Ferroli Domina 80 E, Modena 102 Installation, Service And User Instructions Manual
Appr. nr. B98.01 A - CE 0063 AT 4967
DOMINA 80 E
INSTALLATION, SERVICE AND USER
INSTRUCTIONS
G.C. NO: 47-267-23
COPPER WALL-MOUNTED COMBINATION,
GAS FIRED BOILER FOR CENTRAL HEATING
AND
DOMESTIC HOT WATER PRODUCTION,
FAN ASSISTED, ROOM SEALED COMPARTMENT,
ELECTRONIC FLAME IGNITION AND CONTROL
3543064/1 - 07/99
DOMINA 80 E
2
INDEX
1.0 DESCRIPTION .................................................................................................................... 3
2.0 TECHNICAL AND DIMENSIONAL CHARACTERISTICS ................................................... 4
3.0 INSTALLATION DETAILS.................................................................................................. 11
4.0 COMMISSIONING AND TESTING .................................................................................. 39
5.0 ADJUSTMENT AND GAS CONVERSION........................................................................ 41
6.0 MAINTENANCE AND CLEANING .................................................................................. 44
7.0 REPLACEMENT OF PARTS .............................................................................................. 46
8.0 FAULT FINDING ............................................................................................................... 52
9.0 ELECTRICAL AND FUNCTIONAL SCHEME.................................................................... 61
10. USER INSTRUCTIONS ...................................................................................................... 64
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.
IMPORTANT
From the 1st October 1999 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.
DOMINA 80 E
3
1. DESCRIPTION
1.01 Introduction
The Domina 80 E is defined as a “room sealed” combination boiler, all air required for combustion is taken from
outside the room in which it is installed. It is a new high performance gas fired heat generator for central heating and
domestic hot water production. A special feature of this boiler is its built-in electronic flame ignition and control unit
making burner operation completely automatic and safe. The main components are as follows:
• Copper heat exchanger consisting of three finned tubes specifically shaped for high efficiency.
• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water
heat exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.
• Ceramic fibre insulated combustion chamber
• 12 stainless steel bladed burners specifically designed for this boiler.
• Fan for discharge of combustion products and intake of combustion air.
• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning correctly.
• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.
• Combination gas safety valve with modulator, complete with pressure stabiliser.
• Flowmeter giving the domestic hot water circuit precedence over the central heating circuit.
• Pressure relief valve for the central heating 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 sensor.
• Central heating flow temperature sensor.
1.02 Instructions and regulations
Assembly, installation, first start up and maintenance must be carried out by competent persons only, in accordance
with all current technical regulations and directives.
C.O.S.H.H.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are required
when servicing.
Related Documents
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 PART 1 FLUES
B.S. 5440 PART 2 AIR SUPPLY
B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 1989 GAS INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 1994 INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply
DOMINA 80 E
4
Fig. 1
1
2
3
4
5
15012012070
110
80 80
80
460
Boiler cover
6
1149560609536
100
720
725
16025
10
100
270
460
175100
178
190 270
Boiler connections
95
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Domina 80 E boilers are central heating and domestic hot water heat generators and are produced as
standard to function with natural gas or LPG.
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
DOMINA 80 E
5
N.B. - The gas pressures at the burner and gas flows during the central heating phase given in the table
refer to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced
until the required output level is reached (see figures 4 and 5).
During domestic hot water production, gas pressures to the burner must correspond to the maximum
output given in table for the type of gas.
Gas pressure must be adjusted during maximum draw-off of domestic hot water.
• Maximum working temperature for central heating flow: 85°C
• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.
• Minimuum domestic cold water pressure required for 95% heat input:
- Flow restrictor fitted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
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Gas flow rates to main burners
for central heating
Gas valve
Ø 1/2"
G20 - NG G31 - LPG G20 - NG G31 - LPG
ØØ m
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/h
kg/h
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Technical Data
DOMINA 80 E
6
2.02 Boiler main components
Key
5 Room sealed compartment
7 Gas inlet
8 Domestic hot water outlet
9 Domestic hot water inlet
10 Central heating flow outlet
11 Central heating return inlet
14 Safety valve
16 Fan
19 Combustion chamber
20 Burner assembly
21 Main injector
22 Burner
26 Combustion chamber insulation
27 Copper heat exchanger for central
heating and domestic hot water
28 Flue collector from heat exchanger
32 Central heating pump
34 Central heating flow temperature
sensor
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 heating temperature
adjustment
81 Ignition electrode
82 Sensor electrode
84 Primary gas valve solenoid
85 Secondary gas valve solenoid
90* Flue sampling point
91* Air sampling point
98 On/Off/Reset switch
114 Low water pressure cut off switch
132 Flue gas deflector
136 Flow meter
145 Central heating pressure gauge
157 Domestic hot water temperature
adjustment
189 Boiler shut down warning
190 Burner on indicator
* For use with flue gas analysis equipment
Fig. 2
157 63 98
60
bar
80
50
70
40
°C °C
OFF
RESET
ON
16
27
50
19
49
28
5
20
21
114
14
42
10 7
34
91184 85 44 136
32
36
145
26
0
5
1
2
3
4
6
8
132
90
OUT
IN
MIN
91
189 190
818222
56
62
43
DOMINA 80 E
7
2.03 Boiler water flow diagram
OUT
IN
MIN
AIR
IN
AIR
IN
FLUE
OUT
C.H.
OUT
D.H.W.
OUT
GASIND.H.W.
IN
C.H.
IN
Fig. 3
DOMINA 80 E
8
2.04 Central heating adjustment (not normally required)
To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust
the main burner via the electronic control board (fig. 4 and 5).
The diagrams indicate the variation in heat output to the water as burner working pressure is varied.
Adjusting boiler output to the actual requirements of the central heating system will minimise boiler
cycling thus saving fuel, varying the output has virtually no effect on the efficiency and combustion
characteristics of the boiler.
Diagram of pressures
and outputs with 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
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
789101112 13 14 15 16 17 18 19 20 216
kW
kcal/h
x 1000
mbar
14
6
kW
kcal/h
X 1000
mbar
18 19 20 21 22 23
5
10
15
20
25
30
35
9 1011121314151617
91011121314 18192015 16 178
DOMINA 80 E
9
2.05 Domestic hot water variability characteristics
The temperature of the domestic hot water can be varied from 40 to 55°C by adjusting the boiler
potentiometer.
Diagram of domestic hot water production
Fig. 6
2.06 Pump characteristics
The pump head available for circulating the water is given in fig. 7.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grundfos Pump per formance graph
Note - Minimum flow through boiler heat
exchanger at any time should not fall below 6
litres per minute.
If the total volume of water in the system exceeds
40 litres an additional expansion vessel must be
fitted to the central heating return pipe.
Pump performance curve Grundfos UPS 15-50
0 345678910111213141516
39
40
45
50
55
60
65
Temperatura di erogazione sanitaria °C
Portata sanitaria dm /min.
Potenza caldaia scambiata
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
kcal/h
x1000
3
Temp. entrata acqua sanitaria 15°C
Temperature of domestic hot water intake 15°C
Flow of domestic hot water l/min
Temperature of domestic hot water supply
°
C
Boiler output exchanged kcal/hx1000
Fig. 7
1 2 3 Speed settings
A Boilers pressure drop
B Available pump head C.H.
DOMINA 80 E
10
Fig. 8
Pressure loss diagram
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 8 litre
vessel supplied.
Note:
1. Fill C.H. installation to min. 1.5 bar.
2. Select the expansion vessel for a system
pressure of 2.0 bar.
3. Expansion vessel must be fitted to central
heating return pipe.
4. The standard 7 litre expansion vessel is
charged to 1 bar.
5. The additional expansion vessel should be
charged to 1 bar.
SAFETY VALVE
SETTING (bar)
VESSEL CHARGE
PRESSURE (bar)
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
CONTENT of SYSTEM
3.0
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
LITRES
25 3.5 6.5 13.7 4.7 10.3 8.3
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 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 2.512
H
mbar x 100
DOMINA 80 E
11
3.0 INSTALLATION DETAILS
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.
Location of Boiler
The installation of the Domina 80E 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.
Air Supply
The room or compartment in which 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 rear flues, deduct 91mm plus
distance from side wall for side outlet flues). It is absolutely essential, to ensure that products of
combustion discharging from the terminal cannot re-enter the building, or enter any adjacent building,
through ventilations, windows, doors, natural air infiltration or forced ventilation/air conditioning.
Gas Supply
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.
An existing service pipe must not be used without prior consultation with the Local Gas supplier.
A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 2.73m
3
/h of natural gas, and 2,00 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All
pipework must be adequately supported. An isolating gas valve is provided and should be fitted on the
boiler gas inlet. Please wait 10 minutes when lighting from cold before checking gas rate. Gas pressures
should be checked after the boiler has operated for 10 minutes to reach thermal equilibrium.
DOMINA 80 E
12
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. A typical heating system
with domestic hot water circuit is illustrated in fig. 9.
Important - If thermostatic radiator vales are fitted a bypass must be fitted to ensure a minimum flow rate
through the boiler of 6 l/min. The bypass should be fitted as far as possible from the boiler.
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. 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
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
DOMINA 80 E
13
NOTE: A bypass that will ensure a minimum flow rate of 6 l/min. at all all time must be fitted as far as
possible from the boiler if thermostatic radiator valves are fitted thoughout.
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
Fig. 10
Fig. 9
Gas
Cold water
Additional expansion vessel C.H.
(if required)
Filling
point C.H.
Bypass
DOMINA 80 E
14
CLEARANCES:
* 600mm minimum clearance for servicing access
Top clearance only applies to 100Ø concentric flue system
460 5 min.5 min.
100 min.860200 min.
270 50 mm
600* min.
720
Fig. 11
DOMINA 80 E
15
Terminal Position
POSITION MINIMUM SPACING mm
A Directly below an openable window, air vent, or any other ventilation opening 300
B Below gutters, soil pipes or drainpipes 75
C Below Eaves 100
D Below a Balcony 100
E From vertical drainpipes or soilpipes 75
F From internal or external corners 100
G Above adjacent ground or balcony level 100
H From a surface facing the terminal 600
I Facing another terminal 1,200
J From opening (door/window) in carport into dwelling 1,200
K Vertically from a terminal on the same wall 300
L Horizontally from a terminal on the same wall 300
N Below carport 600
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the
terminal, when the terminal height is less than 2 m from floor level.
Fig. 12
DOMINA 80 E
16
3.01 Boiler Mounting Plate
149
178
131
Fig. 13
DOMINA 80 E
17
3.02 Drilling Template (Standard Rear Flue Application)
Select suitable mounting position for boiler, using the template or mounting plate mark flue outlet and
boiler mounting points. Drill two 10mm holes 70mm deep to accept the wall plugs, fit wall plugs. 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
932 min
178200 min
5 min
125 min280
254.5
295.5 min
21 min
Ø118
183 min
269
Ø 3/4" Ø 1/2" Ø 1/2" Ø 1/2" Ø 1/2" Ø 3/4"
123 4 5 6
Fig. 14
DOMINA 80 E
18
3.03 Drilling Template (Top Flue Application)
Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting
points. Drill two 10mm holes 70mm deep to accept the wall plugs, fit wall plugs. 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. 15
Ø3/4" Ø1/2" Ø1/2" Ø1/2" Ø1/2" Ø3/4"
200
Ø118
150 min
80
21 min
5 min
183 min
295.5 min
200 min
932 min
269
110
12345 6
DOMINA 80 E
19
3.04 Back flue outlet (Diagram 1-9)
Fig. 16a
Fig. 16b
Fig. 16c
1. Core drill 127mm hole (5").
2. Push through the outer flue.
3. Gently pull back until wall seal is flush
with the wall.
DOMINA 80 E
20
Square GasketCircular Gasket
Fig. 16d
Fig. 16e
4. Place wall plate on outer flue ensuring it is level. Mark and drill four holes, two top, for expanding bolts
and two bottom for plugs and screws. Fix plate to wall with the square gasket between the wall and
the plate use the large diameter washers for the bolts and screws.
5. Through plate into air tube, drill two holes and fix in place using two self tapping screws M4 x 6mm
long.
DOMINA 80 E
21
36 mm
Fig. 16f
Fig. 16g
6. Cut the outer flue flush with the flange on the hanging plate.
7. Insert the aluminium flue pipe into white plastic outer flue, making sure the aluminium pipe sits fully
and centrally into the flue terminal. Mark the aluminium flue pipe at the point it is flush with the
mounting plate. Add 36mm to this mark and cut the aluminium inner flue pipe at this point.
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