C. Gas Inlet D. Domestic Cold Water Inlet E. Central Heating Return F. Cylinder Flow G. Cylinder Return GENUS 27 RFFI SYSTEM
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20 B004 3. COMMISSIONING 3.1 Initial Preparation Preliminary electrical system checks to ensure electrical safety must be carried out by a competent person i.e. polarity, earth continuity, resistance to earth and short circuit. Filling the Heating System: Remove the panels of the case and lower the control panel (see point 3.2. for further information). Open the central heating flow and return cocks supplied with the connection kit. Unscrew the cap on the automatic air release valve one full turn and leave open permanently. Close all air release valves on the central heating system. Gradually open valve(s) at the filling point (filling-loop) connection to the central heating system until water is heard to flow, do not open fully. Open each air release tap starting with the lower point and close it only when clear water, free of air, is visible. Purge the air from the pump by unscrewing anticlockwise the pump plug and also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free. Close the pump plug. Continue filling the system until at least 1 bar registers on the pressure gauge. Inspect the system for water soundness and remedy any leaks discovered. Filling of the D.H.W. System: Close all hot water draw-off taps. Open the cold water inlet cock supplied with the connection kit. Open slowly each draw-off tap and close it only when clear water, free of bubbles, is visible Gas Supply: Inspect the entire installation including the gas meter, test for soundness and purge, all as described in BS 6891:1988. Open the gas cock (supplied with the connection kit) to the appliance and check the gas connector on the appliance for leaks. When the installation and filling are completed turn on the central heating system (sect. 3.4) and run it until the temperature has reached the boiler operating temperature. The system must then be immediately flushed through. The flushing procedure must be in line with BS 7593:1992 Code of practice for treatment of water in domestic hot water central heating systems. During this operation, we highly recommend the use of a central heating flushing detergent (Fernox Superfloc or equivalent), whose function is to dissolve any foreign matter that may be in the system. Substances different from these could create serious problems to the pump or other components. The use of an inhibitor in system such as Fernox MB-1 or equivalent is strongly recommended to prevent corrosion (sludge) damaging the boiler and system. Failure to carry out this procedure may invalidate the appliance warranty. To dismantle the front part of the casing, proceed as follows: 1. Loosen the two screws “F” located on the bottom part of the boiler until the first thread on the screws appears; 1 F 3.2 Removing the Casing
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21 B004 3 2. Lift the front panel up until it stops after the click; 3. Remove the front panel from the rest of boiler casing; 4. Unhook the two cords from the location slots. 4 3.3 Control Panel A - Ignition Lockout Reset Button/Safety (Overheat)Thermostat Reset B - Ignition Lockout L.E.D. C - Selector Knob for Summer/Winter/Flue Analysis Modes* D - Low System Water Level L.E.D. E - Temperature Adjustment Knob for Domestic Hot Water F - Heating System Thermometer G - Safety (Overheat)Thermostat Intervention L.E.D. H - Adjustment Knob for Heating Temperature I - On/Off L.E.D. L - On/Off Switch O - System Pressure Gauge * Warning the flue analysis mode must only be selected by a qualified service engineer. 2 GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM
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The boiler was designed to make regulation easy. To access the adjustment and control area, simply remove the cover by unscrewing the screws “A” and “C” and lift up the small service panels “B1” and “B2” respectively. The first provides access to the control (low voltage) P.C.B., while the second makes it possible to work on the power supply P.C.B. A C B1 B2 22 B004 3.4 Initial Start-up The checks to be run before initial start-up are as follows: 1. Make sure that: -the screw on the automatic air valve has been loosened when the system is full; - If the water pressure in the system is below 1 bar, bring it up to the appro- priate level; -Check to see whether the gas cock is closed; -Make sure that the electrical connection has been made properly and that the earth wire is connected to an efficient earthing system; - Supply power to the boiler by pressing the On/Off switch <L> - the L.E.D. “I” will turn on - turn the selector knob “C” to the <winter> setting. This will start the circulation pump. After 7 seconds, the boiler will signal a shut- down due to failure ignition. Leave the boiler as it is until all of the air has been bled from the lines. -Loosen the cap on the head of the pump to eliminate any air pockets; -Repeat the procedure for bleeding the radiators of air; -Open the taps for a brief period; -Check the system pressure and, if it has dropped, open the filling loop again to bring the pressure back up to 1 bar. 2. Check the exhaust flue for the fumes produced by combustion. 3. Make sure that all gate valves are open; 4. Turn on the gas cock and check the seals on the connections, including the one for the burner, making sure that the meter does not signal the passage of gas. Check the connections with a soap solution and eliminate any leaks. 5. Press the reset button “A” for the lighting system; the spark will light the main burner. If the burner does not light the first time, repeat the procedure. 6. Check the minimum and maximum pressure values for the gas going to the burner; adjust it if needed using the values indicated in the table in section 4. (See sect of the servicing manual). The service panel “B2” also provides access to: - the power supply cord connector; - the fuses; - the selector knob for continuous operation of the circulation pump. The service panel “B1” also provides access to: - the potentiometer for regulating the ignition delay (anti-cycling) feature, which can be set from 0 to 2 minutes (factory set at 1 minute); 3.5 Operational Adjustments
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23 B004 3.6 Combustion Analysis The boiler is designed to make it easy to analyse the combustion by-products. Using the especially designed apertures, readings can be taken on the temperature of the combustion by-products and of the combustion air, as well as of the concentrations of O2 and CO2, etc. The best maximum-power test conditions for the heating system are when the selector “C” is turned to the flue analysis setting. The discharge/ventilation of the exhaust fumes can be monitored to check for losses in general pressure in the system. This is done to eliminate the cause of lighting failure with the main burner not indicated by a shutdown status. With a differential manometer connected to the test socket on the combustion chamber, the DP value for the air pressure switch can be taken. The measured value should not be less than 10 mbar under maximum thermal power conditions (with the knob “C” on the flue test setting) in order for the unit to function properly and without interruption. - the potentiometer for regulating the soft-light feature, the setting for which can range from the minimum thermal power to the maximum: - the potentiometer for the maximum thermal power for the heating system, maximum thermal power setting (factory set at the maximum value, unless indicated otherwise on the adhesive sticker located in proximity to the potentiometer); - The connection to the diagnosis device (TCS-TCS2). G20 5 mbar G25 18 mbar G30-31 19 mbar 3.7 Fume Discharge Monitoring
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24 B004 3.9 Draining the System Draining the heating system. The heating system must be emptied as follows: - Turn off the boiler; -Open the drain valve for the system and place a container below to catch the water that comes out; - Empty the system at the lowest points (where present). If you plan on not using the heating system for an extended period of time, it is recommended that you add antifreeze with an ethylene glycol base to the water in the heating lines and radiators if the ambient temperature drops below 0°C during the winter. This makes repeated draining of the entire system unnecessary. Draining the domestic hot water system. Whenever there is the danger of the temperature dropping below the freezing point, the domestic hot water system must be drained as follows: - Turn off the general water valve for the household plumbing system; - Turn on all the hot and cold water taps; - Empty the remaining water from the lowest points in the system (where present). The boiler is equipped with the following safety systems (see section 3.3 for references): 1. - Ignition Failure This control signals an ignition failure on the burner 7 seconds after a lighting failure. The L.E.D. “B” will turn on to signal the shutdown status. The system can be reset by pressing and releasing the button “A” after checking to make sure that the gas valve is open. Repeat this process until the burner lights. 2. - Circulation Failure This control signals that the safety pressure switch on the primary circuit has not sensed a pressure of at least 1 bar within 40 seconds of the activation of the circulation pump, it shuts off the boiler and lights the L.E.D. “D” The system can be reset (after the pressure has been brought up to the proper level) by using the On/Off switch “L”. 3. - Overheating This control shuts off the boiler in the case where the primary circuit reaches a temperature in excess of 110°C. The L.E.D. “G” will come on to signal this shut- off status. After the system has been allowed to cool, the system can be reset by pressing the button “A”. 4. - Limescale Build-up This is an indirect control (actuated through the regulation of the temperature in the primary heat exchanger) on the formation of limescale in the secondary heat exchanger. Regardless of the flow rate and the temperature in the circuit for the domestic hot water, the temperature is limited to 62°C. 5. - Anti-frost Device The boiler is equipped with a device that automatically lights the main burner when the temperature in the delivery line to the system drops below 5°C. The boiler will continue to operate until the temperature in question reaches about 58°C. This device is activated on a properly operating boiler if: - the system pressure is between the acceptable values; - the power supply to the unit is on; - the unit is supplied with gas. This feature is enabled also when the boiler is in summer operating mode. 6. - Safety Shut-off At the start of every lighting phase, the P.C.B. performs a series of internal controls. If a malfunction occurs, the boiler will shutdown until the problem has been resolved. 3.8 Boiler Safety Systems
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CATEGORY II2H3+ Methane Gas Liquid Butane Gas Liquid Propane Gas G20 G30 G31 Recommended Soft-light Pressure (mbar) 5-5.5 17 - 18 18 - 19 Lower Wobbe Index (15°C;1013mbar) MJ/m3h 45.67 80.58 70.69 Nominal Delivery Pressure mbar 20 30 37 Minimum Delivery Pressure mbar 17 20 25 23 MFFI Main Burner: n. 13 jets (ø) mm 1.25 0.72 0.72 Consumption (15°C; 1013mbar) mc/h 2.72 ---- ---- Consumption (15°C; 1013mbar) Kg/h ---- 2.02 2.02 Gas Cock Outlet Pressure max - min mbar 11.4- 2.0 27.5 (*) - 5.0 35.0 (*) - 7.0 27 MFFI - 27 RFFI System Main Burner: n. 15 jets (ø) 1.25 0.72 0.72 Consumption (15°C; 1013mbar) mc/h 3.16 ---- ---- Consumption (15°C; 1013mbar) Kg/h ---- 2.35 2.32 Gas Cock Outlet Pressure: max - min mbar 11.4-2.0 (*) - 5.0 (*) - 7.0 30 MFFI Main Burner: n. 15 jets (ø) 1.30 0.77 0.77 Consumption (15°C; 1013mbar) mc/h 3.49 ---- ---- Consumption (15°C; 1013mbar) Kg/h ---- 2.60 2.57 Gas Cock Outlet Pressure: max - min mbar 11.4-1.4 (*) - 4.1 (*) - 5.6 25 B004 The outlet pressure of the gas cock is obtained by completely loosening the screw on the solenoid. The maximum pressure of the gas to the burner will be equal to the nominal delivery pressure minus the head loss within the gas valve. 4. GAS ADJUSTMENTS (1mbar = 10,197column of water) CATEGORY II2H3+ Methane Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 4.1 Changing the Type of Gas The boiler can be converted to use either methane (natural) gas (G20) or LPG (G30 - G31) by an Authorised Service Centre. The operations that must be performed are the following: 1. Replace the jets on the main burner (see table in section 4); 2. Adjust the maximum and minimum thermal capacity values for the boiler (see table in section 4); 3. Replace the gas rating plate; 4. Adjust the maximum thermal power setting;
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26 B004 It is recommended that the following checks be made on the boiler at least once a year: 1 - Check the seals for the water connections; replacement of any faulty seals. 2 - Check the gas seals; replacement of any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of flue gas (see ref 3.6) and cleaning of the burners if needed. 5 - If called for by check no. 3, dismantling and cleaning of the combustion chamber. 6 - If called for by check no. 4, dismantling and cleaning of the injectors. 7 - Visual check of the primary heat exchanger: - check for overheating in the blade assembly; - clean the exhaust fan if needed. 8 - Adjustment of the flow rate of the gas: flow rate for lighting, partial load and full load. 9 - Check of the heating safety systems: - safety device for maximum temperature; - safety device for maximum pressure. 10 - Check of the gas safety systems: - safety device for lack of gas or flame ionisation (detection electrode); - safety device for gas cock. 11 - Check of the electrical connection (make sure it complies with the instructions in the manual). 12 - Check of domestic hot water production efficiency (delivery rate and tem- perature) 13 - Check of the general performance of the unit. 14 - General check of the discharge/ventilation of the combustion by- products. 5. MAINTENANCE 5. Adjust the soft-light feature; 6. Adjust the delayed lighting feature for the heating system (can be set from 0 to 2 mins.).
