Ideal Boilers Minimizer FF 30 Installation & Servicing
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Ideal Boilers Minimizer FF 30 Installation & Servicing

Ideal Boilers Minimizer FF 30 Installation & Servicing

Wall mounted, fanned, super efficient gas boilers
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Minimiser FF 30-80
Installation & Servicing
Wall Mounted, Fanned, Super Efficient Gas Boilers
Natural Gas Models Only
Minimiser
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.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER
G.C. Appliance No.
Minimiser
FF 60 .........................41 387 19
FF 70 .........................41 387 20
FF 80 .........................41 387 21
G.C. Appliance No.

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Summary of Contents for Ideal Boilers Minimizer FF 30

  • Page 1 Minimiser FF 30-80 Installation & Servicing Wall Mounted, Fanned, Super Efficient Gas Boilers Natural Gas Models Only Minimiser G.C. Appliance No. Minimiser G.C. Appliance No. FF 60 ......41 387 19 FF 30 ......41 387 16 FF 70 ......41 387 20 FF 40 ......

  • Page 2: Table Of Contents

    GENERAL INTRODUCTION CONTENTS 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 Air Supply ..............6 23.4 kW (80,000 Btu/h).

  • Page 3: Health & Safety Document No 635

    PERFORMANCE DATA GENERAL Table 1 - General Data Boiler Size FF 30 FF 40 FF 50 FF 60 FF 70 FF 80 Gas supply connection (in. BSP) " BSP Female) Flow connection 22mm copper (via adaptors 28mm copper (FEMALE) supplied) (MALE) Return connection 22mm copper...

  • Page 4: Boiler Clearances

    GENERAL LOCATION OF BOILER BOILER WATER CONNECTIONS The boiler must be installed on a flat and vertical wall, capable The boiler flow and return pipes are of adequately supporting the weight of the boiler and any supplied fitted to the boiler ready for top ancillary equipment.

  • Page 5: Flue Installation

    GENERAL Bathroom Installations The following notes are intended for general guidance. The boiler may be installed in any room or internal space, 1. The boiler MUST be installed so that the terminal is exposed although particular attention is drawn to the requirements of the to external air.

  • Page 6: Air Supply

    GENERAL Table 4 - Water flow rate and pressure loss IMPORTANT . It is absolutely ESSENTIAL to ensure, in practice, that products of combustion discharging from the Boiler size FF30 FF40 FF50 FF60 FF70 FF80 terminal cannot re-enter the building or any other adjacent building through ventilators, windows, doors, other sources of Boiler 11.7...

  • Page 7: Pump

    GENERAL OPEN VENT SYSTEM REQUIREMENTS all dimensions in mm (in.) 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.
  • Page 8 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.
  • Page 9 GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel The static head available from the cistern should be A diaphragm type expansion vessel must be adequate to provide the desired initial system design connected to a point close to the inlet side of the pressure.

  • Page 10: Water Treatment

    GENERAL SEALED SYSTEM REQUIREMENTS - continued Safety valve setting 3.0 bar 2.5 bar 2.0 bar Vessel charge and initial system pressure Total water content of system Expansion vessel volume litres litres 11.8 10.0 11.7 10.0 17.7 15.0 10.9 15.6 13.4 23.7 11.3 20.0...

  • Page 11: Boiler Exploded Diagram

    INSTALLATION CONDENSATE DRAIN - Refer to Frame 44 Important. A condensate drain is provided on the boiler. This drain must be Any external runs must be insulated connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic - The drain outlet on the boiler is standard "...

  • Page 12: Installation

    INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one Pack A, together Pack A Contents with a standard flue assembly for lengths up to 406mm, rear or Also contained in Pack A: side flue outlet, in Pack B. Hardware Pack (listed below).
  • Page 13 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). Bottom panel 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT.

  • Page 14: Flue Fitting Rear Outlet

    INSTALLATION 15 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 732mm "). Refer to Frame 14. 2. When cutting the ducts always use the cardboard support cutting aid provided. LEGEND 1.

  • Page 15: Mounting The Boiler

    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.
  • Page 16 INSTALLATION 21 CONNECTING THE FLUE TO THE BOILER Heat exchanger sealing panel clips 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.

  • Page 17: Side Outlet

    INSTALLATION 23 FLUE ASSEMBLY - Exploded view 1. An optional flue duct extension kit is required for wall thicknesses greater than : 698 mm (27 ") for RHS flue 614 mm (24 ") for LHS flue (see Frame 14). LEGEND 1.
  • Page 18 INSTALLATION 25 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.
  • Page 19 INSTALLATION 28 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"...

  • Page 20: Extension Ducts - Fitting

    INSTALLATION 30 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.

  • Page 21: 34 Electrical Connections

    INSTALLATION 33 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.

