ferroli Domina N 80 User guide

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DOMINA N 80 DGT

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

INSTALLATION, SERVICE AND USER

INSTRUCTIONS

G.C. NO: 47-267-23

Appr. nr. B97.09 A - CE 0063 AT 4967

3543832/1 - 07/2001

DOMINA N 80 DGT

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 CORGI Registered Installers carry a CORGI ID card and have a registration number. Both should be recorded in your central heating log book. You can check to the CORGI registered

by calling CORGI on 01256 372300".

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 efﬁ ciency. Please see installation and servicing guidelines.

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 speciﬁ cations

provided from them:

• Gas appliances directive 90/396

• Efﬁ ciencies directive 92/42

• Low tension directive 73/23 (modiﬁ ed from the 93/68)

• Electromagnetic compatibility directive 89/396 (modiﬁ ed 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.

INDEX1

1. DESCRIPTION........................................................................................................................................ 3

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS........................................................................................ 4

3. INSTALLATION DETAILS ........................................................................................................................................9

4. COMMISSIONING AND TESTING.......................................................................................................................27

5. ADJUSTMENT AND GAS CONVERSION ............................................................................................................28

6. MAINTENANCE AND CLEANING ......................................................................................................................30

7. REPLACEMENT OF PARTS...................................................................................................................................32

8. FAULT FINDING ................................................................................................................................................... 37

9. ELECTRICAL AND FUNCTIONAL SCHEME ........................................................................................................44

10. USER INSTRUCTIONS ........................................................................................................................................46

DOMINA N 80 DGT

1. DESCRIPTION

1.01 Introduction

The Domina N 80 DGT is deﬁ ned 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 ﬁ red heat generator for central heating and domestic hot water production. A special feature of this boiler is its built-in electr onic ﬂ ame ignition and control unit making burner operation completely automatic and safe. The main components are as follows:

• Copper heat exchanger consisting of three ﬁ nned tubes speciﬁ cally shaped for high efﬁ ciency.

• 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 ﬁ bre insulated combustion chamber

• 12 stainless steel bladed burners speciﬁ cally designed for this boiler.

• Fan for discharge of combustion products and intake of combustion air.

• Differential air pressur e 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 ﬂ ow temperature adjustment thermostat.

• Domestic hot water ﬂ ow temperature adjustment thermostat.

• Central heating limit thermostat.

• Overheat safety thermostat.

• Electronic control unit for automatic ﬂ ame ignition and control.

• Central heating low water pressure cut off switch.

• Domestic hot water ﬂ ow temperature sensor.

• Central heating ﬂ ow temperature sensor.

1.02 Instructions and regulations

Assembly, installation, ﬁ rst 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 2000 FLUES B.S. 5440 Part 2 1989 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 N 80 DGT

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS

2.01 Technical information

Domina N 80 DGT boilers are central heating and domestic hot water heat generators and are produced

as standard to function with natural gas or Liquid Petrolium Gas converted appliances.

460

178

190 270

160100 25 150 25

760

249

272

727

Distance between connections

609536 60 95

Key

1 - 3/4" central heating ﬂ ow outlet 2 - 1/2" domestic hot water ﬂ ow outlet 3 - 1/2 “ gas inlet

Bottom view

100

114

12070 120 150

110

Fig. 1

Top view

4 - 1/2" domestic hot water inlet

5 - 3/4" central heating return inlet

Technical Data

MODEL

Domina N 80 DGT

DOMINA N 80 DGT

Domestic hot

Heat output Heat input

water heat

input

kW kW kW kW kW Litres Litres

23,8 9,7 25,8 11,5 23,8 1,5 0,8

Boiler water

contents

Domestic hot

water contents

MODEL

Domina N 80 DGT

MODEL

Domina N 80 DGT

MODEL

Domina N 80 DGT

Max. working

Connections Expansion vessel

12345Capacity

ШШШШШLitres bar bar bar

3/4” 1/2” 1/2” 1/2” 3/4” 7 1 3 6

Main injectors (mm)

G20 - NG G31 -LPG G20 - NG G31 -LPG

ØØ m

12x1,30 12x0,77 2,73 2,00 H. V K4105G

Gas supply pressures

working

G20 G31

mbar mbar mbar mbar mbar mbar bar

20 37 2,5 11,8 7,8 36,0

Gas flow rates to main burners

for central heating

/h kg/h

Gas pressure at main burner for central heating

G20 G31

min. m min. m

Pre-pressurising

value

pressure

central

heating

circuit

working pressure hot water circuit

Gas valve

Ø1/2

Safety valve

Max.

Max. working

pressure domestic

hot water

G20 G31

Protection

level

Weight

MODEL

Domina N 80 DGT

Domestic hot

water production

with ∆t 30 °C

l/min. l/min. mbar mbar kg

11,3 9,7 11,8 36,0 IP44 38

Domestic hot

water production

with ∆t 35 °C

N.B. - The gas pressures at the burner and gas ﬂ ows 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 ﬁ gures 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 ﬂ ow: 85°C

• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.

• Minimum domestic cold water pressure required for 95% heat input:

- Flow restrictor ﬁ tted (standard) - 1,2 bar;

- Flow restrictor removed - 0,5 bar

DOMINA N 80 DGT

2.02 Boiler main components

132

818222

20 21

OUT

MIN

114

10 874 784 85 44

14 42 9 11

136

2.03 Boiler water ﬂ ow diagram

AIR

FLUE

OUT

MIN

AIR

Fig. 2

145 62

Key

5 Room sealed compartment 7 Gas inlet 8 Domestic hot water outlet 9 Domestic hot water inlet

10 Central heating ﬂ ow 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 ﬂ ow temperature sensor 36 Automatic air vent valve

42 Domestic hot water ﬂ ow temperature sensor

C.H. OUT

D.H.W.

OUT

GASIND.H.W.

43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat

50 Central heating ﬂ ow limit thermostat 56 Expansion vessel 62 Time clock (option)

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 deﬂ ector 136 Flow meter 145 Central heating pressure gauge

* For use with ﬂ ue gas analysis equipment

Fig. 3

C.H.

DOMINA N 80 DGT

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 (ﬁ g. 4 and 5 and see paragraph 5.04 page 29). The diagrams indicate the variation in heat output to the water as burner working pressure is varied. Adjusting boiler output to the actual requirements o f the central heating system will minimise boiler cycling thus saving fuel, varying the output has virtually no effect on the efﬁ ciency and combustion characteristics of the boiler.

Diagram of pressures and outputs with Natural gas

14 13

mbar

kW kcal/h

x 1000

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

Fig. 4

Diagram of pressures and outputs with LPG (Propane)

91011121314151617

kW kcal/h X 1000

91011121314 18192015 16 178

18 19 20 21 22 23

Fig. 5

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

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

Fig. 6

40 39

Temperature of domestic hot water supply °C

Temperature of domestic hot water intake 15°C

0 345678910111213141516

Flow of domestic hot water l/min

Boiler output exchanged kcal/1000

DOMINA N 80 DGT

2.06 Pump characteristics

The pump head available for circulating the water is given in ﬁ g. 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 ﬂ ow 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 ﬁ tted to the central heating return pipe.

1 2 3 Speed settings

A Boilers pressure drop

B Available pump head C.H.

Fig. 7

SIZING OF ADDITIONAL EX PANSION 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. Expansion vessel must be ﬁ tted to central heating return pipe.

3. T he standard 7 litre expansion vessel is charged to 1 bar.

4. The additional expansion vessel should be charged to 1 bar.

mbar x 100

Pressure loss diagram

SAFETY VALVE SETTING (bar)

VESSEL CHARGE PRESSURE (bar)

INITIAL SYSTEM PRESSURE (bar)

TOTAL WATE R CONTENT of SYSTEM

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

For syst. volumes other than those given above, mult. the syst.

0.140 0.259 0.551 0.190 0.412 0.33

volume by the factor across

0.5 1.0 1.5

1.0 1.5 2.0 1.5 2.0 2.0

EX PANSION VESSEL VOLUME (litres)

3.0

m |h

0.5 1.5 2.512

Fig. 8

DOMINA N 80 DGT

3. 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 ﬁ tted in a timber framed building it should be ﬁ tted 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 N 80 DGT must be on a suitable non-combustible load bearing wall which will provide an adequate ﬁ xing 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 ﬂ ue.

Flue System

The boiler allows the ﬂ ue outlet to be taken from the rear of the boiler, from either side or vertically.

A standard ﬂ ue 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 ﬂ ues, deduct 91mm plus distance from side

wall for side outlet ﬂ ues). 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 inﬁ ltration 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 ﬁ tted 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 2.73m3/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 ﬁ tted 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.

Water System

Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.

DOMINA N 80 DGT

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 underﬂ oor 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. C opper 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 ﬁ g. 9.

Important - If thermostatic radiator vales are ﬁ tted a bypass must be ﬁ tted to ensure a minimum ﬂ ow rate through the boiler of 6 l/min. The bypass should be ﬁ tted 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 ﬁ lling 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 ﬁ lling loop is shown in ﬁ g. 10.

Domestic Hot Water

Always ﬁ t 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 ﬁ tted 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

NOTE: A bypass that will ensure a minimum ﬂ ow rate of 6 l/min. at all all time must be ﬁ tted as far as possible

Gas

from the boiler if thermostatic radiator valves are ﬁ tted thoughout.

Key

1. Filling point C.H.

2. Temporary connection

3. Cold water supply

Fig. 10

Cold water

Additional expansion

vessel C.H.

Filling point C.H.

Bypass

Fig. 9

DOMINA N 80 DGT

CLEARANCES:

* 600mm minimum clearance for servicing access

Top clearance only applies to 100Ø concentric ﬂ ue system

Fig. 11

Terminal Position

460 5 min.5 min.

100 min.900

760

200 min.

272 50 mm

600* min.

D, E

Minimum dimensions of ﬂ ue terminal positions

Balanced flues room

Dimensions Terminal position

D 300 mm 75 mm Not allowed 75 mm

E 300 mm 200 mm Not allowed 200 mm

F 600 mm 200 mm Not allowed 200 mm

G 300 mm 150 mmbNot allowed 150 mm

H 600 mm 300 mm Not allowed 200 mm

I 300 mm 300 mm Not allowed 300 mm

J 600 mm 600 mm N/A 600 mm

K 600 mm 1200 mm N/A 1200 mm

L 1200 mm 1200 mm N/A 1200 mm

M 1500 mm 1500 mm N/A 1500 mm

N 300 mm 300 mm N/A 300 mm

O N/A N/A N/A 50 mm

P N/A N/A See Table 2

Q N/A N/A See Table 2

NOTE N/A = Not applicable

In addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric formed for the purpose of accommodating

a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the rated heat inputs as shown.

This dimension may be reduced to 75 mm for appliances of up to 5 kW heat input.

Directly below an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Above an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Horizontally to an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Below gutters, soil pipes or drain pipes

Below eaves

Below balconies or car port roof

From a vertical drain pipe or soil pipe

From an internal or external corner

Above ground roof or balcony level

From a surface facing the terminal (also see 6.1.2)

From a terminal facing the terminal

From an opening in the car port ( e.g. door, window) into the dwelling

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

From the wall on which the terminal is mounted

From a vertical structure on the roof

Above intersection with roof

(kW input expressed in net)

(>14-32 kW) (>32-70 kW)

Natural draught

300 mm

600 mm 1500 mm 2000 mm

300 mm 300 mm 300 mm 600 mm

300 mm 400 mm 600 mm 600 mm

sealed

Fanned

draught

300 mm Not allowed 300 mm

Natural draught

and Fig. 6b

and Fig. 4

Open flues

draught

150 mm

Fanned

N/A

Fig. 12

3.01 Boiler Mounting Plate

DOMINA N 80 DGT

178

131

149

Fig. 13

DOMINA N 80 DGT

3.02 Drilling Template (Standard Rear Flue Application)

Select suitable mounting position for boiler, using the template mark ﬂ ue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, ﬁ t wall plugs. Fit two special wall plugs on the wall as described in the ﬁ g. 14a. 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 ﬁ x using an antitheft nut on the left side and a standard nut (M8) on the right side. Using a core drill cut a 118mm diameter

hole for the ﬂ ue.

Fig. 14a

1. CH ﬂ ow

2. Safety Valve

3. Domestic hot water outlet

4. Gas supply

5. Domestic hot water inlet

6. CH return

183 min

932 min

125 min280

270

178200 min

254.5

Ø118

21 min

Ø 3/4" Ø 1/2" Ø 1/2" Ø 1/2" Ø 1/2" Ø 3/4"

123 4 5 6

5 min

295.5 min

Fig. 14b

DOMINA N 80 DGT

3.03 Drilling Template (Top Flue Application)

diameter hole for the ﬂ ue.

Fig. 15a

183 min

932 min

Ø118

Ø3/4" Ø1/2" Ø1/2" Ø1/2" Ø1/2" Ø3/4"

200

269

110

150 min

21 min

1. CH ﬂ ow

2. Safety Valve

3. Domestic hot water outlet

4. Gas supply

5. Domestic hot water inlet

6. CH return

12345 6

5 min

295.5 min 200 min

Fig. 15b

3.04 Back ﬂ ue outlet (Diagram 1-9)

DOMINA N 80 DGT

1. Core drill 127mm hole (5").

Fig. 16a

4. Place wall plate on outer ﬂ ue ensuring i t i s 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.

2. Push through the outer ﬂ ue. 3. Gently pull back until wall seal is ﬂ ush with the wall.

Fig. 16b Fig. 16c

Square GasketCircular Gasket

5. Through plate into air tube, drill two holes and ﬁ x in place

using two self tapping screws M4 x 6mm long.

6. Cut the outer ﬂ ue ﬂ ush with the ﬂ ange on the hanging plate.

7. Insert the aluminium ﬂ ue pipe into white plastic outer flue, making sure the aluminium pipe

sits fully and centrally into the ﬂ ue terminal. Mark the aluminium ﬂ ue pipe at the point it is ﬂ ush

with the mounting plate. Add 36mm to this mark and cut the

aluminium inner flue pipe at this point.

Fig. 16d

Fig. 16e

36 mm

Fig. 16f

Fig. 16g

+ 33 hidden pages

ferroli Domina N 80 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual