Page 1
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
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2
Page 3
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
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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
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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.
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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.
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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
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8
S.p.A.
124749
1...4
MAN
AUTO
Model Water Bye Laws.
Fig. 2
6
68
98
140
142
141
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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
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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).
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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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Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
A standard flue 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 2815 mm for rear flues and deduct 91 mm plus distance
from side wall for side outlet flues).
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 ventilators, windows, doors, natural air infiltration, or forced
ventilation/air conditioning.
Gas Supply
If necessary the local Gas Region 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 Region.
A gas meter can only be connected by the Local Gas Region, or by a Local Gas Region's Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20 mbar MINIMUM.
Pipework from the meter to the combination boiler must be of an adequate size.
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 fitted on the manifold assembly.
Water System
Central Heating
It must be a sealed system. 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 underfloor 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.
It should be ensured that the boiler heat exchanger is not a natural point for collecting air. A typical heating system
with domestic hot water circuit is illustrated in fig. 6.
Important - A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min. The bypass should
be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout.
Make up Water
Provision must be made for replacing water lost from 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 Bye-law. Again any such connection must be disconnected after use (fig. 7).
Domestic Hot Water
Always fit a water softener or descaler in «hard water areas». A 15 mm copper connection point on the boiler
jig bracket for attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply is
10 bar (145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing valve must
be fitted by the installer into the mains supply in an inconspicuous but accessible position preferable between 3 and 5
metres (10-16 ft) before the appliance. Such a valve must be approved by the Water Research Council.
Attention - Is drawn to the Model Water Bye-laws.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain water
undertakings will not accept their use above ground.
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Fig. 7
NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted
throughout.
Fig. 6
Gas
Cold water
Additional expansion vessel C.H.
(if required)
Filling
point C.H.
Bypass
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
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Built-in Central Heating Water Circulating Pump
The pump head available for circulating the water is given in fig. 8.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph
Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.
If required an additional expansion vessel may be fitted to the central heating return inlet.
If the total volume of water in the system exceeds 40 litres an additional expansion vessel must
be fitted to the central heating return inlet.
Pump performance curve Grundfos UPS 15-50
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
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 7 litre vessel
supplied.
Note
1. Fill C.H. installation to min. 1.5 bar.
2. Select by preference the expansion vessel for
increased system pressure of 2.0 bar
3. Expansion vessel must be fitted to Central Heating
Return Inlet
4. The standard 7 litres expansion vessel is charged
to 1 bar
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Installation
Note - To mount the boiler on the wall, a two person lift will be needed.
1.0 UNPACKING
The appliance is delivered in 2 cartons.
1.1 The large carton contains the boiler, the Installation/Servicing and Users Instructions, external and
internal sensors.
1.2 The second carton contains the mounting jig assembly, complete with isolating valves, the assembly
fixing screws and wall plugs (x4), the boiler mounting nuts and washers (x2), drilling template, flue
assembly and turret.
When the cartons are unpacked examine for any signs of damage in transit. All protective plastic should
be left in place until installation is complete.
2.0 FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
2.1 Select the boiler location carefully ensure that all requirements given in previous text are satisfied.
Fig. 10 will also give guidance to fixing dimensions.
2.2 Locate template on wall, mark the positions of the four jig bracket fixing holes and the flue opening.
2.3 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
2.4 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
2.5 Fit the mounting jig assembly using the four fixing screws provided (Ensure that all the service
cocks are in the OFF position). Operate valves several times to ensure they are free.
2.6 With the exception of the connection to the pressure relief valve, make all the water and
gas connections to the jig bracket valves. Fully tighten (fig. 11). Water connections can be made
with compression or capillary fittings (before the gas inlet to the boiler there must be at least 100
mm of straight before any bends).
3.0 FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
3.1 Select the boiler location carefully ensuring that all the requirements given in previous text are
satisfied.
Fig. 10 will aso give guidance.
