MODENA 102
INSTALLATION, SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-267-24
3543495/0 - 10/99
Appr. nr. B99.06 A - CE 0461 AU 0431
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
MODENA 102
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"
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.
CE MARK
CE mark documents that the Ferroli gas appliances comply with the requirement contained in European
directives applicable to them.
In particular, the appliances comply with the following CEE directives and the technical specifications
provided from them:
•
Gas appliances directive 90/396
•
Efficiencies directive 92/42
•
Low tension directive 73/23 (modified from the 93/68)
•
Electromagnetic compatibility directive 89/396 (modified from the 93/68)
Year 2000 Compliance Declaration
We will guarantee that this products is altogether suitable for the data change in the Year 2000 (boiler has
no dependence from date change) and that no disruptions will occur which is caused by this product.
INDEX
1.0
DESCRIPTION ................................................................................................................................. 3
2.0
TECHNICAL AND DIMENSIONAL CHARACTERISTICS ................................................................ 4
3.0
INSTALLATION DETAILS ............................................................................................................... 11
4.0
COMMISSIONING AND TESTING ............................................................................................... 28
5.0
ADJUSTMENT AND GAS CONVERSION ..................................................................................... 30
6.0
MAINTENANCE AND CLEANING ............................................................................................... 33
7.0
REPLACEMENT OF PARTS ........................................................................................................... 35
8.0
FAULT FINDING ............................................................................................................................ 41
9.0
ELECTRICAL AND FUNCTIONAL SCHEME ................................................................................. 50
10.
USER INSTRUCTIONS ................................................................................................................... 52
2
MODENA 102
1. DESCRIPTION
1.01 Introduction
The Modena 102 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. The main components are as follows:
• Copper heat exchanger consisting of three finned tubes specifically shaped for high efficiency.
• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water
heat exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.
• Ceramic fibre insulated combustion chamber
• 16 stainless steel bladed burners specifically designed for this boiler.
• Fan for discharge of combustion products and intake of combustion air.
• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning
correctly.
• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.
• Combination gas safety valve with modulator, complete with pressure stabiliser.
• Flowmeter giving the domestic hot water circuit precedence over the central heating circuit.
• Pressure relief valve for the central heating circuit set to open at 3 bar.
• Built-in Expansion vessel.
• Variable speed pump.
• Central heating flow temperature adjustment thermostat.
• Domestic hot water flow temperature adjustment thermostat.
• Central heating limit thermostat.
• Overheat safety thermostat.
• Electronic control unit for automatic flame ignition and control.
• Central heating low water pressure cut off switch.
• Domestic hot water flow temperature sensor.
• Central heating flow temperature sensor.
1.02 Instructions and regulations
Assembly, installation, first start up and maintenance must be carried out by competent persons only, in accordance
with all current technical regulations and directives.
C.O.S.H.H.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are required
when servicing.
Related Documents
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1992 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 INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 1994 INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply
3
MODENA 102
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Modena 102 boilers are central heating and domestic hot water heat generators and are produced as standard to
function with natural gas or LPG.
430
362
115
200
Ø60
14
Distance between connections
733
720
77
Ø100
85
189
460
460
60
60
155
110
54
189
120
120
110
200
95
175
36
80
1
2
3
4
Bottom view
Key
1 - 3/4" central heating flow outlet
2 - 1/2" domestic hot water flow outlet
4
5
Fig. 1
Top view
3 - 1/2 “ gas inlet
4 - 1/2" domestic hot water inlet
5 - 3/4" central heating return inlet
MODENA 102
Technical Data
MODEL
Modena 102
kW
kW
kW
kW
kW
Litres
Litres
30.0
12.7
33.1
14.5
30.0
1.5
0.8
1
2
3
4
5
Ø
Ø
Ø
Ø
Ø
Litres
bar
bar
bar
3/4"
1/2"
1/2"
1/2"
3/4"
10
1
3
6
Main injectors (mm)
Modena 102
G20 - NG G31 - LPG
Gas flow rates to main burners
for central heating
G20 - NG
G31 - LPG
Ø
Ø
m3/h
kg/h
16x1,25
16x0,77
3.5
2.6
Gas supply pressures
working
MODEL
Modena 102
G20 - NG
G31 - LPG
mbar
20
G20 - NG
H. V K4105G
G31 - LPG
Safety valve
min.
max.
min.
max.
mbar
mbar
mbar
mbar
mbar
bar
37
2,5
13.0
7.0
35.5
3
Protection
level
Weight
Domestic hot
Domestic hot
water production water production
with ∆t 30° C
with ∆t 35° C
l/min.
14.3
Gas valve
Ø 1/2"
Gas pressure at main burner for central heating
MODEL
Modena 102
Max. working
Max.
pressure
working
central
pressure hot
heating
water circuit
Pre-pressurising
circuit
Capacity
value
Expansion vessel
MODEL
MODEL
Domestic hot
water circuit
contents
Heat output
Connections
Modena 102
Domestic hot
water heat
Boiler water
input
contents
Gross
Heat input
Net
l/min.
12.3
Max. working
pressure domestic
hot water
G20 - NG G31 - LPG
mbar
mbar
13.0
35.5
IP44
kg
48
N.B. - The gas pressures at the burner and gas flows during the central heating phase given in the table refer
to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced until the
required output level is reached (see figures 4 and 5).
During domestic hot water production, gas pressures to the burner must correspond to the maximum output given
in table for the type of gas.
Gas pressure must be adjusted during maximum draw-off of domestic hot water.
• Maximum working temperature for central heating flow: 85°C
• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.
• Minimuum domestic cold water pressure required for 95% heat input:
- Flow restrictor fitted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
5
MODENA 102
2.02 Boiler main components
2.03 Boiler water flow diagram
29 187
43
AIR
IN
FLUE
OUT
AIR
IN
5
16
28
91
90
27
132
50
49
19
56
22
82
81
26
20
21
36
OUT
FERROLI
MIN
IN
32
GRUNDFOS
MIN
IN
OUT
114
34
10
14
8 42 84 7 85 44 9
136
11
2
3
5
0
Fig. 2
98
63
157
62
28
29
32
34
36
6
6
C.H.
OUT
145
42
Key
5
7
8
9
10
11
14
16
19
20
21
22
26
27
Fig. 3
4
1
Room sealed compartment
Gas inlet
Domestic hot water outlet
Domestic hot water inlet
Central heating flow outlet
Central heating return inlet
Safety valve
Fan
Combustion chamber
Burner assembly
Main injector
Burner
Combustion chamber insulation
Copper heat exchanger for central
heating and domestic hot water
Flue collector from heat exchanger
Internal flue exit
Central heating pump
Central heating flow temperature sensor
Automatic air vent valve
43
44
49
50
56
62
63
81
82
84
85
90*
91*
98
114
132
136
145
157
187
D.H.W. GAS D.H.W.
OUT IN
IN
C.H.
IN
Domestic hot water flow
* For use with flue gas analyser
temperature sensor
Air pressure switch
Gas valve
Safety overheat thermostat
Central heating flow limit thermostat
Expansion vessel
Time clock (option)
Central heating temperature adjustment
Ignition electrode
Sensor electrode
Primary gas valve solenoid
Secondary gas valve solenoid
Flue outlet test point
Air test point
On/Off/Reset switch
Low water pressure cut off switch
Flue gas deflector
Flow meter
Central heating pressure gauge
Domestic hot water temperature adjustment
Restrictor
MODENA 102
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.
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 and combustion characteristics of the boiler.
