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Ariston 47-116-15 Boiler User Manual

1. COAXIAL SYSTEMS Fic 2 10 10 IMPORTANT For all flue systems a restrictor must always be inserted into the boiler s flue connector the restrictor must be 43 or 41 in diameter depending on the length of piping indicated in Table 2 1 The diagrams illustrate some of the various designs for coaxial or twin pipe flue systems For further information discharge ventilation accessories see the FLUE PIPE ACCESSORIES MANUAL mit GENUS 23 Exhaust Type Coaxial Systems 60 100 Exhaust Type Twin Pipe Systems 80 80 Restrictor 43 L min 0 5 m L max 2 m Restrictor 43mm Lmax 11 5m L 11 4m m GENUS 27 Exhaust Type Coaxial Systems 60 100 Exhaust Type Twin Pipe Systems 80 80 Restrictor 41mm Lmin 0 5m Lmax 1m Restrictor 41mm NO Restrictor Lmin 2m Lmax 4m NO Restrictor Lmin 11 5m L max 43m Lmin 11 4m L max 40m NO Restrictor Lm
2. FU007A In calculating the lengths of the pipes the maximum length L must also take into consideration the values for the exhaust air intake end terminals as well as 90 elbows for coaxial systems The C52 types must comply with the following requirements 1 The exhaust air intake pipes must have the same diameter of 2 80 mm 2 f elbows are to be inserted into the air intake and or exhaust system the calculation of the overall length must take into consideration the values for each elbow see the FLUE PIPE ACCESSORIES MANUAL 3 he exhaust pipe must protrude by at least 0 5 m above the top of the roof in the event that it is located on the opposite side to the side with the air intake this condition is not obligatory when the air intake and exhaust are located on the same side of the building To connect a room thermostat it is necessary to 1 Open the control panel as indicated in section 3 3 2 Remove the link A from the terminal block on the reverse of the control panel 3 Insert the thermostat cable through the cable grommet and fasten it by means of the cable clamp provided 4 Then connect the thermostat wires to the terminal block 5 If a remote time clock is to be fitted disconnect the integral time clock from the P C B 6 Using a volt free switching time clock connect the switching wires from the time clock following points 1 4 above 7 If using an ext
3. 755 998516 Gasket 7 __57 998565 998636 Gasket fue test pont J 759 998602 Flue 60 998637 7 61 998595 762 998648 Wiring loom fanvair pressure switch o 998566 Fixing clamp fan 1212 9 573446 Fan seal 65 998943 O ing 265x10127 H 9 5 9 998589 By pass pipe 9 9 Panel combustion chamber L H side 6 66 68 _ i i 5 5 780 573576 Compensation tube lt 811 573325 Rve 82 569443 83 572138 Bumerjetwasher 84 998433 Bumerje NG 1 30 NEN et 36 88 90 91 i Toz 93 i 94 95 796 998732 C H return 8 88 998604 997153 998571 998579 Spindle comfort 998862 Cable detection electrode 569720 Blind grommet 573172 Safety valve 1 2 3 bar 998517 998729 Pipe gas valve ipe 998623 Electrode Ignition R H 998622 Electrode Ignition L H 998624 998147 electrode cable rubber 998963 Panel combustion chamber R H side 998924 Panel combustion chamber front 998925 hood 998895 Insulation panel
4. 10 Automatic By pass 4 11 Domestic Hot Water Temperature Probe 12 Secondary Heat Exchanger 5 m Tr 13 Gas Valve 6 14 Domestic Hot Water Flow Switch 15 Domestic Water Inlet Filter 16 Pressure Gauge 17 Safety Valve wa 18 Circulation Pump with Automatic st Se Air Release Valve 8 e 18 NN n 19 Expansion Vessel 9 20 Air Pressure Switch 10 c A Central Heating Flow B CX py EX B Domestic Hot Water Outlet gt 2 C Inlet Gas D Domestic Cold Water Inlet n 12 13 14 15 51017 Central Heating Return 14 3 3 1 COMMISSIONING INITIAL PREPARATION MTS GB Limited support the Zee initiative Within the information pack you will find 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 Preliminary electrical system checks to ensure electrical safety must be carried out by a competent person i e polarity earth continuity resistance to earth and sho
5. Gas rate min 1 26 m3 h 0 94 Kg h 0 93 Kg h Inlet pressure 20 mbar 28 mbar 37 mbar Burner pressure max 11 0 27 7 mbar 35 5 mbar Burner pressure min 1 6 mbar 4 6 mbar 6 0 mbar LL LL N gt 9 S LL LL CN A gt 9 Burner jets 14 x 1 30 14 x 0 77 14 x 0 77 TB012A a Soft light Heating Adjustment Adjustment VRO15A eps 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 10 Removing the spark generator 7 Disconnect ignition leads T by pulling upward Fic 1 27 2 Remove the screw V Fic 1 28 3 Remove the spark generator 1 29 8063 Removing the gas valve 1 Disconnect all the cables from the solenoid and modureg 2 Remove the spark generator See previous section 3 Release the top nut W 1 30 4 Remove the screws X from the bottom of the gas valve pipe Fic 1 31 5 Remove the gas valve Fic 1 32 8063 1 6
6. 570717 998569 7711 998589 By pass pi 121 712 998077 O ring gasket H H 713 998064 00 714 573520 6 715 999103 716 997147 17 997077 718 569236 Temperature probe 719 999613 Howgeup T 720 571547 Diaphragm 721 998099 22 998632 Cable temperature probes To 2 999075 24 998940 Retumgrup H H 25 998424 726 874279 27 998645 728 997089 Gas valve 729 998606 30 998568 31 97182 2 999100 99903 34 998570 LED H To 35 998575 736 998603 12227 37 998572 Spindle 38 997207 39 999059 ao 998824 a 998947 Printed circuitboard OMPT FF O 42 se9711 as 998625 998952 745 998953 746 571548 Flow Switch az 998861 999153 749 998863 573327 Y piece airpress H 51 571651 Airpressure J To 752 997203 Support plate Air pressure switch 53 573329 Pressure intake cover 21212 754 571575 Silicone pipe positive signa
7. Removing the fan Removing the venturi device SERVICING AND REMOVAL OF THE GAS VALVE Setting the gas pressures Removing the spark generator Removing the gas valve ACCESS TO THE WATER CIRCUIT Removing the D H W secondary exchanger Removing the safety valve Removing the automatic air vent Removing the main circuit flow switch Removing the pump Removing the pressure gauge Removing the expansion vessel Removing the overheat thermostat Removing the heating temperature sensor N T C Removing the D H W temperature sensor N T C Hemoving the divertor valve actuator Hemoving the D H W flow switch ACCESS TO THE CoNTROL SYSTEM Checking the fuses Hemoving the time clock Removing the P C B FAULT FINDING FAULT FINDING GUIDE FLOW CHART ELECTRICAL DIAGRAMS SHORT SPARE PARTS LIST 063 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 After servicing preliminary electrical system checks must be carried out to ensure electrical safety i e polarity earth continuity resistance to earth and sho
