ferroli Optima 2001 User guide
2001
VMF7
WALL MOUNTED, ROOM SEALED,
F AN ASSISTED,
GAS CONDENSING COMBINATION BOILER
INSTALLATION
INSTRUCTIONS
Phone numbers:
Installer
Service Engineer
Serial No.
G.C. NO: 47-367-21
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
FOR SERVICE INFORMATION OR
HELP TELEPHONE: 08707 282 885
ALWAYS QUOTE YOUR SERIAL NUMBER
ALL SPECIFICATIONS SUBJECT TO CHANGE
Tel. 08707 282 885 - Fax 08707 282 886
Read these Instructions thoroughly
before using the appliance
FERROLI HELPLINE
FOR IMMEDIATE ASSISTANCE
Appr. Nr. B95.01A CE 0063AQ2150
page INDEX
3 General Description
3 Related Documents
4 Technical Data
5 Appliance Dimensions
6 Boiler Flow Diagram
7 Key of boiler flow diagram
8 Installation Details
8 Location of Boiler
8 Air Supply
8 Condensate
10 Flue System
10 Gas Supply
10 Water System
12 Central Heating Pump
12 Sizing of expansion vessel
13 Installation of Boiler
13 1. Unpacking
13 2. Mounting the Boiler Jig
on the Wall (rear flue)
13 3. Mounting the Boiler Jig
on the Wall (side flue)
14 Drilling template
15 4. Preparing the Flue Assembly
16 5. Connecting the Boiler
18 6. Fitting the Flue Assembly
18 7. Electrical Installation
19 External sensor
20 Setting of compensation curve
21 8. Commissioning & Testing
21 8.1 Filling the Central Heating System
21 8.2 Filling the Domestic Hot Water System
21 8.3 Electricity Supply
21 8.4 The Gas Installation
22 8.5 To Light the Boiler
2001
23 Burner pressure C.H. and D.H.W.
24 Gas pressure adjustment with Honeywell
VR 4605 NA 4003 valve
25 8.7 D.H.W. Burner Pressure
25 9. System operation
25 10. Handing Over to the User
26 General Wiring Diagram
27 Fast fault finding
28 General fault finding
29 Replacement of parts
30 Details GAS valve
30 Details combustion chamber
31 Details Burner
32 Honeywell gas valve
32 Printed circuit board (P.C.B.)
32 Thermostats
33 Temperature sensors
33 Pressure relief valve
33 Pump
34 Automatic air vent
35 Pressure gauge
35 C.H. selector switch
35 Time clock
36 Fault diagnostic/temperature control
36 Air pressure switch
37 C.H. expansion vessel
38 Exploded view gas line, combustion
chamber an draft diverter
39 Exploded view heat exchanger + C.H. and
D.H.W. parts
40 Spare Parts List
41 Domestic Hot Water
Performance + Modureg
42 Special Installation Possibilities
2
2001
General Description
The Ferroli 2001 is a wall mounted, room sealed, fan assisted, condensing combination boiler for Central Heating (C.H.)
and domestic Hot Water (D.H.W.).
The boiler is of light weight construction with two heat exchangers providing Central Heating and Domestic Hot Water from an
integrally designed unit. The boiler contains its own expansion vessel for sealed systems. The wall mounting jig contains all the
isolating cocks for the water and gas supplies which can be fitted to the wall and provided with all the necessary gas and water
connections prior to the boiler being attached. The flue can either be left hand, right hand or rear. There are three flue lengths
available and they are 0.75 metres (for wall thickness up to 565 mm), 2 metres (for wall thickness up to 1815 mm) and 3 metres
(for wall thickness) up to 2815 mm these wall thicknesses assume a rear flue outlet. For side outlet the effective wall thickness for
each flue length is reduced by 91 mm plus the distance of the appliance from the side wall. The Central Heating and the Domestic
Hot Water temperature is controlled by the Honeywell Modureg valve in conjunction with the P.C.B. There is a limit thermostat on
the central heating circuit which operates at 88°C. There is also an overheat cut-off thermostat which will shut the boiler down
completely and this thermostat operates at 100°C. The boiler is fited with its own Central Heating pump. The pump is switched
ON/OFF by the time clock and/or a 24 Volt room thermostat. The pump circuit also has a 6 minute over-run time. There is a Domestic
Hot Water flow switch fitted and when there is a demand for Domestic Hot Water (flow of more than 0.5 gallon/minute, 2.5 litre/
minute) the Central Heating pump is switched off making available the maximum output of the gas burner for Domestic Hot Water.
