Ferroli Optimax 25C- Modena HE Parts list manual

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Boiler Replacement
Optimax 25C-
Modena HE

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
The Installation must comply with the following;
Gas Safety (Installation & Use)
Regulations
The Building Regulations
The Building Regulations (Scotland)
Building Regulations (Northern Ireland)
The Water Fittings Regulations or Water
Byelaws in Scotland
The Current I.E.E. Wiring Regulations
-------------------------------------------------------
BS 5440: Part 1 - Flues.
BS 5440: Part 2 - Ventilation.
BS 6798 - Installation of gas fired hot
water boilers
BS 7671: - Electrical wiring
BS 6891 - Gas Installation
BS 5546 - Installation of hot water
supplies for domestic purposes.
BS 5449 - Forced circulation hot water
systems
BS 7074 - Expansion vessels / sealed
systems
BS 7593 - Treatment of water in domestic
central heating systems.
Introduction
The new Ferroli Modena 32C HE high efficiency condensing combination boiler is an ideal
replacement for the earlier Ferroli Optimax 25C.
The Ferroli Modena 32C HE is smaller, weighs less, has built-in frost protection and an IP protection
rating of IPX5D. This allows direct replacement wherever the existing boiler is legitimately installed
(i.e. Kitchen, Garage, Bathroom, etc.)
Although the actual position of the pipe-work connections differ slightly, the configuration remains
the same, thereby requiring only limited pipe-work alteration.
The electrical connection remains the same, i.e. all models supplied with a factory fitted three core
fly - lead to provide a permanent live connection and all models use the same volt free contacts for
any external system controls.
The flue connection the Optimax 25 C is to the right of centre but providing that there is a minimum
clearance of 35mm to the right of the existing boiler, no alteration to the existing flue position is
necessary.
-----------------------------------------------------------------------------------------------------------------------------
Please note:
This guide refers to the fitting of a replacement boiler
with a standard horizontal flue application only (minor
adjustments may be necessary for other flue
applications –refer to boiler installation instructions)
The work procedures described in this document must
be completed strictly in accordance with the
manufacturer’s installation instructions, current
regulations and relevant standards, and only by
competent person/persons as stated in the Gas Safety
(Installation & Use) Regulations.
Prior to fitting the replacement boiler the entire system
must be thoroughly cleansed and flushed in accordance
with Building Regulations L1A/L1B & BS 7593.

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
Fig.1
Fig.2
Fig.3
Manual Handling
When lifting take suitable safety precautions: keep your back straight, bend knees, do not turn your
body, avoid bending forward or sideways and keep the load as close as possible to your body. Ideally
seek assistance in lifting the boiler.
If possible, use a trolley or other suitable means to carry the boiler to site. Use appropriate
protective clothing and gloves to avoid injury from any sharp edges etc.
REMOVING THE EXISTING OPTIMAX 25C
1. Remove the outer case by undoing the
two case securing screws (A) on the
underside of the boiler. Lower the ‘drop
down controls cover panel’(B) to clear
the controls facia, ease the bottom of
outer case forward and lift off the
retaining lugs (Fig.1)
2. Safely isolate the electricity, gas and
water supplies to the appliance.
Completely drain the boiler and central
heating system and disconnect all existing
pipe-work connections from the
underside of the boiler (Fig.2)
3. Disconnect the electrical supply to the
boiler at the 3 pin plug or fused spur.
Undo the securing screw on the
underside of the boiler and remove the
cover to access the terminal block.
Disconnect the mains electrical supply
lead and any external controls
connections at the terminal block (Fig.3)
Fig.3

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
4. Disconnect and remove the flue from the existing boiler by
undoing the four screws securing the appliance bend to the top
of the boiler (Fig.4)
5. Ensure that all pipe connections are free, move
the base of the boiler forward and lift the boiler
off the hanging bracket tabs and unscrew the
hanging bracket from the wall. (Fig.5)
6. Finally, check that the wall surface is sound, flat and capable of supporting the weight of the
boiler. Make any necessary repairs before installing the new boiler.
7. It is suggested that where possible the existing pipe-
work is cut back approximately 200mm - 300mm for
ease of connecting the existing pipe-work to the new
valves (Fig. 6)
If a stand-off bracket has been used and the pipe-work runs
behind the boiler, then a new stand-off bracket will need to
be fitted and pipes extended to the new valve positions
(see below; paragraph 3-Fig.5)
Fig.4
Fig.6

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
Boiler Pack Contents
INSTALLING THE NEW MODENA C HE
Modena 32C HE Dimensions
1. Check the existing flue terminal position
with regard to possible nuisance “pluming”.
2. Unpack the boiler and check the contents
are complete and undamaged (see opposite)
Please note:
The new flue kit is sold separately
3. Align the fixing template on the wall with
the existing flue hole, ensuring it is level
both horizontally and vertically. Check for
required minimum clearances then mark the
most suitable fixing points for the hanging
bracket. It is advisable to mark the position
of the gas, water and heating pipes at this
point (Fig.5)
4. Drill the wall and fix the hanging bracket
using the wall plugs and fixings provided.
Make sure the bracket is level before
tightening the fixing screws
1 x Modena C HE Boiler
1 x Installation Instructions
1 x Hanging Bracket
1 x Filling Loop
1 x Valve Pack
1 x Condensate Bowl/Hose
1 x Paper Template
Fig.5

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
Fig.6
5. Lay the boiler on its back. Remove the front casing
panel by undoing the two securing screws on the
underside of the case. Ease the lower edge of the
panel forward to clear the controls display and lift
upwards off the frame.
6. Lift the boiler onto the hanging bracket making
sure the lugs on the bracket locate correctly with
the two support brackets on the boiler frame (Fig. 6)
FOR STANDARD HORIZONTAL TELESCOPIC FLUE INSTALLATIONS
UNPACK THE NEW TELESCOPIC FLUE KIT: CODE - 041049G0
7. Remove the protective adhesive cover from the top of the boiler to expose the flue/fixing holes.
Secure the new appliance flue bend to the top of the boiler using the screws and gasket provided
8. Level
8. From the outside, push the flue
terminal length through the
existing hole in the building fabric
and align with the appliance bend.
Lubricate the seal with a suitable
silicone grease and push the flue
pipe fully into the into the
appliance bend.
Ensure the flue terminal is fitted
level.

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
9. Remove the condensate bowl and hose from the
boiler fittings pack. Undo plastic nut (Fig.9-A) and fit
the condensate bowl and washer. Push on the
rubber condensate hose to the trap outlet (Fig.9-B).
10. Connect the safety valve outlet (Fig.9-C) to the
existing 15mm discharge pipe and then connect the
existing condensate pipe to the rubber hose outlet.
Check that both terminate in accordance with –BS
6798.
Take care not to interfere with the new routes for gas,
water and heating pipe connections
11. Fit the valve kit to the connections on the
underside of the boiler using the washers
provided (Fig 10) and reconnect to the existing
pipe-work.
12. Connect the temporary filling loop between
the cold water inlet and the C H return pipe
as close to the boiler as is practical (Fig.11)
Open the CH isolation valves; fill and vent
the system and flush using a commissioning
cleanser. During final filling add a suitable
corrosion inhibitor as per BS 7593.
Check for leaks
A
CH FLOW
B
HOT WATER OUTLET
C
GAS
D
COLD WATER INLET
F
CH RETURN
Fig 10
Fig.9
A
B
C
Condensate bowl,
washer and rubber
hose connection
Fig.11
CH HW GAS COLD CH
FLOW OUTLET WATER RETURN
Temporary filling
loop between
cold inlet &
heating return

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
13. Open the cold water isolation valve and thoroughly flush the cold/hot water pipe-work by
opening all the hot taps.
14. Reinstate the gas supply, purge and test in accordance with BS 6891 and IGE/UP/1.
15. Connect the boiler to the electrical supply;
the boiler is provided with a 1m cable and
plug. Reconnect any external controls to
the volt free terminal block in the boiler.
To access the connections remove the securing
screw and hinge the controls cover to the left.
Connect the external controls to terminal
block (72) as shown in Fig. 12.
Grommets to accept wiring from external controls are
found on the right underside of the boiler.
Please note:
All electrical work must be in accordance with IEE Wiring Regulations - BS 7671:
External controls need to be compliant with Building Regulations L1A/L1B; further information is
available from the “Domestic Building Services Compliance Guide”
Fig.12

BOILER REPLACEMENT: OPTIMAX 25C TO MODENA 32C HE
Fig.13
Fig.14
Fig. 15
Sample points: 1 = Air / 2 = Flue Gas
16. Commissioning the boiler:
(see 3.3 of the Modena C HE Installation Instructions)
Connect a manometer to the inlet test point of the gas
valve (Fig.13)
Set the boiler to operate at maximum by selecting ‘TEST
MODE’ and check that the operational (working) pressure
at the gas inlet pressure test point is 20 mbar.
To enter and exit ‘TEST MODE’, press the CH + &- buttons
simultaneously for 5 seconds (Fig.14)
A pressure of 20 mbar should be obtained with all other
gas appliances operating.
Please note: there may be a pressure loss across the
isolation valve to the gas valve inlet test point of up to 1.3
mbar at maximum.
Remove the manometer & re-tighten the inlet test point.
17. Measure the gas rate of the boiler and check against the
following table;
18. Connect the flue gas analyser to the flue sample point
(Fig.15); with the boiler still in TEST MODE check that the
readings are within the tolerances set out in the table
below;
If the readings are satisfactory, replace the boiler front cover.
Test the correct operation of the boiler, central heating system and DHW.
Advise the customer on the operation of the new boiler and any new controls.
Complete the “Benchmark Log Book

ferroli
Ferroli Limited
Lichfield Road
Branston Industrial
Estate Burton on Trent
DE14 3HD
www.ferroli.co.uk
Boiler replacement
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Whilst every effort is taken to ensure the accuracy of the information contained within the brochure, the details are offered in
good faith and Ferroli Ltd. accepts no liability for matters arising as a result of errors and/or omissions. The information in this
brochure was correct at the time of printing, however specifications and designs may be changed owing to Ferroli’s policy of
continuous product research and development. The technical specifications in the product instruction manual supersedes and
should always be referred to during installation and maintenance. Reproduction of this publication, or any part, is not permitted
without the written consent of Ferroli Ltd at [e-mail]. The statutory rights of the consumer are not affected.
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Training Well trained installers are the key to a safe and efficient heating system.
We offer a choice of training and product awareness courses on our key product
range, including the Modena HE, at Ferroli’s fully equipped training centre in
Burton-upon-Trent and at specialist training locations across the UK. Courses are
aimed at engineers of all levels to ensure that everyone comes away with the skills
and knowledge needed to deliver the first class service that customers expect and
deserve. For more details visit www.ferroli.co.uk/training or ring 0843 479 0009.
Ferroli Domestic Boilers Offering
gas wall mounted units with outputs of
up to 50kW, Ferroli’s stylish, compact
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requirements of every home.
Ferroli Commercial and
Industrial Boilers Ferroli
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Ferroli Spares The popularity of Ferroli as first choice for both domestic and
commercial installations means that heating parts stockists offer readily available
spares for Ferroli boilers. Ferroli has a UK-based fully stocked warehouse
enabling same-day despatch of just about any part needed to keep your Ferroli
boiler running.
Optimax 25C-
Modena HE