Page 1
OPTIMAX 25 OV
wall-mounting,
pre-mixed
condensing gas boiler
INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE
cod. 3544708/3 - 08/2004
Page 2
Optimax 25 OV
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 warnings. Carefully
follow these instructions in order to avoid danger and damage to persons, and or
property.
This symbols calls attention to a note or an important notice for the installer/service
engineer.
• Read the warnings given in this manual thoroughly.
They provide important information for safe installation, use and maintenance
• Keep the manual carefully for future consultation.
• The instruction manual is an integral and essential
part of the product and must be kept safely by the
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 cleaning or maintenance, disconnect the
appliance from the mains via the switch on the
appliance or a suitable isolating device.
• In the event of malfunction or faulty operation, switch
off 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 an authorised service
centre.
• 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 packing 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.
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
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Optimax 25 OV
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
2. INSTALLATION .......................................................................................8
2.1 General Instructions................................................................................................8
2.2 Boiler location .........................................................................................................9
2.3 Water connections ................................................................................................10
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 Wiring diagram .....................................................................................................34
3
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Optimax 25 OV
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing Optimax 25 OV, a FERROLI wall-mounted boiler of the latest generation, fea-
turing advanced design and cutting-edge technology.
Optimax 25 OV 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 ceramic surface pre-mix burner, equipped 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, safety valve, temperature
sensors, a safety thermostat and a fl ue gas 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
or regulate the temperature of the system). 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.
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Optimax 25 OV
1.2 Control panel
fi g. 1
23 41
1 - System temperature adjustment / Summer/Winter selection
This knob is used to adjust the system temperature 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.
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 lock-out.
Pressing the key 3 times within 3 seconds automatically takes you to TEST operation.
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, burner fl ame
established (point at bottom lights up) or should a fault occur the appropriate code will appear within
the display.
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Optimax 25 OV
1.3 Turning ON and OFF
Ignition
• Open the gas isolation valve on the boiler.
• Purge the gas supply taking the necessary precautions.
• Turn on the electrical switch at the 3amp switched fused spur.
• 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 printed circuit board is still powered, heating operation
is disabled and the display appears the frost protection will remain active.
Close the gas isolation valve under 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 (Via 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 set system delivery setpoint temperature. The
boiler turns off when the desired temperature in the rooms is reached, it will re-light when the room
temperature falls below the setpoint level, providing there is still a demand from the time clock.
Heating temperature setting
To set the system delivery temperature, turn the knob (ref. 1 - fi g. 1). It can be varied from a minimum
of 30 °C to a maximum of 90 °C.
Turning the knob sets the required temperature (clockwise to increase, anticlockwise
to decrease) that is shown on the display. During the setting, the display quickly
fl ashes and once defi ned it stops fl ashing after 2 sec. and reverts back to showing
the actual operating temperature.
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 stays active.
Turning it onto (Winter) turns on heating, via the time clock and room thermostat.
If the boiler is also used for hot water production do not select the summer position as this will
disable both heating and hot water modes.
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Optimax 25 OV
1.5 Maintenance
It is strongly recommended that an annual maintenance of the boiler is carried out by a qualifi ed gas
engineer. 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 event of operational faults, the display blinks 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. In the event of a problem with the boiler,
or system the display will show the fault code. There are some faults that will require the end user to
press RESET (2 - fi g. 1); if the boiler fails to start, It is necessary to rectify the fault indicated by the
LED display (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 46).
Example
Fault CureDISPLAY
Make sure that the gas isolation valve on the boiler and on the
Boiler failed to light
If the problem remains after two attempts at resetting, contact your nearest FERROLI Caresafe.
For other faults, refer to section 3.4 “Troubleshooting”.
Before calling the FERROLI Caresafe helpline, check that the problem is not due to there being
no gas or electricity, and that all external controls are wired correctly and calling fo heat.
gas meter are open.
Press the RESET button
(2 Fig. 1).
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Page 8
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, 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:
Optimax 25 OV
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
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Optimax 25 OV
2.2 Boiler location
The unit’s combustion circuit is sealed off from
the installation room. 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.
C
A A
B
D
fi g. 2
Table 1
Minimum Recommended
A
30 mm
B
200 mm
C 280 mm 300 mm
15 mm
D
(via an openable panel)
300 mm
300 mm
> 600 mm
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2.3 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.
If the fl ow and return pipes follow a path where air pockets
could form in certain places, it is advisable to install air vents
at these points. Also, install a drain plug at the lowest point in
the system to allow its complete emptying, when required.
The temperature differential between the fl ow and the return
to the boiler should not exceed 20° C (11° recommended).
Do not use the water system pipes to earth electrical
appliances.
Before installation, thoroughly clean all the pipes of the system
to remove residues or impurities that could affect the unit’s
operation. Flush system in accordance with BS 7593.
Make the connections to the corresponding tappings as shown
in fi g. 3.
Optimax 25 OV
110,5
2
1 4
50 35
50
45
35
fi g. 3
Key
1 CH fl ow (22 mm with compression coupler fi tted)
2 Gas inlet (22 mm with isolation valve)
3 Condense outlet
4 CH return (22 mm with compression coupler fi tted)
It is advisable to install anti-tamper isolation valves between the boiler and heating system allowing
the boiler to be isolated from the system if necessary.
164
95 120
400
201
3
35
185
50
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Optimax 25 OV
The connecting kits shown in fi g. 4 are supplied as standard.
fi g. 4
A
22
mm
X2
Key
A = Nut
B = Compression olive
C = Nipple
F = 1/2 gas seal - Blue
AB
22
mm
X1
ACBB
F
Gas isolation valve
Flow
Return
Appliance
drain OFF valve
Make Up Water
This appliance is designed to work on an open vented fully pumped heating system only, (see fi g 5 page
12). The make up of water must be made via a suitably sized cold feed and expansion tank installed to
the current regulations.
This appliance is not suitable for gravity type installations or primatic type cylinders only indirect ones
should be used.
The system must be fully pumped due to the complex design of the Alluminium Laminar heat exchangers high effi ciency design.
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.
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Optimax 25 OV
Schematic layout for fully pumped heating and hot water.
Static Head
15 mm
min. 2 m
Open
Vent
Motorised valve
22 mm
22 mm
DHW
Balancing
valve
max. 150 mm
Open
Vent
Indirect coil missing
Isolating
Indirect cylinder
valve
To DHW taps
Isolating valve
Drain
Motorised valve
22 mm CH
Radiator Radiator
Flow
CH Pump
Automatic By-pass
Return
Fig. 5
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Optimax 25 OV
Water treatment
When treatment is used ferroli limited recommend only the use of Fernox or Sentinel water treatment
products, which must be used in accordance with the manufactures instructions. for further information
contact:
Fernox Manufacturing Co. LTD. Sentinel Division
Cookson Electronics, Farsyth Road Betz Dearborn LTD
Woking, surry, GU21 5RE Widnes, Cheshire WA8 8ND
Tel: 0870 8700362 Tel: 0151 424 5351
Note - If the boiler is installed in an existing system any unsuitable additives must be removed by tho-
rough cleansing. All systems should be cleansed according to B.S. 7593.
Note - In hard water areas treatment to prevent lime scale may be necessary.
Note - It is important that the correct concentration of the water treatment product is maintained in
accordance with the manufacturers instructions.
2.4 Connection to the gas system
If necessary the local Gas supplier should be consulted, at the installation planning stage, in order to
establish the availability of an adequate supply of gas.
An existing service pipe must not be used whitout prior consultation with the local Gas supplier.
A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.
Installation pipes should be fi tted in accordance with BS6891.
Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection (22 mm).
The complete installation must be tested for gas soundness and purged as described in BS689.
All pipework must be adquately supported. An isolating gas valve is provided and should be
fi tted on the boiler gas inlet. Please wait 10 minutes when ligthing from cold before checking
gas rate. Gas pressures should be checked after the boiler has operated for 10 minutes to reach
thermal equilibrium.
The connecting kits shown in Fig. 4 are supplied as standard.
2.5 Electrical Connections
The unit must be installed in conformity with current national and local regulations.
Connection to the electrical grid
The boiler must be connected to a single-phase, 230 Volt-50 Hz electric line.
The unit’s electrical safety is only guaranteed when correctly connected to an effi cient earthing
system executed according to current safety standards. Have the effi ciency and suitability of the
earthing system checked by professionally qualifi ed personnel. The manufacturer is not responsible
for any damage caused by failure to earth the system. Also make sure that the electrical system
is adequate for the maximum power absorbed by the unit, as specifi ed on the boiler dataplate,
in particular ensuring that the cross sectional area of the system’s cable is suitable for the power
absorbed by the unit.
The boiler is prewired and provided with a cable for connection to the electricity supply. The connections to the supply must be made with a permanent connection and equipped with a double pole switch
whose contacts have a minimum opening of at least 3 mm, and fused at max. 3A between the boiler and
the supply. It is important to respect the polarities (LIVE: brown wire / NEUTRAL: blue wire / EARTH:
yellow-green wire) when connecting to the electrical supply.
