Ferroli Modena 102 Installation, Servicing And User Instructions Manual

Appr. nr. B99.06 A - CE 0461 AU 0431
MODENA 102
Copper Wall-Mounted Combination, Gas Fired Boiler for Central Heating
and Domestic Hot Water Production,
Fan Assisted, Room Sealed Compartment,
Electronic Flame Ignition and Control
INSTALLATION, SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-267-24
MODENA 102
2
CE MARK
CE mark documents that the Ferroli gas appliances comply with the requirement contained in European directives applicable to them. In particular, the appliances comply with the following CEE directives and the technical specifi cations provided from them:
Gas appliances directive 90/396
• Effi ciencies directive 92/42
Low tension directive 73/23 (modifi ed from the 93/68)
Electromagnetic compatibility directive 89/396 (modifi ed from the 93/68)
Year 2000 Compliance Declaration
We will guarantee that this products is altogether suitable for the data change in the Year 2000 (boiler has no dependence from date change) and that no disruptions will occur which is caused by this product.
IMPORTANT
Your "benchmark" Installation, Commissioning and Service Record Log Book will be enclosed in your customer information pack.
"This record must be completed and left with the end user"
"All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both should be recorded in your central heating log book. You can check the installer's CORGI registration by calling CORGI on 01256 372300".
Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and effi ciency. Please see installation and servicing guidelines.
INDEX
1. DESCRIPTION.......................................................................................................................................3
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS ...................................................................... 4
3. INST ALLATION DET AILS ....................................................................................................................... 9
4. COMMISSIONING AND TESTING....................................................................................................... 22
5. ADJUSTMENT AND GAS CONVERSION........................................................................................... 23
6. MAINTENANCE AND CLEANING ....................................................................................................... 25
7. REPLACEMENT OF PARTS ................................................................................................................ 27
8. F A UL T FINDING ................................................................................................................................... 32
9. ELECTRICAL AND FUNCTIONAL SCHEME.......................................................................................39
10. USER INSTRUCTIONS...................................................................................................................... 41
MODENA 102
3
1. DESCRIPTION
1.01 Introduction
The Modena 102 is defi ned as a “room sealed” combination boiler, all air required for combustion is taken from outside the room in which it is installed. It is a new high performance gas fi red heat generator for central heating and domestic hot water production. A special feature of this boiler is its built-in electronic fl ame ignition and control unit making burner operation completely automatic and safe. The main components are as follows:
• Copper heat exchanger consisting of three fi nned tubes specifi cally shaped for high effi ciency.
• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water heat exchang er. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.
• Ceramic fi bre insulated combustion chamber
• 16 stainless steel bladed burners specifi cally designed for this boiler.
Fan for discharge of combustion products and intake of combustion air.
• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning correctly.
• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.
• Combination gas safety valve with modulator, complete with pressure stabiliser.
Flowmeter giving the domestic hot water circuit precedence over the central heating circuit.
• Pressure relief valve for the central heating circuit set to open at 3 bar.
• Built-in Expansion vessel.
• Variable speed pump.
• Central heating fl ow temperature adjustment thermostat.
• Domestic hot water fl ow temperature adjustment thermostat.
• Central heating limit thermostat.
• Overheat safety thermostat.
• Electronic control unit for automatic fl ame ignition and control.
• Central heating low water pressure cut off switch.
• Domestic hot water fl ow temperature sensor.
• Central heating fl ow temperature sensor.
• Safety bracket
1.02 Instructions and regulations
Assembly, installation, fi rst start up and maintenance must be carried out by competent persons only, in accordance with all current technical regulations and directives.
C.O.S.H.H.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are required when servicing.
Related Documents This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996. The Local Building Regulations. The Building Regulations. The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice: B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES B.S. 5440 Part 1 2000 FLUES B.S. 5440 Part 2 1989 AIR SUPPLY B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS B.S. 6891 1989 GAS INSTALLATIONS B.S. 7671 1992 IEE WIRING REGULATIONS B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS B.S. 5482 1994 INSTALLATION OF LPG
Model Water Bye Laws For Northern Ireland the rules in force apply
MODENA 102
4
Fig. 1
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Modena 102 boilers are central heating and domestic hot water heat generators and are produced as standard
to function with natural gas or liquid petrolium gas converted.
Key
1 - 3/4" central heating fl ow outlet 2 - 1/2" domestic hot water ow outlet 3 - 1/2 gas inlet
733
460
430
85
14
362
200
720
Ø60
115
Ø100
75
189
Distance between connections
36 95 60 60 155 54
175
Bottom view
4
23
5
189
460
Top view
120120
200
110
80
110
61
4 - 1/2" domestic hot water inlet
5 - 3/4" central heating return inlet
6 - Pressure relief outlet
MODENA 102
5
N.B. - The gas pressures at the burner and gas fl ows during the central heating phase given in the table refer to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced until the required output level is reached (see fi gures 4 and 5).
During domestic hot water production, gas pressures to the burner must correspond to the maximum output given in table for the type of gas.
Gas pressure must be adjusted during maximum draw-off of domestic hot water.
• Maximum working temperature for central heating ow: 85°C
• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.
• Minimum domestic cold water pressure required for 95% heat input:
- Flow restrictor tted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
Technical Data
MODEL
Heat output
Heat input
Net
Domestic hot
water heat
input
Gross
Boiler water
contents
Domestic hot
water circuit
contents
kW kW kW kW kW Litres Litres
Modena 102 30.0 12.7 33.1 14.5 30.0 1.5 0.8
MODEL
Connections Expansion vessel
Max. working
pressure
central
heating
circuit
Max.
working pressure hot water circuit
12345Capacity
Pre-pressurising
value
ШШШШШLitres bar bar bar
Modena 102 3/4” 1/2” 1/2” 1/2” 3/4” 10 1 3 6
MODEL
Main injectors (mm)
Gas flow rates to main burners
for central heating
Gas valve
Ø1/2”
G20 - NG G31 - LPG G20 - NG G31 - LPG
ØØ m
3
/h kg/h
Modena 102 16x1,25 16x0,75 3.5 2.6 H. V K4105G
MODEL
Gas supply pressures
working
Gas pressure at main burner for central heating
Safety valve
G20 - NG G31 - LPG
G20 - NG G31 - LPG
min. max. min. max.
mbar mbar mbar mbar mbar mbar bar
Modena 102 20 37 2.5 13.0 7.0 35.5 3
MODEL
Domestic hot
water production
with t 30°C
Domestic hot
water production
with t 35°C
Max. working
pressure domestic
hot water
Protection
level
Weight
G20 - NG G31 - LPG
l/min. l/min. mbar mbar kg
Modena 102 14.3 12.3 13.0 35.5 IP44 48
MODENA 102
6
2.03 Boiler water fl ow diagram2.02 Boiler main components
Key
5 Room sealed compartment 7 Gas inlet 8 Domestic hot water outlet 9 Domestic hot water inlet
10 Central heating ow outlet 11 Central heating return inlet 14 Safety valve 16 Fan 19 Combustion chamber
20 Burner assembly 21 Main injector 22 Burner 26 Combustion chamber insulation 27 Copper heat exchanger for central
heating and domestic hot water
28 Flue collector from heat exchanger 29 Internal ue exit
32 Central heating pump 34 Central heating fl ow temperature sensor 36 Automatic air vent valve
Fig. 2
Fig. 3
818222
29 43187
IN
OUT
MIN
GRUNDFOS
FERROLI
114
34
20 21
90
50
16
28
32
26
19
49
132
5
56
27
91
62
10 8 784 85 44
136
14 42 9 11
36
98 63 157 145
0
5
1
2
3
4
6
OUT
I
MIN
AIR
IN
AIR
IN
FLUE
OUT
C.H.
OUT
D.H.W.
OUT
GASIND.H.W.
IN
C.H.
