ariston Genus 23 MFFI User guide

Installation Instructions Type CBoilers 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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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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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 Ser vicing 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

1.1 General Information

User’s

Manual

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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) m

3

/h 2.72/3.32 3.16/3.86 3.16/3.86 3.49/4.05

Gas Consumption after 10 Minutes* m

3

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 V essel 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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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 Valv e (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 Valv e

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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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. Wir ing 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 ( 2ndfamily gases) BS 5546 1990

Flues BS 5440-1 1990 Air supply BS 5440-2 1989

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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

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.

2.4 Clearances

GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM

Fig. 2.1

Fig. 2.2

99

132 67 65

AF CDGE

85

155

208

(F - G)

(A-D-E)

(C)

49

30

110197

450

160

400

60

min 300 - max 350

300

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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 mar ked 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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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 V alv e 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.

ACB 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 fillingloop, 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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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 satisfactor y 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 ter minal guard must be fitted.When ordering a terminal guard, quote the appliance model number.

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

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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

HI

BC

F

D

J

A

E

F

G

K

L

G

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A

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

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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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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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

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

17 m

27 kW

46 m

17 m

30 kW

50 m

15 m

ø 60/100

ø 80

L * < 0.5 m

L < 7 m

L * < 0.5 m

L < 5 m

L * < 0.5 m

L < 7.5 m

L > 4.9 m

L > 6.5 m

L < 5.3 m

L > 4.5 m

(*) L = Length of Piping

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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 Inser t 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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2.11 Electrical Diagram

Legend:

AT = High Voltage P.C.B. BT = Low V oltage 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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GENUS 23/27/30 MFFI

GENUS 27 RFFI SYSTEM

Aa

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GENUS 23/27/30 MFFI

GENUS 27 RFFI SYSTEM

CN202

P

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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 Valv e (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. Saf ety V alv e

18. Water Pressure Gauge

19. Circulation Pump with Automatic Air V alve

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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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, ear th 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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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

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 appropriate 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 shutdown 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

23

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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 O

2

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

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 shutoff 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

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;

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.).

27

B004

6. MISCELLANEOUS

6.1 Wiring Diagram for Two Heating Zones

Based on Honeywell controls

BROWN

BLUE

GREY

ORANGE

GREEN/YELLOW

V4043H

VALVE

5 2 9

10

3

14 35 22

T6360B

ROOM

THERMOSTAT

ZONE1

BROWN

BLUE

GREY

ORANGE

GREEN/YELLOW

V4043H

VALVE

8 2 9

10

3

16

TYPICAL

JUNCTION BOX

• 1

• 2

• 3

• 4

• 5

• 6

• 7

• 8

• 9

1

BOILER ELECTRICAL SUPPLY CABLE

9 10 3 2

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)

the junction box.

A/27 MFFI - A/27 MFFI E N L

Genus 23-27-30 MFFI E N L

Genus 27 RFFI System E N L

31 NL

74 E12

Sunvic ET 1451

Link 2-3-6

Sunvic DHP 2201 6 3 E 1 2

610 2 1

Towerchron FP

25 ENL

64321

14 NL

Pegler Sunvic

SP 50/100 (Link L-3)

SWITCHMASTER 805, 900

Switchmaster

Symphony, Sonata

Switchmaster 400, 600 3 1 N L

to 9 + 10 on

NL

610 2 1

Link 1-5/4-7-9

Towerchron MP

Link 1-4/6-11

Towerchron 2000 HW HTG

ON ON

ACL LS522, LS722 3 4 N L

36 ENL

42 ENL

Randall 922, 972

Link L-2-5

Randall 3020 P

and 3060

BOILER

ZONE 1ZONE 1

PROGRAMMER

38 22

T6360B

ROOM

THERMOSTAT

ZONE 2

L1 N2 E3

240V

MAINS INPUT (3 AMP)

• 10

63 NL

64321

Honeywell ST 699B 1002

Link L-5-8

14 ENL

34 NL

ST 6400/ST 6300 ST 6200 3 4 N L

Drayton T empus 7 3 4 N L

Horstmann 425, 525, 527

Link L-2-5

Landis & Gyr RWB2

Glowworm Mastermind

34 NL

Landis & Gyr RWB20

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

42 E76

Link 1-6

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.

31 ENL

Randall 701, 702

Link L-6-5

Sangamo M5 1 8 E 4 3

Link 1-6

18 E43

Sangamo 410 Form 1

Link 3-6

PROGRAMMER

ZONE 2 ZONE 2

28

B004

6.2 Wiring Diagram for Connection to Ariston Unvented Cylinder

Based on Honeywell controls

14 35 22

T6360B

ROOM

THERMOSTAT

BROWN

BLUE

GREY

ORANGE

GREEN/YELLOW

V4043H

HEATING VAL VE

BROWN

BLUE

GREY

ORANGE

GREEN/YELLOW

V4043H

HOT W A TER VALVE

5 2 9

10

3

8 2 9

10

3

L1 N2 E3

240V

MAINS INPUT (3 AMP)

Cylinder

thermostat

1

C/P

2

Thermal

cut-out

1 C/P

1

BOILER ELECTRICAL SUPPLY CABLE

BOILER

TYPICAL

JUNCTION BOX

• 1

9 10 3 2

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.

A/27 MFFI - A/27 MFFI E N L

Genus 23-27-30 MFFI E N L

Genus 27 RFFI System E N L

• 2

• 3

NL

• 4

ON ON

• 5

25 ENL

64321

14 N L

31 N L

74 E1 2

610 2 1

36 ENL

42 ENL

PROGRAMMER

• 6

• 7

Sunvic ET 1451

Link 2-3-6

Sunvic DHP 2201 6 3 E 1 2

Towerchron FP

Link 1-5/4-7-9

Towerchron MP

Link 1-4/6-11

Towerchron 2000 HW HTG

ACL LS522, LS722 3 4 N L

Randall 922, 972

Link L-2-5

Randall 3020 P

Pegler Sunvic

SP 50/100 (Link L-3)

SWITCHMASTER 805, 900

Switchmaster

Symphony, Sonata

Switchmaster 400, 600 3 1 N L

and 3060

• 8

• 9

• 10

63 N L

64321

1

P

2

8

6

Not used

Honeywell ST 699B 1002

Link L-5-8

14 ENL

34 N L

ST 6400/ST 6300 ST 6200 3 4 N L

Drayton Tempus 7 3 4 N L

Horstmann 425, 525, 527

Link L-2-5

Landis & Gyr RWB2

Glowworm Mastermind

34 N L

Landis & Gyr RWB20

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

42 E7 6

31 ENL

Link 1-6

Randall 701, 702

Link L-6-5

Sangamo M5 1 8 E 4 3

Link 1-6

18 E4 3

Sangamo 410 Form 1

Link 3-6

PROGRAMMER

B004

NOTES

30

B004

NOTES

31

B004

B004 - Cod. 23 99 84 1259 111 - Stampa:

bbiieeffffee

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

Servicing Instructions Type C Boilers G.C.N: 41-116-01

47-116-08 47-116-09 47-116-13

LEA VE THESE INSTRUCTIONS ADJACENT T O THE GAS METER

2

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Page No.

1. SERVICING INSTRUCTIONS

1.1 Replacement of Par ts 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 Ventur i 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.(Secondar y) 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-char t) 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

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 electr ical system checks must be carr ied out to ensure electrical safety (i.e. polarity, ear th continuity, resistance to earth and short circuit).

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

Fig. 1.5

1.

Remove the side panels of sealed chamber

(fig. 1.8)

;

2.

Remove the screws “F” of the bur ner

(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

Fig. 1.6

Fig. 1.7

D

Fig. 1.8

Fig. 1.9

Fig. 1.10

F

push

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

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

K

J

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 remo ve

(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

P

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

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, tur n 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 po wer, disconnect a supply terminal from the modureg and adjust screw “F”. Turn the screw clockwise to increase the pressure and counter-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.

Setting gas pressures

Recommended pressure for slow ignition

NATURAL GAS (G20) BUTANE GAS (G30) PROPANE GAS (G31)

5 mbar - 1.95 in w.g.

18 mbar - 7.0 in w.g. 19 mbar - 7.4 in w.g.

11

B005

Regulating the heating power for

natural gas (G20)

Regulating the heating power for

butane gas (G30)

Regulating the heating power for

propane gas (G31)

T ABLE “A”

model 23 model 27

40 38 36 34

model 23 model 27

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

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

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

Fig. 1.34

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

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

Z

A2

Fig. 1.39

Fig. 1.40

Fig. 1.41

Fig. 1.42

Fig. 1.43

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

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 valv e to the left.

Fig. 1.50

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

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.

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

A8

A9

A10

21

B005

2. FAULT FINDING

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)

Prel imin ary Ch ecks

Make sure that:

1) There is sufficient water in the system

2) The gas is turned on

3) The electricity to the

boiler is on

Press t he

On / Off Button

HAS

THE LI GHT fOR

THE POW ER SU PPLY

COME O N?

YES

NO

1) Check th e fuses

2) Check th e power supply cord, plug and outlet

3) Check/replace the power supply P.C.B.

NO

SUMMER

IS HOT

WATER BEING

DEMA NDED?

NO

FOR B OILERS

EQ UIPPE D WI TH A N

ELECTRONICANT-FREEZE

SYSTEM: HAS THE SAFETY BEEN

TRI GGERED T O ACTIVA TE

THEDEVICE?

(T sensor <5˚C)

SETTING

FOR THE OPE RATING

MODE

FUME DISCHARGE TEST

YES

WINTER

IS HOT

YES

WATER BEING

DEMANDED?

NO

DO THE

TIME CLOCK

AND/ORROOM

THERMOSTAT NEED

TO BE ACTIVATED

NO

FOR B OILERS

EQ UIPPE D WI TH A N

ELECTRONICANT-FREEZE

SYSTEM: HAS THE SAFETY BEEN

TRI GGERED T O ACTIVA TE

THEDEVICE?

(T sensor <5˚C)

NO

A

22

B005

A

DOES THE

CIRCULA TION PUMP

COME ON?

YES

NO

1) Check for air in the system

2) Check the pressure switch for activating pump

3)Check/replacepressure gauge andrefill the the systemproperly

1) Turn the boil er off and then back on again (safety reset)

YES

DOES THE

INSUFFICIENT WATER

INDICATOR LIGHTCOME

ON?(within

40 sec.)

NO

B

POWER TO

THE PUMP?

YES

1) Check to see if pump is stu ck

2)Replacecirculation pump

NO

1) Check wiring

2) Check/repl ace wire to P.C.B.

3) Replace power supply P.C.B.

4) Replace cont rol P.C.B.

5) Check microswitch when hot water is requested.

23

B005

B

DOES THE FAN

COME ON?

YES

C

NO

BOILER

SHUTDOWN?

NO

PUMP

SAFETY DEVICE

ACTIVATED?

NO

INTERNAL

SAFETY DEVICE

FOR PCB

ACTIVATED?

NO

IS THERE POWER

TO THE FAN?

YES

NO

1) Reset the boiler

1) Check/replace differential pressu re sw itch for pump

2) Check/replace w iring

3) Check/replace P.C.B. wire

4) Ch eck/rep lace power supply P.C.B.

5) Check/replace control

P.C.B.

1)

Check/replace air

pressure switch/wiring

2) Check whether reset button isstuck

3)

Check/replace flame

detection electrode

1)

Check/replace wiring Check/replace

2)

3) Check/replace power supplyP.C.B.

4)

Check/replace control

P.C.B.

Check/replace air

5)

pressu re switch

P.C.B. wire

1)Replace fan

24

B005

C

IS

THE AIR PRESSURE

SWITCH ACTIVATED?

YES

ARE THE

FUMES DISCHARGED

CORRECTLY?

YES

DOES THE

BURNER LIGHT?

YES

NO

1) Check flue discharge

2) Check venturi & small pipes

3) Check wire for air press.switch

4) Check/replace air press. switch

5) Check/replace P.C.B. wire

6) Check/replace power P.C.B.

7) Check/replace control P.C.B.

1)Check/replace ignition electrodes

2) Check wiring

3) Check spark generator

4) Check small wire

5) Check power supply P.C.B.

6)Check control P.C.B.

1)Check supply of gas to gas valve

2) Check power supply P.C.B.

3)Check control P.C.B.

4)Checkfunctionality of the gas valve

SAFETY

SHUTDOWN OF THE

BOILER ACTIVATED?

NO

D

YES

NO

1) Check whether flame

detection electrodeis postioned in the flame

2) Check the electrode

3)Check the power P.C.B.

4)Check the control P.C.B.

WAS THE

RESET SWITCH

PRESSED?

YES

Shutdown L.E.D. off

Restart ofthe fan

25

B005

D

THERE STILL A

IS

PROBLEM?

YES

NO

FUNCTIONS

NORMALLY

LISTOF MALFUNCTIONS

Deliveryof hot waterfor domestic use:

1

when thetap isturned on,the burnergoesout.

2

Deliveryof hot waterfor domestic use:

the radiatores areheated in summer mode.

Deliveryof hot waterfor domestic use:

3

water temperature isnot satisfactory.

4

Deliveryof hot waterfor domestic use:

noisyoperation.

POSSIBLE CAUSES

- Air in thesecondaryexchanger

- Hot w ater pressure switch is defective

- 3-way valve is defective

- Check sensors for domestic and heating water

- Check gassettings and regulation

- Check water flow rate

- Check secondary exchanger

- Primary exchanger is defective

- Low water pressure in heating system

- Check gassettings and regulation

- Check ntc sensorfor domestic hotwater

5

Drop/increasein pressure in primary circuit.

6

Repeatedshutdowns.

7

Safety thermostat istriggered repeatedly.

8

When thecold watertap isturnedoff,the

boiler comeson.

9

Temperature of radiators not satisfactory.

- Check for leaks in heating circuit

- Defective water supply inlet valve

- Secondary exchanger isdefective

- Expansion vessel is empty

- Detection electrodes are defective

- Check gassettings and regulation

- Check electrical circuit for flame detection

- Faulty (contacts)N.T.C. sensors-heating/hot water

- Faulty(contacts)N.T.C. sensors-heating/hot water

- Defective (poorly calibrated) safety thermostat

- Presence ofair in the primarywater circuit

- Drop in pressure in the water mains,resulting

in water hammering

- Check N.T.C. sensorforheating

- Check by-pass

- Check gassettings and regulation

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

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 V alv e Relay W = Fan Relay X = Circulation Pump Relay Y = Selector TCS2 Z = Link for Continuous Pump Run Aa = Adaptor (Br itish Gas use only)

A01= Air Pressure Switch A02= Fan A03= Gas V alv e A04= Ignitor A05= Motorised V alv e 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 V alv e Modulator B04= D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only)

B05= Heating Sensor B06= Pressure Switch for Heating Circuit B07= Microswitch for Diver ter 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

28

B005

GENUS 23/27/30 MFFI

GENUS 27 RFFI SYSTEM

Aa

29

B005

GENUS 23/27 MFFI

GENUS 27 RFFI SYSTEM

CN202

P

30

B005

4. SHORT SPARE PARTS LIST

GENUS 23/27 MFFI (SIT Sigma Gas Valve)

2

71

1

2

3

4

5

4

6

7 8 9

10

11

12

13 14

11 15

86

72

73

4

7

87

88

85

89

90

92

91

18

74

62

78

80

83

86

84

85

89

91

94

67 59 56

66 58 5760

65 63666568696370

74

75

76

77

79

81

11

82

102

101

100

95

99

96

84

93

23

6264

98

97

61

74

119 118

103

104

105

106

123

122

121

120

117

124

81

116

109

108

107

115

110

111

48

114

112

301

304

303

302

113

51

44

39

36

301

305

306

55

54

53

52 51 50 49 48 47

46 45

44 43

42 41 40 39

38

16

17 18 19 2320 21 22 24 2625

100 16

364

361

362

27

29 34

323128

3330

35 37

36

363

321

17

371

372

373

374

375

311

22

23/27 MFFI

31

B005

GENUS 30 MFFI (SIT Sigma Gas Valve)

2

72

1

2

3

4

5

4

6

7 8 9

10

11

12

13 14 15

11 16

87

73

74

4

7

88

89

86

90

91

93

92

18

75

63

79

81

84

87

85

86

90

92

95

68 57

67 61

75

76

77

78

80

11

85

94

24

66 64676669706471

82

83

103

102

101

96

100

97

6365

99

98

62

75

104

126

124

120

119

105

106

107

125

123

122

121

118

60 59 58

82

116

117

110 109

108

111

112

49

115

113

301

304

303

302

114

52

45

40

37

301

305

306

56

55

54

53 52 51 50 49 48

47 46

45 44

43 42 41 40

39

17

18 19 20 2421 22 23 25 2726

101 17

364

361

362

28

30 35

333229

3431

36 38

37

363

321

18

371

372

373

374

375

311

23

30 MFFI

32

B005

GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve)

2

73

1

2

3

4

5

4

6

7 8

9

10

11

12

13 14

11

15 16

17

74

75

4

7

11

16

23

76

64

80

82

85

86

90

11

69 61 58

68 60 5962

76

77

78

79

81

83

11

86

89

91

23

67 65686770716572

84

87

95

94

88

6466

63

76

118

114

113

98

97

96

93

99

101

92

117

116

115

112

119

100

83

102

111

104

103

110

105

106 50

109

107

301

304

303

302

108

53

46

41

38

301

305

306

57

56

55 54 53

52 51 50 49

48 47

46 45

44 43 42 41 40

24

1918 21 22 23 26 27 28

252320

20 95

371

372

373

374

375

321

19

362

361

363

29

31

36

3330

34 3532

37

27 MFFI SYSTEM

39

38

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

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

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)

36

B005

GENUS 23/27 MFFI (SIT Tandem Gas Valve)

2

71

1

2

74

67 59 56

66 58 5760

65 63666568696370

6264

61

3

4

5

4

6

7 8 9

10

11

12

13 14

11 15

86

72

73

4

7

87

89

90

18

86

88

85

89

92

91

74

75

62

76

77

78

79

80

81

82

83

84

85

96

101

95

84

94

93

23

74

126

301

125

124

123

122

81

121

120

110

104

105

119

111

109

107

11

97 98

99

100

102

103

104

117

118

112

108

106

113

48

302

116

115

114

51

39

303

304

44

36

301

305

306

55

54

53

52 51 50 49 48 47

46 45

44 43

42 41 40 39

38

16

17 18 19 2320 21 22 24 2625

17

371

99

321

372

373

374

375

16 22

364

322

323

361

362

363

311

27

29 34

323128

3330

35 37

36

23/27 MFFI

37

B005

GENUS 30 MFFI (SIT Tandem Gas Valve)

2

72

1

2

3

4

5

4

6

7 8 9

10

11

12 13

14 15

11 16

87

73

74

4

7

88

89

86

90

91

93

92

19

75

63

79

81

84

87

85

86

90

92

95

68 60 57

67 59 5861

75

76

77

78

80

83

97

85

94

24

66 64676669706471

82

11

98

101

102

103

96

104

99

100

105

6365

62

75

126

122

121

112

111

105

106

128

110

125

124

123

120

108

127

82

119

109

107

118

113

114

49

117

115

301

304

303

302

116

52

45

40

37

301

305

306

56

55

54

53 52 51 50 49 48

47 46

45 44

43 42 41 40

39

17

18 19 20 2421 22 23 25 2726

18

371

100

321

372

373

374

375

17 23

364

322

323

361

362

363

311

28

30 35

333229

3431

36 38

37

30 MFFI

38

B005

GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve)

2

73

1

2

76

69 61 58

68 60 59

67 65686770716572

6466

62

63

3

4

5

4

6

7 8

9

10

11

12

13 14

11

15 16

17

74

75

4

7

90

11

16

23

76

77

64

78

79

80

81

82

83

84

85

86

87

88

86

89

91

11

23

76

121

301

120

119

118

117

83

116 115

11

100

99

98

97

96

95

94

93

101

114

102

103

93

104

92

112

113

107

106

105

108 50

302

111

110

109

53

41

303

304

46

38

301

305

306

57

56

55 54 53

52 51 50 49

48 47

46 45

44 43 42 41 40

1918 21 22 23 26 27 28

24

252320

20 98

371

321

372

373

374

375

322

323

19

362

361

363

29

31

36

3330

34 3532

37

27 MFFI SYSTEM

39

38

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

101

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

102

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)

42

B005

NOTES

43

B005

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 Ser vice Hotline: (01494) 539579

23 99 84 1267 000 - B005 Stampa: Bieffe Recanati

ariston Genus 23 MFFI User guide

Specifications and Main Features

Frequently Asked Questions

User Manual