Ferroli MODENA 80 E, Installation, Servicing And User Instructions Manual

Page 1: ...r Wall Mounted Combination Gas Fired Boiler for Central Heating and Domestic Hot Water Production Fan Assisted Room Sealed Compartment Electronic Flame Ignition and Control 3543230 2 06 2001 INSTALLATION SERVICING AND USER INSTRUCTIONS G C NO 47 267 05 ...

Page 2: ... We will guarantee that this products is altogether suitable for the data change in the Year 2000 boiler has no dependence from date change and that no disruptions will occur which is caused by this product IMPORTANT Your benchmark Installation Commissioning and Service Record Log Book will be enclosed in your customer information pack This record must be completed and left with the end user All C...

Page 3: ...circuit set to open at 3 bar Built in Expansion vessel Variable speed pump Central heating flow temperature adjustment thermostat Domestic hot water flow temperature adjustment thermostat Central heating limit thermostat Overheat safety thermostat Electronic control unit for automatic flame ignition and control Central heating low water pressure cut off switch Domestic hot water flow temperature s...

Page 4: ...with natural gas or Liquid Petroleum Gas converted appliances Key 1 3 4 central heating flow outlet 2 1 2 domestic hot water flow outlet 3 1 2 gas inlet 4 1 2 domestic hot water inlet 5 3 4 central heating return inlet 6 Pressure relief outlet 1 3 4 5 150 120 120 70 110 80 80 80 460 Top view 114 95 60 60 95 36 100 720 725 160 25 10 100 270 460 175 100 Bottom view Distance between connections 95 60...

Page 5: ...ot water heat input Boiler water contents Domestic hot water circuit contents kW kW kW kW kW Litres Litres Modena 80 E 23 8 9 7 25 8 11 5 23 8 1 5 0 8 MODEL Connections Expansion vessel Max working pressure central heating circuit Max working pressure hot water circuit 1 2 3 4 5 Capacity Pre pressurising value Ø Ø Ø Ø Ø Litres bar bar bar Modena 80 E 3 4 1 2 1 2 1 2 3 4 7 1 3 6 MODEL Main injector...

Page 6: ...sensor Fig 2 Fig 3 43 16 27 50 19 49 28 5 20 21 26 132 90 91 81 82 22 56 IN OUT MIN 36 0 5 1 2 3 4 6 98 63 157 145 62 10 8 74 7 84 85 44 136 114 34 14 42 9 11 32 73 36 Automatic air vent valve 42 Domestic hot water flow temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat 50 Central heating flow limit thermostat 56 Expansion vessel 62 Time clock option 63 Central he...

Page 7: ... Natural gas Fig 4 Fig 5 Diagram of pressures and outputs with LPG Propane 2 3 4 5 6 7 8 9 10 11 12 13 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 8 9 10 11 12 13 14 15 16 17 18 19 20 21 kW kcal h x 1000 mbar 14 9 kW kcal h X 1000 mbar 18 19 20 21 22 23 5 10 15 20 25 30 35 9 10 11 12 13 14 15 16 17 9 10 11 12 13 14 18 19 20 15 16 17 8 2 05 Domestic hot water variability characteristics The temper...

Page 8: ...3 14 2 30 9 24 8 100 14 0 25 9 55 1 19 0 41 2 33 1 125 17 5 32 4 68 9 23 7 51 5 41 3 150 21 0 38 8 82 6 28 5 61 8 49 6 175 24 5 45 3 96 4 33 2 72 1 57 9 200 28 0 51 8 110 2 38 0 82 4 66 2 0 140 0 259 0 551 0 190 0 412 0 33 For syst volumes other than those given above mult the syst volume by the factor across m h 3 Q 8 7 6 5 4 3 2 1 0 0 5 1 5 2 5 1 2 H mbar x 100 2 06 Pump characteristics The pump...

Page 9: ...ch the boiler is installed does not require a purpose provided vent when using the standard concentric flue Flue System The boiler allows the flue outlet to be taken from the rear of the boiler from either side or vertically A standard flue length of 0 75 metres is provided Alternative lengths of two or three metres can be supplied equivalent to wall thicknesses of up to 565 1815 and 2815mm for re...

Page 10: ...e boiler s central heating system and the mains water supply The use of mains water to charge and pressurise the system directly is conditional upon the Local Water Byelaws Again any such connection must be disconnected after use A typical temporary filling loop is shown in fig 10 Domestic Hot Water Always fit a scale reducer in hard water areas 18 clarke degrees or over A 15mm copper connection p...

