Ferroli ATLAS Instructions For Use, Installation And Maintenance

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cod. 3540S122 — 12/2009 (Rev. 00)

ATLAS

ISTRUZIONE PER L’USO L'INSTALLAZIONE E LA MANUTENZIONE
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENIMIENTO

KULLANMA, KURULUM VE BAKøM TALIMATLARø

INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE
INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN

ȅǻǾīǴǼȈȋȇdzȈǾȈ, ǼīȀǹȉDZȈȉǹȈǾȈȀǹǿȈȊȃȉdzȇǾȈǾȈ

AANWIJZINGEN VOOR GEBRUIK, INSTALLATIE EN ONDERHOUD

ɊɍɄɈȼɈȾɋɌȼɈɉɈɗɄɋɉɅɍȺɌȺɐɂɂ, ɆɈɇɌȺɀɍɂɌȿɏɈȻɋɅɍɀɂȼȺɇɂɘ

ATLAS

17

EN

cod. 3540S122 - 12/2009 (Rev. 00)

EN

1. GENERAL INSTRUCTIONS

• Carefully read the instructions contained in this instruction booklet.

• After boiler installation, inform the user regarding its operation and give him this
manual, which is an integral and essential part of the product and must be kept with
care for future reference.

• Installation and maintenance must be carried out by professionally qualified person­nel, according to current regulations and the manufacturer's instructions. Do not car­ry out any operation on the sealed control parts.

• Incorrect installation or inadequate maintenance can result in damage or injury. The
Manufacturer declines any liability for damage due to errors in installation and use
or failure to follow the instructions.

• Before carrying out any cleaning or maintenance operation, disconnect the unit from
the power supply using the system switch and/or the special cut-off devices.

• In case of a fault and/or poor operation, deactivate the unit and do not attempt to
repair it or directly intervene. Contact professionally qualified personnel. Repair/re­placement of the products must only be carried out by professionally qualified using
original spare parts. Failure to comply with the above could affect the safety of the
unit.

• This unit must only be used for its intended purpose. Any other use is considered
improper and therefore dangerous.

• The packing materials are potentially hazardous and must not be left within the
reach of children.

• The images given in this manual are a simplified representation of the product. In
this representation there may be slight and insignificant differences with respect to
the product supplied.

2. OPERATING INSTRUCTIONS

2.1 Introduction

Dear Customer,
Thank you for choosing a FERROLI boiler featuring advanced design, cutting-edge

technology, high reliability and quality construction. Please read this manual carefully
since it provides important information on safe installation, use and maintenance.

ATLAS is a high-efficiency heat generator for the production of heating hot water, suita­ble for operation with blown oil or gas burners. The boiler shell consists of cast iron ele­ments, assembled with steel stays and double cones, whose profile is specially designed
with optimum division of the fins, offering high thermal efficiency and therefore high en­ergy-saving.

2.2 Control panel

fig. 1 - Control panel for models ATLAS 32-78

fig. 2 - Control panel for models ATLAS 95

Key

1 = Thermohydrometer
2 = On switch
3 = Manual-reset safety thermostat
4 = 1st stage temperature adjustment knob
5 = 2nd stage temperature adjustment knob

2.3 Turning on and off

Boiler lighting

Open the fuel shutoff valves.
Switch on the power to the unit.
Press button 2 of fig. 1 to feed the boiler and burner. Refer to the burner manual for op-

eration.

Turning the boiler off

For brief shutdown periods just press button 2 of fig. 1 on the control panel , bringing it
to position “0”. For long shutdown periods, as well as operating button 2 also close the
fuel shutoff valve . To avoid damage caused by freezing during long shutdowns in winter,
add a suitable antifreeze to the system or completely drain the system.

2.4 Adjustments

Heating temperature setting

Set the required system temperature with the control thermostat 4 of fig. 1.
For the model ATLAS 95, with the control thermostat 5 then set the temperature of the

2nd stage to a temperature 10°C lower than that of the 1st stage.

A

IMPORTANT: The temperature setting of the 2nd stage must always be
lower than that of the 1st stage..

fig. 3 - Temperature adjustment for model ATLAS 95

Room temperature adjustment (with optional room thermostat)

Using the room thermostat, set the temperature desired in the rooms. If the room ther­mostat is not installed the boiler will keep the heating system at its setpoint temperature.

3. INSTALLATION

3.1 General Instructions

BOILER INSTALLATION MUST ONLY BE PERFORMED BY QUALIFIED PERSON­NEL, IN ACCORDANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL
MANUAL, THE PROVISIONS OF CURRENT LAW, THE PRESCRIPTIONS OF NA­TIONAL AND LOCAL STANDARDS AND THE RULES OF PROPER WORKMANSHIP.