3.2 Locate the template on wall and mark the position of the four jig bracket fixing holes.
3.3 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
3.4 Fit the mounting jig assembly using the four fixing screws provided.
3.5 Extend a horizontal line from the centre of the rear flue outlet to the side wall.
3.6 Mark the centre line (vertically) for the flue assembly hole, and mark the centre of the hole.
3.7 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
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Fig. 10
1 = Electrical cable entry
2 = Gas supply
3 = Domestic Hot Water outlet
4 = Domestic Cold Water Inlet
5 = Outlet Central Heating safety valve
6 = Central Heating flow outlet
7 = Central Heating return inlet
2 = 22 mm
3-4-5 = 15 mm
6-7 = 22 mm
3 Domestic Hot Water
outlet 15 mm
5 Outlet central heating
safety valve 15 mm
Important Note - Always use two spanners to prevent twisting of soft copper pipework.
Note - The central heating safety valve (5) should be piped 15 mm to discharge safely outside the property.
Fig. 11
2 Gas 22 mm
4 Domestic Cold Water inlet 15 mm
6 Central Heating flow outlet 22 mm
7 Central Heating return inlet 22 mm
Important Note - Always use two spanners to prevent twisting of soft copper pipework on the boiler.
Flush out the water system.
Note - The maximum inlet cold water pressure must not exceed 10 bar (145 P.S.I.) and a water governor or a pressure
reducing valve will be required if the pressure is in excess of 5 bar (72 P.S.I.).
Ensure all pipework is adequately supported.
Drilling template
Note - Min 91 for side flue outlet
Fixing stud
boiler
Upper bracket
Note - Min 75 for
side flue outlet
Rear flue outlet
Diam. min. 118 mm
Boiler = 480 mm
Lower bracket
Side flue outlet
Diam. min.
118 mm
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17
Rear flue Outlet
Fig. 12
Aluminium flue pipe length = Plastic air inlet pipe
length plus 50 mm (2") longer.
4.2.1 Accurately measure the Wall thickness (P2).
4.2.2 Accurately measure the distance from the centre of the stud
fixing of the mounting jig assembly to the side wall (Q2).
4.2.3 From the end opposite to the terminal, cut the plastic air duct
(dimension A2) to length (P2 + Q2 + 125 mm).
Note - That the terminal is not included in length A2.
4.2.4 Cut the metal flue duct to length (P2 + Q2 + 175 mm)
(dimension F2).
Note - The metal flue pipe must be 50 mm (2 inches) longer
than the plastic air inlet pipe.
4.2.5 Drill a 3 mm hole 15 mm from the plain end of plastic air duct.
4.2.6 Place flue components to one side to be used later.
Side Flue Outlet
Fig. 13
4.1.1 Accurately measure the Wall thickness (P1)
4.1.2 From the end opposite to the terminal, cut the plastic
air duct (dimension A1) to length (P1 + 105 mm).
Note - That the terminal is not included in A1.
4.1.3 Cut the metal flue duct to length (P1 + 155 mm)
(dimensions F1).
Note - The metal flue pipe must be 50 mm (2 inches)
longer than the plastic air inlet pipe.
4.1.4 Drill a 3 mm hole 15 mm from the plain end of plastic
air duct.
4.1.5 Place flue components to one side to be used later.
4.2
Side Flue Outlet (fig. 13).
Important - The aluminium flue pipe must protrude
into the outside grill by 2 in (50 mm), never cut it to the
same length as the plastic air pipe.
4.0 PREPARING THE FLUE ASSEMBLY
4.1
Rear Flue Outlet (fig. 12)
Important - The aluminium flue pipe must protrude into the outside grill by 2 in (50 mm), never cut it to the same length
as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 50 mm !).
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
F1 (Flue outlet)
Fixing
screwAir sealing sleeve
Fixing screw
A1 (Air intake)
Page 18
18
5.0 CONNECTING THE BOILER
5.1 Place the boiler on its back.
5.2 Remove the boiler base plate, four screws (fig. 16). Remove the plugs fitted to the boiler water
connections.
