modena 80/102- modena he

ferroli

Boiler Replacement

Modena 80/102- Modena HE

BOILER REPLACEMENT: MODENA 80/102 TO MODENA C HE

The Installation must comply with the following;

Gas Safety (Installation & Use) Regulations

The Building Regulations

The Building Regulations (Scotland)

Building Regulations (Northern Ireland)

The Water Fittings Regulations or Water Byelaws in Scotland

The Current I.E.E. Wiring Regulations -------------------------------------------------------

BS 5440: Part 1 - Flues.

BS 5440: Part 2 - Ventilation.

BS 6798 - Installation of gas fired hot water boilers

BS 7671: - Electrical wiring

BS 6891 - Gas Installation

BS 5546 - Installation of hot water supplies for domestic purposes.

BS 5449 - Forced circulation hot water systems

BS 7074 - Expansion vessels / sealed systems

BS 7593 - Treatment of water in domestic central heating systems.

Introduction

The new Ferroli Modena C HE high efficiency condensing combination boiler is an ideal replacement

for the earlier non-condensing Modena 80E or Modena 102.

The new Ferroli Modena C HE is smaller, weighs less, has built-in frost protection and an IP

protection rating of IPX5D. This allows direct replacement wherever the existing boiler is legitimately

installed (i.e. Kitchen, Garage, Bathroom, etc.)

Although the actual position of the pipe-work connections differ slightly, the configuration remains

the same, thereby requiring only limited pipe-work alteration.

The electrical connection remains the same, i.e. all models supplied with a factory fitted three core

fly - lead to provide a permanent live connection and all models use the same volt free contacts for

any external system controls.

This guide refers to the fitting of a replacement boiler with a standard horizontal flue application only (minor adjustments may be necessary for other flue applications – refer to boiler installation instructions)

The flue outlet connection on the new Modena C HE is centrally aligned and is therefore completely compatible with the earlier Modena 102. The flue connection on the Modena 80E is to the left of centre but providing that there is a minimum clearance of 35mm to the left of the existing boiler, no alteration to the existing flue position is necessary.

-----------------------------------------------------------------------------------------------------------------------------

Please note:

As with all condensing boilers it is necessary to check the existing flue terminal position to ensure that the “plume” from the combustion products will not create a ‘nuisance problem’.

A plume displacement kit is available to overcome any such problems.

Consideration must also be given for the provision of a

condensate outlet for the new boiler.

The work procedures described in this document must

be completed strictly in accordance with the

manufacturer’s installation instructions, current

regulations and relevant standards, and only by

competent person/persons as stated in the Gas Safety

(Installation & Use) Regulations.

Prior to fitting the replacement boiler the entire system

must be thoroughly cleansed and flushed in accordance

with Building Regulations L1A/L1B & BS 7593.


Fig.1

Manual Handling

When lifting take suitable safety precautions: keep your back straight, bend knees, do not turn your

body, avoid bending forward or sideways and keep the load as close as possible to your body. Ideally

seek assistance in lifting the boiler.

If possible, use a trolley or other suitable means to carry the boiler to site. Use appropriate

protective clothing and gloves to avoid injury from any sharp edges etc.

------------------------------------------------------------------------------------------------------------------------------------ REMOVE THE EXISTING MODENA 80/102

1. Removal of the outer case:

Hinge down the controls cover

panel and undo the four case

securing screws on the

underside of the boiler. Ease

the lower edge of the case

forward to clear the controls

panel and lift the case upwards

off the retaining lugs (Fig.1)

2. Safely isolate the electricity, gas and water supplies to

the appliance. Completely drain the boiler and central

heating system and disconnect all existing pipe-work

connections from the underside of the boiler (Fig.2)

3. Disconnect the electrical supply to the boiler at the 3

pin plug or fused spur and any external controls

connections at the boiler terminal block 3 & 4 – access

via the panel on the underside of the boiler (Fig. 3)

4. Disconnect and remove the flue from the existing

boiler by undoing the four screws securing the

appliance bend to the top of the boiler (Fig.4)

Case Securing Screws

Fig.2

Fig.3

Fig.4


Boiler Pack Contents

5. Ensure that all pipe connections are free, move the

base of the boiler forward and lift the boiler off the

hanging bracket tabs.

6. Finally, unscrew the hanging bracket from the wall.

7. Check that the wall surface is sound, flat and capable

of supporting the weight of the boiler. Make any necessary repairs before installing the new boiler.

INSTALL THE NEW MODENA C HE 1. Check the existing flue terminal position with

regard to possible nuisance “pluming” and plan the route for the condensate outlet.

2. Unpack the boiler and check the contents are complete and undamaged (see opposite)

Please note: The new flue kit is sold separately

3. Align the fixing template on the wall with the

existing flue hole, ensuring it is level both horizontally and vertically. Check for required minimum clearances then mark the most suitable fixing points for the hanging bracket. It is advisable to mark the position of the gas, water and heating pipes at this point (Fig.5)

4. Drill the wall and fix the hanging bracket using the wall plugs and fixings provided. Make sure the bracket is level before tightening the fixing screws

1 x Modena C HE Boiler

1 x Installation Instructions

1 x Hanging Bracket

1 x Filling Loop

1 x Valve Pack

1 x Condensate Bowl/Hose

1 x Paper Template

Fig.5


Fig.6

5. Lay the boiler on its back. Remove the front casing

panel by undoing the two securing screws on the

underside of the case. Ease the lower edge of the

panel forward to clear the controls display and lift

upwards off the frame.

6. Lift the boiler onto the hanging bracket making sure

the lugs on the bracket locate correctly with the two

support brackets on the boiler frame (Fig. 6)

FOR STANDARD HORIZONTAL TELESCOPIC FLUE INSTALLATIONS

UNPACK THE NEW TELESCOPIC FLUE KIT: CODE - 041049G0

7. Remove the protective adhesive cover from the top of the boiler to expose the flue/fixing holes. Secure the new appliance flue bend to the top of the boiler using the screws and gasket provided

8. From the outside, push the flue terminal length through the existing hole in the building fabric and align with the appliance bend.

Lubricate the seal with a suitable silicone grease and push the flue pipe fully into the into the appliance bend. Ensure the flue terminal is fitted level

Level


9. It is suggested that where possible the existing pipe-work is cut back approximately 200mm - 300mm for ease of connecting the existing pipe-work to the new valves (Fig 8)

If a stand-off bracket has been used and the pipe-work runs behind the boiler, then a new stand-off bracket will need to be fitted and pipes extended to the position previously marked. (paragraph 3.)

10. Remove the condensate bowl and hose from the boiler fittings pack. Undo plastic nut (Fig.9-A) and fit the condensate bowl and washer. Push on the rubber condensate hose to the trap outlet (Fig.9-B).

11. Connect the safety valve outlet (Fig.9-C) to the existing 15mm pipe and then connect the condensate pipe to the rubber hose outlet. Check that both terminate in accordance with – BS 6798. Take care not to interfere with the new routes for gas, water and heating pipe connections

12. Fit the valve kit to the connections on the underside of the boiler using the washers provided (Fig 10) and reconnect to the existing pipe-work.

A CH FLOW B HOTWATER OUTLET C GAS D COLD WATER INLET F CH RETURN

Fig 10

Cut existing pipes back

approx 200mm – 300mm

Fig.8

Fig.9

A B C

Condensate bowl,

washer and rubber

hose connection


13. Connect the temporary filling loop between the

cold water inlet and the CH return pipe as close to the boiler as is practical (Fig.11) Open the CH isolation valves; fill and vent the system and flush using a commissioning cleanser. During final filling add a suitable corrosion inhibitor as per BS 7593. Check for leaks REMOVE AND RETAIN THE TEMPORARY FLEXIBLE CONNECTION OF THE FILLING LOOP AND FIT THE CAPS SUPPLIED.

14. Open the cold water isolation valve and thoroughly flush the cold/hot water pipe-work by opening all the hot taps.

15. Reinstate the gas supply, purge and test in accordance with BS 6891 and IGE/UP/1.

16. Connect the boiler to the electrical supply; the boiler is provided with a 1m cable and plug. Reconnect any external controls to the volt free terminal block in the boiler.

To access the connections remove the securing screw and hinge the controls cover to the left. Connect the external controls to terminal block (72) as shown in Fig. 12.

Grommets to accept wiring from external controls are found on the right underside of the boiler.

Please note:

All electrical work must be in accordance with IEE Wiring Regulations - BS 7671:

External controls need to be compliant with Building Regulations L1A/L1B; further information is available from the “Domestic Building Services Compliance Guide”

CH HW GAS COLD CH

FLOW OUTLET WATER RETURN

Temporary filling

loop between

cold inlet &

heating return

Fig.11

Fig.12


Fig.13

Fig.14

Fig. 15

Sample points: 1 = Air / 2 = Flue Gas

17. Commissioning the boiler:

(See 3.3 of the Modena C HE Installation Instructions)

Connect a manometer to the inlet test point of the gas valve (Fig.13) Set the boiler to operate at maximum by selecting ‘TEST MODE’ and check that the operational (working) pressure at the gas inlet pressure test point is 20 mbar. A pressure of 20 mbar should be obtained with all other gas appliances operating.

To enter and exit ‘TEST MODE’, press the CH + & - buttons simultaneously for 5 seconds (Fig.14)

Please note: there may be a pressure loss across the isolation valve to the gas valve inlet test point of up to 1.3 mbar at maximum.

Remove the manometer & re-tighten the inlet test point.

18. Measure the gas rate of the boiler and check against the following table;

19. Connect the flue gas analyser to the flue sample point (Fig.15); with the boiler still in TEST MODE check that the readings are within the tolerances set out in the table below;

If the readings are satisfactory, replace the boiler front cover.

Test the correct operation of the boiler, central heating system and DHW.

Advise the customer on the operation of the new boiler and any new controls.

Complete the “Benchmark Log Book

ferroli

Ferroli Limited

Lichfield Road

Branston Industrial

Estate Burton on Trent

DE14 3HD

www.ferroli.co.uk

Boiler replacement

Calls to the above numbers are charged at national rate from BT landlines. Calls from mobile networks may be considerably more.Whilst every effort is taken to ensure the accuracy of the information contained within the brochure, the details are offered in good faith and Ferroli Ltd. accepts no liability for matters arising as a result of errors and/or omissions. The information in this brochure was correct at the time of printing, however specifications and designs may be changed owing to Ferroli’s policy of continuous product research and development. The technical specifications in the product instruction manual supersedes and should always be referred to during installation and maintenance. Reproduction of this publication, or any part, is not permitted without the written consent of Ferroli Ltd at [email protected]. The statutory rights of the consumer are not affected.

CONTACT US IN THE UK

SALES 0843 479 [email protected]

SERVICE AND TECHNICAL 0843 479 0479 [email protected]@ferroli.co.ukGENERAL ENQUIRIES

0843 479 0009 [email protected]

TWITTERtwitter.com/ferroliuk

Training Well trained installers are the key to a safe and efficient heating system. We offer a choice of training and product awareness courses on our key product range, including the Modena HE, at Ferroli’s fully equipped training centre in Burton-upon-Trent and at specialist training locations across the UK. Courses are aimed at engineers of all levels to ensure that everyone comes away with the skills and knowledge needed to deliver the first class service that customers expect and deserve. For more details visit www.ferroli.co.uk/training or ring 0843 479 0009.

Ferroli Domestic Boilers Offering gas wall mounted units with outputs of up to 50kW, Ferroli’s stylish, compact domestic boilers provide maximum comfort with minimal fuel usage. With a choice of conventional, condensing and combi technologies, there’s a boiler to match the heating and hot water requirements of every home.

Ferroli Commercial and Industrial Boilers Ferroli commercial boilers for pressure jet oil, forced air gas or dual fuel are factory matched with high efficiency burners to provide outputs of up to 12,350kW, whilst meeting the strictest emissions demands.

Ferroli Spares The popularity of Ferroli as first choice for both domestic and commercial installations means that heating parts stockists offer readily available spares for Ferroli boilers. Ferroli has a UK-based fully stocked warehouse enabling same-day despatch of just about any part needed to keep your Ferroli boiler running.

Modena 80/102- Modena HE

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modena 80/102- modena he

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