Installation manual

ManualsBrandsAriston ManualsBoilerGENUS 27 RFFI SYSTEM

Supplied By www.heating spares.co Tel. 0161 620 6677

Servicing Instructions

Type C Boilers

G.C.N: 41-116-01

47-116-08

47-116-09

47-116-13

LEAVE THESE INSTRUCTIONS

ADJACENT TO THE GAS METER

Summary of content (44 pages)

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Servicing Instructions Type C Boilers G.C.N: 41-116-01 47-116-08 47-116-09 47-116-13 LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Supplied By www.heating spares.co Tel.
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TABLE OF CONTENTS Page No. 1. SERVICING INSTRUCTIONS 1.1 Replacement of Parts 3 1.2 To Gain General Access - Removing the Front Panel - Removing the Bottom Cover - Removing the Side Panels 3 4 4 1.3 Access to the Combustion Chamber - Removing the Sealed Combustion Chamber - Removing the Burner and Injectors - Removing the Electrodes - Removing the Main Heat Exchanger - Removing the Air Pressure Switch - Removing the Venturi Device - Removing the Fan 5 5 6 7 7 8 8 1.
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1. SERVICING INSTRUCTIONS 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).
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Removing the bottom cover 1. Remove the screws “B” B Fig. 1.4 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. C C C Fig. 1.5 4 B005 Supplied By www.heating spares.co Tel.
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1.3 Access to the Combustion Chamber Removing the sealed chamber frontal cover D Removing the combustion cover D E E E Remove the screws “D” E D D E E E Remove the screws “E” Fig. 1.6 Removing the burner and the injectors Fig. 1.7 1. Remove the side panels of sealed chamber (fig. 1.8); 2. Remove the screws “F” of the burner (see fig. 1.9); 3. Remove the burner (see fig. 1.10); 4. Remove the injectors using a No. 7 socket spanner; 5. Replace in reverse order. push F Fig. 1.9 push Fig. 1.
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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); Fig. 1.12 G Fig. 1.13 Fig. 1.11 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). H Fig. 1.14 Fig. 1.
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Removing the main heat exchanger 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). I Fig. 1.17 Fig. 1.16 Removing the air pressure switch 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.
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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 N M Fig. 1.20 Fig. 1.21 Removing the fan 1. Disconnect electrical connections and remove screws “O” using a No. 2 star tipped screwdriver (see fig.1.22); 2. Pull fan to the right and forward and remove (see fig.1.23); 3. Remove fan from mounting plate; 4. Remove screws “P” (see fig.1.24). O O Fig. 1.22 P P Fig. 1.23 8 Fig. 1.
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1.4 Servicing and Removal of the Gas Valve SIT SIGMA SIT TANDEM 1 1 B B A A 2 2 D D C C 3 3 E E 4 4 F F 9 B005 Supplied By www.heating spares.co Tel.
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Setting gas pressures 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”.
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Regulating the heating power for natural gas (G20) model 23 model 27 Regulating the heating power for butane gas (G30) model 23 model 27 Regulating the heating power for propane gas (G31) 40 38 36 34 model 23 model 27 TABLE “A” 11 B005 Supplied By www.heating spares.co Tel.
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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.
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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. Q1 Fig. 1.28 R1 R1 Fig. 1.29 Fig. 1.30 13 B005 Supplied By www.heating spares.co Tel.
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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. S T 1.5 Fig. 1.31 Fig. 1.32 Fig. 1.33 Fig. 1.
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Removing the safety valve 1. Loosen nut “V” (see fig. 1.36); 2. Remove the valve. V Fig. 1.36 Removing the automatic air vent 1. Unscrew valve “W” (see fig. 1.37). W 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. Y Y1 Y1 Fig. 1.38 15 B005 Supplied By www.heating spares.co Tel.
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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). A1 Z A1 Fig. 1.39 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). Fig. 1.41 A2 Fig. 1.42 16 Fig. 1.43 B005 Supplied By www.heating spares.
