Ferroli T-ONE, T-ONE 25 C HE, T-ONE 30 C HE Instructions For Use, Installation And Maintenance
'
cod. 3541D730 — Rev. 00 - 05/2013
T-ONE
INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE
“T-ONE 25 C HE” GC N° 47-267-59
“T-ONE 30 C HE” GC N° 47-267-60
T-ONE C HE
2 EN
cod. 3541D730 - Rev. 00 - 05/2013
B
• Carefully read the warnings in this instruction booklet since they provide important information on safe
installation, use and maintenance.
• This instruction booklet is an integral part of the
product and must be carefully kept by the user for future reference.
• If the unit is sold or transferred to another owner or if
it is to be moved, always make sure that the booklet
accompanies the boiler so that it can be consulted
by the new owner and/or installer.
• Installation and maintenance must be carried out by
professionally qualified personnel, according to current regulations and the manufacturer's instructions.
• Incorrect installation or poor maintenance can cause
damage or physical injury. The manufacturer declines any responsibility for damage caused by errors in installation and use or by failure to follow the
manufacturer's instructions.
• Before carrying out any cleaning or maintenance operation, DISCONNECT AND ISOLATE the boiler from the
electrical power supply.
• In case the unit breaks down and/or functions poorly,
deactivate it, do not make any attempt to repair it or
directly intervene. Contact professionally qualified
personnel. Any repair/replacement of products must
only be carried out by qualified professional personnel using exclusively genuine parts. Failure to comply with the above could affect the safety of the unit.
• Periodical maintenance carried out by qualified personnel is essential for guaranteeing good operation
of the unit.
• This unit must only be used for the purpose for which
it was designed. Any other use is considered improper and therefore hazardous.
• After removing the packing, check the integrity of the
contents. Packing materials must not be left within the
reach of children as they are potentially hazardous.
••In case of doubt do not use the unit, and contact the
supplier.
• The images shown in this manual are a simplified
representation of the product. In this representation
there may be slight, unimportant differences with the
supplied product.
• Whilst every effort is taken to ensure the accuracy of
the information contained within these instructions,
the details are offered in good faith and the Manufacturer accepts no liability for matters arising as a result of errors and/or omissions.
••Due to the Manufacturers continuous product research and development, the details contained in
this manual may not truly reflect the actual product.
IMPORTANT
•
Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the
last pages of this manual. “This record must be completed and left with the end user”.
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 efficiency. Please see installation and servicing guidelines.
•
"Ferroli declare that no substances harmful to health are contained in the appliance or used
during the appliance manufacture”.
B
This symbol indicates "Caution" and is placed next to all safety warnings. Strictly follow
these instructions in order to avoid danger and damage to persons, animals and things.
A
This symbols calls attention to a note or important notice.
2009/142
2006/95
2004/108
The unit must not be used by people (including
children) with limited physical, sensory o mental
abilities or without experience and knowledge of it,
unless instructed or supervised in its use by someone responsible for their safety.
The unit and its accessories must be disposed of
appropriately, in conformity with the current regulations
T-ONE C HE
3
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cod. 3541D730 - Rev. 00 - 05/2013
1 Instructions .............................................................................................................................. 4
1.1 Introduction............................................................................................................................................. 4
1.2 Control panel ..........................................................................................................................................4
1.3 Turning ON and OFF.............................................................................................................................. 5
1.4 Adjustments............................................................................................................................................ 7
2 Installation ................................................................................................................................ 9
2.1 General Instructions ............................................................................................................................... 9
2.2 Place of installation ............................................................................................................................. 10
2.3 Plumbing connections .......................................................................................................................... 10
2.4 Connection to the gas system .............................................................................................................. 12
2.5 Electrical connections........................................................................................................................... 12
2.6 Flue system ..........................................................................................................................................14
2.7 Condensate drain connection............................................................................................................... 18
3 Service and maintenance......................................................................................................20
3.1 Adjustments.......................................................................................................................................... 20
3.2 Start-up................................................................................................................................................. 21
3.3 Commisioning instructions ................................................................................................................... 22
3.4 Routine servicing, maintenance & repair.............................................................................................. 23
3.5 Troubleshooting.................................................................................................................................... 26
4 Technical data and characteristics ...................................................................................... 27
4.1 Dimensions and connections ............................................................................................................... 27
4.2 General view and main components .................................................................................................... 28
4.3 Water circuit ......................................................................................................................................... 29
4.4 Technical data table .............................................................................................................................30
4.5 Diagrams .............................................................................................................................................. 31
4.6 Wiring diagram ..................................................................................................................................... 32
T-ONE C HE
4 EN
cod. 3541D730 - Rev. 00 - 05/2013
1. Instructions
1.1 Introduction
Thank you for choosing the T-ONE C HE, a FERROLI wall-mounted boiler the latest generation appliance, featuring
advanced design and cutting-edge technology.
