Ferroli Xignal Service Instructions Manual

Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DHStockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH

Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH

TEL.:: 0121/3523500 - Fax: 0121/3523510

ALL SPECIFICATIONS SUBJECT TO CHANGEALL SPECIFICATIONS SUBJECT TO CHANGE

ALL SPECIFICATIONS SUBJECT TO CHANGE

Phone numbers:Phone numbers:

Phone numbers:

InstallerInstaller

Installer

Service EngineerService Engineer

Service Engineer

Serial No.Serial No.

Serial No.

Read these Instructions thoroughly beforeRead these Instructions thoroughly before

Read these Instructions thoroughly before

using the applianceusing the appliance

using the appliance

FERROLI HELPLINEFERROLI HELPLINE

FERROLI HELPLINE

FOR SERVICE INFORMATION ORFOR SERVICE INFORMATION OR

FOR SERVICE INFORMATION OR

TEL.: 0121/3523500

ALWAYS QUOTE YOUR SERIAL NUMBERALWAYS QUOTE YOUR SERIAL NUMBER

ALWAYS QUOTE YOUR SERIAL NUMBER

FOR IMMEDIATE ASSISTANCEFOR IMMEDIATE ASSISTANCE

FOR IMMEDIATE ASSISTANCE

TECHNICALTECHNICAL

TECHNICAL

INFORMATIONINFORMATION

INFORMATION

INSTALLATIONINSTALLATION

INSTALLATION

andand

and

SERVICESERVICE

SERVICE

INSTRUCTIONSINSTRUCTIONS

INSTRUCTIONS

WALL MOUNTED, ROOM SEALED,WALL MOUNTED, ROOM SEALED,

WALL MOUNTED, ROOM SEALED,

FAN ASSISTED, GAS COMBINATION BOILER,FAN ASSISTED, GAS COMBINATION BOILER,

FAN ASSISTED, GAS COMBINATION BOILER,

COMPUTERISED AND SYNTHESIZED VOICECOMPUTERISED AND SYNTHESIZED VOICE

COMPUTERISED AND SYNTHESIZED VOICE

01/9801/98

01/98

2

3

INDEXINDEX

INDEX

Page

4.4.

4. Introduction

4.4.

4. Related documents

5.5.

5. General description

6.6.

6. Technical data

7.7.

7. Appliance dimensions

8.8.

8. Boiler flow diagram

9.9.

9. Boiler main parts

10.10.

10. Installation details

10.10.

10. Location of boiler

10.10.

10. Terminal position

10.10.

10. Air supply

11.11.

11. Minimum clearance

12.12.

12. Flue system

12.12.

12. Gas supply

12.12.

12. Water system

14.14.

14. Control heating pump

14.14.

14. Additional expansion vessel

15.15.

15. Installation of boiler

17.17.

17. Preparing flue assembly

18.18.

18. Connecting the boiler

20.20.

20. Fitting the flue assembly

20.20.

20. Electrical installation

21.21.

21. Wiring diagram

22.22.

22. External sensor location

23.23.

23. Gas conversion and adjustments

26.26.

26. Control panel

28.28.

28. Programming heating

29.29.

29. Programming boiler parameters

32.32.

32. Switching boiler on and off

33.33.

33. Routine maintenance

34.34.

34. Diagnosis and troubleshooting

4

IntroductionIntroduction

Introduction

The

XIGNAL CE XIGNAL CE

XIGNAL CE boiler is a high efficiency heat generating appliance of a totally new design. It is environment friendly, gas fired and prduces hot water for both the central heating system and domestic hot water.

The new concept of

XIGNAL CE XIGNAL CE

XIGNAL CE is that it is fitted with a microcomputer to regulate the boiler performance through technically sophisticated controls. This guarantees correct and optimum operation while being extremely simple to use. The diagnostic information and the operative status of the boiler are constantly visible on the display and can also be communicated by synthesized voice.

The boiler operation can be easily programmed be setting four daily heating levels. The fuel management system incorporates an internal and external sensor accurately calculating the heat output required (the temperature of the water in the radiators is regulated depending on the external temperature).