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27 B004 6. MISCELLANEOUS 6.1 Wiring Diagram for Two Heating Zones V4043H VALVE BROWN 8 BLUE 2 GREY 9 ORANGE 10 GREEN/YELLOW 3 Honeywell ST 699B 1002 6 3 N L Link L-5-8 ST 6400/ST 6300 ST 6200 3 4 N L Drayton Tempus 7 3 4 N L Horstmann 425, 525, 527 1 4 E N L Link L-2-5 Landis & Gyr RWB2 3 4 N L Glowworm Mastermind Landis & Gyr RWB20 3 4 N L Microgyr Potterton Miniminder 3 4 N L Potterton EP2000/3000 - 3 4 N L Link L-5 EP2001/3001 Randall 102/102 E 1 2 E 5 6 Link 3-6 Randall 4033 4 2 E 7 6 Link 1-6 Randall 701, 702 3 1 E N L Link L-6-5 Sangamo M5 1 8 E 4 3 Link 1-6 Sangamo 410 Form 1 1 8 E 4 3 Link 3-6 PROGRAMMER 6 4 3 2 1 Pegler Sunvic 2 5 E N L SP 50/100 (Link L-3) Switchmaster 1 4 N L Symphony, Sonata Switchmaster 400, 600 3 1 N L SWITCHMASTER 805, 900 3 1 N L Sunvic ET 1451 7 4 E 1 2 Link 2-3-6 Sunvic DHP 2201 6 3 E 1 2 Towerchron FP 6 1 0 2 1 Link 1-5/4-7-9 Towerchron MP 6 1 0 2 1 Link 1-4/6-11 Towerchron 2000 HW HTG N L ON ON ACL LS522, LS722 3 4 N L Randall 922, 972 3 6 E N L Link L-2-5 Randall 3020 P 4 2 E N L and 3060 PROGRAMMER 6 4 3 2 1 A/27 MFFI - A/27 MFFI E N L Genus 23-27-30 MFFI E N L Genus 27 RFFI System E N L BOILER 9 10 3 2 240V MAINS INPUT (3 AMP) L 1 N 2 E 3 • 1 • 2 • 3 • 4 • 5 • 6 • 7 • 8 • 9 • 10 TYPICAL JUNCTION BOX T6360B ROOM THERMOSTAT 1 6 3 8 2 2 ZONE 2 V4043H VALVE BROWN 5 BLUE 2 GREY 9 ORANGE 10 GREEN/YELLOW 3 T6360B ROOM THERMOSTAT 1 4 3 5 2 2 ZONE1 ZONE 1 ZONE 1 ZONE 2 ZONE 2 1 BOILER ELECTRICAL SUPPLY CABLE Remove internal time clock plug from the the P.C.B. then connect room stat terminal block on the reverse of the boiler control panel (see section 2.10) to 9 + 10 on the junction box. If a room thermostat is not required on Zone 1, insert a link between 4 + 5 on the junction box. If a room thermostat is not requied on Zone 2, insert a link between 6 + 8 on the junction box. Based on Honeywell controls
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28 B004 6.2 Wiring Diagram for Connection to Ariston Unvented Cylinder Honeywell ST 699B 1002 6 3 N L Link L-5-8 ST 6400/ST 6300 ST 6200 3 4 N L Drayton Tempus 7 3 4 N L Horstmann 425, 525, 527 1 4 E N L Link L-2-5 Landis & Gyr RWB2 3 4 N L Glowworm Mastermind Landis & Gyr RWB20 3 4 N L Microgyr Potterton Miniminder 3 4 N L Potterton EP2000/3000 - 3 4 N L Link L-5 EP2001/3001 Randall 102/102 E 1 2 E 5 6 Link 3-6 Randall 4033 4 2 E 7 6 Link 1-6 Randall 701, 702 3 1 E N L Link L-6-5 Sangamo M5 1 8 E 4 3 Link 1-6 Sangamo 410 Form 1 1 8 E 4 3 Link 3-6 PROGRAMMER 6 4 3 2 1 Pegler Sunvic 2 5 E N L SP 50/100 (Link L-3) Switchmaster 1 4 N L Symphony, Sonata Switchmaster 400, 600 3 1 N L SWITCHMASTER 805, 900 3 1 N L Sunvic ET 1451 7 4 E 1 2 Link 2-3-6 Sunvic DHP 2201 6 3 E 1 2 Towerchron FP 6 10 2 1 Link 1-5/4-7-9 Towerchron MP 6 10 2 1 Link 1-4/6-11 Towerchron 2000 HW HTG N L ON ON ACL LS522, LS722 3 4 N L Randall 922, 972 3 6 E N L Link L-2-5 Randall 3020 P 4 2 E N L and 3060 PROGRAMMER 6 4 3 2 1 A/27 MFFI - A/27 MFFI E N L Genus 23-27-30 MFFI E N L Genus 27 RFFI System E N L BOILER 9 10 3 2 • 1 • 2 • 3 • 4 • 5 • 6 • 7 • 8 • 9 • 10 TYPICAL JUNCTION BOX 1 BOILER ELECTRICAL SUPPLY CABLE Remove internal time clock plug from the the P.C.B. then connect room stat terminal block on the reverse of the boiler control panel (see section 2.10) to 9 + 10 on the junction box. T6360B ROOM THERMOSTAT 1 4 3 5 2 2 V4043H HEATING VALVE BROWN 5 BLUE 2 GREY 9 ORANGE 10 GREEN/YELLOW 3 V4043H HOT WATER VALVE BROWN 8 BLUE 2 GREY 9 ORANGE 10 GREEN/YELLOW 3 1 C/P Cylinder thermostat Thermal cut-out 1 8 6 Not used P 2 1 C/P 2 240V MAINS INPUT (3 AMP) L 1 N 2 E 3 Based on Honeywell controls
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B004 NOTES
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30 B004 NOTES
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31 B004
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B004 - Cod. 23 99 84 1259 111 - Stampa: bieffe RECANATI Manufacturer: Merloni TermoSanitari SpA - Italy Commercial subsidiary: MTS (GB) LIMITED MTS Building Hughenden Avenue, High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 - Fax: (01494) 459775 Technical Service Hotline: (01494) 539579
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Servicing Instructions Type C Boilers G.C.N: 41-116-01 47-116-08 47-116-09 47-116-13 LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER
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2 B005 Page No. 1. SERVICING INSTRUCTIONS 1.1 Replacement of Parts 3 1.2 To Gain General Access - Removing the Front Panel 3 - Removing the Bottom Cover 4 - Removing the Side Panels 4 1.3 Access to the Combustion Chamber - Removing the Sealed Combustion Chamber 5 - Removing the Burner and Injectors 5 - Removing the Electrodes 6 - Removing the Main Heat Exchanger 7 - Removing the Air Pressure Switch 7 - Removing the Venturi Device 8 - Removing the Fan 8 1.4 Servicing and Removal of the Gas Valve - Setting Gas Pressure 10 - Removing the Spark Generator (SIT Sigma Gas Valve) 12 - Removing the Spark Generator (SIT Tandem Gas Valve) 13 - Removing the Gas Valve 14 1.5 Access to the Hydraulic Circuit - Removing the D.H.W. (Secondary) Exchanger 14 - Removing the Safety Valve 15 - Removing the Automatic Air Vent 15 - Removing the Main Flow Circuit Switch 15 - Removing the Pump 16 - Removing the Pressure Gauge 16 - Removing the Expansion Vessel 17 - Removing the Overheat Thermostat 17 - Removing the Heating Temperature Sensor (N.T.C.) 17 - Removing the D.H.W. Temperature Sensor (N.T.C.) 18 - Removing the Diverter Valve (Genus 27 RFFI Only) 18 1.6 Access to the Control System - Checking the Fuses 19 - Removing the Time Clock 19 - Removing the P.C.B.s 20 2. FAULT FINDING 2.1 Fault Finding Guide (Flow-chart) 21 2.2 Fault Finding Using the Total Check System 26 3. ELECTRICAL DIAGRAMS 3.1 Electrical Connection 27 3.2 Functional Flow Connection 29 4. SHORT SPARE PARTS LIST 30 TABLE OF CONTENTS
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3 B005 1. SERVICING INSTRUCTIONS The life of individual components vary and they will need servicing or replacing as and when faults develop. The fault finding sequence chart in chapter 2 will help to locate which component is the cause of any malfunction, and instructions for removal, inspection and replacement of the individual parts are given in the following pages. 1.1 Replacement of Parts 1.2 To Gain General Access All testing and maintenance operations on the boiler require the control panel to be lowered. This will also require the removal of the casing. To dismantle the front part of the casing, proceed as follows: 1. Loosen the two screws “A” located on the bottom part of the boiler until the first thread on the screws appears (Fig. 1.1); 2. Lift the front panel up until it stops with a click and remove the front panel from the rest of the casing (Fig. 1.2); 4. Unhook the two cords from the locating slots (Fig. 1.3). A Fig. 1.2 Fig. 1.3 Fig. 1.1 To ensure efficient safe operation, it is recommended that the boiler is serviced annually by a competent person. Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool. Before and after servicing, a combustion analysis should be made via the flue sampling point (please refer to the Installation Manual for further details). After servicing, preliminary electrical system checks must be carried out to ensure electrical safety (i.e. polarity, earth continuity, resistance to earth and short circuit).
