Ariston Boiler 47 116 17 User Manual

Installation

Instructions

Type C Boilers

G.C.N: 41-116-03

47-116-17

Condensing

LEAVE THESE INSTRUCTIONS

WITH THE END-USER

275

Country of destination: GB

LEGEND:

1.3.

OVERALL VIEW

Flue connector

Heating flow temperature probe

Mixer

Condensate collector

Expansion vessel

Condensate trap (tube)

Condensate trap

24 MFFI

Diverter valve

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. Sealed combustion chamber

20. Combustion chamber inspection hatch

21. Fan

22. Ignition and detection electrode

23. Main heat exchanger (aluminium)

24. Automatic by-pass

25. Silencer

2. INSTALLATION

The technical information and instructions provided herein below are

intended for the installer so that the unit may be installed correctly

and safely.

2.1.

REFERENCE STANDARDS

24 RFFI SYSTEM

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 the current Gas Safety (installation & use)

Regulations.

The installation of this appliance must be in accordance with the

relevant requirements of the current Gas Safety (installation & use)

Regulations, the Local Building Regulations, the current I.E.E. 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

BS 6798

BS 5449

1988

1987

1990

Boilers of rated input

not exceeding 60 kW

Forced circulation hot

water system

Installation of gas hot water

supplies for domestic purposes

( 2^ndfamily gases)

Flues

BS 5546

BS 5440-1

BS 5440-2

1990

1989

Air supply

FIG. 1.1

275

2.2.

SITING THE APPLIANCE

2.3.

OVERALL DIMENSIONS

The appliance may be installed in any room or indoor area, although

particular attention is drawn to the requirements of the current I.E.E.

Wiring Regulations, and in Scotland, the electrical provisions of the

Building Regulations applicable in Scotland, with respect to the

installation of the combined appliance in a room containing a bath or

shower.

Where a room-sealed appliance is installed in a room containing

a bath or shower the boiler and any electrical switch or

appliance control, utilising mains electricity should be situated

so that it cannot be touched by a person using the bath or

shower.

LEGEND:

A = Central Heating Flow (3/4”)

B = Domestic Hot Water Outlet (1/2”)

C = Gas Inlet (3/4”)

D = Domestic Cold Water Inlet (1/2”)

E = Central Heating Return (3/4”)

F = Cylinder Flow (3/4”)

G = Cylinder Return (3/4”)

H = Condensate discharge

The location must permit adequate space for servicing and air

circulation around the appliance as indicated in paragraph 2.4.

The location must permit the provision of an adequate flue and

termination.

For unusual locations special procedures may be necessary.

BS 6798-1987 gives detailed guidance on this aspect.

A compartment used to enclose the appliance must be designed

specifically for this purpose. No specific ventilation requirements are

needed for an installation within a cupboard.

This appliance is not suitable for outdoor installation.

The type C appliances (in which the combustion circuit, air vent

intake and combustion chamber are air-tight with respect to the

room in which the appliance is installed) can be installed in any

type of room.

There are no limitations with respect to ventilation and the volume of

the room itself. The boiler must be installed on a solid, permanent

wall to prevent access to the electrical parts (when live) through the

aperture on the back frame.

FIG. 2.1

24 MFFI

181

100

65 67 67 65

155

(A-B-D-E)

208

(C)

24 RFFI SYSTEM

275

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

IMPORTANT!

24 MFFI

In the event that the power supply cable 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 earth symbol; make sure to re-use the ferrule mounted on

the other supply cord;

- The blue wire should be connected to the terminal marked “N”;

- The brown wire should be connected to the terminal marked “L”.

Note: The diagrams for the electrical system are indicated in section

2.11.

Warning, this appliance must be earthed.

External wiring to the appliance must be carried out by a qualified

technician and be in accordance with the current I.E.E. Regulations

and applicable local regulations. The Genus range of boilers are

supplied for connection to a 230 V 50 Hz supply.

The supply must be fused at 3 A.

24 MFFI SYSTEM

The method of connection to the electricity supply must facilitate

complete electrical isolation of the appliance, by the use of a fused

double pole isolator having a contact separation of at least 3 mm in

all poles or alternatively, by means of a 3 A fused three pin plug and

unswitched shuttered socket outlet both complying with BS 1363.

The point of connection to the Electricity supply must be readily

accessible and adjacent to the appliance unless the appliance is

installed in a bathroom when this must be sited outside the

bathroom.

2.7.

GAS CONNECTION

The local gas region contractor connects the gas meter to the

service pipe.

If the gas supply for the boiler serves other appliances ensure that an

adequate supply is available both to the boiler and the other

appliances when they are in use at the same time.

Pipe work must be of an adequate size. Pipes of a smaller size than

the boiler inlet connection should not be used.

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 instructions contained

in the connection kit and the flue kit.

2.6.

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 data table (1.2), where the maximum absorbed power is

also indicated. Make sure that the connections for the neutral and live

wires correspond to the indications in the diagram. The appliance

electrical connections are situated on the reverse of the control panel

(see the servicing manual for further information)

275

2.8.

WATER CONNECTIONS

FIG. 2.5

VIEW OF THE BOILER CONNECTIONS

24 MFFI

Fitting the connection kit to

the ecoGENUS 24 RFFI

SYSTEM only.

It will be noted that the kit has

two connections not required

for this boiler i.e. the domestic

cold inlet “D” and the domestic

hot water outlet “B” (see fig.

2.4).

Although the cold water main supply must be connected to the

isolation valve for the purpose of operating the filling-loop, the

isolation valve is NOT connected to the boiler and should be left

in the OFF position.

The D.H.W. outlet is capped-off on the boiler, therefore not

requiring the isolation valve to be used.

The ecoGENUS 24 RFFI SYSTEM has 2 x 3/4" B.S.P. male

threads for the cylinder flow and return. It is recommended that 2

x 22mm x 3/4" female iron fittings (not supplied) be used on these

connections (using P.T.F.E. tape), before the boiler is mounted on

the wall.

FIG. 2.4

24 MFFI SYSTEM

SYSTEM DESIGN:

This boiler is suitable only for sealed systems.

DRAIN COCKS:

These must be located in accessible positions to permit the

draining of the whole system. The taps must be at least 15mm

nominal size and manufactured in accordance with BS

2870:1980.

S^AFETYVALVE DISCHARGE:

The discharge should terminate facing downwards on the exterior

of the building in a position where discharging (possibly boiling

water & steam) will not create danger or nuisance, but in an easily

visible position, and not cause damage to electrical components

and wiring.

L^EGEND:

A = Central Heating Flow

B = Domestic Hot Water Outlet

C = Gas Inlet

D = Domestic Cold Water Inlet)

E = Central Heating Return

F = Cylinder Flow

The discharge must not be over an entrance or a window or any

other type of public access.

C^ONDENSATEDISCHARGE:

The condensate discharge hose from the boiler must be inserted

by at least 50 mm into a suitable acid resistant pipe - e.g. plastic

waste or overflow pipe. The condensate discharge pipe must have

a continuous fall and preferably be installed and terminated within

the building to prevent freezing.

The discharge pipe must be terminated in a suitable position:

i) Connecting in to an internal soil stack (at least 450 mm above

the invert of the stack). A trap giving a water seal of at least 75

mm must be incorporated into the pipe run , there also must

be an air break upstream of the trap.

ii) Connecting into the waste system of the building such as a

washing machine or sink. The connection must be upstream of

the washing machine/sink (If the connection is down stream of

the waste trap then an additional trap giving a minimum water

seal of 75 mm and an air break must be incorporated in the

pipe run, as above.

G = Cylinder Return

H = Condensate discharge

= Safety valve discharge

C^ENTRALHEATING

Detailed recommendations are given in BS 6798:1987 and BS 5449-

1:1990, the following notes are given for general guidance.

P^IPEWORK:

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.

iii) Terminating into a gully, below the grid level but above the

water level.

iv) Into a soakway.

N^OTE: If any condensate pipe work is to be installed externally,

then it should be kept to a minimum and be insulated with a

waterproof insulation and have a continuous fall.

A^IRRELEASE POINTS:

Particular attention should be paid to pipes passing through

ventilated spaces in roofs and under floors.

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.

B^Y-PASS:

The appliance includes an automatic by-pass valve, which

protects the main heat exchanger in case of reduced or

interrupted water circulation through the heating system, due to

the closing of thermostatic valves or cock-type valves within the

system.

It can accept up to 7 l (1.5 gal) of expansion water. If the heating

circuit has an unusually high water content, calculate the total

275

expansion and add an additional sealed expansion vessel with

adequate capacity.

The minimum acceptable spacing from the terminal to obstructions

and ventilation openings are specified in Fig. 2.6

M^AINSWATER 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.

FIG. 2.6

F^ILLING:

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 F^IG. 2.5). The flexible hose must be removed

once the system has been filled. The D.H.W. inlet valve on the

connection kit has two positions, one for winter and one for the

summer. This enables the flow-rate through the appliance to be

adjusted so that a sensible D.H.W. temperature may be achieved

throughout the year.

D^OMESTICW^ATER

The domestic water must be in accordance with the relevant

recommendation of BS 5546:1990. Copper tubing to BS EN

1057:1996 is recommended for water carrying pipe work and

must be used for pipe work carrying drinking water.

R^ESIDUALHEAD OF THE BOILER

TERMINAL POSITION

A - Directly below an open window or other opening

B - Below gutters, solid pipes or drain pipes

C - Below eaves

300

200

D - Below balconies or car-port roof

E - From vertical drain pipes and soil pipes

F - From internal or external corners

G - Above ground or below balcony level

H - From a surface facing a terminal

I - From a terminal facing a terminal

J - From an opening in the car port

(e.g. door, window) into dwelling

300

600

1200

1500

300

K - Vertically from a terminal in the same wall

L - Horizontally from a terminal in the same wall

In F^IG. 2.11 below, several different types of flue systems are shown.

For additional information regarding the flue accessories, please

consult the Flue Pipe Accessories manual.

2.9.

FLUE CONNECTIONS

FLUE SYSTEM

Exhaust Type

Maximum Extension Diameter

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.

Exhaust/Air

(m)

of Pipes

(mm)

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.

Ø 60/100

Coaxial

Systems

outlet of fumes in

chimney or exhaust flue

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.

C , C , C

31 (S1=S2)

55 (S1+S2)

54 (S2)

Ø 80/80

Ø 80

53,

Twin Pipe

Systems

A suitable terminal guard is available from:

TOWER FLUE COMPONENTS

Morley Road

Tonbridge

Kent TN9 1RA

275

F^IG. 2.11

2.10. ACCESSORY CONNECTION

To carry out the connection for the roomstat or the outdoor sensor,

proceed as follows:

2.10.1. ROOM THERMOSTAT CONNECTION

1. Unscrew the screws “A” and rotate the control panel forwards;

2. 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. Insert the connecting cable into the cable clamp “D” shown in

the figure and fasten it.

4. Remove the grommet “E” shown in the figure, make a hole in it

and pass the connecting cable for the roomstat or the outdoor

sensor through it.

5a. In order to connect up the roomstat, remove the link that is

located in the “F” terminal (marked with the initials “TA”) and

connect the cables.

5b. To connect up the outdoor sensor, insert the cables into the “G”

clamp (marked with the initials “SE”).

6. Return the grommet “E” to its initial position, then close back

the lid and lastly return the control panel to its place.

If a remote time clock is to be fitted, disconnect the integral time

clock plug from the P.C.B.

Using a volt-free switching time clock, connect the switching

wires from the time clock following points 1-6 above.

If using a time clock and room thermostat, these must be

connected in series as per points 1-8 above.

Note: Only a two-wire type room thermostat can be used.

For details on fitting the D.H.W. probe (ecoGENUS 27

RFFI only), please consult the separate instruction

sheet supplied with the probe.

An anti-frost device is built-in to the appliance’s

electronic regulation system.

275

2.10.2. REMOTE CONTROL CONNECTION

2.10.3. ACCESSORY CONNECTION TERMINAL BLOCK

Refer to the illustrations in section 2.10.1.

1. Unscrew the screws “A” and rotate the control panel forwards.

2. 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”.

3. Remove a blind grommet, make a hole in it and pass the

connecting cable of the remote control through it.

4. Connect the cables of the remote control to the flying lead (see

section 2.11.) connected to position C5 on the P.C.B. (positions

with no closed jumper).

5. Bring the grommet back to its initial position, then close the lid

and lastly the control panel.

NOTE: The wiring of the Outdoor Sensor (SE) must be done by using

2 x 0.5 mm²cable this guarantees a maximum length of 50 m.

The sensor must be positioned at least 2 - 2.5 m above the

ground and where possible facing north. The sensor must not

be exposed to direct sunlight.

N^OTE: The wiring of the RC must be done by using 2 x 0.5 mm²cable

this guarantees a maximum length of 500 m.

The “BUS” cable of the RC must be wired separately from the 230

VAC cable.

2.10.4. UNDER FLOOR HEATING CONNECTION

Refer to the illustrations in section 2.10.1.

1. Unscrew the screws “A” and rotate the control panel forwards.

2. Insert the connecting cable of the under floor heating sensor into

the cable gland “B” and open the lid of the instrument panel

after having unscrewed the fastening screws “C”.

3. Remove a blind grommet, make a hole in it and insert the

connecting cable of the under floor heating sensor through it.

4. Remove the jumper located in the flying clamp

5. Connect the cables of the under floor heating sensor to the flying

clamp connected to position C6 on the P.C.B. (in place of the

position previously occupied by the jumper).

6. Bring the grommet back to its initial position, close the lid and

lastly the control panel.

2.10.5. REMOTE CONTROL TERMINAL BLOCK,

CYLINDER PROBE AND SECONDARY OUTLET

CONNECTIONS TO THE P.CB.

JUMPER:

C6 (3-11)

(grey)

UNDER FLOOR

HEATING

SENSOR

C5 (1-2)

(red)

REMOTE CONTROL

SECONDARY OUTLET

(LPG valve,

secondary pump)

C7 (1-9)

(violet)

275

The P.C.B. is fitted with 2 fuses, on the

live and the neutral.

2.11. ELECTRICAL DIAGRAM

The fuse holder contains:

- 5 x 20mm “3.15A Slow” glass fuses

L^EGEND:

B: Control microprocessor

A: JUMPER

C: Flame detection jumper (under no circumstances should this

jumper be moved from the 1-2 position)

D: Anti-cycling device (RA)

E: Maximum heating output regulation (PR)

F: Soft-light regulation (RLA)

G: Operating mode selector knob

H: Heating temperature adjustment

I: Domestic hot water temperature adjustment

J: Remote control module

K: Main microprocessor

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)

L: Relay

N^OTE: under absolutely no circumstances must jumpers 2, 7 and 8

be removed. The opening of such contacts will lead to boiler

malfunction.

M: Fuses (2 x 0.54 A SLOW)

N: Transformer (PRI: 230V-50Hz; SEK: 10V-0,8VA; SEK:10V-3,5VA;

SEK:10V-3,5VA;)

O: Fuses (2 x 3.15 A SLOW)

P: Earth

This is the factory configuration. It is recommended that this set-up

not be changed, unless under the following particular circumstances:

JUMPER 3:

if the contact is closed, the Secondary Output (flying

clamp connected to connection C7; positions 1-9)

controls an LPG valve (optional).

if the contact is closed, the continuous operation of

the pump is selected. If the contact remains open, it

has no effect and there is no change in the

operation of the boiler.

Q: Spark generator

R: Connection to the main P.C.B.

S: Comfort light

JUMPER 4:

T: Programming keys

U: Comfort key

V: Alpha-numeric display

JUMPER 5:

if the contact is closed, the signal transmitted by the

connection of the secondary output clasp

(connected to C7; positions 1-9) relates to a

secondary pump (optional). If the contact remains

open, the output signal controls a zone valve

(optional).

X: Set and reset key

W: Connection to PC

C1 = FAN

“Hall” sensor power supply 12V (red)

“Hall” sensor ground (blue)

Not used

JUMPER 6:

JUMPER 7/8:

not used

Start of coil (black)

N.I.

CONFIGURATION

“Hall” sensor input (white)

End of coil (brown)

N.I. Central heating only

N.I. MFFI

N.I.

Not used

C2 = POWER SUPPLY

RFFI System

Earth (yellow/green)

Not connected

Neutral (blue)

I = inserted (contact closed)

N.I = not inserted (contact open)

Not connected

Live (brown)

N^OTE: it is essential that the operations involving setting of the

jumpers be carried out only with the device turned off.

275

2.12. WATER CIRCUIT DIAGRAMS

C3 = CONNECTION TO ROOMSTAT

Input - 1

Input - 2

24 MFFI

C4 = TIMER

3 V output

Timer ground

Timer output

Not connected

C5 = REMOTE CONTROL (Bus+/Bus-)

Input/output-1

Input/output-2

C6 = SENSOR CONNECTOR

Domestic hot water flow switch (grey)

Main circuit flow switch (grey)

Under floor heating thermostat (grey)

Heating flow sensor (grey)

Heating return sensor (grey)

Domestic hot water sensor (grey)

Not used: jumper

Outdoor sensor (grey)

Domestic hot water flow switch (grey)

Main circuit flow switch (grey)

Under floor heating thermostat (grey)

Flow sensor (grey)

10:

11:

12:

13:

14:

15:

16:

Heating sensor (grey)

Domestic hot water sensor (grey)

Not used: under floor heating

Outdoor sensor (grey)

C7 = EQUIPMENT CONNECTIONS

Secondary output (optional)

Gas valve (white)

LEGEND:

3-way valve neutral (white)

Pump (white)

Fan

Main Heat exchanger

Ignition/detection electrode

Burner

Ionisation (black)

Not connected

Ground

Gas valve

Pump earth (yellow/green)

Secondary output (optional)

Gas valve (brown)

Heating return temperature probe

Heating flow temperature probe

Silencer

10:

11:

12:

13:

14:

15:

16:

3-way valve (domestic hot water) (brown)

3-way valve (heating) (brown)

Pump (brown)

Motorised valve

10 - Automatic by-pass

11 - Main circuit flow switch

12 - Domestic hot water temperature probe

13 - Secondary heat exchanger

14 - Domestic hot water inlet filter

16 - Drain valve

Not connected

Earth

Gas valve earth (yellow/green)

17 - Safety valve

18 - Pressure gauge

19 - Circulation pump with automatic air release valve

20 - Expansion vessel

21 - Condensate trap inspection cap

22 - Condensate trap

23 - Condensate discharge tube

24 - Condensate trap inlet

25 - Injector

26 - Domestic hot water flow switch

275

3. COMMISSIONING

24 RFFI SYSTEM

3.1.

INITIAL PREPARATION

MTS (GB) Limited support the

information pack you will find a copy of the

initiative. Within 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 short circuit.