On the P.C.B. the maximum output for Central Heating can be set. This does not influence the maximum output for domestic hot water.
At the factory the central heating output is pre-set to maximum. The appliance is not suitable for external installation.
This appliance can also be installed using the Ferroli two pipe flue system providing flue lengths up to 20 m (see flue options
instructions).
Related Documents
This appliance must be installed strictly in accordance with these instructions:
The Gas Safety Regulations (Installations & Use) 1994.
The Local Building Regulations.
British Gas - "Guidance notes for the installation of domestic condensing boilers".
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1993 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 INSTALLTIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
Model Water Bye Laws.
3
2001
Technical data
Nominal heat input (gross caloric value) 26.6 kW
Nominal heat output 22.6 kW
Nominal heat output condensing (30-50°C) 24.2 kW
Minimum heat input (gross caloric value) 11.9 kW
Minimum heat output 9.7 kW
Minimum heat output condensing (30-50°C) 10.7 kW
Gas rate 2.53 m
Burner setting pressure 16 mbar (max.)
Minimum burner pressure 3.5 mbar (min.)
Main injector Ø 20 x 0.875 mm
Dimensions (o/all)
Height 1040 mm
Width 480 mm
Depth 360 mm
Weight (net) 65 kg
Weight (gross) 67 kg
Electricity supply: 230V - 50 Hz
Fuse rating:
Mains 3 Amp. (main fuse)
on P.C.B. in boiler F2 Amp (Fast)
Electrical input 150 Watt
Domestic Hot Water flow:
(35°C rise) 9.2 l/min.
Minimum Domestic Hot Water Flow 2.5 l/min.
Maximum domestic cold water
Inlet pressure: 10,0 bar
C.H. Safety valve pressure setting 3 bar
C.H. Expansion vessel capacity 7 litre
Min. heating circuit pressure 0,8 bar
Max. heating circuit pressure 3.0 bar
Boiler water capacity:
Heating 2.5 litre
Domestic hot water 0.8 litre
Pipe connections:
Gas 22 mm
Domestic cold water inlet 15 mm
Domestic cold water outlet 15 mm
Central heating flow 22 mm
Central heating return 22 mm
Pressure relief valve drain 15 mm
Condense drain pipe (rubber hose) 20 mm
Min. installation clearances. Sides:
Left hand 5* mm
Right hand 5* mm
Front 50** mm
Min. height from worktop to base 200 mm
* If using a side outlet flue then the minimum clearance on the flue outlet side of the appliance is increased to 75 mm (3 in.)
** Access to the front of the boiler must be available for maintenance (min. 600 mm)
NATURAL GAS (G20)
3
S/h
(plus access for service)
4
Appliance Dimensions
FRONT VIEW
900
144
163
2001
LEFT SIDE VIEW REAR VIEW
224
221
100
60
76
448
480
12 3 4 5 6 7
Key
1. Electricity cable entry
2. Gas supply
3. Domestic Hot Water outlet
4. Domestic Cold Water inlet
5. Central Heating Pressure relief valve
6. Central Heating Flow outlet
7. Central Heating Return inlet
370
77
77.5507580505097.5
40
Fig. 1
TOP VIEW
5
Boiler Flow Diagram
2001
Fig. 2
6
2001
Key
1. Fixing point
5. Room sealed compartment
7. Gas inlet
8. Domestic hot water outlet
9. Cold water inlet
10. Central heating flow outlet
11. Central heating return inlet
12. D.H.W. draining point
14. Central heating safety valve
16. Fan
19. Combustion - heat exchanging compartment
20. Burner assembly
21. Main injector
22. Burner
26. Combustion chamber insulation
27. Copper heat exchanger for C.H. + D.H.W.
28. Flue collector from heat exchanger
30. Flue/surplus air collector
31. Air pressure control damper
32. Central heating pump
33. C.H. waterway of the heat exchanger
34. C.H. flow temperature sensor
35. Air separator
36. Automatic air vent
37. Cold water inlet filter
39. Cold water flow limiter
41. D.H.W. waterway of the heat exchanger
42. D.H.W. temperature sensor
43. Air pressure switch
46. Operator gas valve
47. Modulating regulator (Modureg) gas valve
48. Burner pressure test point
49. Overheat cut-off thermostat
50. Central heating limit thermostat
51. Central heating frost thermostat
53. Heat exchanger venting point
56. Expansion vessel
58. Fan air outlet pressure test point
59. Flue outlet pressure test point
61. C.H. selector switch
62. Time clock
63. C.H. boiler thermostat
68. Control box with P.C.B.
71. Modulating balance tube
80. 230 V + 24 V roomstat terminal blocks
81. Ignition electrode
82. Flame sensing electrode
83. Automatic ignition control panel
84. 1. gas valve operator 230 V
85. 2. gas valve operator 230 V
86. Automatic control reset knob
100. Fault diagnostic/temperature control panel
101. P.C.B. (printed circuit board)
114. Water pressure switch
132. Flue deflector
136. Flowmeter
145. C.H. pressure gauges
154. Condense drain pipe
157. D.H.W. thermostat
158. Gas inlet pressure test point
161. Condensing heat exchanger
162. D.H.W. coil
172. Setting OTC curve
174. Fault dignostic/temperature control panel with outside
temperature compensation
7
2001
Installation Details
Gas Safety (Installation & Use) Regulations: 1994
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 in your interest and that of safety to ensure that the law is complied with.
Important - If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the
British Gas publication; Guide for Gas Installation in Timber Frame Housing: Reference DM2. If in doubt advice must
be sought from the Local Gas Region of British Gas Plc.
Location of Boiler
The installation of the
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. 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, should be so situated that it cannot be touched by a person using the bath or shower.
Terminal Position
POSITION MINIMUM SPACING (fig. 3) 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 distance
is less than 2 m from the outside floor.
Air Supply
The room in which the boiler is installed does not require a purpose provided vent. If the boiler is installed in a cupboard or
compartment, permanent air vent are required in the cupboard or compartment, one at high level one at low level, either direct
to the outside air to a room. Both high and low level air vents must communicate with the same space.
Minimum effective area requirements of compartment air vents (for cooling purposes only) (fig. 4).
Condensate
The boiler condensate should, if possible, be discharged into the household internal draining system, that is, sink or washing machine
drain. If this is not practicable, discharge can be external, into the household drainage system or a purpose designed soak away.
Shade condensate hose into a "U" prior to entering drainage system to form a water trap. See fig. 5.
Refer to British publication "Guidance notes for the installation of domestic condensing boilers" for further information.
2001 must be on a suitable non-combustible load bearing wall which will provide an
8
2001
Terminal Position Air supply
APPLIANCE
APPLIANCE
LOCATION
IN ROOM NIL
FLUE
SYSTEM
ROOM-SEALED AIR VENT AREAS
Minimum Clearance
Fig. 3
mm
Condensate hose
Internal drainage
system fitted with
"U" bend
IN COMPARTMENT
OPEN TO ROOM
IN COMPARTMENT
OPEN TO OUTSIDE
AIR VENT
AIR VENT
Fig. 4
HIGH LEVEL:
2
238 cm
(37 in.2)
LOW LEVEL:
238 cm2 (37 in.2)
HIGH LEVEL:
2
(18 in.2)
119 cm
LOW LEVEL:
119 cm2 (18 in.2)
NOTES
* If a side outlet flue is to be used, a clearance of 75 mm will be needed on the flue outlet side of the boiler.
** Access to the front of the boiler must be available for maintenance (min. 600 mm).
Fig. 5
9
2001
Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
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 2815 mm for rear flues and deduct 91 mm 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 ventilators, windows, doors, natural air infiltration, or forced ventilation/air conditioning.
The flue must be installed with a fall of: 35 mm per metre (2°)
Gas Supply
If necessary the local Gas Region 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 Region.
A gas meter can only be connected by the Local Gas Region, or by a Local Gas Region's Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20 mbar MINIMUM.
Pipework from the meter to the combination boiler must be of an adequate size, minimum 22 mm.
The boiler requires 2.65 m
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 manifold assembly.
3
/h (93.6 ft3/h) of natural gas.
Water System
Central Heating
It must be a sealed system. 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. It should be ensured that the boiler heat exchanger is not a natural point for collecting
air. A typical heating system with domestic hot water circuit is illustrated in fig. 6.
Important - 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 if thermostatic radiator valves are fitted throughout.
Make up Water
Provision must be made for replacing water lost from 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
Byelaw. Again any such connection must be disconnected after use.
Domestic Hot Water
Always fit a water softener or descaler in «hard water areas». A 15 mm copper connection point on the boiler jig bracket 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 (10-16 ft) 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.
towards the boiler, see fig. 12.
10
2001
Gas
Cold water
Additional expansion vessel C.H.
Filling
point C.H.
Fig. 6
NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout.
(if required)
Bypass
TEMPORARY FILLING LOOP
A temporary filling loop of the above type conforming to WRC
approval should be installed between the cold water mains and the
central heating system.
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
Fig. 7
11
2001
Built-in Central Heating Water Circulating Pump
The pump head available for circulating the water is given in fig. 8.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grunfos Pump performance graph
Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.
If required an additional expansion vessel may be fitted to the central heating return inlet.
If the total volume of water in the system exceeds 40 litres an additional expansion vessel must be fitted to
the central heating return inlet.
Pump performance curve Grundfos UPS 25-60
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
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
200 28.0 51.8 110.2 38.0 82.4 66.2
For syst. volumes other than
those given above, mult. the syst.
volume by the factor across
0.5 1.0 1.5
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
3.0
12
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 7 litre vessel supplied.
Note
1. Fill C.H. installation to min. 1.5 bar.
2. Select by preference the expansion vessel for increased
system pressure of 2.0 bar
3. Expansion vessel must be fitted to Central Heating
Return Inlet
4. The standard 7 litres expansion vessel is charged to 1
bar
Fig. 9
2001
Installation
Note - To mount the boiler on the wall, a two person lift will be needed.
1.0 UNPACKING
The appliance is delivered in 2 cartons.
1.1 The large carton contains the boiler, and the Installation/Servicing and Users Instructions.
1.2 The second carton contains the mounting jig assembly, complete with isolating valves, the assembly fixing
screws and wall plugs (x4), the boiler mounting nuts and washers (x2), drilling template, flue assembly and turret.
When the cartons are unpacked examine for any signs of damage in transit. All protective plastic should be left in place
until installation is complete.
2.0 FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
2.1 Select the boiler location carefully ensure that all requirements given in previous text are satisfied.
Fig. 10 will also give guidance to fixing dimensions.
2.2 Locate template on wall, mark the positions of the four jig bracket fixing holes and the flue opening.
2.3 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
2.4 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
2.5 Fit the top and bottom brackets using the four fixing screws provided (Ensure that all the service cocks are
in the OFF position). Operate valves several times to ensure they are free.
2.6 With the exception of the connection to the pressure relief valve, make all the water and gas connections
to the jig bracket valves. Fully tighten (fig. 11). Water connections can be made with compression or capillary
fittings.
3.0 FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
3.1 Select the boiler location carefully ensuring that all the requirements given in previous text are satisfied.
Fig. 10 will aso give guidance.
3.2 Locate the template on wall and mark the position of the four jig bracket fixing holes.
3.3 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
3.4 Fit the top and bottom brackets using the four fixing screws provided.
3.5 Extend a horizontal line from the centre of the rear flue outlet to the side wall.
3.6 Mark the centre line (vertically) for the flue assembly hole, and mark the centre of the hole.
3.7 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
13
2001
Important Note - Always use two spanners to prevent twisting of soft copper pipework on the boiler.
Flush out the water system.
Note - The maximum inlet cold water pressure must not exceed 10 bar (145 P.S.I.) and a water governor or a pressure
reducing valve will be required if the pressure is in excess of 5 bar (72 P.S.I.).
Ensure all pipework is adequately supported.
Note - Min 91 for side flue outlet
Drilling template
2 Gas 22 mm
Fig. 10
3 Domestic Hot Water
outlet 15 mm
Rear flue outlet
Diam. min. 118 mm
1 = Electrical cable entry
2 = Gas supply
3 = Domestic Hot Water outlet
4 = Domestic Cold Water Inlet
5 = Outlet Central Heating safety valve
6 = Central Heating flow outlet
7 = Central Heating return inlet
2 = 22 mm
3-4-5 = 15 mm
6-7 = 22 mm
5 Outlet central heating
safety valve 15 mm
Upper bracket
Lower bracket
Fixing stud
boiler
Boiler = 480 mm
4 Domestic Cold Water inlet 15 mm
6 Central Heating flow outlet 22 mm
7 Central Heating return inlet 22 mm
40
Side flue outlet
Diam. min. 118 mm
Note - Min 75 for
side flue outlet
Important Note - Always use two spanners to prevent twisting of soft copper pipework.
Note - The central heating safety valve (5) should be piped 15 mm to discharge safely outside the property.
14
Fig. 11
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