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4 B005 Removing the bottom cover 1. Remove the screws “B” Removing the side panels 1. Remove the screws “C”; 2. Pull the panel away from the boiler, then lift the panel up and away from the boiler. Fig. 1.4 B C C C Fig. 1.5
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1. Remove the side panels of sealed chamber (fig. 1.8); 2. Remove the screws “F” of the burner (see fig. 1.9); 3. Remove the burner (see fig. 1.10); 4. Remove the injectors using a No. 7 socket spanner; 5. Replace in reverse order. Removing the burner and the injectors 5 B005 Removing the sealed chamber frontal cover 1.3 Access to the Combustion Chamber Remove the screws “D” Remove the screws “E” Removing the combustion cover E E E E E E E Fig. 1.6 Fig. 1.7 D D D D Fig. 1.8 Fig. 1.9 Fig. 1.10 F push push
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6 B005 Removing the electrodes 1. Remove rubber gasket “G” (see fig. 1.11); 2. Disconnect ignition leads by pulling downward (see fig. 1.12); 3. To remove the flame sensor disconnect the cable at its only connection point close to the P.C.B. (see fig. 1.13); 5. Remove screw “H” using a Philips No. 2 star tip screwdriver (see fig. 1.14); 6. Slide the electrode gently downward (see fig. 1.15). To replace, repeat the steps in reverse order, paying particular attention to the following: a -Centre the electrode in the positioning hole carefully, otherwise the electrode may break; b -Check that the cables have been connected correctly; c -Check that the rubber gasket covers the cable/electrode connection point completely. Fig. 1.11 G Fig. 1.12 Fig. 1.13 Fig. 1.14 Fig. 1.15 H
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1. Disconnect the electrical connections “K” and silicone pipes “L” from their connection points (see fig. 1.18); 2. Remove screws “J” on the top of the sealed chamber (see fig. 1.19); Use a No. 2 star tip screwdriver to remove the switch from the plate. Fig. 1.19 Fig. 1.18 7 B005 1. Drain the boiler of water; 2. Release the two connection nuts “I” connecting the exchanger to the flow and return pipes (see fig. 1.16); 3. Pull it straight out (see fig. 1.17). Removing the main heat exchanger Removing the air pressure switch Fig. 1.16 I Fig. 1.17 L L K J J
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8 B005 1. Disconnect the silicone pipes “M” and remove the screw “N” (see fig. 1.20); 2. Extract the venturi (see fig. 1.21). Removing the venturi device 1. Disconnect electrical connections and remove screws “O” using a No. 2 star tipped screwdriver (see fig.1.22); 2. Pull fan to the right and forward and remove (see fig.1.23); 3. Remove fan from mounting plate; 4. Remove screws “P” (see fig.1.24). Removing the fan M N Fig. 1.20 Fig. 1.21 Fig. 1.22 Fig. 1.23 Fig. 1.24 O O P P
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9 B005 1.4 Servicing and Removal of the Gas Valve 1 2 3 4 A B C E F D SIT TANDEM SIT SIGMA 1 2 3 4 A B C E F D
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10 B005 Setting the minimum and the maximum power of the boiler 1. Check that the supply pressure to the gas valve is a minimum of 20 mbar for natural gas. 2. To do this, remove the screw “A”. Fit the pipe of the pressure gauge to the pressure connection of the gas valve “B”. When you have completed this operation, replace the screw “A” securely into its housing to seal off the gas. 3. To check the pressure supplied by the gas valve to the burner, remove the screw “C”. Fit the pipe of the pressure gauge to the pressure outlet of the gas valve “D”. Disconnect the compensation pipe either from the gas valve or from the sealed chamber. 4. Set the On/Off button to position < I > and the "summer/winter" switch to the winter position. To set the maximum power, turn on the hot water tap and allow the hot water tap to run at a rate of about 8 litres/minute so that the main burner lights. Adjust nut “E” on the modureg to set the gas pressure (displayed on the pressure gauge) corresponding to the maximum power (see table “A” page 11). 5. To set the minimum power, disconnect a supply terminal from the modureg and adjust screw “F”. Turn the screw clockwise to increase the pressure and coun- ter-clockwise to decrease the pressure (displayed on the pressure gauge) corresponding to the minimum power (see table “A” page 11). 6. When you have completed the above operations, turn off the hot water tap, re-connect the supply terminal to the modureg on the gas valve and replace the cap on the screw of the modureg. Setting the maximum heating circuit power 7. To set the maximum heating circuit power, place the On/Off button to position < I > and the "summer/winter" switch to winter position. Turn the knob of the heating thermostat clockwise to maximum; 8. Remove the left hand inspection panel of the P.C.B. and fit a small cross-head screwdriver in to the right hand potentiometer. Turn clockwise to increase the pressure or counter-clockwise to reduce the pressure. Adjust the setting to the required heating pressure value (displayed on the pressure gauge), as indicated in the diagrams shown in page 11. 9. Turn off the boiler by placing the main switch to the "Off" position. Setting pressure for soft ignition. Disconnect the detection electrode connection from the P.C.B. (see fig. 1.13). Start the boiler and during the ignition sequence adjust the centre potentiometer until the gas pressure reads the required gas pressure as per the table below. Once the gas pressure is set turn off the boiler and reconnect the connection to the P.C.B. NB.: It may be necessary to reset the flame failure reset a number of times during this operation. Recommended pressure for slow ignition 5 mbar - 1.95 in w.g. NATURAL GAS (G20) BUTANE GAS (G30) PROPANE GAS (G31) 18 mbar - 7.0 in w.g. 19 mbar - 7.4 in w.g. Setting gas pressures
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11 B005 model 23 model 27 Regulating the heating power for natural gas (G20) model 23 model 27 Regulating the heating power for butane gas (G30) model 23 model 27 34 36 38 40 Regulating the heating power for propane gas (G31) TABLE “A”
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12 B005 10. Remove the pipe from the pressure gauge and connect screw “C” to the pressure outlet in order to seal off the gas. 11. Carefully check the pressure outlets for gas leaks (valve inlet and outlet). IMPORTANT! Whenever you disassemble and reassemble the gas connections, always check for leaks using a soap and water solution. Setting the anti-cycling device This appliance is equipped with a potentiometer which delays the ignition of the heating control and is situated on the P.C.B. (see the electrical diagrams). By adjusting the potentiometer, it is possible to change the time interval between the burner shutting down and its next ignition. It is preset at 1 minute and can be adjusted from 0 to 2 minutes. Use this control in particular situations where continuous shutting down and ignition of the main burner occurs. Anti-cycling Device Soft-light Adjustment Max Heating Adjustment Removing the spark generator (SIT Sigma gas valve) 1. Disconnect ignition leads “Q” by pulling upwards (see fig. 1.25); 2. Remove the screws “R” (see fig. 1.26) with a Pozidrive No. 2 star tip screwdriver; 3. Remove the spark generator. Fig. 1.25 Fig. 1.26 Fig. 1.27 Q R
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13 B005 Removing the spark generator (SIT Tandem gas valve) 1. Disconnect ignition leads “Q1” by pulling upwards (see fig. 1.28); 2. Remove the screws “R1” (see fig. 1.29) with a Pozidrive No. 2 star tip screwdriver; 3. Remove the spark generator. Fig. 1.28 Fig. 1.29 Fig. 1.30 Q1 R1 R1
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14 B005 1.5 Access to Hydraulic Circuits Fig. 1.35 U Removing the gas valve 1. Disconnect all the cables from the solenoid and modureg; 2. Remove the spark generator; 3. Release the top nut “S” using a 30 mm open ended spanner (see fig. 1.31); 4. Remove the screws “T” from the bottom of the gas valve pipe (see fig. 1.32). Attention!! The gas valve is connected with the two pipes (as shown) with an O-ring connection. U Important! Before any component is removed, the boiler must be drained of all water. Removing the D.H.W. (secondary) exchanger 1. Remove the screw “U” (see fig. 1.35); 2. Push the exchanger towards the rear of the boiler, lift upwards and remove out of the front of the boiler; 3. Before replacing the exchanger ensure that the O-rings are in good condition and replace if necessary. Fig. 1.31 Fig. 1.32 Fig. 1.33 S T T Fig. 1.34
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15 B005 Removing the safety valve 1. Loosen nut “V” (see fig. 1.36); 2. Remove the valve. Removing the automatic air vent 1. Unscrew valve “W” (see fig. 1.37). Removing the main circuit flow switch 1. Remove the cable of the main circuit flow switch “Y”; 2. Remove the screws “Y1” (see fig. 1.38); 3. Remove the main circuit flow switch. Fig. 1.36 Fig. 1.37 Fig. 1.38 V W Y Y1 Y1
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16 B005 Removing the pump 1. Unscrew “Z” and remove the electrical connection (see fig. 1.39); 2. Release the nuts “A1” and remove the pump (see fig. 1.40). Removing the pressure gauge 1. Remove the pressure gauge cover by pulling (see fig. 1.41); 2. Release coupling “A2” using a 14 mm open ended spanner (see fig. 1.42); 3. Push the pressure gauge through the control panel from the rear (see fig. 1.43). A1 A1 Z A2 Fig. 1.39 Fig. 1.40 Fig. 1.41 Fig. 1.42 Fig. 1.43
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17 B005 Removing the expansion vessel 1. Remove nut “A3” away from the expansion vessel (see fig. 1.44); 2. Remove nut “A4” (see fig. 1.45); 3. Remove expansion vessel (see fig. 1.46). Removing the overheat thermostat 1. Remove the electrical connector by the overheat thermostat (see fig. 1.47); 2. Pull off the thermostat connections. Then remove the thermostat from the pipe by releasing it’s securing clip. Removing the heating temperature sensor (N.T.C.) 1. Remove the electrical connector by pulling off the thermostat connections and unscrewing the sensor probe with a 14 mm open ended spanner (see fig. 1.48). A3 A4 Fig. 1.44 Fig. 1.45 Fig. 1.47 Fig. 1.48 Fig. 1.46
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18 B005 Removing the D.H.W. temperature sensor (N.T.C.) 1. Remove the electrical connector by pulling off the thermostat connection and unscrew the sensor probe with a 14 mm open ended spanner (see fig. 1.49). Fig. 1.49 Removing the diverter valve (Genus 27 RFFI only) 1. Remove the circlip and pull the diverter valve to the left. Fig. 1.50
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19 B005 Checking fuse 1. Remove the right hand inspection cover (see fig. 1.51); 2. Remove fuse (see fig. 1.52). 1.6 Access to the Control System Removing the time clock 1. Remove left hand inspection cover (see fig. 1.53); 2. Remove electrical connection “A5” of the clock (see fig. 1.54); 3. Unscrew “A6” and remove (see fig. 1.55). Fig. 1.51 Fig. 1.52 Fig. 1.53 Fig. 1.49 Fig. 1.50 A5 A5 A6 A6 N.B. It is possible to by-pass the time clock in the event of failure by simply unplugging the electrical connection from the P.C.B. (see fig. 1.54). This will revert control of the central heating to the room stat connection on the reverse of the control panel.
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20 B005 Removing the P.C.B.s 1. Isolate electricity; 2. Remove the front cover of the boiler; 3. Remove both left and right inspection panels; 4. Remove the pressure gauge cover; 5. Remove the mounting screws “A7’ (see fig. 1.51); 6. Disconnect the connection cable”A8” (see fig. 1.52); 7. To remove the 24V P.C.B.: remove the electrical plug connectors and screws “A9” (see fig. 1.53); 8. To remove the 240V P.C.B.: remove the electrical plug connectors and screws “A10” (see fig. 1.54); 9. Replace either P.C.B. in reverse order. Fig. 1.51 Fig. 1.52 Fig. 1.53 Fig. 1.54 A7 A7 A7 A7 A8 A8 A9 A9 A10 A10
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21 B005 2. FAULT FINDING 1) Thereis sufficient water in thesystem 2) Thegas is turned on 3) Theelectricityto the boiler is on PreliminaryChecks Makesurethat: HAS THE LIGHT fOR THE POWER SUPPLY COME ON? SETTING FOR THE OPERATING MODE IS HOT WATER BEING DEMANDED? NO NO WINTER SUMMER FUME DISCHARGE TEST NO YES YES YES NO NO NO YES YES YES 1)Checkthefuses 2)Checkthepower supplycord,plugand outlet 3)Check/replacethepower supplyP.C.B. Press the On / Off Button FOR BOILERS EQUIPPEDWITHAN ELECTRONICANT-FREEZE SYSTEM:HAS THE SAFETYBEEN TRIGGEREDTO ACTIVATE THE DEVICE? (T sensor <5˚C) FOR BOILERS EQUIPPEDWITHAN ELECTRONICANT-FREEZE SYSTEM:HAS THE SAFETYBEEN TRIGGEREDTO ACTIVATE THE DEVICE? (T sensor <5˚C) DO THE TIME CLOCK AND/OR R O O M THERMOSTAT NEED TO BE ACTIVATED A IS HOT WATER BEING DEMANDED? It is possible to detect and correct any defect by using the standard fault finding diagrams described in this chapter. 2.1 Fault Finding Guide (Flow-chart)
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22 B005 DOES THE CIRCULATIONPUMP COME ON? YES NO NO NO YES YES POWERTO THE PUMP? DOES THE INSUFFICIENT WATER INDICATOR LIGHT COME ON? (within 40sec.) 1)Checkforairin the system 2)Checkthepressureswitch foractivatingpump 3)Check/replacepressure gaugeandrefill the thesystemproperly 1)Turn theboileroff andthen backon again (safetyreset) 1)Checkto seeifpumpis stuck 2)Replacecirculation pump 1) Check wiring 2) Check/replace wire toP.C.B. 3) Replace powersupply P.C.B. 4) Replace control P.C.B. 5) Check micro- switch when hot waterisrequested. A B
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23 B005 DOES THE FAN COME ON? BOILER SHUTDOWN? IS THERE POWER TO THE FAN? NO YES YES YES NO YES NO NO NO 1)Check/replacedifferential pressureswitch forpump 2)Check/replacewiring 3)Check/replaceP.C.B. wire 4)Check/replacepower supplyP.C.B. 5)Check/replacecontrol P.C.B. 1) pressureswitch/wiring 2)Checkwhetherreset button isstuck 3) detection electrode Check/replaceair Check/replaceflame 1) 2) 3)Check/replacepower supplyP.C.B. 4) 5) Check/replacewiring Check/replace Check/replacecontrol P.C.B. Check/replaceair pressureswitch 1)Replacefan 1)Reset theboiler PUMP SAFETYDEVICE ACTIVATED? INTERNAL SAFETYDEVICE FOR PCB ACTIVATED? B C YES P.C.B. wire
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24 B005 DOES THE BURNER LIGHT? YES NO YES YES WAS THE RESET SWITCH PRESSED? YES NO NO NO NO YES 1)Check/replaceignition electrodes 2)Checkwiring 3)Checkspark generator 4)Checksmall wire 5)CheckpowersupplyP.C.B. 6)Checkcontrol P.C.B. 1)Checkwhether flame detection electrodeis postioned in the flame 2)Checktheelectrode 3)Checkthepower P.C.B. 4)Checkthecontrol P.C.B. 1)Checksupplyofgasto gas valve 2)CheckpowersupplyP.C.B. 3)Checkcontrol P.C.B. 4)Checkfunctionalityofthe gas valve Shutdown L.E.D. off Restart ofthefan IS THE AIR PRESSURE SWITCHACTIVATED? ARE THE FUMES DISCHARGED CORRECTLY? SAFETY SHUTDOWNOFTHE BOILER ACTIVATED? 1) Check flue discharge 2) Check venturi & small pipes 3) Check wire forairpress.switch 4) Check/replace airpress. switch 5) Check/replace P.C.B.wire 6) Check/replace powerP.C.B. 7) Check/replace control P.C.B. C D
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25 B005 IS THERE STILL A PROBLEM? FUNCTIONS NORMALLY NO YES LISTOFMALFUNCTIONS POSSIBLE CAUSES 1 2 3 4 5 6 7 8 9 Deliveryofhot waterfordomestic use: when thetapisturnedon,theburnergoesout. Deliveryofhot waterfordomestic use: theradiatoresareheatedin summermode. Deliveryofhot waterfordomestic use: watertemperatureisnot satisfactory. Deliveryofhot waterfordomestic use: noisyoperation. Drop/increasein pressurein primarycircuit. Repeatedshutdowns. Safety thermostat istriggeredrepeatedly. When thecoldwatertapisturnedoff,the boilercomeson. Temperatureofradiatorsnot satisfactory. Deliveryofhot waterfordomestic use: when thetapisturnedon,theburnergoesout. Deliveryofhot waterfordomestic use: theradiatoresareheatedin summermode. Deliveryofhot waterfordomestic use: watertemperatureisnot satisfactory. Deliveryofhot waterfordomestic use: noisyoperation. Drop/increasein pressurein primarycircuit. Repeatedshutdowns. Safety thermostat istriggeredrepeatedly. When thecoldwatertapisturnedoff,the boilercomeson. Temperatureofradiatorsnot satisfactory. - Airin thesecondaryexchanger - Hot waterpressureswitch isdefective - 3-wayvalveisdefective - 3-wayvalveisdefective - Checksensorsfordomestic andheatingwater - Checkgassettingsandregulation - Checkwaterflow rate - Check secondary exchanger - Primaryexchangerisdefective - Low waterpressurein heatingsystem - Checkgassettingsandregulation - Checkntc sensorfordomestic hot water - Checkforleaksin heatingcircuit - Defectivewatersupplyinlet valve - Secondaryexchangerisdefective - Expansion vessel isempty - Detection electrodesaredefective - Checkgassettingsandregulation - Checkelectrical circuit forflamedetection - Faulty(contacts)N.T.C. sensors-heating/hotwater - Defective(poorlycalibrated)safetythermostat - Presenceofairin theprimarywatercircuit - Dropin pressurein thewatermains,resulting in waterhammering - Check N.T.C. sensorforheating - Checkby-pass - Checkgassettingsandregulation - Airin thesecondaryexchanger - Hot waterpressureswitch isdefective - 3-wayvalveisdefective - 3-wayvalveisdefective - Checksensorsfordomestic andheatingwater - Checkgassettingsandregulation - Checkwaterflow rate - Check secondary exchanger - Primaryexchangerisdefective - Low waterpressurein heatingsystem - Checkgassettingsandregulation - Checkntc sensorfordomestic hot water - Checkforleaksin heatingcircuit - Defectivewatersupplyinlet valve - Secondaryexchangerisdefective - Expansion vessel isempty - Detection electrodesaredefective - Checkgassettingsandregulation - Checkelectrical circuit forflamedetection - Faulty(contacts)N.T.C. sensors-heating/hotwater - Defective(poorlycalibrated)safetythermostat - Presenceofairin theprimarywatercircuit - Dropin pressurein thewatermains,resulting in waterhammering - Check N.T.C. sensorforheating - Checkby-pass - Checkgassettingsandregulation D
