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1. SERVICING INSTRUCTIONS
2. FAULT FINDING
3. ELECTRICAL DIAGRAMS
2 B029
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).
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
to be lowered. This will also require the removal of the casing.
Access
To dismantle the front part of the casing, proceed as follows:
1. Remove screw “A” (see fig. 1.1);
2. Lift the front panel up and forward (see fig. 1.2).
B029 3
Removing the side panels
1. Remove the screws “B”;
B 2. Pull the panel away from the boiler, then lift the panel
up and away from the boiler (see fig. 1.2).
Fig. 1.3
To access the areas where the adjustment and control devices are located,
simply remove the plugs by pressing from the inside, unscrew the screws “C”
and remove the bottom part of the instrument panel, rotating it upwards.
C C
4 B029
1.3 Access to the
Combustion Chamber
D D
E E
E
Remove the screws “D”
E
E
D D E
E
Removing the burner and the 1. Remove the side panels of sealed chamber (fig. 1.10);
injectors 2. Remove the screws “F” of the burner (see fig. 1.11);
3. Remove the burner (see fig. 1.12);
4. Remove the injectors using a No. 7 socket spanner;
5. Replace in reverse order.
push
F
Fig. 1.11
push
Fig. 1.10
Fig. 1.12
B029 5
Removing the electrodes 1. Remove rubber gasket “G” (see fig. 1.13);
2. Disconnect ignition leads by pulling downward (see fig. 1.14);
3. To remove the flame sensor, disconnect the cable at its only connection
point close to the P.C.B. (see fig. 1.15);
Fig. 1.14
5. Remove screw “H” using a Philips No. 2 star tip screwdriver (see fig. 1.16);
6. Slide the electrode gently downward (see fig. 1.17).
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 B029
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. 1.18);
3. Pull it straight out (see fig. 1.19).
Removing the air pressure switch 1. Disconnect the electrical connections “K” and silicone pipes “L” from their
connection points (see fig. 1.20);
2. Remove screws “J” on the top of the sealed chamber (see fig. 1.21);
Use a No. 2 star tip screwdriver to remove the switch from the plate.
J J
L
L
Fig. 1.20
Fig. 1.21
B029 7
Removing the venturi device 1. Disconnect the silicone pipes “M” and remove the screw “N”
(see fig. 1.22);
2. Extract the venturi (see fig. 1.23).
M N
Fig. 1.24
8 B029
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
B029 9
Setting gas pressures
10 B029
Regulating the heating power for
natural gas (G20)
model 23
model 27
model 27
model 23
model 27
TABLE “A”
GAS REQUIREMENTS NATURAL GAS (G20) BUTANE GAS (G30) PROPANE GAS (G31)
Gas rate max 3.0 m 3 /h 106.0 ft 3/h 0.88 m3/h 31.1 ft 3 /h 1.15 m 3/h 40.6 ft3/h
Gas rate min 1.2 m 3 /h 42.3 ft 3/h 0.35 m3/h 12.3 ft 3 /h 0.46 m 3/h 16.2 ft3/h
Inlet pressure 20 mbar 7.8 in w .g. 28 mbar 10.9 in w.g. 37 mbar 14.4 in w .g.
Burner pressure max 12.3 mbar 4.8 in w.g. 28 mbar 10.9 in w.g. 37 mbar 14.4 in w .g.
Burner pressure min 2.0 mbar 0.8 in w.g. 5.1 mbar 2.0 in w.g. 7.0 mbar 2.7 in w.g.
B029 11
10. Remove the pipe from the pressure gauge and connect screw “C” to the
pressure outlet in order to seal off the gas.
40 50 60 70 80 11. Carefully check the pressure outlets for gas leaks (valve inlet
C C
and outlet).
IMPORTANT!
Whenever you disassemble and reassemble the gas connections, always
check for leaks using a soap and water solution.
Fig. 1.27
12 B029
Removing the spark generator (SIT Tandem gas
valve)
Q1
Fig. 1.30
R1
R1
B029 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
1.5 Access to the Important! Before any component is removed, the boiler
Hydraulic Circuits must be drained of all water.
Fig. 1.37
14 B029
Removing the safety valve
1. Loosen nut “V” (see fig. 1.38);
2. Remove the valve.
Fig. 1.38
Fig. 1.39
Y1
Y1 Fig. 1.40
B029 15
Removing the pump
1. Unscrew “Z” and remove the electrical connection
(see fig. 1.41);
2. Release the nuts “A1” and remove the pump
(see fig. 1.42).
A1
A1
A2
16 B029
Removing the expansion vessel
1. Remove nut “A3” away from the expansion vessel
(see fig. 1.45);
2. Remove nut “A4” (see fig. 1.46);
3. Remove expansion vessel (see fig. 1.47).
A3
Fig. 1.45
A4
Fig. 1.48
Fig. 1.49
B029 17
1.6 Access to the Control Checking fuse
System 1. Remove the inspection panel
(see fig. 1.6 - 1.7);
2. Remove fuse (see fig. 1.50).
Fig. 1.50
A5
18 B029
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. 1.48). This will
revert control of the central heating to the room stat connection on the reverse
of the control panel.
A6 A6
Fig. 1.53
A9
A8
A7 A8 A9
A7
B029 19
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 PCB
SETTING
SUMMER FOR THE OPERATING
MODE
WINTER
NO NO
FOR BOILERS
EQUIPPED WITH AN DO THE
ELECTRONIC ANT-FREEZE PROGRAMMING
NO SYSTEM: HAS THE SAFETY BEEN YES TIMER AND/OR EXTERNAL NO
TRIGGERED TO ACTIVATE
YES THERMOSTAT NEED
THE DEVICE? TO BE ACTIVATED
(T sensor <5°C)
A
FOR BOILERS
EQUIPPED WITH AN
ELECTRONIC ANT-FREEZE
SYSTEM: HAS THE SAFETY BEEN
TRIGGERED TO ACTIVATE
THE DEVICE?
(T sensor <5°C)
20 B029
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 PCB
2) Check the pressure switch 3) Replace
for activating pump NO 1) Check to see if pump is power supply
3) Check/replace water stuck PCB
gauge and refill the 2) Replace circulation pump 4) Replace control
the system properly PCB
5) Check micro-
switch when hot
1) Turn the boiler off water is requested.
and then back on
again (safety reset)
B029 21
B
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 PCB wire
ACTIVATED? 4) Check/replace power
supply PCB
5) Check/replace control
NO PCB
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 PCB wire
IS THERE POWER
3) Check/replace power
TO THE FAN?
NO supply PCB
4) Check/replace control
PCB
YES 5) Check/replace air
pressure switch
1) Replace fan
22 B029
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 PCB wire
6) Check/replace power PCB
7) Check/replace control PCB
YES
1) Check/replace igniter plugs
2) Check wiring
ARE THE 3) Check starter
FUMES DISCHARGED NO 4) Check small wire
CORRECTLY? 5) Check power supply PCB
6) Check control PCB
YES
1) Check supply of gas to gas
valve
DOES THE 2) Check power supply PCB
BURNER LIGHT? NO 3) Check control PCB
4) Check functionality of the
YES valve
WAS THE
NO RESET SWITCH
D PRESSED?
YES
B029 23
D
IS
THERE STILL A
PROBLEM? YES
NO
FUNCTIONS
NORMALLY
24 B029
2.2 Fault Finding Using the
Total Check System
Malfunction
Pump fed
Main flow switch closed
Air pressure switch N.O.
Flame detected
Water at required temperature
B029 25
Legend:
3. ELECTRICAL
DIAGRAMS AT = High Voltage P.C.B.
BT = Low Voltage P.C.B.
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
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
Aa = Adaptor (British Gas use only)
Colours
Gry = Grey
Rd = Red
Bl = Blue
Grn/Yll = Yellow/Green
Wh = White
Brn = Brown
Blk = Black
Wh/Rd = White/Red
26 B029
A/23 MFFI - A/27 MFFI
EX C-MI/FFI
B029 27
4. SHORT SPARE
PARTS LIST
2 72 71 64 70 69 66 67 68 67 66 65 64 63 62 61 60 59 58 57
4
1
4
2 75
75
3 73
74
126
4 4
75 125
4 4
76
4 124
63 301 4 302 301
77
79 78 123
6 122
80
7 56
7
55
81 116
8 82
82 121 117
115
9 120 118 54
114
10 119
11 113
49 53
112 52
83 104 105 52 51
84 106 50
103 107 49
111 48
11 88 87 100 108
85 45 47
98 102
109 46
86 101
12 89 110
87 86 45
100
13 97 99 44
85 43
14 96 45
90 90 42
41
41
91 29
11 95
15 23 40
92 94 39
39
92
93
38
34
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
102 16
361
362
364
363
321
17 22
371
372 311
373
374
375
A 23/27 MFFI
28 B029
A/23 MFFI - A/27 MFFI (SIT Sigma Gas Valve)
B029 29
A/23 MFFI - A/27 MFFI (SIT Tandem Gas Valve)
30 B029
A 23/27 MFFI (SIT Tandem Gas Valve)
B029 31
Stampa BIEFFE Recanati
23 99 84 1268 000 - B029