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Optima Company 1001 manual

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Table of contents for the manual

  • Page 1

    1001 W ALL MOUNTED, ROOM SEALED, F AN ASSISTED, GAS COMBINA TION BOILER Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD Tel. 08707 282 885 - Fax 08707 282 886 ALL SPECIFICATIONS SUBJECT TO CHANGE Phone numbers: Installer Service Engineer Serial No. Read these Instructions thoroughly before using the appliance F[...]

  • Page 2

    1001 2 page INDEX 3 General Description 3 Related Documents 4 Technical Data 5 Appliance Dimensions 6 Boiler Flow Diagram 7 Key of boiler flow diagram 8 Installation Details 8 Location of Boiler 8 Air 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 1[...]

  • Page 3

    1001 3 General Description The Ferroli 1001 is a wall mounted, room sealed, fan assisted, 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 Hot Water from an integrally designed unit. The boiler contains its own expan[...]

  • Page 4

    1001 4 Technical data NATURAL GAS (G20) PROPANE LPG (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 k[...]

  • Page 5

    1001 5 Appliance Dimensions FRONT VIEW LEFT SIDE VIEW REAR VIEW 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 8 - TOP VIEW 480 900 370 77.5 50[...]

  • Page 6

    1001 6 Boiler Flow Diagram Fig. 2[...]

  • Page 7

    1001 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 15. Air inlet to fan 16. Fan 19. C[...]

  • Page 8

    1001 8 Installation Details 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 [...]

  • Page 9

    1001 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[...]

  • Page 10

    1001 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 f[...]

  • Page 11

    1001 11 Fig. 7 NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout. Fig. 6 Key 1. Filling point C.H. 2. Temporary connection 3. Cold water supply Gas Cold water Additional expansion vessel C.H. (if required) Filling point C.H. Bypass[...]

  • Page 12

    1001 12 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 15-50 UPS series. Grunfos Pump performance graph Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minu[...]

  • Page 13

    1001 13 Installation Note - To mount the boiler on the wall, a two person lift will be needed. 1.0 UNPACKING The appliance is delivered in 2 cartons. 1.1 The large carton contains the boiler, and the Installation/Servicing and Users Instructions. 1.2 The second carton contains the mounting jig assembly, complete with isolating valves, the assembly [...]

  • Page 14

    1001 14 Important Note - Always use two spanners to prevent twisting of soft copper pipework on the boiler. Flush out the water system. Note - The maximum inlet cold water pressure must not exceed 10 bar (145 P.S.I.) and a water governor or a pressure reducing valve will be required if the pressure is in excess of 5 bar (72 P.S.I.). Ensure all pipe[...]

  • Page 15

    1001 15 4.0 PREPARING THE FLUE ASSEMBLY 4.1 Rear Flue Outlet (fig. 12) Important - The aluminium flue pipe must protrude into the outside grill by 60 mm, never cut it to the same length as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 70 mm !). Aluminium flue pipe length = Plastic air inlet pipe length plus 70 mm longer. 4.1.[...]

  • Page 16

    1001 16 Fig. 14 TOP VIEW BOILER SIDE OUTLET 5.0 CONNECTING THE BOILER 5.1 Place the boiler on its back. 5.2 Remove the boiler base plate, four screws (fig. 16). Remove the plugs fitted to the boiler water connections. Remove the bag of sealing washers from the boiler pipework. Remove the front panel by gripping on both sides, sliding up and pulling[...]

  • Page 17

    1001 17 Fixing points Lift here Fig. 15 Fixing screws Fig. 16 Fig. 17[...]

  • Page 18

    1001 18 External controls: room stat or remote time clock in the place of loop terminals 4 and 5. Please note 24 V only, use only voltage free contacts. IMPORTANT If 230 V is connected to terminals 4 or 5, damage will be caused to the P.C.B. Fixing screw front Screw Blue Brown Fig. 19 Fig. 18 6.0 FITTING THE FLUE ASSEMBLY 6.1 With Sufficient Cleara[...]

  • Page 19

    1001 19 8.0 COMMISSIONING AND TESTING 8.1 Filling the Central Heating System Fig. 20 Remove the top front panel by gripping both sides and lifting forward away from main boiler assembly. Loosen the cap of the automatic air vent (fig. 20) and leave it loose. Open the central heating flow and return cocks (fig. 11). Gradually fill the system as detai[...]

  • Page 20

    1001 20 8.5 To Light the Boiler (fig. 21) a. Open controls panel door. b. Switch on electricity supply. c. Adjust room thermostat and all external controls to «ON». Check operation of pump. d. Turn the boiler thermostat to maximum. Fan will run (A waiting time of max 3 minutes before fan will run is possible!), and main burner will light. e. Temp[...]

  • Page 21

    1001 21 Burner Pressure C.H. and D.H.W. 8.6 To Range Rate the Boiler C.H. (not required for standard installations). The boiler can be range rated for an output from 11.8 kW up to 27.9 kW. When the boiler is supplied it is factory set at the maximum output 27.9 kW. Procedure a. Release the control panel fixing screws (fig. 30) and lower panel. b. L[...]

