Page 1
WALL-HUNG COMBINATION BOILER
Central Heating and Instantaneous Domestic Hot Water with TSS
®
Fanned Flue System
Installation and Operating
Instructions
1
2
3
0
4
bar
1
2
3
0
4
bar
c
Calydra comfort 100
c
c
G.C.N: 47-980-21
PLEASE LEAVE THESE INSTRUCTIONS
WITH THE END-USER
GB
IE
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
www.heatingspares247.com
Page 2
2
These instructions are suitable for the following boilers :
Calydra comfort 100
Do not forget the Log Book!
Chaffoteaux & Maury supports Benchmark, the heating industry code to ensure the correct installation, commissioning and
servicing of domestic central heating systems.
To The End User
Make sure you have a completed Log Book for your boiler. This provides a record of the commissioning of your boiler.
It contains important information about your particular installation that may be required by service engineers. The Log Book will
also provide contact details for the installer should you need guidance in the use of this appliance or if there are any problems.
As with your car, your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service
check. The service history of the appliance will be recorded on the Log Book.
In the unlikely event of any problems with your boiler or system you should first contact your installer. If your installer cannot
resolve the problem he should telephone our national service helpline.
This appliance is a combined appliance for the production of Central
Heating (C.H.) and Domestic Hot Water D.H.W.)
This appliance must only be used for the purpose for which it is designed. THe manufacturer declines all responsibility for
improper or negligent use.
A charge may be made if Chaffoteaux & Maury Service is called out to resolve a non-product related fault.
Your statutory rights are not affected.
Do not allow children or inexperienced persons to use the appliance without supervision.
If you smell gas in the room, do not turn on or off light swithces, use the telephone or any other objects that might cause
sparks, open doors and windows to ventilate the room.
Shut the gas mains tap (on the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately.
If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.
Before any intervention within the boiler it is first necessary to isolate the electrical power supply by turning the
external switch to “OFF”
TO CONTACT C&M SERVICE, PLEASE CALL THE NATIONAL WARRANTY HELPLINE ON:
0870 600 9888
To The Installer
As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the End User Please
ensure that your customer is aware of the importance of keeping the Log Book safe as a record of the installation and the
appliance service history.
Please ensure that your customer is aware of the correct operation of the system, boiler and controls.
CUSTOMER CARE
Chaffoteaux & Maury, as a leading brand of domestic and commercial water heating appliances is committed to providing high
quality products and a high quality after sales service. If it is necessary to contact an engineer, then telephone the national
warranty helpline 0870 600 9888.
Advice on installation or servicing can also be obtained by contacting the Technical Department on:
Tel: 0870 241 8180
Fax: 01494 459775
GUARANTEE
The manufacturer`s guarantee is for 12 months from the date of purchase. The guarantee is invalidated if the appliance is not
installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us
in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler
without delay.
STATUTORY REQUIREMENTS
The installation of this appliance must be carried out by a CORGI Registered person or other competent person and in
accordance with the requirements of the Gas Safety (Installation and Use) Regulations and the rules in force.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 3
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Page
CUSTOMER CARE............................................. 2
Guarantee............................................................ 2
Statutory Requirements...................................... 2
Contents .............................................................. 3
INTRODUCTION................................................. 3
DESCRIPTION.................................................... 4
Location of components ...................................... 4
TECHNICAL DATA.............................................. 5
DIMENSIONS...................................................... 6
OPERATION ....................................................... 7
Domestic Hot Water Mode .................................. 7
Central Heating Mode.......................................... 7
INSTALLATION REQUIREMENTS..................... 8
Location............................................................... 8
Flue...................................................................... 8
Ventilation............................................................ 8
Gas Supply.......................................................... 8
Electrical Supply.................................................. 8
INSTALLING THE BOILER ................................. 9
Installation ........................................................... 9
Fitting the horizontal flue ..................................... 9
Making the electrical connections........................ 10
SYSTEM GUIDANCE.......................................... 11
Page
Showers............................................................... 11
Flushing and Water Treatment............................ 11
System Controls
.................................................. 11
By-pass and pump............................................... 11
Expansion Vessel................................................ 11
Filling Point.......................................................... 11
COMMISSIONING AND TESTING ..................... 12
Pre-commissioning.............................................. 12
Domestic Hot Water ............................................ 12
Central Heating.................................................... 12
Lighting the boiler ................................................ 12
Post Commissioning............................................ 12
Handing over to the Householder........................ 12
USER INSTRUCTIONS....................................... 13
Control panel ....................................................... 13
Isolating taps ....................................................... 13
Switching on ........................................................ 13
Hot water ............................................................. 13
Heating ............................................................... 13
Turn off the boiler ................................................ 13
INSTRUCTIONS FOR SETTING THE BUILT-IN
CLOCK ................................................................ 14
GAS CONVERSION............................................ 15
INCORRECT OPERATION................................. 15
By combining their modern highly efficient low water content fanned flue combination boiler concept and the brand new
TSS®“Temperature Stabilised System”, Chaffoteaux & Maury have created a whole new concept.
