ferroli Optimax HE 25 S User guide
OPTIMAX HE 25 S
wall-mounted gas fired,
pre-mix
condensing system boiler
cod. 3540E632 - 04/2007 (Rev. 01)
INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE
Seasonal Efficiency
(SEDBUK)
band A
FOR THE UNITED KINGDOM AND EIRE
G.C. n° 41-267-25
OPTIMAX HE 25 S
IMPORTANT
• Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the
last pages of this manual. “This record must be completed and left with the end user”.
Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.
Benchmark has been introduced to improve the standards of installation and commissioning of
central heating systems in the UK and to encourage the regular servicing of all central heating
systems to ensure safety and efficiency. Please see installation and servicing guidelines.
For EIRE ( Southern Ireland ) it is necessary to complete a “Declaration of Conformity “ to indicate
compliance to I.S. 813. An example of this is given in the current edition of I.S. 813. In addition
it is necessary to complete the “Benchmark” logbook
• "Ferroli declare that no substances harmful to health are contained in the appliance or used
during the appliance manufacture”.
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 must be left with the
end user.
• If the appliance is sold or transferred to another
owner or if the owner moves, leaving the appliance
behind, always ensure that the manual is kept with
the appliance for consultation by the new owner
and /or installer.
• Incorrect installation or poor maintenance absolves
the manufacturer from all liability for damage to
people or property.
• Installation and maintenance must be carried out
in conformity with current legislation, according
to the manufacturer’s instructions and by qualified
personnel.
• Before service or maintenance work is, carried out
isolate the appliance from the mains electricity
supply.
• In the event of malfunction or faulty operation, isolate the appliance. Do not attempt to repair or carry
out any other operation on the appliance directly.
Contact qualified personnel only.
• Repairs or the replacement of components must be
carried out exclusively by qualified personnel using
original spare parts only. Failure to respect the above
may compromise the safety of the appliance.
• To guarantee efficient operation, the appliance must
be serviced once a year by a corgi registered 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.
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Cod. 3540E632 - 04/2007 (Rev. 01)
OPTIMAX HE 25 S
1. OPERATING INSTRUCTIONS .................................................................4
1.1 Introduction ............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Turning ON and OFF ..............................................................................................6
1.4 Adjustments ............................................................................................................7
1.5 Maintenance ............................................................................................................8
1.6 Faults .......................................................................................................................8
2. INSTALLATION .......................................................................................9
2.1 General Instructions ................................................................................................9
2.2 Boiler location .......................................................................................................10
2.3 Boiler water connections ......................................................................................11
2.4 Connection to the gas system ..............................................................................13
2.5 Electrical Connections ..........................................................................................13
2.6 Flue system ...........................................................................................................16
2.7 Condensate outlet connection .............................................................................22
3. SERVICE AND MAINTENANCE ............................................................24
3.1 Adjustments ..........................................................................................................24
3.2 System start-up .....................................................................................................25
3.3 Maintenance ..........................................................................................................26
3.4 Troubleshooting ....................................................................................................28
4. TECHNICAL CHARACTERISTICS AND DATA ..........................................................30
4.1 Dimensions and connections ................................................................................30
4.2 General view and main components ....................................................................31
4.3 Hydraulic diagram .................................................................................................32
4.4 Technical data table ..............................................................................................33
4.5 Diagrams ...............................................................................................................34
4.6 Wiring diagram .....................................................................................................35
BENCHMARK ...........................................................................................36
Cod. 3540E632 - 04/2007 (Rev. 01)
3
OPTIMAX HE 25 S
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing the OPTIMAX HE 25 S, a FERROLI wall-mounted boiler of the latest generation,
featuring advanced design and cutting-edge technology.
OPTIMAX HE 25 S is a high-efficiency condensing pre-mix appliance for heating with extremely low
emissions, running on natural gas or LPG.
The boiler consists of an aluminium laminar heat exchanger providing effective condensation of the
water vapour contained in the flue gases, permitting extremely high efficiency.
Above the heat exchanger, in the boiler, there is a pre-mix burner, with a large ceramic surface, equip-
ped with electronic ignition and ionization flame control, which achieves extremely low emissions while
ensuring high reliability and long life operation.
The boiler is totally room sealed from the installation room: the air needed for combustion is drawn
from outside. The boiler also includes a modulating speed fan, modulating gas valve, pump, expansion
vessel, safety valve, temperature sensors, a safety thermostat and a low water pressure sensor.
Thanks to the microprocessor control and adjustment system with advanced self-diagnosis, unit 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.
4
Cod. 3540E632 - 04/2007 (Rev. 01)
OPTIMAX HE 25 S
1.2 Control panel
8
11
12
21
436
15
comfort
1314
fig. 1
75
eco
reset
1 = Domestic Hot Water temperature setpoint decreasing push button (not used)
2 = Domestic Hot Water temperature setpoint increasing push button (not used)
3 = Central Heating water temperature setpoint decreasing push button
4 = Central Heating water temperature setpoint increasing push button
5 = Display LCD
6 = Reset
7 = On-Off push button
8 = Domestic Hot Water symbol
11 = Multi-function indication
12 = Degrees indication
13 = Central Heating mode operation
14 = Central Heating symbol
15 = Burner on and actual load indication
Indication during boiler operation
Demand mode
The Boiler heat demand (generated by the Programmer, room thermostat and cylinder thermostat) is
indicated by the flashing of the Hot Air symbol over the radiator (part. 13 and 14 – fig. 1). The display
indicates the actual System water temperature (part. 11 – fig. 1).
eco
comfort
reset
fig. 2
Cod. 3540E632 - 04/2007 (Rev. 01)
5
1.3 Turning ON and OFF
Without main power supply
fig. 3 - Boiler without main power supply
To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all
water from the system.
eco
comfort
reset
OPTIMAX HE 25 S
Ignition
Ensure the power is on to the appliance.
eco
comfort
reset
fig. 4 - Ignition
For the first 120 seconds, the display shows FH that identifies the Air purge function.
•
During the first 5 seconds, the display shows the software version of the pcb.
•
Open the gas cock on the boiler and purge the air from the pipework upstream of the gas valve.
•
When the FH disappears, the boiler is ready to function automatically whenever the external controls
•
eco
comfort
reset
fig. 5 - Air purge
are calling for heat.
Turning off
Press the (part. 7 - fig. 1) for 5 seconds.
eco
comfort
reset
fig. 6 - Turning off
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Cod. 3540E632 - 04/2007 (Rev. 01)
OPTIMAX HE 25 S
When the boiler is turned off with this key, the p.c.b is still powered, heating operation is disabled and
the display is off however the frost protection will still be active.
To totally isolate close the gas cock ahead of the boiler and disconnect electrical power.
To avoid damage caused by freezing during long shutdowns in winter, it is advisable to drain all
water from the system.
To turn the boiler on again, press
(part.7 - fig.1) for 5 seconds.
eco
comfort
reset
fig. 7
If there is no heat demand, the display shows the actual water pressure (bar/10).
The boiler is ready to function automatically whenever the external controls are calling for heat.
1.4 Adjustments
Heating temperature setting
To set the system flow temperature, use the CH push buttons (Part. 3 and 4 – fig. 1). It can be
varied from a minimum of 20°C to a maximum of 90°C.
eco
comfort
reset
fig. 8
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).
Cod. 3540E632 - 04/2007 (Rev. 01)
7
OPTIMAX HE 25 S
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 flashes and a fault
identification code appears.
The boiler is equipped with an advanced self-diagnosis system that signals any faults on the display.
Some faults (“A“ indication) cause a boiler shutdown. In this case, operation must be reset manually by
pressing the
Other faults (“F“ indication) cause temporary shutdowns that are automatically reset as soon as the
value causing the fault comes back within the boiler’s normal working range.
Listed below are some anomalies that can be caused by simple, user-solvable problems.
If the problem remains after two attempts at resetting, contact the Ferroli Service Centre.
For other faults, refer to section 3.4 “Troubleshooting”.
reset
(Part. 6 – fig. 1) for 1 second.
Fault Cure
Make sure that the gas cocks ahead of the boiler
and on the meter are open.
No burner ignition
Low system pressure
Before calling a Ferroli service engineer, check that the problem is not due to there being no
gas or electricity, or low system pressure.
Press the RESET button (for 1 second).
In case of repeated shutdowns, contact the Ferroli
Service Department.
Fill the ‘system to 1-1.5 bar.
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Cod. 3540E632 - 04/2007 (Rev. 01)
OPTIMAX HE 25 S
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
COMPETENT WORKMANSHIP.
IN IE, THE INSTALLATION MUST BE CARRIED OUT BY A COMPETENT PERSON IN ACCORDANCE
WITH THE CURRENT EDITION OF I.S. 813 “DOMESTIC GAS INSTALLATIONS”, THE CURRENT BUILDING REGULATIONS AND REFERENCE SHOULD BE MADE TO THE CURRENT ETCI RULES FOR ELECTRICAL INSTALLATIONS.
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
I.S. 813 DOMESTIC GAS INSTALLATIONS (EIRE ONLY)
Model Water Bye Laws
B.S. 5955-8 PLASTIC PIPEWORK INSTALLATION
For Northern Ireland the rules in force apply
Cod. 3540E632 - 04/2007 (Rev. 01)
9
2.2 Boiler location
The unit’s combustion chamber is sealed off
from the installation room and therefore requires no compartment ventilation.
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 designed to be installed on a solid
wall. The wall fixing must ensure a stable and
effective support for the appliance, using the
bracket and fixings supplied.
If the unit is enclosed in a cupboard or mounted alongside, there must be space for normal
maintenance work. Fig. 9 and tab. 1 give the
minimum clearances to leave around the unit.
OPTIMAX HE 25 S
C
A A
B
D
fig. 9
Table 1
Minimum
2,5 cm
A
20 cm
B
C 30 cm
60 cm
D
(via an openable panel)
Safe Handling of Substances
Care should be taken when handling the boiler
insulation panels, which can cause irritation to the skin. No asbestos, mercury or CFCs are included in
any part of the boiler.
Product Handling Advice
When handling or lifting always use safe techniques - keep your back straight, bend your knees, don’t
twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body
as possible.
Where possible transport the boiler using a sack truck or other suitable trolley.
Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the
centre of gravity, repositioning yourself as necessary.
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Cod. 3540E632 - 04/2007 (Rev. 01)
OPTIMAX HE 25 S
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 etc. The flow and return must be a minimum diameter of
22mm for the first 3 metres from the appliance.
If the flow and return pipes follow a path where air pockets could form in certain places, it is essential
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 flow manifold and the return to the boiler should not exceed
20° C.
A minimum flow of 6 litres/min is required through the heat exchanger, calibrated on site. An automatic
by-pass is fitted to the boiler which will provide this flow rate
in most circumstances.
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. 10.
7 6
1 3 5
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)
6 Pressure Relief Valve
7 Condense outlet
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 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 event of an
over-pressurising system.
Make the boiler connection in such a way that its internal pipes are free of stress.
76,2 80,5
82,5 130 131,5 56
fig. 10
216,7
156,7
Cod. 3540E632 - 04/2007 (Rev. 01)
11
The isolation valve kit shown in Fig. 11 is supplied as standard.
Key
A = Nut
B = Compression olive
D = 3/4 seal (green)
E = 1/2 seal (green)
F = 1/2 gas seal (blue)
G = Filter
H = Cap
D
A
B
A
B
Flow isolation valve
RED
F
Gas isolation valve
YELLOW
22
22
OPTIMAX HE 25 S
D
fig. 11
AB
22
BLUE
H
G
Return isolation valve
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.
Attention - is drawn to the Model Water Byelaws.
2
Key
1. C.H. filling valve.
2. Temporary connection.
3. Cold water supply valve.
4. Double check valve.
3
4
1
Fig. 12
12
Cod. 3540E632 - 04/2007 (Rev. 01)
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