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Optia
FF 30 - FF 100
Wall mounted, balanced flue, fanned gas boiler
Installation & Servicing Instructions
For details of document amendments, refer to page 3
Manufactured exclusively for Plumb Center by Ideal Boilers
Supplied By www.heating spares.co Tel. 0161 620 6677
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Summary of Contents for IDEAL Optia FF 30
- Page 1 FF 30 - FF 100 Wall mounted, balanced flue, fanned gas boiler Installation & Servicing Instructions For details of document amendments, refer to page 3 Manufactured exclusively for Plumb Center by Ideal Boilers Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 2 Optia FF - Installation & Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 3 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 Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 4 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...
- Page 5 GENERAL Optia FF CONTENTS Air Supply..............8 Natural Gas only Benchmark Commissioning Checklist ..... 42 Boiler size G.C. Appliance No. PI No. Boiler Clearances ............7 (Benchmark No.) Boiler Exploded View ..........13 FF 30 41-391-54 87AP107 Burner Exploded View ..........40 FF 40 41-391-95 87AP107...
- Page 6 Gas Safety (Installation and Use) Regulations INTRODUCTION • The appropriate Building Regulations either The Building The Optia FF 30-100 is a range of automatically fully controlled, Regulations, The Building Regulations (Scotland), Building wall mounted, balanced flue, fanned gas boilers. Regulations (northern Ireland).
- Page 7 GENERAL 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.
- Page 8 GENERAL containing a bath or shower. For Ireland reference should be Table 3 - Balanced flue terminal position made to the current ETCI rules for electrical installations and Approved Manufacturer’s Clearances I.S.813:2002. Terminal Position Minimum Spacing If the appliance is to be installed in a room containing a bath or 1a.
- Page 9 GENERAL 2. If the boiler is to be installed in a cupboard or compartment, Table 5 - Water flow rate and pressure loss permanent air vents are required (for cooling purposes) in Boiler Size the cupboard/compartment, at both high and low levels. Boiler 8.8 11.7 14.6 17.6 20.5 23.4 29.3 The air vents must either communicate with room/internal...
- Page 10 GENERAL Note. ELECTRICAL SUPPLY WARNING. The appliance MUST be efficiently earthed. Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or Wiring external to the appliance MUST be in accordance with the appliance control utilising mains electricity should be so situated current I.E.E.
- Page 11 GENERAL SEALED SYSTEM REQUIREMENTS Non-return valve Automatic air vent Hosepipe (disconnect after filling) Hose unions Additional stop valve Temporary hose (disconnect Hose connector Double check valve after filling) assembly (note direction of flow) Note. 4. Expansion Vessel The method of filling, refilling, topping up or flushing sealed a.
- Page 12 GENERAL SEALED SYSTEM REQUIREMENTS - continued 7. Mains Connection c. Through a temporary hose connection from a draw-off tap There must be no direct connection to the mains water supply supplied from a service pipe under mains pressure. Where or to the water storage tank supplying domestic water, even the mains pressure is excessive a pressure-reducing valve through a non-return valve, without the approval of the local shall be used to facilitate filling.
- Page 13 INSTALLATION BOILER ASSEMBLY - Exploded view Optia FF 30 shown LEGEND 1A. Heat exchanger. Fan. Collector hood assembly. Flue baffles. Wall mounting plate. Combustion chamber. Tie rods. 44B. Programmer (optional). Main burner. 4A. Pumped flow pipe. Back panel. Control box .
- Page 14 INSTALLATION UNPACKING Pack A Contents The boiler is supplied fully assembled in Pack A, together with The complete boiler a standard flue assembly for lengths up to 600mm (23 "), Installation & Servicing Instructions rear or side flue outlet, in Pack B. User's Instructions Unpack and check the contents.
- Page 15 INSTALLATION PACKAGING AND CASING REMOVAL 1. Unpack the boiler. (a) Casing retaining 2. Remove the casing as follows and place to one side to screws, 2 off avoid damage. a. Undo the 2 casing retaining screws (a) retaining the casing to the back panel. b.
- Page 16 INSTALLATION 11 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 LEGEND provided.
- Page 17 INSTALLATION 14 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.
- Page 18 INSTALLATION 18 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.
- Page 19 INSTALLATION 21 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 ").
- Page 20 INSTALLATION 25 FITTING THE FOAM SEAL 24 CUTTING THE FLUE For flue lengths 114 to 600mm ONLY 1. To determine the position for the foam seal measure the wall thickness and mark it onto the flue, measuring 1. Measure the flue length required (i.e. the distance from from the groove near the terminal.
- Page 21 INSTALLATION 28 FITTING THE SIDE OUTLET PLATES 29 WALL MOUNTING PLATE Note. If the boiler is fitted closer than 25mm to the side wall 1. Fix the mounting plate to the wall with the No.14 x 50mm the side outlet plate must be fitted now. wood screws.
- Page 22 INSTALLATION 31 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.
- Page 23 INSTALLATION 34 FLUE EXTENSION DUCTS - continued General arrangement Flue length Note. Side flue shown. Extension Extension duct tube 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.
- Page 24 INSTALLATION 36 GAS CONNECTION 37 WATER CONNECTIONS Refer to 'Gas Supply ', page 8. 1. Remove the plastic plugs from the flow and Refer to Frame 2 for gas inlet service dimensions. return pipes. A minimum pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating.
- Page 25 INSTALLATION 40 PICTORIAL WIRING LEGEND b - blue bk - black br - brown gy - grey or - orange Thermostat pk - pink sensor - red v - violet w - white y - yellow y/g - yellow/green cla7924 41 MID POSITION VALVE Pumped only Notes.
- Page 26 INSTALLATION 42 TWO SPRING CLOSED VALVE Pumped only 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.
- Page 27 INSTALLATION 44 COMMISSIONING AND TESTING The Benchmark Log Book or equivalent self certification should be completed and signed to demonstrate compliance with Building Regulations. B. GAS INSTALLATION A. ELECTRICAL INSTALLATION 1. The whole of the gas installation, including the meter, MUST 1.
- Page 28 INSTALLATION 46 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.
- Page 29 SERVICING 49 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the g. Check that the flue terminal is unobstructed and that the appliance it is recommended that it is checked at regular flue system is sealed correctly. intervals and serviced as necessary.
- Page 30 SERVICING 52 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.
- Page 31 SERVICING 55 GAS PRESSURE ADJUSTMENT PILOT MAIN BURNER The pilot is factory set to maximum and no further After any servicing, reference should be made to Table 2 adjustment is possible. If, after removing and checking the which quotes details of the rated output with the related injector (as detailed in Frame 61) and ensuring that there burner setting pressure and the heat input.
- Page 32 SERVICING 59 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.
- Page 33 SERVICING 60 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.
- Page 34 SERVICING 62 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.
- Page 35 SERVICING 65 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.
- Page 36 SERVICING 69 HEAT EXCHANGER REPLACEMENT 7. Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates. Note. Refer to Frame 7 (Boiler assembly - Exploded view) for illustration of the procedure detailed below. 8.
- Page 37 FAULT FINDING START Check mains supply and fuses. Reset the overheat 'stat. Set control Is the mains on neon 'I3' illuminated? 'stat to maximum. Allow the boiler Check programmer and system to reach temperature - if the thermostats are all ON. overheat 'stat trips again, measure Check that boiler plug and socket flow temperature.
- Page 38 SHORT LIST OF PARTS When ordering spares please quote: 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. 1. Boiler Model The list is extracted from the British Gas List of Parts, which contains all 2.
- Page 39 LIST OF PARTS 72 SHORT PARTS LIST 13 A cla 6113 73 BOILER CASING ASSEMBLY Optia FF - Installation & Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 40 LIST OF PARTS 74 CONTROL BOX - Exploded View LEGEND 19. Control box. 21. Thermostat potentiometer. 23. Printed circuit board. 26. Thermostat knob. 58. Mains on/off switch. 75 BURNER ASSEMBLY - Exploded View LEGEND 10. Burner manifold 11. Air box and pilot assembly. 12.
- Page 41 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. Install and commission this appliance to manufacturers' instructions...
- Page 42 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...
- Page 43 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.
- Page 44 The code of practice for the installation, commissioning & servicing of central heating systems April 2005 UIN 200 776 A04 Optia Installer/Technical Helpline: 0870 8498057 Supplied By www.heating spares.co Tel. 0161 620 6677...