ideal Optia FF 100 User guide

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FF 30 - FF 100

Wall mounted, balanced flue, fanned gas boiler

Installation & Servicing Instructions

Manufactured exclusively for Plumb Center by Ideal Boilers

Optia

For details of document amendments, refer to page 3

Optia FF - Installation & Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ........... A03 (May 04) to A04 (Apr 05)

• Page 6, Safe Handling

New section added.

• Page 41, Installer Notification Guidelines

New section added for registering the appliance.

• Page 42, Benchmark Commissioning Checklist

New section added.

Caradon Ideal Limited reserve the right to vary specification without notice

Optia FF - Installation & Servicing 3

GENERAL

Table 1 - General Data

Boiler Size FF 30 FF 40 FF 50 FF 60 FF 70 FF 80 FF 100

Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female)

Flow connection 22mm 28mm copper

copper (FEMALE)

Return connection 22mm 28mm copper

copper (FEMALE)

Maximum static water head m (ft.) 30.5 (100)

Minimum static water head m (ft.) 0.45 (1.5)

Electrical supply 230 V 50 Hz Boiler power consumption; 100W

Fuse rating External; 3A Internal; F1A to BS.4265

Water content litre (gal.) 2.7 (0.6) 3.65 (0.8) 4.65 (1.0) 4.65(1.0)

Dry Weight kg (lb) 37.0 (81.6) 42.0 (92.6) 48.0 (105.8) 48.0(105.8)

Maximum installation weight kg (lb) 30.0 (66.2) 34.0 (75.0) 40.0 (88.2) 40.0(88.2)

Boiler size Height mm (in.) 700 (27.5)

Width mm (in.) 380 (15.0)

Depth mm (in.) 300 (11.8)

Flue duct diameter mm (in.) 100 (4.0)

Flue duct length (max) m (ft) 3 (9.8) 0.6 (2)

Table 2 - Performance Data

Boiler Size FF 30 FF 40 FF 50 FF 60 FF 70 FF 80 FF 100

Boiler input kW 10.8 14.5 17.85 21.9 25.3 29.1 36.5

Btu/h x 1000 36.8 49.3 61.0 74.7 85.6 99.3 124.7

Gas consumption l/s 0.275 0.375 0.458 0.567 0.652 0.755 0.947

/h 35.4 47.5 58.7 72.0 83.3 95.6 120.7

Boiler output kW 8.8 11.7 14.7 17.6 20.5 23.4 29.3

Btu/h x 1000 30 40 50 60 70 80 100

Burner Setting pressure (HOT) mbar (in.w.g.) 12.4 (5.0) 11.0 (4.4) 12.7(5.0) 13.7 (5.5) 12.1 (4.8) 12.9 (5.2) 14.0 (5.6)

Seasonal Efficiency (SEDBUK)* (Band D) [79.4]% [78.7]% [79.8]% [78.2]% [78.5]% [78.2]% [78.0]%

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been calculated have been certified by a notified body.

Note. Gas consumption is calculated using a calorific value of

38.7 MJ/m

(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a different calorific value:-

a. FOR L/S - divide the gross heat input (kW) by the gross C.V.

of the gas (MJ/m

b. FOR FT

/H - divide the gross heat input (Btu/h) by the gross

)

C.V. of the gas (Btu/ft3)

Key to symbols

IE = Ireland GB = United Kingdom PMS = Maximum operating pressure of water

& C32 = A room sealed appliance designed for

connection via ducts to a horizontal or vertical terminal, which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is down stream of the combustion chamber.

C72 = A room sealed appliance designed for connection via

concentric vertical ducts and a draught diverter located in the roof space to a secondary flue. The combustion air is taken from the roof space. The fan is down stream of the combustion chamber.

= An appliance designed for use on 2nd Family gas,

Group H only.

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning of this

appliance, care should be taken when handling edges of sheet steel components.

Optia FF - Installation & Servicing

GENERAL

Optia FF

Natural Gas only

Boiler size G.C. Appliance No. PI No.

(Benchmark No.)

FF 30 41-391-54 87AP107

FF 40 41-391-95 87AP107

FF 50 41-391-96 87AP107

FF 60 41-391-97 87AP107

FF 70 41-391-98 87AP107

FF 80 41-391-99 87AP107

FF 100 41-392-01 87AP107

Destination Countries: GB, IE

Appliance Type Boiler size

12 & C32

FF 30, 40, 50, 70

FF 60 & 80 only

FF 100 only

CONTENTS

Air Supply. ..................................................................... 8

Benchmark Commissioning Checklist .....................42

Boiler Clearances .........................................................7

Boiler Exploded View ................................................. 13

Burner Exploded View ................................................40

Control Box Exploded View ...................................... .40

Electrical Connections ............................................... 24

Electrical Regulations ..................................................9

Extension Ducts - Fitting ............................................ 22

External Controls ........................................................24

Fault Finding ................................................................37

Flue Installation ............................................................. 8

Rear installation ......................................................16

Side installation .......................................................19

Gas Safety ..................................................................... 6

Gas Supply .................................................................... 8

Initial Lighting . ............................................................27

Installation .................................................................. 13

Mandatory Requirements ............................................6

Pump ........................................................................... 10

Safe Handling ................................................................ 6

Servicing ..................................................................... 29

Short List of Parts ...................................................... 38

Spares Replacement ................................................. 31

System Electrical Diagrams ......................................25

Terminal Guards. .......................................................... 8

Water and Systems ..................................................... 9

Water Treatment .......................................................... 9

For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page

Make and model .......................................................5

Appliance serial no. on data badge ....................... 13

SEDBUK No. % .........................................................4

Controls

Time and temperature control to heating ......... 25/26

Time and temperature control to hot water ...... 25/26

Heating zone valves .......................................... 25/26

TRV's ......................................................................... 9

Auto bypass ............................................................... 9

Boiler interlock ..........................................................9

For all boilers

Flushing to BS.7593 .................................................9

Inhibitor...................................................................... 9

Central heating mode

Heat input ................................................. to be calculated

Burner operating pressure ....... measure and record

Central heating flow temp. ........ measure and record

Central heating return temp. ..... measure and record

For combination boilers only

Scale reducer .........................................................n/a

Hot water mode

Heat input ...............................................................n/a

Max. operating burner pressure ............................n/a

Max. operating water pressure ..............................n/a

Cold water inlet temp .............................................n/a

Hot water outlet temp. ............................................n/a

Water flow rate at max. setting ............................... n/a

For condensing boilers only

Condensate drain ..................................................n/a

For all boilers: complete, sign & hand over to customer

For assistance see Technical Helpline on the back page

Page

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

Optia FF - Installation & Servicing 5

GENERAL

INTRODUCTION

The Optia FF 30-100 is a range of automatically fully controlled,

wall mounted, balanced flue, fanned gas boilers. The heat exchanger is cast iron. The boiler casing is of white

enamelled mild steel. The boiler casing has a removable controls pod containing a drop-

down door. The boiler thermostat is located behind the drop- down door.

Note. These boilers cannot be used on systems which include gravity circulation.

See Frame 1 for details of the correct boiler tappings to use. The boilers are supplied with a standard flue kit suitable for rear or

side outlet applications from 114 mm (4 (23 1/2").

The boilers are suitable for connection to the following open vented or sealed systems:

! Fully pumped CH and indirect DHW ! Pumped heating only.

! Pumped indirect DHW only.

1/2") to 600 mm

SAFE HANDLING

This boiler may require 2 operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations. Operatives should be knowledgeable in handling techniques

when performing these tasks and the following precautions should be considered:

• Grip the boiler. Refer to Frame 18.

• Split the boiler down to reduce the weight, e.g. remove casing and hardware pack. Refer to Frame 9.

• Be physically capable.

• Use PPE as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.

• Keep back straight.

• Avoid twisting at the waist.

• Avoid upper body/top heavy bending.

• Always grip with the palm of the hand.

• Use designated hand holds.

• Keep load as close to the body as possible.

• Always use assistance if required.

OPTIONAL EXTRA KITS

Downward Piping Kit. Programmer Kit.

Vertex Flue Kit ** - for vertical flue connection Roof Flue Kit * - for vertical flue connection 90° Flue Elbow Kit *

Sealed System Unit* - this fits on top of the appliance. Extension ducts * - up to 3m (118"). Turret Outlet Kit.*

*not available for FF 100, **only suitable for FF60 & FF80

CURRENT GAS SAFETY (INSTALLATION AND USE) REGULATIONS OR RULES IN FORCE.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

• The appropriate Building Regulations either 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.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a Competent Person and installed in accordance with the current edition of I.S.813 "Domestic Gas Installations", the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

Detailed recommendations are contained in the following British Standard Codes of Practice:

BS.6891 Low pressure installation pipes. BS.6798 Installation of gas fired hot water boilers of rated input

BS.5449 Forced circulation hot water systems. BS.5546 Installation of gas hot water supplies for domestic

BS.7593 Treatment of water in domestic hot water central

BS.5440.1 Flues for gas appliances of rated input not exceeding

BS.5440.2 Ventilation for gas appliances of rated input not

Health & Safety Document No. 635 The Electricity at Work Regulations, 1989.

Manufacturer’s notes must NOT be taken in any way as overriding statutory obligations.

IMPORTANT. These appliances are certificated by the British Standards Institution for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing instructions or otherwise recommended by Plumb Center in writing. If in doubt please enquire.

Any direct reconnection of a control device not approved by Plumb Center could invalidate the BSI Certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

not exceeding 60 kW.

purposes (2nd Family Gases).

heating systems.

60 kW.

exceeding 60 kW.

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 this boiler.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable of adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary - unless required by the local authority. The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE/UP/7:1998.

Bathrooms

This range of appliances is rated IP 1XB.

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space

.........continued on page 8

Optia FF - Installation & Servicing

BOILER WATER CONNECTIONS

This appliance in NOT suitable for use in a direct hot water system or for gravity circulation.

FF 70, FF 80 & FF 100 ONLY

must be fitted with the 22mm x 28mm copper sockets, provided in the Hardware Pack, (or equivalent 22mm x 28mm compression fittings ) and the pumped flow and return pipes run in 28mm pipe.

BOILER CLEARANCES

The following minimum clearances must be maintained for operation and servicing.

Additional space will be required for installation, depending upon site conditions.

Side and Rear Flue

a. Provided that the flue hole is cut

accurately, e.g. with a core drill, the flue can be installed from inside the building.

Installation from inside ONLY

b. If a core boring tool is to be used

inside the building; the space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

c. If using the Complete Sealed

System Unit then refer to the instructions packed with the unit for the necessary clearances.

Front View Side View

Pumped flow pipe

12 (1/2")

141 (5 9/16")

700 (27 1/2")

Pumped return pipe

Gas connection

380 (15")

300 (12")

GENERAL

(1 3/4")

Flue terminal

100 (4")

Front clearance: 533mm (21") from the front of the boiler casing.

Minimum front clearance when built in to cupboard is 75 mm (3").

Pelmet restrictions.

If the ability to fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc. this operation can be made easier by first removing the controls pod casing in line with the following instructions:

a. Release the controls pod

casing fixing screws (a) 3 full turns only. Remove the pod by pulling it forward to disengage from the keyhole slots.

b. Undo the 2 screws (b)

retaining casing to the back panel.

c. The casing can now be

removed in the direction of the arrow, first lifting the casing slightly to disengage the casing top return from the back panel. (For this purpose a minimum clearance of 12mm is required between the top of the boiler and pelmet or other similar obstruction.

Gas connection

20 (3/4")

Jacking screw

133 (5 1/4")

300 (12")

44 (1 3/4")

Clas 1783

Optia FF - Installation & Servicing 7

GENERAL

containing a bath or shower. For Ireland reference should be made to the current ETCI rules for electrical installations and I.S.813:2002.

If the appliance is to be installed in a room containing a bath or shower then, providing waterjets are not going to be used for cleaning purposes (such as communal baths/showers), the appliance can be installed in Zone 3, as detailed in BS.7671.

Where installation will be in an unusual location, special procedures may be necessary and BS.6798 gives detailed guidance on this aspect.

Compartment Installations

A compartment used to enclose the boiler MUST be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided it is modified for the purpose.

In both cases details of essential features of cupboards/ compartment design, including airing cupboard installation, are to conform to the following :

! BS. 6798.

! The position selected for installation MUST allow adequate

space for servicing in front of the boiler and for air circulation around the boiler. Refer to 'Air Supply'.

! For the minimum clearances required for safety and

subsequent service refer to the wall mounting diagram, Frame 2. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier.

The boiler is to be installed only on a gas supply with a governed meter.

A gas meter can only be connected by the local gas supplier or by a local regional contractor.

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required. A MINIMUM pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating.

Installation pipes MUST be fitted in accordance with BS. 6891. In IE refer to I.S. 813:2002. Pipework from the meter to the boiler MUST be of an adequate size. FF100 models should be piped in 22mm minimum. The final 1 metre may be run in 15mm if it is visible.

The complete installation MUST be tested for gas soundness and purged as described in the above code.

FLUE INSTALLATION

Pluming may occur at the terminal so terminal positions which would cause a nuisance should be avoided.

The flue must be installed in accordance with the recommendations of BS. 5440-1:2000. In IE refer to I.S. 813:2002.

The following notes are intended for general guidance:-

1. The boiler MUST be installed so that the terminal is exposed to external air.

2. It is important that the position of the terminal allows the free passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3.

4. Where the lowest part of the terminal is fitted less than 2m (6'6") above a balcony, above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard. The minimum spacing in Table 3, Nos. 2,3, 4, 5 and 6 would be 75mm in order to allow a terminal guard to be fitted.

Table 3 - Balanced flue terminal position

Approved Manufacturer’s Clearances

Terminal Position Minimum Spacing

1a. Directly BELOW an opening, air brick,

opening window, etc. 300 mm (12")

1b. Directly ABOVE an opening, air brick,

opening window, etc. 300 mm (12")

1c. HORIZONTALLY to an opening,

air brick, opening window, etc. 300 mm (12")

2. Below guttering, drain pipes or soil pipes 25 mm ( 1")

3. Below eaves 25 mm ( 1")

4. Below balconies or a car port roof 25 mm ( 1")

5. From vertical drain pipes or soil pipes 25 mm ( 1")

6. From an internal or external corner or

to a boundary alongside the terminal 25 mm ( 1")

7. Above adjacent ground, roof or balcony level 300 mm (12")

8. From a surface or a boundary facing the terminal 600 mm (24")

9. From a terminal facing a terminal 1200 mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on the same wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")

Terminals guards are available from boiler suppliers - ask for TFC Flue Guard, Model K1. In case of difficulty seek advice from:

Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge, Kent TN9 1TB. Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445 www.tfc-group.co.uk

Ensure that the guard is fitted centrally.

5. The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building.

6. The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm (1") to combustible material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000. In IE refer to I.S. 813:2002.

7. Where it is essential that the terminal wall plate is fitted, i.e. wall thicknesses over 600mm (23 the minimum spacing in Table 3 Nos. 2,3, 4, 5 and 6 would be 60mm (2 1/2") in order to allow the terminal wall plate to be fitted.

IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice, that products of combustion discharging from the terminal cannot reenter the building or any other adjacent building through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/air conditioning.

If this should occur, the appliance MUST be turned OFF, labelled 'unsafe' and corrective action taken.

1/2") or with an inaccurately cut hole,

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 10.

AIR SUPPLY

Detailed recommendations for air supply are given in BS.5440:2. In IE refer to I.S. 813:2002.

The following notes are for general guidance:

1. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed.

Optia FF - Installation & Servicing

GENERAL

2. If the boiler is to be installed in a cupboard or compartment,

permanent air vents are required (for cooling purposes) in the cupboard/compartment, at both high and low levels. The air vents must either communicate with room/internal space, or be direct to outside air. The minimum effective areas of the permanent air vents, required in the cupboard/ compartment, are specified in Table 4 and are related to maximum rated heat input.

3. Both air vents MUST communicate with the same room or internal space or MUST be on the same wall to outside air.

4. In siting the air vents care must be taken to avoid the freezing of pipework.

Table 4 - High and low vent areas

Boiler Air from room/internal Air direct from

space, cm (in

FF 30 102 (16) 51 (8)

FF 40 135 (21) 68 (11)

FF 50 170 (26) 83 (13)

FF 60 198 (31) 102 (16)

FF 70 231 (36) 116 (18)

FF 80 264 (41) 132 (21)

FF 100 340 (52) 170 (26)

) outside, cm (in2)

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the types of system and correct piping procedure refer to 'Introduction' and Frame 1.

The central heating system should be in accordance with BS.6798 and, in addition, for Smallbore and Microbore systems, BS. 5449.

The domestic hot water system, if applicable, should be in accordance with the relevant recommendations of BS. 5546. Copper tubing to BS. 2871:1 is recommended for water carrying pipework.

The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper.

Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating, nor are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly where pipes run through roof spaces and ventilated under floor spaces.

Boilers not fitted to a sealed system must be vented.

IMPORTANT

A minimum length of 1m of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping. This applies to ALL types of installation.

Draining taps MUST be located in accessible positions, which permit the draining of the whole system - including the boiler and hot water storage vessel. They should be at least nominal size and be in accordance with BS. 2879.

The boiler is fitted with a special drain plug, which is provided, to drain the BOILER ONLY, in the event of the system drain plug being unable to do so. The hydraulic resistance of the boilers, at MAXIMUM OUTPUT with an 11 are shown in Table 5.

Maximum boiler operating temperature should be 82 oC (180 oF).

C (20OF) temperature differential,

1/2" BSP

Table 5 - Water flow rate and pressure loss

Boiler Size FF 30 40 50 60 70 80 100

Boiler kW 8.8 11.7 14.6 17.6 20.5 23.4 29.3 Output Btu/h x 1000 30 40 50 60 70 80 100

Water Flow l/min 11.4 15.2 19.0 22.8 26.5 30.3 38.0 Rate gal/h 150 200 250 300 350 400 500

Pressure mbar 22.0 20.4 31.5 41.7 54.8 77.0 106 Loss in wg 8.9 8.3 12.6 16.7 22.0 30.9 42.5

WATER TREATMENT

These boilers incorporate a cast iron heat exchanger.

IMPORTANT. The application of any other treatment to this product may render the guarantee of Plumb Center INVALID.

Plumb Center recommend Water Treatment in accordance with

the Benchmark Guidance Notes on Water Treatment in Central Heating Systems.

Plumb Center recommend the use of Fernox, GE Betz Sentinel or Salamander water treatment products, which must be used on accordance with the manufacturers instructions.

For further information contact:

Fernox Manufacturing Co. Ltd, Cookson Electronics, Forsyth Road, Sheerwater, Woking, Surrey. GU21 5RZ. Tel. +44 (0) 1799 521133

G E Betz Ltd, Sentinel Division, Foundry Lane, Widnes, Cheshire, WA8 8UD. Tel. +44 (0) 151 424 5351

Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952

Notes.

1. It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS7593:1992 details the steps necessary to clean a domestic heating system.