Diagram of pressures
and outputs with Natural gas
Diagram of pressures and outputs
with LPG (Propane)
35
30
14
13
25
mbar
12
11
20
10
mbar
9
15
8
7
10
6
5
4
5
3
2
kW
kcal/h
x 1000
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Fig. 4
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
kW
kcal/h
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
X 1000
Fig. 5
2.05 Pump characteristics
The pump head available for circulating the water is
given in fig. 6.
N.B. - The pump is factory set at position 3. The pump
is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph
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.
Pump performance curve Grundfos UPS 15-50
1 2 3 Speed settings
A
Boilers pressure drop
B
Available pump head C.H.
Fig. 6
7
MODENA 102
SAFETY VALVE
SETTING (bar)
3.0
VESSEL CHARGE
PRESSURE (bar)
0.5
1.0
1.5
INITIAL SYSTEM
PRESSURE (bar)
1.0
TOTAL WATER
CONTENT of SYSTEM
EXPANSION VESSEL VOLUME (litres)
LITRES
25
50
75
100
125
150
175
200
For syst. volumes other than
those given above, mult. the syst.
volume by the factor across
1.5
2.0
1.5
2.0
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 10
litre vessel supplied.
2.0
3.5
7.0
10.5
14.0
17.5
21.0
24.5
28.0
6.5
12.9
19.4
25.9
32.4
38.8
45.3
51.8
13.7
27.5
41.3
55.1
68.9
82.6
96.4
110.2
4.7
9.5
14.2
19.0
23.7
28.5
33.2
38.0
10.3
20.6
30.9
41.2
51.5
61.8
72.1
82.4
8.3
16.5
24.8
33.1
41.3
49.6
57.9
66.2
0.140
0.259
0.551
0.190
0.412
0.33
Note:
1.
2.
3.
4.
Fill C.H. installation to min. 1.5 bar.
Expansion vessel must be fitted to central
heating return pipe.
The standard 10 litre expansion vessel is
charged to 1 bar.
The additional expansion vessel should be
charged to 1 bar.
Pressure loss diagram
H
mbar x 100
8
7
6
5
4
3
2
1
Fig. 7
Q
0
8
0.5
1
1.5
2
2.5
3
m |h
MODENA 102
3.0 INSTALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1998
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. For Northern Ireland the rules in force apply.
Important - If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute
of Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.
Location of Boiler
The installation of the Modena 102 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.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 room containing a bath or shower any electrical switch or appliance
control utilising mains electricity must be situated so that it cannot be touched by a person using the bath or shower.
Air Supply
The room or compartment in which the boiler is installed does not require a purpose provided vent when using the
standard concentric flue.
Flue System
The boiler allows the flue outlet to be taken from the rear of the boiler, from either side or vertically.
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 2815mm for rear flues, deduct 91mm 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 ventilations, windows, doors,
natural air infiltration or forced ventilation/air conditioning.
Gas Supply
If necessary the local Gas supplier 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 supplier.
A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 3.5 m3/h of natural gas, and 2.60 kg/h of LPG.
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 boiler gas inlet. Please
wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after the boiler
has operated for 10 minutes to reach thermal equilibrium.
Water System
Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.
9
MODENA 102
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part of
the useful heating suface 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. Ensure that the boiler heat exchanger is not a natural
point for air collection. A typical heating system with domestic hot water circuit is illustrated in fig. 8.
Important - If thermostatic radiator vales are fitted 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.
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. A typical
temporary filling loop is shown in fig. 9.
Domestic Hot Water
Always fit a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection point on
the boiler 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 mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing
valve must be fitted by the installer into the mains supply in an inconspicuous but accessible position preferable
between 3 and 5 metres (10-16ft) 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.
Ensure all pipework is adequately supported
NOTE: A bypass must be fitted as far as possible
from the boiler if thermostatic radiator valves are
fitted thoughout.
Gas
Cold water
Additional expansion
vessel C.H.
Filling
point
Bypass
Fig. 8
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
10
Fig. 9
MODENA 102
460
5 min.
360
50 mm
100 min.
5 min.
600* min.
200 min.
852
* 600mm minimum clearance for
servicing access
760
CLEARANCES:
Fig. 10
Terminal Position
Fig. 11
POSITION
A
B
C
D
E
F
G
H
I
J
K
L
N
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
Above adjacent ground or balcony level
From a surface facing the terminal
Facing another terminal
From opening (door/window) in carport into dwelling
Vertically from a terminal on the same wall
Horizontally from a terminal on the same wall
Below carport
mm
300
75
100
100
75
100
100
600
1,200
1,200
300
300
600
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when
the terminal height is less than 2 m from floor level.
11
MODENA 102
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.
77
195 min
Ø120
15
=
=
15
0
955 min
20
200 min
Ø3/4''
Ø1/2''
Ø1/2''
Ø1/2''
Ø1/2''
Ø3/4''
1 2 3
4
5
6
460 min
5 min
Fig. 12
1.
2.
3.
4.
5.
6.
12
CH flow
Safety Valve
Domestic hot water outlet
Gas supply
Domestic hot water inlet
CH return
MODENA 102
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. 13).
N.B.: the diameter of the hole is stamped
on the restrictor
Boiler is fitted with Ø47 restrictor as
standard
Holes Ø : 47 50 52
Ø
Fig. 13
Choice of restrictor:
• With concentric pipes:
- up to 1m long + one bend, use the 52 mm restrictor.
- for flue lengths over 1 metre, use no restrictor.
• With separate pipes:
- Calculate the total flow resistance of the air and flue pipes in metres
(cap. 3.04.2)
- utilise the table shown belaw to choose the more suitable restrictor for
the flow resistance calculated
RESTRICTOR FOR TWO PIPE SYSTEM
ON MODENA 102
Total flow resistance
of flue system
Use
restrictor
size
minimum
maximum
mm
0m
20 m
47
20 m
35 m
50
35 m
45 m
52
45 m
50 m
no restrictor
13
MODENA 102
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. 14
3.03.2 Horizontal concentric connection
A 90° bend (fig. 15) can be supplied for the horizontal connection of air and flue gas pipes. This can be angled towards
the chosen wall in degrees of 45°.
Ø1
25-30 mm
60
Ø2
L
A=L+(85-90)mm
Trim the 60 mm internal
diameter tube
Fig. 15
Ø1=100 Ø2=60
14
Ø1
Ø2
Detail of mounting the bend
MODENA 102
Notes on concentric horizontal installation
To locate the centre of the hole for passing the
pipes through the wall, refer to fig. 12. 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. 16). Outside, the
pipes should protrude from the wall between 10
and 60 mm (fig. 16).
Between 1060mm
Fig. 16
3.03.3 Maximum concentric flue length
First table below shows the maximum flue lengths available for boilers with concentric systems.
For correct calculation remember to include the reduction for bend and flue terminals listed on second table. Please
refer to 3.02 for use of restrictor
Maximum flue lenght permissible
Domina 102
100 mm concentric
125 mm concentric
Vertical
Horizontal*
Vertical
Horizontal*
4m
3m
5m
5m
*For horizontal Flueing the reduction for appliance bend or turret are already included.
100 mm concentric bend 90°
1m
100 mm concentric bend 45°
0,5 m
125 mm concentric bend 90°
0,5 m
125 concentric bend 45°
0,25 m
max. 3 m
Fig. 17a
max. 4 m
Reduction for bend and roof terminals
Fig. 17b
15
MODENA 102
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.
mount the separate outlet kit 1 (see 3.05)
Ø80
Ø80
FLUE
AIR
2
Insert blanking plate
1
in remaining air intake
Fig. 18
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 varied selection of accessories for two pipe systems are available from Ferroli (ref. to page 17). Before installing
your system please check via calculation table at 3.04.2 you are not exceeding the maximum permissible length for
the appliance.