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Optimax 25 OV
Central heating request
The heat demand can be done by the room thermostat (terminal 4-5) or by a switch line phase 230 V
(terminal 4).
Standard Systems
For a general pipe layout and wiring diagram on the “S” and “Y” plan systems please see fi g.
6a, 6b, and 7a, 7b.
OPTIMAX “S” Plan
Pipe layout
OPTIMAX
FERROLI
BOILER
A.A.V
A.A.V
Auto air vent
DHW
zone
valve
Balancing
valve
Remove
connection
between
terminals 4-5
*Note: cold feed and expansion
not shown for clarity
(see fig. 5)
Junction Box
765
8
PROGRAMMER
DHW ON
CH ON
NEUTRAL
LIVE
CH
zone
valve
4321
L
BROWN BLUE
NEL
Terminal 4
SWITCH LINE
Automatic
bypass
(mimimum flow of 6l/min.)
Wiring diagram
12345678910
C.H.
Zone Valve
N
E
L
230 Volt A/C
fused at
3 amps
Room Thermostat
Fig. 6a
14
DHW
zone
valve
Cylinder Thermostat
GREY ORANGE
Fig. 6b
Page 15
Optimax 25 OV
Optimax “Y” Plan
Pipe layout
Wiring diagram
8
OPTIMAX
FERROLI
BOILER
*Note: cold feed and expansion
not shown for clarity
(see fig. 5)
Junction Box
765
4321
NL
L
Terminal 4
SWITCH LINE
Remove
connection
between
terminals 4-5
A.A.V
A.A.V
Auto air vent
Balancing
valve
Automatic
(mimimum flow of 6LTR/min.)
bypass
Honeywell V4073H mid position
The heating system must have an automatic
12345678910
fi g. 7a
bypass capable of
passing 6 litres/minute
N
E
L
240 Volt A/C
fused at 3 amps
PROGRAMMER
NEUTRAL
LIVE
CH ON
DHW ON
DHW OFF
3 WAY ZONE VALVE
BLUE
WHITE
GREY
ORANGE
Room Thermostat
2
C
1
Cylinder Thermostat
fi g. 7b
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Optimax 25 OV
The user must never change the unit’s power cable. If the cable gets damaged, switch off the
unit and have it changed solely by professionally qualifi ed personnel. If changing the electric
power cable, use only “HAR H05 VV-F” 3x0.75 mm2 cable with a maximum outside diameter
of 8 mm.
Access to the electrical terminal board
To access boiler electrical connections remove the screw and drop down electrical cover (fi g. 8). The
layout of the terminals for the various connections is given in the wiring diagram in fi g 9 below.
fi g. 8
Room thermostat
REMOVE CONNECTIONS 4 - 5 IF EXTERNAL
CONTROL FITTED.
WARNING: the room thermostat works at
230V.
External Pump
The external pump must be connected to terminals 5, 6 (earth) and 7 of the terminal block
External
pump
System external
controls
Switch Line 230V
fi g. 9
N
230 V
L
(fi g. 9), to allow the pump over-run circuit to
operate.
2.6 Flue system
The unit is “type C” with a sealed chamber and forced draught, the air inlet and fl ue outlet must be
connected to one of the following fl ue systems. With the aid of the tables and methods of calculation indicated, before commencing installation, it is fi rst necessary to check that the fl ue system does not exceed
the maximum permissible length. The current standards and local regulations must be observed.
8
7
6
5
4
3
2
1
16
It should be noted that only Ferroli fl ue system and accessories should be used on this appliance,
as per BS 5440 2000 and C.E. test certifi cation.
Page 17
Optimax 25 OV
Connection with concentric fl ue system
The unit can be connected to a concentric air/fl ue duct with a wall or rooftop outlet as shown on the
following drawings. Numerous accessories are available on request to meet the various installation
requirements. Please refer to our “fl ue manual” or the price list.
Standard concentric fl ue installation
Standard 1KWMR53A
Flue kit
95
80
Rear Outlet
Side view
P
25
30
View from above
90
125
50*
S
Install level
Drill the wall 10 ÷20 mm
more than the pipe diameter
* = between
10 e 60 mm
* = between
10 e 60 mm
Install level
Drill the wall 10 ÷20 mm
more than the pipe diameter
Side Outlet
Front view
L
50*
DS
View from above
Standard 1KWMR53A
Flue kit
30
95
215 185
80
90
185215
Install level
S
50*
L = S + D + 205 mm
30
95
D
L
215
185
fi g. 10a
Install level
30
95
S
50*
P
P = S + 160 mm
fi g. 10b
Horizontal fl ue installation
1. Defi ne the position for installing the unit.
2. If using standard fl ue (1KWMR53A) this must be installed level, for non-standard fl ue lenghts over
1mtr a fall of 3 mm per metre should be incorporated.
