Ferroli Domina Oasi F 24 E, Ferella Boil F 24 MEL, Kea Air Compact E, Domina Oasi F 30 E, Ferella Boil F 30 MEL Technical Manual

Page 1
DOMINA OASI F 24-30 E
FERELLA BOIL F 24-30 MEL
KEA AIR COMPACT E
Wall-Mounting Gas Boiler
Airtight Chamber, for Heating and Hot
TECHNICAL
MANUAL
EDITION
09•2002
Page 2
2
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
1. Technical characteristics and data ........................................................... 3
1.1 Introduction .............................................................................................................. 3
1.2 Dimensions and connections .................................................................................. 4
1.3 General view and main components .......................................................................8
1.4 Technical data table ............................................................................................... 10
2. Product framework and internal components ........................................ 11
2.1 Hydraulic circuit - heating ...................................................................................... 11
2.2 Hydraulic circuit - tap water ................................................................................... 15
2.3 Gas circuit ............................................................................................................. 17
2.4 Burner unit ............................................................................................................. 21
2.5 Fume circuit .......................................................................................................... 23
2.6 Electrical circuit ..................................................................................................... 27
3. Operation................................................................................................... 30
3.1 Operating principle ................................................................................................ 30
3.2 Operating diagram................................................................................................. 31
3.3 Control panel ......................................................................................................... 32
3.4 Adjustments........................................................................................................... 32
3.5 Setting operating parameters ................................................................................ 33
4. Troubleshooting ....................................................................................... 34
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3
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
1. GENERAL TECHNICAL CHARACTERISTICS AND DATA
1.1 Introduction
Our appliance is a high-efficiency heat generator for central heating and hot-water production running on natural gas or LPG (configurable at the time of installation).
The boiler shell consists of a copper laminar exchanger whose particular shape guarantees high exchange efficiency under all operating conditions and an open-flue burner equipped with electronic ignition and ionization flame control.
The boiler is totally sealed off from the installation room: the air needed for combustion is drawn from outside and the flue gases are expelled by a fan. The boiler outfit moreover includes a stainless steel boiler of 55 or 65 litres for tap water, a variable speed circulator and a fixed speed circulator, an expansion tank for heating and for the boiler, safety valve, filler cock, air pressure switch, water pressure switch, temperature sensors, limiting and safety thermostats.
Thanks to the control and adjustment system, unit operation is for the most part automatic. The power for heating is automatically governed by the control system according to the indoor characteristics, the characteristics of the building and of its location. The tap water capacity is ensured by a boiler that is kept at the required temperature.
There are 5 LEDs on the control panel providing information on the unit's operating status.
General Warnings
Installation and maintenance must be carried out by professionally qualified personnel, according to current regulations and the manufacturer's instructions.
Incorrect installation or poor maintenance can cause damage or physical injury. The manufacturer declines any responsibility for damage caused by errors in installation and use or by failure to follow the manufacturer's instructions given in the instructions manual.
Before carrying out any cleaning or maintenance operation, disconnect the unit from the electrical power supply using the switch and/or the special cut-off devices.
Certification The CE marking demonstrates that Ferroli gas units conform to the requirements contained in the applicable European directives. In particular, this unit complies with the following EU directives:
Gas Appliance Directive 90/396 assimilated with Italian Presidential Decree DPR 15.11.96 no. 661
Efficiency Directive 92/42 assimilated with Italian Presidential Decree DPR 15.11.96 no. 660
Low Voltage Directive 73/23 (amended by 93/68)
Electromagnetic Compatibility Directive 89/336 (amended by 93/68) assimilated with Italian
Presidential Decree DPR 15.11.96 no. 615
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4
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
1.2 Dimensions and connections
Domina Oasi F 24 E version
600
370
800
810
570
85 285
75 85
90
85
80
80
85
120 55 170 100 65 55
35
123 456
Key
1 Gas inlet 2 3/4" System delivery 3 3/4" System return 4 1/2 Hot tap water 5 1/2 Cold tap water 6 1/2 Outlet/Recirculation
Top view
Bottom view
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5
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Ferella Boil F 24 MEL version
& Kea Air Compact E version
600
370
800
810
570
85 285
75 85
90
85
80
80
85
120 55 170 100 65 55
35
123 456
Key
1 Gas inlet 2 3/4" System delivery 3 3/4" System return 4 1/2 Hot tap water 5 1/2 Cold tap water 6 1/2 Outlet/Recirculation
