Ferroli Optima 2001 VMF7 User manual

2001

WALLMOUNTED, ROOM SEALED,

FAN ASSISTED,

GAS CONDENSING COMBINATION BOILER

Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH

Sales: 0121/3523500 - Fax 0121/3523510

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: 0121 352 3500

ALWAYS QUOTE YOUR SERIAL NUMBER

FOR IMMEDIATE ASSISTANCE

VMF7

INSTALLATION

INSTRUCTIONS

Appr. Nr. B95.01A CE 0063AQ2150

G.C. NO: 47-367-21

2001

page INDEX

3General Description

3Related Documents

4Technical Data

5Appliance Dimensions

6Boiler Flow Diagram

7Key of boiler flow diagram

8Installation Details

8Location of Boiler

8Air Supply

8Condensate

10 Flue System

10 Gas Supply

10 Water System

12 Central Heating Pump

12 Sizing of expansion vessel

13 Installation of Boiler

13 1. Unpacking

13 2. Mounting the Boiler Jig

on the Wall (rear flue)

13 3. Mounting the Boiler Jig

on the Wall (side flue)

14 Drilling template

15 4. Preparing the Flue Assembly

16 5. Connecting the Boiler

18 6. Fitting the Flue Assembly

18 7. Electrical Installation

19 External sensor

20 Setting of compensation curve

21 8. Commissioning & Testing

21 8.1 Filling the Central Heating System

21 8.2 FillingtheDomesticHotWaterSystem

21 8.3 Electricity Supply

21 8.4 The Gas Installation

22 8.5 To Light the Boiler

23 Burner pressure C.H. and D.H.W.

24 Gas pressure adjustment with Honeywell

VR 4605 NA 4003 valve

25 8.7 D.H.W. Burner Pressure

25 9. System operation

25 10. Handing Over to the User

26 General Wiring Diagram

27 Fast fault finding

28 General fault finding

29 Replacement of parts

30 Details GAS valve

30 Details combustion chamber

31 Details Burner

32 Honeywell gas valve

32 Printed circuit board (P.C.B.)

32 Thermostats

33 Temperature sensors

33 Pressure relief valve

33 Pump

34 Automatic air vent

35 Pressure gauge

35 C.H. selector switch

35 Time clock

36 Fault diagnostic/temperature control

36 Air pressure switch

37 C.H. expansion vessel

38 Exploded view gas line, combustion

chamber an draft diverter

39 Explodedviewheatexchanger+C.H.and

D.H.W. parts

40 Spare Parts List

41 Domestic Hot Water

Performance + Modureg

42 Special Installation Possibilities

2001

General Description

TheFerroli 2001 isa wall mounted, room sealed, fan assisted,condensing combination boiler for Central Heating (C.H.)

and domestic Hot Water (D.H.W.).

The boiler is of light weight construction with two heat exchangers providing Central Heating and Domestic Hot Water from an

integrally designed unit. The boiler contains its own expansion vessel for sealed systems. The wall mounting jig contains all the

isolating cocks for the water and gas supplies which can be fitted to the wall and provided with all the necessary gas and water

connections prior to the boiler being attached. The flue can either be left hand, right hand or rear. There are three flue lengths

available and they are 0.75 metres (for wall thickness up to 565 mm), 2 metres (for wall thickness up to 1815 mm) and 3 metres

(for wall thickness) up to 2815 mm these wall thicknesses assume a rear flue outlet. For side outlet the effective wall thickness for

each flue length is reduced by 91 mm plus the distance of the appliance from the side wall. The Central Heating and the Domestic

Hot Water temperature is controlled by the Honeywell Modureg valve in conjunction with the P.C.B. There is a limit thermostat on

the central heating circuit which operates at 88°C. There is also an overheat cut-off thermostat which will shut the boiler down

completely and this thermostat operates at 100°C. The boiler is fited with its own Central Heating pump. The pump is switched

ON/OFFbythetimeclock and/ora24Voltroomthermostat.Thepumpcircuitalsohasa6minuteover-runtime.ThereisaDomestic

Hot Water flow switch fitted and when there is a demand for Domestic Hot Water (flow of more than 0.5 gallon/minute, 2.5 litre/

minute)theCentral Heating pump is switched off making availablethemaximumoutputofthegasburnerforDomesticHotWater.

OntheP.C.B.themaximumoutputforCentralHeatingcanbeset.Thisdoesnotinfluencethemaximumoutputfordomestichotwater.

At the factory the central heating output is pre-set to maximum. The appliance is not suitable for external installation.

This appliance can also be installed using the Ferroli two pipe flue system providing flue lengths up to 20 m (see flue options

instructions).

Related Documents

This appliance must be installed strictly in accordance with these instructions:

The Gas Safety Regulations (Installations & Use) 1994.

The Local Building Regulations.

British Gas - "Guidance notes for the installation of domestic condensing boilers".

The Building Regulations.

The Buildings 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 1 FLUES

B.S. 5440 PART 2 AIR 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 INSTALLTIONS

B.S. 7671 1992 IEE WIRING REGULATIONS

B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS

Model Water Bye Laws.

2001

Technical data NATURAL GAS (G20)

Nominal heat input (gross caloric value) 26.6 kW

Nominal heat output 22.6 kW

Nominal heat output condensing (30-50°C) 24.2 kW

Minimum heat input (gross caloric value) 11.9 kW

Minimum heat output 9.7 kW

Minimum heat output condensing (30-50°C) 10.7 kW

Gas rate 2.53 m3S/h

Burner setting pressure 16 mbar (max.)

Minimum burner pressure 3.5 mbar (min.)

Main injector Ø 20 x 0.875 mm

Dimensions (o/all)

Height 1040 mm

Width 480 mm

Depth 360 mm

Weight (net) 65 kg

Weight (gross) 67 kg

Electricity supply: 230V - 50 Hz

Fuse rating:

Mains 3 Amp. (main fuse)

on P.C.B. in boiler F2 Amp (Fast)

Electrical input 150 Watt

Domestic Hot Water flow:

(35°C rise) 9.2 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 2.5 litre

Domestic hot water 0.8 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

Condense drain pipe (rubber hose) 20 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)

2001

Appliance Dimensions

Fig. 1

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

FRONT VIEW LEFT SIDE VIEW REAR VIEW

TOP VIEW

480

163

900

370

448

224

144

77.5507580505097.5

12 3 4 5 6 7

100

221

2001

Boiler Flow Diagram

Fig. 2

2001

Key

1. Fixing point

5. Room sealed compartment

7. Gas inlet

8. Domestic hot water outlet

9. Cold water inlet

10. Central heating flow outlet

11. Central heating return inlet

12. D.H.W. draining point

14. Central heating safety valve

16. Fan

19. Combustion - heat exchanging compartment

20. Burner assembly

21. Main injector

22. Burner

26. Combustion chamber insulation

27. Copper heat exchanger for C.H. + D.H.W.

28. Flue collector from heat exchanger

30. Flue/surplus air collector

31. Air pressure control damper

32. Central heating pump

33. C.H. waterway of the heat exchanger

34. C.H. flow temperature sensor

35. Air separator

36. Automatic air vent

37. Cold water inlet filter

39. Cold water flow limiter

41. D.H.W. waterway of the heat exchanger

42. D.H.W. temperature sensor

43. Air pressure switch

46. Operator gas valve

47. Modulating regulator (Modureg) gas valve

48. Burner pressure test point

49. Overheat cut-off thermostat

50. Central heating limit thermostat

51. Central heating frost thermostat

53. Heat exchanger venting point

56. Expansion vessel

58. Fan air outlet pressure test point

59. Flue outlet pressure test point

61. C.H. selector switch

62. Time clock

63. C.H. boiler thermostat

68. Control box with P.C.B.

71. Modulating balance tube

80. 230 V + 24 V roomstat terminal blocks

81. Ignition electrode

82. Flame sensing electrode

83. Automatic ignition control panel

84. 1. gas valve operator 230 V

85. 2. gas valve operator 230 V

86. Automatic control reset knob

100. Fault diagnostic/temperature control panel

101. P.C.B. (printed circuit board)

114. Water pressure switch

132. Flue deflector

136. Flowmeter

145. C.H. pressure gauges

154. Condense drain pipe

157. D.H.W. thermostat

158. Gas inlet pressure test point

161. Condensing heat exchanger

162. D.H.W. coil

172. Setting OTC curve

174. Fault dignostic/temperature control panel with outside

temperature compensation

2001

Installation Details

Gas Safety (Installation & Use) Regulations: 1994

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 inTimberFrameHousing:ReferenceDM2.Ifindoubtadvicemust

be sought from the Local Gas Region of British Gas Plc.

Location of Boiler

The installation of the 2001 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 roomcontainingabathorshoweranyelectricalswitch orappliance

control utilising mains electricity, should be so situated that it cannot be touched by a person using the bath or shower.

Terminal Position

POSITION MINIMUM SPACING (fig. 3) mm

ADirectly below an openable window, air vent, or any other ventilation opening 300

BBelow gutters, soil pipes or drainpipes 75

CBelow Eaves 100

DBelow a Balcony 100

EFrom vertical drainpipes or soilpipes 75

FFrom internal or external corners 100

GAbove adjacent ground or balcony level 100

HFrom a surface facing the terminal 600

IFacing another terminal 1,200

JFrom opening (door/window) in carport into dwelling 1,200

KVertically from a terminal on the same wall 300

LHorizontally from a terminal on the same wall 300

NBelow 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).

Condensate

Theboilercondensateshould,ifpossible,bedischargedintothehouseholdinternaldrainingsystem,thatis,sinkorwashingmachine

drain. If this is not practicable, discharge can be external, into the household drainage system or a purpose designed soak away.

Shade condensate hose into a "U" prior to entering drainage system to form a water trap. See fig. 5.

Refer to British publication "Guidance notes for the installation of domestic condensing boilers" for further information.

2001

Terminal Position Air supply

Minimum Clearance mm

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:

238 cm2(37 in.2)

LOW LEVEL:

238 cm2(37 in.2)

HIGH LEVEL:

119 cm2(18 in.2)

LOW LEVEL:

119 cm2(18 in.2)

Fig. 3

AIR VENT

Condensate hose

Internal drainage

system fitted with

"U" bend

2001

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.

The flue must be installed with a fall of: 35 mm per metre (2°) towards the boiler, see fig. 12.

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, minimum 22 mm.

The boiler requires 2.65 m3/h (93.6 ft3/h) of natural gas.

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

Byelaw. Again any such connection must be disconnected after use.

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 mainssupplyexceeds5bar(72P.S.I.),awatergovernororpressurereducingvalvemustbefittedbytheinstallerintothemains

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 Byelaws.

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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