SYS 10-23
Wall-Hung, Gas-Fired,
System Boiler,
for Central Heating
INSTALLATION,
MAINTENANCE AND USER
INSTRUCTIONS
cod. 3544570/0 - 10/2003
IMPORTANT
Your "benchmark" Installation, Commissioning and Service Record Log Book will be enclosed in your
customer information pack. "This record must be completed and left with the end user"
"All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both
should be recorded in your central heating log book. You can check with the CORGI registered
by calling CORGI on 01256 372300".
• Carefully read the warnings in this instruction booklet, as they provide important
indications on the safety of installation,
operation and maintenance.
• The instruction booklet is an integral
and essential part of the product and
must be carefully kept by the user for
future reference.
• If the appliance is sold or transferred to
another owner, or if it is moved, always
check that the booklet accompanies the
boiler for reference by the new owner
and/or installer.
• The installation and maintenance operations must be performed according to the
standards in force, the instructions of the
manufacturer and must be carried out by
professionally qualified personnel.
• Incorrect installation or poor maintenance
may cause a damager to persons or
property. The manufacturer declines all
liability for damage deriving from errors
in the installation and maintenance of the
appliance, and where there is a failure
to observe the instructions provided by
the manufacturer.
• Before performing any cleaning or
maintenance operations, disconnect the
appliance from the mains power supply
using the system switch and/or the
corresponding on-off devices.
• In the event of faults and/or poor
operation of the appliance, it should be
deactivated. Do not attempt to repair
the appliance. Contact professionally
qualified personnel only.
• The products must only be repairedreplaced by professionally qualified
personnel, using original spare parts
only. Failure to heed this warning may
affect the safety of the appliance.
• To ensure the correct operation of the
appliance, annual maintenance must be
performed by qualified personnel.
• This appliance must only be used for the
purposes it has specifically been designed
for. All other uses are considered
improper and thus dangerous.
• After having removed the packaging,
check that the contents are intact.
• The parts of the packaging must not be
left within the reach of children, as they
are potential sources of danger.
• In case of doubt do not use the appliance
and contact your supplier.
Certification
This symbol indicates “Warning”
and is placed near all warnings
regarding safety. Such provisions
must be strictly adhered to so as
to avoid danger and damage to
persons and property.
This symbol highlights a note or
an important warning.
The CE Mark attests that Ferroli gas-fired
appliances conform to the requirements
specified in the corresponding European
directives.
In particular, this appliance conforms to
the following EEC directives:
• Directive 90/396, Gas Appliances,
• Directive 92/42, Efficiency,
• Directive 73/23, Low Voltage, (amended
by no. 93/68)
• Directive 89/336, Electromagnetic
Compatibility (amended by no. 93/68)
2
SYS 10-23
1. User/operating instructions....................................................................4
1.1 Introduction.............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Ignition and shut down ...........................................................................................5
1.4 Setting.....................................................................................................................6
1.5 Maintenance............................................................................................................6
2. Installation ..............................................................................................7
2.1 General instructions................................................................................................7
2.2 Place of installation .................................................................................................7
2.3 Water connections ..................................................................................................9
2.4 Gas connection .....................................................................................................11
2.5 Electrical connections ...........................................................................................11
2.6 Flue connections ...................................................................................................14
3. Service and maintenance......................................................................20
3.1 Settings .................................................................................................................20
3.2 Commissioning......................................................................................................21
3.3 Maintenance..........................................................................................................22
3.4 Remplacement of parts.........................................................................................24
4 Characteristics and technical specifi cations...........................................28
4.1 Dimensions and fi ttings ........................................................................................28
4.2 Overall view and main components .....................................................................29
4.3 Hydraulic diagram.................................................................................................30
4.4 Technical data table ..............................................................................................31
4.5 Diagrams ...............................................................................................................32
4.6 Wiring diagram .....................................................................................................33
3
SYS 10-23
1. OPERATING/USER INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for having chosen the SYS 10-23, an advanced-concept FERROLI wall-hung boiler
featuring cutting-edge technology, high reliability and constructional quality. Please carefully read
this manual and leave it with the end user.