IMPORTANT:
Notes on two pipe system installation:
When using the two pipe system the flue discharge pipe must have a 25mm air gap when passing through
combustible materials. Where the flue discharge pipe passes through the airing space of an airing cupboard it must
be protected by a non combustible guard or expanded metal giving an annular air gap of at least 25mm.
Where the flue discharge pipe passes through a wall containing cavity insulation, a non combustible sleeve must be
fitted. Additionally a gap of 25mm between the sleeve and the insulation should be provided by cutting back the
insulation or packing loose fill bead insulation with mineral fibre. Where the flue pipe is run through an unheated roof
space it should be insulated with non combustible insulating material to prevent condensation. The flue pipe should
be supported at intervals of not more than 1.8m and the support should be preferably below a joint.
3.04.2 Two pipe flue system
To determine the maximum length of flue and air pipe permissible.
The calculation is based on a standard reference resistance of 1 metre of 80 mm horizontal air intake pipe. For every
configuration of the two-pipe system all components will have a resistance factor based upon this reference. (I.e. a
90 degree bend fitted in the flue line would attract a resistance factor equivalent to 2.5 Metres of horizontal 80mm
pipe). This is expressed as X metres. Each boiler will have a maximum equivalent length of flue/air pipe and this is
shown in the table as N metres. Therefore when calculating the proposed flue run the equivalent resistance of every
length of pipe and every bend, whether air intake or flue discharge is added together to give an actual total flue
length. The final figure calculated must not exceed the permitted maximum length (N metres) for each boiler type.
Calculation Routine
1. Identify all the components needed to complete the proposed flue/air pipe run.
2. Calculate the sum of all the equivalent lengths (see table at next page).
3. For boilers, which may require a flue restrictor, refer to table at page 13 (par. 3.02) to ascertain the correct size
and add this resistance to your total.
4. Check and verify that the total flue/air pipe length (flow resistance) does not exceed 50 mt. maximum permitted for Modena 102.
IMPORTANT:
Resistance factors apply to standard férroli components only.
The values for condensing boiler will be different.
16
MODENA 102
Male-female flue/Air pipe
1 m - Ø 80
A
c
c
e
s
s
o
r
i
e
s
Ø
Horizontal
FLUE
Vertical
Dscription
Vertical
Vertical
Vertical
AIR
Horizontal
FLUE
Horizontal
AIR
Description
REDUCTION
REDUCTION
Horizontal
Tab. 1 - Pipes and
fittings reduction table
Horizontal
flue terminal
Ø 80 mm
1
1
1
2
5
Female-female bend
45° Ø 80 m
Air intake
terminal
Ø 80 mm
1,2
2,2
Male-female bend
90° Ø 80 m
1,5
2,5
Spigot-and-socket
reduction Ø 100/80 mm
8
0
A
c
c
e
s
s
o
r
i
e
s
2
Outlet flue/air inlet
for concentric system
Ø 100/60 mm
Pipe fitting for
outlet flue
Ø 80 mm
0
4
Ø
Outlet flue/air inlet
for connection
with split end
Ø 80 mm
8
0
12
17
MODENA 102
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: 50 metres
13 m
7
Attention:
Remove the flue diaphragm.
The flue + air Pipes must have a 3% drop away
from the boiler
13 m
6
5 1
2
3
REF.
N° OF PIECES DESCRIPTION
LENGTH OR
REDUCTION
1,5 m
1
1
Air bend 80 mm R/D = 0,75
2
13
Horizontal air pipe
13,0 m
3
1
Air wall terminal
2,0 m
5
1
Flue bend 80 mm R/D = 0,75
2,5 m
6
13
Horizontal flue
26,0 m
7
1
Air wall terminal outlet flue
5,0 m
TOTAL
50,0 m
Fig. 19
3.04.3 Example of installation with two pipe systems
Example of direct roof flue outlet
and wall air inlet
Example of roof inlet/outlet
Example of wall inlet/outlet
Fig. 10a
Fig. 20b
18
Fig. 20c
MODENA 102
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 the wall. To ensure long life, the heating circuit should be correctly sized and fitted with all the controls
necessary to ensure correct functioning and operation. The differential between the boiler flow and return pipes
should not be more than 20°C. You are advised not to use the boiler with return temperatures of less than 50°C in
order to prevent patches of condensation forming, having a corrosive effect on boiler components.
3.06 Boiler water characteristics
If the water is harder than 18 clarke degrees, the water used should be treated to avoid possible scale in the boiler
caused by hard water or corrosion by aggressive water. It should be remembered that as a result of its low thermal
conductivity, even scale of just a few millimetres thick can lead to considerable overheating of the boiler walls,
resulting in serious problems.
IT IS ABSOLUTELY VITAL THAT THE WATER USED IS TREATED IN THE FOLLOWING CASES:
a) Extensive systems (containing large quantities of water);
b) Frequent additions of water to top-up the system;
c) Domestic hot water circuits
If the system requires partial or total emptying, you are recommended to refill it with treated water.
3.07 Filling
When cold, system pressure should be about 1 bar. If while running venting off of air dissolved in the water causes
the pressure of the central heating system to drop below 0.5 bar, the user must utilise a filling loop to bring it back
to the original value. During operation, water pressure in the boiler when hot should be about 1.5 - 2 bars. After filling,
always close and disconnect the filling loop.
Note - If there is a possibility of air pockets forming in certain points of the central heating system flow and return
pipes, you are recommended to fit an air vent valve at these points.
Note - When the boiler is installed below the level of the central heating system, single check valve should be fitted
to prevent gravity circulation around the heating system.
3.08 Gas connection
Gas connection should be carried out using a rigid pipe.
The flow at the gas meter should be sufficient for the simultaneous use at full gas rate of all appliances connected
to it. Connect the gas supply to the boiler according to current regulations. The diameter of the gas tube leaving
the boiler is not the determining factor in choosing the diameter of the pipe between the appliance and the meter.
This must be selected in relation to length and pressure drop and in any instance should not be less than 22mm.
The whole of the gas installation including the meter should be inspected and tested for soundness and purged
in accordance with BS6891-1988.
N.B. - The filling loop will be fitted by the installer at the time of installing the system. It is NOT a part of the boiler.
3.09 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. The boiler must always
be connected to an efficient earth installation. Under the electrical box, there is a 3 pole terminal block for connecting
the boiler to the mains (230 V 50 Hz) and a 2 pole board for connecting a room thermostat (RT). To connect, undo
the screws fixing the terminal block box and connect the wires, ensuring correct polarity of the terminals. It should
be noted that there is low voltage (24 V) between the room thermostat contacts.
When the boiler is connected to an electricity main, it is essential TO OBSERVE CORRECT POLARITIES (LIVE: brown
cable, NEUTRAL: blue cable, EARTH: yellow-green cable).
All wiring must conform to current I.E.E. regulations.
19
MODENA 102
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.
Although this boiler can also be used without a room thermostat, you are recommended to install one for the
following reasons:
Greater comfort conditions due to more accurate control of room temperature.
Greater energy savings.
3.10 Differential air pressure switch (fig. 2 - part 43)
The differential air pressure switch is a safety device which allows the main burner to ignite only after having verified
that the fan is working correctly. If the difference in pressure between the flue gas discharge pipe and the air intake
pipe is not at least equal to the minimum pressure switch calibration value, the pressure switch contacts do not close
and the gas valve is thus prevented from opening.