Top view
Bottom view
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6
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Domina Oasi F 30 E version
600
450
800
810
570
85 365
75 85
90
85
80
80
85
120 55 170 100 65 55
35
123 456
Key
1 Gas inlet 2 3/4" System delivery 3 3/4" System return 4 1/2 Hot tap water 5 1/2 Cold tap water 6 1/2 Outlet/Recirculation
Top view
Bottom view
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7
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Ferella Boil F 30 MEL version
600
450
800
810
570
85 365
75 85
90
85
80
80
85
120 55 170 100 65 55
35
123 456
Key
1 Gas inlet 2 3/4" System delivery 3 3/4" System return 4 1/2 Hot tap water 5 1/2 Cold tap water 6 1/2 Outlet/Recirculation
Top view
Bottom view
Page 8
8
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Key
5 Airtight chamber 7 Gas inlet 8 Tap water outlet
9 Tap water inlet 10 System delivery 11 System return
14a 3-bar safety valve (heating) 14b 7-bar safety valve (boiler)
16 Fan 19 Combustion chamber 20 Burner assembly 21 Main nozzle 22 Burner 26 Combustion chamber insulation 27 Copper exchanger for heating and tap
water
28 Fume manifold 29 Fume outlet manifold 32 Heating circulator 34 Delivery temperature sensor 36 Automatic air vent 40 Tap water expansion tank 43 Air pressure switch 44 Gas valve 49 Safety thermostat 50 Heating thermostat 56 Expansion tank for heating system 63 Heating temperature setting 74 Heating system cock 81 Ignition electrode 82 Detection electrode 84 1st gas valve operator 85 2nd gas valve operator 90 Fume detection point 91 Air detection point 97 Magnesium anode 98 Off-On-Reset switch
114 Water pressure switch 130 Boiler circulator 132 Fume deflector 145 Water gauge 151a Boiler drain cock 151b System drain cock 155 Boiler temperature sensor 157 Tap water temperature setting 179 Check valve 180 Boiler 187 Fume diaphragm 192 Recirculation (when connecting, insert a
T-junction to connect the drain cock)
1.3 General view and main components
F 24 E/MEL version
0
5
1
2
3
4
6
145
179
16 43 563629
187
28
91
90
27 50 49
19 81 82
26
22
20
5
21
114
44
85
84
130
7 14a 10 11 32 74 8180
9
34
40
155
132
192 14b
98 63 157
97
151a
151b
DOMINA OASI – FERELLA BOIL KEA AIR COMPACT E version
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9
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
F 30 E/MEL version
145
0
5
1
2
3
4
6
179
16 43563629
187
28
91
90
27 50 49
19 81 82
26
22
20
5
21
114
44
85
84
130
7 14a 10 11 32 180
34
40
155
132
98 63 157
9
74 8
14b97
192 151a
151b
DOMINA OASI - FERELLA BOIL Version
Key
5 Airtight chamber 7 Gas inlet 8 Tap water outlet
9 Tap water inlet 10 System delivery 11 System return
14a 3-bar safety valve (heating) 14b 7-bar safety valve (boiler)
16 Fan 19 Combustion chamber 20 Burner assembly 21 Main nozzle 22 Burner 26 Combustion chamber insulation 27 Copper exchanger for heating and tap
water
28 Fume manifold 29 Fume outlet manifold 32 Heating circulator 34 Delivery temperature sensor 36 Automatic air vent 40 Tap water expansion tank 43 Air pressure switch 44 Gas valve 49 Safety thermostat 50 Heating thermostat 56 Expansion tank for heating system 63 Heating temperature setting 74 Heating system cock 81 Ignition electrode 82 Detection electrode 84 1st gas valve operator 85 2nd gas valve operator 90 Fume detection point 91 Air detection point 97 Magnesium anode 98 Off-On-Reset switch
114 Water pressure switch 130 Boiler circulator 132 Fume deflector 145 Water gauge 151a Boiler drain cock 151b System drain cock 155 Boiler temperature sensor 157 Tap water temperature setting 179 Check valve 180 Boiler 187 Fume diaphragm 192 Recirculation (when connecting, insert a
T-junction to connect the drain cock)
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10
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
1.4 Technical data table
Gas supply Pmax Pmin
Heating Power (Net Heat Value - Hi)
Useful Heating Power 80˚C - 60˚C
Hot Water Heating Power
Powers Pmax Pmin
kcal/h 20,200 8,300
kW 23.5 9.7
kcal/h 20,200 8,300
kW 23.5 9.7
kcal/h 22,200 9,900
kW 25.8 11.5
Dimensions, weights connections
Depth mm 370
Width mm 600
Height mm 800
Hot water
Minimum working pressure in hot water production bar 0.25
Maximum working pressure in hot water production bar 9
Specific flow rate with t 30˚C l/10 min 150
Specific flow rate with t 30˚C l/min 15
Boiler water content litres 1.5
Expansion tank pre-filling pressure bar 1
Expansion tank capacity litres 6
Minimum working pressure in heating bar 0.8
Maximum working pressure in heating bar 3
Maximum working temperature in heating ˚C 90
Electrical protection rating IP 44
Power voltage/frequency V/Hz 230/50
Max electrical power absorbed W 125
Hot water circuit connections inches 1/2”
Heating system connections inches 3/4”
Gas system connection inches 1/2”
Weight with packing kg 52
Heating
Natural Gas delivery (G20) nm
3
/h 2.73 1.22
Natural Gas main nozzles (G20) mm 12 x 1.30
Pressure at Natural Gas burner (G20) mbar 11.8 2.5
Natural Gas supply pressure (G20) mbar 20.0
LPG burner (G31) Kg/h 2.00 0.89
LPG main nozzles (G31) mm 12 x 0.77
Pressure at LPG burner (G31) mbar 35.0 7.8
LPG supply pressure (G31) mbar 37.0
Safety valve bar 3
Hot water content litres 55
Pmax Pmin
Pmax Pmin
25,800 10,900
30.0 12.7
25,800 10,900
30.0 12.7
28,500 12,500
33.1 14.5
450
600
800
0.25
9
190
19
1.8
1
10
0.8
3
90
44
230/50
125
1/2”
3/4”
1/2”
60
3.50 1.53
16 x 1.25
13.0 2.5
20.0
2.57 1.13
16 x 0.75
35.5 7.0
37.0
3
65
DOMINA OASI - FERELLA BOIL - KEA COMPACT E- MILOS 24 Kw 30 Kw
Electrical power supply
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
2. PRODUCT FRAMEWORK AND INTERNAL COMPONENTS
2.1 Hydraulic circuit – heating
Hydraulic diagram for heating
When there is a call for heat, the room thermostat or control system make the burners ignite and the circulation pump come into operation. The heat contained in the products of combustion is transferred to the water by the system via the exchanger. For more details on the operating logic, refer to chap.3.
20
82
5
29-187
16
-
+
44
7
81
43
32
14
114
34
11 10
49
50
222
36
97
155
130
179
179
74
8
9 192
151
56
Key
5 Airtight chamber 7 Gas inlet 8 Tap water outlet
9 Tap water inlet 10 System delivery 11 System return 14 Safety valve 16 Fan 20 Burner assembly 29 Fume outlet manifold 32 Heating circulator 34 Heating temperature sensor 36 Automatic air vent 43 Air pressure switch 44 Gas valve
49 Safety thermostat 50 Heating thermostat 56 Expansion tank 74 Heating system cock 81 Ignition electrode 82 Detection electrode
97 Magnesium anode 114 Water pressure switch 130 Boiler circulator 151 Boiler drain cock 155 Boiler temperature sensor 179 Check valve 187 Fume diaphragm 192 Recirculation 222 Copper exchanger
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12
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Circulator (230v/50Hz)
Located on the heating circuit return, it is connected directly to the exchanger via special forks and connected to the system via a threaded brass fitting. It has three delivery/head levels (see diagram). Changing the delivery/head changes the speed of the water flowing through the boiler exchanger and as a result the temperature difference (T) between heating delivery and return. Clearly, increasing the delivery of the circulator decreases T and vice versa. If it is not used for a long time, the impeller might jam due to debris in the water. With the front screw it is possible to access the impeller, which can be freed with the aid of a screwdriver. The connection to the expansion tank and the air separator is installed on the pump casing.
Checks
If the pump doesn't work:
Check that the impeller is free to turn by turning the screw on the front with a screwdriver.
Check that both the card and the pump connection are powered.
If there is no power supply, check the card.
If there is power, change the pump.
Key
1 - 2 - 3 = Pump selector position
A = Losses of head 24kW version B = Losses of head 30kW version
m
C.A.
m3/h
0,5
1
1,5
2
2,5
3
3,5
4
0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4 2,6
4,5
5
5,5
6
2,8 3 3,2 3,4 3,6 3,8 40,40,2
0
0
1
2
3
B
A
Air separator and automatic air vent
This is used to expel the air in the tap-water and heating circuit automatically. It can be removed by simply unscrewing it from its seat on the air separator. The function of the latter is to slow down the speed of the water, preventing the air it contains from getting dragged along.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Expansion tank
It is connected via a pipe with a threaded connection close to the air separator. For the 24kW version, it is above the boiler and for the 30kW version, it is in front of the boiler, inside the frame. The expansion tank contains a diaphragm in contact, on one side, with the system water and, on the other side, with the air under pressure (pre-loaded to 1 bar) inside the tank. By the expansion of the diaphragm and ensuing compression of the air, the tank compensates for the thermal expansion of the water in the heating system.
30kW 10-litre version
24kW 6-litre version
Exchanger
The exchanger is a copper laminar assembly. It comprises a thickly finned portion and four circular pipes connected together in series. The water exchanges directly with the combustion gases and makes the system safe via a safety thermostat set to 100°C and the limit thermostat (88°C) located in the exchanger. Due to its shape and design, the heat gets evenly distributed over all the finning, with consequent benefits in terms of exchange efficiency and the life of the exchanger. A special surface treatment protects the exchanger against oxidation and corrosion.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Drain cock
This is located upstream from the tap-water pump and has the function of draining the system.
Safety valve
It opens if the pressure exceeds 3 bars, making boiler operation safer and protecting it against overpressure. You are strongly recommended not to use this valve to drain the system; once open, dirt could remain inside it, preventing it from closing completely.
Check valve
It is necessary to ensure the water flows in one direction only and it is located above the two pumps.
Filler cock
This is located between the heating return and the tap water outlet. It is not fitted on the boiler for some markets such as the British and Belgian ones. For French boilers there is a disconnector to be installed externally.
Water pressure switch
It ensures a minimum pressure for the system. It is normally open (NO) and closes the contact when the pressure exceeds 0.5 bar. It works on low voltage.
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15
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
2.2 Hydraulic circuit – tap water
Hydraulic diagram for tap water
20
82
5
29-187
16
-
+
44
7
81
43
32
14
114
34
11 10
49
50
222
36
97
155
130
179
179
74
8
9 192
151
56
The tap water is supplied via an integrated boiler. It is heated indirectly by a coil in the boiler. The primary water circulates in the coil thanks to a pump and is kept at a temperature of 85°C by the heating sensor. When the temperature detected by the boiler sensor is 1°C lower than the set temperature, the heating pump stops and the tap-water pump starts up immediately. In this way, heating is turned off and the boiler exchanges with the closed circuit water that in its turn yields the heat to the tap water contained in the boiler.
Key
5 Airtight chamber 7 Gas inlet 8 Tap water outlet
9 Tap water inlet 10 System delivery 11 System return 14 Safety valve 16 Fan 20 Burner assembly 29 Fume outlet manifold 32 Heating circulator 34 Heating temperature sensor 36 Automatic air vent 43 Air pressure switch 44 Gas valve
49 Safety thermostat 50 Heating thermostat 56 Expansion tank 74 Heating system cock 81 Ignition electrode 82 Detection electrode
97 Magnesium anode 114 Water pressure switch 130 Boiler circulator 151 Boiler drain cock 155 Boiler temperature sensor 179 Check valve 187 Fume diaphragm 192 Recirculation 222 Copper exchanger
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Boiler
The boiler is made of stainless steel and may be of 55 litres (24 kW) or 65 litres (30 kW). It contains a coil (Aisi 316) whose purpose is to transfer the heat from the primary circuit to the tap-water circuit contained in the boiler. The cold tap-water inlet (with check valve) is located at bottom right of the boiler. Whereas hot tap water comes out on the left. Since the water is stratified inside the boiler according to its temperature, a priming pipe (PVC) is used to draw off the hotter water at the top of the boiler. At the bottom, again, there is a third connection whose job is to drain the boiler via a cock. The boiler's safety valve is located between this cock and the boiler (7 bar). This connection can be utilized if the tap-water system is a ring and therefore needs recirculation. In this case, it is necessary to install the drain cock with a T-junction. At the bottom of the boiler, near the coil inlet and outlet, there is an NTC sensor in contact (see the paragraph on sensors). The entire boiler is insulated with polystyrene. A 2-litre diaphragm expansion tank set to 2.5 bar is installed on the left-hand side. The boiler is flanged at the bottom to permit inspection. There is a magnesium anode on the flange.
1
2
4
5
6
3
Key
1 Boiler 2 Coil 3 Priming pipe 4 NTC sensor 5 Expansion tank connection 6 Anode
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17
DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
20
82
5
29-187
16
-
+
44
7
81
43
32
14
114
34
11 10
49
50
222
36
97
155
130
179
179
74
8
9 192
151
56
2.3 Gas circuit
Gas circuit diagram
Key
5 Airtight chamber 7 Gas inlet 8 Tap water outlet
9 Tap water inlet 10 System delivery 11 System return 14 Safety valve 16 Fan 20 Burner assembly 29 Fume outlet manifold 32 Heating circulator 34 Heating temperature sensor 36 Automatic air vent 43 Air pressure switch 44 Gas valve
49 Safety thermostat 50 Heating thermostat 56 Expansion tank 74 Heating system cock 81 Ignition electrode 82 Detection electrode
97 Magnesium anode 114 Water pressure switch 130 Boiler circulator 151 Boiler drain cock 155 Boiler temperature sensor 179 Check valve 187 Fume diaphragm 192 Recirculation 222 Copper exchanger
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
IN OUT
COMMON
25–50V DC
80–110V DC
B
Gas valve
It supplies gas to the nozzles between a minimum and maximum pressure. For the valve to work correctly, it is necessary for the pressure upstream from it to be stable and suited to the type of gas being used, while the valve will supply a regular pressure to the nozzles. The gas valve contains two operators. The function of the first one is to open or close, while the task of the second one is to modulate the capacity according to the system's requirements. The signal comes from the card (X6-1/2/3/4) and is in the form of continuous voltage. The first operator receives fixed voltage that may be between 80 and 110V DC, for the second operator the voltage will vary between 25 and 54V DC according to the need of the main card.
Checks
If the valve doesn't work:
Check there is gas, and that gas comes out of the valve by means of screw B.
If there is no gas, you must check there is voltage at the operators. This
makes it possible to understand whether the problem lies with the valve (there is voltage at the operators) or with the card (there is no voltage at the contacts X6-1/2/3/4).
Modulation
The control system governs its boiler capacity so as to keep the delivery temperature constant in accordance with the settings on the control panel. The nozzle gas pressure is modulated by the valve and specifically via the 2nd operator. The card provides a change in continuous voltage (between 25 and 54 V DC) according to the difference between the delivery temperature and the set point.
Checks
Modulation can be checked in three ways:
Visually, by checking the flame.
Using a pressure gauge to check the gas pressure downstream from the valve.
Checking the voltage of the second operator on the card (X6, 1/2). This is the most effective method in some
situations. With this test, it is possible to understand whether the problem lies with the valve or with the card.
Note that with very low pressure upstream from the valve, opening the valve may be slow and the boiler could shut down due to failed ignition.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Adjusting burner pressure
Since this unit has flame modulation, there are two fixed pressure settings: the minimum and maximum, which must be as stated in the technical data chart according to the type of gas.
Connect a suitable pressure gauge to pressure point "B" downstream from the gas valve.
Disconnect the pressure compensation tube "F".
Take off the protective cap "C".
Set the potentiometer P3 (on the control card) to minimum
(clockwise).
Run the boiler in heating mode.
Adjust the minimum pressure with the screw "D", clockwise to
decrease it and anticlockwise to increase it.
Set the potentiometer P3 to maximum (anticlockwise).
Turn on the "TEST" function by temporarily bridging X5.
Adjust the maximum pressure with the screw "E", clockwise to
increase it and anticlockwise to decrease it.
Reconnect the pressure compensation tube "F".
Put the protection screw "C" back in.
Disconnect the test jumper.
N.B. The test lasts 5 minutes.
C
IN OUT
F
E
B
A
D
COMMON
25–50V DC
80–110V DC
Key
A Pressure point upstream
B Pressure point downstream C Protection screw D Minimum pressure adjustment
screw
E Maximum pressure adjustment
screw
F Pressure compensation tube
After checking or
adjusting the pres­sure, it is mandatory to seal the adjustment screw with paint or a specific seal.
24 kW version
30 kW version
kW
mbar
18
19
20 21 22 23
5
10
15
20
25
30
35
91011
12 13
14
15
16 17
8
24 25 26 27 28 29 30 31 32 33 34
G31 LPG
G20 Nat. gas
Page 20
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Gas supply conversion
The unit can function with either Natural Gas or LPG and is factory-set for use with one of the two gases, as clearly shown on the packing and on the unit's dataplate. Whenever a different gas to that for which the unit is preset has to be used, a conversion kit will be required, proceeding as follows:
1 Replace the nozzles at the main burner, inserting
the nozzles specified in the technical data table, according to the type of gas used.
2 Adjust the burner minimum and maximum
pressures, setting the values given in the technical data chart for the type of gas used.
3 Move the jumper JP02 on the card, as shown in
the diagram:
4 Apply the sticker, contained in the conversion
kit, near the dataplate as proof of the conversion.
Natural gas operation
LPG operation
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
2.4 Burner unit
Operation
The burner unit comprises a manifold and 12/16 nozzles (depending on the capacity), the burner mount, electrodes and the burner assembly.
Manifold - nozzles
The valve sends gas at a suitable pressure to the manifold, which homogeneously distributes the gas to the single burner stages at the nozzles. It is secured directly to the burner mount. Its positioning must be exact since it affects the air/gas mixture. In addition, the threaded holes forming the seat of the nozzles must be aligned with the respective Venturi tube of the burner. If it were not so, the air/gas mixture would be wrong and there would be poor combustion with an unstable flame. The nozzles are made of brass and machined extremely precisely for their dimensions. There is a seal between the nozzles and the manifold.
Ignition electrode
The ignition electrode is made of a metal alloy (Kanthal) that withstands high temperatures and oxidation. Its base is composed of a ceramic composite of glazed alumina whose purpose is to protect and electrically insulate it. Once the ignition procedure begins, the card powers the electrode with a pulsating voltage of a few kV, a series of electrical discharges is set off between the electrode and the head of the burner (set at a distance of 3.5 mm). Clearly, these sparks are the trigger for the air-gas mixture. It is important for the distance between the electrode and the burner head to be 3 - 4 mm and the discharge to be made at the centre.
Checks
If there is no discharge:
Check whether the boiler shuts down, in which case check the connection of the electrode to the card or whether it discharges at other points; if necessary, check the safety thermostat and the card.
If the boiler does not shut down and the fan keeps on working, check the air pressure switch.
If there is a discharge, but no ignition and after 10 seconds the boiler shuts down, check the gas valve and, if necessary, the card.
If there is a discharge and then a flame, but the boiler still shuts down after 10 seconds, check the detection electrode and its connection.
3.5
±0.5
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Burner assembly
The burner assembly is composed of 12 or 16 burner stages. Each stage is composed of two pressed steel half bearings, with a suitably cut stainless steel head. Gas enters at the bottom of the stage. Thanks to the special Venturi-tube shape of the bottom portion of the stage, the gas "injected" by the nozzle carries with it the primary air needed for combustion. The air-gas mixture thus formed inside the stage is evenly distributed on the burner head. Combustion takes place homogeneously over the entire length of the single stages, with the contribution of the secondary air from the bottom of the burner mount and from the combustion chamber itself. The set of stages in operation forms a single belt of flame, light blue in colour, whose size varies according to the nozzle gas pressure, that is the boiler capacity modulation.
Detection electrode
Made of the same material as the ignition electrode, it is set 11 mm from the burner head. Combustion causes the flame atmosphere to ionize, making it conductive. Thanks to the mass of the burner, making a suitable potential with the electrode produces a flow of direct current on it. For our cards, it is necessary to have an ionizing current of at least 0.5 µA to detect a flame. A mean signal is normally obtained of approximately 2 µA.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
2.5 Fume circuit
Fume deflector and manifold
All forced-flow boilers have a fume deflector above the exchanger whose main task is to make the secondary air crossing the burners uniform, making the flame homogeneous and stable. The fumes then reach a fume manifold whose job is to make them move on to the fan.
Airtight chamber
Its task is to isolate the products of combustion from the area surrounding the boiler. The airtight chamber contains all the components involved in the fume routing. The wires and pipes coming out of its side or lower portion are insulated with silicone seals, while its upper portion is fitted for hooking up with the flues. The cover is sealed off with a porous plate and is fitted with two plugs for using a probe to analyse the fumes and combustion air.
Fan and pressure switch points
Powered at 230V/50Hz by the card (X6 - 7/8), the fan has the job of expelling the products of combustion from the fume chamber. A plate is normally placed above the exchanger to act as a deflector, make the incoming air from the bottom of the burner uniform, make the flame stable and obtain the required air/gas ratio. In order to make sure the fan works properly, there are two pressure points inside it. The first one detects a "static" pressure signal that is positive, the second one detects a "dynamic" pressure signal via an appropriate "Venturi tube", which is negative. With the difference in pressure detected by the two test points it is possible to check whether the fumes are adequately evacuated.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
C
NC
NO
Pressure gauge
pa
Key
NO = Normally open NC = Closed C=Common
Air pressure switch
This is used to check whether the fumes are adequately evacuated. The pressure switch compares the static and dynamic signals coming from the pressure test points on the fan according to the figure. The pressure switch is connected to the card and is normally open (see diagram). Before the card initiates the ignition procedure (opening the valve, etc.), you must make sure that the fan works properly and that the air pressure switch ensures this by closing its contacts. This happens if the difference in pressure is 165±15Pa. So the signal must be at least 180Pa. To open its contacts again, the difference in pressure must drop under 150±13Pa. To perform checks on contact opening and closing, it is always recommended to check directly on the card (X5 - 3/4).
Checks
It is necessary to check:
Whether the electrical connections are correct.
Whether the pressure test point pipes are clean and contain no condensation water.
That the signal is open when the fan is not working.
That the pressure is at least 180Pa and that above this pressure the pressure switch closes its contacts.
If the signal is low, it is necessary to check that the fume diaphragm is correct, the fan has 230V, the
pressure test points are properly inserted and the Venturi tube has no burrs of any kind. Lastly, check that the ends of the pipes are not obstructed.
N.B. The pressure difference must be measured with the airtight chamber closed. The pressure gauge
connections can come out through the hole, which is closed by a silicone plug, on the front of the cover.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Fume ducts
The unit is type C with an airtight chamber and forced draught, the air inlet and fume outlet must be connected to one of the following extraction/suction systems. With the aid of the tables and methods of calculation indicated, before commencing installation, it is first necessary to check that the fume ducts do not exceed the maximum permissible lengths. The current standards and local regulations must be observed.
This C-type unit must be installed using the fume exhaust and suction ducts supplied by FERROLI S.p.A. in accordance with UNI-CIG 7129/92. Failure to use them automatically forfeits all warranty and liability of FERROLI S.p.A.
Diaphragms
Boiler operation requires fitting the diaphragms supplied with the unit as instructed in the following tables. As the resistance of the fume ducts changes, the diaphragms make it possible to keep the combustion parameters (CO2, etc.) within the optimum operating range. Note that with low-resistance fume ducts, a high­resistance diaphragm (small hole diameter) is used and vice versa.
Choosing the diaphragm using separate pipes
Choosing the diaphragm using coaxial pipes
Type
Coaxial
60/100
Length up to:
1 bend + 1 metre
1 bend + 3 metres
1 bend + 3 metres
1 bend + 4 metres
1 bend + 5 metres
Diaphragm
to use
50 mm
No diaph.
45 mm
50 mm
No diaph.
Coaxial
80/125
HF 24
HF 30
52 mm
No diaph.
50 mm
No diaph.
No diaph.
Pipe length
calculated in
linear metres
Diaphragm
to use
45 mm
47 mm
50 mm
No diaph.
Min
0 m
7 m
17 m
32 m
Max
7 m
17 m
32 m
42 m
F 24
F 30
47 mm
50 mm
52 mm
No diaph.
Diaphragm
to use
Min
0 m
15 m
30 m
40 m
Max
15 m
30 m
40 m
45 m
Pipe length
calculated in
linear metres
Boilers are fitted as standard with the smallest diaphragm in the series. Before inserting the fume outlet pipe, it is therefore necessary to check there is the right diaphragm (when it is to be used) and that it is correctly positioned.
Changing the diaphragm
If inserting or changing a diaphragm, it is necessary to remove the fan assembly, take out the fume coupling 1 and insert the required diaphragm 2.
Ø
N.B. The diameter of the hole Ø is stamped on the diaphragm
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Calculation example
Here we give an example of the calculation for a separate fume outlet. We recommend inserting a condensate trap on long vertical sections to prevent condensation getting onto the burner and damaging it. If monitoring the condensate trap is not guaranteed, it must be fitted with a suitable drain pipe and air trap, which in its turn must be appropriately connected to a suitable drain.
Ref.
1 2 3 4 5 6
No.Pieces
1 1 1 1
36
1
Air bend 80 Horizontal air pipe 80 Windproof end piece Condensate collection cup coupling Vertical fume pipe 80 Outlet flue + coupling
Description
Equivalent
loss
1.5 m
1.0 m
2.0 m
3.0 m
36.0 m
4.0 m
47.5 m
Total
1 2 3
4
5
6
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
2.6 Electrical circuit
Electrical terminal board
Follow the instructions given in the figure to access the electrical connection terminal board.
The layout of the terminals for the various connections is given in the wiring diagram.
Wiring diagram
X6
X1
X2 X3
X4
12121312345678910 12345678910111213
21
X5
TEST
Transformer
X12
12
123456789
X10
X8
X7
81 82
PMF03F
JP02 JP01
Nat/LPG
X11
230V 24V
230V
24V
X9
13 2
MV1
MV2
MV3
MV4
98
72
5011415534
32
230V 50Hz
130
44491643
Key
16 Fan 32 Heating circulator 34 Heating temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety thermostat 50 Heating thermostat
72 Room thermostat (not supplied) 81 Ignition electrode
82 Detection electrode 114 Water pressure switch 130 Tap water circulator 155 Boiler sensor
N.B. Respect the phase and neutral connections
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Safety thermostat
X6 - 5/6 has a thermostat with gold contacts that opens if the temperature exceeds 100°C. Connected directly to the ignition and main card, when it opens it cuts off the power supply to the valve directly, shutting down the boiler. It is located on the exchanger delivery pipe in a flat seat.
Limit thermostat
Connected on the main card X4 - 6/7, it is a thermostat with silver contacts that opens if the temperature exceeds 88°C. It requires no manual resetting and closes the contacts again if the temperature falls under 70°C. It is located on a bend in the exchanger pipe in a flat seat.
Ignition + detection electrode, see chap. 2.4 Burner Unit
Main electronic card
The electronic card is a Honeywell PMF03: part of the card works on low voltage (24V) and the remainder on 230V (see diagram) and it is fitted with a fuse (2A). Part of the card is used to control ignition, so it is hooked up to the detection and ignition electrodes and the safety thermostat. There are loads and controls common to the card that have already been described, such as:
Pumps.
Fan.
Gas valve.
Air pressure switch.
There remain some components described hereunder.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Heating and tap water temperature probe
These are NTC sensors that increase their resistance as the temperature decreases and are connected directly to the main card X4 - 24V (heating 12-13, tap water 10-11). The heating sensor performs the antifreeze function too.
NTC sensor
0
3
6
9
12
15
18
21
24
27
30
33
0 20 40 60 80 100 120
Temperature (˚C)
Resistance (K Ohm)
15
50
70
30
90
5
25
40
60
80
100
Temperature (˚C)
Resistance (K Ohm)
3,6
1,7
8
0,92
10
5,3
2,5
1,25
0,68
15,6
25,3
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
3. OPERATION
3.1 Operating principle
When there is a call for heating, the circulator and fan start working; then the air pressure switch enables the control and safety unit to ignite the burner. Via the electronic flame modulation system, the boiler capacity is gradually metered till it reaches the set delivery temperature. If the power needed for the heating plant is lower than the minimum boiler power, when the delivery temperature exceeds the setting of 6°C, the burner switches off and the electronic system enables re-ignition only after another 2 minutes. On reaching the set ambient temperature (room thermostat), the burner switches off and the circulator keeps on working for another 6 minutes to enable better heat distribution throughout the system. If hot tap water is called for during the heating phase, the electrical heating circuit automatically turns off and the hot tap water production circuit switches on. Throughout this phase the heating system circulator stops and the primary circuit circulator starts up to heat the boiler. The boiler detects the tap-water temperature via the NTC sensor. The call for tap water is active when the boiler tap-water temperature measured by the sensor is at least 1°C lower than the temperature set on the potentiometer “C” of the control panel. The call ends when the boiler temperature exceeds the temperature set on the panel by 1 or 2°C.
