Ferroli FERSYSTEM TECH 38 C Instructions For Use, Installation And Maintenance

FERSYSTEM TECH 38 C

INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE

cod. 3540U330 - 09/2009 (Rev. 00)

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Seasonal Efficiency

(SEDBUK)

band A

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

• Read the warnings given in this manual thoroughly.
They provide important information for safe instal­lation, use and maintenance

• By law the instruction manual must be left with the
end user.

• If the appliance is sold or transferred to another
owner or if the owner moves, leaving the appliance
behind, always ensure that the manual is kept with
the appliance for consultation by the new owner
and /or installer.

• Incorrect installation or poor maintenance absolves
the manufacturer from all liability for damage to
people or property.

• Installation and maintenance must be carried out
in conformity with current legislation, according
to the manufacturer’s instructions and by qualified
personnel.

• Before service or maintenance work is, carried out
isolate the appliance from the mains electricity
supply.

• In the event of malfunction or faulty operation, iso­late the appliance. Do not attempt to repair or carry
out any other operation on the appliance directly.
Contact qualified personnel only.

• Repairs or the replacement of components must be
carried out exclusively by qualified personnel using
original spare parts only. Failure to respect the above
may compromise the safety of the appliance.

• To guarantee efficient operation, the appliance must
be serviced once a year by a corgi registered engi­neer.

• The appliance may not be used for purposes other
than those for which it was explicitly designed. Any
other use is considered improper and therefore dan­gerous.

• Incorrect installation and use or failure to follow the
instructions provided by the manufacturer absolve
the manufacturer from all liability for damage.

• After unpacking, check that the contents are complete
and undamaged.

• Keep the packaging out of reach of children as it is
potentially hazardous.

• To clean external parts, use a damp cloth moistened
with soapy water if necessary. Avoid using abrasive
cleaning products and solvents.

This symbol indicates “Caution” and is placed next to all safety information.
Strictly follow these instructions in order to avoid danger and damage to persons,
or property.

This symbol calls attention to a note or important information, please read thor­oughly.

IMPORTANT

• Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the

last pages of this manual. “This record must be completed and left with the end user”.

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.

Benchmark has been introduced to improve the standards of installation and commissioning of
central heating systems in the UK and to encourage the regular servicing of all central heating
systems to ensure safety and efficiency. Please see installation and servicing guidelines.

• "Ferroli declare that no substances harmful to health are contained in the appliance or used

during the appliance manufacture”.

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

1. OPERATING INSTRUCTIONS .................................................................4

1.1 Introduction ............................................................................................................4

1.2 Control panel ..........................................................................................................5

1.3 Turning ON and OFF ..............................................................................................6

1.4 Adjustments ............................................................................................................8

1.5 Maintenance ..........................................................................................................11

1.6 Faults .....................................................................................................................11

2. INSTALLATION .....................................................................................12

2.1 General Instructions ..............................................................................................12

2.2 Boiler location .......................................................................................................13

2.3 Boiler water connections ......................................................................................14

2.4 Connection to the gas system ..............................................................................16

2.5 Electrical Connections ..........................................................................................16

2.6 Flue system ...........................................................................................................18

2.7 Condensate outlet connection .............................................................................23

3. SERVICE AND MAINTENANCE ............................................................25

3.1 Adjustments ..........................................................................................................25

3.2 System start-up .....................................................................................................26

3.3 Maintenance ..........................................................................................................27

3.4 Troubleshooting ....................................................................................................29

4. TECHNICAL CHARACTERISTICS AND DATA ..........................................................31

4.1 Dimensions and connections ................................................................................31

4.2 General view and main components ....................................................................32

4.3 Hydraulic diagram .................................................................................................33

4.4 Technical data table ..............................................................................................34

4.5 Diagrams ...............................................................................................................35

4.6 Wiring diagram .....................................................................................................36

Benchmark ..................................................................................................................38

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

1. OPERATING INSTRUCTIONS

1.1 Introduction

Dear Customer,
Thank you for choosing the FERSYSTEM TECH 38 C, a FERROLI wall-mounted boiler of the latest

generation, featuring advanced design and cutting-edge technology.
FERSYSTEM TECH 38 C is a high-efficiency condensing pre-mix appliance for heating and hot water

production with extremely low emissions, running on natural gas or LPG.
The boiler consists of an aluminium laminar heat exchanger providing effective condensation of the

water vapour contained in the flue gases, permitting extremely high efficiency.
Above the heat exchanger, in the boiler, there is a pre-mix burner, with a large ceramic surface, equip-

ped with electronic ignition and ionization flame control, which achieves extremely low emissions while
ensuring high reliability and long life operation.

The boiler is totally room sealed from the installation room: the air needed for combustion is drawn from
outside. The boiler also includes a modulating speed fan, modulating gas valve, pump, expansion vessel,
safety valve, flow sensor, temperature sensors, a safety thermostat and a low water pressure switch.

Thanks to the twin microprocessor control and adjustment system with advanced self-diagnosis, unit
operation is for the most part automatic. The power for heating is automatically governed by the control
system.

The user only has to set the temperature desired inside the home by means of a room thermostat and
appliance temperature control. The adjustment and control system will provide optimum operation
throughout the year.

The display continuously provides information on the unit’s operating status and it is easily possible
to obtain additional information on the sensor temperatures, set-points, etc. or configure them. Any
operating problems associated with the boiler or system is immediately signalled by the display and, if
possible, corrected automatically.

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

1.2 Control panel

fig. 1

1 = Domestic Hot Water temperature setpoint decreasing push button
2 = Domestic Hot Water temperature setpoint increasing push button
3 = Central Heating water temperature setpoint decreasing push button
4 = Central Heating water temperature setpoint increasing push button
5 = Display LCD
6 = Reset / OTC push button
7 = Economy-Comfort / On-Off push button
8 = Domestic Hot Water symbol
9 = Domestic Hot Water mode operation
11 = Multi-function indication (Flashing during heat exchanger protection)
12 = Economy symbol
13 = Central Heating mode operation
14 = Central Heating symbol
15 = Burner on and actual load indication (Flashing during flame current supervision)

Indication during boiler operation

Central Heating mode

The Central Heating heat demand (generated by the OpenTherm Remote Control, the Room Thermostat
or the Clock) is indicated by the flashing of the Hot Air symbol over the radiator (part. 13 and 14 – fig.

1). The display indicates the actual Central Heating water temperature (part. 11 – fig. 1) and during
central heating off time the text “d2”.

fig. 2

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

Domestic Hot Water mode

The Domestic Hot Water heat demand (generated by the DHW flow sensor or due to a Comfort request)
is indicated by the flashing of the Hot Water symbol under the tap (part. 8 and 9 – fig. 1). The display
indicates the actual Domestic Hot Water temperature (part. 11 – fig. 1) and during domestic hot water
off time the text “d1”.

1.3 Turning ON and OFF

Without main power supply

To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all
water from the system.

Ignition

Ensure the power is on to the appliance.

For the firsts 120 seconds, the display shows FH that identifies the Air purge function.
During the first 5 seconds, the display shows the software version of the pcb.
Open the gas cock on the boiler and purge the air from the pipework upstream of the gas valve.
When the FH disappears, the boiler is ready to function automatically whenever the external controls

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fig. 3

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fig. 4 - Boiler without main power supply

fig. 5 Ignition

fig. 6 Air purge

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

are calling for heat.

Turning off

Press the (part. 7 - fig. 1) for 5 seconds.

When the boiler is turned off with this key, the p.c.b is still powered, heating operation is disabled and
the display is off however the frost protection will still be active.

To totally isolate close the gas cock ahead of the boiler and disconnect electrical power.

To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all
water from the system.

To turn boiler on again, press (part.7 - fig.1) for 5 seconds.

The boiler is ready to function automatically whenever the external controls are calling for heat.

fig. 7 - Turning off

fig. 8

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

1.4 Adjustments

Heating temperature setting

To set the system flow temperature, use the CH push buttons (Part. 3 and 4 – fig. 1). It can be
varied from a minimum of 20°C to a maximum of 90°C.

Domestic hot water temperature setting

To set the hot water temperature, use the DHW push buttons (Part. 1 and 2 – fig. 1). It can be
varied from a minimum of 40°C to a maximum of 55°C.

Room temperature adjustment (using a room thermostat )

Using the room thermostat, set the temperature desired. Controlled by the room thermostat, the boiler
lights and heats the system water to the system delivery setpoint temperature. The burner shuts down
when the desired temperature in the room is reached.

A room thermostat and programmer are a mandatory requirement (Building regulations Doc ‘L’

2002).

Room temperature adjustment (using an optional Remote Control)

Using the remote control, set the temperature desired. The flow temperature will be controlled by the
remote control. For settings and other informations, see the relative manual.

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

Economy/Comfort selection

The unit is equipped with a special internal device that ensures a high hot-water delivery speed and
excellent user comfort. When comfort mode is active the water in the boiler is maintained at a pre-de­termined temperature, which means that hot water is available at the boiler outlet as soon as a tap is
opened, ie with no waiting.

The user can turn the device off (ECO mode) by pressing (part.7 - fig.1). In ECO mode the display

shows the relevant symbol (part. 12 - fig. 1). To turn on COMFORT mode, press (part.7 - fig.1) again,
the ECO symbol will vanish from the display.

Outside temperature compensation

When the (optional) external sensor kit is fitted to the appliance, the system can work in Outside tem­perature compensation mode. In O.T.C. mode the temperature of the heating system is controlled
according to the external climate conditions, this will guarantee a high degree of comfort and energy
saving all year round.

By the CH push buttons (Part. 3 and 4 – fig. 1) is possible to set the maximum flow temperature
for the installation.

O.T.C. setting

To enter the OTC mode, press

reset

(Part. 6 – fig. 1) for 5 seconds.

The display shows CU flashing (fig. 11); to set Curve, use the DHW push buttons (Part. 1 and 2 – fig.

1). It can be varied from 1 to 10, in accordance with the chart (fig. 13). O means no O.T.C. mode.
It is recommended a start point of 20 - 30°C and a flow temperature of 85°C is required for the UK

(Curve 9 or 10).

By pressing the CH push buttons (Part. 3 e 4 – fig. 1), the display shows OF flashing (fig. 12); to
set Offset, use the DHW push buttons (Part. 1 and 2 – fig. 1). It can be varied from 20 to 40, in
accordance with the chart (fig. 14).

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fig. 12

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

To exit the OTC mode, press

reset

(Part. 6 – fig. 1) for 5 seconds.

fig. 13

fig. 14

Maximum boiler flow temperature

Outside temperature

Outside temperature

Outside temperature

Maximum boiler flow temperature

Maximum boiler flow temperature

1.5 Maintenance

It is strongly recommended to carry out annual maintenance of the boiler and heating system. Please
refer to the “maintenance” section in this manual.

The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp
cloth, do not use abrasives or solvents.

1.6 Faults

In the unlikely event of an operating problem, or component failure, the display flashes and a fault
identification code appears.

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

The boiler is equipped with an advanced self-diagnosis system that signals any faults on the display.
Some faults (“A“ indication) cause a boiler shutdown. In this case, operation must be reset manually by

pressing the

reset

(Part. 6 – fig. 1) for 1 second.

Other faults (“F“ indication) cause temporary shutdowns that are automatically reset as soon as the
value causing the fault comes back within the boiler’s normal working range.

Listed below are some anomalies that can be caused by simple, user-solvable problems.
If the problem remains after two attempts at resetting, contact the Ferroli Service Centre.
For other faults, refer to section 3.4 “Troubleshooting”.

Fault Cure

No burner ignition

Make sure that the gas cocks ahead of the boiler
and on the meter are open.

Press the RESET button (for 1 second).
In case of repeated shutdowns, contact the Ferroli

Service centre.

Low system pressure

Fill the ‘system to 1-1.5 bar.

Before calling a Ferroli service engineer, check that the problem is not due to there being no
gas or electricity, or low system pressure.

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FERSYSTEM TECH 38 C

Cod. 3540U330 - 09/2009 (Rev. 00)

2. INSTALLATION

2.1 General Instructions

This device must only be used for the purpose for which it is specially designed. This unit is
designed to heat water to a temperature below boiling point and must be connected to a hea­ting system and/or a water supply system for domestic use, compatible with its performance,
characteristics and its heating capacity. Any other use is considered improper.

BOILER INSTALLATION MUST ONLY BE PERFORMED BY QUALIFIED PERSONNEL, IN ACCORDANCE
WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT
LAW, THE RECOMENDATION OF BS STANDARDS, ANY LOCAL REGULATIONS AND THE RULES OF
COMPETENT WORKMANSHIP.

Incorrect installation can cause damage or physical injury for which the manufacturer declines any
responsibility.

This appliance must be installed strictly in accordance with these instructions and
regulations:

The Gas Safety Regulations (Installations & Use).
The Local Building Regulations.
The Building Regulations (Part L).
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 5440 Part 1 Flues
B.S. 5440 Part 2 Air supply
B.S. 5449 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 GAS INSTALLATIONS
B.S. 7671 IEE WIRING REGULATIONS
B.S. 4814 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 INSTALLATION OF LPG
B.S. 7593 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

Model Water Bye Laws
B.S. 5955-8 PLASTIC PIPEWORK INSTALLATION

For Northern Ireland the rules in force apply