In addition, the electrical circuit of the boiler is designed so that if for any reason the air pressure switch contacts
remain closed when the fan stops, the burner will not start up again.
3.11 Checks
Fill the central heating system as described previously (3.07) and check there are no leaks in the domestic hot water
and boiler water circuits. Check that there are no gas leaks on the boiler or the supply to the boiler. Also check that
the electrical connections are correct.
3.12 Installing a room thermostat (72) (fig. 21)
To connect the thermostat:
Open the electrical box on the base of the appliance and remove the “jumper cable” between terminals 4 and 5.
Connect the room thermostat (72) as shown in figure 21.
20
MODENA 102
3.13 Time clock fixing (optional)
-
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 the main circuit board.
Remove the connector link from the 2 wires located behind the clock position.
Connect these to terminal 3 and 5 of the clock.
Replace everything in reverse order.
Please refer to page 43 of this manual for setting timer.
Terminal 4 & 5 situated
underneath the boiler in the
terminals compartment
4
5
Existing wiring
X2
X6
X3
X1
10
9
8
7
6
5
4
3
2
Terminals for integral clock
situated inside circuit board
compartment
X4
1
2
1
2
1
3
1
13 12 11 10
9
8
7
6
5
4
3
2
1
JP03
X8
X11
X12
2
1
98 7654321
X10
1
2
1 2
3 5
X5
Nat/LPG
JP02
JP01
X7
CLOCK
MF03F
Fig. 20a
Wiring for integral clock and/or external controls
4
72
3
X2
External control
i.e. Room Stat/Clock
X3
X1
8
7
6
5
4
3
2
1
X4
2
1
2
1
3
1
13 12 11 10
9
8
7
6
5
4
3
2
1
JP03
X11
X12
2
1
98 7654321
X10
1 2
2
9
3 5
1
10
VOLTAGE
FREE
SWITCH
X5
Nat/LPG
JP02
JP01
MF03F
CLOCK
Fig. 20b
21
MODENA 102
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 system are open;
• that the central heating system is filled and vented;
• that there are no gas or water leaks from the central heating system or boiler;
• that the electric connections are correct and the earth wire of the boiler is connected to an efficient earthing
installation and a 3amp. fuse is fitted to the isolator;
• that there are no flammable liquids or materials near the boiler;
4.02 Starting up the boiler
•
•
•
•
•
Open the gas cock upstream of the boiler.
Vent air present in the pipe upstream of the gas valve.
Turn on the switch (if present) or plug in the boiler.
Rotate the switch (fig. 2 - part 98) into the ON position.
Check inlet working gas pressure, burner pressures and gas rate.
At this point, choose whether the boiler is to be used for central heating and domestic hot water production or for
domestic hot water production only. If the former is chosen (central heating and domestic hot water production), turn
the knob 63 (fig. 2) to the “Winter” position. Set the knob above 50°C and set the room thermostat (if fitted) to maximum.
The burner ignites and the boiler starts to function automatically, controlled by its control and safety devices.
If the latter is chosen (domestic hot water production only), position the knob 63 (fig. 2) on the “Summer” position. In
this mode the boiler is ready to operate automatically whenever domestic hot water is drawn off.
Note - If after completing the start-up procedure correctly, the burners fail to ignite and the boiler shut down warning
lights up, wait about 15 seconds then rotate the knob 98 (fig. 2) against spring pressure to the RESET position and
release it. The reset electronic control unit will repeat the start-up cycle.
Note - In central heating mode after resetting the boiler will go into it 2 minute delay before starting up again. If after
a second attempt the burners still fail to ignite, consult the paragraph “Troubleshooting”.
Note - If there is a power failure while the boiler is in operation, the burners automatically go out and re-ignite when
the power returns.
4.03 Shutting down
Close the boiler isolation gas cock and turn off the electricity to the boiler.
Important: If the boiler is not to be used for lengthy periods during the winter, to avoid frost damage, you are
recommended to drain the water from the circuits (domestic hot water and central heating). Alternatively, drain the
domestic hot water system only and add special anti-freeze to the central heating system.
4.04 Checks and controls after first start-up
•
•
•
•
•
Check there are no leaks in the gas and water circuits.
Check correct boiler start up by carrying out start up and shut down tests using the boiler stat.
Check the integrity of the air-flue pipes during boiler operation.
Check that the gas consumption indicated on the meter corresponds to that given in Technical Data (page 5).
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.
• Check that in the “Summer” mode, the burner lights up and shuts down correctly when the domestic hot water
tap is turned on and off.
22
MODENA 102
• 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.
• To determine combustion efficiency and the composition of the flue gases (refer to 6.04)
• If any of the above are not correct refer to Technical Data (page 5). Adjustment (page 23) and Troubleshooting
(page 32).
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.
Note - Because correct minimum and maximum pressures are critical to the efficient operation of the
boiler it is ESSENTIAL that the following adjustments are carried out by COMPETENT personnel ONLY.
5.02 Adjusting minimum and maximum pressure Honeywell V K4105G gas valve
-
Connect suitable pressure gauge to burner test point “B” downstream of the gas valve.
-
Disconnect the pressure compensation tube «F».
-
Remove the protective cap «C».
-
Adjust potentiometre P3 (on the main board) at minimum
(anticlockwise).
-
Operate boiler for central heating
-
Adjust minimum pressure by rotating screw «D» clockwise
to reduce pressure and anticlockwise to increase pressure.
-
If it is not possible to achieve the right pressure adjust minimum pressure by potentiometer P5
-
Adjust potentiometre P3 at maximum (clockwise)
-
Adjust max pressure by rotating screw «E», clockwise to
increase pressure and anticlockwise to reduce pressure.
-
Reconnect the pressure compensation tube «F».
-
Replace protective cap «C».
C
Maximum + Minimum possible gas pressures are now set.
Range Rating the central heating is not necessary because
for Central Heating the Auto Range Rating facility will set
the burner pressure to set the system unless the boiler thermostat is set to max, when the burner pressure will go to
max output.
Fig. 22
Legenda
Gas inlet test point
Gas outlet test point (burner pressure)
Protection cap
Min. pressure adjusting screw
Max. pressure adjusting screw
Balancing tube
F
OUT
=
=
=
=
=
=
IN
A
B
C
D
E
F
EB A D
23
MODENA 102
5.03 Adjustment
potentiometers
P1 =
P2 =
P3 =
P4 =
P5 =
-
+
-
+
P5
P4
C.H. temperature adjustment
D.H.W. temperature adjustment
C.H. output adjustment
Ignition gas pressure adjustment
Minimum gas pressur adjustment
P1
+ CH
-
Fig. 23
P2
+ DHW
-
-
+
P3
5.04 Adjusting maximum output for central heating system (fig. 23)
This adjustment must be carried out electronically using the “P3” adjustment screw starting with a cold central
heating system. Connect a pressure gauge to the pressure test point downstream of the gas valve. Rotate the
temperature adjustment screw to maximum then regulate the pressure to the value required, consulting the diagram
(figs. 4 and 5). Once this operation is complete, start up and shut down the burner two or three times using the
thermostat. Check each time that the pressure values remain as adjusted and that the burner ignites correctly.
Otherwise further adjustment is necessary until the pressure remains stable on this value.
N.B. - when carrying out this operation ensure that the boiler thermostat is set to maximum otherwise the
adjustment will not be accurate.
