Ferroli Optima 901 User manual

901
WALLMOUNTED, ROOM SEALED,
FAN ASSISTED, 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
Read these Instructions thoroughly
before using the appliance
INSTALLATION
INSTRUCTIONS
Appr. Nr. B94.01T CE 0063AQ2150
04/98
G.C. NO: 47-267-18

901
2
page INDEX
3General Description
3Related Documents
4Technical Data
5Appliance Dimensions
6Boiler Flow Diagram
7Key of boiler flow diagram
8Installation Details
8Location of Boiler
8Air Supply
10 Flue System
10 Gas Supply
10 Water System
12 Central Heating Pump
12 Sizing of expansion vessel
13 Installation of Boiler
13 1. Unpacking
13 2. Mounting the Boiler Jig
on the Wall (rear flue)
13 3. Mounting the Boiler Jig
on the Wall (side flue)
14 Drilling template
15 4. Preparing the Flue Assembly
16 5. Connecting the Boiler
18 6. Fitting the Flue Assembly
18 7. Electrical Installation
19 8. Commissioning & Testing
19 8.1 Filling the Central Heating System
19 8.2 Filling the Domestic Hot Water System
19 8.3 Electricity Supply
19 8.4 The Gas Installation
19 8.5 To Light the Boiler
21 8.6 To Range Rate the Boiler C.H.
22 Gas pressure adjustment with Honeywell
VR 4605 NA 4003 valve
23 Burner pressure C.H.
24 8.7 D.H.W. Burner Pressure
24 9. System operation
24 10. Handing Over to the User
25 Clock
26 Air pressure switch
27 Spare Parts List
28 DomesticHotWaterPerformance+Modureg
29 General Wiring Diagram
30 Fast Fault Finding
31 Special Installation Possibilities

901
3
General Description
TheFerroli 901isawallmounted,roomsealed,fanassisted,combinationboilerforCentralHeating
(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.
The flue can either be left hand, right hand or rear. There are three flue lengths available and they are 0.75
metres(for wallthickness upto 565mm), 2metres (forwall thicknessup to1815 mm)and 3metres (for wall
thicknessupto2815mm).Thesewallthicknessesassumearearflueaoutlet.Forsideflueoutlettheeffective
wallthickness foreach fluelength isreduced by91 mmplus thedistance ofthe appliancefrom theside wall.
TheCentralHeating and the DomesticHotWatertemperatureiscontrolledbytheHoneywellModuregvalve
in conjunction with the P.C.B. The boiler is fitted with its own Central Heating pump. The pump is switched
ON/OFF by the time clock and/or a 24 Volt room thermostat. The pump circuit also has a 6 minute over-run
time. There is a Domestic Hot Water flow switch fitted and when there is a demand for Domestic Hot
Water (flow of more than 0.5 gallon/minute, 2.5 litre/minute) the Central Heating pump is switched off
making available the maximum output of the gas burner for Domestic Hot Water. On the P.C.B. the output
for Central Heating can be set. However, this is not required for the majorities of installations as the boiler
will automatically adjust its output to the system demand-AUTO-MISER control. This does not influence the
maximum output for domestic hot water. 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 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 INSTALLTIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4841 1991 SPECIFICATION FOR EXPANSION VESSALS
Model Water Bye Laws.

901
4
Technical data (G20) (G31)
Nominal Heat Input D.H.W. & C.H. (gross) 34.8 kW 34.0 kW
Minimum Heat Input D.H.W. & C.H. (gross) 15.1 kW 14.8 kW
Nominal Heat Input D.H.W. & C.H. (net) 31.3 kW 31.3 kW
Minimum Heat Input D.H.W. & C.H. (net) 13.6 kW 13.6 kW
Nominal Heat Output D.H.W. & C.H. 27.9 kW 27.9 kW
Minimum Heat Output D.H.W. & C.H. 11.8 kW 11.8 kW
Gas rate 3.3 m3S/h 2.39 kg/h
Maximum burner pressure 15 mbar 34.5 mbar
Minimum burner pressure 3.5 mbar 6.9 mbar
Injector manifold Ø 1.15 mm 0.72 mm
Pilot injector Ø 0.27 mm 0.22 mm
Dimensions (o/all)
Height 1020 mm
Width 480 mm
Depth 360 mm
Weight (net) 51 kg
Weight (gross) 53 kg
Electricity supply: 230V - 50 Hz
Fuse rating:
Mains 3 Amp. (main fuse)
on P.C.B. in boiler F2 Amp (Fast)
Electrical input 160 Watt
Domestic Hot Water flow:
(35°C rise) 11.4 l/min.
Minimum Domestic Hot Water Flow 2.5 l/min.
Maximum domestic cold water
Inlet pressure: 10,0 bar
C.H. Safety valve pressure setting 3 bar
C.H. Expansion vessel capacity 7 litre
Min. heating circuit pressure 0,8 bar
Max. heating circuit pressure 3.0 bar
Low water pressure switch 0.4 bar
Boiler water capacity:
Heating 1.5 litre
Domestic hot water 0.5 litre
Pipe connections:
Gas 22 mm
Domestic cold water inlet 15 mm
Domestic cold water outlet 15 mm
Central heating flow 22 mm
Central heating return 22 mm
Pressure relief valve drain 15 mm
Min. installation clearances. Sides:
Left hand 5 mm
Right hand 5 mm
Front 50 mm*
(plus access for service)
Min. height from worktop to base 200 mm
PROPANE LPGNATURAL GAS
Notes:
* Access to the front of the boiler must be
available for maintenance (min. 600 mm)

