Ferroli F30E Installation, Servicing And User Instructions Manual
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Ferroli F30E Installation, Servicing And User Instructions Manual

Gas combination boiler for central heating
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FERROLI F30
gas combination boiler for central heating
and hot water production, wall mounted,
copper heat exchanger, fan assisted, room sealed,
electronic fl ame Ignition and control
INSTALLATION, SERVICING AND USER INSTRUCTIONS
G.C. NO: 47-267-32

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Summary of Contents for Ferroli F30E

  • Page 1 FERROLI F30 gas combination boiler for central heating and hot water production, wall mounted, copper heat exchanger, fan assisted, room sealed, electronic fl ame Ignition and control INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-267-32...

  • Page 2: Table Of Contents

    You can check the installer's CORGI registration by calling CORGI on 01256 372300". Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

  • Page 3: Description

    1.01 Introduction The Ferroli F30 is defined as a “room sealed” combination boiler, all air required for combustion is taken from outside the room in which it is installed. It is a new high performance gas fired heat generator for central heating and domestic hot water production.

  • Page 4: Technical And Dimensional Characteristics

    Ferroli F 30 2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS 2.01 Technical information Ferroli F30 boilers are central heating and domestic hot water heat generators and are produced as standard to function with natural gas or liquid petrolium gas converted. Bottom view Top view Ø80...
  • Page 5 Ferroli F 30 Technical Data Domestic hot Heat input Domestic hot Boiler water Heat output water circuit water output contents MODEL contents Litres Litres 30,0 12,7 33,1 14,5 30,0 Ferroli F30 Max. working Max. Connections Expansion vessel pressure working central...
  • Page 6 Ferroli F 30 2.02 Boiler main components 2.03 Boiler water fl ow diagram FLUE FERROLI GRUNDFOS 85 44 Fig. 3 °C °C C.H. D.H.W. D.H.W. C.H. Fig. 2 Domestic hot water flow * For use with flue gas analyser temperature sensor...
  • Page 7 Ferroli F 30 2.04 Central heating adjustment (not normally required) To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main burner via the electronic control board (fig. 4, 5 and see paragraph 5.04 page 24).
  • Page 8 Ferroli F 30 SIZING OF ADDITIONAL EXPANSION VESSELS: SAFETY VALVE Deduct from the value given in the table the 10 SETTING (bar) litre vessel supplied. VESSEL CHARGE PRESSURE (bar) INITIAL SYSTEM Note: PRESSURE (bar) TOTAL WATER 1. Fill C.H. installation to min. 1.5 bar.

  • Page 9: Installation Details

    Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier. Location of Boiler The installation of the Ferroli F30 must be on a suitable non-combustible load bearing wall which will provide an adequate fixing for the boiler mounting safety bracket assembly. The location should be in an area where the water pipes will not be subjected to frost conditions.
  • Page 10 Ferroli F 30 Central Heating Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part of the useful heating suface should be insulated to prevent any heat losses or possible freezing (i.e. in roof spaces or ventilated underfloor spaces).
  • Page 11 Ferroli F 30 5 min. 5 min. 50 mm CLEARANCES: * 600mm minimum clearance for servi- 600* min. cing access Fig. 10 Terminal Position D, E Minimum dimensions of fl ue terminal positions Balanced flues room Open flues sealed Dimensions...
  • Page 12 Ferroli F 30 3.01 Drilling Template (Top Flue Application) Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, fit wall plugs. Fit two special wall plugs on the wall as described in the fig.
  • Page 13 Ferroli F 30 3.02 Restrictor For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of flue restrictor required. Before inserting the flue gas duct in the boiler, check that the restrictor fitted is correct and that it is correctly positioned (see fig.
  • Page 14 Ferroli F 30 3.03 Top Outlet Concentric Flue Connection 3.03.1 Vertical concentric connection A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets at the joints makes this an extremely easy and safe Concentric option.
  • Page 15 Ferroli F 30 Notes on concentric horizontal installation To locate the centre of the hole for passing the pipes through the wall, refer to fig. 12b. Bear in mind that the two concentric pipes must slope downwards away from the boiler at a rate of about 3 mm/m to avoid rainwater entering the boiler.
  • Page 16 2 in remaining air intake. A varied selection of accessories for two pipe systems are available from Ferroli (ref. to page 17). Before installing your system please check via calculation table at 3.04.2 you are not exceeding the maximum permissible length for the appliance.
  • Page 17 Ferroli F 30 3.04.2 (continued) REDUCTION REDUCTION Tab. 1 - Pipes and FLUE FLUE fi ttings reduction table Description Dscription Male-female flue/Air pipe Horizontal 1 m - Ø 80 flue terminal Ø 80 mm Female-female bend Air intake 45° Ø 80 m terminal Ø...
  • Page 18 Ferroli F 30 For further accessories please refer to: "Flue system manual for room sealed boiler" Example of calculation for wall inlet/outlet with 2 pipe system maximum total fl ue length: 50 metres Attention: 13 m 13 m Remove the fl ue diaphragm.
  • Page 19 Ferroli F 30 For installation (back flue connection): For direct back flue connection it is necessary to use the optional kit, and it is required to alter the fan direction inside the boiler. Follow carefully next procedure: Remove fan by pulling off electri- cal connections.
  • Page 20 Ferroli F 30 Fix with the screws (b). Refit wiring connections to fan and air pressure switch tubes ensuring correct orientation. I.E. red tube to air pressure switch connection with red dot (+) and clear tube to air pressure switch connection with no paint marking (-).
  • Page 21 Ferroli F 30 8. Install the inner metal flue into the outlet, up to 9. Make sure the inner flue is fully engaged in the wallplate flange mark. the flue terminal, secure boiler with two nuts and washers, secure bottom of boiler using two 9.
  • Page 22 3.06 Water treatment If water treatment is used ferroli limited recommend only the use of Fernox or Sentinel water treatment products, which must be used in accordance with the manufacturers instructions. For further information contact: Fernox Manufacturing Co. LTD.
  • Page 23 Ferroli F 30 3.09 Electrical connection The boiler must be connected to a single phase 230 V 50 Hz electricity supply with a 3 A max. fuse and a bipolar switch with contact opening of at least 3 mm fitted between the boiler and the electricity supply. The boiler must always be connected to an efficient earth installation.

  • Page 24: Commissioning And Testing

    Ferroli F 30 4. COMMISSIONING AND TESTING 4.01 Checks to be carried out before starting up for the fi rst time When starting the boiler up for the first time check: • that the isolation valves between the boiler and central heating system are open;...

  • Page 25: Adjustment And Gas Conversion

    Ferroli F 30 hot water tap is turned on and off. • Check that the domestic hot water flow and T correspond to the table. Do not rely on empirical measurements. Temperature should be measured using thermometers as near as possible to the boiler, in mind the heat loss from the pipes.
  • Page 26 Customer Technical Service Helpline. 5.09 Gas conversion The following adjustment and conversion operations must be carried out by competent personnel. FERROLI Limited accepts no liability for damage to property or personal injury resulting from tampering with the boiler by unauthorised persons.

  • Page 27: Maintenance And Cleaning

    Ferroli F 30 6. MAINTENANCE AND CLEANING The following operations must be carried out by Corgi registered engineers only. 6.01 Annual Servicing The following should be checked at least once a year: • Water pressure in the central heating system when cold should be about 1 bar. If this is not the case, bring it back to this value.
  • Page 28 Ferroli F 30 16. Clean heat exchanger with a soft brush. 17. Re-assemble baffle, flue hood and fan assembly, secure with screws previously removed. 18. Refit burner assembly and burner rail. 19. Reconnect ignition and flame rectification leads. 20. Reconnect gas union and tighten.

  • Page 29: Replacement Of Parts

    Ferroli F 30 7. REPLACEMENT OF PARTS 7.01 Initial procedure a) Ensure the boiler is cold, electricity supply is isolated, and the gas supply is turned off at the inlet of the boiler b) For replacement of parts where water connections are broken, it will be necessary to isolate and drain either or both the central heating or domestic hot water circuits of the boiler.
  • Page 30 Ferroli F 30 7.05 Air pressure switch (fig. 28) • Isolate electricity • Remove outer case (two screws bottom rear corners) • Open room sealed department • Remove the two screw "A" fixing air pressure switch • Disconnect electrical leads "B"...
  • Page 31 Ferroli F 30 Removal of burner (fig. 30) 7.09 • Isolate gas and electricity supplies • Remove outer case (two screws bottom rear corners) • Remove room sealed cover • Disconnect ignition and flame rectification leads "A" • undo gas rail union "B"...
  • Page 32 Ferroli F 30 7.13 Spark or fl ame detection electrode (fig. 32) • Isolate gas and electricity supply • Remove outer case (two screws bottom rear corners) • Open room sealed compartment and combustion chamber • Identify electrode from fig. 32 •...
  • Page 33 Ferroli F 30 Pump (fig. 34) 7.15 Replacement of pump head • Isolate electricity and flow and return pipes • Remove casing (two screws bottom rear corners). • Remove the two securing screws and lower control panel • Release pressure from boiler via pressure relief valve •...

  • Page 34: Fault Finding

    Ferroli F 30 8. FAULT FINDING Before beginning any fault finding ensure that gas, water and electricity are available. WARNING: DO NOT link any terminals on block X10 or X11 as this will damage the PCB beyond repair. 8.01 Operating Sequence With the power established the boiler is in its stand-by mode i.
  • Page 35 Ferroli F 30 In order, the five lights indicate: 1 Boiler On Indicate 2 Boiler Shut down warning 3 Domestic Hot Water circuit ON 4 Central Heating standby (Flashing Light) Central Heating circuit ON (Permanent Light) 5 Insufficient pressure in Central Heating System (Flashing Light) Electric power supply ON (Permanent Light) Note: Always check for sufficient gas supply (20mbar inlet working pressure for NG and 37mbar for LPG).
  • Page 36 Ferroli F 30 8.04 Temperature sensors (thermistors) Identical, but individual, negative temperature co-efficient (NTC) thermistors are fitted in the C.H. and D.H.W. outlets from the heat exchanger. As the water temperature increases the resistance in the thermistor decreases. This causes the PCB to reduce the voltage to the modureg, in turn reducing the burner pressure.
  • Page 37 Ferroli F 30 8.09 General test and fault fi nding Chart 1 Check electrical supply - C.H. water pressure and frost protection Chek the following carefully before starting • Gas supply is turned on, is adequate and purged • Electricity supply is turned on •...
  • Page 38 Ferroli F 30 Chart 2 Check Domestic Hot Water operation Open DHW taps DHW flow rate at least 2,5 litre/min? Check cold water inlet pressure Check and if necessary Is LED3 on? replace Flow Meter Check if water filter is clean...
  • Page 39 Ferroli F 30 Chart 4 Check fan/fl ue gas system Does fan run? Is air pressure switch activated? Is relay RY100 switch ON? Go to chart 5 Differential air pressure across the air pressure Go to charts 2-3 switch is greater than...
  • Page 40 Ferroli F 30 Chart 6 Check ignition system Is LED1 light on? Is LED2 on Does sparking start without at burner? the boiler sparking Does burner light? Go to chart 5 Re-check air pressure switch Check and if necessary Is LED2 on...

  • Page 41: Electrical And Functional Scheme

    Ferroli F 30 9. ELECTRICAL AND FUNCTIONAL SCHEME 9.01 Main components layout on electronic boards Potentiometer adjustment P1 = Central heating flow temperature adjustment P2 = Domestic hot water temperature adjustment P3 = Central heating flow output adjustment P4 = Ignition gas pressure adjustment...
  • Page 42 Ferroli F 30 9.02 General wiring diagram...

  • Page 43: User Instructions

    Ferroli F 30 10. USER INSTRUCTIONS °C °C Fig. 37 KEY DESCRIPTION Switch OFF/ON/RESET Burner on indicator Central heating flow temperature regulation Boiler shut down warning D.H.W. temperature Domestic hot water circuit on regulation Central heating stand-by Water pressure gauge...
  • Page 44 Ferroli F 30 Boiler lock out In the event of the red lockout light ( ) coming on, the on/off/reset switch (A) should be turned clockwise against the spring tension to the reset position and released (this will put the boiler into three minute delay if in the heating mode).
  • Page 45 Ferroli F 30 Time Clock A 24 hour time clock is fitted to the boiler to control the central heating, this will come into operation when the selector switch is turned to the position marked “heating timed and hot water”.

  • Page 46: Benchmark

    2 6 7 BENCHMARK No. BENCHMARK Please add the first 4 digits of the Boiler serial No to complete the BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No.
  • Page 47 SIGNATURE SERVICE 10 SERVICE 9 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No. COMMENTS COMMENTS SIGNATURE SIGNATURE FERROLI TECHNICAL HELPLINE - 08707 282 885...
  • Page 48 Should you require help during installation call our Technical Helpline on 08707 282 885 option 1 To book a Ferroli service engineer call Ferroli caresafe on 08707 282 885 option 2 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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