Ferroli F24 Installation, Service And User Instructions Manual

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Page 1

Appr. nr. B98.01 A - CE 0063 AT 4967

FERROLI F24

INSTALLATION, SERVICE AND USER

INSTRUCTIONS

G.C. NO: 47-267-31

3544015/0 - 07/2002

Gas Combination Boiler for Central Heating

and Hot Water Production, Wall Mounted,

Copper Heat Exchanger, Fan Assisted,

Room Sealed,

Electronic Flame Ignition and Control

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FERROLI F24

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)

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 register

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.

INDE

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

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

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

4. COMMISSIONING AND TESTING.......................................................................................................................26

5. ADJUSTMENT AND GAS CONVERSION............................................................................................................27

6. MAINTENANCE AND CLEANING ......................................................................................................................29

7. REPLACEMENT OF PARTS...................................................................................................................................31

8. FAULT FINDING ...................................................................................................................................................36

9. ELECTRICAL AND FUNCTIONAL SCHEME........................................................................................................43

10. USER INSTRUCTIONS........................................................................................................................................45

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FERROLI F24

1. DESCRIPTION

1.01 Introduction

The Ferroli F24 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 electronic 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 exchang er. 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 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 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

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FERROLI F24

Fig. 1

Top view

Distance between connections

178

190 270

Bottom view

272

760

249

609536 60 95

460

100

727

114

160100 25 150 25

12070 120 150

110

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS

2.01 Technical information

Ferroli F24 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.

Key 1 - 3/4" central heating ﬂ ow outlet

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

4 - 1/2" domestic hot water inlet 5 - 3/4" central heating return inlet 6 - Pressure relief outlet

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FERROLI F24

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

MODEL

Heat output Heat input

Domestic hot water output

Boiler water

contents

Domestic hot

water contents

kW kW kW kW kW Litres Litres

Ferroli F24

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

MODEL

Connections Expansion vessel

Max. working

pressure

central

heating

circuit

Max.

working pressure hot water circuit

12345Capacity

Pre-pressurising

value

Ø Ø Ø Ø Ø Litres bar bar bar

Ferroli F24

3/4” 1/2”

3/4”

1/2” 3/4” 7 1 3 6

MODEL

Main injectors (mm)

Gas flow rates to main burners

for central heating

Gas valve

Ø1/2

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

ØØ m

/h kg/h

Ferroli F24

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

MODEL

Gas supply pressures

working

Gas pressure at main burner for central heating

Safety valve

G20 G31

min. m min. m

mbar mbar mbar mbar mbar mbar bar

Ferroli F24

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

MODEL

Domestic hot

water production

with ∆t 30 °C

Domestic hot

water production

with ∆t 35 °C

Max. working

pressure domestic

hot water

Protection

level

Weight

G20 G31

l/min. l/min. mbar mbar kg

Ferroli F24

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

Technical Data

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FERROLI F24

2.03 Boiler water ﬂ ow diagram

OUT

MIN

AIR

FLUE

OUT

C.H. OUT

D.H.W.

OUT

GASIND.H.W.

C.H.

Fig. 3

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 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

Fig. 2

20 21

132

818222

OUT

MIN

RESET

OFF

bar

98 63 157 145

°C

10 8 784 85 44

136

114

14 42 9 11

43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat

50 Central heating ﬂ ow limit thermostat 56 Expansion vessel

62 Time clock 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 deﬂ ector 136 Flow meter 145 Central heating pressure gauge 157 Domestic hot water temperature adjustment

* For use with ﬂ ue gas analysis equipment

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FERROLI F24

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 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)

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

kW kcal/h

x 1000

mbar

kW kcal/h X 1000

18 19 20 21 22 23

9 1011121314151617

91011121314 18192015 16 178

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

0 345678910111213141516

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/1000

Fig. 6

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FERROLI F24

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. Expansion vessel must be ﬁ tted to central heating return pipe.

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

4. 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

0.5 1.5 2.512

mbar x 100

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.

Fig. 7

1 2 3 Speed settings A Boilers pressure drop B Available pump head C.H.

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FERROLI F24

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 Ferroli F24 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 provid ed and should be ﬁ tted on the boiler gas inlet. Please wait 10 minutes when lighting from cold befor e 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.

Page 10

FERROLI F24

Fig. 9

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

Gas

Cold water

Additional expansion

vessel C.H.

Filling

point C.H.

Bypass

Fig. 10

Key

1. Filling point C.H.

2. Temporary connection

3. Cold water supply

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FERROLI F24

CLEARANCES:

* 600mm minimum clearance for servicing access

Top clearance only applies to 100Ø concentric ﬂ ue system

460 5 min.5 min.

100 min.900

200 min.

272 50 mm

600* min.

760

Fig. 11

Terminal Position

Fig. 12

D, E

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

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

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

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

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

(>14-32 kW)

(>32-70 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

Dimensions Terminal position

(kW input expressed in net)

Balanced flues room

sealed

Open flues

Natural

draught

Natural draught

Fanned

draught

Fanned

draught

300 mm

600 mm 1500 mm 2000 mm

300 mm Not allowed 300 mm

300 mm 300 mm 300 mm 600 mm

300 mm Not allowed 300 mm

300 mm 400 mm 600 mm 600 mm

300 mm Not allowed 300 mm

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

and Fig. 6b

N/A

Q N/A N/A See Table 2

and Fig. 4

150 mm

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.

Minimum dimensions of ﬂ ue terminal positions

Page 12

FERROLI F24

1. CH ﬂ ow

2. Safety Valve

3. Domestic hot water outlet

4. Gas supply

5. Domestic hot water inlet

6. CH return

Ø3/4" Ø1/2" Ø1/2" Ø1/2" Ø1/2" Ø3/4"

200

Ø118

150 min

5 min

183 min

200 min

970 min

269

110

12345 6

3.01 Drilling Template (Top Flue Application)

Select suitable mounting position for boiler, using the template mark ﬂ ue outlet and boiler mounting points. Drill two 10mm holes 70mm deep to accept the wall plugs. Fit standard wall plugs on the left and right side and the special wall plug in the middle (ﬁ g. 13a). Fix the wall bracket to the wall using standard lock nut (M8) on both sides. Mount the boiler on the wall bracket and ﬁ x using the special antitheft nut (M8) as described in the ﬁ g. 13a. Using a core

drill cut a 118mm diameter hole for the ﬂ ue.

Fig. 13a

Fig. 13b

Page 13

FERROLI F24

3.02 Restrictor

For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of ﬂ ue restrictor required. Before inserting the ﬂ ue gas duct in the boiler, check that the restrictor ﬁ tted is correct and that it is correctly positioned (see ﬁ g. 14).

Holes Ø : 45 47 50

Fig. 14

CHOICE OF RESTRICTOR:

RESTRICTOR FOR TWO PIPE SYSTEM

Total flow resistance

of flue system

Use

restrictor

size

minimum maximum mm

0 m 13 m 45 13 m 23 m 47 23 m 38 m 50 38 m 48 m No restrictor

• With concentric systems:

- Choose correct restrictor from table below.

• With 2 pipe system:

- Calculate the total ﬂ ow resistance of the air and ﬂ ue pipes in metres (cap. 3.04.2)

- utilise the table shown below to choose the more suitable restrictor for the ﬂ ow resistance calculated

RESTRICTOR FOR CONCENTRIC SYSTEM

Flue lenght up to:

Use

restrictor

size

Ccncentric

60 / 100

1 bend + 1 meter 50 mm

1 bend + 3 meters No restrictor

Ccncentric

80 / 125

1 bend + 3 meters 45 mm 1 bend + 4 meters 50 mm 1 bend + 5 meters No restrictor

N.B.: the diameter of the hole is

stamped on the restrictor

No restrictor is required for

back outlet ﬂ ue

Page 14

FERROLI F24

3.03 Top Outlet Concentric Flue Connection

3.03.1 Vertical concentric connection

Fig. 16

A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets at the joints makes this an extremely easy and safe option. For ﬂ ue length up to 1 m long the 50 mmØ restrictor is required. Longer than this no restrictor is required.

Fig. 15

Concentric Vertical Connector

3.03.2 Horizontal concentric connection

A 90° bend (ﬁ g. 16) is supplied for the horizontal connection of air and ﬂ ue gas pipes. This can be oriented towards the chosen wall in degrees of 45°.

Telescopic

125

50*

-3 mm/m

Ø60 Ø80

70 min.

* = between 10 e 60 mm

190 270

L = S + D + 255

Page 15

FERROLI F24

Fig. 17

Notes on concentric horizontal installation

To locate the centre of the hole for passing the pipes through the wall, refer to ﬁ g. 13b. Bear in mind that the two concentric pipes must slope downwards away from the boiler at a rate of about 3 mm/m to avoid rainwater entering the boiler. The concentric pipes making up the air

- ﬂ ue gas duct must be sealed with the gasket where they join the boiler (ﬁ g. 17). Outside, the pipes should protrude from the wall between 10 and 60 mm (ﬁ g. 17).

3.03.3 Maximum concentric ﬂ ue length

First table below shows the maximum ﬂ ue lengths available for boilers with concentric systems. For correct calculation remember to include the reduction for bends on second table. Please refer to

3.02 for use of restrictor.

Maximum flue lenght permissible

100 mm concentric

125 mm concentric

Vertical Horizontal* Vertical Horizontal*

Ferroli F24

m4m3m5m5

Reduction for bend

100 mm concentric bend 90° 1 m 100 mm concentric bend 45° 0,5 m 125 mm concentric bend 90° 0,5 m 125 mm concentric bend 45° 0,25 m

*For horizontal Flueing the reduction for appliance bend or turret are already included.

max. 3 m

concentric

100/60

max. 4 m

concentric 100/60

Fig. 18a

Fig. 18b

Between 10-60 mm

Page 16

FERROLI F24

Fig. 19

Ø80Ø80

AIRFLUE

3.04 Top Outlet: Two Pipe Flue System

3.04.1 Two pipe connection

Two separate ducts Ø80 for air intake and ﬂ ue gas discharge can be directly connected to the boiler. For converson to top outlet (see 3.05) mount the separate outlet kit 1

Insert blanking plate 2 in remaining air intake

Connect ﬂ ue duct to central hole Ø80 and air duct to left or right air intake hole Ø80. Insert blanking plate 2 in remaining air intake.

A varied number of accessories for two pipe systems are available from Ferroli (ref. to page 17). Before installing your system please check via calculation table at 3.08.2 you are not exceeding the maximum

permissible length for the appliance.

Notes on two pipe system installation: When using the two pipe system the ﬂ ue discharge pipe must have a 25mm air gap when passing through

combustible materials. Where the ﬂ ue discharge pipe passes through the airing space of an airing cupboard it must be protected by a non

combustible guard or expanded metal giving an annular air gap of at least 25mm.

Where the ﬂ ue discharge pipe passes through a wall containing cavity insulation, a non combustible sleeve must be ﬁ tted. Additionally a gap of 25mm between the sleeve and the insulation should be provided by cutting back the insulation or packing loose ﬁ ll bead insulation with mineral ﬁ bre. Where the ﬂ ue pipe is run through an unheated roof space it should be insulated with non combustible insulating material to prevent condensation. The ﬂ ue pipe should be supported at intervals of not more than 1.8m and

the support should be preferably below a joint.

3.04.2 Two pipe ﬂ ue system

• Calculating maximum permissible ﬂ ue length.

The calculation method is based on a standard reference parameter (1 metre of horizontal air ﬂ ue 80 diameter 80) for

the maximum length permissible for all the pipes + ﬁ ttings ﬂ ow resistance coefﬁ cient. In other words, for all components

and pipes in the different installation conﬁ gurations (vertical or horizontal, air or ﬂ ue, etc.) and for all the ﬁ ttings, a

ﬂ ow resistance (reduction) equivalent to x metre of horizontal air induction pipe is indicated. For every boiler

model a maximum pipe length is provided, expressed in n metres of horizontal air pipe. In this way, to calculate

the length of a proposed 2 pipe air-ﬂ ue system, add the ﬂ ow resistance (reduction) in equivalent metres-air. For

every component and ﬁ tting present in the system, and to check that the total is less than the maximum length

the permissible for the boiler model.

IMPORTANT: the pipes and ﬁ ttings ﬂ ow resistance (reduction) have been summarised on the following pages.

The ﬂ ow resistance values written refer only to Ferroli pipes and ﬁ ttings.

Calculation routine

1. Utilise the pipes and ﬁ ttings ﬂ ows resistance tables on the following pages and calculate the total ﬂ ow

resistance in metres-air, by adding the ﬂ ow resistances of the components in the whole air-ﬂ ue system, based on their position (vertical or horizontal, air inlet or ﬂ ue outlet).

Please note that the same ﬁ tting, identiﬁ ed by a one code (i.e. 1 pipe diameter 80, code KWMA83A), can offer

different ﬂ ow resistances if positioned as air inlet or ﬂ ue outlet, if placed vertically or horizontally.

The ﬂ ow resistance of the special two pipe ﬂ ue-air adapters do not have to be included in the calculation

as they are already included in the maximum length calculation.

2. For the restrictors, please refer to cap. 3.02 to determinate the correct diaphragm.

3. Check that the total ﬂ ow resistance calculated is less or equal to 48 metre, the maximum permissible for Ferroli F24.

Page 17

FERROLI F24

Air Flue

Vertical

Horizontal

Vertical

Horizontal

Description

Male-female

flue Ø80

Female-female

bend 45° Ø80

Female-female

bend 90° Ø80

Male-female

bend 90° Ø80

Pipe fitting

M/M/F Ø80

with inspecting

plug+trap for

condensate drainage

system

Description

Air terminal of

inlet protection Ø80

Outlet flue air inlet

for concentric system

Ø80

Pipe fitting for

outlet flue Ø80

Outlet flue air inlet for

connection with split end

Ø80

1112

1,2 2,2

1,5 2,5

Reduction

Air Flue

Vertical

Horizontal

Vertical

Horizontal

Condensate flue

outlet

c c e s s

8 0

c c

s s

8 0

Spigot and socket

reduction Ø80/100

Reduction

Airwall terminal

products

of combustion Ø80

Male-female

flue Ø100

Male-female bend

45° Ø100

Male-female

bend 90° Ø100

Air wall terminal

products of

combustion Ø100

Air terminal

of outlet

protection

Ø100

0,4 0,4 0,4 0,8

0,6 1

0,8 1,3

1,5

c c

s s

1 0 0

Spigot and

socket

reduction

Ø 80/100

1,5 3

3.04.3 (continued)

Tab. 1 - Pipes and ﬁ ttings reduction table

Page 18

FERROLI F24

For further accessories please refer to:

"Flue system manual for room sealed

boiler"Example of calculation for wall

inlet/outlet with 2 pipe system

maximum total ﬂ ue length: 48 metres

Attention: Resistance of ﬂ ue restrictor (if req.) is included (see table on page 13) Remove the ﬂ ue restrictor. The ﬂ ue and air pipes must have an inclination downward equal to 3% from boiler to outside.

Fig. 20

Example of wall inlet/outlet

2 pipe application

Example of roof

inlet/outlet

Example of direct roof ﬂ ue outlet

and wall air inlet

3.04.4 Example of other installation with two pipe systems

Fig. 21

Fig. 23Fig. 22

Ref.

N° of

pieces

Description Code

Length or reduction

1 2 3 4 5 6 7

1 1 1

Air bend 80 mm R/D = 0,75 1,5 m Horizontal air pipe 13,0 m Air wall terminal 2,0 m Air inlet closing flange — Flue bend 80 mm R/D = 0,75 2,5 m Horizontal flue 24,0 m Air wall terminal outlet flue 5,0 m

Total 48,0 m

Page 19

FERROLI F24

3.05 For installation (back flue connection):

For direct back flue connection it is necessary to use the optional kit 1KWMR81A, and it is required to alter the fan direction inside the boiler. Follow carefully next procedure:

Fig. 24b

Fig. 24c

Fig. 24d

Remove fan by pulling off electrical connections. Pull off air pressure switch tubes from the air pressure switch remove 2 screws b. Rotate the fan downward to disengage it from the securing pin a.

Take off the four screws which fix the back plate on sealed chamber, remove and rotate the plate through 90° and fit it to the top of the boiler to cover the original flue outlet. Secure it in place with the four screws removed previously.

Remove fan mounting plate by undoing the three fixing screws d. Rotate the fan through 90° so that the fan nozzle points sideways. Fit the fan extension “B” on the fan nozzle and secure it in place using some silicone and “E” screw. Secure the fan to the plate in the new position using screws in position c.

Fig. 24e

Common For rear outlet

For upper outlet

Fig. 24g

For rear outlet

Fig. 24f

For upper outlet

Fig. 24a

Page 20

FERROLI F24

Boiler Mounting Plate

149

178

131

Fig. 25

Fig. 24h

Fix with the screws (b). Reﬁ t wiring connections to fan and air pressure switch tubes ensuring correct

orientation. I.E. red tube to air pressure switch connection with red dot (+) and clear tube to air pressure switch connection with no paint marking (-). Fit the fan into the boiler rotating the front to engage with the pin a. Secure with the screws b.

Rear

Page 21

FERROLI F24

Drilling Template (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. 26a. 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.

1. CH ﬂ ow

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

270

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

123 4 5 6

Fig. 26b

Fig. 26a

Page 22

FERROLI F24

Back ﬂ ue outlet (Diagram 1-9)

Fig. 27a

Fig. 27b Fig. 27c

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

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

Fig. 27d

4. Place wall plate on outer ﬂ ue ensuring it is level. Mark and drill four holes, two top, for expan- ding 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.

Square GasketCircular Gasket

Fig. 27e

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.

Fig. 27f

80 mm

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 p ipe 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. 27g

36 mm

80 mm

Page 23

FERROLI F24

Fig. 27h Fig. 27i

8. Install the inner metal ﬂ ue into the outlet, up to the wallplate ﬂ ange mark.

9. Lift boiler with ﬂ ue in place, engage inner and outer ﬂ ue, slide into position

9. Make sure the inner ﬂ ue is fully engaged in the ﬂ ue terminal, secure boiler with two nuts and washers, sevure bottom of boiler using two screws and washers.

80 mm

36 mm

Page 24

FERROLI F24

3.06 Connecting the central heating and domestic hot water circuits

Connect to the relevant connections as indicated in ﬁ g. 1. Connect the pressure relief valve dischar ge pipe (15mm) to the outside of the building, where possible over a drain. The discharge must be such that it will not be hazardous to occupants and passers-by or cause damage to external electric components or wiring. The pipe should be directed towards the wall. To ensure long life, the heating circuit should be corr ectly sized and ﬁ tted with all the controls necessary to ensure correct functioning and operation. The differential between the boiler ﬂ ow and return pipes should not be more than 20°C. You are advised not to use the boiler with return temperatures of less than 50°C in order to prevent patches of condensation forming and having a corrosive effect on boiler components.

3.07 Water treatment

If water treatment is used ferroli limited recommend only the use of Fernox or Sentinel water treatment pr oducts, which must be used in accordance with the manufacturers instructions. For further information contact:

Fernox Manufacturing Co. LTD. Sentinel Division Tandern house, Marlowe Way Betz Dearborn LTD Croydon, surrey, CRO 4YS Widnes, Cheshire WA8 8ND Tel: 0870 5601 5000 Tel: 0151 424 5351

Note - If the boiler is installed in an existing system any unsuitable additives must be removed by thorough cleansing. All systems should be cleansed according to B.S. 7593.

Note - In hard water areas treatment to prevent lime scale may be necessary. Note - It is important that the correct concentration of the water treatment product is maintained in accordance

with the manufacturers instructions.

3.08 Filling

When cold, system pressure should be about 1 bar. If while running venting off of air dissolved in the water causes the pressure of the central heating system to drop below 0,5 bar, the user must utilise a ﬁ lling loop to bring it back to the original value. During operation, water pressure in the boiler when hot should be about 1.5 - 2 bars. After ﬁ lling, always close and disconnect the ﬁ lling loop.

Note - If ther e is a possibility of air pockets forming in certain points of the central heating system ﬂ ow and return pipes, you are recommended to ﬁ t an air vent valve at these points.

Note - When the boiler is installed below the level of the central heating a system, single check valve should be ﬁ tted in the ﬂ ow to prevent gravity circulation around the heating system.

3.09 Gas connection

Gas connection should be carried out using a rigid pipe. The ﬂ ow at the gas meter should be sufﬁ cient for the simultaneous use at full gas rate of all appliances

connected to it. Connect the gas supply to the boiler according to current regulations. The diameter of the gas tube leaving the boiler is not the determining factor in choosing the diameter of the pipe between the appliance and the meter. This must be selected in relation to length and pressure drop and in any instance should not be less than 22mm.

The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with BS6891-1988.

N.B. - The ﬁ lling loop will be ﬁ tted by the installer in accordance with water by laws at the time of installing the system. It is NOT a part of the boiler.

Page 25

FERROLI F24

3.10 Electrical connection

The boiler must be connected to a single phase 230 V 50 Hz electricity supply with a 3 A max. fuse and a bipolar switch with contact opening of at least 3 mm ﬁ tted between the boiler and the electricity supply. The boiler must always be connected to an efﬁ cient earth installation. Under the electrical box, there is a 3 pole terminal board for connecting the boiler to the mains (230 V 50 Hz) and a 2 pole board for connecting a room thermostat (RT). T o connect, undo the screws ﬁ xing the terminal board box and connect the wires, ensuring correct polarity of the terminals. It should be noted that there is low voltage (24 V) between the room thermostat contacts. When the boiler is connected to an electricity main, it is essential TO OBSERVE CORRECT POLARITIES (LIVE: brown cable, NEUTRAL: blue cable, EARTH: yellow-green cable).

All wiring must conform to current I.E.E. regulations. Note: If the power supply cable has to be replaced, use “0.75mm (24/0.20) heat resisting cable only to BS6500 with a maximum external diameter of 8 mm.

Note - When connecting a room thermostat or external timer, do not link the power supply of these devices to the switching contacts. The switch contacts must be voltage free. Any mains powered devices must utilise mains power solely to drive the timer motor.

Applying mains voltage to the switch contacts will irreparably damage the circuit board.

Although this boiler can also be used without a room thermostat, you are recommended to install one for the following reasons:

Greater comfort conditions due to more accurate control of room temperature. Greater energy savings.

3.11 Differential air pressure switch (ﬁ g. 2 - part 45) The differential air pressure switch is a safety device which allows the main burner to ignite only after having

veriﬁ ed that the fan is working correctly. If the difference in pressur e between the ﬂ ue gas discharge pipe and the air intake pipe is not at least equal to the minimum pressure switch calibration value, the pressur e switch contacts do not close and the gas valve is thus prevented from opening. In addition, the electrical circuit of the boiler is designed so that if for any reason the air pressure switch contacts remain closed when the fan stops, the burner will not start up again.

3.12 Checks

Fill the central heating system as described previously (3.08) and check there are no leaks in the domestic hot water and boiler water circuits. Check that there are no gas leaks on the boiler or the supply to the boiler. Also check that the electrical connections are correct.

3.13 Installing a room thermostat (72) (ﬁ g. 42) To connect the thermostat:

Open the electrical box on the base of the appliance and remove the “jumper cable” between terminals 3 and 4. Connect the room thermostat (72) as shown in ﬁ g. 42.

Page 26

FERROLI F24

4. COMMISSIONING AND TESTING

4.01 Checks to be carried out before starting up for the ﬁ rst time

When starting the boiler up for the ﬁ rst time check:

• that the isolation valves between the boiler and central heating systems are open;

• that the central heating system is ﬁ lled and vented;

• that there are no gas or water leaks from the central heating system or boiler;

• that the electric connections are correct and the earth wire of the boiler is connected to an efﬁ cient earthing installation and a 3amp. fuse is ﬁ tted to the isolator;

• that there are no ﬂ ammable liquids or materials near the boiler;

4.02 Starting up the boiler

• Open the gas cock upstream of the boiler.

• Vent air present in the pipe upstream of the gas valve.

• Turn on electrical supply to the boiler.

• Rotate the ON-OFF RESET switch (ﬁ g. 2 - part 98) into the ON position.

• Check inlet working gas pressure, burner pressures and gas rate.

At this point, choose whether the boiler is to be used for central heating and domestic hot water production or for domestic hot water production only. If the former is chosen (central heating and domestic hot water production), turn the knob 63 (ﬁ g.

2) to the “Winter” position. Set the knob above 50°C and set the room thermostat (if ﬁ tted) to maximum. The burner ignites

and the boiler starts to function automatically , contr olled by its control and safety devices. If the latter is chosen (domestic hot water production only), position the knob 63 (ﬁ g. 2) on the “Summer” position. In this

mode the boiler is ready to operate automatically whenever domestic hot water is drawn off. Note - If after completing the start-up procedure correctly, the burners fail to ignite and the boiler shut down

warning lights up, wait about 15 seconds then rotate the knob 98 (ﬁ g. 2) against spring pressure to the RESET position and release it. The reset electronic control unit will repeat the start-up cycle.

Note - In central heating mode after resetting the boiler will go into it 2 minue delay before starting up again. If after a second attempt the burners still fail to ignite, consult the paragraph “Troubleshooting”.

Note - If there is a power failure while the boiler is in operation, the burners automatically go out and re-ignite when the power returns.

4.03 Shutting down

Close the boiler isolation gas cock and turn off the electricity to the boiler.

Important: If the boiler is not to be used for lengthy periods during the winter, to avoid frost damage, you are recommended to drain the water from the circuits (domestic hot water and central heating). Alternatively , drain the domestic hot water system only and add special anti-freeze to the central heating system.

4.04 Checks and controls after ﬁ rst start-up

• Check there are no leaks in the gas and water circuits.

• Check correct boiler start up by carrying out start up and shut down tests using the boiler stat.

• Check the integrity of the air-ﬂ ue pipes during boiler operation.

• Check that the gas consumption indicated on the meter corresponds to that given in Technical Data (page 5).

• Check that water is circulating correctly. Balance the radiators to ensure that the flow and return differential does not exceed 20°C.

• Check that when operating in the “Winter” mode, the pump stops and domestic hot water is produced correctly when the hot water tap is turned on.

• Check that in the “Summer” mode, the burner lights up and shuts down correctly when the domestic hot water tap is turned on and off.

• Check that the domestic hot water ﬂ ow and T correspond to the table. Do not r ely on empirical measurements. T emperature should be measured using thermometers as near as possible to the boiler, bearing in mind the heat loss from the pipes.

Page 27

FERROLI F24

• Check that the gas valve modulates correctly both during the central heating phase and the domestic hot water production phase.

• Determine the combustion efﬁ ciency and the composition of the ﬂ ue gases (refer to 6.04)

• If any of the above are not correct refer to Technical Data (page 5). Adjustment (refer to 5) and Fault ﬁ nding (page 39).

5. ADJUSTMENT AND GAS CONVERSION

5.01 Adjusting the pressure and ﬂ ow rate to the main burner

This boiler operates on the ﬂ ame modulation principle. It has two ﬁ xed pressure values, minimum and maximum, which must be as shown in the table (pages 5), whichever type of gas is used.

Note - Because correct minimum and maximum pressures are critical to the efficient operation of the boiler it is ESSENTIAL that the following adjustments are carried out by COMPETENT personnel ONLY.

5.02 Adjusting minimum and maximum pressure

Honeywell V K4105G gas valve

- Connect suitable pressure gauge to burner test point “B” downstream of the gas valve.

- Disconnect the pressure compensation tube «F».

- Remove the protective cap «C».

- Adjust potentiometre P3 (on the main board) at

minimum (clockwise).

- Operate boiler for central heating

- Adjust minimum pressure by rotating screw «D»

clockwise toreduce pressure and anticlockwise to increase pressure.

- Adjust potentiometre P3 at maximum (anticlockwise)

- Adjust max pressure by rotating screw «E», clockwise to increase pressure and anticlockwise to reduce pressure.

- Reconnect the pressure compensation tube «F».

- Replace protective cap «C».

Maximum + Minimum possible gas pressures are now set. Range Rating the central heating is not necessary (see paragraph 5.04).

IN OUT

EB A D

Key A = Gas inlet test point

B = Gas outlet test point C = Protection cup D = Min. pressure adjusting screw E = Max. pressure adjusting screw

F = Balancing tube

Fig. 28

Page 28

FERROLI F24

Fig. 29

5.03 Adjustment

potentiometers

+- +-

P2 DHW

P1 CH

5.04 Adjusting maximum output for central heating system (ﬁ g. 29)

This adjustment must be carried out electronically using the “P3” adjustment screw starting with a cold central heating system. Connect a pressure gauge to the pressure test point downstream of the gas valve. Rotate the temperature adjustment screw to maximum then regulate the pressure to the value required, consulting the diagram (ﬁ gs. 4 and 5 - page 7). Once this operation is complete, start up and shut down the burner two or three times using the thermostat. Check each time that the pressure values remain as adjusted and that the burner ignites corr ectly. Otherwise further adjustment is necessary until the pressure remains stable on this value.

N.B. - when carrying out this operation ensure that the boiler thermostat is set to maximum otherwise

the adjustment will not be accurate.

5.05 Adjusting central heating ﬂ ow temperature

Central heating water temperature is adjusted by rotating the control knob (ﬁ g. 2 - part 63). Rotate the knob clockwise to increase water temperature, anticlockwise to reduce water temperature. Temperature can be varied from a minimum of 30°C to a maximum of 85°C. However, we recommend not operating the boiler below 50°C.

5.06 Adjusting room temperature (when a room thermostat is ﬁ tted) Room temperature is controlled by positioning the room thermostat knob to the r equired value. The thermostat automatically

controls the boiler, temporarily interrupting the electrical supply subject to the room heat requir ements.

5.07 Adjusting the central heating ﬂ ow t by varying pump ﬂ ow-head

The thermal head t (the difference in temperature between the delivery water and return water in the central heating circuit) must be less than 20° C. This is obtained by varying pump ﬂ ow rate and head using the multi-speed variator (or switch) on the pump itself. Increasing the pump speed reduces t and vice versa. The minimum differential must not be less than 11°C.

5.08 Adjusting central heating system pressure

The pressure of water in the central heating system, read on the control panel pressure gauge, is adjusted as described in paragraph 3.08 page 24.

N.B. - To avoid incurring unnecessary expense, in the event of boiler shut down, check that this is not caused by a lack of electricity or gas, or low water pressure before calling the Customer Technical Service Helpline.

5.09 Gas conversion

The following adjustment and conversion operations must be carried out by competent personnel. FERROLI Limited accepts no liability for damage to property or personal injury resulting from tampering with the

boiler by unauthorised persons. To convert the boiler from Nat Gas to LPG and vice versa, the main burner injectors must be replaced. Minimum and maximum pressures must then be adjusted on the gas valve (see Adjustment page 28).

Note: After converting the boiler from natural gas to liquid gas, ﬁ t the orange plate in the conversion kit near the data plate.

Note: injector diameters and pressures at the main burner are given in Technical Data (page 5).

P1 = C.H. temperature adjustment P2 = D.H.W. temperature adjustment P3 = C.H. output adjustment P4 = Ignition gas pressure adjustment P5 = Minimum gas pressure adjustment

Page 29

FERROLI F24

6. MAINTENANCE AND CLEANING

The following operations must be carried out by Corgi registered engineers only.

6.01 Annual Servicing

The following should be checked at least once a year:

• Water pressure in the central heating system when cold should be about 1 bar. If this is not the case,

bring it back to this value.

• Check control and safety devices (gas valve, ﬂ ow meter, thermostats, etc) are functioning correctly.

• The burner and heat exchanger must be clean. To avoid damage, always clean them with a soft brush or

compressed air. Never use chemical products.

• The expansion vessel must be checked (precharge 1 bar).

• Check there are no leaks in the gas and water circuits.

• Check the air-ﬂ ue gas duct terminal is free from obstructions and sound.

• The electrodes must be free from corrosion build up and correctly positioned.

• Gas ﬂ ow and pressure must correspond to the values given in the Technical Data (page 5).

• The pump must be free to rotate.

6.02 Cleaning the boiler and burner

The boiler should be serviced annually. The heat exchanger and burner must never be cleaned with chemical products or steel brushes. Particular attention must be paid to all seals and ﬁ xings associated with the room-sealed compartment (gaskets, grommets, etc). Air leakage would cause pressur e inside the compartment to drop, possibly tripping the differential pressur e switch and thus shutting down the boiler. After cleaning particular attention should also be paid to checking stages of start-up and operation of the thermostats, gas valve and pump.

6.03 Servicing procedure

1. Visually check boiler for correct intallation and ﬂ ueing.

2. Isolate electricity supply + check fuse is 3amp.

3. Remove case by undoing the two screws located at the bottom rear corners, lift slightly and pull forward.

4. Carry out preliminary electrical checks at boiler junction box. This is located in the centre of the

boiler at the bottom and can be accessed be the removal of a single screw. Any faults found must be rectiﬁ ed before proceeding.

5. If electrical checks prove O.K. replace cover and secure with screw.

6. Attach a manometer to the boiler gas inlet test point, turn on electricty and ﬁ re boiler for hot water, check

inlet pressure. This should be 20mbar minimum for NG and 37mbar for LPG. If this is not the case there is a supply problem and this will need to be remedied.

7. If inlet pressure is O.K. shut down boiler and remove manometer from gas inlet pressure test point and attach

it to the boiler burner pressure test point. Reseal inlet pressure test point.

8. Fire boiler for hot water and check that the maximum pressure is 11.8mbar for NG and 36.0mbar for LPG.

Turn off tap. Turn P3 on the main circuit board to minimum and ﬁ re the boiler for heating, check that the burner pressure reads 2.5 mbar for NG and 7.8mbar for LPG. Turn P3 back to max position. Shut down boiler, remove manometer, seal test point. If the pressures are not as speciﬁ ed they will need to be adjusted on the gas valve(see page 28 - installation manual).

10. Remove fan by undoing the two fan securing screws tilt the front of the fan upwards (downwards for

rear outlet ﬂ ue) to detach it from the securing pin and withdraw it from the boiler, disconnect the wires and air pressure switch tubes.

11. Take off the combustion chamber cover by removing the three securing screws.

12. Lift off ﬂ ue hood and ﬂ ue bafﬂ e plate.

13. Pull off the ignition and ﬂ ame rectiﬁ cation leads from their respective electrodes.

14. Undo the gas union in the centre of burner rail and take out the two securing screws. Remove the burner

rail and clean rail and injectors.

15. Remove two screws securing the burner assembly and remove the assembly. Clean burners.

16. Clean heat exchanger with a soft brush.

17. Re-assemble bafﬂ e, ﬂ ue hood and fan assembly, secure with screws previously removed.

18. Reﬁ t burner assembly and burner rail.

Page 30

FERROLI F24

19. Reconnect ignition and ﬂ ame rectiﬁ cation leads.

20. Reconnect gas union and tighten.

21. Reﬁ t combustion chamber cover, secure with screws.

22. Examine seals on room sealed cover reﬁ t cover and secure with screws.

23. Turn on gas and electricity.

24. Fire boiler and check all gas joints for soundess.

25. Check ﬂ ame picture and all controls for correct operation.

26. Check room sealed cover for leakage.

27. Check domestic water ﬂ ow rate and temperature is within speciﬁ cations.

28. Check operation of all safety cut off devices.

29. If a combustion analyser is to be used there are test points provided on the front of the room sealed cover.

The right hand grommet is for air and the left hand one is for ﬂ ue gas. The boiler must reach operating temperature before this test is carried out (normally 10-15 minutes). CO/CO2 ratio should not exceed 0.0080. Immediately after servicing (0.0040 at any other time)

30. Reﬁ t case and secure with screws.

31. Leave boiler set to customers requirements.

6.04 Flue Gas Analysis

1. The appliance should be checked visually for obvious defects.

2. After removing the jacket on the boiler there

are two test point, one for ﬂ ue gas and the other for air.

3. Open the air and ﬂ ue gas test points;

4. Introduce the probes as far as the retainer;

5. Turn on the hot water tap;

6. Turn the domestic hot water stat to maxi-

mum;

7. Allow the boiler to reach thermal equilibrium

(10 - 15 min.);

8. Take reading;

9. The CO/CO2 ratio should be 0.0040 or below.

If the reading is above this then a full strip down service must be carried out and the cause remedied.

10. Following a full strip down service and after

reaching thermal equilibrium the permissible reading is 0.008 or below.

N.B.: To ensur e corr ect r eadings the boiler must

have reached normal operating temperature. Testing the boiler before thermal equilibrium has been attained will give incorrect read-

ings.

N.B.: If you have only 1 probe, measure separately air and ﬂ ue gas, close the test point not in use.

FLUE

AIR

Fig. 30

Page 31

FERROLI F24

7. REPLACEMENT OF PARTS

7.01 Initial procedure

a) Ensure the boiler is cold, electricity supply is isolated, and the gas supply is turned off at the

inlet of the boiler

b) For replacement of parts where water connections are broken, it will be necessary to isolate and drain either

or both the central heating or domestic hot water circuits of the boiler only. The cold water mains inlet is isolated at the inlet cock. The D.H.W. is drained by opening a hot tap.

The C.H. ﬂ ow and return cocks are turned off at the isolation cocks. The C.H. is drained via the pressure

relief valve (twist about 1/3 of a turn). c) Remove components following special notice below and replace in reverse order. d) Ensure water and gas washers are in good condition.

7.02 Final procedure

• Re-open cocks and re-charge the system to about 1 bar, and vent boiler and radiators.

Re-charge to 1 bar if necessary.

• Upon completion of the work the following. Should be checked:

I) Gas soundness of all joints II) Water soundness of all joints III) The electricity supply. IV) The pressure of the sealed system and top up where necessary.

7.03 To lower the control panel (ﬁ g. 31)

• Remove the two ﬁ xing screw (ﬁ g. 31) "A"

• Rotate down the front panel "C"

Fig. 31

7.04 Remove and re-presurising of C.H. expansion vessel (ﬁ g. 32)

• Refer to 7.01 a, b

• Isolate electricity and water supplies

• Remove outer case (two screws bottom

rear corners)

• Loosen the "A" connections to expansion vessel

• Remove "B" screw

• Remove the expansion vessel

• Re-assemble in reverse order

• Re-pressure expansion vessel (charge pressure 0,8-1 bar) through the valve "C"

• Ensure pressure relief value is open

(twist about 1/2 of a turn) when repressurizing

Fig. 32

Page 32

FERROLI F24

Fig. 33

7.05 Gas valve (ﬁ g. 33)

• Isolate gas and electricity supplies

• Remove outer case (two screws bottom rear corners)

• Remove the two securing screws and lower control panel

• Disconnect electrical connections from valve ("A")

• Disconnect plastic tube "C"

• Loosen the connection "D" on gas pipe and the gas inlet connection of the boiler "E"

• Remove the two ﬁ xing screw "E" below gas valve

• Slide out gas valve

• Remove four ﬁ xing screw "F" on top of the valve and disconnect the gas pipe

• Remove bottom connection from gas valve.

• Fit top + bottom gas connections to the new gas valve and replace in reverse order

7.07.1 D.H.W. temperature sensor or Central Heating Temperature Sensor

(ﬁ g. 35)

• Isolate electricity and water supplies

• Remove outer case (two screws bottom rear corners)

• Remove the two securing screws and lower control panel

• Identify the sensor from ﬁ gure 35

• Disconnect electrical connection to the sensor

• Drain the affected service either D.H.W. or C.H.

• Unscrew the sensor

• Replace in reverse order

7.07.2 Water Pressure Switch (ﬁ g. 35)

• Isolate electricity and water supplies

• Remove outer case (two screws bottom rear corners)

• Remove the two securing screws and lower control panel

• Identify the switch from ﬁ gure 35

• Disconnect electrical connections + note positions to the switch

• Drain the boiler

• Unscrew the water pressure switch

• Replace in reverse order

7.07.3 Safety Valve (ﬁ g. 35)

• Isolate electricity and water supplies

• Remove outer case (two screws bottom rear corners)

• Remove the two securing screws and lower control panel

• Identify valve from ﬁ g. 35

• Drain the boiler

• Release the outlet union to the valve and undo the valve

union connection

• Remove the valve outlet ﬁ tting

• Replace in reverse order

7.06 Air pressure switch (ﬁ g. 34)

• Isolate electricity

• Remove outer case (two screws bottom rear corners)

• Open room sealed department

• Remove the two screw "A" ﬁ xing air pressure switch

• Disconnect electrical leads "B"

• Remove pressure sensing tubes (white=D; Red=C)

• Note relevant positions of all connections and

replace in reverse order.