F^{ILLING THE}HEATING SYSTEM:

Remove the panels of the case and lower the control panel (see

section 3.2. for further information).

Open the central heating flow and return cocks supplied with the

connection kit.

Unscrew the cap on the automatic air release valve one full turn

and leave open permanently.

Close all air release valves on the central heating system.

Gradually open valve(s) at the filling point (filling-loop) connection

to the central heating system until water is heard to flow, do not

open fully.

Open each air release tap starting with the lower point and close it

only when clear water, free of air, is visible.

Purge the air from the pump by unscrewing 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.

F^{ILLING 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

G^ASSUPPLY:

Inspect the entire installation including the gas meter, test for

soundness and purge, all as described in BS 6891:1988.

Open the gas cock (supplied with the connection kit) to the

appliance and check the gas connector on the appliance for leaks.

L^EGEND:

Fan

When the installation and filling are completed turn on the central

heating system (sect. 3.4) and run it until the temperature has

reached the boiler operating temperature.

The system must then be immediately flushed through.

The flushing procedure must be in line with BS 7593:1992 Code of

practice for treatment of water in domestic hot water central heating

systems.

During this operation, we highly recommend the use of a central

heating flushing detergent (Fernox Superfloc or equivalent), whose

function is to dissolve any foreign matter that may be in the system.

Substances different from these could create serious problems

to the pump or other components.

The use of an inhibitor in the system such as Fernox MB-1 or

equivalent is strongly recommended to prevent corrosion (sludge)

damaging the boiler and system.

Main Heat exchanger

Ignition/detection electrode

Burner

Gas valve

Heating return temperature probe

Heating flow temperature probe

Silencer

Motorised valve

10 - Automatic by-pass

11 - Main circuit flow switch

12 - Non-return valve (integral to Jig Kit)

13 - Filling loop (integral to Jig Kit)

14 - Indirect cylinder expansion vessel

15 - Expansion relief valve

16 - Drain valve

Failure to carry out this procedure may invalidate the appliance

warranty.

17 - Safety valve (3 bar)

18 - Pressure gauge

19 - Circulation pump with automatic air release valve

20 - Expansion vessel

21 - Condensate trap inspection cap

22 - Condensate trap

23 - Condensate discharge tube

24 - Condensate trap inlet

25 - Injector

275

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.

A. Selector Knob for Summer/Winter/Flue Test Modes

B. Domestic Hot Water Temperature Adjustment Knob

C. Central Heating Temperature Adjustment Knob

D. On/Off L.E.D.

E. On/Off Knob

F. “COMFORT” Function Push-button/heating only (RFFI SYSTEM)

G. “COMFORT” Function L.E.D./heating only (RFFI SYSTEM)

H. Reset Button

I. Multifunction Display

J. Heating System Pressure Gauge

K. Time Clock

L. Programming “+” key

M. Programming “-” key

3.4.

INITIAL START-UP

When necessary configure the main P.C.B. according to the following

diagram (please refer to the legend on page 17)

POSITION INSERTED

NOT INSERTED

Secondary outlet (connection The secondary outlet

C7; positions 1-9) controls a

LPG valve (optional).

controls what is

selected by Jumper 5.

Continuous pump operation.

No change in pump

operation.

Secondary output relates to a Secondary output

secondary pump (optional).

controls a zone valve

(optional)

N.I.

CONFIGURATION

N.I. Central heating only

N.I. MFFI

N.I.

Not used

RFFI System

I = inserted (contact closed)

N.I = not inserted (contact open)

SECONDARY OUTLET = conntection C7 (position 1-9 page 17)

1. Make sure that:

the cap of the automatic air release valve is loosened;

the system pressure is at least 1 bar on the pressure gauge;

275

the gas cock is closed;

3.6.

OPERATING PARAMETERS

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. The message “A01”

will appear on the display;

The boiler has been designed to allow easy intervention with regard

to the operating parameters.

3.6.1. CONTROL MODES

The generation of the set-point and the request for heat are clarified

in the following diagram, with regard to the heating mode.

let the pump operate until all the air has escaped from the

system;

repeat the procedure for bleeding the radiators of air;

draw hot water for a short while;

check the system pressure and, if it has gone down, fill it with

water until it returns to 1 bar.

2. Check the flue system for products of combustion.

3. Check that any required local ventilation inlets are open.

4. Fill the boiler condensate trap with water.

N.B. In the event of prolonged period of system shutdown,

the condensate trap should be filled before any renewed use.

A shortage of water in the trap is dangerous because it could

possibly lead to a leakage of fumes into the air.

5. 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.

6. Press the reset button “H” for the lighting system; the spark will

light the main burner. If the burner does not light the first time,

repeat the procedure.

* See section 3.6.2.

The boiler is configured in the factory for the gas type in

question. It is not necessary to regulate the gas type on

installation.

The remote control and the timer are available as an accessory Kit:

in the preceding diagram, it is clear that in the event that a device of

this type is not installed, the calculation of the set-point depends on

an outdoor sensor (if installed) and is carried out by the P.C.B.

N^OTE: a configuration is also possible which allows for the

simultaneous presence of a remote control and an outdoor sensor. In

this case, the flow temperature is calculated as a function of the

external temperature and the room temperature. In this manner, it is

possible to carry out a particularly efficient modulation, which allows

considerable comfort to be obtained, combined with savings in fuel.

The influence of the roomstat and the timer are shown in the

following diagram, taking into consideration the fact that:

N^OTE: the reference values of the CO are contained in the

T^ECHNICALI^NFORMATIONsection on page 4.

3.5.

DISPLAY: MESSAGES SHOWN DURING

NORMAL OPERATION

ON/OFF Room thermostat installed: contact open or closed,

controlled by the room thermostat temperature sensor.

ON/OFF Room thermostat not installed: contact closed (jumper).

Timer installed: contact open or closed, controlled by the timer

settings entered by the user.

Timer not installed: contact open.

Schematic representation of the influence exerted by the roomstat

and by the timer on the request for heat and on the calculation of the

set-point (flow temperature of the primary circuit) by means of the

external temperature values:

LEFT

RIGHT

During operation of the boiler, while it is carrying out its normal

operations, the left-hand display shows a series of characters that

refer to the operations indicated below:

- Diagnostics phase (precedes the other operations)

No request for heat

Heating, burner off

Heating, burner on

Pump overrun for heating

Domestic hot water, burner off

Domestic hot water, burner on

Pump overrun for domestic hot water

Storage cylinder, burner off (SYSTEM version)

Storage cylinder, burner on (SYSTEM version)

N^OTE: the flashing dot on the left-hand display always indicates

“burner off”; if the still dot indicates “burner on”.

The right-hand display (two-digit) shows:

- in HEATING mode: temperature of the heating system flow;

- in DOMESTIC HOT WATER mode: temperature of domestic hot water.

275

3.6.2. OUTDOOR SENSOR

In the case of the use of an outdoor sensor, the microprocessor-

controlled 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".

The type of curve should be chosen in correspondence with the

planned temperature of the system and the nature of the heat loss

present in the building.

The flow temperature directly influences the room temperature,

therefore making reference to the room temperature is equivalent to

indicating variations in the temperature of the building.

P^{ROCEDURES AND PRACTICAL EXAMPLES}:

If the building is always cold, under all external temperature

conditions (and therefore in all seasons), the steps to take are as

follows:

100

The curve must be translated parallel to itself, i.e. raising the flow

temperature (and thereby the room temperature) in parity with the

external temperature.

It is possible to carry out this operation by heating temperature knob.

The konb in vertical position set a temperature oh 20°C. Turning the

knob on the right it’s possible to set a higher room temperature.

+20

-20

The type of curve is entered by means of the controls of the display

P.C.B located under the lid of the P.C.B. itself. To access the

programming buttons (+ / -), raise the lid with a screwdriver as shown

in the illustration.

In this manner, temperatures for the water coming out of the boiler

are set successively higher, which then influence the room

temperature increasing it to the desired settings.

While turning the knob the display shows “d.xx” for few seconds, “xx”

is the room temperature set. Alternatively, it is possible to lower the

output temperature of the boiler if the room temperature is too hot.

It is possible obtain this turning the knob on the left translating lower

the curve.

In the event of the chosen curve not being the most suitable for the

type of system, it may be changed (selecting a more appropriate

one) or moved until the desired thermal behaviour is obtained for the

boiler and the system.

NB: The last effect achieved by adjusting the thermal curves is to change

the behaviour of the system in relation to the room temperature. If

the curve used has been selected underestimating the thermal

needs of the building, i.e. it is too “low”, it is possible that the building

will not heat up sufficiently (the boiler will arrive to the set-point

before the building reaches the desired temperature); the result is

that the building will feel cold.

275

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 “F” appears (using the “+” and “-” keys).

In this manner, the curves may be selected

from 1 to 5.

Alternatively, if the building is too warm in the

winter, while the room temperature is

adequate in warmer seasons, it is necessary

to choose a less steep curve, adjusting it in

the same manner as above.

If the following situation occurs: with low external temperatures (e.g:

winter, -20°C) the building is adequately heated, but with favourable

climatic conditions (e.g: spring, +20°C) it is not sufficiently heated, it is

necessary first to choose a lower curve (“F” on the display and then “-”)

and then turning the heating temperature knob.

In the opposite situation (in which the building is too hot in spring and

adequately heated in winter), a higher curve (“d” and “+”) must first

be chosen and then “moved” turning the heating temperature knob.

