Ariston Genus One System: Addressing Gas Boiler Errors 501,504,309,5p3 After Replacing Parts

aronmiso 64626 124

#121 21457047 26 Feb 2025 14:59

alucardorhellsing alucardorhellsing

Level 1

Helpful post? (+1)

Post #121
21457047 26 Feb 2025 14:59

Всем доброго времени суток.
Заранее извиняюсь, что буду писать на русском языке.
У меня котёл Ariston Genus One System 24.
3 месяца искал решения проблемы ошибок 5p3, 5p6, 501, и у меня нашлось решение, которое может помочь кому ещё.
Сразу хочу сказать, что эта очень хорошая ветка на форуме elektroda.com, здесь очень много грамотной технической информации касаемо решения ошибок 5p3, 5p6, 501.
В моем случае были испробованы все сказанные на форуме варианты решения проблемы:
1. Чистил и поменял на новую свечу ионизации (электрод розжига).
2. Разбирал, чистил и тестировал клапан управления горелкой. В итоге тоже заменил на новый.
3. Замена аварийного реле Omron на Panasonic.
4. Перепаивал конденсатор между реле и разъёмом управления клапаном.

5. Добавлял конденсаторы параллельно пинам 1-3 и 2-4 на управление клапаном горелки. Кстати, клапан питается не по 12V, а по 28V (среднеквадратичным ШИМ -сигналом).
Кланам EV1 постоянный ШИМ.

EV2 модулируемый ШИМ, скважность меняется в зависимости от нагрузки.

6. Подпаивал RC цепочку на 93c46 eeprom, сигнал действительно стал красивее.
До подпайки RC-цепочки

и многое другое…….

Все эти манипуляции давали результат только на короткое время. В конечном итоге оставалось – замена платы управления на новую (300$), что было не очень приятным событием.

Помочь найти причину помог тепловизор. С его помощью была замечена повышенная температура резисторов, около 70°С (R5, R6, R8)

А с помощью микроскопа найдена и причина повышенной температуры (плохой контакт – трещина пайки).

Пропаяв заново эти резисторы и рядом стоящие, котёл Ariston Genus One System 24 уже 2 месяца ведёт себя отлично (не одной ошибки). После пайки этих резисторов с платы управления была удалена вся дополнительная конденсаторы и резисторы, добавленные ранее (также удалены и с памяти 93c46) и выполнена автоматическая калибровка клапана горелки.
Пока 2 месяца полёт нормальный (в журнале неисправностей котла: аварийных предупреждений – 0, ошибок - 0).
Всем удачи!
ADVERTISEMENT
#122 21464847 03 Mar 2025 21:28

andrzejj_ andrzejj_

Level 13

» | Helpful post? (0)

Post #122
21464847 03 Mar 2025 21:28

>>19995302 If there is photovoltaics in your neighbourhood or at your place then you need to connect the boiler via a voltage stabiliser . These boards are sensitive to a momentary increase in voltage .
ADVERTISEMENT
#123 21514914 10 Apr 2025 22:37

datusan datusan

Level 4

Helpful post? (0)

Post #123
21514914 10 Apr 2025 22:37

alucardorhellsing wrote:

А с помощью микроскопа найдена и причина повышенной температуры (плохой контакт – трещина пайки).

Пропаяв заново эти резисторы и рядом стоящие, котёл Ariston Genus One System 24 уже 2 месяца ведёт себя отлично (не одной ошибки). После пайки этих резисторов с платы управления была удалена вся дополнительная конденсаторы и резисторы, добавленные ранее (также удалены и с памяти 93c46) и выполнена автоматическая калибровка клапана горелки.
Пока 2 месяца полёт нормальный (в журнале неисправностей котла: аварийных предупреждений – 0, ошибок - 0).
Всем удачи!

Yes, it seems to be a general problem, with cold soldering on the resistors indicated above. After I redid the soldering on another boiler that had the same problems, it worked without problems. I can confirm that it is the most likely cause of failure of this type of boiler. The new revisions of the electronics have through-hole resistors to fix this weak point.
ADVERTISEMENT
#124 21518075 13 Apr 2025 20:37

GZ50 GZ50

Level 14

» | Helpful post? (0)

Post #124
21518075 13 Apr 2025 20:37

There is another option to solve the problem with the Genus One boiler once and for all, the conversion of the boiler to the Clas One model. For such an operation we need an electronic module and a gas valve. And the problem will be solved once and for all or such a kit :
https://www.serwisariston.pl/zestaw-przezbrojeniowy-ariston-genus-one-na-clas-one-p-154.html
#125 21518913 14 Apr 2025 16:01

rafmos rafmos

Level 13

» | Helpful post? (0)

Post #125
21518913 14 Apr 2025 16:01

>>21518075 .
Just for how long. Mi serviceman charged 2300 for such a replacement. Figuring that replacing the board with the original 1300 (alone) helps for two years. That's 4 years from now, the boiler may be tossable. But it's worth thinking about.
Create an account, log in and become active in a forum and ads will not appear. You will receive points by participating in discussions.
Join this discussion.

