Energy Top W80 – W125 manual
Contents
1. fig 21 ENERGY TOP W 70 W 80 W 125 3 4 Gas connection Before carrying out the connection make sure the unit is arranged for operation with the type of fuel available and carefully clean all the pipes of the gas system to remove any residues that could affect proper boiler operation The gas must be connected to the relevant connection see fig 38 in conformity with the current standards with a rigid metal pipe or with a continuous surface flexible s steel tube installing a gas cock between the system and boiler Make sure all the gas connec tions are tight The gas meter capacity must be suitable for the simultaneous use of all the units connected to it The diameter of the gas pipe leaving the boiler does not deter mine the diameter of the pipe between the unit and the meter it must be chosen accord ing to its length and pressure losses in conformity with the current standards A 3 5 Electrical connections Do not use the gas pipes to earth electrical appliances In case of connection in cascade make sure to install a fuel shutoff valve ex ternally with respect to the modules Connection to the electrical grid The unit s electrical safety is only guaranteed when correctly connected to an efficient earthing system execute2. Fault Fault Possible cause Cure CHECK THE BOILER SHELL AND CLEAN IT IF NECESSARY PXCHANGER SAFETY THER Check the thermostat and replace MOSTAT ACTIVATED lt P it if necessary Check the thermostat wiring Check the regular gas flow to the boiler No gas and that the air has been eliminated from A01 No burner ignition the pipes Check the wiring of the electrode and that Ignition detection electrode fault lit is correctly positioned and free of any deposits Check the gas valve and replace Faulty gas valve Pe it if necessary Insufficient gas supply pressure Check the gas supply pressure Trap blocked Check the trap and clean it if necessary A02 Flame present signal with Electrode fault Check the ionisation electrode wiring burner off Card fault Check the card Heati Check the correct positioning and eating sensor damaged tion of the heati m Overtemperature protec operation of the heating sensor tion activated No water circulation in the system Check the circulating pump Air in the system Vent the system A04 Fume extraction duct Fault F07 generated 3 times in See fault F07 safety device activated the last 24 hours 05 Fan protection activated Fau F15 generated for 1 hour See fault F15 consecutive lonisation electrode fault Check the position of the ionisation el
3. 92 42 EC 2006 95 2004 108 Dante Feoli Ferroli FERROLI S p A Via Ritonda 78 a 37047 San Bonifacio Verona ITALY www ferroli it
4. PkoloLobokolololollc CORO 8 8 16 47 18 19 20 21 122123 124 125126127 28 29 30 31 32 33 13485 OJN BBM 299 aj 138 298 72B 155 256 DSP12C fig 42 Wiring diagram cod 3540 807 Rev 00 12 2013 EN 59 Dichiarazione di conformit II costruttore FERROLI S p A Indirizzo Via Ritonda 78 a 37047 San Bonifacio VR dichiara che questo apparecchio conforme alle seguenti direttive CEE Direttiva Apparecchi a Gas 2009 142 Direttiva Rendimenti 92 42 Direttiva Bassa Tensione 2006 95 Direttiva Compatibilit Elettromagnetica 2004 108 Presidente e Legale rappresentante Cav del Lavoro Dante Declaraci n de conformidad El fabricante FERROLI S p A Direcci n Via Ritonda 78 a 37047 San Bonifacio Verona declara que este equipo satisface las siguientes directivas CEE Directiva de Aparatos de Gas 2009 142 Directiva de Rendimientos 92 42 Directiva de Baja Tensi n 2006 95 Directiva de Compatibilidad Electromagn tica 2004 108 Presidente y representante legal Caballero del Trabajo Dante Fegoli Uygunluk beyani FERR
5. Ogg Bag PIN CE 0461BS0879 EN gt cod 35408807 Rev 00 12 2013 ferroli ENERGY TOP W 70 W 80 W 125 5 5 Diagrams A Pressure losses model ENERGY TOP W 70 W 80 B Pressure losses model ENERGY TOP W 125 Diagram of pressure losses boiler shell only H m 9 8 7 6 5 4 4 B 2 1 A 0 0 1 2 3 4 5 6 Q m h Head and pressure losses with Kit code 042021X0 3 SPEED Circulating Pump Kit H m 9 8 T B 5 4 A 3 2 1 0 0 1 2 3 4 5 6 Q m3 h Head and pressure losses with Kit code 042047X0 3 SPEED HIGH HEAD Circulating Pump Kit H m 10 9 8 B 6 5 A 3 2 1 0 0 1 2 3 4 5 6 Q m3 h Head and pressure losses with Kit code 042043X0 MODULATING Circulating Pump Kit H m 8 7 4 5 4 3 2 1 0 0 1 2 3 4 5 6 Q m3 h 58 EN cod 35405807 Rev 00 12 2013 ENERGY TOP W 70 W 80 W 125 Ferroli 5 6 Wiring diagram 130 307 i
6. Ferroli ENERGY W 70 W 80 W 125 C ISTRUZIONE PER L USO L INSTALLAZIONE E LA MANUTENZIONE ES INSTRUCCIONES DE USO INSTALACI N Y MANTENIMIENTO TR KULLANMA KURULUM VE TALIMATLARI EN INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE FR INSTRUCTIONS D UTILISATION D INSTALLATION ET D ENTRETIEN RO INSTRUCTIUNI DE UTILIZARE INSTALARE SI INTRETINERE RU UA 3 TA cod 35405807 Rev 00 12 2013 Ferroli EN 1 GENERAL WARNINGS Carefully read and follow the instructions contained in this instruction booklet After boiler installation inform the user regarding its operation and give him this manual which is an integral and essential part of the product and must be kept with care for future reference Installation and maintenance must be carried out by professionally qualified person nel in compliance with the current regulations and according to the manufacturer s instructions Do not carry out any operation on the sealed control parts ncorrect installation or inadequate maintenance can result in damage or injury Manufacturer declines any liability for damage due to errors in installation and use or failure to follow the instructions Before carrying out any cleaning or ma
7. To make the measurement it is necessary to 1 Open the air and fume sampling points 2 Insert the probes 3 Press the and buttons for 5 seconds to activate the TEST mode 4 Wait 10 minutes for the boiler to stabilise 5 Take the measurement For natural gas the CO reading must be between 8 7 and 9 For LPG the CO reading must be between 9 5 and 10 gt gt Analyses made with an unstabilised boiler can cause measurement errors 2 e e fig 37 Combustion analysis 4 4 Troubleshooting Diagnostics The boiler is equipped with an advanced self diagnosis system In case of a boiler fault the display will flash together with the fault symbol detail 20 fig 1 indicating the fault code There are faults that cause permanent shutdown marked with the letter A to restore operation just press the RESET button detail 8 fig 1 for 1 second or RESET on the optional remote timer control if installed if the boiler fails to start it is necessary to firstly eliminate the fault Other faults marked with the letter F cause temporary shutdowns that are automatically reset as soon as the value returns within the boiler s normal working range except for fault F37 which is reset by turning the unit off and then on again with button 14 of fig 1 i ET cod 3540 807 Rev 00 12 2013 ENERGY W 70 W 80 W 125 Table of faults Table 5 List of faults
8. detail 7 fig 1 again 2 3 Lighting and turning off Boiler lighting Press the On Off button detail 14 fig 1 fig 4 Boiler lighting Forthe following 120 seconds the display will show FH which identifies the heating system air venting cycle During the first 10 seconds the display will also show the card software release A Display card software release B Controller software release e the gas cock ahead of the boiler When the message FH disappears the boiler is ready to operate automatically in case of a room thermostat demand dp ETI cod 3540 807 Rev 00 12 2013 ENERGY TOP W 70 W 80 Turning the boiler off Press the button eco comfort detail 7 fig 1 for 5 seconds el E fig 5 Turning the boiler off When the boiler is turned off the PCB is still powered Domestic hot water with optional hot water tank installed and heating operation are dis abled The antifreeze system remains activated To relight the boiler press the button eco comfort detail 7 fig 1 again for 5 seconds fig 6 The boiler will be immediately ready to operate whenever domestic hot water is drawn with optional hot water tank installed or in case of a room thermostat demand To completely disconnect the power to the unit press the button detail 14 fig 1 The antifreeze system does not work when the power and or gas to the unit are turned o
9. details 1 and 2 fig 1 together for 10 seconds The boiler will return to standby mode 10 Apply the label contained in the conversion kit near the dataplate 11 Using a combustion analyser connected to the boiler fume outlet make sure the CO content in the fumes with the boiler operating at max and min output com plies with that given in the technical data table for the corresponding type of gas TEST mode activation Press the heating buttons details 3 and 4 fig 1 together for 5 seconds to activate TESTmode The boiler lights at the maximum heating power Range Rated set as de scribed in the following section The heating symbol detail 13 fig 1 and DHW symbol detail 9 fig 1 flash the heat ing power will appear alongside a RANGE RATED Z fig 34 TEST mode heating power 100 To deactivate Test mode repeat the activation sequence The TEST mode is automatically disabled in any case after 15 minutes Heating Capacity Adjustment RANGE RATED This is RANGE RATED boiler according to EN 483 and can be adjusted to the system s thermal requirement by setting the maximum heating capacity for operation in heating mode as follows Putthe boiler in TEST mode see sec 4 1 Press the heating buttons details 3 and 4 fig 1 to increase or decrease the power min 00 max 100 See the diagram Heating Capacity Adjustment fig 35 Press the reset b
10. 125 3 2 Place of installation The combustion circuit is sealed with respect to the place of installation and therefore the unit can be installed in any room However the place of installation must be sufficiently ventilated to prevent the creation of any dangerous conditions in case of even small gas leaks This safety precaution is required by EEC Directive no 90 396 for all gas fired units including those with a so called sealed chamber The unit can also work with air drawn from the installation room B type In this case the room must be provided with adequate ventilation according to current regulations Therefore the place of installation must be free of dust flammable materials or objects or corrosive gases The room must be dry and not subject to freezing The boiler is arranged for wall installation Wall fixing must ensure a stable and effective support for the generator If the unit is enclosed in a cabinet or mounted alongside a space must be pro vided for removing the casing and for normal maintenance operations 3 3 Plumbing connections The heating capacity of the unit must be previously established by calculating the build ing s heat requirement according to the current regulations The system must be provid ed with all the components for correct and regular operation In particular provide for all the protection and safety devices required by the current regulations for the complete modular generator They must b
11. 5 123 Min Heat Output in heating 50 30 kW 18 3 18 3 26 9 P Efficiency Pmax 80 60 98 98 98 Efficiency Pmin 80 60 98 5 98 5 98 5 Efficiency Pmax 50 30 106 106 106 Efficiency Pmin 50 30 107 5 107 5 107 5 196 Efficiency 30 109 109 109 Gas baffle G20 ol 8 50 8 50 94 154 38 Gas supply pressure G20 mbar 20 20 20 CO max G20 9 9 9 193 186 CO min 620 85 85 85 Max gas delivery G20 mh 6 97 7 94 12 38 114 Min gas delivery G20 mh 18 18 2 65 Gas baffle G31 oj 5 8 5 8 70 Gas supply pressure G31 mbar 37 37 37 CO max G31 10 10 10 fig 41 Water circuit CO min G31 9 2 9 2 92 Max gas delivery G31 kg h 5 16 5 87 9 08 Min gas delivery G31 kg h 1 33 1 33 1 96 Efficiency class Directive 92 42 EEC NOx emission class 5 5 5 NOx Max fume temperature 80 C 60 65 65 65 Min fume temperature 80 C 60 C 60 60 60 Max fume temperature 50 C 30 C C 43 43 45 Min fume temperature 50 C 30 C C 33 33 34 Max fume flowrate kg h 127 5 127 5 197 Min fume flowrate kg h 31 4 31 4 44 7 working pressure in heating bar 6 6 6 PMS Min working pressure in heating bar 0 8 0 8 0 8 Max heating temperature 95 95 95 tmax Heating water content litres 5 5 7 Protection rating X5D X5D X5D Power supply voltage ViHz 230V 50Hz 230V 50Hz 230V 50Hz Electrical power input W 70 95 200 Empty weight kg 46 46 51 Type of unit C457