3. In hard water areas, treatment to prevent limescale may be necessary - however the use of artificially softened water is NOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

BOILER CONTROL INTERLOCKS

Plumb Center recommend that heating systems utilising full

thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS. 5449.

Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water.

When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all radiators, or two port valves without end switches, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position.

Optia FF - Installation & Servicing 9

GENERAL

System return

Connections to boiler

Inverted cold feed entry

System flow to pump

150 (6") Max

15mm Cold feed

450 (18") Mimimum

22mm Open vent

Feed / expansion cistern

Water level (cold)

ELECTRICAL SUPPLY

WARNING. The appliance MUST be efficiently earthed. Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply. For Ireland reference should be made to the current ETCI rules for electrical installations.

The point of connection to the mains should be readily accessible and adjacent to the boiler, except that for bathroom installations; the point of connection to the mains MUST be situated outside of the bathroom.

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED

The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.

There should be a minimum height - 450mm (18") - of open vent above cistern water level. If this is impossible refer below.

The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 450mm (18").

The pump MUST be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing an 11°C (20°F) temperature differential (e.g. Grundfos UPS 15/50 or equivalent). The vertical distance between the pump and feed/ expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation. Should these conditions not apply, either lower the pump position or raise the cistern above the minimum requirement specified by Plumb

Center.

Note. A cold water feed must be available back to the boiler, when

all automatic valves are in the closed position (refer to BS. 6798) and when close coupled the feed must not be in a vertical leg.

Note.

Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower. See Frame 38 for details.

The Optia range of boilers can be installed in low head situations by fitting a 'surge arrester' in the expansion pipe as shown.

The following conditions MUST be observed:

1. The surge arrester must be at least 42mm in diameter x 150mm long, thus ensuring a MINIMUM air gap and a MINIMUM depth of water below the static water level (cold) of 75mm.

2. The static water level (cold) must be at least 200mm above the top of the horizontal flow pipe, fitted as shown. The vent connection MUST NOT be made immediately off the top of the boiler, as venting is made less efficient.

3. The maximum practical length of 15mm cold feed pipe should be used in order to reduce the effective volume of system water expanding into the feed/expansion cistern to a minimum.

Note. The pump manufacturers minimum requirements must be complied with.

LOW HEAD INSTALLATIONS

Minimum Requirements

75 (3) Min.

Feed / expansion

cistern

450 (18) Min.

Return

All dimensions in mm (in.). N.B. Imperial dimensions are approximate

200 (8) Min.

Surge arrester

75 (3) Min.

Flow

Highest point of flow or return

22 (3/4)

Open vent

150

(6)

Max

Max. practical

length

Optia FF - Installation & Servicing

Cold

water

level

To pump

SEALED SYSTEM REQUIREMENTS

ecl6060

GENERAL

Hose unions

Temporary hose

(disconnect

after filling)

Non-return

valve

Automatic

air vent

Hosepipe

(disconnect

after filling)

Additional stop valve

Double check valve

assembly

(note direction of flow)

Hose connector

Note.

The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

1. General

a. The installation must comply with the requirements of

BS.6798 and BS.5449.

b. The installation should be designed to work with flow

temperatures of up to 82

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45 lb/in

) and temperature of 110oC. Care should be taken in making all connections so that the risk of leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the relevant requirements of BS.6759 must be fitted in the flow pipe, as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:

a. A non-adjustable pre-set lift pressure not exceeding 3

bar (45 lb./in

)

b. A manual testing device.

c. Provision for connection of a discharge pipe. The valve

or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar (0-60 lb./in2) must be fitted to the system. The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

4. Expansion Vessel

a. A diaphragm type expansion vessel must be

connected at a point close to the inlet side of the pump, the connecting pipe being not less than 15mm ( nominal) size and not incorporating valves of any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to 110

(230

c. The charge pressure must not be less than the static

water head above the vessel The pressure attained in the system when heated to 110 least 0.35 bar (5lb/in

) less than the lift pressure of the

C (230oF) should be at

safety valve.

For guidance on vessel sizing refer to the table in Frame

6. For further details refer to BS.5449. For IE refer to the current edition of I.S. 813.

5. Cylinder

The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0.35 bar

(5lb./in

) in excess of the safety valve setting. Single feed

indirect cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the system, either:

a. From a manually fitted make-up vessel with a readily

visible water level. The vessel should be mounted at least 150mm (6") above the highest point of the system and be connected through a non-return valve to the system, fitted at least 300mm (12") below the make-up vessel on the return side of the domestic hot water cylinder or radiators.

b. Where access to a make-up vessel would be difficult by

pre-pressurisation of the system. Refer to 'Filling.'

1/2"

Optia FF - Installation & Servicing 11

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

7. Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8. Filling

The system may be filled by one of the following methods:

a. Through a cistern, used for no other purposes, via a ball

valve permanently connected directly to a service pipe and / or a cold water distributing pipe.

The static head available from the cistern should be adequate to provide the desired initial system design pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe.

This unit may remain permanently connected to the heating system to provide limited automatic water make-up. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. Through a temporary hose connection from a draw-off tap

supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure-reducing valve shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

A stop valve complying with the requirements of BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting).

A test cock.

A double check valve of an approved type.

• Thoroughly flush out the whole of the system with cold water, without the pump in position.

• With the pump fitted, fill and vent the system until the pressure gauge registers 1.5 bar (21.5lb/in

Examine for leaks.

• Check the operation of the safety valve by manually raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (± 4.3lb/in2.) of the pre-set lift pressure.

• Release water from the system until the initial system design pressure is reached.

• Light the boiler and heat the system to the maximum working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.

• Refill and vent the system.

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by Table 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).

Table 6

Safety valve setting 3.0 bar 2.5 bar 2.0 bar

Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 system pressure bar bar bar bar bar bar bar bar

Total water content of system Expansion vessel volume

(litres) (litres)

25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0

50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0

75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0

100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0

125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0

150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for

other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

Optia FF - Installation & Servicing

BOILER ASSEMBLY - Exploded view

Optia FF 30 shown

INSTALLATION

LEGEND

1A. Heat exchanger.

2. Flue baffles.

3. Tie rods.

4A. Pumped flow pipe.

5A. Pumped return pipe.

6. Collector hood assembly.

7. Combustion chamber.

12. Main burner.

19. Control box .

24. Pressure switch.

30. Fan.

40. Wall mounting plate.

44B. Programmer (optional).

52. Back panel.

59. Limit thermostat

Optia FF - Installation & Servicing 13

INSTALLATION

UNPACKING

The boiler is supplied fully assembled in Pack A, together with a standard flue assembly for lengths up to 600mm (23 rear or side flue outlet, in Pack B.

Unpack and check the contents.

INSTALLATION

1/2"),

Pack A Contents

! The complete boiler ! Installation & Servicing Instructions ! User's Instructions ! Hardware Pack (listed below) ! Wall mounting template ! Wall mounting plate ! Side outlet terminal mounting plate ! Flue extension tube - 1 off ! Boiler sealing ring - 1 off

Hardware Pack Contents

! 50mm x No. 14 wood screw, 4 off

! 50mm x No. 10 wood screw, 8 off

! Wall plug, 12 off

Pack B Contents

! Duct cutting support, 2 off

(cardboard )

! Terminal wall plate, 1 off.

! Terminal grille assy., 1 off.

! Polyurethane foam seal 400 lg., 1 off.

! No. 8 x 8 lg. Pozi pan hd. screws, 3 off.

! M8 washer, 1 off

! 22mm x 28mm copper reducing socket

(FF 70, FF 80 and FF 100 ONLY), 2 off

! M5 wing nut, 3 off

! Sealing plate, 1 off

! M8 x 12 Hx. Hd. screw, 1 off

Optia FF - Installation & Servicing

INSTALLATION

Flue length for rear

Flue length for side

Jacking screw for boiler alignment

PACKAGING AND CASING REMOVAL

1. Unpack the boiler.

2. Remove the casing as follows and place to one side to

avoid damage.

a. Undo the 2 casing retaining screws (a) retaining the

casing to the back panel.

b. Swing the bottom of the boiler casing up until the

controls pod casing has cleared the controls then unhook the top from the back panel.

3. Remove the boiler from its packaging base. The boiler may now be stood upright on its controls support protection frame to ease handling and installation.

4. Unpack the boiler terminal box and, if applicable, the extension flue box(es).

DETERMINING THE FLUE LENGTH

(a) Casing retaining screws, 2 off

INSTALLATION

Packing base

Controls pod casing

It is MOST IMPORTANT that the boiler is installed in a vertical position.

SIDE FLUE INSTALLATION

REAR FLUE INSTALLATION

FLUE KITS

Pack B: supplied as standard.

Pack D*: optional extension kit for side flue or rear

flue outlet. Refer to Frame 33.

1. A maximum of 2 extension ducts (plus the standard flue duct) may be used together.

2. Flue extensions of greater than 1m (39") should be supported with the bracket provided. If the stand-off brackets have been used it is necessary, in order to keep the flue aligned, to use the spacer bracket with the support bracket.

Note.

Vertex and roof flue kits are available as optional extras for vertical flue installation, supplied with separate fitting instructions.

Flue length

Up to 600 B Pack 1 off 200768

600 to 1550* B Pack 1 off + D Pack, 1 off 200768+200769

1550 to 2500* B Pack 1 off + D Pack, 2 off 200768+

2500 to 3000* B Pack 1 off + D Pack, 3 off 200768+

* Not for FF 100 model

Accessories Product No.

