Ferroli Lamborghini EXTREMA 30 C, Lamborghini EXTREMA 38 C Instructions For Use, Installation And Maintenence

6

cod. 3540S060 — 04/2010 (Rev. 00)

EXTREMA C

INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENENCE
FOR THE UNITED KINGDOM AND EIRE

EXTREMA C

B

• Carefully read the warnings in this instruction book­let since they provide important information on safe
installation, use and maintenance.

• This instruction booklet is an integral part of the
product and must be carefully kept by the user for fu­ture reference.

• If the unit is sold or transferred to another owner or if
it is to be moved, always make sure that the booklet
accompanies the boiler so that it can be consulted
by the new owner and/or installer.

• 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.

• Before carrying out any cleaning or maintenance oper­ation, DISCONNECT AND ISOLATE the boiler from the
electrical power supply.

• In case the unit breaks down and/or functions poorly,
deactivate it, do not make any attempt to repair it or
directly intervene. Contact professionally qualified
personnel. Any repair/replacement of products must
only be carried out by qualified professional person­nel using exclusively genuine parts. Failure to com­ply with the above could affect the safety of the unit.

• Periodical maintenance carried out by qualified per­sonnel is essential for guaranteeing good operation
of the unit.

• This unit must only be used for the purpose for which
it was designed. Any other use is considered im­proper and therefore hazardous.

• After removing the packing, check the integrity of the
contents. Packing materials must not be left within the
reach of children as they are potentially hazardous.

• In case of doubt do not use the unit, and contact the
supplier.

• The images shown in this manual are a simplified
representation of the product. In this representation
there may be slight, unimportant differences with the
supplied product.

• Whilst every effort is taken to ensure the accuracy of
the information contained within these instructions,
the details are offered in good faith and the Manufac­turer accepts no liability for matters arising as a re­sult of errors and/or omissions.

• Due to the Manufacturers continuous product re­search and development, the details contained in
this manual may not truly reflect the actual product.

B

A

This symbol indicates "Caution" and is placed next to all safety warnings. Strictly follow
these instructions in order to avoid danger and damage to persons, animals and things.

This symbols calls attention to a note or important notice.

Declaration of conformity

Manufacturer declares that this unit complies with the following EU directives:

• Gas Appliance Directive 90/396

• Efficiency Directive 92/42

• Low Voltage Directive 73/23 (amended by 93/68)

• Electromagnetic Compatibility Directive 89/336 (amended by 93/68)

2 EN

cod. 3540S060 - 03/2010 (Rev. 00)

EXTREMA C

1 Instructions .............................................................................................................................. 4

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

1.2 Control panel .......................................................................................................................................... 4

1.3 Lighting and turning off........................................................................................................................... 6

1.4 Adjustments............................................................................................................................................ 7

2 Installation .............................................................................................................................. 10

2.1 General Instructions .............................................................................................................................10

2.2 Place of installation ............................................................................................................................. 11

2.3 Plumbing connections ..........................................................................................................................11

2.4 Gas connection .................................................................................................................................... 13

2.5 Electrical connections........................................................................................................................... 13

2.6 Flue system .......................................................................................................................................... 14

2.7 Condensate drain connection...............................................................................................................19

3 Service and maintenance......................................................................................................21

3.1 Adjustments.......................................................................................................................................... 21

3.2 Start-up................................................................................................................................................. 22

3.3 Commisioning instructions ................................................................................................................... 22

3.4 Routine servicing, maintenance & repair.............................................................................................. 24

3.5 Troubleshooting.................................................................................................................................... 26

4 Technical data and characteristics ...................................................................................... 28

4.1 Dimensions and connections ............................................................................................................... 28

4.2 General view and main components .................................................................................................... 29

4.3 Water circuit .........................................................................................................................................30

4.4 Technical data table .............................................................................................................................31

4.5 Diagrams .............................................................................................................................................. 32

4.6 Wiring diagram ..................................................................................................................................... 33

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cod. 3540S060 - 03/2010 (Rev. 00)

3

EXTREMA

1. Instructions

1.1 Introduction

Dear Customer

Thank you for choosing an EXTREMA wall-mounted boiler featuring LAMBORGHINI advanced design, cutting-edge
technology, high reliability and quality construction. Please read this manual carefully since it provides important infor­mation on safe installation, use and maintenance.

EXTREMA is a high-efficiency, low emissions premix condensing generator for heating and hot water production, run­ning on natural gas or LPG and equipped with a microprocessor control system.

The boiler shell consists of a stainless steel exchanger and a premix burner equipped with electronic ignition and ion­isation flame control, a modulating speed fan, modulating gas valve and an energy saving modulating pump.

