Technical information | Ariston 41-116-01 Boiler User Manual

Installation Instructions
Type C Boilers
G.C.N:
41-116-01
47-116-08
47-116-09
47-116-13
LEAVE THESE INSTRUCTIONS
ADJACENT TO THE GAS METER
Country of destination: GB
TABLE OF CONTENTS
1.
GENERAL INFORMATION
1.1 General Instructions
1.2 Technical Information
1.3 Overall View
2.
INSTALLATION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
Reference Standards
Siting the Appliance
Overall Dimensions
Clearances
Mounting the Appliance
Electrical Connection
Gas Connection
Water Connections
Flue Connection
Room Thermostat Connection
Electrical/System Diagrams
Water Circuit Diagrams
3.
COMMISSIONING
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Initial Preparation
Removing the Casing
Control Panel
Initial Start-up
Operational Adjustments
Combustion Analysis
Fume Discharge Monitoring
Boiler Safety Systems
Draining the System
4.
GAS ADJUSTMENTS
- Gas Adjustment Table
4.1 Changing the Type of Gas
5.
MAINTENANCE
6.
MISCELLANEOUS
6.1 Wiring Diagram for Two Heating Zones
6.2 Wiring Diagram for Connection to Ariston Unvented Cylinder
2
B004
1.
GENERAL
INFORMATION
This manual is an integral and essential part of the product. It should be kept
with the appliance so that it can be consulted by the user and our authorised
personnel.
Please carefully read the instructions and notices about the unit contained in
this manual, as they provide impor tant information regarding the safe
installation, use and maintenance of the product.
For operating instructions please consult the separate User’s Manual.
User’s
Manual
1.1
General Information
Read the instructions and recommendations in these Installation Instructions
carefully to ensure proper installation, use and maintenance of the appliance.
Keep this manual in a safe place. You may need it for your own reference while
our Servicing Centre technicians or your installer may need to consult it in the
future.
This is a combined appliance for the production of central heating (C.H.) and
domestic hot water (D.H.W.).
This appliance must be used only for the purpose for which it is designed.
The manufacturer declines all liability for damage caused by improper or
negligent use.
No asbestos or other hazardous materials have been used in the fabrication of
this product.
Before connecting the appliance, check that the information shown on the data
plate and the table on pages 4-5 comply with the electric, water and gas mains
of the property. You will find the data plate on the reverse of the control panel.
The gas with which this appliance operates is also shown on the label at the
bottom of the boiler.
Do not install this appliance in a damp environment or close to equipment
which spray water or other liquids.
Do not place objects on the appliance.
Do not allow children or inexperienced persons to use the appliance without
supervision.
If you smell gas in the room, do not turn on light switches, use the telephone or
any other object which might cause sparks.
Open doors and windows immediately to ventilate the room.
Shut the gas mains tap (on the gas meter) or the valve of the gas cylinder and call
your Gas Supplier immediately.
If you are going away for a long period of time, remember to shut the mains gas
tap or the gas cylinder valve.
Always disconnect the appliance either by unplugging it from the mains or
turning off the mains switch before cleaning the appliance or carriyng out
maintenance.
In the case of faults or failure, switch off the appliance and turn off the gas
tap. Do not tamper with the appliance.
For repairs, call your local Authorised 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 seal of water connections, replacing the gaskets if necessary.
2 - Check the seal of the gas connections, replacing the gaskets if necessary.
B004
3
3 - Check the general condition of the appliance and of the combustion
chamber visually.
4 - Visual check of the combustion: clean burners if necessary.
5 - With reference to point 3, dismantle and clean the combustion chamber if
necessary.
6 - With reference to point 4, dismantle and clean the injectors if necessary.
7 - Visual check of the primary heat exchanger:
- check for overheating of the exchangers fins;
- clean the exhaust side of the exchanger and fan if necessary.
8 - Regulate the gas pressure, ignition pressure, partial flame, maximum flame.
9 - Check proper operation of the heating safety system:
- maximum safety temperature;
- maximum safety pressure.
10 - Check the proper operation of the gas safety system:
- gas or flame safety device;
- gas valve safety device.
11 - Check that the electrical connections have been made in compliance with
the instructions shown in the Installation Instructions.
12 - Check the efficiency of the hot water supply (flow and temperature).
13 - Check general operation of the appliance.
14 - Check the exhaust system for the combustion products.