3. Make a hole of diameter 10 - 20 mm greater than the nominal diameter of the concentric pipe
used.
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Optimax 25 OV
4. If necessary, cut the end pipe to size, ensuring that the external pipe protrudes from the wall by
between 10 and 60 mm (fi g. 10a and 10b). Remove the cutting burrs.
5. Connect the fl ue to the boiler, positioning the seals correctly. Seal the fl ue into the wall with silicone
or sand + cement and cover with wall seals provided.
Flue seals should be lubricated with a silicone type grease to prevent damage (grease not supplied)
Vertical Outlet
The total length in equivalent metres of the
concentric fl ue must not exceed the maximum
lengths stated in the following table, note that
each bend gives rise to the stated reduction.
For example, a duct = 60/100 composed of 1
bend of 90° +1 horizontal metre + 2 bends of
45° + 1 horizontal metre has a total equivalent
length of 4 metres.
Table 2a
Maximum permissible
duct length (Horizontal)
Maximum permissible
duct length (Vertical)
Ø mm
60/100
5 m 12 m
6 m 12 m
Ø mm
80/125
Roof end piece
1KWMA83U
Angled roof tile
1KWMA82U
10
1000 125
50
950
Table 2b
Reduction factors for bends
1 m
0,5 m
0,5 m
0,25 m
For the installation:
1. Defi ne the position for installing the unit.
2. Drill the wall for the air/fl ue pipe outlet according to the references stated in the table,
considering that the horizontal sections of
piping must have a gradient of approximately 3 mm per metre of length downwards
to prevent any rainwater getting into the
boiler.
3. Make a hole of diameter 10 - 20 mm greater
than the nominal diameter of the coaxial pipe
used to facilitate insertion.
4. If necessary, cut the end pipe to size, considering that the external pipe must protrude
from the wall by between 10 and 60 mm (Fig.
10a and 10b). Eliminate the cutting burrs and
lubrifi cate seals.
5. Connect the ducts to the boiler, positioning
the gaskets correctly and seal the wall coupling points with special sleeves.
1KWMA56U
50 950
95050
fi g. 10c
50
68
max. 6 mt 60/100
max. 12 mt 80/125
1KWMA71W
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Optimax 25 OV
Connection with 80 mm pipe system
The unit can be connected to a system of separate air/fume ducts for a wall or rooftop outlet
as shown on the drawings 11 - 12 alongside.
Numerous accessories are available on request
to meet the various installation requirements.
The components used most frequently are
stated in tables 4 - 5. Please refer to the fl ue
manual or the price list for additional components.
To check you do not exceed the maximum permissible duct length, it is necessary to make a
simple calculation before installation:
1. For each component, tables 4 - 5 provide
an “equivalent load loss in linear metres”,
depending on the position of installation
of the component (with air suction or fl ue
extraction, vertical or horizontal).
The loss is called “equivalent in linear metres”
since it is compared to the loss of one metre
of duct in air suction (defi ned as equal to 1).
For example, a bend at 90° of Ø80 in fl ue
extraction has an equivalent loss of 2.5 linear
metres, i.e. it has a loss equal to that of 2.5
linear metres of duct in air suction.
Remove
the closing
cap
Ø80
AIR
95
80
3
Ø80
FUMES
KWMR54A
120 185
90
274
84
fi g. 11
2. After completely defi ning the layout of the
two pipe fl ue system, add up the losses in
equivalent metres, depending on the installation position, of all the components and
accessories in the system.
3. Check that the total calculated loss is less
than or equal to 75 equivalent metres, i.e.
the maximum permissible for this model of
boiler.
If the chosen fl ue system exceeds the
maximum permissible limit, it is recommended to use ducts with a larger diameter for some sections.
Table 3
Ref.
1
2
3
4
21
25
Description
Vertical flue pipe Ø80
Vertical air pipe Ø80
Vertical outlet terminal
1
Kit (1KWMR54A)
2
Total
Equivalent
2 1
4
1KWMR54A
loss
33,6 m
25,0 m
12,0 m
0,6 m
71,2 m
fi g. 12
19
Page 20
Table of fl ue and accessory
Table 4 Table 5
Equivalent losses in
metres (linear)
Accessories Ø 80 Accessories Ø 80
Air Flue
Optimax 25 OV
Equivalent losses in
metres (linear)
Air Flue
Description
Pipe Ø 80
male-female
KWMA83W • 1,00 m
Bend 45
° Ø 80 mm
male - female
Bend 90° Ø 80 mm
male - female
Terminal Position
KWMA65W
KWMA01W
Vertical
Horizontal
Vertical
Horizontal
111.62
1.2 1.8
1.5 2.0
Horozontial
flue terminal
Horozontial
air terminal
Vertical flue
terminal
Description
KWMA86A
KWMA85A
KWMA84U
Vertical
Horizontal
2
12
Vertical
Horizontal
5
The stated loss values refer to genuine Ferroli fl ue accessories.
