Fer FERtech 25 OV Instructions For Use, Installation And Maintenance Download Page 16

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FERtech 25 OV

Cod. 3540U431 - 11/2009 (Rev. 00)

Central heating Demand

The heat demand can be controlled by the room thermostat (terminal 5-6) or by a switch line 230 V
(terminal 5).

Standard Systems

For a general pipe layout and wiring diagram on the “S” and “Y” plan systems please see fig.
15a, 15b, and 16a, 16b.

Wiring diagram

4 3 2 1

Junction Box

N E L

Terminal 5 - SWITCH LINE

1 2 3 4 5 6 7 8 9 10

PROGRAMMER

DHW ON

CH ON

NEUTRAL

LIVE

zone

valve

DHW

zone

valve

Room Thermostat

Cylinder Thermostat

230 Vac

BROWN

BLUE

GREY

ORANGE

6 5

Central

heating

pump

N E L

Pre-Fitted flex

from boiler

Fig. 15b

Remove
Link
between
terminals 5-6

OPTIMAX

FERROLI

BOILER

Balancing

valve

C.H.

Zone Valve

Automatic

bypass

(mimimum flow of 6l/min.)

A.A.V

DHW

zone

valve

*Note: cold feed and expansion

not shown for clarity

(see fig. 12)

Auto air vent

Fig. 15a

FERtech “S” Plan

Pipe layout

Summary of Contents for FERtech 25 OV

Page 1: ...FERtech 25 OV INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE cod 3540U431 11 2009 Rev 00 8 Seasonal Efficiency SED BU K band A G C N 41 267 39 ...

Page 2: ...red 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 Afterunpacking checkthatthecontentsarecomplete and undamaged Keep the pack...

Page 3: ...er water connections 11 2 4 Connection to the gas system 14 2 5 Electrical Connections 14 2 6 Flue system 17 2 7 Condensate outlet connection 23 3 SERVICE AND MAINTENANCE 25 3 1 Adjustments 25 3 2 System start up 26 3 3 Maintenance 27 3 4 Troubleshooting 29 4 TECHNICAL CHARACTERISTICS AND DATA 31 4 1 Dimensions and connections 31 4 2 General view and main components 32 4 3 Hydraulic diagram 33 4 4...

Page 4: ...tally 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 safety valve temperature sensors a safety thermostat and a flue gas sensor Thanks to the twin microprocessor control and adjustment system with advanced self diagnosis unit operation is for the most part automatic The power for heatin...

Page 5: ...et 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...

Page 6: ...ir 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 eco comfort part 7 fig 1 for 5 seconds eco comfort reset fig 3 Boile...

Page 7: ...rnal 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 ...

Page 8: ...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...

Page 9: ...on 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 544...

Page 10: ...idwall Thewallfixingmustensureastable andeffectivesupportfortheappliance using the bracket and fixings supplied If the unit is enclosed in a cupboard or mounted 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 irri...

Page 11: ...type A drain cock device at the lowest points in the system to allow complete draining The temperature differential between the flow manifold and the return to the boiler should not exceed 20 C A minimum flow of 6 litres min is required through the heat exchan ger calibrated on site An automatic by pass must be fitted to the system Do not use the water system pipes to earth electrical applian ces ...

Page 12: ...ic type cylinders only indirect ones should be used The system must be fully pumped due to the complex design of the Aluminium Laminar heat exchang ers high efficiency design Attention is drawn to the Model Water Byelaws Fittings manufactured from duplex alpha beta brass are not acceptable for underground use and certain water undertakings will not accept their use above ground The connecting kits...

Page 13: ...Return Open Vent Motorised valve 22 mm DHW Isolating valve CH Pump Automatic By pass Motorised valve 22 mm CH Balancing valve 15 mm 22 mm Indirect cylinder Indirect coil missing 45 5 0 0 m m Open Vent Static Head Radiator Radiator Schematic layout for fully pumped heating and hot water Close couple Fig 12 ...

Page 14: ...iler is installed on an existing system any unsuitable additives must be removed by tho rough cleansing All systems should be cleansed according to B S 7593 Note In hard water areas treatment to prevent lime scale may be necessary Note It is important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers instructions 2 4 Connection to the ...

Page 15: ... of 8 mm Access to the electrical terminal block Follow the instructions given in fig 13 to access the electrical connection terminal block The layout of the terminals for the various connections is given in the wiring diagram in the Technical Data chapter Key 62 Time Clock optional fig 14 Room thermostat Remove connections 5 6 if external control fitted If using external controls the switched lin...

Page 16: ...on Box N E L Terminal 5 SWITCH LINE 1 2 3 4 5 6 7 8 9 10 PROGRAMMER DHW ON CH ON NEUTRAL LIVE CH zone valve DHW zone valve Room Thermostat Cylinder Thermostat N E L 230 Vac BROWN BLUE GREY ORANGE L 6 5 Central heating pump N E L Pre Fitted flex from boiler Fig 15b Remove Link between terminals 5 6 OPTIMAX FERROLI BOILER Balancing valve C H Zone Valve Automatic bypass mimimum flow of 6l min A A V A...

Page 17: ...e air inlet and flue outlet must be connected to one of the following flue systems With the aid of the tables and methods of calculation indi cated before commencing installation it is first necessary to check that the flue system does not exceed the maximum permissible length The current standards and local regulations must be observed It should be noted that only Fer flue system and accessories ...

Page 18: ...meet the various installation requirements Please refer to our flue manual or the price list Standard concentric flue installation Horizontal flue installation 1 Define the position for installing the unit 2 If using standard flue 041025G0 this must be installed level for non standard flue lengths over 1mtr a fall of 3 mm per metre should be incorporated back to the boiler 3 Make a hole of diamete...

Page 19: ...e the required amount of 1mtr flue extensions part number 1KWMA56U inserting them spigot down ensuring the seals are well lubricated with silicone grease not supplied and correctly located into the sockets 3 If required 45 bends Part number1KWMA64A may be used with a resistance value of 0 5mtrs each the flue should be routed in such away to avoid any unnecessary deviation and thus minimise the amo...

Page 20: ...e an equiva lent loss in linear metres depending on the position of installation of the component with air intake or flue extraction vertical or horizontal Thelossiscalled equivalentlength sinceitiscompared to the loss of one metre of flue defined as equal to 1 For example a bend at 90 of Ø80 in flue extraction has an equivalent loss of 2 linear metres i e it has a loss equal to that of 2 linear m...

Page 21: ...Description Horozontial flue terminal Horozontial air terminal Vertical flue terminal 1 1 1 6 2 1 2 1 8 1 5 2 0 Equivalent losses in metres linear 5 2 Air Flue Vertical Horizontal Vertical Horizontal Equivalent losses in metres linear 12 Accessories Ø 80 Accessories Ø 80 Table 4 Table 5 The stated loss values refer to genuine Fer flue accessories Terminal Position P D E Q Q l B C A G F L J H H K N...

Page 22: ...l Vertically from a terminal on the same wall From an opening in the car port e g door window into the dwelling Above ground roof or balcony level 300mm 300mm 300mm 200mm 75mm 200mm 150mm 100mm 300mm 600mm 300mm 300mm 150mm 1200mm 1200mm 1500mm N A A B C D E F G H I J K L M N O P Q NOTE N A Not applicable In addition the terminal should not be nearer than 150mm fanned draught to an opening in the ...

Page 23: ...ble with a vertical progression and with no constrictions Have the flue conveying the hot fumes adequately distanced or isolated from combustible mate rials Be connected to just one unit per floor for at most 6 units in all 8 if there is a compensation duct or opening Have no mechanical suction devices in the main ducts Be at a lower pressure all along their length under conditions of stationary o...

Page 24: ...s the condensate has a ph value of 4 slightly acidic Where it is not possible to terminate internally the condensate discharge pipe may be run outside see below drawing Any external run is subject to freezing in severe weather conditions To avoid this the pipework should be installed to dispose of the condensate quickly with as much as possible run internally before passing through the wall Pipewo...

Page 25: ...llows 1 Remove the casing 2 Open the sealed chamber 3 Release the fixing clip C and remove the gas pipeA from the fan venturi assembly 4 Replace the nozzle B inserted in the gas pipe with that contained in the conversion kit 5 Reassemble the gas pipe A with the clip and check the seal of the connection 6 Apply the plate contained in the conversion kit near the dataplate 7 Refit the sealed chamber ...

Page 26: ...p Ensure the flue system is correctly fitted including terminal locations Ignition Open the gas valve upstream of the boiler Purge the air from the installation pipework to the appliance Switch on the boiler electrical supply Press the eco comfort key on the boiler for 5 seconds part 7 fig 1 The boiler is now ready to function automatically whenever the external controls call for a demand In case ...

Page 27: ...al end piece and ducts must be free of obstructions and leaks The gas and water systems must be sound The burner and exchanger must be clean The electrodes must be free of scale and correctly positioned The system pressure when cold must be approx 1 bar otherwise bring it to that value The expansion vessel must be filled to 1 bar cold with zero system pressure The gas flow and pressure must corres...

Page 28: ...ry to pay attention after performing all these operations to check and carry out all the phases of ignition and thermostat operation the gas valve and circulation pump After these checks make sure there are no gas leaks Combustion analysis It is possible to analyse the combustion through the air and flue sampling points shown in fig 25 To make the measurement it is neces sary to 1 Open the flue sa...

Page 29: ...ode wiring Main board defective Check the PCB A03 High limit protection Flow sensor not active or correctly located Check the correct positioning and operation of the flow sensor No system circulation Check the pump and radiator valves present in the system and automatic by pass A04 Flue gas fault Fault F07 happened 3 times in the last 24 hours Check the flue A05 Fan problem Tachometer signal inte...

Page 30: ...short circuited Check the wiring or change the sensor Sensor damaged or wiring broken Check the wiring or change the sensor F15 Fan problem Tachometer signal interrupted fan connection Check the wiring and fan Fan damaged debris in fan Check the fan clean debris F34 Supply voltage under 180V Electric mains fault Check the electrical system F35 Irregular mains frequency Electric mains fault Check t...

Page 31: ...AL CHARACTERISTICS AND DATA 4 1 Dimensions and connections Key 1 System flow 22 mm compression union 3 Gas inlet 22 mm with isolation valve fitted 5 System return 22 mm compression union fig 26 80 120 45 25 144 35 1 5 120 80 280 400 45 50 213 187 135 3 630 ...

Page 32: ... fan assembly 19 Combustion compartment 22 Main burner 29 Flue Collar 44 Gas valve 201 191 29 22 81 82 161 154 196 19 278 5 16 186 44 7 193 10 11 81 Ignition electrode 82 Ionisation electrode 154 Condensate outlet pipe 161 Heat exchanger 186 Return sensor 191 Flue gas temperature sensor 196 Condensate collector 201 Fan Venturi 278 Double sensor Safety Heating ...

Page 33: ...aulic diagram fig 28 Key 7 Gas inlet 10 CH flow 11 CH return 16 Premix fan assembly 44 Gas valve 154 Condensate outlet pipe 161 Heat exchanger 186 Return sensor 193 Siphon 278 Double sensor Safety Heating 10 7 186 161 278 154 16 11 193 44 Drain off valve ...

Page 34: ...able 10 Gas Injector G20 Natural Gas Gas Injector G31 Propane Electrical protection rating IP Power voltage frequency V Hz X5D 230 50 98 3 97 3 105 4 107 2 109 1 Max working pressure in heating bar 3 0 3 Type of unit C13 C23 C33 C43 C53 C63 C83 B23 B33 PIN CE 0063 BR 3161 kW kW kW m3 h kg h C C kg h bar Min CH Heat input Min useful heat output 80 C 60 C Min useful heat output 50 C 30 C Min natural...

Page 35: ...valve 62 Time clock optional 81 Spark Electrode 82 Ionisation electrode 101 Main p c b 103 Relay 104 Fuse F3 15 amp 186 Return temperature sensor 191 Exhaust temperature sensor 202 Transformer 230V 24V 203 Supply lead 278 Double sensor Safety Heating fig 29 4 5 Wiring diagram ...

Page 36: ...TED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE H...

Page 37: ...NTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 7 DATE ENG...

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Page 40: ...n 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 Lichfield Road Branston Industrial Estate Burton Upon Trent Staffordshire DE14 3HD Should you require any assistance during the installation call our Technical Service Helpline on 0871 559 2927 Should you require a service engineer t...

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