Ferroli XIGNAL CE Technical Information Installation And Service Instructions
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 08707 282 885 - Fax 08707 282 886
ALL SPECIFICATIONS SUBJECT TO CHANGE
Phone numbers:
Installer
Service Engineer
Serial No.
Read these Instructions thoroughly before
using the appliance
FERROLI HELPLINE
FOR SERVICE INFORMATION OR
HELP TELEPHONE: 08707 282 885
ALWAYS QUOTE YOUR SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
TECHNICAL
INFORMATION
INSTALLATION
and
SERVICE
INSTRUCTIONS
WALL MOUNTED, ROOM SEALED,
FAN ASSISTED, GAS COMBINATION BOILER,
COMPUTERISED AND SYNTHESIZED VOICE
01/01
2
3
INDEX
Page
4. Introduction
4. Related documents
5. General description
6. Technical data
7. Appliance dimensions
8. Boiler flow diagram
9. Boiler main parts
10. Installation details
10. Location of boiler
10. Terminal position
10. Air supply
11. Minimum clearance
12. Flue system
12. Gas supply
12. Water system
14. Control heating pump
14. Additional expansion vessel
15. Installation of boiler
17. Preparing flue assembly
18. Connecting the boiler
20. Fitting the flue assembly
20. Electrical installation
21. Wiring diagram
22. External sensor location
23. Gas conversion and adjustments
26. Control panel
28. Programming heating
29. Programming boiler parameters
32. Switching boiler on and off
33. Routine maintenance
34. Diagnosis and troubleshooting
4
Introduction
The 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 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 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 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 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 data
NATURAL GAS (G20) 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.)
Main injector 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
Key
1. Electricity cable entry
2. Gas supply
3. Domestic Hot Water outlet
4. Domestic Cold Water inlet
5. Central Heating Pressure relief valve
6. Central Heating Flow outlet
7. Central Heating Return inlet
Appliance Dimensions
TOP VIEW
FRONT VIEW LEFT SIDE 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
6
68
98
140
142
141
9
Boiler flow diagram
Main parts
1 Fixing point
5 Room sealed compartment
6 Instrument panel
7 Gas inlet
8 Domestic hot water outlet
9 Domestic hot water inlet
10 Central heating flow
11 Central heating return
12 D.H.W. drain point
14 Safety valve
16 Fan
19 Combustion chamber
20 Burner unit
21 Main injector
22 Burner
26 Combustion chamber insulation
27 Copper exchanger for C.H. or D.H.W.
29 Flue outlet manifold
30 Excess air chamber
31 Air pressure control damper
32 C.H. pump
33 Heating water circuit
34 Heating temp. sensor
35 Air separator
36 Automatic air vent
37 Cold water inlet filter
41 Domestic hot water circuit
42 D.H.W. temperature sensor
43 Air pressure switch
44 Gas valve
47 Gas valve modulator
48 Burner pressure test point
49 Overheat thermostat
53 Heat exchanger venting point
54 Temperature sensing phial
56 Expansion tank
57 Fan air inlet pressure test point
58 Fan air outlet pressure test point
59 Flue outlet pressure test point
65 230V line terminal strip and probe connections
68 Control box with P.C.B.
71 Balance tube
81 Ignition electrode
82 Flame sensing electrode
83 Automatic ignition control panel
84 1. gas valve operator 230V
85 2. gas valve operator 230V
87 Venturi test point
96 Control heating limit sensor
98 Main switch
101 P.C.B.
136 Flowmeter
137 Pressure sensor
140 Touch keyboard
141 Loudspeaker
142 Display P.C.B.
158 Gas inlet pressure test point
10
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 - 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 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 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
A Directly below an openable window, air vent, or any other ventilation opening 300
B Below gutters, soil pipes or drainpipes 75
C Below Eaves 100
D Below a Balcony 100
E From vertical drainpipes or soilpipes 75
F From internal or external corners 100
G Above adjacent ground or balcony level 100
H From a surface facing the terminal 600
I Facing another terminal 1,200
J From opening (door/window) in carport into dwelling 1,200
K Vertically from a terminal on the same wall 300
L Horizontally from a terminal on the same wall 300
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 cm2 (38 in.2)
LOW LEVEL:
252 cm2 (38 in.2)
HIGH LEVEL:
126 cm2 (19 in.2)
LOW LEVEL:
126 cm2 (19 in.2)
AIR VENT
AIR VENT
Terminal Position Air supply
Minimum Clearance mm
Fig. 3
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