Test function
Bridging the terminals of connector X5 turns on Test operation. In this mode the boiler works as in heating mode, but tap water operation, idle time and modulation are turned off. The test lasts 5 minutes.
Heating post-circulation
After the call for heating, the circulator performs "post-circulation" for approximately 6 minutes to prevent thermal inertia and balance the system boiler temperature.
Boiler post-circulation
After the call for tap water, the boiler circulator stays in operation for another 2 minutes to prevent thermal inertia and deliver the heat of the exchanger to the tap water. At the end of the two minutes, the boiler can start heating immediately if this is called for.
Circulator anti-locking
If not used for 24 h, the circulator is turned on for a few seconds to prevent it locking due to an extended stoppage during summertime operation.
Gradual starting on heating (gradual increase in heating temperature)
The time to reach the maximum heating temperature is 5 minutes.
Limit thermostat
The 88°C limit thermostat coming on causes the burner to switch off momentarily via the ignition unit and the heating circulator to start up.
Antifreeze protection
The antifreeze function is turned on by the heating temperature sensor when the temperature falls under 5°C. In this phase, both the burner and the circulator start working. When the temperature reaches 15°C, the burner switches off while the circulator keeps on working for another 6 minutes.
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
3.2 Operating diagram
Hot water taps closed
Boiler satisfied
System pressure > 0.8 bar:
LED 5 not blinking
Room thermostat, heating potentiometer on call: LED 4 on
Heating circulator comes on
Heating and boiler sensor enabling signal
88˚C limit thermostat enabling signal.
Air thermostat "NO" contact open, fan starts.
Intake and outlet ducts open, resistance under table limit.
Pressure difference at air pressure switch >180 Pascal (18.00 mm approx.)
Air pressure switch "NO" contact closed.
100˚C safety thermostat enabling signal
Electric discharge to ignition electrode (81).
Continuous voltage of 230 V to the gas valve operators.
Main burner ignition
Flame detection at ionization electrode within 10 sec. (safety time)
End of electric discharge:
Ionization working range
- 1 micro Ampere minimum for safety
- 2/3 micro Ampere minimum for working
Ignition gas adjustment (natural gas or LPG) with potentiometer P4
Hot water taps closed.
Heating adjustment potentiometer "OFF".
Switch "ON".
Electrical power supply on card 230V.
Fuse OK:
LED 5 on
System pressure 0.8 bar: LED 5 not blinking
Call for tap water LED 3 (green) on
Heating temperature adjustment trips; burner and fan switch off
LED 4 off LED 1 off
The circulator is working
The 2 min delay is activated before burner re-ignition:
LED 4 blinking
At the end of the 2 min delay, the burner re-ignites when required
LED 4 on LED 1 on
Room thermostat trips on reaching the set temperature:
LED 4 off LED 1 off
Heating circulator operates for 6 min. (post-circulation)
Boiler satisfied, burner switches off: LED 1 off LED 3 off LED 4 blinking
Boiler circulator operates for 2 minutes
(post-circulation)
Summer
Winter
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
3.3 Control panel
ITEM DESCRIPTION
A OFF/ON/RESET switch
B Heating temperature setting
C Hot water temperature setting
D Water gauge
0
5
1
2
3
4
6
DACB
Standby for heating (blinking light)
Heating required (steady light
Burner on
Shutdown
Hot water required
Low system pressure (blinking light)
Electrical power supply (steady light)
12345
1
2
3
4
5
LED
bar
40
70
50
80
60
C C
bar
3.4 Adjustments
Room temperature adjustment (with room thermostat on)
Using the room thermostat or remote control, set the temperature desired in the rooms. Controlled by the room thermostat, the boiler lights and heats the system water to the set system delivery setpoint temperature. The generator turns off when the desired temperature in the rooms is reached.
If the room thermostat is not installed the boiler will keep the system at the set system delivery setpoint temperature.
System temperature adjustment
With knob “B” on the control panel we can set the required system temperature. To prevent localized condensation on the fume circuit, we recommend a minimum temperature of 60°C.
Hot water temperature adjustment
With knob “C” on the control panel we can set the tap water temperature from 10°C to 65°C (of the boiler).
Summer/Winter selection
Setting the adjustment potentiometer “B” to minimum ( ), the boiler works on Summer”.
Adjusting the heating
∆∆
∆∆
t by changing the circulator delivery-head
The temperature difference t (difference between the system delivery and return heating water temperatures) must be under 20°C and is obtained by changing the circulator delivery-head with its variable speed device (or switch).
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
3.5 Operating parameter adjustment
Boiler parameter adjustment
P1 Temperature adjustment potentiometer.
Controls the heating delivery temperature from 30°C to 85°C. The minimum position selects Summer operation.
P2 Hot tap water adjustment potentiometer.
Controls the hot tap water temperature from 10°C to 65°C.
P3 Heating capacity adjustment potentiometer.
P4 Potentiometer to adjust the burner gas pressure in the ignition phase.
The maximum ignition time is 10 sec. The ignition curve should be regulated taking account of the type of burner and fuel used (natural gas or LPG).
P5 Minimum pressure adjustment potentiometer.
The potentiometer P5 is to be used if it is necessary to adjust the minimum current to the second coil of the gas valve. This adjustment makes it possible to increase the gas valve minimum opening pressure electrically. The potentiometer P5 is used when the mechanical minimum of the gas valve does not enable adequate adjustment.
Jumper operation
JP01
Inserted
Not inserted
Not contemplated
Two-pump system
Jumper JP01: For boiler and tap water
The boilers are made with JP01 not inserted
JP02
Inserted
Not inserted
Natural gas operation
LPG operation
Jumper JP0: Boiler operation with natural gas or LPG
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
4. Troubleshooting
Flow Diagram 1
Checking Electric Power Supply - System Pressure and Antifreeze Protection
Is LED5 on?
Turn the selector onto ON
Heating selector on
summer position " "
Set the temperature of the
hot water to minimum
Are there 230V between
the terminals X1-1 X1-2?
Check and if necessary
change the 2A fuse
YES
Is LED5 on now?
Repair the fault with
the external line
NO NO
Change the
main card
NO
YES
Is LED5 blinking?
YES
Is the pressure
of the water not
between
1 and 1.5 bar?
YES
Take the pressure
to 1 - 1.5 bar
Check the
electrical connection
of the water
pressure switch
NO
Does the fan turn
at top speed?
NO
Proceed with
diagram 2
NO
YES
Does the heating
circulator turn?
If the boiler temperature is
under 5˚C the antifreeze
protection is active
NO
Check the
circulator
connection
YES
Disconnect the heating
temperature sensor
Has the fan stopped?
Change the main card
NO
NO
YES
Check and if
necessary change
the water
pressure switch
First of all, check the following points
The gas cock is open
The electricity is on
The polarity is correct
The system pressure is between 1 and 1.5 bar
The pump turns correctly
YES
The relay RY 101
is closed
Check and if
necessary change
the circulator
Proceed with
diagram 2
YES
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Flow Diagram 2
Checking Hot Water Operation
Flow Diagram 3
Checking Heating Operation
Wait for 2 minutes
Set the hot water
temperature to minimun
Set the temperature for
heating to maximum
Make sure the room
thermostat is activated
Is LED4 blinking?
Does the circulator turn?
YES
YES
Proceed with
diagram 4
Is the relay
RY 101 closed?
Check and if
necessary change
the main card
NO
Has LED4 stopped blinking?
Check and if necessary
change the heating sensor
NO
NO
Is the relay
RY100 closed?
YES
YES
Proceed with
diagram 4
NO
Check the limit
thermostat
YES
Check and if
necessary change
the circulator
Check and if necessary change
the hot water sensor
NO
Is LED3 on?
Set the hot water
temperature to maximum
Check and if necessary change
the flow sensor
LED4 blinking
NO
Is the relay RY 100 closed?
NO
YES
YES
YES
YES
Check and if necessary
change the main card
Check and if necessary
change the limit thermostat
Proceed with
diagram 4
NO
Check the
electrical connection
Is the tap water
circulator turning?
YES
Is the relay
RY 102 closed?
NO
YES
NO
Check the
electrical
connections of
the circulators
Check and if
necessary
change the
main card
Check and if
necessary
change the
circulator
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Flow Diagram 4
Checking Fan/Fume Circuit
Does the fan turn?
Is the relay RY02 closed?
Proceed with diagrams 2-3
NO
Are there 230V at the
fan terminals?
YES
Check the electrical connection
of the air pressure switch
NO
Check and if necessary
change the air pressure switch
NO
Check and if necessary
change the fan
YES
Is the air pressure
switch activated?
YES
NO
Check and if
necessary change
the air pressure
switch
YES
Is the pressure
difference in the air
pressure switch greater
than 180 Pascal?
Proceed with
diagram 5
YES
NO
Check and
clean the fan
Check that the air inlet
and fume outlet are
correct and clean
Check that the Venturi tube and the air pressure switch
tubes are clean
Check that
the diaphragm is correct
NO
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DOMINA OASI F 24 - 30 E
FERELLA BOIL F 24 - 30 MEL
KEA AIR COMPACT E
Version - 09.2002
Flow Diagram 5
Checking Ignition
Flow Diagram 6
Check the Modulation of the Hot Water and Heating
Is LED1 on?
Is there an ignition spark?
Does the burner ignite?
YES
Has LED1 come on
after 10 seconds?
NO
YES
Proceed with
diagram 6
Reset
YES
Does the burner ignite now?
Is there the flame before
the shutdown?
NO
YES
NO
Check and if necessary change
the safety thermostat
Check that the electrodes
are integral and in the
right position
Check and if necessary change
the equipment
Using P4, adjust the
burner ignition pressure
Check and if necessary
clean the burner
Check and if necessary
clean the nozzles
Check and if necessary
clean the detection electrode
Check that the ignition electrode
is in the right position
Check the connections
Check and vent the
gas supply
Check and if necessary
change the gas valve
NO
YES
Check and if necessary
change the ignition card
NO
LED2 (shutdown) comes
on without the
boiler lighting
YES NO
Recheck the air pressure switch
Is there flame modulation
at the burner?
The boiler
works normally
YES
Check and if necessary
change the heating sensor
The boiler works in
heating mode
Is there flame modulation
at the burner?
The boiler
works normally
YES
Check and if necessary
change the heating sensor
The boiler works in hot
water mode
NO NO
Page 38
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Page 40
37047 SAN BONIFACIO - VR - ITALY
tel. 045/6139411 - tlx 480172
fax 045/6100233-6100933
cod. 354M009/0
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