Ferroli MODENA 80 E Installation, Servicing And User Instructions Manual
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Ferroli MODENA 80 E Installation, Servicing And User Instructions Manual

Ferroli MODENA 80 E Installation, Servicing And User Instructions Manual

Copper wall-mounted combination, gas fired boiler for central heating and domestic hot water production, fan assisted, room sealed compartment, electronic flame ignition and control
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MODENA 80 E
C
W
OPPER
G
F
AS
IRED
D
AND
OMESTIC
F
A
AN
SSISTED
E
LECTRONIC
INSTALLATION, SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-267-05
-M
ALL
OUNTED
B
C
OILER FOR
H
W
OT
ATER
, R
S
OOM
EALED
F
I
LAME
GNITION AND
C
OMBINATION
H
ENTRAL
EATING
P
RODUCTION
C
OMPARTMENT
C
ONTROL
,
,
,

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Summary of Contents for Ferroli MODENA 80 E

  • Page 1 MODENA 80 E OPPER OUNTED OMBINATION IRED OILER FOR ENTRAL EATING OMESTIC ATER RODUCTION SSISTED EALED OMPARTMENT LECTRONIC LAME GNITION AND ONTROL INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-267-05...
  • Page 2 "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 1.01 Introduction The Modena 80 E 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

    MODENA 80 E 2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS 2.01 Technical information Modena 80 E boilers are central heating and domestic hot water heat generators and are produced as standard to function with natural gas or LPG. Distance between connections Top view Fig.
  • Page 5 MODENA 80 E Technical Data r t i r t i Ø Ø Ø Ø Ø r t i " " " " " Ø " Ø Ø i n i i n i ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆...
  • Page 6 MODENA 80 E 2.02 Boiler main components 2.03 Boiler water flow diagram FLUE 85 44 Fig. 3 C.H. D.H.W. D.H.W. C.H. Fig. 2 Low water pressure cut off Room sealed compartment Automatic air vent valve switch Domestic hot water flow...
  • Page 7 MODENA 80 E 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 and 5). The diagrams indicate the variation in heat output to the water as burner working pressure is varied.

  • Page 8: Pump Characteristics

    MODENA 80 E 2.06 Pump characteristics The pump head available for circulating the water is given in fig. 7. N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series. Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.

  • Page 9: Installation Details

    MODENA 80 E 3. INSTALLATION DETAILS 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 10 MODENA 80 E Central Heating 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).

  • Page 11: Terminal Position

    MODENA 80 E 5 min. 5 min. 50 mm CLEARANCES: * 600mm minimum clearance for servicing access 600* min. Fig. 11 Terminal Position Fig. 12 POSITION MINIMUM SPACING Directly below an openable window, air vent, or any other ventilation opening...
  • Page 12 MODENA 80 E 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 70mm deep to accept the wall plugs, fit wall plugs. Using a core drill cut a 118mm diameter hole for the flue.
  • Page 13 MODENA 80 E 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 MODENA 80 E 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 Concentric joints makes this an extremely easy and safe option.
  • Page 15 MODENA 80 E Notes on concentric horizontal installation To locate the centre of the hole for passing the pipes through the wall, refer to fig. 15. 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 Connect flue duct to central hole Ø80 and air duct to left or right air intake hole Ø80. Insert blanking plate "2" in remaining air intake. A wide number of accessories for two pipe systems are available from Ferroli (ref. to page 32- 33).
  • Page 17 MODENA 80 E Tab. 1 - Reduction Reduction Flue Flue Description Description Ø Ø Ø...
  • Page 18 MODENA 80 E For further accessories please refer to: "Flue system manual for room sealed boiler" Attention: flow resistance (reduction) equivalent included between 38 and 48 (see table on page 27) Remove the flue diaphragm. Example of calculation for wall inlet/outlet...
  • Page 19 MODENA 80 E 3.05 Connecting the central heating and domestic hot water circuits Connect to the relevant connections as indicated in fig. 1. Connect the pressure relief valve discharge pipe (15mm) to the outside of the building, where possible over a drain. The discharge must be such that it will not be hazardous to occupants and passers-by or cause damage to external electric components or wiring.
  • Page 20 To connect the thermostat: Open the electrical box on the base of the appliance and remove the “jumper cable” between terminals 4 and 5. Connect the room thermostat (72) as shown in figure 48. 3.13 Ferroli Modena boiler programmer fixing (optional) Fig. 29...
  • Page 21 MODENA 80 E - Remove outer case by removing two securing screws from the rear bottom corners and lift off. - Remove screw securing facia panel and swing facia panel down. - Remove rear cover from facia. - Remove clock blanking plate from the boiler facia panel.

  • Page 22: Commissioning And Testing

    MODENA 80 E 4. COMMISSIONING AND TESTING 4.01 Checks to be carried out before starting up for the first time When starting the boiler up for the first time check: • that the gate valves between the boiler and central heating systems are open;...

  • Page 23: Adjustment And Gas Conversion

    MODENA 80 E • 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, bearing in mind the heat loss from the pipes.
  • Page 24 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 25: Maintenance And Cleaning

    MODENA 80 E 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 26 MODENA 80 E 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. 21. Refit combustion chamber cover, secure with screws.

  • Page 27: Replacement Of Parts

    MODENA 80 E 7. REPLACEMENT OF PARTS 7.01 Initial procedure a) 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 only.
  • Page 28 MODENA 80 E 7.05 Gas valve (fig. 37) • Isolate gas and electricity supplies • Remove outer case (two screws bottom rear corners) • Remove the two securing screws and lower control panel • Disconnect electrical connections from valve ("A") •...
  • Page 29 MODENA 80 E 7.08 Removal of burner (fig. 40) • 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 30 MODENA 80 E 7.12 Spark or flame detect electrode (fig. 43) • Isolate gas and electricity supply • Remove outer case (two screws bottom rear corners) • Open room sealed compartment and combustion chamber • Identify electrode from fig. 43 •...
  • Page 31 MODENA 80 E 7.14 Pump (fig. 45) 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 32: Fault Finding

    MODENA 80 E 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 33 MODENA 80 E 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 34 MODENA 80 E 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. The wiring for each thermistor is colour coded red for C.H.
  • Page 35 MODENA 80 E 8.10 General test and fault finding 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 36 MODENA 80 E 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 DHW Sensor Check if water filter is clean...
  • Page 37 MODENA 80 E Chart 4 Check fan/flue 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 38 MODENA 80 E 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 6 Re-check air pressure switch Check and if necessary Is LED2 on...

  • Page 39: Electrical And Functional Scheme

    MODENA 80 E 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 40 MODENA 80 E 9.02 General wiring diagram...
  • Page 41 MODENA 80 E 10. USER INSTRUCTIONS °C °C 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 (Flashing light) Hydrometer Central heating circuit on (Fixing light)

  • Page 42: Minimum Clearance

    MODENA 80 E Boiler lock out In the event of the red lockout light ( ) coming on, the on/off/reset switch (3) 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 43: Reset Button

    MODENA 80 E 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 44 "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.

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