Ariston GENUS 41-116-01 Service Manual
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Ariston GENUS 41-116-01 Service Manual

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See also: Instruction and Installation Manual
Supplied By www.heating spares.co Tel. 0161 620 6677
Servicing Instructions
Type C Boilers
G.C.N:
41-116-01
47-116-08
47-116-09
47-116-13
LEAVE THESE INSTRUCTIONS
ADJACENT TO THE GAS METER

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Summary of Contents for Ariston GENUS 41-116-01

  • Page 1 Servicing Instructions Type C Boilers G.C.N: 41-116-01 47-116-08 47-116-09 47-116-13 LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page No. 1. SERVICING INSTRUCTIONS 1.1 Replacement of Parts 1.2 To Gain General Access - Removing the Front Panel - Removing the Bottom Cover - Removing the Side Panels 1.3 Access to the Combustion Chamber - Removing the Sealed Combustion Chamber - Removing the Burner and Injectors - Removing the Electrodes - Removing the Main Heat Exchanger...

  • Page 3: Servicing Instructions

    To ensure efficient safe operation, it is recommended that the boiler is SERVICING serviced annually by a competent person. 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).

  • Page 4: Removing The Bottom Cover

    Removing the bottom cover 1. Remove the screws “B” Fig. 1.4 Removing the side panels 1. Remove the screws “C”; 2. Pull the panel away from the boiler, then lift the panel up and away from the boiler. Fig. 1.5 B005 Supplied By www.heating spares.co Tel.

  • Page 5: Access To The Combustion Chamber

    Access to the Combustion Chamber Removing the sealed chamber Removing the combustion cover frontal cover Remove the screws “D” Remove the screws “E” Fig. 1.7 Fig. 1.6 Removing the burner and the 1. Remove the side panels of sealed chamber (fig. 1.8) ; injectors 2.

  • Page 6: Removing The Electrodes

    Removing the electrodes 1. Remove rubber gasket “G” (see fig. 1.11) ; 2. Disconnect ignition leads by pulling downward (see fig. 1.12) ; 3. To remove the flame sensor disconnect the cable at its only connection point close to the P.C.B. (see fig. 1.13) ; Fig.

  • Page 7: Removing The Main Heat Exchanger

    Removing the main heat 1. Drain the boiler of water; exchanger 2. Release the two connection nuts “I” connecting the exchanger to the flow and return pipes (see fig. 1.16) ; 3. Pull it straight out (see fig. 1.17). Fig. 1.17 Fig.

  • Page 8: Removing The Venturi Device

    Removing the venturi device 1. Disconnect the silicone pipes “M” and remove the screw “N” (see fig. 1.20) ; 2. Extract the venturi (see fig. 1.21) . Fig. 1.20 Fig. 1.21 Removing the fan 1. Disconnect electrical connections and remove screws “O”...

  • Page 9: Servicing And Removal Of The Gas Valve

    Servicing and Removal of the Gas Valve SIGMA TANDEM B005 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 10: Setting Gas Pressure

    Setting gas pressures Setting the minimum and the maximum power of the boiler 1. Check that the supply pressure to the gas valve is a minimum of 20 mbar for natural gas. 2. To do this, remove the screw “A”. Fit the pipe of the pressure gauge to the pressure connection of the gas valve “B”.
  • Page 11 Regulating the heating power for natural gas (G20) model 23 model 27 Regulating the heating power for butane gas (G30) model 23 model 27 Regulating the heating power for propane gas (G31) model 23 model 27 TABLE “A” B005 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 12: Removing The Spark Generator (Sit Sigma Gas Valve)

    10. Remove the pipe from the pressure gauge and connect screw “C” to the pressure outlet in order to seal off the gas. 11. Carefully check the pressure outlets for gas leaks (valve inlet and outlet). IMPORTANT! Whenever you disassemble and reassemble the gas connections, always check for leaks using a soap and water solution.

  • Page 13: Removing The Spark Generator (Sit Tandem Gas Valve)

    Removing the spark generator (SIT Tandem gas valve) 1. Disconnect ignition leads “Q1” by pulling upwards (see fig. 1.28) ; 2. Remove the screws “R1” (see fig. 1.29) with a Pozidrive No. 2 star tip screwdriver; 3. Remove the spark generator. Fig.

  • Page 14: Removing The Gas Valve

    Removing the gas valve 1. Disconnect all the cables from the solenoid and modureg; 2. Remove the spark generator; 3. Release the top nut “S” using a 30 mm open ended spanner (see fig. 1.31) ; 4. Remove the screws “T” from the bottom of the gas valve pipe (see fig.

  • Page 15: Removing The Safety Valve

    Removing the safety valve 1. Loosen nut “V” (see fig. 1.36); 2. Remove the valve. Fig. 1.36 Removing the automatic air vent 1. Unscrew valve “W” (see fig. 1.37) . Fig. 1.37 Removing the main circuit flow switch 1. Remove the cable of the main circuit flow switch “Y”; 2.

  • Page 16: Removing The Pump

    Removing the pump 1. Unscrew “Z” and remove the electrical connection (see fig. 1.39) ; 2. Release the nuts “A1” and remove the pump (see fig. 1.40) . Fig. 1.39 Fig. 1.40 Removing the pressure gauge 1. Remove the pressure gauge cover by pulling (see fig.

  • Page 17: Removing The Expansion Vessel

    Removing the expansion vessel 1. Remove nut “A3” away from the expansion vessel (see fig. 1.44) ; 2. Remove nut “A4” (see fig. 1.45) ; 3. Remove expansion vessel (see fig. 1.46) . Fig. 1.44 Fig. 1.45 Fig. 1.46 Removing the overheat thermostat 1.

  • Page 18: Removing The D.h.w. Temperature Sensor (N.t.c.)

    Removing the D.H.W. temperature sensor (N.T.C.) 1. Remove the electrical connector by pulling off the thermostat connection and unscrew the sensor probe with a 14 mm open ended spanner (see fig. 1.49) . Fig. 1.49 Removing the diverter valve (Genus 27 RFFI only) 1.

  • Page 19: Access To The Control System

    Access to the Control System Checking fuse 1. Remove the right hand inspection cover (see fig. 1.51) ; 2. Remove fuse (see fig. 1.52) . Fig. 1.51 Fig. 1.52 Removing the time clock 1. Remove left hand inspection cover (see fig. 1.53) ; 2.

  • Page 20: Removing The P.c.b.s

    Removing the P.C.B.s 1. Isolate electricity; 2. Remove the front cover of the boiler; 3. Remove both left and right inspection panels; 4. Remove the pressure gauge cover; 5. Remove the mounting screws “A7’ (see fig. 1.51) ; 6. Disconnect the connection cable”A8” (see fig. 1.52) ; 7.

  • Page 21: Fault Finding

    FAULT FINDING Fault Finding Guide It is possible to detect and correct any defect by using the standard fault finding diagrams described in this chapter. (Flow-chart) Preliminary Checks Make sure that: 1) There is sufficient water in the system 2) The gas is turned on 3) The electricity to the boiler is on Press the...
  • Page 22 DOES THE CIRCULATION PUMP COME ON? POWER TO THE PUMP? DOES THE INSUFFICIENT WATER INDICATOR LIGHT COME 1) Check ON? (within wiring 1) Check for air in the 40 sec.) 2) Check/replace system wire to P.C.B. 2) Check the pressure switch 3) Replace for activating pump 1) Check to see if pump is...
  • Page 23 DOES THE FAN COME ON? BOILER 1) Reset the boiler SHUTDOWN? 1) Check/replace differential pressure switch for pump PUMP 2) Check/replace wi r i n g SAFETY DEVICE 3) Check/repl a ce P.C.B. wire ACTIVATED? 4) Check/repl a ce power supply P.C.B.
  • Page 24 1) Check flue discharge 2) Check venturi & small pipes 3) Check wire for air press.switch THE AIR PRESSURE 4) Check/replace air press. switch SWITCH ACTIVATED? 5) Check/replace P.C.B.wire 6) Check/replace power P.C.B. 7) Check/replace control P.C.B. 1) Check/ replace ignition electrodes 2) Check wiring 3) Check spark generator ARE THE...
  • Page 25 THERE STILL A PROBLEM? FUNCTIONS NORMALLY LIST OF MALFUNCTIONS POSSIBLE CAUSES Delivery of hot water for domestic use: Delivery of hot water for domestic use: - Air in the secondary exchanger - Air in the secondary exchanger when the tap is turned on, the burner goes out. when the tap is turned on, the burner goes out.

  • Page 26: Fault Finding Using The Total Check System

    Fault Finding Using the Total Check System Malfunction Signalling Faulty ventilation system Air pressure switch stuck in N.O. position Boiler Off Faulty reset switch Auto diagnostic state Faulty main circuit flow switch Spark ignition state Boiler functioning normally Faulty flame detection Lockout Faulty overheat thermostat Boiler thermostat satisfied...

  • Page 27: Electrical Diagrams

    Legend: ELECTRIC AT = High Voltage P.C.B. DIAGRAMS BT = 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.
  • Page 28 GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM B005 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 29: Functional Flow Connection

    GENUS 23/27 MFFI GENUS 27 RFFI SYSTEM B005 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 30: Short Spare Parts List

    SHORT SPARE PARTS LIST GENUS 23/27 MFFI (SIT Sigma Gas Valve) 58 57 21 22 34 35 23/27 MFFI B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 31 GENUS 30 MFFI (SIT Sigma Gas Valve) 60 59 58 22 23 35 36 30 MFFI B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 32 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve) 60 59 21 22 23 34 35 27 MFFI SYSTEM B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 33 GENUS 23/27 MFFI (SIT Sigma Gas Valve) G.C. part ARISTON Description Part No. 379816 Expansion vessel 573294 164 225 573520 Gasket 3/4" 997206 Overheat thermostat 573224 Main flow Switch 569236 164 338 Temp probe (C.H.W.) 573340 Microswitch for 3-way/main flow group...
  • Page 34 GENUS 30 MFFI (SIT Sigma Gas Valve) G.C. part ARISTON Description Part No. 379816 Expansion vessel 573294 164 225 573520 Gasket 3/4" 997206 Overheat thermostat 573224 Main flow Switch 569236 164 338 Temp probe (C.H.W.) 573340 Microswitch for 3-way/main flow group...
  • Page 35 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve) G.C. part ARISTON Description Part No. 379816 Expansion vessel 573294 164 225 Gasket 3/4" 573520 Overheat thermostat 997206 Motorised valve motor 997147 573224 Main flow switch 569236 164 338 Temp probe (C.H.W.)
  • Page 36 GENUS 23/27 MFFI (SIT Tandem Gas Valve) 58 57 21 22 34 35 23/27 MFFI B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 37 GENUS 30 MFFI (SIT Tandem Gas Valve) 59 58 22 23 35 36 30 MFFI B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 38 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve) 60 59 34 35 21 22 23 27 MFFI SYSTEM B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 39 GENUS 23/27 MFFI (SIT Tandem Gas Valve) G.C. part ARISTON Description Part No. 573294 379816 Expansion vessel 573520 164 225 Gasket 3/4" Overheat thermostat 997206 Main flow Switch 573224 164 338 Temp probe (C.H.W.) 569236 Microswitch for 3-way/main flow group...
  • Page 40 GENUS 30 MFFI (SIT Tandem Gas Valve) G.C. part ARISTON Description Part No. 379816 573294 Expansion vessel 573520 164 225 Gasket 3/4" 997206 Overheat thermostat Main flow Switch 573224 164 338 Temp probe (C.H.W.) 569236 Microswitch for 3-way/main flow group...
  • Page 41 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve) G.C. part ARISTON Description Part No. 573294 Expansion vessel 573520 164 225 Gasket 3/4" 997206 Overheat thermostat Motorised valve motor 997147 Main flow switch 573224 164 338 Temp probe (C.H.W.) 569236 164 229 Gasket 1/2"...
  • Page 42 NOTES B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 43 B005 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 44 Manufacturer: Merloni TermoSanitari SpA - Italy Commercial subsidiary: MTS (GB) LIMITED MTS Building Hughenden Avenue, High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 - Fax: (01494) 459775 Technical Service Hotline: (01494) 539579 23 99 84 1267 000 - B005 Stampa: Bieffe Recanati Supplied By www.heating spares.co Tel.

This manual is also suitable for:

Genus 47-116-08Genus 47-116-13Genus 47-116-09

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