ferroli Maxima 35 C User guide
MAXIMA 35 C
WALL-MOUNTED GAS FIRED,
RE-MIX
P
ONDENSING COMBINATION BOILER
C
Seasonal Effi ciency
INSTRUCTIONS FOR USE,
INSTALLATION
AND MAINTENANCE
Appr. nr. B02.01 - CE 0063 B0 3924
(SEDBUK)
band A (90,9%)
code 3544452/1 ed. 06/2004
G C N° 47-267-33
Maxima 35 C
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.
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
thourougly.
• Read the warnings given in this manual thoroughly.
They provide important information for safe
installation, 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 parts only. Failure to adhere
to 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
engineer.
• 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.
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
2
Maxima 35 C
1. OPERATING INSTRUCTIONS..................................................................4
1.1 Introduction ............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Operationg instructions..........................................................................................7
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 ......................................................................................12
2.4 Connection to the gas system..............................................................................14
2.5 Electrical Connections ..........................................................................................14
2.6 Flue system ...........................................................................................................17
2.7 Condensate outlet connection .............................................................................23
3. SERVICE AND MAINTENANCE............................................................25
3.1 Adjustments ..........................................................................................................25
3.2 Initial 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
3
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing Maxima 35 C, a FERROLI wall-mounted boiler of the latest generation,
featuring advanced design and cutting-edge technology.
Maxima 35 C is a high-efficiency condensing pre-mix appliance for heating and hot water production
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,
equipped 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,
pumps, expansion vessel, flow meter, safety valve, flow sensor, 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 according to the indoor and outdoor characteristics (with an optional outdoor sensor installed), the
characteristics of the building and of its location. The power for hot water is automatically and continually
governed to ensure a fast delivery and comfort under all operating conditions.
The user only has to set the temperature desired inside the home (by means of an optional room
thermostat or remote control, which is required under the building regulations 2002) or regulate the
temperature of the system, and set the desired outlet temperature for the hot water. 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 C
4
Maxima 35 C
1.2 Control panel
1
17
15 13 16 12 1118 20
19
24
23
21
22
4
30
34
33
ON
5
6
35
OFF
26
27
31
37
7
fig. 1
1 - Summer/Winter selection key
In Winter mode, both heating and hot water production are on; in Summer mode, hot water
production only (the heating display information will disappear in summer mode and the summer
display will illuminate - item 20).
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 8).
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 the fault blinking and RESET being displayed.
6 - Power key
Turning the boiler on and off (on - green light on button pushed in).
7 - Hot water temperature adjustment control
Used to set the hot water temperature, turning the knob clockwise increases the temperature,
anticlockwise decreases it. The adjustment range goes from 40 to 65°C (see page 8).
11 - 12 Hot water temperature display
During operation, the display shows the temperature of the hot water leaving the boiler. When operating
knob “7” the display briefly shows the adjustment temperature being set.
17 - 18 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.
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Maxima 35 C
13 - Fan symbol
This appears when there is a call for heating or hot water, 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.
19 - REMOTE CONTROL symbol
This appears when the remote control is connected to the boiler.
20 - SUMMER symbol
This appears when the SUMMER mode is activated ( - 1 fig. 1).
21 - Heating pump symbol
Appears when the heating pump is operating.
22 - Frost protection
This appears when the boiler automatically comes on in frost protection, that is when the
temperature drops under 5°C.
The appliance stops when it reaches a temperature of 15°C.
23 - Symbol showing demand for heating
Appears when the appliance is in Winter operation, with a demand from external controls.
24 - Delay time symbol
Appears when the appliance is in Standby after Heating operation.
26 - Delay time symbol
Appears when the appliance is in Standby after Hot Water operation.
27 - Symbol showing demand for hot water
Appears when the appliance has a demand for hot water.
30 - System pressure display
Displays the heating system pressure.
31 - Hot water pump symbol
Display when the hot water pump is operating.
37 - Outside temperature compensation
Display outside temperature (in conjunction with optional outside sensor) and allows setting of compensation curve parameters - see page 18)
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 automatically after 15 minutes.
35 - Fault and parameter display
Displays any fault code if they should occur (see page 29 troubleshooting).
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Maxima 35 C
1.3 Operationg instructions
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).
• The boiler is now ready to function automatically whenever hot water is drawn or the clock and
room thermostat calls for heating.
Turning off
Press the ON/OFF key (see fig. 1).
When the boiler is turned off with this button, the P.C.B. is no longer powered and the frost
protection will be disable.
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 optional room thermostat)
Using the room thermostat or remote control, set the temperature desired in the room. Controlled by the
room thermostat, the boiler lights and heats the system water to the set system setpoint temperature.
The burner shuts down when the desired temperature in the rooms is reached.
A room thermostat is a mandatory requirment (building regulations 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.
Domestic hot water temperature adjustment
To set the hot water temperature, use the D.H.W. 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.
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Maxima 35 C
Summer/Winter selection
To select either mode, simply press the key (1 - fig. 1).
On selecting Summer mode, the display shows .
On selecting Summer mode, the frost protection system stays on. The symbol is shown on the
display should the frost protection system come on.
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 identification 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 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.
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Maxima 35 C
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 heating 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
9
Maxima 35 C
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.
C
A A
B
D
fig. 2
Table 1
Minimum
A
5 cm
B
20 cm
C 40 cm
D
60 cm
(via an openable panel)
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Maxima 35 C
Make Up Water
Provision must be made for replacing 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. The supplied temporary filling loop is shown in fig.
4. Ensure the filling point is on the return pipe to the boiler.
Attention - is drawn to the Model Water Byelaws.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and
certain water undertakings will not accept their use above ground.
Ensure all pipework is adequately supported
Hot water
Gas
NOTE: An automatic bypass must
be fitted as far as possible from the
boiler if thermostatic radiator valves
are fitted thoughout.
Automatic
Bypass
3
Additional expansion
vessel C.H. (if required)
Filling
point C.H.
Fig. 3
Key
2
4
1
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
4. Double check valve
Fig. 4
11
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