Ferroli MODENA 80 E User guide

Appr. nr. B97.09 A - CE 0063 AT 4967
MODENA 80 E
Copper Wall-Mounted Combination,
Gas Fired Boiler for Central Heating
andDomestic Hot Water Production,
Fan Assisted, Room Sealed Compartment,
Electronic Flame Ignition andControl
3543230/2 - 06/2001
INSTALLATION,SERVICINGAND
USERINSTRUCTIONS
G.C. NO: 47-267-05

MODENA 80 E
2
IN EX
1 DESCRIPTION 3
TECHNICAL AND DIMENSIONAL CHARACTERISTICS 4
INSTALLATION DETAILS
COMMISSIONINGAND TESTING
ADUSTMENT AND GASCONVERSION 3
MAINTENANCE AND CLEANING
REPLACEMENTOFPARTS
8AULTINDING3
ELECTRICAL AND FNCTIONAL SCHEME3
10USER INSTRUCTIONS 4
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".
Ferroliisamember oftheBenchmarkinitiativeand fullysupportstheaimsof theprogramme.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.

MODENA 80 E
3
1 DESCRIPTION
1.01 Introduction
The Modena80 Eis definedas a“room sealed” combination boiler, all air requiredfor combustion is takenfrom
outsidetheroominwhichitisinstalled.Itisanewhighperformancegasfiredheatgeneratorforcentralheatingand
domestichot waterproduction.Aspecialfeatureofthisboilerisits built-inelectronicflameignition 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
•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.
•Safety bracket
1.02Instructionsand regulations
Assembly,installation, firststartup andmaintenance mustbecarriedout bycompetentpersons only,in accordance
with all current technical regulations and directives.
c.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. 75931992TREATMENT OF WATERINDOMESTIC HOT WATERCENTRALHEATING SYSTEMS
B.S. 5546 1990 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. 76711992IEE WIRING REGULATIONS
B.S. 48141990 SPECIFICATIONFOREXPANSIONVESSELS
B.S. 54821994 INSTALLATIONOF LPG
ModelWaterBye Laws
For Northern Ireland the rulesin force apply

MODENA 80 E
4
Fig. 1
2 TECHNICAL AND DIMENSIONALCHARACTERISTICS
2.01 Technical information
Modena 80 Eboilers are central heating and domestic hot water heat generators and are produced as standard
to function with natural gas or Liquid Petroleum 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
1345
15012012070
110
80 80
80
460
Top view
1149560609536
100
720
725
16025
10
100 270
460
175100
Bottom view
Distance between connections
95
60 120280
26

MODENA 80 E
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 Domestic hot
water heat
input
Boiler water
contents
Domestic hot
water circuit
contents
kW kW kW kW kW Litres Litres
Modena 80 E 23,8 9,7 25,8 11,5 23,8 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 80 E 3/4” 1/2” 1/2” 1/2” 3/4” 7 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 80 E 12x1,30 12x0,77 2,73 2,00 H. V K4105G
MODEL
Gas supply pressures Gas pressure at main burner for central heating Safety valve
G20 - NG G31 - LPG G20 - NG G31 - LPG
minimum nominal minimum nominal
mbar mbar mbar mbar mbar mbar bar
Modena 80 E 20 37 2,5 111,8 7,8 36,0 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 80 E 11,3 9,7 11,8 36,0
IP44
38

MODENA 80 E
6
2.03 Boiler water flow diagram
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
2.02 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
32Central heatingpump
34Central heatingflowtemperature
sensor
Fig.2
Fig.3
43
16
27
50
19
49
28
5
20
21
26
132
90 91
818222
56
IN OUT
MIN
36
05
1234
6
98 63 157 14562
10 874 784 85 44 136
114
34
14 42 9 11
32
73
36Automatic air vent valve
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
*90Flue samplingpoint
*91Air samplingpoint
98On/Off/Reset switch
114Lowwater pressure cut off
switch
132Flue gas deflector
136Flowmeter
145 Central heatingpressure
gauge
157Domestic hot water
temperature adjustment
*For use withflue gas analysis
equipment

MODENA 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).
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 hasvirtually 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
9
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
emperatura di erogazione sanitaria
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/
Temperature of domestichot water supply°C
Boiler output exchanged kcal/
Fig. 6

MODENA 80 E
8
Fig. 8
Pressure loss diagram
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 8litre
vessel supplied.
Note:
1. Fill C.H.installation to min. 1.5bar.
2.Select the expansion vessel for asystem
pressure of 2.0bar.
3.Expansion vessel must be fitted to central
heating return pipe.
4.The standard 7litre expansion vessel is
charged to 1bar.
5.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
EXPANSION 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
H
mbar 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.
Note -Minimum flowthrough boiler heat exchanger at anytime
should not fall below6litres per minute.
Ifthe total volume of water in the system exceeds 40litres
an additional expansion vessel must be fitted to the central
heating return pipe.
Pumpperformance curve Grundfos UPS15-50
Fig. 7
1 2 3 Speed settings
ABoilerspressuredrop
BAvailablepumpheadC.H.

MODENA 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 with the Regulations may leadto
prosecution;it is your responsibility to ensure that the lawis compliedwith.
N.B. For Northern Irelandthe rules in force apply.
Important -Ifthe boileris tobe fittedina timberframedbuildingit shouldbe fittedinaccordancewiththeInstitute
of Gas Engineers document IGE/UP/7.If in doubt advice should be sought fromthe LocalSupplier.
Location of Boiler
The installation of the Modena 80Emust be on a suitable non-combustible loadbearingwall 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 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 from
side wall for side outlet flues).It is absolutely essential, to ensure that products of combustion dischargingfrom
the terminalcannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors,
naturalair infiltration or forcedventilation/air conditioning.
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
pipeworkmust be adequately supported. An isolatinggas valve is providedandshould be fittedon the boiler gas
inlet.Please wait 10minutes when lightingfromcold before checkinggas rate.Gas pressures should be checked
after the boiler has operatedfor 10minutes to reach thermalequilibrium.
WaterSystem
Note -the boileris designedforsealedsystems only andmust NOT be usedon open ventedsystems.

MODENA 80 E
10
Fig. 9
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not 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 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. 9.
Important-Ifthermostaticradiatorvalesarefittedabypassmustbefittedtoensurea minimumflowratethrough
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 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 Gas
Cold water Additional expansion
vessel C.H. (if required)
Filling
point
C.H.
Bypass
NOTE: A bypass that will ensure a minimum
flow rate of 6 L/m at all times must be fitted as
far as possible from the boiler if thermostatic
radiator valves are fitted.
Key
1. Filling point C.H.
2. Temporary connection
3.Coldwater supplyFig. 10

MODENA 80 E
11
Terminal Position
Fig. 12
CLEARANCES:
* 600mm minimum clearance for servicing
access
460 5 min.5 min.
100 min.860
200 min.
270 50 mm
600* min.
720
Fig. 11
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 80 E
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 70mm deep to accept the wall plugs. Fit standard wall plugs on the left and right side and
the special wall plug in the middle (fig. 13a). Fix the wall bracket to the wall using standard lock nut (M8) on both
sides. Mount the boiler on the wall bracket and fix using the special antitheft nut (M8) as described in the fig. 13a.
Using a core drill cut a 118mm diameter hole for the flue.
1. CH flow
2.Safety Valve
3.Domestic hotwateroutlet
4.Gassupply
5.Domestic hotwaterinlet
6.CH return
Fig. 13b
Ø3/4" Ø1/2" Ø1/2" Ø1/2" Ø1/2" Ø3/4"
200
Ø118
165 min
65
21 min
5 min
183 min
295.5 min
200 min
932 min
269
110
125 min
280
123 4 5 6
Fig. 13a

MODENA 80 E
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. 14).
Holes Ø : 45 47 50
Ø
Fig. 14
CHOISE OF RESTRICTOR
RESTRICTOR FOR TWO PIPE SYSTEM
Total flow resistance
of flue system Use
restrictor
size
minimum maximum mm
0 m 13 m 45
13 m 23 m 47
23 m 38 m 50
38 m 48 m No restrictor
•With concentric systems:
-Choose correct restrictor from table below.
•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 CONCENTRIC SYSTEM
Flue lenght up to: Use restrictor
size
Concentric
60 / 100 1 bend + 1 meter 50 mm
1 bend + 3 meters No restrictor
Concentric
80 / 125
1 bend + 3 meters 45 mm
1 bend + 4 meters 50 mm
1 bend + 5 meters No restrictor
N.B.:the diameter ofthe hole is stamped
onthe restrictor
No restrictor is requiredfor back
outlet flue