8. 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 flow rate and temperature 13 General check of the combustion by products of the discharge ventilation System 14 Check of the general performance of the unit Fic 1 0 1 2 OVERALL VIEW 1 LEGEND 1 Flue connector 2 2 Air intake for twin pipe flue systems 3 Fan 4 Combustion chamber hood 5 Main heat exchanger 4 6 Safety thermostat 5 7 Combustion chamber 8 Combustion chamber insulation panel 6 9 7 10 Detection electrode Ignition electrodes 8 12 Motorised diverter valve 9 13 Main circuit temperature probe 14 Main circuit flow switch 15 Domestic hot water temperature probe 16 Gas valve 10 17 S i park generator 11 18 Domestic hot water flow switch 12 19 Domestic cold water inlet filter 20 Secondary heat exchanger 13 21 Circulation pump with automatic air relea
9. ACCESS TO THE WATER CIRCUIT Important Before any component is removed the boiler must be drained of all water Removing the D H W secondary exchanger 7 Remove the screws Y 1 33 1 34 2 Push the exchanger towards the rear of the boiler and lift upwards and remove out of the front of the boiler FIG 1 35 3 Before replacing the exchanger ensure that the O rings are in good condition and replace if necessary 11 Removing the safety valve Removing the main circuit flow switch 1 Loosen nut Z Fic 1 36 2 Unscrew and remove the valve 1 37 1 Remove the cable of the main circuit flow switch B1 FIG 1 40 2 Remove the screws C1 Fic 1 41 3 Remove the main circuit flow switch Removing the automatic air vent 1 Unscrew valve top A1 Fia 1 38 2 Remove valve Fig 1 39 Fig 138 12 063 Removing the pump Remove the U clip D1 Fia 1 41 Remove the retaining clip E1 Fic 1 42 Remove the U clip F1 Fic 1 43 Release the nut G1 Fic 1 44 Remove the pipe H1 Fia 1 45 Remove the screws 11 Fic 1 46 Remove the pump FiG 1 47 NOOO ROHS Fig 141 8063 Removing the pressure
10. ELECTRICAL pee DIAGRAMS a Cl ANDOVOZSFA amp S T A01 02 04 06 07 08 10 11 12 A13 14 A08 05 09 Time Clock Connector Central Heating Selection Winter and Temperature Adjustment Connector for Total Check System Domestic Hot Water Temperature Adjustment Soft light Adjustment Maximum Heating Adjustment On Off Switch On Off L E D Fume Sensor L E D Ignition Failure Lockout L E D Low System Water Level Lack of Circulation L E D Reset Button Economy Comfort Selector Overheat L E D Temperature L E D s Transformer Circulation Pump Relay Fan Relay Gas Valve Relay Motorised Diverter Valve Relay Spark Generator Anti cycling Device Adjustment for Heating Circulation Pump Fan Spark Generator Gas Valve Supply Motorised Diverter Valve Flame Detection Circuit Detection Electrode Main Circuit Temperature Probe Domestic Hot Water Temperature Probe Domestic Hot Water Flow Switch Main Circuit Flow Switch Modulator Air Pressure Switch Safety Thermostat External Room Thermostat Colours Gry Wh Pnk Brn Blk Rd Blk 063 Grey White Pink Brown Blue Black Red Black 23 microGENUS 23 27 MFFI CN201 CN301 CN300 716514 3 8
11. EXHAUST DISCHARGE ANOMALY SHUTDOWN The boiler is fitted with safety devices which in the event of defective discharge of exhaust fumes automatically interrupts the gas supply thereby shutting off the boiler The shutdown of the boiler is temporary and is indicated by the illumination of the yellow L E D E for a period of about 15 minutes Once this time period has passed and the discharge state of exhaust fumes has returned to normal the boiler automatically turns back on 7 SAFETY SHUTDOWN 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 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 Hor 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 ge
12. flow switch B063 15 1 6 ACCESS TO THE CONTROL SYSTEM Removing the time clock Checking the fuses 1 Unplug electrical connection W1 from the clock Fic 1 62 1 Remove the inspection cover on the reverse of the 2 Remove the screws W2 see fig 1 63 control panel Fic 1 60 3 Remove the clock from the panel see fig 1 64 2 Remove the fuses 1 61 1189 jpg 1 63 16 B063 Removing the P C B 1 Isolate electricity 2 Remove the inspection cover from the reverse of the control panel 3 Unplug all electrical connections from the P C B 1 65 4 Remove the screws X1 Fic 1 66 5 Separate the facia panel from the rear of the control panel 1 67 7 Remove the screws Y1 and remove the P C B Fic 1 68 8063 17 2 2 1 FAULT FINDING FAULT FINDING GUIDE It is possible to detect and correct any defect by using the standard fault FLOW CHARTS finding diagrams described in this chapter PRELIMARY CHECK MAKE SURE THAT 1 There is sufficient water in the system 2 The gas is turned on 3 The electrical supply is turned on TURN ON THE ON OFF SWITCH IS THE POWER L E D ON 1 Check the fuses 2 C
13. 8 2 Lift the sealed chamber frontal cover from the locating pins 2 Pull the panel away from the boiler then lift the panel up and FiG 1 7 remove from the boiler FiG 1 9 4 B063 1 3 ACCESS TO THE COMBUSTION CHAMBER Removing the combustion cover 1 Remove the screws E 1 10 2 Lift off the combustion cover Removing the burner and jets 1 Remove the screws F from the burner 1 11 2 Remove the burner 1 12 3 Remove the jets using a No 7 socket spanner 4 Replace in reverse order 8063 Removing the electrodes Before carrying out this procedure unscrew and slide the burner forward see previous section 7 Remove rubber gasket Fig 1 13 2 To remove the detection electrode disconnect the cable at its connection point close to the P C B Fig 1 14 3 Remove screw Fic 1 15 Removing the main heat exchanger 4 Gently slide the electrode downward 1 16 1 Drain the boiler of water 2 Release the overheat thermostat sensor I 1 17 3 Release the two connection nuts J connecting the exchanger to the flow and return pipes Fic 1 18 4 Pull it straight out Fic 1 19 To replace repeat the steps in reverse order paying particular attention to the following
14. Front 98076 View window glass gasket 998939 14 ramp LPG 98075 View window glass ide ide ide ide 98 99 100 4 _101_ 102 103 9 104 9 105 998610 Panel front sealed chamber 301 998477 Casepanel LH side 302 998596 Insert case 303 998476 Casepanel R H side 304 998607 Panel frontcase 311 998941 D HW actuatorKit 321 997029 Operator coils Sit Sigma 331 998490 Centralheatingby pass 332 998718 3 Way spring kit 333 998975 3 Way spring kit DHW ____ 334 998974 Heatingactuatorbush SS 351 998644 O ring AAV 352 998643 AutoAirVent 353 998738 Gasket pump head 354 999207 Pumphead 371 571547 Diaphragm main flow switch 372 571772 Magnet mainflowswitch 373 571771 Spring main flow switch LT E REN S _______ LLL LLLA LLL LLLA L I _____ A Bl LLL LLLA a l 4 ___ ES o E OO UA B ____ LLLA O _____ EJ po 999148 Selector button comfort 5 LLL LLLA LLL LLLA ee LLLA ee ee 1 p LLL 0 _______ ee ee LLL LLLA eee 24 1 e
15. carefully read the instructions and notices about the unit contained in this manual as they provide important sort e GENUS information regarding the safe Manu 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 app
16. gauge 1 Remove the U clip J1 and remove the pressure gauge coupling 1 48 2 Push the pressure gauge through the control panel from the rear FiG 1 49 14 Removing the expansion vessel 1 Loosen nuts K1 and remove the gas pipe Fia 1 50 2 Loosen nut L1 Fic 1 51 3 Remove back nut M1 1 52 4 Remove the expansion vessel Fic 1 53 8063 Removing the overheat thermostat Removing the D H W temperature sensor N T C electrical 7 Pull off the electrical connector Q1 and unscrew the 7 Disconnect the overheat thermostat sensor probe using a suitable spanner Fic 1 57 connections N1 Fia 1 54 2 Then remove the thermostat from its mounting by releasing the securing clip Fic 1 55 z Removing the divertor valve actuator 1 Unplug the electrical connector R1 1 58 2 Release the retaining clip S1 and remove the divertor valve actuator lt Removing the heating temperature sensor N T C Removing the D H W flow switch 1 Pull off the electrical connector P1 and unscrew the 1 Unplug the electrical connector T1 Fia 1 59 2 Release the retaining clip V1 and remove the D H W
17. 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 200 20 p 237 7 Z2 156 2 mcm B Ga B 105 305 68 65167 67 65 68 215 24 gt gt VV AAA ODE 3 4 1 2 3 4 1 2 3 4 Fic 2 1 QTO002A SSS LO KV 60 60 450 O O gt gt gt AME Fic 2 2 DMO004A 25 mm HTO3VV F Fic 2 3 VR001A 2 3 OVERALL DIMENSIONS 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 2 4 CLEARANCES In order to allow for access to the interior of the boiler for maintenance purposes the boiler must be installed in compliance with the minimum clearances indicated in Fic 2 2 2 5 MOUNTING THE APPLIANCE 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 instruct
18. replace main circuit flow switch PUMP PROTECTION 2 Check replace ACTIVATED connection cable 3 Check replace P C B 1 Check replace air INTERNAL pressure switch P C B PROTECTION 2 Check if reset button ACTIVATED is jammed 3 Check replace flame detection electrodes 1 Check replace connection cable 2 Check replace P C B 3 Check replace air pressure switch YES 1 Replace fan FC004Ac 20 B063 IS THE AIR PRESSURE SWITCH NO ACTIVATED 4 CHECK AP ON TEST AP 1 2 mbar 1 Check A P switch cable PRESSURE 2 Check replace A P switch 3 Check replace P C B INTAKE 1 Check exhaust discharge AP lt 1 2 mbar 2 Check venturi amp pipes 3 Check fan efficiency Check replace ignition IS FLUE electrode DISCHARGE NO Check ignition cable NORMAL Check spark generator l Check ignition electrode cable Check replace P C B MES i Check power supply of gas valve IS THE BURNER NO Check replace ALIGHT Check efficiency of gas valve VIES Replace gas valve Check if flame strikes HAS THE detection electrode BOILER SAFETY Check soft light gas SHUTDOWN BEEN pressure ACTIVATED Check replace detection electrode Check replace P C B HAS THE BOILER SAFETY SHUTDOWN BEEN ACTIVATED YES Shutdown L E D off fan restarts FC004Ad B063 21 15 THERE STILL A PROBLEM NO 4
19. 4 49 5 0 96 2 2 0 32 0 39 2 02 2 00 123 7 2 17 5 20 30 37 230 50 140 XAD FAST 2 AT 38 GENUS 27 63AU4549 29 8 12 0 93 5 90 7 0 2 6 3 0 4 60 1 60 3 15 0 37 2 34 2 31 128 8 6 9 8 1 48 5 200 0 25 82 42 56 36 11 4 2 6 2 6 8 0 2 6 1 130 3 20 30 37 230 50 155 X4D FAST 2 AT 39 G C Number 47 116 14 47 116 15 Calculated at 70 maximum output 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 Itd uk E mail info omtsgb ltd uk Technical Service Hot Line 01494 539579 23 99 84 1469 31 2 Stampa bieffe recanan Servicing Instructions Type C Boilers G C N 47 16 14 47 16 15 LEAVE THESE INSTRUCTIONS WITH THE END USER Cb enchmark y The code of practice for the installation commissioning amp servicing of central heating systems Country of destination GB TABLE OF CONTENTS 2 1 SERVICING INSTRUCTIONS REPLACEMENT OF PARTS TO GAIN GENERAL ACCESS Removing the front panel Removing the sealed chamber frontal cover Removing the side panels ACCESS TO THE COMBUSTION CHAMBER Removing the combustion cover Removing the burner and jets Removing the electrodes Removing the main heat exchanger Removing the air pressure switch
20. 74 Main flow switch top cap 375 Main flow switch reed system 381 Burner jet 1 25 full kit Natural gas 382 Burner jet 0 72 full kit LPG Lou ___ 4 E JL 5 4 2 Co SIN N llc 5 ol N N Co co 4 Oc 4 26 B063 Manufacturer Commercial subsidiary Merloni TermoSanitari SpA Italy 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 td uk Technical Service Hot Line 01494 539579 Stampa Bieffe Recanati 23 99 84 1470 312 G ARISTON SPARE PARTS EXPLODED VIEW GAS WALL BOILERS Models MICROGENUS 27 MFFI Edition 2 of 1 February 2000 58 57 5655 9 54 534 52 GS 104 5 103 ND e 0 L A 0090990 ta Fl 36 37 38 cod 998940 MODELS CHARACTERISTICS SERIAL NO VALIDITY MICROGENUS 27 METHANE 0002601386 MFFI MICROGENUS 27 LPG 0002601388 MFFI PART CODE DESCRIPTION REF NOTE 2 998616 73 995776 9 75 573821 SOS 76 999102 Pipe 998580 Gableholder H H 79