Page 11: ...sions Terminal position kW input expressed in net Balanced flues room sealed Open flues Natural draught Natural draught Fanned draught Fanned draught Aa 300 mm 600 mm 1500 mm 2000 mm 300 mm Not allowed 300 mm Ba 300 mm 300 mm 300 mm 600 mm 300 mm Not allowed 300 mm Ca 300 mm 400 mm 600 mm 600 mm 300 mm Not allowed 300 mm D 300 mm 75 mm Not allowed 75 mm E 300 mm 200 mm Not allowed 200 mm F 600 mm ...

Page 12: ...e middle fig 13a Fix the wall bracket to the wall using standard lock nut M8 on both sides Mount the boiler on the wall bracket and fix using the special antitheft nut M8 as described in the fig 13a Using a core drill cut a 118mm diameter hole for the flue 1 CH flow 2 Safety Valve 3 Domestic hot water outlet 4 Gas supply 5 Domestic hot water inlet 6 CH return Fig 13b Ø3 4 Ø1 2 Ø1 2 Ø1 2 Ø1 2 Ø3 4 ...

Page 13: ...ximum mm 0 m 13 m 45 13 m 23 m 47 23 m 38 m 50 38 m 48 m No restrictor With concentric systems Choose correct restrictor from table below With 2 pipe system Calculate the total flow resistance of the air and flue pipes in metres cap 3 04 2 utilise the table shown below to choose the more suitable restrictor for the flow resistance calculated RESTRICTOR FOR CONCENTRIC SYSTEM Flue lenght up to Use r...

Page 14: ... 03 1 Vertical concentric connection Fig 16 A vertical connector can be supplied for vertical discharge with concentric pipes The simple mounting and use of double lip gaskets at the joints makes this an extremely easy and safe option Fig 15 Concentric Vertical Connector 3 03 2 Horizontal concentric connection 1KWMA31Y D S L 125 70 50 30 95 80 80 3 mm m Ø60 Ø80 70 min between 10 e 60 mm 190 270 L ...

Page 15: ...en 10 60mm 3 03 3 Maximum concentric flue length First table below shows the maximum flue lengths available for boilers with concentric systems For correct calculation remember to include the reduction for bends on second table Please refer to 3 02 for use of restrictor Maximum flue lenght permissible 100 mm concentric 125 mm concentric Vertical Horizontal Vertical Horizontal Modena 80 E 4 m 3 m 5...

Page 16: ...ethod is based on a standard reference parameter 1 metre of horizontal air flue 80 diameter 80 for the maximum length permissible for all the pipes fittings flow resistance coefficient In other words for all components and pipes in the different installation configurations vertical or horizontal air or flue etc and for all the fittings a flow resistance reduction equivalent to x metre of horizonta...

Page 17: ...nlet for connection with split end Ø80 1 1 1 2 1 2 2 2 1 5 2 5 1 5 2 5 7 Reduction 2 4 3 Air Flue Vertical Horizontal Vertical Horizontal 12 Condensate flue outlet A c c e s s o r i e s Ø 8 0 A c c e s s o r i e s Ø 8 0 Spigot and socket reduction Ø80 100 0 Reduction Airwall terminal products of combustion Ø80 5 Male female flue Ø100 Male female bend 45 Ø100 Male female bend 90 Ø100 Air wall termi...

Page 18: ...ded between 38 and 48 see table on page 13 Remove the flue diaphragm The flue and air pipes must have an inclination downward equal to 3 from the boiler to outside Example of calculation for wall inlet outlet with 2 pipe system maximum total flue length 48 metres Fig 20 REF N OF PIECES DESCRIPTION CODE LENGTH OR REDUCTION 1 1 Air bend 80 mm R D 0 75 1 5 m 2 13 Horizontal air pipe 13 0 m 3 1 Air wa...

Page 19: ...should be about 1 5 2 bars After filling always close and disconnect the filling loop Note If there is a possibility of air pockets forming in certain points of the central heating system flow and return pipes you are recommended to fit an air vent valve at these points Note When the boiler is installed below the level of the central heating a system single check valve should be fitted in the flow...

Page 20: ...gnite only after having verified that the fan is working correctly If the difference in pressure between the flue gas discharge pipe and the air intake pipe is not at least equal to the minimum pressure switch calibration value the pressure switch contacts do not close and the gas valve is thus prevented from opening In addition the electrical circuit of the boiler is designed so that if for any r...

Page 21: ...inals 1 2 Connect the plug end of the cable to terminal X2 of main circuit board Remove the connector link from the 2 wires located behind the clock position Connect these to terminal 3 and 5 of the clock Replace everything in reverse order Please refer to page 43 of User manual for use of time clock X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 X12 1 2 1 2 3...

Page 22: ...art up procedure correctly the burners fail to ignite and the boiler shut down warning lights up wait about 15 seconds then rotate the knob 98 fig 2 against spring pressure to the RESET position and release it The reset electronic control unit will repeat the start up cycle Note In central heating mode after resetting the boiler will go into it 2 minue delay before starting up again If after a sec...

Page 23: ...re critical to the efficient operation of the boiler it is ESSENTIAL that the following adjustments are carried out by COMPETENT personnel ONLY 5 02 Adjusting minimum and maximum pressure Honeywell V K4105G gas valve Connect suitable pressure gauge to burner test point B downstream of the gas valve Disconnect the pressure compensation tube F Remove the protective cap C Adjust potentiometre P3 on t...

Page 24: ...central heating flow t by varying pump flow head The thermal head t the difference in temperature between the delivery water and return water in the central heating circuit must be less than 20 c This is obtained by varying pump flow rate and head using the multi speed variator or switch on the pump itself Increasing the pump speed reduces t and vice versa The minimum differential must not be less...

Page 25: ... corners lift slightly and pull forward 4 Carry out preliminary electrical checks at boiler junction box This is located in the centre of the boiler at the bottom and can be accessed be the removal of a single screw Any faults found must be rectified before proceeding 5 If electrical checks prove O K replace cover and secure with screw 6 Attach a manometer to the boiler gas inlet test point turn o...

Page 26: ...s CO CO2 ratio should not exceed 0 0040 Immediately after servicing 0 0080 30 Refit case and secure with screws 31 Leave boiler set to customers requirements 6 04 Flue Gas Analysis 1 The appliance should be checked visually for obvious defects 2 After removing the jacket on the boiler there are two test point one for flue gas and the other for air 3 Open the air and flue gas test points 4 Introduc...

Page 27: ...al procedure Re open cocks and re charge the system to about 1 bar and vent boiler and radiators Re charge to 1 bar if necessary Upon completion of the work the following Should be checked I Gas soundness of all joints II Water soundness of all joints III The electricity supply IV The pressure of the sealed system and top up where necessary 7 03 To lower the control panel fig 30 Remove the two fix...

Page 28: ...ain the boiler Release the outlet union to the valve and undo the valve union connection Remove the valve outlet fitting Replace in reverse order Fig 33 Fig 34 7 06 Air pressure switch fig 33 Isolate electricity Remove outer case two screws bottom rear corners Open room sealed department Remove the two screw A fixing air pressure switch Disconnect electrical leads B Remove pressure sensing tubes w...

Page 29: ...36 Isolate gas and electricity supplies Remove outer case two screws bottom rear corners Remove room sealed cover Disconnect fan electrical leads A and note positions Disconnect air pressure tubes from air pressure switch B note positions Undo two screws securing fan assembly C Remove fan from boiler Swap mounting plate over to new fan replace in reverse order 7 11 Limit thermostat or overheat cut...

Page 30: ...heat exchanger close tap Remove outer case two screws bottom rear corners Remove two screws from control panel and tilt forward Take off protective cover from main PCB and unplug flow meter lead from terminal X6 Place a piece of cloth or some other absorbent material over rear of control panel to catch any drops of water that may be released when removing the flow meter Using a 24mm open ended spa...

Page 31: ...ump body by removing the U clip from the left hand side Disconnect the boiler return pipe and disengage the pump lower connection by removing the U clip C Disconnect the pump to heat exchanger connection by removing the U clip F Unscrew the two screws on bottom of pump D Turn the pump body through 90 pull the bottom forward and withdraw the pump body Reassemble in reverse order taking care to ensu...

Page 32: ...he boiler thermostat is set to maximum than the burner pressure will go to maximum effectively bypassing the auto range rating facility Domestic Hot Water Mode External Call for D H W Flow meter registers at least 2 5 litres min flow to the hot water taps Internal Call for D H W Hot water flow temperature sensor 88 C high limit stat and low water pressure switch calling for heat If both internal a...

Page 33: ...uspect the flow meter has not operated Boiler will not light for C H If the boiler works for D H W but not for heating the fault is most likely to be external controls i e clocks or room thermostats Integral clock if fitted or C H sensor If the heating demand light is on the fault is most likely the C H sensor If this light is not on suspect either a clock or room thermostat not calling To overrid...

Page 34: ...output and maximum D H W temperature both are adjustable by the controls on the facia and because the boiler features automatic range rating no adjustments need to be made Electro mechanical relays control pump operation and put switched live to the ignition PCB demand relay they have transparent plastic covers so that their contacts can be seen moving 8 08 Air pressure switch Operating at 230 V A...

Page 35: ...eck water pressure switch wiring connection NO Does fan run at full speed NO Go to CHART 2 NO YES Does CH Pump run If the boiler temperature is less than 5 C frost protection is activated Disconnect CH flowtemp sensor Has fan speed stopped Check and if necessary replace main board NO YES YES Check and if necessary replace water pressure switch Chek the following carefully before starting Gas suppl...

Page 36: ...S YES YES Check and if necessary replace main board Check and if necessary replace limit thermostat Go to chart 4 Wait 2 minutes DHW taps closed Put CH temperature selector to maximum Ensure external controls are calling for heat Is LED4 flashing Does C H pump run YES YES Go to chart 4 Is relay RY101 switch on Check and if necessary replace main board NO Is LED4 flashing Check and if is necessary ...

Page 37: ...switch YES Differential air pressure across the air pressure switch is greater than 180 Pascal Go to chart 5 YES NO Check and clean fan Check flue and air intake are correct and clean Check Venturi and air pressure switch tubes are clean Check restrictor is correct Chart 5 Check D H W and C H modulation Does burner flame modulate Normal operation carry out YES NO Boiler operated on central heating...

Page 38: ...heck electrodes and leads for damage and correct connection Check and if necessary replace P C B Adjust with P4 ignition burner pressure Check and if necessary clean burner Check and if necessary clean injectors Check and if necessary clean flame electrode Check right position of spark electrode Check wires Check gas supply is live and purged Check and if necessary replace gas valve NO YES Check a...

Page 39: ...ature adjustment P3 Central heating flow output adjustment P4 Ignition gas pressure adjustment P5 Minimum adjustment pressure 9 ELECTRICAL AND FUNCTIONAL SCHEME 9 01 Main components layout on electronic boards temp Ohm 10 C 20 kOhm 25 C 10 kOhm 60 C 2 5 kOhm 80 C 1 25 kOhm Temp sensor NTC 34 42 Fig 40 X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 L1 L2 L3 L4 ...

Page 40: ...ral heating pump 34 Central heating fl ow temperature sensor 42 Domestic hot water fl ow temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety thermostat 50 Central heating limit thermostat 62 Time clock option 72 Room thermostat 81 Ignition electrode 82 Sensor electrode 98 Off On Reset switch 114 Low water pressure switch 136 Flow meter Key BR Brown BLUE Blue BL Black W White O Orange ...

Page 41: ...n hot water only from the boiler turn switch A to the on position The top green light on the left side of the control panel is illuminated power on Turn the temperature regulator B to the position Open a hot water tap green light tap symbol comes on fan starts and burner will light Indicated by flame symbol green light coming on The temperature of the hot water can be adjusted by turning the hot w...

Page 42: ...th will suffice Maintenance Férroli recommend that the appliance is serviced at least once every twelve months by a competent engineer Gas Supply It is the law that all gas appliances are installed and serviced by a competent person in accordance with the Gas Safety Regulations Installation Use 1996 and the manufacturers instructions Failure to observe these requirements may lead to prosecution El...

Page 43: ...00 Display 2 1 Use buttons and to set OFF time eg 9 00 Display 3 1 Use button and to set 2nd ON time eg 12 30 Display 4 1 Use button and to set 2nd OFF time eg 14 00 Display 5 1 Use button and to set 3rd ON time eg 16 00 Display 6 1 Use button and to set 3rd OFF time eg 23 30 Display 8 Oncompletionofprogrammingslideswitch A toAutoposition the time of day will be displayed and the central heating w...

Page 44: ...NSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS Please note to avoid incurring unnecessary expense in the event of a boiler shut down check this in not caused by lack of electricity supply gas supply or low water pressure before calling our Customer Service Helpline Should you require help with any difficulties call our Technical Service Helpline ...