Ferroli ROMA 55 FF User guide

These Instructions are to be left with the User or adjacent to the gas meter.
FERROLI ROMA 55 FF
WALL MOUNTED,
FANNED FLUE BOILER
INSTALLATION
& SERVICING
INSTRUCTIONS
G.C. Appliance No. 4126705
Please read these Instructions
thoroughly before using
the appliance
FERROLI HELPINE
FOR SERVICE INFORMATION OR
HELP TELEPHONE: [phone]
ALWAYS QUOTE SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
Phone numbers:
Installer ________________________
Service Engineer _________________
Serial N°________________________

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ROMA 55 FF

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ROMA 55 FF
LIST OF CONTENTS
1 General description and information
2 Technical data
3 Boiler flow diagram
4 Key boiler flow diagram
5 Installation data
5.01 Water systems
5.02 Open (vented) systems
5.03 Sealed systems
5.04 Pump selection
5.05 Drain points
5.06 Hot storage vessel
5.07 Quality of componets
5.08 Corrosion inhibitors, flushing
5.09 Flue system
5.10 Se duct terminator
5.11 Ventilation
6 Terminal position (outside)
7 Terminal position
8 Location
8.01 Boiler location
9 Boiler connection
9.01 Gas supply
10 Electricity supply and connections
11 Boiler flow diagram
12 Electrical functional
13 Illustrated wiring diagram
14 Installation procedure
14.1 Unpacking
14.2 Prepare the boiler
14.3 Prepare the wall
14.4 Prepare the flue and air pipes
14.5 Mouting the boiler
14.6 Connections services
15 Commissioning
16 Fault finding
16.1 Fault finding
16.2 Fault finding
17 Replacement of parts
17.01 General procedures and notes
17.02 Acces
17.03 Fan
17.04 Pilot burner assembly
17.05 Electrode
17.06 Thermocouple
17.07 Thermostats
17.08 Main burner/injectors
17.09 Heat exchanger
17.10 Combustion chamber insulation
17.11 Viewing window
17.12 Pressure switch
17.13 Gas control valve
17.14 Viewing window
17.15 Control box components
18 Routine servicing
18.01 General
18.02 Pre-servicing
18.03 Servicing procedures
18.04 Reassembly
19 Parts
20 Parts list

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ROMA 55 FF
1. General description and information
1.1 Information
1. Installation must be carried out by a competent person, and in accordance with the relevant requirements of the
current issues of:
A. Gas Safety (Installation & Use) Regulations.
B. Building Regulations.
C. Building Standards (Scotland) Regulations.
D. I.E.E. Wiring Regulations.
E. Bye-laws of the local water undertaking.
Guidance on Installation is provided in this booklet, but due account must be taken of the detailed recommendations
of the current issues of:
BS 5440 Part 1: Flues.
BS 5440 Part 2: Ventilations.
BS 6798: Installation.
BS 5449: Pumped systems.
BS 5546: Domestic hot water.
BS 6700: Water supply.
BS 6891: Gas supply.
BS 7074 Part 1: Expansion vessels.
For installation in timber framed buildings, refer to the British Gas Publication Guide for gas installation in timber
framed housing - REF DM2.
2. It is essential that the boiler be installed strictly in accordance with these Instructions and the documents, detailed
above.
3. To avoid the possibility of injury, care must be taken when handling sheet metal componets.
1.2 General description
TheROMA55FFisawallmountedfannedflueboiler,sultableforconnectiontosealed or open vented water systems,
supplying central heating and/or indirect (stored) domestic hot water.
A balanced flue system is supplied, suitable for horizontal and vertical termination only, but which can, if desired, be
taken from the rear, sides or top of the boiler*.
NOTE
* Side exit or vertical exit requires the optional side / vertical flue turret.