The SYS 10-23 is a high efficiency heat generator for central heating systems, operating on
natural gas or LPG.
The boiler can be connected to an external hot water cylinder for the production of domestic
hot water.
The boiler body is made up of a copper heat exchanger, the special shape of which guarantees
high heat exchange efficiency in all operating conditions, and an atmospheric burner featuring
electronic ignition with ionisation flame control.
The boiler is completely sealed from the surrounding environment: the air required for combustion
is taken in from the outside, and a fan is used to expel the flue gases. The accessories supplied with
the boiler also include a variable-speed pump, expansion vessel, safety valve, air pressure switch,
temperature sensors and safety thermostat.
The user simply has to set the temperature required inside the home (using the optional, yet
recommended room thermostat) or set the system temperature and the required domestic hot
water outlet temperature at the cylinder stat. The regulation and control system will then ensure
optimum operation all year round.
4
SYS 10-23
1.2 Control panel
To access the control panel, open the drop down cover.
A On /OFF switch
B CH boiler thermostat
C Rseset knob with lamp
D Central heating pressure gauge
ABCD
fi g. 1
1.3 Ignition and shut-down
Ignition
• Open the gas cock of the boiler.
• Vent air present in the pipe upstream of the gas valve.
• Turn on the switch (if present) or plug upstream of the boiler.
• Turn on the boiler switch
• Rotate the C.H. temperature adjustment knob above Min position.
• Check the external controls are calling for heat.
• At this point, the burner ignites and the boiler starts to function automatically, controlled by
its control and safety devices.
If after completing the start-up procedure correctly, the burner fails to ignite and the boiler shut
down warning lights up, wait about 15 seconds then press the reset switch. The reset electronic
control unit will repeat the start-up cycle. If after a second attempt the burners still fail to ignite,
consult the paragraph “Troubleshooting”.
If there is a power failure while the boiler is in operation, the burners automatically go out
and re-ignite when the power returns.
If the system is filled with very cold water, the boiler will automatically light due to the
frost thermostat sensing the low temperature. The boiler will not shut down, until the water
temperature reaches 10°C.
Shut-down
Close the gas isolation valve upstream of the boiler, push the button “A” to OFF and disconnect
the appliance from the mains power supply.
When the boiler power is off the boiler anti-freeze protection is not active.
For extended periods of inactivity during the winter months, and in order to avoid damage
due to freezing, all the water should be drained from the boiler; alternatively, place approved
antifreeze fluid in the central heating system.
5
SYS 10-23
1.4 Settings
Setting the ambient temperature (using the optional room thermostat)
Set, using the room thermostat, the temperature required inside the rooms. Based on the command
from the room thermostat, the boiler is ignited and heats the system water to the set central
heating outlet temperature. When the required temperature inside the rooms is reached, the
boiler switches off. If no room thermostat is available, the boiler will maintain the system at the
set central heating outlet temperature.
System water pressure control
Manually filling the central heating system with external connection and cock. The filling pressure when
the system is cold, as read on the boiler water pressure gauge, must be around 1.0 bar (at least 0.5
bar). If the pressure drops during operation to a value lower than the minimum described above, the
User must restore the initial value using the filling loop. Once the operation is completed, always close
the filling loop. This device is fitted to the system by the installer.
1.5 Maintenance
It is recommended to have annual service of the appliance performed by qualified personnel. Please
refer to Chap. 3.3 in this manual for further information.
The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp
cloth, dipped in soapy water if necessary. Do not use abrasive detergents or solvents.
6
SYS 10-23
2. INSTALLATION
2.1 General instructions
This appliance must only be used for the purposes it has been specifically designed for. This appliance is
used to heat water to below boiling temperature at atmospheric pressure and must be connected to
a central heating and/or hot warm distribution system, according to its characteristics, performance
and heating capacity. All other uses are considered improper.
THE BOILER MUST ONLY BE INSTALLED BY SPECIALIST AND QUALIFIED PERSONNEL, IN
COMPLETE COMPLIANCE WITH ALL THE INSTRUCTIONS REPORTED IN THIS TECHNICAL MANUAL,
THE LEGAL STANDARDS IN FORCE, THE PRESCRIPTIONS OF STANDARDS AND ANY LOCAL
STANDARDS, AND ACCORDING TO THE RULES OF GOOD PRACTICE.
Incorrect installation may cause damager to persons and property. The manufacturer will not
be held liable in such events.
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use).
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British gas publication DM2 - Guide for installation in timber framed housing.
British Standards Codes of Practice:
B.S. 7593 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 Part 1 FLUES
B.S. 5440 Part 2 AIR SUPPLY
B.S. 5449 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 GAS INSTALLATIONS
B.S. 7671 IEE WIRING REGULATIONS
B.S. 4814 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply
2.2 Place of installation
The appliance’s combustion chamber is sealed from the surrounding environment and as a result the
appliance may be installed in any room without purpose built ventilation. The installation environment
must nonetheless feature sufficient ventilation, to avoid dangerous conditions arising in the event of
even minor gas leaks. These safety standards are imposed by EEC Directive no. 09/396 for all gas
appliances, including the so-called sealed appliances.
The place of installation must in any case be free of dust, inflammable objects or materials and corrosive
gases. The environment must be dry and not prone to freezing.
The boiler is supplied ready for wall-hung installation. The rear frame of the appliance has a series of
slots for fastening it to the wall, using screws with wall plugs. The fastening to the wall must provide
stable and effective support of the appliance.
The boiler must be fastened to a closed part of wall, which is free of apertures or holes behind the frame
of the boiler that may allow the internal components of the boiler to be reached.
If the appliance is enclosed in a cabinet or alongside another appliance, space must be allowed
for normal maintenance operations. Fig. 2 and Tab. 3 show the minimum and recommended space
to be left free around the appliance.
7
Ø118
C
66
A A
B
SYS 10-23
Table 3
Minimum Recommended
A
30 mm
B
200 mm
C 280 mm 300 mm
15 mm
D
(from opening panels)
150 mm
300 mm
> 600 mm
D
fi g. 2
Fixing to the wall
Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting
points. Drill two 10mm holes 90mm deep to accept the wall plugs, fit wall plugs. Fit two special wall
plugs on the wall as described in the fig. 3. Fasten the wall bracket to the wall using an antitheft
nut on the right side and a standard nut (M8) on the left side. Mount the boiler on the wall bracket
and fix using an antitheft nut on the left side and a standard nut (M8) on the right side. Using a core
drill cut a 118mm diameter hole for the flue.
fi g. 3
8
SYS 10-23
2.3 Water connections
The heat capacity of the appliance should be established in advance by calculating the heating
requirements of the building according to the standards in force. For correct operation and long-life
of the boiler, the hydraulic system must be suitably proportioned and always fitted with all the
accessories that guarantee regular operation.
In the case where the central heating outlet and inlet pipes follow paths whereby, at some points,
pockets of air may form, air vent valves should be installed at such points.
In addition, a drain device should be installed at the lowest point in the system, to allow
complete draining.
If the boiler is installed at a lower level than the system, a flow-return valve should be fitted to prevent
the natural circulation of water in the system.
The temperature differential between the outlet and the inlet
of the boiler should not exceed 20°C.
Do not use the water pipes as the earth for electrical
appliances.
Before installation, carefully clean all the pipes in the system to
remove any residues or impurities that may affect the correct
operation of the appliance.
Make the connections to the corresponding fittings, as
shown in fig. 4.
36 155 155 54
Key
1 Central heating outlet, 3/4”
2 Gas inlet, 1/2”
3 Central heating inlet, 3/4”
fi g. 4
It is recommended to fit isolation valves between the boiler and the central heating system; these allow
the boiler to be isolated from the heating system, if necessary.