Remove the bag of sealing washers from the boiler pipework. Remove the front panel by sliding
up and pulling away from the main boiler.
5.3 Lift boiler as shown in fig. 15 onto the top studs and fit supplied nuts and washers hand tight.
5.4 Lift at bottom to engage the water and gas connections. Tighten central heating flow and return,
and the domestic hot water inlet and outlet, using appropriate sealing washers. Tighten the gas
union.
5.5 Screw the pressure relief valve adaptor provided, through the jig bracket into the valve, using
the remaining washer (fig. 17).
5.6 Connect the pressure relief valve discharge pipe (15 mm) to the outside of the building, where
possible over a drain. The discharge must be such that it will not be hazardous to occupants or
passers-by cause damage to external electric components or wiring. The pipe should be directed
towards the wall.
It must not discharge above an entrance or window, or any type of public access. The installer must
consider that the overflow could discharge boiling water.
Fig. 14
Fixing
screws
Flue sealing gasket
Air sealing gasket
TOP VIEW BOILER SIDE OUTLET
Page 19
19
Fixing points
Lift here
Fig. 15
Fixing screws
Fig. 16 Fig. 17
Page 20
20
6.0 FITTING THE FLUE ASSEMBLY
6.1 With Sufficient Clearance To Insert Assembly From Inside
6.1.1 Push the air duct seal onto the air duct at the cut end.
6.1.2 Insert the flue assembly into the wall.
6.1.3 Make good internal wall face.
6.1.4 Fully insert the flue assembly into the turret spigot. Insert the self tapping screw supplied. Fully tighten.
6.1.5 Secure the turret.
6.1.6 Slide the air duct seal over the joint.
6.1.7 Check the terminal relationship with the wall as shown in fig. 12.
6.1.8 Make good the outside wall face, re-weatherproof.
6.2 With insufficient Clearance To Insert Assembly From Inside
6.2.1 From outside, push flue duct, then the air duct through the wall.
6.2.2 Push the air duct seal over the air duct.
6.2.3 Fully insert the flue duct into the turret, then the air duct. Slide, back the seal and secure the air duct with the
self tapping screw provided.
6.2.4 Slide the seal over the joint and secure the turret.
6.2.5 Continue as detailed in 6.1.8 above.
7.0 ELECTRICAL INSTALLATION
Electrical installation must be carried out by a competent electrician. The appliance is to be connected to a 230 V
~ 50 Hz supply (see fig. 18). The supply fuse rating is 3A. The terminals are accessible after removing the white base
plate (see fig. 18).
7.1 Procedure
7.1.1 The supply cable must be no less than 0.75 mm (24x0.2 mm) to BS6500 table 16.
7.1.2 The earth conductor must be cut longer than the live and neutral (fig. 19).
Connect the Supply Cable to the terminal block marked 230 V ~ 50 Hz, L, N, the supply cable is to be connected as follows:
i) Connect the brown wire to the L (live) terminal).
ii) The blue wire to the N (neutral) terminal.
iii) The green/yellow wire to the (earth) terminal.
7.1.3 Secure the cable with the cable clamp. The supply cable can be connected to the mains supply by the use of an unswitched
shuttered socket-outlet in conjunction with the 3A fused 3 pin plug both in accordance with BS 1363. This provides
complete isolation. Alternatively, a fused double pole switch having a contact separation of at least 3 mm, in all poles
and provided just for the boiler and its external controls can be used. A wiring diagram is provided on the appliance,
attached to the rear of the front panel. In addition, there is one in this manual (fig. 25). Attention is drawn to the
requirements of the current I.E.E. Regulation and in Scotland, the electrical provisions of the Building regulations.
Remote sensors
The XIGNAL CE is supplied with an internal and external sensor to ensure maximum fuel savings.
Room Sensor
To be in a position within the property normally used for a room thermostat.
Ensure connections complies with the polarity shown in Figure 18 wired to terminals No. 5 and No. 6.
External Sensor
To be wired to terminals No. 7 and No. 8.
Location of sensor see Figure 21 and 22.
L
N
EXTERNAL
SENSOR
ROOM
SENSOR
3015
20 25
S.p.A.
230 V ~
50Hz
1
2
1
2
3
4
5
6
7
8
9
10
Fig. 18
Fig. 19
Blue
Brown
Screw
Page 21
21
1
2
3
P7
P8
RL1
RL2
RL3
RL4
RL5
P6
12 34
P5
P4
P3
P2
P1
OUT
L
N
140
137
136
65
138
139
2
1
96
141
98
N
L
P12
P9
P10
P11
1
2
3
1
2
3
4
5
6
7
8
9
10
1
2
3
4
HDR1
voice
volume
142
101
123456712
43
47
42
16
32
AUTO
MAN
1...4
49
84
85
8 9
X6
X1
83
X2
312145
X3
X4
X5
67
12
13
1715
16
81
82
34
123 4567
1
2
1
2
1
2
1
2
3
4
5
6
7
8
9
10
X
LOW
VOLTAGE
brown
blue
brown
brown
red
black
grey
black
brown
blue
white
yellow
green
orange
S
S
red
green
black
white
white
red
red
blue
black
grey
white
brown
red
white
green
Wiring diagram
Fig. 20
Ohm value
of the sensors
°C Ohm
25 10 K
40 5,4 K
60 2,5 K
80 1,3 K
KEY
16 Fan
32 C.H. pump
34 Heating temperature sensor
42 D.H.W. temperature sensor
43 Air pressure switch
47 Gas valve modulator
49 Overheat thermostat
65 230V line and probe connection terminal strip
81 Ignition electrode
82 Flame sensing electrode
83 Automatic ignition control panel
84 1. operator 230V gas valve
85 2. operator 230V gas valve
96 C.H. limit sensor
98 Main switch
101 Main P.C.B.
136 Flowmeter
137 Pressure sensor
138 External sensor
139 Room sensor
140 Touch keyboard
141 Loudspeaker
142 Display P.C.B.
x possible connection for standard
room thermostat
Note:
strictly comply with the neutral, line
connection polarities and those of the room sensor.
Page 22
22
External sensor location
The external sensor should preferably be installed
on the North, North-East wall or on the one facing
the majority of the main living rooms in the building.
The sensor must never be exposed to the first
morning sunlight. Where possible, it must never be
subjected to direct sunlight and should be protected
if necessary.
In no case may the sensor be mounted near windows,
doors, ventilation openings, stacks or heat sources
which could alter its reading.
Fig. 22
Fig. 21
Page 23
23
8 Gas conversion
Only Qualified Personnel may carry out the following regulating and conversion operations. Ferroli
S.p.A. declines all responsibility for damage to persons and/or property caused by unauthorized persons
having tampered with the appliance. Proceed with the following conversions if the appliance must be used
with a different type of gas.
To switch from Natural gas to L.P.G. and vice versa, it will be necessary to change the main injectors and
to fit the delayer union to the gas valve (part F. fig. 23). Now adjust the minimum and maximum gas
pressure values on the gas valve (see relative paragraph).
9 Adjustments
Adjusting the pressure and flow rate to the main burner
Being the flame modulating type, this appliance has two fixed pressure values: the minimum and
maximum rate. These must be those indicated in the chart for each type of gas.
Attention - The minimum pressure must be regulated first. This will ensure correct burner
ignition. Following this, regulate the maximum pressure value. Each minimum pressure
adjustment involves a variation to the maximum setting value. Since they are particularly
delicate, the following regulating operations must only be carried out by Specialized
Personnel.
Adjusting the minimum and maximum pressure values
Connect a suitable pressure gauge to the pressure test point above the gas valve.
Keep button
depressed for more than 5 seconds. The following message will appear on the display:
TEST NOT ACTIVATED
CURRENT: 165 mA
Remove protective cap "b" from the top of the coil.