  • Page 22: Internal Wiring

    INSTALLATION 35 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.

  • Page 23: Electrical Systems Diagrams

    INSTALLATION 37 PICTORIAL WIRING LEGEND - blue bk - black br - brown - red - white or - orange - yellow g/y - green/yellow 38 MID POSITION VALVE - pumped only 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring 2.
  • Page 24 INSTALLATION 39 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.

  • Page 25: Frost Protection

    INSTALLATION 41 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.
  • Page 26 INSTALLATION 43 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.

  • Page 27: Gas Connection

    INSTALLATION 45 GAS CONNECTION Ensure that the gas supply pipe does not foul the boiler casing. Refer to Frame 2 for details of the position of the gas onnection. Note. If the pipe run from the meter to the boiler is greater than 3m (10') it is recommended that 22mm O.D.

  • Page 28: Handing Over

    INSTALLATION 48 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.

  • Page 29: Servicing

    SERVICING 50 SERVICING SCHEDULE 7. Clean the heat exchanger. To ensure the continued safe and efficient operation of the Note. This must be done with the heat exchanger and appliance it is recommended that it is checked at regular deposits in a dry condition - refer to Frame 55. intervals and serviced as necessary.

  • Page 30: Burner Removal And Cleaning

    SERVICING 53 FAN REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 2. Disconnect the pressure sensing pipe from the fan. Undo the 2 screws securing the pipe to the fan. b. Undo the 2 screws securing the pipe clamping plate to the manifold block.

  • Page 31: Replacement Of Components

    SERVICING 56 RE-ASSEMBLY Reassemble the boiler in the following order: secure both pipes to the manifold block with the clamping plate. 1. Refit the burner, renewing any damaged or 6. Reconnect the fan electrical leads. deteriorating sealing gaskets. 7. Refit the boiler sealing panel. 2.

  • Page 32: Control Thermostat Replacement

    SERVICING 59 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.

  • Page 33: Spark Generator Replacement

    SERVICING 62 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.

  • Page 34: Burner Replacement

    SERVICING 65 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.

  • Page 35: Gas Control Valve Replacement

    SERVICING 67 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 3. Remove the control panel. Pull off the thermostat knob. b.
  • Page 36 SERVICING 68 GAS CONTROL VALVE REPLACEMENT - continued Manifold block 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.
  • Page 37 SERVICING 70 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. Undo the 2 screws securing the pipe to the fan.
  • Page 38 SERVICING 72 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.

  • Page 39: Heat Exchanger Replacement

    SERVICING 75 HEAT EXCHANGER REPLACEMENT IMPORTANT. Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. Refer also to Frame 10 - 'Boiler exploded view'. Flow 1. Refer to Frame 58. 2. Drain down the system. 3.
  • Page 40 SERVICING 76 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.

  • Page 41: Burner Assembly - Exploded View

    SERVICING 78 BURNER ASSEMBLY - Exploded view LEGEND Burner Spark electrode Burner mounting flange Detection electrode O ring Gasket Gasket O ring (not shown) 10. Burner injector 11. Gas injection pipe 12. O ring 13. Manifold block 14. Gasket 15. Gas valve mounting bracket 16.

  • Page 42: Fault Finding

    FAULT FINDING 80 FAULT FINDING CHART MAIN MENU NB: Start the boiler from cold Does the fan run correctly ? Go to Fault Finding Table 1 Go to Fault Finding Table 2 Is the correct (or higher) burner pressure indicated during an ignition attempt ? Has air been purged out of the gas line ? Purge gas line Is there a spark at the ignition electrodes...
  • Page 43 FAULT FINDING 81 FAULT FINDING CHART 1 - Fan Not Running Correctly NB: Mains supply for this boiler Does the fan run when LED 3, on is 230 V AC 50 Hz the PCB, is lit ? Change fan Is there mains voltage between supply terminals on fan motor ? Check mains supply and fuses.
  • Page 44 FAULT FINDING 82 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.
  • Page 45 FAULT FINDING 83 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 Check connections on Board 37. If no fault (i.e.
  • Page 46 FAULT FINDING 84 FAULT FINDING TABLE 4 - Flame Detection Boiler lights briefly then goes off, leaving LED2 on the PCB lit Is polarity of the supply correct ? Ensure that live is connected to L and neutral to N Remove the fan.

  • Page 47: Short List Of Parts

    SHORT LIST OF PARTS When ordering spares please quote: 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 Boiler model. performance of this appliance. Appliance G.C. number. The list is extracted from the British Gas List of Parts which contains all Description.
  • Page 48 SHORT LIST OF PARTS 85 SHORT PARTS 86 BOILER CASING ASSEMBLY 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, Technical Training P.O.

This manual is also suitable for:

Minimizer ff 40Minimizer ff 50Minimizer ff 60Minimizer ff 70Minimizer ff 80

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