Ferroli Domina 80 E Manual

Appr. nr. B98.01 A - CE 0063 AT 4967
DOMINA 80 E
INSTALLATION, SERVICE AND USER
INSTRUCTIONS
G.C. NO: 47-267-23
Copper Wall-Mounted Combination,
Gas Fired Boiler for Central Heating
andDomestic Hot Water Production,
Fan Assisted,Room Sealed Compartment,
Electronic Flame Ignition andControl
3543064/2 - 06/2001

DOMINA 80 E
2
CE MARK
CE mark documents that the Ferroli gas appliances comply with the requirement contained in
European directives applicable to them.
In particular, the appliances comply with the following CEE directives and the technical specifications
provided from them:
• Gas appliances directive 90/396
• Efficiencies directive 92/42
• Low tension directive 73/23 (modified from the 93/68)
• Electromagnetic compatibility directive 89/396 (modified from the 93/68)
Year 2000 Compliance Declaration
We will guarantee that this products is altogether suitable for the data change in the Year
2000 (boiler has no dependence from date change) and that no disruptions will occur which is
caused by this product.
IMPORTANT
Your"benchmark" Installation,CommissioningandService RecordLogBookwill beenclosed
in yourcustomer information pack.
"Thisrecordmustbecompletedandleftwiththeenduser"
"All CORGI RegisteredInstallerscarryaCORGI IDcardandhavearegistration number.Both
shouldberecordedin yourcentral heatinglogbook. Youcan checkto theCORGI registered
by callingCORGI on 01256 372300".
Ferroli 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. Please see installation and servicing guidelines.
INDEX1
1 DESCRIPTION 3
TECHNICAL AND DIMENSIONAL CHARACTERISTICS
3INSTALLATIN DETAILS
COMMISSIONIN AND TESTIN 7
ADUSTMENT AND ASCONVERSION 8
MAINTENANCE AND CLEANIN 30
7REPLACEMENTPARTS 3
8AULTINDIN 37
ELECTRICAL AND NCTINAL SCHEME
10USERINSTRCTINS

DOMINA 80 E
3
1 DESCRIPTION
1.01 Introduction
The Domina80 Eis definedas a“room sealed” combination boiler, all air requiredfor combustion is takenfrom
outside the room in which it is installed. It is anewhigh performance gas firedheat generator for central heating and
domestic hot waterproduction. Aspecial feature of this boileris its built-in electronic flame ignition and control unit
making burneroperation completely automatic and safe.The main components are as follows:
•Copperheat exchangerconsisting of three finnedtubesspecifically shapedfor high efficiency.
•There are three coppercoils insertedin the three heating circuit tubes. These represent the domestic
hot waterheat exchanger. Their shape and high exchange surface areaenable the full output of the
boilerto be absorbed.
•Ceramic fibre insulatedcombustion chamber
•12 stainless steelbladedburners specifically designedfor this boiler.
•Fan for discharge of combustion products and intake of combustion air.
•Differential air pressure switch.For safety reasons, this ensuresthe burnerignitesonly whenthe fan is functioning correctly.
•Hermetically sealedcompartment made from corrosion-resistant steelenclosing the above components.
•Combination gas safety valve with modulator, complete with pressure stabiliser.
•Flowmetergiving the domestic hot watercircuit precedence overthe central heating circuit.
•Pressure reliefvalve for the central heating circuit setto openat 3bar.
•Built-in Expansion vessel.
•Variable speedpump.
•Central heating flow temperature adjustment thermostat.
•Domestic hot waterflow temperature adjustment thermostat.
•Central heating limit thermostat.
•Overheat safety thermostat.
•Electronic control unit for automatic flame ignition and control.
•Central heating low waterpressure cut off switch.
•Domestic hot waterflow temperature sensor.
•Central heating flow temperature sensor.
1.02Instructionsand regulations
Assembly, installation, first start up and maintenance must be carriedout by competent persons only, in accordance
with all current technical regulations and directives.
OSHH
Materials usedin the manufacture of this appliance are non hazardous and no special precautions are
requiredwhenservicing.
Related Documents
Thisappliancemust beinstalled strictlyin accordancewiththese instructions.
The Gas Safety Regulations (Installations &Use)1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland -Consolidated)Regulations.
British Standards Codesof Practice:
B.S.75931992TREATMENT OF WATERINDOMESTIC HOT WATERCENTRALHEATING SYSTEMS
B.S.5546 1990 INSTALLATIONOF HOT WATERSUPPLIESFORDOMESTIC PURPOSES
B.S.5440 Part 12000 FLUES
B.S.5440 Part 21989 AIRSUPPLY
B.S.5449 1990 FORCED CIRCULATIONHOT WATERSYSTEMS
B.S.6798 1987 INSTALLATIONOF GASFIRED HOT WATERBOILERS
B.S.68911989 GASINSTALLATIONS
B.S.76711992IEE WIRING REGULATIONS
B.S.48141990 SPECIFICATIONFOREXPANSIONVESSELS
B.S.54821994 INSTALLATIONOF LPG
ModelWaterBye Laws
For Northern Ireland the rulesin force apply

DOMINA 80 E
4
Fig. 1
12345
15012012070
110
80 80
80
460
Top view
6
Distance between connections
1149560609536
100
720
725
16025
10
100
270
460
175100
178
190 270
Bottom view
95
2 TECHNICALANDDIMENSIONAL CHARACTERISTICS
2.01 Technical information
Domina 80 E 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"domestichot water flow outlet
3-1/2“gasinlet
4-1/2"domestichot water inlet
5-3/4"central heating return inlet
6-Pressure reliefoutlet

DOMINA 80 E
5
Technical Data
N.B. - The gaspressuresat the burnerandgasflows duringthe central heating phase given in the table refer
tonominal boiler output.Toreduce thisoutput (where necessary), gaspressure must be reduceduntil the
requiredoutput level isreached(see figures4and5).
During domestic hotwater production,gaspressurestothe burnermust correspondtothe maximum
outputgiven in table forthe type ofgas.
Gas pressure must beadjustedduring maximum draw-off ofdomestic hotwater.
•Maximum working temperature forcentral heating flow:85°C
•Maximum temperature ofdomestic hotwater:55°C, adjustable between 40°C and55°C.
•Minimum domestic coldwater pressure requiredfor95% heat input:
- Flowrestrictorfitted(standard)- 1,2 bar;
- Flowrestrictorremoved- 0,5 bar
MODEL Heat output Heat input Domestic hot
water heat
input
Boiler water
contents Domestic hot water contents
kW kW kW kW kW Litres Litres
Domina 80 E 23,8 9,7 25,8 11,5 23,8 1,5 0,8

DOMINA 80 E
6
2.03 Boiler water flow diagram
Fig. 3
2.02 Boiler maincomponents
Key
5 Room sealed compartment
7Gas inlet
8Domestichot water outlet
9Domestichot water inlet
10 Central heating flowoutlet
11 Central heating return inlet
14Safetyvalve
16Fan
19Combustion chamber
20Burner assembly
21Maininjector
22 Burner
26Combustion chamber insulation
27Copper heat exchanger for central heating and
domestichot water
28Fluecollector from heat exchanger
32Central heating pump
34Central heating flowtemperature sensor
36Automaticairvent valve
42Domestichot water flow
temperature sensor
Fig. 2
43Airpressure switch
44 Gas valve
49Safetyoverheat thermostat
50Central heating flowlimitthermostat
56Expansion vessel
62Time clock(option)
63Central heating temperature adjustment
81Ignition electrode
82Sensor electrode
84Primarygas valvesolenoid
85Secondarygas valvesolenoid
90*Fluesampling point
91*Airsampling point
98On/Off/Reset switch
114Lowwater pressure cutoff switch
132Fluegas deflector
136Flowmeter
145 Central heating pressure gauge
157Domestichot water temperature adjustment
*For use withfluegas analysisequipment

