Ferroli Modena 80 E User Manual

MODENA 80 E

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

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

INSTALLATION, SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-267-05

3543230/2 - 10/99

MODENA 80 E

IMPORTANT

From the 1st October 1999 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"

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

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 specifications

provided from them:

• Gas appliances directive 90/396

• Efficiencies directive 92/42

• Low tension directive 73/23 (modified from the 93/68)

• Electromagnetic compatibility directive 89/396 (modified 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.

INDEX

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

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

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

4. COMMISSIONING AND TESTING ..................................................................................................... 22

5. ADJUSTMENT AND GAS CONVERSION ........................................................................................... 23

6. MAINTENANCE AND CLEANING ..................................................................................................... 25

7. REPLACEMENT OF PARTS ................................................................................................................. 27

8. FAULT FINDING .................................................................................................................................. 32

9. ELECTRICAL AND FUNCTIONAL SCHEME ....................................................................................... 39

10. USER INSTRUCTIONS ....................................................................................................................... 41

MODENA 80 E

1. DESCRIPTION

1.01 Introduction

The Modena 80 E is defined 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 fired heat generator for central heating and domestic hot water production. A special feature of this boiler is its built-in electronic flame ignition and control unit making burner operation completely automatic and safe. The main components are as follows:

• Copper heat exchanger consisting of three finned tubes specifically shaped for high efficiency.

• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water heat exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.

• Ceramic fibre insulated combustion chamber

• 12 stainless steel bladed burners specifically 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 flow temperature adjustment thermostat.

• Domestic hot water flow temperature adjustment thermostat.

• Central heating limit thermostat.

• Overheat safety thermostat.

• Electronic control unit for automatic flame ignition and control.

• Central heating low water pressure cut off switch.

• Domestic hot water flow temperature sensor.

• Central heating flow temperature sensor.

1.02 Instructions and regulations

Assembly, installation, first 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 FLUES B.S. 5440 PART 2 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 80 E

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS

2.01 Technical information

Modena 80 E boilers are central heating and domestic hot water heat generators and are produced as standard

to function with natural gas or LPG.

175100

60 120280

16025

725

720

Distance between connections

100

Bottom view

460

Distance between connections

1149560609536

100

270

460

15012012070

Key

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

110

80 80

Top view

Fig. 1

Technical Data

MODENA 80 E

ssorgnodetaluclactupnitaeH

taeH

LEDOM

E08anedoM 8,327,98,525,116,828,210,825,218,325,18,0

LEDOM

E08anedoM "4/3"2/1"2/1"2/1"4/37136

LEDOM

E08anedoM03,1x2177,0x2137,2 00,2 G5014KV.H

tuptuo

WkWkWkWkWkWkWkWkWksertiLsertiL

12345 yticapaC

ШШШШШ sertiLrabrabrab

GN-02GGPL-13GGN-02GGPL-13G

ØØ m

taeH

tupni

snoitcenneClessevnoisnapxE

)mm(srotceyniniaM

GN-02GGPL-13G

.xaM.niM.xaM.niM

h/h/gk

)SCP(eulavtaeh

eulav

gnitaehlartnecrof

citsemoD

retawtoh

taeh

tupni

gnisirusserp-erP

srenrubniamotsetarwolfsaG

relioB retaw

stnetnoc

gnikrow.xaM

erusserp

lartnec

gnitaeh

tiucric

"2/1Ø

tohcitsemoD

tiucricretaw

stnetnoc

.xaM

gnikrow

toherusserp

tiucricretaw

evlavsaG

serusserpylppussaG gnitaehlartnecrofrenrubniamtaerusserpsaG

LEDOM

GN-02GGPL-13G

rabmrabmrabmrabmrabmrabmrab

E08anedoM 02735,28,118,70,633

muminimlanimonmuminimlanimon

tohcitsemoD

LEDOM

htiw∆∆

∆∆C°03t

∆

noitcudorpretaw

htiw∆∆

∆∆C°52t

∆

GN-02GGPL-13G

tohcitsemoD

noitcudorpretaw

GN-02GGPL-13G

gnikrow.xaM

citsemoderusserp

retawtoh

noitcetorP

level

evlavytefaS

thgieW

.nim/l.nim/lrabmrabmgk

E08anedoM3,116,318,110,6344PI83

N.B. - The gas pressures at the burner and gas flows 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 figures 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 flow: 85°C

• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.

• Minimuum domestic cold water pressure required for 95% heat input:

- Flow restrictor fitted (standard) - 1,2 bar;

- Flow restrictor removed - 0,5 bar

MODENA 80 E

2.02 Boiler main components

132

818222

20 21

OUT

MIN

114

10 874 784 85 44

14 42 9 11

136

2.03 Boiler water flow diagram

FLUE

AIR

OUT

16 91

19 26

36 73

OUT

MIN

AIR

Fig. 2

98 63 157 14562

Key

5 Room sealed compartment 7 Gas inlet 8 Domestic hot water outlet 9 Domestic hot water inlet 10 Central heating flow outlet 11 Central heating return inlet 14 Safety valve 16 Fan 19 Combustion chamber 20 Burner assembly 21 Main injector 22 Burner 26 Combustion chamber insulation 27 Copper heat exchanger for central

heating and domestic hot water

28 Flue collector from heat exchanger 32 Central heating pump 34 Central heating flow temperature

sensor

C.H. OUT

36 Automatic air vent valve 42 Domestic hot water flow

temperature sensor

43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat 50 Central heating flow 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 sampling point *91 Air sampling point 98 On/Off/Reset switch

D.H.W.

OUT

Fig. 3

GASIND.H.W.

C.H.

114 Low water pressure cut off

switch

132 Flue gas deflector 136 Flow meter 145 Central heating pressure gauge 157 Domestic hot water

temperature adjustment

* For use with flue gas analysis equipment

MODENA 80 E

2.04 Central heating adjustment (not normally required)

To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main burner via the electronic control board (fig. 4 and 5). 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

14 13

mbar

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

kW kcal/h

x 1000

8 9 10 11 12 13 14 15 16 17 18 19 20 21

Fig. 4

Diagram of pressures and outputs with LPG (Propane)

mbar

9 1011121314151617

kW kcal/h X 1000

91011121314 18192015 16 178

18 19 20 21 22 23

Fig. 5

2.05 Domestic hot water variability characteristics

The temperature of the domestic hot water can be varied

from 40 to 55°C by adjusting the boiler potentiometer.

Diagram of domestic hot water production

Fig. 6

Temperatura di erogazione sanitaria °C

40 39

Temp. entrata acqua sanitaria 15°C

Temperature of domestic hot water intake 15°C

0 345678910111213141516

Temperature of domestic hot water supply

Flow of domestic hot water L/

Portata sanitaria dm /min.

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7

kcal/h

x1000

Boiler output exchanged kcal/

Potenza caldaia scambiata

MODENA 80 E

2.06 Pump characteristics

The pump head available for circulating the water is given in fig. 7.

N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.

Note - Minimum flow 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 fitted to the central heating return pipe.

Pump performance curve Grundfos UPS 15-50

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

Pressure loss diagram

SAFETY VALVE SETTING (bar)

VESSEL CHARGE PRESSURE (bar)

INITIAL SYSTEM PRESSURE (bar)

TOTAL WATER CONTENT of SYSTEM

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

For syst. volumes other than those given above, mult. the syst. volume by the factor across

200 28.0 51.8 110.2 38.0 82.4 66.2

1.0 1.5 2.0 1.5 2.0 2.0

EXPANSION VESSEL VOLUME (litres)

0.140 0.259 0.551 0.190 0.412 0.33

mbar x 100

Fig. 8

3.0

0.5 1.0 1.5

m |h

0.5 1.5 2.512

SIZING OF ADDITIONAL EXPANSION VESSELS:

Deduct from the value given in the table the 8 litre vessel supplied.

Note:

1. Fill C.H. installation to min. 1.5 bar.

2. Select the expansion vessel for a system

pressure of 2.0 bar.

3. Expansion vessel must be fitted to central heating return pipe.

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

5. The additional expansion vessel should be charged to 1 bar.

Fig. 7

MODENA 80 E

3. INSTALLATION DETAILS

Gas Safety (Installation & Use) Regulations: 1996

In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E. Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to prosecution; it is your responsibility to ensure that the law is complied with.

N.B. For Northern Ireland the rules in force apply.

Important - If the boiler is to be fitted in a timber framed building it should be fitted 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 80E must be on a suitable non-combustible load bearing wall which will provide an adequate fixing for the boiler mounting bracket assembly. The location should be in an area where the water pipes will not be subjected to frost conditions. In siting the combination boiler the following limitations must be observed:

The combination boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower.

Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or appliance control utilising mains electricity must be situated so that it cannot be touched by a person using the bath or shower.

Air Supply

The room or compartment in which the boiler is installed does not require a purpose provided vent when using the standard concentric flue.

Flue System

The boiler allows the flue outlet to be taken from the rear of the boiler, from either side or vertically. A standard flue 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 flues, deduct 91mm plus distance from side wall for side outlet flues). It is absolutely essential, to ensure that products of combustion discharging from the terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors, natural air infiltration 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 fitted in accordance with BS6891-1988. Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG. Pipework from the meter to the combination boiler must be of an adequate size. The boiler requires 2.73m3/h of natural gas, and 2,00 kg/h of LPG. Do not use pipes of a smaller size than the combination boiler inlet gas connection. The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework must be adequately supported. An isolating gas valve is provided and should be fitted 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.

Water System

Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.

MODENA 80 E

Central Heating

Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part of the useful heating surface should be insulated to prevent any heat losses or possible freezing (i.e. in roof spaces or ventilated underfloor 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 fig. 9.

Important - If thermostatic radiator vales are fitted a bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min. The bypass should be fitted 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 filling 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 filling loop is shown in fig. 10.

Domestic Hot Water

Always fit 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 fitted 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

Gas

NOTE: A bypass that will ensure a minimum flow rate of 6 L/m at all times must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted.

Cold water

Additional expansion

vessel C.H. (if required)

Filling point C.H.

Bypass

Fig. 9

Key

1. Filling point C.H.

2. Temporary connection

3. Cold water supply Fig. 10

MODENA 80 E

CLEARANCES:

* 600mm minimum clearance for servicing access

Fig. 11

Terminal Position

460 5 min.5 min.

100 min.860200 min.

720

270 50 mm

600* min.

Fig. 12

POSITION MINIMUM SPACING mm

A Directly below an openable window, air vent, or any other ventilation opening 300

B Below gutters, soil pipes or drainpipes 75 C Below Eaves 100

D Below a Balcony 100

E From vertical drainpipes or soilpipes 75

F From internal or external corners 100 G Above adjacent ground or balcony level 100 H From a surface facing the terminal 600

I Facing another terminal 1,200

J From opening (door/window) in carport into dwelling 1,200 K Vertically from a terminal on the same wall 300 L Horizontally from a terminal on the same wall 300

N Below carport 600

A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when the terminal height is less than 2 m from floor level.

MODENA 80 E

3.01 Drilling Template (Top Flue Application)

Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting points. Drill two 10mm holes 70mm deep to accept the wall plugs, fit wall plugs. Using a core drill cut a 118mm diameter hole for the flue.

Ø118

269

183 min

932 min

280

200

21 min

Ø3/4" Ø1/2" Ø1/2" Ø1/2" Ø1/2" Ø3/4"

123 4 5 6

125 min

110

165 min

5 min

295.5 min 200 min

1. CH flow

2. Safety Valve

3. Domestic hot water outlet

4. Gas supply

5. Domestic hot water inlet

6. CH return

Fig. 15

MODENA 80 E

3.02 Restrictor

For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of flue restrictor required. Before inserting the flue gas duct in the boiler, check that the restrictor fitted is correct and that it is correctly positioned (see fig. 18).

N.B.: the diameter of the hole is stamped

on the restrictor

Boiler is fitted with Ø45 restrictor as standard

Holes Ø : 45 47 50

Fig. 18

Choice of restrictor:

• With concentric pipes: - up to 1m long + one bend, use the 50 mm restrictor.

- for flue lengths over 1 meter, use no restrictor.

• With separate pipes: - Calculate the total flow resistance of the air and flue pipes in metres (cap. 3.08.2)

- utilise the table shown above to choose the more suitable restrictor for the flow resistance calculated

METSYSEPIPOWTROFROTCIRTSER

E08ANEDOMNO

ecnatsiserwolflatoT

metsyseulffo

muminimmumixammm

m0m3154

m31m3274 m32m8305 m83m84rotcirtseron

esU

rotcirtser

ezis

MODENA 80 E

3.03 Top Outlet Concentric Flue Connection

3.03.1 Vertical concentric connection

Concentric Vertical Connector

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. 19

3.03.2 Horizontal concentric connection

A 90° bend (fig. 20) can be supplied for the horizontal connection of air and flue gas pipes. This can be oriented towards the chosen wall in degrees of 45°.

Ø1

25-30 mm

Ø2

A=L+(85-90)mm

Detail of mounting the bend

Ø1

Ø2

Ø1=100 Ø2=60

Trim the 60 mm internal diameter tube

Fig. 20

+ 30 hidden pages