The general conditions to follow upon installation are the following:

Warning (see 3.7.2)

* The curves 1,2,3,4,5,6 could be set in the lower temperature;

* The curves 5,6,7,8,9 could be set in the upper temperature;

CURVE 4-5: conventional low temperature boilers (cast iron and

aluminum radiators, radiant plate systems). Planned

temperature 60/45°C.

CURVE 6-7: conventional low temperature boilers (cast iron and

aluminum radiators, radiant plate systems). Planned

temperature 75/60°C.

CURVE 1:

under floor heating (radiant panels at ultra-low

temperature). Planned temperature 30/20°C.

CURVE 8-9: boilers with higher temperatures (radiators, convectors,

fan coils). Planned temperature 90/75°C.

CURVE 2-3: under floor heating (radiant panels, low temperature

radiant plate systems). Planned temperature 40/30°C.

For buildings with standard insulation, materials and exposure, it is recommended initially that the straight line not be moved parallel to itself. If

a timer is installed, it is possible to set different temperatures for daytime and night-time. It is therefore possible to lower the temperature that

the P.C.B. calculates in relation to the values provided by the outdoor sensor by a quantity decided by the user for night-time operation. To do

this, it is necessary to select the night function “u”, in the following manner:

press the reset key for 5 seconds;

press the same key again once to make the “n” character appear;

using the programming keys “+” and “-”, select a value from 0 to 12 depending on the amount of night-time lowering of the temperature

desired.

275

entered may be viewed in the manner described in section 3.6.3.

(the display shows the value with steps of 10).

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. By pressing the

button repeatedly after that, it is possible to read the following

information in sequence:

2. PR - Maximum heating circuit power potentiometer, variable

between the maximum allowed by the boiler and the minimum

(see “T^ECHNICALINFORMATION” table). The boiler is calibrated in

the factory at 70%.

3. RLA - Soft-light potentiometer, variable between the

maximum power (shown on the display as “00”, i.e. 100%) and

Value read on right-hand display

Indication on the

left-hand display

minimum power (shown on the display as “01”, i.e. 1%). The boiler

is calibrated in the factory at a value which is suitable for ignition

with any type of gas (approx. 70%).

The display shows the value between 100% (“00” on the display)

and 1% (“01”) of this interval. The indications on the display with

Flow temperature of the heating circuit (C°)

Return temperature of the heating circuit (C°)

Domestic hot water output temperature (C°)

Ionisation current (expressed in bT)

U/1

U/2

U/5

U/F

U/t

P/A

regard to the power are shown in the graph:

D^{ISPLAY MESSAGE REFERENCE}

Main circuit flow switch

Heating ignition delay (see section 3.6.4. -

expressed in min.x10)

Maximum thermal power for heating (expressed

in a percentage of the difference between the

maximum power allowed by the boiler and the

minimum)

P/-

Soft light power (expressed in a percentage of

the difference between the maximum power

allowed by the boiler and the minimum)

Last safety shut-off (see section 3.7.)

Last shutdown (see section 3.7.)

P/L

3.7.2. SETTING THE TEMPERATURE FIELD

To return to the normal display, press the “H” reset key repeatedly

until all the sequence of “readout” functions have scrolled through the

display and until one of the “display of normal operations” has

appeared (the message that appears will depend on the current

operating mode of the boiler).

Remove the protection of the display using a screwdriver as a lever.

Press the reset button for over 5 seconds. The display will show

“A03”. On pressing the reset button again the display will change to

“R00” (R indicates the setting of the field of regulation of the flow

temperature). Using the button “E”, the setting may be changed. It is

possible to choose two fields of regulation of the flow temperature.

“00” signifies that the flow temperature (which may be set by means

of the knob on the front control panel) may be regulated from 30 to

75°C. “01” signifies that the flow temperature (which also may be set

by means of the knob on the front control panel) may be regulated

from 42 to 82 °C. The factory setting is “00”.

* N^OTE1: U/1 means that “u” and “1” blink alternately on the display

N^OTE2: the value 100% appears as “00” on the display

3.7.

REGULATIONS

3.7.1. POTENTIOMETERS

To access the areas reserved for the regulation and control, open the

control panel, after having first unscrewed the plastic fastening

screws, and raise the rubber protection stopper for the

potentiometers, as shown in the illustration.

3.7.3. COMFORT KEY:

24 MFFI

The boiler allows the convenience level to be increased in the output

of domestic hot water by means of the “COMFORT” function. This

function keeps the secondary exchanger warm during the periods in

which the boiler is inactive, thereby allowing the initial water drawn to

be at a higher temperature. The function may be activated by

pressing the “H” key on the control panel (see section 3.3.). When

the function is active, a green light comes on, again located on the

control panel.

N^OTE: During the overrun period of the pump, the “COMFORT”

function, if selected, is temporarily deactivated. The L.E.D. light

remains on to indicate that the boiler will return to the “COMFORT”

mode once the pump overrun is terminated.

HEATING ONLY KEY:

24 RFFI

This function may be activated by pressing the “H” key on the

control panel (see section 3.3.). When the function is active, a green

light comes on, again located on the control panel. This indicates that

the external indirect cylinder is not maintained at the set temperature,

only the anti-frost protection of the indirect cylinder is active. When

the temperature goes below 5°C, the boiler turns itself on and heats

up the indirect cylinder until the temperature goes over 10°C.

This allows access to the three regulation potentiometers:

1. RA - Ignition delay (anti-cycling device) potentiometer

It is possible to set the ignition delay by adjusting the

potentiometer with a screwdriver. The values that may be

selected range from 0 to 15 min.

The delay has been set at 15 minutes in the factory. The value

275

3.7.4. PUMP OVERRUN

3.7.5. TEST MODE

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

“A” appears on the left-hand display.

The P.C.B. allows the boiler to be forced to the maximum or minimum

power.

To make the boiler operate at maximum power (100%: 24kW), it is

necessary to turn the selector knob “A” (section 3.3.) and, using a

light pressure, bring it to the <

> position. To return the boiler to its

The following modes are available:

normal function, turn the selector “A” to the summer or winter

position.

N^OTE: To force the boiler to its maximum output it is necessary to

completely rotate the potentiometer for maximum heating output

regulation (PR).

1 minute of pump overrun

3 minutes of pump overrun

6 minutes of pump overrun

9 minutes of pump overrun

12 minutes of pump overrun

15 minutes of pump overrun

24 hours of pump overrun

It is also possible to set a continuous pump operation by closing the

contact of jumper 4 (see section 2.12.).

3.7.6. REGULATION MENU TABLE

Summary of the functions accessed when the RESET button is pushed for 5 seconds.

3.8.

BOILER SAFETY SYSTEMS

The boiler is protected from malfunctioning by means of internal

checks by the P.C.B., which brings the boiler to a stop if necessary.

In the event of the boiler being shut off in this manner, a code

appears on the display which refers to the type of shut-off and the

reason behind it.

DISPLAY

A01

CAUSE

Too many attempts to ignite on starting up

After three attempts at ignition, no increase in DT was

detected

A02

There are two types of shut-off:

A03

The heating flow temperature exceeds 100°C during

operation

SAFETY SHUTDOWN :these group of errors (characterised on

the display by the letter “E”) this situation is automatically

removed as soon as the cause behind it is resolved.

As soon as the origin of the shutdown disappears, the boiler

starts up again and returns to its normal operation.

A07

A19

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

A20

A21

SHUTDOWN: (characterised on the display by the letter “A”), it is

not removed unless a manual intervention is made.

The boiler may return to operation only if reset by means of

pressing the button “H” (see illustration on page 18) located at

the centre of the display.

A22

A33

A99

The flow switch does not open

Problem with the fan

Problem with the electronic monitoring

There follows a list of the shutdown modes and the respective codes

shown on the display.

NOTE:

When there is no ignition, check that the gas cock is open.

Shutdown (“A” type): if such a situation occurs, it is necessary to reset

the boiler using the appropriate key. If this shutdown occurs again, an

Authorised Service Centre should be contacted.

Safety shutdown: In the event that a safety shutdown occurs, it is

necessary to contact an Authorised Service Centre.

275

DISPLAY

CAUSE

temperature goes below -3°C, it turns off when the external

temperatures raises above -1°C.

Continuous operation of the pump: select by means of jumper 4

(see paragraph 3.6.6.).

E03

Flow temperature over 100°C while boiler is not in

operation (stand-by)

N^OTE: In all cases, the circulation takes place in the heating system.

The anti-frost device activates only when (with the boiler operating

correctly):

E56

E66

E04

E05

E08

E20

E21

Heating flow temperature probe in open circuit

Heating flow temperature probe short-circuited

Domestic hot water temperature probe in open circuit

Domestic hot water temperature probe in short circuit

Under floor heating temperature probe in open circuit

Flame detected with gas valve closed

the system pressure is correct;

the boiler is electrically powered;

there is a supply of gas.

6. A^NTI-SCALE DEVICE. When producing domestic hot water, the

burner shuts off whenever the output temperature of the hot

water exceeds 62°C or the flow temperature of the primary

circuit exceeds 72°C. It will not turn on if the temperature of the

primary circuit is greater than 72°C.

Error in the electrical connection (live and neutral crossed)

Problem with the 50Hz power supply

E22

E23

E64

E74

E99

Flame detection electrode short-circuited

Heating return temperature probe in open circuit

Heating return temperature probe in short circuit

Problem within the electronic system

3.9.

COMBUSTION ANALYSIS

The boiler is designed to

allow for easy analysis of

There follows a description of the safety functions that most influence

the behaviour of the boiler.

the

combustion.

products

1. FLOW SWITCH. At the beginning of every ignition sequence, the

P.C.B. checks the operation of the main circuit flow switch.

Initially, the pump is off and the flow switch must be open (not

giving consent); if this does not occur within the space of a

minute, the system carries out a shutdown. When the flow switch

is open, the pump is turned on and within one minute the flow

switch must close; if it does not do so, the monitoring

mechanism shuts down the boiler (with the pump off).

Using the special traps, it

is possible to detect the

temperature of the burnt

gas, the combustion air,

the concentrations of O ,

CO , etc.

The maximum heating power test conditions may be optimised by

turning the selector knob “C” to the flue test position.

During normal operation, the flow switch must remain closed; if it

opens for over two seconds, the boiler shuts down, then the

monitoring mechanism will attempt to turn it back on.

3.5.

DRAINING

2. F^AN. On ignition, the fan must rotate at the correct speed,

otherwise the boiler will not attempt to turn itself on. During

operation, the fan rotates at the speed set by the control P.C.B.;

if the number of rotations deviates by more than 300 rpm from

this setting, the boiler shuts off.

The draining of the heating system must be carried out as follows:

Turn off the boiler and the bipolar switch;

Loosen the automatic air release valve (27);

Open the system's discharge valve (18) and gather the water

that comes out in a container;

3. O^VERHEATING. This device shuts down the boiler in the event that

the primary circuit reaches a temperature that exceeds 100°C.

The operation of the overheat monitoring mechanism also

includes the following precautionary measures:

Empty out from the lowest points of the system (where

provided).

If the system is to be left active in areas where the room temperature

may go below 0°C during winter, it is recommended that anti-freeze

liquid be added to the water in the heating system in order to avoid

the need for repeated draining.

After every ignition, the system flow temperature or the

flow/return difference must increase by 3°C in 20 seconds. Until

an increase of 3°C is reached, the boiler remains at the ignition

power. If the increase in temperature does not come about, the

boiler shuts down and will not attempt to re-ignite until the flow

temperature is below 50°C. If after three attempts the

temperature does not increase, the boiler shuts down.

Draining the domestic hot water system

Every time that there is a danger of freezing, the domestic hot water

system must be drained as follows:

close the water mains stop-cock;

open all the hot and cold water outlets;

empty out from the lowest points (where provided).

Before the boiler attempts ignition, the system flow/return

temperature difference must be below 20°C. In order for a

successive attempt at ignition to be carried out, the system must

difference is below 5°C.

If, during operation the return temperature becomes greater than

the flow temperature by more than 5°C, the boiler shuts down

immediately.

4. D^AILYTEST. In order to prevent the shutdown of the components,

the boiler carries out a self-diagnosing test every 24 hours: the

pump turns on for 3 seconds and the diverter valve moves.

5. A^NTI-FROST DEVICE. The boiler is fitted with an anti-frost device

consisting of three separate functions:

Monitoring of the system flow temperature: if this temperature

goes below 5°C, the pump turns on (heating system circulation).

If the temperature goes below 2°C, the boiler turns on at the

minimum power and remains on until the return temperature is

over 10°C.

Outdoor sensor installed: the pump turns on if the external

275

4. GAS ADJUSTMENTS

NOTE: the values refer to the upper calorific power

4.1.

OVERALL VIEW

Type of appliance

Natural Gas

LPG

Marking on the label of characteristics

Further indications

Yellow adhesive label:

calibrated for LPG

Wo=24.3 Kw/m3

(from 20.2 to 24.3

kWh/m3)

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

50mbar

Factory setting for the Wobbe Wo index

in kWh/m3

24.3

11.5

14.1

Factory setting of the thermal capacity

for the production of hot water

Maximum thermal power

70% Maximum thermal power

Factory setting of the thermal capacity

for the heating

4.2.

PRELIMINARIES

Check that the indication for type of appliance (category and type of

gas calibration) reported on the label of characteristics corresponds

to the gas family / group of the gas supply.

The type of of appliance does not

correspond to the gas family of the

gas supply

The appliance cannot be installed or put into operation.

The type of appliance corresponds

to the gas family of the gas supply

Check the regulation according to section 4.3

In the event of the heating power setting being different from the

thermal power setting required, the gas must be adjusted as in

section 4.3. Otherwise, it is enough to check the

correspondence.

Domestic hot water:

Heating:

The type of appliance does not

correspond to the gas supply group

(but corresponds to the family).

Transform the boiler in accordance with section 4.5, after which:

Check the regulation in accordance with 4.3

Carry out the gas regulation in accordance with point 4.3 in

keeping with the thermal power requested.

Domestic hot water:

Heating:

4.3.2. REGULATION OF THE THERMAL POWER

4.3.

GAS REGULATION

To regulate the gas, the sequence described below must be followed.

For the regulation of the gas in the ecoGENUS, two separate

operations are required.

A) Domestic hot water side (test only)

B) Heating side (regulation and test)

Unscrew by 2 to 3 rotations the sealing screws marked “PE” of

the pressure measurement inlet nipple

Connect up a pressure gauge

Place the appliance in operation in accordance with the usage

manual

A) D^{OMESTIC HOT WATER}:

The thermal power for the hot water is set in the factory at the

maximum power.

Measure the connection pressure (dynamic pressure)

For this reason the boiler does not need any regulation of the gas

from the "domestic hot water" side, just a test using the volumetric

method at the gas meter:

4.3.1. INLET PRESSURE TEST

This pressure, for methane gas, must be between 18 and 25 mbar.

In the event that the pressure is outside of the above range, the

boiler must not be placed in operation.

Make sure that there are no other gas appliances in operation

during the test.

Place the boiler in operation in accordance with the usage

manual and draw hot water (tap totally open, temperature knob

at 9).

Turn off the boiler.

Remove the pressure gauge.

Screw in the sealing screws of the pressure measurement inlet

nipple and check the seal.

N^OTE: the test of the volumetric rate of flow must be carried out for at

least two minutes of boiler operating time.

If it proves impossible to eliminate the defect, contact the gas supply

board.

Identify the volumetric rate of flow for the maximum thermal

power from the table at the end of this section.

275

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.

fastening screws and lift up the rubber stopper protecting the

potentiometers (see section 3.7.1.). Rotate the potentiometer PR

to the desired point, checking the set thermal power on the

display (as described in section 3.6.3.) and on the table below.

Test:

Turn the selector knob “A” to the flue test position.

Do not draw hot water.

B) H^EATING:

N^OTE: The test of the volumetric rate of flow must be carried out for at

The thermal power is set in the factory at 70% of the maximum

power (the potentiometer corresponds to the value on the display). In

the event that this setting has to be changed, these steps should be

followed:

least five minutes of boiler operation.

Identify the volumetric rate of flow from the table and make a

note of it here.

Value from the table: ……….l/min.

Identify the volumetric rate of flow at the gas meter and compare

it with that of the table.

open the control panel after having unscrewed the plastic

4.4. CHANGING THE TYPE OF GAS

The boiler may be transformed for use with LPG (G30-G31); the

operation must be performed by an Authorised Service Centre.

The operations to carry out are the following:

1. Replacement of the nozzle (see table);

2. Replacement of the gas label;

3. Regulation of the slow ignition (refer to section 3.7 and the table

in 4.3)

Category

Thermal Capacity min/max

63AT4528

II2H3B/P

8/24

8.8/26.1

7.9/23.3

-/24.5

7.9/23.3

102.2

96.4

103.6

0.42

0.6

2.1

0.2

63AT4528

II2H3B/P

8/24

8.8/26.1

7.9/23.3

-/24.5

7.9/23.3

102.2

96.4

103.6

0.42

0.6

2.1

0.2

Usable Thermal Power min/max (30/40°C)

Usable Thermal Power min/max (60/80°C)

Usable Thermal Power min/max (30/50°C)

Power for Hot Water Production min/max

Efficiency at Nominal Thermal Capacity (30/50°C)

Efficiency at 30% of Nominal Thermal Capacity (47°C of return)

Efficiency at 30% of Nominal Thermal Capacity (30°C of return)

Gas Consumption after 10 Minutes*

m³

Maximum Heat Loss to the Casing (∆T=50°C)

Flue Heat Loss with Burner Operating

Flue Heat Loss with Burner Off

35.1

66.7

42.9

42/82

30/75

36/56

Maximum Discharge of Fumes

Kg/h

°C

35.1

66.7

42.9

42/82

30/75

36/56

Maximum Temperature of Discharge Fumes

Temperature of Discharge Fumes when Heating 30/40°C (1 m of coax.)