Adjust the minimum pressure value using nut "c". Turn this screw anticlockwise to decrease the pressure
or in a clockwise direction to increase it.
Switch the burner off and on three or four times, depressing keys
and , checking each time that the
pressure remains regulated and that the burner regularly ignites. Further adjustment is required if this fails
to occur.
Having terminated this operation, check the maximum pressure value.
TEST ACTIVATED
CURRENT 0 mA
Use buttons on the right to adjust the current to 0 mA.
Press button
. The boiler will operate in TEST mode.
Page 24
24
Delicately depress pin "d" and keep it fully pressed down. If the maximum pressure value must be
adjusted, slowly turn adjuster nut “e” in a clockwise direction to increase the pressure and in an
anticlockwise direction to lower the pressure value.
Having regulated the minimum and maximum pressure values, reset compensating tap "b". The current
value should now be reset to 165 mA.
Disactivate the TEST function by depressing button
. The boiler will now be ready to operate
automatically.
NOTE - The above listed adjustments establish the mechanical travel of the plunger of the “Modureg”
modulator between a minimum and maximum setting.
NOTE - The complete “Modureg” unit must be replaced if the "Modureg" coil fails to operate. Any attempts
to replace the coil alone would irreparably jeopardize the "Modureg" setting.
Anyone carrying out adjustments with these nut should proceed very delicately.
HONEYWELL valve VR 4605 NA 2007 (fig. 18)
Fig. 23
TEST ACTIVATED
CURRENT 165 mA
2
b
a
g
1
f
d
e
c
Key
1. Inlet pressure test point
2. Outlet pressure test point
a. Electrical coil connection
b. Balance cap
c. Minimum pressure regulating nut
d. Maximum pressure pin
e. Maximum pressure regulating nut
f. "Adapter" fitting (only on L.P.G. versions)
g. Protective cap
Page 25
25
Adjustment of the heating ∆t by varying the circulator flow rate-head
Heat variation ∆t (temperature difference in the heating water between the supply and return points of
the system) must be less than 20°C. This is obtained by varying the flow rate head of the circulator using
the multi-speed variator (or switch) of the same. The ∆t value decreases when the speed of the circulator
is increased, and vice versa.
Boiler pressure adjustment
The pressure of the water in the heating plant, indicated by the control panel display, must be regulated
as described in the relative paragraph.
Honeywell VR 4600 N 4002 valve with V7335A4014 Modureg
Gas pressure Adjustment
1 - With the burner lit:
2 - Connect suitable pressure gauge to burner test point "B", and then:
3 - Disconnect air pressure compensation tube "H";
4 - Disconnect the wires from coil "C" of the Modureg;
5 - Remove protective cover "D";
6 - Remove coil "C" by opening the coupling spring "I";
7 - Screw the minimum adjustment screw "E" up tightly. (clockwise)
8 - Unscrew lock nut "F" on sleeve "G";
9 - Adjust maximum pressure by rotating sleeve "G" clockwise to increase
pressure and anticlockwise to reduce pressure;
10 - Tighten sleeve lock but "F" then check that the pressure
is still at the required value;
11 - Adjust minimum pressure by rotating screw "E" anti-
clockwise until the required value is reached;
12 - Fit coil "C" by sliding it into the sleeve, pushing and
rotating it lightly until the coupling spring "I" clicks into
place;
13 - Shut down and ignite the burner, checking that the
minimum pressure value is stable;
14 - Reconnect the wires to coil "C" of the Modureg;
15 - Reconnect air pressure compensation tube "H";
16 - Replace protective cover "D";
17 - Turn burner off, remove pressure gauge, close and test,
test point;
Key
A Test point inlet pressure - B Burner test point - C Coil -
D Protective cover - E Minimum adjustment screw - F Lock nut
- 0G Sleeve - H Pressure compensation tube - I Coupling
spring - L Adapter (for only L.P.G. version)
D
C
E
G
F
H
A
B
I
L
Page 26
26
FIGURE 24: KEYBOARD
The button that activates the vocal messages is situated on its own, in the middle of the control panel. The
reset button is installed under the lighted main switch.