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26 B005 Signalling Boiler Off Auto diagnostic state Spark ignition state Boiler functioning normally Lockout Boiler thermostat satisfied Room thermostat/clock no demand or selector in summer setting Malfunction Faulty ventilation system Air pressure switch stuck in N.O. position Faulty reset switch Faulty main circuit flow switch Faulty flame detection Faulty overheat thermostat Faulty exhaust fumes sensor Faulty heating sensor (N.T.C.) Faulty D.H.W. sensor (N.T.C.) A b C d E F G I m 1 2 3 4 5 6 2.2 Fault Finding Using the Total Check System Pump fed Main flow switch closed Air pressure switch N.O. Flame detected Water at required temperature Room thermostat/clock no demand or selector in summer setting Auto diagnostics faulty Heating temperature control D.H.W. temperature control Heating circuit efficiency control D.H.W.exchanger efficiency control
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27 B005 3. ELECTRIC DIAGRAMS Legend: AT = High Voltage P.C.B. BT = Low Voltage P.C.B. A = Remote Connector Kit B = Flame Failure L.E.D. C = Insufficient Water Pressure L.E.D. D = Water Temperature Indicator L.E.D.s E = Overheat Thermostat Warning L.E.D. F = System Reset Button G = Selector Knob for Operating Mode H = Domestic Hot Water Temp. Adjustment I = Central Heating Temp. Adjustment J = Wire Connector for Room Thermostat K = Connector for Total Check System L = Selector for Local/Remote Control M = Anti-cycling Device Adjustment for Heating N = Soft-light Adjustment O = Max Heating Temperature Adjustment P = Time Clock Connection Q = On/Off L.E.D. R = On/Off Switch S = Interface Wire for P.C.B.s T = Relay Motorised Valve U = Ignitor Relay V = Gas Valve Relay W = Fan Relay X = Circulation Pump Relay Y = Selector TCS2 Z = Link for Continuous Pump Run Aa = Adaptor (British Gas use only) A01 = Air Pressure Switch A02 = Fan A03 = Gas Valve A04 = Ignitor A05 = Motorised Valve A06 = Circulation Pump A07 = Flame Detector A08 = Earth Terminal A09 = Flame Detection Circuit A10 = Flame Indicator L.E.D. A11 = Transformer A12 = Filter B01 = Over Heat Thermostat B02 = External Thermostat B03 = Gas Valve Modulator B04 = D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only) B05 = Heating Sensor B06 = Pressure Switch for Heating Circuit B07 = Microswitch for Diverter Valve (MFFI models only) Colours Gry = Grey Rd = Red Bl = Blue Grn/Yll = Yellow/Green Wh = White Brn = Brown Blk = Black Wh/Rd = White/Red
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28 B005 Aa Aa GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM
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29 B005 CN202 P P GENUS 23/27 MFFI GENUS 27 RFFI SYSTEM
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30 B005 89 55 54 67 59 56 2 11 9 1 2 3 6 7 8 12 13 11 16 17 18 19 23 20 21 22 24 26 25 87 86 85 85 88 86 84 83 95 84 11 118 7 80 62 81 122 120 116 117 110 109 4 4 4 4 89 15 66 58 57 60 123 121 104 108 81 65 63 66 65 68 69 63 70 74 74 62 64 74 124 71 119 73 10 61 72 79 45 44 44 114 53 112 48 49 50 113 111 47 48 51 51 52 46 44 101 115 5 94 100 98 99 98 96 106 14 43 18 302 303 304 306 301 301 305 91 91 90 92 93 23 82 103 78 27 107 32 31 28 29 34 35 37 38 39 40 42 41 33 30 39 36 36 75 76 77 102 97 105 321 361 363 364 362 371 372 373 374 375 311 23/27 MFFI 100 16 22 17 4. SHORT SPARE PARTS LIST GENUS 23/27 MFFI (SIT Sigma Gas Valve)
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31 B005 90 56 55 68 57 2 11 9 1 2 3 6 7 8 12 11 17 18 19 20 24 21 22 23 25 27 26 88 87 86 86 89 87 85 84 96 85 11 119 7 81 63 82 123 121 117 118 111 110 4 4 4 4 90 16 67 61 124 122 105 109 82 66 64 67 66 69 70 64 71 75 75 63 65 75 125 72 120 74 10 62 73 80 46 45 45 115 54 113 49 50 51 114 112 48 49 52 52 53 47 45 102 116 5 95 101 99 100 99 97 107 44 18 302 303 304 306 301 301 305 92 92 91 93 94 24 83 104 79 28 108 33 32 29 30 35 36 38 39 40 41 43 42 34 31 40 37 37 76 77 78 103 98 106 321 361 363 364 362 371 372 373 374 375 311 30 MFFI 101 17 23 18 60 59 58 14 13 15 126 GENUS 30 MFFI (SIT Sigma Gas Valve)
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32 B005 57 56 69 61 58 2 11 9 1 2 3 6 7 8 12 13 11 19 18 21 22 23 26 27 28 113 7 82 64 83 117 115 111 112 105 104 4 4 4 4 15 17 68 60 59 62 118 116 99 100 102 67 65 68 67 70 71 65 72 76 76 64 66 76 119 73 114 75 10 63 74 81 47 46 46 109 55 107 50 51 52 108 106 49 50 53 53 54 48 46 96 110 5 95 93 94 93 86 85 87 86 11 88 101 14 45 302 303 304 306 301 301 16 11 24 89 305 25 23 20 83 91 23 84 98 80 103 33 30 31 36 29 37 39 40 41 42 44 43 34 35 32 41 38 38 77 78 79 97 92 23 90 11 16 371 372 373 374 375 321 362 363 361 27 MFFI SYSTEM 20 95 19 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve)
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33 B005 GENUS 23/27 MFFI (SIT Sigma Gas Valve) 573294 573520 997206 573224 569236 573340 573528 573727 573172 571649 997208 953045 952981 952610 572989 572990 573343 573314 571651 571652 570717 564254 569387 571449 571646 573295 573825 571807 573521 997150 997151 571965 574279 574232 574233 573441 569390 569560 569561 572271 572277 572343 572372 572749 572835 571993 571444 997029 571443 571442 571447 571446 571547 571772 571771 571770 573138 569281 569282 Key no. G.C. part no. ARISTON Part No. Description 1 11 14 17 18 19 23 24 25 28 31 43 45 46 56AB 56CD 57 60 71AB 71CD 74 83 84 86 88AB 88CD 89 91 94 95AB 95CD 98 99 100 106 110 114 116 117 118A 118B 118C 118D 119AB 119CD 301 311 321 361 362 363 364 371 372 373 374 375 381 382 379816 164 225 164 338 164 229 378 814 E03 818 E02 071 379 079 164 230 164 282 379 981 164 261 379 979 379 980 E02 026 E02 078 164 311 Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.) Microswitch for 3-way/main flow group Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" Pressure gauge Time clock P.C.B. E C-MI/FFI P.C.B. EI A-MFFI P.C.B. cable Fan Fan Fan inlet gasket Venturi (exhaust manifold/header) Air pressure switch Air pressure switch Fastening spring Automatic air release valve Gasket 1" O-ring Secondary exchanger (plate-type) exchanger 23kW Secondary exchanger (plate-type) exchanger 27kW O-ring (secondary exchanger) 20-18 O-ring Gasket 3/8" Pump Pump O-ring (13) Gasket Gas valve (SIT Sigma) Spark generator Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main burner Main burner Main exchanger Main exchanger Front panel runner kit D.H.W. actuator kit SIT Sigma gas valve operator coils Heating by-pass kit D.H.W. pressure switch kit 3-way spring kit D.H.W. diaphram valve Main flow switch diaphram Main flow switch magnet Main flow switch spring Main flow switch top cap Main flow switch reed system Burner jet 1.25 full kit (Natural gas) Burner jet 0.72 full kit (LPG) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
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34 B005 GENUS 30 MFFI (SIT Sigma Gas Valve) 573294 573520 997206 573224 569236 573340 573528 573727 573172 571649 997208 953045 952981 952610 572990 573343 571652 570717 564254 569387 571449 573295 573825 571807 573521 997151 571965 574279 574232 574233 573441 569390 569560 569561 998110 998111 572835 573314 571993 571444 997029 571443 571442 571447 571446 571547 571772 571771 571770 573138 998152 998432 Key no. G.C. part no. ARISTON Part No. Description 1 11 15 16 19 20 24 25 26 29 32 44 46 47 57 58 72 75 84 85 87 89 90 92 95 96 99 100 101 107 111 115 117 118 119A 119B 120 126 301 311 321 361 362 363 364 371 372 373 374 375 381 382 379816 164 225 164 338 164 229 378 814 E02 071 379 079 164 230 164 282 379 981 164 261 379 979 379 980 Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.) Microswitch for 3-way/main flow group Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" Pressure gauge Time clock P.C.B. E C-MI/FFI P.C.B. EI A-MFFI P.C.B. cable Fan Fan inlet gasket Air pressure switch Fastening spring Automatic air release valve Gasket 1" O-ring Secondary exchanger (plate-type) exchanger 27kW O-ring (secondary exchanger) O-ring (20-18) Gasket 3/8" Pump O-ring (13) Gasket Gas valve (SIT Sigma) Spark generator Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main exchanger Venturi (exhaust manifold/header) Front panel runner kit D.H.W. actuator kit SIT Sigma gas valve operator coils Heating by-pass kit D.H.W. pressure switch kit 3-way spring kit D.H.W. diaphram valve Main flow switch diaphram Main flow switch magnet Main flow switch spring Main flow switch top cap Main flow switch reed system Burner jet 1.30 full kit (Natural gas) Burner jet 0.77 full kit (LPG) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
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35 B005 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve) 573294 573520 997206 997147 573224 569236 573528 573727 573172 950650 571649 997208 953095 952935 952610 572990 573343 573314 571652 570717 564254 569387 997151 573521 571965 574279 574232 574233 573441 569390 569560 569561 572343 572372 572835 571993 997029 571443 571987 571447 573138 569281 569282 Key no. G.C. part no. ARISTON Part No. Description 1 11 14 17 20 21 23 25 26 28 30 33 45 47 48 58 59 62 73 76 85 86 87 89 93 94 95 101 105 109 111 112 113A 113B 114 301 321 361 362 363 375 381 382 379816 164 225 164 338 164 229 378 814 E02 071 379 079 164 282 379 981 164 261 379 979 379 980 E02 078 164 311 Expansion vessel Gasket 3/4" Overheat thermostat Motorised valve motor Main flow switch Temp probe (C.H.W.) Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" D.H.W. probe Pressure gauge Time clock P.C.B. EB C MI/FFI P.C.B. E A-FFI/P P.C.B. cable Fan Fan inlet gasket Venturi (exhaust manifold/header) Air pressure switch Fastening spring Automatic air release valve Gasket 1" Pump Gasket 3/8" O-ring (13) Gasket Gas valve (SIT Sigma) Spark generator Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main exchanger Front panel runner kit Sit Sigma gas valve operator coils Heating by-pass kit Sanitary pressure switch kit Way and unit kit Main flow switch reed system Burner jet 1.25 full kit (Natural gas) Burner jet 0.72 full kit (LPG)
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36 B005 89 55 54 67 59 56 2 11 9 1 2 3 6 7 8 12 13 11 16 17 18 19 23 20 21 22 24 26 25 87 86 85 85 88 86 84 83 96 84 82 120 7 80 62 81 124 122 118 119 112 108 4 4 4 4 89 15 66 58 57 60 125 123 81 65 63 66 65 68 69 63 70 74 74 62 64 74 126 71 121 73 10 61 72 79 45 44 44 116 53 114 48 49 50 115 113 47 48 51 51 52 46 44 117 5 94 95 14 43 18 302 303 304 306 301 301 305 91 91 90 92 93 23 110 78 27 106 32 31 28 29 34 35 37 38 39 40 42 41 33 30 39 36 36 75 76 77 97 11 111 104 98 99 100 109 107 101 102 104 103 105 16 22 99 23/27 MFFI 17 371 372 373 374 375 361 363 364 362 311 321 322 323 GENUS 23/27 MFFI (SIT Tandem Gas Valve)
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37 B005 90 56 55 68 60 57 2 11 9 1 2 3 6 7 8 12 14 11 17 18 19 20 24 21 22 23 25 27 26 88 87 86 86 89 87 85 84 97 85 83 121 7 81 63 82 125 123 119 120 113 109 4 4 4 4 16 67 59 58 61 126 124 82 66 64 67 66 69 70 64 71 75 75 63 65 75 127 72 122 74 10 62 73 80 46 45 45 117 54 115 49 50 51 116 114 48 49 52 52 53 47 45 118 5 95 96 44 19 302 303 304 306 301 301 305 92 92 91 93 94 24 111 79 28 107 33 32 29 30 35 36 38 39 40 41 43 42 34 31 40 37 37 76 77 78 98 17 23 100 30 MFFI 18 371 372 373 374 375 361 363 364 362 311 321 322 323 11 112 105 99 100 101 110 108 102 103 105 104 106 128 90 13 15 GENUS 30 MFFI (SIT Tandem Gas Valve)
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38 B005 57 56 69 61 58 2 11 9 1 2 3 6 7 8 12 13 11 19 18 21 22 23 26 27 28 115 7 82 64 83 119 117 113 107 106 4 4 4 4 15 17 68 60 59 62 120 118 67 65 68 67 70 71 65 72 76 76 64 66 76 121 73 116 75 10 63 74 81 47 46 46 111 55 109 50 51 52 110 108 49 50 53 53 54 48 46 112 5 86 85 87 86 84 88 14 45 302 303 304 306 301 301 16 11 24 89 305 25 23 20 91 23 101 80 105 33 30 31 36 29 37 39 40 41 42 44 43 34 35 32 41 38 38 77 78 79 100 23 90 11 16 11 83 102 114 93 99 98 97 103 104 96 95 93 94 92 371 372 373 374 375 321 322 323 362 363 361 27 MFFI SYSTEM 20 98 19 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve)