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ROMA 55 FF
2. Technical data
HEAT INPUT 20 KW 68,200 Btu/h 10 kW 34,100 Btu/h
HEAT OUTPUT 16 KW 55,000 Btu/h 7.3 kW 25,000 Btu/h
BURNER PRESSURE 12 mbar 4.7 in wg 2.4 mbar 1.0 in wg
GAS RATE - AFTER 10 MINUTES 1.9 m3/h 66 ft3/H 0.95 m3/h 33 ft3/h
GAS CONNECTION SIZE / POSITION 1/2" Bsp / left hand side, rear base
GAS MAXIMUN OF RANGE MINIMUM OF RANGE
MAXIMUN HEAD OR PRESSURE 30 m 43.5 psi 3.0 bar 43.5 psi
MINIMUM HEAD OR PRESSURE 0.2 m 8" 0.8 bar 11.6 psi
if pressurised type
MAXIMUM FLOW TEMPERATURE 85°C85°C
TEMPERATURE DIFFERENTIAL 11°C beetween flow and return connections, recommended
MINIMUM WATER FLOW RATE 0.36 m3/h 12.7 ft3/h
WATER CONTENT 0.5 litres 0.11 gal.
CONNECTIONS 22 mm compression, right hand side, rear, top
WATER OPEN VENTED SEALED
ELECTRICAL
SUPPLY Mains supply 230 V ~ 50 Hz fused 3 Amp.
POWER CONSUMPTION 50 Watt (without pump)
CONNECTIONS MAINS / CONTROL 5 wire electrical lead
Brown - Live Permanent
Blue - Neutral mains supply
Green/Yellow - Earth 230 V ~
Black - Switched Live from external controls
Red - Live to external controls
CONNECTIONS PUMP 3 wire electrical lead
Brown - Live To
Blue - Neutral circulating
Green/Yellow - Earth pump
}
}

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ROMA 55 FF
3. Boiler flow diagram

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ROMA 55 FF
4. Key boiler flow diagram
POS. G.C. No. DESCRIPTION Q.ty
3. Flue/air intake (side outlet) 1
16. Complete fan RL 85/0034A1 3025LH 422 1
21a. Main injector N.G. 1.25 9
21b. Main injector L.P.G. 0.72 9
23. Thermocouple 1
24. Complete spark electrode 1
25. Pilot 1
27. Copper heat exchanger 1
43. Air pressure switch 1
44. Combination gas valve V4600C 1193 1
49. Overheat cut/off thermostat 1
50. Central heating limit thermostat 1
58. Combustion chamber pressure test point (+) 1
59. Flue outlet pressure test point (-) 1
63. C.H. boiler thermostat 1
66. Microswitch combination gas valve 1
67. Ignition transformer (CAST) 1
79. Capacitor fan IMF 1
80. Complete P.C.B. VF.1 1
87. Venturi flue testpoint 1
103. Relay 1
104. Fuse 2A 1
105. Complete burner set 1
106. Gascock 1
107. Flue/air intake flange rear outlet 1
108. Combustion chamber outlet cover 1
109. Combustion chamber insulation, back and sides 1
110. Eco split wire 1
111. Combustion chamber front panel 1
112. Pilot injector N.G. 0.27 1
112b. Pilot injector L.P.G. 0.22 1
133. Pump overrun thermostat 1

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ROMA 55 FF
5. Installation data
* h = maximum head developed by pump.
5.1 Water System
General
1. The ROMA 55 FF will supply central heating and, via an indirect cylinder, stored hot water.
2. All water systems must be in accordance with the Bye-Laws of the Local Water Undertaking.
3. Only fully pumped systems can be used.
4. Two pipe heating systems are recommended.
5. Systems can be either of the open (vented) or sealed type.
5.2 Open (Vented) System
1. Further guidance: BS 5449, BS 6798 and British Gas Publications.
2. Two typical systems are shown above. Note that close coupled or combined feed and vents are permitted.
3. Cold Feed: Minimum 15 mm copper but minimum 22 mm if combined with open vent.
4. Open Vend: Minimum 22 mm copper.
5. No valves between the boiler and the open vent.
6. A Bypass must be fitted which allows a minimum flow of 6 litres/min. (1.3 gal/min.)
ROMA
MAX. 150 mm.
*h/3 min/mm
INDIRECT
CYLINDER.
ROMA
HEATING
SYSTEM
OPEN VENTED
CLOSE COUPLED
FEED AND VENT.
*h/3 min/mm
INDYRECT
CYLINDER
HEATING
SYSTEM.
OPEN VENTED
FEED ON RETURN

