Ferroli Optima 1001 Installation Instructions Manual
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Ferroli Optima 1001 Installation Instructions Manual

Ferroli Optima 1001 Installation Instructions Manual

Wall mounted, room sealed, fan assisted, gas combination boiler
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FAN ASSISTED, GAS COMBINATION BOILER
Phone numbers:
Installer
Service Engineer
Serial No.
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
WALL MOUNTED, ROOM SEALED,
ALL SPECIFICATIONS SUBJECT TO CHANGE
Tel. 08707 282 885 - Fax 08707 282 886
1001
INSTALLATION
INSTRUCTIONS
Read these Instructions thoroughly
before using the appliance
FERROLI HELPLINE
FOR SERVICE INFORMATION OR
HELP TELEPHONE: 08707 282 885
ALWAYS QUOTE YOUR SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
G.C. NO: 47-267-19
01/01

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  • Page 1 1001 01/01 WALL MOUNTED, ROOM SEALED, FAN ASSISTED, GAS COMBINATION BOILER INSTALLATION INSTRUCTIONS Read these Instructions thoroughly before using the appliance FERROLI HELPLINE Phone numbers: FOR SERVICE INFORMATION OR HELP TELEPHONE: 08707 282 885 Installer ALWAYS QUOTE YOUR SERIAL NUMBER FOR IMMEDIATE ASSISTANCE Service Engineer Serial No.
  • Page 2 1001 page 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.
  • Page 3 1001 General Description The Ferroli 1001 is a 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.
  • Page 4 1001 Technical data NATURAL GAS (G20) PROPANE LPG (G31) Nominal Heat Input D.H.W. & C.H. (gross) 34.8 kW 34.0 kW Minimum Heat Input D.H.W. & C.H. (gross) 15.1 kW 14.8 kW Nominal Heat Input D.H.W. & C.H. (net) 31.3 kW 31.3 kW Minimum Heat Input D.H.W.

  • Page 5: Appliance Dimensions

    1001 Appliance Dimensions FRONT VIEW LEFT SIDE VIEW REAR VIEW 97.5 77.5 1. Electricity cable entry 2. Gas supply Fig. 1 3. Domestic Hot Water outlet 8 - TOP VIEW 4. Domestic Cold Water inlet 5. Central Heating Pressure relief valve 6.
  • Page 6 1001 Boiler Flow Diagram Fig. 2...
  • Page 7 1001 43. Air pressure switch 1. Fixing point 46. Operator gas valve 2. Flue terminal 47. Modulating regulator (Modureg) gas valve 3. Flue/air intake hood 48. Burner pressure test point 4. Sealing gasket 49. Overheat cut-off thermostat 5. Room sealed compartment 50.
  • Page 8 1001 Installation Details Gas Safety (Installation & Use) Regulations: 1994 In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E.
  • Page 9 1001 Terminal Position Fig. 3 Minimum Clearance Fig. 5 NOTES * Access to the front of the boiler must be available for maintenance (min. 600 mm).
  • Page 10 1001 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).
  • Page 11 1001 Cold water Additional expansion vessel C.H. (if required) Filling point C.H. Bypass Fig. 6 NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout. 1. Filling point C.H. Fig. 7 2.
  • Page 12 1001 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.
  • Page 13 1001 Installation Note - To mount the boiler on the wall, a two person lift will be needed. 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.

  • Page 14: Drilling Template

    1001 Important Note - Always use two spanners 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 P.S.I.).

  • Page 15: Preparing The Flue Assembly

    1001 PREPARING THE FLUE ASSEMBLY Rear Flue Outlet (fig. 12) Important - The aluminium flue pipe must protrude into the 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.

  • Page 16: Connecting The Boiler

    1001 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.
  • Page 17 1001 Fixing points Fig. 15 Lift here Fixing screws Fig. 16 Fig. 17...

  • Page 18: Fitting The Flue Assembly

    1001 FITTING THE FLUE ASSEMBLY 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.

  • Page 19: Commissioning And Testing

    1001 COMMISSIONING AND TESTING Filling the Central Heating System Burner pressure Automatic air vent Vent cap test point Heat exchanger vent Pump C.H. pressure gauge C.H. pressure relief valve Gas inlet pressure test point D.H.W. drain point Low water pressure switch Fig.
  • Page 20 1001 Flame viewing opening C.H. pressure gauge C.H. boiler thermostat AUTO AUTO 12: 31 OVERRI DE Flame failure reset knob Time clock (if fitted) C.H./D.H.W. selector switch Domestic hot water thermostat Fault diagnostic lights fig. 21 To Light the Boiler (fig. 21) a.
  • Page 21 1001 Burner Pressure C.H. and D.H.W. To 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.
  • Page 22 1001 Honeywell VR 4605 NA 4003 valve with V7335A4014 Modureg Gas pressure Adjustment With the burner lit: Connect suitable pressure gauge to burner test point "B", and then: Disconnect air pressure compensation tube "H"; Disconnect the wires from coil "C" of the Modureg; Remove protective cover "D";...

  • Page 23: Natural Gas

    1001 Burner Perssure C.H. • Natural gas • L.P.G. (Propane) 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 kcal/h x 1000 Fig. 24a - Burner pressure VS C.H. Load with L.P.G. (G31) (Propane) 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 kcal/h x 1000...

  • Page 24: System Operation

    1001 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.

  • Page 25: Time Clock

    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”. A Slide switch: set clock - auto - set programme AUTO AUTO B Display.
  • Page 26 1001 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 will be shown in the display window (B).

  • Page 27: Spare Parts List

    1001 Spare Parts List Item No. G.C. Part No. Makers Part No No. Off DESCRIPTION 386816 800130 C.H. safety valve 803860 803080 Main injector (Natural Gas) 801850 Main injector (L.P.G.) 800620 Central heating pump 386818 800310 Temperature sensor 394246 801160 Automatic air vent 386829 801220...

  • Page 28: Domestic Hot Water Performance

    1001 Domestic Hot Water Performance Fig. 1 - D.H.W. Pressure Drop VS. flow A =Standard with cold water Flow Restricter B =Cold Water Flow Restricter Removed Fig. 1 Fig. 2 - D.H.W. temperature VS. flow A =Cold Water 15 C B =Cold Water 5 C litres/min Fig.
  • Page 29 1001 16 Fan 32 Central heating pump 230V 11 10 9 8 7 6 5 4 3 2 1 50Hz 34 C.H. flow temperature sensor 42 D.H.W. temperatuure sensor 43 Air pressure switch 46 Operator gas valve 47 Modulating regulator (MODUREG) gas valve 49 Overheat cut-off thermostat 50 Heat exchan.
  • Page 30 1001 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 P.C.B.: 2 Amp.
  • Page 31 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. Ø80 Ø80 = Special two pipe flue adapter 823071 = remove air intake cover Ø...

  • Page 32: Phone Numbers

    Phone numbers: Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS. ALL SPECIFICATIONS SUBJECT TO CHANGE Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD Tel. 08707 282 885 - Fax 08707 282 886...

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