Ferroli SIGMA Installation And Servicing Instructions Download Page 1

Page: 1 / 32

cod. 3544

0/2004

SIGMA

wall mounted cast iron,
gas fi red boiler for central heating
fan assisted, room sealed,
electronic fl ame ig ni tion and control

INSTALLATION AND SERVICING INSTRUCTIONS

Sigma 60 - 100 GC N° 41-267-19

Summary of Contents for SIGMA

Page 1: ...071 2 10 2004 SIGMA wall mounted cast iron gas fired boiler for central heating fan assisted room sealed electronic flame ignition and control INSTALLATION AND SERVICING INSTRUCTIONS Sigma 60 100 GC N 41 267 19 ...

Page 2: ...oli is a member of the Benchmark initiative and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency CE MARK CE mark documents that the Ferroli gas appliances comply with the requireme...

Page 3: ...is its built in electronic flame ignition and control unit making burner operation completely automatic and safe The main components are as follows Cast iron heat exchanger specifically shaped for high efficiency Ceramic fibre insulated combustion chamber One stainless steel bladed burner specifically designed for this boiler Fan for discharge of combustion products and intake of combustion air Di...

Page 4: ...mbar Burner gas pressures G31 LPG Nominal mbar 34 5 Minimum mbar 13 5 Nominal mbar 13 4 Minimum mbar 5 Gas supply pressures G20 NG 29 3 Max kW Min kW 17 9 32 2 Max kW Min kW 20 5 35 7 Max kW Min kW 32 7 Model Sigma 60 100 Heat output Heat input net Heat input gross G31 LPG Ø 0 67 1 1 G20 NG Ø 3 45 Max 2 17 Min 2 52 Max 1 60 Min G20 m3 h NG G31 kg h LPG Injectors mm Gas flow rates N B Maximum worki...

Page 5: ...amber 21 Gas injector 22 Burner 24 Spark and sensor electrode 27 Cast iron heat exchanger 28 Flue collector from heat exchanger 34 Central heating flow temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat 63 Central heating temperature setting 68 Control box with P C B 83 Full sequence automatic control 86 Automatic control reset switch 90 Flue outlet pressure test ...

Page 6: ...boiler is to be fitted in a timber framed building it should be fitted in accordance with the institute of gas engineers publication IGE UP 1 If in doubt advice should be sought from the Local Gas Region of British Gas Plc 2 01 01 Location of Boiler The installation of the Sigma must be on a suitable non combustible load bearing wall which will provide an adequate fixing for the boiler mounting br...

Page 7: ...the combination boiler inlet gascock connection The complete installation must be tested for gas soundness and purged as described in BS6981 1988 All pipework must be adequately supported 2 02 Water System sealed systems Central heating Detailed recommendations are given in BS6798 BS5449 BS6700 and CP342 Part 2 Pipework not forming part of the useful heating suface should be insulated to prevent a...

Page 8: ...t If water treatment is used ferroli limited recommend only the use of Fernox or Sentinel water treatment products which must be used in accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co LTD Sentinel Division Tandern house Marlowe Way Betz Dearborn LTD Croydon surrey CRO 4YS Widnes Cheshire WA8 8ND Tel 0870 5601 5000 Tel 0151 424 5351 Note If th...

Page 9: ...n 250 255 min 200 min 855 min Fig 5 2 04 Wall Mounting 2 04 01 Drilling Template 115 82 Ø118 155 min 138 200 min 643 200 min 450 Minimum clearances and drilling template for standard rear flue Fig 6a Drilling template for orizontal concentric flue ...

Page 10: ...deep to accept the wall plug Using a core drill cut hole for the flue Drill cut a 118 mm diameter hole if it is possible insert the flue pipe from outside of the room drill cut a 127 mm diameter hole if to insert the flue pipe from inside of the room 2 Fig 8 Insert the plastic plugs 3 Fig 9 5a 5b Ø 118 Fig 11a Fig 11b 4a 4b Ø 127 Fig 10a Fig 10b Insert flue pipe from inside of the room core drill ...

Page 11: ... centrally into the flue terminal Fig 16 Fig 17 40 mm Cut the outer flue flush with the flange on the hanging plate Through plate into air tube drill two holes and fix in place using two self tapping screws n 6 x 6mm long 8 9 Fig 14 Fig 15 6 7 Position the wall plate on the wall Fix plate to wall with the square gasket between the wall and the plate use the large diameter washers for the bolts ad ...

Page 12: ...and outer flue slide into position Make sure the inner flue is fully engage in the flue terminal secure boiler with two nuts and washers a and b Fig 18 Fig 19 Fig 20 Remove fan by pulling off electrical connections Pull off air pressure switch tubes from the air pressure switch Remove the two screws a Pull fan Rotate the cover and gasket through 90 and fit it to the rear of the boiler to cover the...

Page 13: ...ated Secure with the screws b Boiler is fitted with rear outlet without restrictor If it necessary to insert the restrictor for top outlet identify on 2 07 the correct restrictor Remove the two screws a from pipe connection b Remove pipe connection b Remove fan mounting plate by undoing the three fixing screws c For top outlet For rear outlet c c c d d d For rear outlet For top outlet Fig 23 a a b...

Page 14: ...rotrude from the wall between 10 and 60 mm Warning Back exit with coaxial bend is not possible 1 Example of concentric flue Ø 100 with appliance bend use 2 06 01 Examples of top flue connection Fig 31 2 06 Top outlet Flue Connection Three different connection are available from top of the boiler using accessories as reported on fig 30a b e c and on examples a next page Fig 30 VerticalConnection co...