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ROMA 55 FF
5.3 Sealed System
1. Further guidance: BS 5449, BS 6798, BS 7074 Part 1, British Gas Publications.
2. Two typical sealed systems are shown, above.
3. COMPONENTS:
a) EXPANDION VESSEL.
To BS 4814. Sized according to BS 5449 and/or BS 7074 Part 1. Positioned on the inlet to the pump.
b) SAFETY VALVE.
Always on the flow and next to the boiler. Non adjustable and set to 3 bar. Routed direct to drain in an area not
susceptable to freezing, nor where it is hazardous. Do not reduce pipe size from that on the valve.
c) PRESSURE GAUGE (May incorporate a temperature gauge).
Must have a fill pressure indicator, and be readily visible to the User. Range 0 to 4 bar.
d) AIR VENT. Highest point of the system.
e) PUMP. Suitable for the system. See 5.4.
f) FILLING POINT.
Shallbeatlowlevel,inaccordancewithlocalWaterAuthorityrequirement,andgenerallyhaveastopvalvetoBS1010,
as well as a double check valve. Filling can be achieved either by means of a temporary hose or via a cistern used for
no other purpose, with a minimum static head of 300 mm to the highest point of system.
g) SYSTEM MAKE UP.
Canbeachieved either automatically - from an independent cistern used for nootherpurpose,orfromamanuallyfilled
top up bottle through a double check valve, OR manually, by a temporary hose connection.
IMPORTANT
Any method of filling and of make up MUST comply with Regulations of the Local Water Authority.
ROMA ROMA
SEALED SYSTEM
PUMP ON THE FLOW SEALED SYSTEM PUMP ON THE FLOW

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ROMA 55 FF
Boiler pressure loss
5.4 Pump selection
Suitable pump should be fitted taking due account of the pressure loss across the boiler.
Pump to comply with BS 1394. A minimum flow rate of 6 litres/min (1.3 gal/min) is required.
5.5 Drain points
Must be provided to enable the system to be drained - taps to BS 2879.
5.6 Hot water storage cylinder
Must be either of the indirect coil type or a direct cylinder suitably adapted by fitment of an immersion calorifier. Direct
cylinders must not be used.
5.7 Quality of components
All components, fittings, and joint must be suitable for temperatures up to 110°C and, for sealed systems, pressures
up to 3 bar.
5.8 Flushing
Anysystem,neworold,mustbeflushedinaccordancewiththeCommissioningInstructions.Itisessentialthatasmuch
residual sludge and debris be removed as is possible.
mbar
litres/sec
gal/min

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ROMA 55 FF
5.9 Flue system
1. Further guidance: BS 5440 Part 1.
2. Flue types: Fanned. Balanced, and hence appliance is room sealed.
3. Termination: Outside. Horizontal. Vertical.
4. Direction: From boiler, to rear, either side and vertical (side & vertical required optional flue turret).
5. Maximum length: Two separate flue kits are available.
KIT Part No. MAXIMUM LENGHT mm
Rear - Inner to outer wallface Side - Boiler side to outer wallface
A (1 m) 3980221 820 808
B (2m) 3980222 Not Permitted 1808
Vertical & Side flue turret part No. 3980220
Vertical terminal part No. 39800570
Order one kit only - joining of flue kits is not permitted.
With vertical termination maximum flue length is 2 metres.
5.10 Se duct termination
Termination in the Se Duct is exactly as termination on an outside wall. No adaptation of the flue system is required.
Simply ensure that the plastic air duct is flush the inside face of the Se Duct.
Do not remove the terminal.
Don't foget that on Se Duct you will need an adequate width inside to push the flue system through any obstructions
before entering the Se Duct. See section 7 (page 13).
5.11 Ventilation
1. Further guidance: BS 5440, Part 2.
2. Ventilation for a room or space: None Required - This is a room sealed appliance.
3. Ventilation for a compartment: Cooling air is required:
MINIMUM AIR VENT FREE AREA. COMPARTMENTS
VENT Compartment ventilated to:
POSITION Room or space Direct to outside
HIGH LEVEL 180 cm290 cm2
LOW LEVEL 180 cm290 cm2

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ROMA 55 FF
6. Terminal position (outside)
AQuinnellBarratt and Quinnell guard(part.no. C2) should bescrewedto the wall centrallyoverthe terminal, when the
distance is less than 2 m above a balcony, above ground or above a flat roof to which people have access.
6.01 Terminal position
Minimum Clearances (mm)
POS. mm TERMINAL POSITION
A300 Directly below an opening
B 75 Below gutters, soil and drain pipes
C 200 Below eaves
D 200 Below balconies, car port roof
E 75 From vertical drain or soil pipe
F 300 From internal or external corner
G 300 Above ground, roof, or balcony
H 600 From surface facing the terminal
I 1200 From terminal facing the terminal
J 1200 From opening in car port, to dwelling
K 1500 Vertically from a terminal on same wall
L 300 Horizontally from a terminal on same wall
1000 • Below plastic gutter Otherwise protect with suitable shield at least 1 m long
500 • Below painted eaves etc.
}

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ROMA 55 FF
7. Terminal position horizontal, seduct, u duct
Standard se duct or u duct
Terminal position - The terminal must be situated relative to the Seduct or U Duct as shown.
Horizontal Only.
Flue lengths - Two lengths are available.
Installation - The exposed wall face MUST be made good and SEALED.
Note that the air duct MUST be retained by screws at the appliance. Further guidance BS 5440: Part 1.
Part No. / Item Rear Flues Side Flues
Wall Thickness Wall Thickness + Distance from side wall
(Max) (Max)
3980221 820 mm 808 mm
3980222 not permited 1808 mm
MAKE GOOD AND SEAL
WALL
FIXING SCREW
AIR INTAKE
FLUE OUTLET
TERMINAL

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ROMA 55 FF
8. Location
1. Further guidance: BS 6798.
2. Notsuitable for external installation.
3. Mustbe mounted on a suitable load bearing flat wall.
4. Combustable wallsare not suitable.
5. Dimensionsof the boiler.
WEIGHT EMPTY 30 kg 66 lb
WEIGHT FULL 30.5 kg 67 lb
HEIGHT 655 mm 26.8 in
WIDTH 370 mm 14.6 in
DEPTH 300 mm 11.7 in
CLEARANCES
IN FRONT 600 mm 24.0 in
TO SIDES 5 mm 0.2 in
ABOVE 100 mm 4.0 in
BELOW 150 mm 6.0 in
6. The space for installation will need to take into account minimum clearences required for safe operation and
subsequent Servicing. Note that the minimum clearance at the front can be via an openable door.
* A top clearance of at least 150 mm (6 in) is desiderable at installation.
7. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements
ofthecurrent.I.E.E.WiringRegulations,and,inScotland,theelectricalprovisionsoftheBuildingRegulationapplicable
in Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. When
this boiler is installed in a room containing a bath 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.

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ROMA 55 FF
8.1 Boiler location
Dimensions (mm)
Minimum Clearances (mm)

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ROMA 55 FF
9. Boiler connections
Gas, Water and Electrical
Front View. All Connections at rear. Side View.
(with optional side flue turret)
A. Air pipe for flue System 4" (100 mm) PLASTIC
G. Gas Service Cock Connection 1/2" BSP FEMALE
F. Flow 22 mm compression
R. Return 22 mm compression
9.1 Gas supply
1. Further guidance: BS 6891, BS 6798, Gas Safety (Installation and Use) Regulations.
2. Ensure the supply pipe is at least the size of the boiler connection (1/2 in BSP or 15 mm copper), and the gas meter
and existing and/or new pipework will serve the maximum gas rate of all the appliance served by the meter.
3. An inlet working pressure of 20 mbar will be required at the boiler.
4. Always test for soundness of gas supply pipes in accordance with BS 6891.

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ROMA 55 FF
10. Electricity supply and connections
Allelectrical installationwork must be carried out by a qualified electrician, and all work shallbe inaccordance with the
current issue of the IEE wiring regulations.
Supplied for use on 230 V ~ 50 Hz supply, protected by a 3 Amp fuse.
The boiler must be earthed.
The method of connection to the mains supply must allow complete isolation from that supply either by:
a) Use of 3 A fused double pole switch having a contact separation of at least 3 mm. Such a switch must supply the
appliance and immediate control circuits only (eg room thermostat, programmer etc.)
OR
b) Use of an unswitched shuttered socket outlet and 3 A fused 3 pin plug both complying with BS 1363.
All external cables must be suitable for mains voltage and should be PVC insulated cable at least 0.75 mm2
(24/0.2 mm), to BS 6500.
All external circuits for the control of the boiler must be wired and isolated from the same isolator as that which serves
the boiler.
PUMP OVERRUNG
THERMOSTAT
C.H. BOILER THERMOSTAT EYELLOW/GREEN
NBLUE
LBROWN
SL BLACK
RRED
Wiring air pressure switch
Brown - Common
Black - NC
Blue - NOAir pressure switch
FUSE F 2 Amp
PUMP
230 V
50 Hz
EXTERNAL
CONTROLS

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ROMA 55 FF
11. Boiler flow diagram
Key
16. Fan
23. Thermocouple
24. Spark electrode
32. Pump (not fitted)
43. Air pressure switch
46. Solenoid gas valve
49. Overheat cut-off thermostat
50. Heat exchanger limit thermostat
63. C.H. boiler thermostat
66. Microswitch combination gas valve
67. Ignition transformer
68. Control box with P.C.B.
79. Capacitor
103. Relay
104. Fuse
133. Pump overrun thermostat

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ROMA 55 FF
12. Electrical functional drawing
Key
16. Fan
23. Thermocouple
24. Spark electrode
32. Pump (not fitted)
43. Air pressure switch
46. Solenoid gas valve
49. Overheat cut-off thermostat
50. Heat exchanger limit thermostat
63. C.H. boiler thermostat
66. Microswitch combination gas valve
67. Ignition transformer
68. Control box with P.C.B.
72. External controls
79. Capacitor
103. Relay
104. Fuse
133. Pump overrun thermostat
230 V ~ 50 Hz
FUSE F 2A (2 Amp Fast)
EXTERNAL
CONTROLS
PUMP
RELAY COILRELAY
GAS VALVE SOLENOID
RELAY
CONTROL
THERMOSTAT
AIR
PRESSURE
SWITCH
LIMIT
THERMOSTAT IGNITER
MICROSWITCH
PUMP OVERRUN
THERMOSTAT
RELAY
1.0 micro
FARAD FAN CAPACITOR
micro Farad

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ROMA 55 FF
13. Illustrated wiring diagram
Key
16. Fan
24. Spark electrode
43. Air pressure switch
44. Combination gas valve
46. Solenoid gas valve
49. Overheat cut-off thermostat
50. Heat exchanger limit thermostat
63. C.H. boiler thermostat
66. Microswitch combination gas valve
67. Ignition transformer
79. Capacitor
133. Pump overrun thermostat
Microswitch
Ignition
transformer
Spark
electrode
Fan
Fan capacitor Pump
230 V Mains
~ 50 Hz Supply
External
Controls
High limit
thermostat
Pump
overrun
thermostat