Ferroli BLUEHELIX 25 K 50 Troubleshooting guide
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(1 (GB) -
INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE
)5 (FR) -
INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN
)5 (BE) -
INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN
1/ (BE) -
AANWIJZINGEN VOOR GEBRUIK, INSTALLATIE EN ONDERHOUD
)
cod. 3541F704 - Rev. 00 - 12/2018
2EN
BLUEHELIX 25K 50
EN (Only for GB market)
1. GENERAL WARNINGS
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2. OPERATING INSTRUCTIONS
2.1 Introduction
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2.2 Control panel
fig. 1 - Control panel
Panel - legend fig. 1
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Indication during operation
Heating
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fig. 2
Domestic hot water (DHW)
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fig. 3
Fault
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2.3 Connection to the power supply, switching on and off
Boiler not electrically powered
fig. 4 - Boiler not electrically powered
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Boiler electrically powered
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fig. 5 - Switching on / Software version
fig. 6 - Venting cycle
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cod. 3541F704 - Rev. 00 - 12/2018
3
EN
BLUEHELIX 25K 50
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Switching the boiler off and on
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fig. 7 - Switching the boiler off
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fig. 8
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2.4 Adjustments
Summer/Winter Switchover
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Heating temperature adjustment
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fig. 9
DHW temperature adjustment
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fig. 10
Room temperature adjustment (with optional room thermostat)
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Room temperature adjustment (with optional remote timer control)
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Hot water tank exclusion (economy)
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Sliding Temperature
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fig. 11 - Example of compensation parallel curve offset
Adjustments from Remote Timer Control
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Table. 1
System water pressure adjustment
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0
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Heating temperature setting
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DHW temperature adjustment
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Summer/Winter Switchover
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Eco/Comfort selection
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Sliding Temperature
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OFFSET = 20 OFFSET = 40
cod. 3541F704 - Rev. 00 - 12/2018
4EN
BLUEHELIX 25K 50
3. INSTALLATION
3.1 General Instructions
BThis unit must only be used for its intended purpose. 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 heating capacity. Any other use is deemed
improper.
THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN COMPLI-
ANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE
PROVISIONS OF CURRENT LAW, THE REQUIREMENTS OF THE TECHNICAL
STANDARDS (BS) AND ANY LOCAL REGULATIONS AND THE RULES OF PROPER
WORKMANSHIP.
Incorrect installation can cause damage or injury for which the manufacturer cannot be
deemed responsible.
The unit must be installed in compliance with these instructions and the following
standards applicable in Great Britain.
Gas Safety Regulations (Installations & Use).
Local Building Regulations.
The Building Regulations (Part L).
The Buildings Standards (Scotland - Consolidated) Regulations).British Standards
Codes of Practice (BSI):
Model Water By-Laws (Great Britain)
For Northern Ireland the relevant laws in force must be observed.
Safe handling of materials
Pay attention when handling the boiler insulation panels as they contain materials that
could irritate the skin.
No part of the boiler contains asbestos, mercury or CFC's.
The use of Personal Protective Equipment (PPE) is always recommended.
Advice for transport and handling
For lifting and transporting always take suitable safety precautions: keep your back
straight, bend knees, do not turn your body, move feet, avoid bending forward or side-
ways and keep the load as close as possible to your body.
If possible, use a trolley or other suitable means to carry the boiler.
Grip the boiler firmly and, before lifting it, try and find the point where the load is concen-
trated in order to establish the centre of gravity and suitably reposition yourself. Ideally
seek assistance in lifting the boiler.
3.2 Place of installation
The combustion circuit is sealed with respect to the place of installation and therefore the
unit can be installed in any room. However, the place of installation must be sufficiently
ventilated to prevent the creation of dangerous conditions in case of even slight gas
leaks. This safety regulation is provided for by EEC Directive no. 2009/142 for all gas
units, including those with a sealed chamber.
In any case, the place of installation must be free of dust, flam-
mable materials or objects or corrosive gases.
The boiler is arranged for wall mounting and comes standard with a hanging bracket. A
paper template for marking the drilling points on the wall is provided in the box. The wall
fixing must ensure stable and effective support for the boiler.
AIf the unit is enclosed in a cabinet or mounted alongside, a space must be pro-
vided for removing the casing and for normal maintenance operations. The min-
imum measurements to be respected are given in fig. 12.
fig. 12 - Minimum distances around the boiler
AMin. 2,5 cm
BMin. 20 cm
CMin. 30 cm
DMin. 60 cm (via an openable panel)
3.3 Plumbing connections
Important
BThe safety valve outlet must be connected to a funnel or collection pipe to pre-
vent water spurting onto the floor in case of overpressure in the heating circuit.
Otherwise, if the discharge valve cuts in and floods the room, the boiler manu-
facturer cannot be held liable.
BBefore installation, carefully clean all the system pipes to remove any residuals
or impurities that could affect proper operation of the unit.
In case of replacement of generators in existing installations, the system must
be completely emptied and cleaned of any sludge and pollutants. For that pur-
pose only use suitable guaranteed products for heating systems (see following
section), that do not harm metals, plastics or rubber. The manufacturer de-
clines any liability for damage caused to the generator by failure to prop-
erly clean the system.
Carry out the relevant connections according to the diagram in fig. 13and the symbols
on the unit.
fig. 13 - Plumbing connections
7 = Gas inlet - 1/2”
8 = DHW outlet - 1/2”
9 = Cold water inlet - 1/2”
10 = System delivery - 3/4”
11 = System return - 3/4”
Antifreeze system, antifreeze fluids, additives and inhibitors
When necessary, antifreeze fluids, additives and inhibitors can be used only if the man-
ufacturer of such fluids or additives guarantees that they are suitable and do not cause
damage to the exchanger or other components and/or materials of the boiler and system.
