ENERGY TOP W 70 - W 80 - W 125
Contents
1. 4 4 Technical data table The column on the right gives the abbreviation used on the dataplate Data Unit Value Value Value wy Model ENERGY TOP W 70 ENERGY TOP W 80 ENERGY TOP W 125 Max heating capacity kW 65 9 75 116 Q Min heating capacity kW 17 17 25 Q Max Heat Output in heating 80 60 C kW 64 6 73 5 113 7 P Min Heat Output in heating 80 60 C kW 16 7 16 7 24 6 P Max Heat Output in heating 50 30 C kW 69 9 79 5 123 P Min Heat Output in heating 50 30 C kW 18 3 18 3 26 9 P Efficiency Pmax 80 60 C 98 98 98 Efficiency Pmin 80 60 C 98 5 98 5 98 5 Efficiency Pmax 50 30 C 106 106 106 Efficiency Pmin 50 30 C 107 5 107 5 107 5 Efficiency 30 109 109 109 Gas diaphragm G20 8 50 8 50 9 4 Gas supply pressure G20 mbar 20 20 20 CO max G20 9 9 9 direi CO min G20 8 5 8 5 8 5 Max gas delivery G20 m3 h 6 97 7 94 12 38 Min gas delivery G20 m3 h 1 8 1 8 2 65 Gas diaphragm G31 5 8 5 8 7 0 Gas supply pressure G31 mbar 37 37 37 CO max G31 10 10 10 CO min G31 9 2 9 2 9 2 Max gas delivery G31 kg h 5 16 5 87 9 08 Min gas delivery G31 kg h 1 33 1 33 1 96 Efficiency class Directive 92 42 EEC AAA A AAA A KA AA NOx emission class 5 5 5 NOx Max fume temperature 80 C 60 C 65 65 65 Min fu2. COMMISSIONING ENG S NAME PRINT CORGI ID No SIGN DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SERVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID
3. P d 6 8 14 7 fig 1 Control panel Key 1 DHW temperature setting decrease button with 12 Eco Economy mode with optional hot water optional hot water tank installed tank installed 2 DHW temperature setting increase button with 13 Heating mode optional hot water tank installed 14 Unit On Off button 3 Heating system temperature setting decrease 15 Burner button 16 Appears on connecting the Remote Timer Con 42 Heating system temperature setting increase trol optional button 17 Information symbol 5 Display 18 Arrow symbol 6 Summer Winter mode selection button 20 Fault 75 Economy Comfort mode selection with optional 21 Circulating pump On Lh hot water tank installed and unit On Off button 22 Appears on connecting the external probe op 8 Reset button tional 9 DHW operation with optional hot water tank in 23 Boiler Off stalled 25 Fault reset request 10 Summer mode 11 Multifunction cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli Indication during operation Heating A heating demand generated by the Room Thermostat or Remote Timer Control or 0 10 Vdc signal is indicated by activation of the circulating pump and the radiator details 13 and 21 fig 1 The display detail 11 fig 1 shows the actual heating delivery temperature and during DHW standby time the mes sage d
4. A ENERGY TOP W 70 W 80 65 ENERGY TOP W 125 63 17 Heating system delivery 32 Gas inlet 5 Heating system return 26 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli 4 2 General view and main components fig 29 General view Model ENERGY TOP W 70 W 80 Pd Model ENERGY TOP W 125 Fan Fume outlet manifold Automatic air vent Gas valve Detection electrode Water pressure switch Return sensor Ignition electrode Fume temperature sensor Condensate tray Air inlet reducer Ignition card Double sensor Safety Heating 27 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 4 3 Plumbing circuit pi 666666666666 D 10 fig 30 Plumbing circuit 7 Gas inlet 82 LY 10 System delivery 114 11 System return 154 16 Fan 186 22 Main burner 188 29 Fume outlet manifold 193 36 Automatic air vent 196 44 Gas valve 278 Sa ON TCR mo 188 gt NE 11 Detection electrode Water pressure switch Condensate outlet pipe Return sensor Ignition electrode Trap Condensate tray Double sensor Safety Heating 28 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 Ferroli
5. Press the button detail 7 fig 1 for 5 seconds fig 5 Turning the boiler off When the boiler is turned off the electronic board is still powered Domestic hot water with optional hot water tank installed and heating operation are disabled The antifreeze system remains activated cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli To relight the boiler press the button cmon detail 7 fig 1 again for 5 seconds reset comfort fig 6 The boiler will be immediately ready to operate whenever domestic hot water is drawn with optional hot water tank in stalled or in case of a room thermostat demand To completely disconnect the power to the unit press the button detail 14 fig 1 The antifreeze system does not work when the power and or gas to the unit are turned off To avoid damage caused by freezing during long idle periods in winter it is advisable to drain all water from the boiler DHW circuit and system or drain just the DHW circuit and add a suitable antifreeze to the heating system complying with that prescribed in sec 2 3 1 4 Adjustments Summer Winter changeover Press the button detail 6 fig 1 for 1 second fig 7 The display activates the Summer symbol detail 10 fig 1 The heating function is deactivated whereas the possible production of do