21. ER 516 17 18 19 20 21 22 23 kCal h x 1000 CG007A model 23 model 27 BURNER PRESSURE 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2627 kW 8 9 10 11 12 13 14 1516 17 18 19 20 21 22 23 kCal h x 1000 OPERATING POWER CG008A Model 23 model 27 BURNER PRESSURE 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2627 kW 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 gt kCal h 1000 OPERATING POWER 009 GAS REQUIREMENTS NATURAL GAS G20 BUTANE GAS G30 PROPANE GAS G31 Gas rate max 2 70 m3 h 2 01 Kg h 2 00 Kg h Gas rate min 1 16 m3 h 0 87 Kg h 0 85 Kg h Inlet pressure 20 mbar 28 mbar 37 mbar Burner pressure max 11 0 mbar 27 7 mbar 35 5 mbar Burner pressure min 2 0 mbar 6 0 mbar 7 3 mbar Burner jets 12 x 1 30 12 x 0 77 12 x 0 77 GAS REQUIREMENTS NATURAL GAS G20 BUTANE GAS G30 PROPANE GAS G31 Gas rate max 3 15 m3 h 2 34 Kg h 2 31 Kg h
22. Installation Instructions Type Boilers G C N 47 16 14 47 116 15 LEAVE THESE INSTRUCTIONS WITH THE END USER 2 The code of practice for the installation commissioning amp servicing of central heating systems ARISTON Country of destination GB GENUS E Pep o a p fio Am s n 9 N Ns T amp ARISTON TABLE OF CONTENTS 1 GENERAL INFORMATION GENERAL INSTRUCTIONS OVERALL VIEW INSTALLATION REFERENCE STANDARDS SITING THE APPLIANCE OVERALL DIMENSIONS CLEARANCES MOUNTING THE APPLIANCE ELECTRICAL CONNECTION GAS CONNECTION WATER CONNECTIONS FLUE CONNECTION 2 10 Room THERMOSTAT CONNECTION 2 11 ELECTRICAL SYSTEM DIAGRAMS 2 12 WATER CIRCUIT DIAGRAMS 6 1 6 2 COMMISSIONING INITIAL PREPARATION CONTROL PANEL REMOVING THE FRONT PANEL INITIAL START UP OPERATIONAL ADJUSTMENTS COMBUSTION ANALYSIS FUME DISCHARGE MONITORING BoiLER SAFETY SYSTEMS DRAINING THE SYSTEM GAS ADJUSTMENTS GAS ADJUSTMENT TABLE CHANGING THE TYPE OF GAS MAINTENANCE MISCELLANEOUS WIRING DIAGRAM FOR TWO HEATING ZONES WIRING DIAGRAM FOR CONNECTION TO AN ARISTON UNVENTED CYLINDER TECHNICAL INFORMATION 1 11 GENERAL INFORMATION GENERAL INSTRUCTIONS 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
23. L Time clock M Heating system pressure gauge 33 REMOVING THE In order to access the inside of the boiler it is necessary to unscrew the fastening screws A of the control panel located on the lower part of the panel itself The control panel moves downward and when pulled forward rotates FRONT PANEL on two lateral hinges The panel stays in a semi horizontal position which allows access to the inner parts of the boiler In order to increase the maneuvering space it is possible to raise the control panel and rotate it to a fully horizontal position 006 7 009 To dismantle the front casing panel it is necessary to 1 Remove the two screws 2 Lift the front casing panel up and forward 16 3 4 INITIAL START UP 3 5 OPERATIONAL ADJUSTMENTS 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 turning the On Off switch A see Fic 3 1 the L E D D will illuminate turn
24. LEGEND A Central Heating Flow B Domestic Hot Water Outlet C Gas Inlet D Domestic Cold Water Inlet E Central Heating Return F 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 7 VOR 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 si
25. NORMAL OPERATION FAULTS POSSIBILE CAUSES VES 1 Drawing D H W air in secondary heat exchanger m When you turn on a tap faulty main circuit flow switch burner switches off faulty D H W flow switch 2 Drawing D H W faulty 3 way valve radiators heat up in summer mode y y 3 Drawing D H W check C H D H W temperature probes insufficient hot water check gas pressures temperature check water flow rate check secondary heat exchanger primary heat exchanger faulty 4 Drawing D H W lime scale deposits noisy operation low heating system water pressure check gas pressures check C H D H W temperature probes 5 Decrease increase check for leaks on the heating circuit heating circuit pressure faulty filling loop faulty secondary heat exchanger expansion vessel faulty Repeated shutdowns faulty detection electrodes check gas settings check flame detection electric circuit f Repeated intervention of safety thermostat C H D H W temperature probes open circuit overheat thermostat not calibrated correctly air in primary water circuit When cold water tap turned off the boiler drop in pressure in the water mains with ignites consequent water hammer Insufficient radiator temperature check C H temperature probe check by pass N check gas pressures E FC004Ae 22 063 3
26. PUE Sey Mu 125 525 Gzy pa e ej LN oo 1s 0069 18 0070 1s adud e o lt e Tur LE OD TO le o Bi I x N lt SH009A 23 7 TECHNICAL INFORMATION CE Certification Heat Input max min kW Heat Output max min kW Efficiency of Nominal Heat Input Efficiency at 30 of Nominal Heat Input Heat Loss to the Casing AT 50 C Flue Heat Loss with Burner Operating Flue Heat Loss with Burner Off Maximum Discharge of Fumes G20 Residual Discharge Head Consumption at Nominal Capacity G20 Gas Consumption after 10 Minutes 15 C 1013 mbar G30 G31 Temp of exhaust fumes at nominal capacity CO Content O Content CO Content Minimum Ambient Temperature Head Loss on Water Side max AT220 C Residual Head of System Heating Temperature Domestic Hot Water Temperature D H W Flow Rate AT 35 C D H W Flow Rate AT 35 C D H W Minimum Flow Rate l min Pressure of Domestic Hot Water max min bar Expansion Vessel Capacity Expansion Vessel Pre load Pressure bar Maximum Water Content of System Maximum Heating Pressure bar Nominal Pressure Natural Gas G20 mbar LPG G30 G31 mbar V Hz max min C max min C l min gal min Electrical Supply Power Consumption W Protection Grade of Electrical System IP Internal Fuse Rating Weight Kg i GENUS 23 63AU4549 25 6 11 0 92 9 91 1 1 0 6 1 0
27. White Pink Brown Blue Black Red Black 4 CN301 CN300 3 2 8171615 ms s t Fic 2 13 CN 302 71 A07 CN 303 FUSE SF014A 2 13 WATER CiRCUIT DIAGRAM Fic 2 14 f LEGEND mer 1 Fan 2 Main Heat Exchanger _ i Overheat Thermostat 20 4 Burner 1 5 Ignition Electrodes 9 19 6 Detection Electrode 2 7 Motorised Valve ES 8 Main Circuit Temperature Probe 3 9 Main Circuit Flow Switch
28. 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 6 063 Removing the air pressure switch Removing the fan 1 Disconnect the electrical connections K and silicon pipes 1 Disconnect electrical connections N and silicon pipes L from their connection points Fia 1 20 Fic 1 23 2 Remove screws M on the top of the sealed chamber 2 Remove screw P and remove the fan collar clamp Q 1 24 3 Unscrew to remove switch from the plate Fic 1 22 3 Remove screws R 1 25 4 Remove fan and mounting plate Fia 1 26 B063 7 1 4 SERVICING AND REMOVAL OF THE GAS VALVE Setting the gas pressures VG001 Aa VG001Ac VG001Ab 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