  • Page 22

    1001 22 Honeywell VR 4605 NA 4003 valve with V7335A4014 Modureg Gas pressure Adjustment 1 - With the burner lit: 2 - Connect suitable pressure gauge to burner test point "B", and then: 3 - Disconnect air pressure compensation tube "H" ; 4 - Disconnect the wires from coil "C" of the Modureg; 5 - Remove protective cover [...]

  • Page 23

    1001 23 Burner Perssure C.H. • Natural gas • L.P.G. (Propane) 5 10 15 20 25 30 35 9 1 01 11 21 31 41 51 61 71 81 92 02 12 22 32 42 5 26 27 28 29 91 0 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8 kW kcal/h x 1000 mbar 36 Fig. 24b - Burner pressure VS C.H. load with natural gas (G20) 1 14 2 3 4 5 6 9 1 01 11 21 31 41 51 6 17 18 19 20 21 22 23 [...]

  • Page 24

    1001 24 8.7 D.H.W. Burner Pressure The domestic hot water burner pressure is not range rateable and not adjustable but the maximum and minimum burner pressure should be checked as follows: a. Check electricity supply is still off. b. Open a D.H.W. tap at high flow until the water runs cool and leave running. c. Switch on the electricity supply. d. [...]

  • Page 25

    1001 25 1.1 Use buttons + and - to set 1st ON time eg. 6:00 Display 2.1 Use buttons + and - to set OFF time, eg. 9:00 Display 3.1 Use button + and - to set 2nd ON time, eg. 12:30 Display 4.1 Use button + and - to set 2nd OFF time eg. 14:00 Display 5.1 Use button + and - to set 3rd ON time, eg. 16:00 Display 6.1 Use button + and - to set 3rd OFF tim[...]

  • Page 26

    1001 26 AIR PRESSURE SWITCH Fig. 46 BLUE BLACK BLACK 1 2 BLACK DL 1E BROWN BLUE 3 3 1 1 2 KROMSCHRODER HUBA 605 2 1 3 BROWN BLUE 3 BROWN KROMSCHRODER HUBA 602 1 2 2 3 HUBA 605 HUBA 602 2 3 1 P1 P2 Plate 2 fixing screw 2 fixing screw White silicone Red silicone tube Fig. 45 Over ride By pressing the over ride button ( E ) the timer programme is over[...]

  • Page 27

    1001 27 12345678 LED 63 157 17 18 100 100 Spare Parts List Item No. G.C. Part No. Makers Part No No. Off DESCRIPTION 14 386816 800130 1 C.H. safety valve 16 - 803860 1 Fan 21 - 803080 20 Main injector (Natural Gas) 21 - 801850 20 Main injector (L.P.G.) 32 - 800620 1 Central heating pump 34 386818 800310 2 Temperature sensor 36 394246 801160 1 Autom[...]

  • Page 28

    1001 28 Domestic Hot Water Performance Fig. 1 - D.H.W. Pressure Drop VS. flow A= Standard with cold water Flow Restricter B= Cold Water Flow Restricter Removed Fig. 2 Fig. 2 - D.H.W. temperature VS. flow A= Cold Water 15 ° C B= Cold Water 5 ° C Fig. 1 90 80 70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 1 1 12 A B ° C litres/min[...]

  • Page 29

    1001 29 16 Fan 32 Central heating pump 34 C.H. flow temperature sensor 42 D.H.W. temperatuure sensor 43 Air pressure switch 46 Operator gas valve 47 Modulating regulator (MODUREG) gas valve 49 Overheat cut-off thermostat 50 Heat exchan. limit thermostat 51 Heat exchan. frost thermostat 61 C.H. selector switch 62 Time clock 63 C.H. boiler thermostat[...]

  • Page 30

    1001 30 General Notes - For use on the 1001 fitted with VMF7 Printed Circuit Board *The central heating pump (32) will run to disperse heat if the temperature at the heat exchanger limit thermostat (50) is too high *The frost thermostat (51) will switch on the boiler for central heating if the temperature is too low. *Fuse on P.C.B.: 2 Amp. LED n ?[...]

  • Page 31

    1001 31 Special Installation Possibilities: Two-pipe air intake/flue outlet Special Air Intake/Flue Outlet The standard Flue/air intake hood on top of the boiler can be replaced by a special two pipe flue adapter. Øi92 Øi82 120 242 126.5 235 160 157 480 2 1 = Special two pipe flue adapter 823071 = remove air intake cover Ø 80 mm 1 2 Ø80 Ø80 1 [...]

  • Page 32

    Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD Tel. 08707 282 885 - Fax 08707 282 886 ALL SPECIFICATIONS SUBJECT TO CHANGE Cod. 3540246/2 - 01/01 Phone numbers: Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.[...]