ferroli Boiler Replacement Maxima 35C- Modena HE

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1 ferroli Boiler Replacement Maxima 35C- Modena HE

2 Introduction Although the new Ferroli Modena 32C HE high efficiency condensing combination boiler has an output slightly less than that of the Ferroli Maxima 35C it will, in the vast majority of cases, be an ideal replacement. The installer will need to check the overall heating requirements of the property, but rarely is the maximum output required solely for central heating; often the main concern being related to the performance of the domestic hot water. The DHW performance of the new Ferroli Modena 32C HE is almost equal to that of the Maxima 35C t 30 0 ; Modena 32C HE = 15.3 l/m - Maxima 35C = 16.5 l/m) The 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. The flue outlet connection on the new Modena C HE is centrally aligned and is therefore completely compatible with the earlier Ferroli Maxima 35C Please note: 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 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 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 Installation of gas fired hot water boilers BS 7671: - Electrical wiring BS Gas Installation BS Installation of hot water supplies for domestic purposes. BS Forced circulation hot water systems BS Expansion vessels / sealed systems BS Treatment of water in domestic central heating systems.

3 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 REMOVING THE EXISTING MAXIMA 35C Fig.1 1. Remove the front panel by undoing the two case securing screws (A) on the underside of the boiler. Ease the lower edge of the front panel forward (B) to clear the controls facia and lift the panel 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) Fig.2 3. Disconnect the electrical supply to the boiler at the 3 pin plug or fused spur. Remove the securing screws (❷) and lower the controls facia panel (❸) (Fig.3) Fig.3

4 4. Undo the securing screw and remove the cover (❹) to access the terminal block at the right hand side of the control facia. Disconnect the mains electrical supply lead and any external controls connections at the terminal block. (Fig.4) Fig.4 5. 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.5) Fig.5 Fig.6 6. Ensure that all pipe connections are free, move the base of the boiler forward and lift the boiler off the hanging bracket tabs and unscrew the hanging bracket from the wall. (Fig.6) 7. Finally, 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.

5 8. It is suggested that where possible the existing pipework is cut back approximately 200mm - 300mm for ease of connecting the existing pipe-work to the new valves (Fig 7) 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 new valve positions (see below; paragraph 3-Fig.5) Fig.7 Cut existing pipes back approx 200mm 300mm INSTALLING THE NEW MODENA C HE 1. Check the existing flue terminal position with regard to possible nuisance pluming. A plume displacement kit is available to overcome any such problems. 2. Unpack the boiler and check the contents are complete and undamaged (see opposite) Please note: The new flue kit is sold separately Boiler Pack Contents 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 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) 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

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) Fig.6 FOR STANDARD HORIZONTAL TELESCOPIC FLUE INSTALLATIONS UNPACK THE NEW TELESCOPIC FLUE KIT: CODE G0 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 8. appliance Level bend. Ensure the flue terminal is fitted level.

7 9. 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). Condensate bowl, washer and rubber hose connection 10. Connect the safety valve outlet (Fig.9-C) to the existing 15mm discharge pipe and then connect the existing condensate pipe to the rubber hose outlet. Check that both terminate in accordance with BS Take care not to interfere with the new routes for gas, water and heating pipe connections Fig.9 C B A 11. 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 B C D F CH FLOW HOT WATER OUTLET GAS COLD WATER INLET CH RETURN Fig Connect the temporary filling loop between the cold water inlet and the C H 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 Check for leaks REMOVE AND RETAIN THE TEMPORARY FLEXIBLE CONNECTION OF THE FILLING LOOP AND FIT THE CAPS SUPPLIED Fig.11 CH HW GAS COLD CH FLOW OUTLET WATER RETURN Temporary filling loop between cold inlet & heating return

8 13. Open the cold water isolation valve and thoroughly flush the cold/hot water pipe-work by opening all the hot taps. 14. Reinstate the gas supply, purge and test in accordance with BS 6891 and IGE/UP/ 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. 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

9 16. Commissioning the boiler: (see 3.3 of the Modena C HE Installation Instructions) Fig.13 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. To enter and exit TEST MODE, press the CH + & - buttons simultaneously for 5 seconds (Fig.14) A pressure of 20 mbar should be obtained with all other gas appliances operating. 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. Fig Measure the gas rate of the boiler and check against the following table; Fig 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; Sample points: 1 = Air / 2 = Flue Gas 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

10 ferroli Boiler replacement 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 or ring 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. Maxima 35C- Modena HE CONTACT US IN THE UK SALES SERVICE AND TECHNICAL GENERAL ENQUIRIES TWITTER twitter.com/ferroliuk Ferroli Limited Lichfield Road Branston Industrial Estate Burton on Trent DE14 3HD 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 The statutory rights of the consumer are not affected.

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