Ferroli TEMPRA Operating and maintenance manual

Appr. nr. B 94.04 A - CE 0063 AQ 2150
Wall mounted fanned
flue boiler
INSTALLATION AND
USE INSTRUCTIONS
Please read these Instructions
thoroughly before using
the appliance
Phone numbers:
Installer ____________________________
Service Engineer _____________________
Serial N°____________________________
These Instructions must be left with the appliance User.
TEMPRA
Wall Mounted
Fan Flue
System boiler

2
TEMPRA
INDEX
1. General description and information
2. Technical specification
3. Installation details
4. Installation
5. Boiler connections
6. Electrical connections
7. Commissioning

3
TEMPRA
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. 1994
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.
BS 7593: Treatment of water in domestic hot water central heating systems.
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 components.
1.2 Introduction
The TEMPRA Boiler is a “room-sealed” appliance: it takes in the air required for combustion and
encloses all the combustion products in an hermetic compartment. The discharge of fumes and
intake of combustion air are managed through air/flue pipes that may be run horizontally in all
directions, or through a concentric flue running vertically or horizontally.
The main components of the boiler are:
- A compact heat exchanger in copper, formed by four pipes with external finning and internal
turbulence activators.
- A combustion chamber insulated to reduce heat loss and thus improve efficiency.
- Nine stainless steel burners, an oxidation- and thermal shock-resistant material specially devel-
oped for this product.
- A fan to discharge combustion products and draw in combustion air.

4
TEMPRA
- A boiler thermostat overheat thermostat and frost thermostat.
- A steel room-sealed compartment treated against corrosion, enclosing all the above components.
- An air differential pressure switch which, to ensure safe operation, allows burner ignition only
when the fan functions normally.
- A newly-designed gas ignition valve assembly, comprising a range rated regulator gas valve and a
flame control device. (Ignition is by an intermittent pilot flame; which lights the main burners.)
- An expansion vessel, pump, automatic air vent and air separator .
- A temperature sensor.
- Pressure gauge.
- Pressure relief valve set at 3 bar.

5
TEMPRA
2. TECHNICAL SPECIFICATION2. TECHNICAL SPECIFICATION
2. TECHNICAL SPECIFICATION2. TECHNICAL SPECIFICATION
2. TECHNICAL SPECIFICATION
2.01. Technical data2.01. Technical data
2.01. Technical data2.01. Technical data
2.01. Technical data
Dimensions
Weight
Width
Height
Depth
mm
mm
mm
kg
Nominal heat input (gross)
Nominal heat input (net)
Nominal heat output
kW
kW
kW
LPG
(G31)
Ø Main injectors
Ø Gas supply
mm
mbar
Number of injectors
Working gas inlet pressure
Burner pressure
Gas rate
N°
mbar
kg/h
m3/h
Maximum system pressure
Ø Water connections
bar
Model
V/HzElectrical supply
Natural gas
(G20)
min
Max mbar
21.6
19.5
17.6
3
3/4"
750
420
275
230/50
40
1/2"
9
1.2
20
5
15
2.06
-
1/2"
9
0.77
37
13
36
1.51
-
kW
kW
kW
12.8
11.5
9.7
Max Min
TEMPRA sealed system boiler
Natural gas (G20) Propane LPG (G31)
kW
kW
kW
21.1
19.5
17.6
kW
kW
kW
12.5
11.5
9.7
Max Min

6
TEMPRA
°C
92
760 750
275
131
Ø 60
50 160 160 50
40 340 40
420
Ø 10
1
3
2
c
b
a
Ø 96
Ø 112
131
270 150
d
4
2.02. Appliance dimensions2.02. Appliance dimensions
2.02. Appliance dimensions2.02. Appliance dimensions
2.02. Appliance dimensions
Fig. 1
KeyKey
KeyKey
Key
1.1.
1.1.
1. Central Heating return inlet
2.2.
2.2.
2. Gas supply
3.3.
3.3.
3. Central Heating flow outlet
4.4.
4.4.
4. Outlet pressure relief valve
a.a.
a.a.
a. C.H. boiler thermostat
b.b.
b.b.
b. Pressure gauges
c.c.
c.c.
c. Main switch
d.d.
d.d.
d. Overheat cut-off thermostat (reset)

7
TEMPRA
5-Room sealed compartment
7-Gas supply
8-Central Heating flow outlet
9-Central Heating return inlet
14 - Safety valve
16 - Fan
19 - Combustion chamber
20 - Burner box
22 - Burner
24/82 - Ignition/flame sensing electrode
25 - Pilot burner
27 - Copper heat exchanger
29 - Tube flue outlet
31 - Flue collector
32 - Pump
43 - Air pressure switch
44 - Gas valve
49 - Overheat cut-off thermostat (reset)
51 - Central heating frost thermostat
52 - Central heating limit thermostat
56 - Expansion vessel
63 - C.H. boiler thermostat
87 - Gas pressure test point
98 - Main switch
145 - Pressure gauges
5
87
43
7
8
44
14 49
29
16
31
25
24/82
51
27
52
9
19
22
3256
20
°C
98 145 63
7
89 49
Outlet
pressure
relief
valve
2.03. Flow diagram2.03. Flow diagram
2.03. Flow diagram2.03. Flow diagram
2.03. Flow diagram
Fig. 2

8
TEMPRA
3.0 INSTALLATION DETAILS
3.1 Gas Safety (Installation & Use) Regulations: 1994
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 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.
3.2 Location of Boiler
The installation of the TEMPRA must be on a suitable non-combustible load bearing wall which will
provide an adequate fixing for the boiler mounting bolts. The location should be in an area where the
water pipes will not be subjected to frost conditions. In siting the boiler the following limitations must
be observed:
The boiler may be installed in any room or internal space, although particular attention is
drawn to the requirements of the current, i.e. wiring regulations and in Scotland the electrical
provisions of the building regulations applicable in Scotland, with respect to the installation of the
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, should be so situated that it cannot be touched
by a person using the bath or shower.
3.3 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
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the
terminal, when the distance is less than 2 m from the outside floor.
3.4 Air Supply
The room in which the boiler is installed does not require a purpose provided vent.

9
TEMPRA
Minimum Clearance mm
Fig. 4
Fig. 3
Terminal Position
123
0 4
C
200 min
25 mm
600**
50
min.
25 mm
200
82
NOTES
** Access to the front of the boiler must be available for maintenance (min. 600 mm).

10
TEMPRA
3.5 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.
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 ventilators, windows, doors, natural air
infiltration, or forced ventilation/air conditioning.
3.6 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 boiler must be of an adequate size.
Do not use pipes of a smaller size than the 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.
3.7 Water System
Central Heating
It must be a sealed system. Detailed recommendations are given in BS6798, BS5449, BS6700 and
CP342Part.2.Pipeworknot forming part of the useful heating surface shouldbeinsulatedtoprevent
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. It should be ensured that the boiler
heatexchanger is not a natural point for collecting air. A typical heating system with domestic hot water
circuit is illustrated in fig. 5-6.
Important - A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min.
3.8 Make up Water
Provision must be made for replacing water lost from 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 Byelaw. Again any such
connection must be disconnected after use fig. 7.
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.

11
TEMPRA
Fig. 7
Key
1.␣ Filling point C.H.
2.␣ Temporary connection
3.␣ Cold water supply
NOTE: A bypass must be fitted to ensure a minimum flow rate of 6 l/min. through the boiler.
Approved
filling
loop
Domestic
Cylinder
2 port motorised
valves
Boiler
Domestic
Cylinder
3 port motorised
valves
Boiler
By Pass
By Pass
Filling point
Filling point
Sealed system - “Y” Plan
Sealed system - “S” Plan
Fig. 5
Fig. 6

12
TEMPRA
3.9 Built-in Central Heating Water Circulating Pump
The pump head available for circulating the water is given in fig. 8.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type UPS 15-50 series.
Grunfos Pump performance graph
Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per
minute.
If required an additional expansion vessel may be fitted to the central heating return inlet.
If the total volume of water in the system exceeds 40 litres an additional expansion vessel
must be fitted to the central heating return inlet.
Pump performance curve Grundfos UPS 15-50
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
SIZING OF ADDITIONAL EXPANSION
VESSELS:
Deduct from the value given in the table the
6 litre vessel supplied.
Note
1.␣ Fill C.H. installation to min. 1.5 bar.
2.␣ Select by preference the expansion vessel
for increased system pressure of 2.0 bar
3.␣ Expansion vessel must be fitted to Central
Heating Return Inlet
4.␣ The standard 6 litres expansion vessel is
charged to 1 bar
Fig. 9
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

13
TEMPRA
4. INSTALLATION
4.1 Unpacking
The appliance is delivered in 2 cartons.
4.1.1 The large carton contains the boiler, and the Installation/Servicing and Users Instructions.
4.1.2 The second carton contains the wall fixing bolts (x2), flue assembly, and boiler bend, gas cock
and 3/4” x 1/2” bush.
4.2 Wall mounting
After selecting a suitable place for the boiler, mark location for fixing holes. Using 8 mm drill, drill
60 mm deep holes to accept fixing bolts and insert. Tighten nuts until secure, then remove nuts
leaving studs protruding, hang boiler and refits nuts to secure.
Fig. 10
cc
cc
ccc
cc
c
dd
dd
d

14
TEMPRA
Outlet and inlet
through a building wall
MAX 3mMAX 3m
MAX 3mMAX 3m
MAX 3m
Maximum permitted length for
concentric flue to be run is 3 m.
4.3 Preparing the flue assembly
The boiler is supplied with 0.75 m of concentric flue which can be run from either side or to the back
of the appliance. If a longer flue is required 2 m and 3 m lengths are avaiable.
An example of using the concentric flue.
Flue connection
Drawing below shows
how concentric flue
should be assembled -
the main points being:
1. Inner flue pipe
(alluminium) needs
to be 85 - 90 mm
longer than plastic
air intake pipe
2. The air intake
(plastic) pipe only
butts to the elbow
3. Care must be taken
not to dislodge “O”
rings
Fig. 12
Fig. 11
L
A=L+(85-90)mm
Ø2
Ø1
Clamp detail
25-30 mm 60
Ø2
Chamfer outer edge of
aluminium pipe to
avoid dislodging "O" rings
Ø1
Ø1=100
Ø2=60
"O" rings

15
TEMPRA
5. Boiler connections
Gas, Water and Electrical
Front View Side View
5.1␣ Gas supply
1. Further guidance: BS 6891, BS 6798, Gas Safety (Installation and Use) Regulations 1994.
2. Ensure the supply pipe, the gas meter and existing or new pipework will serve the maximum gas
rate of all the appliance served by that 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.
5.2 Pressure relief valve
Connect the pressure relief valve discharge pipe (1/2”) to the outside of the building, where possible
over a drain. The discharge must be such that it will not be hazardous to occupants or passers - by or
cause damage to external electrical components or wiring. The pipe should be directed towards the
wall.
123
0 4
C
1. Outlet pressure relief valve 1/2" FEMALE
2. Return 3/4" MALE
3. Gas Service Cock Connection 1/2" FEMALE
4. Flow 3/4" MALE
2413

16
TEMPRA
6.␣ ELECTRICAL SUPPLY AND CONNECTIONS
All electrical installation work must be carried out by a qualified electrician, and all work shall be in
accordance 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.
6.1 Electrical connection
1. The TEMPRA boiler requires a permanent live supply to the appliance (live, neutral and earth)
together with a switched line from the system controls to operate the burner.
2. When using external controls remove link wire betwen terminals 4 -5.
3. Run live connection from terminal 4 to external switch controls and return switch line into
terminal 5.
12
SL
LN
45
3
LN
6 7 8 9 10 11 12
External switch
controls
Electrical
control box
230 V ~
3 Amp fuse
Fig. 18
WARNING: If external controls are fitted to the system, check terminals 1, 2, 4, and 5 to ensure
they are voltage free prior to working on the boiler.

17
TEMPRA
L
N
230 V ~ 3 Amp fuse
98
6
8
32 12 11
S.4585 D
1003
96107145382
83
1643
7
63
9
72
24
4
SL
12
11
C
1
50
10
2
551
176
NONC
C
11
43 16
1112 13910 245678
8324
42 63
13
C
2
98 176
1
N945678 101112L
LN
72 32 50
50Hz
230V 51
NC
NO C
31
24
Wiring 43
C= Brown
NO = Blue
NC = Black
16. Fan
24. Spark electrode
32. Central heating pump
43. Air pressure switch
50. Central heating limit thermostat
51. Central heating frost thermostat
63. C.H. boiler thermostat
72. External controls
83. Full sequence automatic control
98. Switch
176. Overheat CUT-OFF thermostat
6.2 Electrical connections diagram
16. Fan
24. Spark electrode
32. Central heating pump
43. Air pressure switch
50. Central heating limit thermostat
51. Central heating frost thermostat
63. C.H. boiler thermostat
72. External controls
83. Full sequence automatic control
98. Switch
176. Overheat CUT-OFF thermostat
6.3 General wiring diagram

18
TEMPRA
15.␣ Commissioning
Carry out preliminary electrical system checks i.e. EARTH CONTINUITY, RESISTANCE TO EARTH,
SHORT CIRCUIT AND POLARITY using a suitable test meter.
1. Remove the outer case and lower cover.
2. Test for gas soundness up to the boiler service cock - BS 6891.
3. Flush the system cold, without the boiler in circuit.
4. Fill the complete circuit and vent the system, fill to about a=1.5 bar at this stage.
5. Check the system for water soundness, rectifying any leaks.
6. Reduce the pressure to the approximate initial design pressure.
7. Open all radiator valves.
8. Loosen the screw within the pressure test point on the burner supply pipe and attach a suitable
pressure gauge.
9. Open the boiler service cock.
10. Open all doors and windows, loosen the screw in the inlet pressure test point, and purge the gas
supply BS 6891. Retighten the screw. Allow gas to disperse.
11. Set any external control to an ON condition, and turn the thermostat knob to maximum.
12. Turn on the electricity supply. Check that the pump runs.
13. A continuous spark will light the pilot (viewed through window) and the main burner.
14. Heat Input Adjustment. The Input is pre-set to 16.7 kW but can the adjusted to any value in the
range quoted in Technical Data - the burner pressure must always be checked anyway.
Remove the cap from the adjustment screw.
CH HEAT INPUT BURNER PRESSURE CH HEAT OUTPUT
(Gross) kW mbar set to kW
MAX 21.6 15 — 17.6
MED 16.7 8 — 13
MIN 12.8 5 — 9.7
2
1
18
16
14
12
10
8
6
4
2
00 2 4 6 8 1012141618202224
mbar
Burner pressure to C.H. Heat Output 1 / Heat Input 2
kW
21

19
TEMPRA
15. After 10 minutes, adjust the heat input to the required value. (Anticlockwise to decrease).
Replace the cap.
16. NOTE - If the required pressure cannot be obtained, the inlet working pressure should be checked
(20 mbar is required with burner on!)
17. Allow the system to reach heated equilibrium. On sealed systems check that the pressure does not
exceed 2.6 bar (in which case a larger expansion vessel will be needed).
18. Turn off burner.
19. Flush the system whilst hot, and refill.
20. Remove the pressure gauge, tighten the screw.
21. Relight and check for gas soundness.
22. Mark the Data Badge to indicate the set heat input.
23. Replace the lower cover and outer case.
24. Adjust the thermostat control knob to the required setting.
25. Hand over to the user:
a)␣ Explain the function and control of the boiler, including any external controls.
b)␣ Advise against obstruction of purpose provided ventilation, and of the flue terminal.
c)␣ Give advice on frost protection of parts.
d)␣ Advise arrangement of an annual Service Contract.
e)␣ Hand all Instructions and literature to the user.
Key
10. Inlet pressure test point
17. Adjustment screw burner pressure (turn clockwise to increase pressure)
18. Burner pressure test point
10
17
18

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
BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS
MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.
Cod. 3540982/0 - 09/96