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39 B005 GENUS 23/27 MFFI (SIT Tandem Gas Valve) 573294 573520 997206 573224 569236 573340 573528 573727 573172 571649 997208 953045 952981 952610 572989 572990 573343 573314 571651 571652 570717 564254 569387 571449 571646 573295 573825 571807 573521 997150 997151 570732 573023 571965 573441 569390 569560 569561 572271 572277 572343 572372 572749 572835 571993 571444 570712 573740 573745 571443 571442 571447 571446 571547 571772 571771 571770 573138 569281 569282 Key no. G.C. part no. ARISTON Part No. Description 1 11 14 17 18 19 23 24 25 28 31 43 45 46 56AB 56CD 57 60 71AB 71CD 74 83 84 86 88AB 88CD 89 91 94 96AB 96CD 99 104 112 116 118 119 120A 120B 120C 120D 121AB 121CD 301 311 321 322 323 361 362 363 364 371 372 373 374 375 381 382 379816 164 225 164 338 164 229 378 814 E03 818 E02 071 379 079 164 230 164 282 379 976 379 981 164 261 379 979 379 980 E02 026 E02 078 378 978 378 815 164 303 164 311 Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.) Microswitch for 3-way/main flow group Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" Pressure gauge Time clock P.C.B. E C-MI/FFI P.C.B. EI A-MFFI P.C.B. cable Fan Fan Fan inlet gasket Venturi (exhaust manifold/header) Air pressure switch Air pressure switch Fastening spring Automatic air release valve Gasket 1" O-ring Secondary exchanger (plate-type) exchanger 23kW Secondary exchanger (plate-type) exchanger 27kW O-ring (secondary exchanger) O-ring (20-18) Gasket 3/8" Pump Pump Gas valve (SIT Tandem) Spark generator O-ring (13) Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main burner Main burner Main exchanger Main exchanger Front panel runner kit D.H.W. actuator kit SIT Tandem gas valve operator coils SIT Tandem modureg coil Gas modulator cartridge Heating by-pass kit D.H.W. pressure switch kit 3-way spring kit D.H.W. diaphram valve Main flow switch diaphram Main flow switch magnet Main flow switch spring Main flow switch top cap Main flow switch reed system Burner jet 1.25 full kit (Natural gas) Burner jet 0.72 full kit (LPG) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 101
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40 B005 GENUS 30 MFFI (SIT Tandem Gas Valve) 573294 573520 997206 573224 569236 573340 573528 573727 573172 571649 997208 953045 952981 952610 572990 573343 571652 570717 564254 569387 571449 573295 573825 571807 573521 997151 570732 573023 571965 573441 569390 569560 569561 998110 998111 572835 573314 571993 571444 570712 573740 573745 571443 571442 571447 571446 571547 571772 571771 571770 573138 998152 998432 Key no. G.C. part no. ARISTON Part No. Description 1 11 15 18 19 20 24 25 26 29 32 44 46 47 57 58 72 75 84 85 87 89 90 92 95 97 100 105 113 117 119 120 121A 121B 122 128 301 311 321 322 323 361 362 363 364 371 372 373 374 375 381 382 379816 164 225 164 338 164 229 378 814 E02 071 379 079 164 230 164 282 379 976 379 981 164 261 379 979 379 980 378 978 378 815 164 303 Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.) Microswitch for 3-way/main flow group Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" Pressure gauge Time clock P.C.B. E C-MI/FFI P.C.B. EI A-MFFI P.C.B. cable Fan Fan inlet gasket Air pressure switch Fastening spring Automatic air release valve Gasket 1" O-ring Secondary exchanger (plate-type) exchanger 27kW O-ring (secondary exchanger) O-ring (20-18) Gasket 3/8" Pump Gas valve (SIT Tandem) Spark generator O-ring (13) Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main exchanger Venturi (exhaust manifold/header) Front panel runner kit D.H.W. actuator kit SIT Tandem gas valve operator coils SIT Tandem modureg coil Gas modulator cartridge Heating by-pass kit D.H.W. pressure switch kit 3-way spring kit D.H.W. diaphram valve Main flow switch diaphram Main flow switch magnet Main flow switch spring Main flow switch top cap Main flow switch reed system Burner jet 1.30 full kit (Natural gas) Burner jet 0.77 full kit (LPG) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 102
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41 B005 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve) 573294 573520 997206 997147 573224 569236 573528 573727 573172 997274 571649 997208 953095 952935 952610 572990 573343 573314 571652 570717 564254 569387 997151 573521 571965 573023 570732 573441 569390 569560 569561 572343 572372 572835 571993 571444 570712 573740 573745 571443 571442 571447 571547 571772 571771 571770 573138 998152 998432 Key no. G.C. part no. ARISTON Part No. Description 1 11 14 17 20 21 23 25 26 28 30 33 45 47 48 58 59 62 73 76 85 86 87 89 93 96 98 107 111 113 114 115A 115B 115 301 311 321 322 323 361 362 363 371 372 373 374 375 381 382 164 225 164 338 164 229 378 814 E02 071 379 079 164 230 164 282 379 976 379 981 164 261 379 979 379 980 E02 078 378 978 378 815 164 303 164 311 Expansion vessel Gasket 3/4" Overheat thermostat Motorised valve motor Main flow switch Temp probe (C.H.W.) Gasket 1/2" Manual vent cock Safety valve 3 bar 1/2" D.H.W. probe Pressure gauge Time clock P.C.B. EB C MI/FFI P.C.B. E A-FFI/P P.C.B. cable Fan Fan inlet gasket Venturi (exhaust manifold/header) Air pressure switch Fastening spring Automatic air release valve Gasket 1" Pump Gasket 3/8" O-ring (13) Spark generator Gas valve (SIT Tandem) Detection electrode Gasket 1/4" Ignition electrode (R.H.) Ignition electrode (L.H.) Main burner Main burner Main exchanger Front panel runner kit D.H.W. actuator kit SIT Tandem gas valve operator coils SIT Tandem modureg coil Gas modulator cartridge Heating by-pass kit D.H.W. pressure switch kit 3-way spring kit Main flow switch diaphram Main flow switch magnet Main flow switch spring Main flow switch top cap Main flow switch reed system Burner jet 1.25 full kit (Natural gas) Burner jet 0.72 full kit (LPG)
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42 B005 NOTES
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43 B005
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Manufacturer: Merloni TermoSanitari SpA - Italy Commercial subsidiary: MTS (GB) LIMITED MTS Building Hughenden Avenue, High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 - Fax: (01494) 459775 Technical Service Hotline: (01494) 539579 23 99 84 1267 000 - B005 Stampa: Bieffe Recanati
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