1.2
Technical Information
23 MFFI
27 MFFI
27 RFFI SYSTEM
30 MFFI
25.6/11.0
23.1/9.2
90.2
87.8
1.2
8.6
0.4
59
1.15
2.72/3.32
0.32/0.39
2.02/2.00
29.8/12.0
27.3/10.1
91.6
88.3
1.3
7.1
0.4
62
1.4
3.16/3.86
0.37/0.45
2.35/2.32
29.8/12.0
27.3/10.1
91.6
88.3
1.3
7.1
0.4
62
1.4
3.16/3.86
0.37/0.45
2.35/2.32
33.0/12.0
30.3/10.2
92.0
88.6
1.4
6.6
0.4
61
1.4
3.49/4.05
0.41/0.47
2.60/2.57
°C
%
137
5.8
128
6.6
128
6.6
135
7.5
O2 Content
%
9.2
8.0
8.0
8.0
CO Content
Minimum Ambient Temperature
Head Loss on Water Side (max) (³T=20°C)
Residual Head of System
Heating Temperature
Domestic Hot Water Temperature
D.H.W. Flow Rate ³T=35°C
D.H.W. Flow Rate ³T=35°C
D.H.W. Flow Minimum Rate
Pressure of Domestic Hot Water
Expansion Vessel Capacity
Expansion Vessel Pre-load Pressure
Maximum Water Content in System
Maximum Heating Pressure
Nominal Pressure Natural Gas (G20-G25)
Liquid Gas (G30-G31)
Electrical Supply
Power Consumption
Protection Grade of Electrical System
Internal Fuse Rating
Weight
ppm
°C
mbar
bar
max/min °C
max/min °C
l/min
gal/min
l/min
max/min bar
l
bar
l
bar
mbar
mbar
V/Hz
W
IP
32
+5
200
0.25
82/42
56/36
9.5
2.1
2.6
6/0.2
7
1
145
3
20-25
30-37
230 / 50
150
X4D
FAST 2 AT
47
34
+5
200
0.25
82/42
56/36
11.2
2.5
2.6
6/0.2
7
1
145
3
20-25
30-37
230 / 50
190
X4D
FAST 2 AT
47
34
+5
200
0.25
82/42
----------7
1
145
3
20-25
30-37
230 / 50
190
X4D
FAST 2 AT
46.5
49
+5
200
0.25
82/42
56/36
12.3
2.7
2.6
6/.02
7
1
145
3
20-25
30-37
230 / 560
190
X4D
FAST 2 AT
47
47-116-08
47-116-09
41-116-01
47-116-13
CE Certification
Heat Input
Heat Output
Efficiency of Nominal Heat Input
Efficiency at 30% of Nominal Heat Input
Heat Loss to the Casing (³T=50°C)
Flue Heat Loss with Burner Operating
Flue Heat Loss with Burner Off
Maximum Discharge of Fumes (G20-G25)
Residual Discharge Head
Consumption at Nominal Capacity (G20-G25)
Gas Consumption after 10 Minutes*
(15°C, 1013 mbar) (G30-G31)
Temp. of exhaust fumes at nominal
capacity (G20-G25)
CO2 Content
G.C. Number
*Calculated at 70% maximum output
4
max/min kW
max/min kW
%
%
%
%
%
Kg/h
mbar
m3/h
m3
Kg/h
Kg
B004
1.3
Overall View
GENUS 23/27/30 MFFI
GENUS 27 RFFI SYSTEM
Fig. 1.1
Legend:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
B004
Flue Connector
Combustion Chamber Hood
Main Heat Exchanger
Combustion Chamber Insulation Panel
Burner
Expansion Vessel
Overheat Thermostat
Spark Generator
Diverter Valve
(MFFI)
Motorised Valve
(RFFI)
Main Circuit Temperature Probe
Main Circuit Flow Switch
Domestic Hot Water Temperature Probe
Diverter Valve Microswitch
Filter Seat
Drain Valve
Secondary Heat Exchanger
Safety Valve (3 bar)
Circulation Pump with Automatic Air Release Valve
Gas Valve
Detection Electrodes
Ignition Electrodes
Fan
Venturi
Air Pressure Switch
5
2.
2.1
INSTALLATION
Reference Standards
The technical information and instructions provided herein below are intended
for the installer so that the unit may be installed correctly and safely.
The installation and initial startup of the boiler must be by a CORGI Approved
Installer in compliance with the installation standards currently in effect, as well
as with any and all local health and safety standards i.e. CORGI.
This appliance must be installed by a competent installer in
accordance with the current Gas Safety (installation & use)
Regulations
The installation of this appliance must be in accordance with the relevant
requirements of the current Gas Safety (installation & use) Regulations, the
Local Building Regulations, the current I.E.E. 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
Boilers of rated input
not exceeding 60 kW
BS 6798
Forced circulation hot
water system
BS 5449
Installation of gas hot water
supplies for domestic purposes
( 2nd family gases)
BS 5546
Flues
BS 5440-1
Air supply
BS 5440-2
2.2
Siting the Appliance
1988
1987
1990
1990
1990
1989
The appliance may be installed in any room or indoor area, although particular
attention is drawn to the requirements of the current I.E.E. Wiring Regulations,
and in Scotland, the electrical provisions of the Building Regulations applicable
in Scotland, with respect to the installation of the combined appliance in a room
containing a bath or shower.
Where a room-sealed appliance is installed in a room containing a bath or
shower the boiler and any electrical switch or appliance control, utilising
mains electricity should be situated so that it cannot be touched by a
person using the bath or shower.
The location must permit adequate space for servicing and air circulation
around the appliance as indicated in paragraph 2.4.
The location must permit the provision of an adequate flue and termination.
For unusual locations special procedures may be necessary.
BS 6798-1987 gives detailed guidance on this aspect.
A compartment used to enclose the appliance must be designed specifically for
this purpose. No specific ventilation requirements are needed for an installation
within a cupboard
This appliance is not suitable for outdoor installation.
The type C appliances (in which the combustion circuit, air vent intake
and combustion chamber are air-tight with respect to the room in which
the appliance is installed) can be installed in any type of room.
There are no limitations with respect to ventilation and the volume of the room
itself. The boiler must be installed on a solid, permanent wall to prevent access
to the electrical parts (when live) through the aperture on the back frame.
6
B004
GENUS 23/27/30 MFFI
Overall Dimensions
890
2.3
(A-B-D-E)
(C)
GENUS 27 RFFI SYSTEM
5
38
465
30
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”)
99
85
99
(F - G)
155
132
AF
67
65
49
Legend:
(A - D - E)
(C)
208
C DGE
Fig. 2.1
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 clearance requirements indicated in the
diagram below.
GENUS 27 RFFI SYSTEM
160
197
400
110
GENUS 23/27/30 MFFI
60
60
0 nx-5 ai3 m
450
300
Fig. 2.2
B004
7
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)
Fig. 2.3
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
earth symbol; make sure to re-use the ferrule mounted on the other supply
cord;
- The blue wire should be connected to the terminal marked “N”;
- The brown wire should be connected to the terminal marked “L”.
Note: The diagrams for the electrical system are indicated in section 2.11.
Warning, this appliance must be earthed.
External wiring to the appliance must be carried out by a qualified technician
and be in accordance with the current I.E.E. Regulations and applicable local
regulations. The Genus range of boilers are supplied for connection to a 230 V~
50 Hz supply.
The supply must be fused at 3 A.
The method of connection to the electricity supply must facilitate complete
electrical isolation of the appliance, by the use of a fused double pole isolator
having a contact separation of at least 3 mm in all poles or alternatively, by
means of a 3 A fused three pin plug and unswitched shuttered socket outlet
both complying with BS 1363.
The point of connection to the Electricity supply must be readily accessible and
adjacent to the appliance unless the appliance is installed in a bathroom when
this must be sited outside the bathroom.
2.7
8
Gas Connection
The local gas supplier contractor connects the gas meter to the service pipe.
If the gas supply for the boiler serves other appliances ensure that an adequate
supply is available both to the boiler and the other appliances when they are in
use at the same time.
Pipe work must be of an adequate size. Pipes of a smaller size than the boiler
inlet connection should not be used.
B004
2.8
Water Connections
View of the Boiler Connections
GENUS 23/27/30 MFFI
GENUS 27 RFFI SYSTEM
C
C
A
B
D
E
A
D
I
I
F
Legend
E
G
Fig. 2.4
A = Central Heating Flow
B = Domestic Hot Water Outlet
C = Gas Inlet
D = Domestic Cold Water Inlet
E = Central Heating Return
F = Cylinder Flow
G = Cylinder Return
I = Safety Valve
Fig. 2.5
Fitting the connection kit to the
Genus 27 RFFI System only.
It will be noted that the kit has two
connections not required for this boiler
i.e. the domestic cold inlet “E” and the
domestic hot water outlet “B” (see fig.
2.4).
Although the cold water main supply
must be connected to the isolation valve
for the purpose of operating the fillingloop, the isolation valve is NOT
connected to the boiler and should be left
in the OFF position.
The D.H.W. outlet is capped-off on the
boiler, therefore not requiring the
isolation valve to be used.
The Genus 27 RFFI System has 2 x 3/4"
B.S.P. male threads for the cylinder flow
and return. It is recommended that 2 x
22mm x 3/4" female iron fittings (not
supplied) be used on these connections
(using P.T.F.E. tape), before the boiler is
mounted on the wall.
B004
Central Heating
Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990,
the following notes are given for general guidance.
Pipe Work:
Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing
should be either with capillary soldered or compression fittings.
Where possible pipes should have a gradient to ensure air is carried naturally
to air release points and water flows naturally to drain taps.
The appliance has a built-in automatic air release valve, however it should be
ensured as far as possible that the appliance heat exchanger is not a natural
collecting point for air.
Except where providing useful heat, pipes should be insulated to prevent heat
loss and avoid freezing.
Particular attention should be paid to pipes passing through ventilated spaces
in roofs and under floors.
By-pass:
The appliance includes an automatic by-pass valve, which protects the main
heat exchanger in case of reduced or interrupted water circulation through
the heating system, due to the closing of thermostatic valves or cock-type
valves within the system.
System Design:
This boiler is suitable only for sealed systems.
Drain Cocks:
These must be located in accessible positions to permit the draining of the
whole system. The taps must be at least 15mm nominal size and
manufactured in accordance with BS 2870:1980.
Safety Valve Discharge:
The discharge should terminate facing downwards on the exterior of the
building in a position where discharging (possibly boiling water & steam) will
not create danger or nuisance, but in an easily visible position, and not cause
damage to electrical components and wiring.
The discharge must not be over an entrance or a window or any other type of
public access.
9
Air Release Points:
These must be fitted at all high points where air naturally collects and must
be sited to facilitate complete filling of the system.
The appliance has an integral sealed expansion vessel to accommodate the
increase of water value when the system is heated.
It can accept up to 7 l (1.5 gal) of expansion water. If the heating circuit has
an unusually high water content, calculate the total expansion and add an
additional sealed expansion vessel with adequate capacity.
Mains Water Feed - Central Heating:
There must be no direct connection to the mains water supply even through a
non-return valve, without the approval of the Local Water Authority.
Filling:
A temporary method for initially filling the system and replacing lost water
during servicing and initial filling (in accordance with Water Supply Byelaw
14), is provided as an intergal part of the connection kit (see fig. 2.5). The
flexible hose must be removed once the system has been filled. The D.H.W.
inlet valve on the connection kit has two postions, one for winter and one for
the summer. This enables the flow-rate through the appliance to be adjusted
so that a sensible D.H.W. temperature may be achieved throughout the year.
Domestic Water
The domestic water must be in accordance with the relevant recommendation
of BS 5546:1990. Copper tubing to BS EN 1057:1996 is recommended for
water carrying pipe work and must be used for pipe work carrying drinking
water.
Residual Head of the Boiler
27/30 kW
23 kW
2.9
10
Flue Connections
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 ter minal 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.
