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  5. Installation Instructions Manual

Ferroli optima 2001 VMF7 Installation Instructions Manual

Manual is about: WALL MOUNTED, ROOM SEALED, FAN ASSISTED, GAS CONDENSING COMBINATION BOILER

Summary of optima 2001 VMF7

  • Page 1

    2001 wall mounted, room sealed, fan assisted, gas condensing combination boiler stockton close, minworth industrial park, minworth, sutton coldfield, west midlands b76 8dh sales: 0121/3523500 - fax 0121/3523510 all specifications subject to change phone numbers: installer service engineer serial no....

  • Page 2: 2001

    2001 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 8 condensate 10 flue system 10 gas supply 10 water system 12 central heating pump 12 sizing ...

  • Page 3: 2001

    2001 3 general description the ferroli 2001 is a wall mounted, room sealed, fan assisted, condensing combination boiler for central heating (c.H.) and domestic hot water (d.H.W.). The boiler is of light weight construction with two heat exchangers providing central heating and domestic hot water fro...

  • Page 4: 2001

    2001 4 technical data natural gas (g20) nominal heat input (gross caloric value) 26.6 kw nominal heat output 22.6 kw nominal heat output condensing (30-50 ° c) 24.2 kw minimum heat input (gross caloric value) 11.9 kw minimum heat output 9.7 kw minimum heat output condensing (30-50 ° c) 10.7 kw gas r...

  • Page 5: 2001

    2001 5 appliance dimensions 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 front view left side view rear view top view 480 163 900 3...

  • Page 6: 2001

    2001 6 boiler flow diagram fig. 2.

  • Page 7: 2001

    2001 7 key 1. Fixing point 5. Room sealed compartment 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 16. Fan 19. Combustion - heat exchanging compartment 20. Bur...

  • Page 8: 2001

    2001 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....

  • Page 9: 2001

    2001 9 terminal position air supply minimum clearance mm notes * if a side outlet flue is to be used, a clearance of 75 mm will be needed on the flue outlet side of the boiler. ** access to the front of the boiler must be available for maintenance (min. 600 mm). Fig. 5 fig. 4 appliance flue system a...

  • Page 10: 2001

    2001 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 flu...

  • Page 11: 2001

    2001 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: 2001

    2001 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 a...

  • Page 13: 2001

    2001 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 assem...

  • Page 14: 2001

    2001 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 ...

  • Page 15: 2001

    2001 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 2 in (50 mm), never cut it to the same length as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 50 mm !). Aluminium flue pipe lengt...

  • Page 16: 2001

    2001 16 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, slide up...

  • Page 17: 2001

    2001 17 fixing points lift here fig. 15 fixing screws fig. 16 fig. 17.

  • Page 18: 2001

    2001 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. Blue brown fig. 19 fig. 18 6.0 fitting the flue assembly 6...

  • Page 19: 2001

    2001 19 7.3 external compensation sensor (optional) 7.3.1 to be wired to terminals 7 and 8 on the appliance connector box (see fig. 18), low voltage twin wire can used. 7.3.2 external sensor location the external sensor should be installed on the north, north-west wall or on the one facing the major...

  • Page 20: 2001

    2001 20 7.4 setting of compensation curve the boiler can now be regulated to ensure the design critia of the system is matched to the outside tempera- ture 7.4.1 consult the outside compensation graph provided (fig. 19c) 7.4.2 following the bottom ouside temperature line to find the outside temperat...

  • Page 21: 2001

    2001 21 8.0 commissioning and testing 8.1 filling the central heating system fig. 20 remove the top front panel by gripping both sides, slide up to disengage lugs and pull away. Loosen the cap of the automatic air vent (fig. 20) and leave it loose. Open the central heating flow and return cocks (fig...

  • Page 22: 2001

    2001 22 p + - r override 12:31 x x 4 p auto auto i o flame viewing opening c.H. Pressure gauge c.H. Boiler thermostat fault diagnostic lights domestic hot water thermostat time clock flame failure reset knob 8.5 to light the boiler (fig. 21) a. Open controls panel door. B. Switch on electricity supp...

  • Page 23: 2001

    2001 23 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 9.7 kw (33,000 btu/h) up to 22.6 kw (77,000 btu/h). When the boiler is supplied it is factory set at the maximum output 22.6 kw (77,00...

  • Page 24: 2001

    2001 24 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 - remov...

  • Page 25: 2001

    2001 25 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...

  • Page 26: 2001

    2001 26 wiring diagram 16 fan 32 central heating pump 34 c.H. Flow temperature sensor 42 d.H.W. Temperatuure sensor 43 air pressure switch 47 modulating regulator (modureg) gas valve 49 overheat cut-off thermostat 50 heat exchan. Limit thermostat 51 heat exchan. Frost thermostat 56 expansion vessel ...

  • Page 27: 2001

    2001 27 led n ° signification: 1 mains on/low voltage on 2 flowmeter (136) on 3 central heating room thermostat (72) / clock (62) calling 4 sensor (34) or (42) calling for heat 5 central heating waiting time, max. 3 minutes delay following shut off boilerstat (63), clock (62), roomstat (72) or use o...

  • Page 28: 2001

    2001 28 general fault finding engineer please check 1. Gas available (check kitchen and gascocks) 2. Electrical mains is on. 3. Water pressure central heating system (min. 1 bar on pressure gauge) 4. Water flow domestic hot water (min. 0.5 gal/min - 2.5 l/min.) (fills a 1 pint milk bottle max. 15 se...

  • Page 29: 2001

    2001 29 fig. 30 side panel fixing screws fasteners (buckle clips) combustion chamber outer cover fixing screws electric box support fixing screws electric box cover fixing screws side panel / base plate fixing screws fasteners (buckle clips) gas valve fixing screw control panel fixing screw g) base ...

  • Page 30: 2001

    2001 30 key 16. Fan 28. Flue collector from heat exchanger fig. 32 details combustion chamber.

  • Page 31: 2001

    2001 31 fig. 34 union to be released when removing heat exchanger heat exchanger venting cap c.H. Pressure sensing point c.H. Pressure relief valve (drain point) d.H.W. Drain point c.H. Temperature thermometer phial and shim fig. 35 2.0 flowmeter (domestic hot water) and filter a) refer to section 1...

  • Page 32: 2001

    2001 32 fig. 39 3.0 honeywell gas valve (fig. 31) a) refer to section 1, items a, c, d, f, g, h (left hand side panel) and j. B) disconnect the four electrical connections from the top of the valve. C) disconnect modulating balance tube by removing the fixing screw, and gently pull off from the fron...

  • Page 33: 2001

    2001 33 6.0 d.H.W. Temperature sensor or central heating temperature sensor a) refer to section 1, items a, b, c, d, f, g, h (left hand side panel) and k. B) identify the sensor from fig. 2. C) disconnect the electrical connections to the sensor. D) unscrew the temperature sensor. E) re-assemble in ...

  • Page 34: 2001

    2001 34 10.0 pressure gauge a) refer to section 1, items a, b, (central heating), c, d, f, g and j. B) remove the shim then the temperature sensing phial from its pocket (fig. 37). C) unscrew the pressure sensor from its housing (fig. 37). (access from below). D) unscrew the knurled nut from the rea...

  • Page 35: 2001

    2001 35 12.0 removal of the clock a) refer to section 1, items a, c, d, f and j. B) disconnect the electrical connections to the time clock. C) remove the time clock from the control panel (fig. 43). D) re-assemble in reverse order (refer to fig. 43 for replacement of the time clock). Fig. 43 1.1 us...

  • Page 36: 2001

    2001 36 13.0 removal of fault diagnostic/temperature control a) refer to section 1, items a, c, d, f, and j. B) remove p.C.B. Top cover by unscrewing the two fixing screws. C) pull control box front cover forward d) disconnect electrical connections from fault diagnostic control panel e) remove rata...

  • Page 37: 2001

    2001 37 15.0 removal and re-pressurising of c.H. Expansion vessel note - if there is less than 500 mm clearance above the boiler or if the boiler has a rear flue outlet then removal of the expansion vessel can only be achieved by first removing the boiler from the wall. Note - for rear exit flues it...

  • Page 38: 2001

    2001 38 exploded view gas line, combustion chamber and draft diverter key 75 complete combustion chamber 76 combustion chamber insulation back panel 77 combustion chamber insulation side panel 78 flue collector 81 fan 87 panel isolation 88 combustion chamber panel 89 glass window 94 burner box 95 bu...

  • Page 39: 2001

    2001 39 exploded view heat exchanger + c.H. And d.H.W. Parts key 130 copper heat exchanger for c.H. + d.H.W. 131 central heating frost thermostat 132 central heating limit thermostat 133 overheat cut-off thermostat 140 automatic air vent 141 safety valve 143 central heating pump 147 d.H.W. Limit the...

  • Page 40: 2001

    2001 40 spare parts list item no. G.C. Part no. Makers part no no. Off description 14 386816 800130 1 c.H. Safety valve 16 - 803510 1 fan 21 - 803710 20 main injector (natural gas) 32 - 803690 1 central heating pump 34 386818 800310 1 temperature sensor 36 394246 801160 1 automatic air vent 39 38682...

  • Page 41: 2001

    2001 41 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 modulating regulator (modureg) of gas valve 1. Cap (with tube 71) 2. Shaft 3. Adjustment screw for max. Pressure setting 4. Adjustment scr...

  • Page 42: 2001

    2001 42 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. For details see separate instructions; «optional flue systems» top view boiler.

  • Page 43: 2001

    2001 43.

  • Page 44

    Stockton close, minworth industrial park, minworth, sutton coldfield, west midlands b76 8dh tel.: 0121/3523500 - fax 0121/3523510 all specifications subject to change phone numbers: installer service engineer because of our constant endeavour for improvement details may vary slightly from those quot...