MODENA 80 E
14
A 90° bend (fig. 16) is supplied for the horizontal connection of air and flue gas pipes. This can be oriented
towards the chosen wall in degrees of 45°.
3.03 Top Outlet Concentric Flue Connection
3.03.1 Vertical concentric connection
Fig. 16
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. 15
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 80 E
15
Fig. 17
Notes on concentric horizontal installation
To locate the centre of the hole for passing the
pipes through the wall, refer to fig. 13b. 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. 17). Outside, the
pipes should protrude from the wall between 10
and 60 mm (fig. 17).
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
3.02for use of restrictor
Maximum flue lenght permissible 100 mm concentric 125 mm concentric
Vertical Horizontal* Vertical Horizontal*
Modena 80 E 4 m 3 m 5 m 5 m
Reduction for bend
100 mm concentric bend 90°m1
100 mm concentric bend 45°m5,0
125 mm concentric bend 90°m5,0
125 concentric bend 45°m52,0
*For horizontal Flueingthe reduction for appliance bendor turret are already included.
max. 3 m
concentric
100/60
max. 4 m
concentric
100/60
Fig. 18a Fig. 18b

MODENA 80 E
16
Fig. 19
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 to top
outlet (see 3.03) mount the separate outlet kit "1"
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 "2"
in remaining air intake. Awide number 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.
Notes on two pipe system installation:
Whenusingthetwopipesystemthefluedischargepipemusthavea25mmairgapwhenpassingthroughcombustible
materials.Wherethefluedischargepipe passesthroughtheairingspace ofanairing cupboardit mustbeprotected
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
spaceitshouldbeinsulatedwithnoncombustibleinsulatingmaterialtopreventcondensation.Thefluepipeshouldbe
supported at intervals of not more than 1.8m and the support should be preferably below a joint.
3.04.2Two pipe flue system
•Calculatingmaximum permissible flue length.
The calculation method is based on a standard reference parameter (1 metre of horizontal air flue 80 diameter
80) for the maximum length permissible for all the pipes +fittings flow resistance coefficient. In other words,for
all components and pipes in the different installation configurations (vertical or horizontal,air or flue,etc.) and
for all the fittings,a flow resistance (reduction) equivalent to xmetre of horizontal air induction pipe is indicated.
For every boiler model a maximum pipe length is provided,expressed in nmetres of horizontal air pipe. In this
way,to calculate the length of a proposed 2pipe air-flue system,add the flow resistance (reduction) in equivalent
metres-air. For every component and fitting present in the system,and to check that the total is less than the
maximum length the permissible for the boiler model.
MPORTANT: the pipes and fittings flow resistance (reduction) have beensummarised onthe following pages.
The flow resistance values writtenrefer only to Ferroli pipes and fittings.
Calculation routine
1. Utilise the pipes and fittings flows resistance tables on the following pages and calculate the total flow
resistance in metres-air,by adding the flow resistances of the components in the whole air-flue system,based
on their position (vertical or horizontal,air inlet or flue outlet).
Please note that the same fitting,identified by a one code (i.e. 1 pipe diameter 80,code KWMA83A),can offer
different flow resistances if positioned as air inlet or flue outlet,if placed vertically or horizontally.
The flow resistance ofthe special two pipe flue-airadapters do not have to be includedin the calculation
as they are already includedin the maximum lengthcalculation.
2. For the restrictors,please refer to cap. 3.02to determinate the correct diaphragm.
3. Check that the total flow resistance calculated is less or equal to 48 metre,the maximum permissible
for Modena 80E.

MODENA 80 E
17
Air Flue
Vertical Horizontal Vertical Horizontal
Description
Male-female
flue Ø80
Female-female
bend 45°Ø80
Female-female
bend 90°Ø80
Male-female
bend 90°Ø80
Pipe fitting M/M/F Ø80
with inspecting
plug+trap for
condensate drainage
system
Description
Air terminal of
inlet protection Ø80
Outlet flue air inlet
for concentric system
Ø80
Pipe fitting for
outlet flue Ø80
Outlet flue air inlet for
connection with split end
Ø80
1112
1,2 2,2
1,5 2,5
1,5 2,5
7
Reduction
2
4
3
Air Flue
Vertical Horizontal Vertical Horizontal
12
Condensate flue
outlet
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 Ø80/100
0
Reduction
Airwall terminal
products
of combustion Ø80
5
Male-female
flue Ø100
Male-female bend
45°Ø100
Male-female
bend 90°Ø100
Air wall terminal
products of
combustion Ø100
Air terminal
of outlet
protection
Ø100
0,4 0,4 0,4 0,8
0,6 1
0,8 1,3
3
1,5
A
c
c
e
s
s
o
r
i
e
s
Ø
1
0
0
Spigot and
socket
reduction
Ø 80/100
1,5 3
3.04.2 (continued)
Tab. 1 -

MODENA 80 E
18
Example of wall inlet/outlet
2 pipe application
Example of roof inlet/outlet
Example of direct roof flue outlet
andwall airinlet
3.04.3 Example of otherinstallation withtwo pipe systems
Fig. 21
Fig. 22 Fig. 23
Forfurtheraccessoriesplease referto:
"Flue system manual forroom sealedboiler"Attention: flow resistance (reduction) equivalent included
between 38 and 48 (see table on page 13)
Remove the flue diaphragm.
The flue and air pipes must have an inclination downward
equal to 3% from the boiler to outside.
Example of calculation forwall inlet/outlet
with2 pipe system
maximum total flue length:48metres
Fig. 20
REF. N° OF PIECES DESCRIPTION CODE 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
4 1 Air inlet closing flange —
5 1 Flue bend 80 mm R/D = 0,75 2,5 m
6 12 Horizontal flue 24,0 m
7 1 Air wall terminal outlet flue 5,0 m
TOTAL 48,0m

MODENA 80 E
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 towards the wall. To ensure long life, the heating 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 and having a
corrosive effect on boiler components.
3.06Boiler water characteristics
If the water is harder than 18clarke degrees, the water used should be treated to avoid possible scale in the
boiler caused by hard water 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, resulting 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 the minimum level described above, the user must utilise
a filling loop to bring it backto the original 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.
Theflowatthegasmetershouldbesufficientforthesimultaneoususeofallappliancesconnectedtoit.Connectthe
gas supply to the boiler according to current regulations. The diameter of the gas tube leaving the boiler is not the
determiningfactorinchoosingthediameterofthepipebetweentheapplianceandthemeter.Thismustbeselected
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 be inspected and tested for soundness and
purged in accordance with BS6891-1988.
N.B. -The filling loop will be fitted by the installer in accordance with water by laws, at the time of installing
the system. It is NOTa part ofthe boiler.
3.09Electrical connection
The boiler must be connected to a single phase 230 V50 Hz electricity supply with a 3Amax. fuse and a bipolar switch with
contact opening of at least 3mm fitted between the boiler and the electricity supply. The boiler must always be connected to
an efficient earth installation. Under the electrical box, there is a 3pole terminal board for connecting the boiler to the mains
(230V50 Hz) anda 2 pole boardforconnectinga roomthermostat (RT).To connect,undo the screwsfixing theterminal board
boxandconnectthewires,ensuringcorrectpolarityoftheterminals.Itshouldbenotedthatthereislowvoltage(24V)between
the room thermostat contacts. When the boiler is connected to an electricity main, it is essential TOOBSERVE CORRECT
POLARITIES (LIVE: brown cable, NEUTRAL: blue cable, EARTH: yellow-green cable).
All wiring must conform to current I.E.E. regulations.

MODENA 80 E
20
Fig. 24
Note: If the power supply cable has to be replaced, use “0.75mm (24/0.20) heat resisting cable only to BS6500
with a maximum external diameter of 8 mm.
Note - When connecting a room thermostat or external timer, do not linkthe power supply of these 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 of room 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. If the 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 of the boiler is designed so that if for any reason the air pressure switch contacts
remain closed when the fan stops, the burner will not start up again.
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. 41)
To connect the thermostat:
Open the electrical box on the base of the appliance and remove the “jumper cable”between terminals
3and 4.
Connect the room thermostat (72) as shown in figure 41.
3.13 Ferroli Modena boilerprogrammerfixing (optional)