200769, 2 off

200769, 3 off

Optia FF - Installation & Servicing 15

FLUE ASSEMBLY - Exploded View

1. An optional flue

duct extension kit is required for wall thicknesses greater than 600mm (23 1/2") Refer to Frame 10.

2. When cutting the ducts, always use the cardboard support rings provided.

WALL MOUNTING TEMPLATE

INSTALLATION

LEGEND

1. Terminal

2. Weather sea

3. Flue assembly

4. Boiler sealing ring

5. Flue extension tube

Note. The template shows the positions for the fixing holes

and the flue hole centres for standard installation. Care must be taken to ensure the correct holes are drilled.

1. Separate the templates.

2. Tape the templates into the selected position.

3. Ensure squareness by hanging a plumb line as

shown.

4. Mark onto the wall (if required) the following:

a. The wall mounting plate screw positions (choose

one from each group). Note. Mark the centre of the flue hole as well as the circumference.

b. The position of the flue duct hole.

c. Downward pipe routing bracket screw positions.

5. Remove the templates from the wall.

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation,

masonry falling outside of the building does not cause damage or personal injury.

1. Cut the flue hole, preferably with a 125mm (5") core boring tool, ensuring that the hole is square to the wall. If the hole has been quite accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue. However, both wall faces immediately around the cut hole should be flat; make good if necessary. For less accurate holes make good to approximately 125mm (5") diameter at the two wall faces.

2. Drill 4 holes for the wall mounting plate with an 8mm (

16") masonry drill. If the stand-off brackets are used ensure

the correct holes are chosen.

3. Insert the plastic plugs provided.

Note. Check all of the hole positions BEFORE drilling

Note. If the terminal is to be sited within 2540mm of a corner or vertical pipe (refer to Table 3) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. The terminal wall plate need not be fitted.

REAR FLUE OUTLET

Optia FF - Installation & Servicing

INSTALLATION

CUTTING THE FLUE - wall thicknesses of 114 to 600mm

Note. If the stand-off brackets are used it is essential that

30mm is added to the measured wall thickness when marking the flue (to allow for the thickness of the brackets).

1. Measure and note the wall thickness X.

2. Mark the wall thickness onto the flue.

3. To ensure the tube is cut square, mark the flue all the

way round.

4. Cut to length X, using the cardboard ring for support.

5. Remove cardboard ring and remove any burrs.

FITTING THE BOILER SEALING RING TO THE FLUE

1. Fit the boiler sealing ring inside the outer flue duct. Ensure

the boiler sealing ring is fully engaged.

Ensure the notch aligns with the groove on the outer flue duct. This ensures correct alignment of the flue terminal.

2. Drill 3 holes 3.2mm (1/8") dia. through the outer flue duct and boiler sealing ring.

Do NOT drill the inner flue

duct.

3. Insert the self-tapping screws, provided, in order to fix the

boiler sealing ring in position.

FITTING THE FLUE ASSEMBLY

1. Insert the flue extension tube into the flue assembly.

2. Insert the flue assembly through the hole far enough to

allow the rubber seal to unfold completely and form an adequate seal on the outside wall.

3. Ensure the notch is at the top. This will aid the location of the studs into the boiler back panel.

4. Stick the self-adhesive foam strip, provided in the hardware pack, onto the flue immediately behind the boiler sealing ring.

WALL MOUNTING PLATE

1. Fix the mounting plate to the wall with the No.14 x 50mm wood

screws.

2. If downward routing of pipes is required then the downward routing pipe brackets and M8 spacer (supplied in the Downward Piping Kit) should be fitted to the wall mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the wall, through the wall mounting plate.

4. Check with a spirit level that the plate is vertical.

Optia FF - Installation & Servicing 17

REAR FLUE OUTLET

MOUNTING THE BOILER

Note. Have ready to hand the M8 screw,

washer and rectangular plate supplied in the hardware pack. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be fitted to the back of the boiler.

1. Lift the boiler onto the wall mounting plate hooks as shown.

Do not use the burner / controls for lifting

2. Fit the M8 screw, washer and rectangular plate to retain the boiler.

Note.

Before fully tightening the M8 screw, check the boiler alignment, using a spirit level, and adjust as necessary with the jacking screw.

INSTALLATION

CONNECTING THE FLUE TO THE BOILER

1. Pull the flue through the wall mounting plate and

locate the 3 studs in the holes in the back panel.

2. Secure the flue to the boiler using the three M5 wing nuts provided.

3. Pull the flue extension tube and engage onto the fan. Locate and secure with the M4 screw attached to the fan.

Note.

The sealing ring studs will locate in the back panel one way only. This will ensure that the terminal grille is correctly aligned.

TERMINAL WALL PLATE

This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat.

1. Position the terminal wall plate over the terminal.

2. Mark and drill 4 fixing holes with an 7mm (

drill.

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws

provided.

9/32") masonry

Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to the Contents List on Page 5.

REAR FLUE OUTLET

Optia FF - Installation & Servicing

INSTALLATION

Extended centre

line

Terminal mounting plate screw and flue duct hole positions

FLUE ASSEMBLY - Exploded view

For wall thickness 114mm to 600mm

1. An optional flue duct

extension kit is required for lengths (distance from the outside wall to the relevant side of the boiler casing) greater than 600mm (23 1/2"). Refer to Frame 10.

2. When cutting the ducts always use the cardboard support provided.

WALL MOUNTING TEMPLATE

Note. The template shows the positions for the fixing holes and the flue hole

centres for standard installation. If the flow and return pipes are to be routed down behind the boiler the downward routing pipe brackets, supplied with the Downward Piping Kit, must be used. These brackets are secured to the wall mounting plate and it is essential to use only those holes as shown on the wall mounting template. Care MUST be taken to ensure the correct holes are drilled.

LEGEND

1. Terminal

2. Weather seal

3. Flue assembly

4. Boiler sealing plate

5. Flue extension tube

1. Separate the templates.

2. Tape both templates into the selected position locating template B

through an extended centre line as shown.

3. Ensure squareness by hanging a plumb line as shown.

4. Mark onto the wall (if required) the following:

a. The 4 wall mounting plate screw positions (choose one from each

group). If the downward routing pipe brackets are used ensure the correct holes are chosen.

b. The 4 screw positions for the side outlet plate.

c. The position of the flue duct hole (ensure that the correct centre is

marked, depending on whether the downward routing pipe brackets are used or not).

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation, masonry falling

outside of the building does not cause damage or personal injury.

1. Cut the flue hole, preferably with a 125mm (5") core boring tool, ensuring that the hole is square to the wall. If the hole has been accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue. However, both wall faces immediately around the cut hole should be flat; make good if necessary. For less accurate holes make good to approximately 125mm (5") diameter at the 2 wall faces.

2. Drill 4 holes with an 8mm ( plugs provided, for the wall mounting plate.

3. Drill 4 holes with a 7mm (9/32") masonry drill and insert the plastic plugs provided, for the side mounting plate.

Note. If the terminal is to be sited within 25-40mm of a corner or vertical pipe (refer to Table 3) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. The terminal wall plate need not be fitted.

5/16") masonry drill and insert the plastic

Note. Mark the centre of the hole as well as the circumference.

d. The side of the casing nearest the flue outlet.

5. Remove both templates from the wall.

SIDE FLUE OUTLET

Optia FF - Installation & Servicing 19

INSTALLATION

CUTTING THE FLUE For flue lengths 114 to 600mm ONLY

1. Measure the flue length required (i.e. the distance from

the side of the boiler to the outside face of the wall). Refer to Frame 10.

2. Mark the flue length required onto the flue, measuring from the groove near the terminal.

3. To ensure the tube is cut square, mark the flue all the way round.

4. Insert the cardboard duct ring for support and cut to length.

5. Remove cardboard duct ring and remove any burrs.

FITTING THE FOAM SEAL

1. To determine the position for the foam seal measure

the wall thickness and mark it onto the flue, measuring from the groove near the terminal.

2. Wrap the self-adhesive foam strip round the flue, ensuring that the foam is on the terminal side of the line. This seals the gap between the flue and the wall.

For flue lengths greater than 600mm refer to Frames 33 & 34 - Flue extension ducts.

FITTING BOILER SEALING RING TO THE FLUE

1. Fit the boiler sealing ring inside the outer flue duct.

SIDE FLUE OUTLET

Ensure the boiler sealing ring is fully engaged. Ensure the notch aligns with the groove on the outer flue duct. This ensures correct alignment of the flue terminal.

2. Drill 3 holes 3.2mm ( and boiler sealing ring.

3. Insert the self tapping screws, provided, in order to fix the boiler sealing ring in position.

1/8") dia. through the outer flue duct

Do not drill the inner flue duct.

FITTING THE FLUE ASSEMBLY

1. Insert the flue assembly through the hole far enough to

allow the rubber seal to unfold completely and form an adequate seal on the outside wall. This will also ensure the correct alignment of the flue terminal.

2. Ensure the notch is at the top. This will aid the location of the studs into the boiler back panel.

Optia FF - Installation & Servicing

FITTING THE SIDE OUTLET PLATES

INSTALLATION

WALL MOUNTING PLATE

Note. If the boiler is fitted closer than 25mm to the side wall

the side outlet plate must be fitted now.

1. Split the side outlet plate into 2 down the split line.

2. Fit the 2 halves of the side outlet plate to the wall,

ensuring they are behind the boiler sealing ring.

1. Fix the mounting plate to the wall with the No.14 x 50mm wood screws.

2. If downward routing of pipes is required then the downward routing pipe brackets and M8 spacer (supplied in the Downward Piping Kit) should be fitted to the wall mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the wall, through the wall mounting plate.

