Page 1
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 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
Boiler Flow Diagram
2001
Fig. 2
6
Page 7
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
Page 8
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
Page 9
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
Page 10
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
Page 11
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
Page 12
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
Page 13
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
Page 14
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
Page 15
2001
4.0 PREPARING THE FLUE ASSEMBLY
Rear Flue Outlet (fig. 12)
4.1
Important - The aluminium flue pipe must protrude into the outside grill by 2 in (50 mm), never cut it to the same length
as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 50 mm !).
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
F1 (Flue outlet)
÷60 mm
4.1.1 Accurately measure the Wall thickness (P1)
4.1.2 From the end opposite to the terminal, cut the plastic
air duct (dimension A1) to length (P1 + 105 mm).
Note - That the terminal is not included in A1.
4.1.3 Cut the metal flue duct to length (P1 + 155 mm)
(dimensions F1).
Note - The metal flue pipe must be 50 mm (2 inches)
longer than the plastic air inlet pipe.
4.1.4 Drill a 3 mm hole 15 mm from the plain end of plastic
air duct.
4.1.5 Place flue components to one side to be used later.
4.2 Side Flue Outlet (fig. 13).
Important - The aluminium flue pipe must protrude
into the outside grill by 2 in (50 mm), never cut it to the
same length as the plastic air pipe.
K = 10
Fixing screw
Air sealing sleeve
Rear flue Outlet
Fig. 12
Make sure flue slopes 2
boiler that is 35 mm fall per metre of flue length
A1 (Air intake)
° down towards the
Fixing
K
screw
Side Flue Outlet
Fig. 13
Aluminium flue pipe length = Plastic air inlet pipe length
plus 50 mm (2") longer.
4.2.1 Accurately measure the Wall thickness (P2).
4.2.2 Accurately measure the distance from the centre of the stud fixing of the
mounting jig assembly to the side wall (Q2).
4.2.3 From the end opposite to the terminal, cut the plastic air duct (dimension
A2) to length (P2 + Q2 + 125 mm).
Note - That the terminal is not included in length A2.
4.2.4 Cut the metal flue duct to length (P2 + Q2 + 175 mm) (dimension F2).
Note - The metal flue pipe must be 50 mm (2 inches) longer than the
plastic air inlet pipe.
4.2.5 Drill a 3 mm hole 15 mm from the plain end of plastic air duct.
4.2.6 Place flue components to one side to be used later.
15
Page 16
2001
5.0 CONNECTING THE BOILER
5.1 Place the boiler on its back.
5.2 Remove the boiler base plate, four screws (fig. 16). Remove the plugs fitted to the boiler water connections.
Remove the bag of sealing washers from the boiler pipework. Remove the front panel by gripping on both
sides, slide up to disengage lugs and pull away.
5.3 Lift boiler as shown in fig. 15 onto the top studs and fit supplied nuts and washers hand tight.
5.4 Lift at bottom to engage the water and gas connections. Tighten central heating flow and return, and the
domestic hot water inlet and outlet, using appropriate sealing washers. Tighten the gas union.
5.5 Screw the pressure relief valve adaptor provided, through the jig bracket into the valve, using the remaining
washer (fig. 17).
5.6 Connect the pressure relief valve discharge pipe (15 mm) to the outside of the building, where possible over a
drain. The discharge must be such that it will not be hazardous to occupants or passers-by cause damage to
external electric components or wiring. The pipe should be directed towards the wall.
5.7 Connect the condensate hose to discharge into the internal household drainage system as shown in fig. 5.
Refer to British Gas Publication "Guidance notes for the Installation of Domestic Condensing Boilers" for further
information.
It must not discharge above an entrance or window, or any type of public access. The installer must consider
that the overflow could discharge boiling water.
16
Fixing
screws
Flue sealing gasket
Air sealing gasket
TOP VIEW BOILER SIDE OUTLET
Fig. 14
Page 17
Fixing points
2001
Lift here
Fixing screws
Fig. 16 Fig. 17
Fig. 15
17
Page 18
2001
6.0 FITTING THE FLUE ASSEMBLY
6.1 With Sufficient Clearance To Insert Assembly From Inside
6.1.1 Push the air duct seal onto the air duct at the cut end.
6.1.2 Insert the flue assembly into the wall ensuring a 2° slope back to the boiler.
6.1.3 Make good internal wall face.
6.1.4 Fully insert the flue assembly into the turret spigot. Insert the self tapping screw supplied. Fully tighten.
6.1.5 Secure the turret.
6.1.6 Slide the air duct seal over the joint.
6.1.7 Check the terminal relationship with the wall as shown in fig. 12.
6.1.8 Make good the outside wall face, re-weatherproof.
6.2 With insufficient Clearance To Insert Assembly From Inside
6.2.1 From outside, push flue duct, then the air duct through the wall.
6.2.2 Push the air duct seal over the air duct.
6.2.3 Fully insert the flue duct into the turret, then the air duct. Slide, back the seal and secure the air duct with the self
tapping screw provided.
6.2.4 Slide the seal over the joint and secure the turret.
6.2.5 Continue as detailed in 6.1.8 above.
7.0 ELECTRICAL INSTALLATION
Electrical installation must be carried out by a competent electrician. The appliance is to be connected to a 230 V ~ 50
Hz supply (see fig. 18). The supply fuse rating is 3A. The terminals are accessible after removing the white base plate
and single screw securing the terminal cover (see fig. 18).
7.1 Procedure
7.1.1 The supply cable must be no less than 0.75 mm (24x0.2 mm) to BS6500 table 16.
7.1.2 The earth conductor must be cut longer than the live and neutral (fig. 19).
Connect the Supply Cable to the terminal block marked 230 V ~ 50 Hz, L, N, the supply cable is to be connected as follows:
i) Connect the brown wire to the L (live) terminal).
ii) The blue wire to the N (neutral) terminal.
iii) The green/yellow wire to the (earth) terminal.
7.1.3 Secure the cable with the cable clamp. The supply cable can be connected to the mains supply by the use of an unswitched
shuttered socket-outlet in conjunction with the 3A fused 3 pin plug both in accordance with BS 1363. This provides complete
isolation. Alternatively, a fused double pole switch having a contact separation of at least 3 mm, in all poles and provided
just for the boiler and its external controls can be used. A wiring diagram is provided on the appliance, attached to the
rear of the front panel. In addition, there is one in this manual (fig. 25). Attention is drawn to the requirements of the current
I.E.E. Regulation and in Scotland, the electrical provisions of the Building regulations.
7.2 Room Thermostat (fig. 18) (or remote time clock connection)
7.2.1 Please note that the room thermostat, clock switch connection is 24 V. To connect mains voltage to these terminals will
seriously damage the printed circuit board. The room thermostat and clock switch connector block is situated within the
connector box. Twin core cable should be used for this connection (terminals 4 and 5).
7.2.2 If using a remote 230 Volt time clock ensure that the motor and switch connections are totally separate in the clock and
that the switch connections are independent for the 24 Volt terminals (4 and 5) on the boiler.
External controls: room stat or remote time
clock in the place of loop terminals 4 and 5.
Please note 24 V only, use only voltage free
contacts.
IMPORTANT
If 230 V is
connected to
terminals 4 or 5,
damage will be
caused to the
P.C.B.
18
Fig. 18
Screw
Brown
Blue
Fig. 19
Page 19
7.3 External compensation sensor (optional)
7.3.1 To be wired to terminals 7 and 8 on the appliance
connector box (see fig. 18), low voltage twin wire
can used.
7.3.2 External sensor location
The external sensor should be installed on the
North, North-West wall or on the one facing the
majority of the main living rooms in the building.
The sensor must never be exposed to the first
morning sunlight. It must never be subjected to
direct sunlight and should be protected if
necessary.
In no case may the sensor be mounted near windows,
doors, ventilation openings, stacks or heat sources
which could alter its reading.
2001
Fig. 19a
Fig. 19b
19
Page 20
2001
7.4 Setting of compensation curve
The boiler can now be regulated to ensure the design critia of the system is matched to the outside temperature
7.4.1 Consult the outside compensation graph provided (fig. 19c)
7.4.2 Following the bottom ouside temperature line to find the outside temperature. The system is designed for.
7.4.3 Trace a line vertically until you reach the designed system flow temperature.
7.4.4 Read from the graph the number setting that the boiler is to be adjusted to. If the setting is between two
numers this can be set on the boiler, say between 2 and 3.
7.4.5 Remove the plastic cover of the outside compensation adjustment screw on the boiler facia panel (fig. 19d)
90
5
4
80
70
3
60
50
Flow temperature °C
40
2
1
MIN.
°
C
132654
30
20
20 15 10 5 0 -5 -10 -15 -20
Ouside temperature °C
Fig. 19c
7.4.6 By use of a small screwdriver set the arrow on the adjustment screw to desired setting
LEDS
Fig. 19d
Outside compensation
adjustment screw
42
531
MIN.
MAX.
°
C
MAX.
20
Page 21
8.0 COMMISSIONING AND TESTING
8.1 Filling the Central Heating System
2001
Burner pressure
test point
Gas inlet pressure
test point
Remove the top front panel by gripping both sides, slide up to disengage lugs and pull away.
Loosen the cap of the automatic air vent (fig. 20) and leave it loose.
Open the central heating flow and return cocks (fig. 11).
Gradually fill the system as detailed in Make up Water.
While filling, vent the heat exchanger at venting point by loosening cap (fig. 20) and vent each radiator.
Tighten cap on heat exchanger air vent.
Ensure the working pressure, when filled, is between 1 to 1.5 bar on the pressure gauge (see technical data).
Check the system for leaks.
Flush system in accordance with BS 7593.
8.2 Filling the Domestic Hot Water System
Close all hot water draw off points. Open main cold water stop cock and ensure the cold water inlet cock is open at the
boiler jig bracket (fig. 11). Slowly open each hot tap in turn until clean water, free from air pockets, is seen.
Check system for leaks.
8.3 Electricity Supply
Carry out preliminary checks (i.e. earth continuity, polarily short circuit and resistance to earth using a suitable
multimeter).
8.4 The Gas Installation
The whole of the gas installation including the meter, should be inspected and tested for soundness, and purged in
accordance with the recommendations of BS6891-1988.
D.H.W. drain point
Automatic air vent
C.H. pressure relief valve
Fig. 20
Vent cap
Heat exchanger vent
Pump
Pressure gauge
21
Page 22
Flame
failure
reset knob
Condensate hose
C.H./D.H.W. selector switch
Flame viewing
opening
compensation
adjustment screw
C.H. boiler
thermostat
Fault diagnostic lights
2001
Outside
C.H. pressure
P
AUTO
O
I
AUTO
x
4
12:31
x
E
ID
R
R
VE
O
-
+
P
R
Time clock
Domestic hot water thermostat
gauge
fig. 21
8.5 To Light the Boiler (fig. 21)
a. Open controls panel door.
b. Switch on electricity supply.
c. Adjust room thermostat and all external controls to «ON». Check operation of pump.
d. Turn the boiler thermostat to maximum. Fan will run (A waiting time of max 3 minutes before fan will run is possible!), and
main burner will light.
e. Temporarily turn off by switching off electricity supply.
