MODENA 80 E INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-267-05 3543230/2 - 10/99 Appr. nr. B98.
MODENA 80 E IMPORTANT From the 1st October 1999 your "benchmark" Installation, Commissioning and Service Record Log Book will be enclosed in your customer information pack. "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.
MODENA 80 E 1. DESCRIPTION 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. A special feature of this boiler is its built-in electronic flame ignition and control unit making burner operation completely automatic and safe.
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.
MODENA 80 E Technical Data MODEL Heat output kW Modena 80 E Heat input kW kW Heat input calculated on gross Domestic heat value (PCS) hot water heat G20 - NG G31 - LPG input Max. Min. Max. Min.
MODENA 80 E 2.02 Boiler main components 2.03 Boiler water flow diagram AIR IN 43 5 FLUE OUT AIR IN 56 28 16 90 91 132 27 49 50 19 22 82 26 81 20 21 OUT 36 73 MIN IN 32 MIN IN OUT 114 34 10 14 74 8 42 84 7 85 44 9 136 11 2 3 5 0 6 C.H. OUT Fig. 2 98 63 157 62 Fig. 3 4 1 145 D.H.W. GAS D.H.W. OUT IN IN C.H.
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.
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. If the total volume of water in the system exceeds 40 litres an additional expansion vessel must be fitted to the central heating return pipe.
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. Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to prosecution; it is your responsibility to ensure that the law is complied with. N.B.
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). 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.
MODENA 80 E 460 5 min. 270 50 mm 100 min. 5 min. CLEARANCES: 720 600* min. 200 min. 860 * 600mm minimum clearance for servicing access Fig. 11 Terminal Position Fig.
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. 183 min Ø118 80 269 125 min 200 165 min 0 11 932 min 280 21 min 1. 2. 3. 4. 5. 6. 12 Ø1/2" Ø1/2" 1 2 3 200 min 295.
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. 18). N.B.: the diameter of the hole is stamped on the restrictor Boiler is fitted with Ø45 restrictor as standard Holes Ø : 45 47 50 Ø Fig.
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 joints makes this an extremely easy and safe option. Concentric Vertical Connector Fig. 19 3.03.2 Horizontal concentric connection A 90° bend (fig. 20) can be supplied for the horizontal connection of air and flue gas pipes.
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. The concentric pipes making up the air flue gas duct must be sealed with the gasket where they join the boiler (fig. 21). Outside, the pipes should protrude from the wall between 10 and 60 mm (fig. 21).
MODENA 80 E 3.04 Top Outlet: Two Pipe Flue System 3.04.1 Two pipe connection Two separate ducts Ø80 for air intake and flue gas discharge can be directly connected to the boiler. After conversion for top outlet (see 3.05) mount the separate outlet kit "1" Ø80 Ø80 FLUE AIR 2 1 Insert blanking plate in remaining air intake Fig. 23 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.
8 0 2 1,2 2 2,2 1,5 2,5 1,5 2,5 8 0 7 3 0 A c c e s s o r i e s 5 Ø 1 0 0 Outlet flue air inlet for connection with split end Ø80 Ø Male-female flue Ø100 1 Male-female Male-female bend bend 90° Ø100 45° Ø100 1 Pipe fitting for outlet flue Ø80 Outlet flue air inlet for concentric system Ø80 A c c e s s o r i e s Air wall terminal products of combustion Ø100 1 Horizontal Vertical Horizontal Description Air 0,4 0,4 1,5 Horizontal Reduction Vertical Flue Horizontal Vertical A
MODENA 80 E 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 flue length: 48 metres Attention: flow resistance (reduction) equivalent included between 38 and 48 (see table on page 27) Remove the flue diaphragm. The flue and air pipes must have an inclination downward equal to 3%. REF.
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. The pipe should be directed towards to the wall.
MODENA 80 E Note: If the power supply cable has to be replaced, use “0.75mm (24/0.20) cable only to BS6500 with a maximum external diameter of 8 mm. Note - When connecting a room thermostat or external timer, do not link the power supply of these devices to the switching contacts. The switch contacts must be voltage free. Any mains powered devices must utilise mains power solely to drive the timer motor. Applying mains voltage to the switch contacts will irreparably damage the circuit board.
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. Mount clock into facia panel using two screws and spacers provided. Take the black cable containing the blue and brown wires and connect the loose spades to clock terminals 1 & 2. Connect the plug end of the cable to terminal X2 of main circuit board.
MODENA 80 E 4. COMMISSIONING AND TESTING 4.
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. • Check that the gas valve modulates correctly both during the central heating phase and the domestic hot water production phase. • Determine the combustion efficiency and the composition of the flue gases (refer to 8.
MODENA 80 E 5.03 Adjustment potentiometers P1 = C.H. temperature adjustment P2 = D.H.W. temperature adjustment P3 = C.H. output adjustment P4 = Ignition gas pressure adjustment P5 = Factory set - Don't touch - + - + P5 P4 - P1 + CH P2 + DHW - - Fig. 33 + P3 5.04 Adjusting maximum output for central heating system (fig. 33) This adjustment must be carried out electronically using the “P3” adjustment screw starting with a cold central heating system.
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. • Check control and safety devices (gas valve, flow meter, thermostats, etc) are functioning correctly. • The burner and heat exchanger must be clean.
MODENA 80 E 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Re-assemble baffle, flue hood and fan assembly, secure with screws previously removed. Refit burner assembly and burner rail. Reconnect ignition and flame rectification leads. Reconnect gas union and tighten. Refit combustion chamber cover, secure with screws. Examine seals on room sealed cover refit cover and secure with screws. Turn on gas and electricity. Fire boiler and check all gas joints for soundess.
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. The cold water mains inlet is isolated at the inlet cock. The D.H.W. is drained by opening a hot tap. The C.H.
MODENA 80 E 7.05 Gas valve (fig.
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" • Undo two screws securing the burner assembly to the boiler combustion chamber "D" A • Withdraw the burner assembly 7.09 Injectors (fig. 40) D D C B • Proceed as 7.
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 • Unplug electrical connection "A" from sensing electrode • Remove fixing screw and remove flame detect electrode • Remove the two fixing screw from spark electrode plate and remove it. Flame detect Spark A Fig. 43 7.13 D.H.W.
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 • Unplug the pump lead "A" from the pump head • Place a piece of cloth or other absorbent material over the rear of the control panel to catch any drops of water that may fall when the pump head is removed.
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. e. power on but no demand. The operational sequence for C.H. and D.H.W.
MODENA 80 E In order, the five lights indicate: 1 2 3 4 Boiler On Indicate Boiler Shut down warning Domestic Hot Water circuit ON 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). Minimum of 22 mm diameter pipework on C.H. flow and return with adequate by-pass.
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. and blue for D.H.W. The sensors are fitted in wet pockets. 8.
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 • Polarity is correct • CH pressure is set between 1 - 1,5 bar • CH pump spins freely D.H.W.
MODENA 80 E Chart 2 Check Domestic Hot Water operation Open DHW taps NO DHW flow rate at least 2,5 litre/min? YES Check cold water inlet pressure Is LED3 on? Check if water filter is clean NO Check and if necessary replace DHW Sensor YES Check and if necessary replace Flow Sensor YES Is LED4 flashing? NO YES Check and if necessary replace main board Is relay RY100 switch on? NO Go to chart 4 Check and if necessary replace limit thermostat Chart 3 Check Central Heating operation DHW taps clo
MODENA 80 E Chart 4 Check fan/flue gas system Does fan run? NO YES Is relay RY100 switch ON? YES Is air pressure switch activated? NO NO Go to chart 5 Differential air pressure across the air pressure YES switch is greater than 180 Pascal? Go to charts 2-3 Is 230V present across fan terminals? YES NO YES Check and if necessary replace air pressure switch Check and clean fan NO Check air pressure Check and if switch wiring connection necessary replace fan Check flue and air intake are corre
MODENA 80 E Chart 6 Check ignition system Is LED1 light on? Does sparking start at burner? Is LED2 on without the boiler sparking NO YES Does burner light? YES YES Go to chart 6 NO NO Check and if necessary replace P.C.B. Check electrodes and leads for damage and correct connection YES Reset lockout YES Check and if necessary replace P.C.B.
MODENA 80 E 9. ELECTRICAL AND FUNCTIONAL SCHEME 9.
82 16 32 34 42 43 44 49 50 62 Y/G Y/G BL BL X7 X8 9 BR 8 7 Blue BR 10 BR 6 Blue 5 Blue 2 BR 1 BL 1 3 X3 1 BR 230V 98 1 BR BLUE BL W O G R V Key X10 98 7654321 2 24V X12 230V 24V 2 BL X2 Blue 72 Room thermostat 81 Ignition electrode 82 Sensor electrode 98 Off/On/Reset switch 114 Low water pressure switch 136 Flow meter MF03F 1 MV1 W 2 MV2 O 3 MV3 V 4 X1 32 Blue Blue R R 13 12 11 10 6 - G 5 4 + 3 2 BL 1 JP03 X5 62 3 2 M 1 IMPORTANT TES
MODENA 80 E 10. USER INSTRUCTIONS bar 60 70 50 2 3 5 0 °C A a b c C e LED 1 Burner on indicator 2 Boiler shut down warning 3 Domestic hot water circuit on 4 5 bar 6 °C B d 4 1 80 40 Central heating stand-by (Flashing light) Central heating circuit on (Fixing light) Insufficient pressure in central heating system (Flashing light) Electric power supply (Fixing light) E D KEY DESCRIPTION A Switch OFF/ON/RESET B Central heating flow temperature regulation C D.H.W.
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). If the lockout light ( ) illuminates repeatedly, contact an approved Férroli service engineer. Frost Protection In cold weather the boiler may appear to run when there is no demand for heating (i.e.
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”. I F AUTO O AUTO 12:31 4 + P - P A B P D E F R A B x x E OVER RIDE R P D R Slide switch: set clock - auto - set programme Display. Symbol in Display = Timer ON Select programme ON/OFF 1.....
IMPORTANT From the 1st October 1999 your "benchmark" Installation, Commissioning and Service Record Log Book will be enclosed in your customer information pack. "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.
