Optima Company 1001 User's Manual
Contents
1. Fig 24a Burner pressure VS C H Load with L P G G31 Propane 15 14 18 12 11 10 9 8 6 5 4 3 2 1 kW 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Keam 6 7 8 9 10 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Fig 24b Burner pressure VS C H load with natural gas G20 23 OPTIMA 1001 FERROLI 8 7 D H W Burner Pressure The domestic hot water burner pressure is not range rateable and not adjustable but the maximum and minimum burner pressure should be checked as follows a Check electricity supply is still off b Open a D H W tap at high flow until the water runs cool and leave running c Switch on the electricity supply d The pressure should be 14 mbar 0 5 mbar e Disconnect one of the wires from the Modureg fig 22 this will reduce the burner to minimum which should read 3 0 mbar 0 5 mbar If the burner pressure is not as stated check the inlet working pressure fig 22 which should be minimum 20 mbar If that is correct consult Ferroli No attempt should be made to alter D H W burner pressure f Switch off electrical supply and close hot tap g Reconnect the wire to the Modureg Remove pressure gauge tighten the test screws h Replace control pa2. HUBA 605 HUBA 602 3 2 y BLUE HUBA 602 BROWN Fig 46 26 FERROLI Spare Parts List Item No G C Part No Makers Part No No Off 14 16 21 21 32 34 36 39 42 43 44 49 50 51 61 62 81 82 83 100 101 113 136 145 386816 386818 394246 386829 386818 381691 386815 386577 386828 372225 800130 803860 803080 801850 800620 800310 801160 801220 800310 800140 801240 800160 800180 801230 803840 801650 801430 802560 803420 803410 823071 803430 840187 DESCRIPTION 1 1 20 20 Ea A E gna duis E lx cb E Ny m C H safety valve Fan Main injector Natural Gas Main injector L P G Central heating pump Temperature sensor Automatic air vent Cold water flow limiter 10 l min Temperature sensor Air pressure switch Combination gas valve Overheat cut off thermostat Heat exchanger limit thermostat Heat exchanger frost thermostat C H selector switch Time clock Ignition electrode Flame sensing electrode Ignition board Honeywell Fault diagnostic temperature 100 control panel VMF7 Special two pipe flue adapter LED Flowmeter 12345678 C H pressure gauge ig 27 Domestic Hot Water Performance Fig 1 D H W Pressure Drop VS flow A Standard with cold water Flow Restrict
3. 1001 FERROLI General Notes For use on the 1001 fitted with VMF7 Printed Circuit Board The central heating pump 32 will run to disperse heat if the temperature at the heat exchanger limit thermostat 50 is too high The frost thermostat 51 will switch on the boiler for central heating if the temperature is too low Fuse on 2 Amp LED signification Jumpers JP1 JP4 Mains on low voltage on Fitted Not fitted Flowmeter 136 on No waiting time Waiting time on Central heating room thermostat 72 clock 62 calling Fan control Fan control Sensor 34 or 42 calling for heat High amp Low speed High speed only off n Lu Central Heating waiting time max 3 minutes delay following shut off Boilerstat 63 Clock 62 Roomstat 72 or use of Hot Water Temp 890 ohm Demand for heat relay RY2 will be energised sensor 1 h E Air pressure switch 43 on air flow checked 1490 ohm central heating pump If RY1 is not energised on off relay the Central Heating pump E will run fan Check operation using LED s as a fault finding guide First check section A then B then C then D 0 LED off 1 LED on x LED either on off is not important Domestic Hot water tap open Flow rate greater than 2 5 l min POSSIBLE CAUSE OF FAULT No mains electricity switches off fuse blown D H W flowmeter 136 not operating Not requ
4. OPTIMA 1001 01 01 WALL MOUNTED ROOM SEALED FAN ASSISTED GAS COMBINATION BOILER 4 INSTALLATION INSTRUCTIONS 9 9 9 1 FERROLI HELPLINE FOR SERVICE INFORMATION OR HELP TELEPHONE 08707 282 885 Installer ALWAYS QUOTE YOUR SERIAL NUMBER FOR IMMEDIATE ASSISTANCE Phone numbers Service Engineer Serial No FERROLI G C NO 47 267 19 ALL SPECIFICATIONS SUBJECT TO CHANGE Lichfield Road Branston Industrial Estate Burton Upon Trent Staffordshire DE14 3HD Tel 08707 282 885 Fax 08707 282 886 Appr Nr B94 01A CE 0063AQ2150 1001 FERROLI INDEX General Description Related Documents Technical Data Appliance Dimensions Boiler Flow Diagram Key of boiler flow diagram Installation Details Location of Boiler Air Supply Flue System Gas Supply Water System Central Heating Pump Sizing of expansion vessel Installation of Boiler 1 Unpacking 2 Mounting the Boiler Jig on the Wall rear flue 3 Mounting the Boiler Jig on the Wall side flue Drilling template Preparing the Flue Assembly Connecting the Boiler Fitting the Flue Assembly Electrical Installation Commissioning amp Testing 8 1 Filling the Central Heating System 8 2 Filling the Domestic Hot Water System 8 3 Electricity Supply 8 4 The Gas Installation 8 5 To Light the Boiler 8 6 To Range Rate the Boiler C H Gas pressure adjustment with Honeywell VR 4600 N 4002 val
5. 3 3 m S h 2 39 kg h 15 mbar 34 5 mbar 3 5 mbar 6 9 mbar 1 15 mm 0 72 mm 1020 mm 480 mm 360 mm 51 kg 53 kg 230V 50 Hz 3 Amp main fuse F2 Amp Fast 160 Watt 11 4 l min 2 5 l min 10 0 bar 3 bar 7 litre 0 8 bar 3 0 bar 0 4 bar 1 5 litre 0 5 litre 22mm 15 mm 15 mm 22mm 22 15 mm 5mm 5mm 50 mm Access to the front of the boiler must be available for maintenance min 600 mm plus access for service 200 mm FERROLI OPTIMA 1001 Appliance Dimensions FRONT VIEW LEFT SIDE VIEW REAR VIEW 242 900 ESP ES EE END BPP ESE TOT LIALLITLILTILILTLLITILITILIIILI LILLI LE T 157 Key Electricity cable entry 480 Gas supply Fig 1 Domestic Hot Water outlet Domestic Cold Water inlet ae TOP MEW Central Heating Pressure relief valve Central Heating Flow outlet Central Heating Return inlet Air intake for two pipe flue systems Q N OPTIMA 1001 FERROLI Boiler Flow Diagram 5 A 19 49 J EA ANN NN NA NI N S NS TRU TT Y 27 26 21 20 71 48 46 34 47 84 85 n 1 1 S 158 8 12 937136 14 10 114 39 68 101 Fig 2 FERROLI OPTIMA 1001 Key 1 F
6. crease pressure and anticlockwise to reduce pressure 10 Tighten sleeve lock but F then check that the pressure is still at the required value 11 Adjust minimum pressure by rotating screw E anticlockwise until the required value is reached 12 Fitcoil C by sliding it into the sleeve pushing and rotating it lightly until the coupling spring I clicks into place 13 Shut down and ignite the burner checking that the minimum pressure value is stable 14 Reconnectthe wires to coil C of the Modureg 15 Reconnectair pressure compensation tube 16 Replace protective cover D 17 Turn burner off remove pressure gauge close and test test point Key A Test point inlet pressure B Burner test point C Coil D Protective cover E Minimum adjustment screw F Lock nut G Sleeve H Pressure compensation tube I Coupling spring L Adapter for only LPG version 22 FERROLI OPTIMA 1001 Burner Perssure C H 36 Natural gas L P G Propane 35 30 25 20 mbar kW 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 kcal h 40 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 x 1000 1
7. so boiler is calling for heat 4 Check position of flame sensing electrode 82 2 Check first A B and C above LED 6 is ON 5 Check burner gas pressure during ignition 30 FERROLI OPTIMA 1001 Special Installation Possibilities Two pipe air intake flue outlet Special Air Intake Flue Outlet The standard Flue air intake hood on top of the boiler can be replaced by a special two pipe flue adapter 242 7 Special two pipe flue adapter 823071 2 remove air intake cover 80 mm 31 Phone numbers Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS FERROLI ALL SPECIFICATIONS SUBJECT TO CHANGE Lichfield Road Branston Industrial Estate Burton Upon Trent Staffordshire DE14 3HD Tel 08707 282 885 Fax 08707 282 886 01 01 Cod 3540246 2
8. 5 1 0 1 5 PP INITIAL SYSTEM PRESSURE bar 1 0 1 5 20 1 5 20 20 Note WATER 1 Fill C H installation to min 1 5 bar CONTENT of system EXPANSION VESSEL VOLUME litres 2 Select by preference the expansion vessel for LITRES increased system pressure of 2 0 bar 3 Expansion vessel must be fitted to Central Heating Return Inlet 4 The standard 7 litres expansion vessel is charged to 1 bar 12 FERROLI PTIMA 1001 Installation Note To mount the boiler on the wall a two person lift will be needed 1 0 UNPACKING The appliance is delivered in 2 cartons The large carton contains the boiler and the Installation Servicing and Users Instructions The second carton contains the mounting jig assembly complete with isolating valves the assembly fixing screws and wall plugs x4 the boiler mounting nuts and washers x2 drilling template flue assembly and flue bend When the cartons are unpacked examine for any signs of damage in transit All protective plastic should be left in place until installation is complete 2 0 2 1 2 2 24 2 5 2 6 FIXING THE MOUNTING ON THE WALL Rear Wall Flue Applications Select the boiler location carefully ensure that all requirements given in previous text are satisfied Fig 10 will also give guidance to fixing dimensions Locate template on wall mark the positions of the four jig bracket fixing holes and the flue opening
9. cocks fig 11 Gradually fill the system as detailed in Make up Water While filling vent the heat exchanger at venting point by loosening cap fig 20 and vent each radiator Tighten cap on heat exchanger air vent Ensure the working pressure when filled is between 1 to 1 5 bar on the pressure gauge see technical data Check the system for leaks Flush system in accordance with BS 7593 Filling the Domestic Hot Water System Close all hot water draw off points Open main cold water stop cock and ensure the cold water inlet cock is open at the boiler jig bracket fig 11 Slowly open each hot tap in turn until clean water free from air pockets is seen Check system for leaks Electricity Supply Carry out preliminary checks i e earth continuity polarily short circuit and resistance to earth using a suitable multimeter The Gas Installation The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of BS6891 1988 19 OPTIMA 1001 FERROLI Flame viewing opening 99999 C H pressure gauge C H boiler thermostat Flame failure reset knob Time clock if fitted C H D H W selector switch Domestic hot water thermostat Fault diagnostic lights fig 21 85 To Light the Boiler fig 21 Open controls panel door Switch on electricity supply Adjust room thermostat and all exte