5.05 Adjusting central heating flow temperature
Central heating water temperature is adjusted by rotating the control knob (fig. 2 - part 63). Rotate the knob
clockwise to increase water temperature, anticlockwise to reduce water temperature. Temperature can be varied
from a minimum of 30°C to a maximum of 85°C. However, we recommend not operating the boiler below 50°C.
5.06 Adjusting room temperature (when a room thermostat is fitted)
Room temperature is controlled by positioning the room thermostat knob to the required value. The thermostat
automatically controls the boiler, temporarily interrupting the electrical supply subject to the room heat requirements.
5.07 Adjusting the central heating flow ∆t by varying pump flow-head
The thermal head ∆t (the difference in temperature between the delivery water and return water in the central
heating circuit) must be less than 20° c. This is obtained by varying pump flow rate and head using the multi-speed
variator (or switch) on the pump itself. Increasing the pump speed reduces ∆t and vice versa. The minimum
differential must not be less than 11°C.
5.08 Adjusting central heating system pressure
The pressure of water in the central heating system, read on the control panel pressure gauge, is adjusted as
described in paragraph 3.07.
N.B. - To avoid incurring unnecessary expense, in the event of boiler shut down, check that this is not caused by a
lack of electricity or gas, or low water pressure before calling the Customer Technical Service Helpline.
5.09 Gas conversion
The following adjustment and conversion operations must be carried out by competent personnel. FERROLI Limited
accepts no liability for damage to property or personal injury resulting from tampering with the boiler by
unauthorised persons. To convert the boiler from Nat Gas to LPG and vice versa, the main burner injectors must be
replaced. Minimum and maximum pressures must then be adjusted on the gas valve (see Adjustment page 23). JP02
must be moved to the LPG position.
Note: After converting the boiler from natural gas to liquid gas, fit the orange plate in the conversion kit near
the data plate.
Note: injector diameters and pressures at the main burner are given in Technical Data (page 5).
24
MODENA 102
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. To avoid damage, always clean them with a soft brush or compressed air. Never use chemical products.
• The expansion vessel must be checked (precharge 1 bar).
• Check there are no leaks in the gas and water circuits.
• Check the air-flue gas duct terminal is free from obstructions and sound.
• The electrodes must be free from corrosion build up and correctly positioned.
• Gas flow and pressure must correspond to the values given in the Technical Data (page 5).
• The pump must be free to rotate.
6.02 Cleaning the boiler and burner
The boiler should be serviced annually. The heat exchanger and burner must never be cleaned with chemical
products or steel brushes. Particular attention must be paid to all seals and fixings associated with the room-sealed
compartment (gaskets, grommets, etc). Air leakage would cause pressure inside the compartment to drop, possibly tripping the differential pressure switch and thus shutting down the boiler. After cleaning particular attention
should also be paid to checking stages of start-up and operation of the thermostats, gas valve and pump.
6.03 Servicing procedure
1.
2.
3.
4.
5.
6.
7.
8.
10.
11.
12.
13.
14.
15.
16.
Visually check boiler for correct intallation and flueing.
Isolate electricity supply + check fuse is 3amp.
Remove case by undoing the two screws locate at the bottom rear corners, lift slightly and pull forward.
Carry out preliminary electrical checks at boiler junction box. This is located in the centre of the boiler at the
bottom and can be accessed be the removal of a single screw. Any faults found must be rectified before
proceeding.
If electrical checks prove O.K. replace cover and secure with screw.
Attach a manometer to the boiler gas inlet test point, turn on electricty and fire boiler for hot water, check inlet
pressure. This should be 20mbar minimum for NG and 37mbar for LPG. If this is not the case there is a supply
problem and this will need to be remedied.
If inlet pressure is O.K. shut down boiler and remove manometer from gas inlet pressure test point and attach
it to the boiler burner pressure test point. Reseal inlet pressure test point.
Fire boiler for hot water and check that the maximum pressure is 13.0mbar for NG and 35.5mbar for LPG. Turn
off tap. Turn P3 on the main circuit board to minimum and fixe the boiler for heating, check that the burner
pressure reads 2.5 mbar for NG and 7.0mbar for LPG. Turn P3 back to max position. Shut down boiler, remove
manometer, seal test point and re-attach modureg lead. If the pressures are not as specified they will need to
be adjusted on the gas valve(see page 30 - installation manual).
Remove fan by undoing the two fan securing screws tilt the front of the fan upwards to detach it from the
securing pin and withdraw it from the boiler, disconnect the wires and air pressure switch tubes.
Take off the combustion chamber cover by removing the three securing screws.
Lift off flue hood and flue baffle plate.
Pull off the ignition and flame rectification leads from their respective electrodes.
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.
Remove two screws securing the burner assembly and remove the assembly. Clean burners.
Clean heat exchanger with a soft brush.
25
MODENA 102
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.
Check flame picture and all controls for correct operation.
Check room sealed cover for leakage.
Check domestic water flow rate and temperature is within specifications.
Check operation of all safety cut off devices.
If a combustion analyser is to be used there are test points provided on the front of the room sealed cover. The
right hand grommet is for air and the left hand one is for flue gas. The boiler must reach operating temperature before this test is carried out (normally 10-15 minutes). CO/CO2 ratio should not exceed 0.0080. Immediatly
after servicing (0.0040 at any other time)
30. Refit case and secure with screws.
31. Leave boiler set to customers requirements.
6.04 Flue Gas Analysis
1.
The appliance should be checked visually for obvious
defects.
2. After removing the jacket on the boiler there are two
test point, one for flue gas and the other for air.
3. Open the air and flue gas test points;
4. Introduce the probes as far as the retainer;
5. Turn on the hot water tap;
6. Turn the domestic hot water stat to maximum;
7. Allow the boiler to reach thermal equilibrium (10 - 15
min.);
8. Take reading;
9. The CO/CO2 ratio should be 0.0040 or below. If the
reading is above this then a full strip down service
must be carried out and the cause remedied.
10. Following a full strip down service and after reaching
thermal equilibrium the permissible reading is 0.008
or below.
FLUE
AIR
N.B.: To ensure correct readings the boiler must have
reached normal operating temperature. Testing the
boiler before thermal equilibrium has been attained
will give incorrect readings.
Fig. 24
26
MODENA 102
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. 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. flow and return cocks are turned off at the isolation cocks. The C.H. is drained via the pressure relief
valve (twist about 1/3 of a turn).
c) Remove components following special notice below and replace in reverse order.
d) Ensure water and gas washers are in good condition.
7.02 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.
7.03 To lower the control panel (fig. 25)
• Remove the two fixing screw (fig. 25) "A"
• Rotate down the front panel "B"
B
A
Fig. 25
7.04 Remove and re-presurising
of C.H. expansion vessel (fig. 26)
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
Remove "B" screws and metal flange "C"
Remove the expansion vessel from the top of the boiler
Re-assemble in reverse order
Re-pressure expansion vessel
(charge pressure 0,8-1 bar) through the valve "C"
• Ensure pressure relief value is open
(twist about 1/3 of a turn) when repressurizing
B
C
•
•
•
•
•
•
•
•
A
Fig. 26
27
MODENA 102
7.05 Gas valve (fig. 27)
• Isolate gas and electricity supplies
• Remove outer case (two screws bottom rear corners)
• Remove the two securing screws
and lower control panel
• Disconnect electrical connections
from valve ("A")
• Disconnect plastic tube "C"
• Loosen the connection "D" on gas pipe and the gas
inlet connection of the boiler "E"
• Remove the two fixing screw "E" below gas valve
• Slide out gas valve
• Remove four fixing screw "F" on top of
the valve and disconnect the gas pipe
• Remove bottom connection from gas valve.
• Fit top + bottom gas connections to the
new gas valve and replace in reverse order
F
D
C
A
E
Fig. 27
7.06 Air pressure switch (fig. 28)
•
•
•
•
•
•
•
A
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"
Remove pressure sensing tubes (white=D; Red=C)
Note relevant positions of all connections and
replace in reverse order.
B
7.07 D.H.W. temperature sensor or Central Heating Temperature Sensor
(fig. 29)
• Isolate electricity and water supplies
• Remove outer case (two screws bottom rear corners)
• Remove the two securing screws and lower control panel
• Identify the sensor from figure 29
• Disconnect electrical connection to the sensor
• Drain the affected service either D.H.W. or C.H.
• Unscrew the sensor
• Replace in reverse order
7.11 Water Pressure Switch (fig. 29)
• Isolate electricity and water supplies
• Remove outer case (two screws bottom rear corners)
• Remove the two securing screws and lower control panel
• Identify the switch from figure 39
• Disconnect electrical connections + note positions to the switch
• Drain the boiler
• Unscrew the sensor
• Replace in reverse order
7.12 Safety Valve (fig. 29)
• 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. 29
• 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
28
C
D
Fig. 28
Water pressure switch
C.H. sensor
Safety valve
D.H.W. sensor
Fig. 29
MODENA 102
7.08 Removal of burner (fig. 30)
D
D
C
• 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. 30)
B
• Proceed as 7.08
• Remove fixing screw "C" on both
sides of gas manifold
• Remove gas manifold
• Unscrew and remove injectors;
• Clear or change injectors
Fig. 30
7.10 Removal of fan (fig. 31)
• 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 Overheat cut off
switch "B" + note positions
thermostat
• Undo two screws securing fan assembly "C"
• Remove fan from boiler
• Swap mounting plate over to new fan + replace in
reverse order
C
Limit thermostat
A
7.11 Limit thermostat, or overheat
cut off thermostat (fig. 31)
•
•
•
•
•
•
•
•
Isolate electricity
Remove outer case (two screws bottom rear corners)
Remove room sealed cover
Identify the location of thermostat from fig. 31
Pull out thermostat from tube, with its spring
Remove electrical connections from thermostat
Remove spring from thermostat
Replace in reverse order
Fig. 31
B
29
MODENA 102
7.12 Spark or flame detection electrode
(fig. 32)
• Isolate gas and electricity supply
• Remove outer case (two screws bottom rear
corners)
• Open room sealed compartment and
combustion chamber
• Identify electrode from fig. 32
• Unplug electrical connection "A" from sensing
electrode
• Remove fixing screw and remove flame
detection electrode
• Remove the two fixing screw from spark
electrode plate and remove it.
Flame
detect
Spark
A
Fig. 32
7.13 D.H.W. flowmeter
• Isolate electricity and water supplies
• Open a hot water tap to release water
pressure from the domestic side of the heat
exchanger, close tap.
• Remove outer case (two screws bottom rear
corners).
• Remove two screws from control panel and tilt
forward
• Take off protective cover from main PCB and
unplug flow meter lead from terminal X6
• Place a piece of cloth or some other
absorbent material over rear of control panel to
catch any drops of water that may be released
when removing the flow meter
• Using a 24mm open ended spanner, undo flow
meter unions "A" and "B" taking care not to
twist the copper tubing (access through base
panel).
• Remove flow meter, check + clean filter +
restrictor + fit to new flow meter.
• Reassemble in reverse order.
A
B
Take care on correct position of
components as reported in fig. 44b
Key
37
38
39
30
Cold water inlet filter
Gasket
Cold water flow limiter
37
38
39
38
Fig. 33b
Fig. 33a
MODENA 102
7.14 Pump (fig. 34)
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.
• Using a 4mm allen wrench undo the four allen screws
"B" 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.
• Replace electrical connection.
F
E
B
Replacement of pump body (fig. 34)
• Proceed as for removal of pump head
A
• Disconnect the expansion vessel connecting pipe "E"
from the rear of the pump body by removing the U clip
from the left hand side
• Disconnect the boiler return pipe and disengage the
pump lower connection by removing the U clip "C"
• Disconnect the pump to heat exchanger connection by
removing the U clip "F"
• Unscrew the two screws on bottom of pump "D"
• Turn the pump body through 90°, pull the bottom
forward and withdraw the pump body
• Reassemble in reverse order taking care to ensure the
O-rings are in place and undamaged.
C
D
Fig. 34
7.15 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 heat exchanger for both CH + DHW
Remove sealed compartment front panel
Disconnect the overheat thermostat and central heating limit thermostat
Remove the main burner, fan, flue hood and flow meter as described previously
Remove the pump to heat exchanger flow connection and locknut
Undo the domestic water outlet connection and locknut
Lift out heat exchanger
Re-assemble in reverse order
31
MODENA 102
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 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. are as follows:
Central Heating Mode
External Call for Heat: The temperature regulator, built in or remote clock and room thermostat, if fitted, must all
call for heat. This will cause the pump to run.
Internal Call for Heat: C.H. flow temperature sensor, 88°C high limit and low water pressure switch all calling for
heat. If both external and internal calls for heat are present the MF03 PCB will energise.
In demand the fan will go to high speed causing the air pressure switch to operate. If the overheat (100°C) stat is
closed circuit the ignition will operate and the gas valve will be energised.
The burner will light at ignition burner pressure, automatically range rating itself up to the heating load, then
modulating down when the boiler reaches the desired flow temperature. When the central heating is satisfied the
burner will go off and the fan stops i.e. stand-by mode.
Note - If the boiler thermostat is set to maximum than the burner pressure will go to maximum effectively bypassing
the auto range rating facility
Domestic Hot Water Mode
External Call for D.H.W: Flow meter registers at least 2.5 litres/min flow to the hot water taps.
Internal Call for D.H.W: Hot water flow temperature sensor 88°C high limit stat and low water pressure switch calling
for heat.
If both internal and external calls are present the boiler follows the same sequence as for C.H. to light the burner.
However, for D.H.W. the burner will go straight to maximum and then modulate once the water reaches the set
temperature of the control thermostat. Turning the tap off will return the boiler to stand-by mode.
Note: Following shut down of the D.H.W. or C.H. the boiler will go into a three minute central heating delay.
8.02 Limit thermostats
T/Stat
Location
Function
Nominal
Operating
Temperature
Circuit
Wiring
Colours
C.H. Limit
Top RHS
of Heat
Exchanger
Shuts downmain
burner if boiler
thermostat fails
88°C
Low voltage
DC
Blue
Brown
Frost
Incorporated
in C.H.
Sensor
Fires the boiler
and runs pump to
maintain minimum
water temperature
7°C - 14°C
Low voltage
DC
Red
Red
Overheat
Top LHS
of Heat
Exchanger
Protect boiler by
stopping ignition
and cuts power
to gas valve
100°C
240V AC
Brown
Blue
The MFO3 PCB has fivediagnostic lights, each light corresponds to a particular function and will light in turn as the
boiler goes though its sequence of operations.
32
MODENA 102
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. A correctly installed flue system and
a 3 amp fuse.
8.03 MF03 PCB
When operating the C.H. the following lights should be on: 4, 5 and flame on light. For D.H.W. the following lights
should be on: 3, 5 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.
Boiler will not light for D.H.W.
If boiler works for C.H. but not for D.H.W. the fault is most likely to be the flow meter or D.H.W. sensor.
If the tap symbol light is on the fault is the D.H.W. sensor. If this light is not on then suspect the flow meter has not
operated.
Boiler will not light for C.H.
If the boiler works for D.H.W. but not for heating the fault is most likely to be external controls (i.e. clocks or room
thermostats). Integral clock if fitted or C.H. sensor.
If the heating demand light is on the fault is most likely the C.H. sensor. If this light is not on suspect either a clock
or room thermostat not calling.
To override/eliminate any external controls disconnect them from terminal 3 and 4 underneath the boiler and refit
the link wire (see fig. 21b).
Boiler will not light for D.H.W. or C.H.
The fault is likely to be a component common to both services. Open a hot tap to create a demand - is there a spark
at the ignition electrode?
Yes
Suspect gas supply, pressure or gas valve.
No
Is fan running?
Yes
Suspect air pressure switch or overheat stat (if boiler locks out without sparking go to overheat stat)
No
Is low water pressure light Flashing?
Yes
Top up water to above 1 bar. Does the light go out? (if water pressure o/k suspect high limit stat)
Yes
Does fan start?
Yes
Does boiler light?
Yes
Is hot water OK?
Try heating, if heating does not work follow guide for heating faults. Does low water pressure light
go out?
No
Suspect low water pressure switch.
If boiler still does not fire see comprehensive fault finding chart.
33
MODENA 102
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.
8.05 Limit thermostats
Two surface mounted auto reset bi-metal thermostats are located on the heat exchanger secured by spring clips.
Heat sink compound is used.
8.06 Ignition PCB
Located to the right hand side of the electrical control compartment accessed by lowering the facia then removing
the rear cover.
8.07 Main printed circuit board
Secured by flour plastic tabs the PCB is situated inside the control compartment. The transformer for low voltage
AC is attached to the PCB as is the DC rectifier. Potentiometers control C.H. output and maximum D.H.W.
temperature, both are adjustable by the controls on the facia and because the boiler features automatic range rating
no adjustments need to be made. Electro mechanical relays control pump operation and put switched live to the
ignition PCB (demand relay), they have transparent plastic covers so that their contacts can be seen moving.
8.08 Air pressure switch
Operating at 230 V AC and situated next to the fan. Different coloured tubes connect the switch to the fan. It is a
make on pressure switch and only uses two terminals, the middle terminal is not used.
8.09 Short spares list
KEY NO.
(from fig 2 )
DESCRIPTION
PART NO.
G.C. NO.
14
Safety Valve
800130
386-816
16
Fan
800480
E23-851
34
Central Heating Flow Temperature Sensor
800320
E23-839
39
Cold water flow limiter
42
Domestic Hot Water Flow Temperature
Sensor
800320
E23-839
43
Air Pressure Switch
800150
E23-840
44
Honeywell Gas Valve
800266
E23-768
49
Overheat Safety Thermostat 100°C
801270
386-815
50
High Limit Thermostat 88°C
800160
386-577
81
Ignition Electrode °/N fixing Bracket
806460
82
Flame Sensing Electrode
801438
E23-855
136
Flow Meter
803430
E03-340
802180
E23-919
Main PCB MF03
27
34
Heat Exchanger
MODENA 102
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. taps closed
CH Selector to
Summer “ ” position
Put main switch to on
Is LED5 on?
NO
YES
YES
Water pressure
is not set
between
1 - 1,5 bar?
NO
Check and if necessary
replace 2A fuse
NO
Is LED5 ON now?
Set pressure to
1 - 1,5 bar
Check water
pressure
switch wiring
connection
YES
Does fan run at full speed?
YES
NO
YES
Is LED5 flashing?
YES
Is 230V present across
terminals X1-1 X1-2?
Repair external
wiring fault
NO
Replace
main board
NO
Go to CHART 2
Does CH Pump run? NO
Check and if
necessary
replace water
pressure switch
YES
If the boiler temperature
is less than 5°C
frost protection is activated
Disconnect
CH flowtemp sensor
YES
Has fan speed stopped?
NO
Change main board
35
MODENA 102
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 closed
Does pump run?
NO
YES
Put CH temperature selector
to maximum
Go to chart 4
NO
YES
Check and if
necessary replace
main board
YES
Check and if is necessary
replace CH sensor
36
NO
YES
Wait 2 minutes
Is LED4 flashing?
Is relay RY100
switch on
Go to chart 4
NO
YES
NO
Ensure external controls
are calling for heat
Is LED4 flashing?
Is relay RY101
switch on
Check
limit thermostat
Check and if
necessary
replace pump
MODENA 102
Chart 4
Check fan/flue gas system
Does fan run?
NO
YES
Is relay RY100 switch ON?
NO
Is air pressure switch
activated?
YES
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 correct
and clean
NO
Check Venturi and
air pressure switch
tubes are clean
Check and if
necessary replace
air pressure switch
Check restrictor
is correct
Chart 5
Check D.H.W. and C.H. modulation
YES
Normal operation
carry out
Boiler operated
on central heating mode
Boiler operated
on DHW mode
Does burner
flame modulate?
Does burner
flame modulate?
NO
NO
Check wiring connection
to CH sensor
Check wiring connection
to DHW sensor
Check CH sensor
and replace it if necessary
Check DHW sensor
and replace it if necessary
YES
Normal operation
carry out
37
MODENA 102
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.
NO
Is flame present before
lockout condition?
NO
YES
Adjust with P4 ignition
burner pressure
Check and if necessary
clean burner
Check and if necessary
clean injectors
Check and if necessary
clean flame electrode
Check right position
of spark electrode
Check wires
38
Re-check
air pressure switch
Check and if necessary
replace safety thermostat
Is LED2 on
after 10 seconds?
Does burner light now?
NO
Check gas supply
is live and purged
Check and if necessary
replace gas valve
MODENA 102
9. ELECTRICAL AND FUNCTIONAL SCHEME
9.01 Main components layout on electronic boards
Potentiometer adjustment
P1
P2
P3
P4
P5
= Central heating flow temperature adjustment
= Domestic hot water temperature adjustment
= Central heating flow output adjustment
= Ignition gas pressure adjustment
= Minimum adjustment pressure
FAN
PC
PNO
L
N
HL
HL
10
9
8
7
6
5
X1
MV1 MV2 MV3 MV4
N
L
2
1
X2
X3
X4
13 12 11
5
4
X6
4
3
2
1
-
+
-
+
2
1
3
1
10
9
8
7
6
3
2
1
JP03
P5
P4
X8
P1
+ CH
-
P2
+ DHW
-
RY101
X11
X12
2
1
98 7654321
L1
L2
L3
+
P3
L4
1
RY100
X5
2
X10
L5
Nat/LPG
Transformer
X7
JP02
JP01
MF03F
Fig. 35
JP01 ON = Delay between shutdown and re-ignition disabled
JP01 OFF = Delay between shutdown and re-ignition enabled
JP02:
Temp.
sensor
NTC
(34) (42)
temp.
10 °C
25 °C
60 °C
80 °C
Ohm
20
10
2,5
1,25
kOhm
kOhm
kOhm
kOhm
Jumper on for natural gas
Jumper on for LPG
JP03 ON = Max temperature D.H.W. 62°C
JP03 OFF= Max temperature D.H.W. 55°C (standard)
39
16
32
34
42
43
44
49
50
62
72
82
Y/G
Y/G
BL
BL
X7
X8
9
BR
8
7
Blue
BR
10
BR
6
5
MV1
W
81
82
98
114
136
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
Ignition electrode
Sensor electrode
Off/On/Reset switch
Low water pressure switch
Flow meter
MF03F
1
MV2
O
2
MV3
V
3
MV4
R
4
X1
32
Blue
R
R
13 12 11 10
Blue
Brown
Blue
Black
White
Orange
Green
Red
Violet
X4
O
6
-
G
5
4
+
3
2
BL
1
JP03
X5
62
3 2
M 1
IMPORTANT
TEST
5
3
4
72
9.02 General wiring diagram
USE A ROOM THERMOSTAT (24 V)
WITHOUT VOLTAGE TO THE CONTACTS.
CONNECTING 230 V TO THE ROOM
THERMOSTAT TERMINALS WILL
IRREPARABLY DAMAGE THE
ELECTRONIC BOARD.
JP02
JP01
7
Blue
Nat/LPG
8
O
X11
9
BR
34 42 114 50 136
BL
44
W
49
Blue
Fan
Central heating pump
Central heating flow temperature sensor
Domestic hot water flow temperature sensor
Air pressure switch
Gas valve
Safety thermostat
Central heating limit thermostat
Time clock (option)
Room thermostat
Fig. 36
Key
81
X6
16
Blue
43
BL
2
40
1
230V
50Hz
MODENA 102
MODENA 102
10. USER INSTRUCTIONS
2
3
4
1
5
0
A
1
2
3
B
4
C
5
LED
1
Burner on indicator
2
Boiler shut down warning
3
Domestic hot water circuit on
4
5
bar
Central heating stand-by (Flashing light)
Central heating circuit on (Permanent light)
Insufficient pressure in central heating system (Flashing light)
Electric power supply (Permanent light)
E
6
Fig. 37
D
KEY DESCRIPTION
A
Switch OFF/ON/RESET
B
Central heating flow
temperature regulation
C
D.H.W. temperature
regulation
D
Water pressure gauge
E
Time clock (option)
The boiler is designed for use with two types of gas: natural gas NG or propane (LPG). The type of gas can be selected
when purchasing the boiler or the appliance can be converted later on site by a competent person. It operates with
technologically advanced systems such as electronic control, safety and control devices.
The boiler is fitted with automatic electronic ignition so there is no pilot to worry about.
Pull down cover to reveal control facia panel.
Make sure that the gas, water and electricity supplies to the boiler are turned on.
The boiler pressure gauge (D) should read at least 1 bar.
Low pressure will be indicated by flashing light in the middle of the facia illuminating (
Hot Water Only - “SUMMER” (
bar
).
)
To obtain hot water only from the boiler, turn switch (A) to the on position. The top green light on the left side of
the control panel is illuminated (power on
).
Turn the temperature regulator (B) to the
position. Open a hot water tap, green light (tap symbol) comes on,
fan starts and burner will light. Indicated by flame symbol, green light coming on. The temperature of the hot water
can be adjusted by turning the hot water thermostat (B) clockwise to increase and anti-clockwise to decrease the
water temperature.
Heating and Hot Water - "WINTER” (
)
To obtain heating from the boiler, turn the temperature regulator (B) clockwise to the maximum position, ensure that
any other heating controls e.g. room thermostats, clock etc. are in the on position.
The boiler may be in heating delay of three minutes as indicated by the red light (egg timer symbol) on the left of
the facia panel. When this light goes out the green light (radiator symbol) will come on. The fan and pump will run
and the burner will light indicated by the green flame symbol light. Adjust the temperature regulator to the desired
setting. (In winter do not run boiler below 50°C). If a hot water tap is opened whilst the boiler is running for heating
the pump will stop, suspending the heating phase and the boiler will give priority to hot water production. When
the tap is closed the boiler will go into a three minute delay cycle before resuming for heating.
41
MODENA 102
Boiler lock out
In the event of the red lockout light ( ) coming on, the on/off/reset switch (A) 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. clocks or room thermostats
turned off). This is due to the central heating sensor going into frost protection mode. Once the boiler has reached
14°C or more it will close down until either the temperature again falls below 7°C or the clock or room thermostat
is turned on.
For this reason we recommend that the electricity to the boiler is left turned on. If you wish to turn off the electricity
to the boiler in winter you should drain completely the heating and hot water circuits.
Cleaning
The casing requires no special cleaning, a wipe with a soft duster or damp cloth will suffice.
Maintenance
Férroli recommend that the appliance is serviced at least once every twelve months by a competent engineer.
Gas Supply
It is the law that all gas appliances are installed and serviced by a competent person in accordance with the Gas Safety
Regulations (Installation & Use) 1996, and the manufacturers instructions. Failure to observe these requirements may
lead to prosecution.
Electrical Supply
WARNING - This appliance must be earthed.
The electrical wiring must be carried out by a competent electrician.
The colours of the wires in the mains lead of this appliance may not correspond with the coloured markings identifying
the terminal in the plug. Therefore, proceed as follows:
The wire coloured green and yellow must be connected to the terminal in the plug marked with either the letter E
or by the earth symbol or coloured green or green and yellow. The wire coloured blue must be connected to the
terminal marked either with the letter N or coloured black. The wire coloured brown must be connected to the
terminal marked either with the letter L or coloured red.
MINIMUM CLEARANCE
The minimum clearance around the appliance should be as follows:
Sides
Front
Below
Above
42
5mm
600mm
200mm
100mm
MODENA 102
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
OVER RIDE
E
R
P
D R
Slide switch: set clock - auto - set programme
Display. Symbol
in Display = Timer ON
Select programme ON/OFF 1.....8
Push buttons Time + Time Override: Boiler will switch ON if boiler is OFF; and OFF if is ON
I=Heating continuous - AUTO=Heating timed - O=Heating disabled
Reset (with pencil) only with switch A in set clock position
To set time of day
1.
Slide switch (A) to left position
2.
Using button + and - adjust until the correct time is shown on display (B).
Pre Set Programmes. The timer is pre programmed with 3 ON and 3 OFF times.
If these are suitable no programming is required and the slide switch (A) can be moved to the
6:30 - 8:30
12:00 - 12:00 Auto position and the central heating will be ON for these periods.
16:30 : 22:30 (12:00 - 12:00 will not switch on the boiler)
To Set Own ON and OFF times. Symbol
in Display = ON time
1. Slide switch (A) to right position (P)
Display
6:30
1
2. Press button (P)
Display
8:30
2
12:00
3
12:00
4
Display
9:00
2
Display
12:30
3
Display
14:00
4
5.1 Use button + and - to set 3rd ON time, eg. 16:00
16:30
Display
5
6. Press button (P)
Display
1
4.1 Use button + and - to set 2nd OFF time eg. 14:00
5. Press button (P)
Display
6:00
3.1 Use button + and - to set 2nd ON time, eg. 12:30
4. Press button (P)
Display
Display
2.1 Use buttons + and - to set OFF time, eg. 9:00
3. Press button (P)
Display
1.1 Use buttons + and - to set 1st ON time eg. 6:00
16:00
5
6.1 Use button + and - to set 3rd OFF time eg. 23:30
22:30
6
7. The timer can be programmed with up to 8 ON and
8 OFF times by repeating the above procedure.
Display
23:30
6
8. On completion of programming slide switch (A) to Auto position, the time of day will be displayed and the central heating will switch ON and OFF according to the programme set.
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. When the programme is on over ride the sign x will be shown in the display window (B).
Reset Button
By the use of a pencil the reset button can be pushed (R). This will clear all programmes apart from those factory pre set.
Reset is only possible with switch (A) in set Clock position!
43
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"
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.
"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 the installer's CORGI registration by
calling CORGI on 01256 372300".
Should you require help with any difficulties
call our Technical Service Helpline on
0121 352 3200
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.
Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH
Tel: 0121 352 3200 Fax: 0121 352 3210
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