SYS 10-23
INSTALLATION,
MAINTENANCE AND USER
INSTRUCTIONS
cod. 3544570/0 - 02/2004
Wall-Hung, Gas-Fired,
System Boiler,
for Central Heating
IMPORTANT
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"
"All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both
should be recorded in your central heating log book. You can check with the CORGI registered
by calling CORGI on 01256 372300".
• Carefully read the warnings in this instruction booklet, as they provide important
indications on the safety of installation,
operation and maintenance.
• The instruction booklet is an integral and
essential part of the product and must
be kept safely by the user for future
reference.
• If the appliance is sold or transferred to
another owner, or if it is moved, always
check that the booklet accompanies the
boiler for reference by the new owner
and/or installer.
• The installation and maintenance operations must be performed according to the
standards in force, the instructions of the
manufacturer and must be carried out by
professionally qualified personnel.
• Incorrect installation or poor maintenance may cause a damager to persons
or property. The manufacturer declines all
liability for damage deriving from errors
in the installation and maintenance of the
appliance, and where there is a failure to
observe the instructions provided by the
manufacturer.
• Before performing any cleaning or
maintenance operations, disconnect the
appliance from the mains power supply
using the main switched fused spur.
This symbol indicates “Warning”
and is placed near all warnings
regarding safety. Such provisions
must be strictly adhered to so as
to avoid danger and damage to
persons and property.
This symbol highlights a note or
an important warning.
2
• In the event of faults and/or poor
operation of the appliance, it should be
isolated. Do not attempt to repair the
appliance. Contact professionally qualified personnel only at ferroli caresafe.
• The products must only be repairedreplaced by professionally qualified
personnel, using original spare parts
only. Failure to heed this warning may
affect the safety of the appliance.
• To ensure the correct operation of the
appliance, annual maintenance must be
performed by qualified personnel.
• This appliance must only be used for
the purposes it has specifically been
designed for. All other uses are considered improper and thus dangerous.
• After having removed the packaging,
check that the contents are intact.
• The parts of the packaging must not be
left within the reach of children, as they
are potential sources of danger.
• In case of doubt do not use the appliance
and contact your supplier.
Certification
The CE Mark attests that Ferroli gas-fired
appliances conform to the requirements
specified in the corresponding European
directives.
In particular, this appliance conforms to
the following EEC directives:
• Directive 90/396, Gas Appliances,
• Directive 92/42, Efficiency,
• Directive 73/23, Low Voltage, (amended
by no. 93/68)
• Directive 89/336, Electromagnetic
Compatibility (amended by no. 93/68)
SYS 10-23
1. Operating/user instructions ...................................................................4
1.1 Introduction.............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Ignition and shut-down ...........................................................................................5
1.4 Settings ...................................................................................................................6
1.5 Maintenance............................................................................................................6
2. INSTALLATION .......................................................................................7
2.1 General instructions................................................................................................7
2.2 Siting of appliance. .................................................................................................7
2.3 Water connections ..................................................................................................9
2.4 Gas connection .....................................................................................................11
2.5 Electrical connections ...........................................................................................11
2.6 Flues connections .................................................................................................14
3. SERVICE AND MAINTENANCE............................................................20
3.1 Settings .................................................................................................................20
3.2 Commissioning......................................................................................................21
3.3 Maintenance..........................................................................................................22
3.4 Replacement of Parts............................................................................................24
4. CHARACTERISTICS AND TECHNICAL SPECIFICATIONS .....................28
4.1 Dimensions and fittings ........................................................................................28
4.2 Overall view and main components .....................................................................29
4.3 Hydraulic diagram.................................................................................................30
4.4 Technical data table ..............................................................................................31
4.5 Diagrams ...............................................................................................................32
4.6 Internal electrical diagrams...................................................................................33
4.7 Fault finding ..........................................................................................................35
3
SYS 10-23
1. OPERATING/USER INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for having chosen the SYS 10-23, an advanced-concept FERROLI wall-hung boiler featuring
cutting-edge technology, high reliability and constructional quality. Please carefully read this manual
and leave it with the end user.
The SYS 10-23 is a high efficiency heat generator for central heating systems, operating on natural
gas or LPG.
The boiler can be connected to an external hot water cylinder for the production of domestic hot water,
via a “Y” or “S” plan type system.
The boiler body is made up of a copper heat exchanger, the special design of which guarantees high
heat exchange efficiency in all operating conditions, and an atmospheric burner featuring electronic
ignition with ionisation flame control.
The boiler is completely sealed from the surrounding environment: the air required for combustion is
taken in from the outside, and a fan is used to expel the flue gases. The accessories supplied with the
boiler also include a variable-speed pump, expansion vessel, safety valve, air pressure switch, boiler
thermostat, pump overrun and safety thermostat.
The user simply has to set the temperature required inside the home (using the optional, yet recommended room thermostat) or set the system temperature and the required domestic hot water outlet
temperature at the cylinder stat. The regulation and control system will then ensure optimum operation
all year round.
NOTE. External controls not supplied with the boiler.
4
SYS 10-23
1.2 Control panel
To access the control panel, open the drop down cover.
A
B
C
D
On /OFF switch
CH boiler thermostat
Reset knob with lamp
Central heating pressure gauge
A
B
C
D
fig. 1
1.3 Ignition and shut-down
Ignition
• Open the gas cock of the boiler.
• Purge the gas supply of any air upstream of the gas valve.
• Turn on the main switched spur to the boiler.
• Press the boiler switch to on.
• Rotate the C.H. temperature adjustment knob above Min position.
• Check the external controls are calling for heat, i.e clock and room thermostat.
• At this point, the burner ignites and the boiler starts to function automatically, operated by its control
and safety devices.
If after completing the start-up procedure correctly, the burner fails to ignite and the boiler shut
down warning lights up, wait about 15 seconds then press the reset switch. The reset electronic
control unit will repeat the start-up cycle. If after a second attempt the burners still fails to ignite,
consult the paragraph “Troubleshooting”.
If there is a power failure while the boiler is in operation, the burners automatically go out and
re-ignite when the power returns.
If the system is filled with very cold water, the boiler will automatically light due to the frost thermostat sensing the low temperature. The boiler will not shut down, until the water temperature
reaches 10°C.
Shut-down
Close the gas isolation valve , push the button “A” to OFF and disconnect the appliance from the mains
power supply.
When the boiler power is off the boiler anti-freeze protection is not active.
For extended periods of inactivity during the winter months, and in order to avoid damage due to
freezing, all the water should be drained from the boiler; alternatively, place approved antifreeze
fluid in the central heating system.
5
SYS 10-23
1.4 Settings
Setting the ambient temperature (using the optional room thermostat)
Set, using the room thermostat, the temperature required inside the rooms. Based on the demand from
the room thermostat, the boiler is ignited and heats the system water to the set central heating outlet
temperature. When the required temperature inside the rooms is reached, the boiler switches off. A
room thermostat must be used as per the building regulations ‘Part L’ this will maintain the system at
the set central heating outlet temperature and ensure maximum efficiency.
System water pressure control
Using the filling loop and with the system cold top up the water pressure to approximately 1bar. Once
the operation is completed, always close the filling loop. This device is fitted to the system by the installer
on the central heating return pipework.
1.5 Maintenance
It is recommended to have annual service of the appliance performed by qualified personnel. Please
refer to Chap. 3.3 in this manual for further information.
The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp
cloth, dipped in soapy water if necessary. Do not use abrasive detergents or solvents.
6
SYS 10-23
2. INSTALLATION
2.1 General instructions
This appliance must only be used for the purposes it has been specifically designed for. This appliance is
used to heat water to below boiling temperature at atmospheric pressure and must be connected
to a central heating and/or hot warm distribution system, according to its characteristics, performance and heating capacity. All other uses are considered improper.
THE BOILER MUST ONLY BE INSTALLED BY SPECIALIST AND QUALIFIED PERSONNEL, IN
COMPLETE COMPLIANCE WITH ALL THE INSTRUCTIONS REPORTED IN THIS TECHNICAL MANUAL,
THE LEGAL STANDARDS IN FORCE, THE PRESCRIPTIONS OF STANDARDS AND ANY LOCAL STANDARDS, AND ACCORDING TO THE RULES OF GOOD PRACTICE.
Incorrect installation may cause injury or damager to persons and property. The manufacturer will not
be held liable in such events.
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use).
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British gas publication DM2 - Guide for installation in timber framed housing.
British Standards Codes of Practice:
B.S.
B.S.
B.S.
B.S.
B.S.
B.S.
B.S.
B.S.
B.S.
B.S.
7593
5546
5440
5440
5449
6798
6891
7671
4814
5482
Part 1
Part 2
TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
FLUES
AIR SUPPLY
FORCED CIRCULATION HOT WATER SYSTEMS
INSTALLATION OF GAS FIRED HOT WATER BOILERS
GAS INSTALLATIONS
IEE WIRING REGULATIONS
SPECIFICATION FOR EXPANSION VESSELS
INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply
2.2 Siting of appliance.
The appliance’s combustion chamber is sealed from the surrounding environment and as a result the
appliance may be installed in any room without purpose built ventilation. The installation environment
must nonetheless feature sufficient ventilation, to avoid dangerous conditions arising in the event of
even minor gas leaks. These safety standards are imposed by EEC Directive no. 09/396 for all gas appliances, including the so-called sealed appliances.
The place of installation must in any case be free of dust, inflammable objects or materials and corrosive
gases. The environment must be dry and not prone to freezing.
The boiler is supplied ready for wall-hung installation. The rear frame of the appliance has a series of
slots for fastening it to the wall, using screws with wall plugs. The fastening to the wall must provide
stable and effective support of the appliance.
The boiler must be fastened to a closed part of wall, which is free of apertures or holes behind the frame
of the boiler that may allow the internal components of the boiler to be reached.
If the appliance is enclosed in a cabinet or alongside another appliance, minimum clearances must be
adhered to. Fig. 2 and Tab. 3 show the minimum and recommended space to be left free around the
appliance.
7
SYS 10-23
66
C
Ø118
A
A
Table 3
Recommended
A
30 mm
150 mm
B
200 mm
300 mm
C
280 mm
300 mm
D
15 mm
(from opening panels)
> *600 mm
B
Minimum
NOTE: Minimum distance required from front
D
panel of the appliance for servicing 600mm (D)
fig. 2
Fixing to the wall
Select suitable mounting position for boiler. Using the template mark flue outlet and boiler mounting
points. Drill two 10mm holes 90mm deep to accept the wall plugs. Fit two special wall plugs in the wall
as described in the fig. 3. Fasten the wall bracket to the wall using an antitheft nut on the right side and
a standard nut (M8) on the left side. Using a core drill cut a 118mm diameter hole for the flue. Mount
the boiler on the wall bracket and fix using an antitheft nut on the left side and a standard nut (M8) on
the right side.
fig. 3
8
SYS 10-23
2.3 Water connections
The heat capacity of the appliance should be established in advance by calculating the heating requirements of the building according to the standards in force. For correct operation and long-life of the
boiler, the hydraulic system must be suitably proportioned and always fitted with all the accessories
that guarantee correct operation.
In the case where the central heating outlet and inlet pipes follow paths whereby, at some points, pockets
of air may form, air vent valves should be installed at such points.
In addition, a drain device should be installed at the lowest point in the system, to allow complete
draining.
If the boiler is installed at a lower level than the system, a flow-return valve should be fitted to prevent
the natural circulation of water in the system.
The temperature differential between the outlet and the inlet of
36
155
155
54
the boiler should not exceed 20°C. (11°C recommended)
Do not use the water pipes as the earth for electrical
appliances.
Before installation, carefully clean all the pipes in the system to
remove any residues or impurities that may affect the correct
operation of the appliance.
Make the connections to the corresponding fittings, as shown
in fig. 4.
Key
1
2
3
Central heating outlet, 3/4” (22 mm with isolation valve fitted)
Gas inlet, 1/2” (22 mm with isolation valve fitted)
Central heating inlet, 3/4” (22 mm with isolation valve fitted)
1
2
3
fig. 4
It is essential to fit the supplied isolation valves between the boiler and the central heating system; these
allow the boiler to be isolated from the heating system, if necessary.
The discharge of any safety valves must be routed to outside dicharging to ground level 100 mm
from the floor so as not to create a danger to anyone passing, there should be no rise from the
boiler to outside a slight fall is preffered. The manufacturer of the boiler will not be held liable if
this warning is not heeded. Make the connections to the boiler in a way that its internal pipework
is not subject to stress.
9
SYS 10-23
Make Up Water
Provision must be made for replacing water lost from the 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 Byelaws. Again any such
connection must be disconnected after use. The supplied temporary filling loop is shown in fig. 4. Ensure
the filling point is on the return pipe to the boiler.
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.
Key
4
2
3
1
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
4. Double check valve
Fig. 5
Water treatment
if water treatment is used Ferroli Ltd recommend only the use of Fernox or Sentinel water treatment
products, which must be used in accordance with the manufacturers instructions. For further information contact:
Fernox Manufacturing Co. LTD.
Cookson electronics, forsyth road
Sheerwater, working Surrey GU21 5RZ
Tel. 0870 8700362
Sentinel Division
Betz Dearborn LTD
Widnes, Cheshire WA8 5351
Tel. 0151 424 5351
Note - If the boiler is installed in an existing system any unsuitable additives must be removed by thorough cleansing.
All systems should be cleansed according to B.S. 7593.
Note - In hard water areas treatment to prevent lime scale may be necessary.
Note - It is important that the correct concentration of the water treatment product is maintained in
accordance with the manufactures instructions.
Filling the boiler and the system
The filling pressure, when the system is cold, must be around 1 bar (at least 0.5 bar). If the pressure
drops during operation to a value lower than the minimum described above, the User must restore the
initial value using the filling loop. For correct boiler operation, the pressure, when hot, must be around
1,5-2 bar. Once the operation is completed, always close the filling loop. This device is fitted to the
system by the installer.
10
SYS 10-23
2.4 Gas connection
Before making the connections, check that the appliance is configured for operation with the
type of fuel available, and carefully clean all the gas pipes in the system, to remove any residues
that may affect the correct operation of the boiler.
The gas connections must be made using the relative coupling (see fig. 4), according to the standards
in force, with a rigid metal pipe, fitting a gas cock between the system and the boiler. Check that all the
gas connections for soundness.
The capacity of the gas meter must be sufficient for the simultaneous use of all the connected appliances.
The diameter of the gas pipe, which leaves the boiler, does not necessarily determine the choice of the
diameter of the pipe used between the appliance and the gas meter; this must be chosen according to
its length and the pressure drop, according to the standards in force.
Do not use the gas pipes as the earth for electrical appliances.
2.5 Electrical connections
Connection to the mains power supply
The boiler should be connected to a single-phase, 230 Volt-50 Hz electrical power supply.
The electrical safety of the appliance is ensured only when the appliance is correctly connected
to an effective earth system, as prescribed by the safety standards in force. Have professionally
qualified personnel check the efficiency and the rating of the earth system. The manufacturer
is not liable for any damage caused by the appliance not being correctly earthed. In addition,
make sure that the electrical system is adequately rated for the maximum power absorbed by
the appliance, indicated on the boiler rating plate, and in particular that the cross-section of the
wires is suitable for the power absorbed by the appliance.
The boiler is pre-wired and fitted with a cable for connection to the electrical line. The connections to
the mains supply must be made using a fixed connection, featuring a double-pole switch with a contact
opening of at least 3 mm. Max 3A fuses must be installed between the boiler and the line. The correct
polarity must be followed (LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green wire) in the
electrical connections.
The appliance’s power cable must not be replaced by the user. In the event where the cable is
damaged, turn off the appliance and contact professionally qualified personnel to replace it. If
replacing the electrical power cable.
All wiring must conform to current I.E.E. Regulations
Accessing the electrical terminal block
Follow the operation shown in Figs. 6a and 6b to access the electrical terminal block. The layout of
the terminals for the various connections is shown in the wiring diagram, in the chapter on Technical
Specifications.
Fig. 6a
Fig. 6b
11
SYS 10-23
Room thermostat
WARNING: THE ROOM THERMOSTAT MUST HAVE 230V LIVE CONTACTS.
Standard Systems
For a general pipe layout and wiring diagram on the “S” and “Y” plan systems please see fig.
7a, 7b, and 8a, 8b.
SYS “S” Plan
Pipe layout
A.A.V
SYS
FERROLI
BOILER
D.H.W.
Zone Valve
Heating
circuit
Automatic
bypass
(mimimum flow of 6l/min.)
C.H.
Zone Valve
Fig. 7a
Wiring diagram
SYS 10-23 Junction Box
7
6
5
4
L N
3
2
1
E N
L
N
E
L
230 Vac
fused at
3 amps
Terminal 7 - SWITCH LINE
1 2 3 4 5 6 7 8 9 10
PROGRAMMER
DHW ON
CH ON
NEUTRAL
LIVE
Room Thermostat
BROWN
BLUE
CH
zone
valve
DHW
zone
valve
Cylinder Thermostat
GREY
ORANGE
Fig. 7b
12
SYS 10-23
SYS “Y” Plan
Pipe layout
Auto air vent
SYS
FERROLI
BOILER
Heating
circuit
Automatic
bypass
(mimimum flow of 6l/min.)
fig. 8a
Wiring diagram
SYS 10-23 Junction Box
7
6
5 4
L
N
3
2
1
Honeywell V4073H mid position
The heating system must have an automatic
bypass capable of
passing 6 litres/minute
L
N
E
L
240 Vac
fused at 3 amps
Terminal 7 - SWITCH LINE
1 2 3 4 5 6 7 8 9 10
PROGRAMMER
NEUTRAL
LIVE
CH ON
DHW ON
DHW OFF
3 WAY ZONE VALVE
Room Thermostat
BLUE
WHITE
GREY
ORANGE
2
C
1
Cylinder Thermostat
fig. 8b
13
SYS 10-23
2.6 Flues connections
This is a “type C” sealed and forced draught appliance, and as such the air inlet and flue gas outlet must
be connected to one of the exhaust/intake systems indicated below. Using the tables and the methods of
calculation described, first verify, before installation, that the flues do not exceed the maximum allowed
length. The standards in force and local legislation must be adhered to for terminal positions.
Restrictors
For the correct operation of the boiler, the restrictors supplied with the appliance must be fitted, according to the indications shown in the tables below. These tables apply for both vertical and horizontal
applications.
Choice of the restrictors using concentric flue
Table 4b
Table 4a
Type
60/100
80/125
Choice of the restrictors using 2 pipe
system
Length up to:
Restrictor to be used
1 bend + 1 metre
50 mm
1 bend + 3 metres
No restrictor
1 bend + 3 metres
45 mm
1 bend + 4 metres
50 mm
1 bend + 5 metres
No restrictor
Total calculated
flue lenght
Use restrictor
size
Minimum
Maximum
mm
0m
10 m
45 m
10 m
20 m
47 m
20 m
35 m
50 m
35 m
45 m
No restrictor
Replacing the restrictor
To install or change the restrictor, remove the fan
unit, remove the flue gas connecting pipe 1 (as
shown in Fig. 9a) and insert the restrictor 2 (as
shown in Fig. 9b).
1
N.B: The diameter of the
hole is stamped on
the restrictor
fig. 9a
Ø
The Ø45 SYS restrictor is fitted as standard
on the boilers. Before inserting the flue gas
outlet pipe, check that the correct restrictor
is installed (when this needs to be used) and
correctly positioned.
2
fig. 9b
14
SYS 10-23
Connection using concentric flue
For side outlet or roof outlet concentric air/flue gas pipe can be connected directly to the top of the
boiler. Numerous accessories are available upon request for the various different installation requirements. Please refer to the flue accessories catalogue, or the price list.
Side Outlet
Standard flue kit
1KWMA07Y
Front view
Ø60/100
telescopic
L
* = between 10
and 60 mm
Bend 60/100
1KWMA31Y
50* 125
Ø60
Ø100
70
115
115
50
80
192
-3 mm/m
208
D
S
L = Telescopic section
adjustment: max 840mm
min 540mm
Right hand
L = S + D + 263 mm
Rear hand
L = S + 181 mm
Rear view
50
115
196
L
S
70
50* 125
Slope
downwards
by 3 mm/m
Drill the wall 10, 20 mm
greater than the diameter
of the pipe
fig. 10
15
SYS 10-23
100 mm concentric
Vertical
Horizontal*
4m
3m
125 mm concentric
5m
125
10
Roof terminal
1KWMA83U
Sloped tile
1KWMA82U
50
* For horizontal Flueing the reduction for appliance
bend or turret are already included.
100 mm concentric bend 45°
0,5 m
125 mm concentric bend 90°
0,5 m
125 mm concentric bend 45°
0,25 m
50
1m
Max. 4m extension
60/100
1KWMA56U
950
100 mm concentric bend 90°
950
Reduction for bend
950
50
For installation (top flue connection):
Concentric
adapter 60/100
1KWMA33K
53
1. Define the position for the installation of the appliance
2. Drill the wall for the passage of the air/flue gas
pipe according to the references indicated in the
figure, considering that the horizontal sections of
pipe must have a downwards slope of around 3
mm per metre of length, to prevent any rainwater
from entering the boiler.
3. Make a hole that is 10 - 20 mm greater in diameter
than the rated diameter of the concentric pipe used,
to simplify its installation.
4. If necessary, cut the end of the pipes to required
measurement, remembering that the outside part of
the pipes must protrude from the wall by between
10 and 60 mm. Eliminate any burrs from the cut.
5. Connect the pipes to the boiler, positioning the
seals correctly.
max. 4 mt
Maximum flue lenght permissible
Vertical outlet
1000
The total length in linear metres of the concentric
pipes must not exceed the maximum length indicated
in the table below, considering that each bend gives
rise to the reduction indicated. For example, a 60/100
pipe with 1 x 90° bend + 1 metre horizontal + 2 x 45°
bends + 1 metre horizontal, has a total equivalent
length of 4 metres.
fig. 11
vertical flueing installation notes
The installation of a concentric vertical flue can be carried out as follows.
Install the appliance as previously mentioned in this manual.
1. Connect onto the flue assembly at the top of the appliance a concentric vertical adaptor part number
1KWMA33K, it is very important to esure the correct size restrictor ring is fitted if required (see page
14 for restrictor ring sizing and equivalent flue leghts).
