Ferroli OPTIMAX HE PLUS 25 S Fehlerbehebungshandbuch

INSTRUCTIONS 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

(SEDBUK)

band A

OPTIMAX HE PLUS 25 S

2Cod. 3540R540 - 02/2009 (Rev. 00)

• Read the warnings given in this manual thoroughly.

They provide important information for safe instal-

lation, use and maintenance

• By law the instruction manual 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

people or property.

• Installation and maintenance must be carried out

in conformity with current legislation, according

to the manufacturer’s instructions and by qualified

personnel.

• Before service or maintenance work is, carried out

isolate the appliance from the mains electricity

supply.

• In the event of malfunction or faulty operation, iso-

late the appliance. Do not attempt to repair or carry

out any other operation on the appliance directly.

Contact qualified personnel only.

• Repairs or the replacement of components must be

carried out exclusively by qualified personnel using

original spare parts only. Failure to respect the above

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. 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.

• After unpacking, check that the contentsare complete

and undamaged.

• Keep the packaging out of reach of children as it is

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 thor-

oughly.

IMPORTANT

•Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the

last pages of this manual. “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.

•"Ferroli declare that no substances harmful to health are contained in the appliance or used

during the appliance manufacture”.

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

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

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

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

1.3 Turning ON and OFF ..............................................................................................6

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

1.5 Maintenance............................................................................................................8

1.6 Faults.......................................................................................................................8

2. INSTALLATION.......................................................................................9

2.1 General Instructions................................................................................................9

2.2 Boiler location .......................................................................................................10

2.3 Boiler water 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 Technical data table..............................................................................................33

4.5 Diagrams ...............................................................................................................34

4.6 Wiring diagram .....................................................................................................35

BENCHMARK ...........................................................................................36

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OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

1. OPERATING INSTRUCTIONS

1.1 Introduction

Dear Customer,

Thank you for choosing the OPTIMAX HE PLUS 25 S, a FERROLI wall-mounted boiler of the latest

generation, featuring advanced design and cutting-edge technology.

OPTIMAX HE PLUS 25 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 water pressure sensor.

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

ration 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.

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

1.2 Control panel

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reset

815

1314

436

fig. 1

1= Domestic Hot Water temperature setpoint decreasing push button (not used)

2= Domestic Hot Water temperature setpoint increasing push button (not used)

3= Central Heating water temperature setpoint decreasing push button

4= Central Heating water temperature 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

indicated by the flashing of the Hot Air symbol over the radiator (part. 13 and 14 – fig. 1). The display

indicates the actual System water temperature (part. 11 – fig. 1).

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comfort

reset

fig. 2

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

1.3 Turning ON and OFF

Without main power supply

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

water from the system.

Ignition

Ensure the power is on to the appliance.

For the first 120 seconds, the display shows FH that identifies 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.

•

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fig. 3 - Boiler without main power supply

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reset

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fig. 4 - Ignition

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reset

fig. 6 - Turning off

fig. 5 - Air purge

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

When the boiler is turned off with this key, the p.c.b is still powered, heating operation is disabled and

the display is off however the frost protection will still be active.

To totally isolate close the gas cock ahead of the boiler and disconnect electrical power.

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

water from the system.

To turn the boiler on again, press (part.7 - fig.1) for 5 seconds.

If there is no heat demand, the display shows the actual water 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 desired in the rooms. Controlled by the room ther-

mostat, the boiler lights and heats the system water to the system delivery setpoint temperature. The

burner shuts down when the desired temperature in the room is reached.

A room thermostat and programmer are a mandatory requirement (Building regulations Doc ‘L’

2002).

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fig. 7

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fig. 8

1.6 Faults

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

identification code appears.

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

1.5 Maintenance

It is strongly recommended to carry out annual maintenance of the boiler and 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.

The boiler is equipped with an advanced self-diagnosis system that signals any faults on the display.

Some faults (“A“ indication) cause a boiler shutdown. In this case, operation 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 Ferroli Service Centre.

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

Fault Cure

No burner ignition

Make sure that the gas cocks ahead of the boiler

and on the meter are open.

Press the RESET button (for 1 second).

In case of repeatedshutdowns, contact the Ferroli

Service Department.

Low system pressure Fill the ‘system to 1-1.5 bar.

Before calling a Ferroli service engineer, check that the problem is not due to there being no

gas or electricity, or low system pressure.

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

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 heat-

ing 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

COMPETENT WORKMANSHIP.

Incorrect installation 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. 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

OPTIMAX HE PLUS 25 S

Cod. 3540R540 - 02/2009 (Rev. 00)

Minimum

2,5 cm

20 cm

60 cm

(via an openable panel)

C30 cm

Table 1

fig. 9

A A

2.2 Boiler location

The unit’s combustion chamber is sealed off

from the installation room and therefore requi-

res no compartment ventilation.

The installation room must be sufficiently well

ventilated to prevent any dangerous condi-

tions 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 designed 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 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 cause irritation to the skin. No asbestos, mercury or CFCs are included in

any part of the boiler.

Product Handling Advice

When handling or lifting always use safe techniques - keep your back straight, bend your knees, don’t

twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body

as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the

centre of gravity, repositioning yourself as necessary.

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