4. Check with a spirit level that the plate is vertical.

MOUNTING THE BOILER

Notes 1. Have ready to hand the M8 screw, washer and rectangular plate supplied in the hardware pack.

2. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be fitted to the back of the boiler.

1. The boiler is supplied for rear outlet installation. Remove the blanking plate from the direction required and use this to blank off the rear outlet.

2. Lift the boiler onto the wall mounting plate hooks as shown.

Do not use the burner/ controls for lifting.

3. Fit the M8 screw, washer and rectangular plate to retain the boiler.

Note. Before fully tightening the M8 screw check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.

SIDE FLUE OUTLET

Optia FF - Installation & Servicing 21

INSTALLATION

CONNECTING THE FLUE TO THE BOILER

1. Pull the flue through the side outlet plate and locate

the 3 studs in the hole in the side of the boiler.

2. Secure the flue to the boiler using the three M5 nuts

provided.

3. Insert the flue extension tube into the flue.

4. Fit the 90° flue elbow, supplied with the boiler, onto

the fan in the direction required, after first removing the underside screw, which is not required. Secure in position with the screw attached to the fan.

5. Pull the flue extension tube and engage onto the

fan elbow and secure with the screw attached to the elbow.

Note. The sealing ring studs will locate in the back panel one way only. This will ensure that the terminal grille is correctly aligned.

TERMINAL WALL PLATE

This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat.

1. Position the terminal wall plate over the terminal.

2. Drill 4 fixing holes with a 7mm (

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws

provided.

Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to the contents list on Page 5.

FLUE EXTENSION DUCTS -

9/32") masonry drill.

For flue lengths greater than 600mm (Not for FF 100 model)

PACK D Flue extension duct kit contents.

REAR & SIDE FLUE OUTLET

Optia FF - Installation & Servicing

FLUE EXTENSION DUCTS - continued

General arrangement

INSTALLATION

Flue length

Note. Side flue shown.

1. A maximum of 2 extension ducts (plus the standard flue

duct) may be used together.

2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided. If the stand-off brackets have been used it is necessary, in order to keep the flue aligned, to use the spacer bracket with the support bracket.

Flue length Accessories Product No.

Up to 600 B Pack 1 off see Frame 8

600 to 1550

1550 to 2500 * B Pack 1 off + D Pack, 2 off see Frame 8

2500 to 3000 * B Pack 1 off + D Pack, 3 off see Frame 8

* B Pack 1 off + D Pack, 1 off see Frame 8

* Not for FF 100 model

FITTING THE KIT

Extension

tube

Boiler

Extension duct

Flue connector

Standard flue

Terminal grille

1. Remove the cardboard support aid from the flue and place safely to one side.

2. Fit the inner flue extension duct onto the inner flue duct.

3. Fit the outer flue extension duct onto the outer air duct.

4. Drill 3 - 3.2mm ( outer air duct. Do not drill the inner flue

duct.

5. Insert the self tapping screws provided to fix the air duct in position.

6. Repeat steps 1-5 if a second flue extension is required.

1/8") dia. holes through the

REAR & SIDE FLUE OUTLET

Optia FF - Installation & Servicing 23

INSTALLATION

Limit thermostat

Programmer unit

O/heat thermostat

Thermostat sensor

Off On Off On

8 Pin connector to system controls

Optional Programmer Kit

Boiler

Switch

HW CH

ALL EARTHS must be connected (Not all earths are shown for clarity)

Air

pressure switch

y or

Cla 2642

Combined spark & sensing electrode

NTC

P.C.B. 25

GV 1

GV 2

FAN

Main gas

Pilot gas

Fan

Connect to

y/g

com

GAS CONNECTION

Refer to 'Gas Supply ', page 8. Refer to Frame 2 for gas inlet service dimensions.

A minimum pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating. The main gas cock is on the left hand side of the gas control valve, as shown. To facilitate connection the gas cock may be removed from the gas control valve.

ELECTRICAL CONNECTIONS

WARNING. The appliance must be efficiently earthed.

A mains supply of 230 V ~ 50 Hz is required.

All external controls and wiring must be suitable for mains voltage. Wiring

INSTALLATION

should be in 3-core PVC insulated & sheathed cable, not less than

0.75mm local regulations. For IE reference should be made to the current ETCI rules for electrical installations.

Connection must be made in a way that allows complete isolation of the electrical supply - such as a double pole switch, having a 3mm (1/8") contact separation in both poles or a plug and socket, serving only the boiler and system controls. The means of isolation must be accessible to the user after installation.

LEGEND

b blue

bk black

(24 x 0.2mm) to BS. 6500 Table 16 Wiring Regulations and

br brown

gy grey

or orange

pk pink

r red

v violet

w white

y/g yellow/green

WATER CONNECTIONS

1. Remove the plastic plugs from the flow and

return pipes.

2. Make all water connections and check for water soundness.

Flow wiring diagram

EXTERNAL CONTROLS

External wiring must be in accordance with the current I.E.E. (BS 7671) Wiring Regulations. For Ireland reference should be made to the current ETCI rules for electrical installations.

The wiring diagrams illustrated in Frames 41-43 cover the systems most likely to be fitted to this appliance.

For wiring external controls to the Optia FF boiler, reference should be made to the system wiring diagrams supplied by the relevant manufacturer, in conjunction with the wiring diagrams shown in Frames 41-43.

Difficulty in wiring should not arise, providing the following directions are observed:

1. Controls that switch the system on or off, e.g. a time switch, must be wired, in series, in the live mains lead to the boiler.

Note. If the optional Programmer Kit is to be fitted refer to the instructions provided with the kit and Frame 39.

1. Remove the control box securing screws. Swing the box down into the servicing position. Refer to Frame 46.

2. Route the mains cable into the box from the RHS of the boiler.

3. Connect the live, neutral and earth wires into the terminal strip as shown.

4. Secure the mains lead with the cable clamp.

5. On completion of all wiring connections, relocate the control box and secure.

2. Controls that override an on/off control, e.g. frost thermostat, must be wired into the mains lead, in parallel, with the control(s) to be overridden. Refer to Frame 43.

3. If a proprietary system is used, follow the instructions supplied by the manufacturer.

4. System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted.

Advice on required modifications to the wiring may be obtained from the component manufacturers.

Notes.

1. Connection between a frost thermostat and the time

control should be made without disturbing other wiring.

2. A frost thermostat should be sited in a cool place in the house, but where it can sense heat from the system.

Optia FF - Installation & Servicing

PICTORIAL WIRING

LEGEND b-blue

bk - black br - brown gy - grey or - orange pk - pink r-red v-violet w-white y-yellow y/g - yellow/green

INSTALLATION

Thermostat

sensor

INSTALLATION

MID POSITION VALVE

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity when wiring.

2. Numbering of terminals on thermostats is specific to the manufacturer.

3. This is a fully controlled system - set the boiler thermostat to maximum.

4. Switchmaster 'Midi' is similar in operation but the wiring differs slightly

- see the manufacturer's literature.

cla7924

Pumped only

LEGEND b-blue

bk - black br - brown gy - grey or - orange pk - pink r-red v-violet w-white y-yellow y/g - yellow/green

Optia FF - Installation & Servicing 25

TWO SPRING CLOSED VALVE

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity when wiring.

2. Numbering of terminals on thermostats is specific to the manufacturer.

3. This is a fully controlled system - set the boiler thermostat to maximum.

INSTALLATION

4. Switchmaster valve has grey and

orange auxiliary switch leads but the grey wire must be connected to the live supply.

INSTALLATION

Pumped only

LEGEND

b blue

bk black

br brown

r red

y yellow

FROST PROTECTION

Central heating systems fitted wholly inside the house do not

normally require frost protection as the house acts as a

'storage heater' and can normally be left at least 24 hrs. without

frost damage. However, if parts of the pipework run outside

the house or if the boiler will be left off for more than a day or

so, then a frost thermostat should be wired into the system.

This is usually done at the programmer, in which case the

programme selector switches are set to OFF and all other

controls MUST be left in the running position.

The frost thermostat should be sited in a cold place but where

it can sense heat from the system.

Wiring should be as shown, with minimal disturbance to other

wiring of the programmer.

w white

gy grey

y/g yellow/green

or orange

v violet

pk pink

Designation of the terminals will vary but the programmer and

thermostat manufacturer's leaflets will give full details.

If a boiler is installed in a garage it may be necessary to fit a

pipe thermostat.

Diagram A shows a double pole frost thermostat, which should

suffice for all systems which do not use the OFF terminals of

the programmer.

Diagram B shows a 'change-over' frost 'stat, which will cover

most systems which do use CH OFF. If, however, on such a

system the HW pipework is in an isolated part of the house, a

second frost 'stat may be used to protect it. If in doubt, ask your

installer for advice.

Optia FF - Installation & Servicing

INSTALLATION

COMMISSIONING AND TESTING

The Benchmark Log Book or equivalent self certification should be completed and signed to demonstrate compliance with Building Regulations.

A. ELECTRICAL INSTALLATION

1. Checks to ensure electrical safety should be carried

out by a competent person.

2. ALWAYS carry out preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit using a suitable test meter.

WARNING. Whilst effecting the required gas soundness test and purging air from the gas

installation open all windows and doors, extinguish naked lights and DO NOT SMOKE.

INITIAL LIGHTING

TO LIGHT THE BOILER

1. Check that all the drain cocks are closed, and any valves in

the flow and return are open.

2. Check that the gas service cock (B) is OPEN and the boiler

mains On/Off switch is OFF.

