Ferroli MODENA 80 E User guide

Appr. nr. B98.01 A - CE 0063 AT 4967
MODENA 80 E
COPPER WALL-MOUNTED COMBINATION,
GAS FIRED BOILER FOR CENTRAL HEATING
AND DOMESTIC HOT WATER PRODUCTION,
FAN ASSISTED, ROOM SEALED COMPARTMENT,
ELECTRONIC FLAME IGNITION AND CONTROL
3543230/2 - 10/99
INSTALLATION, SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-267-05

MODENA 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
From the 1st October 1999 your "benchmark" Installation, Commissioning and Service Record Log
Book will be enclosed in your customer information pack.
"This record must be completed and left with the end user"
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.
INDEX
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 80 E
3
1. DESCRIPTION
1.01 Introduction
The Modena 80 E is defined as a “room sealed” combination boiler, all air required for combustion is taken from
outside the room in which it is installed. It is a new high performance gas fired heat generator for central heating and
domestic hot water production. A special feature of this boiler is its built-in electronic flame ignition and control unit
making burner operation completely automatic and safe. The main components are as follows:
• Copper heat exchanger consisting of three finned tubes specifically shaped for high efficiency.
• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water
heat exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.
• Ceramic fibre insulated combustion chamber
• 12 stainless steel bladed burners specifically designed for this boiler.
• Fan for discharge of combustion products and intake of combustion air.
• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning correctly.
• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.
• Combination gas safety valve with modulator, complete with pressure stabiliser.
• Flowmeter giving the domestic hot water circuit precedence over the central heating circuit.
• Pressure relief valve for the central heating circuit set to open at 3 bar.
• Built-in Expansion vessel.
• Variable speed pump.
• Central heating flow temperature adjustment thermostat.
• Domestic hot water flow temperature adjustment thermostat.
• Central heating limit thermostat.
• Overheat safety thermostat.
• Electronic control unit for automatic flame ignition and control.
• Central heating low water pressure cut off switch.
• Domestic hot water flow temperature sensor.
• Central heating flow temperature sensor.
1.02 Instructions and regulations
Assembly, installation, first start up and maintenance must be carried out by competent persons only, in accordance
with all current technical regulations and directives.
c.o.s.h.h.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are required
when servicing.
Related Documents
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 PART 1 FLUES
B.S. 5440 PART 2 AIR SUPPLY
B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 1989 GAS INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 1994 INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply

MODENA 80 E
4
Fig. 1
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Modena 80 E boilers are central heating and domestic hot water heat generators and are produced as standard
to function with natural gas or LPG.
Key
1 - 3/4" central heating flow outlet
2 - 1/2" domestic hot water flow outlet
3 - 1/2 “ gas inlet
4 - 1/2" domestic hot water inlet
5 - 3/4" central heating return inlet
6 - Pressure relief outlet
12345
15012012070
110
80 80
80
460
Top view
1149560609536
100
720
725
16025
10
100
270
460
175100
Bottom view
Distance between connections
Distance
between
connections
95
60 120280

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 until the
required output level is reached (see figures 4 and 5).
During domestic hot water production, gas pressures to the burner must correspond to the maximum output given
in table for the type of gas.
Gas pressure must be adjusted during maximum draw-off of domestic hot water.
• Maximum working temperature for central heating flow: 85°C
• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.
• Minimuum domestic cold water pressure required for 95% heat input:
- Flow restrictor fitted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
Technical Data
LEDOM
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GN-02GGPL-13G
.xaM.niM.xaM.niM
WkWkWkWkWkWkWkWkWksertiLsertiL
E08anedoM 8,327,98,525,116,828,210,825,218,325,18,0
LEDOM
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ØØØØØ sertiLrabrabrab
E08anedoM "4/3"2/1"2/1"2/1"4/37136
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GN-02GGPL-13GGN-02GGPL-13G
ØØ m
3
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E08anedoM03,1x2177,0x2137,2 00,2 G5014KV.H
LEDOM
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evlavytefaS
GN-02GGPL-13G GN-02GGPL-13G
muminimlanimonmuminimlanimon
rabmrabmrabmrabmrabmrabmrab
E08anedoM 02735,28,118,70,633
LEDOM
tohcitsemoD
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E08anedoM3,116,318,110,6344PI83

MODENA 80 E
6
2.03 Boiler water flow diagram
OUT
IN
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 main components
Key
5Room sealed compartment
7Gas inlet
8Domestic hot water outlet
9Domestic hot water inlet
10 Central heating flow outlet
11 Central heating return inlet
14 Safety valve
16 Fan
19 Combustion chamber
20 Burner assembly
21 Main injector
22 Burner
26 Combustion chamber insulation
27 Copper heat exchanger for central
heating and domestic hot water
28 Flue collector from heat exchanger
32 Central heating pump
34 Central heating flow temperature
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
36 Automatic air vent valve
42 Domestic hot water flow
temperature sensor
43 Air pressure switch
44 Gas valve
49 Safety overheat thermostat
50 Central heating flow limit
thermostat
56 Expansion vessel
62 Time clock (option)
63 Central heating temperature
adjustment
81 Ignition electrode
82 Sensor electrode
84 Primary gas valve solenoid
85 Secondary gas valve solenoid
*90 Flue sampling point
*91 Air sampling point
98 On/Off/Reset switch
114 Low water pressure cut off
switch
132 Flue gas deflector
136 Flow meter
145 Central heating pressure gauge
157 Domestic hot water
temperature adjustment
* For use with flue gas analysis
equipment

MODENA 80 E
7
2.04 Central heating adjustment (not normally required)
To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main
burner via the electronic control board (fig. 4 and 5).
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 virtually no effect on the efficiency and combustion characteristics of the 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
mbar
18 19 20 21 22 23
5
10
15
20
25
30
35
9 1011121314151617
91011121314 18192015 16 178
2.05 Domestic hot water variability characteristics
The temperature of the domestic hot water can be varied
from 40 to 55°C by adjusting the boiler potentiometer.
Diagram of domestic hot water production
0 345678910111213141516
39
40
45
50
55
60
65
Temperatura di erogazione sanitaria °C
Portata sanitaria dm /min.
Potenza caldaia scambiata
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
kcal/h x1000
3
Temp. entrata acqua sanitaria 15°C
Temperature of domestic hot water intake 15°C
Flow of domestic hot water L/
Temperature of domestic hot 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 8 litre
vessel supplied.
Note:
1. Fill C.H. installation to min. 1.5 bar.
2. Select the expansion vessel for a system
pressure of 2.0 bar.
3. Expansion vessel must be fitted to central
heating return pipe.
4. The standard 7 litre expansion vessel is
charged to 1 bar.
5. The additional expansion vessel should be
charged to 1 bar.
SAFETY VALVE
SETTING (bar)
VESSEL CHARGE
PRESSURE (bar)
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
CONTENT of SYSTEM
3.0
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
LITRES
25 3.5 6.5 13.7 4.7 10.3 8.3
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 14.2 30.9 24.8
100 14.0 25.9 55.1 19.0 41.2 33.1
125 17.5 32.4 68.9 23.7 51.5 41.3
150 21.0 38.8 82.6 28.5 61.8 49.6
175 24.5 45.3 96.4 33.2 72.1 57.9
200 28.0 51.8 110.2 38.0 82.4 66.2
0.140 0.259 0.551 0.190 0.412 0.33
For syst. volumes other than
those given above, mult. the syst.
volume by the 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 Pump characteristics
The pump head available for circulating the water is given in fig. 7.
N.B. - The pump is factory set at position 3. The pump is a
Grundfos type 15-50 UPS series.
Note - Minimum flow through boiler heat exchanger at any time
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 UPS 15-50
Fig. 7
1 2 3 Speed settings
ABoilers pressure drop
BAvailable pump head C.H.

MODENA 80 E
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 boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute
of Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.
Location of Boiler
The installation of the Modena 80E must be on a suitable non-combustible load bearing wall which will provide an
adequate fixing for the boiler mounting bracket assembly. The location should be in an area where the water pipes
will not be subjected to frost conditions. In siting the combination boiler the following limitations must be observed:
The combination boiler may be installed in any room or internal space, although particular attention is drawn to the
requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the building
regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal
space containing a bath or shower.
Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or appliance
control utilising mains electricity must be situated so that it cannot be touched by a person using the bath or shower.
Air Supply
The room or compartment in which the boiler is installed does not require a purpose provided vent when using the
standard concentric flue.
Flue System
The boiler allows the flue outlet to be taken from the rear of the boiler, from either side or vertically.
A standard flue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied
(equivalent to wall thicknesses of up to 565, 1815 and 2815mm for rear flues, deduct 91mm plus distance from side
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 planning stage, in order to establish the
availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the Local Gas supplier.
A gas 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 working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 2.73m3/h of natural gas, and 2,00 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework
must be adequately supported. An isolating gas valve is provided and should be fitted on the boiler gas inlet. Please
wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after the boiler
has operated for 10 minutes to reach thermal equilibrium.
Water System
Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.

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 - If thermostatic radiator vales are fitted a bypass must be fitted to ensure a minimum flow rate through
the boiler of 6 l/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. 10.
Domestic Hot 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 5 bar (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
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. Cold water supply Fig. 10