Important Note: If the burner stops for C.H. only after a waiting time of 3 minutes will the boiler will light again!
22
Page 23
2001
Burner Pressure C.H. and D.H.W.
8.6 To Range Rate the Boiler C.H. (not required for standard installations).
The boiler can be range rated for an output from 9.7 kW (33,000 btu/h) up to 22.6 kW (77,000 Btu/h). When the boiler is supplied
it is factory set at the maximum output 22.6 kW (77,000 Btu/h).
Procedure
a. Release the control panel fixing screws (fig. 30) and lower panel.
b. Loosen the screw in the burner pressure test point (fig. 22) and attach a gauge.
c. Switch on the electricity supply to relight the main burner.
Balance tube
Fig. 22
12 1
11 10
987654321
X1
13
P1
Fig. 24
174
LED
Test point burner pressure
Gas valve
Modureg
Gas inlet pressure test point
12
6 5
234
X2
1
7263512 910
X3
P2
X8
63
172
X4
X5
2
X7
L7
RY1
RY2
JP1
TR1
157
MIN
43
21
230V
50Hz
123456789
341
1
X6
2AT
F1
RY4
JP4
MAX
MIN
P2P1
Fig. 23
Note 1 - Modulation is available on central heating, so the
procedures must be carried out while the system is relatively
cold. Recheck boiler thermostat is set to maximum.
d. Adjust the potentiometer P1 on the PCB (fig. 24) in the
control panel until the required burner pressure is obtained
(Anticlockwise to reduce the pressure).
Note 2 - Short circuit 12-13 only on connector X3 on the P.C.B.
- Boiler starts for C.H.
- Waiting time is excluded
Note 3 - The range of inputs with corresponding burner
pressure is given on the Data badge which is situated behind
the top front panel. Further informations is on (fig. 23).
e. With the pressure set, turn off the electrical supply and mark
the set input on the Data badge (with sticker supplied).
Burner Pressure C.H. and D.H.W.
P1 =C.H. range rating to be set on site (if required)
P2 =D.H.W. temperature (factory set, not to be adjusted)
P1 Adjust with screwdriver!
JP1 Not Fitted
JP4 Not fitted
MAX
Btu/h x 1000
23
Page 24
2001
Honeywell VR 4605 NA 4003 valve
with V7335A4014 Modureg
Gas pressure Adjustment
1 - With the burner lit:
2 - Connect suitable pressure gauge to burner test point "B", and then:
3 - Disconnect air pressure compensation tube "H";
4 - Disconnect the wires from coil "C" of the Modureg;
5 - Remove protective cover "D";
6 - Remove coil "C" by opening the coupling spring "I";
7 - Screw the minimum adjustment screw "E" up tightly. (clockwise)
8 - Unscrew lock nut "F" on sleeve "G";
9 - Adjust maximum pressure by rotating sleeve "G" clockwise to in-
crease pressure and anticlockwise to reduce pressure;
10 - Tighten sleeve lock but "F" then check that the pressure is still at the
required value;
11 - Adjust minimum pressure by rotating screw "E" anticlockwise
until the required value is reached;
12 - Fit coil "C" by sliding it into the sleeve, pushing
and rotating it lightly until the coupling spring "I"
clicks into place;
13 - Shut down and ignite the burner, checking that
the minimum pressure value is stable;
14 - Reconnect the wires to coil "C" of the Modureg;
15 - Reconnect air pressure compensation tube "H";
16 - Replace protective cover "D";
17 - Turn burner off, remove pressure gauge, close
and test, test point;
I
H
D
C
E
G
F
Key
A - Test point inlet pressure
B - Burner test point
C - Coil
D - Protective cover
E - Minimum adjustment screw
F - Lock nut
G - Sleeve
H - Pressure compensation tube
I - Coupling spring
L - Adapter (for only G.L.P. version)
24
A
L
B
Page 25
2001
8.7 D.H.W. Burner Pressure
The domestic hot water burner pressure is not range rateable and not adjustable but the maximum and minimum burner
pressure should be checked as follows:
a. Check electricity supply is still off.
b. Open a D.H.W. tap at high flow until the water runs cool and leave running.
c. Switch on the electricity supply.
d. The pressure should be 16 mbar -/+ 0.5 mbar.
e. Disconnect one of the wires from the «Modureg» (fig. 22), this will reduce the burner to minimum which should read
3.5 mbar +/- 0.5 mbar. If the burner pressure is not as stated check the inlet working pressure (fig. 22) which should
be minimum 20 mbar. If that is correct, consult Ferroli. No attempt should be made to alter D.H.W. burner pressure.
f. Switch off electrical supply and close hot tap.
g. Reconnect the wire to the «Modureg». Remove pressure gauge, tighten the test screws.
h. Replace control panel (2 screws).
i. Turn on electricity supply, open a hot tap to full flow and when the burner lights, test for gas soundness with a leak detection
fluid around the gas valve and connections including the pressure test point screws.
9.0 SYSTEM OPERATION
Let the boiler operate normally on central heating for about 30 minutes.
I) Vent radiators.
II) Vent heat exchanger.
III) Examine all pipework for leakage, also check for leaks from the condensate drainage system.
IV) Turn on a D.H.W. tap and check that the C.H. pump stops running.
V) As the D.H.W. temperature reaches 60°C check the burner for modulation.
Switch off electricity.
Drain down the central heating system fully, when hot. Following BS 7593 - 1993
Refill the system as previously instructed. Repeat the venting.
Examine the system's water pressure and top up as necessary.
Replace the casing front panel and close the control panel cover.
10.0 HANDING OVER TO THE USER
After completion of installation and commissioning of the system:
a. Hand over the User's Instructions' to the Householder and explain His/Her responsability under the Gas safety (Installation
and Use) Regulations 1984.
b. Explain and demonstrate the lighting and shutting down procedure.
c. Explain the operation of the boiler including the use and adjustment of ALL system controls.
Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the
system remaining inoperative during frost conditions.
d. Stress the importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be
carried out at LEAST ONCE A YEAR.
Important:
Advise the user that the Optima 2001, like all other condensing boilers will produce a plume of condensation from the flue
terminal in cold weather, this is quite normal.
25
Page 26
2001
Wiring diagram
NOTE:
THE TRANSFORMER ON THE P.C.B. HAS A BUILT-IN
OVERHEAT PROTECTION.
IF THIS IS OPEN, ALL LED'S WILL BE OFF BUT THE C.H.
PUMP (32) WILL RUN
SWITCH OFF THE BOILER FOR AT LEAST
20 MINUTES
90
80
70
60
50
40
30
20
20 15 10 5 0 -5 -10 -15 -20
CONNECTOR X7
1-2 = 230 V
5
4
3
2
1
63
164
172
LED
174
43
21
16 Fan
32 Central heating pump
34 C.H. flow temperature sensor
42 D.H.W. temperatuure sensor
43 Air pressure switch
47 Modulating regulator
(MODUREG) gas valve
49 Overheat cut-off thermostat
50 Heat exchan. limit thermostat
51 Heat exchan. frost thermostat
56 Expansion vessel
61 C.H. selector switch
62 Time clock
63 C.H. boiler thermostat
68 Control box with P.C.B.
72 Room thermostat (not fitted)
80 Five pole terminal 240V + 24V
81 spark electrode
82 Flame sensing electrode
83 Automatic ignition control panel
84 1. gas valve operator
85 2. gas valve operator
86 automatic control reset knob
101 P.C.B.
114 Water pressure switch
136 Flowmeter
138 Outside temperature sensor
145 C.H. pressure gauge
157 D.H.W. thermostat
169 Suppression filter
172 Setting OTC curve
174 Fault diagnostic/temperature
control panel with outside temperature
compensation
24 V
47
51
50
34
42
114
136
+
-
OUT
X1
11
10
12
13 7
12 8
X3
X2
43
197 26
52843
910
1
26135
X8
12 1
11 10
X1
P1
230V ~ 50 Hz.
HONEYWELL S 4561 A 1015(2)
83
9
8
2
1
3
4
129
21
X4
4
5
6
X5
54213
9
876
X7
X6
12
312
VMF7
CONNECTOR X2
A D.H.W. FLOWSWITCH (ON-OFF)
CAN BE CONNECTED
987654321
13
JP1 and JP4: Jumpers
JP1 Is not required
JP4 Is not required
P1 = C.H. max. output (to be set on site)
P2 = D.H.W. temperature (factory set)
234
X2
1
7263512 910
X8
X7
X3
P2
RY1
RY2
JP1
TR1
61. C.H. selector switch
Heating timed
and hot water
12 1476521313
M
12
X6
X5
X4
X3
3
81
84
49
169
80
16
43
32
5
Hot water only Heating
82
85
L
230V
N
1
2
4
bad
24V
72
CONNECTOR X3
SHORT CIRCUIT 12-13
- BOILER STARTS FOR C.H.
- WAITING TIME IS
EXCLUDED
6 5
X4
X5
2
1
L7
6745
138
12
230V
50Hz
123456789
341
X6
2AT
F1
RY4
JP4
continuous and
hot water
80
26
Page 27
2001
General Notes - For use on the 2001 fitted with VMF7 Printed Circuit Board
*The central heating pump (32) will run to disperse heat if the temperature at the heat exchanger limit thermostat (50) is too high
*The frost thermostat (51) will switch on the boiler for central heating if the temperature is too low.
*Fuse on P.C.B.: 2 Amp.
RY not energised
RY energised
RELAY RY
RY1 central heating pump
RY2 on/off relay
RY4 fan
Note
If RY1 is not energised
the Central Heating pump
will run
Jumpers JP1 - JP4
Fitted Not fitted
JP1 No waiting time Waiting time on
JP4 Fan control Fan control
High & Low speed High speed only/off
Check operation using LED's as a fault finding guide. First check section A, then B, then C, then D.
0 = LED off 1 = LED on x = LED either on/off is not important
Domestic Hot water tap open (Flow rate greater than 2,5 l/min)
LED OK FAULT POSSIBLE CAUSE OF FAULT
1 1 0 No mains electricity/switches off/fuse blown.
2 1 0 D.H.W. flowmeter (136) not operating.
3 X X Not required for D.H.W.
4 1 0 - D.H.W. sensor (42) not connected or D.H.W. temperature too high
A
5 0 1 - Waiting time operating: replace P.C.B.
6 1 0 Short circuit on D.H.W. sensor (42) or resistance lower than 500 Ohm
LED n° signification:
1 Mains on/low voltage on
2 Flowmeter (136) on
3 Central heating room thermostat (72) / clock (62) calling
4 Sensor (34) or (42) calling for heat
5 Central Heating waiting time, max. 3 minutes delay following shut off
Boilerstat (63), Clock (62), Roomstat (72) or use of Hot Water
6 Demand for heat - relay (RY2) will be energised
7 Air pressure switch (43) on, air flow checked
OTS (138) = Outside temperature sensor
temp. Ohm OTS(138) Ohm
Temp.
sensor
(34) (42)
- C.H. limit thermostat (50) open circuit (pump run)
- C.H. water pressure low (114 open circuit)
10° C 890 ohm -10°C 55K
25° C 1000 ohm 0°C 32K
60° C 1300 ohm 10°C 20K
80°C 1490 ohm 20°C 12,5K
30°C8K
CENTRAL HEATING ON Room stat (72) at Max, HW tap closed
LED OK FAULT POSSIBLE CAUSE OF FAULT
1 1 0 No main electricity/switches off, fuse blown.
2 0 1 Hot water tap open - D.H.W. flowmeter (136) contact closed
3 1 0 Roomstat (72) or clock (62) not calling for heat
4 1 0 - Central heating sensor (34) not connected or
B
5 0 1 Waiting time still operating (max. 3 minutes)
6 1 0 - C.H. sensor (34) short circuit or resistance lower than 500 ohm
GENERAL TEST FOR D.H.W. AND CENTRAL HEATING (First check A and B above)
LED/REL. OK FAULT POSSIBLE CAUSE OF FAULT
RY2 energised not energised Check first A and B above
RY4 energised not energised Air pressure switch (43) not in NC position or miswired:
C
7 1 0 - fan (16) not running at full speed or
- boiler temperature too high or
- boiler thermostat (61) below CH temperature
- C.H. limit thermostat (50) open circuit (pump will run)
- C.H. water pressure low (114 open circuit)
- check wiring
- fan (16) at low speed remove jumper JP4
- air flow too low:
- air pressure switch (43) faulty
IGNITION OF BURNER (AUTOMATIC IGNITION)
1 Fan (16) should run at full speed (open hot tap or set controls
D
so boiler is calling for heat).
2 Check first A, B and C above (LED 6 is ON?)
3 Check spark and position of spark electrode (81)
4 Check position of flame sensing electrode (82)
5 Check burner gas pressure during ignition
27
Page 28
2001
General fault finding
Engineer Please Check
1. Gas available (check kitchen and gascocks)
2. Electrical mains is on.
3. Water pressure Central Heating System (min. 1 bar on pressure gauge)
4. Water flow domestic hot water (min. 0.5 Gal/min - 2.5 L/min.) (fills a 1 pint milk bottle max. 15 seconds).
5. Is central heating pump running.
6. Air inlet/flue outlet free from obstacles.
7. Are all service cocks open?
8. Is at least one radiator valve or bypass in Central
Heating system open?
Always follow the complete General test Procedure to
make sure that no fault remains unnoticed.
Never disconnect any wire without previous testing. It is
possible that a fault disappears after disconnecting and
rewiring the electrical connections, this fault will return.
Never pull on the wires in the terminals.
To disconnect the terminal pull on the insulation cover,
keeping the terminal pushed back.
The relays on the P.C.B. can be checked. The relays have
transparent covers and the position of the contacts can be
verified (to see if a relay is energised or not see fig. 28).
Top view relay
Replacement of Parts
1.0 INITIAL PROCEDURE
Before work commences ensure that:
a) The boiler is cold, electricity supply is isolated, and the gas supply is turned off at the inlet of the boiler (fig. 1).
b) For replacement of parts where water connections are broken, it will be necessary to isolate and drain either or both
the central heating or domestic hot water circuits of the boiler only. The cold water mains inlet is isolated at the inlet
cock (fig. 1). The D.H.W. is drained via drain cap (fig. 34).
The C.H. flow and return cocks are turned off at the isolation cocks (fig. 1). The C.H. is drained via the pressure relief valve
(twist about 1/2 of a turn).
Important
c) Upon completion of the work the following (details of which are included in the commissioning section):
Should be checked:
I) Gas soundness of all joints.
II) Water soundness of all joints.
III) The electricity supply.
IV) The pressure of the sealed system and top up where necessary.
d) Replace all components in reverse order, observing any special notes given.
e) Removal of Outer Casing
Note - It may not be necessary to remove all the outer casing. Refer to individual sections for the extent to which the outer case
needs to be removed.
f) Front Panel
Grip on both sides and lift away from the main boiler assembly.
Relay
not energised
Relay
energised
Fig. 28
28
Page 29
2001
g) Base Plate
Remove the four fixing screws (fig. 16).
h) Side Panels
For each panel, remove two fixing screws at base of appliance and single fixing screw at top of appliance (fig. 30).
Also remove hinged control panel cover.
Note - The panels are located in keyhole slots, push panels upwards and pull away.
i) Removal of Combustion Chamber Outer Cover
Remove the five combustion chamber outer cover fixing screws and undo four buckle clips (fig. 30) to remove cover.
j) To Remove Control Panel
Hinge control panel cover downwards.
The two control panel securing screws can now be removed (fig. 30), remove C/H and D.H.W. thermostat knobs hinge control
panel forwards and disengage from bottom lugs, the control panel can now be removed.
k) To lower control box frame
Remove screw securing gas control valve to frame.
Remove the base plate (g) above.
Remove the two screws securing the frame to the back panel.
Side panel fixing screws
Fasteners
(buckle clips)
Combustion chamber
outer cover fixing screws
Electric box support
fixing screws
Side panel / base plate
fixing screws
Gas valve fixing screw
Fasteners
(buckle clips)
Electric box cover
fixing screws
Control panel
fixing screw
Fig. 30
29
Page 30
Details Combustion Chamber
2001
Key
16. Fan
28. Flue collector
from heat exchanger
30
Fig. 32
Page 31
2001
Caleffi
Details Burner
Key
81. Ignition electrode
82. Flame sensing electrode
Fig. 33
2.0 FLOWMETER (Domestic Hot Water) AND FILTER
a) Refer to section 1, items a, b, c, d, f and g (drain D.H.W. only fig. 34).
b) Undo the flow switch unions and carefully lower the flow switch taking care not to lose either the (three) sealing washers,
filter or flow restrictor.
c) Disconnect the electrical connections to the flowmeter.
d) Re-assemble in reverse order, ensuring that the filter, flow restrictor and sealing washers are in the correct position
(fig. 35). The polarity for the electrical wiring is immaterial.
Union to be released when
removing heat exchanger
Heat exchanger
venting cap
C.H. pressure
sensing point
C.H. temperature thermometer
phial and shim
D.H.W.
drain point
Fig. 34
C.H. pressure
relief valve
(drain point)
37
37 Cold water inlet filter
136 Flowmeter
39 Cold water flow restricter
136
Fig. 35
39
31
Page 32
2001
3.0 HONEYWELL GAS VALVE (fig. 31)
a) Refer to Section 1, items a, c, d, f, g, h (left hand side panel) and j.
b) Disconnect the four electrical connections from the top of the valve.
c) Disconnect modulating balance tube by removing the fixing screw, and gently pull off from the front of the valve.
d) Disconnect the gas supply to the gas valve at the inlet union.
e) Remove the screw securing the base of the gas valve to the control box frame of the appliance.
f) Remove the four Allen screw which secure the inlet supply pipe to the gas valve.
(Take care not to lose the sealing washer).
g) Undo the union which is on the burner supply pipe and withdraw gas valve towards front.
h) Re-assemble in reverse order. Re-connect electrical connection in accordance with the wiring diagram (fig. 25).
i) Fully test the operation of the new gas valve and reset burner pressures as prescribed (see commissioning).
4.0 P.C.B.
a) Refer to section 1, items a, c, d, f and j.
b) Unscrew two fixing screws on the P.C.B. top cover plate, lift and disconnect all connectors from P.C.B. (fig. 39).
c) Unscrew upper fixing screws from P.C.B.
d) Gently pull P.C.B. off mounting studs and remove.
e) Re-assemble in reverse order (Refer to wiring diagram fig. 25).
f) Range rate the boiler C.H. and check the operation of the controls (See commissioning).
Cover plate
fixing screws
P.C.B. connectors
P.C.B. upper
fixing screws
C.H. selector switch
Fault diagnostic/temperature
5.0 CENTRAL HEATING LIMIT THERMOSTAT, OR FROST THERMOSTAT, OR OVERHEAT CUT OFF THERMOSTAT
a) Refer to Section 1, items a, d, f and i.
b) Refer to fig. 2 to identify the location of respective thermostat.
c) Remove two spring clips (with a pair of pliers).
d) Disconnect electrical connections to the thermostat.
e) Re-assemble in reverse order (Polarity Immaterial). Heat sink compound, must be used.
control panel
Time clock
Fig. 39
32
Page 33
2001
6.0 D.H.W. TEMPERATURE SENSOR OR CENTRAL HEATING TEMPERATURE SENSOR
a) Refer to section 1, items a, b, c, d, f, g, h (left hand side panel) and k.
b) Identify the sensor from fig. 2.
c) Disconnect the electrical connections to the sensor.
d) Unscrew the temperature sensor.
e) Re-assemble in reverse order (Polarity Immaterial).
7.0 PRESSURE RELIEF VALVE
a) Refer to section 1, items a, b, (central heating) c, d, and g.
Note - If this valve is not working correctly then the water can only be drained from the appliance by, removing the pressure
relief valve.
b) Release the outlet union to the valve and undo the valve union connection, taking care not to lose the sealing washers.
c) Remove the pressure relief valve outlet fitting.
d) Re-assemble in reverse order, and check the operation of new valve.
8.0 PUMP
a) Refer to section 1, items a, b (central heating), c, d, f, g, h (right hand side panel), j and k.
b) Loosen the two pump union connections.
c) Remove electrical cover on pump, one screw (fig. 40). (Rotate pump to remove cover).
d) Disconnect the live, neutral and earth connection.
e) Release the cable retaining gland and pull the cable clear.
f) Disconnect the two pump union connections. Remove pump (Retain washers if not re-newing).
g) Re-assemble in reverse order (fig. 40).
Note - Ensure the arrow indicating the direction of flow, on the pump housing is pointing upwards, and the speed setting is at 3.
9.0 AUTOMATIC AIR VENT
a) Refer to Section 1, items a, b (central heating), c, d, f, g, h, (right hand side panel) and k.
b) Loosen the pump union connections and swivel the pump to the right.
c) Unscrew the automatic air vent (fig. 2, item 36).
d) Re-assemble in reverse order ensuring the «O» ring is fitted (fig. 41) and that the venting cap is loose.
Replace pump ensuring that the arrow indicating flow points upwards.
Washer
Venting cap
Cover fixing screw
Fig. 40
Automatic air vent
O-ring
Washer
Fig. 41
33
Page 34
2001
10.0 PRESSURE GAUGE
a) Refer to Section 1, items a, b, (central heating), c, d, f, g and j.
b) Remove the shim then the temperature sensing phial from its pocket (fig. 37).
c) Unscrew the pressure sensor from its housing (fig. 37). (Access from below).
d) Unscrew the knurled nut from the rear of the gauge, and remove the gauge
forwards.
11.0 REMOVAL OF C.H. SELECTOR SWITCH
a) Refer to section 1, items a, c, d, f and j.
b) Disconnect the electrical connections to the selector switch (fig. 42).
c) Pull off selector switch knob.
d) Unscrew the two fixing screws exposed when the knob is removed.
e) Re-assemble in reverse order (refer to fig. 42 for wiring). Check the
operation of the new switch.
Fig. 42
Terminal No. 09
Brown
White
Time Clock
A 24 hour time clock is fitted to the boiler to control the central heating, this will come into operation when the selector
switch is turned to the position marked “heating timed and hot water”.
Black
Black
Terminal No. 10
Black
Black
Terminal No.
Terminal No. 5
AUTO
AUTO
P
F
OI
12:31
4
x
x
OVER RIDE
-
+
P
R
RDP
A Slide switch: set clock - auto - set programme
A
B Display. Symbol in Display = Timer ON
P Select programme ON/OFF 1.....8
B
D Push buttons Time + Time
E
E Override: Boiler will switch ON if boiler is OFF;
-
and OFF if is ON
F I=Heating continuous - AUTO=Heating timed - O=Heating disabled
R Reset (with pencil) only with switch A in set clock position
To set time of day
1. Slide switch (A) to left position
2. Using button + and
-
adjust until the correct time is shown on display (B).
Pre Set Programmes. The timer is pre programmed with 3 ON and 3 OFF times.
6:30 - 8:30
12:00 - 12:00
16:30 : 23:30
If these are suitable no programming is required and the slide switch (A) can be
moved to the Auto position and the central heating will be ON for these periods.
(12:00 - 12:00 will not switch on the boiler)
34
Page 35
2001
To Set Own ON and OFF times. Symbol in Display = ON time
1. Slide switch (A) to right position (P)
Display
2. Press button (P)
Display
3. Press button (P)
Display
4. Press button (P)
Display
5. Press button (P)
Display
6. Press button (P)
Display
7. The timer can be programmed with up to 8 ON and
8 OFF times by repeating the above procedure.
Over ride
By pressing the over ride button (E) the timer programme is over ridden ie, if programme is in OFF time it will come ON and
if in ON time will go OFF.
The timer will revert back to it set programme on reaching the next ON or OFF time.
When the programme is on over ride the sign will be shown in the display window (B).
Reset Button
By the use of a pencil the reset button can be pushed (R). This will clear all programmes
apart from those factory pre set.
Reset is only possible with switch (A) in set Clock position!
6:30
8:30
12:00
12:00
16:30
22:30
1 6:00
2 9:00
3 12:30
4
5
6
x
1.1 Use buttons + and - to set 1st ON time eg. 6:00
Display
2.1 Use buttons + and - to set OFF time, eg. 9:00
Display
3.1 Use button + and - to set 2nd ON time, eg. 12:30
Display
4.1 Use button + and - to set 2nd OFF time eg. 14:00
Display
5.1 Use button + and - to set 3rd ON time, eg. 16:00
Display
6.1 Use button + and - to set 3rd OFF time eg. 23:30
Display
8. On completion of programming slide switch (A) to Auto
position, the time of day will be displayed and the central heating will switch ON and OFF according to the
programme set.
14:00
16:00
23:30
1
2
3
4
5
6
12.0 REMOVAL OF THE CLOCK
a) Refer to section 1, items a, c, d, f and j.
b) Disconnect the electrical connections to the time clock.
c) Remove the time clock from the control panel (fig. 43).
d) Re-assemble in reverse order (refer to fig. 43 for replacement of the
time clock).
Fig. 43
35
Page 36
2001
13.0 REMOVAL OF FAULT DIAGNOSTIC/TEMPERATURE CONTROL
a) Refer to Section 1, items a, c, d, f, and j.
b) Remove P.C.B. top cover by unscrewing the two fixing screws.
c) Pull control box front cover forward
d) Disconnect electrical connections from fault diagnostic control panel
e) Remove rataining nuts from the C.H. and D.H.W.thermostat spindles, remove fault diagnostic/temperature control panel.
f) Re-assemble in reverse order.
14.0 AIR PRESSURE SWITCH
a) Refer to Section 1, items a, c, d, f, and i.
b) Remove the two screws securing the air collection plate (fig. 45), and withdraw the plate complete with the air pressure
switch (Take care not to lose «P» clip).
c) Disconnect electrical leads to air pressure switch.
d) Remove pressure sensing tubes.
e) Remove the pressure switch, 2 screws.
f) Re-assemble in reverse order (refer to fig. 46 for wiring).
White silicone tube
P1
36
Red silicone tube
BROWN
3
BLACK
BLUE
3
BROWN
3
BLUE
KROMSCHRODER
DL 1E
1
HUBA 605
2
1
HUBA 602
1
P2
Fig. 45
KROMSCHRODER
2
BLUE
BLACK
2
BLACK
BROWN
2
1
3
1
3
2
HUBA 605
HUBA 602
23
1
Fig. 46
Page 37
2001
15.0 REMOVAL AND RE-PRESSURISING OF C.H. EXPANSION VESSEL
Note - If there is less than 500 mm clearance above the boiler or if the boiler has a rear flue outlet then removal of the
expansion vessel can only be achieved by first removing the boiler from the wall.
Note - For rear exit flues it is not recommended that the flue and air duct be removed from the wall. Either remove the boiler
leaving the ducts in place or insert an equivalent vessel in the central heating return to the boiler.
a) Removal of expansion vessel.
I) Refer to section 1, items a, b and c (Drain C.H. side of boiler).
II) Remove the two screws from the expansion vessel securing plate, (fig. 47) which can be found at the top back of the boiler.
III) Undo the compression fitting on the top of the expansion vessel (fig. 47).
IV) Remove the expansion vessel.
V) Re-assemble in reverse order.
b) Re-pressuring of expansion vessel. (Charge pressure 0,8 - 1,0 bar).
I) Close the C.H. flow and return cocks on boiler and drain the boiler (fig. 20).
II) The schrader valve is positioned on the top right hand side of the expansion vessel, behind the inlet connection.
III) Re-open C.H. flow and return cocks and re-charge the system to between 1 & 1,5 bar and vent the boiler and radiators.
Expansion vessel retaining plate
retaining plate
Fixing screws
Fig. 47
Expansion vessel
support
37
Page 38
2001
Exploded view gas line, combustion chamber and draft diverter
Key
75 Complete combustion chamber
76 Combustion chamber insulation back panel
77 Combustion chamber insulation side panel
78 Flue collector
81 Fan
87 Panel isolation
88 Combustion chamber panel
89 Glass window
94 Burner box
38
Fig. 49
95 Burner Venturi
96 Injector
104 pressure test point
105 Gas valve
108 Inlet tube gas valve
111 Ignition electrode
112 Ignition electrode support
113 Flame sensing electrode
Page 39
2001
Exploded view heat exchanger + C.H. and D.H.W. parts
Fig. 50
Key
130 Copper heat exchanger for C.H. + D.H.W.
131 Central heating frost thermostat
132 Central heating limit thermostat
133 Overheat cut-off thermostat
140 Automatic air vent
141 Safety valve
143 Central heating pump
147 D.H.W. limit thermostat
148 Flue deflector
149 Temperature sensor
151 Cold water inlet filter
152 Cold water flow limiter
154 Flowmeter
155 Condensing heat exchanger
39
Page 40
2001
Spare Parts List
Item No. G.C. Part No. Makers Part No No. Off DESCRIPTION
14 386816 800130 1 C.H. safety valve
16 - 803510 1 Fan
21 - 803710 20 Main injector (Natural Gas)
32 - 803690 1 Central heating pump
34 386818 800310 1 Temperature sensor
36 394246 801160 1 Automatic air vent
39 386829 801220 1 Cold water flow limiter 10 l/min.
42 386818 800310 1 Temperature sensor
43 381691 800140 1 Air pressure switch
44 - 802640 1 Combination gas valve
49 - 800170 1 Overheat cut-off thermostat
50 386577 800160 1 Heat exchanger limit thermostat
51 386828 800180 1 Heat exchanger frost thermostat
61 372225 801230 1 C.H.selector switch
62 - 980383 1 Time clock
81 - 803720 1 Ignition electrode
82 - 803730 1 Flame sensing electrode
83 - 802560 1 Ignition board Honeywell
174 - 803700 1 Fault diagnostic/temperature control panel
101 - 803410 1 P.C.B. VMF7
113 - 1KWMA50U 1 Special two pipe flue/air adapter
136 - 803430 1 Flowmeter
145 - 803890 1 C.H. pressure gauge
with outside temperature compensation
40
Page 41
Domestic Hot Water Performance
Fig. 1 - D.H.W. Pressure Drop VS. flow
A=Standard with cold water Flow Restricter
B=Cold Water Flow Restricter Removed
90
80
70
°C
60
Fig. 2 - D.H.W.
temperature VS. flow
A=Cold Water 15°C
B=Cold Water 5°C
50
40
30
20
10
0 1 2 3 4 5 6 7 8 9 10 11 12
Modulating regulator (Modureg) of gas valve
1. Cap (with tube 71)
2. Shaft
3. Adjustment screw for max. pressure setting
4. Adjustment screw for min. pressure setting
5. 6,3 mm AMP terminals
6. «O» ring
71. Modulating balance tube
If necessary replace complete MODUREG
2001
Fig. 1
A
B
litres/min
Fig. 2
Pressure Minimum Maximum
settings mbar mbar
Natural Gas 2.7 14.5
41
Page 42
2001
Special Installation Possibilities: Two-pipe air intake/flue outlet
Special Air Intake/Flue Outlet
The standard Flue/air intake hood on top of the boiler can be replaced by a special two pipe flue adapter.
For details see separate instructions;
«Optional flue systems»
42
top view boiler
Page 43
2001
43
Page 44
Phone numbers:
Installer
Service Engineer
BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS
MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.
ALL SPECIFICATIONS SUBJECT TO CHANGE
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 08707 282 885 - Fax 08707 282 886
Cod. 3540244/1 - 01/01
Loading...