Ferroli optima 201 User manual

WALLMOUNTED,
GAS COMBINATION BOILER
Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH
Tel.: [phone] - Fax [phone]
ALL SPECIFICATIONS SUBJECT TO CHANGE
Phone numbers:
Installer
Service Engineer
Serial No.
FERROLI HELPLINE
FOR SERVICE INFORMATION OR
HELP TELEPHONE: [phone]
ALWAYS QUOTE YOUR SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
201
W.R.C. No. 9207075
LEAVE THESE INSTRUCTIONS
ADJACENT TO THE GAS METER
INSTALLATION
INSTRUCTIONS
Appr. Nr. B94.05T CE 0063AQ2150

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page INDEX
3General Description
3Related Documents
4Technical Data
5Appliance Dimensions
6Boiler Flow Diagram
8Installation Details
81. Location of Boiler
82. Air Supply
83. Flue System
10 4. Gas Supply
11 5. Water System
12 Central Heating Pump
13 Sizing of expansion vessel
15 Installation of Boiler
15 1. Unpacking
15 2. Mounting the Boiler Jig
on the Wall
16 3. Connecting the Boiler
17 4. Electrical Installation
18 Time clock
19 Removal of clock
20 5. Commissioning & Testing
20 5.1Filling the Central Heating System
20 5.2FillingtheDomesticHotWaterSystem
20 5.3Electricity Supply
20 5.4The Gas Installation
21 5.5To Light the Boiler
22 5.6To Range Rate the Boiler C.H.
23 Gas pressure adjustment with Honeywell
VR 4600 N 4002 valve
24 5.7D.H.W. Burner Pressure
24 6. System operation
24 7. Handing Over to the User
25 General Wiring Diagram
26 ElectricalFunctionalFlowWiringDiagram
27 Domestic Hot Water
Performance + Modureg
28 Spare parts list
For "Fast" Fault Finding see separate instructions inside the electrical control box or page 59

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General Description
The Ferroli 201 is a wall mounted combination boiler for Central Heating (C.H.) and domestic Hot
Water (D.H.W.).
The boiler is of light weight construction and the heat exchanger provides Central Heating and Domestic
HotWaterfromanintegrallydesignedunit.Theboilercontainsitsownexpansionvesselforsealedsystems.
The wall mounting jig contains all the isolating cocks for the water and gas supplies which can be fitted to
the wall and provided with all the necessary gas and water connections prior to the boiler being attached.
TheCentralHeating and the DomesticHotWatertemperatureiscontrolledbytheHoneywellModuregvalve
inconjunctionwiththeP.C.B.There isalimitthermostatonthecentralheatingcircuitwhichoperatesat88°C.
There is also an overheat cut-off thermostat which will shut the boiler down completely and this thermostat
operates at 100°C. The boiler is fited with its own Central Heating pump. The pump is switched ON/OFF
bythetimeclock and/ora24Voltroomthermostat.Thepumpcircuitalsohasa6minuteover-runtime.There
is a Domestic Hot Water flow switch fitted and when there is a demand for Domestic Hot Water (flow
ofmorethan0.5gallon/minute,2.5litre/minute)theCentral Heating pump is switched off making available
themaximumoutputofthegasburnerforDomesticHotWater.OntheP.C.B.themaximumoutputforCentral
Heating can be set. This does not influence the maximum output for domestic hot water.
At the factory the central heating output is pre-set to maximum. The appliance is not suitable for external
installation.
Related Documents
This appliance must be installed strictly in accordance with these instructions:
The Gas Safety Regulations (Installations & Use) 1994.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1993 TREATMENTOFWATERINDOMESTICHOTWATERCENTRALHEATINGSYSTEMS
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. 4841 1990 SPECIFICATION FOR EXPANSION VESSALS
Model Water Bye Laws.

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Technical Data G20 G31
Nominal Heat Input D.H.W. & C.H. (gross) 28.6 kW 28.0 kW
Minimum Heat Input D.H.W. & C.H. (gross) 12.8 kW 12.5 kW
Nominal Heat Input D.H.W. & C.H. (net) 25.8 kW 25.8 kW
Minimum Heat Input D.H.W. & C.H. (net) 11.5 kW 11.5 kW
Nominal Heat Output D.H.W. & C.H. 23.3 kW 23.3 kW
Minimum Heat Output D.H.W. & C.H. 9.7 kW 9.7 kW
(See section 8.6 for range setting of Central Heating - D.H.W. is preset and not adjustable)
Maximum Gas Rate 2.72 m3/h 2.66 m3/h
Maximum Burner Pressure 14.5 mbar 36.0 mbar
Minimum Burner Pressure 2.7 mbar 7.9 mbar
Injector Marking (Main Burners) 210
Injector Size (4 off) 2.10 mm
Pilot Injector Marking 38/33A
Dimensions (overall):
Height 1020 mm
Width 480 mm
Depth 360 mm
Weight (nett) 51 kg
Weight (gross) 53 kg
Electricity supply: 230 V ~ 50 Hz
External fuse 3 A
Internal fuses on P.C.B. F2A to BS4265 - (2 Amp. Fast)
Electrical Input 150 W
Central Heating:
Max. Flow Temperature 85°C
Temperature Rise Across Boiler 20°C
Domestic Hot Water Flow:
30°C Rise 11.1 litres/min.
32°C Rise 10.4 litres/min.
35°C Rise 9.5 litres/min.
40°C Rise 8.3 litres/min.
Minimum Domestic Hot Water Flow 2.5 litres/min.
Maximum Domestic Cold Water Inlet pressure 10 bar
Minimum Heating Circuit Pressure 0.8 bar
Maximum Heating Circuit Pressure 3.0 bar
Boiler Water Capacity: Heating 2.0 litres
Domestic Hot Water 0.5 litres
Connections:
Gas 22 mm
Domestic Hot Water Outlet 15 mm
Domestic Cold Water Inlet 15 mm
Pressure Relief Valve Drain 15 mm
Central Heating Flow 22 mm
Central Heating Return 22 mm
Minimum Installation Clearances:
Sides -Left hand 5 mm*
Right hand 5 mm*
Front 50 mm**
Minimum Clearance below 200 mm
Minimum Clearance above 100 mm
Notes:
* If using a side outlet flue then the
minimum clearance on the flue outlet
sideoftheappliancemustbeincreased
to 75 mm (3 in).
** Accesstothefrontoftheboilermustbe
availableformaintenance(min.600mm)

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Appliance Dimensions
Fig. 1
Key
1. Electricity cable entry
2. Gas supply
3. Domestic Hot Water outlet
4. Domestic Cold Water inlet
5. Central Heating Pressure relief valve
6. Central Heating Flow outlet
7. Central Heating Return inlet

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Boiler Flow Diagram
Fig. 2

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Key
1. Fixing point
6. Control panel
7. Gas inlet
8. Domestic hot water outlet
9. Cold water inlet
10. Central heating flow outlet
11. Central heating return inlet
12. D.H.W. draining point
14. Central heating safety valve
20. Burner assembly
21. Main injector (4)
22. Burner (4)
23. Thermocouple
24. Spark electrode
25. Pilot
26. Combustion chamber insulation
32. Central heating pump
33. C.H. waterway of the heat exchanger
34. C.H. flow temperature sensor
35. Air separator
36. Automatic air vent
37. Cold water inlet filter
39. Cold water flow limiter
40. Domestic hot water expansion vessel (optional)
41. D.H.W. waterway of the heat exchanger
Gas Safety (Installation & Use) Regulations: 1994
Intheinterestofsafety,itisthelawthatallgasappliancesareinstalledbyacompetentpersoninaccordance
with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current
I.E.E. Regulations and the byelawsof the Local WaterUndertaking.FailuretocomplywiththeRegulations
may lead to prosecution; it is in your interest and that of safety to ensure that the law is complied with.
Important - If the boiler is to be fitted in a timber framed buiding it should be fitted in accordance
with the British Gas publication; Guide for Gas Installation in Timber Frame Housing: Reference DM2.
If in doubt advice must be sought from the Local Gas Region of British Gas Plc.
42. D.H.W. temperature sensor
44. Combination gas valve
45. Knob gas valve
46. Operator gas valve
47. Modulating regulator (Modureg) gas valve
48. Burner pressure test point
49. Overheat cut-off thermostat
50. Central heating limit thermostat
52. D.H.W. limit thermostat
53. Heat exchanger venting point
60. Extended control knob to gas valve
61. C.H. selector switch
62. Time clock
63. C.H. boiler thermostat
66. Microswitch combination gas valve
67. Ignition transformer
68. Control box with P.C.B.
72. Room thermostat (not fitted)
73. Frost thermostat (not fitted)
74. Expansion vessel
76. Air filter
80. 240 V + 24 V roomstat terminal blocks
101. P.C.B. (printed circuit board)
114. Water pressure switch
136. Flowmeter
145. C.H. pressure gauges
158. Gas inlet pressure test point

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Installation Details
Location of Boiler
The installation of the 201 must be on a suitable non-combustible load bearing wall which will
provide an adequate fixing for the boiler mounting bracket assembly. A satisfactory flue with a minimum of
600mm (2 ft.) rising vertically above thedraught diverter must also be provided,terminating in a British Gas
Approved cowl.
The location must also provide adequate room for servicing.
The location must also be provided with an adequate air supply for combustion purposes. The boiler must
not be installed in a room containing a bath or shower, or in a bedroom or bed-sitting room. In installations
of an unusual location, special procedures are necessary and BS 6798 gives detailed guidance on this
aspect. The location should be as centralised as possible with the water piping system and in an area not
subjected to frost conditions.
Flue system
DetailedrecommendationsforfluearegiveninBS5440Part.1.Thefollowingnotesareintendedforgeneral
guidance. The cross sectional area of flue serving the boiler must not be less than the area of the flue outlet
of the appliance.
The flue should terminate in accordance with BS 5440 Part 1. The boiler has a flue spigot designed for
aluminium or stainless steel flue pipe. If double walled flue pipe is used, it should be of a type accepted by
BritishGas.Alwaysuseasplitfluecliporflangedjointabovethefluedivertertoallowtheremovaloftheboiler.
A vertically rising flue above the diverter for a minimum length of 600 mm (2 ft.) is required before any bend
isfitted,whichshouldnotbea90°pattern.Thefluepipemustbeadequatelysupportedandnotbeincontact
with any inflammable material.
If any existing chimney is to be used, it should be lined with a stainless steel flexible liner or any other liner
acceptable to British Gas. (Chimneys lined with salt glazed earthenware pipes are acceptable if the pipes
conform to BS 65.). The number of metal flue liner joints should be kept to the minimum for connecting the
boiler to an existing flue, the flue must be clean of any soot or loose material. Dampers must be removed.
Theflueshouldbe,asfarasispractical,verticallyrisingwiththeavoidanceofhorizontalruns.Themetalflue
pipe listed above should form the initial connection from the boiler to the existing chimney (and liner). Refer
to page 12 if an extraction fan is fitted in the area.
Air supply
Detailedrecommendationsaregivenin BS 5440 Part. 2. The following notes are intended to give guidance.
Room or internal air space supply:
The 201 requires a permanent air vent for combustion air either from the room direct to outside air
ortoanadjacentroomwhichmustitselfhaveapermanentairventofthesamesize,directtooutsideair.The
minimum size of this air vent must be: 94 cm2free a (14 in2). A proprietry air vent may be marked with its
effectivefreearea,ifnot,thisinfor-mationcanusuallybesuppliedbythemaker.Theventshouldbedesigned
to diffuse the air in windy conditions and should be sited to reduce room draughts, i.e. at top level. The
aperture in the vent should not pass preferably, a 10 mm (318 in.) ball but allow the entry of a 5 mm (3116
in.) ball. (Additional gauzes or screens should not be used).
Existing air vents should be taken into account when assessing air vent requirements. An air vent in an
internalwallshouldnotcommunicatewithabedroom,toilet,bathroomorkitchenandshouldnotbemorethan
450 mm (18 in.) above floor level in order to reduce the spread of smoke in the event of a fire. An air vent
directtooutsideairmustnotbeloca-tedlessthan600mm(2ft.)awayfromanypartofanopenfluedterminal.

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Cupboard or compartment air supply:
Iftheapplianceis to be installed in a compartment or cupboard ifexisting,it should be of sufficient size. This
compart-ment or cupboard must have permanent air vents for combustion air, flue dilution and cooling
purpose!s,theventsbeingpositionedathighandlowlevel.Thefollowingminimumsizeofairvents(freearea)
are required:
Position of Air vent Air from room or internal space Air direct from outside
High 252 cm2(38 in2) 126 cm2(19 in2)
Low 504 cm2(76 in2) 252 cm2(38 in2)
NOTE
Both air vents must communicate with the same room or must be on the same outside wall to outside air.
Wherecupboard compartmentairventsareopentoaroom,theroomitselfmusthaveapermanentairvent(s)
as previously specified.
IMPORTANT
If the boiler is installed in hair dressers premises, ventilation must not be from areas in which aerosol hair
spray is being used. Any spray or materials emitting volatile vapours can be a source of ignition from the
perrnanent pilot of the boiler. Propellants of aerosol srays and fumes of volatile compounds in addition to
being highly flammable in many cases, will also change to corrosive hydrochloric acid when exposed to the
productsof combustion of the boiler. Theresultsmaybe hazardous, causing service problems andproduce
failure.
Minimum clearances
Fig. 3
200

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Cupboard or compartment installation
1. Boiler in a room 2. Boiler in a cupboard
Vented to a room 3. Boiler in a cupboard Vented to outside
Fig. 4
Effect of an extract fan
If there is type of extract fan fitted in the premises, there is the possibility with open flued appliances, that if inadequate
freshairventsarenotprovided,spillageofproductsfromthefluedivertercouldtakeplace,whenthefanisinoperation.
Where such installations are found, a test for spillage must be carried out as described in Part. 1 of BS 5440, and the
necessary action taken.
Gas Supply
If necessary the local Gas Region 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 Region.
A gas meter can only be connected by the Local Gas Region, or by a Local Gas Region's Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 2.72 m3/h of natural gas.
WE REQUIRE 22 mm PIPE FROM THE METER TO THE BOILER.
The complete installation must be tested for gas soundness and purged as described in BS6891-1988. All pipework must be
adequately supported. An isolating gas valve is provided and should be fitted on manifold assembly.
Water System