Ferroli OPTIMAX HE 25 S, Instructions For Use, Installation And Maintenance

Page 1: ...TRUCTIONS FOR USE INSTALLATION AND MAINTENANCE OPTIMAX HE PLUS 25 S wall mounted gas fired pre mix condensing system boiler cod 3540R540 02 2009 Rev 00 5 G C n 41 267 32 Seasonal Efficiency SED BU K band A ...

Page 2: ...ed engi neer The appliance may not be used for purposes other than those for which it was explicitly designed Any other use is considered improper and therefore dan gerous Incorrect installation and use or failure to follow the instructions provided by the manufacturer absolve the manufacturer from all liability for damage Afterunpacking checkthatthecontentsarecomplete and undamaged Keep the packa...

Page 3: ...ter connections 11 2 4 Connection to the gas system 13 2 5 Electrical Connections 13 2 6 Flue system 16 2 7 Condensate outlet connection 22 3 SERVICE AND MAINTENANCE 24 3 1 Adjustments 24 3 2 System start up 25 3 3 Maintenance 26 3 4 Troubleshooting 28 4 TECHNICAL CHARACTERISTICS AND DATA 30 4 1 Dimensions and connections 30 4 2 General view and main components 31 4 3 Hydraulic diagram 32 4 4 Tech...

Page 4: ... boiler is totally room sealed from the installation room the air needed for combustion is drawn from outside The boiler also includes a modulating speed fan modulating gas valve pump expansion vessel safety valve temperature sensors a safety thermostat and a low water pressure sensor Thanks to the microprocessor control and adjustment system with advanced self diagnosis unit ope ration is for the...

Page 5: ...setpoint increasing push button 5 Display LCD 6 Reset 7 On Off push button 8 Domestic Hot Water symbol 11 Multi function indication 12 Degrees indication 13 Central Heating mode operation 14 Central Heating symbol 15 Burner on and actual load indication Indication during boiler operation Demand mode The Boiler heat demand generated by the Programmer room thermostat and cylinder thermostat is indic...

Page 6: ...ies the Air purge function During the first 5 seconds the display shows the software version of the pcb Open the gas cock on the boiler and purge the air from the pipework upstream of the gas valve When the FH disappears the boiler is ready to function automatically whenever the external controls are calling for heat Turning off Press the part 7 fig 1 for 5 seconds eco comfort reset fig 3 Boiler w...

Page 7: ...r pressure bar 10 The boiler is ready to function automatically whenever the external controls are calling for heat 1 4 Adjustments Heating temperature setting To set the system flow temperature use the CH push buttons Part 3 and 4 fig 1 It can be varied from a minimum of 20 C to a maximum of 90 C Room temperature adjustment using a room thermostat Using the room thermostat set the temperature des...

Page 8: ...tion must be reset manually by pressing the reset Part 6 fig 1 for 1 second Other faults F indication cause temporary shutdowns that are automatically reset as soon as the value causing the fault comes back within the boiler s normal working range Listed below are some anomalies that can be caused by simple user solvable problems If the problem remains after two attempts at resetting contact the F...

Page 9: ...ation can cause damage or physical injury for which the manufacturer declines any re sponsibility This appliance must be installed strictly in accordance with these instructions and regulations The Gas Safety Regulations Installations Use The Local Building Regulations The Building Regulations Part L The Buildings Standards Scotland Consolidated Regulations British Standards Codes of Practice B S ...

Page 10: ... wall The wall fixing must ensure a stable and effective support for the appliance using the bracket and fixings supplied If the unit is enclosed in a cupboard or moun ted alongside there must be space for normal maintenance work Fig 9 and tab 1 give the minimum clearances to leave around the unit Safe Handling of Substances Care should be taken when handling the boiler insulation panels which can...

Page 11: ...mstances Do not use the water system pipes to earth electrical appliances Before installation carefully flush all the pipes of the heating system to remove residues or impurities that could affect the unit s operation BS 7593 Building regs Doc L Make the connections to the appliance as shown in fig 10 Key 1 System flow 22 mm with isolation valve fitted 3 Gas inlet 22 mm with isolation valve fitted...

Page 12: ...g water lost from the sealed system Reference should be made to BS6798 for methods of filling and making up sealed systems There must be no direct connection between the boiler s central heating system and the mains water supply The use of mains water to charge and pressurise the system directly is conditional upon the Local Water Byelaws Again any such connection must be disconnected after use En...

Page 13: ...Note If the boiler is installed on an existing system any unsuitable additives must be removed by tho rough cleansing All systems should be cleansed according to B S 7593 Note In hard water areas treatment to prevent lime scale may be necessary Note It is important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers instructions 2 4 Conn...

Page 14: ...eter of 8 mm Access to the electrical terminal block Follow the instructions given in fig 13 to access the electrical connection terminal block The layout of the terminals for the various connections is given in the wiring diagram in the Technical Data chapter Key 62 Time Clock optional fig 14 Room thermostat Remove connections 5 6 if external control fitted If using external controls the switched...

Page 15: ...am on the S and Y plan systems please see fig 15a 15b and 16a 16b OPTIMAX S Plan Wiring diagram OPTIMAX FERROLI BOILER D H W Zone Valve C H Zone Valve Auto air vent 4 3 2 1 Junction Box N E L Terminal 5 SWITCH LINE 1 2 3 4 5 6 7 8 9 10 PROGRAMMER DHW ON CH ON NEUTRAL LIVE CH zone valve DHW zone valve Room Thermostat Cylinder Thermostat N E L 230 Vac BROWN BLUE GREY ORANGE L 6 5 Fig 15a Fig 15b Rem...

Page 16: ...between terminals 5 6 Pipe layout 2 6 Flue system The unit is type C with a sealed chamber and forced draught the air inlet and flue outlet must be connected to one of the following flue systems With the aid of the tables and methods of calculation indi cated before commencing installation it is first necessary to check that the flue system does not exceed the maximum permissible length The curren...

Page 17: ...f 3 mm per metre should be incorporated back to the boiler 3 Make a hole of diameter 10 20 mm greater than the nominal diameter of the concentric pipe used 4 If necessary cut the terminal length to size ensuring that the external pipe protrudes from the wall by between 10 and 60 mm fig 17a and 17b Remove the cutting burrs 5 Connect the flue to the boiler positioning the seals correctly Seal the fl...

Page 18: ...umber 041002X0 2 Use the required amount of 1mtr flue extensions part number 1KWMA56U inserting them spigot down ensuring the seals are well lubricated with silicone grease not supplied and correctly located into the sockets 3 If required 45 bends Part number1KWMA64A may be used with a resistance value of 0 5mtrs each the flue should be routed in such away to avoid any unnecessary deviation and th...

Page 19: ... 5 provide an equiva lent loss in linear metres depending on the position of installation of the component with air intake or flue extraction vertical or horizontal Thelossiscalled equivalentlength sinceitiscompared to the loss of one metre of flue defined as equal to 1 For example a bend at 90 of Ø80 in flue extraction has an equivalent loss of 2 linear metres i e it has a loss equal to that of 2...

Page 20: ... Description Horozontial flue terminal Horozontial air terminal Vertical flue terminal 1 1 1 6 2 1 2 1 8 1 5 2 0 Equivalent losses in metres linear 5 2 Air Flue Vertical Horizontal Vertical Horizontal Equivalent losses in metres linear 12 Accessories Ø 80 Accessories Ø 80 Table 4 Table 5 The stated loss values refer to genuine Ferroli flue accessories Terminal Position P D E Q Q l B C A G F L J H ...

Page 21: ...f Horizontally from a terminal on the same wall Vertically from a terminal on the same wall From an opening in the car port e g door window into the dwelling Above ground roof or balcony level 300mm 300mm 300mm 200mm 75mm 200mm 150mm 100mm 300mm 600mm 300mm 300mm 150mm 1200mm 1200mm 1500mm N A A B C D E F G H I J K L M N O P Q NOTE N A Not applicable In addition the terminal should not be nearer t...

Page 22: ...ermissible with a vertical progression and with no constrictions Have the flue conveying the hot fumes adequately distanced or isolated from combustible mate rials Be connected to just one unit per floor for at most 6 units in all 8 if there is a compensation duct or opening Have no mechanical suction devices in the main ducts Be at a lower pressure all along their length under conditions of stati...

Page 23: ...r as the condensate has a ph value of 4 slightly acidic Where it is not possible to terminate internally the condensate discharge pipe may be run outside see below drawing Any external run is subject to freezing in severe weather conditions To avoid this the pipework should be installed to dispose of the condensate quickly with as much as possible run internally before passing through the wall Pip...

Page 24: ...g as follows 1 Remove the casing 2 Open the sealed chamber 3 Release the fixing clip C and remove the gas pipeA from the fan venturi assembly 4 Replace the nozzle B inserted in the gas pipe with that contained in the conversion kit 5 Reassemble the gas pipe A with the clip and check the seal of the connection 6 Apply the plate contained in the conversion kit near the dataplate 7 Refit the sealed c...

Page 25: ...and spin the pump Ensure the flue system is correctly fitted including terminal locations Ignition Open the gas valve upstream of the boiler Purge the air from the installation pipework to the appliance Switch on the boiler electrical supply Press the key on the boiler for 5 seconds part 7 fig 1 The boiler is now ready to function automatically whenever the external controls call for a demand In c...

Page 26: ...terminal end piece and ducts must be free of obstructions and leaks The gas and water systems must be sound The burner and exchanger must be clean The electrodes must be free of scale and correctly positioned The system pressure when cold must be approx 1 bar otherwise bring it to that value The expansion vessel must be filled to 1 bar cold with zero system pressure The gas flow and pressure must ...

Page 27: ...mber gaskets cable clamps etc In addition it is necessary to pay attention after performing all these operations to check and carry out all the phases of ignition and thermostat operation the gas valve and circulation pump After these checks make sure there are no gas leaks Combustion analysis It is possible to analyse the combustion through the air and flue sampling points shown in fig 25 To make...

Page 28: ...ctrode wiring Main board defective Check the PCB A03 High limit protection Flow sensor not active or correctly located Check the correct positioning and operation of the flow sensor No system circulation Check the pump and radiator valves present in the system and automatic by pass A04 Flue gas fault Fault F07 happened 3 times in the last 24 hours Check the flue A05 Fan problem Tachometer signal i...

Page 29: ... the wiring and fan Fan damaged debris in fan Check the fan clean debris F34 Supply voltage under 180V Electric mains fault Check the electrical system F35 Irregular mains frequency Electric mains fault Check the electrical system F37 Incorrect system water pressure Pressure too low Fill the system Sensor damaged Check the sensor F40 Incorrect system water pressure Pressure too high above 3 5 bar ...

Page 30: ...TA 4 1 Dimensions and connections 6 Pressure Relief Valve Key 1 System flow 22 mm with isolation valve fitted 3 Gas inlet 22 mm with isolation valve fitted 5 System return 22 mm with isolation valve fitted c w filter fig 26 82 5 130 131 5 56 181 233 1 3 6 5 700 400 80 80 120 120 195 330 ...

Page 31: ...ue Collar 32 Pump 36 Automatic air vent 44 Gas valve 56 Expansion vessel 81 Spark Electrode 56 22 19 161 196 186 36 114 32 11 7 44 10 193 278 81 82 16 5 29 191 14 241 145 154 201 82 Ionisation electrode 114 Water pressure switch 145 System pressure gauge 154 Condensate outlet pipe 161 Heat exchanger 186 Return sensor 191 Flue gas temperature sensor 193 Siphon 196 Condensate collector 201 Fan Ventu...

Page 32: ...lief valve 16 Premix fan assembly 32 Pump 36 Automatic air vent 44 Gas valve 56 Expansion vessel 114 Water pressure switch 154 Condensate outlet pipe 161 Heat exchanger 186 Return sensor 193 Siphon 196 Condensate collector 241 Automatic by pass 278 Double sensor Safety Heathing 56 44 14 32 11 10 7 241 114 36 186 161 278 193 154 16 196 ...

Page 33: ...rective Table 10 Gas injector G20 Natural Gas Gas injector G31 Propane Electrical protection rating IP Power voltage frequency V Hz X5D 230 50 98 3 97 3 105 4 107 2 109 1 Max working pressure in heating bar 3 0 8 Type of unit C13 C23 C33 C43 C53 C63 C83 B23 B33 PIN NUMBER 0063 BR 3161 Heating expansion tank prefilling pressure Heating expansion tank capacity litres bar 8 1 kW kW kW m3 h kg h C C k...

Page 34: ... HE PLUS 25 S Cod 3540R540 02 2009 Rev 00 4 5 Diagrams Head available for the system fig 29 Key 1 2 3 Pump selector positions A Boiler losses of head 0 1 2 3 4 5 6 7 0 500 1 000 1 500 2 000 Q l h H m H2O A 3 2 1 ...

Page 35: ...optional 81 Spark Electrode 82 Ionisation electrode 101 Main p c b 103 Relay 104 Fuse 114 Water pressure switch 186 Return temperature sensor 191 Exhaust temperature sensor 202 Transformer 230V 24V 203 Supply lead 278 Double sensor Safety Heating fig 30 Cod 3540R540 02 2009 Rev 00 4 6 Wiring diagram ...

Page 36: ...TED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts 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 H...

Page 37: ...NTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 7 DATE ENG...

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Page 40: ...t 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 Should you require any assistance during the installation call our Technical Service Helpline on 08707 282 885 option 1 Should you require a ...