3. Fitting the Boiler Casing

The boiler casing must be refitted with the controls support casing attached for alignment purposes. Lift the boiler casing up to the boiler assembly, with the casing top angled forward. Hook the top edge of the boiler casing into the channel on the top of the boiler assembly. Swing the bottom of the casing down and secure with the 2 captive screws.

The casing must seat correctly and compress the sealing strip to make an airtight joint. Visually check the side seals but, if side clearances are limited, then check that the top and bottom edges of the casing are correctly located.

If the Sealed System Unit is fitted remove the unit casing in order to inspect the top casing seal.

To gain access to the gas valve:

a. Remove the controls support casing. Release the

controls support front fixing screws 3 turns only. Remove the pod by pulling it forward to disengage from the keyhole slots.

b. Remove the control box securing screws and swing it

down into the servicing position. See diagram B.

4. Slacken the screw in the burner pressure test point (F) and

connect a gas pressure gauge via a flexible tube.

5. Swing the control box back into its working position.

6. Press the overheat thermostat reset button (J).

B. GAS INSTALLATION

1. The whole of the gas installation, including the meter, MUST

be inspected and tested for soundness, and purged in accordance with the recommendations of BS. 6891. In IE refer to I.S.813:2002.

2. Purging air from the gas installation may be expedited by loosening the union on the gas service cock on the boiler and purging until gas is detected.

3. Retighten the union and check for gas soundness.

LEGEND

A Sightglass. B Gas service cock. C Inlet pressure test point. D Thermostat knob

7. Switch the electricity supply ON and check that all external

controls are calling for heat.

8. Set the boiler thermostat knob (D) to position 6 and the boiler Mains On/Off switch to ON. The fan will start. After the fan has run for a few seconds the pilot solenoid valve should open and the intermittent spark commence, continuing until the pilot is established. The main burner will then cross-light smoothly. If this sequence does not occur, refer to the Fault Finding section.

9. Test for gas soundness around ALL boiler gas components using leak detection fluid.

10. Operate the for 10 minutes to stabilise the burner temperature.

11. The boiler is pre-set at the factory to its nominal rating. If the burner pressure measured is incorrect it may be reset using the following procedure. Refer to Table 2 (page 4):

a. Set the mains On/Off switch to OFF.

b. Switch the electricity supply OFF.

c. Swing the control box down into the servicing position.

d. Remove the main burner adjuster cover.

e. Turn the adjusting screw clockwise to INCREASE the

pressure, or anticlockwise to DECREASE the pressure.

f. Swing the control box back into its working position.

g. Switch the electricity supply ON.

h. Set the mains On/Off switch to ON and check the new

setting pressure.

12. If necessary repeat steps 12a to h until the required pressure is achieved. Record this value in the Benchmark log book.

13. Set the main On/Off switch to OFF.

14. Switch the electricity supply OFF.

15. Swing the control box down into the servicing position.

16. Refit the main burner pressure adjuster cover.

17. Remove the pressure gauge and tube. Retighten the

sealing screw in the pressure test point. Ensure a gas tight seal is made.

E Main burner pressure adjuster. F Burner pressure test point. H Boiler mains on/off switch. J Overheat thermostat reset

button.

INSTALLATION

Optia FF - Installation & Servicing 27

INITIAL LIGHTING - continued

18. Swing the control box back into

its working position and secure.

19. Remove the boiler casing.

20. Refit the controls pod to the

boiler casing and tighten the 2 front fixing screws.

21. Refit the complete casing to the boiler.

22. Close the pod door.

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation:

1. Set the boiler thermostat knob to position 6 and operate the

mains on/off switch. Check that the main burner lights and extinguishes in response.

2. The correct operation of ANY programmer and all other system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.

3. Check that the casing is sealed correctly and compressing the sealing strip all around the casing.

4. Water Circulating System

a. With the system HOT, examine all water connections for

soundness.

b. With the system still hot, turn off the gas, water and

electricity supplies to the boiler and drain down, in order to complete the flushing process.

c. Refill and vent the system, clear all air locks and again

check for water soundness.

HANDING OVER

After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions:

1. Hand the User's Instructions to the Householder and

explain his or her responsibilities under the current Gas Safety (Installation and Use) Regulations or rules in force.

2. Draw attention to the Lighting Instruction label affixed to the controls pod door.

3. Explain and demonstrate the lighting and shutting down procedures.

4. The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the Householder, to ensure the greatest possible fuel economy, consistent with household requirements of both heating and hot water consumption. Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

5. Explain the function and the use of the boiler thermostat and external controls.

d. Balance the system.

5. Finally, set the controls to the user's requirements.

The temperatures quoted below are approximate and vary between installations.

Knob Setting Flow Temperature

°C °F

1 54 130

2 60 140

3 66 150

4 71 160

5 77 170

6 82 180

WARNING.

The boiler MUST NOT be operated with the casing removed.

6. Explain the function of the boiler overheat thermostat and emphasise that if cutout persists, the boiler should be turned off and a registered CORGI installer consulted. In IE contact a Competent Person.

7. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system.

8. If any programmer is fitted draw attention to the Programmer User's Instructions and hand them to the Householder.

9. After installation and commissioning please complete the

Commissioning Checklist before handover to the customer. For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to I.S.

813:2002.

10. Stress the importance of regular servicing by a CORGI

registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR. In IE servicing work must be carried out by a Competent Person.

Optia FF - Installation & Servicing

SERVICING SCHEDULE

SERVICING

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage, but should be carried out at least annually. It is the law that any service work must be carried out by CORGI registered installer. In IE service work must be carried out by a Competent Person.

a. Light the boiler and carry out a pre-service check, noting

any operational faults. Operate the boiler for at least 20 minutes. Check the gas consumption.

b. Connect a suitable gas analyser to the sampling point on

the top RHS of the back panel. For correct boiler operation the CO/CO than 0.004 ratio. If this is the case and the gas input is at least 90% of the nominal, then no further action need be taken. If not, proceed to paragraph c.

c. Clean the main burner. Refer to Frame 53. d. Clean the heat exchanger. Refer to Frame 52. e. Clean the main and pilot injectors. Refer to Frame 53. f. Remove any debris from inside the base of the casing.

BOILER CASING REMOVAL

content of the flue gas should not be greater

g. Check that the flue terminal is unobstructed and that the

flue system is sealed correctly.

h. If the appliance has been installed in a compartment,

check that the ventilation areas are clear.

The servicing procedures are covered more fully in Frames 50 to 71 and must be carried out in sequence.

WARNING

Disconnect the electrical supply and turn off gas supply.

IMPORTANT. After completing the servicing or exchange of components always test for gas soundness and carry out functional checks as appropriate.

When work is complete the casing MUST be correctly refitted, ensuring that a good seal is made.

he boiler must NOT be operated if the casing is not fitted.

Note. In order to carry out either servicing or replacement of components, the boiler casing must be removed. Refer to Frame 50.

i. Complete the service section of the Benchmark

Commissioning Checklist.

1. If the Sealed System Unit is fitted lift off the casing.

2. Open the controls pod door and release the 2 captive screws

at the bottom of the casing. Swing the bottom of the boiler casing out until the controls pod casing has cleared the controls, then unhook the casing top from the pack panel. Retain the casing in a safe place. Where the removal of the casing is impaired by a pelmet, the instruction in Frame 2 should be followed.

3. Isolate the gas supply at the service cock fitted to the boiler.

BURNER AND AIR BOX REMOVAL

1. Remove the screw retaining the front burner support

strap to the combustion chamber. Remove the M5 pozi situated at the LH bottom rear of the burner and pull the burner downwards to disengage the retention tab. Remove the burner to a safe place for inspection and cleaning.

2. Remove the control box fixing screw. Pull the box forward and downward to disengage.

SERVICING

3. Pull the HT lead connection off the printed circuit board

and pull the lead upwards through the bottom panel grommet.

4. Remove the 4 screws retaining the air box/pilot assembly to the vertical manifold and carefully remove the assembly.

Optia FF - Installation & Servicing 29

SERVICING

CLEANING THE FAN ASSEMBLY / THE FLUEWAYS

1. Remove the 2 silicon rubber tubes from the fan sensing

points.

2. Disconnect the fan leads.

3a. Rear flue

Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue.

3b.Side or top flue

Slacken off two M4 screws securing the flue elbow and flue connector. Disconnect the flue connector from the elbow and slide into the flue. Remove the flue elbow.

4. Disconnect the silicon rubber tube from the rear of the collector hood.

5. Slacken the two M5 nuts on the front tie rods, releasing the tie rods from the combustion chamber.

6. Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood/fan assembly.

7. Check that the fan impeller runs freely. Remove any debris from the impeller with a soft brush.

8. Remove the flue baffles.

9. Remove all loose deposits from the heat exchanger,

particularly between the fins, using a suitable brush.

10. Reassemble in reverse order, ensuring the fan leads and 3 sensing tubes are reconnected.

CLEANING THE BURNER AND PILOT ASSEMBLY

1. Brush off any deposits that may have fallen on to the

burner head (ensuring the flame ports are unobstructed)

SERVICING

and remove any debris that may have collected.

Note. Brushes with metallic bristles must not be used.

2. Remove the main burner injector and ensure there is no

blockage or damage. Clean or renew as necessary.

3. Refit the injector, using an approved jointing compound sparingly.

4. Inspect the pilot burner and ignition / detection electrode. Ensure that they are clean and in good condition.

REASSEMBLY

Reassemble the boiler in the following order.

1. Refit the flue baffles.

2. Inspect the collector hood rope gasket and replace, if

necessary, ensuring that the self adhesive rope is fitted centrally on to the lip of the collector hood / fan assembly. The boiler efficiency will be adversely affected if incorrectly fitted. Refit the collector hood and retain with the 2 front tie rods and the rear central fixing screw. Tighten the nuts and screw. Ensure that the sealing gasket is compressed. Refit the pressure pipe.

3. Refit the positive pressure tubes on the top of the fan housing. Reconnect the electrical leads.

Check that:

a. The pilot burner injector is not blocked or damaged.

Refer to Frame 61 for removal details.

b. The pilot burner is clean and unobstructed.

c. The ignition / detection electrode is clean and

undamaged.

d. The ignition / detection lead is in good condition.

e. The spark gap is correct (refer to Frame 61) Clean or

renew as necessary.

Note. The pilot shield is located around the pilot assembly bracket and is located by the electrode retaining nut.

5. Reconnect the gas supply and the electrical wiring. Refer to Frames 36 & 38.

6. Check the sightglass in the boiler casing. Clean or renew as necessary. Refer to Frame 57.

7. Check for gas soundness. Check the gas service cock and pressure test point.

8. Refit the boiler casing (refer to Frame 46). Note that it is not necessary to disturb the controls casing pod.

9. Close the controls pod door.

4. Refit the air box assembly and burner. Ensure that the

burner front fixing is refitted.

Optia FF - Installation & Servicing

GAS PRESSURE ADJUSTMENT

SERVICING

PILOT

The pilot is factory set to maximum and no further adjustment is possible. If, after removing and checking the injector (as detailed in Frame 61) and ensuring that there is an inlet pressure of 20 mbar available, the pilot does not light then contact Optia Technical Helpline 0870 8498057.

Relight in accordance with 'Initial Lighting', Frame 45.

REPLACEMENT OF PARTS

GENERAL

When replacing any component:

1. Isolate the electricity supply.

2. Turn OFF the gas supply.

3. Remove the boiler casing. Refer to Frame 50.

IMPORTANT. When work is complete the casing must

be correctly refitted, ensuring that a good seal is made.

MAIN BURNER

After any servicing, reference should be made to Table 2 which quotes details of the rated output with the related burner setting pressure and the heat input. Any required adjustments should be made by using the pressure adjustment screw.

Refer to 'initial Lighting', Frame 45.

Note. In order to assist fault finding, the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler conditions:

Neon I3. Mains electricity ON.

Neon SG1. Flashes to indicate ignition operation (stops after

detection).

The boiler MUST NOT be operated if the casing is not fitted.

SIGHTGLASS REPLACEMENT

1. Refer to Frame 56.

2. Unfasten the 2 nuts and washers holding the

sightglass assembly to the casing front panel.

3. When fixing the new assembly ensure that the parts are in the correct order. The frame must have the return edge at the bottom.

4. Retighten the 2 nuts to ensure an airtight seal. Do NOT overtighten.

6. Replace the boiler casing. Refer to Frame 54.

OVERHEAT THERMOSTAT REPLACEMENT

1. Refer to Frame 56.

2. Remove the control box fixing screws.

3. Swing the control box down into the servicing position.

SERVICING

4. Pull off the electrical connections at the thermostat. Remove

the backnut retaining the thermostat to the bracket. Withdraw the thermostat phial from the heat exchanger pocket.

5. Fit the new thermostat and reassemble in reverse order.

6. Check the operation of the boiler.

Optia FF - Installation & Servicing 31

THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD & ON/OFF SWITCH REPLACEMENT

Refer also to Frame 56.

A. Remove the fixing screws

B. Swing the control box down into the servicing position.

Thermostat control

1. Pull the knob off the shaft.

2. Remove the backnut securing the thermostat control to

the control box.

3. Pull off the Molex connector from the printed circuit board.

4. Replace and reassemble in reverse order.

Thermistor sensor lead

5. Pull the sensor lead connector off the printed circuit

board and cut the cable strap securing the thermistor harness to the bottom panel of the control box (if fitted) and remove the strap.

6. Remove the sensor from the heat exchanger pocket and unclip from the back panel.

7. Remove the strain relief bush from the back panel base.

8. Remove the sensor lead through the grommet in the control box.

9. Replace and reassemble in reverse

SERVICING

order, ensuring the new cable strap is fitted and securing the thermistor harness.

SERVICING

On/off switch

10. Disconnect the

electrical connectors from the rear of the switch.

11. Press in the 2 side retaining clips and remove the switch.

12. Reassemble in reverse order.

Optia FF - Installation & Servicing

SERVICING

LIMIT THERMOSTAT REPLACEMENT

1. Refer to Frame 56.

2. Remove the limit thermostat assembly from the boiler

flow pipe.

3. Disconnect the electrical connectors

4. Replace and reassemble in reverse order, taking care to

correctly position the limit thermostat as shown in the orientation diagram opposite.

PILOT BURNER REPLACEMENT

1. Refer to Frame 56.

2. Remove the burner and air box assembly. Refer to Frame

51.

3. Remove the electrode retaining nut and remove the pilot shield and electrode.

4. Unscrew the central pilot fixing screw and lift the pilot clear of the pilot injector. The pilot injector may now be unscrewed if required.

5. Replace the pilot burner (injector if necessary) and retain with the M4 screw previously removed. Ensure the copper sealing washer is replaced when refitting the pilot injector.

SERVICING

6. Replace the electrode and pilot shield, retaining

both with the electrode nut. Check the spark gap.

7. Reassemble in reverse order.

8. Check the operation of the boiler.

9. The pilot is factory set to maximum and no further

adjustment is possible. Ensure there is an inlet pressure of 20 mbar available. Also check burner ignition and cross-lighting.

Optia FF - Installation & Servicing 33

SERVICING

IGNITION ELECTRODE AND LEAD REPLACEMENT

1. Refer to Frame 56.

2. Remove the burner and air box assembly. Refer to Frame 51.

3. Remove the electrode retaining nut.

4. Remove the pilot shield.

5. Remove the ignition electrode and integral lead.

6. Refit the new electrode and lead in reverse order.

Ensure that the pilot shield is replaced.

7. Check the spark gap. Refer to Frame 61.

8. Reassemble in reverse order.

9. Check the operation of the boiler.

MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT

1. Refer to Frame 56.

2. Remove the screw retaining the front

burner support strap to the combustion chamber.

3. Remove the M5 pozi screw, situated at the left hand bottom rear of the burner. Pull the burner downward to disengage the retention tab and remove the burner.

SERVICING

4. At this stage the main burner injector can

be removed, checked, cleaned or replaced as required. Ensure that a new copper sealing washer is used.

5. Fit the new burner, ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order.

6. Check the burner for cross-lighting and flame stability.

GAS CONTROL VALVE REPLACEMENT

Note. Refer also to Frame 75 of 'Exploded Views' for illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the burner and air box assembly. Refer to

Frame 51.

3. Remove the fixing screws. Swing the control box down into the servicing position.

4. Disconnect the gas control valve electrical leads.

5. Undo the gas cock union .

6. Whilst supporting the gas control valve, remove the 2

screws retaining the manifold to the back panel.

7. Remove the gas control / manifold assembly.

8. Remove the 4 screws retaining the manifold to the gas

control valve, and fit the manifold to the new valve. Ensure that the new control is fitted the correct way round (an arrow engraved on back indicates the direction of flow).

9. Transfer the gas cock union to the new gas control valve, using an approved jointing compound.

10. Reassemble in reverse order.

11. Check the operation of the boiler.

Optia FF - Installation & Servicing

SERVICING

FAN REPLACEMENT

1. Refer to Frame 56

2. Remove the 2 silicon rubber tubes from the fan sensing points.

3. Disconnect the fan leads.

4a. Rear flue. Slacken the M4 screw securing the flue connector to the

fan. Disconnect the connector from the fan and slide into the flue.

4b. Side or top flue. Slacken off two M4 screws securing the flue elbow

and flue connector. Disconnect the flue connector from the elbow and slide into the flue. Remove the flue elbow.

5. Disconnect the silicon rubber tube from the rear of the collector hood.

6. Slacken the two M5 nuts on the front tie rods, releasing the tie rods

from the combustion chamber.

7. Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood / fan assembly.

8. Remove the three M4 screws retaining the fan to the collector hood.

9. Fit the new fan and reassemble in reverse order, ensuring the fan

leads and 3 sensing tubes are reconnected.

10. Check the operation of the boiler.

AIR PRESSURE SWITCH (APS) REPLACEMENT

1. Refer to Frame 56.

2. Remove the APS fixing screw.

3. Remove both sensing tubes from the APS.

4. Remove the 3 electrical connections from the APS.

5. Fit the new APS and reassemble in reverse order.

6. Check the operation of the boiler.

PRINTED CIRCUIT BOARD (PCB) REPLACEMENT

Note. Refer to Frame 74 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the fixing screws and swing the control box

down into the servicing position.

3. Disconnect the detection lead from the PCB.

4. Unplug all the Molex connectors from the PCB.

SERVICING

5. Disengage the PCB from the mounting posts and withdraw

from the control box.

6. Fit the new PCB and reassemble in reverse order.

7. Check the operation of the boiler.

Fuse.

To change the fuse, prise it out of the holder and disengage the fuse. Refer to Frame 74 for fuse location.

COMBUSTION CHAMBER INSULATION REPLACEMENT

1. Refer to Frame 56.

2. Remove the burner and air box assembly.

Refer to Frame 51.

3. Remove the 4 tie rods.

4. Remove the combustion chamber.

5. Remove the 2 side panel retaining brackets.

6. Remove the side insulation panels.

7. Remove the front and rear

insulation panels.

8. Fit the new front and rear insulation panels.

9. Fit the new side panels and retain with the brackets and screws previously removed.

10. Reassemble in reverse order.

Optia FF - Installation & Servicing 35

SERVICING

HEAT EXCHANGER REPLACEMENT

Note. Refer to Frame 7 (Boiler assembly - Exploded view)

for illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the burner / air box assembly. Refer to Frame

51.

7. Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates.

8. Slacken 3 turns only the 4 heat exchanger / interpanel retaining screws.

9. Lift the heat exchanger / interpanel assembly upward and forward to disengage key hole fixings. Pull the assembly downwards to clear the water pipes from the back panel.

3. Drain the system.

4. Disconnect the water connections. If compression

fittings are used then cut the pipes both above and below the fittings in order to allow the heat exchanger assembly to be removed. Remove the heat exchanger drain plug and drain the residual water into a suitable receptacle.

5. Remove the fan / collector hood assembly. Refer to Frame 52.

6. Remove the combustion chamber by unscrewing the 4 tie rods.

CASING SEAL REPLACEMENT

1. Refer to Frame 56.

2. Remove the old seal from the casing surround

and thoroughly clean the casing surfaces.

3. Fit the new self adhesive seals.

SERVICING

4. Replace the boiler casing.

10. Remove the 2 rubber sealing grommets from the top of the

back panel to facilitate fitting the new assembly.

11. Fit the new heat exchanger assembly, complete with water pipes, and hang it on the key hole slots and screws. Retighten the screws.

12. Replace the 2 rubber sealing grommets.

13. Reassemble in reverse order.

14. Remake all water connections, ensuring that the

compression fittings (if used) are correctly refitted.

15. Fully test all functions, including water and gas soundness.

Note.

Model FF 100 does not have air deflector baffles fitted to casing bottom.

PROGRAMMER REPLACEMENT (IF FITTED)

1. Refer to Frame 56.

2. Remove the fixing screws and swing the

control box down into the servicing position.

3. Pull off the terminal connections from back of programmer.

4. Compress the lugs at each side of the programmer and withdraw it from the control panel.

5. Fit the new programmer in reverse order.

6. Set the programmer to the desired

programme and check the operation of the boiler.

Optia FF - Installation & Servicing

START

Is the mains on neon 'I3' illuminated?

YES

Is there a live supply on EITHER

terminal of overheat 'stat?

YES

Is there a live supply on BOTH

terminals of overheat 'stat?

FAULT FINDING

Check mains supply and fuses.

Check programmer and system

thermostats are all ON.

Check that boiler plug and socket

are OK and fully connected.

Can the overheat 'stat

be reset when the

system is cold ?

YES

Reset the overheat 'stat. Set control

'stat to maximum. Allow the boiler

to reach temperature - if the

overheat 'stat trips again, measure

flow temperature.

If above 90°C replace control 'stat.

If below 90°C replace overheat 'stat.

Replace the overheat thermostat

Check that the boiler thermostat is

set at maximum and the mains on/off

switch is ON. Is the fan turning ?

YES

Is there a supply on the fan

connector at PCB ('Molex'

marked 'FAN'?).

YES

Is there a supply at the fan?

YES

Change

fan

Is the ignition electrode sparking?

YES

Does the pilot light ?

Is there a gas

supply to the

boiler?

Does the spark

stop after the

pilot is lit?

YES

Rectify bad connection

YES

YESNO

Remove the sensor

(NTC) from the PCB.

Is the fan turning ?

Has the fuse blown on PCB ?

Is there a live supply on the

violet lead to pressure switch?

Is there a live supply on the red

lead to the pressure switch?

Is there a live supply on

BOTH terminals of limit stat?

Is there a regular spark from

tube 'SG1' on the PCB?

Is the boiler casing

correctly fitted?

YES

Replace the sensor

Replace fuse BUT, before

attempting to start boiler, check for

short between live and neutral,

also between live and earth, on all

items plugged into PCB

Check all connections to PCB.

If no error found, replace PCB.

Check connections and leads to

pressure switch. If no fault found

change pressure switch.

Check PCB by substitution

Change limit thermostat

Check gap at ignition electrode.

Check electrode and lead are

undamaged and not close to

earthed metalwork.

Check all connections to PCB.

If no fault found change PCB.

Is the pilot

injector blocked?

Ensure pilot and

main gas valve

leads are not crossed over.

Is there a supply

voltage at pilot

gas valve?

YES

Replace

gas valve

Check all connections to PCB.

If no fault found, replace PCB

Check the

polarity of the

mains supply.

Check the

continuity of

the ignition

lead from

connector to

electrode.

Does the

spark now

cease when

gas is lit?

Does main burner

cross-light from pilot?

Is there a supply on terminals

of main gas valve?

Is the main burner

injector clear?

YES

Replace main gas

solenoid valve

Check pressure switch

sensing pipes for

blockages, bad connections

and reversed connection.

Is pressure difference at

switch greater than

0.9 mbar?

YES

Change

pressure switch

Change

fan

Optia FF - Installation & Servicing 37

FAULT FINDING FAULT FINDING FAULT FINDING

SHORT LIST OF PARTS

The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance.

The list is extracted from the British Gas List of Parts, which contains all available spare parts.

The full list is held by British Gas and Plumb Center.

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Plumb Center.

Key No. GC Part No. Description Qty. Product No.

9 E83-619 Sightglass assembly kit 1 171 414

12 Main burner

E72-529 FF 30 & FF 40 1 171 012 E72-531 FF 50 & FF 60 1 171 013 E85-891 FF 70, FF 80 & FF 100 1 171 416

13 Main burner injector

E85-308 FF 30 1 171 424 E83-624 FF 40 1 171 425 E83-625 FF 50 171 426 E83-626 FF 60 1 171 427 E87-010 FF 70 1 171 428 E87-013 FF 80 1 171 429 E87-016 FF 100 1 171 430

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

Pilot burner injector:

14 E83-627 FF 30-80 1 171 434

E80-493 FF 100 1 171 435

15 Pilot burner head Q359A with:

E83-630 injector FF 30-80 1 171 438 E87-018 injector FF 100 1 171 439

17 E83-633 Gas valve kit 1 171 441

18 E83-635 Ignition electrode complete with lead and backnut 410 mm lg. 1 171 442

19 E83-637 Control box assembly, including PCB 1 171 894

23 H20-882 PCB25E 1 173 799

24 E83-653 Pressure switch: 1 171 454

30 Fan assembly:

E83-665 FF 30-80 1 171 461 E87-032 FF 100 1 171 462

35 Boiler casing assembly complete with sightglass assy,

insulation and M5 x 16 dogpoint pozi pan hd: H09-122 FF 30-80 1 173 614 H09-123 FF 100 1 173 615

37 H08-644 Controls casing door with Lighting Instructions 1 173 572

39 E85-313 Casing seal pack complete with screws 1 171 479

45 E83-682 Overheat thermostat 1 171 950

59 E97-310 Limit thermostat 1 173 353

Optia FF - Installation & Servicing

SHORT PARTS LIST

LIST OF PARTS

13 A

BOILER CASING ASSEMBLY

cla 6113

Optia FF - Installation & Servicing 39

CONTROL BOX - Exploded View

LIST OF PARTS

LEGEND

19. Control box.

21. Thermostat potentiometer.

23. Printed circuit board.

26. Thermostat knob.

58. Mains on/off switch.

BURNER ASSEMBLY - Exploded View

LEGEND

10. Burner manifold

11. Air box and pilot assembly.

12. Main burner.

13. Main burner injector.

16. Pilot shield.

17. Gas control valve.

42. Gas service cock.

Optia FF - Installation & Servicing

INSTALLER NOTIFICATION GUIDELINES

IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE

In addition a change to Building Regulations (England and Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Competent Person's

SELF CERTIFICATION SCHEME

BUILDING CONTROL

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Choose

Buildings Regulations

notification route

Contact your relevant

Local Authority

Building Control (LABC) who

ill arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authorit

y Building

Control (LABC) scheme

on members behalf

Scheme members only:

Call CORGI on 0870 88 88 777

or log onto:

www.corgi-notify.com

within 10 days

You must ensure that the

notification num

ber

issued by CORGI is written

onto the Benchmark Checklist

CORGI will record the data and

will send a certificate of

compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

Optia FF - Installation & Servicing 41

CONTROLS

To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROLTO HEATING ROOM T/STAT& PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROLTO HOT WATER CYLINDER T/STAT& PROGRAMMER/TIMER

COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERÕS INSTRUCTIONS? THE SYSTEM CLEANER USED THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3/hr BURNER OPERATING PRESSURE (IF APPLICABLE) mbar CENTRAL HEATING FLOW TEMPERATURE

CENTRAL HEATING RETURN TEMPERATURE

FOR COMBINATION BOILERS ONLY

HAS AWATER SCALE REDUCER BEEN FITTED? YES NO WHATTYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar COLD WATER INLETTEMPERATURE

HOT WATER OUTLET TEMPERATURE

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 HEATING AND HOTWATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULA

TIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENTHAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS

IF REQUIRED BY

THE MANUFACTURER, HAVE YOU RECORDED ACO/CO

TIO READING? N/A YES CO/CO

TIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

m3/hr

/hr

COMMISSIONING ENG'S NAME

PRINT CORGI ID No. SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

COLLECTIVE MARK

N/A

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls

SERVICE 1

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 2

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 3

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 4

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 5

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 6

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 7

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 8

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNA

TURE

SERVICE 9

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 10

DATE ENGINEER NAME COMPANYNAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

The code of practice for the installation,

commissioning & servicing of central heating systems

Optia Installer/Technical Helpline: 0870 8498057

April 2005 UIN 200 776 A04

ideal Optia FF 100 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual