Ferroli MAXIMA 35 S Instructions For Use, Installation And Maintenance
Appr. nr. B02.01 - CE 0063 B0 3924
MAXIMA 35 S
WALL-MOUNTING GAS BOILER,
P
RE-MIXED
CONDENSING SYSTEM BOILER
INSTRUCTIONS FOR USE,
INSTALLATION
AND MAINTENANCE
code 3544786/0 ed. 01/2004
G C N° 47-267-21
Seasonal Effi ciency
(SEDBUK)
band A (91,0%)
Maxima 35 S
2
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 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.
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.
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
3
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
4
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
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1.2 Control panel
ON
OFF
4
6
15 13 16 1118
34
30
35
5
17
21
22
23
24
10
9
8
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.
6
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 automatically 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
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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 thermostat, 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 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 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
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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
Maxima 35 S
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Minimum
A
B
D
2,5 cm
20 cm
60 cm
(via an openable panel)
C 40 cm
Table 1
fig. 2
A A
B
D
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.
Maxima 35 S
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fig. 3
1 3 5
24024043240 240
60
200
138
138 53
7
288
8
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 plumbing 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 brickwork 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).
Maxima 35 S
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Fig. 5
3
2
1
4
Key
A = Nut
B = Compression olive
D = 3/4 seal (green)
F = 1/2 gas seal (blue)
G = Filter
H = Cap
Flow isolation valve
Gas isolation valve
Return isolation valve
22
22
22
A
A
AB
B
B
D
D
F
G
H
RED
YELLOW
BLUE
fig. 4
The Isolation valve kits shown in fig. 4 are supplied as standard.
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. Ensure the filling point is on the return pipe to the boiler.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain
water undertakings will not accept their use above ground.
Key
1.
C.H. filling valve.
2. Temporary connection.
3. Cold water supply valve.
4. Double check valve.
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