2. Using the required amount of 1mtr flue extensions (part number 1KWMA56U) inserting them spigot
down ensuring the seals are well lubricated with silicone grease (not supplied) and correctly located
3. If required 45° bends (part number 1KWMA64A) may be used with a resistance value of 0.5mtrs
each, the flue should be routed in such away to avoid any unnecessary devition and thus minimise
the amount of bends required.
4. The termination should be made through our concentric flue outlet (part number 1KWMA83U) in conjunction with a roof slate pitched (part number 1KWMA82U) flat roof (part number 1KWMA81U).
5. All flue installations must comply with BS5440 part 1 and must only be of Fèrroli manufacture. The
vertical flue must continually rise and be supported throughout its lenght.
The flue must be inspected whilst commissioning the appliance to esure it is sound throughout it
length.
16
SYS 10-23
Connection using two pipe system
The appliance may be connected to a system of separate air/flue gas pipes with wall or roof outlet,
as shown in drawings 12 to the side. Numerous accessories are available upon request for the various
different installation requirements. The most frequently-used components are shown in Tables 7 - 8 - 9.
Please refer to the flue accessories catalogue or the price list for other components.
To check that the maximum allowed length of the pipes is not exceeded, a simple calculation must be
performed before installation:
1. For each component, Tables 7 - 8 - 9 list a pressure drop in “equivalent air-metres”, depending on the
position of installation of the component itself (air intake or flue gas outlet, vertical or horizontal).
This drop is called “equivalent air-metres” as it relates to the pressure drop of one metre of air intake
pipe (defined as being equal to 1). For example, a 90° bend in a Ø80 flue gas outlet has a pressure
drop equivalent to 2.5 air-metres, that is, equal to 2.5 linear metres of air intake pipe.
2. Once having completely defined the layout of the two pipe flue system, add the pressure drops in
equivalent-metres, according to the position of installation of all the components and accessories in
the system.
3. Check that the total pressure drop calculated is less than or equal to 45 equivalent metres, that is,
the maximum allowable for this model of boiler.
7
6
5
1
2
3
4
fig. 12
Table 6
Ref.
N° Pieces
Equivalente
pressure drop
Description
1
1
Air bend Ø80 R/D = 0,75
2
10
Horizontal air pipe
3
1
Air wall terminal
4
1
Air inlet closing flange
5
1
Flue bend 80 mm R/D = 0,75
6
7
12
1
Horizontal flue
Air wall terminal outlet flue
1,5 m
10,0 m
2,0 m
included
2,5 m
24,0 m
5,0 m
Total
45,0 m
17
Ø
8
0
18
Airwall terminal
Condensate flue Male-female Male-female Male-female
products
outlet
bend 90° Ø80 bend 45° Ø80
flue Ø80
of combustion Ø80
A
c
c
e
s
s
o
r
i
e
s
Air terminal of
inlet protection
Ø80
Description
1
1
Horizontal
Vertical
Horizontal
1
2
1,2
2,2
1,5
2,5
3
Table 8
Description
A
c
c
e
s
s
o
r
i
e
s
Ø
Air
12
8
0
5
2
The pressure drop values described refer to original Ferroli pipes and accessories.
Horizontal
Flue
Vertical
Reduction
Horizontal
Vertical
Air
Outlet flue air inlet for
connection with split end
Ø80
Table 7
Vertical
SYS 10-23
Pipes and fittings reduction table
Reduction
Flue
SYS 10-23
Flue terminal positions
Q
l
Q
Q
P
F
D, E
N
G
M
C
L
N
H
A
H
M
B
J
K
Fig. 13
Minimum Dimensions of Flue Terminal Positions
A
B
C
Directly below an opening, air brick,
opening windows, etc.
Above an opening, air brick,
300mm
300mm
opening windows, etc.
Horizontally to an opening, air brick,
opening windows, etc.
300mm
D
Below gutters, soil pipes or drain pipes
75mm
E
Below eaves
200mm
F
Below balconies or car port roof
200mm
G
From a vertical drain pipe or soil pipe
150mm
H
From an internal or external corner
100mm
I
Above ground roof or balcony level
300mm
J
From a surface facing the terminal
600mm
K
From a terminal facing the terminal
1200mm
L
From an opening in the car port (e.g. door,
window) into the dwelling
1200mm
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
300mm
O
From the wall on which the terminal is mounted
P
From a vertical structure on the roof
150mm
Q
Above intersection with roof
300mm
N/A
NOTE
N/A = Not applicable
Condensing Terminal Positions: If the flue is to be terminated at low level, then the
potential effect of the plume must be considered.
The plume should not be directed:
across a frequently used access route
towards a window or door
across a neighbouring property
19
SYS 10-23
3. SERVICE AND MAINTENANCE
3.1 Settings
All the adjustment and conversion operations must be performed by Qualified Personnel, such as personnel from the Local Customer Service Centre.
FERROLI Ltd. declines all liability for damage to property or injury to persons arising from work undertaken to the appliance by non-authorised persons
Conversion of supply gas
The appliance can operate on Natural Gas or LPG as the supply gas, and is factory configured for use
with one of the two gases, as is clearly marked on the packaging and on the rating plate on the appliance itself. If the appliance has to be used with a gas other than the one it has been set for, the special
conversion kit must be used, as shown below:
1 Replace the injectors in the main burner, installing the injectors indicated in technical data table in
Chap. 4.4, according to the type of gas used
2 Adjust the minimum and maximum pressures of the burner (ref. corresponding paragraph), setting
the values indicated in technical data table for the type of gas used.
3 Change the position of Jumper 02 on the electronic board (ref. corresponding paragraph).
4 Apply the adhesive label in the conversion kit next to the rating plate, to confirm the conversion
operation.
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. 14).
Adjust the gas pressure at the burner by turning the pressure
regulating screw: turn it clockwise to increase the burner
pressure and anticlockwise to decrease it.
The diagrams indicate the variation in heat output to the
water as burner working pressure is varied (fig. 28).
Adjusting boiler output to the actual requirements of the
central heating system will minimise boiler cycling thus saving
fuel, varying the output has virtually no effect on the efficiency
Pressure regulator
and combustion characteristics of the boiler.
protection plug
Natural gaz
LPG
Min soft setting
2 mbar
Mid soft setting
4 mbar
Max soft setting
6 mbar
Min soft setting
5 mbar
Mid soft setting
12 mbar
Max soft setting
20 mbar
Soft light
adjustment
Outlet
pressure
Test Point
OUT
The appliance has a soft light facility to ensure a quiet ignition sequence.
Measuring the gas pressures during ignition is done via the
outlet test point on the gas valve, the pressure should be
kept to a minimum, but sufficient to ensure correct cross
lighting of the burner.
I
Adjusting the soft light facility
Inlet
pressure
Test Point
Inlet
gascock
fig. 14
20
SYS 10-23
3.2 Commissioning
The appliance must only be commissioned for use by Qualified Personnel,
Before igniting the boiler:
• Open the isolation valves between the boiler and systems.
• Check the gas system for soundness, and ensure their are no leaks.
• Fill the system with water to approximately 1bar pressure and ensure that the air contained in the
boiler and the system has been completely vented, by opening the air vent valve on the boiler and
any vent valves installed within the system.
• Check that there are no water leaks in the heating system, in the domestic hot water circuits, in the
connections or in the boiler.
• Check the correct connection of the electrical system.
• Check that the appliance is correctly earthed.
• Check that there are no flammable liquids or materials in the immediate vicinity of the boiler.
Igniting the boiler
•
•
•
•
Open the gas isolation valve upstream of the boiler.
Purge the air in the gas supply pipework upstream from the gas valve.
Place the main switch in the ON position.
Place the control knob “B” in the Winter position to a value higher than 50°C and set the room thermostat, to the required temperature value. At this point, the burner will ignite and the boiler will start
operating automatically, managed by its control and safety devices.
• Checking gas inlet pressure
- Connect a pressure gauge to inlet test point;
- Check the pressure gauge is reading 20 mbar (+/-1 mbar);
- Check that this pressure remains as above with any other gas appliances in the house turned on;
- If the pressure is below this reading it should be investigated before continuing as this is a sign of
an incorrect or partially blocked gas supply;
- Turn-off appliance;
- Remove pressure gauge, tighten test point and test with leak detection fluid.
• Check that the burner pressure and gas rate for the heating system are correct.
21
SYS 10-23
If, after correctly having performed the ignition operations, the burner does not ignite and the shutdown warning light is on, wait around 15 seconds and then push the reset button “A” (Fig. 1) and
release it. The control unit will be reset and will repeat the ignition cycle. If, after a number of attempts,
the burner does not ignite, refer to the paragraph “Troubleshooting”.
In the case of power failures while the boiler is in operation, the burners will switch off. When
mains power returns, the burners will automatically re-ignite.
Checks during operation
•
•
•
•
Check the gas supply and the water system for tightness.
Check the efficiency of the flues and air-flue gas pipes during the operation of the boiler.
Check that the water circulation between the boiler and the systems is correct 11°C ∆T.
Check the correct ignition of the boiler, by performing a series of ignition and shut-down tests using
the room thermostat and the time clock.
• Ensure that the consumption of gas indicated by the gsa meter corresponds to the values shown in
the technical data table in Chap. 4 section 4.4
• Flush and treat the system as per BS7593, whilst balancing the radiators and indirect hot water supplys.
Shut-down
See page 5 of this manual.
3.3 Maintenance
The following operations must only be performed by Qualified Personnel
Seasonal
checks on the boiler and the stack
The following checks should be made on the appliance at least once a year:
•
•
•
•
•
•
•
•
•
22
The control and safety devices (gas valve, thermostats, etc.) must be working correctly.
The air-flue gas terminals must be free of obstacles and not have any leaks.
The water systems and the gas supply must be sound.
The burner and the heat exchanger must be clean. Follow the instructions in the next paragraph.
The electrodes must be free of deposits and positioned correctly;
(Ignition electrode gap 3.5mm)
(Flame sensing electrode 12 to 15mm).
The pressure of the water in the system when cold must be around 1 bar; if not, restore this value.
The expansion vessel must be full (1bar air pressure when cold and system at zero pressure).
The gas rate and the pressure must correspond to the values indicated in the corresponding tables.
The circulation pump must free and not be blocked.
SYS 10-23
Opening the casing
To open the boiler casing:
1 Using a screwdriver, completely remove the 2 screws,
“A”
2 Open the control panel “B” by pulling down
3 Unscrew the 2 screws “C”
4 Remove the casing “D” by pulling out at base and lifting
off the top hooks.
D
D
B
C
A
fig. 15
Cleaning the boiler and the burner
The heat exchanger should be cleaned using an appropriately sized flue brush, to remove any deposits
within the exchanger fins.
Clean the burner in a similar manner ensuring the ports and mixing venturis are clear, alternatively you
can use compressed air although care should be taken not too inhale any dust particles.
Clean the burner injectors, do not use wire to do this as you may block or oversize the ports this may
adversely effect the running of the appliance.
After these checks, ensure that there are no gas leaks.
Analysis of combustion
Two test points are installed inside the boiler, one for the flue gases and the other for the intake air.
To make the measurements, proceed as follows:
1) Remove the boiler casing
2) Open the air and flue gas sample points in the sealed
compartment;
3) Insert the probes as far as possible;
4) Operate the boiler
5) Adjust the boiler temperature to the maximum setting.