Page 15: ...ic Vertical Horizontal 100 mm concentric back exit Sigma 60 100 4 m 3 m 5 m 5 m 1 m For horizontal flueing the reduction for appliance bend are already included Sigma 60 100 A B C Restrictor pipe configuration L 2m L 2m 1m 2m L L 1m Ø47 Ø43 Ø 47 Ø 43 No restrictor L 1m No restrictor L 2m 3m L 3m No restrictor Boiler is fitted with rear outlet without restrictor For instruction on changing restrict...

Page 16: ...ORTANT the pipes and fittings flow resistance reduction have been summarised on the following page The flow resistance values written refer only to Ferroli pipes and fittings 2 Verify that the total flow resistance calculated is less or equal to 40 metre 3 Choose the more suitable restrictor from table below Description Ref Connection for concentric pipe cod KWMR52A 1 N of pieces Length reduction ...

Page 17: ...17 Sigma Pipe and fittings reduction table shown in Metres ...

Page 18: ... pipe or soil pipe From an internal or external corner Above ground roof or balcony level From a surface facing the terminal also see 6 1 2 From a terminal facing the terminal From an opening in the car port e g door window into the dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical struc...

Page 19: ... electrode 32 Central heating pump not fitted 34 Central heating flow temperature sensor 43 Air pressure switch 49 Safety thermostat 63 C H temperature adjustment 72 External controls 83 Full sequence automatic control on gas valve 86 Reset switch 101 Main P C B 121 Boiler shut down warning Led Fig 40a If there are no external controlsfitted connectthe SWLterminaltopermanent live in the junction b...

Page 20: ...he paragraph Troubleshooting Note If there is a power failure while the boiler is in operation the burners automatically go out and re ignite when the power returns WARNING If the system is filled with very cold water the boiler will automatically light due to the frost thermostat sensing the low temperature The boiler will not shut down until the water temperature reaches 10 C 3 03 Shutting down ...

Page 21: ...byturningthepressure regulating screw turn it clockwise to increase the burner pressure and anticlockwise to decrease it The diagrams indicate the variation in heat output to the water as burner working pressure is varied fig 42a and 42b Adjusting boiler output to the actual requirements of the central heating system will minimise boiler cycling thus saving fuel varying the output has virtually no...

Page 22: ...tomer Technical Service Helpline 4 05 Determining combustion efficiency and the composition of the flue gases On the boiler there are two test points one for flue gas and the other for air To carry out the tests proceed as follows 1 Open the air and flue gas test points 2 Introduce the probes 3 Switch ON the boiler N B To ensure correct readings the boiler must have reached normal operating temper...

Page 23: ...iated with the room sealed compartment gaskets grommets etc Air leakage would cause pressure inside the compartment to drop possibly tripping the differential pressure switch and thus shutting down the boiler After cleaning particular attention should also be paid to checking stages of start up and operation of the thermostats gas valve and pump If performing combustion analysis prior to servicing...

Page 24: ... suitable soft brush DO NOT DAMAGE THE REAR INSULATION and clean out the combustion chamber 15 EXAMING seals on the room sealed compartment from panel and if necessary replace 16 Re assemble in reverse order 17 Re instate gas and electric supply 18 Fire the boiler and check all gas joint for soundness 19 Re check burner pressure 20 Check flame picture and all controls for correct operation 21 Chec...

Page 25: ...rse order adding more heat sink compound if necessary 7 04 Air Pressure Switch Removal fig 46 a Remove electrical connection and tubes from the air pressure switch noting their position b Remove the 2 screws a that secure the air pressure switch to the electrical contacts cover c Replace in reverse order 7 05 Temperature Sensor fig 46 a Remove electrical connection from sensor b Drain off the wate...

Page 26: ...the housing c Remove the electrical connections from the PCB noting their position d Remove the 2 plastic nuts from outside the housing that hold the fixing pins in place and gently push the pin inside the housing e Very carefully push the reset button c inside the housing and remove the PCB f Remove the fixing pins from the PCB and swap over to the replacement g Replace in reverse order 7 09 Heat...

Page 27: ...en its N O and common contact the voltage at the overheat thermostat to earth drops to almost zero The white wire of the fan becomes a neutral and the fan runs The air pressure switch operates to make a circuit between its N O and common contacts If the overheat thermostat is closed circuit the ignition electrode will spark the gas valve opens and the burner lights 8 02 Troubleshooting Quick refer...

Page 28: ...s consumption Boiler dirty Check and clean heat exchanger Boiler inadequate Check that the boiler is correctly sized for the requirements of the central heating system Condensate in boiler Thermostat set too low Adjust thermostat to a higher temperature more than 50 C Incorrect gas rate Check that gas consumption is correct and adjust pressure if necessary Boiler sooting Faulty flame adjustment Ch...

Page 29: ...30 v at both fan terminals to earth check mains supply and fuse check external controls resistance of the temp sensor between 80 kohm at 80 c and 1mohm at 25 c change main pcb yes no change temperature sensore check air pressure switch and change if necessary change overheat thermostat yes yes yes burner lights but boiler continues to spark and locks out no no eletrode sparks yes no no with fan ru...

Page 30: ...m see paragraph 3 07 the pump signal is an input for electronic device If the pump is not running and there is heat demand the temperature control is set on 50 C and after 3 minutes slow start time this level switches to a fixed value of 70 C With the knob in OFF position the call for heat is disabled but if the temperature in the ambient comes below 5 C a frost protection overrules the off state ...

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Page 32: ...NSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS 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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