Ferroli OPTIMAX HE PLUS 25 S Troubleshooting guide

INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE
OPTIMAX HE PLUS 25 S
wall-mounted gas fired,
pre-mix
condensing system boiler
cod. 3540R540 - 02/2009 (Rev. 00)
5
G.C. n° 41-267-32
Seasonal Efficiency
(SEDBUK)
band A

OPTIMAX HE PLUS 25 S
2Cod. 3540R540 - 02/2009 (Rev. 00)
• 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 the contentsare 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 symbols 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.
•"Ferroli declare that no substances harmful to health are contained in the appliance or used
during the appliance manufacture”.

OPTIMAX HE PLUS 25 S
3
Cod. 3540R540 - 02/2009 (Rev. 00)
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
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OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing the OPTIMAX HE PLUS 25 S, a FERROLI wall-mounted boiler of the latest
generation, featuring advanced design and cutting-edge technology.
OPTIMAX HE PLUS 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 ope-
ration 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 PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
1.2 Control panel
eco
comfort
reset
815
1314
12
11
21
436
75
fig. 1
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

6
OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
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 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
are calling for heat.
Turning off
Press the (part. 7 - fig. 1) for 5 seconds.
•
•
•
•
eco
comfort
reset
fig. 3 - Boiler without main power supply
eco
comfort
reset
eco
comfort
reset
fig. 4 - Ignition
eco
comfort
reset
fig. 6 - Turning off
fig. 5 - Air purge

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OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
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.
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.
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).
eco
comfort
reset
fig. 7
eco
comfort
reset
fig. 8

1.6 Faults
In the unlikely event of an operating problem, or component failure, the display flashes and a fault
identification code appears.
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OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
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.
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
reset
(Part. 6 – fig. 1) for 1 second.
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”.
Fault Cure
No burner ignition
Make sure that the gas cocks ahead of the boiler
and on the meter are open.
Press the RESET button (for 1 second).
In case of repeatedshutdowns, contact the Ferroli
Service Department.
Low system pressure Fill the ‘system to 1-1.5 bar.
Before calling a Ferroli service engineer, check that the problem is not due to there being no
gas or electricity, or low system pressure.

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OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
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 heat-
ing 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.
Incorrect installation can cause damage or physical injury for which the manufacturer declines any re-
sponsibility.
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

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OPTIMAX HE PLUS 25 S
Cod. 3540R540 - 02/2009 (Rev. 00)
Minimum
A
B
D
2,5 cm
20 cm
60 cm
(via an openable panel)
C30 cm
Table 1
fig. 9
A A
B
D
C
2.2 Boiler location
The unit’s combustion chamber is sealed off
from the installation room and therefore requi-
res no compartment ventilation.
The installation room must be sufficiently well
ventilated to prevent any dangerous condi-
tions 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 moun-
ted alongside, there must be space for normal
maintenance work. Fig. 9 and tab. 1 give the
minimum clearances to leave around the unit.
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.