Ferroli optima 801, Installation Instructions Manual

Page 1: ...ax 0121 3523510 ALL SPECIFICATIONS SUBJECT TO CHANGE Phone numbers Installer Service Engineer Serial No Read these Instructions thoroughly before using the appliance FERROLI HELPLINE FOR SERVICE INFORMATION OR HELP TELEPHONE 0121 3523500 ALWAYS QUOTE YOUR SERIAL NUMBER FOR IMMEDIATE ASSISTANCE INSTALLATION INSTRUCTIONS Appr Nr B94 02A CE 0063AQ2150 04 98 G C NO 47 267 17 ...

Page 2: ...flue 14 Drilling template 15 Preparing the Flue Assembly 15 Connecting the Boiler 18 Fitting the Flue Assembly 18 Electrical Installation 19 Commissioning Testing 19 Filling the Central Heating System 19 Filling the Domestic Hot Water System 19 Electricity Supply 19 The Gas Installation 20 To Light the Boiler 21 To Range Rate the Boiler C H 22 Gas pressure adjustment with Honeywell VR 4600 N 4002 ...

Page 3: ... and or a 24 Volt room thermostat The pump circuit also has a 6 minute over run time There is a Domestic Hot Water flow switch fitted and when there is a demand for Domestic Hot Water the Central Heating pump is switched off making available the maximum output of the gas burner for Domestic Hot Water On the P C B the output for Central Heating can be set However this is not required for the majori...

Page 4: ...cal Input 150 W Central Heating Max Flow Temperature 85 C Temperature Rise Across Boiler 20 C Domestic Hot Water Flow 30 C Rise 11 1 litres min 32 C Rise 10 4 litres min 35 C Rise 9 5 litres min 40 C Rise 8 3 litres min Minimum Domestic Hot Water Flow 2 5 litres min Maximum Domestic Cold Water Inlet pressure 10 bar Minimum Heating Circuit Pressure 0 8 bar Maximum Heating Circuit Pressure 3 0 bar L...

Page 5: ...stic Hot Water outlet 4 Domestic Cold Water inlet 5 Central Heating Pressure relief valve 6 Central Heating Flow outlet 7 Central Heating Return inlet 8 Air intake for two pipe flue systems 8 TOP VIEW 480 900 370 77 5 50 75 80 50 50 97 5 1 2 3 4 5 6 7 40 85 242 235 60 100 Ø i 9 2 Øi82 1 2 0 242 1 2 6 5 235 160 157 480 ...

Page 6: ...801 6 Boiler Flow Diagram Fig 2 ...

Page 7: ...erature sensor 43 Air pressure switch 44 Operator gas valve 47 Modulating regulator Modureg gas valve 48 Burner pressure test point 49 Overheat cut off thermostat 50 Central heating limit thermostat 51 Central heating frost thermostat 53 Heat exchanger venting point 56 Expansion vessel 58 Fan air outlet pressure test point 59 Flue outlet pressure test point 61 C H selector switch 62 Time clock if ...

Page 8: ... particular attention is drawn to the requirements of the current i e wiring regulations and in Scotland the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the combination boiler in a room or internal space containing a bath or shower Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch ...

Page 9: ...ig 5 Fig 3 Minimum Clearance mm NOTES If a side outlet flue is to be used a clearance of 75 mm will be needed on the flue outlet side of the boiler Access to the front of the boiler must be available for maintenance min 600 mm ...

Page 10: ...ces or ventilated underfloor spaces Drain taps should be positioned at the lowest point of the system in accessible locations to permit the whole system to be drained down The drain taps should be in accordance with BS2879 Copper tubing to BS2871 Part 1 is recommended for water carrying pipework Pipework in horizontal runs should have a gradient where possible to facilitate the removal of air It s...

Page 11: ...2 Temporary connection 3 Cold water supply Gas Cold water Additional expansion vessel C H if required Filling point C H Bypass NOTE A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout ...

Page 12: ...EXPANSION VESSELS Deduct from the value given in the table the 7 litre vessel supplied Note 1 Fill C H installation to min 1 5 bar 2 Select by preference the expansion vessel for increased system pressure of 2 0 bar 3 Expansion vessel must be fitted to Central Heating Return Inlet 4 The standard 7 litres expansion vessel is charged to 1 bar Fig 9 SAFETY VALVE SETTING bar VESSEL CHARGE PRESSURE bar...

Page 13: ...ccept the wall plugs and insert wall plugs 2 5 Fit the mounting jig assembly using the four fixing screws provided Ensure that all the service cocks are in the OFF position Operate valves several times to ensure they are free 2 6 With the exception of the connection to the pressure relief valve make all the water and gas connections to the jig bracket valves Fully tighten fig 11 Water connections ...

Page 14: ...ve 15 mm 4 Domestic Cold Water inlet 15 mm 6 Central Heating flow outlet 22 mm 7 Central Heating return inlet 22 mm Important Note Always use two spanners to prevent twisting of soft copper pipework Note The central heating safety valve 5 should be piped 15 mm to discharge safely outside the property Fig 10 1 Electrical cable entry 2 Gas supply 3 Domestic Hot Water outlet 4 Domestic Cold Water Inl...

Page 15: ... side to be used later Side Flue Outlet Fig 13 4 2 Side Flue Outlet fig 13 Important The aluminium flue pipe must protrude into the outside grill by 60 mm never cut it to the same length as the plastic air pipe Aluminium flue pipe length Plastic air inlet pipe length plus 70 mm longer 4 2 1 Accurately measure the Wall thickness P2 4 2 2 Accurately measure the distance from the centre of the stud f...

Page 16: ...return and the domestic hot water inlet and outlet using appropriate sealing washers Tighten the gas union 5 5 Screw the pressure relief valve adaptor provided through the jig bracket into the valve using the remaining washer fig 17 5 6 Connect the pressure relief valve discharge pipe 15 mm to the outside of the building where possible over a drain The discharge must be such that it will not be ha...

Page 17: ...801 17 Fixing points Lift here Fig 15 Fixing screws Fig 16 Fig 17 ...

Page 18: ... The supply cable must be no less than 0 75 mm 24x0 2 mm to BS6500 table 16 7 1 2 Theearthconductormustbecutlongerthantheliveandneutral fig 19 ConnecttheSupplyCabletotheterminal block marked 240 V 50 Hz L N the supply cable is to be connected as follows i Connect the brown wire to the L live terminal ii The blue wire to the N neutral terminal iii The green yellow wire to the earth terminal 7 1 3 S...

Page 19: ...Tighten cap on heat exchanger air vent Ensure the working pressure when filled is between 1 to 1 5 bar on the pressure gauge see technical data Check the system for leaks Flush system in accordance with BS 7593 8 2 Filling the Domestic Hot Water System Close all hot water draw off points Open main cold water stop cock and ensure the cold water inlet cock is open at the boiler jig bracket fig 11 Sl...

Page 20: ... minutes before fan will run is possible and main burner will light e Temporarily turn off by switching off electricity supply Important Note If the burner stops for C H only after a waiting time of 3 minutes will the boiler light again P P AUTO R OVERRIDE 12 31 x x 4 AUTO Flame viewing opening C H pressure gauge C H boiler thermostat Fault diagnostic lights Domestic hot water thermostat Time cloc...

Page 21: ...ntiometer P1 on the PCB fig 24 in the controlpaneluntiltherequiredburnerpressureisobtained Anticlockwise to reduce the pressure Note 2 The range of inputs with corresponding burner pressure is given on the Data badge which is situated behind the top front panel Further informations is on fig 23 e Withthepressureset turnofftheelectricalsupplyand mark the set input on the Data badge with sticker sup...

Page 22: ...t F then check that the pressure is still at the required value 11 Adjust minimum pressure by rotating screw E anticlockwise until the required value is reached 12 Fit coil C by sliding it into the sleeve pushing and rotating it lightly until the coupling spring I clicks into place 13 Shut down and ignite the burner checking that the minimum pressure value is stable 14 Reconnect the wires to coil ...

Page 23: ... OPERATION Let the boiler operate normally on central heating for about 30 minutes I Vent radiators II Vent heat exchanger III Examine all pipework for leakage IV Turn on a D H W tap and check that the C H pump stops running V As the D H W temperature reaches 60 C check the burner for modulation Switch off electricity Drain down the central heating system fully and flush in accordance with B S 759...

Page 24: ... will come into operation when the selector switch is turned to the position marked heating timed and hot water AUTO R OVER RIDE 12 31 x x 4 A B E R D P AUTO P O I F P To set time of day 1 Slide switch A to left position 2 Using button and adjust until the correct time is shown on display B Pre Set Programmes The timer is pre programmed with 3 ON and 3 OFF times 6 30 8 30 12 00 12 00 16 30 23 30 6...

Page 25: ...OFF The timer will revert back to it set programme on reaching the next ON or OFF time When the programme is on over ride the sign will be shown in the display window B Reset Button By the use of a pencil the reset button can be pushed R This will clear all programmes apart from those factory pre set Reset is only possible with switch A in set Clock position x ...

Page 26: ...lt min 42 386818 800310 2 Temperature sensor 43 381691 800140 1 Air pressure switch 44 802500 1 Combination gas valve 49 386815 801240 1 Overheat cut off thermostat 50 386577 800160 1 Heat exchanger limit thermostat 51 386828 800180 1 Heat exchanger frost thermostat 61 372225 801230 1 C H selector switch 62 803840 1 Time clock 81 801440 1 Ignition electrode 82 801430 1 Flame sensing electrode 83 8...

Page 27: ...c Hot Water Performance Fig 1 D H W Pressure Drop VS flow A Standard with cold water Flow Restricter B Cold Water Flow Restricter Removed Fig 2 Fig 2 D H W temperature VS flow A Cold Water 15 C B Cold Water 5 C Fig 1 ...

Page 28: ...water only Heating continuous and hot water 72 Room thermostat not fitted 80 Five pole terminal 240V 24V 81 spark electrode 82 Flame sensing electrode 83 Automatic ignition control panel 84 1 gas valve operator 85 2 gas valve operator 86 automatic control reset knob 101 P C B 114 Low water pressure switch 136 Flowmeter 145 C H pressure switch 157 D H W thermostat 164 Fault diagnostic temperature c...

Page 29: ...d not energised Air pressure switch 43 not in NC position or miswired check wiring fan 16 at low speed remove jumper JP4 7 1 0 fan 16 not running at full speed or air flow too low air pressure switch 43 faulty B CENTRAL HEATING ON Room stat 72 at Max HW tap closed LED OK FAULT POSSIBLE CAUSE OF FAULT 1 1 0 No main electricity switches off fuse blown 2 0 1 Hot water tap open D H W flowmeter 136 con...

Page 30: ...t Special Air Intake Flue Outlet The standard Flue air intake hood on top of the boiler can be replaced by a special two pipe flue adapter Ø i 9 2 Øi82 1 2 0 242 1 2 6 5 235 160 157 480 2 1 Special two pipe flue adapter 823071 remove air intake cover Ø 80 mm 1 2 Ø80 Ø80 1 2 ...

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Page 32: ...est Midlands B76 8DH Tel 0121 3523500 Fax 0121 3523510 ALL SPECIFICATIONS SUBJECT TO CHANGE Cod 3540250 2 04 98 Phone numbers Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS ...