Ferroli Modena 102 User guide

Appr. nr. B99.06 A - CE 0461 AU 0431
MODENA 102
Copper Wall-Mounted Combination,
Gas Fired Boiler for Central Heating
andDomestic Hot Water Production,
Fan Assisted, Room Sealed Compartment,
Electronic Flame Ignition andControl
3543495/0 - 06/2002
INSTALLATION,SERVICINGAND
USERINSTRUCTIONS
G.C. NO: 47-267-24

MODENA 102
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.Bothshould
berecordedin yourcentral heatinglogbook. Youcan checktheinstaller's CORGI registration
by callingCORGI on 01256 372300".
FerroliisamemberoftheBenchmarkinitiativeandfullysupportstheaimsoftheprogramme.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.
NDEX
1. DESCRIPTION....................................................................................................................................... 3
2.TECHNICAL AND DIMENSIONAL CHARACTERISTICS...................................................................... 4
3. INSTALLATION DETAILS ....................................................................................................................... 9
4. COMMISSIONING AND TESTING....................................................................................................... 22
5. ADJUSTMENT AND GAS CONVERSION........................................................................................... 23
6. MAINTENANCE AND CLEANING ....................................................................................................... 25
7. REPLACEMENT OF PARTS ................................................................................................................ 27
8. FAULT FINDING ................................................................................................................................... 32
9. ELECTRICAL AND FUNCTIONAL SCHEME....................................................................................... 39
10. USER INSTRUCTIONS...................................................................................................................... 41

MODENA 102
3
1. DESCRIPTION
1.01 Introduction
The Modena102is definedas a“room sealed” combination boiler, all air requiredfor combustion is takenfrom
outsidetheroominwhichitisinstalled.Itisanewhighperformancegasfiredheatgenerator forcentralheatingand
domestichot waterproduction.Aspecialfeatureofthis boileris itsbuilt-inelectronicflame ignition andcontrolunit
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
•16 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.
•Safety bracket
1.02Instructionsand regulations
Assembly,installation,first start upand maintenancemust becarriedout bycompetent personsonly,in accordance
with all current technical regulations and directives.
.O.S.H.H.
Materials usedin the manufacture of this appliance are non hazardous and no special precautions are
requiredwhenservicing.
Related Documents
Thisappliancemust beinstalled strictlyin accordancewiththeseinstructions.
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. 75931992 TREATMENT OF WATERINDOMESTIC HOT WATERCENTRALHEATING SYSTEMS
B.S. 55461990 INSTALLATIONOF HOT WATERSUPPLIES FORDOMESTIC 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 GAS FIRED HOT WATERBOILERS
B.S. 68911989 GAS INSTALLATIONS
B.S. 76711992 IEE WIRING REGULATIONS
B.S. 48141990 SPECIFICATIONFOREXPANSIONVESSELS
B.S. 5482 1994 INSTALLATIONOF LPG
ModelWaterBye Laws
For Northern Ireland the rulesin force apply

MODENA 102
4
Fig. 1
2.TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Modena 102 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.
Key
1 -3/4"central heating flow outlet
2-1/2"domestichot water flow outlet
3-1/2“gasinlet
733
460
430
85
14
362
200
720
Ø60
115
Ø100
75
189
Distance between connections
36 95 60 60 155 54
175
Bottom view
4
23 5
189
460
Top view
120120
200
110
80
110
61
4-1/2"domestichot water inlet
5-3/4"central heating return inlet
6-Pressure reliefoutlet

MODENA 102
5
N.B. - The gas pressures at the burner and gas flows during the central heating phase given in the table refer
to nominal boiler output.To reduce this output (where necessary), gas pressure must be reduced untilthe
required output levelis reached (see figures 4and 5).
During domestic hotwater production,gas pressures to the burner must 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
TechnicalData
MODEL Heat output Heat input
Net
Domestic hot
water heat
input
Gross
Boiler water
contents
Domestic hot
water circuit
contents
kW kW kW kW kW Litres Litres
Modena 102 30.0 12.7 33.1 14.5 30.0 1.5 0.8
MODEL
Connections Expansion vessel Max. working
pressure
central
heating
circuit
Max.
working
pressure hot
water circuit
12345Capacity Pre-pressurising
value
ØØØØØLitres bar bar bar
Modena 102 3/4” 1/2” 1/2” 1/2” 3/4” 10 1 3 6
MODEL Main injectors (mm) Gas flow rates to main burners
for central heating Gas valve
Ø1/2”
G20 - NG G31 - LPG G20 - NG G31 - LPG
ØØ m
3
/h kg/h
Modena 102 16x1,25 16x0,75 3.5 2.6 H. V K4105G
MODEL
Gas supply pressures
working Gas pressure at main burner for central heating Safety valve
G20 - NG G31 - LPG G20 - NG G31 - LPG
min. max. min. max.
mbar mbar mbar mbar mbar mbar bar
Modena 102 20 37 2.5 13.0 7.0 35.5 3
MODEL
Domestic hot
water production
with ∆t 30°C
Domestic hot
water production
with ∆t 35°C
Max. working
pressure domestic
hot water Protection
level Weight
G20 - NG G31 - LPG
l/min. l/min. mbar mbar kg
Modena 102 14.3 12.3 13.0 35.5 IP44 48

MODENA 102
6
2.03 Boiler water flow diagram2.02 Boiler maincomponents
Key
5 Room sealed compartment
7Gas inlet
8Domestic hot water outlet
9Domestic hot water inlet
10 Central heatingflowoutlet
11 Central heatingreturn inlet
14Safetyvalve
16Fan
19Combustion chamber
20Burner assembly
21Main injector
22 Burner
26Combustion chamber insulation
27Copper heat exchanger for central
heatingand domestic hot water
28Flue collector from heat exchanger
29Internal flue exit
32Central heatingpump
34Central heatingflowtemperature sensor
36Automatic air vent valve
Fig.2
Fig.3
818222
29 43187
IN OUT
MIN
GRUNDFOS
FERROLI
114
34
20
21
90
50
16
28
32
26
19
49
132
5
56
27
91
62
10 8 784 85 44 136 14 42 9 11
36
98 63 157 145
05
1234
6
OUT
I
MIN
AIR
IN
AIR
IN
FLUE
OUT
C.H.
OUT D.H.W. OUT GAS IN D.H.W. IN C.H. IN
42Domestic hot water flow
temperature sensor
43Air pressure switch
44 Gas valve
49Safetyoverheat thermostat
50Central heatingflowlimit thermostat
56Expansion vessel
62Time clock(option)
63Central heatingtemperature adjustment
81Ignition electrode
82Sensor electrode
84Primarygas valve solenoid
85Secondarygas valve solenoid
90*Flue outlet test point
91*Air test point
98On/Off/Reset switch
114Lowwater pressure cut off switch
132Flue gas deflector
136Flowmeter
145Central heatingpressure gauge
157Domestic hot water temperature adjustment
187Restrictor
*For use withflue gas analyser

MODENA 102
7
2.05 Pump characteristics
The pump head available for circulating the water
is given in fig. 6.
N.B. -Thepump is factorysetat position 3. Thepump
is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph
Note-Minimum flowthroughboiler heat exchangerat
anytime should not fall below 6 litres per minute.
If the total volume of water in the system exceeds 40
litres an additional expansion vessel must be fitted to
the central heating return pipe.
Pump performance curve Grundfos UPS15-50
Fig. 6
12 3Speed settings
ABoilers pressure drop
BAvailable pump head C.H.
2.04Centralheatingadjustment (not normallyrequired)
To adjust boiler heat input (thus also regulating heat output to the central heating water)simplyadjust the main
burner via the electronic control board (fig. 4,5and see paragraph 5.04page 24).
The diagrams indicate the variation in heat output to the water as burner working pressure is varied.
Adjusting boiler output to the actual requirements of the central heating system will minimise boiler
cycling thus saving fuel,varying the output has virtuallyno effect on the efficiencyand combustion
characteristics of the boiler.
Diagram ofpressures
and outputs with Naturalgas
Fig. 4Fig. 5
Diagram ofpressures and outputs
with LPG(Propane)
2
3
4
5
6
7
8
9
10
11
12
13
12 13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20 21
kW
kcal/h
x 1000
mbar
14
25 26 27 28 29 30 31
22 23 24 25 26
kW
kcal/h
X 1000
m
b
ar
18 19 20 21 22 23
5
10
15
20
25
30
35
12 13 14 15 16 17
11 12 13 14 18 19 2015 16 17
25 26 27 28 29 3024
21 25 2622 23 24

MODENA 102
8
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 10
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 10 litre 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
0.51.0 1.5
1.0 1.52.0 1.52.0 2.0
EXPANSION VESSEL VOLUME (litres)
LITRES
253.56.513.74.710.38.3
507.0 12.927.59.520.616.5
7510.519.441.314.230.924.8
100 14.0 25.955.1 19.0 41.233.1
12517.532.468.923.751.541.3
15021.0 38.882.628.561.849.6
17524.545.396.433.272.1 57.9
200 28.0 51.8110.238.0 82.466.2
0.1400.2590.5510.1900.4120.33
Forsyst.volumesotherthan
thosegivenabove,mult.thesyst.
volumebythefactoracross
Fig. 7
Pressureloss diagram
m |h
3
Q
8
7
6
5
4
3
2
1
00.5 1.5 2.512
H
mbar x 100

MODENA 102
9
3. INSTALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1996
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.
Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to
prosecution; it is your responsibility to ensure that the law is complied with.
N.B. For Northern Ireland the rules in force apply.
Important-If the boileristobe fitted ina timberframedbuildingitshouldbe fittedin accordancewiththe Instituteof
Gas Engineers document IGE/UP/7. If in doubt advice should be sought fromthe Local Supplier.
Location of Boiler
The installation of the Modena 102 must be on a suitable non-combustible load bearingwall which will
provide an adequate fixingfor the boiler mountingsafety bracket assembly. The location should be in an
area where the water pipes will not be subjected to frost conditions. In sitingthe combination boiler the
followinglimitations must be observed:
The combination boiler may be installed in any roomor internal space,although particular attention is drawn
to the requirements of the current I.E.E. wiringregulations and in Scotland the electrical provisions of the
buildingregulations applicable in Scotland,with respect to the installation of the combination boiler in a room
or internal space containinga bath or shower.
Where a roomsealed appliance is installed in a roomcontaininga bath or shower any electrical switch
or appliance control utilisingmains electricity must be situated so that it cannot be touched by a person
usingthe bath or shower.
Air Supply
The roomor compartment in which the boiler is installed does not require a purpose provided vent when
usingthe standard concentric flue.
Flue System
The boiler allows the flue outlet to be taken fromthe rear of the boiler,fromeither side or vertically.
Astandard flue 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 and 2815mm for rear flues,deduct 91mm plus distance fromside
wall for side outlet flues). It is absolutely essential, to ensure that products of combustion discharging from the
terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors,
natural air infiltration or forced ventilation/air conditioning.
Gas Supply
If necessary the local Gas 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 used without prior consultation with the Local Gas supplier.
Agas meter can only be connected by the Local Gas supplier,or by a Local Gas suppliers Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet workingpressure must be 20mbar MINIMUM,for NGand 37mbar minimumfor LPG.
Pipeworkfromthe meter to the combination boiler must be of an adequate size.
The boiler requires 3.5m3/h of natural gas,and 2.60 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework
must be adequately supported. An isolatinggas valve is provided and should be fitted on the boiler gas inlet.
Please wait 10 minutes when lightingfromcold before checkinggas rate. Gas pressures should be checked after
the boiler has operated for 10minutes to reach thermal equilibrium.

MODENA 102
10
Water System
Note - the boiler is designed for sealed systems only and must NOT be used on open vented 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 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 1 is recommended for water carrying pipework.
Pipework in 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. 8.
Important -If thermostatic radiator vales are fitted a bypass must be fitted to ensure a minimum flowrate through
the boiler of 6l/min. The bypass should be fitted as far as possible from the boiler.
Make Up Water
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. 9.
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.). If the cold mains supply exceeds 5bar (72 P.S.I.), a water governor or pressure
reducing valve must be fitted by the installer into the mains supply in an inconspicuous but accessible position
preferable between 3 and 5 metres (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 pipework is adequately supported
NOTE: A bypass must be fitted as far as possible
from the boiler if thermostatic radiator valves are
fitted thoughout.
Fig. 8
Gas
Cold water Additional expansion vessel
C.H. (if required)
Filling
point C.H.
Bypass
Key
1.Filling point C.H.
2.Temporary connection
3.Cold water supply Fig. 9

MODENA 102
11
Terminal Position
Fig. 11
CLEARANCES:
* 600mm minimum clearance for servi-
cing access
460 5 min.5 min.
100 min.852
360 50 mm
600* min.
760
200 min.
Fig. 10
P
D, E
Q
Q
l
BC
A
G
F
L
J
HH
K
N
N
MM
Q
Directly below an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)
(>14-32 kW)
(>32-70 kW)
Above an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)
(>14-32 kW)
(>32-70 kW)
Horizontally to an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)
(>14-32 kW)
(>32-70 kW)
Below gutters, soil pipes or drain pipes
Below eaves
Below balconies or car port roof
From a vertical drain 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 structure on the roof
Above 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
Aa300 mm
600 mm
1500 mm
2000 mm
300 mm Not allowed 300 mm
Ba300 mm
300 mm
300 mm
600 mm
300 mm Not allowed 300 mm
Ca300 mm
400 mm
600 mm
600 mm
300 mm Not allowed 300 mm
D300 mm 75 mm Not allowed 75 mm
E300 mm 200 mm Not allowed 200 mm
F600 mm 200 mm Not allowed 200 mm
G300 mm 150 mmbNot allowed 150 mm
H600 mm 300 mm Not allowed 200 mm
I300 mm 300 mm Not allowed 300 mm
J600 mm 600 mm N/A 600 mm
K600 mm 1200 mm N/A 1200 mm
L1200 mm 1200 mm N/A 1200 mm
M1500 mm 1500 mm N/A 1500 mm
N300 mm 300 mm N/A 300 mm
ON/A N/A N/A 50 mm
PN/A N/A See Table 2
and Fig. 6b N/A
QN/A N/A See Table 2
and Fig. 4 150 mm
NOTE N/A = Not applicable
aIn addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric formed for the purpose of accommodating
a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the rated heat inputs as shown.
bThis dimension may be reduced to 75 mm for appliances of up to 5 kW heat input.
Minimum dimensions offlue terminal positions

MODENA 102
12
3.01 Drilling Template (Top Flue Application)
Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting points.
Drill two 10mm holes 90mm deep to accept the wall plugs, fit wall plugs. Fit two special wall plugs on the wall as
described in the fig. 12a. Fasten the wall 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 (22 mm)
2.Safety Valve (15mm)
3.Domestic hotwateroutlet (15mm)
4.Gassupply (22 mm)
5.Domestic hotwaterinlet (15mm)
6.CH return(22 mm)
Fig. 12b
75
5 min
195 min
200 min
955 min
200
460 min
123 4 5 6
15 15
Ø3/4''Ø3/4'' Ø1/2''Ø1/2''Ø1/2''Ø1/2''
==
Ø120
jig bracket
Fig. 12a

MODENA 102
13
3.02 Restrictor
For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below.
Determine the correct size of flue restrictor required. Before inserting the flue gas duct in the boiler, check that
the restrictor fitted is correct and that it is correctly positioned (see fig. 13).
Holes Ø : 47 50 52
Ø
Fig. 13
Choice ofrestrictor:
•With concentric pipes:-up to 1m long +one bend, use the 52 mm restrictor.
-for flue lengths over 1 metre, use no restrictor.
•With 2 pipe system:-Calculate the total flow resistance of the air and flue pipes in metres
(cap. 3.04.2)
-utilise the table shown below to choose the more suitable restrictor for
the flow resistance calculated
RESTRICTOR FOR TWO PIPE SYSTEM
ON MODENA 102
Total flow resistance
of flue system
Use
restrictor
size
minimum maximum mm
0 m 20m 47
20 m 35 m 50
35 m 45 m 52
45 m 50 m no restrictor
N.B.:the diameter ofthe hole is stamped
onthe restrictor
No restrictor is requiredfor back
outlet flue

MODENA 102
14
A 90° bend (fig. 15) is supplied for the horizontal connection of air and flue gas pipes. This can be angled
towards the chosen wall in degrees of 45°.
3.03 Top Outlet Concentric Flue Connection
3.03.1 Vertical concentric connection
Fig. 15
A vertical connector can be supplied for vertical
discharge with concentric pipes.
The simple mounting and use of double lip gaskets
at the joints makes this an extremelyeasyand safe
option.
Fig. 14
Concentric
Vertical
Connector
3.03.2Horizontal concentric connection
1KWMA31Y
DS
L
125
70
50*
30
95
80
80 -3 mm/m
Ø60 Ø80
70 min.
* = between 10 e 60 mm
190 270
L=S=D=255

MODENA 102
15
Fig. 16
Notes on concentric horizontal installa-
tion
To locate the centre of the hole for passing the
pipes through the wall, refer to fig. 12b. Bear in
mind that the two concentric pipes must slope
downwards away from the boiler at a rate of
about 3 mm/m to avoid rainwater entering the
boiler. The concentric pipes making up the air
- flue gas duct must be sealed with the gasket
where they join the boiler (fig. 16). Outside, the
pipes should protrude from the wall between 10
and 60 mm (fig. 16).
Between
10-60mm
3.03.3 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
3.02 for use of restrictor
Maximum flue lenght permissible 100 mm concentric 125 mm concentric
Vertical Horizontal* Vertical Horizontal*
Modena 102 4 m 3 m 5 m 5 m
Reduction for bend
100 mm concentric bend 90°1 m
100 mm concentric bend 45°0,5 m
125 mm concentric bend 90°0,5 m
125 mm concentric bend 45°,0,25 m
*For horizontal Flueingthe reduction for appliance bendor turret are already included.
max. 3 m
max. 4 m
Fig. 17a Fig. 17b

MODENA 102
16
Fig. 18
Ø80Ø80
AIRFLUE
1
2
3.04 Top Outlet: Two Pipe Flue System
3.04.1 Two pipe connection
Two separate ducts Ø80 for air intake and flue gas
discharge can be directly connected to the boiler.
For conversion mount the separate outlet kit 1 to
top outlet (see 3.03)
Insert blankingplate 2
in remainingairintake
Connect flue duct to central hole Ø80 and air duct to
left or right air intake hole Ø80. Insert blanking plate 2in remaining air intake.
Avaried selection of accessories for two pipe systems are available from Ferroli (ref. to page 17). Before
installing your system please check via calculation table at 3.04.2you are not exceeding the maximum
permissible length for the appliance.
IMPORTANT:
Notes on two pipe system installation:
Whenusingthetwopipesystemthefluedischargepipemusthavea25mmairgapwhenpassingthroughcombustible
materials.Wherethe flue dischargepipepassesthroughtheairingspace of anairing cupboarditmustbe protected
by a non combustible guard or expanded metal giving an annular air gap of at least 25mm.
Where the flue discharge pipe passes through a wall containing cavity insulation,a non combustible sleeve
must be fitted. Additionally a gap of 25mm between the sleeve and the insulation should be provided by
cutting back the insulation or packing loose fill bead insulation with mineral fibre. Where the flue pipe is
run through an unheated roof space it should be insulated with non combustible insulating material to
prevent condensation. The flue pipe should be supported at intervals of not more than 1.8m and the support
should be preferably below a joint.
3.04.2Two pipe flue system
To determine the maximum lengthofflue andairpipe permissible.
The calculation is based on a standard reference resistance of 1 metre of 80 mm horizontal air intake pipe. For
every configuration of the two-pipe system all components will have a resistance factor based upon this reference.
(I.e. a 90 degree bend fitted in the flue line would attract a resistance factor equivalent to 2.5Metres of horizontal
80mm pipe). This is expressed as Xmetres. Each boiler will have a maximum equivalent length of flue/air pipe
and this is shown in the table as Nmetres. Therefore when calculating the proposed flue run the equivalent
resistance of every length of pipe and every bend,whether air intake or flue discharge is added together to
give an actual total flue length. The final figure calculated must not exceed the permitted maximum length
(Nmetres) for each boiler type.
Calculation Routine
1. Identify all the components needed to complete the proposed flue/air pipe run.
2. Calculate the sum of all the equivalent lengths (see table at next page).
3. For boilers,which may require a flue restrictor,refer to table at page 13 (par. 3.02) to ascertain the correct
size and add this resistance to your total.
4. Check and verify that the total flue/air pipe length (flow resistance) does not exceed 50 mt. maximum
permitted for Modena102.
MPORTANT: Resistance factors apply to standard férroli components only.

MODENA 102
17
AIR FLUE
Vertical Horizontal Vertical Horizontal
Description
Male-female flue/Air pipe
1 m - Ø 80
Female-female bend
45°Ø 80 m
Male-female bend
90°Ø 80 m
Dscription
Horizontal
flue terminal
Ø 80 mm
Air intake
terminal
Ø 80 mm
Outlet flue/air inlet
for concentric system
Ø 100/60 mm
Pipe fitting for
outlet flue
Ø 80 mm
Outlet flue/air inlet
for connection
with split end
Ø 80 mm
1112
1,2 2,2
1,5 2,5
REDUCTION
5
2
4
AIR FLUE
Vertical Horizontal Vertical Horizontal
REDUCTION
12
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 Ø 100/80 mm
0
3.04.2 (continued)
Tab. 1 - Pipes and
fittings reduction table

MODENA 102
18
For further accessories please refer to:
"Flue system manual for room sealed boiler"
Example of calculation for wall inlet/outlet
with 2 pipe system
maximum total flue length: 50 metres Attention:
Remove the flue diaphragm.
The flue + air Pipes must have a 3% drop away
from the boiler to outside
7 6 325 1
13 m 13 m
Fig. 19
Example of wall inlet/outlet
2pipe application
Example of roof inlet/outlet
Example of direct roof flue outlet
and wall air inlet
3.04.3 Example of other installation with two pipe systems
Fig. 20a
Fig. 20bFig. 20c
REF.N° OF PIECESDESCRIPTION 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
5 1 Flue bend 80 mm R/D = 0,75 2,5 m
6 13 Horizontal flue 26,0 m
7 1 Air wall terminal outlet flue 5,0 m
TOTAL50,0 m

MODENA 102
19
3.05 Connecting the central heating and domestic hot water circuits
Connect to the relevant connections as indicated in fig. 1. Connect the pressure relief valve discharge pipe
(15mm) to the outside of the building, where possible over a drain. The discharge must be such that it will
not be hazardous to occupants and passers-by or cause damage to external electric components or wiring.
The pipe should be directed towardsthe bwall. To ensure long life,the bheating circuit should be correctly
sized and fitted with all the controls necessary to ensure correct functioning and operation. The differential
between the boiler flow and return pipes should not be more than 20°C. You are advised not to use the
boiler with return temperatures of less than 50°C in order to prevent patches of condensation forming, having
a corrosive effect on boiler components.
3.06Boiler water characteristics
Ifthe bwater is harder than 18clarke degrees,the bwater used should be treated to avoid possible scale in the
boiler caused by hardbwater or corrosion by aggressive water.It should be remembered that as a result of its
low thermal conductivity, even scale of just a few millimetres thickcan lead to considerable overheating of
the boiler walls,tresulting in serious problems.
IT IS ABSOLUTELY VITAL THAT THE WATER USED IS TREATED IN THE FOLLOWING CASES:
a) Extensive systems (containing large quantities of water);
b) Frequent additions of water to top-up the system;
c) Domestic hot water circuits
If the system requires partial or total emptying, you are recommended to refill it with treated water.
3.07Filling
When cold, system pressure should be about 1 bar. If while running venting off of air dissolved in the water causes
the pressure of the central heating system to drop below 0.5 bar,the buser must utilise a filling loop to bring it
backto te boriginal value. During operation, water pressure in the boiler when hot should be about 1.5 - 2 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 checkvalve should be
fitted in the flow to prevent gravity circulation around the heating system.
3.08Gas connection
Gas connection should be carried out using a rigid pipe.
The flow at the gas meter should be sufficient for the simultaneousbuse at full gas rate of all appliances
connected to it. Connect the gas supply to te bboiler according to current regulations. The diameter of
the gas tube leaving the boiler is not the determining factor in choosing the diameter of the pipe between
the appliance and the meter. This must be selected in relation to length and pressure drop and in any
instance should not be less than 22mm.
The whole ofthe gas installation including the meter should

MODENA 102
20
When the boiler is connected to an electricity main, it is essential TO OBSERVE CORRECT POLARITIES (LIVE:
brown cable, NEUTRAL: blue cable, EARTH: yellow-green cable).
All wiring must conform to current I.E.E.regulations.
Note: Ifthe power supply cable has to be replaced, use “0.75mm (24/0.20) heat resisting cable only to
BS6500 with a maximum external diameter of8mm.
Note - When connecting a room thermostat or external timer, do not linkthe power supply ofthese devices
to the switching contacts.The switch contacts must be voltage free.Any mains powered devices must utilise
mains power solely to drive the timer motor.
Applying mains voltageto theswitch contactswill irreparably damagethecircuitboard.
Although this boiler can also be used without a room thermostat, you are recommended to install one
for the following reasons:
Greater comfort conditions due to more accurate control ofroom temperature.
Greater energy savings.
3.10 Differential air pressureswitch (fig.2- part 43)
The differential air pressure switch is a safety device which allows the main burner to ignite only after having
verified that the fan is working correctly.Ifthe 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 ofthe boiler is designed so that iffor any reason the air pressure switch contacts
remain closed when the fan stops, the burner will not start upagain.
3.11 Checks
Fill the central heating system as described previously (3.07) and checkthere are no leaks in the domestic hot
water and boiler water circuits.Checkthat there are no gas leaks on the boiler or the supply to the boiler.Also
checkthat the electrical connections are correct.
3.12Installing aroomthermostat(72) (fig.21b)
To connect the thermostat:
Open the electrical boxon the base ofthe appliance and remove the “jumper cable”between terminals
3and 4.
Connect the room thermostat (72) as shown in figure 21b.