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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). A3 Fig. 1.44 A4 Fig. 1.45 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. Fig. 1.47 Removing the heating temperature sensor (N.T.C.) 1.
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Removing the D.H.W. temperature sensor (N.T.C.) 1. Remove the electrical connector by pulling off the thermostat connection and unscrew the sensor probe with a 14 mm open ended spanner (see fig. 1.49). Fig. 1.49 Removing the diverter valve (Genus 27 RFFI only) 1. Remove the circlip and pull the diverter valve to the left. Fig. 1.50 18 B005 Supplied By www.heating spares.co Tel.
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1.6 Access to the Control System Checking fuse 1. Remove the right hand inspection cover (see fig. 1.51); 2. Remove fuse (see fig. 1.52). Fig. 1.51 Fig. 1.52 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). 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).
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A7 A7 A7 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.
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2. 2.1 FAULT FINDING Fault Finding Guide (Flow-chart) It is possible to detect and correct any defect by using the standard fault finding diagrams described in this chapter. Preliminary Checks 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 the On / Off Button HAS THE LIGHT fOR THE POWER SUPPLY COME ON? NO 1) Check the fuses 2) Check the power supply cord, plug and outlet 3) Check/replace the power supply P.C.B.
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A DOES THE CIRCULATION PUMP COME ON? NO YES POWER TO THE PUMP? YES 1) Check for air in the system 2) Check the pressure switch for activating pump 3) Check/replace pressure gauge and refill the the system properly DOES THE INSUFFICIENT WATER INDICATOR LIGHT COME ON? (within 40 sec.) NO 1) Turn the boiler off and then back on again (safety reset) NO YES 1) Check to see if pump is stuck 2) Replace circulation pump 1) Check wiring 2) Check/replace wire to P.C.B. 3) Replace power supply P.C.B.
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B DOES THE FAN COME ON? YES NO BOILER SHUTDOWN? YES 1) Reset the boiler YES 1) Check/replace differential pressure switch for pump 2) Check/replace wiring 3) Check/replace P.C.B. wire 4) Check/replace power supply P.C.B. 5) Check/replace control P.C.B.
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C IS THE AIR PRESSURE SWITCH ACTIVATED? NO YES ARE THE FUMES DISCHARGED CORRECTLY? 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.
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D IS THERE STILL A PROBLEM? YES NO FUNCTIONS NORMALLY LIST OF MALFUNCTIONS POSSIBLE CAUSES 1 Delivery of hot water for domestic use: when the tap is turned on, the burner goes out. - Air in the secondary exchanger - Hot water pressure switch is defective - 3-way valve is defective 2 Delivery of hot water for domestic use: the radiatores are heated in summer mode. - 3-way valve is defective 3 Delivery of hot water for domestic use: water temperature is not satisfactory.
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2.2 Fault Finding Using the Total Check System Malfunction Signalling Boiler Off 1 2 3 4 5 6 Auto diagnostic state A b C d Faulty ventilation system E F G I m Faulty flame detection Air pressure switch stuck in N.O.
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3. ELECTRIC DIAGRAMS Legend: AT BT A B C D E F G H I J K L M N O P Q R S T U V W X Y Z Aa = = = = = = = = = = = = = = = = = = = = = = = = = = = = = High Voltage P.C.B. Low Voltage P.C.B. Remote Connector Kit Flame Failure L.E.D. Insufficient Water Pressure L.E.D. Water Temperature Indicator L.E.D.s Overheat Thermostat Warning L.E.D. System Reset Button Selector Knob for Operating Mode Domestic Hot Water Temp. Adjustment Central Heating Temp.
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GENUS 23/27/30 MFFI Aa GENUS 27 RFFI SYSTEM Aa 28 B005 Supplied By www.heating spares.co Tel.
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GENUS 23/27 MFFI CN202 P GENUS 27 RFFI SYSTEM P 29 B005 Supplied By www.heating spares.co Tel.
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4.
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GENUS 30 MFFI (SIT Sigma Gas Valve) 2 72 71 64 70 69 66 67 68 67 66 65 64 63 62 61 60 59 58 57 1 2 75 75 73 3 126 74 125 301 301 4 4 5 75 4 124 76 4 63 79 6 123 77 122 78 7 302 303 305 306 304 121 80 56 7 81 8 120 9 82 10 119 118 11 116 117 111 83 103 84 88 11 87 85 12 86 87 96 86 89 14 95 90 92 19 53 52 51 50 49 48 107 110 109 47 46 45 108 45 98 85 44 45 43 42 41 40 40 39 93 18 18 106 99 101 94 24 16 17 54 90 91 11 114 113 112 49 52
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GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve) 2 73 72 65 71 70 67 68 69 68 67 66 65 64 63 62 61 60 59 58 1 2 76 76 74 3 75 119 301 301 4 4 5 76 4 118 77 4 64 117 78 116 79 80 6 302 305 306 304 303 115 81 57 7 7 82 8 9 113 112 83 10 56 109 83 110 114 108 111 55 107 106 11 54 105 50 84 97 98 85 11 99 96 87 12 101 93 95 86 53 52 51 50 49 53 100 104 102 48 47 46 103 94 93 13 14 88 46 92 45 86 46 89 11 44 43 42 41 40 90 11 15 16 16 11 41 91 2
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GENUS 23/27 MFFI (SIT Sigma Gas Valve) Key no. G.C. part no. 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 ARISTON Part No.
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GENUS 30 MFFI (SIT Sigma Gas Valve) Key no. G.C. part no. 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 ARISTON Part No. Description Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.
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GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve) Key no. G.C. part no. 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 Description 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.
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GENUS 23/27 MFFI (SIT Tandem Gas Valve) 2 71 70 63 69 68 65 66 67 66 65 64 63 62 61 60 59 58 57 56 1 2 74 74 72 3 73 126 301 301 4 4 5 74 4 125 75 4 62 124 76 78 6 123 77 7 302 303 305 306 304 122 79 55 7 80 8 9 81 10 120 119 11 82 97 87 85 99 86 100 96 85 88 94 91 18 104 107 46 45 44 44 43 44 104 42 41 40 105 39 39 38 92 91 18 17 51 106 93 23 15 16 84 89 90 11 52 51 50 49 48 47 102 103 95 89 53 109 101 13 14 112 115 114 113 48 108
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GENUS 30 MFFI (SIT Tandem Gas Valve) 2 72 71 64 70 69 66 67 68 67 66 65 64 63 62 61 60 59 58 57 1 2 75 75 73 3 128 74 127 301 4 301 4 5 75 4 126 76 4 63 79 6 125 77 124 78 7 302 123 80 303 305 306 304 56 7 81 8 122 9 82 10 121 120 11 83 98 88 86 87 86 89 100 101 97 14 95 92 18 19 105 108 47 46 45 45 44 45 105 43 42 41 106 40 40 39 93 92 19 17 85 94 24 16 52 107 90 91 11 53 52 51 50 49 48 103 104 96 90 54 110 102 13 15 116 115 114 49
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GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve) 2 73 72 65 71 70 67 68 69 68 67 66 65 64 63 62 61 60 59 58 1 2 76 76 74 3 75 121 301 301 4 4 5 76 4 120 77 4 64 119 78 118 79 80 6 302 305 306 304 303 117 81 57 7 7 82 8 9 115 10 11 83 112 100 85 11 101 98 97 87 12 107 102 54 50 53 52 51 50 49 53 106 93 104 48 47 46 105 96 13 14 55 109 108 103 99 86 110 113 114 84 56 111 83 116 46 95 94 88 45 86 93 89 11 46 44 43 42 41 40 92 90 11 15 11
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GENUS 23/27 MFFI (SIT Tandem Gas Valve) Key no. G.C. part no. 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 99 101 104 112 116 118 119 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 ARISTON Part No.
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GENUS 30 MFFI (SIT Tandem Gas Valve) Key no. G.C. part no. 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 97 100 102 105 113 117 119 120 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 ARISTON Part No. Description Expansion vessel Gasket 3/4" Overheat thermostat Main flow Switch Temp probe (C.H.W.
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GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve) Key no. 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 G.C. part no. 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 Description Expansion vessel Gasket 3/4" Overheat thermostat Motorised valve motor Main flow switch Temp probe (C.H.W.
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NOTES 42 B005 Supplied By www.heating spares.co Tel.
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B005 Supplied By www.heating spares.co Tel.
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Manufacturer: Merloni TermoSanitari SpA - Italy Commercial subsidiary: MTS (GB) LIMITED MTS Building Hughenden Avenue, High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 Fax: (01494) 459775 Technical Service Hotline: (01494) 539579 23 99 84 1267 000 - B005 Supplied By www.heating spares.co Tel.