6) Wait 10-15 minutes to allow the boiler to reach stable
operating conditions*
7) Take a reading with your flue gas analyser.
8) CO/CO2 ratio should be 0.004 or below. If above a
full service is required to find the cause and then RETEST.
9) Following a full service the permissible reading is now
0.008 or below.
Flue
gas
Air
*Testing before thermal equilibrium has been reached will give incorrect readings.
fig. 16
23
SYS 10-23
3.4 Replacement of Parts
Initial procedure
a) Ensure the boiler is cold, electricity supply is isolated, and the gas supply is turned off at the inlet
valve on the boiler
b) For replacement of parts where water connections are broken, it will be necessary to isolate and drain
the water circuits of the boiler only. The cold water mains inlet is isolated at the inlet cock.
The C.H. flow and return cocks are turned off at the isolation valves. The C.H. is drained via the drain
off valve on the appliance.
c) Remove components as shown below and replace in reverse order.
d) Ensure water and gas washers are in good condition.
Final procedure
• Re-open cocks and re-charge the system to about 1 bar, and vent boiler and radiators.
Re-charge to 1 bar if necessary.
• Upon completion of the work the following, should be checked:
I) Gas soundness of all joints
II) Water soundness of all joints
III) The electricity supply.
IV) The pressure of the sealed system and top up where necessary.
To lower the control panel
• Remove the two fixing screw "A"
• Rotate down the front panel "B"
B
A
fig. 17
Remove and re-presurising of C.H. expansion vessel
•
•
•
•
•
•
•
•
Refer to 3.4 a, b
Isolate electricity and water supplies
Remove outer case (two screws bottom rear corners)
Loosen the "A" connection to the expansion vessel
Loosen screws “B" and remove the bracket
Remove the expansion vessel
Re-assemble in reverse order using the new vessel
Check the expansion vessel pressure;
(charge pressure 0,8-1 bar) through the valve "C"
• Ensure pressure relief value is open
(twist about 1/2 of a turn) when re pressurizing and
refill the system ensuring there are no leaks.
It may be necessary to remove the boiler to
change the expansion vessel due to site restrictions.
B
A
C
fig. 18
24
SYS 10-23
F
Gas valve (fig. 19)
• 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
• Disconnect plastic compensation tube "C"
• Loosen the connection "D" on gas outlet pipe and
the gas valve inlet connection on the boiler
• Remove the fixing screw "E" below gas valve
• Slide out gas valve
• Remove four fixing screw "F" on top of the valve and
disconnect the gas outlet pipe
• Replace the gas outlet seal.
• Replace in reverse order with the new gas valve and
follow the commissioning procedure section 3.2
D
C
E
Fig. 19
Air pressure switch (fig. 20)
• Isolate electricity
• Remove outer case (two screws bottom rear corners)
• Open room sealed department ( four screws two
either side)
• Remove the two screw "A" fixing air pressure
switch
• Disconnect electrical leads "B"
• Remove pressure sensing tubes (white=D; Red=C)
• Note relevant positions of all connections and
replace in reverse order.
A
B
Safety Valve (fig. 21)
• Isolate electricity and water supplies
• Remove outer case (two screws bottom rear corners)
• Remove the two securing screws and lower control
panel
• Identify valve from fig. 21
• Drain the boiler
• Release the outlet union to the valve and undo the
valve union connection
• Remove the valve outlet fitting
• Replace in reverse order and refill the
system to 1bar.
C
D
Fig. 20
Safety valve
Fig. 21
25
SYS 10-23
Removal of burner (fig. 22)
• 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"
• Withdraw the burner assembly
D
C
D
A
B
Injectors (fig. 22)
• Proceed as above
• Remove fixing screw "C" on both sides of gas
manifold
• Remove gas manifold
• Unscrew and remove injectors;
• Clean or change injectors
fig. 22
Removal of fan (fig. 23)
•
•
•
•
•
•
•
•
Isolate gas and electricity supplies
Remove outer case (two screws bottom rear corners)
Remove room sealed cover
Disconnect fan electrical leads "A"and note positions
Disconnect air pressure tubes from air pressure switch "B" + note positions
Undo two screws securing fan assembly "C"
Remove fan from boiler
Swap mounting plate over to new fan + replace in reverse order
Limit thermostat, or overheat cut off thermostat (fig. 23)
•
•
•
•
•
•
•
•
Isolate electricity
Remove outer case (two screws bottom rear corners)
Remove room sealed cover ( four screws two either side)
Identify the location of the faulty thermostat from fig 23
Remove the thermostat from heatexchanger tube, with its clip
Remove electrical connections from thermostat
C
Remove clip from thermostat
Replace in reverse order
Overheat cut off
fig. 23
26
B
A
Limit
thermostat
SYS 10-23
Spark or flame detect electrode (fig. 24)
•
•
•
•
•
•
•
Isolate gas and electricity supply
Remove outer case (two screws bottom rear corners)
Open room sealed compartment and combustion chamber as previously mentioned
Identify electrode from fig. 24
Unplug electrical connection "A" from the electrode to be replaced
Unscrew the fixing screw and remove faulty electrode
Replace in reverse order, Flame detection gap 12 to15mm Spark electrode gap 3.5mm
Flame detect
Spark
A
Fig. 24
Pump
Replacement of pump head
• Isolate electricity and close the flow and return isolation valves
• Remove casing (two screws bottom rear corners).
• Remove the two securing screws and lower control panel
• Release pressure from boiler via a suitable drain off point
• Unplug the pump lead 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.
• Using a 4mm allen key undo the four allen screws in the pump head, lift away pump head from the
pump body
• fit new head into pump body and secure with the allen screws tightening evenly.
• re fill the system to 1bar vent and spin new pump
• Replace electrical connection.
Removal of heat exchanger
•
•
•
•
•
•
•
•
•
•
•
Isolate gas, water and electricity supplies
Remove casing (2 screws bottom corners)
Remove the two securing screws and lower control panel
Drain the boiler ensuring the heat exchanger is empty!
Remove sealed compartment front panel
Disconnect the overheat thermostat and central heating limit thermostat
Remove the main burner, fan, flue hood and air pressure switch as described previously
Remove the pump to heat exchanger return connection and lower locknut
Undo the heatexchanger flow connection and lower locknut
Lift out heat exchanger
Re-assemble in reverse order ensuring no leaks, commission appliance as per section 3.3
27
SYS 10-23
4. CHARACTERISTICS AND TECHNICAL SPECIFICATIONS
4.1 Dimensions and fittings
1
2
3
Key
1 Central Heating flow
2 Gas supply
3 Central Heating return
fig. 25
28
SYS 10-23
4.2 Overall view and main components
29 187
43
5
16
28
27
49
50
19
26
22
82
81
133
56
51
32
14
7
188
44
63
5
7
10
11
14
16
19
20
21
22
26
27
28
29
32
43
44
49
50
20
21
10
Key
83
129
51
56
63
81
82
83
129
133
145
187
188
Room sealed compartment
Gas inlet
Central heating flow
Central heating return
Safety valve
Fan
Combustion chamber
Burner assembly
Injectors x 12
Burners x 12
Combustion chamber insulation
Copper heat exchanger
Flue collector from heat
exchanger
Fan adaptor ring
Central heating pump
Air pressure switch
Gas valve
Safety overheat thermostat
Central heating flow limit
thermostat
Central heating frost thermostat
Expansion vessel
CH boiler thermostat
Ignition electrode
Flame sensor electrode
Full auto control unit
Reset knob with lamp
Pump overrun thermostat
Central heating pressure gauge
Flue restrictor
ON/OFF switch
11
145
fig. 26
29
SYS 10-23
4.3 Hydraulic diagram
43
29-187
-
+
16
5
49
50
56
81
82
20
44
32
14
10
7
11
fig. 27
Key
5
7
10
11
14
16
20
29
32
30
Room sealed compartment
Gas inlet
Central heating flow
Central heating return
Safety valve
Fan
Burner assembly
Fan adaptor ring
Central heating pump
43
44
49
50
56
81
82
187
Air pressure switch
Gas valve
Safety overheat thermostat
Central heating flow limit thermostat
Expansion vessel
Ignition electrode
Flame sensor electrode
Flue restrictor
SYS 10-23
4.4 Technical data table
Output
Nominal Heat Input (Net)
Nominal Heat Output
kW
kW
Gas supply
Main injectors, Natural Gas (G20)
mm
Supply pressure, Natural Gas (G20)
mbar
Burner pressure, Natural Gas (G20)
mbar
nm3/h
Natural gas rate (G20)
Main injectors, LPG (G31)
mm
Pmax
Pmin
25,8
23,3
11,2
9,7
Pmax
Pmin
12 x 1.3
20,0
11,8
2,5
2,73
1,19
12 x 0.77
Supply pressure, LPG (G31)
mbar
Burner pressure, LPG (G31)
mbar
36,0
7,0
kg/h
2,00
0,87
LPG gas rate (G31)
36,0
Central heating
°C
90
Maximum central heating operating pressure
bar
3
Safety valve
bar
3
Minimum central heating operating pressure
bar
0,8
Maximum central heating operating temperature
Expansion vessel capacity
Expansion vessel pre-fill pressure
Hot water capacity
litres
8
bar
1
litres
1,5
Height
mm
720
Width
mm
400
Depth
mm
370
kg
35
Dimensions, weights, fittings
Weight with packaging
Gas system fittings (with isolation valve fitted)
mm
22
C.H. flow (with isolation valve fitted)
mm
22
Central heating return (with isolation valve fitted)
mm
22
Power supply
Max Power Absorbed
Power supply voltage/frequency
Index of protection
W
V/Hz
IP
125
230/50
X4D
31
SYS 10-23
4.5 Diagrams
Pressure - output diagrams
fig. 28
Discharge head available to system
H [m H2O] 7
6
3
5
2
4
3
1
A
2
1
0
0
500
1.000
Legenda
1 - 2 - 3 = Pump switch positions
A = Boiler pressure drop
32
fig. 29
1.500
2.000 Q [l/h]
SYS 10-23
4.6 Internal electrical diagrams
fig. 30a
16
24
32
43
44
49
50
51
62
63
82
83
98
129
133
Fan
Spark electrode
Central heathing
Air pressure switch
Combination gas valve
Overheat Cut-Off thermostat
Central heating limit thermostat
Central heating frost thermostat
External control (switched live 230V A/C)
C.H. boiler thermostat
Ionisation electrode
Full sequence automatic control
main switch
Reset knob with lamp
pump overrun
NOTE: Dotted lines indicate connections to be performed during installation
33
SYS 10-23
fig. 30b
16
24
32
43
44
49
50
51
62
63
82
83
98
129
133
Fan
Spark electrode
Central heathing
Air pressure switch
Combination gas valve
Overheat Cut-Off thermostat
Central heating limit thermostat
Central heating frost thermostat
External control (switched live 230V A/C)
C.H. boiler thermostat
Ionisation electrode
Full sequence automatic control
main switch
Reset knob with lamp
pump overrun
NOTE: Dotted lines indicate connections to be performed during installation
34
SYS 10-23
4.7 Fault finding
35
Should you require help with any difficulties
call our Technical Service Helpline on
08707 282 885
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.
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 08707 282 885 - Fax 08707 282 886
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