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 Reference Standards
2.2 Siting the Appliance
2.3 Overall Dimensions
2.4 Clearances
2.5 Mounting the Appliance
2.6 Electrical Connection
2.7 Gas Connection
2.8 Water Connections
2.9 Flue Connection
2.10 Room Thermostat Connection
2.11 Electrical/System Diagrams
2.12 Water Circuit Diagrams

3. COMMISSIONING
3.1 Initial Preparation
3.2 Removing the Casing
3.3 Control Panel
3.4 Initial Start-up
3.5 Operational Adjustments
3.6 Combustion Analysis
3.7 Fume Discharge Monitoring
3.8 Boiler Safety Systems
3.9 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 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
INFORMATION 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

CE Certification
Heat Input max/min kW 25.6/11.0 29.8/12.0 29.8/12.0 33.0/12.0
Heat Output max/min kW 23.1/9.2 27.3/10.1 27.3/10.1 30.3/10.2
Efficiency of Nominal Heat Input % 90.2 91.6 91.6 92.0
Efficiency at 30% of Nominal Heat Input % 87.8 88.3 88.3 88.6
Heat Loss to the Casing (³T=50°C) % 1.2 1.3 1.3 1.4
Flue Heat Loss with Burner Operating % 8.6 7.1 7.1 6.6
Flue Heat Loss with Burner Off % 0.4 0.4 0.4 0.4
Maximum Discharge of Fumes (G20-G25) Kg/h 59 62 62 61
Residual Discharge Head mbar 1.15 1.4 1.4 1.4
Consumption at Nominal Capacity (G20-G25) m3/h 2.72/3.32 3.16/3.86 3.16/3.86 3.49/4.05
Gas Consumption after 10 Minutes* m3 0.32/0.39 0.37/0.45 0.37/0.45 0.41/0.47
(15°C, 1013 mbar) (G30-G31) Kg/h 2.02/2.00 2.35/2.32 2.35/2.32 2.60/2.57
Temp. of exhaust fumes at nominal
capacity (G20-G25) °C 137 128 128 135
CO2 Content % 5.8 6.6 6.6 7.5
O2 Content % 9.2 8.0 8.0 8.0
CO Content ppm 32 34 34 49
Minimum Ambient Temperature °C +5 +5 +5 +5
Head Loss on Water Side (max) (³T=20°C) mbar 200 200 200 200
Residual Head of System bar 0.25 0.25 0.25 0.25
Heating Temperature max/min °C 82/42 82/42 82/42 82/42
Domestic Hot Water Temperature max/min °C 56/36 56/36 --- 56/36
D.H.W. Flow Rate ³T=35°C l/min 9.5 11.2 --- 12.3
D.H.W. Flow Rate ³T=35°C gal/min 2.1 2.5 --- 2.7
D.H.W. Flow Minimum Rate l/min 2.6 2.6 --- 2.6
Pressure of Domestic Hot Water max/min bar 6/0.2 6/0.2 --- 6/.02
Expansion Vessel Capacity l 7 7 7 7
Expansion Vessel Pre-load Pressure bar 1 1 1 1
Maximum Water Content in System l 145 145 145 145
Maximum Heating Pressure bar 3 3 3 3
Nominal Pressure Natural Gas (G20-G25) mbar 20-25 20-25 20-25 20-25
Liquid Gas (G30-G31) mbar 30-37 30-37 30-37 30-37
Electrical Supply V/Hz 230 / 50 230 / 50 230 / 50 230 / 560
Power Consumption W 150 190 190 190
Protection Grade of Electrical System IP X4D X4D X4D X4D
Internal Fuse Rating FAST 2 AT FAST 2 AT FAST 2 AT FAST 2 AT
Weight Kg 47 47 46.5 47

G.C. Number 47-116-08 47-116-09 41-116-01 47-116-13

*Calculated at 70% maximum output

4 B004
1.3 Overall View

GENUS 23/27/30 MFFI GENUS 27 RFFI SYSTEM

Fig. 1.1
Legend:

1. Flue Connector
2. Combustion Chamber Hood
3. Main Heat Exchanger
4. Combustion Chamber Insulation Panel
5. Burner
6. Expansion Vessel
7. Overheat Thermostat
8. Spark Generator
9. Diverter Valve (MFFI)
Motorised Valve (RFFI)
10. Main Circuit Temperature Probe
11. Main Circuit Flow Switch
12. Domestic Hot Water Temperature Probe
13. Diverter Valve Microswitch
14. Filter Seat
15. Drain Valve
16. Secondary Heat Exchanger
17. Safety Valve (3 bar)
18. Circulation Pump with Automatic Air Release Valve
19. Gas Valve
20. Detection Electrodes
21. Ignition Electrodes
22. Fan
23. Venturi
24. Air Pressure Switch

B004 5
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.

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
2.1 Reference Standards 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 1988
Boilers of rated input
not exceeding 60 kW BS 6798 1987
Forced circulation hot
water system BS 5449 1990
Installation of gas hot water
supplies for domestic purposes
( 2nd family gases) BS 5546 1990
Flues BS 5440-1 1990
Air supply BS 5440-2 1989

2.2 Siting the Appliance 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
2.3 Overall Dimensions GENUS 23/27/30 MFFI

890 (A-B-D-E)

(C)

GENUS 27 RFFI SYSTEM

38
5

465

Legend:

A = Central Heating Flow (3/4”)

49
B = Domestic Hot Water Outlet (1/2”)

30
C = Gas Inlet (3/4”) 99 99
85 (F - G)
D = Domestic Cold Water Inlet (1/2”) 155 (A - D - E)
132 67 65
E = Central Heating Return (3/4”) 208 (C)
F = Cylinder Flow (3/4”)
G = Cylinder Return (3/4”) AF 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 23/27/30 MFFI GENUS 27 RFFI SYSTEM

110

400
160
197

60 60

450
0 nx-5 ai3 m

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 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.

8 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 E
I I
F G

Legend 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

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
Fig. 2.5 should be either with capillary soldered or compression fittings.
Where possible pipes should have a gradient to ensure air is carried naturally
Fitting the connection kit to the to air release points and water flows naturally to drain taps.
Genus 27 RFFI System only. 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
It will be noted that the kit has two
connections not required for this boiler collecting point for air.
i.e. the domestic cold inlet “E” and the Except where providing useful heat, pipes should be insulated to prevent heat
domestic hot water outlet “B” (see fig. loss and avoid freezing.
2.4). Particular attention should be paid to pipes passing through ventilated spaces
Although the cold water main supply in roofs and under floors.
must be connected to the isolation valve By-pass:
for the purpose of operating the filling- The appliance includes an automatic by-pass valve, which protects the main
loop, the isolation valve is NOT heat exchanger in case of reduced or interrupted water circulation through
connected to the boiler and should be left
the heating system, due to the closing of thermostatic valves or cock-type
in the OFF position.
The D.H.W. outlet is capped-off on the valves within the system.
boiler, therefore not requiring the System Design:
isolation valve to be used. This boiler is suitable only for sealed systems.
The Genus 27 RFFI System has 2 x 3/4" Drain Cocks:
B.S.P. male threads for the cylinder flow These must be located in accessible positions to permit the draining of the
and return. It is recommended that 2 x whole system. The taps must be at least 15mm nominal size and
22mm x 3/4" female iron fittings (not manufactured in accordance with BS 2870:1980.
supplied) be used on these connections Safety Valve Discharge:
(using P.T.F.E. tape), before the boiler is
The discharge should terminate facing downwards on the exterior of the
mounted on the wall.
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.
B004 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 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.