901
5
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
8. Air intake for two pipe flue systems
FRONT VIEW LEFT SIDE VIEW REAR VIEW
8 - TOP VIEW
480
900
370
77.5507580505097.5
12 3 4 5 6 7
40
85
242 235
60
100
Øi92
Øi82
120
242
126.5
235
160
157
480

901
6
Boiler Flow Diagram
Fig. 2

901
7
Key
1. Fixing point
2. Flue terminal
3. Flue/air intake hood
4. Sealing gasket
5. Room sealed compartment
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
16. Fan
19. Combustion - heat exchanging compartment
20. Burner assembly
21. Injector manifold
22. Burner
23. Thermocouple
24. Spark electrode
25. Pilot
26. Combustion chamber insulation
27. Copper heat exchanger for C.H. + D.H.W.
28. Flue collector from heat exchanger
29. Internal flue exit
30. Flue/surplus air collector
31. Air pressure control damper
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
41. D.H.W. waterway of the heat exchanger
42. D.H.W. temperature sensor
43. Air pressure switch
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 100°C
50. Central heating limit thermostat 88°C
51. Central heating frost thermostat
53. Heat exchanger venting point
56. Expansion vessel
58. Fan air outlet pressure test point
59. Flue outlet pressure test 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.
69. Inner flue duct
70. Outer air intake duct
71. Modulating balance tube
80. 230 V + 24 V roomstat terminal blocks
87. Venturi test point
101. P.C.B. (printed circuit board)
114. Low water pressure switch
136.Flowmeter
145. C.H. pressure gauges
158. Gas inlet pressure test point

901
8
Installation Details
Gas Safety (Installation & Use) Regulations: 1984
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.
Location of Boiler
The installation of the 901 must be on a suitable non-combustible load bearing wall which will
provideanadequatefixingfortheboilermountingbracketassembly.Thelocationshouldbeinanareawhere
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 thecurrent,i.e.wiringregulationsandinScotlandtheelectricalprovisions
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 abath or shower any electrical switch
or appliance control utilising mains electricity, should be so situated that it cannot be touched by a person
using the bath or shower.
Terminal Position
POSITION MINIMUM SPACING (fig. 3) mm
ADirectly below an openable window, air vent, or any other ventilation opening 300
BBelow gutters, soil pipes or drainpipes 75
CBelow Eaves 100
DBelow a Balcony 100
EFrom vertical drainpipes or soilpipes 75
FFrom internal or external corners 100
GAbove adjacent ground or balcony level 100
HFrom a surface facing the terminal 600
IFacing another terminal 1,200
JFrom opening (door/window) in carport into dwelling 1,200
KVertically from a terminal on the same wall 300
LHorizontally from a terminal on the same wall 300
NBelow carport 600
AQuinnel Barrat and Quinnel guard (part.No.C2) should be screwed to thewallcentrally over the terminal,
when the distance is less than 2 m from the outside floor.
Air Supply
Theroom,cupboardorcompartmentinwhichtheboilerisinstalleddoesnotrequireapurposeprovidedvent.

901
9
Terminal Position
Minimum Clearance mm
NOTES
* Access to the front of the boiler must be available for maintenance (min. 600 mm).
Fig. 5
Fig. 3

901
10
Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
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 2815 mm for rear flues and deduct 91 mm plus distance
from side wall for side outlet flues).
It is absolutely essential, to ensure that productsofcombustiondischarging from the terminalcannotre-enter
the building, or enter any adjacent building, through ventilators, windows, doors, natural air infiltration, or forced
ventilation/air conditioning.
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.
Appliance inlet working pressure must be 20 mbar MINIMUM.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 3.3 m3/h (116 ft3/h) of natural gas.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
ThecompleteinstallationmustbetestedforgassoundnessandpurgedasdescribedinBS6981-1988.Allpipework
must be adequately supported. An isolating gas valve is provided and should be fitted on the manifold assembly.
Water System
Central Heating
It must be a sealed system. Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342
Part.2.Pipeworknot forming part of the useful heating surface shouldbeinsulatedtopreventanyheatlosses
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
draintapsshould be in accordancewithBS2879. Copper tubingto 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. Itshouldbe ensured thattheboiler heat exchangerisnot a naturalpointfor collectingair.A typical heating
system with domestic hot water circuit is illustrated in fig. 6.
Important - A bypassmustbefittedtoensureaminimumflowratethroughtheboilerof6l/min.Thebypassshould
be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout.
Make up Water
Provision must be made for replacing water lost from sealedsystem. 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
centralheatingsystemandthemains water supply. Theuseofmainswatertochargeandpressurisethesystem
directly,is conditional upon the LocalWater Byelaw.Again any suchconnection mustbe disconnected after use.
Domestic Hot Water
Always fit a water softener or descaler in «hard water areas». A 15 mm copper connection point on the boiler
jig bracket for attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply
is10bar(145P.S.I.).Ifthecold mainssupplyexceeds5bar(72P.S.I.),awatergovernororpressurereducingvalve
must be fitted by the installer into the mains supply in an inconspicuous but accessible position preferable between
3 and 5 metres (10-16 ft) 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 notacceptableforundergrounduseandcertain
water undertakings will not accept their use above ground.