B004
A suitable terminal guard is available from:
TOWER FLUE COMPONENTS
Morley Road
Tonbridge
Kent TN9 1RA
The minimum acceptable spacing from the terminal to obstructions and
ventilation openings are specified in Fig. 2.6
BC
F
G
F D
HI
J
A
E
L
K
TERMINAL POSITION
mm
A - Directly below an open window or other opening
B - Below gutters, solid pipes or drain pipes
C - Below eaves
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
K - Vertically from a terminal in the same wall
L - Horizontally from a terminal in the same wall
300
75
200
200
75
300
300
600
1200
G
Fig. 2.6
1200
1500
300
The boiler is designed to be connected to a coaxial flue discharge system.
Ø 60/100 mm
Fig. 2.7
B004
11
In addition, it is also possible to use a split system by fitting a special adapter to
the flue discharge collar and using one of the apertures for the air vent intake
located on the top part of the combustion chamber (A).
Ø 80 mm
A
A
A
Ø 80 mm
Fig. 2.8
This procedure must be done as follows:
1 - Remove the air vent intake you want to use, in the area indicated in
Fig. 2.9, by breaking the perforated ring.
2 - Use a tool to grasp the lid and remove it completely.
3 - Clean any burrs or sharp edges with a knife or an appropriate tool.
A
Fig. 2.9
12
Fig. 2.10
B004
In Fig. 2.11 below, several different types of flue systems are shown.
For additional information regarding the flue accessories, please consult the
Flue Pipe Accessories manual.
Fig. 2.11
B004
13
Coaxial
Systems
Twin Pipe
Systems
Exhaust Type
30 kW
Use of Restrictor on Discharge Side
L * < 0.5 m
27 kW
L * < 0.5 m
23kW
L * < 0.5 m
45 mm
30 kW
ø 60/100
42 mm
23kW
27 kW
3m
Diameter of
Pipes
(mm)
4m
L * < 0.5 m
Maximum Extension
Exhaust/Air
23 kW - 27 kW
30kW
C12 (xx)
L * < 0.5 m
L > 4.5 m
L * < 0.5 m
L > 6.5 m
L > 4.5 m
ø 60/100
L > 4.9 m
L > 6.5 m
L > 4.5 m
3m
L < 7.5 m
L > 4.9 m
L > 6.5 m
L > 4.5 m
4m
L<5m
L < 7.5 m
L > 4.9 m
L < 5.3 m
C32 (xx)
L<7m
L<5m
L < 7.5 m
L > 4.9 m
L * < 0.5 m
30 kW
ø 80
L<7m
L<5m
L < 7.5 m
L * < 0.5 m
27 kW
50 m
ø 80
L<7m
L<5m
L * < 0.5 m
23 kW
46 m
50 m
ø 80
L<7m
ø 60/100
54 m
46 m
50 m
ø 80
3m
C12 (xy)
54 m
46 m
15 m
4m
C32 (xy)
54 m
17 m
C42 (xx)
C42 (xy)
17 m
Risk of Condensation Forming
(*) L = Length of Piping
14
C52 (xy)
In calculating the lengths of the
pipes, the maximum length must also
take into consideration the values for
the exhaust/air intake end terminals,
as well as 90° elbows for coaxial
systems.
The C52 types must comply with the
following requirements:
1. The discharge/intake vent pipes
must have the same diameter of ø
80 mm.
2. The maximum combined flue
length is 17 m for Models Genus
23/27 MFFI/RFFI and 15 m for
Model Genus 30 MFFI. In this case
the minimum length for the air
intake pipe is 1 meter ; the
maximum length of ver tical
exhaust pipe must be a maximum
of 12 m.
3. If an elbow is inserted into the
discharge/ventilation system, the
calculation of the overall extension
must take into consideration the
values for each curve, as indicated
in the table.
4. The exhaust pipe must extend at
least 0.5 m above the ridge of the
roof if it is located on a side other
than that for the air intake (this is
not obligatory if the exhaust and air
intake pipes are located on the
same side of the building).
B004
2.10 Room Thermostat
Connection
In order to perform this procedure, remove the boiler casing as indicated in
section 3.2. Then proceed as follows:
1 Remove the two screws “A” in order to remove the cover, release the two
clips “B” and lift and rotate down the control panel box.
2 Open the cover “C” on the left hand side of the compartment.
3 Insert the wire for the connection of the room thermostat into the cable
clamp “D”, as indicated in photo 3.
1
2
B
3
D
C
A
4 Remove the grommet “E” shown in the photo 4, make a hole in it and pass
the room thermostat wire through.
5 Remove the link located in the terminal block and connect the wire.
6 Replace the grommet and the terminal block to their original positions, close
the cover on the grommet compartment and fasten the wire-clamp “D” in
place.
7 If a remote time clock is to be fitted, disconnect the integral time clock plug
from the P.C.B.
8 Using a volt-free switching time clock, connect the switching wires from the
time clock following points 1-6 above.
9 If using a time clock and room thermostat, these must be connected in
series as per points 1-8 above.
Note: Only a two-wire type room thermostat can be used.
For details on fitting the D.H.W. probe (Genus 27 RFFI only),
please consult the separate instruction sheet supplied with the
probe.
An anti-frost device is built-in to the appliance’s electronic
regulation system.
4
5
E
B004
6
D
15
2.11
Electrical Diagram
Legend:
AT
BT
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Aa
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
High Voltage P.C.B.
Low Voltage P.C.B.
Remote Connector Kit
Flame Failure L.E.D.
Insufficient Water Pressure L.E.D.
Water Temperature Indicator L.E.D.s
Overheat Thermostat Warning L.E.D.
System Reset Button
Selector Knob for Operating Mode
Domestic Hot Water Temp. Adjustment
Central Heating Temp. Adjustment
Wire Connector for Room Thermostat
Connector for Total Check System
Selector for Local/Remote Control
Anti-cycling Device Adjustment for Heating
Soft-light Adjustment
Max Heating Temperature Adjustment
Time Clock Connection
On/Off L.E.D.
On/Off Switch
Interface Wire for P.C.B.s
Relay Motorised Valve
Ignitor Relay
Gas Valve Relay
Fan Relay
Circulation Pump Relay
Selector TCS2
Link for Continuous Pump Run
Adaptor (British Gas use only)
A01 =
A02 =
A03 =
A04 =
A05 =
A06 =
A07 =
A08 =
A09 =
A10 =
A11 =
A12 =
Air Pressure Switch
Fan
Gas Valve
Ignitor
Motorised Valve
Circulation Pump
Flame Detector
Earth Terminal
Flame Detection Circuit
Flame Indicator L.E.D.
Transformer
Filter
B01 =
B02 =
B03 =
B04 =
Over Heat Thermostat
External Thermostat
Gas Valve Modulator
D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only)
B05 =
B06 =
B07 =
Heating Sensor
Pressure Switch for Heating Circuit
Microswitch for Diverter Valve (MFFI models only)
Colours
Gry
Rd
Bl
Grn/Yll
Wh
Brn
Blk
Wh/Rd
16
= Grey
= Red
= Blue
= Yellow/Green
= White
= Brown
= Black
= White/Red
B004
GENUS 23/27/30 MFFI
Aa
GENUS 27 RFFI SYSTEM
Aa
B004
17
GENUS 23/27/30 MFFI
CN202
P
GENUS 27 RFFI SYSTEM
P
18
B004
2.12
Water Circuit Diagram
GENUS 23/27/30 MFFI
Legend
1. Air Pressure Switch
2. Fan
3. Main Heat Exchanger
4. Burner
5. Electronic Ignitor and
Electronic Flame Detector
6. Gas Valve
7. Overheat Thermostat
8. Heating Sensor
9. Diverter Valve (MFFI)
Motorised Valve (RFFI)
10. Main Flow Switch Including
Safety Pressure Switch for
Primary Circuit
11. Automatic By-pass
12. Microswitch for Diverter Valve
13. Sensor for Domestic Hot Water
14. Secondary Heat Exchanger
15. Domestic Water Inlet Filter
16. Drain Valve
17. Safety Valve
GENUS 27 RFFI SYSTEM
18. Water Pressure Gauge
19. Circulation Pump with Automatic
Air Valve
20. Expansion Vessel
A. Central Heating Flow
B. Domestic Hot Water Outlet
C. Gas Inlet
D. Domestic Cold Water Inlet
E. Central Heating Return
F. Cylinder Flow
G. Cylinder Return
B004
19
3.
COMMISSIONING
3.1
Initial Preparation
Preliminary electrical system checks to ensure electrical safety must be carried
out by a competent person i.e. polarity, earth continuity, resistance to earth and
short circuit.
Filling the Heating System:
Remove the panels of the case and lower the control panel (see point 3.2. for
further information).
Open the central heating flow and return cocks supplied with the connection
kit.
Unscrew the cap on the automatic air release valve one full turn and leave
open permanently.
Close all air release valves on the central heating system.
Gradually open valve(s) at the filling point (filling-loop) connection to the
central heating system until water is heard to flow, do not open fully.
Open each air release tap starting with the lower point and close it only when
clear water, free of air, is visible.
Purge the air from the pump by unscrewing anticlockwise the pump plug and
also manually rotate the pump shaft in the direction indicated by the pump
label to ensure the pump is free.
Close the pump plug.
Continue filling the system until at least 1 bar registers on the pressure
gauge.
Inspect the system for water soundness and remedy any leaks discovered.
Filling of the D.H.W. System:
Close all hot water draw-off taps.
Open the cold water inlet cock supplied with the connection kit.
Open slowly each draw-off tap and close it only when clear water, free of
bubbles, is visible
Gas Supply:
Inspect the entire installation including the gas meter, test for soundness and
purge, all as described in BS 6891:1988.
Open the gas cock (supplied with the connection kit) to the appliance and
check the gas connector on the appliance for leaks.
When the installation and filling are completed turn on the central heating
system (sect. 3.4) and run it until the temperature has reached the boiler
operating temperature. The system must then be immediately flushed through.
The flushing procedure must be in line with BS 7593:1992 Code of practice for
treatment of water in domestic hot water central heating systems.
During this operation, we highly recommend the use of a central heating
flushing detergent (Fernox Superfloc or equivalent), whose function is to
dissolve any foreign matter that may be in the system.
Substances different from these could create serious problems to the
pump or other components.
The use of an inhibitor in system such as Fernox MB-1 or equivalent is strongly
recommended to prevent corrosion (sludge) damaging the boiler and system.
Failure to carry out this procedure may invalidate the appliance warranty.
3.2
Removing the Casing
1
To dismantle the front part of
the casing, proceed as follows:
1. Loosen the two screws “F”
located on the bottom part
of the boiler until the
first thread on the screws
appears;
F
20
B004
2
3
4
2. Lift the front panel up until it stops after the click;
3. Remove the front panel from the rest of boiler casing;
4. Unhook the two cords from the location slots.
3.3
Control Panel
GENUS 23/27/30 MFFI
A - Ignition Lockout Reset
Button/Safety
(Overheat)Thermostat Reset
B - Ignition Lockout L.E.D.
C - Selector Knob for
Summer/Winter/Flue Analysis
Modes*
D - Low System Water Level L.E.D.
E - Temperature Adjustment Knob
for Domestic Hot Water
F - Heating System Thermometer
G - Safety (Overheat)Thermostat
GENUS 27 RFFI SYSTEM
Intervention L.E.D.
H - Adjustment Knob for Heating
Temperature
I - On/Off L.E.D.
L - On/Off Switch
O - System Pressure Gauge
* Warning the flue analysis mode must only be selected by a qualified service engineer.
B004
21
3.4
Initial Start-up
The checks to be run before initial start-up are as follows:
1. Make sure that:
- the screw on the automatic air valve has been loosened when the
system is full;
- If the water pressure in the system is below 1 bar, bring it up to the appropriate level;
- Check to see whether the gas cock is closed;
- Make sure that the electrical connection has been made properly and that
the earth wire is connected to an efficient earthing system;
- Supply power to the boiler by pressing the On/Off switch <L> - the L.E.D. “I”
will turn on - turn the selector knob “C” to the <winter> setting. This will
start the circulation pump. After 7 seconds, the boiler will signal a shutdown due to failure ignition. Leave the boiler as it is until all of the air has
been bled from the lines.
- Loosen the cap on the head of the pump to eliminate any air pockets;
- Repeat the procedure for bleeding the radiators of air;
- Open the taps for a brief period;
- Check the system pressure and, if it has dropped, open the filling loop
again to bring the pressure back up to 1 bar.
2. Check the exhaust flue for the fumes produced by combustion.
3. Make sure that all gate valves are open;
4. Turn on the gas cock and check the seals on the connections, including the
one for the burner, making sure that the meter does not signal the passage
of gas. Check the connections with a soap solution and eliminate any leaks.
5. Press the reset button “A” for the lighting system; the spark will light the
main burner. If the burner does not light the first time, repeat the procedure.
6. Check the minimum and maximum pressure values for the gas going to the
burner; adjust it if needed using the values indicated in the table in
section 4.
(See sect of the servicing manual).
3.5
Operational
Adjustments
The boiler was designed to make regulation easy. To access the adjustment
and control area, simply remove the cover by unscrewing the screws “A” and
“C” and lift up the small service panels “B1” and “B2” respectively. The first
provides access to the control (low voltage) P.C.B., while the second makes it
possible to work on the power supply P.C.B.
A
B1
B2
C
The service panel “B2” also provides access to:
- the power supply cord connector;
- the fuses;
- the selector knob for continuous
operation of the circulation pump.
The service panel “B1” also provides access to:
- the potentiometer for regulating the ignition delay (anti-cycling) feature, which
can be set from 0 to 2 minutes (factory set at 1 minute);
22
B004
- the potentiometer for regulating the soft-light feature, the setting for which
can range from the minimum thermal power to the maximum:
G20
G25
G30-31
5 mbar
18 mbar
19 mbar
- the potentiometer for the maximum thermal power for the heating system,
maximum thermal power setting (factory set at the maximum value, unless
indicated otherwise on the adhesive sticker located in proximity to the
potentiometer);
- The connection to the diagnosis device (TCS-TCS2).
3.6
Combustion Analysis
The boiler is designed to make it easy to analyse the combustion by-products.
Using the especially designed apertures, readings can be taken on the
temperature of the combustion by-products and of the combustion air, as well
as of the concentrations of O2 and CO2, etc.
The best maximum-power test conditions for the heating system are when the
selector “C” is turned to the flue analysis setting.
3.7
B004
Fume Discharge
Monitoring
The discharge/ventilation of the exhaust fumes can be monitored to check for
losses in general pressure in the system. This is done to eliminate the cause of
lighting failure with the main burner not indicated by a shutdown status.
With a differential manometer connected to the test socket on the combustion
chamber, the DP value for the air pressure switch can be taken. The measured
value should not be less than 10 mbar under maximum thermal power
conditions (with the knob “C” on the flue test setting) in order for the unit to
function properly and without interruption.
23
3.8
Boiler Safety
Systems
The boiler is equipped with the following safety systems (see section 3.3 for
references):
1. - Ignition Failure
This control signals an ignition failure on the burner 7 seconds after a lighting
failure. The L.E.D. “B” will turn on to signal the shutdown status.
The system can be reset by pressing and releasing the button “A” after
checking to make sure that the gas valve is open. Repeat this process until the
burner lights.
2. - Circulation Failure
This control signals that the safety pressure switch on the primary circuit has
not sensed a pressure of at least 1 bar within 40 seconds of the activation of
the circulation pump, it shuts off the boiler and lights the L.E.D. “D” The system
can be reset (after the pressure has been brought up to the proper level) by
using the On/Off switch “L”.
3. - Overheating
This control shuts off the boiler in the case where the primary circuit reaches a
temperature in excess of 110°C. The L.E.D. “G” will come on to signal this shutoff status. After the system has been allowed to cool, the system can be reset
by pressing the button “A”.
4. - Limescale Build-up
This is an indirect control (actuated through the regulation of the temperature in
the primary heat exchanger) on the formation of limescale in the secondary
heat exchanger. Regardless of the flow rate and the temperature in the circuit
for the domestic hot water, the temperature is limited to 62°C.
5. - Anti-frost Device
The boiler is equipped with a device that automatically lights the main burner
when the temperature in the delivery line to the system drops below 5°C. The
boiler will continue to operate until the temperature in question reaches about
58°C.
This device is activated on a properly operating boiler if:
- the system pressure is between the acceptable values;
- the power supply to the unit is on;
- the unit is supplied with gas.
This feature is enabled also when the boiler is in summer operating mode.
6. - Safety Shut-off
At the start of every lighting phase, the P.C.B. performs a series of internal
controls. If a malfunction occurs, the boiler will shutdown until the problem has
been resolved.
3.9
Draining the System
Draining the heating system.
The heating system must be emptied as follows:
- Turn off the boiler;
-Open the drain valve for the system and place a container below to catch
the water that comes out;
- Empty the system at the lowest points (where present). If you plan on not
using the heating system for an extended period of time, it is recommended
that you add antifreeze with an ethylene glycol base to the water in the
heating lines and radiators if the ambient temperature drops below 0°C during
the winter.
This makes repeated draining of the entire system unnecessary.
Draining the domestic hot water system.
Whenever there is the danger of the temperature dropping below the freezing
point, the domestic hot water system must be drained as follows:
- Turn off the general water valve for the household plumbing system;
- Turn on all the hot and cold water taps;
- Empty the remaining water from the lowest points in the system (where
present).
24
B004
4.
GAS ADJUSTMENTS
CATEGORY II2H3+
Lower Wobbe Index (15°C;1013mbar)
Nominal Delivery Pressure
Minimum Delivery Pressure
Methane Gas
G20
MJ/m3h
mbar
mbar
Liquid Butane Gas
G30
45.67
20
17
Liquid Propane Gas
G31
80.58
30
20
70.69
37
25
0.72
---2.02
0.72
---2.02
23 MFFI
Main Burner: n. 13 jets (ø)
Consumption (15°C; 1013mbar)
Consumption (15°C; 1013mbar)
Gas Cock Outlet Pressure
max - min
mm
mc/h
Kg/h
1.25
2.72
----
mbar
11.4- 2.0
mc/h
Kg/h
1.25
3.16
----
mbar
11.4-2.0
mc/h
Kg/h
1.30
3.49
----
mbar
11.4-1.4
27.5 (*) - 5.0
35.0 (*) - 7.0
27 MFFI - 27 RFFI System
Main Burner: n. 15 jets (ø)
Consumption (15°C; 1013mbar)
Consumption (15°C; 1013mbar)
Gas Cock Outlet Pressure:
max - min
0.72
---2.35
0.72
---2.32
(*) - 5.0
(*) - 7.0
0.77
---2.60
0.77
---2.57
(*) - 4.1
(*) - 5.6
30 MFFI
Main Burner: n. 15 jets (ø)
Consumption (15°C; 1013mbar)
Consumption (15°C; 1013mbar)
Gas Cock Outlet Pressure:
max - min
(1mbar = 10,197column of water)
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 Type of
Gas
CATEGORY II2H3+
Recommended Soft-light Pressure
(mbar)
B004
The boiler can be converted to use either methane (natural) gas (G20) or
LPG (G30 - G31) by an Authorised Service Centre.
The operations that must be performed are the following:
1. Replace the jets on the main burner (see table in section 4);
2. Adjust the maximum and minimum thermal capacity values for the boiler
(see table in section 4);
3. Replace the gas rating plate;
4. Adjust the maximum thermal power setting;
Methane Gas
Liquid Butane Gas
Liquid Propane Gas
G20
G30
G31
5-5.5
17 - 18
18 - 19
25
5. Adjust the soft-light feature;
6. Adjust the delayed lighting feature for the heating system (can be set from
0 to 2 mins.).
5.
26
MAINTENANCE
It is recommended that the following checks be made on the boiler at
least once a year:
1 - Check the seals for the water connections; replacement of any faulty seals.
2 - Check the gas seals; replacement of any faulty gas seals.
3 - Visual check of the entire unit.
4 - Visual check of the combustion process or analysis of flue gas (see ref 3.6)
and cleaning of the burners if needed.
5 - If called for by check no. 3, dismantling and cleaning of the combustion
chamber.
6 - If called for by check no. 4, dismantling and cleaning of the injectors.
7 - Visual check of the primary heat exchanger:
- check for overheating in the blade assembly;
- clean the exhaust fan if needed.
8 - Adjustment of the flow rate of the gas: flow rate for lighting, partial load and
full load.
9 - Check of the heating safety systems:
- safety device for maximum temperature;
- safety device for maximum pressure.
10 - Check of the gas safety systems:
- safety device for lack of gas or flame ionisation (detection electrode);
- safety device for gas cock.
11 - Check of the electrical connection (make sure it complies with the
instructions in the manual).
12 - Check of domestic hot water production efficiency (delivery rate and temperature)
13 - Check of the general performance of the unit.
14 - General check of the discharge/ventilation of the combustion byproducts.
B004
B004
240V
MAINS INPUT (3 AMP)
3
8
2
2
T6360B
ROOM
THERMOSTAT
ZONE 2
L
1
N
2
E
3
4
E
8
E
1
2
4
4
E
E
E
5
N
N
3
L
4
N
7
6
L
N
N
L
L
3
L
6
L
6
Towerchron MP
Link 1-4/6-11
ZONE 2
4
Randall 3020 P
and 3060
4
3
E
1 0
1 0
4
1
1
E
N
2
6
E
E
N
HW HTG
ON ON
1
L
N
N
N
2
2
1
L
2
N
L
L
L
L
L
1
1
2
ZONE 1
PROGRAMMER
3
Randall 922, 972
Link L-2-5
ACL LS522, LS722
Towerchron 2000
6
Towerchron FP
Link 1-5/4-7-9
3
7
Sunvic ET 1451
Link 2-3-6
Sunvic DHP 2201
3
N
• 3
ZONE 1
6
3
SWITCHMASTER 805, 900
Switchmaster 400, 600
4
E
E
E
N L
N L
N L
1
Based on Honeywell controls
BOILER
Remove internal time clock plug
from the the P.C.B. then connect
room stat terminal block on the
reverse of the boiler control panel
(see section 2.10) to 9 + 10 on
the junction box.
PROGRAMMER
8
2
4
4
N
1
Switchmaster
Symphony, Sonata
L
2
BOILER ELECTRICAL SUPPLY CABLE
ZONE 2
Sangamo 410 Form 1
Link 3-6
1
3
Randall 701, 702
Link L-6-5
Sangamo M5
Link 1-6
4
Randall 4033
Link 1-6
1
3
Randall 102/102 E
Link 3-6
Potterton EP2000/3000 Link L-5 EP2001/3001
3
Landis & Gyr RWB20
Microgyr
3
3
Landis & Gyr RWB2
Glowworm Mastermind
• 10
E
• 9
4
3
1
GREEN/YELLOW
• 7
Horstmann 425, 525, 527
Link L-2-5
9
10
L
GREY
ORANGE
• 6
L
2
1
6
N
8
BLUE
N
BROWN
Potterton Miniminder
4
1
4
• 5
3
• 4
A/27 MFFI - A/27 MFFI
Genus 23-27-30 MFFI
Genus 27 RFFI System
2
N
2
E
• 1
5
5
TYPICAL
JUNCTION BOX
2
3
3
3
Pegler Sunvic
SP 50/100 (Link L-3)
V4043H
VALVE
10
GREEN/YELLOW
9
10
Drayton Tempus 7
L
4
1
9
ORANGE
N
T6360B
ROOM
THERMOSTAT
2
2
3
GREY
3
ZONE1
4
5
BLUE
6
BROWN
6
V4043H
VALVE
1
Wiring Diagram for
Two Heating Zones
2
6.1
ST 6400/ST 6300 ST 6200 3
3
MISCELLANEOUS
4
1
Honeywell ST 699B 1002
Link L-5-8
6
6.
• 2
• 8
If a room thermostat is not required on Zone 1, insert a link
between 4 + 5 on the junction box.
If a room thermostat is not requied on Zone 2, insert a link
between 6 + 8 on the junction box.
27
1
2
28
C/P
Cylinder
thermostat
Thermal
cut-out
1 C/P
1
8
P
6
2
Not
used
Sangamo 410 Form 1
Link 3-6
4
8
8
1
2
2
4
4
E
E
E
E
E
E
4
4
N
7
5
N
N
N
N
N
3
3
L
6
6
L
L
L
L
L
4
Randall 3020 P
and 3060
E
E
HTG
ON
E
E
N
N
N
N
2
2
1
1
N
N
N
N
• 3
L
L
L
L
1
1
2
2
L
L
L
L
PROGRAMMER
2
6
3
Randall 922, 972
Link L-2-5
10
4
6
Towerchron MP
Link 1-4/6-11
10
3
6
Towerchron FP
Link 1-5/4-7-9
3
ACL LS522, LS722
6
Sunvic DHP 2201
4
HW
ON
7
Sunvic ET 1451
Link 2-3-6
1
1
4
Towerchron 2000
3
3
SWITCHMASTER 805, 900
Switchmaster 400, 600
1
Switchmaster
Symphony, Sonata
E
A/27 MFFI - A/27 MFFI
Genus 23-27-30 MFFI
Genus 27 RFFI System
9
Remove internal time clock plug
from the the P.C.B. then connect
room stat terminal block on the
reverse of the boiler control panel
(see section 2.10) to 9 + 10 on
the junction box.
2
N
N
N
3
E
E
E
L
L
L
1
Based on Honeywell controls
BOILER
10
BOILER ELECTRICAL SUPPLY CABLE
PROGRAMMER
1
1
3
Sangamo M5
Link 1-6
4
1
Randall 102/102 E
Link 3-6
Randall 701, 702
Link L-6-5
3
Potterton EP2000/3000 Link L-5 EP2001/3001
Randall 4033
Link 1-6
3
3
• 10
Potterton Miniminder
240V
MAINS INPUT (3 AMP)
Landis & Gyr RWB20
Microgyr
3
4
E
• 9
3
2
Landis & Gyr RWB2
Glowworm Mastermind
N
4
1
1
L
• 7
Horstmann 425, 525, 527
Link L-2-5
3
L
V4043H
HOT WATER VALVE
L
GREEN/YELLOW
• 6
N
10
N
ORANGE
4
9
4
GREY
• 5
3
2
3
BLUE
5
• 4
Drayton Tempus 7
8
ST 6400/ST 6300 ST 6200
BROWN
2
V4043H
HEATING VALVE
Pegler Sunvic
SP 50/100 (Link L-3)
3
L
10
GREEN/YELLOW
N
9
ORANGE
• 1
3
TYPICAL
JUNCTION BOX
6
2
GREY
1
5
BLUE
2
T6360B
ROOM
THERMOSTAT
3
BROWN
4
2
6
2
1
5
2
3
3
4
4
1
Honeywell ST 699B 1002
Link L-5-8
6
6.2
Wiring Diagram for
Connection to Ariston
Unvented Cylinder
• 2
• 8
B004
NOTES
B004
NOTES
B004
30
31
B004
Merloni TermoSanitari SpA - Italy
Commercial subsidiary: MTS (GB) LIMITED
MTS Building
Hughenden Avenue,
High Wycombe
Bucks HP13 5FT
Telephone: (01494) 755600 Fax: (01494) 459775
Technical Service Hotline: (01494) 539579
B004 - Cod. 23 99 84 1259 111 - Stampa: bieffe RECANATI
Manufacturer:
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