Ferroli SYS 10-23 Instructions de montage

SYS 10 - 23

wall-hung, gas-ﬁred,

system boiler,

for central heating

INSTALLATION, MAINTENANCE AND USER INSTRUCTIONS

cod. 3544570/2 - 04/2005

Sys 10 - 23

This symbol indicates “Warning”

and is placed near all warnings

regarding safety. Such provisions

must be strictly adhered to so as

to avoid danger and damage to

persons and property.

This symbol highlights a note or an

important warning.

Certification

The CE Mark attests that Ferroli gas-fired

appliances conform to the requirements

specified in the corresponding European

directives.

In particular, this appliance conforms to

the following EEC directives:

• Directive 90/396, Gas Appliances,

• Directive 92/42, Efficiency,

• Directive 73/23, Low Voltage, (amended

by no. 93/68)

• Directive 89/336, Electromagnetic

Compatibility (amended by no. 93/68)

IMPORTANT

Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the last

pages of this manual. This record must be completed and left with the end user.

"All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both should

be recorded in your central heating log book. You can check with the CORGI registered by calling

CORGI on 01256 372300".

• Carefully read the warnings in this instruc-

tion booklet, as they provide important

indications on the safety of installation,

operation and maintenance.

• The instruction booklet is an integral and

essential part of the product and must

be kept safely by the user for future

reference.

• If the appliance is sold or transferred to

another owner, or if it is moved, always

check that the booklet accompanies the

boiler for reference by the new owner

and/or installer.

• The installation and maintenance opera-

tionsmustbeperformedaccordingtothe

standards in force, the instructions of the

manufacturer and must be carried out by

professionally qualified personnel.

• Incorrect installation or poor mainte-

nance may cause a damager to persons

orproperty.Themanufacturerdeclinesall

liability for damage deriving from errors

in the installation and maintenance of the

appliance, and where there is a failure to

observe the instructions provided by the

manufacturer.

• Before performing any cleaning or

maintenance operations, disconnect the

appliance from the mains power supply

using the main switched fused spur.

• In the event of faults and/or poor

operation of the appliance, it should be

isolated. Do not attempt to repair the

appliance. Contact professionally quali-

fied personnel only at ferroli caresafe.

• The products must only be repaired-

replaced by professionally qualified

personnel, using original spare parts

only. Failure to heed this warning may

affect the safety of the appliance.

• To ensure the correct operation of the

appliance, annual maintenance must be

performed by qualified personnel.

• This appliance must only be used for

the purposes it has specifically been

designed for. All other uses are consid-

ered improper and thus dangerous.

• After having removed the packaging,

check that the contents are intact.

• The parts of the packaging must not be

left within the reach of children, as they

are potential sources of danger.

• In case of doubt do not use the appliance

and contact your supplier.

Sys 10 - 23

1. Operating/user instructions ...................................................................4

1.1 Introduction ............................................................................................................4

1.2 Control panel ..........................................................................................................4

1.3 Ignition and shut-down...........................................................................................5

1.4 Settings ...................................................................................................................5

1.5 Maintenance............................................................................................................5

2. INSTALLATION .......................................................................................6

2.1 General instructions................................................................................................6

2.2 Siting of appliance. .................................................................................................6

2.3 Water connections ..................................................................................................8

2.4 Gas connection .....................................................................................................10

2.5 Electrical connections ...........................................................................................10

2.6 Flues connections .................................................................................................14

3. SERVICE AND MAINTENANCE............................................................20

3.1 Settings .................................................................................................................20

3.2 Commissioning......................................................................................................21

3.3 Maintenance..........................................................................................................22

3.4 Replacement of Parts............................................................................................24

4. CHARACTERISTICS AND TECHNICAL SPECIFICATIONS .....................28

4.1 Dimensions and fittings ........................................................................................28

4.2 Overall view and main components .....................................................................29

4.3 Hydraulic diagram.................................................................................................30

4.4 Technical data table..............................................................................................31

4.5 Diagrams ...............................................................................................................32

4.6 Internal electrical diagrams...................................................................................33

4.7 Fault finding ..........................................................................................................35

BENCHMARK ...........................................................................................36

Sys 10 - 23

fig. 1

ABCD

A On /OFF switch

B CH boiler thermostat

C Reset knob with lamp

D Central heating pressure gauge

1. OPERATING/USER INSTRUCTIONS

1.1 Introduction

Dear Customer,

Thank you for having chosen the SYS 10-23, an advanced-concept FERROLI wall-hung boiler featuring

cutting-edge technology, high reliability and constructional quality. Please carefully read this manual

and leave it with the end user.

The SYS 10-23 is a high efficiency heat generator for central heating systems, operating on natural

gas or LPG.

The boiler can be connected to an external hot water cylinder for the production of domestic hot water,

via a “Y” or “S” plan type system.

The boiler body is made up of a copper heat exchanger, the special design of which guarantees high

heat exchange efficiency in all operating conditions, and an atmospheric burner featuring electronic

ignition with ionisation flame control.

The boiler is completely sealed from the surrounding environment: the air required for combustion is

taken in from the outside, and a fan is used to expel the flue gases. The accessories supplied with the

boiler also include a variable-speed pump, expansion vessel, safety valve, air pressure switch, boiler

thermostat, pump overrun and safety thermostat.

The user simply has to set the temperature required inside the home (using the optional, yet recom-

mended room thermostat) or set the system temperature and the required domestic hot water outlet

temperature at the cylinder stat. The regulation and control system will then ensure optimum operation

all year round.

NOTE. External controls not supplied with the boiler.

1.2 Control panel

To access the control panel, open the drop down cover.

Sys 10 - 23

1.3 Ignition and shut-down

Ignition

• Open the gas cock of the boiler.

• Purge the gas supply of any air upstream of the gas valve.

• Turn on the main switched spur to the boiler.

• Press the boiler switch to on.

• Rotate the C.H. temperature adjustment knob above Min position.

• At this point, the burner ignites and the boiler starts to function automatically, operated by its control

and safety devices.

If after completing the start-up procedure correctly, the burner fails to ignite and the boiler shut

down warning lights up, wait about 15 seconds then press the reset switch. The reset electronic

control unit will repeat the start-up cycle. If after a second attempt the burners still fails to ignite,

consult the paragraph “Troubleshooting”.

If there is a power failure while the boiler is in operation, the burners automatically go out and

re-ignite when the power returns.

If the system is filled with very cold water, the boiler will automatically light due to the frost ther-

mostat sensing the low temperature. The boiler will not shut down, until the water temperature

reaches 10°C.

Shut-down

Close the gas isolation valve , push the button “A” to OFF and disconnect the appliance from the mains

power supply.

When the boiler power is off the boiler anti-freeze protection is not active.

For extended periods of inactivity during the winter months, and in order to avoid damage due to

freezing, all the water should be drained from the boiler; alternatively, place approved antifreeze

fluid in the central heating system.

1.4 Settings

Setting the ambient temperature (using the optional room thermostat)

Set, using the room thermostat, the temperature required inside the rooms. Based on the demand from

the room thermostat, the boiler is ignited and heats the system water to the set central heating outlet

temperature. When the required temperature inside the rooms is reached, the boiler switches off. A

room thermostat must be used as per the building regulations ‘Part L’ this will maintain the system at

the set central heating outlet temperature and ensure maximum efficiency.

System water pressure control

Using the filling loop and with the system cold top up the water pressure to approximately 1bar. Once

the operation is completed, always close the filling loop. This device is fitted to the system by the installer

on the central heating return pipework.

1.5 Maintenance

It is recommended to have annual service of the appliance performed by qualified personnel. Please

refer to Chap. 3.3 in this manual for further information.

The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp

cloth, dipped in soapy water if necessary. Do not use abrasive detergents or solvents.

Sys 10 - 23

2. INSTALLATION

2.1 General instructions

This appliance must only be used for the purposes it has been specifically designed for. This appliance is

used to heat water to below boiling temperature at atmospheric pressure and must be connected

to a central heating and/or hot warm distribution system, according to its characteristics, perform-

ance and heating capacity. All other uses are considered improper.

THE BOILER MUST ONLY BE INSTALLED BY SPECIALIST AND QUALIFIED PERSONNEL, IN

COMPLETE COMPLIANCE WITH ALL THE INSTRUCTIONS REPORTED IN THIS TECHNICAL MANUAL,

THE LEGAL STANDARDS IN FORCE, THE PRESCRIPTIONS OF STANDARDS AND ANY LOCAL STAND-

ARDS, AND ACCORDING TO THE RULES OF GOOD PRACTICE.

Incorrect installation may cause injury or damager to persons and property. The manufacturer will not

be held liable in such events.

This appliance must be installed strictly in accordance with these instructions.

The Gas Safety Regulations (Installations & Use).

The Local Building Regulations.

The Building Regulations.

The Buildings Standards (Scotland - Consolidated) Regulations.

British gas publication DM2 - Guide for installation in timber framed housing.

British Standards Codes of Practice:

B.S. 7593 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS

B.S. 5546 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

B.S. 5440 Part 1 FLUES

B.S. 5440 Part 2 AIR SUPPLY

B.S. 5449 FORCED CIRCULATION HOT WATER SYSTEMS

B.S. 6798 INSTALLATION OF GAS FIRED HOT WATER BOILERS

B.S. 6891 GAS INSTALLATIONS

B.S. 7671 IEE WIRING REGULATIONS

B.S. 4814 SPECIFICATION FOR EXPANSION VESSELS

B.S. 5482 INSTALLATION OF LPG

Model Water Bye Laws

For Northern Ireland the rules in force apply

2.2 Siting of appliance.

The appliance’s combustion chamber is sealed from the surrounding environment and as a result the

appliance may be installed in any room without purpose built ventilation. The installation environment

must nonetheless feature sufficient ventilation, to avoid dangerous conditions arising in the event of

even minor gas leaks. These safety standards are imposed by EEC Directive no. 09/396 for all gas appli-

ances, including the so-called sealed appliances.

The place of installation must in any case be free of dust, inflammable objects or materials and corrosive

gases. The environment must be dry and not prone to freezing.

The boiler is supplied ready for wall-hung installation. The rear frame of the appliance has a series of

slots for fastening it to the wall, using screws with wall plugs. The fastening to the wall must provide

stable and effective support of the appliance.

The boiler must be fastened to a closed part of wall, which is free of apertures or holes behind the frame

of the boiler that may allow the internal components of the boiler to be reached.

If the appliance is enclosed in a cabinet or alongside another appliance, minimum clearances must be

adhered to. Fig. 2 and Tab. 3 show the minimum and recommended space to be left free around the

appliance.

Sys 10 - 23

A A

Ø118

> *600 mm

Minimum Recommended

30 mm

200 mm

15 mm

(from opening panels)

150 mm

300 mm

C280 mm 300 mm

Table 3

fig. 2

fig. 3

Fixing to the wall

Select suitable mounting position for boiler. Using the template mark flue outlet and boiler mounting

points. Drill two 10mm holes 90mm deep to accept the wall plugs. Fit two special wall plugs in the wall

as described in the fig. 3. Fasten the wall bracket to the wall using an antitheft nut on the right side and

a standard nut (M8) on the left side. Using a core drill cut a 118mm diameter hole for the flue. Mount

the boiler on the wall bracket and fix using an antitheft nut on the left side and a standard nut (M8) on

the right side.

NOTE: M

inimum distance required from front

panel of the appliance for servicing 600mm (D)

Sys 10 - 23

Key

1Central heating outlet, 3/4” (22 mm with isolation valve fitted)

2Gas inlet, 1/2” (22 mm with isolation valve fitted)

3Central heating inlet, 3/4” (22 mm with isolation valve fitted)

fig. 4

36 155 155 54

123

2.3 Water connections

The heat capacity of the appliance should be established in advance by calculating the heating require-

ments of the building according to the standards in force. For correct operation and long-life of the

boiler, the hydraulic system must be suitably proportioned and always fitted with all the accessories

that guarantee correct operation.

In the case where the central heating outlet and inlet pipes follow paths whereby, at some points, pockets

of air may form, air vent valves should be installed at such points.

In addition, a drain device should be installed at the lowest point in the system, to allow complete

draining.

If the boiler is installed at a lower level than the system, a flow-return valve should be fitted to prevent

the natural circulation of water in the system.

The temperature differential between the outlet and the inlet of

the boiler should not exceed 20°C. (11°C recommended)

Do not use the water pipes as the earth for electrical

appliances.

Before installation, carefully clean all the pipes in the system to

remove any residues or impurities that may affect the correct

operation of the appliance.

Make the connections to the corresponding fittings, as shown

in fig. 4.

It is essential to fit the supplied isolation valves between the boiler and the central heating system; these

allow the boiler to be isolated from the heating system, if necessary.

The discharge of any safety valves must be routed to outside dicharging to ground level 100 mm

from the floor so as not to create a danger to anyone passing, there should be no rise from the

boiler to outside a slight fall is preffered. The manufacturer of the boiler will not be held liable if

this warning is not heeded. Make the connections to the boiler in a way that its internal pipework

is not subject to stress.

Sys 10 - 23

Water treatment

if water treatment is used Ferroli Ltd recommend only the use of Fernox or Sentinel water treatment

products, which must be used in accordance with the manufacturers instructions. For further informa-

tion contact:

Fernox Manufacturing Co. LTD. Sentinel Division

Cookson electronics, forsyth road Betz Dearborn LTD

Sheerwater, working Surrey GU21 5RZ Widnes, Cheshire WA8 5351

Tel. 0870 8700362 Tel. 0151 424 5351

Note - If the boiler is installed in an existing system any unsuitable additives must be removed by thor-

ough cleansing.

All systems should be cleansed according to B.S. 7593.

Note - In hard water areas treatment to prevent lime scale may be necessary.

Note - It is important that the correct concentration of the water treatment product is maintained in

accordance with the manufactures instructions.

Filling the boiler and the system

The filling pressure, when the system is cold, must be around 1 bar (at least 0.5 bar). If the pressure

drops during operation to a value lower than the minimum described above, the User must restore the

initial value using the filling loop. For correct boiler operation, the pressure, when hot, must be around

1,5-2 bar. Once the operation is completed, always close the filling loop. This device is fitted to the

system by the installer.

Make Up Water

Provision must be made for replacing water lost from the 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 Byelaws. Again any such

connection must be disconnected after use. The supplied temporary filling loop is shown in fig. 4. Ensure

the filling point is on the return pipe to the boiler.

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.

Key

1. Filling point C.H.

2. Temporary connection

3. Cold water supply

4. Double check valve

Fig. 5

Sys 10 - 23

Fig. 6a Fig. 6b

2.4 Gas connection

Before making the connections, check that the appliance is configured for operation with the

type of fuel available, and carefully clean all the gas pipes in the system, to remove any residues

that may affect the correct operation of the boiler.

The gas connections must be made using the relative coupling (see fig. 4), according to the standards

in force, with a rigid metal pipe, fitting a gas cock between the system and the boiler. Check that all the

gas connections for soundness.

The capacity of the gas meter must be sufficient for the simultaneous use of all the connected appliances.

The diameter of the gas pipe, which leaves the boiler, does not necessarily determine the choice of the

diameter of the pipe used between the appliance and the gas meter; this must be chosen according to

its length and the pressure drop, according to the standards in force.

Do not use the gas pipes as the earth for electrical appliances.

2.5 Electrical connections

Connection to the mains power supply

The boiler should be connected to a single-phase, 230 Volt-50 Hz electrical power supply.

The electrical safety of the appliance is ensured only when the appliance is correctly connected

to an effective earth system, as prescribed by the safety standards in force. Have professionally

qualified personnel check the efficiency and the rating of the earth system. The manufacturer

is not liable for any damage caused by the appliance not being correctly earthed. In addition,

make sure that the electrical system is adequately rated for the maximum power absorbed by

the appliance, indicated on the boiler rating plate, and in particular that the cross-section of the

wires is suitable for the power absorbed by the appliance.

The boiler is pre-wired and fitted with a cable for connection to the electrical line. The connections to

the mains supply must be made using a fixed connection, featuring a double-pole switch with a contact

opening of at least 3 mm. Max 3A fuses must be installed between the boiler and the line. The correct

polarity must be followed (LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green wire) in the

electrical connections.

The appliance’s power cable must not be replaced by the user. In the event where the cable is

damaged, turn off the appliance and contact professionally qualified personnel to replace it. If

replacing the electrical power cable.

All wiring must conform to current I.E.E. Regulations

Accessing the electrical terminal block

Follow the operation shown in Figs. 6a and 6b to access the electrical terminal block. The layout of

the terminals for the various connections is shown in the wiring diagram, in the chapter on Technical

Specifications.

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