29. c 0 o Ee 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 MAINS INPUT 3 AMP SH010A 22 WiRING DIAGRAM FOR CONNECTION TO AN 7 2 ARISTON UNVENTED CYLINDER uo peseg 021109 reverse of the boiler control panel see section 2 10 to 9 10 on room stat terminal block on the the junction box Remove internal time clock plug from the the P C B then connect LLI lt gt DL A gt lt LL O LLI LLI LLI O 44 LEC SANI TYPICAL JUNCTION BOX lt 5 328 C C 0 0906 pue d 0206 MAP 216 226 LL 9 p L di uo1U9JeM 6 2 9 XUI d4 9 6 0 LSP 13 MUNS ejeuos AuoydwAs 52 6 1 001 06 dS JAUNS 10 8 2 9 10 GREENYELLOW V4043H HEATING VALVE GREENYELLOW V4043H HOT WATER VALVE 9 6 10 017 9 Yur GW owebues 2592101 CUL 104 9 2507 Epued 9 6 3 00 60 1006 100044 9 10 0006 000043 0 9 04 Jepuiuuluiy J BOJIIN 028 1 9 510081 LUOMMO S CEM 149 SI
30. 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 10 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 Start the boiler and during the ignition sequence adjust the left hand 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 re connect 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 NATURAL GAS 220 BUTANE GAS 030 PROPANE GAS G31 Recommended pressure for soft light ignition 8 mbar 16 mbar 16 mbar 8063 Regulating the heating power for natural gas G20 Regulating the heating power for butane gas G30 Regulating the heating power for propane gas G31 TABLE A 8063 Model 23 model 27 BURNER PRESSURE M OPO ON 8 9 10 11 12 13 141516 17 18 19 20 21 22 23 24 25 2627 kW 9 10 11 12 13 14 1 OPERATING POW
31. e LLLA ee ee LLLA __ _ _______ LLL LLLA 17 PART CODE DESCRIPTION REF NOTE 374 571770 Main flow switch top cap 2 375 998172 Mainflowswitchreedsystem 381 998716 Burner jet full kit NG 382 998717 Burner jet full kit LPG 22 NOTE DESCRIPTION 11 Notsuppliedasasparepart o O 12 Notillustrated
32. ernal time clock and room thermostat these must be connected in series as points 1 7 above Note Only a two wire type room thermostat can be used An anti frost device is built in to the appliance s electronic regulation system Fo016A 12 017 2 12 ELECTRICAL DIAGRAM LEGEND A B ANDOVOZSFA amp S T Fic 2 12 Time Clock Connector Central Heating Selection Winter and Temperature Adjustment Connector for Total Check System Domestic Hot Water Temperature Adjustment Soft light Adjustment Maximum Heating Adjustment On Off Switch On Off L E D Fume Sensor L E D Ignition Failure Lockout L E D Low System Water Level Lack of Circulation L E D Reset Button Economy Comfort Selector Overheat L E D Temperature L E D s Transformer Circulation Pump Relay Fan Relay Gas Valve Relay Motorised Diverter Valve Relay Spark Generator Anti cycling Device Adjustment for Heating 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Colours Gry Wh Pnk Brn Blk Rd Blk Circulation Pump Fan Spark Generator Gas Valve Supply Motorised Diverter Valve Flame Detection Circuit Detection Electrode Main Circuit Temperature Probe Domestic Hot Water Temperature Probe Domestic Hot Water Flow Switch Main Circuit Flow Switch Modulator Air Pressure Switch Safety Thermostat External Room Thermostat Grey
33. fety 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 the circulation pump comes to a halt and the red L E D J illuminates The system may be reset after re establishing the correct level of pressure in the boiler turning the A knob OVERHEATING This control shuts off the boiler in the case where the primary circuit reaches a temperature in excess of 105 C The red L E D s I and will illuminate to signal this shutdown status The system can be reset by waiting a few minutes for the primary exchanger to cool down and then by pressing and releasing the H button LIMESCALE BUILD UP The boiler is equipped with a device that limits the formation of Limescale in the secondary exchanger by controlling the temperature of the domestic hot water max 61 C and also controlling the temperature of the water in the primary heating circuit 18 3 9 DRAINING THE SYSTEM 5 ANTI FROST DEVICE The boiler is equipped with a device that in the event of the water temperature going below 5 C the 3 way diverter valve switches to domestic hot water and the burner ignites at the minimum power until the boiler water reaches a temperature of about 50 C This device operates only if the boiler is functioning perfectly and the system pressure Is sufficient the boiler is powered electrically the gas is distributed 6
34. gs can be taken for the temperature of the combustion by products and of the combustion air as well as of the concentrations of O and etc To access these intakes it is necessary to unscrew the front screw and remove the metal plate with sealing gasket The best test conditions with the maximum heating power are achieved by turning the selector knob to the max position and removing the electrical connection to the heating sensor see section 6 In the boiler it is possible to monitor the correct operation of the flue exhaust air intake checking for a loss of general pressure in the system Through the use of a differential manometer connected to the test points of the combustion chamber it is possible to detect the AP of operation of the air pressure switch The value detected should not be less than 0 55 mbar for 23kW and 0 75 mbar for 27KW under conditions of maximum thermal power in order for the boiler to function properly and without interruption The boiler is fitted with the following devices see section 3 2 for references diz IGNITION FAILURE This control signals an ignition failure on the burner 7 seconds after a lighting failure The L E D F will illuminate to signal the shutdown status The system can be reset by pressing and releasing the button H after checking to make sure that the gas cock Is open CIRCULATION FAILURE This control signals that the sa
35. gt gt ns z x tn SE017A yan 954315 CMP1 FFI CN 202111213 415 6 CN 203 CN 302 OO CN 303 FUSE A A03 A 05 1 1 A 05 3 8063 24 4 SHORT SPARE PARTS LIST microGENUS 23 27 107 8 106 codes 998836 999091 352 MODELS MICROGENUS 23 MFFI CHARACTERISTICS METHANE 36 37 38 SERIAL NO VALIDITY 2320005600001 MICROGENUS 23 MFFI LPG 2320005600001 MICROGENUS 27 MFFI METHANE 2320005600001 MICROGENUS 27 MFFI LPG 2320005600001 8063 25 microGENUS 23 27 MFFI Roy Description A Expansion vessel 998616 Gasket 3 8 573521 O ring 998077 Gasket 3 4 573520 Motor 3 Way valve 997147 Fixing clip motor 997077 Temperature probe C H W 569236 Flo