P
Q
l
Q
D, E
Q
F
J
L
B
G
C
A
H
N
MM
N
H
K
fi g. 13
20
Page 21
Optimax 25 OV
Minimum Dimensions of Flue Terminal Positions
A
B
C
D
E
F
G
H
I
J
K
L
Directly below an opening, air brick,
opening windows, etc.
Above an opening, air brick,
opening windows, etc.
Horizontally to an opening, air brick,
opening windows, etc.
Below gutters, soil pipes or drain pipes
Below eaves
Below balconies or car port roof
From a vertical drain pipe or soil pipe
From an internal or external corner
Above ground roof or balcony level
From a surface facing the terminal
From a terminal facing the terminal
From an opening in the car port (e.g. door,
window) into the dwelling
300mm
300mm
300mm
75mm
200mm
200mm
150mm
100mm
300mm
600mm
1200mm
1200mm
M
N
O
P
Q
NOTE
N/A = Not applicable
In addition, the terminal should not be nearer than 150mm (fanned draugt) or
300mm (natural draugt) to an opening in the building fabric formed for the purpose
of accommodating a built-in element such as a window frame.
Condensing Terminal Positions: If the flue is to be terminated at low level, then the
potential effect of the plume must be considered.
The plume should not be directed:
Vertically from a terminal on the same wall
Horizontally from a terminal on the same wall
From the wall on which the terminal is mounted
From a vertical structure on the roof
Above intersection with roof
across a frequently used access route
towards a window or door
across a neighbouring property
1500mm
300mm
N/A
150mm
300mm
21
Page 22
Optimax 25 OV
Connection to collective fl ues or single fl ues with natural draught
If you are then going to connect the Optimax 25 OV boiler to a collective fl ue or a single fl ue with
natural draught, the fl ue must be expressly designed by professionally qualifi ed technical personnel in
conformity with the standards and rules in force.
In particular, fl ues must have the following characteristics:
• Be sized according to the method of calculation stated in the standard
• Be airtight to the products of combustion, resistant to the fumes and heat and waterproof for the
condensate
• Have a circular or quadrangular cross-section (some hydraulically equivalent sections are permissible),
with a vertical progression and with no constrictions
• Have the fl ue conveying the hot fumes adequately distanced or isolated from combustible materials
• Be connected to just one unit per fl oor, for at most 6 units in all (8 if there is a compensation duct or
opening)
• Have no mechanical suction devices in the main ducts
• Be at a lower pressure, all along their length, under conditions of stationary operation
• Have at their base a collection chamber for solid materials or condensation of at least 0.5 m, equipped
with a metal door with an airtight closure.
2.7 Condensate outlet connection
A
B
0,5 lt.
22
fi g. 14
The boiler is equipped with an internal air-trap to drain off the condensate. Fit the inspection bowl A
and the hose B, pushing it on for approximately 3 cm and securing it with a hose clamp.
Fill the air-trap with approximately 0.5 ltrs of water and connect the hose to the household waste
system.
Page 23
Optimax 25 OV
Condensate discharge
Where possible the condensate should discharge into an internal soil pipe or waste system. The minimum
pipe diameter required is 22 mm, a trap has already been fi tted to the appliance with a fl exible tail to
facilitate the connection to the condensate discharge pipe.
The pipe should be a solvent weld plastic, not copper, as the condensate has a ph value of 4 (slightly
acidic).
Where it is not possible to terminate internally, the condensate discharge pipe may be run outside (see
below drawing).
Any external run is subjet to freezing, in severe weather conditions. To avoid this the pipework should
be installed to dispose of the condensate quickly, with as much as possible run internally, before passing
through the wall.
Pipework external to the building should be increased in diameter to 32 or 40 mm solvent weld. It should
be run to a external drain or soakaway, with a maximum lenth of 3 metres.
If a soakaway (condensate absorption point) is used, it should be constructed as shown below.
Internal
External
32/40mm Solvent pipework
Cement motar seal
25mm
100mm Dia tube
Lime stone chippings
Hole depth 400mm
Ground level (either/Or)
2 x 10 mm holes
3 holes per row
Bottom sealed
fi g. 15
Note As an alternative you can use a purpose made soakaway such as the Mc Alpine one, code
SOAK1GR. This only requires the limestone chippings and the waste pipe from the the appliance
to the soakaway.
23
Page 24
Optimax 25 OV
3. SERVICE AND MAINTENANCE
3.1 Adjustments
All adjustment and conversion operations must be carried out by Qualifi ed Personnel such as the personnel of the Local After-Sales Technical Service.
FERROLI declines any responsibility for damage or physical injury caused by unqualifi ed and unauthorized
persons tampering with the device.
Gas supply conversion
The unit can function with either Natural Gas or LPG and is factory-set for use with one of the two gases,
as clearly shown on the packing and on the unit’s dataplate. Whenever a different gas to that for which
the unit is preset has to be used, a conversion kit will be required, proceeding as follows:
1 Remove the casing.
2 Open the airtight chamber.
3 Unscrew the gas coupling A on the air/gas mixer.
4 Replace the injector in the mixer with the one contained in the conversion kit.
5 Refi t the coupling A and check the connection is gastight.
6 Apply the sticker, contained in the conversion kit, near the dataplate.
7 Fit the airtight chamber and casing back on.
8 Check working pressure.
9 Set CO2 mixture as detailed (page 27).
A
Nozzle Ø
Natural gas LPG
See Technical data table
24
fi g. 16
Page 25
Optimax 25 OV
3.2 System start-up
Commissioning must be performed by Qualifi ed Personnel.
Checks to be made at fi rst ignition, and after all maintenance operations that involved disconnecting from the systems or an intervention on safety devices or parts of the boiler:
Before lighting the boiler:
• Open any isolation valves between the boiler and the systems.
• Check the tightness of the gas system, proceeding with caution and use gas leak detection fl uid to
detect any leaks in connections.
• Fill the water system and make sure that all air contained in the boiler and the system has been vented
by opening the air vent valve on the boiler and any vent valves on the system.
• Make sure there are no water leaks in the system, hot water circuits, connections or boiler.
• Make sure the electrical system is properly connected.
• Make sure that the unit is connected to a good earthing system.
• Make sure there are no fl ammable liquids or materials in the immediate vicinity of the boiler.
• Ensure the fl ue system is correctly installed, including terminal locations.
Ignition
• Open the gas isolation valve upstream of the boiler.
• Purge the gas supply and appliance
• Switch on the boiler 3amp fused spur.
• The boiler is now ready to function automatically whenever the external controls call for heating.
In case of an electrical power failure while the boiler is working, the burner will go out. When
power returns, the boiler will run the self-test cycle again, after which the burner will automatically
re-ignite (if there is still demand for heat).
Checks during operation
• Check the tightness of the gas circuit and water systems.
• Check the effi ciency of the fl ue and air-fl ue ducts while the boiler is working.
• Check that the water is circulating properly between the boiler and the system.
• Make sure that the boiler modulates correctly.
• Check the proper ignition of the boiler by performing various tests, turning it on and off with the
room thermostat or remote control.
• Make sure that the fuel consumption indicated on the meter corresponds to that given in the technical
data table in chap. 4.
• Check the parameters are programmed correctly and perform any required customization (power,
temperatures, etc.).
Turning off
Press the key for 5 seconds (see fi g. 1).
When the boiler is turned off with this key, the printed circuit board is still powered, heating operation
is disabled and the display appears but the frost protection, will still operate.
Close the gas isolation valve on 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 boiler, or add a suitable antifreeze to the heating system.
25
Page 26
Optimax 25 OV
3.3 Maintenance
The following operations are strictly reserved for Qualifi ed Personnel, such as corgi registered
engineers or Ferroli personnel.
Seasonal inspection of the boiler and fl ue
It is advisable to carry out the following checks at least once a year:
• The control and safety devices (gas valve, thermostats, etc.) must function correctly.
• The fl ue terminal end piece and ducts must be free of obstructions and leaks.
• The gas and water systems must be sound.
• The burner and exchanger must be clean.
• The electrodes must be free of scale and correctly positioned.
• The system vented to ensure no air present.
• The expansion vessel must be fi lled to 1 bar cold with zero system pressure.
• The gas fl ow and pressure must correspond to that given in the respective tables.
26
Page 27
Optimax 25 OV
Opening the casing
To open the boiler casing, you need to follow the sequence
given below and the instructions of fi g. 17.
1 Using a screwdriver, fully unscrew the 2 screws “A ”
2 Open by lowering the panel “B ”
3 Lift and take off the panel “C ”
C
B
fi g. 17
A
A
Cleaning the boiler and burner
The body and burner must not be cleaned with chemical products or wire brushes. Special care must
be taken over all the sealing systems pertaining to the sealed chamber (gaskets, cable clamps, etc.). In
addition, it is necessary to pay attention after performing all these operations to check and carry out all
the phases of ignition and thermostat operation and the gas valve.
After these checks, make sure there are no gas leaks.
Combustion analysis
It is possible to analyse the combustion through
the air and fume sampling points shown in fi g.
18.
To make the measurement, it is necessary to:
1) Open the air and fume sampling points
2) Insert the probes;
3) Press RESET key for 3 times in the
3 seconds to turn on TEST mode;
4) Wait 10 minutes for the boiler to stabilize
5) Take the measurement.
Air
Fumes
Air Fumes
CO2 = 8,7÷9 % for NAT GAS
CO2 = 9,5÷10 % for L.P.G.
Analyses made with an unstabilized boiler can cause measurement errors.
fi g. 18
27
Page 28
Optimax 25 OV
3.4 Troubleshooting
Fault Diagnosis
In the event of operating problems or trouble, the display fl ashes and a fault identifi cation code
appears.
There are faults that in order to restore operation the RESET button must be pressed or (ref.2 - fi g. 1);
if the boiler fails to start, it is necessary to resolve the fault (from no. 1 to no. 24). Other faults cause
temporary shutdowns that are automatically reset as soon as the value comes back within the boiler’s
normal working range (faults from 25 to 46).
When the boiler starts functioning normally again, the display stops fl ashing and the fault code disappears.
Table 6
Fault Possible cause Cure
F1
F2
F3
F5
No burner ignition • No gas
• Detection or ignition
electrode fault
• Defective gas valve
• Incorrect inlet gas pressure
• Siphon obstructed
flame detected with the
burner off
Safety thermostat trips • Flow sensor not active
Fan problem
• Ionization electrode
defected
• Main board defected
• No system circulation
• Tachometer signal
interrupted
• Fan damaged
• Check the regular gas flow to the
boiler and the air has been
purged from the pipes.
• Check that the electrodes are
correctly positioned and free of
any deposits
• Check and change the gas valve
• Check inlet gas pressure
• Check and if necessary change the
siphon
• Check the ionizing electrode wiring
• Check the CVBC
• Check the correct positioning
and operation of the Flow sensor
• Check the pump and radiator valves
present in the system
• Check the wiring
• Check the fan
28
F8
F9
F10
÷
F22
No flame after the ignition
phase
No communication between
the electronic unit and the
gas valve
Microprocessor trouble • Microprocessor operating
• PCB trouble
• Mains interference
• Incorrect wiring
• Damaged valve
trouble
• Check and if necessary change
the PCB
• Check the earthing
• Check the wiring
• Check the components
• Change the valve
• Cut off and restore the electricity
supply. If the trouble remains, check
and/or change the main CVBC unit
Page 29
Optimax 25 OV
Fault Possible cause Cure
F25
F26
F30
F31
F34
F35
Software fault • Software operating fault • Cut off and restore the electricity
supply. If the trouble remains,
check and/or change the main CVBC
No flame after the ignition
phase (5 times in 4 min.)
Flow sensor fault
Flow sensor fault • Sensor damaged or wiring
Supply voltage under 190V.
or over 250V.
Irregular mains frequency • Electric mains fault • Check the electrical system
• Detection electrode faut
• Flame instable
• Incorrect valve gas Offset
• Flue gas circuit obstructed
• Siphon obstructed
• Sensor damaged or short
circuited
broken
• Electric mains fault • Check the electrical system
• Check that the electrode is correct
positioned and is necessary change
it
• Check the burner
• Check Offset at the minimum power
• Check if flue gas circuit is free
• Clean and if necessary change the
siphon
• Check the wiring or change
the sensor
• Check the wiring or change
the sensor
F36
F37
F43
F44
F45
F46
Electronic PCB trouble
Incorrect system water
pressure
Return sensor fault
Return sensor fault
Flue sensor fault
Flue sensor fault
• Change the electronic CVBC
• Wiring broken • Check connection betwenn 5-8
terminals of X7 on the display board
• Sensor damaged or wiring
shorted
• Sensor damaged or wiring
broken
• Sensor damaged or wiring
shorted
• Sensor damaged or wiring
broken
• Check the wiring or change the
sensor
• Check the wiring or change the
sensor
• Check the wiring or change the
sensor
• Check the wiring or change the
sensor
29
Page 30
Optimax 25 OV
4 TECHNICAL CHARACTERISTICS AND DATA
4.1 Dimensions and connections
Bottom view
2
164
400
50 35
45
35
13
30
274
Key
1 CH fl ow
2 Gas inlet
3 CH return
4 Condense outlet
fi g. 19
4
164 201 35
95 120 185
2
13
Top view
50
Page 31
Optimax 25 OV
4.2 General view and main components
16
34
49
22
161
196
10
11
29
Flue gas sensor
21
201
5
186
82
188
Viewing window
19
44
Key
5 Airtight chamber
7 Gas inlet
10 CH fl ow
11 CH return
16 Premix fan
19 Combustion chamber
21 Gas injector
22 Ceramic burner
29 Flue outlet manifold
34 Heating fl ow sensor
44 Gas valve
49 Safety thermostat
82 Ionisation probe
83 C.V.B.C unit
154 Condensate outlet pipe
161 Heat exchanger
175 Transformer
186 Return sensor
188 Ignition electrode
196 Condensate collector
201 Fan Venturi
175
83
7 154 Drain off valve
fi g. 20
31
Page 32
4.3 Hydraulic diagram
16
34
49
Optimax 25 OV
1110
201
161
186
Key
7 Gas inlet
10 CH fl ow
11 CH return
16 Premix fan assembly
34 Flow temperature sensor
44 Gas valve
154
44
7
fi g. 21
49 Safety thermostat
154 Condensate outlet pipe
161 Heat exchanger
186 Return sensor
201 Fan Venturi
32
Page 33
Optimax 25 OV
4.4 Technical data table
Table 7
Powers
Hi Heating power
Useful Heating Power 80° C - 60° C
Useful Heating Power 50° C - 30° C
Natural Gas delivery (G20)
Natural Gas supply pressure (G20)
LPG flow rate (G31)
LPG supply pressure (G31)
kW 25,2 7,5
kW 24,7 7,3
kW 26,4 8,0
3
m
/h 2,67 0,79
mbar 20 20
kg/h 1,96 0,58
mbar 37 37
Combustion
CO2 (G20 - Natural Gas) %
Gas nozzle (G20 - Natural Gas)
CO2 (G31 - Propane) %
Gas nozzle (G31 - Propane)
Flue temperature 80° C-60° C °C
Flue temperature 50° C-30° C °C
Flue flow rate kg/h
Quantity of condensate kg/h
pH of condensation water pH
Energy marking (92/42 EEC directive)
NOx emission class
Heating
Heating temperature adjustment range °C
Maximum working pressure in heating bar
Minimum working pressure in heating bar
Expansion vessel capacity litres
Expansion vessel pre-filling pressure bar
Total boiler water content litres
Dimensions, weights connections
Height mm
Width mm
Depth mm
Weight empty kg
Gas system connection
Heating system connections
Maximum length of separate flues D=80*
(*Measurement given in equivalent linear metres – cfr FERROLI calculation system)
m
Electrical power supply
Max electrical power absorbed W
Pmax Pmin
Pmax
9,0
10
65
46
43
3,3
eq
Pmin
8,7
5,4
9,5
4,0
60
31
13
1,4
4,1
5
30 - 90
3
0.8
8
1
1,7
720
400
358
34
22
22
75
50
33
Page 34
4.5 Wiring diagram
Optimax 25 OV
81
82
S4965V1018
DC F02.1
34
186
T
49
191
L
N
X1
510
49
38
27
16
X12
816
715
614
513
412
311
210
19
X11
36
25
14
V1
44
V2
X3 X6 X1 X7 X5X2
32
Remove if
external control
fitted 230Vac
230 V
8
7
6
5
4
N
3
2
L
1
175
F2A
Key
16 Fan
32 Central heating pump (not supplied)
34 C.h. fl ow temperature sensor
44 Combination gas valve
49 Overheat cut-off thermostat
81 Spark electrode
82 Ionisation probe
175 Transformer
186 Return sensor
191 Flue temperature sensor
24 V.
456
123
34
12
fi g. 22
678910
12345
DSP49A1100
CPD5.1
123456
6785
1234
TACHO
GND
PWM
24V
16
34
Page 35
Page 36
Should you require help during installation
call our Technical Helpline on
08707 282 885 option 1
To book a Ferroli service engineer
call Ferroli caresafe on
08707 282 885 option 2
Phone numbers:
Installer
Service Engineer
BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS
MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.
ALL SPECIFICATIONS SUBJECT TO CHANGE
Please note - to avoid incurring unnecessary expense, in the event of a boiler shut down, check this is
not caused by lack of electricity supply, gas supply or low water pressure before calling our Customer
Service Helpline.
Lichfi eld Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD
Tel. 08707 282 885 - Fax 08707 282 886
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