Ferroli MODENA S HE User manual

Ferroli
Modena HE
21st Century Design for 21st Century Life

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
Introduction
The new Ferroli Modena C HE high efficiency condensing combination boiler is an ideal replacement
for the earlier non-condensing Modena 80E or Modena 102.
The new Ferroli Modena C HE is smaller, weighs less, has built-in frost protection and an IP
protection rating of IPX5D. This allows direct replacement wherever the existing boiler is legitimately
installed (i.e. Kitchen, Garage, Bathroom, etc.)
Although the actual position of the pipe-work connections differ slightly, the configuration remains
the same, thereby requiring only limited pipe-work alteration.
The electrical connection remains the same, i.e. all models supplied with a factory fitted three core
fly - lead to provide a permanent live connection and all models use the same volt free contacts for
any external system controls.
This guide refers to the fitting of a replacement boiler with a standard horizontal flue application
only (minor adjustments may be necessary for other flue applications – refer to boiler installation
instructions)
The flue outlet connection on the new Modena C HE is centrally aligned and is therefore completely
compatible with the earlier Modena 102. The flue connection on the Modena 80E is to the left of
centre but providing that there is a minimum clearance of 15mm to the left of the existing boiler, no
alteration to the existing flue position is necessary.
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Please note:
As with all condensing boilers it is necessary to check
the existing flue terminal position to ensure that the
“plume” from the combustion products will not create a
‘nuisance problem’.
A plume displacement kit is available to overcome any
such problems.
Consideration must also be given for the provision of a
condensate outlet for the new boiler.
The work procedures described in this document must
be completed strictly in accordance with the
manufacturer’s installation instructions, current
regulations and relevant standards, and only by
competent person/persons as stated in the Gas Safety
(Installation & Use) Regulations.
Prior to fitting the replacement boiler the entire system
must be thoroughly cleansed and flushed in accordance
with Building Regulations L1A/L1B & BS 7593.
The Installation must comply with the following;
• Gas Safety (Installation & Use)
Regulations
• The Building Regulations
• The Building Regulations (Scotland)
• Building Regulations (Northern Ireland)
• The Water Fittings Regulations or Water
Byelaws in Scotland
• The Current I.E.E. Wiring Regulations
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• BS 5440: Part 1 - Flues.
• BS 5440: Part 2 - Ventilation.
• BS 6798 - Installation of gas fired hot
water boilers
• BS 7671: - Electrical wiring
• BS 6891 - Gas Installation
• BS 5546 - Installation of hot water
supplies for domestic purposes.
• BS 5449 - Forced circulation hot water
systems
• BS 7074 - Expansion vessels / sealed
systems
• BS 7593 - Treatment of water in domestic
central heating systems.

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
Manual Handling
When lifting take suitable safety precautions: keep your back straight, bend knees, do not turn your
body, avoid bending forward or sideways and keep the load as close as possible to your body. Ideally
seek assistance in lifting the boiler.
If possible, use a trolley or other suitable means to carry the boiler to site. Use appropriate
protective clothing and gloves to avoid injury from any sharp edges etc.
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REMOVE THE EXISTING MODENA 80/102
1. Removal of the outer case:
Hinge down the controls cover
panel and undo the four case
securing screws on the
underside of the boiler. Ease
the lower edge of the case
forward to clear the controls
panel and lift the case upwards
off the retaining lugs (Fig.1)
Case Securing Screws
Fig.1
2. Safely isolate the electricity, gas and water supplies
to the appliance. Completely drain the boiler and
central heating system and disconnect all existing pipe-
work connections from the underside of the boiler
(Fig.2)
3. Disconnect the electrical supply to the boiler at the 3
pin plug or fused spur and any external controls
connections at the boiler terminal block 3 & 4 – access
via the panel on the underside of the boiler (Fig. 3)
4. Disconnect and remove the flue from the existing
boiler by undoing the four screws securing the
appliance bend to the top of the boiler (Fig.4)
Fig.3
Fig.4
Fig.2

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
5. Ensure that all pipe connections are free, move
the base of the boiler forward and lift the boiler off
the hanging bracket tabs.
Finally, unscrew the hanging bracket from the wall.
Check that the wall surface is sound, flat and capable
of supporting the weight of the boiler. Make any
necessary repairs before installing the new boiler.
INSTALL THE NEW MODENA C HE
1. Check the existing flue terminal position with
regard to possible nuisance “pluming” and plan
the route for the condensate outlet.
2. Unpack the boiler and check the contents are
complete and undamaged (see opposite)
Please note:
The new flue kit is sold separately
3. Align the fixing template on the wall with the
existing flue hole, ensuring it is level both
horizontally and vertically. Check for required
minimum clearances then mark the most
suitable fixing points for the hanging bracket. It
is advisable to mark the position of the gas,
water and heating pipes at this point (Fig.5)
4. Drill the wall and fix the hanging bracket
using the wall plugs and fixings provided. Make
sure the bracket is level before tightening the
fixing screws
Boiler Pack Contents
1 x Modena C HE Boiler
1 x Installation Instructions
1 x Hanging Bracket
1 x Filling Loop
1 x Valve Pack
1 x Condensate Bowl/Hose
1 x Paper Template
Fig.5

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
5. Lay the boiler on its back. Remove the front casing
panel by undoing the two securing screws on the
underside of the case. Ease the lower edge of the
panel forward to clear the controls display and lift
upwards off the frame.
6. Lift the boiler onto the hanging bracket making
sure the lugs on the bracket locate correctly with
the two support brackets on the boiler frame (Fig. 6)
FOR STANDARD HORIZONTAL TELESCOPIC FLUE INSTALLATIONS
Fig.6
UNPACK THE NEW TELESCOPIC FLUE KIT: CODE - 041049G0
7. Remove the protective adhesive cover from the top of the boiler to expose the flue/fixing holes.
Secure the new appliance flue bend to the top of the boiler using the screws and gasket provided
8. From the outside, push the flue
terminal length through the existing
hole in the building fabric and align
with the appliance bend.
Lubricate the seal with a suitable
silicone grease and push the flue
pipe fully into the into the appliance
bend. Ensure the flue terminal is
fitted level
Level

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
9. It is suggested that where possible the existing
pipe-work is cut back approximately 200mm - 300mm
for ease of connecting the existing pipe-work to the
new valves (Fig 8)
If a stand-off bracket has been used and the pipe-work runs
behind the boiler, then a new stand-off bracket will need to
be fitted and pipes extended to the position previously
marked. (paragraph 3.)
10. Remove the condensate bowl and hose from the
boiler fittings pack. Undo plastic nut (Fig.9-A) and fit
the condensate bowl and washer. Push on the rubber
condensate hose to the trap outlet (Fig.9-B).
Fig.8
Cut existing pipes back
approx 200mm – 300mm
Condensate bowl,
washer and rubber
hose connection
Connect the safety valve outlet (Fig.9-C) to the
existing 15mm pipe and then connect the condensate
pipe to the rubber hose outlet. Check that both
terminate in accordance with – BS 6798.
Take care not to interfere with the new routes for
gas, water and heating pipe connections
Fig.9
C B A
Fig 10
10. Fit the valve kit to the connections on the
underside of the boiler using the washers provided
(Fig 10) and reconnect to the existing pipe-work.
A CH FLOW
B
HOT WATER OUTLET
C
GAS
D
COLD WATER INLET
F
CH RETURN

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
11. Connect the temporary filling loop between
the cold water inlet and the CH return pipe as
close to the boiler as is practical Fig.11
Open the CH isolation valves; fill and vent the
system and flush using a commissioning
cleanser. During final filling add a suitable
corrosion inhibitor as per BS 7593.
Check for leaks
REMOVE AND RETAIN THE TEMPORARY
FLEXIBLE CONNECTION OF THE FILLING LOOP
AND FIT THE CAPS SUPPLIED.
12. Open the cold water isolation valve and
Fig.11
CH HW GAS COLD CH
Temporary filling
loop between
cold inlet &
heating return
thoroughly flush the cold/hot water pipe-work
by opening all the hot taps.
13. Reinstate the gas supply, purge and test in
accordance with BS 6891 and IGE/UP/1.
14. Connect the boiler to the electrical supply;
the boiler is provided with a 1m cable and plug.
Reconnect any external controls to the volt free
terminal block in the boiler.
To access the connections remove the securing
screw and hinge the controls cover to the left.
Connect the external controls to terminal block
(72) as shown in Fig. 12.
Grommets to accept wiring from external
controls are found on the right underside of the
boiler.
Please note:
All electrical work must be in accordance with
IEE Wiring Regulations - BS 7671:
External controls need to be compliant with
Building Regulations L1A/L1B; further
information is available from the “Domestic
Building Services Compliance Guide”
FLOW OUTLET WATER RETURN
Fig.12

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C E
18. Commissioning the boiler:
(See 3.3 of the Modena C HE Installation Instructions)
Connect a manometer to the inlet test point of the gas
valve (Fig.13)
Set the boiler to operate at maximum by selecting ‘TEST
MODE’ and check that the operational (working)
pressure at the gas inlet pressure test point is 20 mbar.
A pressure of 20 mbar should be obtained with all other
gas appliances operating.
To enter and exit ‘TEST MODE’, press the CH + & -
buttons simultaneously for 5 seconds (Fig.14)
Please note: there may be a pressure loss across the
isolation valve to the gas valve inlet test point of up to
1.3 mbar at maximum.
Remove the manometer & re-tighten the inlet test point.
14. Measure the gas rate of the boiler and check against
the following table;
15. Connect the flue gas analyser to the flue sample
point (Fig.15); with the boiler still in TEST MODE check
that the readings are within the tolerances set out in the
table below;
Fig.13
Fig.14
Fig. 15
Sample points: 1 = Air / 2 = Flue Gas
•If the readings are satisfactory, replace the boiler front cover.
•Test the correct operation of the boiler, central heating system and DHW.
•Advise the customer on the operation of the new boiler and any new controls.
•Complete the “Benchmark Log Book

Ferroli
21st Century Design for 21st Century Life
www.ferroli.co.uk
0843 479 0009
Ferroli Limited
Lichfield Road
Branston Industrial Estate
Burton upon Trent
Staffordshire
DE14 3HD
Modena HE