Ferroli DOMINA N 80 Installation, Service And User Instructions Manual Download Page 1

Page: 1 / 52

Appr

. nr

. B98.01 A - CE 0063 A

T 4967

DOMINA N 80

INSTALLATION, SERVICE AND USER

INSTRUCTIONS

G.C. NO: 47-267-23

Copper Wall-Mounted Combination,

Gas Fired Boiler for Central Heating

and Domestic Hot Water Production,

Fan Assisted, Room Sealed Compartment,

Electronic Flame Ignition and Control

3543711/0 - 06/2001

Summary of Contents for DOMINA N 80

Page 1: ...ALLATION SERVICE AND USER INSTRUCTIONS G C NO 47 267 23 Copper Wall Mounted Combination Gas Fired Boiler for Central Heating and Domestic Hot Water Production Fan Assisted Room Sealed Compartment Electronic Flame Ignition and Control 3543711 0 06 2001 ...

Page 2: ... be enclosed in your customer information pack This record must be completed and left with the end user All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your central heating log book You can check to the CORGI registered by calling CORGI on 01256 372300 Ferroli is a member of the Benchmark initiative and fully supports the aims of the ...

Page 3: ...eating circuit set to open at 3 bar Built in Expansion vessel Variable speed pump Central heating flow temperature adjustment thermostat Domestic hot water flow temperature adjustment thermostat Central heating limit thermostat Overheat safety thermostat Electronic control unit for automatic flame ignition and control Central heating low water pressure cut off switch Domestic hot water flow temper...

Page 4: ...NAL CHARACTERISTICS 2 01 Technical information Domina N 80 boilers are central heating and domestic hot water heat generators and are produced as standard to function with natural gas or Liquid Petrolium Gas converted appliances Key 1 3 4 central heating flow outlet 2 1 2 domestic hot water flow outlet 3 1 2 gas inlet 4 1 2 domestic hot water inlet 5 3 4 central heating return inlet 6 Pressure rel...

Page 5: ...mestic hot water heat input Boiler water contents Domestic hot water contents kW kW kW kW kW Litres Litres Domina N 80 23 8 9 7 25 8 11 5 23 8 1 5 0 8 MODEL Connections Expansion vessel Max working pressure central heating circuit Max working pressure hot water circuit 1 2 3 4 5 Capacity Pre pressurising value Ø Ø Ø Ø Ø Litres bar bar bar Domina N 80 3 4 1 2 1 2 1 2 3 4 7 1 3 6 MODEL Main injector...

Page 6: ...r 36 Automatic air vent valve 42 Domestic hot water flow temperature sensor Fig 2 43 16 27 50 19 49 28 5 20 21 26 132 90 91 81 82 22 56 IN OUT MIN R E S E T O F F ON 0 5 1 2 3 4 6 bar 98 63 157 145 C C 62 10 8 74 7 84 85 44 136 32 36 114 34 14 42 9 11 43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat 50 Central heating flow limit thermostat 56 Expansion vessel 62 Time clock option ...

Page 7: ...s and outputs with Natural gas Fig 4 Fig 5 Diagram of pressures and outputs with LPG Propane 2 3 4 5 6 7 8 9 10 11 12 13 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 8 9 10 11 12 13 14 15 16 17 18 19 20 21 kW kcal h x 1000 mbar 14 kW kcal h X 1000 mbar 18 19 20 21 22 23 5 10 15 20 25 30 35 9 10 11 12 13 14 15 16 17 9 10 11 12 13 14 18 19 20 15 16 17 8 2 05 Domestic hot water variability characteri...

Page 8: ...5 9 55 1 19 0 41 2 33 1 125 17 5 32 4 68 9 23 7 51 5 41 3 150 21 0 38 8 82 6 28 5 61 8 49 6 175 24 5 45 3 96 4 33 2 72 1 57 9 200 28 0 51 8 110 2 38 0 82 4 66 2 0 140 0 259 0 551 0 190 0 412 0 33 For syst volumes other than those given above mult the syst volume by the factor across m h 3 Q 8 7 6 5 4 3 2 1 0 0 5 1 5 2 5 1 2 H mbar x 100 2 06 Pump characteristics The pump head available for circula...

Page 9: ...he boiler is installed does not require a purpose provided vent when using the standard concentric flue Flue System The boiler allows the flue outlet to be taken from the rear of the boiler from either side or vertically A standard flue length of 0 75 metres is provided Alternative lengths of two or three metres can be supplied equivalent to wall thicknesses of up to 565 1815 and 2815mm for rear f...

Page 10: ...boiler s central heating system and the mains water supply The use of mains water to charge and pressurise the system directly is conditional upon the Local Water Byelaws Again any such connection must be disconnected after use A typical temporary filling loop is shown in fig 10 Domestic Hot Water Always fit a scale reducer in hard water areas 18 clarke degrees or over A 15mm copper connection poi...

Page 11: ... intersection with roof Dimensions Terminal position kW input expressed in net Balanced flues room sealed Open flues Natural draught Natural draught Fanned draught Fanned draught Aa 300 mm 600 mm 1500 mm 2000 mm 300 mm Not allowed 300 mm Ba 300 mm 300 mm 300 mm 600 mm 300 mm Not allowed 300 mm Ca 300 mm 400 mm 600 mm 600 mm 300 mm Not allowed 300 mm D 300 mm 75 mm Not allowed 75 mm E 300 mm 200 mm...

Page 12: ...DOMINA N 80 12 3 01 Boiler Mounting Plate 149 178 131 Fig 13 ...

Page 13: ...l bracket to the wall using an antitheft nut on the right side and a standard nut M8 on the left side Mount the boiler on the wall bracket and fix using an antitheft nut on the left side and a standard nut M8 on the right side Using a core drill cut a 118mm diameter hole for the flue 1 CH flow 2 Safety Valve 3 Domestic hot water outlet 4 Gas supply 5 Domestic hot water inlet 6 CH return 932 min 17...

Page 14: ... bracket to the wall using an antitheft nut on the right side and a standard nut M8 on the left side Mount the boiler on the wall bracket and fix using an antitheft nut on the left side and a standard nut M8 on the right side Using a core drill cut a 118mm diameter hole for the flue 1 CH flow 2 Safety Valve 3 Domestic hot water outlet 4 Gas supply 5 Domestic hot water inlet 6 CH return Fig 15b Ø3 ...

Page 15: ...l and the plate use the large diameter washers for the bolts and screws Square Gasket Circular Gasket Fig 16e 5 Through plate into air tube drill two holes and fix in place using two self tapping screws M4 x 6mm long 6 Cut the outer flue flush with the flange on the hanging plate Fig 16f 7 Insert the aluminium flue pipe into white plastic outer flue making sure the aluminium pipe sits fully and ce...

Page 16: ...p outlet flueing Fig 16h Fig 16i 8 Install the inner metal flue into the outlet up to the wallplate flange mark 9 Lift boiler with flue in place engage inner and outer flue slide into position 9 Make sure the inner flue is fully engaged in the flue terminal secure boiler with two nuts and washers sevure bottom of boiler using two screws and washers Rear 1 b b 1 2 2 a Rear Take off the four screws ...

Page 17: ...ure the seals are in place Fig 17i b b a Fix with the screws b Refit wiring connections to fan and air pressure switch tubes ensuring correct orientation I E red tube to air pressure switch connection with red dot and clear tube to air pressure switch connection with no paint marking Fit the fan into the boiler rotating the front upwards to engage with the pin a Secure with the screws b Fig 17l Fi...

Page 18: ...ximum mm 0 m 13 m 45 13 m 23 m 47 23 m 38 m 50 38 m 48 m No restrictor With concentric systems Choose correct restrictor from table below With 2 pipe system Calculate the total flow resistance of the air and flue pipes in metres cap 3 08 2 utilise the table shown below to choose the more suitable restrictor for the flow resistance calculated RESTRICTOR FOR CONCENTRIC SYSTEM Flue lenght up to Use r...

Page 19: ...an extremely easy and safe option For flue length up to 1 m long the 50 mmØ restrictor is required Longer than this no restrictor is required Fig 19 Concentric Vertical Connector 3 07 2 Horizontal concentric connection A 90 bend fig 20 is supplied for the horizontal connection of air and flue gas pipes This can be oriented towards the chosen wall in degrees of 45 1KWMA31Y D S L 125 70 50 30 95 80 ...

Page 20: ...n 10 60mm 3 07 3 Maximum concentric flue length First table below shows the maximum flue lengths available for boilers with concentric systems For correct calculation remember to include the reduction for bends on second table Please refer to 3 06 for use of restrictor Maximum flue lenght permissible 100 mm concentric 125 mm concentric Vertical Horizontal Vertical Horizontal Domina N 80 m 4 m 3 m ...

Page 21: ...ulation method is based on a standard reference parameter 1 metre of horizontal air flue 80 diameter 80 for the maximum length permissible for all the pipes fittings flow resistance coefficient In other words for all components and pipes in the different installation configurations vertical or horizontal air or flue etc and for all the fittings a flow resistance reduction equivalent to x metre of ...

Page 22: ...n with split end Ø80 1 1 1 2 1 2 2 2 1 5 2 5 1 5 2 5 7 Reduction 2 4 3 Air Flue Vertical Horizontal Vertical Horizontal 12 Condensate flue outlet A c c e s s o r i e s Ø 8 0 A c c e s s o r i e s Ø 8 0 Spigot and socket reduction Ø80 100 0 Reduction Airwall terminal products of combustion Ø80 5 Male female flue Ø100 Male female bend 45 Ø100 Male female bend 90 Ø100 Air wall terminal products of co...

Page 23: ...system maximum total flue length 48 metres Fig 24 REF N OF PIECES DESCRIPTION CODE LENGTH OR REDUCTION 1 1 Air bend 80 mm R D 0 75 1 5 m 2 13 Horizontal air pipe 13 0 m 3 1 Air wall terminal 2 0 m 4 1 Air inlet closing flange 5 1 Flue bend 80 mm R D 0 75 2 5 m 6 12 Horizontal flue 24 0 m 7 1 Air wall terminal outlet flue 5 0 m TOTAL 48 0 m Example of wall inlet outlet 2 pipe application Example of...

Page 24: ...bars After filling always close and disconnect the filling loop Note If there is a possibility of air pockets forming in certain points of the central heating system flow and return pipes you are recommended to fit an air vent valve at these points Note When the boiler is installed below the level of the central heating a system single check valve should be fitted in the flow to prevent gravity ci...

Page 25: ...ows the main burner to ignite only after having verified that the fan is working correctly If the difference in pressure between the flue gas discharge pipe and the air intake pipe is not at least equal to the minimum pressure switch calibration value the pressure switch contacts do not close and the gas valve is thus prevented from opening In addition the electrical circuit of the boiler is desig...

Page 26: ...wires located behind the clock position Connect these to terminal 3 and 5 of the clock Replace everything in reverse order Please refer to page 48 of User manual for use of time clock X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 X12 1 2 1 2 3 4 5 6 7 8 9 X10 X8 X7 MF03F JP02 JP01 JP03 Nat LPG X11 CLOCK X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 ...

Page 27: ...hen rotate the knob 98 fig 2 against spring pressure to the RESET position and release it The reset electronic control unit will repeat the start up cycle Note In central heating mode after resetting the boiler will go into it 2 minue delay before starting up again If after a second attempt the burners still fail to ignite consult the paragraph Troubleshooting Note If there is a power failure whil...

Page 28: ...out by COMPETENT personnel ONLY 5 02 Adjusting minimum and maximum pressure Honeywell V K4105G gas valve Connect suitable pressure gauge to burner test point B downstream of the gas valve Disconnect the pressure compensation tube F Remove the protective cap C Adjust potentiometre P3 on the main board at minimum clockwise Operate boiler for central heating Adjust minimum pressure by rotating screw ...

Page 29: ...ly subject to the room heat requirements 5 07 Adjusting the central heating flow t by varying pump flow head The thermal head t the difference in temperature between the delivery water and return water in the central heating circuit must be less than 20 C This is obtained by varying pump flow rate and head using the multi speed variator or switch on the pump itself Increasing the pump speed reduce...

Page 30: ...r junction box This is located in the centre of the boiler at the bottom and can be accessed be the removal of a single screw Any faults found must be rectified before proceeding 5 If electrical checks prove O K replace cover and secure with screw 6 Attach a manometer to the boiler gas inlet test point turn on electricty and fire boiler for hot water check inlet pressure This should be 20mbar mini...

Page 31: ...0 at any other time 30 Refit case and secure with screws 31 Leave boiler set to customers requirements 6 04 Flue Gas Analysis 1 The appliance should be checked visually for obvious defects 2 After removing the jacket on the boiler there are two test point one for flue gas and the other for air 3 Open the air and flue gas test points 4 Introduce the probes as far as the retainer 5 Turn on the hot w...

Page 32: ...ndition 7 02 Final procedure Re open cocks and re charge the system to about 1 bar and vent boiler and radiators Re charge to 1 bar if necessary Upon completion of the work the following Should be checked I Gas soundness of all joints II Water soundness of all joints III The electricity supply IV The pressure of the sealed system and top up where necessary 7 03 To lower the control panel fig 34 Re...

Page 33: ... C H Unscrew the sensor Replace in reverse order 7 07 2 Water Pressure Switch fig 38 Isolate electricity and water supplies Remove outer case two screws bottom rear corners Remove the two securing screws and lower control panel Identify the switch from figure 38 Disconnect electrical connections note positions to the switch Drain the boiler Unscrew the sensor Replace in reverse order 7 07 3 Safety...

Page 34: ...olate gas and electricity supplies Remove outer case two screws bottom rear corners Remove room sealed cover Disconnect fan electrical leads A and note positions Disconnect air pressure tubes from air pressure switch B note positions Undo two screws securing fan assembly C Remove fan from boiler Swap mounting plate over to new fan replace in reverse order 7 11 Limit thermostat or overheat cut off ...

Page 35: ...heat exchanger close tap Remove outer case two screws bottom rear corners Remove two screws from control panel and tilt forward Take off protective cover from main PCB and unplug flow meter lead from terminal X6 Place a piece of cloth or some other absorbent material over rear of control panel to catch any drops of water that may be released when removing the flow meter Using a 24mm open ended spa...

Page 36: ...onnecting pipe E from the rear of the pump body by removing the clip from the left hand side Disconnect the boiler return pipe Disconnect the pump to heat exchanger connection by removing the clip F Unscrew the nut on bottom of pump D Turn the pump body through 90 pull the bottom forward and withdraw the pump body Reassemble in reverse order taking care to ensure the O rings are in place and undam...

Page 37: ...he boiler thermostat is set to maximum than the burner pressure will go to maximum effectively bypassing the auto range rating facility Domestic Hot Water Mode External Call for D H W Flow meter registers at least 2 5 litres min flow to the hot water taps Internal Call for D H W Hot water flow temperature sensor 88 C high limit stat and low water pressure switch calling for heat If both internal a...

Page 38: ...uspect the flow meter has not operated Boiler will not light for C H If the boiler works for D H W but not for heating the fault is most likely to be external controls i e clocks or room thermostats Integral clock if fitted or C H sensor If the heating demand light is on the fault is most likely the C H sensor If this light is not on suspect either a clock or room thermostat not calling To overrid...

Page 39: ...output and maximum D H W temperature both are adjustable by the controls on the facia and because the boiler features automatic range rating no adjustments need to be made Electro mechanical relays control pump operation and put switched live to the ignition PCB demand relay they have transparent plastic covers so that their contacts can be seen moving 8 08 Air pressure switch Operating at 230 V A...

Page 40: ...board NO YES Is LED5 flashing YES Water pressure is not set between 1 1 5 bar YES Set pressure to 1 1 5 bar Check water pressure switch wiring connection NO Does fan run at full speed NO Go to CHART 2 NO YES Does CH Pump run If the boiler temperature is less than 5 C frost protection is activated Disconnect CH flowtemp sensor Has fan speed stopped Change main board NO YES YES Check and if necessar...

Page 41: ...ck if water filter is clean NO YES YES YES Check and if necessary replace main board Check and if necessary replace limit thermostat Go to chart 4 NO CHART 2 Check Domestic Hot Water operation CHART 3 Check Central Heating operation Wait 2 minutes DHW taps closed Put CH temperature selector to maximum Ensure external controls are calling for heat Is LED4 flashing Does pump run YES YES Go to chart ...

Page 42: ...s the air pressure switch is greater than 180 Pascal Go to chart 5 YES NO Check and clean fan Check flue and air intake are correct and clean Check Venturi and air pressure switch tubes are clean Check restrictor is correct Chart 5 Check D H W and C H modulation CHART 6 Check DHW and CH modulation Does burner flame modulate Check wiring connection to CH sensor Normal operation carry out YES NO Che...

Page 43: ...ty thermostat Check electrodes and leads for damage and correct connection Check and if necessary replace P C B Adjust with P4 ignition burner pressure Check and if necessary clean burner Check and if necessary clean injectors Check and if necessary clean flame electrode Check right position of spark electrode Check wires Check gas supply is live and purged Check and if necessary replace gas valve...

Page 44: ...erature adjustment P3 Central heating flow output adjustment P4 Ignition gas pressure adjustment P5 Factory set don t touch 9 ELECTRICAL AND FUNCTIONAL SCHEME 9 01 Main components layout on electronic boards temp Ohm 10 C 20 kOhm 25 C 10 kOhm 60 C 2 5 kOhm 80 C 1 25 kOhm Temp sensor NTC 34 42 Fig 44 X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 L1 L2 L3 L4 L5...

Page 45: ... 230 V TO THE ROOM THERMOSTAT TERMINALS WILL IRREPARABLY DAMAGE THE ELECTRONIC BOARD 72 Room thermostat 81 Ignition electrode 82 Sensor electrode 98 Off On Reset switch 114 Low water pressure switch 136 Flow meter 9 02 General wiring diagram X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 TEST X12 1 2 1 2 3 4 5 6 7 8 9 X10 W O V R X8 X7 81 82 MF03F JP02 JP01 JP...

Page 46: ...g bar Hot Water Only SUMMER To obtain hot water only from the boiler turn switch A to the on position The top green light on the left side of the control panel is illuminated power on Turn the temperature regulator B to the position Open a hot water tap green light tap symbol comes on fan starts and burner will light Indicated by flame symbol green light coming on The temperature of the hot water ...

Page 47: ...ure to observe these requirements may lead to prosecution Electrical Supply WARNING This appliance must be earthed The electrical wiring must be carried out by a competent electrician The colours of the wires in the mains lead of this appliance may not correspond with the coloured markings identifying the terminal in the plug Therefore proceed as follows The wire coloured green and yellow must be ...

Page 48: ...6 00 Display 2 1 Use buttons and to set OFF time eg 9 00 Display 3 1 Use button and to set 2nd ON time eg 12 30 Display 4 1 Use button and to set 2nd OFF time eg 14 00 Display 5 1 Use button and to set 3rd ON time eg 16 00 Display 6 1 Use button and to set 3rd OFF time eg 23 30 Display 8 On completion of programming slide switch A to Auto position thetimeofdaywillbedisplayedandthecentralheatingwil...

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Page 52: ...nt Staffordshire DE14 3HD Tel 08707 282 885 Fax 08707 282 886 ALL SPECIFICATIONS SUBJECT TO CHANGE Please note to avoid incurring unnecessary expense in the event of a boiler shut down check this in not caused by lack of electricity supply gas supply or low water pressure before calling our Customer Service Helpline Should you require help with any difficulties call our Technical Service Helpline ...

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Ferroli DOMINA N 80, Installation, Service And User Instructions Manual

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