Each button possesses a single distinct function:
10. Control panel
Open the hinged door for access to the programming keyboard and combined display.
The instructions enabling the user to program the system are affixed to the inner part of the
door.
KEYBOARD
The touch keyboard has been designed for immediate and simple programming. The buttons are logically
grouped according to the function in question.
The six buttons on the left of the display are used to program the daily heating function while the six buttons
on the right are used to set the boiler parameters.
MAN
AUTO
1...6
Main switch:
powers the boiler
Boiler release: resets operation after a
boiler block
Activates daily programming
Disactivates daily programming
Time setting:
used to set the time
Programming of the 6 daily heating
levels
Vocal communication
Heating temperature adjustment and selection
of external probe compensating curve
Hot water temperature adjustment and
delivered temperature display
Summer selection
Winter selection
AUTO
MAN
1...6
Page 27
27
The following symbols may appear in the middle of the display:
- - : indicates that daily programming has been activated
W-: indicates the hold status (2 minutes) after the maximum heating temperature has been reached, or
after hot water has been used.
At the beginning of a demand for heating or hot water, the display will indicate the type of demand for
8 sec. and, if hot water has been used, the relative flow rate.
17:00
W 1,5 BAR70 °C
WINTER
Heating flow
temperature
time
system pressure
Summer Winter
selection
HEATING
DEMAND
D.H.W. DEMAND
FLOW RATE 13 L./MM.
END OF HEATING
DURATION 8 MIN.
END OF D.H.W.
DURATION 30 SEC.
DISPLAY
The alphanumerical display with 2 lines of 16 characters allows the user to check the operational
parameters of the boiler at any moment and to check the duration at the end of sanitary water production
or heating mode. The programmed values can also be displayed, plus the relative flow rate and
temperature during the production of sanitary water. Any faults are immediately indicated by the display
which starts to flash.
Indications during operation:
During operation, the display showes the time, the temperature of the water in the radiators, the pressure
in the plumbing circuit, the choice of summer or winter operation and timed or manual programming.
The type and length of the demand will be displayed for 8 sec. at the end of the demand for heating or
hot water.
SPEAKING FUNCTION
Press key
and the computer will communicate the operative status of the boiler, the ambient
temperature and any faults by synthesized voice.
Page 28
28
10.1 Programming the daily heating function
Clock adjustment
Press key
Adjust the time using the left-hand keys .
Use the left-hand keys
to regulate the time at which the Level is to begin.
Set the required Level temperature (between 5 and 30° C) using the right-hand keys
.
Note: If a temperature of >30°C is set in one of the 6 Levels, the room sensor will control the heating
function throughout the entire duration of that Level, as in manual operation.
Activating and disactivating daily programming
Press the key
AUTO
to activate the daily heating program (symbol will appear on the display ).
Press key
MAN
to disactivate the daily program (symbol will disappear from the display and heating
will be controlled by the room sensor).
LEVEL 3
12:00 20.0 °C
LEVEL 2
9:00 18.0 °C
LEVEL 1
7:00 20.0 °C
LEVEL 4
14:00 18.0 °C
LEVEL 6
23:00 16.0 °C
LEVEL 5
17:00 20.0 °C
Programming the 4 daily heating levels
Press the key once or several
1...4
times to set the programming level (respectively Levels 1-2-
3-4-5-6).
SET TIME
18:10
Page 29
29
10.2 Programming the boiler parameters
General information
For access to the boiler programming parameters, just depress the relative function keys. The
display indications will consequently change. Note that each key correspond to a single
function.
After having selected a function, it will be possible to quit data entry mode in two ways:
- automatically after 8 sec. if no key has been pressed
- by pressing the same function key again.