12. not in any case reduce the hardness to values below 15 F Decree 236 88 for uses of water intended for human consumption Water treatment is indispensable in the case of very large systems or with frequent replenishing of water in the system If partial or total emptying of the system becomes necessary in these cases it is advisable to refill it with treated water Antifreeze system antifreeze fluids additives and inhibitors The boiler is equipped with an antifreeze system that turns on the boiler in heating mode when the system delivery water temperature falls under 6 The device will not come on if the electricity and or gas supply to the unit are cut off If it becomes necessary it is permissible to use antifreeze fluid additives and inhibitors only if the manufacturer of these fluids or additives guarantees they are suitable for this use and cause no damage to the heat exchanger or other components and or materials of the boiler unit and sys tem It is prohibited to use generic antifreeze fluid additives or inhibitors that are not ex pressly suited for use in heating systems and compatible with the materials of the boiler unit and system Optional kits The following kits are available on request code 042021X0 3 SPEED Circulating Pump Kit code 042047X0 3 SPEED HIGH HEAD Circulating Pump Kit code 042043X0 MODULATING Circulating Pump Kit The Kits contain see fig 15 1 CIRCULATING PUMP The diagrams of the circulating
13. 5 Hot water tank temperature probe not supplied 298 Cascade temperature sensor not supplied 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied SM Delivery probe supplied with kit FZ4 TS Safety thermostat not supplied PZ Zone pump not supplied FZ4 Zone regulator Parameters Each system requires a different parametrisation Follow the procedure for accessing the two menus given below for the parameters to be modified refer to the tables given alongside the plumbing diagrams Service Menu The card Service Menu is accessed by pressing the Reset button for 10 seconds Press the Heating buttons to select tS In Hi or rE tS means Transparent Pa rameters Menu In Information Menu Hi History Menu and rE History Menu Reset Select tS and press the Reset button The card is equipped with 29 transparent parameters also modifiable from Remote Con trol Service Menu Press the Heating buttons to scroll the list of parameters in increasing or decreasing or der Press the DHW buttons to modify the value of a parameter the change will be au tomatically saved Press the Reset button to return to the Service Menu Press the Reset button for 10 sec onds to exit to the card Service Menu System Type Menu Press the Summer Winter button for 10 seconds to access the card System Type Menu The card has 21 transparent parameters
14. NERGY TOP W 70 W 80 W 125 3 7 Condensate drain connection The boiler is equipped with a trap to drain condensate Carry out the following instruc tions for fitting 1 Fixthe support bracket A to the bottom of the boiler 2 Connect the preformed black tube B to the condensate drain S on the bottom of the boiler fixing it with a clamp 3 Remove the trap ring nut C and insert the preformed black tube B in the special opening making sure to fit the seal D 4 Refitthe trap ring nut insert it in the bracket and fix with the special clip E 5 Connectthe flexible tube F from the trap to the condensate drain system fig 28 Condensate drain connection 4 SERVICE AND MAINTENANCE All adjustment conversion startup and maintenance operations described below must only be carried out by Qualified Personnel meeting the professional technical require ments prescribed by current regulations such as those of the Local After Sales Techni cal Service FERROLI declines any liability for damage and or injury caused by unqualified and un authorised persons tampering with the unit 4 1 Adjustments Gas conversion The unit can operate on Natural Gas or LPG and is factory set for use with one of these two gases as clearly shown on the packing and on the dataplate Whenever a different gas to that for which the unit is set has to be used the special conversion kit will be re quired proceeding as follows Disconnec
15. OLI S p A Adres Via Ritonda 78 a 37047 San Bonifacio VR bu cihazin asagida yer alan AET EEC y nergelerine uygunluk oldugunu beyan etmektedir e 2009 142 Gazla calistirilan niteler Y netmelik 92 42 Randiman Verimlilik Y netmeligi e Y nerge 2006 95 D s k Voltaj e 2004 108 Elektromanyetik Uygunluk Y netmeligi Baskan ve yasal temsilci Dep Dante Declaration of conformity Manufacturer FERROLI S p A Address Via Ritonda 78 a 37047 San Bonifacio VR Italy declares that this unit complies with the following EU directives e Gas Appliance Directive 2009 142 Efficiency Directive 92 42 Low Voltage Directive 2006 95 Electromagnetic Compatibility Directive 2004 108 President and Legal Representative Cav del Lavoro ante Ferroli C C C C D claration de conformit Le constructeur FERROLI S p A C Adresse Via Ritonda 78 a 37047 San Bonifacio VR d clare que cet appareil est conforme aux directives CEE ci dessous Directives appareils gaz 2009 142 Directive rendements 92 42 Directive basse tension 2006 95 Directive Compatibilit Electromagn tique 2004 108 Pr sident et fond de pouvoirs Cav du travail Dante Fergoli EM Declaratie de conformitate Produc tor FERROLI S p A C Via Ritonda 78 37047 San Bonifacio VR declar c acest aparat este in conformitate cu urm toarele directive CEE D
16. Press the Heating buttons to scroll the list of parameters in increasing or decreasing or der Press the DHW buttons to modify the value of a parameter the change will be au tomatically saved Press the Summer Winter button for 10 seconds to exit the card System Type Menu W 125 One direct heating circuit Ferroli Check Change parameter P02 of the Transparent Parameters Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 fig 16 One direct heating circuit and one DHW circuit with pump Check Change parameter P02 of the Transparent Parameters Menu to 5 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 fig 17 One direct heating circuit and one DHW circuit with diverter valve Check Change parameter P02 of the Transparent Parameters Menu to 6 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 Change parameter 11 of the System Type Menu to 1 72139 cod 35408807 Rev 00 12 2013 EX li ferroli Two direct heating ci
17. ating pump not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 Diverter valve not supplied A Heating phase B DHW phase Neutral NOTE For valves with 2 wires and spring return use the connections B and C 130 DHW circulating pump not supplied 138 External probe not supplied 139 Remote timer control not supplied 155 Hot water tank temperature probe not supplied 256 Modulating heating circulating pump signal 298 Cascade temperature sensor not supplied 299 Input 0 10 Vdc 300 Burner lit contact voltage free contact 301 Fault contact voltage free contact 302 Remote reset input 230 Volt 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied For the connection in cascade Note The boiler s electronics can manage up to 6 modules 1 Connect the modules as shown in fig 24 example with 4 modules A B D 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 28 20 30 31 32 33 34 35 28 29 30 31 32 33 34 35 fig 24 Connection in cascade 1st Module 2nd Module 3rd Module 4th Module W 125 Ferroli 2 Carry out all the electrical connections terminals 4 to 27 on module no 1 3 On the remaining modules only connect the power supply and pos
18. ation on the remote timer control please refer to its user s manual Sliding temperature When the optional external probe is installed the corresponding symbol detail 22 fig 1 is activated on the control panel display detail 5 fig 1 The boiler control system works with Sliding Temperature In this mode the heating system temperature is controlled according to the outside weather conditions in order to ensure high comfort and energy saving throughout the year In particular as the outside temperature increases the sys tem delivery temperature is decreased according to a specific compensation curve With Sliding Temperature adjustment the temperature set with the heating buttons details 3 and 4 fig 1 becomes the maximum system delivery temperature It is advisable to set a maximum value to allow system adjustment throughout its useful operating range The boiler must be adjusted at the time of installation by qualified personnel Adjust ments can in any case be made by the user to improve comfort Compensation curve and curve offset Press the reset button detail 8 fig 1 for 5 seconds to display the actual compensation curve fig 10 which can be modified with the DHW buttons details 1 and 2 fig 1 Adjust the required curve from 1 to 10 according to the characteristic fig 12 By setting the curve to 0 sliding temperature adjustment is disabled Press the heating buttons details 3 and 4 fig 1 t
19. ct the sales network FERROLI The boiler s electronics can in any case manage a cascade of up to 6 modules To cre ate systems in cascade with 5 or 6 modules it is necessary to have suitably sized water gas manifolds complete with all the safety devices required by the current regulations as well as single fume exhausts or fume manifolds in low pressure not supplied in stalled by a qualified technician When two or more generators ENERGY TOP W 70 W 80 W 125 are installed in cas cade with the original kits FERROLI respecting the instructions given in this manual they can be considered as a single equivalent heat generator with a total capacity equal to the sum of powers of all the units connected cascade All the requirements of the current standards and regulations applicable to this equiva lent generator with total heating capacity must be met In particular the place of instal lation safety devices and fume exhaust system must be adequate for the total heating capacity of the bank of units In fact each ENERGY TOP W 70 W 80 W 125 is a complete and independent heat generator equipped with its own safety devices In case of overtemperature lack of wa ter or no circulation in the unit the protection devices cause the unit to switch off or shut down preventing it from working The installation instructions given in the following paragraphs concern single units and connection in cascade ENERGY TOP W 70 W 80 W
20. d according to current safety standards Have the efficiency and suitability of the earthing system checked by professionally qualified personnel The manufacturer is not responsible for any damage caused by failure to earth the system Also make sure that the electrical system is adequate for the maximum power absorbed by the unit as specified on the boiler dataplate The boiler is prewired and provided with a Y cable and plug for connection to the elec tricity line The connections to the grid must be made with a permanent connection and equipped with a bipolar switch whose contacts have a minimum opening of at least 3 mm interposing fuses of max 3A between the boiler and the line It is important to re spect the polarities LINE brown wire NEUTRAL blue wire EARTH yellow green wire in making connections to the electrical line During installation or when changing the power cable the earth wire must be left 2 cm longer than the others The user must never change the unit s power cable If the cable gets damaged Switch off the unit and have it changed solely by professionally qualified person nel If changing the electric power cable use solely HAR H05 VV F 3x0 75 mm2 cable with a maximum outside diameter of 8 mm Room thermostat optional CAUTION The room thermostat must have clean contacts CONNECTING 230 V TO THE TERMINALS OF THE ROOM THERMOSTAT WILL IRREPA RABLY DAMAGE THE ELECTRONIC CARD When connecting a remote time
21. e installed on the hot water circuit delivery piping imme diately after the last module within a distance of not more than 0 5 metres with no shut off devices in between The unit is not supplied with an expansion tank therefore its connection must be carried out by the Installer The safety valve outlet must be connected to a funnel or collection pipe to pre vent water spurting onto the floor in case of overpressure in the heating circuit Otherwise if the discharge valve cuts in and floods the room the boiler manu facturer cannot be held liable Do not use the water system pipes to earth electrical appliances Before installation carefully clean all the system pipes to remove any residuals or impu rities that could affect proper operation of the unit Also a filter must be installed on the system return piping to prevent impurities or sludge from the system clogging and damaging the heat generators The filter must be installed when replacing generators in existing systems The manufacturer declines any liability for damage caused to the generator by fail ure to install or inadequate installation of this filter Carry out the relevant connections according to the diagram in sec 5 1 and the symbols given on the unit System water charcteristics In the presence of water harder than 25 Fr 1 F 10ppm CaCO the use of suitably treated water is advisable in order to avoid possible scaling in the boiler The treatment must