DOMINA 80 E
7
2.04 Central heating adjustment (not normally required)
To adjust boiler heat input (thusalso regulatingheat output to the central heatingwater) simply adjust the main
burner via the electroniccontrol board (fig. 4and 5and see paragraph 5.04 page 29).The diagramsindicate the
variation in heat output to the water asburner workingpressure isvaried.Adjustingboiler output to the actual
requirementsofthe central heatingsystem will minimise boiler cyclingthussavingfuel,varyingthe output has
virtually no effect on the efficiency and combustion characteristics ofthe boiler.
Diagram of pressures
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
m
b
ar
18 19 20 21 22 23
5
10
15
20
25
30
35
9 1011121314151617
91011121314 18192015 16 178
2.05Domestichot water variabilitycharacteristics
The temperature ofthe domestichot water can
be varied from 40 to 55°C by adjustingthe boiler
potentiometer.
Diagram of domestichot water production
0 345678910111213141516
39
40
45
50
55
60
65
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Temperature of domestichot water intake 15°C
Flow of domestichot water l/min
Temperature of domestichot water supply°C
Boiler output exchanged kcal/1000
Fig. 6

DOMINA 80 E
8
Fig. 8
Pressure loss diagram
SIZING OF ADDITIONAL EX PANSION VESSELS:
Deduct from the value given in the table the 8 litre
vessel supplied.
Note:
1. Fill C.H. installation to min. 1.5bar.
2.Expansion vessel must be fitted to central
heating return pipe.
3.The standard 7litre expansion vessel is
charged to 1bar.
4.The additional expansion vessel should be
charged to 1bar.
SAFETYVALVE
SETTING (bar)
VESSEL CHARGE
PRESSURE(bar)
INITIAL SYSTEM
PRESSURE(bar)
TOTAL WATER
CONTENT ofSYSTEM
3.0
0.51.01.5
1.01.52.01.52.02.0
EX PANSION VESSEL VOLUME(litres)
LITRES
253.56.513.74.710.38.3
507.012.927.59.520.616.5
7510.519.441.314.230.924.8
100 14.025.955.119.041.233.1
12517.532.468.923.751.541.3
15021.038.8 82.628.561.8 49.6
17524.545.396.433.272.157.9
200 28.051.8 110.238.082.466.2
0.1400.2590.551 0.1900.4120.33
For syst.volumes other than
those givenabove,mult.the syst.
volume bythe factor across
m |h
3
Q
8
7
6
5
4
3
2
1
00.5 1.5 2.512
Hmbar x 100
2.06 Pumpcharacteristics
The pump head available for circulating the water is given
in fig. 7.
N.B.-The pump is factoryset at position 3. The pump is a
Grundfos type 15-50UPSseries.
Grundfos Pumpper formance graph
Note -Minimum flowthrough boiler heat exchanger at any
time should not fall below6litres per minute.
If the total volume of water in the system exceeds 40litres
an additional expansion vessel must be fitted to the central
heating return pipe.
Fig. 7
1 2 3 Speed settings
ABoilerspressuredrop
BAvailablepumpheadC.H.

DOMINA 80 E
9
3 INSTALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1996
In the interest of safety, it is the lawthat all gas appliances are installedby a competent person in accordance
with the above Regulations, BuildingRegulations/BuildingStandards Scotland, Codes of Practice, current I.E.E.
Regulations andthe byelaws of the LocalWater Undertaking. Failure to comply withthe Regulations may leadto
prosecution;it is yourresponsibility to ensure that the lawis compliedwith.
N.B.For Northern Irelandthe rules in force apply.
Important -If the boiler is to be fittedin a timber framedbuildingit should be fittedin accordance with the Institute of
Gas Engineers document IGE/UP/7.If in doubt advice should be sought fromthe LocalSupplier.
Location of Boiler
The installation of the Domina 80Emust be on a suitable non-combustible loadbearingwall which will
provide an adequate fixingfor the boiler mountingbracket assembly.The location should be in an area
where the water pipes will not be subjectedto frost conditions.In sitingthe combination boiler the
followinglimitations must be observed:
The combination boiler may be installedin any roomor internalspace, although particular attention is drawn
to the requirements of the current I.E.E. wiringregulations andin Scotlandthe electricalprovisions of the
buildingregulations applicable in Scotland, with respect to the installation of the combination boiler in a room
or internalspace containinga bath or shower.
Where a roomsealedappliance is installedin a roomcontaininga bath or shower any electricalswitch
or appliance controlutilisingmains electricity must be situatedso that it cannot be touchedby a person
usingthe bath or shower.
AirSupply
The roomor compartment in which the boiler is installeddoes not require a purpose providedvent when
usingthe standardconcentricflue.
Flue System
The boiler allows the flue outlet to be taken fromthe rear of the boiler, fromeither side or vertically.
Astandardflue length of 0.75metres is provided. Alternative lengths of two or three metres can be supplied
(equivalent to wall thicknesses of up to 565, 1815 and2815mm for rear flues, deduct 91mm plus distance fromside
wall for side outlet flues).It is absolutely essential, to ensure that products of combustion discharging fromthe
terminal cannot re-enterthe building,orenterany adjacent building,throughventilations,windows,doors,
natural airinfiltration orforcedventilation/airconditioning.
Gas Supply
If necessary the localGas supplier should be consulted, at the installation planningstage, in order to establish
the availability of an adequate supply of gas.
An existingservice pipe must not be usedwithout prior consultation with the LocalGas supplier.
Agas meter can only be connectedby the LocalGas supplier, or by a LocalGas suppliers Contractor.
Installation pipes should be fittedin accordance with BS6891-1988.
Appliance inlet workingpressure must be 20mbar MINIMUM, for NGand37mbar minimum for LPG.
Pipeworkfromthe meter to the combination boiler must be of an adequate size.
The boiler requires 2.73m3/h of naturalgas, and2,00 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be testedfor gas soundness andpurgedas describedin BS6981-1988.All pipework
must be adequately supported. An isolatinggas valve is providedandshould be fittedon the boiler gas inlet.
Please wait 10minutes when lightingfromcold before checkinggas rate.Gas pressures shouldbe checkedafter
the boilerhas operatedfor10minutes to reachthermal equilibrium.
WaterSystem
Note -the boileris designedforsealedsystems only andmust NOT be usedon open ventedsystems.

DOMINA 80 E
10
NOTE: A bypass that will ensure a minimum flow rate of
6 l/min. at all all time must be fitted as far as possible
from the boiler if thermostatic radiator valves are fitted
thoughout
Fig. 9
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipeworknot 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 1is recommended for water carrying pipework. Pipeworkin
horizontal runs should have a gradient where possible to facilitate the removal of air. Ensure that the
boiler heat exchanger is not a natural point for air collection. A typical heating system with domestic
hot water circuit is illustrated in fig. 9.
Important -If thermostatic radiator vales are fitted a bypass must be fittedtoensure a minimumflowrate through
the boiler of6l/min. The bypass should be fitted as far as possible from the boiler.
Make UpWater
Provision must be made for replacing water lost from the 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 Byelaws. Again any such connection must be disconnected after use.
A typical temporary filling loop is shown in fig. 10.
DomesticHot Water
Always fit a scale reducer in "hard water areas"(18 clarke degrees or over)". A 15mm copper connection point
on the boiler for attaching to the main supply is provided. The maximum domestic water pressure for the
inlet supply is 10 bar (145 P.S.I.). Ifthe coldmainssupplyexceeds 5bar (72 P.S.I.), a water governor
or pressure reducing valve must be fittedby the installer into the mains supply in an inconspicuous but
accessible position preferable between 3and 5metres (10-16ft)before the appliance. Such a valve must
be approved by the Water Research Council.
Attention -is drawn to the Model Water Byelaws.
Fittings manufactured from duplex(alpha-beta)brass are not acceptable for underground use and certain water
undertakings will not accept their use above ground.
Ensure all pipeworkis adequately supported
Gas
Cold water
Additional expansion
vessel C.H.
Filling
point C.H.
Bypass
Fig. 10
Key
1. Filling point C.H.
2. Temporary connection
3.Coldwater supply