Ariston 41-116-06, Installation Instructions Manual

Page 1: ...Installation Instructions Type C Boilers G C N 41 116 06 41 116 07 LEAVE THESE INSTRUCTIONS WITH THE END USER Country of destination GB ...

Page 2: ...0 ROOM THERMOSTAT CONNECTION 2 11 ELECTRICAL DIAGRAMS 2 12 GAS AND WATER CIRCUITS 3 D H W STORAGE CYLINDER 3 1 2 PORT AND 3 PORT VALVE INSTALLATIONS 3 2 DOMESTIC HOT WATER PRIORITY KIT 4 COMMISSIONING 4 1 INITIAL PREPARATION 4 2 CONTROL PANEL 4 3 REMOVING THE FRONT PANEL 4 4 INITIAL START UP 4 5 OPERATIONAL ADJUSTMENTS 4 6 COMBUSTION ANALYSIS 4 7 FUME DISCHARGE MONITORING 4 8 DRAINING THE SYSTEM 5...

Page 3: ...a 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...

Page 4: ...f 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 General check of the combustion by products of the discharge ventilation system 13 Check of the general performance of the unit LEGEND 1 Flue connector 2 Air intake for twin pipe flue systems 3 Fan 4 Combustion chamber hood 5 Ma...

Page 5: ...e 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 procedur...

Page 6: ...n IMPORTANT In the event that the power supply cord must be changed replace it with one with the same specifications Make the connections to the terminal board located within the control panel as follows The yellow green wire should be connected to the terminal marked with the symbol The blue wire should be connected to the terminal marked N The brown wire should be connected to the terminal E L N...

Page 7: ...iagrams for the electrical system are indicated in section 2 12 Warning this appliance must be earthed External wiring to the appliance must be carried out by a competent person and be in accordance with the current I E E Regulations and applicable local regulations The microSYSTEM 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 co...

Page 8: ...DISCHARGE The discharge should terminate facing downward 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 AIR RELEASE POINTS These must be f...

Page 9: ...l is less than 2 metres above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be fitted When ordering a terminal guard quote the appliance model number A suitable terminal guard is available from TOWER FLUE COMPONENTS Morley Road Tonbridge Kent TN9 1RA The minimum acceptable spacing from the terminal to obstructions and ventilation openin...

Page 10: ...t the elbow into the air intake until it reaches the lower end There is no need to use gaskets or sealing compounds 10 IMPORTANT For all flue systems a restrictor must always be inserted into the boiler s flue connector the restrictor must be Ø 46 or Ø 41 in diameter depending on the length of piping indicated in TABLE 2 1 FIG 2 9 and FIG 2 10 illustrate some of the various designs for coaxial or ...

Page 11: ...t Type C12 xy C32 xy C42 xy C52 xy C82 xy Restrictor ø 46 mm L max 25 m L max 22 m Maximum Extension Exhaust Air 34 m 34 m 34 m 31 m Risk of Condensation Forming Twin Pipe Systems ø 80 80 Piping not insulated ø 46 restrictor NO restrictor 3 0 m 4 5 m 3 3 m 4 8 m Piping insulated ø 46 restrictor NO restrictor 12 5 m 16 0 m 14 0 m 17 8 m 21 RFFI 28 RFFI TWIN PIPE SYSTEMS FIG 2 10 In calculating the ...

Page 12: ... switching wires to the position 5 and 6 and remove the wire link for three wire thermostats connect the neutral to terminal N 4 For the time clock connect the clock switching wires to the positions 3 and 4 and connect the clock motor electrical supply to the terminals marked L and N Note A frost thermostat is built in to the appliance For connection to control systems with zone valves for hot wat...

Page 13: ...re Switch A02 Frost Thermostat A03 Modulator A04 Circulation Pump A05 Regulation Thermostat A06 External Control System A07 Time Clock Connector A08 External Room Thermostat A09 Air Pressure Switch A10 Fan A11 Overheat Thermostat A12 Spark Generator Gas Valve Supply A13 Detection Electrode Colours Wh White Bl Blue Gry Grey Brn Brown Blk Black Rd Red Grn Yll Yellow Green ...

Page 14: ...egulation thermostat 8 Frost thermostat 9 Gas valve 10 Pump pressure switch 11 Safety valve 3 bar 12 Boiler drain valve 13 Automatic by pass 14 Pressure gauge 15 Circulation pump with automatic air release valve 16 Expansion vessel 17 Air pressure switch A Central Heating Flow B Inlet Gas C Central Heating Return 2 12 GAS AND WATER CIRCUITS FIG 2 14 FIG 2 13 ...