Boiler flow temperature
Digit key
. The following display message will appear
The delivery temperature may be regulated between 30° C and 85° C by means of the right-hand keys
NOTE: When the external sensor is connected, set the temperature to 85°C and choose the compensation
curve.
Setting the compensation curve of the external probe
Compensation curves must be set according to the characteristics of the heating system and the structural
features of the building. This function is only activated when the external probe is connected.
Press key
twice for access to the programming mode. The following message will appear on the
CONTROL TEMP.
C.H.: 85 °C
display:
Set the desired curve (from 1 to 10) using the right-hand keys . Consult the table on the following
page in order to choose the most suitable curve.
The external sensor will be disactivated if 0 is entered for the compensation curve.
C.H.: 7
SELECT OTC CURVE
Page 30
30
Graph of plant delivery temperatures according to the external temperature and the set compensation
curve.
+20 +10
0 -10 -20
40
30
50
60
70
80
85
35
45
55
65
75
+15 +5 -5 -15
10
9
8
7
6
5
4
3
2
1
TEMPERATURA ESTERNA (°C)
TEMPERATURA MANDATA IMPIANTO (°C)
Fig. 25
EXTERNAL TEMPERATURE (°C)
CENTRAL HEATING FLOW TEMPERATURE (
°
C)
Page 31
31
Regulating the hot water temperature
Press key
once.
Set the temperature of the hot water to the required value between 40 and 65°C using the right-hand keys
. It is unadvisable to exceed a temperature of 50°C.
Also remember that, when multiplied by the water flow rate per minute and for 60 minutes, the product
of the temperature difference between the D.H.W. output and input in the boiler cannot exceed the
effective rating of the boiler itself.
CONTROL TEMP.
D.H.W.: 50 °C
Hot water temperature and flow rate display
Press key twice. The flow rate will appear on the lower left-hand side of the display with the temperature
on the right.
FLOW D.H.W. TEMP.
13 L./M. 50 °C
Page 32
32
10.3 Switching the boiler on and off
Inspections to make when switching on for the first time
When the boiler is being switched on for the first time, it is advisable to check that:
the on-off valves between the boiler and systems are open;
the entire system is well charged and vented;
there are no gas or water leaks from the system or boiler;
the electric connection is correct and that the earth wire is connected to an efficient earthing system;
there are no inflammable liquids or materials in the immediate vicinity of the boiler;
the gas pressure and flow rate values are those required for heating.
Switching on the boiler
• Open the gas cock prior to the boiler.
• Purge gas supply.
• Power the boiler by means of the main switch.
• Select summer or winter operation by means of the relative buttons.
• Adjust the knob of the room sensor to the desired value (if winter mode is selected) or open a hot water
tap.
Switching off
Close the gas cock prior to the boiler and turn off the main switch.
Warnings - If the boiler is to remain inactive during the winter period, it is advisable to drain off all the
water in order to prevent damage due to freezing. Failing this, just drain off the hot water and put a special
antifreeze product into the heating system.
Inspections and monitoring after ignition
When switching on for the first time:
Check that the gas and plumbing systems are sound.
Check that the boiler ignites correctly. Test this by switching it on and off a few times by means of the
regulating thermostat.
Check the efficiency of the air-flue pipe during boiler operation.
Check that the fuel consumption indicated by the meter corresponds to that indicated in the technical data.
Check that water correctly circulates between the boiler and systems.
Check that when a hot water tap opens during "Winter" mode, the circulator stops and regular production
of hot water occurs.
Check that the burner switches on and off in the correct way when the hot water tap opens and closes
in "Summer" mode.
Check that the gas valve modulates correctly during both the heating and hot water production phases.
Page 33
33
11 Maintenance and troubleshooting
11.1 Routine maintenance
Only Qualified Personnel must carry out the following operations.