36. heck the power supply cable plug and outlet 3 Check replace the power supply to the P C B POSTION OF THE WINTER SELECTOR ECONOMY ECONOMY Comfort CONFORT COMFORT SELECTOR SELECTOR NO NO H Economy Economy Comfort D H W IS BEING DRAWN D H W IS BEING DRAWN Check reset system pressure 2 Check restore gas supply 3 Check replace short MUST circuited heating probe TIME CLOCK 4 Check replace siezed pump THERMOSTAT BE ACTIVATED Check reset the FOR BOILERS system pressure WITH ELECTRONIC ANTI FROST DEVICE 2 PROTECTION IS ACTIVATED Se T IF HEATING TEMP circuited heating probe IS lt 5 C Check replace siezed pump FOR BOILERS WITH ELECTRONIC ANTI FROST DEVICE PROTECTION IS ACTIVATED IF HEATING TEMP IS lt 5 C FC004Aa 18 063 IS THE PUMP RUNNING POWER THE PUMP DOES THE WATER L E D ILLUMINATE WITHIN 40 SECS 1 Check if there is air in the System 2 Check main circuit flow switch operation 3 Check pressure on the water gauge and fill system to return to 1 bar 1 Check that the pump is not stuck 2 Release replace pump 1 Turn the boiler off then on protection reset 1 Check pump cable 2 Check replace P C B 3 Check main flow main switch operation when drawing D H W FC004Ab 063 19 1 Check
37. in 1m L max 4 m NO Restrictor L min 34 m L max 54 m Maximum Extension Exhaust Air Maximum Extension Exhaust Air Maximum Extension Exhaust Air Maximum Extension Exhaust Air TABLE 2 1 Risk of Condensation Forming Piping not gps 0 43 restrictor Piping insulated 43 restrictor NO NONE NONE NONE NONE Risk of Condensation Forming Piping not eaters 43 restrictor Piping insulated 43 restrictor NO Risk of Condensation Forming Piping not insulated Piping insulated 41 restrictor NO restrictor 0 41 restrictor NO restrictor NONE NONE NONE NONE Risk of Condensation Forming Piping not insulated Piping insulated 41 restrictor NO restrictor 2 41 restrictor NO restrictor L Sum of the total length of exhaust air intake piping TWIN PIPE SYSTEMS Fic 2 11 2 10 Room THERMOSTAT CONNECTION
38. ion by products of the discharge ventilation system Check of the general performance of the unit 21 MISCELLANEOUS 7 WiRING DIAGRAM FOR 7 1 Two HEATING ZONES S oJ1uoo uo peseg 021109 reverse of the boiler control panel see section 2 10 to 9 10 on room stat terminal block on the the junction box Remove internal time clock plug from the the P C B then connect LLI lt gt A A lt LL O LLI LLI oc 133 2 6 SANNIO TYPICAL JUNCTION BOX e GREENYELLOW lt 5 Tel C 0 0906 40206 lfepuey 2621011 216 226 9 7 L YUN dN 6 2 b S ur d4 U0J 919M0 9 6 0 LSP 19 MUNS ejeuog Auoudu S Je SeuluoJMs 13101 001 06 dS dIAUNS e GREENYELLOW 9 6 XUr 10 01 9 Mul GW owebues 6 9 1 ul 2027102 9 Yul 660 9 Yul 3 00 60 1006 100044 61041 000 000 40 04 ERE JOPUIWIUIY uouenog AKBoJoI N 028 1 9 sipu puluJe se A UJO0MMO E afale la sere 1 ufi 15 009 19009915 8 AUI 1 5 cto isos 6360 ROOM THERMOSTAT AC S o E N c oO
39. ions contained in the connection kit and the flue kit 2 7 ELECTRICAL CONNECTION For safety purposes have a competent person carefully check the electrical system in the property as the manufacturer will not be held liable for damage caused by the failure to earth the appliance properly or by anomalies in the supply of power Make sure that the residential electrical system is adequate for the maximum power absorbed by the unit which is indicated on the rating plate In addition check that the section of cabling is appropriate for the power absorbed by the boiler The boiler operates with alternating current as indicated in the technical information table section in 6 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 IMPORTANT In the event that the power supply cord must be changed replace it with one with the same specifications Make the connections to the terminal board located within the control panel as follows The yellow green wire should be connected to the terminal marked with the symbol make sure 10 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 termina
40. l 2 8 GAS CONNECTION 2 9 WATER CONNECTIONS Fic 2 5 002 marked P 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 in accordance with the current 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 15 installed in a bathroom when this must be sited outside the bathroom The local gas region contractor connects the gas meter to the service pipe If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time Pipe work must be of an adequate size Pipes of a smaller size than the boiler inlet connection should not be used VIEW OF THE BOILER CONNECTIONS 5 008
41. liance 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 carrying out maintenance In the case of faults or failure switch off the appliance and turn off the gas tap Do not tamper with the appliance For repairs call your local Authorised Servicing Centre and request the use of original spare parts For in guarantee repairs contact MTS GB Limited Check the following at least once a year 1 Check the seals for the water connections 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 combustion by products see section 3 6 and cleaning of the burner if needed 3 5 If called for by point 3 dismantling and cleaning of the combustion chamber 6 lf called for by point 4 dismantling and cleaning of the burner jets
42. n 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 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 FUO10A The boiler is designed to be connected to a coaxial flue discharge system 25 In addition it is also possible to use a split twin pipe system by fitting a special adaptor to the flue connector and using the aperture for the air vent intake located on the top part of the combustion chamber To utilise the air intake it is necessary to 1 Remove the bottom of the air intake by cutting it with a suitable knife see 2 8 2 Insert the elbow into the air intake until it reaches the lower end There is no need to use gaskets or sealing componds The components marked in 2 9 are present or absent depending on the type of flue system used by the installer