XIGNAL CE XIGNAL CE

XIGNAL CE has a new generation gas burner ensuring perfect combustion with high flame efficiency and low emissions of pulluting gases like NOx and CO

2

. The burner is ignited and monitored electronically ensuring the burner performance functions completely automatic and safe. This system also isolates the boiler from the domestic environment, ensuring total safety.

XIGNAL CE XIGNAL CE

XIGNAL CE heat exchanger is made entirely of copper this ensures high efficiency even when the heating is low, protection against rust and oxidation makes the heat exchanger both reliable and long lasting.

Related Documents

The appliance must be installed strictly in accordance with these instructions: The Gas Safety Regulations (Installation & Use) 1984. The Local Building Regulations. The Building Regulations. The Building Standards (Scotland - Consolidated) Regulations. British Standards Codes of Practice: B.S. 7593 - 1993 Treatment of water in domestic hot water central heating systems.

B.S. 5546 - 1990 Installation of hot water supplies for domestic purposes B.S. 5440 - Part 1FLUES B.S. 5440 - Part 2AIR SUPPLY B.S. 5449 - 1990 FORCED CIRCULATION HOT WATER SYSTEMS B.S. 6798 - 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS B.S. 6891 - 1989 GAS INSTALLATIONS B.S. 7671 - 1992 IEE WIRING REGULATIONS

5

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

The boiler is able to operate with two types of fuel gas: natural or propane (L.P.G.). The type of gas should be chosen when the boiler is ordered. Conversions can also be carried out during the installation phase

.The boiler is controlled by an internal microcomputer and all settings to the regulating systems are carried out on the assembly line by use of software. This ensures that the set values always remain absolutely accurate throughout plant use

The user may program and select the various options through the control panel. These functions include summer/winter operation, choice of the sanitary water temperature and that of the plant delivery, daily program setting and activation, boiler release.

The heating function is only activated when Winter operation is selected (key

). The microcomputer handles the heating function either according to the set daily program or according to the temperature set on the knob of the ambient unit. In both cases, the demand for heat will activate the circulation pump, the fan and the electronic equipment to start the burner. The burner ignites at a power value that will have been preset according to the fuelling gas. If the pressure in the heating system is less than 0.5 bar or more than 2.5 bar, the microcomputer will prevent boiler operation for safety reasons.

During operation, the plant delivery temperature is regulated according to the external temperature (detected by the relative probe). Temperature regulation will be proportional to the compensating curve set on installation according to the structural characteristics of both the building and system.

When the temperature of the water in the boiler approaches the value established by the computer, the valve will reduce the amount of gas (modulating) delivered to the main burner in order to keep the water temperature near to the required value. If the water temperature reaches the preset value, the burner will go out and will wait 2 minutes until igniting again. Having terminated the demand for heat, the burner will stop while the circulator will continue to operate for six minutes so that the temperature is evenly distributed throughout the system.

If hot water is used during the heating system, the microcomputer will detect this by means of the flowmeter and will disactivate the heating function. This stops the circulator and activates hot water production. Hot water is constantly maintained at the set value even during different water flow rates. This is due to a correct establishment of the outlet flow of hot water and adequate modulation of the burner rating. Once use of hot water ceases, the computer will wait for 2 minutes before re-activating the heating function.

Only hot water production is activated during "Summer" operation. However, the circulating pump of the heating function will operate for 1 sec. at the end of each demand for water in order to prevent the pump itself from sticking.

The microcomputer continuously checks that boiler operation is correct. In the event of faults, these are immediately visualized (the display will flash) and notified by synthesized voice when the relative button is depressed. Boiler operation will be inhibited until the fault is rectified or, in some cases, until the boiler is manually reset. All faults are memorized by the microcomputer together with the other operational parameters. This enables the technical assistance service to proceed with a correct diagnosis.