The discharge of any safety valves must be routed to outside dicharging to ground level
100 mm from the floor so as not to create a danger to anyone passing. The manufacturer
of the boiler will not be held liable if this warning is not heeded, and the discharge valve
intervenes and floods the room.
Make the connections to the boiler in a way that its internal tubing is not subject to stress.
123
9
SYS 10-23
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. The supplied temporary filling loop is shown in fig.
4. Ensure the filling point is on the return pipe to the boiler.
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.
2
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
4. Double check valve
3
4
1
Fig. 5
Water treatment
if water treatment is used Ferroli Ltd recommend only the use of Fernox or Sentinel water
treatment products, which must be used in accordance with the manufacturers instructions. For
further information contact:
Fernox Manufacturing Co. LTD. Sentinel Division
Tandern house, Marlowe Way Betz Dearborn LTD
Croydon, surrey, CRO 4YS Widnes, Cheshire WA8 5351
Tel. 02870 5601 5000 Tel. 0151 424 5351
Note - If the boiler is installed in an existing system any unsuitable additives must be removed
by thorough cleansing.
All systems should be cleansed according to B.S. 7593.
Note - In hard water areas treatment to prevent lime scale may be necessary.
Note - It is important that the correct concentration of the water treatment product is maintained in
accordance with the manufactures instructions.
Filling the boiler and the system
The filling pressure, when the system is cold, must be around 1 bar (at least 0.5 bar). If the pressure
drops during operation to a value lower than the minimum described above, the User must restore
the initial value using the filling loop. For correct boiler operation, the pressure, when hot, must
be around 1,5-2 bar. Once the operation is completed, always close the filling loop. This device
is fitted to the system by the installer.
10
SYS 10-23
2.4 Gas connection
Before making the connections, check that the appliance is configured for operation with the
type of fuel available, and carefully clean all the gas pipes in the system, to remove any residues
that may affect the correct operation of the boiler.
The gas connections must be made using the relative coupling (see fig. 4), according to the standards in
force, with a rigid metal pipe, or a stainless steel flexible continuous-wall pipe, fitting a gas cock between
the system and the boiler. Check that all the gas connections for soudness.
The capacity of the gas meter must be sufficient for the simultaneous use of all the connected appliances.
The diameter of the gas pipe, which leaves the boiler, does not necessarily determine the choice of the
diameter of the pipe used between the appliance and the gas meter; this must be chosen according to
its length and the pressure drop, according to the standards in force.
Do not use the gas pipes as the earth for electrical appliances.
2.5 Electrical connections
Connection to the mains power supply
The boiler should be connected to a single-phase, 230 Volt-50 Hz electrical line.
The electrical safety of the appliance is ensured only when the appliance is correctly connected
to an effective earth system, as prescribed by the safety standards in force. Have professionally
qualified personnel check the efficiency and the rating of the earth system. The manufacturer
is not liable for any damage caused by the appliance not being correctly earthed. In addition,
make sure that the electrical system is adequately rated for the maximum power absorbed by
the appliance, indicated on the boiler rating plate, and in particular that the cross-section of the
wires is suitable for the power absorbed by the appliance.
The boiler is pre-wired and fitted with a cable for connection to the electrical line. The connections
to the mains supply must be made using a fixed connection, featuring a double-pole switch with
a contact opening of at least 3 mm. Max 3A fuses must be installed between the boiler and the
line. The correct polarity must be followed (LINE: brown wire / NEUTRAL: blue wire / EARTH:
yellow-green wire) in the electrical connections.
The appliance’s power cable must not be replaced by the user. In the event where the cable is
damaged, turn off the appliance and contact professionally qualified personnel to replace it.
If replacing the electrical power cable.
All wiring must conform to current I.E.E. Regulations
Accessing the electrical terminal block
Follow the operation shown in Figs. 6a and 6b to access the electrical terminal block. The layout
of the terminals for the various connections is shown in the wiring diagram, in the chapter on
Technical Specifications.
Fig. 6a Fig. 6b
11
Loading...