3.2 Place of installation

The boiler must be installed in a special room with ventilation openings towards the out­side in conformity with current regulations. If there are several burners or extraction units
that can work together in the same room, the ventilation openings must be sized for si­multaneous operation of all the units. The place of installation must be free of flammable
objects or materials, corrosive gases, volatile substances or dusts which, sucked by the
burner fan, can obstruct the pipes inside the burner or the combustion head. The room
must be dry and not exposed to rain, snow or frost.

A

If the unit is enclosed in a cabinet or mounted alongside, a space must be pro­vided for removing the casing and for normal maintenance operations. In par­ticular, after boiler installation with burner on the front door, make sure the front
door can open freely without the burner striking walls or other obstacles.

3.3 Plumbing connections

The heating capacity of the unit must be previously established by calculating the build­ing's heat requirement according to current regulations. The system must be provided
with all the components for correct and regular operation. It is advisable to install shutoff
valves between the boiler and heating system allowing the boiler to be isolated from the
system if necessary.

B

The safety valve outlet must be connected to a funnel or collection pipe to pre­vent water spurting onto the floor in case of overpressure in the heating circuit.
Otherwise, if the discharge valve cuts in and floods the room, the boiler manu­facturer cannot be held liable.

Do not use the water system pipes to earth electrical appliances.

Before installation, carefully wash all the pipes of the system to remove any residuals or
impurities that could affect proper operation of the unit.

Carry out the relevant connections according to the diagram in and thecap. 5 symbols
given on the unit.

A

The unit is not supplied with an expansion tank; its connection must therefore
be carried out by the installer. The pressure in the system, when cold, must be
1 bar.

Water system characteristics

In the presence of water harder than 25° Fr (1°F = 10ppm CaCO3), use suitably treated
water in order to avoid possible scaling in the boiler. Treatment must not reduce the hard­ness to values below 15°F (Decree 236/88 for uses of water intended for human con­sumption). Treatment of the water used is indispensable in case of very large systems
or with frequent introduction of replenishing water in the system.

B

If water softeners are installed at the boiler cold water inlet, make sure not to
reduce the water hardness too much, as this could cause early deterioration of
the magnesium anode in the hot water tank.

0 120

60

80

100

40

20

°C

0

30 60

90

°C

1

2

3 4

1

2

3

5

4

90

0

60 30 60

90

0

30

°C

on

off

0 120

60

80

100

40

20

°C

-10°C

60 60

4 5

ATLAS

18

EN

cod. 3540S122 - 12/2009 (Rev. 00)

Antifreeze system, antifreeze fluids, additives and inhibitors

The boiler is equipped with an antifreeze system that turns on the boiler in heating mode
when the system delivery water temperature falls under 6°C. The device will not come
on if the electricity and/or gas supply to the unit are cut off. If it becomes necessary, it is
permissible to use antifreeze fluid, additives and inhibitors only if the manufacturer of
these fluids or additives guarantees they are suitable for this use and cause no damage
to the heat exchanger or other components and/or materials of the boiler unit and sys­tem. It is prohibited to use generic antifreeze fluid, additives or inhibitors that are not ex­pressly suited for use in heating systems and compatible with the materials of the boiler
unit and system.

3.4 Burner connection

An oil or gas burner, with blown air for pressured furnaces, can be used if its operation
characteristics are suitable for the size of the boiler furnace and its overpressure. The
choice of burner must be made beforehand, following the manufacturer's instructions,
according to the work range, fuel consumption and pressures, as well as the length of
the firebox. Install the burner in compliance with the Manufacturer's instructions.

3.5 Electrical connections

Connection to the electrical grid

B

The unit's electrical safety is only guaranteed when correctly connected to an
efficient earthing system executed according to current safety standards. Have
the efficiency and suitability of the earthing system checked by professionally
qualified personnel. The manufacturer is not responsible for any damage
caused by failure to earth the system. Also make sure that the electrical system
is adequate for the maximum power absorbed by the unit, as specified on the
boiler dataplate.

The boiler is prewired and provided with a Y-cable and plug for connection to the elec­tricity line. The connections to the grid must be made with a permanent connection and
equipped with a bipolar switch whose contacts have a minimum opening of at least 3
mm, interposing fuses of max. 3A between the boiler and the line. It is important to re­spect the polarities (LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green
wire) in making connections to the electrical line. During installation or when changing
the power cable, the earth wire must be left 2 cm longer than the others.

B

The user must never change the unit's power cable. If the cable gets damaged,
switch off the unit and have it changed solely by professionally qualified person­nel. If changing the electric power cable, use solely “HAR H05 VV-F” 3x0.75
mm2 cable with a maximum outside diameter of 8 mm.

Accessing the electrical terminal block

Undo the two screws “A” located on the top part of the control panel and remove the
cover “B“.

fig. 4 - Accessing the terminal block

3.6 Connection to the flue

The unit must be connected to a flue designed and built in compliance with current reg­ulations. The pipe between the boiler and flue must be made from material suitable for
the purpose, i.e. heat and corrosion resistant. Ensure the seal at the joints and insulate
the entire pipe between boiler and flue, to prevent the formation of condensate.

4. SERVICE AND MAINTENANCE

All adjustment, conversion, start-up and maintenance operations described below must
only be carried out by Qualified Personnel (meeting the professional technical require­ments prescribed by current regulations) such as those of the Local After-Sales Techni­cal Service.

FERROLI declines any liability for damage and/or injury caused by unqualified and un­authorised people tampering with the unit.

4.1 Adjustments

Burner adjustment

Boiler efficiency and correct operation depend above all on accurate burner adjustments.
Carefully follow the Manufacturer's instructions. The two-stage burners must have the
first stage adjusted to a power level not below the boiler's rated min. power. The power
of the second stage must not be higher than the boiler's rated max. power.

4.2 Start-up

B

Checks to be made at first lighting and after all maintenance operations that in­volved disconnecting from the systems or an operation on safety devices or
parts of the boiler:

Before lighting the boiler

• Open any on-off valves between the boiler and the systems.

• Check the seal of the fuel system.

• Check correct prefilling of the expansion tank.

• Fill the water system and make sure that all air contained in the boiler and the sys­tem has been vented, by opening the air valve on the boiler and any air valves on
the system.

• Make sure there are no water leaks in the system, domestic hot water circuits, con­nections or boiler.

• Check correct connection of the electrical system and efficiency of the earthing sys­tem

• Make sure there are no flammable liquids or materials in the immediate vicinity of
the boiler

Checks during operation

• Light the unit on as described in sec. 2.3.

• Make sure the fuel circuit and water systems are tight.

• Check the efficiency of the flue and air/fume ducts while the boiler is working.

• Make sure the water is circulating properly between the boiler and the systems.

• Check proper lighting of the boiler by doing several tests, turning it on and off with
the room thermostat or remote control.

• Make sure the fuel consumption indicated on the meter matches that given in the
technical data table on sec. 5.3.

• Make sure the fumebox and burner door are tight.

• Make sure the burner works properly. This check must be made with the special in­struments, following the manufacturer's instructions.

4.3 Maintenance

Periodical check

To ensure correct operation of the unit over time, have qualified personnel carry out a
yearly check, providing for the following:

• The control and safety devices must function correctly.

• The fume evacuation circuit must be perfectly efficient.

• Make sure there are no obstructions or dents in the fuel supply and return pipes.

• Clean the filter of the fuel suction line.

• Measure the correct fuel consumption

• Clean the combustion head in the fuel outlet zone, on the swirl disc.

• Leave the burner on at max. for about ten minutes, then analyse the combustion,
checking:

- Correct setting of the elements specified in this manual.

- Temperatures of fumes at the flue

- CO

2

percentage content

• The air/fume terminal and ducts must be free of obstructions and leaks

• The burner and exchanger must be clean and free of deposits. For cleaning do not
use chemical products or wire brushes.

• The fuel and water systems must be tight.

• The water pressure in the system when cold must be approx. 1 bar; otherwise bring
it to that value.

• The circulating pump must not be blocked.

• The expansion tank (not supplied) must be filled.

A

The boiler casing, control panel and aesthetic parts can be cleaned with a soft
damp cloth, if necessary soaked in soapy water. Do not use any abrasive de­tergents and solvents.

Boiler cleaning

1. Disconnect the power supply to the boiler.

2. Remove the front top and bottom panel.

3. Open the door by undoing the knobs.

4. Clean the inside of the boiler and the entire path of exhaust fumes, using a tube
brush or compressed air.

5. Then close the door, securing it with the knob.

To clean the burner, refer to the Manufacturer's instructions.

4.4 Troubleshooting

Fault

Two shutdown conditions resettable by the user can occur :

A Burner shutdown signalled by the special indicator. Refer to the burner manual.
B Cutting in of the safety thermostat, which occurs when the boiler temperature

reaches a value beyond which a dangerous condition may be created. To re­store operation, unscrew cap 3 of fig. 1 and press the reset button below.

If the problem persists, request the assistance of Qualified Personnel or the After-Sales
Centre.

In case of a fault and/or poor operation, deactivate the unit, do not try to fix the problem
or directly carry out any operation. Contact authorised and professionally qualified per­sonnel.

A

1

2

B