Calydra comfort
This unique combination is able to provide the user with hot water immediately at the outlet of the appliance and stable
temperatures at both extremely low flow rates or when several taps are opened together.
The TSS®is a 5 litres, independently controlled mini unvented storage cylinder, powered by a 3 kW coil. It works in
1
Contents
Introduction
In GB it is necessary to comply with the Water Supply (Water Fittings) Regulation 1999, for Scotland, The Water Bylaws 2000,
Scotland. The Centora Green is an approved product under the Water Regulations.
To comply with the Water Regulations, your attention is drawn to The Water Regulations guide published by the the Water
Regulations Advisory Scheme (WRAS) gives full details of the requirements. In IE the requirements given under the current
edition of I.S.813 must be followed. installation must also comply with the current bylaws of Local Water Undertakings.
Installation should also be carried out in accordance with Building Regulations, Local Authority Building Standards (Scotland)
Regulations and current editions of the following British Standards Codes of practice: BS 7593, BS 5440 parts 1 and 2, BS
5449, BS 7593, BS 6798, BS 5546, BS 7074, BS 7671 and document IGE/UP/7.
In the Republic the Republic of Ireland the installation should be carried out in accordance with the following codes of practice:
I.S.813 Domestic Gas Installation, the following BS Standards give valuable information: BS 5546, BS 5449, BS 7074 and BS
7593.
The electrical connections must be made in accordance for GB with current I.EE. Wiring Regulations, in Scotland with the
electrical provisions of the Building Regulations applicable in Scotland, the Safety Document 635 The Electricity at Work
Regulation and in the Republic of Ireland in accordance with I.S.813 and the current ETCI rules.
The Centora Green does not contain any asbestos or asbestos products, or mercury derivatives. Additional CFC’s have not
been used in this product.The appliance does not contain any potential hazard in relation to the COSHH regulations.
If there is a possibility of the incoming mains water pressure exceeding 10 bar then a suitable pressure limiting valve must be
fitted where pressures exceed 6 bars a pressure limiting valve is preferred.
Precautions: During servicing, keep the dust generation to a minimum and avoid inhaling any dust and contact with the skin
and eyes. Normal handling and use will not present any discomfort, although some people with a history of skin complaints
may be susceptible to irritation. When disposing of the ceramic lining, ensure that it is securely wrapped and wash hands after
contact.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 4
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2
Location of components
1 - Air pressure switch
2 - Steel chassis complete with expansion vessel
3 - Flue hood with fan
4 - Main heat exchanger
5 - Combustion chamber
6 - Multi- gas burner assembly including ignition and
ionisation electrodes
7 - Pump
8 - Central Heating flow switch
9 - Automatic air separator and automatic vent
10 - D.H.W. detector
11 - Sealed chamber
12 - Electrical box
13 - Overheat safety cut-out
14 - Gas valve assembly
15 - TSS ®(mini cylinder)
16 - Central Heating control thermistor
17 - Three way valve
18 - TSS®control thermistor
19 - Domestic Hot Water flow switch
20 - Secondary heat exchanger
21 - D.H.W. pressure relief valve
22 - Isolation valves support bracket
23 - On/Off switch
OFF
«
O
»
ON «
I»
24 - Domestic Hot Water temperature adjustment
25 - Heating flow temperature control knob
26 - Heating temperature indicator lights
27 - Green indicator - Power ON
28- Orange indicator - Burner ON
29 - Red indicator - Lock out / flame failure
30 - Reset button
31 - Pressure gauge
32 - D.H.W. mode indicator
33 - Central Heating mode indicator
K - Flue kit fixing point (refer to kit manual)
15
16
17
22
19
10
18
8
21
Fig. 2
9
2
1
3
4
5
6
7
12
13
11
14
Fig. 1
K
20
Description
conjunction with the Chaffoteaux & Maury low pressure instantaneous domestic hot water system.