Fig. 34

C.H. sensor

Water pressure switch

D.H.W. sensor

Safety valve

Fig. 35

Page 33

FERROLI F24

7.08 Removal of burner (ﬁ g. 36)

• Isolate gas and electricity supplies

• Remove outer case (two screws bottom rear

corners)

• Remove room sealed cover

• Disconnect ignition and ﬂ ame rectiﬁ cation

leads "A"

• undo gas rail union "B"

• Undo two screws securing the burner assembly

to the boiler combustion chamber "D"

• Withdraw the burner assembly

7.09 Injectors (ﬁ g. 36)

• Proceed as 7.08

• Remove ﬁ xing screw "C" on both

sides of gas collector

• Remove gas collector

• Unscrew and remove injectors;

• Clear or change injectors

Fig. 36

7.10 Removal of fan (ﬁ g. 37)

• Isolate gas and electricity supplies

• Remove outer case (two screws bottom rear

corners)

• Remove room sealed cover

• Disconnect fan electrical leads "A"and note

positions

• Disconnect air pressure tubes from air pressure

switch "B" + note positions

• Undo two screws securing fan assembly "C"

• Remove fan from boiler

• Swap mounting plate over to new fan + replace

in reverse order

7.11 Limit thermostat, or overheat cut off

thermostat (ﬁ g. 37)

• Isolate electricity

• Remove outer case (two screws bottom rear

corners)

• Remove room sealed cover

• Identify the location of thermostat from ﬁ g. 37

• Pull out thermostat from tube, with its spring

• Remove electrical connections from thermostat

• Remove spring from thermostat

• Replace in reverse order

Fig. 37

Overheat cut off Limit thermostat

Page 34

FERROLI F24

7.12 Spark or ﬂ ame detect electrode

(ﬁ g. 38)

• Isolate gas and electricity supply

• Remove outer case (two screws bottom rear

corners)

• Open room sealed compartment and

combustion chamber

• Identify electrode from ﬁ g. 38

• Unplug electrical connection "A" from sensing

electrode

• Remove ﬁ xing screw and remove ﬂ ame detect

electrode

• Remove the two ﬁ xing screw from spark

electrode plate and remove it.

Spark

Flame detect

Fig. 38

7.13 D.H.W. ﬂ owmeter

• Isolate electricity and water supplies

• Open a hot water tap to release water pressure

from the domestic side of the heat exchanger, close tap.

• Remove outer case (two screws bottom rear

corners).

• Remove two screws from control panel and tilt

forward

• Take off protective cover from main PCB and

unplug ﬂ ow meter lead from terminal X4.

• Place a piece of cloth or some other absorbent

material over rear of control panel to catch any drops of water that may be released when removing the ﬂ ow meter

• Using a 24mm open ended spanner, undo ﬂ ow

meter unions "A" and "B" taking care not to twist the copper tubing (access through base panel).

• Remove ﬂ ow meter, check + clean ﬁ lter +

restrictor + ﬁ t to new ﬂ ow meter.

• Reassemble in reverse order.

A B

Fig. 39a

37 3938 38

Key

37 Cold water inlet ﬁ lter 38 Gasket 39 Cold water ﬂ ow limiter

Take care on correct position of components as reported in ﬁ g. 39b

Fig. 39b

Page 35

FERROLI F24

7.14 Pump (ﬁ g. 40)

Replacement of pump head

• Isolate electricity and ﬂ ow and return pipes

• Remove casing (two screws bottom rear corners).

• Remove the two securing screws and lower control

panel

• Release pressure from boiler via pressure relief valve

• Unplug the pump lead "A" from the pump head

• Place a piece of cloth or other absorbent material

over the rear of the control panel to catch any drops of water that may fall when the pump head is removed.

• Using a 4mm allen wrench undo the four allen screws

"B" in the pump head, lift away pump head from the pump body

• ﬁ t new head into pump body and secure with the

allen screws tightening evenly.

• Replace electrical connection.

Replacement of pump body (ﬁ g. 40)

• Proceed as for removal of pump head

• Disconnect the expansion vessel connecting pipe "E"

from the rear of the pump body by removing the clip from the left hand side

• Disconnect the boiler return pipe

• Disconnect the pump to heat exchanger connection

by removing the clip "F"

• Unscrew the nut on bottom of pump "D"

• Turn the pump body through 90°, pull the bottom

forward and withdraw the pump body

• Reassemble in reverse order taking care to ensure the

O-rings are in place and undamaged.

Fig. 40

7.15 Removal of heat exchanger

• Isolate gas, water and electricity supplies

• Remove casing (2 screws bottom corners)

• Remove the two securing screws and lower control panel

• Drain heat exchanger for both CH + DHW

• Remove sealed compartment front panel

• Disconnect the overheat thermostat and central heating limit thermostat

• Remove the main burner, fan, ﬂ ue hood and ﬂ ow meter as described previously

• Remove the pump to heat exchanger ﬂ ow connection and locknut

• Undo the domestic water outlet connection and locknut

• Lift out heat exchanger

• Re-assemble in reverse order

Page 36

FERROLI F24

8. FAULT FINDING

Before beginning any fault ﬁ nding ensure that gas, water and electricity are available. WARNING: DO NOT link any terminals on block X10 or X11 as this will damage the PCB beyond repair.

8.01 Operating Sequence

With the power established the boiler is in its stand-by mode i. e. power on but no demand. The operational sequence for C.H. and D.H.W. are as follows:

Central Heating Mode External Call for Heat: The temperature regulator, built in or remote clock and room thermostat, if ﬁ tted, must

all call for heat. This will cause the pump to run. Internal Call for Heat: C.H. ﬂ ow temperature sensor, 88°C high limit and low water pressure switch all calling for

heat. If both external and internal calls for heat are present the MF03 PCB will energise. In demand the fan will go to high speed causing the air pressure switch to operate. If the overheat (100°C) stat is

closed circuit the ignition will operate and the gas valve will be energised.

The burner will light at ignition burner pressure, automatically range rating itself up to the heating load, then modulating down when the boiler reaches the desired ﬂ ow temperature. When the central heating is satisﬁ ed the burner will go off and the fan stops i.e. stand-by mode.

Note - If the boiler thermostat is set to maximum than the burner pressure will go to maximum effectively bypassing the auto range rating facility

Domestic Hot Water Mode External Call for D.H.W: Flow meter registers at least 2.5 litres/min ﬂ ow to the hot water taps.

Internal Call for D.H.W: Hot water ﬂ ow temperature sensor 88°C high limit stat and low water pressure switch calling for heat.

If both internal and external calls are present the boiler follows the same sequence as for C.H. to light the burner. However, for D.H.W. the burner will go straight to maximum and then modulate once the water reaches the set temperature of the control thermostat. Turning the tap off will return the boiler to stand-by mode.

Note: Following shut down of the D.H.W. or C.H. the boiler will go into a three minute central heating delay.

8.02 Limit thermostats

T/Stat Location Function Nominal Circuit Wiring Operating Colours Temperature

C.H. Limit Top RHS Shuts downmain 88°C Low voltage Blue

of Heat burner if boiler DC Brown Exchanger thermostat fails

Frost Incorporated Fires the boiler 7°C - 14°C Low voltage Red in C.H. and runs pump to DC Red Sensor maintain minimum water temperature

Overheat Top LHS Protect boiler by 100°C 240V AC Brown of Heat stopping ignition Blue Exchanger and cuts power to gas valve

The MFO3 PCB has ﬁ vediagnostic lights, each light corresponds to a particular function and will light in turn as the boiler goes though its sequence of operations.

Page 37

FERROLI F24

In order, the ﬁ ve lights indicate: 1 Boiler On Indicate

2 Boiler Shut down warning 3 Domestic Hot Water circuit ON 4 Central Heating standby (Flashing Light) Central Heating circuit ON (Permanent Light) 5 Insufﬁ cient pressure in Central Heating System (Flashing Light) Electric power supply ON (Permanent Light)

Note: Always check for sufﬁ cient gas supply (20mbar inlet working pressure for NG and 37mbar for LPG). Minimum of 22 mm diameter pipework on C.H. ﬂ ow and return with adequate by-pass. A correctly installed ﬂ ue system and a 3 amp fuse.

8.03 MF03 PCB

When operating the C.H. the following lights should be on: 4, 5 and ﬂ ame on light. For D.H.W. the following lights should be on: 3, 5 and ﬂ ame on light.

If the boiler works for C.H. but not D.H.W., or vice versa, a number of components must be functioning and can, therefore, be eliminated as being at fault.

Boiler will not light for D.H.W.

If boiler works for C.H. but not for D.H.W. the fault is most likely to be the ﬂ ow meter or D.H.W. sensor. If the tap symbol light is on the fault is the D.H.W. sensor. If this light is not on then suspect the ﬂ ow meter has not operated.

Boiler will not light for C.H.

If the boiler works for D.H.W . but not for heating the fault is most likely to be external contr ols (i.e. clocks or room thermostats). Integral clock if ﬁ tted or C.H. sensor.

If the heating demand light is on the fault is most likely the C.H. sensor. If this light is not on suspect either a clock or room thermostat not calling.

To override/eliminate any external controls disconnect them from terminal 3 and 4 underneath the boiler and reﬁ t the link wire (see ﬁ g. 42).

Boiler will not light for D.H.W. or C.H.

The fault is likely to be a component common to both services. Open a hot tap to create a demand - is there a spark at the ignition electrode?

Yes Suspect gas supply, pressure or gas valve. No Is fan running? Yes Suspect air pressure switch or overheat stat (if boiler locks out without sparking go to overheat stat) No Is low water pressure light Flashing?

Yes Top up water to above 1 bar. Does the light go out? (if water pressure o/k suspect high limit stat) Yes Does fan start? Yes Does boiler light? Yes Is hot water OK?

Try heating, if heating does not work follow guide for heating faults. Does low water pressure

light go out?

No Suspect low water pressure switch.

If boiler still does not ﬁ re see comprehensive fault ﬁ nding chart.

Page 38

FERROLI F24

8.04 Temperature sensors (thermistors)

Identical, but individual, negative temperature co-efﬁ cient (NTC) thermistors are ﬁ tted in the C.H. and D.H.W . outlets from the heat exchanger . As the water temperature increases the resistance in the thermistor decr eases. This causes the PCB to reduce the voltage to the modureg, in turn reducing the burner pressur e. The wiring for each thermistor is colour coded red for C.H. and blue for D.H.W. The sensors are ﬁ tted in wet pockets.

8.05 Limit thermostats

Two surface mounted auto reset bi-metal thermostats are located on the heat exchanger secured by spring clips. Heat sink compound is used.

8.06 Main printed circuit board

Secured by ﬂ our plastic tabs the PCB is situated inside the control compartment. The transformer for low voltage AC is attached to the PCB as is the DC rectiﬁ er. Potentiometers control C.H. output and maximum D.H.W. temperature, both are adjustable by the controls on the facia and because the boiler features automatic range rating no adjustments need to be made. Electro mechanical relays control pump operation and put switched live to the ignition PCB (demand relay), they have transparent plastic covers so that their contacts can be seen moving.

8.07 Air pressure switch

Operating at 230 V AC and situated next to the fan. Different coloured tubes connect the switch to the fan. It is a make on pressure switch and only uses two terminals, the middle terminal is not used.

8.08 Short spares list

KEY NO. DESCRIPTION PART NO. G.C. NO. (from ﬁ g 2 )

14 Safety Valve C/W Manifold 805880 E39-485

16 Fan assembly 800480 E23-851 34 Central Heating Flow Temperature Sensor 800320 E23-839 42 Domestic Hot Water Flow Temperature Sensor 800320 E23-839 43 Air Pressure Switch 800150 E23-840 44 Gas Valve - VK4105G 808000 E23-768 49 Overheat Safety Thermostat 100°C 801240 386-815 50 High Limit Thermostat 88°C 800160 386-577 81 Ignition Electrode 806258 E26-348 82 Flame Sensing Electrode 801438 E23-855 136 Flow Meter C/W Elbow 805910 E39-465 Main PCB MF03 805900 E39-470 27 Heat Exchanger 807480 E77-470

Page 39

FERROLI F24

8.09 General test and fault ﬁ nding

Chart 1

Check electrical supply - C.H. water pressure and frost protection

Is LED5 on?

Put main switch to on

CH Selector to

Summer “ ” position

D.H.W. taps closed

Is 230V present across

terminals X1-1 X1-2?

Check and if necessary

replace 2A fuse

YES

Is LED5 ON now?

Repair external

wiring fault

NO NO

Replace

main board

YES

Is LED5 flashing?

YES

Water pressure

is not set

between

1 - 1,5 bar?

YES

Set pressure to

1 - 1,5 bar

Check water

pressure

switch wiring

connection

Does fan run at full speed?

Go to CHART 2

YES

Does CH Pump run?

If the boiler temperature

is less than 5°C

frost protection is activated

Disconnect

CH flowtemp sensor

Has fan speed stopped?

Change main board

YES

Check and if

necessary

replace water

pressure switch

Chek the following carefully before starting

• Gas supply is turned on, is adequate and purged

• Electricity supply is turned on

• Polarity is correct

• CH pressure is set between 1 - 1,5 bar

• CH pump spins freely

YES

Page 40

FERROLI F24

Chart 2

Check Domestic Hot Water operation

Chart 3

Check Central Heating operation

Check and if necessary

replace DHW Sensor

Is LED3 on?

Open DHW taps

DHW flow rate at

least 2,5 litre/min?

Check cold water

inlet pressure

Check and if necessary

replace Flow meter

Is LED4 flashing?

Is relay RY100 switch on?

YES

Check if water

filter is clean

YES

Check and if necessary

replace main board

Check and if necessary

replace limit thermostat

Go to

chart 4

Wait 2 minutes

DHW taps closed

Put CH temperature selector

to maximum

Ensure external controls

are calling for heat

Is LED4 flashing?

Does pump run?

YES

Go to chart 4

Is relay RY101

switch on

Check and if

necessary replace

main board

Is LED4 flashing?

Check and if is necessary

replace CH sensor

YES

Is relay RY100

switch on

YES

Go to chart 4

Check

limit thermostat

YES

Check and if

necessary

replace pump

Page 41

FERROLI F24

Chart 4

Check fan/ﬂ ue gas system

Does fan run?

Is relay RY100 switch ON?

Go to charts 2-3

Is 230V present across

fan terminals?

YES

Check air pressure

switch wiring connection

Check and if

necessary replace

air pressure switch

Check and if

necessary replace fan

YES

Is air pressure switch

activated?

YES

Check and if

necessary replace

air pressure switch

YES

Differential air pressure

across the air pressure

switch is greater than

180 Pascal?

Go to chart 5

YES

Check and clean fan

Check flue and air

intake are correct

and clean

Check Venturi and

air pressure switch

tubes are clean

Check restrictor

is correct

Chart 5

Check D.H.W. and C.H. modulation

Does burner

flame modulate?

Check wiring connection

to CH sensor

Normal operation

carry out

YES

Check CH sensor

and replace it if necessary

Boiler operated

on central heating mode

Does burner

flame modulate?

Check wiring connection

to DHW sensor

Normal operation

carry out

YES

Check DHW sensor

and replace it if necessary

Boiler operated

on DHW mode

Page 42

FERROLI F24

Chart 6

Check ignition system

Is LED1 light on?

Does sparking start

at burner?

Does burner light?

YES

Is LED2 on

after 10 seconds?

YES

Go to chart 6

Reset lockout

YES

Does burner light now?

Is flame present before

lockout condition?

YES

Check and if necessary

replace safety thermostat

Check electrodes and

leads for damage

and correct connection

Check and if necessary

replace P.C.B.

Adjust with P4 ignition

burner pressure

Check and if necessary

clean burner

Check and if necessary

clean injectors

Check and if necessary

clean flame electrode

Check right position

of spark electrode

Check wires

Check gas supply is live and purged

Check and if necessary

replace gas valve

YES

Check and if necessary

replace P.C.B.

Is LED2 on

without

the boiler sparking

YES NO

Re-check

air pressure switch

Page 43

FERROLI F24

JP01 ON =

Delay between shutdown and re-ignition disabled

JP01 OFF =

Delay between shutdown and re-ignition enabled

JP02:

Jumper on for natural gas

Jumper on for LPG

JP03 ON = Max temperature D.H.W. 62°C JP03 OFF= Max temperature D.H.W. 55°C (standard)

Potentiometer adjustment P1 = Central heating ﬂ ow temperature adjustment

P2 = Domestic hot water temperature adjustment P3 = Central heating ﬂ ow output adjustment P4 = Ignition gas pressure adjustment P5 = Minimum gas pressure adjustment

9. ELECTRICAL AND FUNCTIONAL SCHEME

9.01 Main components layout on electronic boards

temp. Ohm

10 °C 20 kOhm 25 °C 10 kOhm 60 °C 2,5 kOhm 80 °C 1,25 kOhm

Temp.

sensor

NTC

(34) (42)

Fig. 41

X1 X2 X3 X4

12121312345678910 123

678910

111213

+- +-

Transformer

P2 DHW

X12

JP02 JP01

JP03

123456789

X10

Nat/LPG

P1 CH

X11

RY100

RY101

PC PNO L N HL HL MV1 MV2 MV3 MV4

FAN

MF03F

Page 44

FERROLI F24

Key

16 Fan

32 Central heating pump

34 Central heating ﬂ ow temperature sensor

42 Domestic hot water ﬂ ow temperature sensor

43 Air pressure switch

44 Gas valve

49 Safety thermostat

50 Central heating limit thermostat

62 Time clock

Key

BR Brown

BLUE Blue

BL Black

W White

O Orange

G Green

R Red

V Violet

IMPORTANT

USE A ROOM THERMOSTAT (24 V)

WITHOUT VOLTAGE TO THE CONTACTS.

CONNECTING 230 V TO THE ROOM

THERMOSTAT TERMINALS WILL

IRREPARABLY DAMAGE THE

ELECTRONIC BOARD.

72 Room thermostat

81 Ignition electrode

82 Sensor electrode

98 Off/On/Reset switch

114 Low water pressure switch

136 Flow meter

9.02 General wiring diagram

X2 X3

12121312345678910 12345678910111213

TEST

X12

123456789

X10

81 82

MF03F

JP02

JP01

JP03

Nat/LPG

X11

230V 24V

230V

24V

1 M

Blue

MV1

MV2

MV3

MV4

Blue

Y/G

136501144234

44491643

230V

50Hz

Fig. 42

Page 45

FERROLI F24

Fig. 43

10. USER INSTRUCTIONS

The boiler is designed for use with two types of gas: natural gas NG or propane (LPG). The type of gas can be selected when purchasing the boiler or the appliance can be converted later on site by a competent person. It operates with technologically advanced systems such as electronic control, safety and control devices. The boiler is ﬁ tted with automatic electronic ignition so there is no pilot to worry about. Pull down cover to reveal control facia panel. Make sure that the gas, water and electricity supplies to the boiler are turned on. The boiler pressure gauge (D) should read at least 1 bar.

Low pressure will be indicated by ﬂ ashing light in the middle of the facia illuminating (

bar

Hot Water Only - “SUMMER” (

)

To obtain hot water only from the boiler, turn switch (A) to the on position. The top green light on the left side of the control panel is illuminated (power on ).

Turn the temperature regulator (B) to the

position. Open a hot water tap, green light (tap symbol) comes on, fan starts and burner will light. Indicated by ﬂ ame symbol, green light coming on. The temperature of the hot water can be adjusted by turning the hot water thermostat (C) clockwise to increase and anti-clockwise

to decrease the water temperature.

Heating and Hot Water - "WINTER” (

)

To obtain heating from the boiler, turn the temperature regulator (B) clockwise to the maximum position, ensure that any other heating controls e.g. room thermostats, clock etc. are in the on position.

The boiler may be in heating delay of three minutes as indicated by the red light (egg timer symbol) on the left of the facia panel. When this light goes out the green light (radiator symbol) will come on. The fan and pump will

run and the burner will light indicated by the green ﬂ ame symbol light. Adjust the temperature regulator to the desired setting. (In winter do not run boiler below 50°C). If a hot water tap is opened whilst the boiler is running for heating the pump will stop, suspending the heating phase and the boiler will give

priority to hot water production. When the tap is closed the boiler will go into a three minute delay cycle before resuming for heating.

KEY DESCRIPTION

A Switch OFF/ON/RESET B Central heating flow

temperature regulation

C D.H.W. temperature

regulation

D Water pressure gauge E Time clock

bar

RESET

OFF

bar

ABC D

°C

Burner on indicator Boiler shut down warning Domestic hot water circuit on

Central heating stand-by

(Flashing light)

Central heating circuit on

(Permanent light)

Insufficient pressure in central heating system

(Flashing light)

Electric power supply

(Permanent light)

12345

1 2 3

LED

Page 46

FERROLI F24

Frost Protection

In cold weather the boiler may appear to run when there is no demand for heating (i.e. clocks or room thermostats turned off). This is due to the central heating sensor going into frost protection mode. Once the boiler has reached 14°C or more it will close down until either the temperature again falls below 7°C or the clock or room thermostat is turned on.

For this reason we recommend that the electricity to the boiler is left turned on. If you wish to turn off the electricity to the boiler in winter you should drain completely the heating and hot water circuits.

Cleaning

The casing requires no special cleaning, a wipe with a soft duster or damp cloth will sufﬁ ce.

Maintenance

Férroli recommend that the appliance is serviced at least once every twelve months by a competent engineer.

Gas Supply

It is the law that all gas appliances are installed and serviced by a competent person in accordance with the Gas Safety Regulations (Installation & Use) 1996, and the manufacturers instructions. Failure to observe these requirements may lead to prosecution.

Electrical Supply

WARNING - This appliance must be earthed.

The electrical wiring must be carried out by a competent electrician. The colours of the wires in the mains lead of this appliance may not correspond with the coloured markings

identifying the terminal in the plug. Therefore, proceed as follows: The wire coloured green and yellow must be connected to the terminal in the plug marked with either the letter

E or by the earth symbol or coloured green or green and yellow. The wire coloured blue must be connected to the terminal marked either with the letter N or coloured black. The wire coloured brown must be connected to the terminal marked either with the letter L or coloured red.

MINIMUM CLEARANCE

The minimum clearance around the appliance should be as follows: Sides 5mm

Front 600mm

Below 200mm Above 100mm Top Flueing

Boiler lock out

In the event of the red lockout light ( ) coming on, the on/off/r eset switch (A) should be turned clockwise against the spring tension to the reset position and released (this will put the boiler into three minute delay if in the heating

mode). If the lockout light ( ) illuminates repeatedly, contact an approved Férroli service engineer.

Page 47

FERROLI F24

Time Clock

A 24 hour time clock is ﬁ tted to the boiler to control the central heating, this will come into operation when the selector switch is turned to the position marked “heating timed and hot water”.

AUTO

OVER RIDE

B E

RDP

AUTO

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 : 22:30

To Set Own ON and OFF times. Symbol in Display = ON time

If these are suitable no programming is required and the slide switch (A) can be moved to the Auto position and the central heating will be ON for these periods. (12:00 - 12:00 will not switch on the boiler)

A Slide switch: set clock - auto - set programme B Display. Symbol in Display = Timer ON

P Select programme ON/OFF 1.....8

D Push buttons Time + Time

E Override: Boiler will switch ON if it is OFF; and OFF if it is ON

F I=Heating continuous - AUTO=Heating timed - O=Heating disabled

R Reset (with pencil) only with switch A in set clock position

1.1 Use buttons + and - to set 1st ON time eg. 6:00 Display

2.1 Use buttons + and - to set OFF time, eg. 9:00 Display

3.1 Use button + and - to set 2nd ON time, eg. 12:30 Display

4.1 Use button + and - to set 2nd OFF time eg. 14:00 Display

5.1 Use button + and - to set 3rd ON time, eg. 16:00 Display

6.1 Use button + and - to set 3rd OFF time eg. 23:30 Display

8. On completion of programming slide switch (A) to Auto position, the time of day will be displayed and the central heating will switch ON and OFF according to the programme set.

1. Slide switch (A) to right position (P) Display

2. Press button (P) Display

3. Press button (P) Display

4. Press button (P) Display

5. Press button (P) Display

6. Press button (P) Display

7. The timer can be programmed with up to 8 ON and 8 OFF times by repeating the above procedure.

6:30 1

8:30 2

12:00 3

12:00 4

6:00 1

9:00 2

12:30 3

14:00 4

16:30 5

22:30 6

16:00 5

23:30 6

Over ride

By pressing the over ride button (E) the timer programme is over ridden ie, if programme is in OFF time it will come ON and if in ON time will go 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!

Page 48

Phone numbers: Installer Service Engineer

BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.

Lichﬁ eld Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD

Tel. 08707 282 885 - Fax 08707 282 886

ALL SPECIFICATIONS SUBJECT TO CHANGE

Please note - to avoid incurring unnecessary expense, in the event of a boiler shut down, check

this in not caused by lack of electricity supply, gas supply or low water pressure before calling our

Customer Service Helpline.

Should you require help with any difﬁ culties

call our Technical Service Helpline on

08707 282 885