6

Technical dataTechnical data

Technical data

NATURAL GAS (G20)NATURAL GAS (G20)

NATURAL GAS (G20)

PROPANE LPG (G31)PROPANE LPG (G31)

PROPANE LPG (G31)

Nominal heat input (gross caloric value) 34.8 kW 34.0 kW Minimum heat input (gross caloric value) 15.1 kW 14.8 kW Nominal heat input (net caloric value) 31.3 kW 31.3 kW Minimum heat input (net caloric value) 13.6 kW 13.6 kW Nominal heat output 27.9 kW 27.9 kW Minimum heat output 11.8 kW 11.8 kW

Gas rate 3.27 m

3

S/h 2.40 kg/h

Burner setting pressure 15,0 mbar (max.) 34,5 mbar (max.) Minimum burner pressure 3,0 mbar (min.) 6,9 mbar (min.)

Injector manifold Ø 1.15 mm 0.72 mm Dimensions (o/all) Height 1020 mm Width 480 mm Depth 360 mm

Weight (net) 51 kg Weight (gross) 53 kg

Electricity supply: 230V - 50 Hz Fuse rating:

Mains 2 Amp. (main fuse) on P.C.B. in boiler F2 Amp (Fast)

Electrical input 150 Watt Domestic Hot Water flow:

(35°C rise) 11.4 l/min. Minimum Domestic Hot Water Flow 2.5 l/min. Maximum domestic cold water Inlet pressure: 10,0 bar

C.H. Safety valve pressure setting 3 bar C.H. Expansion vessel capacity 7 litre Min. heating circuit pressure 0,8 bar Max. heating circuit pressure 3.0 bar

Boiler water capacity: Heating 1.5 litre Domestic hot water 0.5 litre

Pipe connections: Gas 22 mm Domestic cold water inlet 15 mm Domestic cold water outlet 15 mm Central heating flow 22 mm Central heating return 22 mm Pressure relief valve drain 15 mm

Min. installation clearances. Sides: Left hand 5* mm Right hand 5* mm Front 50** mm

(plus access for service)

Min. height from worktop to base 200 mm * If using a side outlet flue then the minimum clearance on the flue outlet side of the appliance is increased to 75 mm (3 in.)

** Access to the front of the boiler must be available for maintenance (min. 600 mm) The maximum working temperature of the central heating water is 85°C. The maximum domestic hot water production temperature is 65°C, which can be regulated from 40 to 65°C.

7

KeyKey

Key

1. 1.

1. Electricity cable entry

2.2.

2. Gas supply

3. 3.

3. Domestic Hot Water outlet

4. 4.

4. Domestic Cold Water inlet

5.5.

5. Central Heating Pressure relief valve

6. 6.

6. Central Heating Flow outlet

7. 7.

7. Central Heating Return inlet

Appliance DimensionsAppliance Dimensions

Appliance Dimensions

TOP VIEWTOP VIEW

TOP VIEW

FRONT VIEWFRONT VIEW

FRONT VIEW

LEFT SIDE VIEWLEFT SIDE VIEW

LEFT SIDE VIEW

REAR VIEWREAR VIEW

REAR VIEW

480

163

900

370

448

66

213

144

77.5507580505097.5

12 3 4 5 67

40

100

60

8

S.p.A.

124749

1...4

MAN

AUTO

Model Water Bye Laws.

