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01/01
1001
WALL MOUNTED, ROOM SEALED,
FAN ASSISTED, GAS COMBINATION BOILER
INSTALLATION
INSTRUCTIONS
Read these Instructions thoroughly
before using the appliance
FERROLI HELPLINE
Phone numbers:
FOR SERVICE INFORMATION OR
HELP TELEPHONE: 08707 282 885
Installer
ALWAYS QUOTE YOUR SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
Service Engineer
Serial No.
G.C. NO: 47-267-19
ALL SPECIFICATIONS SUBJECT TO CHANGE
Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 0870
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1001 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 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. Prepar
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1001 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 expansion vessel for sealed systems. The wall mounting jig contains all the isolating cocks for the water and gas supplies which can be fitted to t
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1001 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 kW Minimum Heat Output D.H.W. & C.H. 11.8 kW 11.8 kW 3 Gas rate 3.3 m S/h 2.39 kg/h Maximum burner pressure 15 mbar 34.5 mbar Minimum burner pressure 3.5 mbar 6.9 mbar Inj
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Øi82 160 1001 Appliance Dimensions FRONT VIEW LEFT SIDE VIEW REAR VIEW 242 235 480 370 12 3 4 5 6 7 235 97.5 50 50 80 75 50 77.5 Key 480 1. Electricity cable entry 2. Gas supply Fig. 1 3. Domestic Hot Water outlet 8 - TOP VIEW 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 5 120 Øi92 126.5 900 85 40 242 60 100 157
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1001 Boiler Flow Diagram Fig. 2 6
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1001 Key 43. Air pressure switch 1. Fixing point 46. Operator gas valve 2. Flue terminal 47. Modulating regulator (Modureg) gas valve 3. Flue/air intake hood 48. Burner pressure test point 4. Sealing gasket 49. Overheat cut-off thermostat 5. Room sealed compartment 50. Central heating limit thermostat 6. Control panel 51. Central heating frost thermostat 7. Gas inlet 53. Heat exchanger venting point 8. Domestic hot water outlet 56. Expansion vessel 9. Cold water inlet 58. Fan air outlet pressu
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1001 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 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
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1001 Terminal Position Fig. 3 Minimum Clearance mm Fig. 5 NOTES * Access to the front of the boiler must be available for maintenance (min. 600 mm). 9
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1001 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 products of combustion discharging from the terminal cannot re-enter the build
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1001 Gas Cold water Additional expansion vessel C.H. (if required) Filling point C.H. Bypass Fig. 6 NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout. Key 1. Filling point C.H. Fig. 7 2. Temporary connection 3. Cold water supply 11
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1001 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 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 e
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1001 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 fixing screws and wall plugs (x4), the boiler mounting nuts and washers (x2), drilling template, flue assembly and flue bend. When the cartons are unp
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1001 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 pipework is adequately supported. Rear flue outlet Drilling template Diam. min. 118 mm Fixing stud Upper bracket Side flue outlet boiler Di
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1001 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. K = 10 mm min. F1 (Flue outlet) 60 mm max. 4.1.1 Accurately measure the Wall thickness (P1) 4.1.2 From the end opposite to the terminal, cut
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1001 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 away from the main boiler. 5.3 Lift boiler as shown in fig. 15 onto the top studs and fit supplied nuts and washers hand tight. 5.4 Lift at bottom to engage the water and
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1001 Fixing points Fig. 15 Lift here Fixing screws Fig. 16 Fig. 17 17
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1001 6.0 FITTING THE FLUE ASSEMBLY 6.1 With Sufficient Clearance To Insert Assembly From Inside 6.1.1 Insert the flue assembly into the wall. 6.1.2 Insert the flue bend in the top plate of the boiler 6.1.3 Secure the flue bend. 6.1.4 Fully insert the flue assembly into the boiler flue bend. Insert the self tapping screw supplied. Fully tighten. 6.1.5 Check the terminal relationship with the wall as shown in fig. 12. 6.1.6 Make good internal wall face. 6.1.7 Make good the outside wall face, re-
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1001 8.0 COMMISSIONING AND TESTING 8.1 Filling the Central Heating System Burner pressure Automatic air vent Vent cap test point Heat exchanger vent Pump C.H. pressure gauge C.H. pressure relief valve Gas inlet pressure test point D.H.W. drain point Low water pressure switch 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
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1001 Flame viewing opening C.H. pressure gauge C.H. boiler thermostat Flame failure reset knob Time clock (if fitted) C.H./D.H.W. selector switch Domestic hot water thermostat Fault diagnostic lights fig. 21 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