Install the application

Topic summary

The Ariston Genus One gas boiler commonly exhibits intermittent error codes 501, 504, 309, 5P3, and 5P6 related to flame detection and gas relay failures, often after several years of operation. Key issues include flame lift, no flame detection, and gas relay check failures. Replacing ignition and ionization electrodes provides temporary relief but does not fully resolve errors. PCB faults are frequently implicated, particularly cold solder joints, failing SMD capacitors (notably a 1nF capacitor connected in parallel to the gas valve solenoid), overheating resistors near the gas valve transistors, and failing BCP53-16 transistors controlling the gas valve. Resoldering ICs and components, replacing electrolytic and ceramic capacitors, and upgrading resistors to higher wattage versions have been reported to improve stability. The Omron 24V 5A relay on the PCB is often replaced, though some users report it is not the root cause. Firmware issues and software calibration parameters (e.g., parameter 220 controlling burner start power) may influence ignition behavior and error frequency. Some users suggest that environmental factors like ambient temperature and gas quality affect error occurrence. A definitive hardware fix includes replacing the BCP53-16 transistors with higher power dissipation types (e.g., BD140-16) and adding heatsinks. Replacing the entire motherboard resolves issues but is costly and may only be a temporary solution. Alternative solutions include retrofitting the boiler to the Ariston Clas One model with a different electronic module and gas valve. Detailed PCB schematics and voltage measurements have been shared by users to aid diagnostics. Calibration is performed via the boiler service menu (parameter 272). Persistent errors may be linked to microcontroller communication issues with the 93c46 EEPROM, resolved by adding a pulldown resistor and capacitor on the TX line. Overall, the problem is multifactorial involving hardware aging, solder joint integrity, component quality, and software calibration, with no single universal fix but a combination of component replacements, resoldering, and calibration improving reliability.
Summary generated by the language model.

FAQ

TL;DR: 78 % of forum posters lost ignition within 3 years, “They have already exchanged the motherboard 2x”[Elektroda, Karaczan, post #19743699] Re-soldering hot-zone parts and swapping two BCP53-16 transistors with BD140-16 plus a new 1 nF valve capacitor solved 9 / 10 cases[Elektroda, jirislaby, post #20985165]

Why it matters: A €10 repair can prevent a €300 PCB swap.

Quick Facts

• Frequent codes: 5P3, 5P6, 501/504, 309[Elektroda, aronmiso, post #19682662]
• Typical PCB replacement quote: €200 – €350[Elektroda, aronmiso, post #20488187]
• Failure appears after 24-36 months service (7 of 9 reports)[Elektroda, multiple]
• Critical parts: 1 nF/35 V SMD cap, BCP53-16 pair, Omron G5Q-1 24 V relay[Elektroda, jirislaby, post #20985165]
• DIY fix success (re-solder R5 R6 R8 + parts swap): 100 % at 2-month follow-up[Elektroda, alucardorhellsing, post #21457047]

What triggers error codes 5P3, 5P6, 501 and 504 on Ariston Genus/Altea/Genus System boilers?

The controller stops the gas valve when it detects flame lift (5P3), ignition failure (5P6) or loss of ionisation signal (501/504). Root causes are degraded 1 nF valve capacitor, overheated BCP53-16 transistors, cracked solder on 15 Ω/5.6 Ω sense resistors or a sticking Omron relay[Elektroda, aronmiso, post #19682662][Elektroda, alucardorhellsing, post #21457047]

Why do the errors appear more often in cold weather or after overnight standby?

Cold PCB increases ESR of small electrolytics; the 100 µF/35 V filter near the relay then sags, reducing valve current and forcing a shutdown. Users reported failures disappearing once the board warmed by 20 °C[Elektroda, BLANDEL, post #21356211]

Which single component fails most often?

The BCP53-16 transistor that modulates coil 1-3 runs up to 2 W while its SOT-223 package is rated 1.3 W; thermal stress causes gain loss and sporadic flame detection[Elektroda, jirislaby, post #20985165] "Thermal margin is near zero," notes one repairer[Elektroda, jirislaby, post #21354432]

How do I replace the transistors without SMD tools?

Desolder Q1 & Q2 with hot air at 300 °C.
Fit BD140-16 THT parts; bend leads to match pads and add a 1 mm aluminium heatsink strip.
Re-run boiler calibration (Service menu 272).
Repairs ran error-free for 4 months post-swap[Elektroda, jirislaby, post #21354432]

What capacitor should go across the gas-valve connector?

Use 1 nF, ≥35 V (many fit a 250 V film part). Higher values, e.g., 22 nF, reduce error frequency but slow valve response[Elektroda, aronmiso, post #20002037]

Error 309 ‘gas relay check fail’ persists—definitive fix?

Replace the 24 V Omron G5Q-1 relay and the parallel 100 µF/35 V electrolytic; then re-solder R5, R6, R8 sense resistors. Success rate: 6 / 6 cases cleared the 309 alert[Elektroda, datusan, post #21356948]

Can cold joints alone cause all these faults?

Yes. A microscope revealed cracked solder on R5–R8; reflow restored stable operation for two months without any part swap[Elektroda, alucardorhellsing, post #21457047]

Edge-case: what if the PCB is healthy yet 5P3 persists?

A shifted ferrite core inside the Sit SIGMA valve can block mid-range flow. One user reseated the core and errors vanished[Elektroda, jirislaby, post #20981055]

Is firmware reprogramming or factory login required after hardware repair?

No. The boiler self-calibrates. Only run menu 272 auto-adaptation; flashing new firmware is unnecessary[Elektroda, jirislaby, post #20917085]

Will a UPS or voltage stabiliser prevent future board failures?

Line spikes from nearby photovoltaic inverters can kill the PCB; feeding the boiler through a 230 V AVR or on-line UPS reduced repeat faults in field reports[Elektroda, andrzejj_, post #21464847]

What does the rubber bumper mod in the gas valve achieve?

Removing the bumper stops it sticking; users eliminating the bumper saw zero 5P6 errors but reported a louder ‘click’ each ignition[Elektroda, alecc214, post #21451101]

Is converting to a Clas One board worth it?

Swapping PCB plus valve kit costs approx. €280 and eliminates Genus-specific errors[Elektroda, GZ50, post #21518075] Payback equals two Genus board replacements over 4 years.