OPTIMAX 25 C
wall-mounted gas fi red,
pre-mix
condensing combination boiler
INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE
G C N° 47-267-34
cod. 3544782/1 - 08/2004
Optimax 25 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 effi ciency.
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 thoroughly.
• Read the warnings given in this manual thoroughly.
They provide important information for safe installation, use and maintenance
• By law the instruction manual 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 qualifi ed
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, isolate the appliance. Do not attempt to repair or carry
out any other operation on the appliance directly.
Contact qualifi ed personnel only.
• Repairs or the replacement of components must be
carried out exclusively by qualifi ed personnel using
original spare parts only. Failure to respect the above
my compromise the safety of the appliance.
• To guarantee effi cient 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. Any
other use is considered improper and therefore dangerous.
• 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 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.
2
Optimax 25 C
1. OPERATING INSTRUCTIONS..................................................................4
1.1 Introduction.............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Turning ON and OFF ..............................................................................................6
1.4 Adjustments ............................................................................................................6
1.5 Maintenance............................................................................................................7
1.6 Faults.......................................................................................................................7
1.7 Optional Time Clock ...............................................................................................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 ...........................................................................................................14
2.7 Condensate outlet connection .............................................................................20
2.8 Ferroli Optimax (optional) Time clock installation. ..............................................22
3. SERVICE AND MAINTENANCE............................................................23
3.1 Adjustments ..........................................................................................................23
3.2 System 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
3
Optimax 25 C
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing Optimax 25 C, a FERROLI wall-mounted boiler of the latest generation, featuring
advanced design and cutting-edge technology.
Optimax 25 C is a high-effi ciency condensing pre-mix appliance for heating with extremely low emis-
sions, 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 fl ue gases, permitting extremely high effi ciency.
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 fl ame 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, fl ow sensor, temperature sensors, a safety thermostat and a low pressure switch.
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 confi gure them. Any
operating problems associated with the boiler or system is immediately signalled by the display and, if
possible, corrected automatically.
4
Optimax 25 C
1.2 Control panel
°C°C
fi g. 1
23 41 5
1 - System temperature adjustment / Summer/Winter selection
This knob is used to adjust the system temperature from 20°C to 90°C and can switch over between
summer / winter. To increase the system temperature, turn the knob clockwise; anticlockwise to decrease
it. To select the summer mode, turn it anticlockwise to the minimum setting. (See page 6)
2 - ON-OFF / Reset / Test
Holding the key down for at least 5 seconds turns off the boiler. To turn it back on, press the key again
for 5 seconds.
Pressing the key resets boiler operation after a shutdown or lock-out.
Pressing the key 3 times within 5 seconds automatically takes you to TEST operation, (15mins at maxi-
mum heating output) to exit test mode repeat the process by pressing the key a further 3 times within
5 seconds.
3 - Multi-function
In combination with the reset key, this is used to access the Installer menu.
4 - Operating display
On stand-by and during boiler operation this indicates the boiler operating temperature, (a fl ame point
at the bottom of the display will illuminate to indicate the burner has lit) or a fault code if a problem
occurs.
5 - 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 6).
5
Optimax 25 C
1.3 Turning ON and OFF
Ignition
• Open the gas cock on the boiler.
• Purge the air from the pipework upstream of the gas valve.
• Ensure the power is on to the appliance.
• Press the key to turn the appliance on (fi g 1 item 2)
• The boiler is now ready to function automatically whenever the external controls are calling for
heat.
Turning off
Press the key for 5 seconds (see fi g. 1).
When the boiler is turned off with this key, the p.c.b is still powered, heating operation is disabled and
the display appears 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.
1.4 Adjustments
Room temperature adjustment (using a room thermostat )
Using the room thermostat, set the temperature desired in the rooms. Controlled by the room thermostat, 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).
Heating temperature setting
To set the system fl ow temperature, use the C.H control knob (ref. 1 - fi g. 1). It can
be varied from a minimum of 20°C to a maximum of 90°C.
To set the central heating 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 fl ash for 5 seconds and
display the set point temperature. It will then revert to showing the 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. It can be varied from
a minimum of 40°C to a maximum of 65°C.
When adjusting the control knob the display will fl ash for 5 seconds and
display the set point temperature. It will then revert to showing the actual
temperature.
6
Optimax 25 C
Summer/Winter selection
To select Summer/Winter, use knob 1 (fi g. 1).
Turning it onto (Summer) turns off the heating function but the frost protection remains active.
Turning it onto (Winter) turns on heating, via the room stat and programmer.
The boiler can still produce domestic hot water during summer mode whenever there is a demmand.
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.
1.6 Faults
In the unlikely event of an operating problem, or component failure, the display fl ashes and a fault
identifi cation code appears.
Listed below are the faults that can be caused by simple, user-detectable problems.
The boiler is equipped with an advanced self-diagnosis system. Should a fault occur with the boiler, the
display will show the fault code. There are some faults that in order to restore operation it requires you
to press RESET (2 - fi g. 1); if the boiler fails to start, it may be necessary to rectify the fault indicated
by the operating LEDs (faults from 1 to 26); other faults cause temporary shutdown that are automatically
reset as soon as the value comes back within the boiler’s normal working range (faults from 30 to 47).
Example
Fault CureDISPLAY
Make sure that the gas isolation valve up-stream of the boiler
Boiler failed to light
Insufficient system pressure
and on the meter are open.
Press the RESET button
Fill the system to 1-1.5 bar by use of the filling loop.
(2 Fig. 1).
If the problem remains after two attempts at resetting, contact your nearest FERROLI Caresafe.
For further fault codes, refer to section 3.4 “Troubleshooting”.
Before calling the FERROLI Caresafe centre, check that the problem is not due to an installation
error or there being no gas or electricity.
7
Optimax 25 C
1.7 Optional Time Clock
If a ferroli 24 hour time clock is fi tted to the boiler this will control the central heating, the pre set times
will only come into operation when both selector switches are moved to the “Auto” position.
AUTO
AUTO
P
F
To set time of day
1. Slide switch (A) to left position
2. Using button + and - adjust until the correct time is shown on display (B).
Pre Set Programmes. The timer is pre programmed with 3 ON and 3 OFF times.
6:30 - 8:30
12:00 - 12:00
16:30 - 22:30
To Set Own ON and OFF times. Symbol in Display = ON time
1. Slide switch (A) to right position (P)
Display
2. Press button (P)
Display
OI
4
x
OVER RIDE
-
+
P
R
RDP
If these are suitable no programming is required and the slide switch (A) can be moved to the Auto
position and the central heating will be ON for these periods.
(12:00 - 12:00 will not
A
B
x
E
6:30
8:30
A Slide switch: set clock - auto - set programme
B Display. Symbol in Display = Timer ON
P Select programme ON/OFF 1.....8
D Push buttons Time + Time
E Over-ride: Boiler will switch ON if it is OFF; and OFF if it is ON
F I=Heating continuous - AUTO=Heating timed - O=Heating disabled
R Reset (with pencil) only with switch A in set clock position
switch on the boiler)
1
2
-
1.1 Use buttons + and - to set 1st ON time eg. 6:00
Display
2.1 Use buttons + and - to set OFF time, eg. 9:00
Display
6:00
9:00
1
2
3. Press button (P)
Display
4. Press button (P)
Display
5. Press button (P)
Display
6. Press button (P)
Display
7. The timer can be programmed with up to 8 ON and
8 OFF times by repeating the above procedure.
Over ride
By pressing the over ride button (E) the timer programme is over ridden ie, if programme is in OFF time it will come ON
and if in ON time will go OFF.
The timer will revert back to it set programme on reaching the next ON or OFF time.
When the programme is on over ride the sign
Reset Button
By the use of a pencil the reset button can be pushed (R). This will clear all programmes apart from those factory pre set.
Reset is only possible with switch (A) in set Clock position!
12:00
12:00
16:30
22:30
3
4
5
6
will be shown in the display window (B).
3.1 Use button + and - to set 2nd ON time, eg. 12:30
Display
4.1 Use button + and - to set 2nd OFF time eg. 14:00
Display
5.1 Use button + and - to set 3rd ON time, eg. 16:00
Display
6.1 Use button + and - to set 3rd OFF time eg. 23:30
Display
8. On completion of programming slide switch (A) to
Auto position, the time of day will be displayed and the
central heating will switch ON and OFF according to the
programme set.
12:30
14:00
16:00
23:30
3
4
5
6
8
Optimax 25 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
2.2 Boiler location
The unit’s combustion circuit is sealed off from
the installation room and therefore requires no
compartment ventilation.
The installation room must be suffi ciently 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, fl ammable 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 fi xing must ensure a stable and
effective support for the appliance, using the
bracket and fi xings 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.
Optimax 25 C
C
A A
B
D
Table 1
Minimum
A
2,5 cm
B
20 cm
C 30 cm
60 cm
D
(via an openable panel)
fi g. 2
10
Optimax 25 C
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. The fl ow and return
must be a minimum diameter of 22mm for the fi rst 3 meters from the appliance.
If the fl ow 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 cock device at the lowest points in the
system to allow complete draining.
The temperature differential between the fl ow manifold and the return to the boiler should not exceed
20° C.
A minimum fl ow of 6 litres/min is requied through the heat exchanger, it is therefore essential to fi t 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 fl ush 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 fi g. 5.
Key
1 System fl ow (22 mm with isolation valve fi tted)
2 DHW outlet (15 mm with isolation valve fi tted)
3 Gas inlet (22 mm with isolation valve fi tted)
4 Cold main inlet (15 mm with isolation valve fi tted)
5 System return - 22 mm with isolation valve fi tted (c/w fi lter)
6 System drain
7 Condense outlet
6
1 2 3 5
40 68 107 77,5 57,5 50
7 4
400
fi g. 5
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 15mm 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 fl oods 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).
11
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