Do not use generic antifreeze fluids, additives or inhibitors that are not specific for use in
heating systems and compatible with the materials of the boiler and system.
B.S.
5440 Part 1 Flues
B.S.
5440 Part 2 Air flow and ventilation
B.S.
5449 ......... Forced circulation hot water production systems
B.S.
6798 ......... Installation of gas-fired boilers for hot water
B.S.
6891 ......... Gas systems
B.S.
7671 ......... IEE wiring system standards
B.S.
4814 ......... Specifications for expansion tanks
B.S.
5482 ......... LPG systems
B.S.
7593 ......... Water treatment in central heating systems for DHW production
B.S.
5546 ......... Installation of systems for DHW production
B.S.
5955-8 ......... Installation of plastic pipes
D
A A
B
C
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9
11
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174
41 69 149 117 132 92
cod. 3541F704 - Rev. 00 - 12/2018
5
EN
BLUEHELIX 25K 50
Water system characteristics
In the presence of water harder than 25° Fr (1°F = 10ppm CaCO3), use suitably treated
water in order to avoid possible scaling in the boiler.
Antifreeze kit for outdoor installation (optional)
In case of installation outdoors in a partially protected place for temperatures lower than
-5°C and down to -15°C, the boiler must be equipped with the antifreeze kit to protect the
tap water circuit and air trap. The kit comprises a thermostat, electric heaters and a heat-
er for the air trap. Connect the kit to the electronic card and install the thermostat and
heaters on the tap water pipes as directed in the instructions attached to the kit.
3.4 Gas connection
BBefore making the connection, ensure that the unit is arranged for operation
with the type of fuel available.
The gas must be connected to the relevant connection (see fig. 13) in conformity with the
current standards, using a rigid metal pipe or a continuous surface flexible s/steel tube
and installing a gas cock between the system and boiler. Make sure all the gas connec-
tions are tight.
3.5 Electrical connections
BThe unit must be connected to an efficient earthing system in accordance with
the current safety standards. Have the efficiency and suitability of the earthing
system checked by professionally qualified personnel; the manufacturer de-
clines any liability for damage caused by failure to earth the system.
The boiler is prewired and provided with a "Y" type cable (without plug) for con-
nection to the electric line. The connection to the mains must be permanent and
have a bipolar switch with contact gap of at least 3 mm, interposing fuses of
max. 3A between the boiler and the line. Make sure to respect the polarities
(LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green wire) in the
connections to the electric line.
BThe power cable must not be replaced by the user. If the cable is damaged, turn
the unit off and have the cable replaced exclusively by professionally qualified
personnel. In case of replacement, use exclusively “HAR H05 VV-F” 3x0.75
mm2 cable with maximum ext. diameter of 8 mm.
Room thermostat (optional)
BIMPORTANT: THE ROOM THERMOSTAT MUST HAVE VOLTAGE-FREE
CONTACTS. CONNECTING 230V TO THE ROOM THERMOSTAT TERMI-
NALS WILL PERMANENTLY DAMAGE THE PCB.
When connecting a time control or timer, do not take the power supply for such
devices from their cutoff contacts. Their power supply must be taken with a di-
rect connection from the mains or with batteries, depending on the type of de-
vice.
Accessing the electrical terminal block
The electrical terminal block (fig. 14) can be accessed after removing the front panel (***
'Opening the front panel' on page 8 ***). The arrangement of the terminals for the various
connections is also given in the wiring diagram in fig. 34.
fig. 14 - Accessing the terminal block
3.6 Fume ducts
Important
The unit is “type C” with sealed chamber and forced draught; the air inlet and fume outlet
must be connected to one of the following extraction/suction systems. Before installation,
check and carefully observe the above prescriptions. Also, comply with the provisions
concerning the positioning of wall and/or roof terminals and the minimum distances from
windows, walls, vents, etc.
Connection with coaxial pipes
Standard connection with coaxial pipes (code 041049G0)
fig. 15 - Standard connection
Other connection with coaxial pipes
fig. 16 - Examples of connection with coaxial pipes ( = Air / = Fumes)
Table. 2 - Typology
For coaxial connection, fit the unit with one of the following starting accessories. For the
wall hole dimensions, refer to the figure on the cover. Any horizontal sections of the fume
exhaust must be kept sloping slightly towards the boiler, to prevent any condensate from
flowing back towards the outside and causing dripping.
fig. 17 - Starting accessory for coaxial ducts
138
1 2 3 4
A
72
139
Type Description
C1X
Wall horizontal exhaust and inlet
C3X
Roof vertical exhaust and inlet
Between
10 - 60 mm
Between
10 - 60 mm
320
125
200
80600
Ø100
125
110
80600
Ø100
Drill the wall 10 - 20 mm
m re than the
pipe diameter
Rear utlet
Side view
Side utlet
Fr nt view
200
400
C
1X
C
1X
C
3X
C
3X
C
3X
C
1X
Ø 100
Ø 60
041001X0
Ø 100
Ø 60
120
142
041002X0
Ø 80
Ø 127
120
147
041006X0
cod. 3541F704 - Rev. 00 - 12/2018
6EN
BLUEHELIX 25K 50
Table. 3 - Max. length of coaxial pipes
Connection with separate pipes
fig. 18 - Examples of connection with separate pipes ( = Air / = Fumes)
Table. 4 - Typology
For the connection of separate ducts, fit the unit with the following starting accessory:
fig. 19 - Starting accessory for separate ducts
Before installation, make sure the maximum permissible length has not been exceeded,
by means of a simple calculation:
1. Completely establish the layout of the system of split flues, including accessories
and outlet terminals.
2. Consult the table 6 and identify the losses in meq (equivalent metres) of every com-
ponent, according to the installation position.
3. Check that the sum total of losses is less than or equal to the maximum permissible
length in table 5.
Table. 5 - Maximum length of separate ducts
Table. 6 - Accessories
Connection to collective flues
fig. 20 - Examples of connection to flues ( = Air / = Fumes)
Table. 7 - Typology
If the boiler is to be connected BLUEHELIX 25 K 50 to a collective flue or a single flue
with natural draught, the flue or chimney must be expressly designed by professionally
qualified technical personnel in conformity with the current regulations and be suitable
for sealed chamber units equipped with fan.
3.7 Condensate drain connection
The boiler has an internal trap for draining condensate. Fit the inspection union Aand
the hose B, pressing it in. Fill the trap with about 0.5 L of water and connect the hose to
the disposal system.
BATTENTION: The unit must never be operated with the trap empty!
fig. 21 - Condensate outlet connection
Coaxial 60/100 Coaxial 80/125
BLUEHELIX 25 K 50 BLUEHELIX 25 K 50
Max. permissible length
(horizontal) 7 m
28 m
Max. permissible length
(vertical) 8 m
Reduction factor
90° bend 1 m 0.5 m
Reduction factor
45° bend
0.5 m
0.25 m
Type Description
C1X
Wall horizontal exhaust and intake. The inlet/outlet terminals must be concentric or close enough to be
undergo similar wind conditions (within 50 cm)
C3X
Roof vertical exhaust and intake. Inlet/outlet terminals like for C12
C5X
Wall or roof exhaust and intake separate or in any case in areas with different pressures. The exhaust and
intake must not be positioned on opposite walls.
C6X
Intake and exhaust with separately certified pipes (EN 1856/1)
B2X
Intake from installation room and wall or roof exhaust
IMPORTANT - THE ROOM MUST BE PROVIDED WITH APPROPRIATE VENTILATION
BLUEHELIX 25 K 50
Max. permissible length
80 m
eq
C5x
C
3x
B2x C1x
max 50 cm
Ø 81Ø 81
Ø 65
Ø 87
Ø 65
041039X0
Losses in m
eq
Air
inlet
Fume exhaust
Vertical Horizontal
Ø 80
PIPE
1 m M/F 1KWMA83W 1.0 1.6 2.0
BEND
45° M/F 1KWMA65W 1.2 1.8
90° M/F 1KWMA01W 1,5 2.0
PIPE SECTION
with test point 1KWMA70W 0.3 0.3
TERMINAL
air, wall 1KWMA85A 2.0 -
fumes, wall with antiwind 1KWMA86A - 5.0
FLUE
Split air/fumes 80/80 010027X0 - 12.0
Fume outlet only Ø80 010026X0 +
1KWMA86U
-4.0
Ø 60
PIPE
1 m M/F 1KWMA89W 6.0
BEND
90° M/F 1KWMA88W 4.5
REDUCTION
80/60 041050X0 5.0
TERMINAL
fumes, wall with antiwind 1KWMA90A 7.0
ATTENTION: CONSIDER THE HIGH PRESSURE LOSSES OF Ø60 ACCESSORIES; USE
THEM ONLY IF NECESSARY AND AT THE LAST FUME EXHAUST SECTION.
Type Description
C2X
Intake and exhaust in common flue (intake and exhaust in same flue)
C4X
Intake and exhaust in common and separate flues , but undergoing similar wind conditions
C8X
Exhaust in single or common flue and wall intake
B3X
Intake from installation room by means of concentric duct (that encloses the exhaust) and exhaust in common flue with
natural draught
IMPORTANT - THE ROOM MUST BE PROVIDED WITH APPROPRIATE VENTILATION
C8X C2X
C4X
A
B
0,5lt
cod. 3541F704 - Rev. 00 - 12/2018
7
EN
BLUEHELIX 25K 50
Condensate drain
The condensate should be run inside as far as is practicably possible. For that purpose, use a pipe of at
least 22 mm diameter and a trap with flexible connection supplied with the unit to facilitate connection of
the condensate drain pipe.
The pipe must be in solvent weld plastic and not in copper, since the condensate has a pH of 4 (slightly
acid).
If the condensate drain pipe cannot be ended on the inside, it is advisable to run it outside as shown in
the following figure.
The pipe sections going to the outside are exposed to the risk of freezing in particularly extreme weather
conditions. To prevent this from occurring, it is advisable to reduce the length of the condensate drain
pipes and run them on the inside, as much as possible, before going to the outside. It may also be nec-
essary to insulate the condensate pipe or apply a trace heating device to prevent freezing of the con-
densate.
The pipes outside the building must be in solvent weld plastic with increased diameter of up to 32 or 40
mm with a maximum run of 3m for connection to a condensate collection soakaway or external drain.
If using a condensate collection soakaway, it must be as indicated in the figure below, or use a specific
system (such as Mc Alpine SOAK1GR) available from the majority of plumbing and heathing suppliers.
fig. 22 - Condensate drain
4. SERVICE AND MAINTENANCE
4.1 Adjustments
Gas conversion
The unit can operate on Natural Gas or LPG and is factory-set for use with one of these two gases, as
clearly shown on the packing and on the data plate. Whenever a different gas to that for which the unit
is arranged has to be used, a conversion kit will be required, proceeding as follows:
1. Remove the front panel (
see
*** 'Opening the front panel' on page 8 ***
).
2. Undo the screw and rotate the control panel (see
fig. 23
).
3. Unscrew ring
C
and remove gas pipe
A
from the gas valve (see
fig. 24
).
4. Replace nozzle
B
inserted in the gas pipe with that contained in the conversion kit, interposing seal
D
(see
fig. 24
).
5. Refit gas pipe
A
and check the tightness of the connection.