The ‘Calydra comfort’, as well as providing hot water, provides central heating. The boiler is designed for sealed systems only.
A one speed circulating pump, diverter valve, expansion vessel as well as a pressure gauge and safety valve are included
within the boiler.
The ‘Calydra comfort’ provides the advantages of mains pressure hot water to taps and showers. Supplied directly from the
main water supply the ‘Calydra comfort’ does not need a separate feed cistern or vent pipe in the loft space.
The ‘Calydra comfort’ has been tested and approved by the WRc as meeting with the requirements of the Water Regulations
Authority.
The boiler has been tested and approved to carry the CE mark.
The ‘Calydra comfort’ can be installed with the standard horizontal flue, raised horizontal, concentric vertical, twin pipe flue or
SEduct arrangements. Adapters, bends and other accessories are available on request.
The boiler is packed in TWO cartons:
1. The boiler.
2. The flue assembly and fixing kit.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
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Page 5
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3
Calydra comfort 100
Appliance category Cat Ii
2H 3+
Gross heat input C.H. & D.H.W.
Maximum in kW 34.6
Maximum in Btu/h 117,900
Heat output C.H. & D.H.W.
Maximum in kW 28
Maximum in Btu/h 95,600
C.H. operating temperature
Max: 85° C
Min: 35°C
C.H. circuit pressure
Min operating in bar 0.7
in lb/in
2
10
Max operating in bar 2.5
in lb/in
2
36.3
D.H.W. flow rates
@
∆
∆
T 30
o
C in l/min 13.9
in gal/min 3.06
@
∆
∆
T 35
o
C in l/min 11.9
in gal/min 2.62
Cold water mains pressures
Min operating in bar 0.5
in lb/in
2
7.25
Max operating in bar 10
in lb/in
2
145
Flow limiter rate in l/min 10
Compartment ventilation not required
Natural Gas G20
Gas rate
Maximum in m
3
/h 3.29
Maximum in ft
3
/h 116
Inlet pressure
Nominal in mbar 20
Nominal in in wg 8
Burner pressure
Nominal in mbar 12.8
Nominal in in wg 5.1
Burner injector diameter
Natural Gas G20 in mm 1.28
Calydra comfort 100
Propane L.P.G. G31
Gas rate
Maximum in kg/h 2.42
Maximum in ft
3
/h 44.8
Inlet pressure
Nominal in mbar 37
Nominal in in wg 14.8
Burner pressure
Nominal in mbar 30.4
Nominal in in wg 12.2
Butane L.P.G. G30
Gas rate
Maximum in kg/h 2.45
Maximum in Lbs/h 5.40
Inlet pressure
Nominal in mbar 28
Nominal in in wg 11.2
Burner pressure
Nominal in mbar 24
Nominal in in wg 9.6
Burner injector diameter
L.P.G. G30 and G31 in mm 0.76
Safety discharge
in bar 3
in lb/in
2
43.5
Expansion vessel
Pre-charge pressure in bar 0.7
Pre-charge pressure in lb/in
2
10
Nett capacity at 3 bar in litres 6
Automatic by-pass
Electrical characteristics
Supply 230V~
Consumption 150 W
Protection IP4 XD
Fuse n°1 2 A
Fuse n°2 1.25 A
External controls 24V~
I
reset
Fig.3
32
31
30
23
25
33
26
24
27
28
29
Technical Data
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 6
6
4
All dimensions in mm
Ø 100
Type C 12
206
143
Ø 125
Ø 80
120
Ø 80
Type C 32 xx
Type C 32 xy
250
Ø 80
250
Fig. 4
Type C 32 xxType C12, C42
Type C 32 xy
The boiler is suitable for the 3 flue types:
•
Type C 12 or C 42
• Type C 32 xx
• Type C 32 xy
Weights
With packaging :
- Calydra comfort 100 : 40.5kg
Without packaging :
- Calydra comfort 100 : 38.5kg
Lift weight :
- Calydra comfort 100 : 32.5kg
Tails diameter
I Safety valve outlet
ø 15 mm
J Central Heating flow
ø 22 mm
K D.H.W. outlet
ø 15 mm
L Gas supply
ø 22 mm
M Cold water inlet
ø 15 mm
N Central Heating return
ø 22 mm
Outer case dimensions :
- Width :
440 (minimum space required 450)
- Height : 850
- Depth : 380
Minimum clearances :
- Both sides 5 mm
- Above casing
170 mm
- Below casing 200 mm
- Front ( for servicing) 500 mm
- Front (in operation) 5 mm
JKLMN
I
54 54 54 54
68
360
2605050
738
850
380
212
Safety valve
centre line
Dimensions
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 7
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Domestic Hot Water Mode
In order to supply hot water, the main switch 23 (Fig.5) must
be in the ON position I This will be confirmed by the green
indicator light 27 (fig. 5). Turn the D.H.W. temperature
adjustment knob 24 clockwise to establish the green D.H.W.
indicator 32 (Fig.5).
The hot water temperature in the mini cylinder can be
adjusted between 40 and 60°C using the control knob 24
(Fig.5).
When a tap or shower is turned on, the flow of mains water,
above 2 l/min, will activate the 3 way valve 17
(Fig.2) to move to the D.H.W. position. The pump will now
circulate primary water heated by the main heat exchanger
through the secondary heat exchanger.
The first stage solenoid a (Fig.6) and the safety solenoid c
(Fig.6) open together to allow gas to the burner. The ignition
sequence begins and a continuous high speed spark ignites
the gas. As soon as a flame is detected the orange indicator
bulb 28 (Fig.5) will light and the second stage solenoid b
(Fig.6) opens to allow the full gas rate. If a flame is not
detected, after 8 seconds, the security solenoid closes and
shuts off the gas. The red lockout indicator bulb 29
(Fig.5) will show. Over 2 l/min, the D.H.W. temperature is
controlled by the D.H.W. control thermistor d (Fig.6) and the
heating control thermistor e (Fig.6), but dependant upon the
position of the D.H.W. temperature adjustment knob 24
(Fig.5). This system anticipates the changes of temperature
in the secondary heat exchanger and ensures accurate
temperature regulation.
When the tap is closed the burner is extinguished and the
pump stops. (unless the TSS®thermistor is calling for heat,
in which case the burner will remain on at a low rate and the
pump will continue running until the mini cylinder thermistor is
satisfied). The boiler will now stay in the hot water mode for
30 seconds to be ready for a subsequent draw off
Priority is given to a demand for hot water. This will interrupt
the central heating for the duration of hot water delivery or
recovery of the mini cylinder.
When the boiler has been in standby in hot water mode for
some time or when drawing D.H.W. at flow rates of less than
2 l/min the temperature in the mini cylinder will eventually
decrease and the TSS®control thermistor f (Fig.6) will call for
heat, Causing the pump and burner to operate, until the
TSS®thermistor is satisfied.
5
Fig.5
Fig. 6
Central Heating Mode
To be able to supply heating, the main switch 23 (Fig.5) must be in
the I position. This will be confirmed by the green indicator light
27 (Fig.5). Turn the temperature control knob 25 clockwise to
establish the green heating indicator 33 (Fig.5).
When there is a demand for heating (either from the room
thermostat or the clock) and the boiler temperature control is
calling for heat. The pump starts allowing the ignition sequence to
begin. The first stage solenoid a (Fig.6) and safety solenoid c (Fig.
6) open together to allow gas to the burner. The ignition sequence
begins and a continuous high speed spark ignites the gas. As soon
as a flame is detected the orange indicator bulb 28 (Fig 5) will
light. After 45 seconds the second stage solenoid b (Fig 6) opens
to allow the full gas rate. If a flame is not detected, after 8 seconds,
the security solenoid closes and shuts off the gas. The red lockout
indicator bulb 29 (fig. 5) will show.
The central heating flow temperature is controlled by the central
heating control thermistor e (Fig 6). The boiler has been designed
to minimise cycling and will not attempt to relight for at least 3
minutes after the boiler thermostat has been satisfied (it is possible
to reduce the time to 30 seconds if necessary). When the room
thermostat is satisfied the burner will switch off and the pump will
remain running for a further 4 minutes before it to stops.
NB : It is possible to override the 3 minute delay by pressing the
RESET button 30 (Fig 5).
abc
d
e
I
reset
32
31
30
23
25
33
26
24
27
28
29
f
Operation
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 8
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6
Location
The boiler can be installed on any suitable internal wall.
Provision must be made to allow the correct routing of the flue
and siting of the terminal to allow the safe and efficient
removal of the flue products. A compartment or cupboard may
be used provided that it has been purpose-built or modified for
the purpose. It is not necessary to provide permanent
ventilation for cooling purposes. Detailed recommendations
are given in BS 5440 pt 2. If it is proposed that it is installed in
a timber framed building then reference must be made to
British Gas Document DM2, or advice sought from CORGI.
Flue
Detailed information on the flue assembly is contained in the
appropriate starter pack.
The boiler must be installed so that the flue terminal is
exposed to the free passage of external air at all times. It must
not be allowed to discharge into another room or space such
as an outhouse or closed lean-to. The minimum acceptable
clearances are shown below:
- A Directly below an opening, window, etc
300 mm
- B Above an opening, window, etc 300 mm
- C Horizontally to an opening, window, etc 300 mm
- D Below gutters, soils pipes or drain pipes 75 mm
- E Below eaves 200 mm
- F Below balconies or car port roof 200 mm
- G From a vertical drain pipe or soil pipe 150 mm
- H From an internal or external corner 300 mm
- I Above ground roof or balcony level 300 mm
- J From a surface facing the terminal 600 mm
- K From a terminal facing the terminal 1200 mm
- L From an opening in the car port into the dwelling1200 mm
- M Vertically from a terminal on the same wall 1500 mm
- N Horizontally from a terminal on the same wall 300 mm
- Q Fixed by Ubbink Rolux 4 GM flue terminal
It may be necessary to protect the terminal with a guard.
Reference should be made to the Building Regulations for
guidance. Suitable guards may be obtained from the following
manufacturer:
Quinnel Barret & Quinnel Wireworks
Old Kent Road
London SE15 1NL
Tel: (020) 7639 1357
Ventilation
The room in which the boiler is installed does not require specific
ventilation. If it is installed in a cupboard or compartment
permanent ventilation is not required for cooling purposes.
Gas Supply
The gas installation and soundness testing must be in
accordance with the requirements of BS 6891.The boiler
requires a minimum 22 mm supply. (Ensure that the pipe
size is adequate for demand including other gas appliances
on the same supply).
Electrical Supply
The appliance requires an earthed 230V - 50 Hz supply and
must be in accordance with current I.E.E. regulations. It must
also be possible to be able to completely isolate the
appliance electrically. Connection should be via a 3 amp
fused double-pole isolating switch with contact separation of
at least 3 mm on both poles. Alternatively, a fused 3 Amp. 3
pin plug and unswitched socket may be used, provided it is
not used in a room containing a bath or shower. It should
only supply the appliance.
Fig. 7
A
B
G
H
J
C
L
M
N
K
I
D,E
F
Q
H
N
M
Q
Q
I
Installation Requirements
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
www.heatingspares247.com
Page 9
9
Fig. 8
1
2
3
0
4
bar
Fig. 9
7
Fig. 10
L
A
A
A
A
Fitting the Horizontal Flue
The instructions for the vertical and biflux (twin pipe) flue options are included with the relevant adapter kits.
The standard flue supplied with the appliance is suitable for lengths from 300 mm minimum to 720 mm maximum. This means
for rear flueing, the standard kit will accommodate a maximum wall thickness of 600 mm, and for side flueing a maximum wall
thickness of 587 mm. This takes into account the minimum appliance side clearances of 5 mm.
If the fixing is a rear exit flue, the template provides the position of the centre for drilling the flue hole with a core drill.
If the flue is a side exit installation then calculate the position of the hole with a slope of 5 mm / metre away from the boiler to
the terminal. The flue should fall slightly to the terminal.
Place the boiler on the wall on the hanging bracket. Using (Fig.4) for reference, connect the gas and water pipes and the
valves to the base of the appliance using the tails provided. There is a space of 190 mm between the valves and the wall to
make these connections.
Connecting the Boiler to the System
Attention ! Connecting tails are delivered with the boiler. You could ask your local dealer or Chaffoteaux et Maury Ltd for first
installation tails kit or to replace existing boilers such as old Chaffoteaux et Maury models.
Before fitting the tails onto the connecting bracket, please check the correct location of the flow restrictor L (fig.10) on the main inlet.
Safety Valve Drains
The pressure relief valve tube is clear silicone. It should terminate below the boiler over a tundish or
22 mm pipe (see I Fig 4) which should in turn discharge safely outside the premises. Care should be taken that it does not
terminate over an entrance or window or where a discharge of heated water could endanger occupants or passers by.
The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or
unnecessary scaling of the heat exchanger.
Please check that you are familiar with the installation requirements before commencing work.(section 6)
Method of Positioning the Boiler on The Wall.
The paper template can be used to ensure the correct positioning of kitchen cabinets etc. It also details the commissioning
instructions.
The paper template has to be fixed to the wall and used to locate the position of the hanging bracket and the centre for the flue
hole.
Drill and plug the wall and secure the hanging bracket using the screws provided. Remove the boiler from its packaging as
shown in Fig.8 and remove the outer case as shown in Fig.9.
Installing the Boiler
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
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Page 10
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8
ADJUSTMENT
Choice of Mode :
- Function without room thermostat, bridge S remains in place.
- Function with room thermostat, remove bridge S, room thermostat connected as shown on connector D (Fig.11).
The external control switches both burner and pump. The
external control switches the pump off after a delay of 3 min 30
seconds
Choice of Boiler Operation :
In order to make these adjustments you will need to access the
front of the electrical box.
Isolate the mains electrical supply to boiler.
Remove the boiler outer casing.
Remove the rubber cover E (Fig.12) on the front of electrical
box.
Adjustment on the PCB Central Heating Mode (Fig.13) :
- P3 : potentiometer TAC (Temporisation Anti Cycle)
may now
be adjusted between 30 seconds and 3 minutes (see
detail) (factory set at 3 minutes).
- JP3 : the spade connector (Fig.14) allows the gas rate to be
reduced to 1/3 performance by positioning the spade
across the pins as shown (Fig.14).
Full performance across pins as shown (Fig.14).
After completing the adjustments replace the rubber cover and
refit the outer casing.
C10C10
C11C11
C38C38
J1J1
J2J2
J5J5
MV1MV1
R72R72
R73R73
R75R75
R76R76
1
2
HOR
N
L
THERMOSTAT
N
L
J9
J10
J11
TA
24 V
230 V
P3
Fig. 13
Fig. 12
(P3-P4-P5)
mini maxi
P3
Detail
P3
P3
1/3
3/3
P3
1/3
J1
J2
S
Connector D
T.A.
Mains supply cable
Room thermostat
Fig. 11
C
E
B
Making the Electrical Connections:
Connect the live and neutral wires of the main cable. Note: The
connections should be made so that should the lead be pulled
from its anchorage, the current carrying wires become taut
before the earth wire.
If using a room thermostat or other external control, undo the
two retaining screws B, remove cover C (Fig.12), they can be
connected in place of the link on the multipin plug.D.
Connect the multipin plug into the socket on the power board.
Replace the cover.
Fig. 14
Installing the Boiler (contiunued)
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
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Page 11
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9
The boiler is suitable for sealed systems only. The
maximum cold water mains pressure for the appliance is 10
bar. All fittings and pipework connected to the appliance
should be of the same standard. If there is a possibility of
the incoming mains pressure exceeding 10 bar, particularly
at night, then a suitable pressure limiting valve must be
fitted.
The boiler is designed to provide hot water on demand. If
there is a requirement for greater demands, for example if
the property has several bathrooms and cloakrooms, a
vented or unvented hot water storage system should be
used.
Showers
Any shower valves used with the appliance should be of a
thermostatic or pressure balanced type. Refer to the shower
manufacturer for performance guidance and suitability.
Flushing and Water Treatment
The performance of the appliance could be impaired by
system debris or the effects of corrosion. The system must
be flushed thoroughly to remove metal filings, solder,
machining oils and other fluxes and greases before
connecting the boiler. If it is an existing system, an
appropriate flushing and descaling agent should be used.
Refer to BS 7593: 1992 for guidance. For more information
on the use of corrosion inhibitors, flushing and descaling
agents, advice can be sought from the manufacturers of
water treatment products such as:
Betz Dearborn Ltd
Foundry Lane
Widnes
Cheshire
WA8 8UD
Tel: (0151) 424 5351
Fernox Manufacturing
Britannica Works
Clavering
Essex
CB11 4QZ
Tel: (01799) 550811
System Controls
The boiler is electrically controlled and is suitable for most
modern electronic time and temperature controls. The
addition of such external controls can be beneficial to the
efficient operation of the system. The boiler connections for
external controls are 24V and so only controls of 24V or that
have voltage free contacts should be used.
By-pass and Pump
The boiler is fitted with an automatic by-pass. .
Expansion Vessel
The expansion vessel is pre-charged to 0.7 bar (10 lb/in
2
).
The vessel is suitable for systems up to 145 litres capacity.
For systems of greater capacity an additional expansion
vessel will be required. Refer to the chart below and BS
7074 pt 1 or BS 5449.
Filling Point
Provision must be made to be able to charge the system on
commissioning and to make up any subsequent pressure
loss.
The method of connection must utilise approved equipment
and must comply with the water regulations. A filling loop
can be installed so as to be hidden beneath the boiler.
20 40 60 80 100 120Pf140 160 180 200 220 240
0,7
0,8
0,9
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
80°C
70
°C
60°C
50°C
40
°C
260
Pression à froid pour le circuit chauffage (en bar)
Liters
Pressure
System capacity chart
Fig. 15
System Guidance
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 12
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10
Pre-commissioning
Ensure that the system has been adequately flushed.
Purge gas supply of air and test for soundness.
Carry out final electrical tests to ensure the correct polarity
and earthing continuity.
D.H.W.
Open the main cold feed valve.
Open all hot taps to purge the D.H.W. system.
Check for water soundness.
Check flow rate at the bath tap is set correctly (see
technical data).
Central Heating
Open flow and return valves on the boiler 34 and 38
(Fig.16)
Open the automatic air vent 9 (Fig.16)
Fill system and vent radiators.
Set system pressure and remove filling loop.
Check for leaks.
Manually check pump is free to turn.
Switch on electrical supply.
Turn selector switch 23 (Fig.17) to position I
Turn the boiler thermostat to maximum.
Allow pump to run for several minutes.
Isolate electrical supply.
Drain boiler and check water filter for installation debris.
Replace filter and recharge system.
Lighting the Boiler
Connect gas pressure gauge to test point 14 (Fig.16).
Turn on the gas supply and boiler gas tap 36 (Fig.16).
Ensure electrical supply is on.
Ensure all external controls are calling for heat.
Turn selector switch 23 (Fig.17) to position I.
Turn the boiler thermostat to maximum 25 (Fig 17).
The boiler will light.
Allow the boiler to heat system.
Check the inlet gas pressure by connecting a gas pressure
gauge to test point 14 (Fig. 16) (working pressure) while
boiler is operating in hot water mode. (Refer to technical
data).
Check the operation of the boiler controls and safety
devices.(see separate servicing leaflet for details)
Set the by-pass (Refer to system guidance).
Re-flush the system to remove any dissolved oils and
fluxes.
Recharge system pressure and introduce any water
treatment as required.
Post Commissioning
Ensure system pressure has been set correctly.
Set boiler thermostat and controls.
Set programmer to End Users requirements.
Set external controls.
Ensure the Log Book is fully completed with your contact
details and required readings and details of the installation.
Handing Over to the End User
Demonstrate the lighting and operation of the boiler.
Demonstrate how to maintain the system pressure.
Demonstrate the operation and setting of the built-in clock.
Explain the benefits of annual maintenance by a competent
person.
Explain how to register guarantee.
Ensure the End User countersigns the Log Book to confirm
that these demonstrations have been carried out and
understood.
Detail for the adjustment of the by-pass
Fig.16
34
35
36
41
37
38
39
40
42
P
P
E
E
Isolating screw on - :
by-pass shut
Isolating screw on + :
by-pass open
9
14
Comissioning and Testing
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 13
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11
Switching on
1) Check that the gas service valve is opened at the gas
meter and mains power is on.
2) Check that pressure in Central Heating system is above
0.7 bar and below 1.5 bar with the pressure gauge 31.
3) Open the gas service valve 36.
4) The boiler is now ready to use.
Hot Water
1) Turn mains switch 23 to position I . The green "power on"
indicator 27 will light.
Turn the D.H.W. temperature control knob clockwise 24.
The D.H.W. indicator will light 32.
2) Turn on a hot water tap, the orange "burner on" indicator
will light 28 and the water will become hot.
Heating
1) Turn mains switch 23 to on position I . The green "power
on" indicator
will light 27.
Turn the C.H. temperature control knob clockwise 25. The
C.H. indicator will light 33.
3) If the room thermostat (if fitted), the boiler temperature
control
and the clock (if fitted) are all calling for heat,
the orange "burner on" indicator will light
and the heating will be on.
When there is a need for hot water while the heating is on, it
is only necessary to turn on a hot tap. The heating will be
interrupted momentarily while the hot water is being
delivered. The boiler will switch back automatically to
heating when the tap is turned off.
Note: If the boiler has been turned off for some time the first
attempt to light it may result in a lock-out
If this
happens press the reset button 30 and the boiler will light.
To Turn Boiler Off Completely
1) Turn the main switch 23 to the off position O.
2) Turn the gas service valve 36 OFF.
Control Panel (Fig.17)
23. Two position selector switch
O
= Switched OFF
I = Switched ON
24. = Domestic Hot Water temperature control knob
25. = Central Heating flow temperature control knob
26. Central Heating temperature indicator lights
27. Green indicator - Power ON
28. Orange indicator - Burner ON
29. Red indicator - Lock-out/flame failure
30 “RESET” Reset button
31. Pressure gauge
32.
=- D.H.W. mode indicator
33. =- Central Heating mode indicator
Isolating Valves (Fig 16)
Valves shown in open position
34. C.H. flow isolating valve
35. Domestic Hot Water outlet
36. Gas service valve
37. Water service valve
38. C.H. return isolating valve
I
reset
Fig.17
32
31
30
23
25
33
26
24
27
28
29
User’s Instructions
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
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Page 14
14
Fig.18
12
1. General Layout
The mechanical clock covers a 24 hour period. Each tappet
represents 15 minutes A (Fig.19). An override switch is
located on the clock B (Fig 19).
2. To Set the Time
To set the time of day, grasp the outer edge of the dial and
turn slowly clockwise until the correct time is lined up with
the arrow C (fig. 19).
3. To Set the "On" and "Off" Times
The clock uses a 24 hour system. (e.g. 8 =8.00 am and
18 = 6.00 pm) "ON" periods are set by sliding all tappets
between the "ON" time and the "OFF" time to the outer edge
of the dial.The tappets remaining at the centre of the dial are
the "OFF" periods.
4. To Select Function Mode
Put the selector switch B to symbol to control the boiler
by the clock. Put the switch B to «I» to select permanent
operation or to «0» to turn heating off permanently.
Fig.19
11
22
33
44
55
66
77
88
99
1010
1111
1212
1313
1414
1515
1616
1717
1818
1919
2020
2121
2222
2323
2424
99
66
1212
I
A
C
B
Instruction for Setting the Built in Clock
Helpful suggestions
- Periodically check the system pressure using the pressure gauge and make sure that the pressure is between 1.0 and 1.5
bar when the system is off and cool. If the pressure is below the minimum recommended value, the pressure must be
brought into the acceptable range. Consult your installer for checking and refilling the system.
If the pressure level drops on a frequent basis, it is likely there is a water leak in the system.
If this is the case, your
installer must inspect the system.
- The outer panel of the boiler’s case must only be cleaned with a damp cloth, do not use abrasive cleaners. The control
panel can be wiped with either a damp or dry cloth. Spray polishes must not be used on the control panel surface or
knobs. Care must be taken in preventing any liquid entering the appliance.
- If the water is exceptionally hard, install a water softerner so that the efficiency of the boiler remains the same over time as
this will consume less gas.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
www.heatingspares247.com
Page 15
15
This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.
13
14
If these solutions do not cure the fault, call a qualified professional
Fault
The boiler doesn’t start
Red indicator alight
Noises in CH system
Radiators rise in temperature During
summer season
Cause
No gas, no water or no electricity
Air in the gas pipe
Room thermostat switched off
Ignition lockout
Air presence in CH system or.
Insufficient pressure
Gravity effect in the CH system
Solution
Check the water pressure in the central
heating system and external electrical
supply, check that the gas supply is on,
should there still be a problem contact
your local service centre.
Contact your local service centre.
Turn up the room thermostat
Wait for a few minutes
Press the reset button 36 (fig.21) the red
led will go out and the boiler attempts to
re-light.
If the red indicator lights too frequently,
please call your local service centre.
Purge of air the system and rise up the
system pressure (chapter 8)
Close the heating flow isolating valve.
Don’t forget to open it again when you
will start heating.
Gas Conversion
Incorrect Operation
Notes
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
www.heatingspares247.com
Page 16
1309145 - 02/2002
Chaffoteaux & Maury are continuously improving their products and therefore reserve the right to change specifications without
prior notice and accepts no liability for any errors or omission in the information contained in this document.
Manufacturer: Chaffoteaux & Maury - France
Commercial subsidiary: MTS (GB) Limited
MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT
Telephone: (01494) 755600
Fax: (01494)
459775
Internet: www.chaffoteaux.co.uk
E-mail: info@uk.mtsgroup.com
Technical Support Help Line: 0870 241 8180
Customer Service Help Desk:
0870 600 9888
This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388
www.heatingspares247.com
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