Seasonal inspections of the boiler
It is advisable to have Qualified Personnel check the appliance at least once a year:
The pressure of the water in the cold plant must be between 0.5 and 1 bar. Check that it does not exceed
1.5 bar when hot;
The control and safety devices (gas valve, flow switches, thermostats, etc.) must operate correctly;
The burner and exchanger must be clean. Use soft brushes or compressed air to prevent the parts from
being damaged. never use chemical products;
The expansion tank must be full;
The gas and water systems must be sound;
The end part of the air-flue duct must be free from obstructions and must not leak;
The electrodes must be free from deposits and correctly positioned;
The gas flow rate and pressure must correspond to the indications in the relative tables;
The circulation pump must spin free.
Cleaning the boiler and burner
The boiler needs no particular maintenance. Just clean it once a year. Never use chemical products or
steel brushes to clean the casing or the burner.
Particular care must be taken of all retention systems pertaining to the hermetic chamber (seals, cable
clamps, etc.). This will prevent air leaks which, causing a pressure drop in the chamber itself, could activate
the differential pressure switch which would block the boiler.
After all these operations have been carried out, particular care must also be taken to check
and carry out all ignition and operation phases of the thermostats, gas valve and circulation
pump.
Check that there are no gas leaks after these inspections.
Page 34
34
11.2 Diagnosis and troubleshooting
The microcomputer will make a complete diagnosis during boiler operation. When a fault is detected,
the display will flash and give an error message. Boiler operation will be inhibited and reset at the end
of the fault. Manual reset is sometimes necessary (digit key
).
List of diagnostic messages
The display and vocal message clearly indicate all types of fault. The following table lists the most common
causes that may have generated the faults. Symbol
in the right-hand column indicates that manual
reset is necessary.
Causes and remedies Reset
(Display off)
No 230V power supply
Wait until 230V power returns
Check 230V power supply and fuse
No gas
Check gas system
Defective gas valve
Repair or replace the valve
Clogged injectors
Thoroughly clean the injectors
Gas pressure too low
Check pressure
No spark between electrodes during ignition phase
Check that the boiler is connected to the main
with a good ground connection
Check safety thermostat
Check that the electrodes are correctly positioned
and without incrustations
Check electrical power supply
Check that the Phase-Neutral are not inverted
Check ignition P.C.B. and
electrical connections
Check ignition P.C.B.and
electrical connections
Leaks from the gas valve
Display message
ER 1 IGNITION
PROBLEM
ER 2 IGNITION
PROBLEM
ER 3 FLAME LOST
EXTINGUISHED
ER 4 FLAME NOT
DURING OPERATION
Page 35
35
ER 7 FAULT
C.H. SENSOR
ER 8 FAULT
S.H.W. SENSOR
PROTECT SENSOR
ER 9 FAULT
ER 6 BROKEN
PROTECT SENSOR
ER 5 FAULT
AIR PRESS SWITCH
Defective pressure switch or clogged tubes
Check connections
Replace pressure switch or clean tubes
Water temperature too high
Defective heating temperature sensor
Check connections or replace the sensor
Defective hot water temperature sensor
Check connections or replace the sensor
Defective temperature limit sensor
Check connections or replace the sensor
Plumbing system empty
Check plumbing system
Expansion tank defective
Check expansion tank
Leaks from supply cock
Check plumbing system
Expansion tank defective
Check expansion tank
The plant has been filled when cold at
an excessively high pressure
Reset the plant to an adequate pressure
Defective gas valve modulator
Check the coil
No power to Modureg
Check electrical connection
Blocked circulation pump
Release circulator by removing the plug,
then turn the shaft with a screwdriver
Check or replace the condenser or circulator
The water temperature has reached
the safety limit.
ER 10 WATER PESSURE
TOO LOW
ER 11 WATER PRESSURE
TOO HIGH
ER 12 FAULT
ER 14 BAD WATER
CIRCULATION
ER 15 BROKEN
ABOVE LIMIT
MODUREG
Page 36
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 08707 282 885 - Fax 08707 282 886
ALL SPECIFICATIONS SUBJECT TO CHANGE
Cod. 3540243/0 - 01/01
Phone numbers:
Installer
Service Engineer
BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS
MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.
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