The sealed chamber unit is suitable for indoor installation or outdoors in a partially protected place (according to EN
297/A6) with temperatures to -5°C.

1.2 Control panel

12 11 13 27 18 17 15 16 19 26 21 25 23 24

68 9 1072 1 14 20 22 3 4

fig. 1 - Control panel

5

Key

1 = DHW temperature setting decrease button
2 = DHW temperature setting increase button
3 = Heating system temperature setting decrease

button

4 = Heating system temperature setting increase

button

5 = Display
6 = Summer / Winter mode selection button
7 = Economy / Comfort mode selection button
8 = Reset button
9 = Unit On / Off button
10 = "Sliding Temperature" menu button
11 = Set DHW temperature reached
12 = DHW symbol
13 = DHW mode
14 = DHW outlet temperature / setting (blinking dur-

ing “pump overrun” function)

15 = Eco (Economy) or Comfort mode

4 EN

cod. 3540S060 - 04/2010 (Rev. 00)

16 = External sensor temperature (with optional ex-

ternal sensor)

17 = Appears on connecting the external sensor or

the Remote Timer Control (optionals)

18 = Room temperature (with optional Remote Timer

Control)

19 = Burner lit and actual power (blinking during

"Flame protection" function)

20 = Winter mode
21 = Heating system pressure
22 = Fault
23 = Heating delivery temperature / setting (blinking

during “pump overrun” function)

24 = Heating symbol
25 = Heating mode
26 = Set heating delivery temperature reached
27 = Summer mode

EXTREMA

Indication during operation

Heating (fig. 2)

A heating demand (generated by the Room Thermostat or Remote Timer Control) is indicated by flashing of the hot air
symbol (details 24 and 25 of fig. 1).

The display (detail 23 - fig. 1) shows the actual heating delivery temperature and the message "d2" during heating
standby time.

The heating graduation marks (detail 26 - fig. 1) light up as the heating sensor temperature reaches the set value.

fig. 2

Domestic hot water (DHW) fig. 3

A DHW demand (generated by drawing domestic hot water) is indicated by flashing of the hot water symbol (details 12
and 13 of fig. 1).

The display (detail 14 - fig. 1) shows the actual hot water outlet temperature and the message "d1"during DHW standby
time.

The DHW graduation marks (detail 11 - fig. 1) light up as the DHW sensor temperature reaches the set value.

fig. 3

Comfort (fig. 4)

A Comfort demand (for maintaining the temperature inside the boiler) is indicated by flashing of the COMFORT symbol
(details 15 and 13 - fig. 1). When in Comfort mode, the DHW within the boiler is kept warm for rapid delivery to the taps.

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fig. 4

cod. 3540S060 - 04/2010 (Rev. 00)

5EN

1.3 Lighting and turning off

Boiler not electrically powered (fig. 5)

The frost protection system does not work

B

Boiler lighting (fig. 6)

Switch on the power to the unit.

• For the following 120 seconds the display will show

• During the first 5 seconds the display will also

• Open the gas cock ahead of the boiler.

• When the message FH disappears, the boiler is

when the power and/or gas to the unit are
turned off. To avoid damage caused by
freezing during long idle periods in winter, it
is advisable to drain all water from the boiler,
DHW circuit and system; or drain just the
DHW circuit and add a suitable antifreeze to
the heating system.

FH which identifies the heating system air venting
cycle.

show the PCB software version.

ready to operate automatically whenever domestic
hot water is drawn or in case of a room thermostat
demand.

EXTREMA

fig. 5 - Boiler not electrically powered

fig. 6 - Boiler lighting

Turning the boiler off (fig. 7)

Press the on/off button (detail 9 - fig. 1) for 1 second.

fig. 7 - Turning the boiler off

When the boiler is turned off, the PCB is still powered.

Domestic hot water and heating are disabled. The
frost protection system remains activated.

To relight the boiler, press the on/off button (detail 9 ­fig. 1) again for 1 second.

fig. 8 - Relighting the Boiler

The boiler will be immediately ready to operate whenever domestic hot water is drawn or in case of a room thermostat
demand.

6 EN

cod. 3540S060 - 04/2010 (Rev. 00)

EXTREMA

1.4 Adjustments

Summer/Winter Switchover (fig. 9)

Press the summer/winter button (detail 6 - fig. 1) for 1 second.

fig. 9

The display activates the Summer symbol (detail 27 - fig. 1): the boiler will only deliver domestic hot water. The frost
protection system remains activated.

To deactivate the Summer mode, press the summer/winter button (detail 6 - fig. 1) again for 1 second.