6. fig 2 DHW circuit with optional hot water tank installed A hot water tank heating demand is indicated by activation of the circulating pump and the tap details 9 and 21 fig 1 The display detail 11 fig 1 shows the actual hot water tank sensor temperature and during heating standby time the message d Exclude hot water tank economy Hot water tank temperature maintaining heating can be excluded by the user If excluded domestic hot water will not be delivered The hot water tank can be deactivated by the user ECO mode by pressing the button 5 detail 7 fig 1 In ECO mode the display activates the symbol detail 12 fig 1 To activate COMFORT mode press the button feien detail 7 fig 1 again cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 1 3 Turning on and off Boiler lighting Press the On Off button detail 14 fig 1 fig 4 Boiler lighting en For the following 120 seconds the display will show FH which identifies the heating system air venting cycle During the first 10 seconds the display will also show the card software release A Display card software release B Controller software release Open the gas valve ahead of the boiler When the message FH disappears the boiler is ready to operate automatically in case of a room thermostat de mand Turning the boiler off
7. 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli Activating TEST mode Press the heating buttons DO details 3 and 4 fig 1 at the same time for 5 seconds to activate the TEST mode The boiler lights at the maximum heating power set as described in the following section The heating symbol detail 13 fig 1 and DHW symbol detail 9 fig 1 flash on the display the heating power will be displayed alongside fig 25 TEST mode heating power 100 To deactivate TEST mode repeat the activation sequence In any case TEST mode is disabled automatically after 15 minutes Heating power adjustment To adjust the heating power switch the boiler to TEST mode see sec 3 1 Press the heating buttons DO details 3 and 4 fig 1 to increase or decrease the power min 00 max 100 Press the button detail 8 fig 1 within 5 seconds max power will remain that just set Exit TEST mode see sec 3 1 3 2 Start up Checks to be made at first lighting and after all maintenance operations that involved disconnection from the systems or an operation on safety devices or parts of the boiler Before lighting the boiler Open any on off valves between the boiler and the systems Check the tightness of the gas system proceeding with caution and using a soap and water solution to detect any leaks in connections Check correct prefilling of the expansion tank ref sec 4 4 Fill
8. Wiring diagram 16 Fan 138 External probe not supplied 32 Heating circulating pump not supplied 139 Remote timer control not supplied 42 DHW temperature sensor not supplied 186 Return sensor 44 Gas valve 191 Fume temperature sensor 72 Room thermostat not supplied 278 Double sensor Safety Heating 81 Ignition electrode 298 Cascade temperature sensor not supplied 82 Detection electrode 299 Input 0 10 Vdc 95 Diverter valve not supplied 300 Burner On contact voltage free contact 98 Switch 301 Fault contact voltage free contact 114 Water pressure switch 302 Remote reset input 230 Volt 31 cod 35401161 12 2008 Rev 00 BENCHMARK No 2 6 7 ben ch Ori f N Please add the first 4 digits of the Boiler serial No to complete the BENCHMARK No BOILER SERIAL No NOTIFICATION No CONTROLS comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL
9. 80 ENERGY TOP W 125 Coaxial 80 125 Coaxial 80 125 Max permissible length 4m 2m Reduction factor 90 bend 0 5m 0 5m Reduction factor 45 bend 0 25 0 25 m 17 EN cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 Connection with separate pipes Wo fig 22 Examples of connection with separate pipes Z gt Air ii Fumes Separate 280 ducts can be connected directly to the unit Before proceeding with installation make sure the maximum permissible length has not been exceeded by means of a simple calculation 1 Completely establish the layout of the system of split flues including accessories and outlet terminals 2 Consult the table 4 and identify the losses in Meg equivalent metres of every component according to the instal lation position 3 Check that the sum total of losses is less than or equal to the maximum permissible length in table 3 Table 3 Max length separate ducts Separate ducts ENERGY TOP W 70 W 80 ENERGY TOP W 125 Max permissible length 20 Meg 10 Meg Table 4 Accessories Losses in Meg Air Fume exhaust inlet Vertical Horizontal 80 PIPE 1mM F 1KWMA83W 1 0 1 6 2 0 BEND 45 M F 1KWMA65W 1 2 1 8 90 M F 1KWMAO1W 1 5 2 0 PIPE SECTION with test point 1KWMA7OW 0 3 0 3 TERMINAL air wall 1KWMA85A 2 0 fumes wall wit
10. BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m3 hr ft hr BURNER OPERATING PRESSURE IF APPLICABLE NA mbar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES nol WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE m hr f amp hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES _ FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS I IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A COICO RATIO READING YES CO CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
11. Wiring shorted Check the wiring or replace the sensor Wiring disconnected No 230V power supply Check the 3 pole connector wiring F15 Fan fault Tachometric signal interrupted Check the 5 pole connector wiring Fan damaged Check the fan F34 Supply voltage under 170V Electric mains trouble Check the electrical system F35 Irregular mains frequency Electric mains trouble Check the electrical system Pressure too low Fill the system F37 Incorrect system water N m pressure ater pressure switch not con Gh ck the sensor nected or damaged Probe damaged oF wiring Check the wiring or replace the sensor shorted F39 External probe fault Probe disconnected after acti Reconnect the external probe or disable the sliding vating the sliding temperature temperature dic Delivery sensor disconnected Check the correct positioning and operation of the A41 Sensor positioning from the pipe heating sensor F42 Heating sensor fault Sensor damaged Replace the sensor No communication Controller not connected Connect the controller to the gas valve A62 between electronic control ler and gas valve Damaged valve Change the valve cod 35401161 12 2008 Rev 00 25 Ferroli ENERGY TOP W 70 W 80 W 125 4 Technical data and characteristics 4 1 Dimensions and connections fig 28 Dimensions and connections
12. boiler operating at max and min output corresponds to that given in the technical data table for the corresponding type of gas Make sure the fuel consumption indicated on the meter matches that given in the technical data table on sec 4 4 Check the correct programming of the parameters and carry out any necessary customization compensation curve power temperatures etc Maintenance Periodical check To keep the unit working properly over time it is necessary to have qualified personnel make an annual check that in cludes the following tests The control and safety devices gas valve flow meter thermostats etc must function correctly The fume extraction circuit must be fully efficient The airtight chamber must be sealed The air fume end piece and ducts must be free of obstructions and leaks The condensate evacuation system must be efficient with no leakage or obstructions The burner and exchanger must be clean and free of scale When cleaning do not use chemical products or wire brushes The electrode must be free of scale and properly positioned The gas and water systems must be airtight The water pressure in the cold water system must be about 1 bar otherwise bring it to that value The circulation pump must not be blocked The expansion tank must be filled The gas flow and pressure must correspond to that given in the respective tables The boiler casing panel and aesthetic parts can be cleaned with a sof
13. of the heating system is adjusted according outside weather conditions in order to ensure high comfort and en ergy saving throughout the year In particular as the outside temperature increases the system delivery temperature decreases according to a given compensation curve With Sliding Temperature adjustment the temperature set with the heating buttons C O details 3 and 4 fig 1 becomes the maximum system delivery temperature It is advisable to set a maximum value to allow system adjustment throughout its useful operating range The boiler must be adjusted at the time of installation by qualified personnel Possible adjustments can in any case be made by the user to improve comfort cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli Compensation curve and curve offset Press the button detail 8 fig 1 for 5 seconds to display the actual compensation curve fig 10 which can be modified with the buttons OC details 1 and 2 fig 1 Adjust the required curve from 1 to 10 according to the characteristic fig 12 By setting the curve to 0 sliding temperature adjustment is disabled wy LUDA fig 10 Compensation curve Press the heating buttons Cc details 3 and 4 fig 1 to access parallel curve offset fig 13 modifiable with the DHW buttons details 1 and 2 fig 1 iri fig 11 Parallel curve offset Press the button de
14. the water system and make sure all air contained in the boiler and the system has been vented by opening the air vent valve on the boiler and any vent valves on the system Fill the condensate trap and check correct connection of the condensate elimination system Make sure there are no water leaks in the system DHW circuits connections or boiler Check correct connection of the electrical system and efficiency of the earthing system Make sure the gas pressure value for heating is that required Make sure there are no flammable liquids or materials in the immediate vicinity of the boiler 21 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 Checks during operation 3 3 Turn the unit on as described in sec 1 3 Make sure the fuel circuit and water systems are tight Check the efficiency of the flue and air fume ducts while the boiler is working Check the correct tightness and functionality of the condensate elimination system and trap Make sure the water is circulating properly between the boiler and the systems Make sure the gas valve modulates correctly in the heating and domestic hot water production phases Check proper boiler lighting by doing several tests turning it on and off with the room thermostat or remote control Using a combustion analyser connected to the boiler fume outlet check that the co content in the fumes with the
15. 1 Dimensions and connections ssssssseene n menn nenne nnnn nnn nsn nn nnn nnne nenne nna 26 4 2 General view and main components cccccccecceceeceeeeeeeeeeeeeeeeeeeeecnnnnneaeeceeeeeeeeeeeeeeeeeeeseeeseseeesenseeseees 27 28 444 Technicalidata table cisions octets As ae REALS Rane 29 4 5 DIAGRAMS TEE 30 4 6 Wining CIA QUAN EUER 31 ANI cod 35401161 12 2008 Rev 00 3 Ferroli ENERGY TOP W 70 W 80 W 125 1 Operating instructions 1 1 Introduction uu Dear Customer Thank you for choosing ENERGY TOP W 70 W 80 W 125 a wall mounted boiler featuring FERROLI advanced de sign cutting edge technology high reliability and quality construction Please read this manual carefully since it pro vides important information on safe installation use and maintenance ENERGY TOP W 70 W 80 W 125 is a high efficiency low emissions sealed chamber premix condensing heat gen erator for heating running on natural gas or LPG and equipped with a microprocessor control system The boiler shell consists of an aluminium finned tube exchanger and a premix burner in steel equipped with electronic ignition and ionisation flame control a modulating speed fan and a modulating gas valve ENERGY TOP W 70 W 80 W 125 is a heat generator arranged to operate alone or in cascade 1 2 Control panel 16 17 18 2023 5
16. CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE FERROLI TECHNICAL HELPLINE 08707 282 885 Should you require any assistance during the installation call our Technical Service Helpline on 08707 282 885 option 1 Should you require a service engineer to visit call our service centre on 08707 282 885 option 2 For U K and Northern Ireland For EIRE only call HEATOVENT on 014508166 Phone numbers Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS Ferroli ALL SPECIFICATIONS SUBJECT TO CHANGE Please note to avoid incurring unnecessary expense in the event of a boiler shut down check this is not caused by lack of electricity supply gas supply or low water pressure before calling our Customer Service Helpline Lichfield Road Branston Industrial Estate Burton Upon Trent Staffordshire DE14 3HD Tel 08707 282 885 Fax 08707 282 886 EIRE only HEATOVENT Greenhills Industrial Estate Greenhills Road Walkinstown Dublin 12 IRELAND Tel 014508166 Fax 014508501
17. Ferroli ENERGY TOP W 70 W 80 W 125 cme UAR INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE INSTRUCTIONS D UTILISATION D INSTALLATION ET D ENTRETIEN ISTRUZIONE PER L USO L INSTALLAZIONE E LA MANUTENZIONE INSTRUCCIONES DE USO INSTALACION Y MANTENIMIENTO BETRIEBS INSTALLATIONS UND WARTUNGSANLEITUNG cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 A Carefully read the warnings in this instruction book let since they provide important information on safe installation use and maintenance This instruction booklet is an integral part of the product and must be carefully kept by the user for fu ture reference If the unit is sold or transferred to another owner or if itis to be moved always make sure that the booklet accompanies the boiler so that it can be consulted by the new owner and or installer Installation and maintenance must be carried out by professionally qualified personnel according to cur rent regulations and the manufacturer s instructions Incorrect installation or poor maintenance can cause damage or physical injury The manufacturer de clines any responsibility for damage caused by er rors in installation and use or by failure to follow the manufacturer s instructions Before carrying out any cleaning or maintenance op eration disconnect the unit from the electrical power supply using the switch and or the special cut off de vices I
18. anged to operate alone or in cascade bank When two or more generators ENERGY TOP W 70 W 80 W 125 are installed in cascade with the original kits FER ROLI respecting the prescriptions of this manual they can be considered as a single heat generator of total power equal to the sum of the powers of all the units connected in cascade All the requirements of the current standards and regulations applicable to this equivalent generator with total heating capacity must be met In particular the place of installation safety devices and fume exhaust system must be adequate for the total heating capacity of the bank of units In fact each ENERGY TOP W 70 W 80 W 125 is a complete and independent heat generator equipped with its own safety devices In case of overtemperature a lack of water or no circulation in the unit the protection devices cause the unit to switch off or shut down preventing it from working The installation instructions given in the following paragraphs concern both single units and connection in cascade 2 2 Place of installation The combustion circuit is sealed with respect to the place of installation and therefore the unit can be installed in any room However the place of installation must be sufficiently ventilated to prevent the creation of any dangerous condi tions in case of even small gas leaks This safety precaution is required by EEC Directive no 90 396 for all gas fired units including those with a
19. d relieves the manufacturer of any liability For fume ducts longer than 1 m during installation take in account the natural expansion of the materials when the boiler is operating To prevent deformations leave an expansion space of approx 2 4 mm for every metre of pipe 2 4mm fig 19 Expansion 16 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli Connection with coaxial pipes a 9 gl fig 20 Examples of connection with coaxial pipes gt Air mp Fumes For coaxial connection fit the unit with one of the following starting accessories For the wall hole dimensions refer to sec 4 1 Any horizontal sections of the fume exhaust must be kept sloping slightly towards the boiler to prevent pos sible condensate from flowing back towards the outside and causing dripping 167 225 o8b 80 120 fig 21 Starting accessories for coaxial ducts 041007X0 Before proceeding with installation check with table 2 that the maximum permissible length is not exceeded bearing in mind that every coaxial bend gives rise to the reduction indicated in the table For example a 80 125 duct comprising a 90 bend 1 horizontal metre has a total equivalent length of 1 5 metres Table 2 Max length coaxial ducts ENERGY W 70 W
20. ed water Antifreeze system antifreeze fluids additives and inhibitors The boiler is equipped with an antifreeze system that turns on the boiler in heating mode when the system delivery water temperature falls under 6 C The device will not come on if the electricity and or gas supply to the unit are cut off If it becomes necessary it is permissible to use antifreeze fluid additives and inhibitors only if the manufacturer of these fluids or additives guarantees they are suitable for this use and cause no damage to the heat exchanger or other com ponents and or materials of the boiler unit and system It is prohibited to use generic antifreeze fluid additives or inhib itors that are not expressly suited for use in heating systems and compatible with the materials of the boiler unit and system Optional kits The following kits are available on request fig 15 Optional Kits 1 code 042021X0 High head PUMP KIT H m a DON CO 0 4 2 3 4 5 6 7 Q m h fig 16 Pump head 13 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 2 code 042023X0 3 way COCK KIT Male 1 1 2 with non return valve and safety valve It enables shutting off for maintenance operations in conformity with ISPESL requi
21. h antiwind 1KWMA86A 5 0 18 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli 2 7 Condensate drain connection The boiler is equipped with a trap to drain condensate Carry out the following instructions for fitting 1 Fix the support bracket A to the bottom of the boiler 2 Connect the preformed black tube B to the condensate drain S on the bottom of the boiler fixing it with a clamp 3 Remove the trap ring nut C and insert the preformed black tube B in the special opening making sure to fit the w seal D Refit the trap ring nut insert it in the bracket and fix with the special clip E Connect the flexible tube F from the trap to the condensate drain system eu fig 23 Condensate drain connection cod 35401161 12 2008 Rev 00 19 Ferroli ENERGY TOP W 70 W 80 W 125 3 Service and maintenance All adjustment conversion startup and maintenance operations described below must only be carried out by Qualified Per sonnel meeting the professional technical requirements prescribed by current regulations such as those of the Local After Sales Technical Service FERROLI declines any liability for damage and or injury caused by unqualified and unauthorised people tampering with the unit 3 1 Adjustments Gas conversion The unit can operate on Natura
22. l Gas or LPG and is factory set for use with one of these two gases as clearly shown on the packing and on the dataplate Whenever a different gas to that for which the unit is arranged has to be used a conversion kit will be required proceeding as follows 1 a Na Remove the casing 2 Loosen the gas valve fixing ring 3 4 Undo the three fixing screws and remove the gas valve C Replace the gas valve D positioning it inside the gasket E with that contained in the conversion kit Refit the parts and check the tightness Modify the parameter for the type of gas put the boiler on standby press the DHW buttons details 1 and 2 fig 1 at the same time for 10 seconds the display shows P01 flash ing press the DHW buttons details 1 and 2 fig 1 at the same time to set the parameter 00 for natural gas or 01 for LPG press the DHW buttons details 1 and 2 fig 1 at the same time for 10 seconds the boiler will go back on standby Apply the label contained in the conversion kit near the dataplate Using a combustion analyser connected to the boiler fume outlet make sure the CO content in the fumes with the boiler operating at max and min output matches that given in the technical data table for the corresponding type of gas fig 24 Gas conversion Model ENERGY TOP W 70 W 80 Model ENERGY TOP W 125 20 cod 35401161
23. lowing EU directives Gas Appliance Directive 90 396 Efficiency Directive 92 42 Low Voltage Directive 73 23 amended by 93 68 Electromagnetic Compatibility Directive 89 336 amended by 93 68 President and Legal Representative Cav del Lavoro Dante Ferroli cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli 1 Operating 4 A 4 1 2 Control Pamel 4 1 3 Turning on off SRRRRR 6 1 5 7 Z Installation siria aaa adas 12 2 1 Goneral INSHFUCTIONS 0onni 12 2 2 Place OF installaatio ooo ooo 12 2 3 Plumbing 5 rcm 12 24 GAS COMMECUOM IN 14 2 5 Electrical 14 VASE FUMe QUES RETENIR 16 2 7 Condensate drain 19 3 Service and maintenandce s ica 20 NN 20 eare e T e E T TE E T 21 39 MAINTE MANGE PERAE EEEE E E AS E E E E E 22 3 4 eud eij me 24 4 Technical data and characteristics 26 4
24. me temperature 80 C 60 C 60 60 60 Y Max fume temperature 50 C 30 C 43 43 45 Min fume temperature 50 C 30 C 33 33 34 Max fume flowrate kg h 127 5 127 5 197 Min fume flowrate kg h 31 4 31 4 44 7 Max working pressure in heating bar 6 6 6 PMS Min working pressure in heating bar 0 8 0 8 0 8 Max heating temperature 95 95 95 tmax Heating water content litres 5 5 7 Protection rating IP X5D X5D X5D Power supply voltage V Hz 230V 50Hz 230V 50Hz 230V 50Hz Electrical absorption 70 95 200 Empty weight kg 46 46 51 Type of unit 7 Ogg Baz 0461850879 29 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 4 5 Diagrams Pressure losses 1 mC A e gt o o a m3 h mC A m3 h fig 31 Pressure loss diagrams A Boiler pressure losses Model diagram ENERGY TOP W 70 W 80 Model diagram ENERGY TOP W 125 Na 30 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli 4 6 Wiring diagram DBM12R DBM12K v1 44 278 OROA ROROROROROROA RO 4 5 6 7 10 1 12 14 45 FUSE id BABA e E uii 9 300 301 302 95 fig 32
25. mestic hot water with optional external hot water tank remains activated The antifreeze system re mains activated To deactivate Summer mode press the button detail 6 fig 1 again for 1 second cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 Heating temperature adjustment Operate the heating buttons DO details 3 and 4 fig 1 to adjust the temperature from a min of 20 C to a max of 90 C fig 8 DHW temperature adjustment with optional hot water tank installed Operate the DHW buttons D details 1 and 2 fig 1 to adjust the temperature from a min of 10 C to a max of 65 C fig 9 Room temperature adjustment with optional room thermostat Using the room thermostat set the temperature required in the rooms Room temperature adjustment with optional remote timer control Using the remote timer control set the temperature desired in the rooms The boiler unit will set the system water ac cording to the required room temperature For information on the remote timer control please refer to its user s manual Sliding Temperature When the optional external probe is installed the corresponding symbol detail 22 fig 1 is activated on the control panel display detail 5 fig 1 The boiler control system operates with Sliding Temperature In this mode the temper ature
26. mmended Accessing the electrical terminal block To access the terminal block A fig 18 it is necessary to remove the front panel see fig 26 remove the fixing screw B and turn the control panel as indicated in fig 18 The layout of the terminals for the various connections is also given in the wiring diagram in fig 32 fig 18 Accessing the terminal block 15 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 2 6 Fume ducts The unit is a type with sealed chamber and forced draught the air inlet and fume outlet must be connected to one of the extraction inlet systems indicated below The unit is approved to work with all the Cxy and Bxy flue configurations given on the dataplate some configurations are given by way of example in this section Some configurations howev er may be expressly limited or not permitted by local regulations standards or laws Before proceeding with installation check and carefully observe the relevant prescriptions Also comply with the provisions concerning the positioning of wall and or roof terminals and the minimum distances from windows walls ventilation openings etc This C type unit must be installed using the inlet and fume exhaust ducts supplied by the manufacturer in con formity with UNI CIG 7129 92 Failure to use them automatically invalidates every warranty an
27. n case the unit breaks down and or functions poorly deactivate it do not make any attempt to repair it or directly intervene Contact professionally qualified personnel Any repair replacement of products must only be carried out by qualified professional person nel using exclusively genuine parts Failure to com ply with the above could affect the safety of the unit Periodical maintenance carried out by qualified per sonnel is essential for guaranteeing good operation of the unit This unit must only be used for the purpose for which it was designed Any other use is considered im proper and therefore hazardous After removing the packing check the integrity of the contents Packing materials must not be left within the reach of children as they are potentially hazard ous In case of doubt do not use the unit and contact the supplier The images shown in this manual are a simplified representation of the product In this representation there may be slight unimportant differences with the supplied product This symbol indicates Caution and is placed next to all safety warnings Strictly follow these instructions in order to avoid danger and damage to persons animals and things A This symbols calls attention to a note or important notice Declaration of conformity Manufacturer FERROLI S p A Address Via Ritonda 78 a 37047 San Bonifacio VR Italy declares that this unit complies with the fol
28. press the RESET button detail 8 fig 1 for 1 second or use the RESET on the optional remote timer control if installed if the boiler fails to start it is necessary to first eliminate the fault Other faults marked with the letter F cause temporary shutdowns that are automatically reset as soon as the value returns within the boiler s normal working range Table 5 List of faults Faut Fault Possible cause Cure code Check the regular gas flow to the boiler and that the air No gas do has been eliminated from the pipes Detection ignition electrode fault at ites pc of pn that it is correctly 01 The burner fails to light posionec Ceposits Faulty gas valve Check the gas valve and replace it if necessary Insufficient gas supply pressure Check the gas supply pressure Trap blocked Check the trap and clean it if necessary m Flame present signal with Electrode fault Check the ionisation electrode wiring burner off Card fault Check the card Heating sensor damaged Check the correct positioning and operation of the heating sensor A03 protection No water circulation in the sys activation tem Check the circulating pump Air in the system Vent the system Fume extraction duct safety Fault F07 generated 3 times in See fault F07 A04 device activation the last 24 ho
29. rements and can be used as a local shutoff for the connection of several units in bank The third way must be connected to an atmospheric discharge manifold In this way with the valve in the open position the boiler ex changer is connected to the delivery manifold and in the closed position through the third way the exchanger communicates with the atmospheric discharge manifold This valve therefore also acts as a boiler discharge 3 code 042022X0 COCK KIT Male Female 1 1 2 In combination with the 3 way valve described above it enables shutting off for maintenance opera tions in conformity with ISPESL requirements and can be used as a local shutoff for the connection of several units in bank 2 4 Gas connection Before making the connection ensure that the unit is arranged for operation with the type of fuel available and carefully clean all the gas system pipes to remove any residuals that could affect boiler operation The gas must be connected to the relevant connection see cap 2 3 Plumbing connections in conformity with current standards with a rigid metal pipe or with a continuous flexible s steel tube installing a gas cock between the system and boiler Make sure all the gas connections are tight The gas meter capacity must be suitable for the simultaneous use of all the units connected to it The diameter of the gas pipe leaving the boiler does not determine the diameter of the pipe between the unit and the meter it m
30. rwise if the discharge valve cuts in and floods the room the boiler manufacturer cannot be held liable Do not use the water system pipes to earth electrical appliances Before installation carefully wash all the pipes of the system to remove any residuals or impurities that could affect prop er operation of the unit A filter must be also installed on the system return piping to prevent impurities or sludge from the system clog ging and damaging the heat generators The filter MUST be installed when replacing generators in existing systems The manufacturer declines any liability for damage caused to the generator by failure to install or inadequate installation of this filter Carry out the relevant connections according to the diagram in sec 4 1 and the symbols given on the unit 12 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli System water charcteristics In the presence of water harder than 25 Fr 1 F 10ppm CaCO the use of suitably treated water is advisable in order to avoid possible scaling in the boiler The treatment must not in any case reduce the hardness to values below 15 F Decree 236 88 for uses of water intended for human consumption Water treatment is indispensable in the case of very large systems or with frequent replenishing of water in the system If partial or total emptying of the system be comes necessary in these cases it is advisable to refill it with treat
31. so called sealed chamber The unit can also work with air drawn from the installation room B type In this case the room must be provided with adequate ventilation according to current regulations Therefore the place of installation must be free of dust flammable materials or objects or corrosive gases The room must be dry and not subject to freezing The boiler is arranged for wall installation Wall fixing must ensure a stable and effective support for the generator If the unit is enclosed in a cabinet or mounted alongside a space must be provided for removing the casing and for normal maintenance operations 2 3 Plumbing connections The heating capacity of the unit must be previously established by calculating the building s heat requirement according to current regulations The system must be provided with all the components for proper and regular operation In par ticular provide for all the protection and safety devices required by current regulations for the complete modular gener ator They must be installed on the hot water circuit delivery piping immediately downstream of the last module within a distance of 0 5 m with no shutoff devices in between The unit is not supplied with an expansion tank its connection must therefore be carried out by the Installer The safety valve outlet must be connected to a funnel or collection pipe to prevent water spurting onto the floor in case of overpressure in the heating circuit Othe
32. t damp cloth possibly soaked in soapy water Do not use any abrasive detergents and solvents 22 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli Opening the casing To open the boiler casing fig 26 1 Undo the screws A 2 Open turning the casing B 3 Lift and remove the casing B BY Fo fig 26 Opening the casing Combustion analysis Combustion can be analysed through the air sampling point detail 2 and fume sampling point detail 1 shown in fig 27 To perform the test Open the air and fume sampling points Insert the probes Press the and buttons for 5 seconds to activate the TEST mode Wait 10 minutes for the boiler to stabilise Take the measurement guido For natural gas the CO reading must be between 8 7 and 9 For LPG the CO reading must be between 9 5 and 10 IS Analyses made with an unstabilised boiler can cause measurement errors fig 27 Combustion analysis 23 cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 3 4 Troubleshooting Diagnostics The boiler is equipped with an advanced self diagnosis system In case of a boiler fault the display will flash together with the fault symbol detail 20 fig 1 indicating the fault code There are faults that cause permanent shutdowns marked with the letter A to restore operation
33. tail 8 fig 1 again for 5 seconds to exit parallel curve adjustment mode Y cod 35401161 12 2008 Rev 00 Ferroli ENERGY TOP W 70 W 80 W 125 If the room temperature is lower than the required value it is advisable to set a higher order curve and vice versa Pro ceed by increasing or decreasing in steps of one and check the result in the room 90 85 80 sol aol 30 20 aaa aaa daas ra pi Prga i aaa 20 fig 12 Compensation curves OFFSET 20 90 85 80 70 60 50 40 30 20 OFFSET 40 90 85 80 70 60 50 40 30 20 fig 13 Example of parallel compensation curve shift If the Remote Timer Control optional is connected to the boiler the above adjustments are managed accord ing to that given in table 1 Table 1 Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel DHW temperature adjustment with optional hot water tank installed Adjustment can be made from the Remote Timer Control menu and the boiler control panel Summer Winter changeover Summer mode has priority over a possible Remote Timer Control heating demand Eco Comfort selection with optional hot water tank installed On disabling DHW from the Remote Timer Control menu the boiler selects the Economy mode In this condition
34. the button detail 7 fig 1 on the boiler panel is disabled On enabling DHW from the Remote Timer Control menu the boiler selects the Comfort mode In this condition it is possible select one of the two modes with the button 3 detail 7 fig 1 Sliding Temperature Both the Remote Timer Control and the boiler card manage Sliding Tempera ture adjustment of the two the Sliding Temperature of the boiler card has pri ority 10 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 Ferroli Water system pressure adjustment The filling pressure with the system cold must be approx 1 0 bar If the system pressure falls to values below minimum the boiler card will activate fault F37 fig 14 fig 14 System low pressure fault Once the system pressure is restored the boiler will activate the 120 second air venting cycle indicated on the display by FH cod 35401161 12 2008 Rev 00 11 Ferroli ENERGY TOP W 70 W 80 W 125 2 Installation 2 1 General Instructions THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL IN COMPLIANCE WITH ALL THE IN STRUCTIONS GIVEN IN THIS TECHNICAL MANUAL THE PROVISIONS OF CURRENT LAW THE NATIONAL AND LOCAL REGULATIONS AND THE RULES OF PROPER WORKMANSHIP ENERGY TOP W 70 W 80 W 125 is a high efficiency heat generator arr
35. the cable gets damaged switch off the unit and have it changed solely by professionally qualified personnel If changing the electric power cable use solely HAR H05 VV F 3x0 75 mm2 cable with a maximum outside diameter of 8 mm Room thermostat optional CAUTION The room thermostat must have clean contacts CONNECTING 230 V TO THE TERMINALS OF THE ROOM THERMOSTAT WILL IRREPARABLY DAMAGE THE ELECTRONIC CARD When connecting a remote timer control or a timer switch do not take the power supply for these devices from their cut out contacts Their power supply must be taken with a direct connection from the mains or with bat teries depending on the kind of device 14 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 ferroli External probe optional Connect the probe to its respective terminals The maximum permissible length for the boiler external probe connec tion electrical cable is 50 m A normal 2 wire cable can be used The external probe should preferably be installed on the North North West wall or that facing the largest area of living room The probe must never be exposed to the early morning sun or insofar as possible direct sunlight protect it if necessary In any case the probe must not be installed near windows doors ventilation openings flues or heat sources that could affect the reading wy Eh X al X gt _ fig 17 External probe positioning not reco
36. urs A05 Fan protection activation F15 generated or pour See fault F15 consecutive lonisation electrode fault Check the position of the ionisation electrode and replace it if necessary Flame unstable Check the burner A06 No flame atter ignition Gas valve Offset fault Check the Offset adjustment at minimum power stage 6 times in 4 min Remove the obstruction from the flue fume extraction air fume ducts blocked a and air inlet ducts and terminals Trap blocked Check the trap and clean it if necessary Flue partially obstructed or insuf Check the efficiency of the flue fume extraction ducts ficient and outlet terminal F07 High fume temperature Check the correct positioning and operation of the Fume sensor position fume sensor Sensor damaged F10 Delivery sensor 1 fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F11 Return sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F12 DHW sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected 24 cod 35401161 12 2008 Rev 00 ENERGY TOP W 70 W 80 W 125 Ferroli F Fault Possible cause Cure code Sensor damaged F13 Fume sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F14 Delivery sensor 2 fault
37. ust be chosen according to its length and loss of pressure in conformity with current standards Do not use the gas pipes to earth electrical appliances In case of connection in cascade make sure to install a fuel shutoff valve externally with respect to the mod ules 2 5 Electrical connections Connection to the electrical grid The unit s electrical safety is only guaranteed when correctly connected to an efficient earthing system exe cuted according to current safety standards Have the efficiency and suitability of the earthing system checked by professionally qualified personnel The manufacturer is not responsible for any damage caused by failure to earth the system Also make sure that the electrical system is adequate for the maximum power absorbed by the unit as specified on the boiler dataplate The boiler is prewired and provided with a Y cable and plug for connection to the electricity line The connections to the grid must be made with a permanent connection and equipped with a bipolar switch whose contacts have a minimum opening of at least 3 mm interposing fuses of max 3A between the boiler and the line It is important to respect the polarities LINE brown wire NEUTRAL blue wire EARTH yellow green wire in making connections to the electrical line During installation or when changing the power cable the earth wire must be left 2 cm longer than the others The user must never change the unit s power cable If
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