10. not accept their use above ground 10 FERROLI OPTIMA 1001 Gas Cold water 8 3X p Additional expansion vessel C H T M if required 14 Filing 2 point C H Fig 6 NOTE A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout Y gt Key 1 Filling point C H 2 Temporary connection Fig 7 3 Cold water supply 11 OPTIMA 1001 FERROLI Built in Central Heating Water Circulating Pump The pump head available for circulating the water is given in fig 8 N B The pump is factory set at position 3 The pump is a Grundfos type 15 50 UPS series Grunfos Pump performance graph Note Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute If required an additional expansion vessel may be fitted to the central heating return inlet If the total volume of water in the system exceeds 40 litres an additional expansion vessel must be fitted to the central heating return inlet Pump performance curve Grundfos UPS 15 50 in wg mbar 240 500 180 120 60 1 2 3 Speed settings A Boiler pressure drop B Max available pump head C H 0 0 litres sec 0 0 2 0 4 0 6 Fig 8 SAFETY VALVE SIZING OF ADDITIONAL EXPANSION VESSELS ISETTING bar Deduct from the value given in the table the 7 litre VESSEL CHARGE vessel supplied PRESSURE bar 0
11. Carefully cut the circular hole 118 mm minimum diameter for the flue assembly Using a 10 mm drill drill 70 mm deep holes to accept the wall plugs and insert wall plugs Fit the mounting jig assembly using the four fixing screws provided Ensure that all the service cocks are in the OFF position Operate valves several times to ensure they are free With the exception of the connection to the pressure relief valve make all the water and gas connections to the jig bracket valves Fully tighten fig 11 Water connections can be made with compression or capillary fittings before the gas inlet to the boiler there must be at least 100 mm of straight before any bends FIXING THE MOUNTING JIG ON THE WALL Side Wall Flue Applications Selectthe boiler location carefully ensuring that all the requirements given in previous text are satisfied Fig 10 will aso give guidance Locate the template on wall and mark the position of the four jig bracket fixing holes Using a 10 mm drill drill 70 mm deep holes to accept the wall plugs and insert wall plugs Fit the mounting jig assembly using the four fixing screws provided Extend a horizontal line from the centre of the rear flue outlet to the side wall Mark the centre line vertically for the flue assembly hole and mark the centre of the hole Carefully cut the circular hole 118 mm minimum diameter for the flue assembly 13 OPTIMA 1001 FERROLI Important Note Always use two spa
12. NSTALLATION OF GAS FIRED HOT WATER BOILERS B S 6891 1989 GAS INSTALLTIONS B S 7671 1992 IEE WIRING REGULATIONS B S 4841 1990 SPECIFICATION FOR EXPANSION VESSALS Model Water Bye Laws OPTIMA 1001 FERROLI Technical data Nominal Heat Input D H W amp C H gross Minimum Heat Input D H W amp C H gross Nominal Heat Input D H W amp C H net Minimum Heat Input D H W amp C H net Nominal Heat Output D H W amp C H Minimum Heat Output D H W amp C H Gas rate Maximum burner pressure Minimum burner pressure Injector manifold Dimensions o all Height Width Depth Weight net Weight gross Electricity supply Fuse rating Mains on P C B in boiler Electrical input Domestic Hot Water flow 35 rise Minimum Domestic Hot Water Flow Maximum domestic cold water Inlet pressure C H Safety valve pressure setting C H Expansion vessel capacity Min heating circuit pressure Max heating circuit pressure Low water pressure switch Boiler water capacity Heating Domestic hot water Pipe connections Gas Domestic cold water inlet Domestic cold water outlet Central heating flow Central heating return Pressure relief valve drain Min installation clearances Sides Left hand Right hand Front Min height from worktop to base NATURAL GAS G20 PROPANE LPG G31 34 8 kW 34 0 kW 15 1 kW 14 8 kW 31 3 kW 31 3 kW 13 6 kW 13 6 kW 27 9 kW 27 9 kW 11 8 kW 11 8 kW
13. a qualified Heating Engineer and that a comprehensive service should be carried out at LEAST ONCE A YEAR 24 FERROLI OPTIMA 1001 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 Slide switch set clock auto set programme Display Symbol cj 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 o A If these are suitable no programming is required and the slide switch A can be 16 30 23 30 moved to the Auto position and the central heating will be ON for these periods 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 1 1 Use buttons and to set 1st ON time eg 6 00 2 Press button 2 1 Use buttons and to set OFF time eg 9 00 3 Press button P 3 1 Use button and to set 2nd ON
14. connected by the Local Gas Region or by a Local Gas Region s Contractor Installation pipes should be fitted in accordance with BS6891 1988 Appliance inlet working pressure must be 20 mbar MINIMUM Pipework from the meter to the combination boiler must be of an adequate size The boiler requires 3 3 m h 116 ft3 h of natural gas Do not use pipes of a smaller size than the combination boiler inlet gas connection The complete installation must be tested for gas soundness and purged as described in BS6981 1988 pipework must be adequately supported An isolating gas valve is provided and should be fitted on the manifold assembly Water System Central Heating It must be a sealed system Detailed recommendations are given in 56798 BS5449 BS6700 and CP342 Part 2 Pipework not forming part of the useful heating surface should be insulated to prevent any heat losses or possible freezing i e in roof spaces or ventilated underfloor spaces Drain taps should be positioned at the lowest point of the system in accessible locations to permit the whole system to be drained down The drain taps should be in accordance with BS2879 Copper tubing to BS2871 Part 1 is recommended for water carrying pipework Pipework in horizontal runs should have a gradient where possible to facilitate the removal of air It should be ensured that the boiler heat exchanger is not a natural point for collecting air A typical heating system with domestic hot wate
15. connection 7 2 1 Please note that the room thermostat clock switch connection is 24 V To connect mains voltage to these terminals will seriously damage the printed circuit board The room thermostat and clock switch connector block is situated within the connector box Twin core cable should be used for this connection terminals 4 and 5 7 2 2 f using a remote 240 Volt time clock ensure thatthe motor and switch connections are totally separate in the clock and that the switch connections are independent for the 24 Volt terminals 4 and 5 on the boiler External controls room stat or remote time clock in the place of loop terminals 4 and 5 Please note 24 V only use only voltage free contacts IMPORTANT If 230 V is connected to terminals 4 or 5 damage will be caused to the P C B Screw Fig 19 Fixing screw front 18 FERROLI OPTIMA 1001 8 0 8 1 8 2 8 3 8 4 Burner pressure COMMISSIONING AND TESTING Filling the Central Heating System test point Heat exchanger vent Pump C H pressure gauge Gas inlet pressure C H pressure relief valve fest point D H W drain point Low water pressure switch Fig 20 Remove the top front panel by gripping both sides and lifting forward away from main boiler assembly Loosen the cap of the automatic air vent fig 20 and leave it loose Open the central heating flow and return
16. dow or any type of public access The installer must consider that the overflow could discharge boiling water 16 TOP VIEW BOILER SIDE OUTLET Fig 14 FERROLI OPTIMA 1001 Fixing points Fig 15 Fig 16 Fig 17 OPTIMA 1001 FERROLI 6 0 FITTING THE FLUE ASSEMBLY 61 With Sufficient Clearance To Insert Assembly From Inside 6 1 1 Insert the flue assembly into the wall 6 1 2 Insert the flue bend in the top plate of the boiler 6 1 3 Secure the flue bend 6 1 4 Fully insert the flue assembly into the boiler flue bend Insert the self tapping screw supplied Fully tighten 6 1 5 Check the terminal relationship with the wall as shown in fig 12 6 1 6 Make good internal wall face 6 1 7 Make good the outside wall face re weatherproof 6 2 With insufficient Clearance To Insert Assembly From Inside 6 2 1 Insert the flue bend in the top plate of the boiler 6 2 2 Secure the flue bend 6 2 3 From outside push flue duct then the air duct through the wall 6 2 4 Fully insert the flue duct into the flue bend then the air duct Securethe air duct with the self tapping screw provided 6 2 5 Continue as detailed in 6 1 5 above 7 0 ELECTRICAL INSTALLATION Electrical installation must be carried out by a competent e
17. er B Water Flow Restricter Removed Bar 0 50 100 gall h 150 90 80 70 60 50 Fig 2 D H W B temperature VS flow A Cold Water 15 C 30 B Water 5 C 20 10 c 28 FERROLI OPTIMA 1001 16 Fan 32 Central heating pump wanwoe7es4a21 4321 EI m 34 flow temperature sensor Eee 42 D H W temperatuure sensor 43 Air pressure switch 46 Operator gas valve 47 Modulating regulator O MODUREG gas valve P P2 1 a 49 Overheat cut off thermostat 0 0 50 exchan limit thermostat 51 Heat exchan frost thermostat re 61 C H selector switch d Je ES 62 Time clock 63 boiler thermostat E 68 Control box with P C B id 72 Room thermostat not fitted DP 80 Five pole terminal 240 24V 34 81 spark electrode JP1 and JP4 Jumpers a 82 Flame sensing electrode JP1 Is not required 84 85 83 Automatic igniti
18. h the P C B The boiler is fitted with its own Central Heating pump The pump is switched ON OFF by the time clock and or a 24 Volt room thermostat The pump circuit also has a 6 minute over run time There is a Domestic Hot Water flow switch fitted and when there is a demand for Domestic Hot Water flow of more than 0 5 gallon minute 2 5 litre minute the Central Heating pump is switched off making available the maximum output of the gas burner for Domestic Hot Water On the P C B the output for Central Heating can be set However this is not required for the majority of installations as the boiler will automatically adjust its output to the system demand AUTO MISER control This does not influence the maximum output for domestic hot water At the factory the central heating output is pre set to maximum The appliance is not suitable for external installation Related Documents This appliance must be installed strictly in accordance with these instructions The Gas Safety Regulations Installations amp Use 1994 The Local Building Regulations The Building Regulations The Buildings Standards Scotland Consolidated Regulations British Standards Codes of Practice B S 7593 1993 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS B S 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES B S 5440 PART 1 FLUES B S 5440 PART2 AIR SUPPLY B S 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS B S 6798 1987 I
19. he outside grill by 60 mm never cut it to the same length as the plastic air pipe aluminium flue pipe plastic air inlet pipe 70 mm Aluminium flue pipe length Plastic air inlet pipe length plus 70 mm longer 10 mm min F1 Flue outlet 60 mm max 4 1 1 Accurately measure the Wall thickness P1 4 1 2 From the end opposite to the terminal cut the plastic air duct dimension A1 to length P1 192 mm Note That the terminal is not included in Al 4 1 3 Cut the aluminium flue duct to length P1 262 mm dimensions F1 Note The aluminium flue pipe must be 70 mm longer than the plastic air inlet pipe 4 1 4 Drill a 8 mm hole 15 mm from the plain end of plastic air duct 4 1 5 Place flue components to one side to be used later Rear flue Outlet Fig 12 A1 Air intake 4 2 Side Flue Outlet fig 13 Important The aluminium flue pipe must protrude into the outside grill by 60 mm never cutitto the same length as the plastic air pipe Aluminium flue pipe length Plastic air inlet pipe length plus 70 mm longer 4 2 1 Accurately measure the Wall thickness P2 4 2 2 Accurately measure the distance from the centre of the stud fixing of the mounting jig assembly to the side wall Q2 4 2 3 Fromthe end opposite to the terminal cut the plastic air duct dimension A2 to length P2 Q2 180 mm Note That the terminal is not included in length A2 4 2 4 Cut the aluminium flue d
20. ired for D H W D H W sensor 42 not connected or D H W temperature too high Waiting time operating replace P C B Short circuit on D H W sensor 42 or resistance lower than 500 Ohm C H limit thermostat 50 open circuit pump run C H water pressure low 114 open circuit Room stat 72 at Max HW tap closed POSSIBLE CAUSE OF FAULT No main electricity switches off fuse blown Hot water tap open D H W flowmeter 136 contact closed Roomstat 72 or clock 62 not calling for heat Central heating sensor 34 not connected or boiler temperature too high or boiler thermostat 61 below CH temperature Waiting time still operating max 3 minutes sensor 34 short circuit or resistance lower than 500 ohm limit thermostat 50 open circuit pump will run water pressure low 114 open circuit H W AND CENTRAL HEATING First check A and B above FAULT POSSIBLE CAUSE OF FAULT energised not energised Check first A and B above energised not energised Air pressure switch 43 not in NC position or miswired check wiring fan 16 at low speed remove jumper JP4 fan 16 not running at full speed or air flow too low air pressure switch 43 faulty IGNITION OF BURNER AUTOMATIC IGNITION 1 Fan 16 should run at full speed open hot tap or set controls 3 Check spark and position of spark electrode 81
21. ixing point 2 Flue terminal 3 Flue air intake hood 4 Sealing gasket 5 Room sealed compartment 6 Control panel 7 Gasinlet 8 Domestic hot water outlet 9 Cold water inlet 10 Central heating flow outlet 11 Central heating return inlet 12 D H W draining point 14 Central heating safety valve 15 Air inlet to fan 16 Fan 19 Combustion heat exchanging compartment 20 Burner assembly 21 Injector manifold 22 Burner 26 Combustion chamber insulation 27 Copper heat exchanger for C H D H W 28 Flue collector from heat exchanger 29 Internal flue exit 30 Flue surplus air collector 31 Air pressure control damper 32 Central heating pump 33 C H waterway of the heat exchanger 34 C H flow temperature sensor 35 Air separator 36 Automatic air vent 37 Cold water inlet filter 39 Cold water flow limiter 41 D H W waterway of the heat exchanger 42 D H W temperature sensor 43 46 47 48 49 50 51 53 56 58 59 61 62 63 68 69 70 71 80 81 82 83 84 85 86 87 100 101 114 136 145 157 158 Air pressure switch Operator gas valve Modulating regulator Modureg gas valve Burner pressure test point Overheat cut off thermostat Central heating limit thermostat Central heating frost thermostat Heat exchanger venting point Expansion vessel Fan air outlet pressure test point Flue outlet pressure test point C H selector switch Time clock C H boiler thermo
22. lectrician The appliance is to be connected to a 240 V 50 Hz supply see fig 18 The supply fuse rating is The terminals are accessible after removing the white base plate and single screw securing the terminal cover see fig 18 7 1 Procedure 7 1 1 The supply cable must be no less than 0 75 mm 24x0 2 mm to BS6500 table 16 7 1 2 The earth conductor must be cut longer than the live and neutral fig 19 Connect the Supply Cable to the terminal block marked 240 V 50 Hz N the supply cable is to be connected as follows i Connect the brown wire to the L live terminal ii The blue wire to the N neutral terminal iii The green yellow wire to the earth terminal 7 1 8 Secure the cable with the cable clamp The supply cable can be connected to the mains supply by the use of an unswitched shuttered socket outlet in conjunction with the 3A fused 3 pin plug both in accordance with BS 1363 This provides complete isolation Alternatively a fused double pole switch having a contact separation of at least 3 mm in all poles and provided just for the boiler and its external controls can be used A wiring diagram is provided on the appliance attached to the rear of the front panel In addition there is one in this manual fig 25 Attention is drawn to the requirements of the current I E E Regulation and in Scotland the electrical provisions of the Building regulations 7 2 Thermostat fig 18 or remote time clock
23. nel 2 screws i Turnonelectricity supply open a hot tap to full flow and when the burner lights test for gas soundness with a leak detection fluid around the gas valve and connections including the pressure test point Screws 9 0 SYSTEM OPERATION Let the boiler operate normally on central heating for about 30 minutes l Vent radiators I Vent heat exchanger lll Examine all pipework for leakage IV Turn on a D H W tap and check that the C H pump stops running V As the D H W temperature reaches 60 C check the burner for modulation Switch off electricity Drain down the central heating system fully when hot Refill the system as previously instructed Repeat the venting Examine the system s water pressure and top up as necessary Replace the casing front panel and close the control panel cover 10 0 HANDING OVER TO THE USER After completion of installation and commissioning of the system HandovertheUser s Instructions to the Householder and explain His Her responsability under the Gas safety Installation and Use Regulations 1994 b Explain and demonstrate the lighting and shutting down procedure Explain the operation of the boiler including the use and adjustment of ALL system controls Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions d Stress the importance of regular servicing by
24. nners to prevent twisting of soft copper pipework on the boiler Flush out the water system Note The maximum inlet cold water pressure must not exceed 10 bar 145 P S I and a water governor or a pressure reducing valve will be required if the pressure is in excess of 5 bar 72 5 1 Ensure all pipework is adequately supported Drilling template Rear flue outlet Diam min 118 mm J Upper bracket Fixing stud J Side flue outlet boiler Diam min 118 mm 887 Boiler 480 mm Lower bracket Fig 10 1 Electrical cable entry 2 Gas supply 3 Domestic Hot Water outlet 4 Domestic Cold Water Inlet 5 Outlet Central Heating safety valve 6 Central Heating flow outlet 7 Central Heating return inlet 2 22 3 4 5 15 6 7 22 4 Domestic Cold Water inlet 15 mm 3 Domestic Hot Water 5 Outlet central heating 6 Central Heating flow outlet 22 mm 2 Gas 22 mm outlet 15 mm safety valve 15 mm 7 Central Heating return inlet 22 mm E 11 Important Note Always use two spanners to prevent twisting of soft copper pipework 9 Note The central heating safety valve 5 should be piped 15 mm to discharge safely outside the property 14 FERROLI OPTIMA 1001 4 0 PREPARING THE FLUE ASSEMBLY 4 1 Rear Flue Outlet fig 12 Important The aluminium flue pipe must protrude into t
25. on control panel 1 4 Is not required S ie vave Sand P1 C H max output to be set on site 86 automatic control reset knob Pave DEW temperature factory 580 101 P C B 114 Low water pressure switch 81 eH Selector Switch 136 Flowmeter UE Pop 145 C H Pressure switch A 1 157 D H W thermostat a be d abed abcd 164 Fault diagnostic temperature control panel amp LS Heating timed Hot water only Heating 24V 230V 50 Hz and hot water continuous and hot water RED _ x T NOTE B RENT THE TRANSFORMER ON THE P C B HAS A 059255002 BUILT IN OVERHEAT PROTECTION a IF THIS IS OPEN ALL LED S WILL BE OFF BUT nisse THE C H PUMP 32 WILL RUN AA 1566 5s SWITCH OFF THE BOILER FOR AT LEAST THH ow HI 20 MINUTES ouT 3 129 80 HHHH E TM 4 I r Es 230v CONNECTOR 2 121509876 54321 4321 54 w N EEES M A D H W FLOW 098789 eet 21 oH SWITCH ON OFF CAN ITERE L2 xf 3 TERMINALS 1 AND 3 gt x i ee CONNECTOR L Css y 6 Da SHORT CIRCUIT 12 13 E WW BOILER STARTS FOR C H WAITING TIME IS EXCLUDED WEZ 102 MAX BURNER PRESSURE C H CHEDKED SET WITH P1 OOOOOO x 29
26. r circuit is illustrated in fig 6 Important A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l min The bypass should be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout Make up Water Provision must be made for replacing water lost from sealed system Reference should be made to BS6798 for methods of filling and making up sealed systems There must be no direct connection between the boiler s central heating system and the mains water supply The use of mains water to charge and pressurise the system directly is conditional upon the Local Water Byelaw Again any such connection must be disconnected after use Domestic Hot Water Always fit a water softener or descaler in hard water areas A 15 mm copper connection point on the boiler jig bracket for attaching to the main supply is provided The maximum domestic water pressure for the inlet supply is 10 bar 145 P S I If the cold mains supply exceeds 5 bar 72 9 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 16 ft before the appliance Such a valve must be approved by the Water Research Council Attention 15 drawn to the Model Water Byelaws Fittings manufactured from duplex alpha beta brass are not acceptable for underground use and certain water undertakings will
27. rnal controls to Check operation of pump Turn the boiler thermostat to maximum Fan will run A waiting time of max 3 minutes before fan will run is possible and main burner will light e Temporarily turn off by switching off electricity supply apop Important Note If the burner stops for C H only after a waiting time of 3 minutes will the boiler light again 20 FERROLI OPTIMA 1001 Burner Pressure C H and D H W 8 6 Range Rate the Boiler C H not required for standard installations The boiler can be range rated for an output from 11 8 KW up to 27 9 kW When the boiler is supplied it is factory set at the maximum output 27 9 kW Procedure a Release the control panel fixing screws fig 30 and lower panel b Loosen the screw in the burner pressure test point fig 22 and attach a gauge Switch on the electricity supply to relight the main burner Balance tube __ Test point burner pressure Gas valve Modureg Fig 22 Gas inlet pressure test point A E d z z z 2 P2 Minimum Maximum settings mbar mbar Natural Gas 3 0 15 0 L P G 6 9 34 5 Note 1 Modulation is available on central heating so the procedures must be carried out while the system is relatively cold Recheck boiler thermostat is set to maximum d Adjust the potentiometer P1 on the PCB fig 24 in the control panel until
28. stat Control box with P C B Inner flue duct Outer air intake duct Modulating balance tube 230 V 24 V roomstat terminal blocks Ignition electrode Flame sensing electrode Automatic ignition control panel 1 gas valve operator 230 V 2 gas valve operator 230 V Automatic control reset knob Venturi test point Fault diagnostic temperature control panel P C B printed circuit board LOW Water pressure switch Flowmeter C H pressure gauges D H W thermostat Gas inlet pressure test point OPTIMA 1001 FERROLI Installation Details Gas Safety Installation amp Use Regulations 1994 In the interest of safety itis the law that all gas appliances are installed by a competent person in accordance with the above Regulations Building Regulations Building Standards Scotland Codes of Practice current I E E Regulations and the byelaws of the Local Water Undertaking Failure to comply with the Regulations may lead to prosecution it is in your interest and that of safety to ensure that the law is complied with Important If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the British Gas publication Guide for Gas Installation in Timber Frame Housing Reference DM2 If in doubt advice must be sought from the Local Gas Region of British Gas Plc Location of Boiler The installation of the 1001 must be on a suitable non combustible load bearing wall which will provide an adequate fi
29. t and Quinnel guard part No C2 should be screwed to the wall centrally over the terminal when the distance is less than 2 m from the outside floor Air Supply The room cupboard or compartment in which the boiler is installed does not require a purpose provided vent FERROLI OPTIMA 1001 Terminal Position Minimum Clearance mm 5 min 480 5 min i 370 50 mm NOTES Access to the front of the boiler must be available for maintenance min 600 mm Anun e a OPTIMA 1001 FERROLI Flue system The boiler allows the flue outlet to be taken from the rear of the boiler or from either side A standard flue length of 0 75 metres is provided Alternative lengths of two or three metres can be supplied equivalent to wall thicknesses of up to 565 1815 and 2815 mm for rear flues and deduct 91 mm plus distance from side wall for side outlet flues It is absolutely essential to ensure that products of combustion discharging from the terminal cannot re enter the building or enter any adjacent building through ventilators windows doors natural air infiltration or forced ventilation air conditioning Gas Supply If necessary the local Gas Region should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must not be used without prior consultation with the Local Gas Region A gas meter can only be
30. the required burner pressure is obtained Anticlockwise to reduce the pressure Note 2 The range of inputs with corresponding burner pressure is given on the Data badge which is situated behind the top front panel Further informations is on fig 23 e With the pressure set turn off the electrical supply and mark the set input on the Data badge with sticker supplied Burner Pressure C H and D H W P1 C H range rating to be set on site P2 D H W temperature factory set not to be adjusted P1 Adjust with screwdriver 1234109876 54321 4321 H Xi loop 6 Bie see 52 9 87 6854321 1312 109 765 321 w w w w lt 21 3 1 m x7 v Fi RY4 Qo JP4 Z xaje Fig 23 21 OPTIMA 1001 FERROLI Honeywell VR 4605 NA 4003 valve with V7335A4014 Modureg Gas pressure Adjustment 1 With the burner lit 2 Connect suitable pressure gauge to burner test point B and then 3 Disconnect air pressure compensation tube 4 Disconnect the wires from coil C of the Modureg 5 Remove protective cover D 6 Remove coil C by opening the coupling spring I 7 Screw the minimum adjustment screw E up tightly clockwise 8 Unscrew lock nut on sleeve G 9 Adjust maximum pressure by rotating sleeve G clockwise to in
31. time eg 12 30 7 13 Display 12 00 3 Display 12 90 3 4 Press button 4 1 Use button and to set 2nd OFF time eg 14 00 5 Press button P 5 1 Use button and to set 3rd ON time eg 16 00 Display Display 6 Press button 6 1 Use button and to set 3rd OFF time eg 23 30 Display Display 7 The timer can be programmed with up to 8 ON and 8 Oncompletion of programming slide switch to Auto 8 OFF times by repeating the above procedure position the time of day will be displayed and the cen tral heating will switch ON and OFF according to the programme set 25 OPTIMA 1001 FERROLI 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 AIR PRESSURE SWITCH White silicone Red silicone tube KROMSCHRODER KROMSCHRODER DL 1E
32. uct to length P2 Q2 250 mm dimension F2 Side Flue Outlet Note The aluminium flue pipe must be 70 mm longer than the plastic air inlet pipe Fig 13 P2 4 2 5 Drilla3mm hole 15 mm from the plain end of plastic air duct 4 2 6 Place flue components to one side to be used later 15 5 0 5 1 5 2 5 3 5 4 5 5 5 6 OPTIMA 1001 FERROLI CONNECTING THE BOILER Place the boiler on its back Remove the boiler base plate four screws fig 16 Remove the plugs fitted to the boiler water connections Remove the bag of sealing washers from the boiler pipework Remove the front panel by gripping on both sides sliding up and pulling away from the main boiler Lift boiler as shown in fig 15 onto the top studs and fit supplied nuts and washers hand tight Lift at bottom to engage the water and gas connections Tighten central heating flow and return and the domestic hot water inlet and outlet using appropriate sealing washers Tighten the gas union Screw the pressure relief valve adaptor provided through the jig bracket into the valve using the remaining washer fig 17 Connectthe pressure relief valve discharge pipe 15 mm to the outside of the building where possible over adrain The discharge must be such that it will not be hazardous to occupants or passers by cause damage to external electric components or wiring The pipe should be directed towards the wall It must not discharge above an entrance or win
33. ve Burner pressure C H 8 7 D H W Burner Pressure 9 System operation 10 Handing Over to the User Time clock Air pressure switch Spare Parts List Domestic Hot Water Performance Modureg General Wiring Diagram Fast Fault Finding Special Installation Possibilities FERROLI OPTIMA 1001 General Description The Ferroli ZPTIMA 1001 is wall mounted room sealed fan assisted combination boiler for Central Heating C H and domestic Hot Water D H W The boiler is of light weight construction and the heat exchanger provides Central Heating and Domestic Hot Water from an integrally designed unit The boiler contains its own expansion vessel for sealed systems The wall mounting jig contains all the isolating cocks for the water and gas supplies which can be fitted to the wall and provided with all the necessary gas and water connections prior to the boiler being attached The flue can either be left hand right hand or rear There are three flue lengths available and they are 0 75 metres for wall thickness up to 565 mm 2 metres for wall thickness up to 1815 mm and 3 metres for wall thickness up to 2815 mm these wall thicknesses assume a rear flue outlet For side outlet the effective wall thickness for each flue length is reduced by 91 mm plus the distance of the appliance from the side wall The Central Heating and the Domestic Hot Water temperature is controlled by the Honeywell Modureg valve in conjunction wit
34. xing for the boiler mounting bracket assembly The location should be in an area where the water pipes will not be subjected to frost conditions In siting the combination boiler the following limitations must be observed The combination boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current i e wiring regulations and in Scotlandthe 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 should be so situated that it cannot be touched by a person using the bath or shower Terminal Position POSITION MINIMUM SPACING 3 mm A Directly below an openable window air vent or any other ventilation opening 300 B Below gutters soil pipes or drainpipes 75 Below Eaves 100 D Below a Balcony 100 E From vertical drainpipes or soilpipes 75 F From internal or external corners 100 G Above adjacent ground or balcony level 100 H From a surface facing the terminal 600 1 Facing another terminal 1 200 J From opening door window in carport into dwelling 1 200 K Vertically from a terminal on the same wall 300 L Horizontally from a terminal on the same wall 300 N Below carport 600 A Quinnel Barra
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