Heating temperature setting (fig. 10)

Use the heating buttons (details 3 and 4 - fig. 1) to adjust the temperature from a min. of 20°C to a max. of 90°C.

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fig. 10

DHW temperature adjustment (fig. 11)

Operate the DHW buttons (details 1 and 2 - fig. 1) to adjust the temperature from a min. of 40°C to a max. of 55°C.

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fig. 11

Room temperature adjustment (with optional room thermostat)

It is normal practise for a room thermostat to be connected to the boiler. The room thermostat will control the system to
the desired room temperature and if it is a programmable type, it will allow for different temperature levels to be set
throughout the day. The boiler will modulate its output to maintain the required room temperature.

Please refer to the specific instructions for the room thermostat for further guidance.

cod. 3540S060 - 04/2010 (Rev. 00)

7EN

EXTREMA

ECO/COMFORT selection

The unit has a function that ensures a high domestic hot water delivery speed and maximum comfort for the user. When
the device is activated (COMFORT mode), the water contained in the boiler is kept hot, therefore ensuring rapid avail­ability of hot water on opening the tap, without waiting times.

The device can be deactivated by the user (ECO mode) by pressing the eco/comfort button (detail 7 - fig. 1). To acti­vate the COMFORT mode, press the eco/comfort button (detail 7 - fig. 1) again.

Outside Temperature Compensation (O.T.C)

When the optional external sensor is installed, the control panel display (detail 5 - fig. 1) shows the actual outside tem­perature detected by the external sensor. In this mode, the heating system temperature is adjusted according to the
outside weather conditions, to ensure the high comfort and energy saving throughout the year. In particular, as the out­side temperature increases, the system delivery temperature decreases according to a specific "compensation curve"
(fig. 12).

The maximum system delivery temperature can be set with the heating buttons (details 3 & 4 - fig. 1).

The boiler must be regulated at the time of installation by qualified personnel. Possible adjustments can in any case be
made by the user to improve comfort.

Compensation curve and curve offset (Only required if external sensor is installed)

Press the mode button (detail 10 - fig. 1) once to display the actual compensation curve value (fig. 12) which can be
modified with the DHW buttons (details 1 and 2 - fig. 1).

Adjust the required curve from 1 to 10 according to the characteristic (fig. 14).

By setting the curve to 0, sliding temperature adjustment is disabled.

It is recommended that a start point of 20 to 30°C and a flow temperature of 85°C is suitable for the UK (Curve
9 or 10).

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fig. 12 - Compensation curve

Press the heating buttons (details 3 and 4 - fig. 1) to access parallel curve offset (fig. 13), modifiable with the DHW but­tons (details 1 and 2 - fig. 1).

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fig. 13 - Parallel curve offset

Press the mode button (detail 10 - fig. 1) again to exit the parallel curve adjustment mode.

If the room temperature is lower than the required value, it is advisable to set a higher order curve and vice versa. Pro­ceed by increasing or decreasing in steps of one and check the result in the room (fig. 15).

8 EN

cod. 3540S060 - 04/2010 (Rev. 00)

EXTREMA

90
85
80

70

60

50

40

30

Maximum boiler flow temperature

20

20 10 0 -10 -20

Outside Air Temperature

fig. 14 - Compensation curves

OFFSET = 20 OFFSET = 40

90
85
80

70

60

50

40

30

Maximum boiler flow temperature

20

20 10 0 -10 -20

Outside Air Temperature

8910

7

6

5

4

3

2

1

90
85
80

70

60

50

40

30

Maximum boiler flow temperature

20

68910 7

5

4

3

2

1

568910 7

4

3

2

1

20 10 0 -10 -20

Outside Air Temperature

fig. 15 - Example of compensation parallel curve offset

Water system pressure adjustment

The filling pressure with system cold, read on the boiler water gauge, must be approx. 1.0 bar. If the system pressure
falls to values below minimum, the boiler PCB will display fault F37 (fig. 16).

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fig. 16 - Low system pressure fault

Once the system pressure is restored, the boiler will activate the 120-second air venting cycle indicated on the
display by FH.

cod. 3540S060 - 04/2010 (Rev. 00)

9EN

EXTREMA

2. Installation

2.1 General Instructions

This unit must only be used for its intended purpose. This unit is designed to heat water to a temperature below

B

THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN COMPLIANCE WITH ALL THE IN­STRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT LAW, THE REQUIRE­MENTS OF THE TECHNICAL STANDARDS (BS) AND ANY LOCAL REGULATIONS AND THE RULES OF PROPER
WORKMANSHIP.

Incorrect installation can cause damage or injury for which the manufacturer cannot be deemed responsible.

The unit must be installed in compliance with these instructions and the following standards applicable in
Great Britain.

Gas Safety Regulations (Installations & Use).

Local Building Regulations.

The Building Regulations (Part L).

The Buildings Standards (Scotland - Consolidated) Regulations).British Standards Codes of Practice (BSI):

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 heating capacity. Any other use is deemed improper.

B.S. 5440 Part 1 Flues

B.S. 5440 Part 2 Air flow and ventilation

B.S. 5449 ......... Forced circulation hot water production systems

B.S. 6798 ......... Installation of gas-fired boilers for hot water

B.S. 6891 ......... Gas systems

B.S. 7671 ......... IEE wiring system standards

B.S. 4814 ......... Specifications for expansion tanks

B.S. 5482 ......... LPG systems

B.S. 7593 ......... Water treatment in central heating systems for DHW production

B.S. 5546 ......... Installation of systems for DHW production

Model Water By-Laws (Great Britain)

B.S. 5955-8 ......... Installation of plastic pipes

For Northern Ireland the relevant laws in force must be observed.

Safe handling of materials

Pay attention when handling the boiler insulation panels because the material they are made of could irritate the skin.
No part of the boiler contains asbestos, mercury or CFC's.

Advice for transport and handling

For lifting and transport always take suitable safety precautions: keep your back straight, bend knees, do not turn your
body, move feet, avoid bending forward or sideways and keep the load as close as possible to your body.

If possible, use a trolley or other suitable means to carry the boiler.

Grip the boiler firmly and, before lifting it, try and find the point where the load is concentrated in order to establish the
centre of gravity and suitably reposition yourself. Ideally seek assistance in lifting the boiler.

10 EN

cod. 3540S060 - 04/2010 (Rev. 00)

EXTREMA

2.2 Place of installation

The combustion circuit is sealed with respect to the
place of installation and therefore the unit can be in­stalled in any room. However, the place of installation
must be sufficiently ventilated to prevent the creation
of dangerous conditions in case of even slight gas
leaks. This safety regulation is provided for by EEC Di­rective no. 90/396 for all gas units, including those with
a sealed chamber.

The unit is suitable for operation in a partially protect­ed place in conformity with EN 297 pr A6, with mini­mum temperature -5°C. It is advisable to install the
boiler under the slope of a roof, inside a balcony or in
a sheltered recess.

In any case, the place of installation must be free of
dust, flammable materials or objects or corrosive gas­es.

The boiler is arranged for wall mounting and comes
standard with a hanging bracket. A paper template for
marking the drilling points on the wall is provided in the
box. The wall fixing must ensure stable and effective
support for the generator.

A

If the unit is enclosed in a cabinet or mounted
alongside, a space must be provided for re­moving the casing and for normal mainte­nance operations. The minimum
measurements to be respected are given in
fig. 17.

C

A

D

fig. 17 - Minimum distances around the boiler

A Min. 1 cm
B Min. 15 cm
C Min. 30 cm
D Min. 32 cm (via an openable panel)

A

B

2.3 Plumbing connections

Important

The heating capacity of the boiler must be previously established by calculating the building's heat requirement accord­ing to the current regulations. To ensure proper operation and long boiler life, the plumbing system must be adequately
sized and complete with all the necessary accessories, including a room thermostat, a termostatic radiator valve (TRV),
etc. The system flow and return pipes must have a diameter of at least 22 mm for the first 3 m of length from the unit.

If the system delivery and return pipes follow a path where air pockets could form in certain places, it is advisable to
install vent valves at these points. Also, install type "A" drain cocks at the lowest points in the system to allow complete
emptying.

The temperature drop between the delivery manifold and the return to the boiler should not exceed 20 °C.

A flow rate of at least 6 litres/min through the heat exchanger is required. An automatic bypass installed in the boiler
guarantees maintaining of the required flow rate.

Do not use the water system pipes to earth electrical appliances.

B

Before installation, carefully wash all the heating system pipes to remove any residuals or impurities that could affect
proper operation of the unit (as required by BS 7593 Building regs Doc L).

Carry out the connections to the unit as indicated in fig. 36.

The safety valve discharge must be connected to a 15 mm diameter copper pipe descending from the boiler

B

to run off system water in case of overpressure in the heating circuit. Otherwise, if the discharge valve cuts in
and floods the room, the boiler manufacturer cannot be held liable. The discharge must be run to the outside
of the building to prevent the risk of damage or injury caused by discharged hot water in case of overpressure
in the system.

cod. 3540S060 - 04/2010 (Rev. 00)

11EN