43. neral 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 19 4 GAS ADJUSTMENTS CATEGORY 12 3 Methane Gas Liquid Butane Gas Liquid Propane Gas G20 G30 G31 Lower Wobbe Index 15 C 1013mbar Nominal Delivery Pressure Minimum Delivery Pressure 23 MFFI Main Burner 13 jets 0 Consumption 15 C 1013mbar Consumption 15 C 1013mbar Gas Cock Outlet Pressure max min 27 MFFI Main Burner n 15 jets 0 Consumption 15 C 1013mbar Consumption 15 C 1013mbar Gas Cock Outlet Pressure max min 1 mbar 2 10 197 mmc a 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 1 CHANGING THE The boiler can be converted to use either methane natural gas G20 TvPE or GAS 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 5 Adjust the soft light feature 6 Adjust the ignition delay feature for the heating sys
44. pliance for leaks When the installation and filling are completed turn on the central heating system section 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 the system such as Fernox MB 1 or equivalent is strongly recommended to prevent corrosion sludge damaging the boiler and system Failure to carry out this procedure may invalidate the appliance warranty 15 3 2 CONTROL PANEL LEGEND On Off knob lt Domestic hot water temperature adjustment knob 9 C Central heating selection winter and temperature E adjustment knob D On Off L E D green E Fume sensor L E D yellow F Ignition failure lockout L E D red G Economy Comfort mode selection knob H Ignition failure lockout and or overheat reset button Overheat L E D red J Low system water level L E D red A Fic 3 1 K Central heating temperature L E D yellow
45. rk and must be used for pipe work carrying drinking water RESIDUAL HEAD OF THE BOILER 0 100 20 39 40 50 60 700 800 909 100 1100 1200 1300 1400 VR003A 2 9 FLUE CONNECTIONS Fic 2 6 3 60 100 mm FLuE SYSTEM The provision for satisfactory flue termination must be made as described in BS 5440 1 The appliance must be installed so that the flue terminal is exposed to outdoor air The terminal must not discharge into another room or space such as an outhouse or lean to It is important that the position of the terminal allows a free passage of air across it at all times The terminal should be located with due regard for the damage or discolouration that might occur on buildings in the vicinity In cold or humid weather water vapour may condense on leaving the flue terminal The effect of such steaming must be considered If the terminal is less than 2 metres above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be fitted When ordering a terminal guard quote the appliance model number 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 2 6 TERMINAL POSTION mm A Directly below a
46. rt circuit 1 1 REPLACEMENT Or PARTS The life of individual components varies and they will need servicing or replacing as and when faults develop The fault finding sequence chart in chapter 2 will help to locate which component is the cause of any malfunction and instructions for removal inspection and replacement of the individual parts are given in the following pages 1 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 Removing the front panel 1 Loosen the fastening screws A of the control panel located on the lower part of the panel itself Fic 1 1 063 control panel moves downward and when pulled forward rotates on two lateral hinges the panel stays in a semi horizontal position which allows access to the inner parts of the boiler FiG 1 2 In order to increase the manouvering space it is possible to raise the control panel and rotate it to a fully horizontal position Fic 1 3 Remove the screws from the front panel bottom lip Fia 1 4 Lift the front panel from the raised screws at the the top of the casing 1 5 FO016A 15 eps Removing the sealed chamber frontal cover Removing the side panels 1 Remove the screws 1 6 1 Remove the four screws D for each side panel FiG 1
47. rt circuit FiLLING THE HEATING SYSTEM Hemove the panels of the case and lower the control panel see section 3 3 for further information Open the central heating flow and return cocks supplied with the connection kit 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 ap
48. se valve 14 22 Safety valve 3 bar 23 Expansion vessel 24 Air pressure switch 25 Combustion analysis intakes 15 16 17 1819 20 INO13A 2 2 1 2 2 INSTALLATION REFERENCE STANDARDS SITING THE APPLIANCE The technical information and instructions provided herein below are intended for the installer so that the unit may be installed correctly and Safely The installation and initial start up of the boiler must be by a CORGI 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 current Gas Safety installation amp use Regulations The installation of this appliance must be in accordance with the relevant requirements of the current Gas Safety installation amp use Regulations the Local Building Regulations the current Wiring Regulations the byelaws of the local water authority and in Scotland in accordance with the Building Standards Scotland Regulation and Health and Safety document No 635 Electricity at work regs 1989 Installation should also comply with the following British Standard Codes of Practice 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 purpo
49. selector knob G allows the user to choose the economy mode position E or the comfort mode position C The economy mode is the normal state for the operation of the boiler since the domestic water is heated up only when a tap is turned on The comfort mode is a special operating state because the water contained in the secondary exchanger and in the primary exchanger is kept in a preheated condition thereby allowing a quicker delivery of domestic water when required The latter is therefore the more convenient choice To access the areas in which adjustments are made it is necessary to open the control panel as indicated in section 3 3 then remove the rear inspection cover by unscrewing the two screws Access is thereby provided to the P C B and to the following components 1 2 3 4 the power supply cable connector the fuses the soft light potentiometer the setting for which can range from the minimum thermal power to the maximum the maximum thermal heating power potentiometer adjustable by the minimum to maximum power already calibrated in the factory to 7096 of the maximum thermal power the potentiometer for adjusting the ignition delay anti cycling feature which can be set from 0 to 2 minutes set in the factory at one minute the time clock connector 17 3 7 3 8 COMBUSTION ANALYSIS FUME DISCHARGE MONITORING BoILER SAFETY SYSTEMS The flue connector has two apertures readin
50. ses 219 family gases BS 5546 1990 Flues BS 5440 1 1990 Air supply BS 5440 2 1989 The appliance may be installed in any room or indoor area although particular attention is drawn to the requirements of the current 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 the installation within a cupboard This appliance is not suitable for outdoor installation The type C appliances in which the combustion circuit air vent intake and combustion chamber are air tight with respect to the room in which the appliance 15 installed can be installed in any type of room There are
51. tem can be set from 0 to 2 mins CATEGORY II2H3 Methane Liquid Gas Propane G20 Gas G31 Recommended Soft 20 5 MAINTENANCE It is recommended that the following inspections be carried out on the boiler at least once a year d 2 cm 4 5 6 7 10 ii 12 13 14 Check the seals for the water connections replacement of any faulty seals Check the gas seals replacement of any faulty gas seals Visual check of the entire unit Visual check of the combustion process or analysis of combustion by products see section 3 6 and cleaning of the burner if needed If called for by point 3 dismantling and cleaning of the combustion chamber If called for by point 4 dismantling and cleaning of the burner jets Visual check of the primary heat exchanger check for overheating in the blade assembly clean the exhaust fan if needed Adjustment of the flow rate of the gas flow rate for lighting partial load and full load Check of the heating safety systems safety device for maximum temperature safety device for maximum pressure Check of the gas safety systems safety device for lack of gas or flame ionisation detection electrode safety device for gas cock Check of the electrical connection make sure it complies with the instructions in the manual Check of domestic hot water production efficiency flow rate and temperature General check of the combust
52. the pressure supplied by the gas valve to the burner remove the screw 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 lt L D gt and the summer winter switch to the winter position To set the maximum power turn on the hot water tap and allow the hot water tap to run at a rate of about 8 litres minute so that the main burner lights Adjust nut E on the modureg to set the gas pressure displayed on the pressure gauge corresponding to the maximum power see TABLE A page 9 5 To set the minimum power disconnect a supply terminal from the modureg and adjust screw F Turn the screw clockwise to increase the pressure and coun ter clockwise to decrease the pressure displayed the pressure gauge corresponding to the minimum power see TABLE A page 9 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 T lo set the maximum heating circuit power place the On Off button to position lt I gt and the summer winter switch to winter position Turn the knob of the heating thermostat clockwise to maximum 8 Remove the inspection panel of the P C B and fit a small
53. the selector knob to the winter central heating position This will start the circulation pump After 7 seconds the boiler will signal a shutdown due to ignition failure Leave the boiler as it is until all of the air has been bled from the 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 Check the exhaust flue for the fumes produced by combustion Make sure that all gate valves are open 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 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 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 the relative section for burner pressure adjustment within the servicing manual See section 3 2 for references it is possible to Set the temperature of the heating system by adjusting the knob Set the temperature of the domestic hot water by turning knob B The
54. w group 998613 20 E24077 __ Diaphragm main flow switch 571547 20 21 998099 998940 998424 574279 998645 997089 998836 999091 999599 998947 999245 0 3989 571651 99939 998894 997206 998620 998893 998618 998669 998887 998939 0 1646 573295 0 3825 573172 998623 998622 998624 998941 997029 998490 998718 998975 998974 998644 998643 998738 998961 999207 571547 571772 571771 571770 998172 998716 998717 Main circuit flow switch Return group O rino Gasket Spark generator Gas valve SIT 845 SIGMA 33 AB Pump 33 CD Pump Time clock P C B Pressure gauge 02AB Air pressure switch Air pressure switch 66AB_ _______ 66CD Fan Thermostat overheat 7448 __ __________ exchanger 74CD Main exchanger 75A Burner 12 ramp natural gas 75B Burner 12 ramp LPG 75C Burner 14 ramp natural gas 79D Burner 14 ramp LPG 76 Secondary exchanger p type 23kW 6CD Secondary exchanger p type 27kW O ring secondary exchanger Safety valve 1 2 3 bar Electrode Ignition R H Electrode Ignition L H 100 Detection electrode DHV actuator kit 321 Operator coils SIT SIGMA 331 Central heating by pass kit 332 Heating spring kit 333 3 way spring kit 334 Actuator bush 351 Gasket auto air vent 352 Auto air vent 353 Gasket pump head 354 AB Pump head Gold 15 5 354 CD Pump head 371 Diaphragm main flow switch 3 2 Magnet main flow switch 373 Spring main flow switch 3
55. ze and manufactured in accordance with BS 2870 1980 SAFETY VALVE DISCHARGE The discharge should terminate facing downward on the exterior of the building in a position where discharging possibly boiling water amp 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 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 6 1 3 gal of expansion water If the heating circuit has an unusually high water content calculate the total expansion and add an additional sealed expansion vessel with adequate capacity 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 in accordance with Water Supply Byelaw 14 must be provided 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 wo

Ariston 47-116-15 Boiler User Manual

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