Ideal Boilers Minimizer FF 30 Installation & Servicing Download Page 41

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Minimiser

Installation

LEGEND

Control box.

Control box retaining screw.

'Burner on' neon.

Boiler control thermostat.

Thermostat knob.

Cable entries.

Control box mounting
pivots.

Printed circuit board
mounting posts (4).

Printed circuit board no. 37.

78 BURNER ASSEMBLY - Exploded view

SER

VICING

SERVICING

LEGEND

Burner

Spark electrode

Burner mounting
flange

Detection electrode

O ring

Gasket

O ring (not shown)

Fan

10.

Burner injector

. 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

79 CONTROL BOX ASSEMBLY - Exploded view

20.

Burner pressure sensing pipe

21.

O ring

22.

Fan pressure sensing pipe

23.

Sensing pipe clamping plate

Summary of Contents for Minimizer FF 30

Page 1: ...80 41 387 21 Natural Gas Models Only Minimiser G C Appliance No FF 30 41 387 16 FF 40 41 387 17 FF 50 41 387 18 Wall Mounted Fanned Super Efficient Gas Boilers Installation Servicing 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 ...

Page 2: ...r 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 Wal...

Page 3: ...r 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 GENERAL PERFORMANCE DATA Table 2 Performance Data Table 1 General Data Notes To obtain the gas consumption a For l s divide the gross heat...

Page 4: ...ation 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 ...

Page 5: ... 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 GENERAL 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...

Page 6: ... 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 110 C 20 0 F temperature differential are shown in Table 4 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 30 000 40 000 50 000 60 000 70 000 80 000 Water Flow l sec 0 19 0 25 0 32 0 3...

Page 7: ...ture 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 st...

Page 8: ...ith 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...

Page 9: ... still hot Refill and vent the system Adjust the initial pressure to the required value 4 Expansion Vessel 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 ...

Page 10: ...iler 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 Sentinel Division Grace Dearborn Ltd Widnes Cheshire WA8 8UD 0151 424 5351 IMPORTANT The application of any other treatment to this pr...

Page 11: ...drain outlet on the boiler is standard 3 4 22 mm overflow pipe 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 LEGEND 1 Fan assembly 2 Flue outlet elbow 3 Inter panel 4 Return pipe 5 Flow pipe 6 Wall mo...

Page 12: ...10 pozi pan head screw 4 off M5 Form C washers 4 off 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 Hardware Pack Pack A Contents Also contained in Pack A z Hardware Pack listed below z These Installation Servicing Instructions z The Use...

Page 13: ...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 Flue length dimension Flue Rear flue Right hand side Left hand side packs dimn X flue dimn Y flue dimn Z required 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 m...

Page 14: ...When cutting the ducts always use the cardboard support cutting aid provided 1 An optional flue duct extension kit is required for wall thicknesses greater than 732mm 28 3 4 Refer to Frame 14 4 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 ...

Page 15: ...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 20 MOUNTING THE BOILER 1 Lift the boiler onto ...

Page 16: ...e turret on to the top of the boiler sealing between the turret and the connector tube with the sealant provided 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 This plate allows neat concealment and full compression of the rubber seal Its use is not essential if the...

Page 17: ... 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 23 FLUE ASSEMBLY Exploded view 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 flu...

Page 18: ...ith 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 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 accuratel...

Page 19: ...E FLUE OUTLET Sealing panel Clips 1 Undo the three clips retaining the boiler sealing panel 2 Swing the panel 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 ...

Page 20: ...curately 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 1 4 masonry drill 3 Insert the 4 plastic plugs provided 4 Secure the plate with 4 of the No 10 x 2 screws provided Note If the terminal is less than 2m 6 6 above ground level an approved terminal guard should be fitted Refer to the Flue Installation Page 5 30 TERMIN...

Page 21: ...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 12 Cut to length using the cardboard support aid 13 Remove the cardboard support and any burrs 33 FITTING THE KIT INSTALLATION INSTALLATION 34 ELECTRICAL CONNECTIONS Appliances fitted with a REAR outlet flue plea...

Page 22: ... 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 Flow wiring diagram LEGEND b blue bk black br brown r re...

Page 23: ...y 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 w white g y green yellow gy grey or orange v violet pk pink LEGEND b blue bk black br brown r red y yellow INSTALLATION LEGEND b blue bk black br brown r red w white or orange y yellow g y green yellow ...

Page 24: ...ing 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 1 Some earth wires are omitted for clarity ensure proper earth continuity when wiring 2 Numbering of thermostat termina...

Page 25: ...at 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 ter...

Page 26: ...tre line of boiler Condensate drain 42 mm 145 mm 6 4 3 2 1 Pipework shown as a dotted line is not supplied Note The drain connection is located at the rear of the controls compartment Refer also to the British Gas document Guidance Notes for the Installation of Domestic Gas Condensing Boilers 1989 72 mm with stand off bracket The condensate drain provided on the boiler must be connected to a drain...

Page 27: ...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 te...

Page 28: ...Safety Installation and Use Regulations 1994 2 Draw attention to the Lighting Instruction label affixed to the controls pod door 3 Explain and demonstrate the lighting and shutting down procedures 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household require...

Page 29: ... 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 th...

Page 30: ...al 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 r...

Page 31: ...rder 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 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 WHEN REPLACING ANY COMPONENT After any servicing reference should be made to Table 2 page 3 or the data plat...

Page 32: ...el 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 6 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 fr...

Page 33: ...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 63 SPARK AND DETECTION ELECTRODE REPLACEMENT Note The spark electrodes are replaced as a pair the d...

Page 34: ...s 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 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 bu...

Page 35: ...taining screws and withdraw the panel 4 Remove the fan unit refer to Frame 53 5 Disconnect the burner pressure sensing pipe refer to Frame 65 step 4 a 7 Undo the gas cock union connection 6 Undo the two retaining screws and unplug the electrical leads from the gas valve 9 Supporting the valve undo the three retaining screws and withdraw the gas valve complete with mounting bracket and manifold blo...

Page 36: ...e new solenoid 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 Solenoid 11 10 Manifold block 10 Undo the retaining nut and withdraw the manifold from the gas valve mounting...

Page 37: ...nnect 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 b...

Page 38: ...t the new neon and re assemble in reverse order SERVICING 3 4 a 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 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 5 Unplug the following leads from the PCB a Gas ...

Page 39: ... flow and return pipes from the system pipework close to the boiler SERVICING Flow pipe Return pipe 16 Bosses Flow 14 Support Boiler Heat exchanger 12 11 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...

Page 40: ...ompress 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 76 BOILER SEALING PANEL SEAL REPLACEMENT 2 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 ...

Page 41: ...GEND 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 11 18 1 2 7 79 CONTROL BOX ASSEMBLY Exploded view 5 4 6 9 1 7 3 4 9 10 12 16 17 13 20 Burner pressure sensi...

Page 42: ...ding Table 1 NO NO NO NO NO YES Purge gas line MAIN MENU NB Start the boiler from cold YES but only for a few seconds 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...

Page 43: ... moisture If no fault found check Board 37 by substitution YES NO YES Return to main menu The fan should now run Has fuse blown on Board 37 Fuse is OK if LED 4 is lit YES Is there mains voltage on BOTH terminals of boiler control thermostat YES 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 c...

Page 44: ...heck for blocked air duct Check the connections at the pressure switch wires on 1 and 3 if OK change the pressure switch NO YES YES but only with the boiler sealing plate removed 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 Remove connectors With mains OFF check continuity of l...

Page 45: ... externally to the burner YES Rectify poor connections or replace spark generator or electrodes Replace faulty spark generator YES Remove fan and burner assy Is there a significant amount of water in the combustion chamber Check condensate discharge system for blockage air lock or freezing YES NO Fit new ignition electrode assembly Is there mains voltage on Board 37 terminals for the spark generat...

Page 46: ...electrode Exit Check all connections on Board 37 If no fault found check Board 37 by substitution Boiler should now light Is polarity of the supply correct Ensure that live is connected to L and neutral to N YES YES Remove burner assembly Is there a significant amount of water in the combustion chamber covering part of the detection electrode NO Re assemble boiler Does the boiler now light YES Che...

Page 47: ...x 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 genera...

Page 48: ...upport Scotland N England Midlands Tel 01482 498 636 Southern England S Wales Tel 01482 498 660 Fax 01482 498 666 Publications literature Tel 01482 498 467 Customer Care Technical Support 18 21 20 19 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 Bo...

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