Ferroli TEMPRA 30 Installation, Service And User Instructions Manual

Appr. nr. B99.05 A - CE 0461 BL 0521

TEMPRA 30

INSTALLATION, SERVICE AND USER

INSTRUCTIONS

COPPER WALL-MOUNTED SYSTEM,

GAS FIRED BOILER FOR CENTRAL HEATING,

FAN ASSISTED, ROOM SEALED COMPARTMENT,

ELECTRONIC FLAME IGNITION AND CONTROL

cod. 3543822/1 - 03/2004

TEMPRA 30

CE MARK

CE mark documents that the Ferroli gas appliances comply with the requirement contained in

European directives applicable to them.

In particular, the appliances comply with the following CEE directives and the technical speciﬁ cations

provided from them:

• Gas appliances directive 90/396

• Efﬁ ciencies directive 92/42

• Low tension directive 73/23 (modiﬁ ed from the 93/68)

• Electromagnetic compatibility directive 89/396 (modiﬁ ed from the 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 register

by calling CORGI on 01256 372300".

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efﬁ ciency. Please see installation and servicing guidelines.

INDEX

1. DESCRIPTION.................................................................................................................................... 3

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS................................................................... 4

3. INSTALLATION DETAILS.................................................................................................................... 9

4. COMMISSIONING AND TESTING.................................................................................................. 28

5. ADJUSTMENT AND GAS CONVERSION ....................................................................................... 29

6. MAINTENANCE AND CLEANING ................................................................................................. 31

7. REMPLACEMENT OF PARTS........................................................................................................... 33

8. FAULT FINDING............................................................................................................................... 37

9. ELECTRICAL AND FUNCTIONAL SCHEME .................................................................................. 39

10. USER INSTRUCTIONS ................................................................................................................... 41

TEMPRA 30

1. DESCRIPTION

1.01 Introduction

The Tempra 30 is deﬁ ned as a “room sealed” boiler, all air required for combustion is taken from outside the room in which it is installed. It is a new high performance gas ﬁ red heat generator for central heating. A special feature of this boiler is its built-in electronic ﬂ ame ignition and control unit making burner operation completely automatic and safe. The main components are as follows:

• Copper heat exchanger consisting of four ﬁ nned tubes speciﬁ cally shaped for high efﬁ ciency.

• Ceramic ﬁ bre insulated combustion chamber

• 16 stainless steel bladed burners speciﬁ cally designed for this boiler.

• Fan for discharge of combustion products and intake of combustion air.

• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning correctly.

• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.

• Combination gas safety valve with modulator, complete with pressure stabiliser.

• Pressure relief valve for the central heating circuit set to open at 3 bar.

• Built-in Expansion vessel.

• Variable speed pump.

• Central heating ﬂ ow temperature adjustment thermostat.

• Central heating limit thermostat.

• Overheat safety thermostat.

• Electronic control unit for automatic ﬂ ame ignition and control.

• Central heating ﬂ ow temperature sensor.

1.02 Instructions and regulations

Assembly, installation, ﬁ rst start up and maintenance must be carried out by competent persons only, in accordance with all current technical regulations and directives.

C.O.S.H.H.

Materials used in the manufacture of this appliance are non hazardous and no special precautions are required when servicing.

Related Documents This appliance must be installed strictly in accordance with these instructions.

The Gas Safety Regulations (Installations & Use) 1996. The Local Building Regulations. The Building Regulations. The Buildings Standards (Scotland - Consolidated) Regulations.

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

TEMPRA 30

Fig. 1

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS

2.01 Technical information

Tempra 30 boilers are central heating generators and are produced as standard to function with natural

gas or Liquid Petrolium Gas converted appliances.

Key

1. Central Heating flow

2. Gas supply

3. Central Heating return

189

175

155

363

460

692

15 430 15

Ø80 Ø80 Ø80

760

120 120

36 215 54

165

110

202

110

TEMPRA 30

N.B. - The gas pressures at the burner and gas ﬂ ows during the central heating phase given in the table refer

to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced until the required output level is reached (see ﬁ gures 4 and 5).

• Maximum working temperature for central heating ﬂ ow: 85°C

Technical Data

Gas supply

Pmax Pmin

Nominal Heat Input (Net)

Nominal Heat Output

Output

Pmax Pmin

kW 30,0 12,7

kW 33,1 14,5

Dimensions, weights, fittings

Depth mm 363

Width mm 460

Height mm 760

Hot water capacity litres 1,7

Expansion vessel pre-fill pressure bar 1

Expansion vessel capacity litres 10

Minimum central heating operating pressure bar 0,8

Maximum central heating operating pressure bar 3

Maximum central heating operating temperature °C90

Index of protection IP 44

Power supply

Power supply voltage/frequency V/Hz 230/50

Max Power Absorbed W 125

C.H. return (with isolation valve fitted) mm 22

C.H. flow (with isolation valve fitted) mm 22

Gas system fittings (with isolation valve fitted) mm 22

Weight with packaging kg 45

Central heating

Natural gas rate (G20) nm3/h 3,50 1,53

Main injectors, Natural Gas (G20) mm 16 x 1.25

Burner pressure, Natural Gas (G20) mbar 13,0 2,5

Supply pressure, Natural Gas (G20) mbar 20,0

LPG gas rate (G31) kg/h 2,57 1,13

Main injectors, LPG (G31) mm 12 x 0.75

Burner pressure, LPG (G31) mbar 35,5 7,0

Supply pressure, LPG (G31) mbar 35,5

Safety valve bar 3

TEMPRA 30

2.03 Boiler water ﬂ ow diagram

Fig. 3

2.02 Boiler main components

Key 5

Room sealed compartment

Gas inlet

Central heating ﬂ ow

Central heating return

Safety valve

Fan

Combustion chamber

Burner assembly

Main injector

Burner

Combustion chamber insulation

Copper heat exchanger

Flue collector from heat exchanger

Internal ﬂ ue exit

Central heating pump

Central heating ﬂ ow temperature sensor

Fig. 2

Automatic air vent valve

Air pressure switch

Gas valve

Safety overheat thermostat

Central heating ﬂ ow limit thermostat

Expansion vessel

Time clock (option)

Central heating temperature adjustment

Ignition electrode

Sensor electrode

Primary gas valve solenoid

Secondary gas valve solenoid

On/Off/Reset switch

145

Central heating pressure gauge

187

Flue restrictor

R E

S E

bar

98 63 145

117 44858410

20 21

°C

29 187

22 82 81

222

29-187

10 7 11

TEMPRA 30

2.04 Central heating adjustment (not normally required)

To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main burner via the electronic control board (ﬁ g. 4 and see paragraph 5.04). The diagrams indicate the variation in heat output to the water as burner working pressure is varied. Adjusting boiler output to the actual requirements of the central heating system will minimise boiler cycling thus saving fuel, varying the output has virtually no effect on the efficiency and combustion characteristics of the boiler.

Diagram of pressures and outputs with Natural gas and with LPG (Propane)

Fig. 4

G31

G20

14 18 19 2015 16 17 14 18 1915 16 17

kW kcal/h

X 1000

18 19 20 21 22 23

9 1011121314151617

9101112138

25 26 27 28 29 3024

TEMPRA 30

Fig. 6

Pressure loss diagram

SIZING OF ADDITIONAL EXPANSION VESSELS:

Deduct from the value given in the table the 10 litre vessel supplied.

Note:

1. Fill C.H. installation to min. 1.5 bar.

2. Expansion vessel must be ﬁ tted to central heating

return pipe.

3. The standard 10 litre expansion vessel is charged to 1 bar.

4. The additional expansion vessel should be charged to 1 bar.

SAFETY VALVE SETTING (bar)

VESSEL CHARGE PRESSURE (bar)

INITIAL SYSTEM PRESSURE (bar)

TOTAL WATER CONTENT of SYSTEM

3.0

0.5 1.0 1.5

1.0 1.5 2.0 1.5 2.0 2.0

EXPANSION VESSEL VOLUME (litres)

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

0.140 0.259 0.551 0.190 0.412 0.33

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

2.05 Pump characteristics

The pump head available for circulating the water is given in ﬁ g.

N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.

Grundfos Pump per formance graph

Note - Minimum ﬂ ow through boiler heat exchanger at any

time should not fall below 6 litres per minute.

If the total volume of water in the system exceeds 40 litres an additional expansion vessel must be ﬁ tted to the central heating return pipe.

Fig. 5

1 2 3

Speed settings

Boilers pressure drop

Available pump head C.H.

m |h

0.5 1.5 2.512

mbar x 100

TEMPRA 30

3. INSTALLATION DETAILS

Gas Safety (Installation & Use) Regulations

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 your responsibility to ensure that the law is complied with.

N.B. For Northern Ireland the rules in force apply.

Important - If the boiler is to be ﬁ tted in a timber framed building it should be ﬁ tted in accordance with the Institute of

Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.

Location of Boiler

The installation of the Tempra 30 must be on a suitable non-combustible load bearing wall which will provide an adequate ﬁ xing 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 boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.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 must be situated so that it cannot be touched by a person using the bath or shower.

Air Supply

The room or compartment in which the boiler is installed does not require a purpose provided vent when using the standard concentric ﬂ ue.

Flue System

The boiler allows the ﬂ ue outlet to be taken from the rear of the boiler, from either side or vertically. A standard ﬂ ue 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 2815mm for rear ﬂ ues, deduct 91mm plus distance from side wall for side outlet ﬂ ues). 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 ventilations, windows, doors, natural air inﬁ ltration or forced ventilation/air conditioning.

Gas Supply

If necessary the local Gas supplier 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 supplier. A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor. Installation pipes should be ﬁ tted in accordance with BS6891-1988. Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG. Pipework from the meter to the boiler must be of an adequate size. The boiler requires 3.5 m3/h of natural gas, and 2,6 kg/h of LPG. 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 ﬁ tted on the boiler gas inlet. Please wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after

the boiler has operated for 10 minutes to reach thermal equilibrium.

TEMPRA 30

NOTE: A by-pass that will ensure a minimum ﬂ ow rate of 6 l/min. at all all time must be ﬁ tted as far as possible from the boiler if thermostatic radiator valves are ﬁ tted thoughout.

Fig. 7

Central Heating

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 underﬂ oor 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. Ensure that the boiler heat exchanger is not a natural point for air collection. A typical heating system with domestic hot water circuit is illustrated in ﬁ g. 9.

Important - If thermostatic radiator vales are ﬁ tted a automatic bypass must be ﬁ tted to ensure a minimum ﬂ ow rate through the boiler of 6 l/min. The bypass should be ﬁ tted as far as possible from the boiler.

Make Up Water

Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798, for methods of ﬁ lling 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.

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.

Ensure all pipework is adequately supported

Gas

Additional expansion vessel C.H.

(if required)

By-pass

AUTOMATIC BY-PASS

The by-pass must be capable of passing 6 l/min of water when all the trv’s are shut down

TEMPRA 30

CLEARANCES:

* 600mm minimum clearance for servicing access

Top clearance only applies to 100Ø concentric ﬂ ue system

Fig. 8

Terminal Position

Fig. 9

460 5 min.5 min.

100 min.900

200 min.

363 50 mm

600* min.

760

D, E

Directly below an opening, air brick, opening windows, etc.

Above an opening, air brick, opening windows, etc.

Horizontally to an opening, air brick, opening windows, etc.

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

Dimensions Terminal position

(kW input expressed in net)

Balanced flues room

sealed

Fanned

draught

300 mm

D 75 mm

E 200 mm

F 200 mm

G 150 mm

H 300 mm

I 300 mm

J 600 mm

K 1200 mm

L 1200 mm

M 1500 mm

N 300 mm

O N/A

P N/A

Q N/A

NOTE N/A = Not applicable

In 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.

Minimum dimensions of ﬂ ue terminal positions

TEMPRA 30

3.01 Drilling Template (Top Flue Application)

Select suitable mounting position for boiler, using the template mark ﬂ ue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, ﬁ t wall plugs. Fit two special wall plugs on the wall as described in the ﬁ g. 10a. Fasten the wall bracket to the wall using two standard nuts (M8). Mount the boiler on the wall bracket and ﬁ x using two standard nuts (M8). Using a core drill cut a

118mm diameter hole for the ﬂ ue.

1. CH ﬂ ow (22 mm)

4. Gas supply (22 mm)

6. CH return (22 mm)

Fig. 10b

5 min

195 min

200 min

955 min

200

460 min

14 6

15 15

Ø3/4''Ø3/4'' Ø1/2''

Ø120

jig bracket

9292157

Fig. 10a

TEMPRA 30

3.02 Restrictor

For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of ﬂ ue restrictor required. Before inserting the ﬂ ue gas duct in the boiler, check that the restrictor ﬁ tted is correct and that it is correctly positioned (see ﬁ g. 11).

N.B.: the diameter of the hole is

stamped on the restrictor

Boiler is fitted with Ø47

restrictor as standard

Holes Ø : 45 47 50

Fig. 11

CHOICE OF RESTRICTOR:

RESTRICTOR FOR TWO PIPE SYSTEM

Total flow resistance

of flue system

Use

restrictor

size

minimum maximum mm

0 m 15 m 47 15 m 30 m 50 30 m 40 m 52 40 m 45 m No restrictor

• With concentric systems:

- Choose correct restrictor from table below.

• With 2 pipe system:

- Calculate the total ﬂ ow resistance of the air and ﬂ ue pipes in metres (cap. 3.04.2)

- utilise the table shown below to choose the more suitable restrictor for the ﬂ ow resistance calculated

RESTRICTOR FOR CONCENTRIC SYSTEM

Flue lenght up to:

Use

restrictor

size

Concentric

60 / 100

1 bend + 1 meter 52 mm

1 bend + 3 meters No restrictor

Concentric

80 / 125

1 bend + 3 meters 50 mm

1 bend + 4 meters

No restrictor

1 bend + 5 meters

TEMPRA 30

3.03 Top Outlet Concentric Flue Connection

3.03.1 Vertical concentric connection

1KWMA31Y

125

50*

-3 mm/m

Ø60 Ø80

70 min.

* = between 10 e 60 mm

230 230

Fig. 13

A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets at the joints makes this an extremely easy and safe option. For ﬂ ue length up to 1 m long the 50 mmØ restrictor is required. Longer than this no restrictor is required.

Fig. 12

Concentric Vertical Connector

3.03.2 Horizontal concentric connection

A 90° bend (ﬁ g. 13) is supplied for the horizontal connection of air and ﬂ ue gas pipes. This can be oriented towards the chosen wall in degrees of 45°.

Slope downwards away from the boiler at a rate of about 3 mm/m to avoid rainwater entering the boiler.

L = S + D + 165

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Ferroli TEMPRA 30 Installation, Service And User Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual