Ferroli ENERGY TOP W 80 Troubleshooting guide

3540I160
cod. 3540I160 — 05/2008 (Rev. 00)
ENERGY TOP W 80 - W 125
INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE
INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN
ISTRUZIONE PER L’USO L'INSTALLAZIONE E LA MANUTENZIONE
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENIMIENTO
BETRIEBS-, INSTALLATIONS- UND WARTUNGSANLEITUNG

ENERGY TOP W 80 - W 125
2EN
B
Declaration of conformity
Manufacturer: FERROLI S.p.A.
Address: Via Ritonda 78/a 37047 San Bonifacio VR Italy
declares that this unit complies with the following EU directives:
• Gas Appliance Directive 90/396
• Efficiency Directive 92/42
• Low Voltage Directive 73/23 (amended by 93/68)
• Electromagnetic Compatibility Directive 89/336 (amended by 93/68)
President and Legal Representative
Cav. del Lavoro
Dante Ferroli
BThis symbol indicates "Caution" and is placed next to all safety warnings. Strictly follow
these instructions in order to avoid danger and damage to persons, animals and things.
AThis symbols calls attention to a note or important notice.
cod. 3540I160 - 05/2008 (Rev. 00)
• Carefully read the warnings in this instruction book-
let since they provide important information on safe
installation, use and maintenance.
• This instruction booklet is an integral part of the
product and must be carefully kept by the user for fu-
ture reference.
• If the unit is sold or transferred to another owner or if
it is to be moved, always make sure that the booklet
accompanies the boiler so that it can be consulted
by the new owner and/or installer.
• Installation and maintenance must be carried out by
professionally qualified personnel, according to cur-
rent regulations and the manufacturer's instructions.
• Incorrect installation or poor maintenance can cause
damage or physical injury. The manufacturer de-
clines any responsibility for damage caused by er-
rors in installation and use or by failure to follow the
manufacturer's instructions.
• Before carrying out any cleaning or maintenance op-
eration, disconnect the unit from the electrical power
supply using the switch and/or the special cut-off de-
vices.
• In case the unit breaks down and/or functions poorly,
deactivate it, do not make any attempt to repair it or
directly intervene. Contact professionally qualified
personnel. Any repair/replacement of products must
only be carried out by qualified professional person-
nel using exclusively genuine parts. Failure to com-
ply with the above could affect the safety of the unit.
• Periodical maintenance carried out by qualified per-
sonnel is essential for guaranteeing good operation
of the unit.
• This unit must only be used for the purpose for which
it was designed. Any other use is considered im-
proper and therefore hazardous.
• After removing the packing, check the integrity of the
contents. Packing materials must not be left within
the reach of children as they are potentially hazard-
ous.
• In case of doubt do not use the unit, and contact the
supplier.
• The images shown in this manual are a simplified
representation of the product. In this representation
there may be slight, unimportant differences with the
supplied product.

ENERGY TOP W 80 - W 125
3
3540I160 cod. 3540I160 - 05/2008 (Rev. 00)
1 Operating instructions ............................................................................................................ 4
1.1 Introduction.............................................................................................................................................4
1.2 Control panel ..........................................................................................................................................4
1.3 Turning on and off ..................................................................................................................................6
1.4 Adjustments............................................................................................................................................7
2 Installation.............................................................................................................................. 11
2.1 General Instructions .............................................................................................................................11
2.2 Place of installation ..............................................................................................................................11
2.3 Plumbing connections ..........................................................................................................................11
2.4 Gas connection ....................................................................................................................................14
2.5 Electrical connections...........................................................................................................................14
2.6 Fume ducts...........................................................................................................................................16
2.7 Condensate drain connection...............................................................................................................19
3 Service and maintenance...................................................................................................... 20
3.1 Adjustments..........................................................................................................................................20
3.2 Start-up.................................................................................................................................................21
3.3 Maintenance.........................................................................................................................................22
3.4 Troubleshooting....................................................................................................................................24
4 Technical data and characteristics ...................................................................................... 26
4.1 Dimensions and connections ...............................................................................................................26
4.2 General view and main components ....................................................................................................27
4.3 Plumbing circuit ...................................................................................................................................28
4.4 Technical data table .............................................................................................................................29
4.5 Diagrams ..............................................................................................................................................30
4.6 Wiring diagram .....................................................................................................................................31

ENERGY TOP W 80 - W 125
4EN
cod. 3540I160 - 05/2008 (Rev. 00)
1. Operating instructions
1.1 Introduction
Dear Customer,
Thank you for choosing ENERGY TOP W 80 - W 125, a wall-mounted boiler featuring FERROLIadvanced design, cut-
ting-edge technology, high reliability and quality construction. Please read this manual carefully since it provides impor-
tant information on safe installation, use and maintenance.
ENERGY TOP W 80 - W 125 is a high efficiency, low emissions sealed chamber premix condensing heat generator
for heating, running on natural gas or LPG and equipped with a microprocessor control system.
The boiler shell consists of an aluminium finned tube exchanger and a premix burner in steel, equipped with electronic
ignition and ionisation flame control, a modulating speed fan and a modulating gas valve. ENERGY TOP W 80 - W 125
is a heat generator arranged to operate alone or in cascade.
1.2 Control panel
fig. 1 - Control panel
Key
1 = DHW temperature setting decrease button (with
optional hot water tank installed)
2 = DHW temperature setting increase button (with
optional hot water tank installed)
3 = Heating system temperature setting decrease
button
4 = Heating system temperature setting increase
button
5 = Display
6 = Summer/Winter mode selection button
7 = Economy/Comfort mode selection (with optional
hot water tank installed) and unit On/Off button
8 = Reset button
9 = DHW operation (with optional hot water tank in-
stalled)
10 = Summer mode
11 = Multifunction
12 = Eco (Economy) mode (with optional hot water
tank installed)
13 = Heating mode
14 = Unit On / Off button
15 = Burner On
16 = Appears on connecting the Remote Timer Con-
trol (optional)
17 = Information symbol
18 = Arrow symbol
20 = Fault
21 = Circulating pump On
22 = Appears on connecting the external probe (op-
tional)
23 = Boiler Off
25 = Fault reset request
17 18 2320
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22
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21
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6814
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ENERGY TOP W 80 - W 125
5EN cod. 3540I160 - 05/2008 (Rev. 00)
Indication during operation
Heating
A heating demand (generated by the Room Thermostat or Remote Timer Control or 0-10 Vdc signal) is indicated by
activation of the circulating pump and the radiator (details 13 and 21 - fig. 1).
The display (detail 11 - fig. 1) shows the actual heating delivery temperature and during DHW standby time, the mes-
sage “d”.
fig. 2
DHW circuit (with optional hot water tank installed)
A hot water tank heating demand is indicated by activation of the circulating pump and the tap (details 9 and 21 fig. 1).
The display (detail 11 - fig. 1) shows the actual hot water tank sensor temperature and during heating standby time, the
message “d“.
fig. 3 -
Exclude hot water tank (economy)
Hot water tank temperature maintaining/heating can be excluded by the user. If excluded, domestic hot water will not
be delivered. The hot water tank can be deactivated by the user (ECO mode) by pressing the button (detail 7 -
fig. 1). In ECO mode the display activates the symbol (detail 12 - fig. 1). To activate COMFORT mode, press the
button (detail 7 - fig. 1) again.
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ENERGY TOP W 80 - W 125
6EN
cod. 3540I160 - 05/2008 (Rev. 00)
1.3 Turning on and off
Boiler lighting
Press the On/Off button (detail 14 fig. 1).
fig. 4 - Boiler lighting
• For the following 120 seconds the display will show FH which identifies the heating system air venting cycle.
• During the first 10 seconds the display will also show the card software release (A = Display card software release
/ B = Controller software release).
• Open the gas valve ahead of the boiler.
• When the message FH disappears, the boiler is ready to operate automatically in case of a room thermostat de-
mand.
Turning the boiler off
Press the button (detail 7 - fig. 1) for 5 seconds.
fig. 5 - Turning the boiler off
When the boiler is turned off, the electronic board is still powered.
Domestic hot water (with optional hot water tank installed) and heating operation are disabled. The antifreeze system
remains activated.
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A
B
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ENERGY TOP W 80 - W 125
7EN cod. 3540I160 - 05/2008 (Rev. 00)
To relight the boiler, press the button (detail 7 fig. 1) again for 5 seconds.
fig. 6
The boiler will be immediately ready to operate whenever domestic hot water is drawn (with optional hot water tank in-
stalled) or in case of a room thermostat demand.
To completely disconnect the power to the unit, press the button detail 14 fig. 1.
BThe antifreeze system does not work when the power and/or gas to the unit are turned off. To avoid damage
caused by freezing during long idle periods in winter, it is advisable to drain all water from the boiler, DHW
circuit and system; or drain just the DHW circuit and add a suitable antifreeze to the heating system, complying
with that prescribed in sec. 2.3.
1.4 Adjustments
Summer/Winter changeover
Press the button detail 6 - fig. 1 for 1 second.
fig. 7
The display activates the Summer symbol detail 10 - fig. 1. The heating function is deactivated, whereas the possible
production of domestic hot water (with optional external hot water tank) remains activated. The antifreeze system re-
mains activated.
To deactivate Summer mode, press the button (detail 6 - fig. 1) again for 1 second.
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ENERGY TOP W 80 - W 125
8EN
cod. 3540I160 - 05/2008 (Rev. 00)
Heating temperature adjustment
Operate the heating buttons (details 3 and 4 - fig. 1) to adjust the temperature from a min. of 20 °C to a
max. of 90 °C.
fig. 8
DHW temperature adjustment (with optional hot water tank installed)
Operate the DHW buttons (details 1 and 2 - fig. 1) to adjust the temperature from a min. of 10 °C to a max.
of 65°C.
fig. 9
Room temperature adjustment (with optional room thermostat)
Using the room thermostat, set the temperature required in the rooms.
Room temperature adjustment (with optional remote timer control)
Using the remote timer control, set the temperature desired in the rooms. The boiler unit will set the system water ac-
cording to the required room temperature. For information on the remote timer control, please refer to its user's manual.
Sliding Temperature
When the optional external probe is installed the corresponding symbol (detail 22 - fig. 1) is activated on the control
panel display (detail 5 - fig. 1). The boiler control system operates with "Sliding Temperature”. In this mode, the temper-
ature of the heating system is adjusted according outside weather conditions, in order to ensure high comfort and en-
ergy saving throughout the year. In particular, as the outside temperature increases the system delivery temperature
decreases according to a given “compensation curve”.
With Sliding Temperature adjustment, the temperature set with the heating buttons (details 3 and 4 - fig. 1)
becomes the maximum system delivery temperature. It is advisable to set a maximum value to allow system adjustment
throughout its useful operating range..
The boiler must be adjusted at the time of installation by qualified personnel. Possible adjustments can in any case be
made by the user to improve comfort.
Compensation curve and curve offset
Press the button (detail 8 - fig. 1) for 5 seconds, to display the actual compensation curve (fig. 10) which can
be modified with the DHW buttons (details 1 and 2 - fig. 1).
Adjust the required curve from 1 to 10 according to the characteristic (fig. 12).
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ENERGY TOP W 80 - W 125
9EN cod. 3540I160 - 05/2008 (Rev. 00)
By setting the curve to 0, sliding temperature adjustment is disabled.
fig. 10 - Compensation curve
Press the heating buttons (details 3 and 4 - fig. 1) to access parallel curve offset (fig. 13), modifiable with
the DHW buttons (details 1 and 2 - fig. 1).
fig. 11 - Parallel curve offset
Press the button (detail 8 - fig. 1) again for 5 seconds to exit parallel curve adjustment mode.
If the room temperature is lower than the required value, it is advisable to set a higher order curve and vice versa. Pro-
ceed by increasing or decreasing in steps of one and check the result in the room.
fig. 12 - Compensation curves
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20
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90
85
20 10 0 -10 -20
1
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68910 7

ENERGY TOP W 80 - W 125
10 EN
cod. 3540I160 - 05/2008 (Rev. 00)
fig. 13 - Example of parallel compensation curve shift
AIf the Remote Timer Control (optional) is connected to the boiler, the above adjustments are managed accord-
ing to that given in table 1.
Table. 1
Water system pressure adjustment
The filling pressure with the system cold must be approx. 1.0 bar. If the system pressure falls to values below minimum,
the boiler card will activate fault F37 (fig. 14).
fig. 14 - System low pressure fault
AOnce the system pressure is restored, the boiler will activate the 120-second air venting cycle indicated on the
display by FH.
Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler
control panel.
DHW temperature adjustment (with optional hot
water tank installed)
Adjustment can be made from the Remote Timer Control menu and the boiler
control panel.
Summer/Winter changeover Summer mode has priority over a possible Remote Timer Control heating
demand.
Eco/Comfort selection (with optional hot water tank
installed)
On disabling DHW from the Remote Timer Control menu, the boiler selects
the Economy mode. In this condition, the button (detail 7 - fig. 1) on
the boiler panel is disabled.
On enabling DHW from the Remote Timer Control menu, the boiler selects
the Comfort mode. In this condition it is possible select one of the two modes
with the button (detail 7 - fig. 1).
Sliding Temperature Both the Remote Timer Control and the boiler card manage Sliding Tempera-
ture adjustment: of the two, the Sliding Temperature of the boiler card has pri-
ority.
20
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20 10 0 -10 -20
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OFFSET = 20 OFFSET = 40
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