T-ONE C HE is a high-efficiency condensing pre-mix appliance for central heating and hot water production, running
on natural gas or LPG, generating extremely low emissions.
The boiler is constructed with a stainless steel heat exchanger providing effective condensation of the water vapour contained in the flue gases, permitting extremely high efficiency.
Inside the boiler there is a premix burner with an integral fan, with a large stainless steel surface.
The boiler is totally room sealed from the installation room: the air needed for combustion is drawn from outside. The
boiler also includes a modulating speed fan, modulating gas valve, pump, expansion vessel, safety valve, flow sensor,
safety and control double temperature sensors, a safety thermostat and a low water pressure switch.
Thanks to the microprocessor control and adjustment system with advanced self-diagnosis, unit operation is for the
most part automatic. The power for heating is automatically governed by the control system.
The display continuously provides information on the unit’s operating status and it is easily possible to obtain additional
information on the sensor temperatures, set-points, etc. or configure them. Any operating problems associated with the
boiler or system is immediately signalled by the display and, if possible, corrected automatically.
1.2 Control panel
fig. 1 - Control panel
Key
1 = Domestic Hot Water temperature setpoint de-
creasing push button
2 = Domestic Hot Water temperature setpoint in-
creasing push button
3 = Central Heating water temperature setpoint de-
creasing push button
4 = Central Heating water temperature setpoint in-
creasing push button
5 = Display LCD
6 = Reset / OTC push button
7 = Economy-Comfort / On-Off push button
8 = Domestic Hot Water symbol
9 = Domestic Hot Water mode operation
11 = Multi-function indication (Flashing during heat
exchanger protection)
12 = Economy symbol
13 = Central Heating mode operation
14 = Central Heating symbol
15 = Burner on and actual load indication (Flashing
during flame current supervision)
16 = Service tool connector
9
15
1312
11 8 1
36
72
16414
Clock
predisposition
5
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cod. 3541D730 - Rev. 00 - 05/2013
Indication during boiler operation
Central Heating mode
The Central Heating heat demand (generated by the OpenTherm Remote Control, the Room Thermostat or the Clock)
is indicated by the flashing of the Hot Air symbol over the radiator (part. 13 and 14 - fig. 1). The display indicates the
actual Central Heating water temperature (part. 11 - fig. 1) and during central heating off time the text “d2”.
fig. 2
Domestic hot water mode
The Domestic Hot Water heat demand (generated by the DHW flow sensor or due to a Comfort request) is indicated by
the flashing of the Hot Water symbol under the tap (part. 8 and 9 - fig. 1). The display indicates the actual Domestic Hot
Water temperature (part. 11 - fig. 1) and during domestic hot water off time the text “d1”.
fig. 3
1.3 Turning ON and OFF
Without main power supply
fig. 4 - Boiler without main power supply
B
To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all water from
the system.
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cod. 3541D730 - Rev. 00 - 05/2013
Ignition
Ensure the power is on to the appliance.
fig. 5 - Ignition fig. 6 - Air purge
• For the firsts 300 seconds, the display shows FH that identifies the Air purge function.
• During the first 5 seconds, the display shows the software version of the pcb.
• Open the gas cock on the boiler and purge the air from the pipework upstream of the gas valve.
• When the FH disappears, the boiler is ready to function automatically whenever the external controls are calling for heat.
Turning off
Press the on/off button (part. 7 - fig. 1) for 5 seconds.
fig. 7 - Turning off
When the boiler is turned off with this key, the p.c.b is still powered, heating operation is disabled and the display is off
however the frost protection will still be active.
To totally isolate close the gas cock ahead of the boiler and disconnect electrical power.
B
To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all water from
the system.
To turn boiler on again, press the on/off button (part. 7 - fig. 1) for 5 seconds
fig. 8
The boiler is ready to function automatically whenever the external controls are calling for heat.
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cod. 3541D730 - Rev. 00 - 05/2013
1.4 Adjustments
Heating temperature setting
To set the system flow temperature, use the CH push buttons (part. 3 and 4 - fig. 1). It can be varied from a minimum
of 20°C to a maximum of 80°C.
fig. 9
Domestic hot water temperature setting
To set the hot water temperature, use the DHW push buttons (part. 1 and 2 - fig. 1). It can be varied from a minimum of
40°C to a maximum of 55°C.
fig. 10
Room temperature adjustment (using a room thermostat)
Using the room thermostat, set the temperature desired. Controlled by the room thermostat, the boiler lights and heats
the system water to the system delivery setpoint temperature. The burner shuts down when the desired temperature in
the room is reached.