Fig. 2

66

6

6868

68

9898

98

140140

140

142142

142

141141

141

9

Boiler flow diagramBoiler flow diagram

Boiler flow diagram

Main partsMain parts

Main parts 11

11

1 Fixing point 55

55

5 Room sealed compartment 66

66

6 Instrument panel 77

77

7 Gas inlet 88

88

8 Domestic hot water outlet 99

99

9 Domestic hot water inlet 1010

1010

10 Central heating flow 1111

1111

11 Central heating return 1212

1212

12 D.H.W. drain point 1414

1414

14 Safety valve 1616

1616

16 Fan 1919

1919

19 Combustion chamber 2020

2020

20 Burner unit 2121

2121

21 Injector manifold 2222

2222

22 Burner 2626

2626

26 Combustion chamber insulation 2727

2727

27 Copper exchanger for C.H. or D.H.W. 2929

2929

29 Flue outlet manifold 3030

3030

30 Excess air chamber 3131

3131

31 Air pressure control damper 3232

3232

32 C.H. pump 3333

3333

33 Heating water circuit 3434

3434

34 Heating temp. sensor 3535

3535

35 Air separator 3636

3636

36 Automatic air vent 3737

3737

37 Cold water inlet filter 4141

4141

41 Domestic hot water circuit 4242

4242

42 D.H.W. temperature sensor

4343

43 Air pressure switch 4444

4444

44 Gas valve 4747

4747

47 Gas valve modulator 4848

4848

48 Burner pressure test point 4949

4949

49 Overheat thermostat 5353

5353

53 Heat exchanger venting point 5454

5454

54 Temperature sensing phial 5656

5656

56 Expansion tank 5757

5757

57 Fan air inlet pressure test point 5858

5858

58 Fan air outlet pressure test point 5959

5959

59 Flue outlet pressure test point 6565

6565

65 230V line terminal strip and probe connections 6868

6868

68 Control box with P.C.B. 7171

7171

71 Balance tube 8181

8181

81 Ignition electrode 8282

8282

82 Flame sensing electrode 8383

8383

83 Automatic ignition control panel 8484

8484

84 1. gas valve operator 230V 8585

8585

85 2. gas valve operator 230V 8787

8787

87 Venturi test point 9696

9696

96 Control heating limit sensor 9898

9898

98 Main switch 101101

101101

101 P.C.B. 136136

136136

136 Flowmeter 137137

137137

137 Pressure sensor 140140

140140

140 Touch keyboard 141141

141141

141 Loudspeaker 142142

142142

142 Display P.C.B. 158158

158158

158 Gas inlet pressure test point

10

Installation DetailsInstallation Details

Installation Details

Gas Safety (Installation & Use) Regulations: 1984 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 - Important -

Important - If the boiler is to be fitted in a timber framed building 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.

Location of Boiler The installation of the

XIGNAL CE XIGNAL CE

XIGNAL CE must be on a suitable non-combustible load bearing wall which will provide an adequate fixing 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 must

must be

observed: The combination 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 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, should be so situated that it cannot be touched by a person using the bath or shower.

Terminal Position

POS. MINIMUM SPACING (fig. 3) mm

AA

A Directly below an openable window, air vent, or any other ventilation opening 300 BB

BB

B Below gutters, soil pipes or drainpipes 75 CC

CC

C Below Eaves 100 DD

DD

D Below a Balcony 100

EE

E From vertical drainpipes or soilpipes 75

FF

F From internal or external corners 100

GG

G Above adjacent ground or balcony level 100 HH

HH

H From a surface facing the terminal 600

II

I Facing another terminal 1,200

JJ

J From opening (door/window) in carport into dwelling 1,200

KK

K Vertically from a terminal on the same wall 300

LL

L Horizontally from a terminal on the same wall 300

NN

N Below carport 600

A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when the distance is less than 2 m from the outside floor.

Air Supply The room in which the boiler is installed does not require a purpose provided vent. If the boiler is installed in a cupboard or compartment, permanent air vent are required in the cupboard or compartment, one at high level one at low level, either direct to the outside air to a room. Both high and low level air vents must communicate with the same space.

Minimum effective area requirements of compartment air vents (for cooling purposes only) (fig. 4).

11

NOTES **

**

* If a side outlet flue is to be used, a clearance of 75 mm will be needed on the flue outlet side of the boiler. ** Access to the front of the boiler must be available for maintenance (min. 600 mm).

Fig. 5

Fig. 4

APPLIANCE

FLUE

SYSTEM

APPLIANCE LOCATION

ROOM-SEALED AIR VENT AREAS

IN ROOM NIL

IN COMPARTMENT OPEN TO ROOM

IN COMPARTMENT OPEN TO OUTSIDE

HIGH LEVEL: 252 cm

2

(38 in.2)

LOW LEVEL: 252 cm

2

(38 in.2)

HIGH LEVEL: 126 cm

2

(19 in.2)

LOW LEVEL: 126 cm

2

(19 in.2)

AIR VENT

Terminal PositionTerminal Position

Terminal Position

Air supplyAir supply

Air supply

Minimum Clearance Minimum Clearance

Minimum Clearance mm

Fig. 3

Ferroli Xignal Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual