Ariston 41-116-07 User Manual

Installation Instructions Type C Boilers
G.C.N: 41-116-06
41-116-07
LEAVE THESE INSTRUCTIONS WITH THE END-USER
2
TABLE OF CONTENTS
1. GENERAL INFORMATION
1.1 G
ENERAL I
NSTRUCTIONS
1.2 O
VERALL V
IEW
2. INSTALLATION
2.1 R
EFERENCE 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 W
ATER CONNECTIONS
2.9 F
LUE CONNECTION
2.10 R
OOM THERMOSTAT CONNECTION
2.11 ELECTRICAL DIAGRAMS
2.12 G
AS AND WATER CIRCUITS
3. D.H.W. STORAGE CYLINDER
3.1 2
PORT AND 3 PORT VALVE INSTALLATIONS
3.2 DOMESTIC HOT WATER PRIORITY KIT
4. COMMISSIONING
4.1 I
NITIAL PREPARATION
4.2 C
ONTROL PANEL
4.3 R
EMOVING THE FRONT PANEL
4.4 I
NITIAL START UP
4.5 OPERATIONAL ADJUSTMENTS
4.6 COMBUSTION ANALYSIS
4.7 FUME DISCHARGE MONITORING
4.8 DRAINING THE SYSTEM
5. GAS ADJUSTMENTS
GAS ADJUSTMENT TABLE
5.1 CHANGING THE TYPE OF GAS
6. MAINTENANCE
7. TECHNICAL INFORMATION
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 an appliance for the production of central heating (C.H.). 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 in section 7 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 (at or adjacent to 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 carrying 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 seals for the water connections; replace any faulty seals. 2 - Check the gas seals;replace any faulty gas seals. 3 - Visual check of the entire unit.
1. GENERAL INFORMATION
3
1.1 GENERAL INSTRUCTIONS
4
4 - Visual check of the combustion process or analysis of combustion by-
products (see section 4.5) and cleaning of the burner if needed.
5 - If called for by point. 3, dismantling and cleaning of the combustion
chamber. 6 - If called for by point. 4, dismantling and cleaning of the burner jets. 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 (overheat thermostat);
- safety device for maximum pressure (safety valve).
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- General check of the combustion by-products of the
discharge/ventilation system.
13- Check of the general performance of the unit.
LEGEND:
1. Flue connector
2. Air intake for twin pipe flue systems
3. Fan
4. Combustion chamber hood
5. Main heat exchanger
6. Safety thermostat
7. Combustion chamber
8. Combustion chamber insulation panel
9. Detection electrode
10. Ignition electrodes
11. Burner
12. Regulation thermostat
13. Frost thermostat
14. Pump pressure switch
15. Safety valve (3 bar)
16. Automatic By-pass
17. Gas valve
18. Spark generator
19. Boiler drain valve
20. Circulation pump with automatic air release valve
21. Expansion vessel
22. Air pressure take-off point
23. Air pressure switch
24. Combustion analysis points
1.2 O
VERALL VIEW
FIG. 1.0
5
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 start up of the boiler must be by a CORGI Registered 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 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 regulations 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. Wir ing Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the 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 appliance 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 the 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.
Secondary ventilation is not required with this boiler. The boiler must be installed on a solid, permanent wall to prevent access from the rear.
2.1 REFERENCE STANDARDS
2. INSTALLATION
2.2 SITING THE APPLIANCE
BS 7593:1992 Treatment of water in domestic hot water central
heating systems
BS 5546:1990 Installation of hot water supplies for domestic
purposes BS 5440-1:1990 Flues BS 5440-2:1989 Air supply BS 5449:1990 Forced circulation hot water systems BS 6789:1987 Installation of gas fired hot water boilers of rated
input not exceeding 60kW BS 6891:1989 Installation of low pressure gas pipe up to 28mm BS 7671:1992 IEE wiring regulations BS 4814:1990 Specification for expansion vessels BS 5482:1994 Installation of LPG
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 information table in section 7, 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 under the inspection cover (see the servicing manual for further information)
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 “”symbol;
- The blue wire should be connected to the terminal marked “N”;
- The brown wire should be connected to the terminal
6
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.
2.6 ELECTRICAL CONNECTION
2.5 MOUNTING THE APPLIANCE
LEGEND:
A = Central Heating Flow (3/4”) C = Gas Inlet (3/4”) E = Central Heating Return (3/4”) mm = Clearances
2.3 OVERALL DIMENSIONS
In order to allow for access to the interior of the boiler for maintenance purposes, the boiler must be installed in compliance with the minimum clearances indicated in F
IG. 2.1
2.4 CLEARANCES
F
IG. 2.1
F
IG. 2.2
132 132
C
400 mm
60 mm
450 mm
E
300 mm
N L
E
VIEW OF THE BOILER CONNECTIONS
LEGEND:
A = Central Heating Flow C = Gas Inlet E = Central Heating Return F = Safety Valve G = Pump transportation screw
(remove before igniting the boiler)
H = Automatic By-pass pipe
CENTRAL HEATING
Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance.
2.8 WATER CONNECTIONS
2.7 GAS CONNECTION
The local gas region 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.
7
marked L”. Note:The diagrams f or the electrical system are indicated in section 2.12.
Warning,this appliance must be earthed.
External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regulations and applicable local regulations. The microSYSTEM 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 (see section 2.2).
FIG. 2.3
F
IG. 2.4
F
A
D
B
C
E
SC004A
8
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.
B
Y-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 radiator 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 and should be fitted at all low points.The taps must be at least 15mm nominal size and manufactured in accordance with BS 2870:1980.
S
AFETY VALVE DISCHARGE:
The discharge should terminate facing downward 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
IR 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 volume when the system is heated. It can accept up to 6 litre (1.3 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. This should be located on the return pipe work as close as possible to the pump inlet.
M
AINS 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.
F
ILLING:
A temporary method for initially filling the system and replacing lost water during servicing and initial filling (in accordance with current Water Regulations), is provided as an integral part of the connection kit (see F
IG.
2.4).The flexible hose must be removed once the system has been filled.
RESIDUAL HEAD OF THE BOILER
Ø 60/100 mm
F
IG. 2.6
The boiler is designed to be connected to a coaxial flue discharge system.
9
2.9 FLUE CONNECTIONS
FLUE
SYSTEM
The provision for satisfactory flue ter mination must be made in accordance with BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outside 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 plumingmust 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 ter minal guard, quote the appliance model number. 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 F
IG. 2.5.
T
ERMINALPOSITION
mm
A - Directly below an openable window or other opening 300 B - Below gutters, soil 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 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
FIG. 2.5
HI
BC
F
D
J
A
E
F
G
K
L
G
Ø 80 mm
In addition, it is also possible to use a split (twin pipe) system by fitting a special adaptor to the flue connector and using the aperture for the air vent intake located on the top part of the combustion chamber. To utilise the air intake it is necessary to:
1. Remove the bottom of the air intake by cutting it with a suitable knife (see F
IG. 2.7);
2. Insert the elbow into the air intake until it reaches the lower end.(There is no need to use gaskets or sealing compounds).
10
I
MPORTANT
!
For all flue systems, a restrictor must always be inserted into the boilers flue connector; the restrictor must be Ø 46 or Ø 41 in diameter depending on the length of piping indicated inT
ABLE 2.1.
FIG 2.9 and FIG 2.10 illustrate some
of the various designs for coaxial or twin pipe flue systems. For further information on discharge/ventilation accessories, see the F
LUE PIPE ACCESSORIES
MANUAL.
COAXIAL SYSTEMS
F
IG. 2.7
F
IG. 2.8
F
IG. 2.9
L = Sum of the total length of exhaust + air intake piping.
11
Exhaust
Type
C12 (xx) C32 (xx) C42 (xx)
Restrictor
ø 46 mm
L min = 0.5 m
L max = 1 m
Maximum Extension Exhaust/Air
L = 4 m
Risk of Condensation Forming
Coaxial
Systems
ø 60/100
Piping not insulated
ø 46
restrictor NO restrictor
NONE NONE
Piping insulated
ø 46
restrictor NO restrictor
NONE NONE
Exhaust
Type
C12 (xx) C32 (xx) C42 (xx)
Restrictor
ø 41 mm
L min = 0.5 m
L max = 1 m
Maximum Extension Exhaust/Air
L = 4 m
Risk of Condensation Forming
Coaxial
Systems
ø 60/100
Piping not insulated
ø 41
restrictor NO restrictor
NONE NONE
Piping insulated
ø 41
restrictor NO restrictor
NONE NONE
TABLE 2.1
Exhaust
Type
C12 (xy) C32 (xy) C42 (xy)
C52 (xy) C82 (xy)
Restrictor
ø 41 mm
L max = 38 m
L max = 34 m
Maximum Extension Exhaust/Air
62 m 62 m 62 m
54 m
Risk of Condensation Forming
Twin Pipe
Systems
ø 80/80
Piping not insulated
ø 41
restrictor NO restrictor
8 m 11 m
8 m 11 m
Piping insulated
ø 41
restrictor NO restrictor
19 m 31 m
19 m 31 m
21 RFFI
28 RFFI
Exhaust
Type
C12 (xy) C32 (xy) C42 (xy)
C52 (xy) C82 (xy)
Restrictor
ø 46 mm
L max = 25 m
L max = 22 m
Maximum
Extension Exhaust/Air
34 m 34 m 34 m
31 m
Risk of Condensation Forming
Twin Pipe
Systems
ø 80/80
Piping not insulated
ø 46
restrictor NO restrictor
3.0 m 4.5 m
3.3 m 4.8 m
Piping insulated
ø 46
restrictor NO restrictor
12.5 m 16.0 m
14.0 m 17.8 m
21 RFFI
28 RFFI
TWIN PIPE
SYSTEMS
FIG. 2.10
In calculating the lengths of the pipes, the maximum length “L” 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 exhaust/ air intake pipes must
have the same diameter of
ø 80 mm.
2 - If elbows are to be inserted into the
air intake and/or exhaust system, the calculation of the overall length must take into consideration the values for each elbow, see the F
LUE PIPE
ACCESSORIES MANUAL.
3 - The exhaust pipe must protrude by at
least 0.5 m above the top of the roof in the event that it is located on the opposite side of the building to the side with the air intake (this condition is not obligatory when the air intake and exhaust are located on the same side of the building).
12
To connect a room thermostat and/or time clock, it is necessary to:
1. - Open the control panel as indicated in section 4.3;
2.- Remove screws Aand remove the inspection cover from the reverse of the control panel;
3. - For the room-thermostat connect the thermostat switching wires to the position 5 and 6 and remove the wire link (for three-wire thermostats connect the neutral to ter minal N);
4. - For the time clock connect the clock switching wires to the positions 3 and 4 and connect the clock motor electrical supply to the terminals marked L and N.
Note: A frost thermostat is built-in to the appliance.
For connection to control systems with zone valves for hot water cylinders see section 3.
2.10 ROOM THERMOSTAT CONNECTION
A
2.11 ELECTRICAL DIAGRAM
13
FIG. 2.12
LEGEND:
A - On/Off Switch B - On/Off L.E.D. C - Heating Switch D - Heating L.E.D. E - Reset Button F - Ignition Failure (Lockout) L.E.D.
A01 - Pump Pressure Switch A02 - Frost Thermostat A03 - Modulator A04 - Circulation Pump A05 - Regulation Thermostat A06 - External Control System A07 - Time Clock Connector A08 - External (Room) Thermostat A09 - Air Pressure Switch A10 - Fan
A11 - Overheat Thermostat A12 - Spark Generator/Gas Valve Supply A13 - Detection Electrode
Colours: Wh -White Bl -Blue Gry -Grey Brn -Brown Blk -Black Rd -Red Grn/Yll-Yellow/Green
14
LEGEND:
1. Fan
2. Main heat exchanger
3. Overheat thermostat
4. Burner
5. Ignition electrodes
6. Detection electrode
7. Regulation thermostat
8. Frost thermostat
9. Gas valve
10. Pump pressure switch
11. Safety valve (3 bar)
12. Boiler drain valve
13. Automatic by-pass
14. Pressure gauge
15. Circulation pump with automatic air release valve
16. Expansion vessel
17. Air pressure switch
A. Central Heating Flow B. Inlet Gas C. Central Heating Return
2.12 G
AS AND W
ATER CIRCUITS
F
IG. 2.14
FIG. 2.13
1
2 3
4 5
6 7
8 9
10
17
16
15 14
13
11
12
15
3. D.H.W. STORAGE CYLINDER
The microSYSTEM can be connected to a storage cylinder (both open-vented and unvented) for the production of domestic hot water (D.H.W.). Cylinders of different capacities can be used depending on site requirements (see T
ABLE
3.1 for a
selection of ARISTON unvented cylinders).
F
IG. 3.2
3 port valve installation
F
IG. 3.1
2 port valve installation
3.1 2
PORT AND 3 PORT VALVE
INSTALLATIONS
Wiring to 2 port valve installation using an external 2 channel programmer Type Danfoss FP715 Type Honeywell ST6400C
FIG. 3.3
16
TABLE 3.1
Wiring to 3 port valve installation using an external 2 channel programmer Type Danfoss FP715 Type Honeywell ST6400C
FIG
. 3.4
NOTE: When using a 3 por t valve installation in conjunction with an unvented cylinder it
will be necessary to use a 2 por t valve on the cylinder flow connection in addition to the 3- port valve to satisfy Building Regulations.
Technical Data Capacity Coil C.H.W. D.H.W. Max Heating Heat Ioss
Surface Flow/rate Flow/rate Output
MODEL It. m Contract STI 125 Indirect 125 0.75 0.5 194 11.3 2
Comfort STI 125 Indirect 125 0.75 0.5 256 14.9 2.2 Contract STI 150 Indirect 150 0.93 1 353 20.5
Comfort STI 150 Indirect 150 0.93 0.5 256 14.9 2.4 Contract STI 210 indirect 200 0.93 1 353 20.5
Comfort STI 210 Indirect 200 0.93 0.5 256 14.9 2.9 Contract STI 300 Indirect 300 0.93 1 353 20.5
2
m3/h It/h kW kWh/24h
1 266 15.5 2 340 19.8
2 451 26.2
2 451 26.2
2 451 26.2
SB 125 Indirect 125 1 0.5 190 11 1.72
1 318 18.5 2 496 28.8
SB 150 Indirect 150 1 0.5 190 11 1.75
1 318 18.5 2 496 28.8
SB 200 Indirect 200 1.3 0.5 190 11 2.1
1 318 18.5 2 496 28.8
17
MTS (GB) Limited support the initiative.Within the information pack you will find a copy of the logbook. It is important that this is completed in the presence of your customer, they are shown how to use it, and it is signed by them. Please instr uct your customer that they must have their logbook with them whenever they contact a service engineer or us.
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.
F
ILLING THE HEATING SYSTEM:
Remove the panels of the case and lower the control panel (see section
3.3 for further information). Open the central heating flow and return cocks supplied with the connection kit (there are two isolation points on the return connection). 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 lowest point and close it only when clear water, free of air, is visible.
Purge the air from the pump by unscrewing anticlockwise and removing the pump plug and also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free.
Refit the pump plug. Continue filling the system until at least 1.5 bar registers on the pressure gauge. Inspect the system for water leaks and remedy any leaks discovered.
G
AS SUPPLY:
Inspect the entire installation including the gas meter, test for soundness and purge the supply as described in BS 6891:1988. Open the gas cock (supplied with the connection kit) to the appliance and check the gas connections on the appliance for leaks.
4. COMMISSIONING
4.1 INITIAL PREPARA TION
Boiler microSYSTEM microSYSTEM
21 RFFI 28 RFFI
Cylinder
= Ideal
= Possible
The microSYSTEM is able to be connected to a specially designed kit for the management of D.H.W.production.This kit gives prior ity to production of D.H.W. unlike traditional systems where the boiler power is split between C.H. and D.H.W. This generally enables a smaller storage cylinder to be chosen as the boilers full output will be channelled into the cylinder allowing for a quick heat-up.
The kit (ARISTON part number
706329) can be obtained from an
ARISTON supplier. The kit consits of:
1) Electronic module able to plug into the boilers P.C.B;
2) 3-way priority valve with actuator for connection to the boiler’s flow outlet;
3) A limit thermostat (80˚C) to check the water temperature of the heating flow to the cylinder, to be installed within the boiler;
4) Pipes and accessories.
Contract STI 125 Indirect Comfort STI 125 Indirect Contract STI 150 Indirect Comfort STI 150 Indirect Contract STI 210 Indirect Comfort STI 210 Indirect Contract STI 300 Indirect SB 125 Indirect SB 150 Indirect SB 200 Indirect
TABLE
3.2
3.2 DOMESTIC HOT WATER PRIORITY KIT
In order to access the inside of the boiler, it is necessary to unscrew the fastening screws Aof the control panel located on the lower part of the panel itself. The control panel moves downward and when pulled forward rotates on two lateral hinges. The panel stays in a semi-horizontal position, which allows access to the inner parts of the boiler. In order to increase the manoeuvring space, it is possible to raise the control panel and rotate it to a fully horizontal position.
18
4.3 R
EMOVING THE
FRONT PANEL
1
2
3
A
L
EGEND:
A - On/Off button B - On/Off L.E.D. green (frost protection active) C - Central Heating button D - Cental Heating active L.E.D. green E - Ignition failure (lockout) and/or overheat reset button F - Ignition failure (lockout) and/or overheat L.E.D. red G -Central heating temperature adjustment H - Energy Saving System (ESS) I - Knock-out for time clock J - Heating system pressure gauge
4.2 C
ONTROL P
ANEL
F
IG. 4.1
When the installation and filling are completed turn on the central heating system (section 4.4) 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 the 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.
19
The flue connector has two apertures, readings can be
taken for the temperature of the combustion by-products and of the combustion air, as well as of the concentrations of O
2
and CO2, etc. .
To access these intakes it is necessary to unscrew the front screw and remove the metal plate with sealing gasket. To achieve the best test conditions, turn the central heating adjustment knob Gto the maxposition and remove the electrical connection to the heating sensor (see section 6.). This will allow the appliance to operate at the maximum heating power.
4.5 COMBUSTION ANALYSIS
4.4 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 1.5 bar, bring it up to the appropriate level;
-Ensure that 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 pushing the On/Off button A(see
F
IG.4.1) - the L.E.D. “B” will illuminate. Then push the button “C” in for
central heating - the L.E.D. Dwill illuminate. This will star t the circulation pump. After 7 seconds, the boiler will signal a shutdown due to ignition failure.Leave the boiler as it is until all of the air has been bled from the system.
-Loosen the cap on the head of the pump to eliminate any air pockets;
-Repeat the procedure for bleeding the radiators of air;
- Check the system pressure and, if it has dropped, open the filling loop again to bring the pressure back up to 1.5 bar.
2. Make sure that all gate valves are open;
3. Turn on the gas cock and check the seals on the connections with an approved soap solution and eliminate any leaks.
4. Press the reset button Efor the lighting system; the spark will light the main burner. If the burner does not light the first time, repeat the procedure.
5. 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 5 (See the relative section for burner pressure adjustment within the servicing manual).
B
4
5
To dismantle the front casing panel it is necessary to: 1 - Remove the two screws B”; 2 - Move the front casing panel up and lift forward.
FIG. 4.2
The boiler is fitted with the following devices (see section 4.2 for references).
1 - IGNITION FAILURE
:
This indicates ignition failure when a flame is not detected within 7 seconds of starting an ignition sequence. The L.E.D. Fwill illuminate to signal the shutdown status. The system can be reset by pressing and releasing the button E” after checking to make sure that the gas cock is open.
2 - I
NSUFFICIENT SYSTEM PRESSURE:
In the event of insufficient water pressure in the heating system, a safety device will shutdown the boiler. Check the system pressure on the pressure gauge Jand if it is less than 0.4 bar refill the system to
1.5 bar. Once the system pressure is at the correct level the boiler will ignite automatically.
3 - OVERHEATING:
This control shuts off the boiler in the case where the primary circuit reaches a temperature in excess of 105°C. The red L.E.D. Fwill illuminate to signal this shutdown status. The system can be reset by waiting a few minutes for the primary exchanger to cool down and then by pressing and releasing the E button.
4. ANTI-FROST DEVICE: The boiler is equipped with a device that, in the event of the water temperature going below 6°C, the burner ignites at the minimum power until the boiler water reaches a temperature of 16°C. This device operates only if the boiler is functioning perfectly and:
- the system pressure is sufficient;
- the boiler is powered electrically - L.E.D. Billuminated;
- the gas is turned on.
5 - EXHAUST DISCHARGE ANOMALY SHUTDOWN:
The boiler is fitted with safety devices, which in the event of defective discharge of exhaust fumes, automatically interrupts the gas supply, thereby shutting off the boiler. The shutdown of the boiler is temporary and when the discharge state of exhaust fumes has returned to normal, the boiler automatically turns back on
20
4.7 BOILER S
AFETY SYSTEMS
The heating system must be emptied as follows:
- Turn off the boiler;
- Attach a hose pipe and open the drain valve;
- Empty the system at the lowest points (where present). When the heating system is unused 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.
4.8 D
RAINING THE SYSTEM
In the boiler, it is possible to monitor the correct operation of the flue exhaust/air intake, checking for a loss of general pressure in the system. Through the use of a differential manometer connected to the test points of the combustion chamber, it is possible to detect the P of operation of the air pressure switch. The value detected should not be less than 0.55 mbar under conditions of maximum thermal power in order for the boiler to function properly and without interruption.
4.6 FUME DISCHARGE MONITORING
FIG. 4.3
21
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 5);
2. Adjust the maximum and minimum thermal capacity values for the boiler (see table in section 5);
3. Replace the gas rating plate;
4. Adjust the maximum thermal power setting;
5. Adjust the soft-light feature (open the cover of the regulation screw on the
gas valve (see F
IG. 5.1). Rotate clockwise from min. to max. as per
installation requirements).
5.1 C
HANGING THE
T
YPE OF GAS
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.
[1 mbar = 10,197 mmc.a.]
5. GAS ADJUSTMENTS
Lower Wobbe Index (15°C;1013mbar) MJ/m3h Nominal Delivery Pressure mbar Minimum Delivery Pressure mbar
21 RFFI
Main Burner: n. 12 jets (ø)mm Consumption (15°C; 1013mbar) m
3
/h Consumption (15°C; 1013mbar) Kg/h Gas Burner Pressure: max - min mbar
28 RFFI
Main Burner: n. 14 jets (ø) Consumption (15°C; 1013mbar) m
3
/h Consumption (15°C; 1013mbar) Kg/h Gas Burner Pressure: max - min mbar
CATEGORY II2H3+ Methane Gas
G20
Liquid Butane Gas
G30
Liquid Propane Gas
G31
45.67 20 17
1.30
2.4 - 1.05
----
8.5 - 1.7
1.30
3.15 -1.26
----
11.0 - 1.6
80.58 29 20
0.77
----
1.78 - 0.78
27.5 - 6.2
0.77
----
1.78 - 0.78
27.7 - 4.6
80.58 37 25
0.77
----
1.76 - 0.77
37.4 - 8.0
0.77
----
1.76 - 0.77
35.5 - 6.0
VG002Ab
TABLE 5.1
F
IG. 5.1
22
It is recommended that the following inspections be carried out on the boiler at least once a year:
1 - Check the seals for the water connections; replace any faulty seals. 2 - Check the gas seals;replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of combustion by-
products (see section 4.5) and cleaning of the burner if needed.
5 - If called for by point. 3, dismantling and cleaning of the combustion
chamber. 6 - If called for by point. 4, dismantling and cleaning of the burner jets. 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 (overheat thermostat);
- safety device for maximum pressure (safety valve).
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- General check of the combustion by-products of the
discharge/ventilation system.
13- Check of the general performance of the unit.
6. MAINTENANCE
23
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 Internet: http://www.mtsgb.ltd.uk E-mail: info@mtsgb.ltd.uk
Technical Service Hot Line: (01494) 539579
23 99 84 1549 000 - Stampa: bieffe RECANATI
CE Certification Heat Input max/min kW Heat Output max/min kW Efficiency of Nominal Heat Input % Efficiency at 30% of Nominal Heat Input % Heat Loss to the Casing (T=50°C) % Flue Heat Loss with Burner Operating % Flue Heat Loss with Burner Off % Maximum Discharge of Fumes (G20) Kg/h Residual Discharge Head mbar Consumption at Nominal Capacity(G20) m
3
/h
Gas Consumption after 10 Minutes* m
3
(15°C, 1013 mbar) (G30-G31) Kg/h Temp .of exhaust fumes at nominal capacity °C CO2 Content %
O2 Content % CO Content ppm
Minimum Ambient Temperature °C Head Loss on Water Side (max) (T=20°C) mbar Residual Head of System bar Heating Temperature max/min °C Expansion V essel Capacity l Expansion Vessel Pre-load Pressure bar Maximum Water Content of System l Maximum Heating Pressure bar Nominal Pressure Natural Gas (G20) mbar
LPG (G30-G31) mbar Electrical Supply V/Hz Power Consumption W Protection Grade of Electrical System IP Internal Fuse Rating Weight Kg
G.C. Number
28 RFFI
6. TECHNICAL INFORMATION
63AU4549
22.7/10.0
21.0/8.7
92.8
90.8
1.2
6.0
0.2
46.2
0.70
2.4
0.32/0.39
1.78/1.76
117.2
6.81 9
20 +5
200
0.25
82/42
6 1
130
3
20
30-37
230/50
155
X4D
FAST 2 AT
39
41-116-06
63AU4549
29.8/12.0
27.8/10.5
93.5
90.7
0.2
6.3
0.4 60
1.60
3.15
0.37
2.34/2.31
128.8
6.9
8.1 48
+5
200
0.25
82/42
6 1
130
3
20
30-37
230/50
155
X4D
FAST 2 AT
39
41-116-07
21 RFFI
*Calculated at 70% maximum output
Servicing Instructions Type C Boilers
G.C.N: 41-116-06
41-116-07
LEAVE THESE INSTRUCTIONS WITH THE END-USER
2
1. SERVICING INSTRUCTIONS
1.1 REPLACEMENT OF PARTS
1.2 TO GAIN GENERAL ACCESS
- Removing the front panel
- Removing the sealed chamber front cover
- Removing the side panels
1.3 A
CCESS TO THE COMBUSTION CHAMBER
- Removing the combustion cover
- Removing the burner and jets
- Removing the electrodes
- Removing the main heat exchanger
- Removing the air pressure switch
- Removing the fan
1.4 S
ERVICING AND
REMOVAL OF THE GAS VALVE
- Setting the gas pressures
- Removing the spark generator
- Removing the gas valve
1.5 A
CCESS TO THE WATER CIRCUIT
- Removing the pump pressure switch
- Removing the safety valve
- Removing the automatic air vent
- Removing the pump
- Removing the pressure gauge
- Removing the expansion vessel
- Removing the overheat thermostat
- Removing the frost thermostat
- Removing the regulation thermostat
1.6 A
CCESS TO THE CONTROL SYSTEM
- Checking the fuses
- Removing the P.C.B.s
2. FAULT FINDING
2.1 FAULT FINDING GUIDE (FLOW-CHARTS)
3. ELECTRICAL DIAGRAMS
4. SHORT SPARE PARTS LIST
TABLE OF CONTENTS
2. The control panel moves downward and when pulled forward,
rotates on two lateral hinges; the panel stays in a semi­horizontal position, which allows access to the inner parts of the boiler (F
IG. 1.2);
3. In order to increase the manouvering space, it is possible to raise the control panel and rotate it to a fully horizontal position (F
IG. 1.3);
4. Remove the screws “B”from the front panel bottom lip (F
IG. 1.4);
5. Lift the front panel up and forward from the raised screws at the the top of the casing (F
IG. 1.5).
FIG. 1.4
B
FIG. 1.5
3
1. SERVICING INSTRUCTIONS
The life of individual components varies 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 R
EPLACEMENT 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.
1.2.1 Removing the front panel
1. Loosen the fastening screws “A”of the control panel located on
the lower part of the panel itself. (F
IG. 1.1);
A
FIG. 1.3
F
IG. 1.1
FIG. 1.2
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 shor t circuit).
4
1.2.2 Removing the sealed chamber front cover
1. Remove the screws “C”(FIG. 1.6);
2. Lift the sealed chamber front cover from the locating pins
(FIG. 1.7).
FIG. 1.6
C
C
FIG. 1.7
1.2.3 Removing the side panels
1. Remove the four screws “D” for each side panel (FIG.1.8);
2. Pull the panel away from the boiler at the base, then lift the
panel up and remove from the boiler.
D
D
D
FIG. 1.8
1.3.3 Removing the electrodes
Before carrying out this procedure, unscrew and slide the burner forward (see previous section).
1. Remove rubber gasket “G” (F
IG. 1.12);
2. To remove the detection electrode disconnect the cable
at its connection point close to the P.C.B. (F
IG. 1.13);
FIG. 1.12
G
F
IG. 1.13
1.3.2 Removing the burner and jets
1. Remove the screws “F”from the burner (F
IG. 1.10);
2. Remove the burner (FIG. 1.11);
3. Disconnect the electrodes (see section 1.3.3);
4. Remove the jets using a No.7 socket spanner;
5. Replace in reverse order.
5
1.3.1 Removing the combustion cover
1. Remove the screws “E” (F
IG. 1.9);
2. Lift off the combustion cover.
1.3 ACCESS TO THE COMBUSTION CHAMBER
E
E
E
FIG. 1.9
FIG. 1.10
Fig. 1.11
F
F
6
3. Remove screw “H”(F
IG. 1.14);
4. Gently slide the electrode downward (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 -Ensure that the left hand and right hand electrodes are
located the correct way round (facing each other), to give the correct spark gap;
c -Check that the cables have been connected correctly; d -Check that the rubber gasket cov ers the cable/ electrode
connection point completely.
F
IG. 1.14
FIG. 1.15
H
1. Drain the boiler of water;
2. Release the overheat thermostat sensor “I” (F
IG. 1.16);
3. Release the two connection nuts “J” connecting the exchanger to the flow and return pipes (F
IG. 1.17);
4. Remove the heat exchanger by sliding forward (F
IG.
1.18).
1.3.4 Removing the main heat exchanger
FIG. 1.17
J
Fig. 1.16
I
FIG. 1.18
1. Disconnect electrical connections “N” and silicon pipe “O” (F
IG.1.22);
2. Remove screw “P” and remove the fan collar clamp “Q” (FIG
.1.23);
3. Remove screws “R” (F
IG.1.24);
4. Remove fan and mounting plate (FIG.1.25).
1.3.6 Removing the fan
1. Disconnect the electrical connections “K” and silicone
pipes “L” from their connection points (F
IG. 1.19);
2. Remove screws “M” on the top of the sealed chamber (F
IG. 1.20);
3. Lift out the air pressure switch (F
IG. 1.21);
4. Unscrew to remove the switch from the plate.
FIG. 1.20
FIG. 1.19
7
1.3.5 Removing the air pressure switch
L
L
K
M
M
F
IG. 1.21
FIG. 1.24
R
R
F
IG. 1.23
P
Q
FIG. 1.22
N
O
F
IG. 1.25
8
1.4 SERVICING AND REMOVAL
OF THE GAS VALVE
1.4.1 Setting the gas pressures
1
2
3
4
A
B
C
F
G
D
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.Turn off the gas supply at the isolation point under the boiler
2. To do this, slacken the screw “A”.
Fit the pipe of the pressure gauge to the inlet pressure test point of the gas valve “B”.
T urn on the gas suppl y at the isolation point under the boiler and with the boiler running, read the inlet working pressure on the gauge. When you have completed this operation, turn off the gas supply at the isolation point under the boiler, remove the pressure gauge and tighten the screw “A” securely into its housing to seal off the gas.T urn on the gas supply at the isolation point under the boiler and test the screw for gas escaping with an approved soap and water solution.
3. To check the pressure supplied by the gas valve to the burner, with the
boiler turned off, slacken the screw “C”.Fit the pipe of the pressure gauge to the outlet pressure test point of the gas valve “D”. Disconnect the compensation pipe “E”either from the gas valve or from the sealed chamber.
4. Push the On/Off button to “ON”position -green light- and push the Heating button to “ON” position -green light­Turn on the boiler by setting the external controls. Adjust the 10mm nut “F” on the modureg to set the gas pressure Tur n the nut clockwise to increase and anti clockwise to decrease the pressure until the required pressure is achieved (see T
ABLE A page 9)
5. To set the minimum power, disconnect the supply cable from the modureg
and adjust screw “G” whilst holding nut “F”. Turn the screw clockwise to increase the pressure and anticlockwise to decrease the pressure until the required pressure is achieved (see T
ABLE
A page 9)
6. When you have completed the above operations, turn off the external
controls, re-connect the supply terminal to the modureg on the gas valve and replace the cap on the screw of the modureg.
Setting pressure for soft ignition.
The soft light pressure is factory set. If the ignition is not regular (e.g: not complete bur ner ignition or ignition noise) check the soft light regulator position. The soft light pressure will need adjusting as follows:
- Turn off electrical supply;
- referring to diagram 5, open the dust cap of the soft light regulator, by
unscrewing in clockwise direction the white screw;
- turn the adjustment screw one step in the direction max to increase or in
the direction min to decrease the soft light pressure;
- after each adjustment of the regulator, turn on the electrical supply and
recheck burner ignition (wait 20 seconds between each cycle to allow the gas valves’internal servo system to reset). When the required level is achieved, close the dust cap.
7. Remove the pipe from the pressure gauge and connect screw “C” to the pressure outlet in order to seal off the gas.
8. 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 an approved soap and water solution.
VG002Ac
VG002Ad
VG002Af
VG002Ae
E
VG002Ab
5
9
Regulating the heating power for
natural gas (G20)
Regulating the heating power for
butane gas (G30)
Regulating the heating power for
propane gas (G31)
TABLE A
21 kW
28 kW
21 kW
28 kW
21 kW
28 kW
CG004A
CG005A
CG006A
TB005A
GAS BURNER PRESSURE
GAS BURNER PRESSURE
OPERATING POWER
OPERATING POWER
GAS BURNER PRESSURE
21 RFFI
28 RFFI
2.4
1.05 20
8.5 3.3
1.7
3.15
1.26
11
1.6 14 x 1.30
84.7
37.0
0.7
111.1
44.5
4.3
0.6
OPERATING POWER
1.78 1.7662.8 62.1
0.78
27.5
6.2
2.34
0.94
27.7
4.6
27.5 27.2
10.7
2.4
82.6
33.2
10.8
1.8
14 x 0.77
0.77
37.4
8.0
2.31
0.93
35.5
6.0
14.6
3.1
81.5
32.8
13.8
2.3
14 x 0.77
10
F
IG. 1.28
FIG. 1.29
FIG. 1.30
U
V
V
1.4.3 Removing the gas valve
Impor
tant! Before removing the gas valve, ensure the gas
supply is turned off.
1. Disconnect all the cables from the solenoid and modureg;
2. Remove the spark generator (see previous section);
3. Release the top nut U(F
IG. 1.28);
4. Remove the screws “Vfrom the bottom of the gas valve pipe (FIG. 1.29);
5. Remove the gas valve (F
IG. 1.30).
1.4.2 Removing the spark generator
1. Disconnect ignition leads Sby pulling upward
(F
IG. 1.26);
2. Remove the screw T(FIG. 1.27);
3. Remove the spark generator by pulling forward from the
gas valve.
FIG. 1.27
FIG. 1.26
S
T
11
1. 5. 2 Removing the safety valve
1. Loosen nut Y(F
IG. 1.33);
2. Disconnect the discharge pipe work from below the boiler;
3. Unscrew and remove the valve.
1.5.3 Removing the automatic air vent
1. Unscrew valve top Z(FIG. 1.34);
2. Remove valve complete with float (F
IG 1.35).
FIG. 1.33
FIG. 1.34
Y
Z
FIG. 1.35
Impor
tant!
Before any component is removed, the boiler
must be drained of all water.
1.5 ACCESS TO THE WATER CIRCUIT
FIG. 1.31
W
FIG. 1.32
X
1.5.1 Removing the pump pressure switch
1. Remove the cable of the pump pressure switch W
(Fig. 1.31);
2. Unscrew the pump pressure switch by using a spanner on the nut “X”(F
IG. 1.32);
3. Remove the pump pressure switch.
12
1.5.4 Removing the pump
1. Remove the U-clips A1and B1(F
IG. 1.36);
2. Remove the retaining clip C1(FIG. 1.37);
3. Release the nut D1(FIG. 1.38);
4. Remove the pipe E1(F
IG. 1.39);
5. Remove the screw F1(FIG. 1.40);
6. Remove the pump (FIG. 1.41).
FIG.1.37
FIG.1.36
F
IG.1.38
C1
A1
B1
FIG
. 1.39
FIG. 1.40
FIG. 1.41
D1
E1
F1
13
1.5.6 Removing the expansion vessel
1. Release nuts H1and remove the gas pipe (F
IG. 1.44);
2. Release nut I1(FIG. 1.45);
3. Remove lock-nut J1(FIG. 1.46);
4. Remove the expansion vessel (F
IG. 1.47).
1.5.5 Removing the pressure gauge
1. Remove the U-clip G1and remove the pressure gauge
coupling (F
IG. 1.42);
2. Push the pressure gauge through the control panel from
the rear (F
IG. 1.43).
FIG. 1.42
FIG. 1.44
G1
F
IG. 1.43
H1
I1
F
IG. 1.45
F
IG. 1.46
FIG. 1.47
H1
J1
14
1.5.6 Removing the overheat thermostat
1. Disconnect the overheat thermostat electrical
connections K1(F
IG. 1.48);
2. Then remove the thermostat from its mounting by
releasing the securing clip (F
IG. 1.49).
1.5.7 Removing the frost thermostat
1. Disconnect the frost thermostat electrical connection
L1(F
IG. 1.50);
2. Then remove the thermostat from its mounting by
releasing the securing clip (F
IG. 1.51).
1.5.8 Removing the regulation thermostat
1. Remove the regulation thermostat sensor from its
mounting by releasing the securing clip “M1” (F
IG. 1.52);
2. Separate the facia panel from the rear of the control panel (see section 1.6.2);
3. Remove the electrical connections “N1 from the regulation thermostat (F
IG. 1.53);
4. Pull the regulation knob from the spindle of the thermostat;
5. Remove the thermostat from the control panel facia by unscrewing the mounting screws.
FIG. 1.48
FIG. 1.49
K1
F
IG. 1.52
FIG. 1.51
M1
L1
FIG. 1.50
FIG. 1.53
N1
15
1.6.2 Removing the P.C.B.s
1. Isolate electricity;
2. Remove the screws O1(F
IG. 1.56);
3. Separate the facia panel from the rear of the control panel;
4. Unplug all electrical connections from the P.C.B. and remove the screws “P1” and remove the P.C.B. (F
IG.
1.57).
F
IG. 1.56
O1
O1
O1
O1
O1
P1
P1
P1
P1
O1
F
IG. 1.57
1.6.1 Checking the fuse
1. Remove the inspection cover on the reverse of the
control panel (F
IG. 1.54);
2. Remove the fuse mounted on the reverse of the inspection cover (F
IG. 1.55).
1.6 ACCESS TO THE CONTROL SYSTEM
F
IG. 1.54
FIG. 1.55
Important! Isolate the electrical supply to the boiler before accessing the control panel.
16
B063
2. FAULT FINDING
P
RELIMINARY CHECKS
MAKE SURE THAT
:
IS
THE SUPPLY
L.E.D. ILLUMINATED?
IS
THE L.E.D.
ILLUMINATED?
NO
NO
NO
YES
NO
1 - CHECK THE FUSES 2 - CHECK THERE IS POWER
SUPPLIED TO THE
P.C.B.S
3 - CHECK/REPLACE THE P.C.B.
(CT1)
1 - C
HECK THE INTEGRITY
OF THE
L.E.D.
2-C
HECK/REPLACE THE P.C.B.
(CT1)
P
RESS THE
ON
/
OFF BUTTON
P
RESS THE CENTRAL
HEATING BUTTON
FROST
PROTECTION IS
ACTIVATED <5¡C. IS THE
FROSTPROTECTION
REQUESTED?
IS
TIME CLOCK/
PROGRAMMER
AND/OR ROOM
CALLING FOR
HEATING?
THE
THERMOSTAT
A
1 - THERE IS SUFFICIENT
WATER IN THE SYSTEM
2 - THE GAS IS TURNED ON 3 - THE ELECTRICAL SUPPLY
IS TURNED ON
YES
YES
YES
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-CHARTS)
FC002Aa
17
B063
A
FC002Ab
IS THE PUMP
RUNNING?
YES
IS THE FAN
RUNNING?
NO
POWER TO
THE PUMP?
YES
1 - CHECK THE OPERATION
OF THE PUMP
2 - RELEASE/REPLACE THE
PUMP
NO
NO
1 - CHECK THE PUMP CABLE 2-CHECK/REPLACE P.C.B.
(CT1)
3 - CHECK THE SYSTEM
PRESSURE GAUGE IS AT
1.5 BAR
YES
B
BOILER
SHUTDOWN?
NO
INTERNAL
P.C.B. PROTECTION
ACTIVATED?
NO
POWER TO
THE FAN?
YES
1 - REPLACE THE FAN
YES
YES
NO
1 - RESET THE BOILER
1 - CHECK/REPLACE AIR
PRESSURE SWITCH AND CABLE
2 - CHECK IF THE RESET
IS JAMMED
3 - CHECK/REPLACE
DETECTION ELECTRODE
1 - CHECK/REPLACE FAN
CONNECTION CABLE
2 - CHECK/REPLACE P .C.B. 3 - C
HECK/REPLACE AIR
PRESSURE SWITCH
18
B063
B
NOISEY OPERATION
DECREASE/INCREASE OF HEATING CIRCUIT
PRESSURE
REPEATED SHUTDOWNS
REPEATED OPERATION OF SAFETY THERMOSTAT
INSUFFICIENT RADIATOR TEMPERATURE
- MAIN HEAT EXCHANGER FAULTY OR BLOCKED
WITH LIME-SCALE DEPOSITS
- LOW HEATING SYSTEM WATER PRESSURE
- CHECK GAS PRESSURES
- CHECK HEATING THERMOSTAT
- CHECK FAN
- CHECK PUMP
- CHECK FOR LEAKS ON THE HEATING CIRCUIT
- FAULTY FILLING LOOP
- FAULTY EXPANSION VESSEL
- F
AULTY DETECTION ELECTRODES
- C
HECK GAS PRESSURES
- C
HECK FLAME DETECTION ELECTRICAL CIRCUIT
- F
AULTY HEATING THERMOSTAT
- F
AULTY OVERHEAT THERMOSTAT
- P
RESENCE OF AIR IN THE HEATING CIRCUIT
- C
HECK BURNER PRESSURES
- C
HECK EXCHANGER FLUEWAY
- CHECK HEATING THERMOSTAT
- CHECK BY-PASS
- CHECK GAS PRESSURE
FC002Ac
IS THE
AIR PRESSURE SWITCH
ACTIVATED?
NO
CHECK
P ON PRESSURE
TEST POINT
P mbar0.5
1 - CHECK AIR PRESSURE
SWITCH CABLE
2 - CHECK/REPLACE AIR
PRESSURE SWITCH
3 - CHECK/REPLACE P.C.B.
(CBM2)
YES
DOES
THE SPARK
SEQUENCE
START?
YES
IS THE BURNER
ALIGHT?
YES
HAS THE
BOILER SAFETY
SHUTDOWN BEEN
ACTIVATED?
NO
NO
NO
YES
PRESS THE RESET
BOILER
WORKING?
YES
P 0.5 mbar
HECK/REPLACE IGNITION
1 - C
ELECTRODES
2 - CHECK THE CABLES 3 - CHECK SPARK GENERATOR 4 - CHECK IGNITION ELECTRODE
CABLES
1 - CHECK POWER SUPPLY TO
THE GAS VALVE
2 - CHECK OPERATION OF THE
GAS VALVE
3 - REPLACE THE GAS VALVE
BUTTON
1 - CHECK IF THE FLAME
NO
2 - CHECK THE SOFT-LIGHT 3 - CHECK/REPLACE DETECTION
4-C
STRIKES THE DETECTION ELECTRODE
GAS PRESSURE ELECTRODE
1 - CHECK EXHAUST DISCHARGE 2 - CHECK VENTURI AND TUBES 3 - CHECK THE FAN EFFICIENCY 4 - REPLACE FAN
5-CHECK/REPLACE P.C.B. (CBM2)
HECK/REPLACE P.C.B. (CBM2)
4 - C
HECK/REPLACE
P.C.B. (CBM2)
IS
THERE STILL
A PROBLEM?
NO
NORMAL
OPERATION
NORMAL
OPERATION
NOISEY OPERATION
1
FAULT LIST
YES
DECREASE/INCREASE OF HEATING CIRCUIT
2
PRESSURE
REPEATED SHUTDOWNS
3
4
REPEATED OPERATION OF SAFETY THERMOSTAT
5
INSUFFICIENT RADIATOR TEMPERATURE
POSSIBLE CAUSES
- MAIN HEAT EXCHANGER FAULTY OR BLOCKED
- LOW HEATING SYSTEM WATER PRESSURE
- CHECK GAS PRESSURES
- CHECK HEATING THERMOSTAT
- CHECK FAN
- CHECK PUMP
- CHECK FOR LEAKS ON THE HEATING CIRCUIT
- FAULTY FILLING LOOP
- FAULTY EXPANSION VESSEL
- F
- C
- C
- F
- F
- P
- C
- C
- CHECK HEATING THERMOSTAT
- CHECK BY-PASS
- CHECK GAS PRESSURE
-SCALE DEPOSITS
WITH LIME
AULTY DETECTION ELECTRODES HECK GAS PRESSURES HECK FLAME DETECTION ELECTRICAL CIRCUIT
AULTY HEATING THERMOSTAT AULTY OVERHEAT THERMOSTAT RESENCE OF AIR IN THE HEATING CIRCUIT HECK BURNER PRESSURES HECK EXCHANGER FLUEWAY
19
B063
3. ELECTRICAL DIAGRAMS
SE011A
L
EGEND:
A - On/Off Switch B - On/Off L.E.D. C - Heating Switch D - Heating L.E.D. E - Reset Button F - Ignition Failure (Lockout) L.E.D.
A01 - Pump Pressure Switch A02 - Frost Thermostat A03 - Modulator A04 - Circulation Pump A05 - Regulation Thermostat
A06 - External Control System A07 - Time Clock Connector A08 - External (Room) Thermostat A09 - Air Pressure Switch A10 - Fan A11 - Overheat Thermostat A12 - Spark Generator/Gas Valve Supply A13 - Detection Electrode
Colours: Wh -White Bl -Blue Gry -Grey Brn -Brown Blk -Black Rd -Red Grn/Yll-Yellow/Green
20
B063
SF008A
21
B063
4. SHORT SPARE PARTS LIST
microSYSTEM 21/28 RFFI
ES002A
11 1165676869 64
71 70
66
63 61
62
4
10 11
12
13 14
15 16
17
13
1
2
3
72
12
73
11
79
64
75
11
74
80
81 82
76
77
78
83
84
13
85
11
64
86
107
103
88 87
106
105
104
102
101
13
89
5 6
7 8 9
19
80
99
60
59
31
98
64
100
90
97
96 95
94
92
304
301 302 303
47
93
91
58
57
56 55
54
53 52 51
50
49 48
47 46
45
18
19 20
351
352
21 2322
353
33
354
1324 30 31 32 37 38
29
28272625
38 3839
44
42
4036 3733 34 35
41 43
21/28 RFFI
22
B063
998616 573521 573520 570760 998612 573528 998447 569390 998627 999542 574279 999475 998809 999476 998424 998836 999091 999577 999499 999245 998517 998484 571651 997182 998943 998489 999894 998620 998893 999538 998618 998669 998887 998939 998433 998434 999501 950030 998623 998622 998624 998644 998643 998738 998961 999207 998716 998717
Key
no.
G.C. part
no.
ARISTON
Part No.
Description
2
5 13 16 18 19 21 22 23 25 26 27 29 30 31
33AB
33CD
45 48 49 55
60AB
60CD
73 75
76AB
76CD
78AB
78CD
81
83A 83B 83C
83D 87AC 87BD
93 95 97 98
99 351 352 353
354AB
354CD
361 362
164 282 164 225
164 229 164 261
E03 818
E24 076 E24 075
Expansion vessel Gasket 3/8" Gasket 3/4" Thermostat (frost) Flow group Gasket 1/2" Safety valve (1/4" 3 bar) Gasket 1/4" Pump pressure switch Spark Generator Gasket Gas valve Auto air vent Return group O-ring Pump Pump Thermostat (regulation) P.C.B. (CBM2 AT-FFI2X) Pressure gauge Gasket Air pressure switch Air pressure switch Gasket O-ring (2.65 x 10.27) Fan Fan Main exchanger Main exchanger Thermostat (overheat) Burner 12 ramp (natural gas) Burner 12 ramp (LPG) Burner 14 ramp (natural gas) Burner 14 ramp (LPG) Burner jet (natural gas 1.30) Burner jet (LPG 0.77) P.C.B. (CT1) Fast fuse 2AT Electrode (ignition R.H.) Electrode (ignition L.H.) Detection electrode O-ring (A.A.V.) Auto air vent Gasket (pump head) Pump head Pump head 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
microSYSTEM 21/28 RFFI
23
B063
NOTES
23 99 84 1550 000 -
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 Internet: http://www.mtsgb.ltd.uk E-mail: info@mtsgb.ltd.uk
Technical Service Hot Line: (01494) 539579
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