Ferroli TEMPRA 12, TEMPRA 18 Installation, Maintenance And User Instructions
TEMPRA 12 - 18
wall-hung, gas-fi red,
system boiler,
for central heating
INSTALLATION, MAINTENANCE AND USER INSTRUCTIONS
cod. 3543724/6 - 05/2005
TEMPRA 12: G.C. N° 41-267-11
TEMPRA 18: G.C. N° 41-267-12
2
Tempra 12 - 18
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.
• 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
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)
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".
3
Tempra 12 - 18
1. Operating/user instructions ...................................................................4
1.1 Introduction ............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Ignition and shut-down...........................................................................................5
1.4 Settings ...................................................................................................................6
1.5 Maintenance............................................................................................................6
1.6 Troubleshooting......................................................................................................6
2. Installation ..............................................................................................7
2.1 General instructions................................................................................................7
2.2 Place of installation .................................................................................................7
2.3 Water connections ..................................................................................................9
2.4 Gas connection .....................................................................................................10
2.5 Electrical connections ...........................................................................................11
2.6 Flues connections .................................................................................................14
3. Service and maintenance......................................................................22
3.1 Settings .................................................................................................................22
3.2 Commissioning......................................................................................................24
3.3 Maintenance..........................................................................................................25
3.4 Replacement of Parts............................................................................................27
3.5 Troubleshooting....................................................................................................31
4. Characteristics and technical specifi cations..........................................34
4.1 Dimensions and fittings ........................................................................................34
4.2 Overall view and main components .....................................................................35
4.3 Hydraulic diagram.................................................................................................36
4.4 Technical data table..............................................................................................37
4.5 Diagrams ...............................................................................................................38
4.6 Wiring diagram .....................................................................................................39
Benchmark................................................................................................40
4
Tempra 12 - 18
1. OPERATING/USER INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for having chosen the Tempra 12/18, 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 Tempra 12/18 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 microprocessor-based control system means that the operation of the appliance is almost completely
automatic. The central heating output is automatically regulated by the control system according to
requirements. The domestic hot water output (with external hot water cylinder installed) is automatically
and continuously controlled to ensure both comfort and economical operation.
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.
5
Tempra 12 - 18
1.2 Control panel
To access the control panel, open the drop down cover.
0
5
1
2
3
4
6
CEAB D
POS. DESCRIPTION
A OFF/ON/RESET switch
B Central heating temperature
setting
C Water pressure gauge
D Domestic hot water storage
temperature setting (with optional kit)
E Clock position (optional)(EIRE only)
bar
Burner on signal
Lock-out warning signal
Stand-by in central heating operation (light flashing)
Central heating request (light on)
Mains power (light on)
ab de
a
b
d
e
LED
Table 1
1.3 Ignition and shut-down
Ignition
• Open the gas isolation valve upstream of the boiler.
• Ensure 230V supply is present at the boiler.
• Place the main switch “A” in the ON position.
• Place knob “B” in the Winter position and set the room thermostat, if fitted, to the required
temperature value. At this point, the burner will ignite and the boiler will start operating automatically,
managed by its control and safety devices.
If, after having correctly performed the ignition operations, the burners do not ignite and the
lock-out warning light is on, wait around 15 seconds, then turn knob A to the RESET position
and release it. The control unit will be reset and will repeat the ignition cycle. If, after a number
of attempts, the burners does not ignite, refer to the paragraph on troubleshooting.
Shut-down
Close the gas isolation valve upstream of the boiler, turn knob “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, both the domestic hot water and
the central heating system; alternatively, drain only the domestic hot water and place approved
antifreeze fluid in the central heating system.
fig. 1
6
Tempra 12 - 18
Before calling the service centre, check that the problem is not due to no gas or mains power
supply.
Table 2
Boiler locked-out
LED Problem Solution
Check if the gas isolation valve upstream of the boiler and on the counter are open.
Turn knob “A” Fig. 1 to “Reset” and then release it.
In the event of repeated boiler lock-out, contact the nearest service centre.
1.4 Settings
Summer/Winter setting and system temperature control
With knob “B” Fig. 1 in the position of the symbol (Summer), the central heating function is
deactivated. This is only for use with optional water control kit. With the knob “B” Fig. 1 in the position of
the symbol (Winter), both the central heating function and domestic hot water are active, if used with
an external clock/programmer knob “B” must be kept in the winter position and the clock/programmer
used to control the central heating and hot water. Turning the knob clockwise increases the central heating
water temperature, anticlockwise decreases it. The temperature can be set from a minimum of 35° to a
maximum of 85°. It is not recommended, however, to operate the boiler below 45°.
Setting the ambient temperature (using the optional room thermostat)
Set, using the room thermostat or remote control, 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 or remote control is available, the boiler will maintain the
system at the set central heating outlet temperature.
Domestic hot water temperature control
Set the hot water cylinder temperature, using knob “D” (supplied in the optional kit).
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.
1.6 Troubleshooting
Any anomalies or operating faults are signalled by the LEDs on the control panel. The following table lists
the faults that may arise due to simple problems that can be resolved by the user.
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Tempra 12 - 18
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.
8
Tempra 12 - 18
Fixing to the wall
For Top Flue connections.
Select suitable position for boiler, using the template mark
flue outlet and boiler mounting points. Drill two 10 mm holes
70 mm deep to accept the wall plugs. Fix the wall bracket to
the wall using standard lock nut (M8) on both sides. Mount the
boiler on the wall bracket and fix using the special antitheft
nut (M8) as described in the fig. 3a. Mount the boiler on the
wall bracket.
For Back Flue connections.
Select suitable position for boiler, using the plate inserted in
the optional “back flue outlet kit” mark flue hole and plate
fixing points.
Follow procedure in 2.6 for boiler transformation and mounting.
fig. 3b
Boiler
dimensions
100 1802595
165 115
720 13
160
12485
400
36 155
16.5
120
120
A A
B
D
C
> 500 mm
Minimum Recommended
A
B
D
30 mm
150 mm
15 mm
(from opening panels)
150 mm
300 mm
C 150 mm 300 mm
Table 3
fig. 2
16.5
117.5 117.5
Øi 100
290
235
133 16.53831
102.5 177.5
20 260 10
fig. 4
fig. 3a
9
Tempra 12 - 18
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. 5.
Key
1 Central heating outlet, 3/4”
2 Gas inlet, 1/2”
3 Central heating inlet, 3/4”
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.
fig. 5
36 12485
98
2
3
1
155
10
Tempra 12 - 18
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.
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. 5), 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.
VESSEL CHARGE
PRESSURE (bar)
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
CONTENT of SYSTEM
Litres
25
50
75
100
125
150
175
200
For syst. volumes other than
those given above, must. the syst.
volume by the factor across
0.5 1.0 1.5
1.0 1.5 2.01.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
3.5
7.0
10.5
14.0
17.5
21.0
24.5
28.0
6.5
12.9
19.4
25.9
32.4
38.8
45.3
51.8
13.7
27.5
41.3
55.1
68.9
82.6
96.4
110.2
4.7
9.5
14.2
19.0
23.7
28.5
33.2
38.0
10.3
20.6
30.9
41.2
51.5
61.8
72.1
82.4
8.3
16.5
24.8
33.1
41.3
49.6
57.9
66.2
0.140 0.190 0.330.259 0.551 0.412
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Tempra 12 - 18
Room thermostat
WARNING: THE ROOM THERMOSTAT MUST HAVE 230V LIVE CONTACTS.
Standard Systems
For a general pipe layout and wiring diagram on the “S” and “Y” plan systems please see
fig. 6A, 6B, 6C and 6D.
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
12
Tempra 12 - 18
Tempra 12/18 “S” Plan
Pipe layout
Wiring diagram
FERROLI
TEMPRA
BOILER
12/18
D.H.W.
Zone Valve
A.A.V
C.H.
Zone Valve
To ensure a passage of 6ltrs
per minute an Automatic
by-pass must be fitted.
(Building regulation part L)
10987654
321
Tempra 12/18 Junction Box
ENEL
diverter valve
(optional)
9&10
optional
cylinder
sersor
Terminal 8 - SWITCH LINE
12345678910
PROGRAMMER
DHW ON
CH ON
NEUTRAL
LIVE
CH
zone
valve
DHW
zone
valve
Room Thermostat
Cylinder Thermostat
N
E
L
230 Vac
fused at
3 amps
BROWN BLUE
GREY ORANGE
NL
1112
Fig. 6c
Fig. 6d
13
Tempra 12 - 18
Tempra 12/18 “Y” Plan
Pipe layout
FERROLI
TEMPRA
12/18
Auto air vent
To ensure a passage of 6ltrs
per minute an Automatic
by-pass must be fitted.
(Building regulation Document L
April 2001)
“Y” Plan valve
Wiring diagram
10987654321
Tempra 12/18 Junction Box
NL
12345678910
PROGRAMMER
NEUTRAL
LIVE
CH ON
DHW ON
DHW OFF
BLUE
WHITE
GREY
ORANGE
Room Thermostat
Cylinder Thermostat
N
E
L
240 Vac
fused at 3 amps
Honeywell V4073H mid position
The heating system must have a bypass capable of
passing 6 litres/minute if TRV are fitted throughout
3 WAY ZONE VALVE
2
1
C
NL
Terminal 8 - SWITCH LINE
1112
Fig. 6e
Fig. 6f
14
Tempra 12 - 18
Ø
Replacing the restrictor
To install or change the restrictor, remove the fan unit,
remove the flue gas connecting pipe 1 (as shown in Fig.
8a) and insert the diaphragm 2 (as shown in Fig. 8b).
Type
60/100
Length up to:
1 bend + 1 metre
1 bend + 3 metres
1 bend + 3 metres
1 bend + 4 metres
1 bend + 5 metres
Restrictor to be used
80/125
Table 4a
Tempra 12 Tempra 18
37 mm
37 mm
43 mm
47 mm
43 mm
47 mm
Total calculated
flue lenght
Use restrictor
Min
0 m
10 m
15 m
20 m
30 m
35 m
40 m
Max
10 m
15 m
20 m
30 m
35 m
40 m
45 m
Table 4b
Tempra12Tempra
18
43 mm
47 mm
37 mm
Choice of the restrictors using
concentric flue
Choice of the restrictors using 2
pipe system
2.6 Flues connections
This is a “type C” sealed and forced draught appliance, and as such the air inlet and flue gas
outlet must be connected to one of the exhaust/intake systems indicated below. Using the
tables and the methods of calculation described, first verify, before installation, that the flues
do not exceed the maximum allowed length. The standards in force and local legislation must
be adhered to for terminal positions.
Restrictors
For the operation of the boiler, the restrictors supplied with the appliance must be fitted, according to
the indications shown in the tables below.
The Ø37 for Tempra 12 and Ø43 for Tempra
18 restrictor is fitted as standard on the boilers.
Before inserting the flue gas outlet pipe, check
that the correct restrictor is installed (when this
needs to be used) and correctly positioned.
N.B.:
The diameter Ø of the hole is stamped on the restrictor
fig. 7
fig. 8a
8b
2
1
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