Minimum Room Temperature

Heating Temperature min/max (High Temperature range)

Heating Temperature min/max (Low Temperature range)

Temperature of Water for Domestic Use min/max

Class NOX

9.3

CO Content

9.3

O Content

53.5

0.65(64)

200

0.2

CO Content

ppm

mbar

mbar(Pa)

mbar

bar

53.5

0.65(64)

200

0.2

Inlet Pressure/Methane Gas G20 (boiler at maximum)

Inlet Pressure/Liquid Gas G30 - G31 (boiler at maximum)

Residual Discharge Head

Maximum Head Loss on Water Side (∆T=20°C)

Residual Head of System (60/80°C)

Maximum Heating Pressure

bar

130

Maximum Water Content in System

Expansion Vessel Capacity

130

Expansion Vessel Pre-load Pressure

Pressure of Water for Domestic Use min/max

Nominal Capacity of Hot Water for Heating (residual head 0.25 bar)

bar

l/h

l/min

l/h

0.2/8-10

820

---

1.8

0.2/8-10

820

13.4

11.1

9.6

D.H.W. Flow Rate:

∆T=25°C

∆T=30°C

∆T=35°C

D.H.W. Flow Minimum Rate

2.5

1.8

Quantity of Condensed Water with a (30/40°C)

pH Condensation Value

Electrical Supply

Power Consumption

Protection Grade of Electrical System

Internal Fuse Rating

3.5÷4

230/50

130

4XD

3.15 SLOW

465

890

385

3/4

3.5÷4

230/50

130

4XD

3.15 SLOW

465

V/Hz

Width

Height

Depth

890

385

3/4

1/2

3/4

Central Heating Connections

Domestic Hot Water Connections

Gas Connection

BSP

1/2

3/4

44.5

Net Weight

41-116-03

G.C. Number

41-116-17

Manufacturer:

Merloni TermoSanitari SpA - Italy

*Calculated at 70% maximum output

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: [email protected]

Technical Service Hot Line: (01494) 539579

23 99 84 1439 112

Servicing

Instructions

Type C Boilers

G.C.N: 41-116-03

47-116-17

Condensing

LEAVE THESE INSTRUCTIONS

WITH THE END-USER

Country of destination: GB

SERVICING INSTRUCTIONS

TABLE OF CONTENTS

1.1

1.2

REPLACEMENT OF PARTS

TO GAIN GENERAL ACCESS

- Lowering the control panel and removing the front panel

- Removing the side panels

1.3

A^{CCESS 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

1.4

1.5

A^{CCESS TO THE}GAS VALVE

- Removing the gas valve

A^{CCESS 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 diverter valve actuator

- Removing the D.H.W. flow switch

- Removing the pump

- Removing the pressure gauge

- Removing the expansion vessel

- Removing the D.H.W. temperature sensor (N.T.C.)

- Removing the C.H. flow temperature sensor (N.T.C.)

- Removing the C.H. return temperature sensor (N.T.C.)

1.6

A^{CCESS TO THE}CONTROL SYSTEM

- Checking the fuses

- Removing the time clock

- Removing the P.C.B.s

2.1

FAULT FINDING

FAULT FINDING GUIDE (FLOW-CHART)

ELECTRICAL DIAGRAMS

SHORT SPARE PARTS LIST

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).

After servicing, preliminary electrical system checks must be carried out to

ensure electrical safety (i.e. polarity, earth continuity, resistance to earth and

short circuit).

The life of individual components vary and they will need servicing or

replacing as and when faults develop.

The fault finding sequence chart in chapter 2 will help to locate which

component is the cause of any malfunction, and instructions for removal,

inspection and replacement of the individual parts are given in the following

pages.

1.1

1.2

REPLACEMENT

OF PARTS

All testing and maintenance operations on the boiler require the control panel

to be lowered. This will also require the removal of the casing.

TO GAIN GENERAL

ACCESS

To lower the control panel and dismantle the front part of the casing,

proceed as follows:

1. Unscrew screws “A” (1/4 turn only) (F^IG. 1.1 + FIG. 1.2) and rotate the

control panel forward;

2. Unscrew the screws “B” (FIG. 1.3) and unhook the front panel by lifting it.

FIG. 1.2

FIG. 1.1

FIG. 1.3

Removing the side panels

1.3

ACCESS TO THE

COMBUSTION CHAMBER

1. Remove the screws “C” (F^IG. 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” (F^IG. 1.5);

2. Pull the cover away from the boiler (FIG. 1.6).

FIG. 1.5

FIG. 1.4

FIG. 1.6

Removing the fan

1. Loosen nut “E” (F^IG. 1.7);

FIG. 1.9

2. Pull off the hose “F” and disconnect the electrical

connector “G” (FIG. 1.8);

3. Remove the nuts “H” (F^IG. 1.9);

4. Pull the fan away from the exchanger (FIG. 1.10).

FIG. 1.7

FIG. 1.10

FIG. 1.8

Removing the burner

With the fan removed (see previous section);

1. Slide the burner from its housing (F^IG. 1.11).

FIG. 1.14

Removing the combustion chamber inspection panel

FIG. 1.11

1. Remove the four nuts “K” (F^IG. 1.15);

2. Remove the inspection panel (FIG. 1.16).

Removing the electrodes

1. Pull off the ignition cable “I” (F^IG. 1.12);

2. Remove the two allen bolts “J” (FIG. 1.13);

3. Extract the electodes (F^IG. 1.14).

FIG. 1.15

FIG. 1.16

FIG. 1.12

FIG. 1.13

Removing the condensate collector

1. Remove the nuts “L” from each side of front of the

collector (F^IG. 1.17);

2. Remove the nuts “M” from each side of rear of the

collector (F^IG. 1.18);

3. Release the condesate trap union “N” (FIG. 1.19);

4. Separate the collector from the combustion

chamber(F^IG. 1.20);

5. Remove the condensate collector (FIG. 1.21).

FIG. 1.19

FIG. 1.17

FIG. 1.20

FIG. 1.18

FIG. 1.21

Removing the injector

Removing the condensate trap

See the section on removing the fan before carring out this

procedure

1. Loosen the union “O” (FIG. 1.22);

2. Remove the condensate trap (FIG. 1.23).

1. Disconnect all connections from the fan and remove

(F^IG. 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).

Fig. 1.24

FIG. 1.22

Fig. 1.23

Fig. 1.25

FIG. 1.26

FIG. 1.27

1.4

ACCESS TO THE GAS VALVE

Removing the gas valve

1. Disconnect the electrical connection “R” from the gas

valve (F^IG. 128);

2. Release the top nut “S” (FIG. 1.29);

3. Remove the screws “T” from the bottom of the gas valve

pipe (F^IG. 1.30);

4. Remove the gas valve (FIG. 1.31).

FIG. 1.30

FIG. 1.28

FIG. 1.31

FIG. 1.29

Removing the safety valve

1.5

ACCESS TO THE WATER CIRCUIT

1. Loosen union “W” (Fig. 1.35);

2. Unscrew and remove the valve (Fig. 1.36).

Important! Before any component is removed, the boiler

must be drained of all water.

Removing the D.H.W. (secondary)

exchanger

1. Remove the screw “U” (F^IG. 1.32);

2. Remove the screw “V” (F^IG. 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. Before replacing the exchanger ensure that the O-rings

are in good condition and replace if necessary.

FIG. 1.35

FIG. 1.32

FIG. 1.33

FIG. 1.36

FIG. 1.34

Removing the automatic air vent

Removing the diverter valve actuator

1. Unscrew valve “X” (F^IG. 1.37);

2. Remove (FIG. 1.38).

1. Unplug the electrical connector “Z” (F^IG. 1.41);

2. Release the retaining clip “A1” and remove the diverter

valve actuator (FIG. 1.42).

FIG. 1.41

FIG. 1.37

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” (F^IG. 1.40);

1. Release the retaining clip “B1” (F^IG. 1.43);

2. Remove the main circuit flow switch.

2. Remove the D.H.W. flow switch.

FIG. 1.43

FIG. 1.40

Removing the pump

1. Unplug the electrical connection “C1” (F^IG. 1.44);

2. Release the nut “D1” (FIG. 1.45);

3. Release the nut “E1” (FIG. 1.46);

4. Remove the pump (F^IG. 1.47).

FIG. 1.46

FIG. 1.44

FIG. 1.47

FIG. 1.45

Removing the pressure gauge

Removing the expansion vessel

See the section on removing the condesate trap before

carrying out this procedure

1. Release coupling “F1” (F^IG. 1.48);

2. Ease the pressure gauge “G1” through the control panel

from the rear (FIG. 1.49);

1. Loosen nut “H1” (F^IG. 1.51);

3. Remove the pressure gauge. (F^IG1.50).

2. Loosen nut “I1” and remove backnut “J1” (FIG. 1.52);

3. Remove the expansion vessel (FIG. 1.53).

FIG. 1.48

FIG. 1.51

FIG. 1.49

FIG. 1.52

FIG. 1.50

FIG. 1.53

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”

(F^IG. 1.55).

FIG. 1.57

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” (F^IG. 1.59).

FIG. 1.54

FIG. 1.55

FIG. 1.58

Removing the C.H. flow temperature probe (N.T.C.)

1. Remove the electrical connector “M1” by pulling off

(Fig. 1.56);

2. Unscrew and remove the C.H.flow temperature probe

“N1” (F^IG. 1.57).

FIG. 1.59

FIG. 1.56

Removing the time clock

1. Remove the inspection cover on the reverse of the

control panel (F^IG. 1.60);

1.6

ACCESS TO THE CONTROL SYSTEM

2. Lower the time clock door (FIG. 1.62);

3. Unplug the electrical connection “R1” from the time clock

(F^IG. 1.63);

Checking the fuses

1. Remove the inspection cover on the reverse of the

control panel (FIG. 1.60);

4. Gently squeeze each end of the time clock and push

through the control panel (FIG. 1.64).

2. Remove the fuses by pushing and rotating fuse holders

“Q1” (F^IG. 1.61).

FIG. 1.60

FIG. 1.62

FIG. 1.61

FIG. 1.63

FIG. 1.64

Removing the P.C.B.s

1. Remove the inspection cover on the reverse of the

control panel (F^IG. 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” (F^IG. 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) (F^IG. 1.70);

8. Remove the main P.C.B. (FIG. 1.71);

9. Remove the display P.C.B. mounting screws “W1’ (F^IG.

1.72);

10.Remove the display P.C.B. (F^IG. 1.73);

11.Replace either P.C.B. in reverse order.

FIG. 1.68

FIG. 1.65

FIG. 1.69

FIG. 1.66

FIG. 1.70

FIG. 1.67

FIG. 1.71

FIG. 1.72

FIG. 1.73

FAULT FINDING

It is possible to detect and correct any defect by using the standard fault

finding diagrams described in this chapter.

2.1

FAULT FINDING GUIDE

(FLOW-CHARTS)

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

IS THE

POWER L.E.D. AND

DISPLAY ON?

1. Check the fuses

2. Check the power supply to

the control panel

3. Check/replace the

ON/OFF button

4. Check the connection between

the main and display P.C.B.s

5. Check/replace the

YES

DOES A STOP CODE

APPEAR ON THE DISPLAY?

TABLE

I and II

main and display P.C.B.s

POSITION OF THE SUMMER/

WINTER SELECTOR

WINTER

SUMMER

COMFORT

SELECTOR ON/OFF:

green L.E.D. on

COMFORT

SELECTOR ON/OFF:

green L.E.D. on

YES: COMFORT ON

NO:

COMFORT OFF

NO:

YES YES

Flow

temperature

<40°C

Flow

temperature

<40°C

COMFORT OFF

NO NO

Flow

temperature

>50°C

Flow

temperature

>50°C

YES

D.H.W.

IS BEING

DRAWN?

D.H.W.

IS BEING

DRAWN?

YES

MUST

THE TIME CLOCK

AND/OR ROOM THERMOSTAT

BE ACTIVATED?

YES

BUILT-IN

ELECTRONIC

BUILT-IN

ELECTRONIC

ANTI-FROST DEVICE:

Is there a condition for it to be active?

(- flow temp. < 3°C

Is there a condition for it to be active?

(- flow temp. < 3°C

YES

- outdoor temp. < -3°C (outdoor sensor optional)

- Jumper 4 selects the pump

for continuous

- outdoor temp. < -3°C (outdoor sensor optional)

- Jumper 4 selects the pump

for continuous

operation)

THERE IS NO CALL FOR PUMP OPERATION

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

IS THE

POWER L.E.D. AND

DISPLAY ON?

1. Check the fuses

2. Check the power supply to

the control panel

3. Check/replace the

ON/OFF button

4. Check the connection between

the main and display P.C.B.s

5. Check/replace the

YES

DOES A STOP CODE

APPEAR ON THE DISPLAY?

TABLE

I and II

main and display P.C.B.s

POSITION OF THE SUMMER/

WINTER SELECTOR

SUMMER

WINTER

OFF (green L.E.D. off):

cylinder active

OFF (green L.E.D. off):

cylinder active

C.H. ONLY

SELECTOR

ON/OFF

C.H. ONLY

SELECTOR

ON/OFF

The

C.H. flow

temperature

The

C.H. flow

temperature

ON (green L.E.D. on):

cylinder excluded

ON (green L.E.D. on):

cylinder excluded

is lower than 80°C

and the temperature of the

cylinder is at least 5°C

below the one

is lower than 80°C

and the temperature of the

cylinder is at least 5°C

below the one

YES YES

selected.

MUST

THE TIME CLOCK

AND/OR ROOM THERMOSTAT

BE ACTIVATED?

YES

BUILT-IN

ELECTRONIC

BUILT-IN

ELECTRONIC

ANTI-FROST DEVICE:

Is there a condition for it to be active?

(- flow temp. < 3°C

Is there a condition for it to be active?

(- flow temp. < 3°C

YES

- outdoor temp. < -3°C (outdoor sensor optional)

- Jumper 4 selects the pump

for continuous

- outdoor temp. < -3°C (outdoor sensor optional)

- Jumper 4 selects the pump

for continuous

operation)

THERE IS NO CALL FOR PUMP OPERATION

Model 24 MFFI/24RFFI System

IS THE

PUMP RUNNING?

YES

POWER TO

THE PUMP?

YES

1. Check pump cable

2. Check/replace

main P.C.B.

THE MAIN

CIRCUIT FLOW SWITCH

WORKING CORRECTLY?

A21: does not close

A22: does not open

1. Check if there is air in

the system

2. Check the main circuit flow

switch operation

YES

3. Check the pressure on the

water gauge and fill system

to 1 bar

Release/replace

pump

YES

Push the

RESET button

Model 24 MFFI/24RFFI System

IS THE FAN

RUNNING?

DOES CODE

A33 APPEAR?

YES

1. Check the fan cable

2. Replace the fan

3. Replace the main P.C.B.

Replace

the main P.C.B.

1. Check/replace ignition

electrode

2. Check ignition cable

3. Check/replace the main P.C.B.

IGNITION

SPARKS ARE GENERATED

REGULARLY?

YES

1. Check the power supply

of the gas valve.

2. Check for an air

pressure signal

3. Check the gas pressure

on the burner

IS THE BURNER

ALIGHT?

4. Check the soft-light

adjustment

YES

5. Replace the gas valve

6. Check/replace the

main P.C.B.

BOILER HAS

SHUTDOWN?

YES

1. Table II

2. Press RESET

YES

THERE STILL

A PROBLEM?

1. Table III

NORMAL

OPERATION

TABLE I

DISPLAY

A01

C^AUSE

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

A02

A03

A07

A19

A20

A21

A22

A33

A99

The flow switch does not open

Problem with the fan

Problem with the electronic monitoring

TABLE II

DISPLAY

C^AUSE

E03

Flow temperature over 100°C while boiler is not in operation

(stand-by)

E56

E66

E04

E05

E08

E20

E21

E22

E23

E64

E74

E99

Heating flow temperature probe in open circuit

Heating flow temperature probe

Domestic hot water temperature probe in open circuit

Domestic hot water temperature probe in short circuit

Under floor heating temperature probe in open circuit

Flame detected with gas valve closed

Error in the electrical connection (live and neutral crossed)

Problem with the 50Hz power supply

Flame detection electrode short-circuited

Heating return temperature probe in open circuit

Heating return temperature probe in short circuit

Problem within the electronic system

TABLE III

F^AULTS

P^OSSIBLECAUSES

1. Drawing D.H.W:

Radiators heat up in summer

mode

- faulty 3-way valve

2. Drawing D.H.W:

Insufficient hot water temperature

- check C.H./D.H.W. temperature probes

- check gas pressures

- check water flow rate

- check secondary heat exchanger

3. Drawing D.H.W:

Noisy operation

- primary heat exchanger faulty or lime-scale deposits

- low heating system water pressure

- check gas pressures

- check C.H./D.H.W. temperature probes

4. Decrease/increase heating circuit

pressure

- check for leaks on the heating circuit

- faulty filling-loop

- faulty secondary heat exchanger

- expansion vessel faulty

5. When cold water tap turned off, the - drop in pressure in the water mains, with

boiler ignites

consequent water hammer

6. Insufficient radiator temperature

- check C.H. temperature probe

- check by-pass

- check gas pressures

L^EGEND:

A:JUMPER

3. ELECTRICAL

DIAGRAMS

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)

N^OTE: 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. It is recommended that this set-up not be

changed, unless under the following particular circumstances:

JUMPER 3: if the contact is closed, the Secondary Output (flying clamp

connected to connection C7; positions 1-9) controls a LPG valve

(optional).

JUMPER 4: if the contact is closed, the continuous operation of the pump is

selected. If the contact remains open, it has no effect and there is

no change in the operation of the boiler.

JUMPER 5: if the contact is closed, the signal transmitted by the connection of

the secondary output clasp (connected to C7; positions 1-9)

relates to a secondary pump (optional). If the contact remains

open, the output signal controls a zone valve (optional).

JUMPER 6: not used

JUMPER 7/8:

N.I.

CONFIGURATION

Central heating only

MFFI

Not used

RFFI System

I = inserted (contact closed)

N.I = not inserted (contact open)

N^OTE: it is essential that the operations involving setting of the jumpers be

carried out only with the device turned off.

B: Control microprocessor

C: Flame detection jumper (under no circumstances should this jumper be

moved from the 1-2 position)

D: Anti-cycling device (RA)

E: Maximum heating output regulation (PR)

F: Soft-light regulation (RLA)

G: Operating mode selector knob

H: Heating temperature adjustment

I: Domestic hot water temperature adjustment

J: Remote control module

K: Main microprocessor

L: Relay

M: Fuses (2 x 0.54 A SLOW)

N: Transformer (PRI: 230V-50Hz; SEK: 10V-0,8VA; SEK:10V-3,5VA; SEK:10V-

3,5VA;)

O: Fuses (2 x 3.15 A SLOW)

P: Earth

Q: Spark generator

R: Connection to the main P.C.B.

S: Comfort light

T: Programming keys

U: Comfort key

V: Alpha-numeric display

X: Set and reset key

W: Connection to PC

C1 = FAN

“Hall” sensor power supply 12V (red)

“Hall” sensor ground (blue)

Not used

Start of coil (black)

“Hall” sensor input (white)

End of coil (brown)

C2 = POWER SUPPLY

Earth (yellow/green)

Not connected

Neutral (blue)

Not connected

Live (brown)

C3 = CONNECTION TO ROOMSTAT

Input - 1

Input - 2

C4 = TIMER

3 V output

Timer ground

Timer output

Not connected

C5 = REMOTE CONTROL (Bus+/Bus-)

Input/output-1

Input/output-2

C6 = SENSOR CONNECTOR

Domestic hot water flow switch (grey)

Main circuit flow switch (grey)

Under floor heating thermostat (grey)

Heating flow sensor (grey)

Heating return sensor (grey)

Domestic hot water sensor (grey)

Not used: jumper

Outdoor sensor (grey)

Domestic hot water flow switch (grey)

10: Main circuit flow switch (grey)

11: Under floor heating thermostat (grey)

12: Flow sensor (grey)

13: Heating sensor (grey)

14: Domestic hot water sensor (grey)

15: Not used: under floor heating

16: Outdoor sensor (grey)

C7 = EQUIPMENT CONNECTIONS

Secondary output (optional)

Gas valve (white)

3-way valve neutral (white)

Pump (white)

Ionisation (black)

Not connected

Ground

Pump earth (yellow/green)

Secondary output (optional)

10: Gas valve (brown)

11: 3-way valve (domestic hot water) (brown)

12: 3-way valve (heating) (brown)

13: Pump (brown)

14: Not connected

15: Earth

16: Gas valve earth (yellow/green)

ecoGENUS 24 MFFI - ecoGENUS 24 RFFI

4. SHORT SPARE

PARTS LIST

ecoGENUS - 24 MFFI

56 49 51 52 55 54

53 52 51 50 49

48 47 46

108

107

106

301

302

301

105

104

103

102

101

100

14 15 16 17 18 19

29 30

311

313

312

331

332

336

335

333

334

333

24 MFFI

ecoGENUS - 24 MFFI

Key

no.

G.C. part

no.

ARISTON

Part No.

Description

E25 417

164 225

164 338

E25 427

E25 429

573294

573520

569236

997147

997077

998127

571438

998802

998144

573727

573172

573528

997207

571649

998765

569390

998672

998668

998459

998889

998888

998651

998077

998894

997206

997151

569387

573521

564264

998791

998792

573768

998801

998670

571444

571441

574248

998490

571987

571441

574248

571447

998013

Expansion vessel

Gasket 3/4"

Temperature probe (C.H.W.)

Motor (3-way valve)

Fixing clip (motor)

Flow group

Gas valve

Micro switch set (main flow & D.H.W.)

Return group

Manual vent cock

Safety valve 1/2" 3 bar)

Gasket 1/2"

Time clock

Pressure gauge

P.C.B. (display)

Gasket 1/4"

Electrode (ignition/detection)

Burner

Electrode cable (resistive)

Fan cable & sensor

Fan

Injector (G20)

O-ring gasket

Secondary exchanger (p-type 27kW)

O-ring (secondary exchanger)

Pump

Gasket 1"

Gasket 3/8"

Auto air vent

Condensate Trap

Cap (trap filling)

Gasket (airtight - condensate trap)

P.C.B. (main)

Main exchanger (aluminium)

D.H.W. actuator Kit

Heating pressure switch kit

Pressure cover

Central heating by-pass kit

D.H.W. pressure switch kit

Heating pressure switch kit

Pressure cover

378 814

E26 378

164 229

E26 819

E25 437

164 261

E26 657

E26 658

E25 518

164 230

164 282

379 079

106

311

312

313

331

332

333

334

335

336

E25 581

E24 077

3-way spring kit

Heating actuator bush

ecoGENUS - 24 RFFI SYSTEM

57 50 52 53 56 55

54 53 52 51 50

49 48 47

106

105

104

301

302

301

103

102

101

100

15 16

17 18 19 20

21 22 21

24 25

30 31

331

336

335

332

333

334

333

24 RFFI SYSTEM

ecoGENUS - 24 RFFI SYSTEM

Key

no.

G.C. part

no.

ARISTON

Part No.

Description

E25 417

164 225

164 338

E25 427

E25 429

573294

573520

569236

997147

997077

998456

571438

573528

997828

573727

573172

997207

571649

998765

569390

998672

998668

998889

998888

998651

998783

997151

569387

573521

998791

573768

998792

564254

998459

998801

998670

571987

571443

571441

574248

571447

998013

Expansion vessel

Gasket 3/4"

Temperature probe (C.H.W.)

Motor (3- Way valve)

Fixing clip (motor)

Flow group

Gas valve

Gasket 1/2"

Return group

Manual vent cock

Safety valve 1/2" 3 bar)

Time clock

Pressure gauge

P.C.B. (display)

Gasket 1/4"

Electrode (ignition/detection)

Burner

Fan cable & sensor

Fan

75A

75B

164 229

378 814

E26 378

E26 819

E25 437

164 261

Injector (G20)

Injector (G30)

Pump

Gasket 1"

E25 518

164 230

164 282

Gasket 3/8"

Condensate Trap

Gasket (airtight - condensate trap)

Cap (trap filling)

Auto air vent

Electrode cable (resistive)

P.C.B. (main)

Main exchanger (aluminium)

D.H.W. pressure switch kit

Central heating by-pass kit

Heating pressure switch kit

Pressure cover

379 079

104

331

332

333

334

335

336

E24 077

3-way spring kit

Heating actuator bush

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: [email protected]

Technical Service Hot Line: (01494) 539579

SPARE PARTS EXPLODED VIEW

GAS WALL BOILERS

Models

ECOGENUS 24 MFFI

Edition 1 of 1 December 1999

56 49 51 52 55 54

53 52 51 50 49

48 47 46

108

107

106

301

302

301

105

104

103

102

101

100

14 15 16 17 18 19

29 30

code 998144

code 571438

311

313

312

code 998127

331

332

336

335

333

MODELS

ECOGENUS 24 MFFI

CHARACTERISTICS

SERIAL NO:

VALIDITY

REF.

334

333

METHANE

9933500098

PART. CODE DESCRIPTION

REF.

NOTE

573294 Expansion vessel

573310 Expansion vessel insert

574302 Casing support bracket (Plastic)

573244 3/8" lock nut

------

Frame

Hydraulic group support

573520 Gasket 3/4"

569236 Temperature probe (C.H.W.)

998655 Pipe (C.H. flow)

998656 Pipe (gas valve/burner jet)

997147 Motor (3-Way valve)

997077 Fixing clip (motor)

998127 Flow group

570615 1/8" Brass plug

571438 Gas valve

565048 O-ring gasket (gas valve)

998665 Union (gas valve)

573793 Intake (pressure - control valve)

573824 Bracket (M/Flow Micro Switch)

998802 Micro switch set (main flow & D.H.W.)

998144 Return group

573727 Manual vent cock

573172 Safety valve (1/2" 3 bar)

573528 Gasket 1/2"

573311 Pipe (expansion vessel)

998674 Wiring (power supply)

573302 Summer/Winter selector kit

998747 Control knob kit

998661 Door (instruction/time clock)

997207 Time clock

998772 On/off push button kit

998778 Control panel (front)

998751 Button (reset)

999073 Cover (display)

998766 Film (display)

998381 Pin (front cover)

998739 Fixing spring (front cover)

571649 Pressure gauge

------

Control panel

571562 Cable clamp

998765 P.C.B. (display)

569390 Gasket 1/4"

------

Cover (connectors)

999060 Low voltage wiring

998676 High voltage wiring

998076 View window glass gasket

998075 View window glass

574104 Panel (sealed chamber - front)

573247 Panel (sealed chamber - side)

------

Sealed chamber

573865 Flue gasket

573330 Air return cover

573326 Flue intake plug

998474 Flue exhaust manifold / header

573337 Gasket (flue manifold)

572984 Casing support bracket

570717 Spring (fastening)

998666 Nipple (gas - 3/4" M/M)

998785 Dowel (M6x35)

998782 View window glass

998775 Retaining ring (D=16mm)

998672 Electrode (Ignition/Detection)

998767 Cap (electrodes)

998668 Burner

998680 Gasket (elbow)

PART. CODE DESCRIPTION

REF.

NOTE

998788 Elbow (fan)

------ Flame mirror

998786 Diaphragm (condensing boiler)

998654 Pipe (C.H. return)

998459 Electrode cable (resistive)

999071 Pipe (fan suction silencer)

998889 Fan cable & sensor

998888 Fan

998681 Gasket (fan inlet)

998651 Injector (G20)

570772 Cable holder

998065 By-pass pipe

998077 O-ring gasket

998064 Spring (by-pass pipe)

573295 Secondary exchanger (p-type 27kW)

573825 O-Ring (secondary exchanger)

573576 Compensation tube

997151 Pump

569387 Gasket 1"

998019 Pipe (safety valve outlet)

998567 Safety valve outlet pipe ring nut

573521 Gasket 3/8"

998413 Pipe (condensate - plastic)

564254 Auto air vent

998791 Condensate Trap

998792 Cap (trap filling)

573768 Gasket (airtight - condensate trap)

998412 Pipe (drain - plastic)

998787 Condensate tray (aluminium)

998808 Gasket (adhesive - 10x5 mm)

998784 Fixing nut (tray rear)

998801 P.C.B. (main)

998382 Grommet (regulation access)

569720 Blind grommet

100

101

102

103

104

105

106

107

108

998653 L.E.D. lens

569424 On/off neon switch

998460 Gasket (igniter insulation)

998777 Aluminium inspection lid

573766 Front cover gasket

------

998670 Main exchanger (aluminium)

------ Top fixing bracket

Bottom fixing bracket

998423 Lip gasket (D=66 mm)

301

302

998414 Case panel (side)

998478 Case panel (front)

311

312

313

571444 D.H.W. actuator Kit

571441 Heating pressure switch kit

574248 Pressure cover

331

332

333

334

335

336

998490 Central heating by-pass kit

571987 D.H.W. pressure switch kit

571441 Heating pressure switch kit

574248 Pressure cover

571447 3-Way spring kit

998013 Heating actuator bush

NOTE DESCRIPTION

Not supplied as a spare part

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