Ferroli Sigma 30 FF 41-267-07 Installation And Servicing Instruction
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Ferroli Sigma 30 FF 41-267-07 Installation And Servicing Instruction

Wall mounted cast iron, gas fired boiler for central heating fan assisted, room sealed, electronic flame ignition and control
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G
AS
E
LECTRONIC
G.C. NO:
Sigma 30 FF 41 - 267 - 07
Sigma 40 FF 41 - 267 - 08
Sigma 50 FF 41 - 267 - 09
Sigma 60 FF 41 - 267 - 10
SIGMA
W
M
ALL
OUNTED
F
B
IRED
OILER FOR
F
A
AN
SSISTED
F
LAME
INSTALLATION AND
SERVICING INSTRUCTIONS
C
I
AST
RON
C
ENTRAL
, R
S
OOM
EALED
I
GNITION AND
,
H
EATING
,
C
ONTROL

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Summary of Contents for Ferroli Sigma 30 FF 41-267-07

  • Page 1 SIGMA OUNTED IRED OILER FOR ENTRAL EATING SSISTED EALED LECTRONIC LAME GNITION AND ONTROL G.C. NO: Sigma 30 FF 41 - 267 - 07 Sigma 40 FF 41 - 267 - 08 Sigma 50 FF 41 - 267 - 09 Sigma 60 FF 41 - 267 - 10 INSTALLATION AND SERVICING INSTRUCTIONS...

  • Page 2: Table Of Contents

    This record must be completed and left with the end user. Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

  • Page 3: Technical Caracteristics

    Sigma 1. TECHNICAL CARACTERISTICS 1.01 Introduction The Sigma is defined as a “room sealed” 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, which is designed to provide indirect hot water and/or central heating.
  • Page 4 Sigma 1.03 Technical data Heat Heat Gas flow rates Injectors Heat input input (mm) output Model (net) (gross) G20 m /h-NG G31 kg/h-LPG G20-NG G31-LPG Ø Ø Sigma 30 10,9 1,03 0,64 0,77 0,48 Sigma 40 11,7 13,0 14,4 10,5 1,37 0,99 1,02...
  • Page 5 Sigma 1.04 General Layout and Main Components 1 Fixing points 5 Room sealed compartment 7 Inlet gas-cock 10 Central heating flow outlet 11 Central heating return inlet 16 Fan 19 Combustion chamber 21 Gas injector 22 Burner 24 Spark and sensor electrode 27 Cast iron heat exchanger 28 Flue collector from heat exchanger 34 Central heating flow...

  • Page 6: Installation

    Sigma 2. INSTALLATION 2.01 Important notices Assembly, installation, first start up and maintenance must be carried out by competent persons only, in accordance with all current technical regulations and directives. Gas Safety (Installation & Use) Regulations: 1996 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.
  • Page 7 Sigma 2.01.04 Gas Supply If necessary the local Gas supplier 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 supplier. A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.
  • Page 8 Sigma Important - If thermostatic radiator valves are fitted throughout 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. 2.02.01 Make Up Water Provision must be made for replacing water lost from the sealed system.

  • Page 9: Sigma

    Sigma 2.02.06 Boiler water characteristics If the water is harder than 18 clarke degrees, the water used should be treated to avoid possible scale in the boiler caused by hard water or corrosion by aggressive water. It should be remembered that as a result of its low thermal conductivity, even scale of just a few millimetres thick can lead to considerable overheating of the boiler walls, resulting in serious problems.
  • Page 10 Sigma 2.04.02 Wall mounting instructions for Rear Flue Application Fig. 7 Fig. 8 Fig. 9 Select suitable mounting position for Drill four 10 mm holes 70 mm deep to Insert the plastic plugs. boiler. Refer to fig. 6 for dimensions and accept the wall plug.
  • Page 11 Sigma Fig. 12 Fig. 13 Gently pull back until wall seal is flush with the wall. Position the wall plate on the wall. Fix plate to wall with the square gasket between the wall and the plate use the large diameter washers for the bolts ad screws.
  • Page 12 Sigma Fig. 18 Fig. 19 Fig. 20 Install the inner metal flue "a" into the Lift boiler with flue pipe in place, en- Make sure the inner flue is fully engage adapter "b". gage inner and outer flue, slide into in the flue terminal, secure boiler with position.
  • Page 13 Sigma For rear outlet Common For top outlet For top For rear outlet outlet Fig. 23 Fig. 24 Remove fan mounting plate by undoing Rotate the fan through 90° so that the fan nozzle points upward. Secure the fan the three fixing screws "c". to the plate in the new position using screws in position "d".
  • Page 14 Sigma 2.06 Top outlet Flue Connection Three different connection are available from top of the boiler, using accessories as reported on fig. 30a, b e c and on examples a next page. Top outlet horizontal Top outlet two Top outlet vertical concentric flue pipe system concentric flue...
  • Page 15 Sigma 2.07 Restrictor and max flue length 2.07.01 Concentric Flue system First table below shows the maximum flue lengths available for boilers with concentric systems. For correct calculation remember to include the reduction for bend and flue terminals listed on second table. 100 mm 100 mm contentric 125 mm concentric...
  • Page 16 IMPORTANT: the pipes and fittings flow resistance (reduction) have been summarised on the following page. The flow resistance values written refer only to Ferroli pipes and fittings. Verify that the total flow resistance calculated is less or equal to 50 meter for Sigma 30 and 50 and 40 meter for Sigma 40 and 60.
  • Page 17 Sigma 2.07.03 Terminal Position Pos. Minimum spacing ............. mm Directly below an openable window, air vent, or any other ventilation opening ........... 300 Below gutters, soil pipes or drainpipes ........75 Below Eaves ................100 Below a Balcony ..............100 From vertical drainpipes or soilpipes ........
  • Page 18 Sigma 2.08.01 Schematic wiring diagram for fully pumped system 230V ~ 50 Hz SwL L N PL Blue G C P Fully pumped Fig. 40 Colors key 16 Fan 24 Spark and sensor elecktrode BR Brown G Grey 32 Central heating pump (not fitted) Blue Blue R Red 34 Central heating flow temperature...

  • Page 19: Commissioning And Testing

    Sigma 3. COMMISSIONING AND TESTING 3.01 Checks to be carried out before starting up for the first time When firing the boiler up for the first time, it is good practice to check: that the isolation valves between the boiler and central heating systems are open; that the central heating system is well filled and vented;...

  • Page 20: Adjustment

    Sigma 4. ADJUSTMENT 4.01 Adjusting the gas pressure and heat output The following adjustments must be carried out by qualified personnel only. To adjust boiler heat input simply adjust the burner pressure gas via the pressure regulator on the gas valve (fig. 41). Pressure regulator Adjust the gas pressure at the burner by turning the pressure protection plug...

  • Page 21: Gas Conversion

    5. GAS CONVERSION The following adjustment and conversion operations must be carried out by qualified personnel. FERROLI Limited accepts no liability for damage to property or personal injury resulting from tampering with the boiler by unauthorised persons.

  • Page 22: Maintenance And Cleaning

    Sigma 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.
  • Page 23 Sigma 7) If inlet working pressure is ok using the test point on the gas valve marked OUT check the burner pressure. Burner pressures for the required heat output can be obtained from fig. 42a for natural gas and fig. 42b for LPG. The burner pressure is adjusted by the pressure regulating screw on the gas valve see section 4.01 for detail.

  • Page 24: Replacement Of Parts

    Sigma 7. REPLACEMENT OF PARTS Before commencing with the replacement of any parts, ensure the gas and electricity are isolated. 7.01 Boiler exploded view Fig. 45 Short Spares List ° ° ° Key N Description PART N G.C. N Fan assembly (Sigma 30, 40, 50, 60) 800480 Injector Plate 2.60 (NG) Sigma 30 806295...
  • Page 25 Sigma 7.03 To remove Outer Cover a. Remove 3 fixing screws from the bottom of the cover. b. Gently pull out the sides of the cover at the bottom and lift off the top fixing lugs. 7.04 Removal of Fan Assembly (rear flueing) fig. 46 a.
  • Page 26 Sigma 7.09 Gas Valve (fig. 49) a. Remove 4 screws "a" that secure the gas inlet isolation cock to the bottom of the gas valve. b. Remove the full sequence PCB "b" and housing from the gas valve (1 screw) and place to one side. Remove balance tube and earth lead from the gas valve.

  • Page 27: Fault Finding

    Sigma 8. FAULT FINDING Before commencing any fault finding procedure on the boiler, ensure electricity is on to the appliance, the gas supply is turned on, purged and is sound, and the system is full of water. Note: in certain condition the fan and overheat thermostat may have 230 v at their terminals, but the fan will not run. Intermittent problem may be due to the temperature sensor breaking down when under load although the resistance value may be within the stated range.
  • Page 28 Sigma Check the safety thermostat Check the electrode is positioned correctly and free from corrosion deposits Control thermostat set too low Check the electric supply Check the electronic control unit Check the live-neutral wires are not reversed Burner goes out Insufficient gas supply Check gas pressure to main burner Boiler dirty...
  • Page 29 Sigma 8.03 General test and fault finding chart fan runs boiler does not work 230V at live connection check mains supply of terminal block and fuse eletrode 230V at switched check external sparks live connection of controls terminal block boiler resistance of the temp 230 v on grey wire of locks out...

  • Page 30: User Instructions

    "This record must be completed and left with the end user" Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
  • Page 31 Sigma...
  • Page 32 Should you require help with any difficulties call our Technical Service Helpline on 0121 352 3200 Phone numbers: Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS. ALL SPECIFICATIONS SUBJECT TO CHANGE Please note - to avoid incurring unnecessary expense, in the event of a boiler shut down, check this in not caused by lack of electricity supply, gas supply or low water pressure before calling our Customer Service Helpline.

This manual is also suitable for:

Sigma 40 ff 41-267-08Sigma 50 ff 41-267-09Sigma 60 ff 41-267-10

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