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Minimiser FF 30-80

Installation & Servicing

Wall Mounted, Fanned, Super Efficient Gas Boilers

Natural Gas Models Only

Minimiser G.C. Appliance No.

FF 30 .........................41 387 16

FF 40 .........................41 387 17

FF 50 .........................41 387 18

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.

Minimiser G.C. Appliance No.

FF 60 .........................41 387 19

FF 70 .........................41 387 20

FF 80 .........................41 387 21

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER

GENERAL

CONTENTS

Air Supply ...................................................................... 6

INTRODUCTION

Minimiser FF 30-80 are fully automatically controlled, wall mounted, low water content, balanced flue, fanned super efficient condensing gas boilers. They are spot-rated to provide central heating outputs of 8.8 kW (30,000 Btu/h) to

23.4 kW (80,000 Btu/h).

Boiler Clearances .......................................................... 4

Boiler Exploded Diagram ........................................... 11

Electrical Connections ............................................... 21

Electrical Supply ........................................................... 6

Electrical Systems Diagrams ..................................... 23

Extension Ducts - Fitting ............................................ 20

Fault Finding ............................................................... 42

Flow Wiring Diagram .................................................. 22

Flue Fitting

Rear outlet .............................................................. 14

Side outlet .............................................................. 17

Flue Installation ............................................................. 5

Gas Safety (Installation & Use)

Regulations, 1994 ......................................................... 2

Gas Supply .................................................................... 5

Health & Safety Document No 635 .............................. 3

Due to the high efficiency of the boiler a plume of water vapour will form at the flue terminal during operation.

The boiler casing is of white painted mild steel with a dropdown control pod door. The controls pod, also of white painted mild steel, has fixed sides and a removable bottom panel.

The boiler thermostat is located behind the controls pod door.

The heat exchanger is of aluminium.

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

The boilers are suitable for connection to fully pumped, open vented or sealed water systems. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

OPTIONAL EXTRA KITS

Programmer Kit Fits neatly within the casing, is available.

Separate fitting instructions are included with this kit.

Roof Flue Kit For vertical flue connection.

Powered Vertical For extended vertical flue connection. Flue (K Pack)

Extension Ducts Up to 3.1m (122") are available.

Wall Mounting Enables the boiler to be mounted with the Stand-off Kit Front flush with 300mm deep kitchen units.

Installation ................................................................... 12

Mandatory Requirements ............................................. 4

Pump ............................................................................ 7

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

Short List of Parts ....................................................... 47

System Diagrams .......................................................... 7

Terminal Guards............................................................ 5

Water Connections ....................................................... 4

Water and Systems ....................................................... 6

Wiring Diagrams.......................................................... 22

GAS SAFETY (INSTALLATION AND USE) REGULATIONS, 1994

It is law that all gas appliances are installed and serviced by a CORGI registered installer (identified by with the above regulations. Failure to install appliances

correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

The installation of the boiler MUST also be in accordance with the latest I.E.E Wiring Regulations, local building regulations, bye-laws of the local water authority, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority.

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 not exceeding 60 kW.

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for

domestic purposes (2nd Family Gases)

BS. 5440:1 Flues (for gas appliances of rated input not

exceeding 60 kW)

BS. 5440:2 Ventilation (for gas appliances of rated input not

exceeding 60 kW)

) in accordance

Minimiser - Installation

PERFORMANCE DATA

Table 1 - General Data

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

Gas supply connection (in. BSP) Rc

Flow connection 22mm copper (via adaptors 28mm copper

(FEMALE) supplied) (MALE)

Return connection 22mm copper (via adaptors 28mm copper

(FEMALE) supplied) (MALE)

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 50W

Fuse rating External: 3A Internal: F2A to BS 4265

Water content litre (gal.) 1.65 (0.36) 1.95 (0.43)

Dry Weight kg (lb.) 26.0 (57.3) 27.0 (59.5)

Boiler size Height mm (in.) 600 (23.6)

Width mm (in.) 390 (15.0)

Depth mm (in.) 270 (10.6)

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

1/2 (1/2" BSP Female)

GENERAL

Table 2 - Performance Data

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

Boiler input Nett kW 9.2 12.3 15.3 18.4 21.5 24.6

CV Btu/h 31,400 42,000 52,200 62,800 73,400 84,000

Boiler input Gross kW 10.2 13.6 17.0 20.4 23.9 27.3

CV Btu/h 34,900 46,500 58,100 69,800 81,400 93,000

Gas consumption l/s (cu.ft/h) 0.26 (33.6) 0.35 (44.9) 0.44 (56.1) 0.53 (67.3) 0.62 (78.6) 0.70 (89.8)

Boiler output 70° C Mean water kW 8.8 11.7 14.7 17.6 20.5 23.4

temperature Btu/h 30,000 40,000 50,000 60,000 70,000 80,000

40° C Mean water kW 9.4 12.5 15.7 18.8 21.9 25.1 temperature Btu/h 32,100 42,800 53,500 64,200 74,900 85,600

Burner Setting mbar 10.7 10.0 8.6 10.5 5.3 8.8

pressure (HOT) in.w.g. 4.3 4.0 3.5 4.2 2.1 3.5

HEALTH & SAFETY DOCUMENT NO 635

Notes.

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

To obtain the gas consumption:-

IMPORTANT. These appliances are CE certificated for safety and performance. It is, therefore, important that no external

a. For l/s divide the gross heat input (kW) by

C.V. of the gas (MJ/m3)

b. For ft3/h divide the gross heat input (Btu/h)

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

control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Caradon Ideal Ltd. could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

Minimiser - Installation

GENERAL

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler ready for top connection but can be removed and adapted for bottom connection, if required, either before or after the boiler is hung on the wall - refer to Frame 43.

Notes.

a. For the 70 and 80 boilers, 28mm (1")

flow and return pipes should be used to and from the boiler.

For the 30 to 60 boilers, 22mm (3/4") pipes may be used to connect the boiler, using the 28mm x 22mm adaptors supplied in the hardware pack.

b. This appliance is NOT suitable for use

with a direct hot water cylinder.

BOILER CLEARANCES all dimensions in mm (in.)

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 where wall thicknesses do not exceed 600mm (24"). Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside.

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.

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 British Gas publication 'Guide for Gas Installations in Timber Frame Housing', reference DM2.

REAR FLUE ONLY

MIN. Top clearance required = 145 mm (5 3/4")

SIDE FLUE ONLY

Horizontal length of flue Top clearance from centre line of boiler required (MIN.)

to outside wall Dimn. A

0.5 m 160 mm (6

1.0 m 180 mm (7 7/8")

1.5 m 205 mm (8 1/16")

2.0 m 225 mm (8

2.5 m 250 mm (9 3/4")

3.0 m 270 mm (10 5/8")

5/16")

7/8")

Front clearance: 450mm (17 3/4") from the front of the boiler casing. The minimum front clearance when built in to a cupboard is 5mm (1/4")

Minimiser - Installation

GENERAL

Bathroom Installations

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. (BS7671) 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 containing a bath or shower.

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.

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 should be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided that it is modified for the purpose.

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

z BS. 6798.

z The position selected for installation MUST allow adequate

space for servicing in front of the boiler. Ventilation of the compartment is not necessary.

z For the minimum clearances required for safety and

subsequent service, see the wall mounting template and 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.

A gas meter can only be connected by the local gas supplier or by a registered CORGI engineer.

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 working gas pressure of 20 mbar MUST be available at the boiler inlet.

Installation pipes MUST be fitted in accordance with BS. 6891. Pipework from the meter to the boiler MUST be of an adequate size, i.e. not less than 15mm O.D. Note. For pipe runs greater

than 3m (10'), 22mm O.D. pipe is recommended.

Do not use pipes of smaller size than the boiler inlet gas connection.

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

FLUE INSTALLATION

Pluming will occur at the termination so, where possible, terminal positions which could cause this nuisance should be avoided.

The flue must be installed in accordance with the recommendations of BS. 5440: Part 1.

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.

Note positions 2-6 : Due to the terminal design, installation is possible with clearances less than those specified in BS 5440, Part 1.

Table 3 - Balanced flue terminal position

Terminal Position

1. Directly below or alongside an

openable window, air vent or other 300 mm (12") ventilation opening

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 internal or external corners 25 mm ( 1")

7. Above adjacent ground, roof or

balcony level 300 mm (12")

8. From a surface 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")

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.

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

Tower Flue Components Ltd., Vale Rise, Tonbridge, Kent TN9 1TB Telephone No. 01732 351 555.

Ensure that the guard is fitted centrally.

5. Where the terminal is fitted within 850mm (34") of a plastic or painted gutter or 450mm (18") of painted eaves then an aluminium shield at least 750mm (30") long should be fitted to the underside of the gutter or painted surface.

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: 1990.

7. Where it is essential that the terminal wall plate is fitted, i.e. wall thicknesses over 610mm (24") or with an inaccurately cut hole, the minimum spacing in Table 3, Nos. 2, 3, 4, 5 and 6 would be 60mm (2.4") in order to allow the terminal wall plate to be fitted.

Minimum Spacing

Minimiser - Installation

GENERAL

IMPORTANT. It is absolutely ESSENTIAL to ensure, in

practice, that products of combustion discharging from the terminal cannot re-enter 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 as 'unsafe' and corrective action taken.

