Ferroli ARENA 30 A Installation And Operating Instructions Manual
ARENA 30 A
WALL-HUNG, PRE-MIX
GAS-FIRED CONDENSING BOILER
INSTALLATION
AND
OPERATING INSTRUCTIONS
Appr. nr. B99.15 A - CE 0063 BL 3475
cod. 3543694/1 ediz. 06/2002
ARENA 30 A
2
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”.
Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.
Benchmark has been introduced to improve the standards of installation and commissioning of central
heating systems in the UK and to encourage the regular servicing of all central heating systems to
ensure safety and efficiency.
Please see installation and servicing guidlines.
CE MARK
CE mark documents that the Ferroli gas appliances comply with the requirement contained in
European directives applicable to them.
In particular, the appliances comply with the following CEE directives and the technical specifications
provided from them:
• Gas appliances directive 90/396
• Efficiencies directive 92/42
• Low tension directive 73/23 (modified from the 93/68)
• Electromagnetic compatibility directive 89/396 (modified from the 93/68)
Year 2000 Compliance Declaration
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.
ARENA 30 A
3
• Read the warnings given in this manual
thoroughly. They provide important information for safe installation, use and
maintenance
• Keep the manual carefully for future
consultation.
• The instruction manual is an integral and
essential part of the product and must
be kept by the user.
• If the appliance is sold or transferred to
another owner or if the owner moves,
leaving the appliance behind, always
ensure that the manual is kept with the
appliance for consultation by the new
owner and /or installer.
• Incorrect installation or poor maintenance absolves the manufacturer from
all liability for damage to people or
things.
• Installation and maintenance must be
carried out i conformity with current
legislation, according to the manufacturer’s instructions and by qualified personnel.
• Before cleaning or maintenance, disconnect the appliance from the mains
via the switch on the appliance or a
suitable isolating device.
• In the event of malfunction or faulty
operation, deactivate the appliance. Do
not attempt to repair or carry out any
other operation on the appliance directly. Contact qualified personnel only.
• Repairs or the replacement of components must be carried out exclusively by
qualified personnel using original spare
parts only. Failure to respect the above
my compromise the safety of the appliance.
• To guarantee efficient operation, the
appliance must be serviced once a year
by an authorised service centre.
• The appliance may not be used for purposes other than those for which it was
explicitly designed. Any other use is
considered improper and therefore dangerous.
• Incorrect installation and use or failure
to follow the instructions provided by
the manufacturer absolve the manufacturer from all liability for damage.
• After unpacking, check that the contents are whole and undamaged.
• Keep packing out of reach of children as
it is potentially hazardous.
• To clean external parts, use a damp
cloth moistened with soapy water if necessary. Avoid using abrasive cleaning
products and solvents.
ARENA 30 A
4
INDEX
1. CHARACTERISTICS AND TECHNICAL DATA ............................................................. 5
1.1 Introduction ..........................................................................................................5
1.2 Structural charateristics ........................................................................................6
1.3 Technical data table ..............................................................................................9
1.4 Diagrams .............................................................................................................10
1.5 Functional flow chart ..........................................................................................11
2. INSTALLATION ......................................................................................................... 12
2.1 General Instructions ........................................................................................... 12
2.2 Positioning and wall mounting ...........................................................................12
2.3 Connection to the hydraulic system................................................................... 13
2.4 Characteristics of the boiler water .....................................................................14
2.5 Connection to the gas system............................................................................ 14
2.6 DHW storage connection ...................................................................................15
2.7 Condensation discharge connection ..................................................................15
2.8 Electrical connections .........................................................................................16
2.9 Positioning the external probe........................................................................... 17
2.10 Flues .................................................................................................................. 18
2.11 Connection to concentric pipes .......................................................................18
2.12 Connection to separate pipes ..........................................................................20
2.13 Table of losses for piping and accessories .......................................................21
2.14 Terminal Position .............................................................................................. 24
3. SERVICE AND MAINTENANCE ............................................................................... 25
3.1 Settings ...............................................................................................................25
3.2 Commissioning and testing ................................................................................28
3.3 Maintenance .......................................................................................................29
3.4 Replacement of parts .........................................................................................33
3.5 Troubleshooting.................................................................................................. 36
4. OPERATING INSTRUCTIONS ................................................................................... 39
4.1 Operation and controls ......................................................................................39
4.2 Boiler control panel ............................................................................................39
4.3 Ignition ................................................................................................................40
4.4 Shut-down ........................................................................................................... 40
4.5 Operating indications on the display .................................................................40
4.6 Accessing the operating menu........................................................................... 40
4.7 Setting the heating system temperature ...........................................................41
4.8 Setting the domestic hot water temperature ....................................................41
4.9 Summer/Winter Selection .................................................................................. 41
4.10 DHW storage exclusion ....................................................................................41
4.11 Outside temperature compensation ................................................................42
4.12 Maintenance .....................................................................................................42
4.13 Anomalies .........................................................................................................42
ARENA 30 A
5
1.1 Introduction
Dear Customer,
Thank you for having chosen the Arena 30 A, the latest generation FERROLI wall-hung boiler, featuring
advanced design and cutting-edge technology.
The Arena 30 A is a pre-mix condensing thermal generator for heating and the production of domestic hot
water, with very high thermal efficiency and very low emissions, fired by natural gas or LPG.
The boiler body is made up of a prismatic mono-block heat exchanger, with a hexagonal base made from
aluminium alloy, inserted in a cylindrical steel jacket, with water cavity, and insulated externally with highdensity foam. The special design of the heat exchanger allows effective condensation of the water vapour
contained in the flue gases, making the Arena highly efficient. The heat exchanger has been designed to
maintain its characteristics of high thermal exchange over time.
Inside the aluminium mono-block heat exchanger, in a cooled combustion chamber, lies the pre-mix burner
assembly, with a radial shape and metallic surfaces, featuring electronic ignition with ionisation flame control,
which allows extremely low emission values, and at the same time guarantees high reliability and constant
operation over time.
The combustion circuit and the air intake are sealed from the installation environment.
The boiler is fitted with a variable speed fan and built-in modulating gas valve, connected directly to the
outside.
The boiler is preset for connection with external DHW storage. An internal circulator for DHW, connection
dedicated to DHW storage, DHW probe make the connection extremely simple.
The boiler control and regulation system is microprocessor-based, with advanced self-diagnostics. The user
interface, made up of a keypad and display, is user-friendly, and shows the operating status of the appliance
at all times. The operating parameters and the data logs are saved internally and can be called up using the
Personal Computer interface to simplify Service operations.
The heat output is regulated continuously across the entire operating range (also with DHW storage), with
temperature-scrolling climate control, which automatically adapts the operating mode to the characteristics
of the internal and external environments, of the building and its location.
Completing the fitted devices are a variable-speed heating pump and a fixed-speed domestic hot water
pump, a high-capacity expansion vessel, flowmeter, safety valve, drain cock, water pressure switch, flue gas
sensor, temperature sensors and safety thermostat.
1. CHARACTERISTICS AND TECHNICAL DATA
ARENA 30 A
6
1.2 Structural charateristics
Dimensions and connections
Key
1 Heating outlet
2 DHW storage flow
3 Gas inlet
4 DHW storage return
5 Heating return
6 Drain cock
7 Safety valve
8 Flue gas outlet
9 Air inlet
Fig. 1
205
220
60
110120
8
9
73109,56262109,544
139
368
760
460
1 2 3 4 5
6
7
ARENA 30 A
7
Overall view and main components
Key
14 Safety valve
16 Fan
32 Heating pump
34 Heating temperature sensor
35 Auto air vent
44 Gas valve
49 Safety thermostat
56 Expansion vessel
69 Flue gas outlet pipe
70 Air intake pipe
114 Water pressure switch
151 System drain cock
161 Condensing heat exchanger
179 Non-return valve
186 Return sensor
191 Flue gas temperature sensor
213 Flexible inlet air pipe coupling
214 Flue gas outlet reducer
215 Air inlet reducer
216 Domestic hot water pump
217 Boiler body lagging
220 Ignition board
Fig. 2
114
213
14
220 16 151
32
216
56
44
69
70
215
214
179
161
217
186
49
34
35
191
ARENA 30 A
8
Heating
outlet
Gas
inlet
DHW
storage
inlet
Heating
inlet
Air
inlet
Flue gas
outlet
1644
56
49
191
32
34
186
22
82
188
216
114 14
Condensation
discharge
221
DHW
storage
outlet
179
179
Key
14 Safety valve
16 Fan
22 Main burner assembly
32 Heating pump
34 Heating temperature sensor
44 Gas valve
49 Safety thermostat
56 Expansion vessel
82 Detection electrode
114 Water pressure switch
179 Non-return valve
186 Return sensor
188 Ignition electrode
191 Flue gas temperature sensor
216 Domestic hot water pump
221 Bypass cock
Hydraulic diagram
Fig. 3
ARENA 30 A
9
Heating
Maximum operating temperature, heating °C
Maximum operating pressure, heating bar
Minimum operating pressure, heating bar
Expansion vessel capacity litri
Expansion vessel pre-fill pressure bar
Boiler total water content litri
Dimensions, weights, conections
Height mm
Width mm
Depth mm
Empty weight kg
Gas system connections poll.
Heating system connections poll.
Domestic hot water storage connections poll.
Condensation discharge (flexible pipe) mm
Maximum length separate flues D=80*
m
eq
(*Values expressed in equivalent air metres - refer to FERROLI calculation system)
Electrical power supply
Max Electrical Power Consumption W
Pump electrical power consumption (Speed I-II-III) W
Power supply voltage/frequency V/Hz
85
3
0,8
12
1
11,8
760
460
368
55
1/2”
3/4”
3/4”
15x20
100
150
48-67-93
230/50
Power
Heat rate Hi
Heat rate Hs
Natural Gas rate (G20)
Natural gas supply pressure (G20)
LPG Gas rate (G31)
LPG Gas supply pressure (G31)
Pmax Pmin
kW 31,5 8,2
kcal/h 27.090 7.052
nm
3
/h 3,27 0,80
mbar 20 20
kg/h 2,44 0,60
mbar 37 37
Useful heat output 80°C - 60°C
Useful heat output 50°C - 30°C
Combustion
CO2 (Natural Gas - G20) %
CO2 (LPG - G31) %
Flue gas temperature 80°C-60°C °C
Flue gas temperature 50°C-30°C °C
Flue gas flow rate kg/h
Quantity of condensation kg/h
pH of condensation water pH
Pmax
9,5
10,2
70
40
49
3,3
Pmin
9,0
9,5
65
32
13
1,4
4,1
kW 30,9 7,6
kcal/h 26.574 6.536
kW 34,3 8,4
kcal/h 29.498 7.224
kW 30,0 7,4
kcal/h 25.800 6.364
1.3 Technical data table
ARENA 30 A
10
6,0
III
II
I
0,0
1,0
2,0
3,0
4,0
5,0
0 0,5 1 1,5 2 2,5 3
Q (m3/h)
3,5 4
H (m C.A.)
1.4 Diagrams
Heating pump head
Loss of boiler pressure
Fig. 4
Fig. 5
6,0
41,5 2 2,5 3 3,5
Q (m3/h)
1,0
2,0
3,0
4,0
5,0
1
0,0
0 0,5
H (m C.A.)
ARENA 30 A
11
1.5 Functional flow chart
Fig. 6
13
1
2
151412111087654
1245678101112
NL
3
2
1
24 V AC
24 V AC
X2
X1
131415
X5
X6
175
X10
X11
PC
3
2
X3
X4
1
2
3
6
7
8
9
10
11
12
S4575B 1033
12
11
10
8
7
5
4
2
1
9
6
16
-
-
DMF04
NL
L
N
NL
114
12
1110987654321
X7
---
191
72
32
98
130
186
188 82
34
139
138
49
4
5
NL
230 V
50 Hz
230 V
50 Hz
83
101
42
230V 50Hz Low voltage
Eco/Comfort
selection
12
1
Legenda
16 Fan
32 Central heating pump
34 C. H. flow temperature sensor
42 D. H. W. temperature sensor
49 Overheat cut-off thermostat
72 Room thermostat (not fitted)
82 Ionisation electrode
83 Full sequence automatic control
98 Switch
101 Main P.C.B.
114 Water pressure switch
130 D.H.W. pump
138 Outside temperature sensor
139 Room unit (not fitted)
175 Transformer
186 Return temperature sensor
188 Hot surface igniter
191 Exhaust temperature sensor
ARENA 30 A
12
> 50 cm
Minimum Recommended
A
B
D
3 cm
15 cm (20 cm from DHW storage)
1,5 cm
(from any openable panel)
15 cm
30 cm
C 10 cm 15 cm
A A
B
D
C
2. INSTALLATION
2.1 General Instructions
Gas Safety (Installation & Use) Regulations: 1996
In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance
with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current
I.E.E. Regulations and the byelaws of the
Local Water Undertaking. Failure to comply
with the Regulations may lead to prosecution;
it is your responsibility to ensure that the law
is complied with.
N.B. For Northern Ireland the rules in force
apply.
IMPORTANT If the boiler is to be fitted in
a timber framed building it
should be fitted in
accordance with the
Institute of Gas Engineers
document IGE/UP/7. If in
doubt advice should be
sought from the Local
Supplier.
WARNING!! This appliance must be installed
in a room with sufficient ventilation, to avoid
dangerous conditions arising in the event of,
even minor, gas leaks. These safety standards
are imposed by the EEC Directive no. 09/396
for all gas appliances, including the so-called
sealed appliances.
2.2 Positioning and wall
mounting
The installation of the ARENA must be on a
suitable non-combustible load bearing wall
which will provide an adequate fixing for the
boiler mounting bracket assembly. The location should be in an area where the water
pipes will not be subjected to frost conditions.
In siting the combination boiler the following
limitations must be observed:
The combination boiler may be installed in any
room or internal space, 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 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 or
appliance control utilising mains electricity must be situated so that it cannot be touched by a person using
the bath or shower.
The boiler is supplied ready for wall-hung installation. The rear frame of the appliance has a series of slots
Fig. 7a
ARENA 30 A
13
Arena
30 A
748
460
44 109,5 62 62 109,5 73
16 16
11
16
205
220
60
110120
8
9
7511061,561,511045
139
368
760
460
1 2 3 4 5
6
115
Ø 3/4” Ø 1/2” Ø 3/4”
Kit Ferroli
cod. 1KWMA78Y
A
A
B
C
106
16,5
139
2 3 4 51
6
for fastening it to the wall, using screws with metal wall plugs.
The fastening to the wall must provide stable and effective
support of the appliance.
The boiler must be fastened to a closed part of wall, which is
free of apertures or holes behind the frame of the boiler that
may allow the internal components of the boiler to be reached.
If the appliance is enclosed in a cabinet or alongside another
appliance, space must be allowed for normal maintenance
operations. Fig. 7 shows the minimum and recommended
space to be left free around the appliance.
The boiler is supplied with a paper drilling template used to
trace the holes for fastening the appliance onto the wall.
Furthermore, upon request a metal version of the wall drilling
template is available, which can be reused for more than one
appliance.
Position the drilling template on the part of the wall chosen
for the installation of the boiler; using a spirit level, check that
the lower bracket is perfectly horizontal. Temporarily fasten
the drilling template to the wall using some adesive tape.
Trace the fastening points “A”. Drill two 10 mm holes 90 mm
deep to accept the wall plugs, fit wall plugs. Fit two special
wall plugs on the wall as described in the fig. 7c. Fasten the
wall bracket to the wall using an antitheft nut on the right side
and a standard nut (M8) on the left side. Mount the
boiler on the wall bracket and fix using an antitheft
nut on the left side and a standard nut (M8) on the
right side.. The connection for the water and gas
pipes to the boiler are then defined, from “B” lines
(for vertical connections) or from ”C” holes for
horizontal connections (using optional Ferroli kit).
Note If there is no drilling template for mounting
the appliance, simply fasten the boiler to
the wall using suitable support screws with
metal wall plugs, through the holes in the
boiler frame.
Key
1 Heating outlet
2 DHW storage flow
3 Gas inlet
4 DHW storage return
5 Heating return
6 Drain cock
Fig. 8
2.3 Connection to the hydraulic system
Make the connections to the corresponding couplings, according to the
positions indicated in Fig. 3.
Fig. 7b
Fig. 7c
ARENA 30 A
14
In addition, shut-off valves should be installed between the boiler and the heating system to allow, if
necessary, the boiler to be isolated from the system. If a non-return valve is also installed in the domestic hot
water circuit, a safety valve must be fitted between the boiler and this circuit.
The discharge of the safety valve must be connected to a funnel or collection pipe, to avoid water leaking
onto the ground in the event of excessive pressure in the heating circuit.
Make the connections to the boiler so as its internal pipes are not subject to stress. For proper operation and
long-life of the boiler, the hydraulic system must be correctly proportioned and always complete with all the
accessories required to guarantee regular operation and conduction.
Upon request a connection kit can be supplied, simplifying connection to the system.
2.4 Characteristics of the boiler water
In the presence of water with hardness above 18 Clarke degrees, the water should be suitably treated, to avoid
any deposits in the boiler caused by hard water, or corrosion caused by aggressive water. It should also be
remembered that even minor deposits measuring just a few millimetres thick can cause, due to their low
thermal conductivity, significant overheating of the walls of the boiler, with consequent and serious problems.
The water must always be treated in the case of very large systems (with high water capacity) or systems with
the frequent inlet of recovered water. If, in these cases, the system needs to be partially or completely
emptied, it must be refilled with treated water.
Water System
Note The boiler is designed for sealed systems only and must NOT be used on open vented systems.
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming
part of the useful heating surface should be insulated to prevent any heat losses or possible freezing (i.e. in
roof spaces 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. Ensure that
the boiler heat exchanger is not a natural point for air collection.
Make Up Water
Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798,
for methods of filling and making up sealed systems. There must be no direct connection between the 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.
Domestic Hot Water
Always fit a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection
point on the boiler for attaching to the main supply is provided. The maximum domestic water pressure for
the inlet supply is 10 bar (145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor
or pressure reducing valve must be fitted by the installer into the mains supply in an inconspicuous but
accessible position preferable between 3 and 5 metres (10-16ft) before the appliance. Such a valve must be
approved by the Water Research Council.
Attention - is drawn to the Model Water Byelaws.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain
water undertakings will not accept their use above ground.
Ensure all pipework is adequately supported.
2.5 Connection to the gas system
If necessary the local Gas supplier should be consulted, at the installation planning stage, in order to establish
the availability of an adequate supply of gas.
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