Repair of Ferroli gas boilers: how to find and correct an error in the operation of the unit according to the code

The basis of autonomous heating systems is most often a reliable gas unit from a responsible supplier.But even the products of companies that are highly rated in terms of the quality of the equipment they produce have problems. Sometimes it is necessary to repair Ferroli gas boilers; not only gas workers, but also the owners themselves can handle it.

Devices of this brand do not differ much from each other in terms of their operating principle. Therefore, the problems they encounter are typical. Ways to solve the problems that have arisen are also well researched.

We will tell you how to correctly identify the malfunction. We will help you understand the problems and correctly decipher the error code that appears on the electronic display of the unit. Compliance with our recommendations will provide home craftsmen with a positive result from their efforts.

Fault indications on different models

Ferroli boilers are equipped with a self-diagnosis system and, if an emergency occurs, they give the user an error code. Knowing the type of malfunction, you can quickly find the cause of its occurrence. Many breakdowns do not require special knowledge to fix.

The manufacturer divided all the problems that arise during the operation of Ferroli boilers into 2 categories:

• Critical errors causing complete blocking. Indicated by the letter “A” before the code. If such a malfunction occurs, it is necessary to fix the problem and restart the boiler by pressing the “reset” or “reset” key.
• Problems causing temporary shutdown of the boiler or one of its components. Indicated by the letter “F” before the code. The automation waits for the situation to normalize, after which it will restart the boiler itself.

Error code information can be displayed on the LCD or remote control. For older models, you can find out the type of failure by looking at the indicators.

If the boiler does not have an LCD display, the type of error can be recognized by the flashing lights. For each problem, the user manual describes a unique combination of indicator behavior

Also, sometimes a code starting with the letter “D” appears on the screen. This is technical information warning the user that the boiler is changing from one mode to another.

List of errors in Ferroli gas boilers

Below is a list of faults with Ferroli gas boilers, sorted by ascending error code. For each problem, ways to solve it are proposed, starting with the easiest.

Error A01 – the burner did not light. A common problem, as there are many reasons for its occurrence:

• Lack of gas. It is necessary to check that all shut-off valves are open. If the gas was recently connected, then before starting the boiler you need to bleed the air.
• Insufficient ignition power. This indicator must be adjusted according to the instructions in the user manual.
• Gas valve malfunction. It is possible that the wiring was incorrectly connected or there is a defect in the cable. There is also a possibility that the valve itself may be faulty, in which case it will need to be replaced.
• Problem with the ionization electrode. You need to check the nominal gap, which should be about 3 mm, make sure the cable is in good condition and, finally, clean this part from dirt.

If all else fails, then the control board error remains. Although this is an unlikely event, since self-diagnosis is good at identifying problems with the boiler electronics.

Insufficient liquefied gas pressure can be caused by the onset of cold weather. This happens if the gas tank is filled with a “summer” mixture. The boiler will have nothing to do with it

Error A02 – signal about the presence of a flame when the burner is off. The most likely problem is current leakage from the ionization electrode circuit. You need to check the wiring for physical damage and short circuits. The cause of the breakdown may also be a malfunction of the boiler board.

Error A03 – boiler overheating. The most likely source of the problem is poor coolant circulation in the circuit.

This most often happens for three reasons:

• clogging;
• airiness of the system;
• malfunction of the built-in circulation pump.

In any of these cases, strained operation of the pump will be heard. If water is pumped normally, then you can check the temperature sensor itself and the wiring to it.

Error F04 – the smoke thermostat worked. High exhaust temperature means the heat exchanger is dirty. Also, the sensor may be triggered when a draft tipping effect occurs.

Basically, the malfunction occurs due to problems with chimney of a gas boiler. This can be either design miscalculations (small pipe diameter or strong wind load at the outlet), or a narrowing of the passage due to the entry of foreign objects or the accumulation of a layer of soot. Therefore, first of all, you need to check the smoke exhaust path.

Calculating the parameters of a chimney for a gas boiler must be taken seriously. The remodeling will take a lot of time, during which there will be no heating

You also need to look at the temperature setting for the sensor. It must match the boiler model. And finally, the sensor itself may fail. In this case, it will have to be replaced.

Error F05 – fan malfunction. Depending on the model, the malfunction is determined either by the fan load readings or by the opening of the pressure switch contacts.