6. Apply the label, contained in the conversion kit, near the data plate.
7. Refit the front panel.
8.
Modify the parameter for the type of gas
:
SXWWKHERLOHULQVWDQGE\PRGH
SUHVVWKH'+:EXWWRQVGHWDLOVDQG
fig. 1
for 10 seconds: the display shows “
b01
“ flash-
ing.
SUHVVWKH'+:EXWWRQVGHWDLOVRU
fig. 1
to set parameter
00
(for operation with natural
gas) or
01
(for operation with LPG).
SUHVVWKH
heating +
button (detail 4 -
fig. 1
) until
“b06”
flashes on the display.
SUHVVWKH
DHW
buttons (details 1 or 2 -
fig. 1
) to set parameter
55
(for operation with natural
gas) or
70
(for operation with LPG).
SUHVVWKH'+:EXWWRQVGHWDLOVDQG
fig. 1
for 10 seconds.
WKHERLOHUZLOOUHWXUQWRVWDQGE\PRGH
9. Using a combustion analyser connected to the boiler fume outlet, check that the CO
2
content in the
fumes, with the boiler operating at max. and min. output, matches that given in the technical data
table for the corresponding type of gas.
fig. 23
fig. 24
TEST mode activation
Press the heating buttons (details 3 and 4 - fig. 1) together for 5 seconds to activate the
TEST mode. The boiler lights at the maximum heating power set as described in the fol-
lowing section.
7KHKHDWLQJDQG'+:V\PEROVILJ IODVKRQWKHGLVSOD\WKHKHDWLQJSRZHUZLOODS
pear alongside.
fig. 25 - TEST mode (heating power = 100%)
Press the heating buttons (details 3 and 4 - fig. 1) to increase or decrease the power
(Min.=0%, Max.=100%).
%\SUHVVLQJWKH'+:“-” button (detail 1 - fig. 1), boiler output is immediately adjusted
WRPLQ%\SUHVVLQJWKH'+:“+” button (detail 2 - fig. 1), boiler output is immedi-
ately adjusted to max. (100%).
,IWKH7(67PRGHLVDFWLYDWHGDQGHQRXJKKRWZDWHULVGUDZQWRDFWLYDWHWKH'+:PRGH
WKHERLOHUUHPDLQVLQ7(67PRGHEXWWKHZD\YDOYHJRHVWR'+:
To deactivate the TEST mode, press the heating buttons (details 3 and 4 - fig. 1) together
for 5 seconds.
The TEST mode is automatically deactivated in any case after 15 minutes or on stopping
RIKRWZDWHUGUDZLQJLIHQRXJKKRWZDWHUKDVEHHQGUDZQWRDFWLYDWHWKH'+:PRGH
Heating power adjustment
To adjust the heating power, switch the boiler to TEST mode (see sec. 4.1). Press the
heating buttons fig. 1 (details 3 and 4 - ) to increase or decrease the power (min. = 00 -
max. = 100). Press the RESET button within 5 seconds and the max. power will remain
that just set. Exit TEST mode (see sec. 4.1).
4.2 Startup
Before lighting the boiler
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)LOOWKHZDWHUV\VWHPDQGPDNHVXUHDOODLUFRQWDLQHGLQWKHERLOHUDQGWKHV\VWHP
has been vented.
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er.
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tem.
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0DNHVXUHWKHUHDUHQRIODPPDEOHOLTXLGVRUPDWHULDOVLQWKHLPPHGLDWHYLFLQLW\RI
the boiler
External
32/40mm Solvent weld p pework 2.5° M n mum fall. See below
Cement seal
100mm D a tube
Bottom sealed
L me stone ch pp ngs
Ground level (e ther/Or)
Hole depth 400mm
25mm
2 Rows of
3x12 mm Holes
nternal
-300mm
2.5° M n mum fall
A
C
B
D
0
1
4
2
3
cod. 3541F704 - Rev. 00 - 12/2018
8EN
BLUEHELIX 25K 50
Checks during operation
6ZLWFKWKHXQLWRQ
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WUDS
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WHFKQLFDOGDWDWDEOHRQFDS
0DNHVXUHWKDWZLWKQRKHDWLQJGHPDQGWKHEXUQHUFRUUHFWO\OLJKWVRQRSHQLQJDKRW
ZDWHUWDS&KHFNWKDWWKHKHDWLQJFLUFXODWLQJSXPSVWRSVRQRSHQLQJDKRWZDWHUWDS
GXULQJKHDWLQJRSHUDWLRQDQGWKHUHLVDUHJXODUSURGXFWLRQRIKRWZDWHU
&KHFNFRUUHFWSURJUDPPLQJRIWKHSDUDPHWHUVDQGFDUU\RXWDQ\UHTXLUHGFXVWRPL
VDWLRQFRPSHQVDWLRQFXUYHSRZHUWHPSHUDWXUHVHWF
4.3 Commissioning instructions
General
PLEASE NOTE:7KHFRPEXVWLRQIRUWKLVDSSOLDQFHKDVEHHQFKHFNHGDGMXVWHGDQGSUH
VHWDWWKHIDFWRU\IRURSHUDWLRQRQWKHJDVW\SHGHILQHGRQWKHDSSOLDQFHGDWDSODWH
+DYLQJFKHFNHG
7KDWWKHERLOHUKDVEHHQLQVWDOOHGLQDFFRUGDQFHZLWKWKHVHLQVWUXFWLRQV
7KHLQWHJULW\RIWKHIOXHV\VWHPDQGWKHIOXHVHDOV
7KHLQWHJULW\RIWKHERLOHUFRPEXVWLRQFLUFXLWDQGWKHUHOHYDQWVHDOV
Check the operational (working) gas inlet pressure
6HWXSWKHERLOHUWRRSHUDWHDWPD[LPXPUDWHDVGHVFULEHGRIFDS
:LWKWKHERLOHURSHUDWLQJDWPD[LPXPUDWHFKHFNWKDWWKHRSHUDWLRQDOZRUNLQJJDVSUHV
VXUHDWWKHLQOHWJDVSUHVVXUHWHVWSRLQWVHHILJ FRPSOLHVZLWKWKHUHTXLUHPHQWVRI
FDS
(QVXUHWKDWWKLVLQOHWSUHVVXUHFDQEHREWDLQHGZLWKDOORWKHUJDVDSSOLDQFHVLQWKHSURS
HUW\ZRUNLQJ
fig. 26
Measure the gas rate
0HDVXUHWKHJDVUDWHDQGFKHFNDJDLQVWIROORZLQJWDEOH
4.4 Routine servicing, maintenance & repair
General
PLEASE NOTE:'XULQJURXWLQHVHUYLFLQJDQGDIWHUDQ\PDLQWHQDQFHRUFKDQJHRISDUW
RIWKHFRPEXVWLRQFLUFXLWZHUHFRPPHQGWKDWWKHIROORZLQJLVFKHFNHG
7KHLQWHJULW\RIWKHIOXHV\VWHPDQGWKHIOXHVHDOV
7KHLQWHJULW\RIWKHERLOHUFRPEXVWLRQFLUFXLWDQGWKHUHOHYDQWVHDOV
7KH RSHUDWLRQDO ZRUNLQJ JDV LQOHW SUHVVXUH DW PD[LPXP UDWH DV GHVFULEHG LQ
FDS
7KHJDVUDWHDVGHVFULEHGLQFDS
7KHFRPEXVWLRQSHUIRUPDQFHDVGHVFULEHGLQFDS &RPEXVWLRQFKHFN
Competence to carry out the check of combustion performance
PLEASE NOTE:%6Specification for installation and maintenance of
gas-fired boilers of rated input not exceeding 70 kW netDGYLVHVWKDW
7KHSHUVRQFDUU\LQJRXWDFRPEXVWLRQPHDVXUHPHQWVKRXOGKDYHEHHQDVVHVVHG
DVFRPSHWHQWLQWKHXVHRIDIOXHJDVDQDO\VHUDQGWKHLQWHUSUHWDWLRQRIWKHUHVXOWV
7KHIOXHJDVDQDO\VHUXVHGVKRXOGEHRQHPHHWLQJWKHUHTXLUHPHQWVRI%6RU
%6(1DQGEHFDOLEUDWHGLQDFFRUGDQFHZLWKWKHDQDO\VHUPDQXIDFWXUHUV¶
UHTXLUHPHQWVDQG
&RPSHWHQFHFDQEHGHPRQVWUDWHGE\VDWLVIDFWRU\FRPSOHWLRQRIWKH&3$$&6DV
VHVVPHQWZKLFKFRYHUVWKHXVHRIHOHFWURQLFSRUWDEOHFRPEXVWLRQJDVDQDO\VHUVLQ
DFFRUGDQFHZLWK%63DUWVWR
Periodical check
7RNHHSWKHXQLWZRUNLQJSURSHUO\RYHUWLPHLWLVQHFHVVDU\WRKDYHTXDOLILHGSHUVRQQHO
PDNHDQDQQXDOFKHFNWKDWLQFOXGHVWKHIROORZLQJWHVWV
7KHFRQWURODQGVDIHW\GHYLFHVJDVYDOYHIORZPHWHUWKHUPRVWDWVHWFPXVWIXQF
WLRQFRUUHFWO\
7KHIOXHSLSHPXVWEHIXOO\HIILFLHQW
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WLRQV
7KHEXUQHUDQGH[FKDQJHUPXVWEHFOHDQDQGIUHHRIVFDOH:KHQFOHDQLQJGRQRW
XVHFKHPLFDOSURGXFWVRUZLUHEUXVKHV
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7KHJDVDQGZDWHUV\VWHPVPXVWEHOHDNIUHH
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WKDWYDOXH
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A7KHERLOHUFDVLQJSDQHODQGDHVWKHWLFSDUWVFDQEHFOHDQHGZLWKDVRIWGDPS
FORWKSRVVLEO\VRDNHGLQVRDS\ZDWHU'RQRWXVHDQ\DEUDVLYHGHWHUJHQWVDQG
VROYHQWV
Opening the front panel
7RRSHQWKHERLOHUFDVLQJ
8QGRWKHVFUHZVAVHHILJ
3XOOWKHSDQHOBRXWZDUGVDQGUHOHDVHLWIURPWKHXSSHUIDVWHQLQJV
BBefore carrying out any operation inside the boiler, disconnect the power
and close the gas cock upstream
fig. 27 - Front panel opening
Combustion check
&RQQHFWWKHIOXHJDVDQDO\]HUWRWKHIOXHJDVVDPSOLQJSRLQWDVVKRZQLQWKHILJ DQG
FKHFNFRPEXVWLRQDVGHVFULEHGLQWDEOH DQGWDEOH
3UHVVWKH&+EXWWRQVWRJHWKHUIRUVHFRQGVWRSODFHERLOHULQWRWHVWPRGH
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7DNHWKHPHDVXUHPHQWDQGUHFRUG
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VWDELOL]HIRUDIXUWKHUPLQXWHV
7DNHWKHPHDVXUHPHQWDQGUHFRUG
fig. 28 - Flue gas sampling point
1 $LU2 )OXHJDV
GAS RATES (NATURAL GAS)
AFTER 10 MINUTES FROM COLD
BOILER MODEL Maximum rate Minimum rate
P
3
K IW
3
K P
3
K IW
3
K
BLUEHELIX 25 K 50
0.61 21.57
Inlet test po nt
A
A
B
1
212
cod. 3541F704 - Rev. 00 - 12/2018
9
EN
BLUEHELIX 25K 50
Tabella. 8 - Maximum rate
Tabella. 9 - Minimum rate
If the combustion reading is greater than the acceptable value AND the integrity of
the complete flue system and combustion circuit seals have been verified and the
inlet gas pressure (and gas rate) have been verified, proceed as in cap. Setting the
Air/Gas Ratio valve.
