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
2
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
3
GENERAL
1
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.
2
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")
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
5
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.
0
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.
6
Minimiser - Installation
GENERAL
3
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.
4
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
7
GENERAL
5
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
6
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
2
).
2
)
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.
2
) must be fitted to the system. The gauge should
8
Minimiser - Installation
7
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
2
) 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
2
(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.
or
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
2
). 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
2.
) 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
9
GENERAL
8
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
9
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.
10
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.
10
BOILER ASSEMBLY - Exploded view
16
23
INSTALLATION
Important.
Any external runs must be insulated
The drain outlet on the boiler is standard
(22 mm) overflow pipe.
5
4
21
7
3/4"
2
22
20
6
11
1
9
15
14
8
3
19
INSTALLATION
18
17
12
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
10
13. Gas service cock
14. Main burner
15. Boiler drain point
16. Heat exchanger
17. Dry fire thermostat
18. Spark generator
13
19. Gas valve
20. Condensate siphon
21. Overheat thermostat
22. Flue gas sampling point
23. Flue thermostat
11
INSTALLATION
11
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
12
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.
12
Minimiser - Installation
13
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).
14
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.
0
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.
13
INSTALLATION
15
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.
16
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.
4
5
7
3
1
2
LEGEND
6
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.
17
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.
14
Minimiser - Installation
18
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.
19
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
20
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
15
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