Ferroli OPTIMAX HE 38 C Troubleshooting guide

OPTIMAX HE 38 C
wall-mounted gas fired,
pre-mix
condensing combination boiler
cod. 3540F17/1 - 11/2006 (Rev. 01)

INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE
FOR THE UNITED KINGDON AND EIRE
GC N° 47-267-43

OPTIMAX HE 38 C
2
• Read the warnings given in this manual thoroughly.
They provide important information for safe instal-
lation, 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, 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
may 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 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.
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 symbol calls attention to a note or important information, please read thor-
oughly.
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”.

OPTIMAX HE 38 C
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1. OPERATING INSTRUCTIONS .................................................................4
1.1 Introduction ............................................................................................................4
1.2 Control panel ..........................................................................................................5
1.3 Turning ON and OFF ..............................................................................................6
1.4 Adjustments ............................................................................................................8
1.5 Maintenance..........................................................................................................11
1.6 Faults.....................................................................................................................11
2. INSTALLATION.....................................................................................12
2.1 General Instructions..............................................................................................12
2.2 Boiler location .......................................................................................................13
2.3 Boiler water connections ......................................................................................14
2.4 Connection to the gas system..............................................................................16
2.5 Electrical Connections ..........................................................................................16
2.6 Flue system ...........................................................................................................18
2.7 Condensate outlet connection .............................................................................24
3. SERVICE AND MAINTENANCE............................................................26
3.1 Adjustments ..........................................................................................................26
3.2 System start-up.....................................................................................................27
3.3 Maintenance..........................................................................................................28
3.4 Troubleshooting....................................................................................................30
4. TECHNICAL CHARACTERISTICS AND DATA.............................................................32
4.1 Dimensions and connections ................................................................................32
4.2 General view and main components ....................................................................33
4.3 Hydraulic diagram.................................................................................................34
4.4 Technical data table..............................................................................................35
4.5 Diagrams ...............................................................................................................36
4.6 Wiring diagram .....................................................................................................37
BENCHMARK ...........................................................................................38
cod. 3540F17/1


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OPTIMAX HE 38 C
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing the OPTIMAX HE 38 C, a FERROLI wall-mounted boiler of the latest generation,
featuring advanced design and cutting-edge technology.
OPTIMAX HE 38 C is a high-efficiency condensing pre-mix appliance for heating and hot water pro-
duction 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, flow sensor, temperature sensors, a safety thermostat and a low water 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.

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OPTIMAX HE 38 C
1.2 Control panel
eco
comfort
reset
89
15
1314
12
11
10
21
436
75
fig. 1
1 = Domestic Hot Water temperature setpoint decreasing push button
2 = Domestic Hot Water temperature setpoint increasing push button
3 = Central Heating water temperature setpoint decreasing push button
4 = Central Heating water temperature setpoint increasing push button
5 = Display LCD
6 = Reset / Summer-Winter / OTC push button
7 = Economy-Comfort / On-Off push button
8 = Domestic Hot Water symbol
9 = Domestic Hot Water mode operation
10 = Summer symbol
11 = Multi-function indication
12 = Economy symbol
13 = Central Heating mode operation
14 = Central Heating symbol
15 = Burner on and actual load indication
Indication during boiler operation
Central Heating mode
The Central Heating heat demand (generated by the OpenTherm Remote Control, the Room Thermostat
or the Clock) is indicated by the flashing of the Hot Air symbol over the radiator (part. 13 and 14 – fig.
1). The display indicates the actual Central Heating water temperature (part. 11 – fig. 1).
eco
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fig. 2

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OPTIMAX HE 38 C
Domestic Hot Water mode
The Domestic Hot Water heat demand (generated by the DHW flow sensor or due to a Comfort request)
is indicated by the flashing of the Hot Water symbol under the tap (part. 8 and 9 – fig. 1). The display
indicates the actual Domestic Hot Water temperature (part. 11 – fig. 1).
1.3 Turning ON and OFF
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.
Ignition
Ensure the power is on to the appliance.
For the firsts 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
are calling for heat.
•
•
•
•
eco
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fig. 3
eco
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fig. 4 - Boiler without main power supply
eco
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eco
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fig. 5 Ignition

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OPTIMAX HE 38 C
Turning off
Press the (part. 7 - fig. 1) for 5 seconds.
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 boiler on again, press (part.7 - fig.1) for 5 seconds.
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.
eco
comfort
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fig. 6 - Turning off
eco
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reset
fig. 7

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OPTIMAX HE 38 C
1.4 Adjustments
Summer/Winter selection
To select Summer, press the
reset
(Part. 6 – fig. 1) for 1 seconds when the boiler is in Winter mode.
The display will show the Summer icon (Part 10 – fig. 1): the boiler can still produce domestic hot water
whenever there is a demand. The frost protection remains active.
To select Winter mode, press the
reset
(Part. 6 – fig. 1) for 1 second when the boiler is in Summer
mode.
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.
Domestic hot water temperature setting
To set the hot water temperature, use the DHW push buttons (Part. 1 and 2 – fig. 1). It can be
varied from a minimum of 40°C to a maximum of 55°C.
eco
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fig. 8
eco
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fig. 9
eco
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fig. 10

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OPTIMAX HE 38 C
Room temperature adjustment (using a room thermostat )
Using the room thermostat, set the temperature desired. 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).
Room temperature adjustment (using an optional Remote Control)
Using the remote control, set the temperature desired. The flow temperature will be control by the
remote controlled. For settings and other informations, see the relative manual.
Economy/Comfort selection
The unit is equipped with a special internal device that ensures a high hot-water delivery speed and
excellent user comfort. When comfort mode is active the water in the boiler is maintained at a pre-de-
termined temperature, which means that hot water is available at the boiler outlet as soon as a tap is
opened, ie with no waiting.
The user can turn the device off (ECO mode) by pressing (part.7 - fig.1). In ECO mode the display
shows the relevant symbol (part. 12 - fig. 1). To turn on COMFORT mode, press (part.7 - fig.1) again,
the ECO symbol will vanish from the display.
Outside temperature compensation
When the (optional) external sensor kit is fitted to the appliance, the system can work in Outside tem-
perature compensation mode. In O.T.C. mode the temperature of the heating system is controlled
according to the external climate conditions, this will guarantee a high degree of comfort and energy
saving all year round.
By the CH push buttons (Part. 3 and 4 – fig. 1) is possible to set the maximum flow temperature
for the installation.
O.T.C. setting
To enter the OTC mode, press
reset
(Part. 6 – fig. 1) for 5 seconds.
The display shows CU flashing (fig. 11); to set Curve, use the DHW push buttons (Part. 1 and 2 – fig.
1). It can be varied from 1 to 10, in accordance with the chart (fig. 13). O means no O.T.C. mode.
It is recommended a start point of 20 - 30 * C and a flow temperature of 85*C is required for the UK
( Curve 9 or 10 )
eco
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fig. 11

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OPTIMAX HE 38 C
By pressing the CH push buttons (Part. 3 e 4 – fig. 1), the display shows OF flashing (fig. 12); to
set Offset, use the DHW push buttons (Part. 1 and 2 – fig. 1). It can be varied from 20 to 40, in
accordance with the chart (fig. 14).
To exit the OTC mode, press
reset
(Part. 6 – fig. 1) for 5 seconds.
eco
comfort
reset
fig. 12
fig. 13
fig. 14
Maximum boiler flow temperature
Outside temperature
Outside temperature Outside temperature
Maximum boiler flow temperature
Maximum boiler flow temperature