Installation Instructions Type C Boilers G.C.
TABLE OF CONTENTS 1. GENERAL INFORMATION 1. 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. GENERAL INFORMATION 1.1. 1.3. 2. GENERAL INFORMATION OVERALL VIEW INSTALLATION 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.10.1. 2.10.2. 2.10.3. 2.10.4. 2.10.5. 2.11. 2.12. 3. COMMISSIONING 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.6.1. 3.6.2. 3.6.3. 3.7. 3.7.1. 3.7.2. 3.7.3. 3.7.4. 3.7.5.
1.3. OVERALL VIEW LEGEND: 1. Flue connector 2. Heating flow temperature probe 3. Mixer 4. Condensate collector 5. Expansion vessel 6. Condensate trap (tube) 7. Condensate trap 8. Diverter valve 9. Main circuit flow switch 10. Domestic hot water temperature probe 11. Control panel 12. Gas valve 13. Domestic hot water flow switch 14. Drain valve 15. Safety valve (3 bar) 16. Secondary heat exchanger 17. Circulation pump with automatic air release valve 18. Heating return temperature probe 19.
2.2. SITING THE APPLIANCE 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.
2.4. MINIMUM CLEARANCES FIG. 2.3 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. FIG. 2.2 24 MFFI IMPORTANT! In the event that the power supply cable must be changed, replace it with one with the same specifications.
2.8. WATER CONNECTIONS FIG. 2.5 VIEW OF THE BOILER CONNECTIONS 24 MFFI C A B D E I H FIG. 2.4 24 MFFI SYSTEM C A D E I F G H LEGEND: A B C D E F G H I = = = = = = = = = Central Heating Flow Domestic Hot Water Outlet Gas Inlet Domestic Cold Water Inlet) Central Heating Return Cylinder Flow Cylinder Return Condensate discharge Safety valve discharge CENTRAL HEATING Detailed recommendations are given in BS 6798:1987 and BS 54491:1990, the following notes are given for general guidance.
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 integral part of the connection kit (see FIG. 2.5).
FIG. 2.11 1 2.10. ACCESSORY CONNECTION B To carry out the connection for the roomstat or the outdoor sensor, proceed as follows: D C A 2.10.1. ROOM THERMOSTAT CONNECTION 2 1. 2. Unscrew the screws “A” and rotate the control panel forwards; Insert the connection cable for the thermostat or the outdoor sensor into the cable gland “B” and open the lid of the control panel after having first unscrewed fastening screws “C”. 3.
2.10.2. REMOTE CONTROL CONNECTION 2.10.3. ACCESSORY CONNECTION TERMINAL BLOCK Refer to the illustrations in section 2.10.1. 1. 2. 3. 4. 5. Unscrew the screws “A” and rotate the control panel forwards. Insert the connecting cables of the remote control into the cable gland “B” and open the lid of the control panel after having unscrewed the fastening screws “C”. Remove a blind grommet, make a hole in it and pass the connecting cable of the remote control through it.
2.11. ELECTRICAL DIAGRAM LEGEND: A: JUMPER When needed, the P.C.B. allows the different options to be selected by means of a wire link. The boiler has the following basic arrangement: 1 OPEN 2 CLOSED (jumper) 3 OPEN 4 OPEN 5 OPEN 6 OPEN 7 CLOSED 8 OPEN (MFFI); CLOSED (SYSTEM) NOTE: under absolutely no circumstances must jumpers 2, 7 and 8 be removed. The opening of such contacts will lead to boiler malfunction. This is the factory configuration.
2.12.
24 RFFI SYSTEM 3. COMMISSIONING 3.1. INITIAL PREPARATION 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 us it, and it is signed by them. Please instruct your customer that they must have their logbook with them whenever they contact a service engineer or us.
3.2. REMOVING THE CASING 3.3. CONTROL PANEL To disassemble the front casing panel, follow these steps: 1. Unscrew the screws “A” (1/4 turn only) and rotate the control panel forwards; 2. Unscrew the screws “B”; 3. Unhook the front panel of the casing by lifting it. To disassemble the side panels, follow these steps: 4. Unscrew the screws “C” (at bottom) fastening the side panels; 5. Lift and unhook the panels. 1 A 3 2 B A. B. C. D. E. F. G. H. I. J. K. L. M.
- - 2. 3. 4. 5. 6. the gas cock is closed; the electrical connection has been carried out in the correct manner. To allow the air to escape from the system, proceed as follows: turn on the On/off knob “D” and position the selector knob “A” in the “winter” position. The boiler pump will start up and three consecutive attempts will be made to ignite the burner. After the third attempt, the electronic system will shutdown the boiler, because the supply of gas has been cut off.
3.6.2. OUTDOOR SENSOR In the case of the use of an outdoor sensor, the microprocessorcontrolled P.C.B. calculates the most suitable flow temperature, taking into account the external temperature and the type of system. The microprocessor is capable of doing this because it is possible to establish a link between the external temperature and the flow temperature of the heating system water. This link translates into a "thermal curve".
If the room temperature is too cold during the winter (while in spring the temperature is adequate), it is necessary to enter a steeper curve. To do this, press the reset button for 5 seconds and then press it repeatedly until the letter “FF” appears (using the “+” and “-” keys). In this manner, the curves may be selected from 1 to 5.
3.6.3. SETTINGS DISPLAY The boiler is designed to monitor some operating variables and settings by means of the display on the front control panel. Keeping the reset key pressed for over 10 seconds allows access to the “readout” function of the main system variables.
3.7.4. PUMP OVERRUN The pump overrun may be varied (after the burner has been turned off). To access this function, it is necessary to press the reset button for over 5 seconds and then press it repeatedly until the character “AA” appears on the left-hand display. The following modes are available: 01 1 minute of pump overrun 03 3 minutes of pump overrun 06 6 minutes of pump overrun 09 9 minutes of pump overrun 12 12 minutes of pump overrun 15 15 minutes of pump overrun CO 24 hours of pump overrun 3.7.5.
DISPLAY E03 CAUSE Flow temperature over 100°C while boiler is not in operation (stand-by) E56 Heating flow temperature probe in open circuit E66 Heating flow temperature probe short-circuited E04 Domestic hot water temperature probe in open circuit E05 Domestic hot water temperature probe in short circuit E08 Under floor heating temperature probe in open circuit E20 Flame detected with gas valve closed E21 Error in the electrical connection (live and neutral crossed) E22 Problem with the 50
4. GAS ADJUSTMENTS 4.1. OVERALL VIEW NOTE: the values refer to the upper calorific power Natural Gas Type of appliance Marking on the label of characteristics Further indications Factory setting for the Wobbe Wo index in kWh/m3 LL E LPG Yellow adhesive label: calibrated for 'L' type methane Wo=11.5 Kw/m3 (from 9.5 to 12.4 kWh/m) 20mbar Yellow adhesive label: calibrated for 'H' type methane Wo=14.1 Kw/m3 (from 11.4 to 15.2 kWh/m3) 20mbar Yellow adhesive label: calibrated for LPG Wo=24.
- Make a note of the value here. Value from table: ................l/min. Identify the volumetric rate of flow at the gas meter and compare it with that of the table. Differences greater than +/- 5 % are not allowed: contact the Authorised Service Centre and do not place the boiler in operation. B) HEATING: The thermal power is set in the factory at 70% of the maximum power (the potentiometer corresponds to the value on the display).
5. ZONE VALVES 6. MAINTENANCE The boiler is capable of managing a heating system that uses zone valves. The electrical connection of these valves is carried out by means of the appropriate ter minal board (indicated in the “ELECTRICAL CONNECTION” section). By way of example, two possible types of systems would be: 1. System with 2 valves with independent regulation of the zones (day and night). 2. System with 1 valve (regulation of the night zone subordinated to that of the day).
6.4. OPERATIONAL TEST After having carried out the maintenance operations, fill the heating circuit to a pressure of approx. 1.5 bar and release the air from the system. Also fill the domestic hot water system. Place the boiler in operation. If necessary, release the air again from the heating system. Check the settings and the correct functioning of all the control, regulation and monitoring parts. Check the seal and the correct functioning of the system for expelling fumes/drawing of combustion air.
7.
Servicing Instructions Type C Boilers G.C.
TABLE OF CONTENTS 2 1. SERVICING INSTRUCTIONS 1.1 REPLACEMENT 1.2 TO GAIN GENERAL ACCESS - Lowering the control panel and removing the front panel - Removing the side panels 1.3 ACCESS TO THE COMBUSTION CHAMBER - Removing the sealed chamber front cover - Removing the fan - Removing the burner - Removing the electrodes - Removing the heat exchanger inspection panel - Removing the condensate collector - Removing the condensate trap - Removing the injector 1.
1. To ensure efficient safe operation, it is recommended that the boiler is serviced annually by a competent person. SERVICING INSTRUCTIONS 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).