The following nodes need to be checked:

• Chimney. The passage can be severely narrowed due to a design error, a foreign object, or an incorrectly selected diaphragm. In this case, a narrowing of the air flow will occur and the pressure switch will operate.
• Fan. It happens that it does not start at all when the ignition starts. Then you need to check the wiring, contacts or motor. The bearing may also fail, causing the fan to make a hum and its blades to rotate more slowly.
• Pressure switch. The contacts may come loose or the device itself may break.

Error A06 – the fire goes out immediately after ignition.

There are two almost equally probable reasons for the error:

• Insufficient pressure in the gas line. It is necessary to check the shut-off equipment. If it is completely open and the pressure is poor, then you need to contact your gas supplier.
• The minimum pressure value for the gas flow is set too low. You need to re-calibrate.

Error F07 – one of the parameters of the electronic board is incorrectly set. If the automation itself cannot cope and the Ferroli gas boiler does not start, then you need to go into the menu and check the settings.

Modern Ferroli boiler models have an advanced settings system. Sometimes the user gets too carried away with the simulation, which leads to system errors

Error F08 – overheating of the heating water (HW) heat exchanger. If the temperature in the circuit is 100 °C or higher for 5 seconds, this fact will be recorded. If repeated frequently, error A03 will occur.Situation F08 is not displayed on the screen and does not cause the process to stop. However, it remains in the event register.

Error A09 – problem with the gas valve. The simplest situation involves a power failure. In this case, you need to check the contacts or change the wires. It is also possible that there is a break or short circuit inside the valve.

Error F10 – malfunction of the temperature sensor on the water supply to the circuit. There are 3 possible scenarios:

• Opening contacts. It is necessary to disconnect the connectors and then connect them tightly again.
• Broken wire or short circuit. You need to ring the wire. If the problem is confirmed, it will have to be replaced.
• There is a break inside the NTC sensor itself. It needs to be removed and tested for resistance.

Error F11 – malfunction of the hot water supply temperature sensor. The actions are the same as for error F10. The main difference between events F10 and F11 is that if there is a problem with the DHW, the boiler will continue to operate only in heating mode. And with problem F10, the boiler will stop.

The resistance of a standard semiconductor temperature sensor (NTC) varies with temperature. Using an ordinary ohmmeter you can determine its suitability for further work.

Error F14 – malfunction of the temperature sensor at the water inlet to the heat exchanger. The situation is similar to fault code F10.

Error A16 – problem with the gas valve. Occurs if the flame does not go out within 5 seconds after the command to stop the gas supply. Typically this situation is caused by an electrical problem with the valve, which will require replacement.

The most common problem that causes gas valve failure is a break in the inductor.In this case, it is easier to completely replace the part than to look for the breakdown location

Error F20 – the problem is related to the overall quality control of the combustion process. In this case, the boiler does not stop.

This is a complex situation, as there can be many reasons for its occurrence:

• Malfunction of the smoke removal system. You must act as for errors F04 and F05.
• Malfunction or incorrect operation of the ionization electrode. You need to check the nominal gap, which should be about 3 mm, make sure the cable is in good condition and, finally, clean this part from dirt.
• Gas valve malfunction. It will have to be replaced.
• Control board faulty. Replacement.

Error A21 – if situation F20 occurs 6 times within 10 minutes, the boiler stops.

Error F34 – insufficient network voltage. Different models have different thresholds, but usually a signal about poor current quality occurs at 170-180 V. Operating with such network parameters leads to the risk of damage to the boiler electronics.

In order to ensure the safety and durability of expensive equipment, it is necessary to make it a rule that a gas boiler from Ferroli or another manufacturer is not connected to the circuit without stabilizer. Sometimes, in places where there are frequent power outages, it is advisable to install a battery system to support autonomous power supply.

The gas boiler is connected to the network through a voltage stabilizer. If the house has a lot of expensive electronics, then it may be better to install an input stabilizer

Error F35 – the current frequency is incorrectly set. The boiler electronics operate at a frequency of 50/60 Hz. The current power supply value must be set in the menu.

Error F37 – opening of the pressure switch contacts for 5 or more seconds.If the value becomes less than 0.8 bar, the boiler stops.

This situation occurs in two cases:

• There is a leak coolant. You need to check the entire circuit for leaks. After eliminating the problem, you should recharge the system to the required pressure.
• The pressure sensor may fail. If so, then it will have to be replaced.

Error F39 – problem with the outside temperature sensor. To ensure weather-dependent control of heating, an outdoor thermometer can be connected to the boiler. However, this creates another prerequisite for a malfunction to occur - if the signal disappears, then this error occurs.

As with all temperature sensors, you need to check the contacts, ring the wire and test the thermostat itself.

Error F40 – too much pressure in the heating system (occurs in closed circuits). You need to check the pressure. If it is really high, then you need to lower it to a value of about 1.5 bar and check the operation of the safety valve. Most likely, that's the problem.

If the pressure was normal (the exact value at which the boiler stops can be found in the operating manual), then the problem is in the sensor. It needs to be replaced.

The membrane tank and valve (left) are located inside the boiler. As the temperature increases, the volume of water increases, as a result, the pressure rises and the fuse trips, dumping excess coolant outside the circuit

Error A41 – there is no change in the temperature of the heated water. The temperature sensor could simply move away from the pipe, or the problems described for error F10 may have arisen.

Error F42 – the difference in the readings of the water temperature sensor in the circuit and the overheating sensor is more than 12 °C.This means that one of the devices produces a significant error, which can lead to non-operation (or vice versa - false operation) of emergency mechanisms.

You can determine a faulty thermistor using an ohmmeter and a resistance table, or you can simply replace both sensors with new ones.

The immersion temperature sensor is fixed in the pipe using a thread. Its wires are connected to the control unit using a standard connector. Therefore, when replacing, you won’t have to solder anything.

Error F43 – heat exchanger overheating. The situation may be caused by the following problems:

• The position of the shut-off valves does not correspond to the gas pressure. In this case, excessive heat generation occurs in the combustion chamber. You need to set the correct boiler settings.
• The permissible heat exchanger heating rate parameter is underestimated. You need to check its value in the menu.
• Poor water circulation in the circuit. The reasons and actions are the same as for error A03.
• The temperature sensor is faulty. You need to check its connection or replace it.

Error F47 – no signal from the pressure switch in the heating circuit. First you need to check the contacts, then ring the signal wire from the sensor to the board. If they are ok, then you will have to replace the relay.

Error A48/A49 – problem of the gas valve in the electrical part. There are two possible reasons: a breakdown of the valve itself (you need to ring its coil) or the control board. The broken part will need to be replaced.

In the case of the board, a reboot may help. If the boiler still works after this, then you need to understand that this is a temporary solution, since the capacitors on the board have begun to age.

The electronics of gas boilers can be repaired at computer repair centers.The main problems with boards and sensors are the same

Error F50 – the gas valve circuit is open or the current on the modulation coil is below the minimum threshold. The causes of the malfunction and ways to solve them are the same as for error A48.

Error A51 – long period of burner flame extinction. The causes of the problem and steps to resolve them are the same as for error F20.

Original and compatible units

If any part of the boiler breaks down and cannot be repaired, the problem of replacement arises. Ferroli equipment is not so widespread that you can be sure that you can quickly find an original part. However, many sensors and tubes have a universal format, in which case it is possible to purchase products from a third-party manufacturer.

For Ferroli boilers, the original spare parts are as follows:

• control board;
• gas valve;
• ignition and combustion unit;
• make-up unit (tap);
• chimney fan;
• display and control knobs;
• heat exchanger (original mounting);
• expansion tank.

When replacing the feed tap, it is imperative to know the boiler model, since Ferroli has two very similar varieties of this part.

Circulation pump, safety valves, temperature and pressure sensors, pressure switch, flow switch, wiring, insulation elements, anodes can be purchased compatible. But it is important that their technical characteristics completely coincide.

Conclusions and useful video on the topic

An example of solving an elementary problem in the event of a boiler breakdown associated with an error in the readings of the air pressure switch. Quick repairs on your own:

Cleaning the chimney system using a vacuum cleaner:

You can repair a Ferroli gas boiler yourself if you know the type of error and how to eliminate it.However, it should be remembered that gas equipment is an element of increased danger. Therefore, it is better to entrust all maintenance and repair work to representatives of the gas service with which the contract has been concluded.

In the block below you can share your own experience in cleaning and restoring the performance of gas boilers from an Italian manufacturer. It is possible that you have useful information that is worth sharing with site visitors. Share information and photos on the topic of the article, please ask questions.