A
A room thermostat and programmer are a mandatory requirement (Building regulations Doc ‘L’ 2002).
Room temperature adjustment (using an optional Remote Control)
Using the remote control, set the temperature desired. The flow temperature will be controlled by the remote control.
For settings and other informations, see the relative manual.
Economy/Comfort selection
The unit is equipped with a special internal device that ensures a high hot-water delivery speed and excellent user comfort. When comfort mode is active the water in the boiler is maintained at a pre-determined temperature, which means
that hot water is available at the boiler outlet as soon as a tap is opened, ie with no waiting.
The user can turn the device off (ECO mode) by pressing economy/comfort button (part.7 - fig. 1).
In ECO mode the display shows the relevant symbol (part. 12 - fig. 1). To turn on COMFORT mode, press economy/
comfort button (part. 7 - fig. 1) again, the ECO symbol will vanish from the display.
Outside temperature compensation
When the (optional) external sensor kit is fitted to the appliance, the system can work in Outside temperature compensation mode. In O.T.C. mode the temperature of the heating system is controlled according to the external climate conditions, this will guarantee a high degree of comfort and energy saving all year round.
By the CH push buttons (part. 3 and 4 - fig. 1) is possible to set the maximum flow temperature for the installation.
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cod. 3541D730 - Rev. 00 - 05/2013
O.T.C. setting
To enter the OTC mode, press OTC button (part. 6 - fig. 1) for 5 seconds.
The display shows CU flashing (fig. 11); to set Curve, use the DHW push buttons (part. 1 and 2 - fig. 1). It can be varied
from 1 to 10, in accordance with the chart (fig. 13). O means no O.T.C. mode.
It is recommended a start point of 20 - 30°C and a flow temperature of 85°C is required for the UK (Curve 9 or 10).
fig. 11
By pressing the CH push buttons (part. 3 e 4 - fig. 1), the display shows OF flashing (fig. 12); to set Offset, use the DHW
push buttons (part. 1 and 2 - fig. 1). It can be varied from 20 to 40, in accordance with the chart (fig. 14).
fig. 12
To exit the OTC mode, press OTC button (part. 6 - fig. 1) for 5 seconds.
fig. 13 - Compensation curves
fig. 14 - Example of compensation parallel curve offset
20
30
40
50
60
70
80
90
85
20 10 0 -10 -20
1
2
3
4
5
68910 7
Maximum boiler flow temperature
Outside Air Temperature
20
30
40
50
60
70
80
90
85
20 10 0 -10 -20
1
2
3
4
5
6
8910
7
20 10 0 -10 -20
20
30
40
50
60
70
80
90
85
1
2
3
4
568910 7
OFFSET = 20 OFFSET = 40
Maximum boiler flow temperature
Outside Air Temperature
Maximum boiler flow temperature
Outside Air Temperature
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cod. 3541D730 - Rev. 00 - 05/2013
2. Installation
2.1 General Instructions
B
This unit must only be used for its intended purpose. This unit is designed to heat water to a temperature below
boiling point and must be connected to a heating system and/or a water supply system for domestic use, compatible with its performance, characteristics and heating capacity. Any other use is deemed improper.
THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN COMPLIANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT LAW, THE REQUIREMENTS OF THE TECHNICAL STANDARDS (BS) AND ANY LOCAL REGULATIONS AND THE RULES OF PROPER
WORKMANSHIP.
Incorrect installation can cause damage or injury for which the manufacturer cannot be deemed responsible.
The unit must be installed in compliance with these instructions and the following standards applicable in
Great Britain.
Gas Safety Regulations (Installations & Use).
Local Building Regulations.
The Building Regulations (Part L).
The Buildings Standards (Scotland - Consolidated) Regulations).British Standards Codes of Practice (BSI):
Model Water By-Laws (Great Britain)
For Northern Ireland the relevant laws in force must be observed.
Safe handling of materials
Pay attention when handling the boiler insulation panels because the material they are made of could irritate the skin.
No part of the boiler contains asbestos, mercury or CFC's.
Advice for transport and handling
For lifting and transport always take suitable safety precautions: keep your back straight, bend knees, do not turn your
body, move feet, avoid bending forward or sideways and keep the load as close as possible to your body.
If possible, use a trolley or other suitable means to carry the boiler.
Grip the boiler firmly and, before lifting it, try and find the point where the load is concentrated in order to establish the
centre of gravity and suitably reposition yourself. Ideally seek assistance in lifting the boiler.
B.S. 5440 Part 1 Flues
B.S. 5440 Part 2 Air flow and ventilation
B.S. 5449 ......... Forced circulation hot water production systems
B.S. 6798 ......... Installation of gas-fired boilers for hot water
B.S. 6891 ......... Gas systems
B.S. 7671 ......... IEE wiring system standards
B.S. 4814 ......... Specifications for expansion tanks
B.S. 5482 ......... LPG systems
B.S. 7593 ......... Water treatment in central heating systems for DHW production
B.S. 5546 ......... Installation of systems for DHW production
B.S. 5955-8 ......... Installation of plastic pipes
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cod. 3541D730 - Rev. 00 - 05/2013
2.2 Place of installation
The combustion circuit is sealed with respect to the
place of installation and therefore the unit can be installed in any room. However, the place of installation
must be sufficiently ventilated to prevent the creation
of dangerous conditions in case of even slight gas
leaks. This safety regulation is provided for by EEC Directive no. 90/396 for all gas units, including those with
a sealed chamber.
In any case, the place of installation must be free of dust,
flammable materials or objects or corrosive gases.
The boiler is arranged for wall mounting and comes
standard with a hanging bracket. A paper template for
marking the drilling points on the wall is provided in the
box. The wall fixing must ensure stable and effective
support for the generator.
A
If the unit is enclosed in a cabinet or mounted
alongside, a space must be provided for removing the casing and for normal maintenance operations. The minimum
measurements to be respected are given in
fig. 15.
fig. 15 - Minimum distances around the boiler
A Min. 2,5 cm
B Min. 10 cm
C Min. 30 cm
D Min. 30 cm (via an openable panel)
2.3 Plumbing connections
Important
The heating capacity of the boiler must be previously established by calculating the building's heat requirement according
to the current regulations. To ensure proper operation and long boiler life, the plumbing system must be adequately sized
and complete with all the necessary accessories, including a room thermostat, a thermostatic radiator valve (TRV), etc.
The system flow and return pipes must have a diameter of at least 22 mm for the first 3 m of length from the unit.
If the system delivery and return pipes follow a path where air pockets could form in certain places, it is advisable to
install vent valves at these points. Also, install type "A" drain cocks at the lowest points in the system to allow complete
emptying.
The temperature drop between the delivery manifold and the return to the boiler should not exceed 20 °C.
A flow rate of at least 6 litres/min through the heat exchanger is required. Bypass installed in the boiler guarantees maintaining of the required flow rate.
B
Do not use the water system pipes to earth electrical appliances.
Before installation, carefully
flush all the heating system pipes to remove any residuals or impurities that could affect
proper operation of the unit (as required by BS 7593 Building regs Doc L).
Carry out the connections to the unit as indicated in fig. 34.
B
The safety valve discharge must be connected to a 15 mm diameter copper pipe descending from the boiler
to run off system water in case of overpressure in the heating circuit.
Otherwise, the boiler manufacturer
cannot be held liable if the discharge valve operates and floods the room. The discharge must be run
to the outside of the building to prevent the risk of damage or injury caused by discharged hot water in case
of overpressure in the system.
Connections to the boiler are to be made in such a way as to ensure that its internal pipes and fittings are free of stress.
If a non-return valve is installed also on the DHW circuit (if provided for), it is necessary to install a safety valve between
the boiler and circuit (with non-return valve at least 3 metres from the boiler) or an expansion tank for domestic use.
D
A A
B
C
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cod. 3541D730 - Rev. 00 - 05/2013
Shutoff valve kit
The shutoff valves supplied (see fig. 16) must be installed between the boiler and heating system to allow the boiler to
be isolated from the system if necessary.
fig. 16 - Shutoff valve kit
A Delivery cock 3/4”
B Domestic hot water outlet connection 1/2”
C Gas cock 1/2” (yellow)
D Cold water inlet connection 1/2”
F System return cock 3/4”
M Manometer
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. Ensure the filling
point is on the return pipe to the boiler.
Attention - is drawn to the Model Water Byelaws.
Filling system in fig. 17 is supplied with boiler.
B
C
D
F
A
M
Key
1. C.H. filling valve
2. Temporary connection
3. Cold water supply valve
4. Double check valve
fig. 17 - Filling system (supplied with boiler)
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