22. eck that includes the following tests The control and safety devices gas valve flow meter thermostats etc must func tion correctly The fume extraction circuit must be fully efficient The airtight chamber must be sealed The air fume end piece and ducts must be free of obstructions and leaks The condensate evacuation system must be efficient with no leakage or obstructions The burner and exchanger must be clean and free of scale When cleaning do not use chemical products or wire brushes The electrode must be free of scale and properly positioned The gas and water systems must be airtight The water pressure in the cold water system must be about 1 bar otherwise bring it to that value The circulation pump must not be blocked The expansion tank must be filled The gas flow and pressure must correspond to that given in the respective tables The boiler casing panel and aesthetic parts can be cleaned with a soft damp cloth possibly soaked in soapy water Do not use any abrasive detergents and solvents ENERGY TOP W 70 W 80 W 125 Opening the casing To open the boiler casing fig 36 1 Undo the screws A 2 Open turning the casing B 3 Lift and remove the casing B O fig 36 Opening the casing Combustion analysis Combustion can be analysed through the air sampling point detail 2 and fume sam pling point detail 1 shown in fig 37
23. ectrode and replace it if necessary Flame unstable Check the burner No flame after ignition Gas valve Offset fault Check the Offset adjustment at minimum A06 stage power 6 times in 4 minutes Remove the obstruction from the flue air fume ducts obstructed fume extraction ducts and air inlet and terminals Trap blocked Check the trap and clean it if necessary Flue partially obstructed or insuffi Check the efficiency of the flue fume N cient extraction ducts and outlet terminal F07 High fume temperature F n Check the correct positioning and ume sensor position operation of the fume sensor Sensor damaged F10 Delivery sensor 1 fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F11 Return sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F12 DHW sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F13 Fume sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F14 sensor 2 fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected No 230V power supply Check the 3 pin connector wiring F15 Fan fault Tachometric signal interrupted Check the 5 pin connector wiring Fan damaged Check the fan F34 Supply voltage under Electric mains trouble Check the electrical system F35 Faulty mains frequency Electric main
24. ength of 1 5 metres Table 2 Max length coaxial ducts ENERGY TOP W 70 W 80 ENERGY TOP W 125 Coaxial 80 125 Coaxial 80 125 Max permissible length 4m 2m Reduction factor 90 bend 0 5m 0 5m Reduction factor 45 bend 0 25m 0 25m Connection with separate pipes Wo w 9 a fig 27 Examples of connection with separate pipes gt Air gt Fumes Separate 80 ducts can be connected directly to the unit Before proceeding with installation make sure the maximum permissible length has not been exceeded by means of a simple calculation 1 Establish the layout of the system of split flues including accessories and outlet ter minals 2 Consult the table 4 and identify the losses in m equivalent metres of every com ponent according to the installation position 3 Check that the sum total of losses is less than or equal to the maximum permissible length in table 3 Table 3 Max length separate ducts Separate ducts ENERGYTOPW70 W80 ENERGY TOP W 125 Max permissible length 20 Maj 10 Maj Table 4 Accessories Losses in Maj Air Fume exhaust Vertical Horizontal 980 1 m M F 1KWMA83W 1 0 1 6 2 0 BEND 45 1KWMA65W 12 1 8 90 1KWMAO1W 15 20 PIPE SECTION with test point 1KWMAZOW 0 3 0 3 TERMINAL air wall 1KWMA85A 20 fumes wall with antiwind 1KWMA86A 5 0 E
25. er DBM12 internal error Check the earth connection and replace A65 the controller if necessary F66 5 TECHNICAL DATA AND CHARACTERISTICS Key of figures cap 5 7 10 11 16 22 29 32 36 38 44 72 72b 81 82 95 98 114 130 138 139 154 155 186 191 193 196 215 220 256 278 298 299 300 301 302 306 307 345 Gas inlet System delivery System return Fan Main burner Fume outlet manifold Heating circulating pump not supplied Automatic air vent Flow switch Gas valve Room thermostat not supplied Second room thermostat not supplied Ignition electrode Detection electrode Diverter valve not supplied A Heating phase B DHW phase Neutral NOTE For valves with 2 wires and spring return use the connections B and C Switch Water pressure switch DHW circulating pump not supplied External probe not supplied Remote timer control not supplied Condensate drain pipe Hot water tank temperature probe not supplied Return sensor Fume temperature sensor Trap Condensate tray Air inlet reducer Ignition card Modulating heating circulating pump signal Double sensor Safety Heating Cascade temperature sensor not supplied Input 0 10 Vdc Burner lit contact voltage free contact Fault contact voltage free contact Remote reset input 230 Volt Heating system circulating pump not supplied Heating system second circulating pump not supplied Exchange
26. ff To avoid damage caused by freezing during long idle periods in win ter itis advisable to drain all water from the boiler DHW circuit and system or drain just the DHW circuit and add a suitable antifreeze to the heating system complying with that prescribed in sec 3 3 2 4 Adjustments Summer Winter Switchover Press the button ve detail 6 fig 1 for 1 second The display activates the Summer symbol detail 10 fig 1 The heating function is de activated whereas the possible production of domestic hot water with optional external hot water tank remains activated The antifreeze system remains activated To deactivate Summer mode press the button METE detail 6 fig 1 again for 1 second Heating temperature adjustment Use the heating buttons details 3 and 4 fig 1 to adjust the temperature from a min of 20 C to a max of 90 C DHW temperature adjustment with optional hot water tank installed Use the DHW buttons details 1 and 2 fig 1 to adjust the temperature from a min of 10 to a max of 65 W 125 Room temperature adjustment with optional room thermostat Ferroli Using the room thermostat set the temperature required in the rooms Room temperature adjustment with optional remote timer control Using the remote timer control set the temperature desired in the rooms The boiler unit will set the system water according to the required room temperature For inform
27. fficiency of the earthing system Make sure the gas pressure value for heating is that required Make sure there are no flammable liquids or materials in the immediate vicinity of the boiler Checks during operation Turn the unit on as described in sec 2 3 Make sure the fuel circuit and water systems are tight e Check the efficiency of the flue and air fume ducts while the boiler is working Check the correct tightness and functionality of the condensate elimination system and trap Make sure the water is circulating properly between the boiler and the systems Make sure the gas valve modulates correctly in the heating and domestic hot water production phases Check proper boiler lighting by doing several tests turning it on and off with the room thermostat or remote control Using a combustion analyser connected to the boiler fume outlet check that the CO content in the fumes with the boiler operating at max and min output corre sponds to that given in the technical data table for the corresponding type of gas Make sure the fuel consumption indicated on the meter matches that given in the technical data table on sec 5 4 Check the correct programming of the parameters and carry out any necessary cus tomization compensation curve power temperatures etc 4 3 Maintenance Periodical check To keep the unit working properly over time it is necessary to have qualified personnel make an annual ch
28. intenance operation disconnect the unit from the electrical power supply using the switch and or the special cut off devices ncase of a fault and or poor operation deactivate the unit and do not try to repair it or directly intervene Contact professionally qualified personnel Any repair re placement of the products must only be carried out by qualified personnel using orig inal replacement parts Failure to comply with the above could affect the safety of the unit This unit must only be used for its intended purpose Any other use is deemed im proper and therefore hazardous The packing materials are potentially hazardous and must not be left within the reach of children The unit must not be used by people including children with limited physical sen sory or mental abilities or without experience and knowledge of it unless instructed or supervised in its use by someone responsible for their safety The unit and its accessories must be appropriately disposed of in compliance with the current regulations The images given in this manual are a simplified representation of the product In this representation there may be slight and insignificant differences with respect to the product supplied 2 OPERATING INSTRUCTIONS 2 1 Introduction Dear Customer Thank you for choosing ENERGY TOP W 70 W 80 W 125 a wall mounted boiler fea turing FERROLIadvanced design cutting edge technology high reliabilit
29. irectiva Aparate cu Gaz 2009 142 Directiva Randament 92 42 Directiva Joas Tensiune 2006 95 Directiva Compatibilitate Electromagnetic 2004 108 Presedinte si reprezentant legal Cavaler al Muncii Dante Feyroli EN FERROLI S p A C anpec Via Ritonda 78 a 37047 San Bonifacio VR CEE no 2009 142 no 92 42 no 2006 95 2004 108 Dante Feryoli npo FERROLI S p A C Via Ritonda 78 a 37047 San Bonifacio VR 2009 142
30. nu the boiler selects the Economy mode In this condition the button detail 7 fig 1 on the boiler panel is disabled On enabling DHW from the Remote Timer Control menu the boiler selects the Comfort mode In this condition it is possible select one of the two modes with the button detail 7 fig 1 Both the Remote Timer Control and the boiler card manage Sliding Temperature adjustment of the two the Sliding Temperature of the boiler card has priority Sliding Temperature Plumbing system pressure adjustment The filling pressure with the system cold must be approx 1 0 bar If the system pressure falls to values below minimum the boiler card will activate fault F37 fig 14 CHa 7 fig 14 Low system pressure fault Once the system pressure is restored the boiler will activate the 120 second air venting cycle indicated on the display by FH 3 INSTALLATION 3 1 General Instructions THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL IN COMPLI ANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL THE PROVISIONS OF CURRENT LAW THE NATIONAL AND LOCAL REGULATIONS AND THE RULES OF PROPER WORKMANSHIP ENERGY TOP W 70 W 80 W 125 is a heat generator arranged to operate alone or in cascade bank To install up to 4 generators in bank appropriate accessories consisting of support frames water gas and fume manifolds are available on request consult the price list or conta
31. o access parallel curve offset fig 13 modifiable with the DHW buttons details 1 and 2 fig 1 2 fii muc 3n LI ZILI JE fig 11 Curve parallel offset Press the reset button detail 8 fig 1 again for 5 seconds to exit parallel curve adjust ment mode If the room temperature is lower than the required value it is advisable to set a higher order curve and vice versa Proceed by increasing or decreasing in steps of one and check the result in the room 90 85 80 sol sol aol 30 20 fig 12 Compensation curves OFFSET 40 10 9 OFFSET 20 20 10 0 40020 20 10 0 10 20 fig 13 Example of compensation parallel curve offset cod 35408807 Rev 00 12 2013 EX 9 Ferroli If the Remote Timer Control optional is connected to the boiler the above ad justments are managed according to that given in table 1 Table 1 Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel DHW temperature adjustment with optional hot water tank installed Adjustment can be made from the Remote Timer Control menu and the boiler control panel Summer Winter Switchover Summer mode has priority over a possible Remote Timer Control heating demand Eco Comfort selection with optional hot water tank installed On disabling DHW from the Remote Timer Control me
32. pumps are given in sec 5 5 2 3 way COCK Male 1 1 2 with non return valve and safety valve It enables shutoff for maintenance operations in conformity with ISPESL re quirements and can be used as a local shutoff in the connection of several units in bank The third way must be connected to an atmospheric discharge manifold Thus with the valve in the open position the boiler exchanger is connected to the delivery manifold and in the closed position through the third way the exchanger communicates with the atmospheric discharge mani fold This valve therefore also acts as a boiler discharge ii ET cod 3540 807 Rev 00 12 2013 ENERGY TOP W 70 W 80 3 COCK Male Female 1 1 2 In combination with the previous 3 way valve it enables shutoff for mainte nance operations in conformity with ISPESL requirements and can be used as a local shutoff in the connection of several units in bank fig 15 Contents of optional Kits Plumbing circuit examples Key of examples liu ISPESL safety devices When required not supplied D Hydraulic separator not supplied 32 Circulating pump not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 3 way valve with spring return at rest on DHW side not supplied 130 Hot water tank circulating pump not supplied 138 External probe not supplied 139 Remote control not supplied 15
33. r control or a timer switch do not take the pow er supply for these devices from their cut out contacts Their power supply must be taken with a direct connection from the mains or with batteries depending on the kind of device External probe optional Connect the probe to the respective terminals The maximum permissible length of the electric cable connecting the boiler external probe is 50 m A common 2 wire cable can be used The external probe should preferably be installed on the North North West wall or on the wall facing most of the main living room The probe must never be exposed to the early morning sun and in general as far as possible it should not be exposed to direct sunlight protect it if necessary In any case the probe must not be installed near windows doors vents flues or heat sources that could affect the reading X x BA ina NN x fig 22 Inadvisable positioning of external probe cod 35408807 Rev 00 12 2013 ENERGY TOP W 70 W 80 Accessing the electrical terminal block The electrical terminal block can be accessed after removing the front panel Make the electrical connections as shown in the wiring diagram in fig 42 16 17 18 19 20 21 22 23 24 25 26 27 Lollolololollall 0505050505055 fig 23 Electrical terminal block 32 Circul
34. r safety thermostat cod 35408807 Rev 00 12 2013 55 ferroli ENERGY TOP W 70 W 80 W 125 5 1 Dimensions and connections 50 Generalview and main components ma o 900 945 440 A ENERGY TOP W 70 W 80 65 ENERGY TOP W 125 63 1 Heating system delivery 1 1 2 F 3 Gas inlet 1 M 5z Heating system return 1 1 2 F fig 40 Genera view ENERGY TOP W 125 56 EN cod 35408807 Rev 00 12 2013 ENERGY TOP W 70 W 80 5 3 Water circuit W 125 5 4 Technical data table Factory settings Ferroli 29 a The unit is factory set to 80 power 16 Technical data 36 44 The column on the right gives the abbreviation used on the dataplate 345 Data Unit Value Value Value 81 Model ENERGY TOP ENERGY TOP ENERGY TOP 2 8 N E W 70 W80 W 125 2 Max heating capacity kW 65 9 75 116 Q 2 82 Min heating capacity kW 17 17 25 Q 2 Max Heat Output in heating 80 60 C KW 64 6 73 5 113 7 Nd 22 Min Heat Output in heating 80 60 kW 16 7 16 7 24 6 P Max Heat Output in heating 50 30 kW 69 9 79
35. rcuits Check Change parameter P02 of the Transparent Parameters Menu to 4 Change parameter P 01 of the System Type Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type to 1 fig 19 Two mixed heating circuits and one direct heating circuit Check Change parameter P02 of the Transparent Parameters Menu to 4 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type to 1 For the electrical connection and the zone system settings refer to the FZ4 zone reg ulator handbook fig 20 Two mixed heating circuits one direct heating circuit and one DHW circuit with pump Check Change parameter P02 of the Transparent Parameters Menu to 5 Change parameter P 02 of the System Type to 1 Change parameter P 09 of the System Type to 1 For the electrical connection and the zone system settings refer to the FZ4 zone reg ulator handbook Zona 3
36. s trouble Check the electrical system Insufficient system pressure or the system water pressure or for air circulation in the system Flowswitch or pressure z z 7 F37 Switch contact open Circulating pump not working Check the circulating pump 20 Wrong card parameter setting Check the card parameter and modify it if necessary F38 Flowswitch contact Flowswitch dirty or blocked Clean the flowswitch or replace it if neces blocked closed sary Probe damaged or wiring shorted Check the wiring or replace the sensor F39 External probe fault Probe disconnected after activat Reconnect the external probe or disable ing the sliding temperature the sliding temperature Sensor positioning Delivery sensor disconnected Check he correct positioning and from the pipe operation of the heating sensor A42 Heating sensor fault Sensor damaged Replace the sensor Ferroli Fault a Codd Fault Possible cause Cure F42 Heating sensor fault Sensor damaged Replace the sensor Sensor damaged F50 Rx 2 Temperature sen Wiring shorted Check the wiring or replace the sensor Wiring disconnected A61 Controller DBM12 fault Controller DBM12 internal error earth connection and replace the controller if necessary No communication Controller not connected Connect the controller to the gas valve A62 between controller and gas valve Valve damaged Replace the valve A63 s Controller DBM12 fault Controll
37. sible contacts for burner lit 300 fault contact 301 and remote reset input 302 4 Switch on the power to the entire cascade 5 After the FH procedure check correct operation of the cascade Module 1 arrow symbol at top left of the display Module 2 arrow symbol at bottom right of the display Module 3 arrow symbol at bottom right of the display Module 4 arrow symbol at top right of the display If this does not occur disconnect the power and check the wiring in fig 24 Settings adjustments must be made on all the modules Possible faults If the electrical connection of a module is disconnected for any reason module 1 will ac tivate fault F70 If the electrical connection of a module is disconnected for any reason the next module will activate fault F71 3 6 Fume ducts The unit is a C type with sealed chamber and forced draught the air inlet and fume out let must be connected to one of the following extraction suction systems The unit is ap proved to operate with all the Cxy and Bxy flue configurations given on the dataplate some configurations are given by way of example in this section Some configurations may be expressly limited or not permitted by law standards or local regulations Before proceeding with installation check and carefully observe the above mentioned prescrip tions Also comply with the provisions on the positioning of wall and or roof terminals and the minimum distances from
38. t the power supply to the boiler Remove the casing Detach the electrical connections from the gas valve controller Unscrew the gas valve e fixing ring fig 29 A fig 30 Undo the two fixing screws B and remove the fan assembly as indicated in fig 29 for the model ENERGY TOP W 70 W 80 and in fig 30 for the model ENERGY TOP W 125 gt IEN cod 35405807 00 12 2013 ENERGY W 70 W 80 fig 30 model ENERGY TOP W 125 6 Undo the screws and remove the fan D fig 31 only model ENERGY TOP W 125 fig 31 model ENERGY TOP W 125 7 Undo the fixing screws E fig 32 model ENERGY TOP W 70 W 80 and fig 33 model ENERGY TOP W 125 and remove the gas valve fig 32 model ENERGY TOP W 70 W 80 fig 33 model ENERGY TOP W 125 W 125 Ferroli 8 Replace the gas nozzle F see fig 32 for the model ENERGY TOP W 70 W 80 and fig 33 the model ENERGY TOP W 125 with the one contained in the conver sion kit positioning it inside the seal Refit the parts and check the tightness 9 Modify the parameter for the type of gas putthe boiler in standby mode e press the DHW buttons details 1 and 2 fig 1 together for 10 seconds the display shows PO1 flashing e press the DHW buttons details 1 and 2 fig 1 together to set the parameter 00 for natural gas or 01 for LPG e press the DHW buttons
39. t water tank installed 13 Heating mode 14 Unit On Off button 15 16 Appears on connecting the Remote Timer Control optional 17 Information symbol 18 Arrow symbol 20 Fault 21 Circulating pump 22 7 Appears on connecting the external probe optional 23 Boiler Off 25 Fault reset request Indication during operation Heating A heating demand generated by the Room Thermostat or Remote Timer Control or 0 10 Vdc signal is indicated by activation of the circulating pump and the radiator details 13 and 21 fig 1 The display detail 11 fig 1 shows the actual heating delivery temperature and during DHW standby time the message d fig 2 DHW circuit with optional hot water tank installed A hot water tank heating demand is indicated by activation of the circulating pump and the tap details 9 and 21 fig 1 The display detail 11 fig 1 shows the actual hot water tank sensor temperature and during heating standby time the message d fig 3 Exclude hot water storage tank economy Hot water tank temperature maintaining heating can be excluded by the user If exclud ed domestic hot water will not be delivered The hot water tank can be deactivated by the user ECO mode by pressing the eco comfort button detail 7 fig 1 In ECO mode the display activates the symbol detail 12 fig 1 To activate the COMFORT mode press the eco comfort button
40. utton detail 8 fig 1 within 5 seconds and the maximum heating capacity will remain that just set Exit TEST mode see sec 4 1 THE HEATING CAPACITY ADJUSTMENT THUS SET ENSURES KEEPING OF THE EFFICIENCY VALUES DECLARED ON cap 5 4 Heating power adjustment diagram kW B Electronic Board Parameter B 100 90 80 70 60 50 40 30 20 10 0 0 20 40 60 80 100 120 140 fig 35 cod 35408807 Rev 00 12 2013 EN gt Ferroli 4 2 Start up Checks to be made at first lighting and after all maintenance operations that involved disconnection from the systems or an operation on safety devices or parts of the boiler Before lighting the boiler Open any on off valves between the boiler and the systems Check the tightness of the gas system proceeding with caution and using a soap and water solution to detect any leaks in connections Check correct prefilling of the expansion tank ref sec 5 4 Fil the water system and make sure all air contained in the boiler and the system has been vented by opening the air vent valve on the boiler and any vent valves on the system Fil the condensate trap and check correct connection of the condensate elimination system Make sure there are no water leaks in the system DHW circuits connections or boiler Check correct connection of the electrical system and e
41. windows walls vents etc This C type unit must be installed using the inlet and fume exhaust ducts sup plied by the manufacturer in accordance with UNI CIG 7129 92 Failure to use them automatically invalidates every warranty and relieves the manufacturer of any liability For fume exhaust pipes longer than 1 metre during installation take into ac count the natural expansion of the materials when the boiler is operating To prevent deformations leave an expansion space of approx 2 4 mm for every metre of pipe Connection with coaxial pipes a a fig 25 Examples of connection with coaxial pipes Z gt Air Fumes For coaxial connection fit the unit with one of the following starting accessories For the wall hole dimensions refer to sec 5 1 Any horizontal sections of the fume exhaust must be kept sloping slightly towards the boiler to prevent condensate from flowing back to wards the outside and causing dripping 167 225 280 080 120 fig 26 Starting accessories for coaxial ducts 041007X0 cod 35408807 Rev 00 12 2013 EN ferroli Before proceeding with installation check with table 2 that the maximum permissible length is not exceeded bearing in mind that every coaxial bend gives rise to the reduc tion indicated in the table For example a 80 125 duct comprising a 90 bend 1 hor izontal metre has a total equivalent l
42. y and quality construction Please read this manual carefully since it provides important information on safe installation use and maintenance ENERGY TOP W 70 W 80 W 125 is a high efficiency low emissions sealed chamber premix condensing heat generator for heating running on natural gas or LPG and equipped with a microprocessor control system The boiler shell consists of an aluminium finned tube exchanger and a premix burner in steel equipped with electronic ignition and ionisation flame control a modulating speed fan and a modulating gas valve ENERGY TOP W 70 W 80 W 125 is a heat generator arranged to operate alone or in cascade 2 2 Control panel 16 17 18 P ade a 21 MS Lo 1 20 23 5 se IE lt ese TE 6 8 14 7 fig 1 Control panel Key 1 DHW temperature setting decrease button with optional hot water tank in stalled 2 DHW temperature setting increase button with optional hot water tank in stalled 3 Heating system temperature setting decrease button 4 Heating system temperature setting increase button 5 Display 6 Summer Winter mode selection button 7 Economy Comfort mode selection with optional hot water tank installed and unit On Off button 8 Reset button 9z DHW operation with optional hot water tank installed ENERGY TOP W 70 W 80 W 125 10 Summer mode 11 Multifunction 12 Eco Economy mode with optional ho
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