IN
42 Domestic hot water fl ow temperature sensor
43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat
50 Central heating fl ow limit thermostat 56 Expansion vessel
62 Time clock (option) 63 Central heating temperature adjustment
81 Ignition electrode 82 Sensor electrode 84 Primary gas valve solenoid 85 Secondary gas valve solenoid
90* Flue outlet test point 91* Air test point 98 On/Off/Reset switch
114 Low water pressure cut off switch 132 Flue gas de ector 136 Flow meter 145 Central heating pressure gauge 157 Domestic hot water temperature adjustment 187 Restrictor
* For use with ue gas analyser
MODENA 102
7
2.05 Pump characteristics
The pump head available for circulating the water is given in fi g. 6.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph Note - Minimum fl ow through boiler heat exchanger at
any time should not fall below 6 litres per minute. If the total volume of water in the system exceeds 40
litres an additional expansion vessel must be fi tted to the central heating return pipe.
Pump performance curve Grundfos UPS 15-50
Fig. 6
1 2 3 Speed settings
A Boilers pressure drop
B Available pump head C.H.
2.04 Central heating adjustment (not normally required) To ad just boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main
burner via the electronic control board (fi g. 4, 5 and see paragraph 5.04 page 24). The diagrams indicate the variation in heat output to the water as burner working pressure is varied. Adjusting boiler output to the actual requirements of the central heating system will minimise boiler cycling thus saving fuel, varying the output has virtually no effect on the efficiency and combustion characteristics of the boiler.
Diagram of pressures and outputs with Natural gas
Fig. 4 Fig. 5
Diagram of pressures and outputs with LPG (Propane)
2
3
4
5
6
7
8
9
10
11
12
13
12 13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20 21
kW kcal/h
x 1000
mbar
14
25 26 27 28 29 30 31
22 23 24 25 26
kW kcal/h X 1000
m
b
ar
18 19 20 21 22 23
5
10
15
20
25
30
35
12 13 14 15 16 17
11 12 13 14 18 19 2015 16 17
25 26 27 28 29 3024
21 25 2622 23 24
MODENA 102
8
SIZING OF ADDITIONAL EXPANSION VESSELS: Deduct from the value given in the table the 10
litre vessel supplied. Note:
1. Fill C.H. installation to min. 1.5 bar.
2. Expansion vessel must be tted to central heating return pipe.
3. The standard 10 litre expansion vessel is charged to 1 bar.
4. The additional expansion vessel should be charged to 1 bar.
SAFETY VALVE SETTING (bar)
VESSEL CHARGE PRESSURE (bar)
INITIAL SYSTEM PRESSURE (bar)
TOTAL WATER CONTENT of SYSTEM
3.0
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
LITRES 25 3.5 6.5 13.7 4.7 10.3 8.3 50 7.0 12.9 27.5 9.5 20.6 16.5 75 10.5 19.4 41.3 14.2 30.9 24.8 100 14.0 25.9 55.1 19.0 41.2 33.1 125 17.5 32.4 68.9 23.7 51.5 41.3 150 21.0 38.8 82.6 28.5 61.8 49.6 175 24.5 45.3 96.4 33.2 72.1 57.9 200 28.0 51.8 110.2 38.0 82.4 66.2
0.140 0.259 0.551 0.190 0.412 0.33
For syst. volumes other than those given above, mult. the syst. volume by the factor across
Fig. 7
Pressure loss diagram
m |h
3
Q
8
7
6
5
4
3
2
1
0
0.5 1.5 2.512
H
mbar x 100
MODENA 102
9
3. INST ALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1996 In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance
with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E. Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to prosecution; it is your responsibility to ensure that the law is complied with.
N.B. For Northern Ireland the rules in force apply. Important - If the boiler is to be tted in a timber framed building it should be tted in accordance with the Institute of
Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.
Location of Boiler
The installation of the Modena 102 must be on a suitable non-combustible load bearing wall which will provide an adequate xing for the boiler mounting safety bracket assembly. The location should be in an area where the water pipes will not be subjected to frost conditions. In siting the combination boiler the following limitations must be observed:
The combination boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower.
Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or appliance control utilising mains electricity must be situated so that it cannot be touched by a person using the bath or shower.
Air Supply
The room or compartment in which the boiler is installed does not require a purpose provided vent when using the standard concentric fl ue.
Flue System
The boiler allows the ue outlet to be taken from the rear of the boiler, from either side or vertically.
A standard ue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied (equivalent to wall thicknesses of up to 565, 1815 and 2815mm for rear ues, deduct 91mm plus distance from side
wall for side outlet fl ues). It is absolutely essential, to ensure that pr oducts of combustion discharging fr om the terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors, natural air infi ltration or forced ventilation/air conditioning.
Gas Supply
If necessary the local Gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the Local Gas supplier. A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor. Installation pipes should be fi tted in accordance with BS6891-1988. Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 3.5 m3/h of natural gas, and 2.60 kg/h of LPG. Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework must be adequately supported. An isolating gas valve is provided and should be fi tted on the boiler gas inlet. Please wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after
the boiler has operated for 10 minutes to reach thermal equilibrium.
MODENA 102
10
Water System Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part of the useful heating suface should be insulated to prevent any heat losses or possible freezing (i.e. in roof spaces or ventilated underfl oor spaces). Drain taps should be positioned at the lowest point of the system in accessible locations to permit the whole system to be drained down. The drain taps should be in accordance with BS2879. Copper tubing to BS2871, Part 1 is recommended for water carrying pipework. Pipework in horizontal runs should have a gradient where possible to facilitate the removal of air. Ensure that the boiler heat exchanger is not a natural point for air collection. A typical heating system with domestic hot water circuit is illustrated in fi g. 8.
Important - If thermostatic radiator vales are fi tted a bypass must be fi tted to ensure a minimum fl ow rate thr ough the boiler of 6 l/min. The bypass should be fi tted as far as possible from the boiler.
Make Up Water
Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798, for methods of fi lling and making up sealed systems. There must be no direct connection between the boiler's central heating system and the mains water supply. The use of mains water to charge and pressurise the system directly , is conditional upon the Local Water Byelaws. Again any such connection must be disconnected after use. A typical temporary fi lling loop is shown in fi g. 9.
Domestic Hot Water
Always fi t a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection point on the boiler for attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply is 10 bar (145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing valve must be tted by the installer into the mains supply in an inconspicuous but accessible position preferable between 3 and 5 metres (10-16ft) before the appliance. Such a valve must be approved by the Water Research Council.
Attention - is drawn to the Model Water Byelaws. Fittings manufactured from duplex (alpha-beta)
brass are not acceptable for underground use and certain water undertakings will not accept their use above ground.
Ensure all pipework is adequately supported
NOTE: A bypass must be fi tted as far as possible from the boiler if thermostatic radiator valves are fi tted thoughout.
Fig. 8
Gas
Cold water
Additional expansion vessel
C.H. (if required)
Filling point C.H.
Bypass
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
Fig. 9
MODENA 102
11
Terminal Position
Fig. 11
CLEARANCES:
* 600mm minimum clearance for servi-
cing access
460 5 min.5 min.
100 min.852
360 50 mm
600* min.
760
200 min.
Fig. 10
P
D, E
Q
Q
l
B
C
A
G
F
L
J
H
H
K
N
N
MM
Q
Directly below an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)
(>14-32 kW) (>32-70 kW)
Above an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)
(>14-32 kW) (>32-70 kW)
Horizontally to an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)
(>14-32 kW)
(>32-70 kW) Below gutters, soil pipes or drain pipes Below eaves Below balconies or car port roof From a vertical drain pipe or soil pipe From an internal or external corner Above ground roof or balcony level From a surface facing the terminal
(also see 6.1.2) From a terminal facing the terminal From an opening in the car port ( e.g. door,
window) into the dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical structure on the roof
Above intersection with roof
Dimensions Terminal position
(kW input expressed in net)
Balanced flues room
sealed
Open flues
Natural draught
Natural draught
Fanned
draught
Fanned
draught
A
a
300 mm
600 mm 1500 mm 2000 mm
300 mm Not allowed 300 mm
B
a
300 mm 300 mm 300 mm 600 mm
300 mm Not allowed 300 mm
C
a
300 mm 400 mm 600 mm 600 mm
300 mm Not allowed 300 mm
D 300 mm 75 mm Not allowed 75 mm E 300 mm 200 mm Not allowed 200 mm F 600 mm 200 mm Not allowed 200 mm G 300 mm 150 mmbNot allowed 150 mm H 600 mm 300 mm Not allowed 200 mm I 300 mm 300 mm Not allowed 300 mm J 600 mm 600 mm N/A 600 mm
K 600 mm 1200 mm N/A 1200 mm L 1200 mm 1200 mm N/A 1200 mm
M 1500 mm 1500 mm N/A 1500 mm N 300 mm 300 mm N/A 300 mm O N/A N/A N/A 50 mm P N/A N/A See Table 2
and Fig. 6b
N/A
Q N/A N/A See Table 2
and Fig. 4
150 mm
NOTE N/A = Not applicable
a
In addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric formed for the purpose of accommodating
a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the rated heat inputs as shown.
b
This dimension may be reduced to 75 mm for appliances of up to 5 kW heat input.
Minimum dimensions of fl ue terminal positions
MODENA 102
12
3.01 Drilling Template (Top Flue Application)
Select suitable mounting position for boiler, using the template mark fl ue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, fi t wall plugs. Fit two special wall plugs on the wall as described in the fi g. 12a. Fasten the wall bracket to the wall using an antitheft nut on the right side and a standard nut (M8) on the left side. Mount the boiler on the wall bracket and fi x using an antitheft nut on the left side and a standard nut (M8) on the right side. Using a core drill cut a 118mm diameter hole for the fl ue.
1. CH fl ow (22 mm)
2. Safety Valve (15 mm)
3. Domestic hot water outlet (15 mm)
4. Gas supply (22 mm)
5. Domestic hot water inlet (15 mm)
6. CH return (22 mm)
Fig. 12b
75
5 min
195 min
200 min
955 min
200
460 min
123 4 5 6
15 15
Ø3/4''Ø3/4'' Ø1/2''Ø1/2''Ø1/2''Ø1/2''
==
Ø120
jig bracket
Fig. 12a
MODENA 102
13
3.02 Restrictor
For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of fl ue restrictor required. Before inserting the fl ue gas duct in the boiler, check that the restrictor fi tted is correct and that it is correctly positioned (see fi g. 13).
Holes Ø : 47 50 52
Ø
Fig. 13
Choice of restrictor:
With concentric pipes: - up to 1m long + one bend, use the 52 mm restrictor.
- for fl ue lengths over 1 metre, use no restrictor.
• With 2 pipe system: - Calculate the total fl ow resistance of the air and fl ue pipes in metres (cap. 3.04.2)
- utilise the table shown below to choose the more suitable restrictor for the fl ow resistance calculated
RESTRICTOR FOR TWO PIPE SYSTEM
ON MODENA 102
Total flow resistance
of flue system
Use
restrictor
size
minimum maximum mm
0 m 20m 47 20 m 35 m 50 35 m 45 m 52 45 m 50 m no restrictor
N.B.: the diameter of the hole is stamped
on the restrictor
No restrictor is required for back
outlet ue
MODENA 102
14
A 90° bend (fi g. 15) is supplied for the horizontal connection of air and fl ue gas pipes. This can be angled towards the chosen wall in degrees of 45°.
3.03 Top Outlet Concentric Flue Connection
3.03.1 Vertical concentric connection
Fig. 15
A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets at the joints makes this an extremely easy and safe option.
Fig. 14
Concentric Vertical Connector
3.03.2 Horizontal concentric connection
1KWMA31Y
DS
L
125
70
50*
30
95
80
80
-3 mm/m
Ø60 Ø80
70 min.
* = between 10 e 60 mm
190 270
L = S = D = 255
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