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Ferroli Domina 80 E Installation, Service 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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DOMINA 80 E
C
W
OPPER
G
F
AS
IRED
D
AND
OMESTIC
F
A
AN
SSISTED
E
LECTRONIC
INSTALLATION, SERVICE AND USER
G.C. NO: 47-267-23
-M
ALL
OUNTED
B
C
OILER FOR
H
W
OT
ATER
, R
S
OOM
EALED
F
I
LAME
GNITION AND
INSTRUCTIONS
C
OMBINATION
H
ENTRAL
EATING
P
RODUCTION
C
OMPARTMENT
C
ONTROL
,
,
,

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  • Page 1 DOMINA 80 E OPPER OUNTED OMBINATION IRED OILER FOR ENTRAL EATING OMESTIC ATER RODUCTION SSISTED EALED OMPARTMENT LECTRONIC LAME GNITION AND ONTROL INSTALLATION, SERVICE AND USER INSTRUCTIONS G.C. NO: 47-267-23...

  • 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: Description

    1.01 Introduction The Domina 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

    DOMINA 80 E 2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS 2.01 Technical information Domina 80 E boilers are central heating and domestic hot water heat generators and are produced as standard to function with natural gas or LPG. Boiler cover 1 - 3/4" central heating flow outlet Boiler connections 2 - 1/2"...

  • Page 5: Technical Data

    DOMINA 80 E Technical Data r t i r t i Ø Ø Ø Ø Ø r t i " " " " " Gas flow rates to main burners Main inyectors (mm) for central heating Gas valve MODEL G20 - NG G31 - LPG...
  • Page 6 DOMINA 80 E 2.02 Boiler main components Room sealed compartment Gas inlet Domestic hot water outlet Domestic hot water inlet Central heating flow outlet Central heating return inlet Safety valve Combustion chamber Burner assembly Main injector Burner Combustion chamber insulation...
  • Page 7 DOMINA 80 E 2.03 Boiler water flow diagram FLUE C.H. D.H.W. D.H.W. C.H. Fig. 3...
  • Page 8 DOMINA 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 9 DOMINA 80 E 2.05 Domestic hot water variability characteristics The temperature of the domestic hot water can be varied from 40 to 55°C by adjusting the boiler potentiometer. Diagram of domestic hot water production Fig. 6 ° Temperature of domestic hot water intake 15 Temp.
  • Page 10 DOMINA 80 E SAFETY VALVE SIZING OF ADDITIONAL EXPANSION VESSELS: SETTING (bar) VESSEL CHARGE Deduct from the value given in the table the 8 litre PRESSURE (bar) vessel supplied. INITIAL SYSTEM PRESSURE (bar) TOTAL WATER Note: EXPANSION VESSEL VOLUME (litres) CONTENT of SYSTEM Fill C.H.

  • Page 11: Installation Details

    DOMINA 80 E 3.0 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 12 DOMINA 80 E Water System Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems. 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.
  • Page 13 DOMINA 80 E Cold water Additional expansion vessel C.H. (if required) Filling point C.H. Bypass Fig. 9 NOTE: A bypass that will ensure a minimum flow rate of 6 l/min. at all all time must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted thoughout.
  • Page 14 DOMINA 80 E 5 min. 5 min. 50 mm 600* min. Fig. 11 CLEARANCES: * 600mm minimum clearance for servicing access Top clearance only applies to 100Ø concentric flue system...
  • Page 15 DOMINA 80 E Terminal Position Fig. 12 POSITION MINIMUM SPACING Directly below an openable window, air vent, or any other ventilation opening Below gutters, soil pipes or drainpipes Below Eaves Below a Balcony From vertical drainpipes or soilpipes From internal or external corners...
  • Page 16 DOMINA 80 E 3.01 Boiler Mounting Plate Fig. 13...
  • Page 17 DOMINA 80 E 3.02 Drilling Template (Standard Rear Flue Application) Select suitable mounting position for boiler, using the template or mounting plate 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 18 DOMINA 80 E 3.03 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 19 DOMINA 80 E 3.04 Back flue outlet (Diagram 1-9) 1. Core drill 127mm hole (5"). Fig. 16a 2. Push through the outer flue. Fig. 16b 3. Gently pull back until wall seal is flush with the wall. Fig. 16c...
  • Page 20 DOMINA 80 E 4. Place wall plate on outer flue ensuring it is level. Mark and drill four holes, two top, for expanding bolts and two bottom for plugs and screws. Fix plate to wall with the square gasket between the wall and the plate use the large diameter washers for the bolts and screws.
  • Page 21 DOMINA 80 E Cut the outer flue flush with the flange on the hanging plate. Fig. 16f 7. Insert the aluminium flue pipe into white plastic outer flue, making sure the aluminium pipe sits fully and centrally into the flue terminal. Mark the aluminium flue pipe at the point it is flush with the mounting plate.
  • Page 22 DOMINA 80 E 8. Install the inner metal flue into the outlet, up to the wallplate flange mark. 9. Lift boiler with flue in place, engage inner and outer flue, slide into position Fig. 16h 9. Make sure the inner flue is fully engaged in the flue terminal, secure boiler with two nuts and washers, sevure bottom of boiler using two screws and washers.
  • Page 23 DOMINA 80 E 3.05 Domina top outlet flue conversion Remove fan by pulling off electrical connections. Pull off air pressure switch tubes from the air pressure switch remove 2 screws b. Rotate the fan upward to disengage it from the securing pin a.
  • Page 24 DOMINA 80 E Take off the four screws which fix the top sealed chamber cover, remove the cover and gasket. Rotate the cover and gasket through 90° and fit it to the rear of the boiler to cover the original flue outlet. Secure them both in place with the four screws removed previously.
  • Page 25 DOMINA 80 E Fit the connector e to the fan nozzle Ensure the seals are in place Fig. 17i Fig. 17l Fix with the screws (b) refit wiring connections to fan and air pressure switch tubes ensuring correct orientation. I.E.
  • Page 26 DOMINA 80 E Fig. 17o Fig. 17p Rotate the fan connector e until it locates into the stop then secure it with the screw f. SIDE CONCENTRIC OUTLET Fig. 17q VERTICAL CONCENTRIC OUTLET Fig. 17r...
  • Page 27 DOMINA 80 E 3.06 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. 18).
  • Page 28 DOMINA 80 E 3.07 Top Outlet Concentric Flue Connection 3.07.1 Vertical concentric connection A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets Concentric at the joints makes this an extremely easy and safe Vertical option.
  • Page 29 DOMINA 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...
  • Page 30 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). Before installing your system please check via calculation table at 3.08.2 you are not exceeding the maximum permissible length for the appliance.
  • Page 31 IMPORTANT: the pipes and fittings flow resistance (reduction) have been summarised on the fol- lowing pages. The flow resistance values written refer only to Ferroli pipes and fittings. CALCULATION ROUTINE 1.
  • Page 32 DOMINA 80 E Tab. 1 - Pipes and REDUCTION REDUCTION fittings reduction table FLUE FLUE Description Dscription Male-female flue Air wall terminal 1 m - Ø 80 products of combustion Ø 80 mm Female-female bend Air terminal 45° Ø 80 m of inlet protection Ø...
  • Page 33 DOMINA 80 E REDUCTION REDUCTION FLUE FLUE Description Description Male-female flue Air wall terminal 1 m - Ø 100 products of combustion Ø 100 Air terminal Male-female bend of outlet protection 45° Ø 100 mm Ø 100 mm Male-female bend Spigot-and-socket reduction 90°...
  • Page 34 DOMINA 80 E 3.08.3 Example of installation with two pipe systems Example of roof inlet/outlet Example of wall inlet/outlet Fig. 25 Fig. 26 Example of direct roof flue outlet and wall air inlet Fig. 28...
  • Page 35 DOMINA 80 E 3.09 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 36 DOMINA 80 E 3.13 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.
  • Page 37 DOMINA 80 E 3.17 Ferroli Domina boiler programmer fixing (optional) Fig. 29 - 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.
  • Page 38 DOMINA 80 E Wiring for integral clock and/or external controls VOLTAGE External control FREE i.e. Room Stat/Clock SWITCH 9 8 7 6 5 4 3 2 1 1 2 3 CLOCK Fig. 31...

  • Page 39: Commissioning And Testing

    DOMINA 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 40 DOMINA 80 E • Check that water is circulating correctly. Balance the radiators to ensure that the flow and return differential does not exceed 20°C. • Check that when operating in the “Winter” mode, the pump stops and domestic hot water is produced correctly when the hot water tap is turned on.

  • Page 41: Adjustment And Gas Conversion

    DOMINA 80 E 5. ADJUSTMENT AND GAS CONVERSION 5.01 Adjusting the pressure and flow rate to the main burner This boiler operates on the flame modulation principle. It has two fixed pressure values, minimum and maximum, which must be as shown in the table (pages 5), whichever type of gas is used.
  • Page 42 DOMINA 80 E 5.03 Adjustment potentiometers On the main P.C.B. P1 = C.H. temperature adjustment P2 = D.H.W. temperature adjustment P3 = C.H. output adjustment On Ignition Board Fig. 33 P4 = Ignition gas pressure adjustment P5 = Factory set - Don't touch 5.04 Adjusting maximum output for central heating system (fig.
  • Page 43 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. To convert the boiler from Nat Gas to LPG and vice versa, the main burner injectors must be replaced.

  • Page 44: Maintenance And Cleaning

    DOMINA 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 45 DOMINA 80 E 11. Take off the combustion chamber cover by removing the three securing screws. 12. Lift off flue hood and flue baffle plate. 13. Pull off the ignition and flame rectification leads from their respective electrodes. 14. Undo the gas union in the centre of burner rail and take out the two securing screws. Remove the burner rail and clean rail and injectors.

  • Page 46: Replacement Of Parts

    DOMINA 80 E 7.0 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 47 DOMINA 80 E 7.04 Remove and re-presurising of C.H. expansion vessel (fig. 36) • Refer to 7.01 a, b • Isolate electricity and water supplies • Remove outer case (two screws bottom rear corners) • Loosen the "A" connections to expansion vessel •...
  • Page 48 DOMINA 80 E 7.06 Air pressure switch (fig. 38) • 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 49 DOMINA 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 50 DOMINA 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 51 DOMINA 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 52: Fault Finding

    DOMINA 80 E 8.0 FAULT FINDING Before beginning any fault finding ensure that gas, water and electricity are available. WARNING: DO NOT link any terminals on block X8 or X4 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 53 DOMINA 80 E 8.02 Limit thermostats T/Stat Location Function Nominal Circuit Wiring Operating Colours Temperature C.H. Limit Top RHS Shuts downmain 88°C Low voltage Blue of Heat burner if boiler Brown Exchanger thermostat fails Frost Incorporated Fires the boiler 7°C - 14°C Low voltage in C.H.
  • Page 54 DOMINA 80 E 8.03 MF02 PCB When operating for C.H. the following lights should be on: 1, 3 and flame on light. for D.H.W. the following lights should be on: 1, 2, and flame on light. If the boiler works for C.H. but not D.H.W., or vice versa, a number of components must be functioning and can, therefore, be eliminated as being at fault.
  • Page 55 DOMINA 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.
  • Page 56 DOMINA 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 57 DOMINA 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 led2 “ ” light on? replace DHW Sensor Check if water...
  • Page 58 DOMINA 80 E Chart 4 Check fan/flue gas system Does fan run? Is air pressure switch activated? Is 230V present across terminals X1-3 and X1-6 of ignition control? Go to chart 5 Differential air pressure across the air pressure Is relay RY02 switch ON?
  • Page 59 DOMINA 80 E Chart 5 Check ignition system Is led “ “ on? Does red leds Does sparking start out light come on at burner? without the boiler sparking Does burner light? Go to chart 6 re-check air pressure switch...
  • Page 60 DOMINA 80 E Chart 6 Check D.H.W. and C.H. modulation Boiler operated Boiler operated on central heating mode on DHW mode Does burner Does burner flame modulate? flame modulate? Normal operation Check wiring connection Check wiring connection Normal operation carry out...

  • Page 61: Electrical And Functional Scheme

    DOMINA 80 E 9. Electrical and functional scheme 9.01 Main components layout on electronic boards Potentiometer adjustment Location P1 = Central heating flow temperature adjustment P.C.B. main board P2 = Domestic hot water temperature adjustment P.C.B. main board P3 = Central heating flow output adjustment P.C.B.
  • Page 62 DOMINA 80 E 9.02 General wiring diagram...
  • Page 63 DOMINA 80 E 9.03 Functional flow diagram (MF02 + S4562DM1006) X1-1 X1-2 Main Board Reset X4-2 X4-1 RY01 X2-3 X2-1 230V AC Transformer 24V AC X7-1 X7-2 X10-1 X10-2 JP01 JP02 JP04 Test Switch X3-1 X3-4 X1-7 X1-3 Ignition RY02...

  • Page 64: User Instructions

    DOMINA 80 E 10. USER INSTRUCTIONS Normal - Electric power supply - Domestic hot water circuit on RESET - Central heating circuit on - Central heating stand-by °C °C - Insufficient pressure Front panel in central heating system 1 = D.H.W. temperature regulation...
  • Page 65 DOMINA 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 66 DOMINA 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 67 DOMINA 80 E Over ride By pressing the over ride button (E) the timer programme is over ridden ie, if programme is in OFF time it will come ON and if in ON time will go OFF. The timer will revert back to it set programme on reaching the next ON or OFF time.
  • Page 68 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:

Modena 102

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