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 11 - Unpacking.

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS 6798, Clause 12, and BS 5440:2 may be disregarded.

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the types of system and correct piping procedure see Frames 1 and 3 to 8.

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

WATER TREATMENT - see Frame 9

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.

Table 4 - Water flow rate and pressure loss

Boiler size FF30 FF40 FF50 FF60 FF70 FF80

Boiler kW 8.8 11.7 14.7 17.6 20.5 23.4

Output Btu/h

Water Flow l/sec 0.19 0.25 0.32 0.38 0.44 0.51

Rate gpm 2.5 3.3 4.2 5.0 5.8 6.7

Pressure kPa 4.2 6.7 10.0 13.7 11.2 13.7

Loss m 0.4 0.7 1.0 1.4 1.2 1.4

30,000 40,000 50,000 60,000 70,000 80,000

ft 1.4 2.3 3.3 4.6 3.8 4.6

THERMOSTATIC RADIATOR VALVES (TRV)

Caradon Ideal Ltd. 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.

When thermostatic radiator valves are used, the space heating temperature control over a living area having a heating requirement of at least 60% of the boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves. A higher proportion of TRVs may be used, provided that a bypass between the boiler flow and return is fitted, to ensure adequate flow when all TRVs are closed - however this is NOT recommended as a large proportion of TRV's can restrict water circulation and inhibit the condensing mode of condensing boilers, reducing fuel economy.

For further information refer to the 'Good Practice Guide 143', publication of the Energy Efficiency Office, available from the Building Research Establishment, Garston, Watford WD2 7JR. Tel: 01923 664 258

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 underfloor spaces.

The boiler must be vented.

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 Table 4.

C (20 0F) temperature differential, are shown in

1/2" BSP

ELECTRICAL SUPPLY

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations which apply.

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

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 34 for details.

Minimiser - Installation

GENERAL

OPEN VENT SYSTEM REQUIREMENTS

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.

Note. Combined feed and vent pipes may also be fitted.

There should be a minimum height, 450mm (18"), of open vent above the cistern water level. If this is not possible refer to Frame 5. The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 450 mm (18"). The pump must be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing a maximum 11°C (20°F) temperature differential across the boiler with the whole of the heating circuit open (e.g. Grundfos UPS 15/50, 15/60 or equivalent). With the minimum flow circuit allowed by the controls the differential must not exceed 15 °C.

The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer's 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 Caradon Ideal

Ltd. The isolation valves should be fitted as close to the pump as possible.

SCHEMATIC PIPEWORK AND SYSTEM BALANCING

all dimensions in mm (in.)

Return & flow connections

FF 30 - 60 = 22 mm

FF 70 - 80 = 28 mm

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load at least 60% of the boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available (see footnote re. thermostatic radiator valves).

Balancing

1. Set the programmer to ON for both

CH and HW. Turn the cylinder thermostat down. Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the open position. Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than 15°C apart. These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on remaining radiators to give around 11°C temperature drop at each radiator.

3. Turn up the cylinder thermostat and adjust the cylinder balancing valve so that the cylinder achieves a maximum flow consistent with adequate flow to the radiators. Check that with only the domestic hot water loop in circuit a differential temperature of 15 °C across the boiler is not exceeded.

4. Adjust room and cylinder thermostats and programmer to NORMAL settings.

Thermostatic Radiator Valves

Caradon Ideal Ltd. support the recommendations made in BS. 5449,

and by leading manufacturers of domestic heating controls, that heating systems utilising the thermostatic radiator valve control of temperature in individual rooms shall also be fitted with a room thermostat, controlling the temperature in a space served by radiators not fitted with such a valve.

Such an arrangement will provide for potentially more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods - thus saving electrical energy.

It is, therefore, strongly recommended that, when thermostatic radiator valves are used, space heating temperature control over a living/dining area or a hallway having a heating requirement of at least 60% of the boiler heat output, is achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves.

Minimiser - Installation

GENERAL

LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT

This arrangement is useful for large systems where radiators at the extremities are difficult to vent. This can lead to pumping over with conventional feed and vent arrangements.

The following conditions MUST be observed:

1. The top of the automatic air vent must be below the cold water level.

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 22mm cold feed pipe should be used in order to reduce the effective volume of hot system water expanding into the feed/ expansion cistern to a minimum.

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

All dimensions in mm (in.).

NB. Imperial dimensions are approximate

SEALED SYSTEM REQUIREMENTS

Note.The method of filling, refilling, topping up or

flushing sealed primary hot water circuit 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.

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45lb/in and temperature of 110°C. 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 preset lift pressure not

exceeding 3bar (45lb/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/in be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

) must be fitted to the system. The gauge should

Minimiser - Installation

SEALED SYSTEM REQUIREMENTS - continued

4. Expansion Vessel

GENERAL

a. A diaphragm type expansion vessel must be

connected to a point close to the inlet side of the pump, the connecting pipe being not less than 15 mm

1/2" 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° C (230° F).

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° C (230° F) should be at least 0.35 bar (5 Ib/in

) less than the lift pressure of the safety valve. For guidance on vessel sizing refer to the table in Frame 8.

For further details refer to BS. 5449, BS. 7074:1 and the British Gas Corporation publication 'Material and Installation Specifications for Domestic Central Heating and Hot Water'.

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

(5 Ib/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 filled make-up vessel with a readily

visible water level. The vessel should be mounted at least 150 mm (6") above the highest point of the system, and be connected through a non-return valve to the system, fitted at least 300 mm (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', below.

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/in

) 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.

• Adjust the initial pressure to the required value.

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 the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 83° C).

Minimiser - Installation

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

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

25 litres 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

WATER TREATMENT

The Minimiser boiler has an ALUMINIUM alloy heat exchanger

If water treatment is used Caradon Ideal recommend only the use of FERNOX-COPAL or SENTINEL X100 water treatment products, which must be used in accordance with the manufacturers' instructions. For further information contact:-

Fernox Manufacturing Co. Ltd.

Britannica Works

Clavering

Essex

CB11 4QZ

01799 550811

Sentinel Division

Grace Dearborn Ltd.

Widnes

Cheshire

WA8 8UD

0151 424 5351

IMPORTANT.

The application of any other treatment to this product will render the guarantee of Caradon Ideal invalid.

Notes.

1. It is most important that the correct concentration of the water treatment product 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. BS. 7593:1992 details the steps necessary to clean a domestic central heating system.

3. In hard water areas, treatment to prevent lime scale 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.

Minimiser - Installation

CONDENSATE DRAIN - Refer to Frame 44

A condensate drain is provided on the boiler. This drain must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic -

no other materials may be used.

BOILER ASSEMBLY - Exploded view

INSTALLATION

Important.

Any external runs must be insulated

The drain outlet on the boiler is standard (22 mm) overflow pipe.

3/4"

INSTALLATION

LEGEND

1. Fan assembly

2. Flue outlet elbow

3. Inter-panel

4. Return pipe

5. Flow pipe

6. Wall mounting plate

Minimiser - Installation

7. Control thermostat

8. Pressure sensing pipes

9. Back panel

10. Programmer (optional)

11. Pressure switch

12. Control box

13. Gas service cock

14. Main burner

15. Boiler drain point

16. Heat exchanger

17. Dry fire thermostat

18. Spark generator

19. Gas valve

20. Condensate siphon

21. Overheat thermostat

22. Flue gas sampling point

23. Flue thermostat

INSTALLATION

UNPACKING

The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 406mm, rear or side flue outlet, in Pack B.

Optional extras, if ordered. (Programmer Kit, Roof Flue Kit, Extension Duct Kit D and Wall Mounting Stand-off Kit) are available in separate boxes.

Unpack and check the contents.

INSTALLATION

Pack A Contents

Also contained in Pack A:

z Hardware Pack (listed below).

z These Installation & Servicing Instructions.

z The User's Instructions.

Hardware Pack

z 50mm x No.10 wood screws -

3 off

z Wall plugs (TP2B ) - 3 off

z Water treatment warning label

z Flue connector tube

z Condensate drain adaptor

z 22mm x 28mm flow and

return pipe connectors (FF30 to FF60 boilers ONLY)

Pack B Contents

No. 8 x 8mm self tapping screws - 2 off.

Flue support cutting aid - 1 off.

Tube of sealant -1 off.

No.10 x 2" screws - 4 off.

Rawlplugs - 4 off.

M5 x 10 pozi-pan head screw - 4 off.

M5 Form C washers - 4 off

PACKAGING AND PANEL REMOVAL

1. Unpack the boiler.

Note. The hardware pack and wall mounting plate are

within the cardboard infill pieces.

2. Swing open the controls pod door.

3. Remove the single screw retaining the casing front

panel.

4. Lift the front panel upward and forward and place to one side to avoid damage.

5. Close the controls pod door.

6. Remove the boiler from its packaging base.

Minimiser - Installation

BOTTOM PANEL REMOVAL

1. Undo the three retaining screws.

2. Push the panel backward then to the right to withdraw it

from the boiler.

3. Unpack the boiler flue kit (and extension packs, if used).

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

INSTALLATION

Bottom panel

INSTALLATION

IMPORTANT. The boiler MUST be installed in a vertical position

Dimension X - Wall thickness

Dimension Y - Wall thickness plus

boiler spacing (RHS)

Dimension Z - Wall thickness plus

boiler spacing (LHS)

Flue length dimension Flue

Rear flue Right hand side Left hand side packs

dimn. X flue dimn. Y flue dimn. Z required

FLUE KITS

114 - 732 mm 114 - 614 mm 114 - 698 mm Pack B, cut down

(4 1/2 - 28 3/4") (4 1/2 - 24 1/8" ) (4 1/2 - 27 1/2" ) as in Frames 18 & 26

732 - 1931 mm 614 - 1813 mm 698 - 1897 mm Pack B (1 off) and

(28 3/4 - 76") (24 1/8 - 71 3/8") (27 1/2 - 74 3/4") Pack D (1 off)

1931 - 3130 mm 1813 - 3012 mm 1897 - 3096 mm Pack B (1 off) and

(76 - 123 1/4") (71 3/8 - 118 5/8") (74 3/4 - 121 7/8") Pack D (2 off )

Notes.

1. The flue duct MUST be inclined at 2.5 to allow condensate to drain back into the boiler and out through the condensate drain.

to the horizontal

Minimiser - Installation

Pack B - supplied as standard

Pack D - optional extension kit for side flue

or rear flue outlet. Refer to 'Flue Extension Ducts'

2. If the front of the boiler is to be flush with the front of 300mm deep kitchen units then the optional stand-off bracket kit should be used. Care must be taken when cutting the ducts and marking the wall to suit this condition.

INSTALLATION

FLUE ASSEMBLY - Exploded View

1. An optional flue duct extension kit is required for

wall thicknesses greater than 732mm

3/4"). Refer to Frame 14.

(28

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

WALL MOUNTING TEMPLATE

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.

LEGEND

1. Terminal.

2. Weather seal.

3. Duct assembly.

4. Flue Turret

5. Angle plate

6. No. 8 x 8 fixing screw

7. M5 x 10 pozi screws (4)

1. Separate the templates and discard template B.

2. Tape template into the selected position.

3. Ensure squareness by hanging a plumbline as shown.

4. Mark onto the wall the following:

a The plate screw positions (choose one from each group)

and lower fixing screw position.

b The position of the flue duct hole.

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

circumference

5. Remove the template 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 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat.

2. Drill 3 holes with a 7mm (1/4") masonry drill and insert the plastic plugs provided, for the wall mounting plate and the jacking screw plate.

3. Locate two No.10 x 2" screws in the wall mounting plate (one at each side, in any of the 3 holes provided at each side) and screw home.

REAR FLUE OUTLET

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.

Minimiser - Installation

CUTTING THE FLUE Wall thicknesses of 114 to 600mm

Note.

If the optional standoff bracket kit is used it is essential that 30 mm is added to the measured wall thickness when marking the flue (to allow for the thickness of the brackets).

1. Measure and note wall thickness X.

INSTALLATION

2. Add 61mm (2

the groove, cut the tube.

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

4. Cut to length, using the cardboard support aid.

5. Remove the cardboard support and any burrs.

ASSEMBLING THE FLUE

1. Using the tube of sealant provided, apply sealant right round

the inside of the flue tube on the turret.

2. Fit the 'cut to length' flue on to the flue turret.

Note.

Ensure the groove in the flue aligns with the top of the turret.

3. Drill a 3.2mm dia. hole through the hole provided in the turret and through the outer flue duct.

4. Using the self tapping screw provided, fix the flue assembly to the turret.

3/8") to dimension X and, measuring from

cardboard

support cutting aid

MOUNTING THE BOILER

1. Lift the boiler onto the wall mounting plate, as

shown.

2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.

3. Align the hole in the jacking plate with the predrilled hole in the wall and fix in position with the No.10 x 2" screw provided.

Note.

If the front of the boiler is to be flush with the front of 300mm deep kitchen units then the optional stand-off bracket kit should be used - refer to the fitting instructions supplied with the kit.

Minimiser - Installation

REAR FLUE OUTLET

INSTALLATION

CONNECTING THE FLUE TO THE BOILER

sealing panel

clips

Heat exchanger

1. Undo the three clips retaining the boiler sealing panel.

2. Swing the panel open to the left and disengage it from the boiler.

3. Fit the flue connector tube (supplied in the hardware pack) to the top of the heat exchanger, ensuring that the seal is in place.

4. Insert the flue assembly through the hole in the wall far enough to allow the rubber seal to unfold completely and form an adequate seal on the outside wall.

5. Pull the flue back and locate the flue turret on to the top of the boiler, sealing between the turret and the connector tube with the sealant provided.

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 'Flue Installation', Page 5.

1/4") masonry drill.

6. Secure the flue turret assembly on the top of the boiler using four M5 x 10mm screws provided in Pack B.

Note. It is now necessary to make good the inside wall face around the flue.

PROCEED TO FRAME 34

REAR FLUE OUTLET

Minimiser - Installation

FLUE ASSEMBLY - Exploded view

1. An optional flue duct extension kit is

required for wall thicknesses greater than :

INSTALLATION

698 mm (27

614 mm (24

(see Frame 14).

2. When cutting the ducts

always use the

cardboard support

cutting aid provided.

WALL MOUNTING TEMPLATE

Note.

The template shows the positions for the fixing holes and the flue hole centres for standard installation and for using the standoff brackets. Care MUST be taken to ensure the correct holes are drilled.

1/2") for RHS flue

1/8") for LHS flue

LEGEND

1. Terminal

2. Weather seal

3. Duct assembly

4. Angle plate

5. Flue turret

6. No.8 x 8 fixing screw

7. M5 x 10 pozi screws (4)

1. Separate the templates.

2. Tape both templates into the selected position, locating

template B through an extended centre line as shown ensure that it is the right way up for the flue hand required.

3. Ensure squareness by hanging a plumbline as shown.

4. Mark onto the wall the following:

a The two wall mounting plate screw positions (choose

one from each group) and the jacking screw position.

b The position of the flue duct hole (see diagram below,

and template)

Note.

Mark the centre of the hole as well as the circumference

5. Remove both templates from the wall.

Note.

If the boiler is to be fitted flush with 300mm kitchen units using the stand-off brackets ensure the wall is marked to suit this condition (the dotted flue hole outlines on the template).

SIDE FLUE OUTLET

Minimiser - Installation

INSTALLATION

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 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat.

2. Drill 3 holes with a 7mm ( plugs, provided, for the wall mounting plate and the jacking screw 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.

3. Locate 2 of the No.10 x 2" screws in the wall mounting plate (1 at each side, in any of the 3 holes provided at each side) and screw home.

CUTTING THE FLUE - For flue lengths 114 to 600mm ONLY

1. The flue cut length is calculated as follows:-

a. Measure and note the wall thickness X

b. Add dimension H, measured in Frame 24.

c. For right hand side flue add 181mm (7 1/8")

d. For left hand side flue add 96mm (3 3/4")

i.e. X + H + 181mm (7

X + H + 96mm (3 3/4") for LHS

2. Measure from the groove and cut the tube.

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

SIDE FLUE OUTLET

all the way round.

4. Cut to length, using the cardboard support aid.

5. Remove the cardboard support and remove

any burrs.

1/4") masonry drill and insert the plastic

1/8") for RHS

FOR FLUE LENGTHS GREATER THAN 600mm REFER TO FRAMES 31, 32 & 33 - FLUE EXTENSION DUCTS

ASSEMBLING THE FLUE

1. Using the tube of sealant provided, apply sealant right

round the inside of the flue tube on the turret.

2. Fit the 'cut to length' flue on to the flue turret.

Note.

Ensure the groove in the flue aligns with the top of the turret.

3. Drill a 3.2mm dia. hole through the hole provided in the turret and through the outer flue duct.

4. Using the self tapping screw provided, fix the flue assembly to the turret.

cardboard support cutting aid

Minimiser - Installation

MOUNTING THE BOILER

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

2. Check the boiler alignment using a spirit level and adjust

as necessary with the jacking screw.

3. Align the hole in the jacking plate with the pre-drilled hole in the wall and fix in position with the No.10 x 2" screw provided.

Note. If the front of the boiler is to be flush with the front of 300mm deep kitchen units then the optional stand off bracket kit should be used - refer to the fitting instructions supplied with the kit.

CONNECTING THE FLUE TO THE BOILER

INSTALLATION

Clips

Sealing

panel

1. Undo the three clips retaining the boiler sealing panel.

2. Swing the panel to the left and disengage it from the boiler.

Heat

exchanger

SIDE FLUE OUTLET

3. Fit the flue connector tube (supplied in the hardware

pack) to the top of the heat exchanger, ensuring that the seal is in place.

4. Insert the flue assembly through the hole in the wall far enough to allow the rubber seal to unfold completely and form an adequate seal on the outside wall.

Minimiser - Installation

5. Pull the flue back and locate the flue turret on to the top of the boiler, sealing between the turret and connector tube, with the sealant provided.

6. Secure the flue turret assembly on the top of the boiler, using four of M5 x 10mm screws provided in Pack B.

Note.

It is now necessary to make good the inside wall face around the flue

INSTALLATION

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,

INSTALLATION

an approved terminal guard should be fitted. Refer to the Flue Installation, Page 5.

FLUE EXTENSION DUCTS - For flue lengths greater than 600mm

1/4") masonry drill.

PACK D FLUE EXTENSION DUCT KIT CONTENTS.

32 FLUE EXTENSION DUCTS - continued

Use a maximum of two extension ducts only

General arrangement

Note. Side flue shown

maximum of two extension ducts (plus

1. A the standard flue duct) may be used together.

2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided.

Minimiser - Installation

FITTING THE KIT

IMPORTANT. At each joint, seal the inner flue tube, using the

sealant provided.

Note. Remove the cardboard support aid from the end of the standard flue duct (Pack B).

1. Remove the flue extension tube from the flue and place safely to one side.

2. Fit the flue extension connector on to the standard flue duct.

INSTALLATION

3. Drill three 3.2mm dia. equally spaced holes through the

flue connector and the outer flue duct. Do not drill the inner flue duct.

4. Insert the self tapping screws, provided, to fix the connector in position.

5. Fit the inner flue duct into the connector.

6. Fit the outer flue duct into the connector.

7. Drill three 3.2mm dia equally spaced holes through the flue

connector and the outer flue duct. Do not drill the inner flue duct.

8. Insert the self tapping screws, provided, to fix the connector in position.

9. Repeat steps 5 - 8 if a second flue extension duct is required.

10. Measure and mark the flue length required onto the flue, measuring from the groove near the terminal.

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

INSTALLATION

12. Cut to length, using the cardboard support aid.

13. Remove the cardboard support and any burrs.

Appliances fitted with a REAR outlet flue; please refer to Frame 19

Appliances fitted with a

ELECTRICAL CONNECTIONS

WARNING. This 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 should be 3 core PVC insulated cable NOT LESS than 0.75 mm2 (24 x 0.2mm) and to BS. 6500, Table 16.

SIDE

outlet flue; please refer to Frame 27

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations.

The supply connection is intended to be made via a double pole switch, having a 3mm ( poles, serving only the boiler and system controls.

The fuse rating should be 3 A.

1/8") contact separation in both

Minimiser - Installation

INSTALLATION

INTERNAL WIRING

Note. If the programmer kit is to be fitted refer to the instructions provided with the kit, and Frame 36.

Incoming mains wiring detail

A pictorial wiring diagram is shown in Frame 37 .

1. Route the mains cable into the bottom RHS rear of the casing.

2. Swing the terminal strip bracket out.

3. Wire the live and neutral into the terminal strip.

4. Connect the earth wire to the earth post.

Note. Ensure that the lengths of the current carrying conductors are

shorter than the earth conductor so that if the cable slips in its

INSTALLATION

anchorage the current carrying conductors become taut before the earth conductor.

5. Secure the mains lead with the cable clamp.

6. Swing the terminal strip bracket back into its working position.

Flow wiring diagram

LEGEND b - blue bk - black

br - brown r - red o - orange

w - white y - yellow

EXTERNAL WIRING

External wiring MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations.

The wiring diagrams illustrated in Frames 38 to 41 cover the systems most likely to be used with this appliance.

For wiring external controls to the Minimiser boiler, reference should be made to the systems wiring diagram supplied by the relevant manufacturer in conjunction with the wiring diagrams shown in Frames 38 to 41.

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

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

2. Controls that override an on/off control, e.g. a frost thermostat, MUST be wired into the mains supply, in parallel, with the controls to be overridden. Refer to Frame 42.

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

4. The pump must always be wired in parallel with the boiler.

5. SYSTEM DESIGNS FEATURING CONTROLS OR

WIRING ARRANGEMENTS WHICH ALLOW THE BOILER TO FIRE WHEN THERE IS NO PUMPED CIRCULATION TAKING PLACE MUST NOT BE FITTED.

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

Minimiser - Installation

PICTORIAL WIRING

LEGEND

b - blue

bk - black

INSTALLATION

br - brown

r - red

w - white

or - orange

y - yellow

g/y - green/yellow

MID POSITION VALVE - pumped only

1. Some earth wires are omitted for clarity. Ensure

proper earth continuity when wiring

2. This is a fully controlled system - set the boiler thermostat to MAXIMUM.

INSTALLATION

3. Numbering of thermostat terminals applies only to

the manufacturer mentioned.

LEGEND

b - blue

bk - black

br - brown

r - red

y - yellow

w - white

g/y - green/yellow

gy - grey

or - orange

v - violet

pk - pink

Minimiser - Installation

INSTALLATION

DIVERTER VALVE - pumped only

1. Some earth wires are omitted for clarity -

ensure proper earth continuity when wiring.

2. This is a fully controlled system - set the boiler thermostat to MAXIMUM.

3. Numbering of thermostat terminals applies only to the manufacturer mentioned.

4. The boiler should be sized for radiator load only.

5. A clock 'stat may be used instead of separate room 'stat and time switch.

INSTALLATION

LEGEND

b - blue

br - brown

bk - black

ONE VALVE IN HEATING CIRCUIT - pumped only

1. Some earth wires are omitted for clarity - ensure

proper earth continuity when wiring.

2. Numbering of thermostat terminals applies only to the manufacturer mentioned.

LEGEND

b - blue

bk - black

br - brown

r - red

y - yellow

w - white

g/y - green/yellow

gy - grey

or - orange

v - violet

pk - pink

r - red

y - yellow

w - white

g/y - green/yellow

Minimiser - Installation

TWO SPRING CLOSED VALVES - pumped only

1. Some earth wires are omitted for clarity -

ensure proper earth continuity when wiring.

2. This is a fully controlled system - set the

boiler thermostat to MAXIMUM.

3. Numbering of thermostat terminals applies

only to the manufacturer mentioned.

LEGEND

INSTALLATION

b - blue

bk - black

br - brown

r - red

y - yellow

w - white

g/y - green/yellow

gy - grey

or - orange

v - violet

pk - pink

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 hours without frost damage.

INSTALLATION

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 programmer 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.

Designation of the terminals will vary but the programmer and thermostat manufacturers' leaflets will give full details.

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 'changeover' frost thermostat, 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 thermostat may be used to protect it. If in doubt ask your installer for advice.

Note.

If the boiler is installed in a garage it may be necessary to fit a pipe thermostat.

Minimiser - Installation

INSTALLATION

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler and ready for top connection.

Note. For boiler sizes FF30 to FF60 use the 28mm x 22mm connectors supplied in the hardware pack, to reduce the boiler flow and return pipes to 22mm.

TOP CONNECTION

Connect the system pipework to the boiler flow and return pipes.

BOTTOM CONNECTION

1. Remove the retaining pin and withdraw the thermostat phial from

the pocket.

INSTALLATION

2. Disconnect the electrical leads from the overheat thermostat.

3. Undo the flow and return pipe unions and withdraw the pipes from

the boiler.

4. Cut off the spun ends of the pipes and connect pipes of suitable length to terminate 50mm (2") outside the bottom of the boiler casing.

5. Refit the pipe assemblies to the flow and return bosses, ensuring that the gaskets are in position. Note. Fit the return pipe assembly first.

6. Fit an automatic air vent to the top of the return pipe assembly and a manual air vent to the top of the flow pipe assembly (where pressures may at times be negative).

7. Connect the system pipework to the flow and return pipes at the bottom of the boiler.

8. Reconnect the overheat thermostat electrical leads and re-insert the boiler thermostat phial into the pocket, retaining it with the split pin.

CONDENSATE DRAIN

Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989)

Centre line of boiler

Pipework shown as a dotted line is not supplied

The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.

The drainage pipework must be arranged so that obstruction (e.g. through freezing) of external drainage pipe does not give rise to spillage within the dwelling.

Important. Any external runs must be insulated.

Excessive external pipe runs should be avoided in order to prevent possible freezing.

All pipework and fittings in the condensate drain system must be made of plastic. No other materials may be used.

The drain outlet on the boiler is standard 22mm overflow pipe. This size must not be reduced in any part of its length.

Condensate drain

Note.

145 mm

The drain connection is located at the rear of the controls compartment

The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building.

(72 mm

42 mm

with stand-off bracket)

In order to defer the onset of freezing of the condensate drain when the pipe is run externally the pipe should be run as far as possible within the building.

The boiler condensate drain connection is suitable for Bartol 'Polypipe' tubing. An adaptor is supplied to allow the use of Marley 'Terrain' tubing, which is slightly larger. This adaptor should be sealed to the Marley 'Terrain' tubing and to the boiler condensate drain, using a suitable plastic tube adhesive.

Minimiser - Installation

INSTALLATION

GAS CONNECTION

Refer to Frame 2 for details of the position of the gas onnection.

A MINIMUM working gas pressure of 20 mbar (8" w.g.) must be available at the boiler inlet with the boiler firing. Refer to Frame 47 or 'Servicing' for details of the pressure test point position.

Extend a gas supply pipe NOT LESS THAN 15mm O.D. to the boiler and connect to the gas service cock, situated at the bottom right hand side of the boiler. The connection MUST be from the RHS rear of the boiler and from either ABOVE or BELOW. Do not route the pipe behind the

control box.

Ensure that the gas supply pipe does not foul the boiler casing.

Note. If the pipe run from the meter to the boiler is greater than 3m (10') it is recommended that 22mm O.D. pipe is used.

To facilitate connection, it is recommended that the gas service cock is not removed from the gas control valve.

A 1/2" BSP x 15mm connector, pre-fitted with a short stub connection, should be screwed into the cock, using a suitable sealant.

IMPORTANT. The gas service cock contains a non-metallic seal so must not be overheated when making capillary connections.

COMMISSIONING AND TESTING

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out by a

competent person.

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

RNING. 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.

B. Gas Installation

1. The whole of the gas installation, including the meter, should be

inspected and tested for soundness and purged in accordance with the recommendations of BS. 6891.

2. Purge air from the gas installation by loosening the gas cock union and purge until gas is smelled.

3. Retighten the union and test for gas soundness.

INSTALLATION

INITIAL LIGHTING

LEGEND

A 'Burner on' neon

B Thermostat knob

C Gas service cock

D Inlet pressure test point

E Burner pressure test point

F Burner pressure adjuster

1. Check that the system has been filled and that the boiler is not air

locked - air in the system could trip the dry fire 'stat (H)

2. Check that all the drain cocks are closed and any valves in the flow and return are open.

3. Check that the electrical supply is OFF.

4. Check that the flue 'stat (L) is calling for heat - press the reset

button.

5. Refit the boiler sealing panel - refer to Frame 21.

6. Check that the gas service cock (C) is ON and that the boiler

thermostat knob (B) is OFF.

7. Check that the dry fire thermostat (H) and overheat thermostat (J) are calling for heat - press the reset buttons.

8. Remove the screw in the burner pressure test point (E) and connect a gas pressure gauge via a flexible tube.

9. Switch the electricity supply ON and check that all external controls are calling for heat.

10. Set the boiler thermostat knob (B) to position 6. The gas control solenoid valve should open and the spark commence, continuing until the burner is established.

11. Check that the burner lights smoothly and that the 'Burner on' neon (A) illuminates. If this does not occur within 10 seconds, turn the thermostat knob to OFF, wait for 5 seconds then repeat step 10. If the burner still does not light refer to the 'Fault Finding' section.

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

13. Operate the boiler for 20 minutes to stabilise the burner temperature.

G Fan pressure test point (Hi)

H Dry fire thermostat reset button

I Fan pressure test point (Lo)

J Overheat thermostat reset button

K Flue gas sampling point

L Flue 'stat reset button (behind

sealing panel)

Note. Boiler is shown with the front panel removed and the controls

drop down door open

F E

14. The boiler is spot rated. Check that the burner pressure

corresponds to the setting given on the data plate, located at the RHS of the boiler casing. Adjust as necessary via the adjuster screw (F). Prise aside the plastic cover and turn the screw CLOCKWISE to reduce the pressure or ANTICLOCKWISE to increase the pressure. Refit the cover.

15. Set the thermostat knob (B) to OFF.

16. Switch the electricity supply OFF.

17. Remove the pressure gauge and tube. Replace the sealing screw

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

18. Refit the boiler front and bottom panels, using the screws previously removed.

19. Close the controls pod door.

Minimiser - Installation

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation

1. Operate the thermostat knob and check that the burner and 'Burner on' neon, light and extinguish 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. Water circulation system:

Note. Fernox Superfloc flushing solution should be used during the flushing procedure - refer to Frame 9.

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 to complete the

flushing process.

INSTALLATION

c. Refill and vent the system, add inhibitor (see Frame 9), clear all air locks and again check for water soundness.

Adhere the water treatment warning label, supplied in the hardware pack, in a prominent position on the system, to prevent the use of incorrect water treatment additives.

d. Balance the system (see Frame 4).

4. Check the condensate drain for leaks and check that it is

discharging correctly

5. Finally set the controls to the User’s requirements.

• If an optional programmer kit is fitted then refer to the

instructions supplied with the kit.

• The temperatures quoted alongside are approximate, and

vary between installations.

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 Gas Safety (Installation and Use) Regulations 1994.

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

Knob Setting Flow Temperature

°C °F

1 50 120

2 60 140

3 66 150

4 71 160

5 77 170

6 82 180

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.

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

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.

7. If any programmer kit is fitted then draw attention to the Programmer Kit User's Instructions and hand them to the householder.

8. 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.

Minimiser - Installation

SERVICING SCHEDULE

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 a registered CORGI installer.

1. Remove the boiler bottom panel - refer to Frame 59, step 4.

2. Light the boiler and carry out a pre-service check, noting any operational faults.

3. Check the operation of the pressure switch - refer to Frame

51.

4. Relight the boiler and operate for at least 20 minutes. Check the gas consumption.

5. Connect a suitable gas analyser to the sampling point on top of the boiler - refer to Frame 51 (optional test).

For correct boiler operation the CO/CO gas should not be greater 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 step 6.

6. Clean the main burner.

content of the flue

SERVICING

7. Clean the heat exchanger.

Note. This must be done with the heat exchanger and

deposits in a dry condition - refer to Frame 55.

8. Check the main injector for blockage or damage.

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

flue system is sealed correctly.

The servicing procedures are covered more fully in Frames 51 to 57 and MUST be carried out in sequence.

WARNING. Always turn off the gas supply at the gas service cock, and switch off and disconnect the electricity supply to the appliance before servicing.

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

Note. In order to carry out either servicing or replacement of components the boiler front panel and sealing panel must be removed - refer to Frames 12 and 52.

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

DO NOT OPERATE THE BOILER IF THE SEALING PANEL IS NOT FITTED.

PRESSURE SWITCH OPERATION

1. Connect a flexible tube to the pressure switch tapping,

located at the bottom of the boiler, behind the control box.

Flue gas

sampling point

Control box

Flexible

tube

Pressure

switch tapping

BOILER SEALING PANEL REMOVAL

1. Turn off the gas supply at the gas service cock and

disconnect the electricity supply.

Retaining clips

SERVICING

2. With the boiler running, blow gently into the tube. The

burner should shut down and the 'Burner on' neon extinguish. The fan should continue to run. If this does not occur replace the pressure switch - refer to Frame 71.

3. Remove the flexible tube and refit the boiler bottom panel.

Note. The pressure switch tapping does not have a cap or

sealing screw and MUST be left open to atmosphere.

Minimiser - Installation

2. Remove boiler front panel as described in Frame 12.

3. Release the three retaining clips on the right hand side

of the panel.

4. Swing the panel open to the left and disengage it from the boiler.

SERVICING

FAN REMOVAL AND CLEANING

1. Disconnect the electrical leads from the fan.

2. Disconnect the pressure sensing pipe from the fan.

a. Undo the 2 screws securing the pipe to the fan.

b. Undo the 2 screws securing the pipe clamping plate to the

manifold block.

c. Withdraw the clamping plate.

d. Withdraw the pipe from the boiler.

3. Press the retaining bracket lever upwards and rotate the fan

body to the right to disengage the fan scroll from the bracket. Continue rotating to disengage the bayonet fixing on the fan outlet.

4. Withdraw the fan.

5. Check that the fan impeller runs freely. Clean with a soft

brush or renew as necessary - refer to Frame 70.

Note. Always take care when handling the fan, in order to preserve the balance of the impeller.

BURNER REMOVAL AND CLEANING

(a)

Manifold block

Gasket

Clamping plate

(d)

Fan pressure sensing pipe

(c)

(b)

Burner pressure sensing pipe

1. Disconnect the 2 ignition leads and one detection lead from the electrodes.

2. Disconnect the pressure sensing pipe from the burner. Pull the pipe downward to disengage it from the burner mounting plate.

3. Undo the 3 fixing screws securing the burner assembly.

SERVICING

4. Withdraw the burner assembly downward and out of the

heat exchanger.

5. Brush off any deposits that may have collected on the burner, ensuring that the flame ports are unobstructed.

Note. Brushes with metallic bristles MUST NOT be used.

6. Inspect the spark and detection electrodes. Ensure they

are clean and in good condition - replace if necessary.

7. Check the spark and electrode gaps are correct.

8. Check that the spark and detection leads are in good

condition and renew as necessary

CLEANING THE HEAT EXCHANGER

Dimensions in mm.

Spark electrodes

Detection electrode

IMPORTANT. Deposits are most effectively removed from the fins if they are dry. Ensure this by running the pre-service checks with the boiler thermostat set to maximum to avoid condensing conditions.

1. Place a plastic sheet or similar beneath the boiler

and remove all visible loose deposits from the heat exchanger fins, using a suitable brush.

2. Take care to clean debris from the ledge inside

the combustion chamber.

Minimiser - Installation

RE-ASSEMBLY

SERVICING

Reassemble the boiler in the following order:

1. Refit the burner, renewing any damaged or deteriorating sealing gaskets.

2. Reconnect the 2 ignition leads and the detection lead.

3. Reconnect the pressure sensing pipe to the burner.

4. Refit the fan, engaging it in the bayonet fixing and

locating it in the retaining bracket. Ensure that the O ring seal is in place.

5. Reconnect the pressure sensing pipe to the fan and

secure both pipes to the manifold block with the clamping plate.

6. Reconnect the fan electrical leads.

7. Refit the boiler sealing panel.

IMPORTANT. Ensure the boiler sealing panel is

correctly fitted and that a good seal is made.

8. Refit the boiler front panel.

9. Turn on the gas supply at the gas service cock.

10.Reconnect the electrical supply.

Note. The fan and burner pressure sensing pipes must be tested for gas soundness

BURNER PRESSURE CHECK

After any servicing, reference should be made to Table 2, page 3 (or the data plate), which quote details of the burner pressures for the boiler models.

The burner pressure should be checked against these values and adjusted accordingly - refer to 'Initial Lighting', Frame 47.

If the burner pressure is very low check the fan pressure - refer to Fault Finding Frame 82.

REPLACEMENT OF COMPONENTS

GENERAL

WHEN REPLACING ANY COMPONENT

1. Isolate the electricity supply

2. Turn off the gas supply.

3. Remove the boiler front panel and sealing panel - refer to Frames 12 and 52.

IMPORTANT. When work is complete the sealing panel must be correctly fitted, ensuring that a good seal is made.

Note.

In order to assist fault finding, the control box printed circuit board is fitted with three indicator lights which represent the following boiler conditions - refer to Frame 72.

SERVICING

LED 2 Lockout

LED 3 Fan on

LED 4 Mains electricity on

THE BOILER MUST NOT BE OPERATED IF THE SEALING PANEL IS NOT FITTED.

Minimiser - Installation

SERVICING

CONTROL THERMOSTAT REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view' and Frame

37 'Pictorial wiring.'

1. Refer to Frame 58. Note. The sealing panel need not be removed.

2. Remove the split pin and withdraw the thermostat phial

from the pocket - refer to Frame 60.

3. Release the thermostat capillary from its retaining clips.

4. Remove the boiler bottom panel.

a. Undo the three retaining screws.

b. Push the panel backward then to the right to

withdraw it from the boiler.

5. Pull off the thermostat knob.

6. Undo the control box retaining screw.

7. Push the control box back then drop the front of the

box. If access is restricted pull the control box forward and remove.

8. Disconnect the thermostat electrical leads.

9. Undo the retaining nut and withdraw the thermostat.

10. Fit the new thermostat and reassemble in reverse order,

ensuring that the thermostat capillary is correctly routed.

OVERHEAT THERMOSTAT REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view' and Frame 37 'Pictorial wiring.'

SERVICING

1. Refer to Frame 58.

Note. The sealing panel need not be removed.

2. Disconnect the overheat thermostat electrical leads.

3. Undo the two securing screws and withdraw the thermostat.

4. Fit the new overheat thermostat and reassemble in reverse order.

DRY FIRE THERMOSTAT REPLACEMENT

Boiler flow pipe

Control

Refer also to Frame 10 'Boiler exploded view'.

1. Refer to Frame 58.

2. Disconnect the spark electrode leads.

3. Remove the fan assembly - refer to Frame 53.

4. Disengage the thermostat capillary from the

retaining clip.

5. Withdraw the thermostat phial from the pocket.

thermostat

capillary

Note. Take care not to damage the thermostat capillary

when inserting it into the pocket.

6. Disconnect the thermostat electrical leads.

7. Undo the thermostat retaining nut and withdraw the

thermostat.

8. Fit the new dry fire thermostat and reassemble in

reverse order.

Minimiser - Installation

FLUE THERMOSTAT REPLACEMENT

Refer also to Frame 10 'Boiler exploded view' and Frame 37

'Pictorial wiring.'

1. Refer to Frame 58.

2. Disconnect the flue thermostat electrical leads.

3. Unscrew the thermostat from the side of the heat

exchanger.

4. Fit the new flue thermostat and reassemble in reverse order.

SERVICING

SPARK AND DETECTION ELECTRODE REPLACEMENT

Refer also to Frame 10 'Boiler exploded view.'

1. Refer to Frame 58.

2. Remove the fan assembly - refer to Frame 53.

3. Remove the burner assembly - refer to Frame 65,

steps 3 to 6.

4. Disconnect the electrode leads as required.

5. Undo the electrode securing bracket screws as required.

6. Fit new electrodes as necessary, ensuring that the

gaskets are in good condition and sealing correctly renew as necessary.

7. Check the spark / detection gaps.

8. Reassemble in reverse order.

9. Check the ignition and operation of the burner.

Note. The spark electrodes are replaced as a pair; the detection electrode is a single probe.

SPARK GENERATOR REPLACEMENT

Detection electrode

electrode

Dimensions in mm.

12 ± 1

4 ± 1

Spark

Burner

10 ± 1

SERVICING

Detection electrode

1. Refer to Frame 58.

2. Disconnect the leads from the spark

electrodes

3. Disconnect the electrical leads from the spark generator.

4. Undo the single screw fixing on the spark generator

5. Fit the new spark generator and re-assemble in reverse order.

6. Check the ignition and operation of the burner.

Minimiser - Installation

SERVICING

BURNER REPLACEMENT

1. Refer to Frame 58.

2. Remove the fan assembly - refer to Frame 53.

3. Disconnect the 2 ignition leads and one detection lead

from the electrodes.

4. Disconnect the pressure sensing pipe from the burner. Pull the pipe downward to disengage it from the burner mounting plate.

5. Undo the 3 fixing screws securing the burner assembly

6. Withdraw the burner assembly downward and out of

the heat exchanger.

7. Remove the spark and detection electrodes - refer to Frame 63.

8. Remove the 3 securing screws and withdraw the burner from the mounting flange.

9. Fit the new burner, replacing any damaged or deteriorating gaskets.

Note. There are 2 graphite gaskets under the burner sensor casting. It is IMPERATIVE that BOTH be replaced before the burner is refitted.

10. Reassemble in reverse order.

Note. Check the spark and

detection gaps - refer to Frame 63.

SERVICING

BURNER INJECTOR REPLACEMENT

Burner

Gasket

Graphite gaskets

(2 off)

Burner mounting flange

1. Refer to Frame 58.

2. Remove the fan assembly - refer

to Frame 53.

Injector

Injection pipe

3. Unscrew the injector from the gas injection pipe.

4. Fit the new injector using a suitable jointing compound sparingly.

5. Reassemble in reverse order.

Minimiser - Installation

GAS CONTROL VALVE REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view.'

1. Refer to Frame 58.

2. Remove the casing bottom panel - refer to Frame

59.

3. Remove the control panel.

a. Pull off the thermostat knob.

b. Undo the control box retaining screw - refer to

Frame 59.

c. Supporting the control panel, undo the two

retaining screws and withdraw the panel.

4. Remove the fan unit - refer to Frame 53.

SERVICING

5. Disconnect the burner pressure sensing pipe - refer to

Frame 65, step 4.

6. Undo the two retaining screws and unplug the electrical leads from the gas valve.

SERVICING

7. Undo the gas cock union connection.

Inter panel

8. Undo the two extended nuts retaining the gas injection pipe and withdraw the pipe, taking care not to lose the O ring seal.

9. Supporting the valve, undo the three retaining screws and withdraw the gas valve, complete with mounting bracket and manifold block.

Minimiser - Installation

Manifold block

SERVICING

GAS CONTROL VALVE REPLACEMENT - continued

10. Undo the retaining nut and withdraw the manifold

from the gas valve mounting bracket.

11. Undo the 6 retaining screws and separate the gas valve from the mounting bracket.

12. Transfer the bracket and manifold to the new gas valve, ensuring that any damaged or deteriorating gaskets are replaced.

Manifold block

13. Transfer the gas cock union to the new gas valve, using a suitable approved jointing compound, sparingly.

SERVICING

Mounting

bracket

14. Fit the new gas valve in reverse order, ensuring that the gas injection pipe O ring seal is refitted.

15. Check the operation of the new gas valve.

16. Operate the boiler for at least 20 minutes and set the burner pressure to the value shown on the data plate refer to Frame 47.

GAS CONTROL VALVE SOLENOID REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view'.

To replace either solenoid follow steps 1 - 6.

1. Refer to Frame 58. Note. The sealing panel need not be removed.

2. Remove the control panel - refer to Frame 67.

3. Undo the retaining screw and unplug the electrical lead

from the solenoid.

4. Undo the 2 securing screws and remove the solenoid.

5. Fit the new solenoid and re-assemble in reverse order.

6. Check the operation of the new solenoid.

Solenoid

Minimiser - Installation

FAN UNIT REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view'.

1. Refer to Frame 58.

2. Disconnect the electrical leads from the fan.

3. Disconnect the pressure sensing pipe from

the fan.

a. Undo the 2 screws securing the pipe to

the fan.

b. Undo the 2 screws securing the pipe

clamping plate to the manifold block.

c. Withdraw the clamping plate.

d. Withdraw the pipe from the boiler.

4. Press the retaining bracket lever upward and

rotate the fan body to the right to disengage the fan scroll from the bracket. Continue rotating to disengage the bayonet fixing on the fan outlet.

5. Withdraw the fan.

Note. Always take care when handling the fan

in order to preserve the balance of the impeller.

6. Fit the new fan in reverse order, ensuring that:

a. The O ring seal is correctly refitted.

b. The sensing pipe clamping plate is

correctly refitted.

7. Check the operation of the new fan.

(a)

Manifold block

Gasket

Clamping plate

(b)

SERVICING

(d)

Fan pressure sensing pipe

(c)

Burner pressure sensing pipe

SERVICING

PRESSURE SWITCH REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view'.

1. Refer to Frame 58.

2. Remove the fan unit - refer to Frame 53.

3. Disconnect the pressure sensing pipe from the

switch, noting its position - tapping P1(+).

4. Disconnect the electrical leads from the switch, noting their position. Connections are made to terminals 1 and 3.

5. Undo the securing screw and withdraw the switch.

6. Fit the new switch in reverse order

7. Check the operation of the new switch - refer

to Frame 51.

Minimiser - Installation

SERVICING

PRINTED CIRCUIT BOARD REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view'. & Frame 37 - 'Pictorial wiring'.

1. Refer to Frame 58. Note. The sealing panel need not be removed.

2. Remove the boiler bottom panel - refer to Frame 59, step 4.

3. Open the controls pod door and pull off the thermostat knob.

4. Undo the control box securing screw and swing the box into the 'servicing'

position. If access if restricted pull the box forward and free from the boiler refer to Frame 59.

LED

Fuse

PCB

6. Squeeze the retaining tabs on the two location pins and withdraw the PCB, complete with the other 2 pins. Transfer these pins to the new PCB..

5. Unplug the following leads from the PCB:

a. Gas valve lead

b. Flame detection lead

c. 'Burner on' neon lead

d. Fan lead

e. Mains input lead

SERVICING

'BURNER ON' NEON REPLACEMENT

Refer also to Frame 37 - Pictorial Wiring.

1. Refer to Frame 58. Note. The sealing panel need not be

removed.

2. Swing the control box into its 'servicing' position - refer to Frame 72, steps 1-4 .

CONDENSATE SIPHON REPLACEMENT

Refer also to Frame 10 - 'Boiler exploded view'.

1. Refer to Frame 58.

2. Remove the fan unit - refer to Frame 53.

3. Remove the gas injection pipe - refer to Frame 67, step 8.

4. Disconnect the spark and detector leads - refer to Frame 63.

5. Disconnect the condensate drain from the bottom of the boiler.

6. Undo the siphon union connection.

7. Fit the new PCB and re-assemble in reverse order.

Ensure that all electrical connections are correctly remade.

8. Check the operation of the boiler.

3. Unplug the 'Burner on' neon lead from the PCB - refer to

Frame 72.

4. Prise the neon out of the lens holder.

5. Fit the new neon and re-assemble in reverse order.

Siphon

7. Push the siphon down slightly to clear the union, tilt forward and withdraw it from the boiler.

8. Fit the new siphon and reassemble in reverse order, replacing any damaged or deteriorating sealing gasket.

Minimiser - Installation

HEAT EXCHANGER REPLACEMENT

IMPORTANT. Before starting the removal procedure, protect the gas and

electrical controls with a waterproof sheet or plastic bag.

SERVICING

Refer also to Frame 10 - 'Boiler exploded view'.

1. Refer to Frame 58.

2. Drain down the system.

3. Drain the heat exchanger via the drain point,

taking care to protect electrical components from water.

4. Remove the fan assembly - refer to Frame

53.

5. Remove the burner assembly - refer to Frame 65.

6. Remove the gas injection pipe - refer to Frame 67.

7. Remove the spark generator - refer to Frame

64.

8. Remove the back retaining screw.

9. Withdraw the dry fire thermostat phial from

its pocket - refer to Frame 61.

10. Remove the condensate siphon - refer to Frame 74.

Support

Boiler

Flow

Bosses

Flow pipe

Return pipe

11. Disconnect the flue gas sampling tube from the top of the heat exchanger.

12. Remove the flue thermostat - refer to Frame

62.

13. Disconnect the boiler flow and return pipes from the system pipework close to the boiler.

Heat exchanger

3 Return

14. Remove the control thermostat phial from its pocket - refer to Frame 59.

15. Disconnect the overheat 'stat electrical leads.

16. Undo the flow and return pipe union nuts and pull the pipes clear

of the flow and return bosses.

17. Undo the four flow and return boss retaining screws.

18. While supporting the heat exchanger from below, withdraw the

bosses from the flow and return tappings. If necessary, the bosses may be 'jacked' out by screwing the retaining screws into the two threaded holes in each flange. Check the O rings for damage and replace if necessary.

19. Lower the heat exchanger to disengage from the flue connector tube, and withdraw it from the boiler.

20. Fit the new heat exchanger and re-assemble in reverse order.

IMPORTANT

The flow and return bosses are not common and MUST be refitted in their correct positions.

18 17

SERVICING

Minimiser - Installation

The FLOW connection boss has a COARSE thread.

FINE

The RETURN connection boss has a

thread.

SERVICING

BOILER SEALING PANEL SEAL REPLACEMENT

1. Refer to Frame 58.

2. Remove the old seal from the casing and

thoroughly clean the casing surfaces.

3. Fit the new self adhesive seals.

4. Re-assemble in reverse order.

Note.

Ensure that the boiler sealing panel is correctly seated, compressing the sealing strip to make an airtight joint.

PROGRAMMER REPLACEMENT (IF FITTED)

1. Refer to Frame 58.

2. Remove the casing front panel - refer to Frame 12.

3. Remove the boiler bottom panel - refer to Frame 59,

step 4.

4. Disconnect the six leads from the back of the programmer, noting their positions.

5. Remove the control panel - refer to Frame 67, step 3.

SERVICING

6. Undo the two retaining screws and withdraw the

programmer, complete with mounting bracket, from the control panel.

7. Compress the clips on the sides of the programmer and withdraw it from the retaining bracket.

8. Fit the new programmer and reassemble in reverse order.

9. Check the operation of the new programmer.

LEGEND b blue bk black

br brown

r red y yellow pk pink

y bk r pk br b

Minimiser - Installation

BURNER ASSEMBLY - Exploded view

SERVICING

LEGEND

1. Burner

2. Spark electrode

3. Burner mounting

flange

4. Detection electrode

5. O ring

6. Gasket

7. Gasket

8. O ring (not shown)

9. Fan

10. Burner injector

11. Gas injection pipe

12. O ring

13. Manifold block

14. Gasket

15. Gas valve mounting

bracket

16. Gasket

17. Gas valve

18. Gas service cock

19. Gasket

20. Burner pressure sensing pipe

21. O ring

22. Fan pressure sensing pipe

23. Sensing pipe clamping plate

SERVICING

CONTROL BOX ASSEMBLY - Exploded view

LEGEND

1. Control box.

2. Control box retaining screw.

3. 'Burner on' neon.

4. Boiler control thermostat.

5. Thermostat knob.

6. Cable entries.

7. Control box mounting

pivots.

8. Printed circuit board mounting posts (4).

9. Printed circuit board no. 37.

Minimiser - Installation

FAULT FINDING

FAULT FINDING CHART

MAIN MENU

NB: Start the boiler from cold

Does the fan run correctly ?

YES

Is the correct (or higher) burner pressure

indicated during an ignition attempt ?

YES

Has air been purged out of the gas line ?

YES

Is there a spark at the ignition electrodes

during an ignition attempt ?

YES

Does the boiler light ?

YES

Exit

YES - but only for a few seconds

Go to Fault Finding Table 1

Go to Fault Finding Table 2

Purge gas line

Go to Fault Finding Table 3

Go back to Fault Finding Table 3

Go to Fault Finding Table 4

Note.

The correct sequence of operation during ignition is as follows:-

1. Mains to boiler with all boiler thermostats calling for heat.

2. If the fuse on PCB 37 is OK, LEDs 2, 3 and 4 illuminate and the fan starts.

3. After 8 seconds LED 2 goes OFF, the spark starts and the gas valve opens.

4. If a flame is detected the spark stops, LED 2 stays OFF and the 'Burner on' neon lights.

5. If a flame is not detected the spark stops, the gas valve closes, the fan continues to run and LED 2 comes ON.

FAULT FINDING

Minimiser - Installation

FAULT FINDING CHART 1 - Fan Not Running Correctly

FAULT FINDING

Does the fan run when LED 3, on

the PCB, is lit ?

Is there mains voltage between supply

terminals on fan motor ?

Is there mains voltage between boiler

supply terminals L and N ?

YES

Is there mains voltage on BOTH terminals of

overheat thermostat ? (see footnote)

YES

NB: Mains supply for this boiler

is 230 V AC 50 Hz

Change fan

Check mains supply and fuses.

Check system controls are calling for heat.

Check operation of motorised valves and

switches therein

Can overheat 'stat be

reset when system cold ?

YES

Reset overheat 'stat. Set control 'stat to maximum. Allow boiler to reach temperature.

If overheat 'stat trips again, measure flow temp: If over 90° C replace control 'stat If under 90° C replace overheat 'stat

Replace

overheat 'stat

Is there mains voltage on BOTH terminals

of boiler control thermostat ?

YES

Is there mains voltage between supply

terminals of Board 37 ?

YES

Has fuse blown on

Board 37 ?

(Fuse is OK if LED 4

is lit)

YES

The fan should now run

Check the 'stat is fully on and that the boiler is

not up to temperature. If the 'stat is still open

Replace fuse. Before refiring, check all

Check all connections to Board 37.

If no fault found, check Board 37 by substitution

circuit, replace it.

Recheck supply route to Board 37

components / leads connected to

Board 37 for faults

Check for moisture.

YES

Return to main

FOOT NOTE.

Presence of live supply on a terminal may be checked with a multimeter set to the appropriate AC range (apply the other probe of the meter to Mains neutral, e.g. on terminal N of the incoming supply).

Minimiser - Installation

FAULT FINDING

FAULT FINDING TABLE 2 - Burner Pressure Incorrect or Zero

Notes.

1. The burner pressure is regulated by the gas valve, according to the air flow generated by the fan, and on cold

ignition should be slightly higher than the value quoted on the Data Plate.

2. Equilibrium fan pressures should be as follows: (± 0.2 mbar) with 300mm flue length

Boiler Pressure mbar

FF 30 1.6

FF 40 1.7

To check the pressure connect an inclined gauge manometer to test points (G) and (I) - refer to Frame 47

Is the appliance gas cock fully open ?

YES

Is the gas supply pressure adequate at the

appliance inlet during an ignition attempt

(i.e. when LED 2 goes OFF) ?

YES

Are air and flue ducts free from blockage ?

YES

Are the fan and burner pressure sensing pipes

correctly connected, free from damage and

unobstructed by solid matter or moisture ?

YES

Has the flue thermostat tripped ?

Boiler Pressure mbar

FF 50 1.5

FF 60 1.6

Is the supply pressure

correct at the gas meter ?

Clear blockage and take steps to prevent recurrence

Rectify fault and take steps to prevent recurrence

YES

Boiler Pressure mbar

FF 70 0.7

FF 80 1.3

YES

Determine the cause of pressure loss

(e.g. supply pipe too small ?) and rectify

Can the 'stat be reset when the boiler is cold ?

Contact the

gas supplier

Is there continuity between the terminals of the

flue 'stat ?

YES

Has the dry fire thermostat tripped ?

Is there continuity between the terminals of the

dry fire 'stat ?

YES

Is there live on the red lead of the gas valve connector

on Board 37 during an ignition trial period ?

YES

Is there live on the connector in the control box, which

joins the red lead from the dry fire 'stat to the brown

lead from the gas valve, during an ignition trial period ?

Check the connections at

the pressure switch.

(wires on 1

and 3) - if OK change the

pressure switch

Check for blocked air duct

YES - but only with the boiler sealing plate removed

YES

Replace the flue 'stat.

Return to main menu

Can the 'stat be reset when the boiler is cold ?

Check boiler is full of water.

Return to main menu

Replace the dry fire 'stat.

Return to main menu

Check Board 37 by substitution

Are both connectors correctly fitted to the gas valve ?

Reset 'stat. Check boiler is

full of water.

Return to main menu

YES

Reset 'stat.

YES

Remove connectors. With mains OFF, check continuity of

leads from each socket unit back to the corresponding

terminals in the control box. Are leads in good order ?

Change lead assembly Check gas valve by substitution

YES

FAULT FINDING

Return to main menu

Minimiser - Installation

FAULT FINDING TABLE 3 - Spark Generation and Ignition

Fan and gas supply OK.

Ignition spark suspect

Is there mains voltage on Board 37

terminals for the spark generator during

ignition trial period

(i.e. when LED 2 goes OFF briefly)?

YES

Is there mains voltage at the spark generator

during ignition trial period ?

YES

FAULT FINDING

Check connections on Board 37. If no fault

found check Board 37 by substitution

Check leads to the spark generator

Are the leads at the spark generator correctly

fitted to the tags ?

Disconnect HT leads from the spark electrodes.

Place the leads so that the connectors are

3-5mm apart and clear of other metalwork.

TURN OFF BOILER GAS COCK

Is there a spark between HT leads during an

ignition trial period ?

YES

Remove fan and burner assy.

Is there a significant amount of water in the

combustion chamber ?

Connect spark leads to the electrode

terminals.

Check that the gap between terminals is

3-5mm and that the distance to the flame strip

is 12mm (± 1mm).

With gas OFF do another ignition cycle.

Is the spark OK now ?

YES

Rectify faulty connection

Is there evidence of the spark 'tracking' (jumping

across electrodes) externally to the burner ?

YES

Rectify poor connections or replace spark

generator or electrodes

Replace faulty spark generator

Check condensate discharge system for

blockage, air lock or freezing

Fit new ignition electrode assembly

Re-assemble and restore gas supply. Boiler

should now light and 'Burner on' neon illuminate

Minimiser - Installation

Return to Main Menu

FAULT FINDING

FAULT FINDING TABLE 4 - Flame Detection

Boiler lights briefly then goes off, leaving LED2

Is polarity of the supply correct ? Ensure that

live is connected to L and neutral to N

Remove the fan. Is the detection lead

undamaged and attached to the electrode ?

Remove burner assembly.

Is there a significant amount of water in the

combustion chamber (covering part of the

detection electrode) ?

on the PCB lit

YES

Check condensate discharge system for

blockage, air locking or freezing

Condensate pipe run must be in minimum

22mm plastic pipe, run steadily downhill and

indoors, where possible

Outdoor runs should be avoided or minimised

Check detection electrode visually for

damage / contamination.

If possible, check insulation resistance, which

should be at least 100 Megaohms.

Check lead for electrical continuity.

Check that the electrode is in the flame area and

is 10mm (± 1mm) from the burner

Re-assemble boiler.

Does the boiler now light ?

YES

Exit

Check all connections on Board 37.

If no fault found, check Board 37 by substitution.

Boiler should now light

FAULT FINDING

Minimiser - Installation

SHORT LIST OF PARTS

The following are parts commonly required as replacements, due to damage or expendability. Their failure or absence is likely to affect the safety and/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, Caradon Ideal distributors and merchants.

Key No. G.C. Part No. Description Qty. Product No.

1 Main burner

. Bray No. AB 6600 FF 30 1 076 527 . Bray No. AB 6603 FF 40 1 076 753 . Bray No. AB 6601 FF 50 1 076 754 . Bray No. AB 6604 FF 60 1 076 755 . Bray No. AB 6602 FF 70 - 80 1 076 756

2 Main burner injector

398 043 Bray Cat. 10 size 800 FF 30 1 004 858 393 050 Bray Cat. 10 size 1150 FF 40 1 003 205 390 058 Bray Cat. 10 size 1600 FF 50 1 003 362 398 059 Bray Cat. 10 size 1700 FF 60 1 004 305

. Bray Cat. 10 size 3000 FF 70 1 112 935 . Bray Cat. 10 size 2700 FF 80 1 112 936

3 . Gas control valve - SIT NOVAMIX 0828110 1 076 757

4 . Control box, including control thermostat, printed circuit

board and 'Burner on' neon 1 111 781

5 . Flame detection electrode and gasket

MORGAN MATROCK No. SKNP 2505 1 076 758

6 . Spark electrode - MORGAN MATROCK No. SKNP 2504

and gasket 1 076 816

7 . 'Burner on' neon assembly - READILEADS 1 138 139

8 . Pressure switch - SIT.0380.048 1 112 417

9 . Automatic ignition printed circuit board - PACTROL PCB No. 37 1 111 748

10 . Spark generator assembly - PACTROL 1 112 216

11 . Control thermostat - RANCO K36P1331 1 111 853

12 382 873 Overheat thermostat - ELMWOOD 2455 RM-98727 1 076 817

13 . Dry fire thermostat - RANCO LM7 P5077 1 111 854

14 . Flue thermostat - ELMWOOD 1 138 097

15 . Siphon assembly - ALTEKNIC 1 076 819

16 . Control thermostat knob 1 111 904

17 . Fan assembly - SIFAN No. WFFB 0226 018 FF 30 1 138 125

. SIFAN No. WFFB 0226 018 FF 40 1 138 126 . SIFAN No. WFFB 0226 019 FF 50 1 138 127

SIFAN No. WFFB 0226 019 FF 60 1 138 128 SIFAN No. WFFB 0226 020 FF 70 1 138 129 SIFAN No. WFFB 0226 020 FF 80 1 138 130

18 . Boiler front panel, painted white with bottom trim 1 112 584

19 . Controls pod door, painted white 1 076 820

20 . Boiler bottom panel, painted white 1 076 821

21 . Control panel, painted white 1 076 822

22 . Casing seals Long (sides) 1 076 823

Short (top, bottom) 1 076 823

23 . Burner sensing pipe 1 076 824

24 . Fan pressure sensing pipe 1 076 902

When ordering spares please quote:

1. Boiler model.

2. Appliance G.C. number.

3. Description.

4. Quantity.

5. Product No.

Minimiser - Installation

SHORT LIST OF PARTS

SHORT PARTS

BOILER CASING ASSEMBLY

Technical Training

The Caradon Ideal Technical Training Centre offers a series of

first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring:

.............................. Alexa Beadle on 01482 498 432

Customer Care & Technical Support

Please use the following numbers for speedy assistance.

Ideal Parts. .................................. Tel: 01482 498 665

................................................... Fax: 01482 498 489

Customer Care & Technical Support.

Scotland/N. England/Midlands ..... Tel: 01482 498 636

Southern England/S. Wales ......... Tel: 01482 498 660

................................................... Fax: 01482 498 666

CARADON IDEAL Ltd. pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

CARADON IDEAL Ltd,

P.O. Box 103,

National Avenue,

Kingston upon Hull,

HU5 4JN.

Telephone: 01482 492 251 Fax: 01482 448 858.

Registration No. London 322 137.

Registered Office:

National Avenue, Kingston upon Hull, HU5 4JN.

A subsidiary of Caradon p.l.c

February 1997 111 813 A05

Publications/literature. ............... Tel: 01482 498 467

Printed in England

ideal Minimiser FF 30 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual