Ferroli Optimax 25 C Troubleshooting guide

OPTIMAX 25 C

wall-mounted gas ﬁred,

pre-mix

condensing combination boiler

cod. 3544782/1 - 08/2004

G C N° 47-267-34

INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE

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 efﬁciency.

Please see installation and servicing guidelines.

• Read the warnings given in this manual thoroughly.

They provide important information for safe instal-

lation, 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 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, iso-

late 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

my compromise the safety of the appliance.

• To guarantee efﬁcient operation, the appliance must

be serviced once a year by a corgi registered engi-

neer.

• 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 dan-

gerous.

• 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 thecontents arecomplete

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.

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 thor-

oughly.

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

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-efﬁciency 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 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, ﬂow 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 conﬁgure them. Any

operating problems associated with the boiler or system is immediately signalled by the display and, if

possible, corrected automatically.

Optimax 25 C

1.2 Control panel

23 41 5

°C°C

ﬁg. 1

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 ﬂame 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, anti-

clockwise decreases it. The adjustment range goes from 40 to 65°C (see page 6).

Optimax 25 C

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 ther-

mostat, 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 ﬂow temperature, use the C.H control knob (ref. 1 - ﬁg. 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 ﬂash for 5 seconds and

display the set point temperature. It will then revert to showing the actual

temperature.

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 (ﬁg 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 ﬁg. 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.

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 ﬂash for 5 seconds and

display the set point temperature. It will then revert to showing the actual

temperature.

Optimax 25 C

Example

Boiler failed to light

Insufficient system pressure

Make sure that the gas isolation valve up-stream of the boiler

and on the meter are open.

Press the RESET button (2 Fig. 1).

Fill the system to 1-1.5 bar by use of the filling loop.

Fault CureDISPLAY

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.

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 - ﬁg. 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).

Summer/Winter selection

To select Summer/Winter, use knob 1 (ﬁg. 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 dem-

mand.

Before calling the FERROLI Caresafe centre, check that the problem is not due to an installation

error or there being no gas or electricity.

If the problem remains after two attempts at resetting, contact your nearest FERROLI Caresafe.

For further fault codes, refer to section 3.4 “Troubleshooting”.

Optimax 25 C

AUTO

OVER RIDE

RDP

AUTO P

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.

To Set Own ON and OFF times. Symbol in Display = ON time

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 switch on the boiler)

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

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.

1. Slide switch (A) to right position (P)

Display

2. Press button (P)

Display

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.

6:30

8:30

12:00

6:00

9:00

12:30

14:00

16:30

22:30

16:00

23:30

6:30 - 8:30

12:00 - 12:00

16:30 - 22:30

1.7 Optional Time Clock

If a ferroli 24 hour time clock is ﬁtted 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.

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 Ain set clock position

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 will be shown in the display window (B).

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!

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 hea-

ting 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

Optimax 25 C

Minimum

2,5 cm

20 cm

60 cm

(via an openable panel)

C30 cm

Table 1

ﬁg. 2

A A

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 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, inclu-

ding 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 moun-

ted alongside, there must be space for normal

maintenance work. Fig. 2 and tab. 1 give the

minimum clearances to leave around the unit.

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