10 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
F D G
J
HI
A E

L K
TERMINAL POSITION mm
G

A - Directly below an open window or other opening 300

Fig. 2.6 B - Below gutters, solid pipes or drain pipes 75
C - Below eaves 200
D - Below balconies or car-port roof 200
E - From vertical drain pipes and soil pipes 75
F - From internal or external corners 300
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
J - From an opening in the car port
(e.g. door, window) into dwelling 1200
K - Vertically from a terminal in the same wall 1500
L - Horizontally from a terminal in the same wall 300

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
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.

Fig. 2.9 Fig. 2.10

12 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
In calculating the lengths of the

Twin Pipe
Systems

Systems
Coaxial
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

Exhaust Type
systems.

C52 (xy)

C42 (xy)

C32 (xy)

C12 (xy)

C42 (xx)

C32 (xx)

C12 (xx)
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

23 kW

23 kW - 27 kW
17 m

54 m

54 m

54 m

Maximum Extension
length is 17 m for Models Genus
23/27 MFFI/RFFI and 15 m for

4m

4m

4m

Exhaust/Air
Model Genus 30 MFFI. In this case

27 kW
the minimum length for the air
17 m

46 m

46 m

46 m
intake pipe is 1 meter ; the
maximum length of ver tical
exhaust pipe must be a maximum

30kW
30 kW
15 m

50 m

50 m

50 m
of 12 m.

3m

3m

3m
3. If an elbow is inserted into the
discharge/ventilation system, the
calculation of the overall extension

Diameter of
must take into consideration the

ø 60/100

ø 60/100

ø 60/100
values for each curve, as indicated

Pipes
(mm)
ø 80

ø 80

ø 80

ø 80
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

L * < 0.5 m

L * < 0.5 m

L * < 0.5 m

Use of Restrictor on Discharge Side

L<7m

L<7m

L<7m

L<7m

not obligatory if the exhaust and air

23kW
intake pipes are located on the

42 mm
same side of the building). L * < 0.5 m

L * < 0.5 m

L * < 0.5 m

27 kW
L<5m

L<5m

L<5m

L<5m

L * < 0.5 m

L * < 0.5 m

L * < 0.5 m
L < 7.5 m

L < 7.5 m

L < 7.5 m

L < 7.5 m

45 mm
30 kW
L > 4.9 m

L > 4.9 m

L > 4.9 m

L > 4.9 m

Risk of Condensation Forming

23kW
L < 5.3 m

L > 6.5 m

L > 6.5 m

L > 6.5 m

27 kW
(*) L = Length of Piping

L > 4.5 m

L > 4.5 m

L > 4.5 m

L > 4.5 m

30 kW

14 B004
2.10 Room Thermostat In order to perform this procedure, remove the boiler casing as indicated in
Connection 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 B 2 3

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 6

E D

B004 15
2.11 Electrical Diagram Legend:

AT = High Voltage P.C.B.

BT = Low Voltage P.C.B.
A = Remote Connector Kit
B = Flame Failure L.E.D.
C = Insufficient Water Pressure L.E.D.
D = Water Temperature Indicator L.E.D.s
E = Overheat Thermostat Warning L.E.D.
F = System Reset Button
G = Selector Knob for Operating Mode
H = Domestic Hot Water Temp. Adjustment
I = Central Heating Temp. Adjustment
J = Wire Connector for Room Thermostat
K = Connector for Total Check System
L = Selector for Local/Remote Control
M = Anti-cycling Device Adjustment for Heating
N = Soft-light Adjustment
O = Max Heating Temperature Adjustment
P = Time Clock Connection
Q = On/Off L.E.D.
R = On/Off Switch
S = Interface Wire for P.C.B.s
T = Relay Motorised Valve
U = Ignitor Relay
V = Gas Valve Relay
W = Fan Relay
X = Circulation Pump Relay
Y = Selector TCS2
Z = Link for Continuous Pump Run
Aa = Adaptor (British Gas use only)

A01 = Air Pressure Switch

A02 = Fan
A03 = Gas Valve
A04 = Ignitor
A05 = Motorised Valve
A06 = Circulation Pump
A07 = Flame Detector
A08 = Earth Terminal
A09 = Flame Detection Circuit
A10 = Flame Indicator L.E.D.
A11 = Transformer
A12 = Filter

B01 = Over Heat Thermostat

B02 = External Thermostat
B03 = Gas Valve Modulator
B04 = D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only)

B05 = Heating Sensor

B06 = Pressure Switch for Heating Circuit
B07 = Microswitch for Diverter Valve (MFFI models only)

Colours

Gry = Grey
Rd = Red
Bl = Blue
Grn/Yll = Yellow/Green
Wh = White
Brn = Brown
Blk = Black
Wh/Rd = White/Red
16 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

Legend
GENUS 23/27/30 MFFI
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
18. Water Pressure Gauge
GENUS 27 RFFI SYSTEM
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;

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

A - Ignition Lockout Reset

GENUS 23/27/30 MFFI
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
Intervention L.E.D.
GENUS 27 RFFI SYSTEM 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 appro-
priate 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 shut-
down 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 The boiler was designed to make regulation easy. To access the adjustment
Adjustments 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.

B1 B2
A 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 5 mbar
G25 18 mbar
G30-31 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 Fume Discharge The discharge/ventilation of the exhaust fumes can be monitored to check for
Monitoring 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.

B004 23
3.8 Boiler Safety The boiler is equipped with the following safety systems (see section 3.3 for
Systems 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 shut-
off 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+ Methane Gas Liquid Butane Gas Liquid Propane Gas
G20 G30 G31

Lower Wobbe Index (15°C;1013mbar) MJ/m3h 45.67 80.58 70.69

Nominal Delivery Pressure mbar 20 30 37
Minimum Delivery Pressure mbar 17 20 25

23 MFFI

Main Burner: n. 13 jets (ø) mm 1.25 0.72 0.72

Consumption (15°C; 1013mbar) mc/h 2.72 ---- ----
Consumption (15°C; 1013mbar) Kg/h ---- 2.02 2.02
Gas Cock Outlet Pressure
max - min mbar 11.4- 2.0 27.5 (*) - 5.0 35.0 (*) - 7.0

27 MFFI - 27 RFFI System

Main Burner: n. 15 jets (ø) 1.25 0.72 0.72

Consumption (15°C; 1013mbar) mc/h 3.16 ---- ----
Consumption (15°C; 1013mbar) Kg/h ---- 2.35 2.32
Gas Cock Outlet Pressure:
max - min mbar 11.4-2.0 (*) - 5.0 (*) - 7.0

30 MFFI

Main Burner: n. 15 jets (ø) 1.30 0.77 0.77

Consumption (15°C; 1013mbar) mc/h 3.49 ---- ----
Consumption (15°C; 1013mbar) Kg/h ---- 2.60 2.57
Gas Cock Outlet Pressure:
max - min mbar 11.4-1.4 (*) - 4.1 (*) - 5.6

(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 The boiler can be converted to use either methane (natural) gas (G20) or
Gas 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;

CATEGORY II2H3+ Methane Gas Liquid Butane Gas Liquid Propane Gas

G20 G30 G31

Recommended Soft-light Pressure

(mbar) 5-5.5 17 - 18 18 - 19

B004 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. 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 tem-
perature)
13 - Check of the general performance of the unit.
14 - General check of the discharge/ventilation of the combustion by-
products.

26 B004
 6.

B004
6.1

2
3
1
2
3
1

E
N

240V
BLUE
BLUE

ROOM
ROOM

GREY
GREY

VALVE
VALVE

T6360B
T6360B

V4043H
V4043H

BROWN
BROWN

ORANGE
ORANGE

GREEN/YELLOW
GREEN/YELLOW

THERMOSTAT
THERMOSTAT

MAINS INPUT (3 AMP)

ZONE1

ZONE 2
2
8
6
2
5
4

3
9
2
8
3
9
2
5

3
2
1
10
10
Wiring Diagram for
Two Heating Zones
MISCELLANEOUS

• 9
• 8
• 7
• 6
• 5
• 4
• 3
• 2
• 1

• 10
TYPICAL
JUNCTION BOX
6 4 3 2 1 6 4 3 2 1 9 10 3 2 1

Honeywell ST 699B 1002 6 3 N L Pegler Sunvic 2 5 E N L A/27 MFFI - A/27 MFFI E N L

Link L-5-8 SP 50/100 (Link L-3) Genus 23-27-30 MFFI E N L
ST 6400/ST 6300 ST 6200 3 4 N L Switchmaster Genus 27 RFFI System E N L
1 4 N L
Symphony, Sonata
Drayton Tempus 7 3 4 N L
Switchmaster 400, 600 3 1 N L
Horstmann 425, 525, 527 1 4 E N L
Link L-2-5 SWITCHMASTER 805, 900 3 1 N L
Landis & Gyr RWB2 3 4 N L Sunvic ET 1451 7 4 E 1 2
Glowworm Mastermind Link 2-3-6
Landis & Gyr RWB20 3 4 N L Sunvic DHP 2201 6 3 E 1 2
Microgyr
Towerchron FP 6 1 0 2 1
Potterton Miniminder 3 4 N L Link 1-5/4-7-9
Potterton EP2000/3000 - 3 4 N L Towerchron MP 6 1 0 2 1
the junction box.

Link L-5 EP2001/3001 Link 1-4/6-11

Randall 102/102 E 1 2 E 5 6 Towerchron 2000 HW HTG N L
Link 3-6 ON ON
Randall 4033 4 2 E 7 6 ACL LS522, LS722 3 4 N L
Link 1-6
Randall 922, 972 3 6 E N L
Randall 701, 702 3 1 E N L Link L-2-5
Link L-6-5
room stat terminal block on the

Randall 3020 P
(see section 2.10) to 9 + 10 on

4 2 E N L
Remove internal time clock plug
from the the P.C.B. then connect

Sangamo M5 1 8 E 4 3 and 3060

reverse of the boiler control panel

Link 1-6
Sangamo 410 Form 1 1 8 E 4 3
BOILER ELECTRICAL SUPPLY CABLE

Link 3-6

If a room thermostat is not requied on Zone 2, insert a link

between 6 + 8 on the junction box.
between 4 + 5 on the junction box.
If a room thermostat is not required on Zone 1, insert a link
PROGRAMMER PROGRAMMER BOILER

ZONE 2 ZONE 1 ZONE 2 ZONE 1

27
Based on Honeywell controls
28
6.2

2
1
L
2
3
1

E
N

240V
BLUE
BLUE
ROOM

GREY
GREY

Cylinder
T6360B

V4043H
V4043H

BROWN
BROWN

thermostat

C/P
ORANGE
ORANGE

GREEN/YELLOW
GREEN/YELLOW
THERMOSTAT

HEATING VALVE

HOT WATER VALVE

MAINS INPUT (3 AMP)

2
5
4

cut-out
Thermal
3
2
1
3
9
2
8
3
9
2
5

1 C/P
10
10

2
1

P
Unvented Cylinder
Wiring Diagram for
Connection to Ariston

6
8

Not
used
• 9
• 8
• 7
• 6
• 5
• 4
• 3
• 2
• 1

• 10
TYPICAL
JUNCTION BOX

6 4 3 2 1 6 4 3 2 1 9 10 3 2 1

Honeywell ST 699B 1002 6 3 N L Pegler Sunvic 2 5 E N L A/27 MFFI - A/27 MFFI E N L

Link L-5-8 SP 50/100 (Link L-3) Genus 23-27-30 MFFI E N L
ST 6400/ST 6300 ST 6200 3 4 N L Switchmaster Genus 27 RFFI System E N L
1 4 N L
Symphony, Sonata
Drayton Tempus 7 3 4 N L
Switchmaster 400, 600 3 1 N L
Horstmann 425, 525, 527 1 4 E N L
Link L-2-5 SWITCHMASTER 805, 900 3 1 N L
Landis & Gyr RWB2 3 4 N L Sunvic ET 1451 7 4 E 1 2
Glowworm Mastermind Link 2-3-6
Landis & Gyr RWB20 3 4 N L Sunvic DHP 2201 6 3 E 1 2
Microgyr
Towerchron FP 6 10 2 1
Potterton Miniminder 3 4 N L Link 1-5/4-7-9
Potterton EP2000/3000 - 3 4 N L Towerchron MP 6 10 2 1
the junction box.

Link L-5 EP2001/3001 Link 1-4/6-11

Randall 102/102 E 1 2 E 5 6 Towerchron 2000 HW HTG N L
Link 3-6 ON ON
Randall 4033 4 2 E 7 6 ACL LS522, LS722 3 4 N L
Link 1-6
Randall 922, 972 3 6 E N L
Randall 701, 702 3 1 E N L Link L-2-5
Link L-6-5
room stat terminal block on the

Randall 3020 P
(see section 2.10) to 9 + 10 on

4 2 E N L
Remove internal time clock plug
from the the P.C.B. then connect

Sangamo M5 1 8 E 4 3 and 3060

reverse of the boiler control panel

Link 1-6
Sangamo 410 Form 1 1 8 E 4 3
BOILER ELECTRICAL SUPPLY CABLE

Link 3-6

PROGRAMMER PROGRAMMER BOILER

Based on Honeywell controls

B004
NOTES

B004
NOTES

B004 30
31 B004
 B004 - Cod. 23 99 84 1259 111 - Stampa: bieffe RECANATI

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
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
TABLE OF CONTENTS
Page No.

1. SERVICING INSTRUCTIONS

1.1 Replacement of Parts 3

1.2 To Gain General Access

- Removing the Front Panel 3
- Removing the Bottom Cover 4
- Removing the Side Panels 4

1.3 Access to the Combustion Chamber

- Removing the Sealed Combustion Chamber 5
- Removing the Burner and Injectors 5
- Removing the Electrodes 6
- Removing the Main Heat Exchanger 7
- Removing the Air Pressure Switch 7
- Removing the Venturi Device 8
- Removing the Fan 8

1.4 Servicing and Removal of the Gas Valve

- Setting Gas Pressure 10
- Removing the Spark Generator (SIT Sigma Gas Valve) 12
- Removing the Spark Generator (SIT Tandem Gas Valve) 13
- Removing the Gas Valve 14

1.5 Access to the Hydraulic Circuit

- Removing the D.H.W. (Secondary) Exchanger 14
- Removing the Safety Valve 15
- Removing the Automatic Air Vent 15
- Removing the Main Flow Circuit Switch 15
- Removing the Pump 16
- Removing the Pressure Gauge 16
- Removing the Expansion Vessel 17
- Removing the Overheat Thermostat 17
- Removing the Heating Temperature Sensor (N.T.C.) 17
- Removing the D.H.W. Temperature Sensor (N.T.C.) 18
- Removing the Diverter Valve (Genus 27 RFFI Only) 18

1.6 Access to the Control System

- Checking the Fuses 19
- Removing the Time Clock 19
- Removing the P.C.B.s 20

2. FAULT FINDING

2.1 Fault Finding Guide (Flow-chart) 21

2.2 Fault Finding Using the Total Check System 26

3. ELECTRICAL DIAGRAMS

3.1 Electrical Connection 27

3.2 Functional Flow Connection 29

4. SHORT SPARE PARTS LIST 30

2 B005
 To ensure efficient safe operation, it is recommended that the boiler is
1. 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).