Setting the Air/Gas Ratio valve
There are two adjustments possible on the air/gas ratio valve, the throttle setting at max-
imum rate and the offset setting at minimum rate. If either setting is adjusted the com-
bustion values must be rechecked at both rates.
At Maximum Rate:
1. Adjust the boiler to maximum rate in cap. 4.3 Test Mode.
2. Wait 10 minutes to allow the boiler to stabilize.
3. Now adjust the Throttle setting (fig. 29 - screw A) until the CO2is at the correct
SETTING LEVEL (see table 8), confirm that the CO/CO2ratio is within limits (clock-
wise to increase gas).
NOTE: ADJUST IN STEPS OF NO MORE THAN 1/8 OF A TURN AND WAIT 1 MINUTE
AFTER EACH ADJUSTMENT TO ALLOW THE SETTING TO STABILISE.
In the event that the CO2setting level with an acceptable CO/CO2ratio cannot be
obtained please contact the helpline number.
Should you require any assistance during the set up procedure call our Technical
service helpline or should you require a service engineer to visit call our service centre
at numbers listed on last page of this manual.
At Minimum Rate:
1. Adjust the boiler to minimum output and allow the boiler to stabilize.
2. Now adjust the offset pressure setting (fig. 29 - screw B) until the CO2is at the
correct SETTING LEVEL (see table 9), confirm that the CO/CO2ratio is within limits
(clockwise to increase gas).
NOTE: ADJUST IN STEPS OF NO MORE THAN 1/8 OF A TURN AND WAIT 1 MINUTE
AFTER EACH ADJUSTMENT TO ALLOW THE SETTING TO STABILISE.
Re-check the Minimum Rate
Turn off the boiler and then turn it back on and put in Test Mode at maximum for 1minute.
Reduce to minimum and re-check the minimum rate output ensuring the CO2 setting lev-
el has remained unchanged and confirm that the CO/CO2ratio is within limits.
In the event that the CO2setting level with an acceptable CO/CO2ratio cannot be
obtained please contact the helpline number.
Should you require any assistance during the set up procedure call our Technical
service helpline or should you require a service engineer to visit call our service centre
at numbers listed on last page of this manual.
fig. 29 - Gas valve
AThrottle
BOffset adjustment
NOTE: In the event that an acceptable setting level cannot be obtained it will be neces-
sary to change the Air/Gas Ratio Valve.
4.5 Troubleshooting
Diagnostics
In case of operation faults or problems, the display flashes and the fault identification
code appears.
There are faults that cause permanent shutdown (marked with the letter “A”): to restore
operation just press the reset button (detail 6 -fig. 1) for 1 second or RESET on the op-
tional remote timer control if installed; if the boiler fails to start, it is necessary to firstly
eliminate the fault.
Faults marked with the letter “F” cause temporary shutdowns that are automatically reset
as soon as the value returns within the boiler's normal working range.
Table of faults
Table. 10 - List of faults
NATURAL GAS ACCEPTABLE
COMBUSTION RANGE
MAXIMUM RATE AFTER 10 MINUTES FROM COLD
Boiler Model CO/CO
2
RATIO CO
2
NG CO
2
LPG
BLUEHELIX 25 K 50
0.004 8,7 ÷ 9,2 10 ÷ 10,5
NATURAL GAS ACCEPTABLE
COMBUSTION RANGE
MINIMUM RATE AFTER 10 MINUTES FROM COLD
Boiler Model
CO/CO
2
RATIO
CO
2
NG CO
2
LPG
BLUEHELIX 25 K 50
0.004 8,2 ÷ 8,7 9,5 ÷ 10,0
A
B
A
Fault code Fault Possible cause Cure
A01
No burner ignition
No gas
Check the regular gas flow to the
boiler and that the air has been elimi-
nated from the pipes
Ignition/detection elec-
trode fault
Check the wiring of the electrode and
that it is correctly positioned and free
of any deposits
Faulty gas valve Check the gas valve and replace it if
necessary
Insufficient gas supply
pressure Check the gas supply pressure
Trap blocked Check the trap and clean it if neces-
sary
A02
Flame present signal
with burner off
Electrode fault Check the ionisation electrode wiring
Card fault Check the card
A03
Overtemperature pro-
tection activation
Heating sensor damaged Check the correct positioning and
operation of the heating sensor
No water circulation in
the system Check the circulating pump
Air in the system Vent the system
A04
Fume extraction duct
safety device activation
Fault F07 generated 3
times in the last 24 hours
See fault F07
A05
Fan protection activated Fault F15 generated for 1
hour (consecutive) See fault F15
A06
No flame after ignition
stage (6 times in 4 min-
utes)
Ionisation electrode fault Check the position of the ionisation
electrode and replace it if necessary
Flame unstable Check the burner
Gas valve Offset fault Check the Offset adjustment at mini-
mum power
air/fume ducts obstructed
Remove the obstruction from the flue,
fume extraction ducts and air inlet
and terminals
Trap blocked Check the trap and clean it if neces-
sary
F07
High fume temperature
The fume probe detects
an excessive tempera-
ture
Check the exchanger
F10
Delivery sensor 1 fault
Sensor damaged Check the wiring or replace the sen-
sor
Wiring shorted
Wiring disconnected
F11
Return sensor fault
Sensor damaged Check the wiring or replace the sen-
sor
Wiring shorted
Wiring disconnected
F12
DHW sensor fault
Sensor damaged Check the wiring or replace the sen-
sor
Wiring shorted
Wiring disconnected
F13
Fume probe fault
Probe damaged Check the wiring or replace the fume
probe
Wiring shorted
Wiring disconnected
F14
Delivery sensor 2 fault
Sensor damaged Check the wiring or replace the sen-
sor
Wiring shorted
Wiring disconnected
F15
Fan fault
No 230V power supply Check the 8-pin connector wiring
Tachometric signal inter-
rupted Check the 8-pin connector wiring
Fan damaged Check the fan
F34
Supply voltage under
170V Electric mains trouble Check the electrical system
F35
Faulty mains frequency Electric mains trouble Check the electrical system
F37
Incorrect system water
pressure
Pressure too low Fill the system
Water pressure switch
damaged or not con-
nected
Check the sensor
cod. 3541F704 - Rev. 00 - 12/2018
10 EN
BLUEHELIX 25K 50
5. TECHNICAL DATA AND CHARACTERISTICS
Table. 11 - Key of figures cap. 5
5.1 Dimensions and connections
fig. 30 - Dimensions and connections
5.2 General view and main components
fig. 31 - Front view
F39
External probe fault
Probe damaged or wiring
shorted
Check the wiring or replace the sen-
sor
Probe disconnected after
activating the sliding
temperature
Reconnect the external probe or dis-
able the sliding temperature
Sensor positioning Check the correct positioning and
operation of the heating sensor
A42
Heating sensor fault Sensor damaged Replace the sensor
F43
Exchanger protection
activation.
No system H
2
O circula-
tion Check the circulating pump
Air in the system Vent the system
F52
Heating sensor fault Sensor damaged Replace the sensor
A61
Controller
ABM03&
fault Controller
ABM03&
inter-
nal error
Check the earth connection and
replace the controller if necessary.
A62
No communication
between controller and
gas valve
Controller not connected Connect the controller to the gas
valve
Valve damaged Replace the valve
A63
F64
A65
F66
Controller
ABM03&
fault Controller
ABM03&
inter-
nal error
Check the earth connection and
replace the controller if necessary.
A23
A24
F20
F21
A26
F40
F47
Card parameter fault Wrong card parameter
setting
Check the card parameter and mod-
ify it if necessary.
7
Gas inlet
139
Remote timer control (optional)
10
System delivery
154
Condensate drain pipe
11
System return
180
Hot water tank
14a
DHW safety valve
186
Return sensor
14b
System safety valve
191
Fume temperature sensor
16
Fan
193
Trap
32
Heating circulating pump
197
Manual vent
36
Automatic air vent
209
Hot water tank delivery
40
DHW expansion tank
210
Hot water tank return
44
Gas valve
232
DHW safety valve
56
Expansion tank
233
Hot water tank drain cock
72
Room thermostat (not supplied)
243
Hot water tank temperature sensor
81
Ionisation/ignition electrode
256
Modulating heating circulating pump signal
95
Diverter valve
278
Double sensor (Safety + Heating)
104
Fuse
350
Fan/Burner assembly
114
Water pressure switch
A
ON/OFF switch (configurable)
138
External probe (optional)
Fault code Fault Possible cause Cure
800
600
776
75
Ø
120/130
283
306
A41
A44
Heating sensor detached
from pipe
E
D
cod. 3541F704 - Rev. 00 - 12/2018
11
EN
BLUEHELIX 25K 50
5.3 Water circuit
fig. 32 - Water circuit
5.4 Diagrams
Circulating pump head / pressure losses
fig. 33 - Circulating pump head / Pressure losses BLUEHELIX 25 K 50
A = Boiler pressure losses
B = Circulating pump min. speed
C = Circulating pump max. speed
AFor correct modulation, the speed selector on the pump must be set to III.
10 11
209 210
278 193
154
32
36
56
180
40
95
233
232
186
243
114
Q [l/h]
H [m H2O]
C
B
A
0 0.5 1 1.5 2 2.5 3
6
5
4
3
2
1
0
Data Unit BLUEHELIX 25 K 50
Max. heating capacity kW 25.0 (Q)
Min. heating capacity kW 5.8 (Q)
Max. Heat Output in heating (80/60°C) kW 24.5 (P)
Min. Heat Output in heating (80/60°C) kW 5.7 (P)
Max. Heat Output in heating (50/30°C) kW 26.5
Min. Heat Output in heating (50/30°C) kW 6.2
Max. heating capacity in hot water production kW 27.5
Min. heating capacity in hot water production kW 5.8
Max. Heat Output in hot water production kW 27.0
Min. Heat Output in hot water production kW 5.
Efficiency Pmax (80-60°C) % 98.
Efficiency Pmin (80-60°C) % 97.8
Efficiency Pmax (50-30°C) % 106.1
Efficiency Pmin (50-30°C) % 107.5
Efficiency 30% % 108.8
NOx emission class - 5 (NOx)
Gas supply pressure G20 mbar 20
Max. gas delivery G20 m
3
/h 2.91
Min. gas delivery G20 m
3
/h 0.61
CO
2
max. G20 % 9.
CO
2
min. G20 % 8.70
Gas supply pressure G31 mbar 37
Max. gas delivery G31 kg/h 2.1
Min. gas delivery G31 kg/h 0.45
CO
2
max. G31 % 10.70
CO
2
min. G31 % 9.80
Max. working pressure in heating bar 3 (PMS)
Min. working pressure in heating bar 0.8
Max. heating temperature °C 9(tmax)
Heating water content litres.
Heating expansion tank capacity litres 8
Heating expansion tank prefilling pressure bar 0.8
Max. working pressure in hot water production bar 9 (PMW)
Min. working pressure in hot water production bar 0.3
DHW content litres 50
DHW expansion tank capacity litres 2
DHW expansion tank prefilling pressure bar 3
DHW flow rate Dt 30°C l/10min 175
DHW flow rate Dt 30°C l/h 820 (D)
Protection rating IP X5D
Power supply voltage V/Hz 230V/50Hz
Electrical power input W 8
Empty weight kg 5
Type of unit C13-C23-C33-C43-C53-C63-C83-B23-B33
PIN CE 0461CM0988
cod. 3541F704 - Rev. 00 - 12/2018
12 EN
BLUEHELIX 25K 50
MODEL: BLUEHELIX 25 K 50
A
25
94
24,5
5,1
88,3
98,9
0,039
0,011
0,003
0,038
0,000
46
54
27
XL
A
0,ϭϲϲ
ϯ6
86
22,ϲϵϯ
1ϳ
Item
Useful heat out put
Useful efficiency
Auxiliary electricity consumption
Other items
For combination heaters
Seasonal space heating energy efficiency class
Rated heat output
Seasonal space heating energy efficiency
Useful heat output at rated heat output and high-temperature regime (*)
Useful heat output at 30% of rated heat output and low-temperature regime (**)
Useful efficiency at rated heat output and high-temperature regime (*)
Useful efficiency at 30% of rated heat output and low-temperature regime (**)
At full load
At part load
In standby mode
Standby heat loss
Ignition burner power consumption
Annual energy consumption
Sound power level
Emissions of nitrogen oxides
Declared load profile
Water heating energy efficiency class
Daily electricity consumption
Annual electricity consumption
Water heating energy efficiency
Daily fuel consumption
Annual fuel consumption
Trademark: FERROLI
Condensing boiler: YES
Low-temperature boiler (**): NO
B1 Boiler: NO
Combination heater: YES
Cogeneration space heater: NO
(*) High-temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet.
(**) Low temperature means for condensing boilers 30°C, for low-temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet).
Symbol Unit Value
Pn
P4
P1
elmax
elmin
PSB
Pstby
Pign
QHE
LWA
NOx
Qelec
AEC
Qfuel
AFC
kW
%
kW
kW
%
%
kW
kW
kW
kW
kW
GJ
dB
mg/kWh
kWh
kWh
%
kWh
GJ
Șs
Ș4
Ș1
Șwh
cod. 3541F704 - Rev. 00 - 12/2018
13
EN
BLUEHELIX 25K 50
5.5 Wiring diagram
fig. 34 - Wiring diagram
AAttention: Remove the jumper on the terminal block before connecting the room thermostat or remote timer control.
278
T° T°
32
191
T°
243
16
N
L
138
186
44
114
139
72
230Vac
50Hz
LC32
321
95
A
PWN
256
GND
5 6 7 8 9 10 11 12 1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
1
8
GND
+Vcc
TACHO
PWM
1 2 3 4
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
3 41 2
104
FUSE 3.15A
250V
81
T1
X4 X3 X2 X1
18 12
1
2
1
1
1
X6
24
230V
1
2
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cod. 3541F704 - Rev. 00 - 12/2018
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www.centralheating.co.uk
Benchmark Commissioning and
Servicing Section
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This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
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GAS BOILER SYSTEM COMMISSIONING CHECKLIST
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Service Provider
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56EN cod. 3541P151 - Rev. 00 - 11/2018
BLUEHELIX TECH RRT 18S / 24S / 30S
Before contacting Ferroli please have available the
completed BENCHMARK document (located in the back of this manual),
boiler serial number and model detail.
For Technical assistance during the installation, call our
Technical Helpline on 0 .
You will be required to provide your Gas Safe Register Number.
Should you require a Service Engineer to visit, call our
Service Centre on .
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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
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19
FR
BLUEHELIX 25K 50
FR (Uniquement pour le marché français)
1. DISPOSITIONS GÉNÉRALES
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2. CONSIGNES D'UTILISATION
2.1 Introduction
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BLUEHELIX 25 K 50HVWXQJpQpUDWHXUWKHUPLTXHjFKDPEUHpWDQFKHDYHFéchangeur
en acierSRXUODSURGXFWLRQGHDXFKDXGHVDQLWDLUHLQWpJUpHHWavec brûleur à prémé-
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2.2 Tableau des commandes
fig. 1 - Panneau de contrôle
Légende panneau fig. 1
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Indication durant le fonctionnement
Chauffage
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GHjGLVWDQFHHVWLQGLTXpHSDUOHFOLJQRWHPHQWGHODLUFKDXGDXGHVVXVGXUDGLDWHXUVXU
ODIILFKHXU
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fig. 2
Sanitaire
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fig. 3
Anomalie
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2.3 Branchement au réseau électrique, mise en marche et arrêt
Chaudière non alimentée électriquement
fig. 4 - Chaudière non alimentée électriquement
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Chaudière alimentée électriquement
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fig. 5 - Mise en marche / Version logiciel
fig. 6 - Cycle de purge de l'air
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cod. 3541F704 - Rev. 00 - 12/2018
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Extinction et allumage chaudière
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fig. 7 - Arrêt chaudière
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fig. 8
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2.4 Réglages
Commutation Été/Hiver
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Réglage de la température de chauffage
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fig. 9
Réglage de la température d'eau chaude sanitaire
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fig. 10
Réglage de la température ambiante (avec thermostat d'ambiance en option)
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Régulation de la température ambiante (par chronocommande à distance en op-
tion)
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Exclusion du ballon (economy)
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Température évolutive
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fig. 11 - Exemple de déplacement parallèle des courbes de compensation
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OFFSET = 20 OFFSET = 40
cod. 3541F704 - Rev. 00 - 12/2018
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