Removing the side panels 1.3 ACCESS TO THE COMBUSTION CHAMBER 1. Remove the screws “C” (FIG. 1.4); 2. Pull each panel away from the boiler, then lift the panel up and away from the boiler. Removing the sealed chamber front cover 1. Remove the screws “D” (FIG. 1.5); 2. Pull the cover away from the boiler (FIG. 1.6). C C D D D D FIG. 1.5 C C FIG. 1.4 FIG. 1.
Removing the fan 1. Loosen nut “E” (FIG. 1.7); 2. Pull off the hose “F” and disconnect the electrical connector “G” (FIG. 1.8); 3. Remove the nuts “H” (FIG. 1.9); 4. Pull the fan away from the exchanger (FIG. 1.10). FIG. 1.9 H H H E FIG. 1.7 F FIG. 1.10 G FIG. 1.
Removing the burner With the fan removed (see previous section); 1. Slide the burner from its housing (FIG. 1.11). FIG. 1.14 Removing the combustion chamber inspection panel FIG. 1.11 1. Remove the four nuts “K” (FIG. 1.15); 2. Remove the inspection panel (FIG. 1.16). Removing the electrodes 1. Pull off the ignition cable “I” (FIG. 1.12); 2. Remove the two allen bolts “J” (FIG. 1.13); 3. Extract the electodes (FIG. 1.14). K K I K K FIG. 1.15 FIG. 1.12 FIG. 1.16 J J FIG. 1.
Removing the condensate collector 1. Remove the nuts “L” from each side of front of the collector (FIG. 1.17); 2. Remove the nuts “M” from each side of rear of the collector (FIG. 1.18); 3. Release the condesate trap union “N” (FIG. 1.19); 4. Separate the collector from the combustion chamber(FIG. 1.20); 5. Remove the condensate collector (FIG. 1.21). N FIG. 1.19 L FIG. 1.17 FIG. 1.20 M FIG. 1.18 FIG. 1.
Removing the condensate trap Removing the injector 1. Loosen the union “O” (FIG. 1.22); 2. Remove the condensate trap (FIG. 1.23). See the section on removing the fan before carring out this procedure 1. Disconnect all connections from the fan and remove (FIG. 124); 2. Remove the four screws “P” (FIG. 125); 3. Unscrew the injector “Q” using a suitable screwdriver (FIG. 126); 4. Remove the injector (FIG. 127). O Fig. 1.24 FIG. 1.22 P Fig. 1.23 Fig. 1.
Q FIG. 1.26 FIG. 1.
1.4 ACCESS TO THE GAS VALVE Removing the gas valve 1. Disconnect the electrical connection “R” from the gas valve (FIG. 128); 2. Release the top nut “S” (FIG. 1.29); 3. Remove the screws “T” from the bottom of the gas valve pipe (FIG. 1.30); 4. Remove the gas valve (FIG. 1.31). T FIG. 1.30 R FIG. 1.28 S FIG. 1.29 10 FIG. 1.
1.5 ACCESS TO THE WATER CIRCUIT Important! Before any component is removed, the boiler must be drained of all water. Removing the safety valve 1. Loosen union “W” (Fig. 1.35); 2. Unscrew and remove the valve (Fig. 1.36). Removing the D.H.W. (secondary) exchanger 1. Remove the screw “U” (FIG. 1.32); 2. Remove the screw “V” (FIG. 1.33); 3. Push the exchanger towards the rear of the boiler, lift upwards and remove from the front of the boiler (FIG. 1.34); 4.
Removing the automatic air vent Removing the diverter valve actuator 1. Unscrew valve “X” (FIG. 1.37); 2. Remove (FIG. 1.38). 1. Unplug the electrical connector “Z” (FIG. 1.41); 2. Release the retaining clip “A1” and remove the diverter valve actuator (FIG. 1.42). Z X FIG. 1.41 FIG. 1.37 A1 FIG. 1.42 FIG. 1.38 Removing the main circuit flow switch Removing the D.H.W. flow switch 1. Release the retaining clip “Y” (FIG. 1.40); 2. Remove the main circuit flow switch. 1.
Removing the pump 1. 2. 3. 4. Unplug the electrical connection “C1” (FIG. 1.44); Release the nut “D1” (FIG. 1.45); Release the nut “E1” (FIG. 1.46); Remove the pump (FIG. 1.47). C1 E1 FIG. 1.46 FIG. 1.44 D1 FIG. 1.47 FIG. 1.
Removing the pressure gauge Removing the expansion vessel 1. Release coupling “F1” (FIG. 1.48); 2. Ease the pressure gauge “G1” through the control panel from the rear (FIG. 1.49); 3. Remove the pressure gauge. (FIG 1.50). See the section on removing the condesate trap before carrying out this procedure 1. Loosen nut “H1” (FIG. 1.51); 2. Loosen nut “I1” and remove backnut “J1” (FIG. 1.52); 3. Remove the expansion vessel (FIG. 1.53). H1 F1 FIG. 1.48 FIG. 1.51 G1 J1 I1 14 FIG. 1.49 FIG. 1.52 FIG.
Removing the D.H.W. temperature probe (N.T.C.) (MFFI only) 1. Remove the electrical connector “K1” by pulling off (Fig. 1.54); 2. Unscrew and remove the D.H.W. temperature probe “L1” (FIG. 1.55). N1 FIG. 1.57 K1 Removing the C.H. return temperature probe (N.T.C.) 1. Remove the electrical connector “O1” by pulling off (Fig. 1.58); 2. Unscrew and remove the C.H. return temperature probe “P1” (FIG. 1.59). FIG. 1.54 O1 L1 FIG. 1.55 FIG. 1.58 Removing the C.H. flow temperature probe (N.T.C.) 1.
1.6 ACCESS TO THE CONTROL SYSTEM Checking the fuses 1. Remove the inspection cover on the reverse of the control panel (FIG. 1.60); 2. Remove the fuses by pushing and rotating fuse holders “Q1” (FIG. 1.61). Removing the time clock 1. Remove the inspection cover on the reverse of the control panel (FIG. 1.60); 2. Lower the time clock door (FIG. 1.62); 3. Unplug the electrical connection “R1” from the time clock (FIG. 1.63); 4.
Removing the P.C.B.s 1. Remove the inspection cover on the reverse of the control panel (FIG. 1.60); 2. Remove the screws “S1” (FIG. 1.65 & FIG. 1.66); 3. Remove the facia panel (FIG. 1.67); 5. Disconnect the connection cable ”T1” (FIG. 1.68); 6. Unplug the electrical connectors “U1” from the main P.C.B. (Fig. 1.69); 7. Remove the main P.C.B. mounting screws “V1’ (four in total) (FIG. 1.70); 8. Remove the main P.C.B. (FIG. 1.71); 9. Remove the display P.C.B. mounting screws “W1’ (FIG. 1.72); 10.
W1 W1 W1 W1 FIG. 1.72 FIG. 1.
2. 2.1 FAULT FINDING FAULT FINDING GUIDE (FLOW-CHARTS) It is possible to detect and correct any defect by using the standard fault finding diagrams described in this chapter. Model 24 MFFI MAKE SURE THAT: 1. There is sufficient water in the system 2. The gas is turned on 3. The electrical supply is turned on PUSH THE ON/OFF BUTTON TO ON NO IS THE POWER L.E.D.
Model 24 RFFI System MAKE SURE THAT: 1. There is sufficient water in the system 2. The gas is turned on 3. The electrical supply is turned on PUSH THE ON/OFF BUTTON TO ON NO IS THE POWER L.E.D. AND DISPLAY ON? TABLE I and II YES DOES A STOP CODE APPEAR ON THE DISPLAY? POSITION OF THE SUMMER/ WINTER SELECTOR SUMMER C.H. ONLY SELECTOR ON/OFF ON (green L.E.D. on): cylinder excluded 1. Check the fuses 2. Check the power supply to the control panel 3. Check/replace the ON/OFF button 4.
Model 24 MFFI/24RFFI System A IS THE PUMP RUNNING? NO YES POWER TO THE PUMP? YES IS THE MAIN CIRCUIT FLOW SWITCH WORKING CORRECTLY? A21: does not close A22: does not open NO 1. Check if there is air in the system 2. Check the main circuit flow switch operation 3. Check the pressure on the water gauge and fill system to 1 bar NO 1. Check pump cable 2. Check/replace main P.C.B.
Model 24 MFFI/24RFFI System B IS THE FAN RUNNING? NO DOES CODE A33 APPEAR? YES NO Replace the main P.C.B. IGNITION SPARKS ARE GENERATED REGULARLY? NO YES 1. Check the fan cable 2. Replace the fan 3. Replace the main P.C.B. 1. Check/replace ignition electrode 2. Check ignition cable 3. Check/replace the main P.C.B. YES IS THE BURNER ALIGHT? YES 1. Check the power supply of the gas valve. 2. Check for an air pressure signal NO 3. Check the gas pressure on the burner 4.
TABLE I DISPLAY A01 A02 A03 A07 A19 A20 A21 A22 A33 A99 CAUSE Too many attempts to ignite on starting up After three attempts at ignition, no increase in ∆T was detected The heating flow temperature exceeds 100°C during operation Too many failures to flame in one period during operation The flame was detected after the gas valve had closed The flame was detected before the gas valve opened The flow switch does not close The flow switch does not open Problem with the fan Problem with the electronic monitori
3. ELECTRICAL DIAGRAMS LEGEND: A: JUMPER When needed, the P.C.B. allows the different options to be selected by means of a wire link. The boiler has the following basic arrangement: 1 OPEN 2 CLOSED (jumper) 3 OPEN 4 OPEN 5 OPEN 6 OPEN 7 CLOSED 8 OPEN (MFFI); CLOSED (SYSTEM) NOTE: under absolutely no circumstances must jumpers 2, 7 and 8 be removed. The opening of such contacts will lead to boiler malfunction. This is the factory configuration.
C1 = FAN 1: “Hall” sensor power supply 12V (red) 2: “Hall” sensor ground (blue) 3: Not used 4: Start of coil (black) 5: “Hall” sensor input (white) 6: End of coil (brown) C2 = POWER SUPPLY 1: Earth (yellow/green) 2: Earth (yellow/green) 3: Not connected 4: Neutral (blue) 5: Not connected 6: Live (brown) C3 = CONNECTION TO ROOMSTAT 1: Input - 1 2: Input - 2 C4 = TIMER 1: 3 V output 2: Timer ground 3: Timer output 4: Not connected C5 = REMOTE CONTROL (Bus+/Bus-) 1: Input/output-1 2: Input/output-2 C6 = 1: 2:
ecoGENUS 24 MFFI - ecoGENUS 24 RFFI 26
4.
ecoGENUS - 24 MFFI 28 Key no. G.C. part no. 1 7 8 11 12 13 15 20 21 22 23 24 30 38 41 42 62 64 70 72 73 75 78 80 81 83 84 87 89 90 91 92 97 106 311 312 313 331 332 333 334 335 336 E25 417 164 225 164 338 E25 427 E25 429 378 814 E26 378 164 229 E26 819 E25 437 164 261 E26 657 E26 658 E25 518 164 230 164 282 379 079 E25 581 E24 077 ARISTON Part No. Description Expansion vessel Gasket 3/4" Temperature probe (C.H.W.
ecoGENUS - 24 RFFI SYSTEM 2 57 50 52 53 56 55 54 53 52 51 50 49 48 47 3 1 3 2 58 3 58 3 3 3 3 3 106 58 59 58 4 66 67 105 104 60 65 301 302 301 61 5 60 76 7 68 69 75 74 6 64 63 7 102 73 70 8 46 103 62 59 45 101 8 60 44 7 93 71 91 9 72 77 94 89 90 80 43 42 92 87 88 100 99 95 41 86 79 40 39 38 37 36 35 96 97 7 78 7 19 10 80 18 11 11 12 84 83 82 81 98 34 38 37 85 34 33 7 32 29 13 14 15 16 8 17 18 19 20 23 21 22 21 23 24 25 21
ecoGENUS - 24 RFFI SYSTEM 30 Key no. G.C. part no. 1 7 8 12 13 14 17 21 23 24 25 31 39 42 43 63 65 71 73 75A 75B 79 80 84 86 87 88 90 91 95 104 331 332 333 334 335 336 E25 417 164 225 164 338 E25 427 E25 429 164 229 378 814 E26 378 E26 819 E25 437 164 261 E25 518 164 230 164 282 379 079 E24 077 ARISTON Part No. Description Expansion vessel Gasket 3/4" Temperature probe (C.H.W.
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.
SPARE PARTS EXPLODED VIEW GAS WALL BOILERS Models ECOGENUS 24 MFFI Edition 1 of 1 December 1999
2 56 49 51 52 55 54 53 52 51 50 49 48 47 46 3 1 3 2 57 3 57 3 3 3 3 3 108 57 58 57 4 65 66 59 64 107 106 301 302 301 60 5 59 67 68 75 74 6 76 63 62 7 104 73 7 69 8 59 43 95 72 77 42 41 94 96 70 78 79 10 93 71 80 91 92 89 90 102 101 97 40 84 99 81 88 83 82 7 17 16 39 38 37 36 35 34 98 81 7 44 103 8 7 9 45 105 61 58 100 33 37 36 84 86 85 19 87 33 32 11 31 28 12 13 8 14 15 16 17 18 20 19 code 998144 21 22 23 24 25 26 27 28 29
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