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).

1.1 Replacement The life of individual components vary and they will need servicing or
replacing as and when faults develop.
of Parts
The fault finding sequence chart in chapter 2 will help to locate which
component is the cause of any malfunction, and instructions for removal,
inspection and replacement of the individual parts are given in the following
pages.

1.2 To Gain General All testing and maintenance operations on the boiler require the control panel
Access to be lowered. This will also require the removal of the casing.

To dismantle the front part of the casing, proceed as follows:

1. Loosen the two screws “A” located on the bottom part of the boiler until
the first thread on the screws appears (Fig. 1.1);
2. Lift the front panel up until it stops with a click and remove the front
panel from the rest of the casing (Fig. 1.2);
4. Unhook the two cords from the locating slots (Fig. 1.3).

Fig. 1.3

Fig. 1.1

Fig. 1.2

B005 3
Removing the bottom cover

1. Remove the screws “B”

Fig. 1.4

Removing the side panels

C
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

4 B005
1.3 Access to the
Combustion Chamber

Removing the sealed chamber Removing the combustion cover

frontal cover

D D

E E
E
Remove the screws “D”

E
E

D D E
E

Remove the screws “E”

Fig. 1.6 Fig. 1.7

Removing the burner and the 1. Remove the side panels of sealed chamber (fig. 1.8);
injectors 2. Remove the screws “F” of the burner (see fig. 1.9);
3. Remove the burner (see fig. 1.10);
4. Remove the injectors using a No. 7 socket spanner;
5. Replace in reverse order.

push
F

Fig. 1.9

push

Fig. 1.8
Fig. 1.10

B005 5
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. 1.12

Fig. 1.11 Fig. 1.13

5. Remove screw “H” using a Philips No. 2 star tip screwdriver (see fig. 1.14);
6. Slide the electrode gently downward (see fig. 1.15).

Fig. 1.14 Fig. 1.15

To replace, repeat the steps in reverse order, paying particular attention to the
following:
a - Centre the electrode in the positioning hole carefully, otherwise the
electrode may break;
b -Check that the cables have been connected correctly;
c - Check that the rubber gasket covers the cable/electrode connection
point completely.

6 B005
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. 1.16 Fig. 1.17

Removing the air pressure switch 1. Disconnect the electrical connections “K” and silicone pipes “L” from their
connection points (see fig. 1.18);
2. Remove screws “J” on the top of the sealed chamber (see fig. 1.19);
Use a No. 2 star tip screwdriver to remove the switch from the plate.

J J
L

L
Fig. 1.18

Fig. 1.19

B005 7
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).

M N

Fig. 1.20 Fig. 1.21

Removing the fan

1. Disconnect electrical connections and remove screws

“O” using a No. 2 star tipped screwdriver (see fig.1.22);
2. Pull fan to the right and forward and remove (see fig.1.23);
3. Remove fan from mounting plate;
4. Remove screws “P” (see fig.1.24).

Fig. 1.22

Fig. 1.23 Fig. 1.24

8 B005
1.4 Servicing and Removal
of the Gas Valve

SIT SIT
SIGMA 1 TANDEM 1

B B

A
A

2 2

D
D
C C

3 3

4 4

B005 9
 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”.
When you have completed this operation, replace the screw “A” securely
into its housing to seal off the gas.
3. To check the pressure supplied by the gas valve to the burner, remove the
screw “C”. Fit the pipe of the pressure gauge to the pressure outlet of the
gas valve “D”.
Disconnect the compensation pipe either from the gas valve or from the
sealed chamber.
4. Set the On/Off button to position < I > and the "summer/winter" switch to
the winter position.
To set the maximum power, turn on the hot water tap and allow the hot
water tap to run at a rate of about 8 litres/minute so that the main burner
lights.
Adjust nut “E” on the modureg to set the gas pressure (displayed on the
pressure gauge) corresponding to the maximum power (see table “A” page 11).
5. To set the minimum power, disconnect a supply terminal from the modureg
and adjust screw “F”.
Turn the screw clockwise to increase the pressure and coun-
ter-clockwise to decrease the pressure (displayed on the
pressure gauge) corresponding to the minimum power (see table “A” page
11).
6. When you have completed the above operations, turn off the
hot water tap, re-connect the supply terminal to the modureg
on the gas valve and replace the cap on the screw of the
modureg.

Setting the maximum heating circuit power

7. To set the maximum heating circuit power, place the
On/Off button to position < I > and the "summer/winter" switch to winter
position.
Turn the knob of the heating thermostat clockwise to maximum;
8. Remove the left hand inspection panel of the P.C.B. and fit a small
cross-head screwdriver in to the right hand potentiometer. Turn clockwise
to increase the pressure or counter-clockwise to reduce the pressure.
Adjust the setting to the required heating pressure value (displayed on the
pressure gauge), as indicated in the diagrams shown in page 11.
9. Turn off the boiler by placing the main switch to the "Off" position.

Setting pressure for soft ignition.

Disconnect the detection electrode connection from the P.C.B. (see fig.
1.13).
Start the boiler and during the ignition sequence adjust the centre
potentiometer until the gas pressure reads the required gas pressure as
per the table below.
Once the gas pressure is set turn off the boiler and reconnect the
connection to the P.C.B.
NB.: It may be necessary to reset the flame failure reset a number of times
during this operation.

NATURAL GAS (G20) BUTANE GAS (G30) PROPANE GAS (G31)

Recommended pressure for

slow ignition 5 mbar - 1.95 in w.g. 18 mbar - 7.0 in w.g. 19 mbar - 7.4 in w.g.

10 B005
 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) 40
38
36
34

model 23

model 27

TABLE “A”

B005 11
 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.

Setting the anti-cycling device

This appliance is equipped with a potentiometer which delays the ignition of
the heating control and is situated on the P.C.B. (see the electrical diagrams).
By adjusting the potentiometer, it is possible to change the time interval
between the burner shutting down and its next ignition.
It is preset at 1 minute and can be adjusted from 0 to 2 minutes.
Anti-cycling Soft-light Max Heating Use this control in particular situations where continuous shutting down and
Device Adjustment Adjustment
ignition of the main burner occurs.

Removing the spark generator (SIT Sigma gas valve)

1. Disconnect ignition leads “Q” by pulling upwards

(see fig. 1.25);
2. Remove the screws “R” (see fig. 1.26) with a Pozidrive
No. 2 star tip screwdriver;
Q 3. Remove the spark generator.

Fig. 1.25

Fig. 1.26 Fig. 1.27

12 B005
 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.

Q1

Fig. 1.28

R1

R1

Fig. 1.29 Fig. 1.30

B005 13
 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. 1.32).
Attention!! The gas valve is connected with the two pipes
(as shown) with an O-ring connection.

T T

Fig. 1.31 Fig. 1.32

Fig. 1.33 Fig. 1.34

1.5 Access to Hydraulic Important! Before any component is removed, the boiler
Circuits must be drained of all water.

Removing the D.H.W. (secondary)

exchanger
1. Remove the screw “U” (see fig. 1.35);
2. Push the exchanger towards the rear of the
boiler, lift upwards and remove out of the
front of the boiler;
U U 3. Before replacing the exchanger ensure that
the O-rings are in good condition and
replace if necessary.

Fig. 1.35

14 B005
 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. Remove the screws “Y1” (see fig. 1.38);
3. Remove the main circuit flow switch.

Y1

Y1 Fig. 1.38

B005 15
 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).

A1

A1

Fig. 1.39 Fig. 1.40

Removing the pressure gauge

1. Remove the pressure gauge cover by pulling
(see fig. 1.41);
2. Release coupling “A2” using a 14 mm open ended
spanner (see fig. 1.42);
3. Push the pressure gauge through the control panel
from the rear (see fig. 1.43).

Fig. 1.41

A2

Fig. 1.42 Fig. 1.43

16 B005
 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).

A3

Fig. 1.44

A4

Fig. 1.45 Fig. 1.46

Removing the overheat thermostat

1. Remove the electrical connector by the overheat
thermostat (see fig. 1.47);
2. Pull off the thermostat connections. Then remove the
thermostat from the pipe by releasing it’s securing clip.

Fig. 1.47

Removing the heating temperature sensor (N.T.C.)

1. Remove the electrical connector by pulling off the
thermostat connections and unscrewing the sensor
probe with a 14 mm open ended spanner (see fig.
1.48).

Fig. 1.48

B005 17
 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. Remove the circlip and pull the diverter valve to the left.

Fig. 1.50

18 B005
1.6 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. Remove electrical connection “A5” of the clock (see fig.
1.54);
3. Unscrew “A6” and remove (see fig. 1.55).

N.B.
It is possible to by-pass the time clock in the event of
failure by simply unplugging the electrical connection from
the P.C.B. (see fig. 1.54). This will revert control of the
central heating to the room stat connection on the reverse
of the control panel.

Fig. 1.53

A5

A6
A5 A6

Fig. 1.49 Fig. 1.50

B005 19
 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. To remove the 24V P.C.B.: remove the electrical plug
A7 A7 connectors and screws “A9” (see fig. 1.53);
8. To remove the 240V P.C.B.: remove the electrical plug
connectors and screws “A10” (see fig. 1.54);
9. Replace either P.C.B. in reverse order.
A7
A7
Fig. 1.51

A10
A9

A8 A9 A10
A8

Fig. 1.52 Fig. 1.53 Fig. 1.54

20 B005
2. FAULT FINDING

2.1 Fault Finding Guide It is possible to detect and correct any defect by using the standard fault
(Flow-chart) finding diagrams described in this chapter.

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
On / Off Button

HAS
THE LIGHT fOR
THE POWER SUPPLY NO
COME ON?
1) Check the fuses
YES 2) Check the power
supply cord, plug and
outlet
3) Check/replace the power
supply P.C.B.

SETTING
SUMMER FOR THE OPERATING
MODE
WINTER

FUME DISCHARGE TEST

IS HOT IS HOT
WATER BEING YES YES WATER BEING
DEMANDED? DEMANDED?

NO NO

FOR BOILERS
EQUIPPED WITH AN DO THE
ELECTRONIC ANT-FREEZE TIME CLOCK
NO SYSTEM: HAS THE SAFETY BEEN YES AND/OR R O O M
TRIGGERED TO ACTIVATE
YES THERMOSTAT NEED
THE DEVICE? TO BE ACTIVATED
(T sensor <5C̊)

NO

FOR BOILERS
EQUIPPED WITH AN
ELECTRONIC ANT-FREEZE
SYSTEM: HAS THE SAFETY BEEN
YES TRIGGERED TO ACTIVATE
NO
THE DEVICE?
(T sensor <5C̊)

A
B005 21
 A

DOES THE
CIRCULATION PUMP NO
COME ON?

YES
POWER TO
THE PUMP? NO

YES
DOES THE
INSUFFICIENT WATER
YES 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 NO 1) Check to see if pump is power supply
3) Check/replace pressure stuck P.C.B.
gauge and refill the 2) Replace circulation pump 4) Replace control
the system properly P.C.B.
5) Check micro-
switch when hot
1) Turn the boiler off water is requested.
and then back on
again (safety reset)

22 B005
 B

DOES THE FAN

COME ON? NO

YES BOILER
SHUTDOWN? YES 1) Reset the boiler

NO

C PUMP
1) Check/replace differential
pressure switch for pump
2) Check/replace wiring
SAFETY DEVICE YES 3) Check/replace P.C.B. wire
ACTIVATED? 4) Check/replace power
supply P.C.B.
5) Check/replace control
NO P.C.B.

1) Check/replace air
INTERNAL pressure switch/wiring
SAFETY DEVICE 2) Check whether reset
FOR PCB YES button is stuck
ACTIVATED? 3) Check/replace flame
detection electrode
NO
1) Check/replace wiring
2) Check/replace P.C.B. wire
IS THERE POWER
3) Check/replace power
TO THE FAN?
NO supply P.C.B.
4) Check/replace control
P.C.B.
YES 5) Check/replace air
pressure switch

1) Replace fan

B005 23
 C
1) Check flue discharge
2) Check venturi & small pipes
IS 3) Check wire for air press.switch
THE AIR PRESSURE 4) Check/replace air press. switch
SWITCH ACTIVATED?
NO
5) Check/replace P.C.B.wire
6) Check/replace power P.C.B.
7) Check/replace control P.C.B.
YES
1) Check/replace ignition electrodes
2) Check wiring
ARE THE 3) Check spark generator
FUMES DISCHARGED NO 4) Check small wire
CORRECTLY? 5) Check power supply P.C.B.
6) Check control P.C.B.

YES
1) Check supply of gas to gas
valve
DOES THE 2) Check power supply P.C.B.
BURNER LIGHT? NO 3) Check control P.C.B.
4) Check functionality of the gas
YES valve

1) Check whether flame

SAFETY detection electrode is
SHUTDOWN OF THE postioned in the flame
BOILER ACTIVATED? YES 2) Check the electrode
3) Check the power P.C.B.
4) Check the control P.C.B.
NO

WAS THE
NO RESET SWITCH

D PRESSED?

YES

Shutdown L.E.D. off

Restart of the fan

24 B005
 D

IS
THERE STILL A
PROBLEM? YES

NO

FUNCTIONS
NORMALLY

LIST OF MALFUNCTIONS POSSIBLE CAUSES

1 Delivery of hot water for domestic use: - Air in the secondary exchanger
when the tap is turned on, the burner goes out. - Hot water pressure switch is defective
- 3-way valve is defective

2 Delivery of hot water for domestic use: - 3-way valve is defective

the radiatores are heated in summer mode.

3 Delivery of hot water for domestic use: - Check sensors for domestic and heating water
water temperature is not satisfactory. - Check gas settings and regulation
- Check water flow rate
- Check secondary exchanger

4 Delivery of hot water for domestic use: - Primary exchanger is defective

noisy operation. - Low water pressure in heating system
- Check gas settings and regulation
- Check ntc sensor for domestic hot water
5 Drop/increase in pressure in primary circuit. - Check for leaks in heating circuit
- Defective water supply inlet valve
- Secondary exchanger is defective
- Expansion vessel is empty

6 Repeated shutdowns. - Detection electrodes are defective

- Check gas settings and regulation
- Check electrical circuit for flamedetection

7 Safety thermostat is triggered repeatedly. - Faulty(contacts)N.T.C. sensors-heating/hot water

- Defective (poorly calibrated) safety thermostat
- Presence of air in the primary water circuit

8 When the cold water tap is turned off, the - Drop in pressure in the water mains, resulting
boiler comes on. in water hammering

9 Temperature of radiators not satisfactory. - Check N.T.C. sensor for heating

- Check by-pass
- Check gas settings and regulation

B005 25
2.2 Fault Finding Using the
Total Check System
Malfunction

Signalling A Faulty ventilation system

b Air pressure switch stuck in N.O. position
Boiler Off C Faulty reset switch
1 Auto diagnostic state d Faulty main circuit flow switch
2 Spark ignition state
3 Boiler functioning normally E Faulty flame detection
4 Lockout F Faulty overheat thermostat
5 Boiler thermostat satisfied G Faulty exhaust fumes sensor
6 Room thermostat/clock no demand or I Faulty heating sensor (N.T.C.)
selector in summer setting m Faulty D.H.W. sensor (N.T.C.)

Pump fed
Main flow switch closed
Air pressure switch N.O.
Flame detected
Water at required temperature

Room thermostat/clock no demand or

selector in summer setting

Auto diagnostics faulty

D.H.W. exchanger efficiency control

Heating circuit efficiency control

Heating temperature control

D.H.W. temperature control

26 B005
 Legend:
3. ELECTRIC
DIAGRAMS AT = High Voltage P.C.B.
BT = Low Voltage P.C.B.
A = Remote Connector Kit
B = Flame Failure L.E.D.
C = Insufficient Water Pressure L.E.D.
D = Water Temperature Indicator L.E.D.s
E = Overheat Thermostat Warning L.E.D.
F = System Reset Button
G = Selector Knob for Operating Mode
H = Domestic Hot Water Temp. Adjustment
I = Central Heating Temp. Adjustment
J = Wire Connector for Room Thermostat
K = Connector for Total Check System
L = Selector for Local/Remote Control
M = Anti-cycling Device Adjustment for Heating
N = Soft-light Adjustment
O = Max Heating Temperature Adjustment
P = Time Clock Connection
Q = On/Off L.E.D.
R = On/Off Switch
S = Interface Wire for P.C.B.s
T = Relay Motorised Valve
U = Ignitor Relay
V = Gas Valve Relay
W = Fan Relay
X = Circulation Pump Relay
Y = Selector TCS2
Z = Link for Continuous Pump Run
Aa = Adaptor (British Gas use only)

A01 = Air Pressure Switch

A02 = Fan
A03 = Gas Valve
A04 = Ignitor
A05 = Motorised Valve
A06 = Circulation Pump
A07 = Flame Detector
A08 = Earth Terminal
A09 = Flame Detection Circuit
A10 = Flame Indicator L.E.D.
A11 = Transformer
A12 = Filter

B01 = Over Heat Thermostat

B02 = External Thermostat
B03 = Gas Valve Modulator
B04 = D.H.W. Probe Sensor Cylinder (RFFI SYSTEM models only)

B05 = Heating Sensor

B06 = Pressure Switch for Heating Circuit
B07 = Microswitch for Diverter Valve (MFFI models only)

Colours

Gry = Grey
Rd = Red
Bl = Blue
Grn/Yll = Yellow/Green
Wh = White
Brn = Brown
Blk = Black
Wh/Rd = White/Red
B005 27
 GENUS 23/27/30 MFFI

Aa

GENUS 27 RFFI SYSTEM

Aa

28 B005
 GENUS 23/27 MFFI

CN202
P

GENUS 27 RFFI SYSTEM

P

B005 29
4. SHORT SPARE
PARTS LIST

GENUS 23/27 MFFI (SIT Sigma Gas Valve)

2 71 70 63 69 68 65 66 67 66 65 64 63 62 61 60 59 58 57 56

2 74

74
3 72
73
124
301
301
4 4

74 123
4
75
4 122
62
76
77 121 302 303 304 305 306
78
6 120
79
7 55
7
54
80 114
8 81
119 115
113
9 81 118 116
112 53
10 117
11 111
48 52
110 51
82 102 103 50
51
83 104 49
101 105 48
109 47
11 87 86 98
106
84 95 100 108
44 46
85 99
88 45
12 85 107
86 98
96 44
97
13 84 43
14 94
89 89 44 42
90 41
11 93 40
15 23 39 39
91 92 38
91
18 36

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

100 16
361
362
364

363

321

17 22
371
372 311
373
374

375
23/27 MFFI

30 B005
 GENUS 30 MFFI (SIT Sigma Gas Valve)

2 72 71 64 70 69 66 67 68 67 66 65 64 63 62 61 60 59 58 57

2 75

75 126
3 73
74
125
301
301
4 4

75 124
4
76
4 123
63
77
78 122 302 303 304 305 306
79
6 121
80
7 56
7
55
81 115
8 82
120 116
114
9 82 119 117
113 54
10 118
11 112
49 53
111 52
83 103 104 51
52
84 105 50
102 106 49
110 48
11 88 87 99
107
85 96 101 109
45 47
86 100
89 46
12 86 108
87 99
97 45
13 98
85 44
14 95
90 90 45
15 43
91 42
11 94 41
16 24 40 40
92 93 39
92
18 37

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

101 17
361
362
364

363

321

18 23
371
372 311
373
374

375
30 MFFI

B005 31
 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve)

2 73 72 65 71 70 67 68 69 68 67 66 65 64 63 62 61 60 59 58

2 76

76
3 74
75
119
301
301
4 4

76 118
4
77
4 117
64
78
80 79 116 302 303 304 305 306
6 115
81
7 57

7 56
82
8 83 109
114 110
111 108
9 113 55
107
10 83 112
106 54
11
105 50 53
84 97 98 53 52
99
85 100 51
11 96 50
101 104 49
86 93
87 95 102 46 48
12 103
94 47

13 93 46
14 88 92 45
86
46 44
11 89
43
90 42
15 11 91 41 41
11 23 40
16 16
38
23
17

18 19 20 21 22 23 24 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

20 95

371
372
373
374

321
375

19
362

361

363 27 MFFI SYSTEM

32 B005
 GENUS 23/27 MFFI (SIT Sigma Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 379816 Expansion vessel 1 573294
11 164 225 Gasket 3/4" 573520
14 Overheat thermostat 1 997206
17 Main flow Switch 1 573224
18 164 338 Temp probe (C.H.W.) 1 569236
19 Microswitch for 3-way/main flow group 1 573340
23 164 229 Gasket 1/2" 573528
24 378 814 Manual vent cock 1 573727
25 Safety valve 3 bar 1/2" 1 573172
28 Pressure gauge 1 571649
31 Time clock 1 997208
43 P.C.B. E C-MI/FFI 1 953045
45 P.C.B. EI A-MFFI 1 952981
46 P.C.B. cable 1 952610
56AB Fan 1 572989
56CD Fan 1 572990
57 Fan inlet gasket 1 573343
60 Venturi (exhaust manifold/header) 1 573314
71AB E03 818 Air pressure switch 1 571651
71CD E02 071 Air pressure switch 1 571652
74 Fastening spring 570717
83 379 079 Automatic air release valve 564254
84 164 230 Gasket 1" 1 569387
86 O-ring 1 571449
88AB Secondary exchanger (plate-type) exchanger 23kW 571646
88CD Secondary exchanger (plate-type) exchanger 27kW 573295
89 O-ring (secondary exchanger) 1 573825
91 20-18 O-ring 571807
94 164 282 Gasket 3/8" 1 573521
95AB Pump 1 997150
95CD Pump 1 997151
98 O-ring (13) 1 571965
99 Gasket 574279
100 Gas valve (SIT Sigma) 1 574232
106 Spark generator 1 574233
110 379 981 Detection electrode 1 573441
114 164 261 Gasket 1/4" 1 569390
116 379 979 Ignition electrode (R.H.) 1 569560
117 379 980 Ignition electrode (L.H.) 1 569561
118A E02 026 Main burner 1 572271
118B Main burner 1 572277
118C E02 078 Main burner 1 572343
118D Main burner 1 572372
119AB Main exchanger 1 572749
119CD Main exchanger 1 572835
301 Front panel runner kit 571993
311 D.H.W. actuator kit 571444
321 SIT Sigma gas valve operator coils 997029
361 Heating by-pass kit 571443
362 D.H.W. pressure switch kit 571442
363 3-way spring kit 571447
364 D.H.W. diaphram valve 571446
371 Main flow switch diaphram 571547
372 Main flow switch magnet 571772
373 Main flow switch spring 571771
374 Main flow switch top cap 571770
375 Main flow switch reed system 573138
381 164 311 Burner jet 1.25 full kit (Natural gas) 569281
382 Burner jet 0.72 full kit (LPG) 569282

B005 33
 GENUS 30 MFFI (SIT Sigma Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 379816 Expansion vessel 1 573294
11 164 225 Gasket 3/4" 573520
15 Overheat thermostat 1 997206
16 Main flow Switch 1 573224
19 164 338 Temp probe (C.H.W.) 1 569236
20 Microswitch for 3-way/main flow group 1 573340
24 164 229 Gasket 1/2" 573528
25 378 814 Manual vent cock 1 573727
26 Safety valve 3 bar 1/2" 1 573172
29 Pressure gauge 1 571649
32 Time clock 1 997208
44 P.C.B. E C-MI/FFI 1 953045
46 P.C.B. EI A-MFFI 1 952981
47 P.C.B. cable 1 952610
57 Fan 1 572990
58 Fan inlet gasket 1 573343
72 E02 071 Air pressure switch 1 571652
75 Fastening spring 1 570717
84 379 079 Automatic air release valve 1 564254
85 164 230 Gasket 1" 1 569387
87 O-ring 571449
89 Secondary exchanger (plate-type) exchanger 27kW 573295
90 O-ring (secondary exchanger) 1 573825
92 O-ring (20-18) 1 571807
95 164 282 Gasket 3/8" 573521
96 Pump 997151
99 O-ring (13) 1 571965
100 Gasket 574279
101 Gas valve (SIT Sigma) 1 574232
107 Spark generator 1 574233
111 379 981 Detection electrode 1 573441
115 164 261 Gasket 1/4" 1 569390
117 379 979 Ignition electrode (R.H.) 569560
118 379 980 Ignition electrode (L.H.) 1 569561
119A Main burner 1 998110
119B Main burner 1 998111
120 Main exchanger 1 572835
126 Venturi (exhaust manifold/header) 1 573314
301 Front panel runner kit 1 571993
311 D.H.W. actuator kit 1 571444
321 SIT Sigma gas valve operator coils 1 997029
361 Heating by-pass kit 1 571443
362 D.H.W. pressure switch kit 1 571442
363 3-way spring kit 1 571447
364 D.H.W. diaphram valve 1 571446
371 Main flow switch diaphram 571547
372 Main flow switch magnet 571772
373 Main flow switch spring 571771
374 Main flow switch top cap 571770
375 Main flow switch reed system 573138
381 Burner jet 1.30 full kit (Natural gas) 998152
382 Burner jet 0.77 full kit (LPG) 998432

34 B005
 GENUS 27 RFFI SYSTEM (SIT Sigma Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 379816 Expansion vessel 573294
11 164 225 Gasket 3/4" 573520
14 Overheat thermostat 997206
17 Motorised valve motor 997147
20 Main flow switch 573224
21 164 338 Temp probe (C.H.W.) 569236
23 164 229 Gasket 1/2" 573528
25 378 814 Manual vent cock 573727
26 Safety valve 3 bar 1/2" 573172
28 D.H.W. probe 950650
30 Pressure gauge 571649
33 Time clock 997208
45 P.C.B. EB C MI/FFI 953095
47 P.C.B. E A-FFI/P 952935
48 P.C.B. cable 952610
58 Fan 572990
59 Fan inlet gasket 573343
62 Venturi (exhaust manifold/header) 573314
73 E02 071 Air pressure switch 571652
76 Fastening spring 570717
85 Automatic air release valve 564254
86 379 079 Gasket 1" 569387
87 Pump 997151
89 164 282 Gasket 3/8" 573521
93 O-ring (13) 571965
94 Gasket 574279
95 Gas valve (SIT Sigma) 574232
101 Spark generator 574233
105 379 981 Detection electrode 573441
109 164 261 Gasket 1/4" 569390
111 379 979 Ignition electrode (R.H.) 569560
112 379 980 Ignition electrode (L.H.) 569561
113A E02 078 Main burner 572343
113B Main burner 572372
114 Main exchanger 572835
301 Front panel runner kit 571993
321 Sit Sigma gas valve operator coils 997029
361 Heating by-pass kit 571443
362 Sanitary pressure switch kit 571987
363 Way and unit kit 571447
375 Main flow switch reed system 573138
381 164 311 Burner jet 1.25 full kit (Natural gas) 569281
382 Burner jet 0.72 full kit (LPG) 569282

B005 35
 GENUS 23/27 MFFI (SIT Tandem Gas Valve)

2 71 70 63 69 68 65 66 67 66 65 64 63 62 61 60 59 58 57 56

2 74

74
3 72
73
126
301
301
4 4

74 125
4
75
4 124
62
76
77 123 302 303 304 305 306
78
6 122
79
7 55
7
54
80 116
8 81
121 117
115
9 81 120 118
114 53
10 119
11 113
48 52
111 112 51
82 97 110 51 50
83 109 49
98 48
108 47
11 87 86 99 104
84 96 100 107 44 46
85
88 45
12 85 101 106
86
102 44
95
13 103 43
84
14 94
89 89 44
104 42
90 105 41
11 93 40
15 23 39 39
91 92 38
91
18 36

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

17 99
371 321
372
373
374
322

375 323

16 22
361
362
364 311

363

23/27 MFFI

36 B005
 GENUS 30 MFFI (SIT Tandem Gas Valve)

2 72 71 64 70 69 66 67 68 67 66 65 64 63 62 61 60 59 58 57

2 75

75
3 73 128
74
127
301
301
4 4

75 126
4
76
4 125
63
77
78 124
79 302 303 304 305 306
6 123
80
7
56
7
81 117 55
8 82
122 118
116
9 82 121 119
115 54
10 120
11 114
49 53
112 113 52
83 98 111 52 51
84 110 50
99 49
109 48
11 88 87 100 105
85 97 101 108 45 47
86
89 46
12 86 102 107
87
103 45
13 96
85 104 44
14 95
90 90 105 45
15 43
91 106 42
11 94 41
16 24 40 40
92 93 39
92
19 37

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

18 100
371 321
372
373
374
322

375 323

17 23
361
362
364 311

363

30 MFFI

B005 37
 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve)

2 73 72 65 71 70 67 68 69 68 67 66 65 64 63 62 61 60 59 58

2 76

76
3 74
75
121
301
301
4 4

76 120
4
77
4 119
64
78
80 79 118 302 303 304 305 306
6 117
81
7 57

7 56
82
8 83 111
116 112
110
9 115 113 55
109
10 108 54
11 114
83
107 50 53
102
84 100 101 53 52
85 103 51
99
11 50
106 49
86 98 93
87 97 104
12 46 48
105 47
96
13 95 46
14 88 94 45
86
93
46 44
11 89
92 43
90 42
15 11 91 41 41
11 23 40
16 16
38
23
17

18 19 20 21 22 23 24 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

20 98

371 321
372
373
374
322

323
375

19
362

361

363 27 MFFI SYSTEM

38 B005
 GENUS 23/27 MFFI (SIT Tandem Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 379816 Expansion vessel 1 573294
11 164 225 Gasket 3/4" 573520
14 Overheat thermostat 1 997206
17 Main flow Switch 1 573224
18 164 338 Temp probe (C.H.W.) 1 569236
19 Microswitch for 3-way/main flow group 1 573340
23 164 229 Gasket 1/2" 573528
24 378 814 Manual vent cock 1 573727
25 Safety valve 3 bar 1/2" 1 573172
28 Pressure gauge 1 571649
31 Time clock 1 997208
43 P.C.B. E C-MI/FFI 1 953045
45 P.C.B. EI A-MFFI 1 952981
46 P.C.B. cable 1 952610
56AB Fan 1 572989
56CD Fan 1 572990
57 Fan inlet gasket 1 573343
60 Venturi (exhaust manifold/header) 1 573314
71AB E03 818 Air pressure switch 1 571651
71CD E02 071 Air pressure switch 1 571652
74 Fastening spring 570717
83 379 079 Automatic air release valve 564254
84 164 230 Gasket 1" 1 569387
86 O-ring 1 571449
88AB Secondary exchanger (plate-type) exchanger 23kW 571646
88CD Secondary exchanger (plate-type) exchanger 27kW 573295
89 O-ring (secondary exchanger) 1 573825
91 O-ring (20-18) 571807
94 164 282 Gasket 3/8" 1 573521
96AB Pump 1 997150
96CD Pump 1 997151
99 379 976 Gas valve (SIT Tandem) 1 570732
101 Spark generator 573023
104 O-ring (13) 1 571965
112 379 981 Detection electrode 1 573441
116 164 261 Gasket 1/4" 1 569390
118 379 979 Ignition electrode (R.H.) 1 569560
119 379 980 Ignition electrode (L.H.) 1 569561
120A E02 026 Main burner 1 572271
120B Main burner 1 572277
120C E02 078 Main burner 1 572343
120D Main burner 1 572372
121AB Main exchanger 1 572749
121CD Main exchanger 1 572835
301 Front panel runner kit 1 571993
311 D.H.W. actuator kit 571444
321 378 978 SIT Tandem gas valve operator coils 570712
322 378 815 SIT Tandem modureg coil 573740
323 164 303 Gas modulator cartridge 573745
361 Heating by-pass kit 571443
362 D.H.W. pressure switch kit 571442
363 3-way spring kit 571447
364 D.H.W. diaphram valve 571446
371 Main flow switch diaphram 571547
372 Main flow switch magnet 571772
373 Main flow switch spring 571771
374 Main flow switch top cap 571770
375 Main flow switch reed system 573138
381 164 311 Burner jet 1.25 full kit (Natural gas) 569281
382 Burner jet 0.72 full kit (LPG) 569282

B005 39
 GENUS 30 MFFI (SIT Tandem Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 379816 Expansion vessel 1 573294
11 164 225 Gasket 3/4" 573520
15 Overheat thermostat 1 997206
18 Main flow Switch 1 573224
19 164 338 Temp probe (C.H.W.) 1 569236
20 Microswitch for 3-way/main flow group 1 573340
24 164 229 Gasket 1/2" 573528
25 378 814 Manual vent cock 1 573727
26 Safety valve 3 bar 1/2" 1 573172
29 Pressure gauge 1 571649
32 Time clock 1 997208
44 P.C.B. E C-MI/FFI 1 953045
46 P.C.B. EI A-MFFI 1 952981
47 P.C.B. cable 1 952610
57 Fan 1 572990
58 Fan inlet gasket 1 573343
72 E02 071 Air pressure switch 1 571652
75 Fastening spring 1 570717
84 379 079 Automatic air release valve 1 564254
85 164 230 Gasket 1" 1 569387
87 O-ring 571449
89 Secondary exchanger (plate-type) exchanger 27kW 573295
90 O-ring (secondary exchanger) 1 573825
92 O-ring (20-18) 1 571807
95 164 282 Gasket 3/8" 573521
97 Pump 997151
100 379 976 Gas valve (SIT Tandem) 1 570732
102 Spark generator 573023
105 O-ring (13) 1 571965
113 379 981 Detection electrode 1 573441
117 164 261 Gasket 1/4" 1 569390
119 379 979 Ignition electrode (R.H.) 1 569560
120 379 980 Ignition electrode (L.H.) 569561
121A Main burner 1 998110
121B Main burner 1 998111
122 Main exchanger 1 572835
128 Venturi (exhaust manifold/header) 1 573314
301 Front panel runner kit 1 571993
311 D.H.W. actuator kit 1 571444
321 378 978 SIT Tandem gas valve operator coils 1 570712
322 378 815 SIT Tandem modureg coil 1 573740
323 164 303 Gas modulator cartridge 1 573745
361 Heating by-pass kit 1 571443
362 D.H.W. pressure switch kit 1 571442
363 3-way spring kit 1 571447
364 D.H.W. diaphram valve 571446
371 Main flow switch diaphram 571547
372 Main flow switch magnet 571772
373 Main flow switch spring 571771
374 Main flow switch top cap 571770
375 Main flow switch reed system 573138
381 Burner jet 1.30 full kit (Natural gas) 998152
382 Burner jet 0.77 full kit (LPG) 998432

40 B005
 GENUS 27 RFFI SYSTEM (SIT Tandem Gas Valve)

Key G.C. part ARISTON

no. no. Description Part No.
1 Expansion vessel 573294
11 164 225 Gasket 3/4" 573520
14 Overheat thermostat 997206
17 Motorised valve motor 997147
20 Main flow switch 573224
21 164 338 Temp probe (C.H.W.) 569236
23 164 229 Gasket 1/2" 573528
25 378 814 Manual vent cock 573727
26 Safety valve 3 bar 1/2" 573172
28 D.H.W. probe 997274
30 Pressure gauge 571649
33 Time clock 997208
45 P.C.B. EB C MI/FFI 953095
47 P.C.B. E A-FFI/P 952935
48 P.C.B. cable 952610
58 Fan 572990
59 Fan inlet gasket 573343
62 Venturi (exhaust manifold/header) 573314
73 E02 071 Air pressure switch 571652
76 Fastening spring 570717
85 379 079 Automatic air release valve 564254
86 164 230 Gasket 1" 569387
87 Pump 997151
89 164 282 Gasket 3/8" 573521
93 O-ring (13) 571965
96 Spark generator 573023
98 379 976 Gas valve (SIT Tandem) 570732
107 379 981 Detection electrode 573441
111 164 261 Gasket 1/4" 569390
113 379 979 Ignition electrode (R.H.) 569560
114 379 980 Ignition electrode (L.H.) 569561
115A E02 078 Main burner 572343
115B Main burner 572372
115 Main exchanger 572835
301 Front panel runner kit 571993
311 D.H.W. actuator kit 571444
321 378 978 SIT Tandem gas valve operator coils 570712
322 378 815 SIT Tandem modureg coil 573740
323 164 303 Gas modulator cartridge 573745
361 Heating by-pass kit 571443
362 D.H.W. pressure switch kit 571442
363 3-way spring kit 571447
371 Main flow switch diaphram 571547
372 Main flow switch magnet 571772
373 Main flow switch spring 571771
374 Main flow switch top cap 571770
375 Main flow switch reed system 573138
381 164 311 Burner jet 1.25 full kit (Natural gas) 998152
382 Burner jet 0.72 full kit (LPG) 998432

B005 41
NOTES

42 B005
B005 43
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