Page 15: ...ders of different capacities can be used depending on site requirements see TABLE 3 1 for a selection of ARISTON unvented cylinders FIG 3 2 3 port valve installation FIG 3 1 2 port valve installation 3 1 2 PORT AND 3 PORT VALVE INSTALLATIONS Wiring to 2 port valve installation using an external 2 channel programmer Type Danfoss FP715 Type Honeywell ST6400C FIG 3 3 ...

Page 16: ...210 Indirect 200 0 93 0 5 256 14 9 2 9 Contract STI 300 Indirect 300 0 93 1 353 20 5 2 451 26 2 SB 125 Indirect 125 1 0 5 190 11 1 72 1 318 18 5 2 496 28 8 SB 150 Indirect 150 1 0 5 190 11 1 75 1 318 18 5 2 496 28 8 SB 200 Indirect 200 1 3 0 5 190 11 2 1 1 318 18 5 2 496 28 8 TABLE 3 1 Wiring to 3 port valve installation using an external 2 channel programmer Type Danfoss FP715 Type Honeywell ST64...

Page 17: ...ee Refit the pump plug Continue filling the system until at least 1 5 bar registers on the pressure gauge Inspect the system for water leaks and remedy any leaks discovered GAS SUPPLY Inspect the entire installation including the gas meter test for soundness and purge the supply as described in BS 6891 1988 Open the gas cock supplied with the connection kit to the appliance and check the gas conne...

Page 18: ...H Energy Saving System ESS I Knock out for time clock J Heating system pressure gauge 4 2 CONTROL PANEL FIG 4 1 When the installation and filling are completed turn on the central heating system section 4 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 o...

Page 19: ... Off button A see FIG 4 1 the L E D B will illuminate Then push the button C in for central heating the L E D D will illuminate This will start the circulation pump After 7 seconds the boiler will signal a shutdown due to ignition failure Leave the boiler as it is until all of the air has been bled from the system Loosen the cap on the head of the pump to eliminate any air pockets Repeat the proce...

Page 20: ...tly and the system pressure is sufficient the boiler is powered electrically L E D B illuminated the gas is turned on 5 EXHAUST DISCHARGE ANOMALY SHUTDOWN The boiler is fitted with safety devices which in the event of defective discharge of exhaust fumes automatically interrupts the gas supply thereby shutting off the boiler The shutdown of the boiler is temporary and when the discharge state of e...

Page 21: ...letely 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 1 mbar 10 197 mmc a 5 GAS ADJUSTMENTS Lower Wobbe Index 15 C 1013mbar MJ m3 h Nominal Delivery Pressure mbar Minimum Delivery Pressure mbar 21 RFFI Main Burner n 12 jets ø mm Consumption 15 C 1013mbar m3 h Consumption 15 C ...

Page 22: ...jets 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 overheat thermostat safety device for maximum pressure safety valve 10 Check of the gas safety systems safe...

Page 23: ...23 ...

Page 24: ... exhaust fumes at nominal capacity C CO2 Content O2 Content CO Content ppm Minimum Ambient Temperature C Head Loss on Water Side max T 20 C mbar Residual Head of System bar Heating Temperature max min C Expansion Vessel Capacity l Expansion Vessel Pre load Pressure bar Maximum Water Content of System l Maximum Heating Pressure bar Nominal Pressure Natural Gas G20 mbar LPG G30 G31 mbar Electrical S...

Page 25: ...Servicing Instructions Type C Boilers G C N 41 116 06 41 116 07 LEAVE THESE INSTRUCTIONS WITH THE END USER Country of destination GB ...

Page 26: ... REMOVAL OF THE GAS VALVE Setting the gas pressures Removing the spark generator Removing the gas valve 1 5 ACCESS TO THE WATER CIRCUIT Removing the pump pressure switch Removing the safety valve Removing the automatic air vent Removing the pump Removing the pressure gauge Removing the expansion vessel Removing the overheat thermostat Removing the frost thermostat Removing the regulation thermosta...

Page 27: ...ection and replacement of the individual parts are given in the following pages 1 1 REPLACEMENT OF PARTS 1 2 TO GAIN GENERAL ACCESS All testing and maintenance operations on the boiler require the control panel to be lowered This will also require the removal of the casing 1 2 1 Removing the front panel 1 Loosen the fastening screws A of the control panel located on the lower part of the panel its...

Page 28: ...ft the sealed chamber front cover from the locating pins FIG 1 7 FIG 1 6 C C FIG 1 7 1 2 3 Removing the side panels 1 Remove the four screws D for each side panel FIG 1 8 2 Pull the panel away from the boiler at the base then lift the panel up and remove from the boiler D D D FIG 1 8 ...

Page 29: ... to the P C B FIG 1 13 FIG 1 12 G FIG 1 13 1 3 2 Removing the burner and jets 1 Remove the screws F from the burner FIG 1 10 2 Remove the burner FIG 1 11 3 Disconnect the electrodes see section 1 3 3 4 Remove the jets using a No 7 socket spanner 5 Replace in reverse order 5 1 3 1 Removing the combustion cover 1 Remove the screws E FIG 1 9 2 Lift off the combustion cover 1 3 ACCESS TO THE COMBUSTIO...

Page 30: ...orrect way round facing each other to give the correct spark gap c Check that the cables have been connected correctly d Check that the rubber gasket covers the cable electrode connection point completely FIG 1 14 FIG 1 15 H 1 Drain the boiler of water 2 Release the overheat thermostat sensor I FIG 1 16 3 Release the two connection nuts J connecting the exchanger to the flow and return pipes FIG 1...

Page 31: ...3 6 Removing the fan 1 Disconnect the electrical connections K and silicone pipes L from their connection points FIG 1 19 2 Remove screws M on the top of the sealed chamber FIG 1 20 3 Lift out the air pressure switch FIG 1 21 4 Unscrew to remove the switch from the plate FIG 1 20 FIG 1 19 7 1 3 5 Removing the air pressure switch L L K M M FIG 1 21 FIG 1 24 R R FIG 1 23 P Q FIG 1 22 N O FIG 1 25 ...

Page 32: ...crease the pressure until the required pressure is achieved see TABLE A page 9 5 To set the minimum power disconnect the supply cable from the modureg and adjust screw G whilst holding nut F Turn the screw clockwise to increase the pressure and anticlockwise to decrease the pressure until the required pressure is achieved see TABLE A page 9 6 When you have completed the above operations turn off t...

Page 33: ...G POWER Regulating the heating power for propane gas G31 21 RFFI 28 RFFI 2 4 20 8 5 3 3 0 7 1 7 1 05 3 15 1 26 11 1 6 84 7 111 1 1 78 1 76 62 8 62 1 27 5 27 2 14 6 3 1 37 4 0 78 0 77 27 5 6 2 2 4 8 0 10 7 37 0 44 5 2 34 0 94 82 6 33 2 2 31 0 93 81 5 32 8 4 3 0 6 27 7 4 6 10 8 1 8 35 5 6 0 13 8 2 3 14 x 1 30 14 x 0 77 14 x 0 77 TABLE A 21 kW 28 kW 21 kW 28 kW 21 kW 28 kW CG004A CG005A CG006A TB005A...

Page 34: ...eg 2 Remove the spark generator see previous section 3 Release the top nut U FIG 1 28 4 Remove the screws V from the bottom of the gas valve pipe FIG 1 29 5 Remove the gas valve FIG 1 30 1 4 2 Removing the spark generator 1 Disconnect ignition leads S by pulling upward FIG 1 26 2 Remove the screw T FIG 1 27 3 Remove the spark generator by pulling forward from the gas valve FIG 1 27 FIG 1 26 S T ...

Page 35: ... 2 Remove valve complete with float FIG 1 35 FIG 1 33 FIG 1 34 Y Z FIG 1 35 Important Before any component is removed the boiler must be drained of all water 1 5 ACCESS TO THE WATER CIRCUIT FIG 1 31 W FIG 1 32 X 1 5 1 Removing the pump pressure switch 1 Remove the cable of the pump pressure switch W Fig 1 31 2 Unscrew the pump pressure switch by using a spanner on the nut X FIG 1 32 3 Remove the p...

Page 36: ... A1 and B1 FIG 1 36 2 Remove the retaining clip C1 FIG 1 37 3 Release the nut D1 FIG 1 38 4 Remove the pipe E1 FIG 1 39 5 Remove the screw F1 FIG 1 40 6 Remove the pump FIG 1 41 FIG 1 37 FIG 1 36 FIG 1 38 C1 A1 B1 FIG 1 39 FIG 1 40 FIG 1 41 D1 E1 F1 ...

Page 37: ...3 Remove lock nut J1 FIG 1 46 4 Remove the expansion vessel FIG 1 47 1 5 5 Removing the pressure gauge 1 Remove the U clip G1 and remove the pressure gauge coupling FIG 1 42 2 Push the pressure gauge through the control panel from the rear FIG 1 43 FIG 1 42 FIG 1 44 G1 FIG 1 43 H1 I1 FIG 1 45 FIG 1 46 FIG 1 47 H1 J1 ...

Page 38: ... releasing the securing clip FIG 1 51 1 5 8 Removing the regulation thermostat 1 Remove the regulation thermostat sensor from its mounting by releasing the securing clip M1 FIG 1 52 2 Separate the facia panel from the rear of the control panel see section 1 6 2 3 Remove the electrical connections N1 from the regulation thermostat FIG 1 53 4 Pull the regulation knob from the spindle of the thermost...

Page 39: ...ve the screws P1 and remove the P C B FIG 1 57 FIG 1 56 O1 O1 O1 O1 O1 P1 P1 P1 P1 O1 FIG 1 57 1 6 1 Checking the fuse 1 Remove the inspection cover on the reverse of the control panel FIG 1 54 2 Remove the fuse mounted on the reverse of the inspection cover FIG 1 55 1 6 ACCESS TO THE CONTROL SYSTEM FIG 1 54 FIG 1 55 Important Isolate the electrical supply to the boiler before accessing the contro...

Page 40: ... C B CT1 PRESS THE ON OFF BUTTON PRESS THE CENTRAL HEATING BUTTON FROST PROTECTION IS ACTIVATED 5 C IS THE FROSTPROTECTION REQUESTED IS TIME CLOCK PROGRAMMER AND OR ROOM CALLING FOR HEATING THE THERMOSTAT A 1 THERE IS SUFFICIENT WATER IN THE SYSTEM 2 THE GAS IS TURNED ON 3 THE ELECTRICAL SUPPLY IS TURNED ON YES YES YES It is possible to detect and correct any defect by using the standard fault fin...

Page 41: ...E IS AT 1 5 BAR A IS THE FAN RUNNING BOILER SHUTDOWN POWER T O THE FAN NO YES YES NO YES NO NO YES 1 CHECK REPLACE AIR PRESSURE SWITCH AND CABLE 2 CHECK IF THE RESET DETECTION ELECTRODE IS JAMMED 3 CHECK REPLACE 1 CHECK REPLACE FAN CONNECTION CABLE 2 CHECK REPLACE P C B 3 CHECK REPLACE AIR PRESSURE SWITCH 1 REPLACE THE FAN 1 RESET THE BOILER INTERNAL P C B PROTECTION ACTIVATED B NO YES FC002Ab ...

Page 42: ...HEATING CIRCUIT PRESSURE REPEATED SHUTDOWNS REPEATED SHUTDOWNS REPEATED OPERATION OF SAFETY THERMOSTAT REPEATED OPERATION OF SAFETY THERMOSTAT INSUFFICIENT RADIATOR TEMPERATURE INSUFFICIENT RADIATOR TEMPERATURE MAIN HEAT EXCHANGER FAULTY OR BLOCKED WITH LIME SCALE DEPOSITS LOW HEATING SYSTEM WATER PRESSURE CHECK GAS PRESSURES CHECK HEATING THERMOSTAT CHECK FAN CHECK PUMP MAIN HEAT EXCHANGER FAULTY...

Page 43: ...re Switch A02 Frost Thermostat A03 Modulator A04 Circulation Pump A05 Regulation Thermostat A06 External Control System A07 Time Clock Connector A08 External Room Thermostat A09 Air Pressure Switch A10 Fan A11 Overheat Thermostat A12 Spark Generator Gas Valve Supply A13 Detection Electrode Colours Wh White Bl Blue Gry Grey Brn Brown Blk Black Rd Red Grn Yll Yellow Green ...

Page 44: ...20 B063 SF008A ...

Page 45: ... 107 105 103 75 76 102 13 64 66 11 64 64 82 59 89 74 13 24 30 31 32 37 38 13 19 20 16 14 17 15 58 57 56 55 54 53 49 41 43 47 48 46 45 44 50 42 13 94 21 23 22 19 301 302 303 304 38 38 39 93 47 29 85 51 52 96 95 92 40 36 37 33 34 35 90 18 84 86 13 28 27 26 25 6 83 87 88 8 5 31 78 73 71 70 91 4 SHORT SPARE PARTS LIST microSYSTEM 21 28 RFFI ES002A ...

Page 46: ...l Gasket 3 8 Gasket 3 4 Thermostat frost Flow group Gasket 1 2 Safety valve 1 4 3 bar Gasket 1 4 Pump pressure switch Spark Generator Gasket Gas valve Auto air vent Return group O ring Pump Pump Thermostat regulation P C B CBM2 AT FFI2X Pressure gauge Gasket Air pressure switch Air pressure switch Gasket O ring 2 65 x 10 27 Fan Fan Main exchanger Main exchanger Thermostat overheat Burner 12 ramp n...

Page 47: ...23 B063 NOTES ...

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