ferroli Tempra 1218 User guide

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Page 1

TEMPRA

Wall Mounted

Fan Flue

System boiler

Phone numbers:

Installer ____________________________

Service Engineer _____________________ Serial N° ____________________________

These Instructions must be left with the appliance User.

Appr. nr. B 94.04 A - CE 0063 AQ 2150

Wall mounted fanned

flue boiler

INSTALLATION AND

USE INSTRUCTIONS

Please read these Instructions

thoroughly before using

the appliance

Page 2

INDEX

1. General description and information

2. Technical specification

3. Installation details

4. Installation

5. Boiler connections

6. Electrical connections

7. Commissioning

TEMPRA

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1. GENERAL DESCRIPTION AND INFORMATION

1.1 Information

1. Installation must be carried out by a competent person, and in accordance with the relevant

requirements of the current issues of:

A. Gas Safety (Installation & Use) Regulations. 1994 B. Building Regulations. C. Building Standards (Scotland) Regulations. D. I.E.E. Wiring Regulations. E. Bye-laws of the local water undertaking.

Guidance on Installation is provided in this booklet, but due account must be taken of the detailed recommendations of the current issues of:

BS 5440 Part 1 2000: Flues. BS 5440 Part 2 1989: Air supply. BS 6798: Installation. BS 5449: Pumped systems. BS 5546: Domestic hot water. BS 6700: Water supply. BS 6891: Gas supply. BS 7074 Part 1: Expansion vessels. BS 7593: Treatment of water in domestic hot water central heating systems.

For installation in timber framed buildings, refer to the British Gas Publication Guide for gas installation in timber framed housing - REF DM2.

2. It is essential that the boiler be installed strictly in accordance with these Instructions and the

documents, detailed above.

3. To avoid the possibility of injury, care must be taken when handling sheet metal components.

1.2 Introduction

The TEMPRA Boiler is a “room-sealed” appliance: it takes in the air required for combustion and encloses all the combustion products in an hermetic compartment. The discharge of fumes and intake of combustion air are managed through air/flue pipes that may be run horizontally in all directions, or through a concentric flue running vertically or horizontally.

The main components of the boiler are:

- A compact heat exchanger in copper, formed by four pipes with external finning and internal turbulence activators.

- A combustion chamber insulated to reduce heat loss and thus improve efficiency.

- Nine stainless steel burners, an oxidation- and thermal shock-resistant material specially developed for this product.

- A fan to discharge combustion products and draw in combustion air.

TEMPRA

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- A boiler thermostat overheat thermostat and frost thermostat.

- A steel room-sealed compartment treated against corrosion, enclosing all the above components.

- An air differential pressure switch which, to ensure safe operation, allows burner ignition only when the fan functions normally.

- A newly-designed gas ignition valve assembly, comprising a range rated regulator gas valve and a flame control device. (Ignition is by an intermittent pilot flame; which lights the main burners.)

- An expansion vessel, pump, automatic air vent and air separator .

- A temperature sensor.

- Pressure gauge.

- Pressure relief valve set at 3 bar.

TEMPRA

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2. TECHNICAL SPECIFICA TION

2.01. Technical data

Model

Nominal heat input (gross) Nominal heat input (net) Nominal heat output

ﬂ Main injectors ﬂ Gas supply Number of injectors Working gas inlet pressure

Burner pressure

min Max

Natural gas (G20) Propane LPG (G31)

Max Min

21.6

19.5

17.6

N¡ mbar mbar mbar

TEMPRA sealed system boiler

Max Min

12.8

11.5

9.7

Natural gas

(G20)

1.2

1/2"

kW kW kW

21.1

19.5

17.6

kW kW

LPG

(G31)

0.77

1/2"

9 37 13 36

12.5

11.5

9.7

Gas rate

Maximum system pressure ﬂ Water connections

Dimensions

Weight

Electrical supply

Height Width Depth

m3/h

kg/h

bar

mm mm mm kg

V/Hz

2.06

1.51

3/4"

750 420 275

230/50

TEMPRA

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2.02. Appliance dimensions

Ø 10

420

340

275

131

Ø 60

760

750

b a

50 160 160 50

270 150

Ø 96

Ø 112

°C

Key

131

1. Central Heating return inlet

2. Gas supply

3. Central Heating flow outlet

4. Outlet pressure relief valve a. C.H. boiler thermostat b. Pressure gauges c. Main switch d. Overheat cut-off thermostat (reset)

Fig. 1

TEMPRA

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2.03. Flow diagram

24/82 20

27 52

5-Room sealed compartment 7-Gas supply 8-Central Heating flow outlet

9-Central Heating return inlet 14 - Safety valve 16 - Fan 19 - Combustion chamber 20 - Burner box 22 - Burner

24/82 - Ignition/flame sensing electrode

25 - Pilot burner 27 - Copper heat exchanger 29 - Tube flue outlet

3256

14 49

98 145 63

Outlet

pressure

relief valve

°C

Fig. 2

31 - Flue collector 32 - Pump 43 - Air pressure switch 44 - Gas valve 49 - Overheat cut-off thermostat (reset) 51 - Central heating frost thermostat 52 - Central heating limit thermostat 56 - Expansion vessel 63 - C.H. boiler thermostat 87 - Gas pressure test point 98 - Main switch

145 - Pressure gauges

TEMPRA

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3.0 INSTALLATION DETAILS

3.1 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 buiding 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.

3.2 Location of Boiler

The installation of the TEMPRA must be on a suitable non-combustible load bearing wall which will provide an adequate fixing for the boiler mounting bolts. The location should be in an area where the water pipes will not be subjected to frost conditions. In siting the boiler the following limitations must be observed:

The 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 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.

3.3 Terminal Position

D, E

Fig. 3

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Minimum dimensions of flue terminal positions

Balanced flues room

Dimensions Terminal position

D 300 mm 75 mm Not allowed 75 mm E 300 mm 200 mm Not allowed 200 mm F 600 mm 200 mm Not allowed 200 mm G 300 mm 150 mmbNot allowed 150 mm H 600 mm 300 mm Not allowed 200 mm I 300 mm 300 mm Not allowed 300 mm J 600 mm 600 mm N/A 600 mm

K 600 mm 1200 mm N/A 1200 mm L 1200 mm 1200 mm N/A 1200 mm

M 1500 mm 1500 mm N/A 1500 mm N 300 mm 300 mm N/A 300 mm O N/A N/A N/A 50 mm P N/A N/A See Table 2

Q N/A N/A See Table 2

NOTE N/A = Not applicable

n addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric formed for the purpose of accommodating

a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the rated heat inputs as shown.

This dimension may be reduced to 75 mm for appliances of up to 5 kW heat input.

Directly below an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Above an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Horizontally to an opening, air brick, (0-7 kW) opening windows, etc. (>7-14 kW)

Below gutters, soil pipes or drain pipes Below eaves Below balconies or car port roof From a vertical drain pipe or soil pipe From an internal or external corner Above ground roof or balcony level From a surface facing the terminal

(also see 6.1.2) From a terminal facing the terminal From an opening in the car port ( e.g. door,

window) into the dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical structure on the roof

Above intersection with roof

(kW input expressed in net)

(>14-32 kW) (>32-70 kW)

Natural draught

300 mm

600 mm 1500 mm 2000 mm

300 mm 300 mm 300 mm 600 mm

300 mm 400 mm 600 mm 600 mm

sealed

Fanned

draught

300 mm Not allowed 300 mm

Natural draught

and Fig. 6b

and Fig. 4

Open flues

Fanned

draught

150 mm

N/A

Minimum Clearance mm

200

25 mm

200 min

min.

25 mm

600**

123

0 4

Fig. 4

NOTES

** Access to the front of the boiler must be available for maintenance (min. 600 mm).

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3.4 Air Supply

The room in which the boiler is installed does not require a purpose provided vent.

3.5 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. 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.

3.6 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 boiler must be of an adequate size. Do not use pipes of a smaller size than the 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.

3.7 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. 5-6.

Important - A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min.

3.8 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 fig. 7.

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.

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Sealed system - “Y” Plan

Fig. 5

Fig. 6

Filling point

Domestic Cylinder

Boiler

By Pass

Sealed system - “S” Plan

Domestic Cylinder

Boiler

By Pass

3 port motorised valves

2 port motorised valves

NOTE: A bypass must be fitted to ensure a minimum flow rate of 6 l/min. through the boiler.

Approved filling loop

Key

1. Filling point C.H.

Fig. 7

2. Temporary connection

3. Cold water supply

TEMPRA

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3.9 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 UPS 15-50 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 15-50

SAFETY VALVE SETTING (bar)

VESSEL CHARGE PRESSURE (bar)

INITIAL SYSTEM PRESSURE (bar)

TOTAL WATER CONTENT of SYSTEM

LITRES

25 3.5 6.5 13.7 4.7 10.3 8.3 50 7.0 12.9 27.5 9.5 20.6 16.5

75 10.5 19.4 41.3 14.2 30.9 24.8 100 14.0 25.9 55.1 19.0 41.2 33.1 125 17.5 32.4 68.9 23.7 51.5 41.3 150 21.0 38.8 82.6 28.5 61.8 49.6 175 24.5 45.3 96.4 33.2 72.1 57.9

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

200 28.0 51.8 110.2 38.0 82.4 66.2

3.0

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

1 2 3 Speed settings A Boiler pressure drop B Max. available pump head C.H.

Fig. 8

SIZING OF ADDITIONAL EXPANSION VESSELS:

Deduct from the value given in the table the 6 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 6 litres expansion vessel is charged to 1 bar

Fig. 9

TEMPRA

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4. INSTALLATION

4.1 Unpacking

The appliance is delivered in 2 cartons.

4.1.1 The large carton contains the boiler, and the Installation/Servicing and Users Instructions.

4.1.2 The second carton contains the wall fixing bolts (x2), flue assembly, and boiler bend, gas cock and 3/4” x 1/2” bush.

4.2 Wall mounting

After selecting a suitable place for the boiler, mark location for fixing holes. Using 8 mm drill, drill 60 mm deep holes to accept fixing bolts and insert. Tighten nuts until secure, then remove nuts leaving studs protruding, hang boiler and refits nuts to secure.

Fig. 10

TEMPRA

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4.3 Preparing the flue assembly

The boiler is supplied with 0.75 m of concentric flue which can be run from either side or to the back of the appliance. If a longer flue is required 2 m and 3 m lengths are avaiable.

An example of using the concentric flue.

Outlet and inlet through a building wall

Flue connection

MAX 3m

Maximum permitted length for concentric flue to be run is 3 m.

Fig. 11

Drawing below shows how concentric flue should be assembled the main points being:

1. Inner flue pipe

(alluminium) needs to be 85 - 90 mm longer than plastic air intake pipe

2. The air intake

(plastic) pipe only butts to the elbow

3. Care must be taken

not to dislodge “O” rings

Ø1=100 Ø2=60

Chamfer outer edge of aluminium pipe to avoid dislodging "O" rings

25-30 mm

"O" rings

Fig. 12

Ø1

Ø2

A=L+(85-90)mm

Clamp detail

Ø1

Ø2

TEMPRA

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5. Boiler connections

Gas, Water and Electrical

123

0 4

2413

Front View Side View

1. Outlet pressure relief valve 1/2" FEMALE

2. Return 3/4" MALE

3. Gas Service Cock Connection 1/2" FEMALE

4. Flow 3/4" MALE

5.1 Gas supply

1. Further guidance: BS 6891, BS 6798, Gas Safety (Installation and Use) Regulations 1994.

2. Ensure the supply pipe, the gas meter and existing or new pipework will serve the maximum gas

rate of all the appliance served by that meter.

3. An inlet working pressure of 20 mbar will be required at the boiler.

4. Always test for soundness of gas supply pipes in accordance with BS 6891.

5.2 Pressure relief valve

Connect the pressure relief valve discharge pipe (1/2”) 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 or cause damage to external electrical components or wiring. The pipe should be directed towards the wall.

TEMPRA

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6. ELECTRICAL SUPPLY AND CONNECTIONS

All electrical installation work must be carried out by a qualified electrician, and all work shall be in accordance with the current issue of the IEE wiring regulations. Supplied for use on 230 V ~ 50 Hz supply, protected by a 3 Amp fuse.

The boiler must be earthed.

The method of connection to the mains supply must allow complete isolation from that supply either by: a) Use of 3 A fused double pole switch having a contact separation of at least 3 mm. Such a switch must supply the appliance and immediate control circuits only (eg room thermostat, programmer etc.)

OR b) Use of an unswitched shuttered socket outlet and 3 A fused 3 pin plug both complying with BS 1363.

All external cables must be suitable for mains voltage and should be PVC insulated cable at least 0.75 mm2 (24/0.2 mm), to BS 6500. All external circuits for the control of the boiler must be wired and isolated from the same isolator as that which serves the boiler.

6.1 Electrical connection

1. The TEMPRA boiler requires a permanent live supply to the appliance (live, neutral and earth)

together with a switched line from the system controls to operate the burner.

2. When using external controls remove link wire betwen terminals 4 -5.

3. Run live connection from terminal 4 to external switch controls and return switch line into

terminal 5.

6 7 8 9 10 11 12

Electrical

230 V ~ 3 Amp fuse

External switch controls

Fig. 18

control box

WARNING: If external controls are fitted to the system, check terminals 1, 2, 4, and 5 to ensure

they are voltage free prior to working on the boiler.

TEMPRA

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6.2 Electrical connections diagram

8324

1112 13910 245678

16. Fan

24. Spark electrode

32. Central heating pump

43. Air pressure switch

50. Central heating limit thermostat

51. Central heating frost thermostat

63. C.H. boiler thermostat

72. External controls

83. Full sequence automatic control

98. Switch

176. Overheat CUT-OFF thermostat

6.3 General wiring diagram

N945678 101112L

230V

72 32 50

50Hz

176

C = Brown NO = Blue NC = Black

Wiring 43

16. Fan

24. Spark electrode

32. Central heating pump

43. Air pressure switch

50. Central heating limit thermostat

51. Central heating frost thermostat

63. C.H. boiler thermostat

72. External controls

83. Full sequence automatic control

98. Switch

176. Overheat CUT-OFF thermostat

230 V ~

3 Amp fuse

TEMPRA

176

S.4585 D 1003

NONC

96107145382

1643

Page 18

15. Commissioning

Carry out preliminary electrical system checks i.e. EARTH CONTINUITY, RESISTANCE TO EARTH, SHORT CIRCUIT AND POLARITY using a suitable test meter.

1. Remove the outer case and lower cover.

2. Test for gas soundness up to the boiler service cock - BS 6891.

3. Flush the system cold, without the boiler in circuit.

4. Fill the complete circuit and vent the system, fill to about a=1.5 bar at this stage.

5. Check the system for water soundness, rectifying any leaks.

6. Reduce the pressure to the approximate initial design pressure.

7. Open all radiator valves.

8. Loosen the screw within the pressure test point on the burner supply pipe and attach a suitable

pressure gauge.

9. Open the boiler service cock.

10. Open all doors and windows, loosen the screw in the inlet pressure test point, and purge the gas

supply BS 6891. Retighten the screw. Allow gas to disperse.

11. Set any external control to an ON condition, and turn the thermostat knob to maximum.

12. Turn on the electricity supply. Check that the pump runs.

13. A continuous spark will light the pilot (viewed through window) and the main burner.

14. Heat Input Adjustment. The Input is pre-set to 16.7 kW but can the adjusted to any value in the

range quoted in Technical Data - the burner pressure must always be checked anyway. Remove the cap from the adjustment screw.

CH HEAT INPUT BURNER PRESSURE CH HEAT OUTPUT

MAX 21.6 15 — 17.6 MED 16.7 8 — 13

MIN 12.8 5 — 9.7

(Gross) kW mbar set to kW

Burner pressure to C.H. Heat Output 1 / Heat Input 2

mbar

0 2 4 6 8 1012141618202224

TEMPRA

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Key

10. Inlet pressure test point

17. Adjustment screw burner pressure (turn clockwise to increase pressure)

18. Burner pressure test point

15. After 10 minutes, adjust the heat input to the required value. (Anticlockwise to decrease).

Replace the cap.

16. NOTE - If the required pressure cannot be obtained, the inlet working pressure should be checked (20 mbar is required with burner on!)

17. Allow the system to reach heated equilibrium. On sealed systems check that the pressure does not exceed 2.6 bar (in which case a larger expansion vessel will be needed).

18. Turn off burner.

19. Flush the system whilst hot, and refill.

20. Remove the pressure gauge, tighten the screw.

21. Relight and check for gas soundness.

22. Mark the Data Badge to indicate the set heat input.

23. Replace the lower cover and outer case.

24. Adjust the thermostat control knob to the required setting.

25. Hand over to the user: a) Explain the function and control of the boiler, including any external controls. b) Advise against obstruction of purpose provided ventilation, and of the flue terminal. c) Give advice on frost protection of parts. d) Advise arrangement of an annual Service Contract. e) Hand all Instructions and literature to the user.

TEMPRA

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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. 3540982/0 - 06/2001