Ferroli MAXIMA 35 S Fehlerbehebungshandbuch

Appr. nr. B02.01 - CE 0063 B0 3924

MAXIMA 35 S

WALL-MOUNTING GAS BOILER,

PRE-MIXED

CONDENSING SYSTEM BOILER

INSTRUCTIONS FOR USE,

INSTALLATION

AND MAINTENANCE

code 3544786/0 ed. 01/2004

G C N° 47-267-21

Seasonal Efﬁciency

(SEDBUK)

band A (91,0%)

Maxima 35 S

IMPORTANT

Your “benchmark” Installation, Commissioning and Service Record Log Book will be enclosed in

your customer information pack.

“This record must be completed and left with the end user”.

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.

Benchmark has been introduced to improve the standards of installation and commissioning of central

heating systems in the UK and to encourage the regular servicing of all central heating systems to

ensure safety and efficiency.

Please see installation and servicing guidelines.

• Read the warnings given in this manual thoroughly.

They provide important information for safe instal-

lation, use and maintenance

• The instruction manual, by law must be left with the

end user.

• If the appliance is sold or transferred to another

owner or if the owner moves, leaving the appliance

behind, always ensure that the manual is kept with

the appliance for consultation by the new owner

and /or installer.

• Incorrect installation or poor maintenance absolves

the manufacturer from all liability for damage to

persons and property.

• Installation and maintenance must be carried out

in accordance with current legislation, according

to the manufacturer’s instructions and by qualified

corgi registered engineer.

• Before service or maintenance work is carried out

isolate the appliance from the mains electricity

supply.

• In the event of malfunction or faulty operation, isolate

the appliance. Do not attempt to repair or carry out

any other operation on the appliance directly. Contact

Ferroli or a qualified engineer only.

• Repairs or the replacement of components must be

carried out exclusively by qualified personnel using

original spare partsonly. Failure toadhere to theabove

may compromise the safety of the appliance.

• To guarantee efficient operation, the appliance must

be serviced once a year by a Corgi registered engi-

neer.

• The appliance may not be used for purposes other

than those for which it was explicitly designed.

• Incorrect installation and use or failure to follow the

instructions provided by the manufacturer absolve

the manufacturer from all liability for damage.

• After unpacking, check that the contents are correct

and undamaged.

• Keep packing out of reach of children as it could be

potentially hazardous.

• To clean external parts, use a damp cloth moistened

with soapy water if necessary. Avoid using abrasive

cleaning products and solvents.

This symbol indicates “Caution” and is placed next to all safety information.

Strictly follow these instructions in order to avoid danger and damage to persons

or property.

This symbols calls attention to a note or important information, please read thou-

rougly.

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 following 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

Maxima 35 S

1. OPERATING INSTRUCTIONS..................................................................4

1.1 Introduction ............................................................................................................4

1.2 Control panel ..........................................................................................................5

1.3 Turning ON and OFF ..............................................................................................7

1.4 Adjustments ............................................................................................................7

1.5 Maintenance............................................................................................................7

1.6 Faults.......................................................................................................................7

2. INSTALLATION .......................................................................................8

2.1 General Instructions................................................................................................8

2.2 Boiler location .........................................................................................................9

2.3 Boiler water connections ......................................................................................10

2.4 Connection to the gas system..............................................................................12

2.5 Electrical Connections ..........................................................................................12

2.6 Flue system ...........................................................................................................15

2.7 Condensate outlet connection .............................................................................21

3. SERVICE AND MAINTENANCE............................................................23

3.1 Adjustments ..........................................................................................................23

3.2 Initial start-up........................................................................................................24

3.3 Maintenance..........................................................................................................25

3.4 Troubleshooting....................................................................................................27

4 TECHNICAL CHARACTERISTICS AND DATA.........................................29

4.1 Dimensions and connections ................................................................................29

4.2 General view and main components ....................................................................30

4.3 Hydraulic diagram.................................................................................................31

4.4 Technical data table..............................................................................................32

4.5 Diagrams ...............................................................................................................33

4.6 Wiring diagram .....................................................................................................34

Maxima 35 S

1. OPERATING INSTRUCTIONS

1.1 Introduction

Dear Customer,

Thank you for choosing Maxima 35 S, a FERROLI wall-mounted boiler of the latest generation, featuring

advanced design and cutting-edge technology.

Maxima 35 S is a high-efficiency condensing pre-mix appliance for heating with extremely low emissions,

running on natural gas or LPG.

The boiler consists of an aluminium laminar heat exchanger providing effective condensation of the

water vapour contained in the flue gases, permitting extremely high efficiency.

Above the heat exchanger, in the boiler, there is a pre-mix burner, with a large ceramic surface, equip-

ped with electronic ignition and ionization flame control, which achieves extremely low emissions while

ensuring high reliability and long life operation.

The 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 pressure sensor.

Thanks to the twin microprocessor control and adjustment system with advanced self-diagnosis, unit

operation is for the most part automatic. The power for heating is automatically governed by the control

system.

The user only has to set the temperature desired inside the home by means of a room thermostat and

appliance temperature control. The adjustment and control system will provide optimum operation

throughout the year.

The display continuously provides information on the unit’s operating status and it is easily possible

to obtain additional information on the sensor temperatures, set-points, etc. or configure them. Any

operating problems associated with the boiler or system is immediately signalled by the display and, if

possible, corrected automatically.

Maxima 35 S

1.2 Control panel

OFF

15 13 16 1118

fig. 1

4 - Heating temperature adjustment control

To increase the heating temperature, turn the knob clockwise; anticlockwise to decrease it.

The adjustment range goes from 20 to 90°C (see page 7).

5 - RESET key

The Reset key is used to reset boiler operation when it has shut down.

To reset the boiler, press Reset (5 - fig. 1).

The shutdown condition is indicated by a fault code flashing and RESET being displayed.

6 - Power key

Turning the boiler on and off (on - green light on button pushed in).

8 - Mode key

Multifunction key.

9 - MINUS key

The MINUS key is used, toghether with PLUS key, to enter/exit the INSTALLER TEST mode (15mins).

10 - PLUS key

The PLUS key is used, toghether with MINUS key, to enter/exit the INSTALLER TEST mode (15mins).

11 - Return heating temperature display

In stand-by mode, the display shows the temperature of the return heating leaving the boiler.

Maxima 35 S

13 - Fan symbol

This appears when there is a call for heating, and the fan is operating.

15 - Ignition symbol

The ignition symbol appears during the ignition phase.

16 - Flame symbol

Indicates the burner is on, the small rising bars to the right indicate the burner output 1=low, 5=high.

17 - Radiator symbol

Displayed during demand or when the appliance is in standby.

18 - Flow heating temperature display

During operation, the display shows the temperature of the heating water leaving the boiler. When

operating knob “4” the display briefly shows the adjustment temperature being set ( see page 7 section

1.4 adjustments).

21 - Heating pump symbol

Displayed when the heating pump is operating.

22 - Appliance Frost protection

This appears when the boiler automatically comes on in frost protection, that is when the appliance

temperature drops under 5°C.

The appliance shuts down when it reaches a flow temperature of 15°C.

23 - Symbol showing demand for heating

Displayed when the appliance has a demand from external controls.

24 - Delay time symbol

Displayed when the appliance is in Stand-by after the set point operating temperature is achieved.

30 - System pressure display

Displays the heating system pressure (see page 11).

34 - TEST symbol

Boiler operating in TEST mode (full power). To turn on TEST mode, hold down the “+” and “-” keys for

3 seconds. Press the “+” and “-” keys for another 3 seconds to exit. TEST operation turns off automa-

tically after 15 minutes (Boiler operates at 100% whilst in test mode).

35 - Fault and parameter display

Displays any fault code if they should occur (see page 27 troubleshooting).

Maxima 35 S

1.3 Turning ON and OFF

Ignition

• Open the gas isolation valve upstream of the boiler.

• Purge the air from the pipe upstream of the gas valve.

• Ensure power is on to appliance.

• Press the ON/OFF key in to turn on boiler (see fig. 1 Item 6).

• The boiler is now ready to function automatically whenever the externals controls are calling.

Turning off

Press the ON/OFF key (see fig. 1 Item 6).

When the boiler is turned off with this button, the P.C.B. is no longer powered and the frost

protection will be disabled.

Close the gas cock upstream of the boiler and disconnect the electrical power supply.

To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all

water from the boiler, the tap water and the system water.

1.4 Adjustments

Room temperature adjustment (with a room thermostat)

Using the room thermostat, set the temperature desired in the room. Controlled by the room thermo-

stat, the boiler lights and heats the system water to the system setpoint temperature. The burner shuts

down when the desired temperature in the room is reached.

A room thermostat & programmer is a mandatory requirment (building regs Doc “L” 2002).

C.H. temperature adjustment

To set the system flow temperature, use the C.H. control knob. Turning it

clockwise increases the temperature, turning it anticlockwise decreases it.

When adjusting the control knob the display will flash for 5 seconds and

display the set point temperature. It will then revert to showing actual

temperature.

1.5 Maintenance

It is strongly recommended to carry out annual maintenance on the boiler and the heating system. Please

refer to the “maintenance” section in this manual.

The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp

cloth. Do not use abrasives or solvents.

1.6 Faults

In the unlikely event of an operating problem or component failure, the display flashes and a fault iden-

tification code appears.

Faults marked with the letter “F” cause temporary shutdowns that are automatically reset as soon as

the value comes back within the boiler’s normal working range.

If together with the fault the display also shows RESET, the user must reset boiler operation by pressing

the key (5 - fig. 1). The ignition cycle will thus be repeated.

If the problem remains after two attempts at resetting, contact the Ferroli Service Centre.

For other faults, refer to page 27 section 3.4 “Troubleshooting.”

Before calling the Ferroli service centre, check that the problem is not due to an installation error

or a problem with the gas/electricity or low water pressure in the system.

Maxima 35 S

2. INSTALLATION

2.1 General Instructions

This device must only be used for the purpose for which it is specially designed. This unit is

designed to heat water to a temperature below boiling point and must be connected to a hea-

ting system and/or a water supply system for domestic use, compatible with its performance,

characteristics and its heating capacity. Any other use is considered improper.

BOILER INSTALLATION MUST ONLY BE PERFORMED BY QUALIFIED PERSONNEL, IN ACCORDANCE

WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT

LAW, THE RECOMENDATION OF BS STANDARDS, ANY LOCAL REGULATIONS AND THE RULES OF

COMPEDENT WORKMANSHIP.

Incorrect installation can cause damage or physical injury for which the manufacturer declines any

responsibility.

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. 5440 Part 1 Flues

B.S. 5440 Part 2 Air supply

B.S. 5449 FORCED CIRCULATION HOT WATER SYSTEMS

B.S. 6798 INSTALLATION OF GAS FIRED HOT WATER BOILERS

B.S. 6891 GAS INSTALLATIONS

B.S. 7671 IEE WIRING REGULATIONS

B.S. 4814 SPECIFICATION FOR EXPANSION VESSELS

B.S. 5482 INSTALLATION OF LPG

B.S. 7593 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS

B.S. 5546 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

Model Water Bye Laws

B.S. 5955-8 PLASTIC PIPEWORK INSTALLATION

For Northern Ireland the rules in force apply

Maxima 35 S

Minimum

2,5 cm

20 cm

60 cm

(via an openable panel)

C40 cm

Table 1

fig. 2

A A

2.2 Boiler location

The unit’s combustion circuit is sealed off from the installation room. The installation room must be

sufficiently well ventilated to prevent any dangerous conditions from forming in the event of even slight

gas leakage. This safety standard is required by the EEC Directive no. 90/396 for all gas units, including

those with a so-called sealed chamber.

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 design to be installed on a solid 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 cupboard or mounted alongside, there must be space for normal maintenance

work. Fig. 2 and tab. 1 give the minimum clearances to leave around the unit.

Maxima 35 S

fig. 3

1 3 5

240240

240 240

200

138

138 53

288

2.3 Boiler water connections

The heating capacity of the unit should be previously established by calculating the building’s heat

requirement according to current regulations. For good operation and long life of the boiler, the plum-

bing system must be well proportioned and always complete with all those accessories that guarantee

regular operation and running, room thermostat, trv’s and automatic bypass etc.

If the flow and return pipes follow a path where air pockets could form in certain places, it is esential to

install vent valves at these points. Also, install type “A” drain cocks at the lowest points in the system

to allow complete draining.

The temperature differential between the flow manifold and the return to the boiler should not exceed

20° C.

A minimum flow of 6 litres/min is requied through the heat exchanger, it is therefore essential to fit a

automatic bypass a min of 3 meters away from the appliance, calobrated on site.

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. 3.

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)

7 Condense outlet

8 Safety valve discharge 1/2” f/I

It is essential to install the isolation valves supplied between the boiler and heating system, allowing the

boiler to be isolated from the system if necessary.

The safety valve outlet must be connected to a 15 mm diameter copper pipe (with a continual

fall from the boiler) to allow system water out onto the ground in the event of over-pressure in

the heating circuit. If this is not done, and the drain valve trips and floods the room, the boiler

manufacturer is not to be held responsible. The outlet should face back against the outer bri-

ckwork or building face to prevent harm or injury from hot water discharging in the evet of an

over-pressuried system.

Make the boiler connection in such a way that its internal pipes are free of stress. If a check valve is

installed on the tap water circuit (where applicable), it is necessary to mount a safety valve between the

boiler and this circuit (check valve minimum 3 meters from boiler).

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