Chaffoteaux & Maury Britony FlexiFlue Installation And Servicing Instructions

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Page 1

Britony

GC. No. 52.98022

(For use on natural gas only)

FlexiHue

installation and

servicing instructions

(leave these instructions with the user)

The model number and serial number of this heater are on the data badge which is found inside rear case at lower left hand side.

These numbers should be used when ordering replacement parts.

LookhgGood.HeathgBetter

Page 2

GENERAL

The Britony FlexiFlue is a room sealed, fanned balanced flue, multipoint water heater. The flue which is 100 mm (4”) diameter pipe, can be directed to the rear or to either side. The maximum recommended flue length is 3 metres for straight application and 1.6 metres total when using a bend.

The appliance is for connectton to a mains cold water supply only. A permanent electrical connection is required and should be provided by use of a fused spur. The external elec-

trical supply should be via a double pole switch having 3 mm. contact separation in both poles. If the appliance is installed in a bathroom the fused spur must be external to the bathroom.

When on pilot only the fan runs at ‘low speed’ increasing to normal speed when there is a demand for hot water. Included are a pressure switch, which operates if the fan stalls or if the flue is obstructed, and a low temperature sensor which wili turn off the fan when the appliance is running on pilot only (fan low speed) in the event of low air temperatures iike!y to cause freezing in the appliance.

Note: GasSafetylnstallaticnand UseReg 1984. Itisthelawthatallgasappliancesareinstalled byC.0.R.G.I. registered persons in accordance 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 compliance with the law.

1.1

1.2

Guarantee

The guarantee on this appliance is void if it is not installed in accordance with the recommendations made herein or in a manner approved by the manufacturer.

Dimensions

B C

E F

N P S T V

mm ins.

658 25.9 395 270 10.6 100 4.0

40 1.6 385 15.15 438 17.25 778 30.6 728

53 2.1

55 2.15

98 3.8

70 2.75 285 11.22

105 199 7.8

290

90 868

15.5

28.6

4.13

11.4

3.54

34.14

L ’

B ’

-I- l/’

r/4

3 ‘1

/,/ ,/“/

,/”

‘,’ A;

,’

Page 3

1.3

Technical Data

Heatinputnominal ...................................

Heatoutputnominal .................................

Gas rate (maximum) ..................................

Burner pressure .....................................

Burnerpressuretolerance ............................

Main burner injectors .................................

Pilot injectors .......................................

Manifold restrictor ...................................

Water flow rate - raised 50 “C (90 Water flow rate - raised 25 “C (45

Min. water pressure selector closed. ....................

Min. water pressure selector open ......................

Max.waterpressure .................................

Electrical supply - 240 V 50 Hz fused 3 A

The minimum water pressure is for the correct operation of the appliance only. An additional allowance must be made for the resistance of pipework and fittings particularly where showers and washing machines are used. This should be equivalent to 2 m. (6,5 ft) head.

Water inlet (Compression type fittings) ..................

Water outlet (Compression type fittings) ................

Gas (Compression type fittings) ........................

Height (including flue bend) ............................

Width ..............................................

Depth ..............................................

Weight - Car-toned ...................................

Weight - Lift ........................................

Minimum clearances - top (above flue) .................

- bottom (below case) .............

sides. ..........................

- front ..........................

Hole for the air inlet duct .............................

"F)

....................

"F)

....................

29.9 kW 22,7 kW

2.70 m3/h 9,1 mbar

2 1.0 mbar

I,28 mm diam.

0,23 mm

5.3 mm diam.

3,2 to 6.5 I/min

6.5 to 13 I/min OS bar I,0 bar

10 bar

Right hand connection

Left hand connection 15 mm Copper

Centre connection 15 mm Copper

778 mm 30,6 in 395 mm 270 mm IO,6 in

24.3 kg. 53,6 Ibs. 15 kg. 33,l Ibs.

50 mm

178 mm 7 in

25 mm

600 mm

102 mm diam.

102000 Btu/h

77452 Btu/h

9535 fP/h

3,7 in.w.g.

2 0,4 in.w.g.

0.7 to I,43 gpm I,43 to 2.8 gpm

16,5 ft (7,5 psi)

33,0 ft (15 psi)

150 psi.

15 mm Copper

15,5 in

2 in

1 in

24 in

4.2 in. djam.

The Britony FlexiFlue is supplied in one carton.

Page 4

3 L+

INSTALLATION REQUIREMENTS

2.1

INSTALLING THE APPLIANCE

A vertical flat area is required for the appliance : 1006 mm high x 445 mm wide (39.6 in x 17.5 In). The surface on which the appliance is mounted must be of a non combustible material.

3.1

Packaging

The appliance is attached to the wall via the mounting bracket and two bottom screw fixings. The appliance is packed in a

single carton. Remove contents from carton and check against list.

1) APPLIANCE - Assembled with trims.

2) FLUE ASSEMBLY : a) Air inlet duct complete with terminal. b) 2nd section flue duct (inside air inlet duct). c) Flue turret with 1st section flue duct fitted

Plastic turret cover.

3) ACCESSORY BOX - containing : - mounting bracket

- gas and water connections with washers, nuts and olives

- flue locking ring and ‘0’ ring seal

- 2 gaskets

- 4 wall mounting screws

- 4 turret fixing screws 2 turret cover fixing screws

- 1 gas control knob 1 temperature selector knob

Page 8

3.2

Preparing and fitting the appliance

107diam

9-=

A-

197,5 mm minimum

-I

Preparation :

Remove the bottom trim by pulling forwards.

- Slide the controls facla plate (P) upwards to disengage from retaining bracket.

- Release the front case by removing the four fixing screws and washers positioned at the top, bottom and centre of appliance.

- Remove the front case by lifting off the top locatlng lugs and pulling forward to clear the water section at the base of the appliance.

NOTE : A template is not supplied with this appliance. Particular care is therefore necessary to ensure that the appliance mounting bracket is frtted level and positioned accurately. When using extended flues, a fall of 5 mm per metre length should be provided. (From turret to terminal).

Refer to the drawings opposite for rear and side flue applications and/or to the dimensions given.

- Set out an drill hole flue using a 107 mm core

drill.

Using the dimension 290 mm (11.4 in) accurately mark position for bracket.

Drill and plug the wall.

3.3

Flue Length

Rear Outlet

Side Outlet

I - Hang the appliance on the bracket, and re-check

for level. Mark bottom fixing holes, remove appliance, drill and plug the wall to suit No. 12 screws.

- Re-hang appliance and secure with screws provi-

Minimum Wall Thickness 3 in (75 mm)

Wall thickness

Flue duct length = wall thickness + 25 mm Air inlet duct length = wall thickness + 25 mm

EM up to

+DM

500 mm to 1400

Dehv I extn

with

appliance

up to 612.5 mm

Delivered with

apphance

Pt No. 62823 = GC No 264 459

500

Pt No

62823

Over 612.5 mm

Extension available

PI No. 62823

1401 mm

to 2300

extn.

62823

2300

extn.

62823

2787

EM = Wall thickness DM = Distance from wail to case m

Flue duct length EM + DM + 130 mm Air inlet duct length EM + DM + 130 mm

Page 9

3.4

Other flue arrangements

II---

1. Distance from internal corner 300 mm without kit, 150 mm with kit no. 76216 (GC No, 264 833).

2. Distance below balconies or eaves 200 mm without kit, 150 mm with kit no. 76216. (GC No. 264 833).

3. Appliance is normally supplied packed with standard 650 mm straight flue section. Additional straight extention lengths of 1 metre. Part No. 62823 (GC No 264 459). can be used up to a total straight length of 3 metres. It is also possible to incorporate one bend in the flue using Part No. 65572 (GC No. 264 835). In this case the length Ll + L2 should not exceed 1,6 metres horizonially.

3.5

Fitting the flue

- Measure the wall thickness and cut flue duct and air inlet duct to required length, (see Section 1.4).

- Peel off protective paper from adhesive side of cork gasket (A) and place on mating side of flue turret(B) lining up screw holes and press down.

- Wcpcking ring 0 and ‘0’ ring over the air inlet

- Fit flue duct and turret so that it engages into the terminal.

- Engage locking ring over lugs by turning in an anticlockwise direction viewed from behind turret.

D - Pass the assembled flue through the wall.

- If long flue sections are used (up to 3 metres) and difficulty is found, these can be assembled whilst being passed through the wall.

- Seat the turret onto the top of the appljance ensuring the gaskets are in position.

- Secure with 4 screws provided.

- Do not fit plastic turret cover or the front case un-

til electrical connections have been made and the appliance tested for gas and water soundness (see Section 5.1).

- A sealing ring (D) is supplied which can be used to

seal the air inlet duct to wall joint-externally.

- Make good inside wall surface.

Page 10

3.6

Gas Connection

Fit the gas service cock provided using the fine filter/washer to seal the connection. Fit the nut and olive onto the 15 mm gas supply pipe and tighten.

Test the complete gas installation for soundness and purge.

3.7

3.8

Water connections

Electrical connections

Remove the plastic covers protecting the water in-

let and the water outlet connections.

Fit the water service cock provided to the right

hand connection at the bottom of the appliance

using the coarse filter/washer to seal the connec-

tion.

Fit the nuts and olives onto the supply and delivery pipes.

Connect the inlet supply to the water service cock

and tighten.

The water service cock supplied with the appliance

incorporates a drain plug.

Ensure that all water connections are fully tightened.

3.8.1. Pressure Switch

Connect the wires at the top of the appliance to the pressure switch.

The

grey

I) contact.

The

Fit the flue turret cover passing the wire through

one of the slots provided and secure with the

screws provided.

See figure.

wire is connected to normally closed (NC

pink

wire to the normally open (NO 2) contact.

violet

wire to the common (P) contact.

‘

3.82. Mains Connection

Pass 0.75 mm2 heat resisting cable through cable

gland.

The earth wire (green yellow) must be connected to the earth pillar ( + L

The live (brown) and neutral (blue) should be

connected as indicated into the terminal block.

Check that component plugs are pushed home.

Check for continuity, polarity and earthing.

Page 11

APPLICATIONS OF THE BRITONY FLEXIFLUE

The appliance is designed to serve a variety of hot water draw off points including washing machines and showers. The appliance can be connected to all hot water draw-off points in the installation. If more than one outlet is open simultaneously the total flow of water cannot exceed that quoted in the Technical Data.

The appliance is comptatible with most current automatic washing machines but care should be taken to ensure that the machine is capable of accepting water at the de-

sign flow of the appliance. Hot and cold fill machines nor-

mally require a hot water temperature of 60 “C (140 “F), the appliance producing approximately 6.5 I/min

(1.44gpm) at this temperature. The advice of the was-

hing machine manufacturers should be sought but gene-

rally it is only necessary to remove the water flow restrictor (if fitted) in the hot water inlet connection of the ma-

chine to obtain a satisfactory appliance operation.

Do not use the appliance with push on hand showers that fit over existing hot and cold water taps or with mixer taps unless both supplies come from the same source.

Showers forming part of bath mixers are not recommen-

ded for satisfactory operation of the appliance.

Pipework

4.1

The following notes are for general guidance only.

0) The appliance performance may be affected if the installation has old pipework forming dead-legs or air reservoirs. Always ensure that any old pipework is ei-

ther removed or capped off immediately adjacent to the pipework that will be in use.

(ii) The size of the pipework between the appliance and the

various draw-off points should be sized to ensure an ade-

quate flow at all draw-off points when used individually.

(iii) A check should be made of all stop cocks in the inco-

ming supply and it should be ensured that they are of

the fixed jumper pattern. Loose jumpers can be pin-

ned or soldered into position.

Bri(-any FlexiFlue I::::::::.:.:.:.:.:.:.:.:.:.:.:.:

HOT

. ..__.____._...

. . . . . . . . . . . . . .

. . . ..__.........

.,..._.________.

. . . . . . . . . . . . .

.._.............

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_._.............

.,..............

.~.~.~,‘.~.~.~.‘.‘.‘.~.~.~.~...’

. . . .._..........

,...............

. . . . . . . . . . . . . . .

,~_‘_~_~.‘.‘.‘.~.~.~.‘.~.‘.‘.~.’

. . . . . . . . . . . . . . . .

,___.._..........

.‘_‘_‘_~_‘.‘.‘_‘_‘.‘.‘.~.‘.~.‘.‘,

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. ..__._.._._.....

.‘.‘.‘.‘.‘,‘.‘.‘...~.~.~.~.~.~.~

.‘.~.~.~.~,‘.~_‘_‘_

.‘_‘.‘_‘.~,~.~.~.‘.~.‘.~.‘.~,‘.’

_‘_~_‘_‘_‘.~.‘.~.~.~.~.‘.‘.‘.‘.

. _ .

. .

The appliance can be used to supply hot water to a separate shower draw-off, The appliance should not be

used to supply more than one shower mixing valve. The recommended pipework arrangement for a single shower head is shown above and the hot supply to the mixing valve

should be the first draw off. Suitable shower mixing valves

are manufactured by :

Caradon Mira Ltd Cromwell Road, Cheltenham Gloucester GL52 5EP Tel : 0242 27953

Barking Grohe 1 River Road Barking Essex IG11 OHD

Tel : 081-594-8898

HOT WATER

COLD WATER

(iiii) If the appliance is installed on a supply or distribution

pipe containing a non-return valve, combinations of check

valve, or any equipment containing such devices, then

provision must be hade to accomodate an expansion of at least 4 % of the volume of water contained within the installation.

(V) Expansion vessels must be fitted on the supply pipe betweenthenon-returnvalve,combinationsofcheckvalve, or any equipment containing such divices. and the appliance.

Aqualisa Products Ltd Horton’s Way London Road

Westerham

Kent TN16 IBT Tel : 0959 63240

New Team Ltd Brunell Road Earlstree Ind Estate, Corby Northants NN 17 2LF

Tel : 0536 62822

Page 12

COMMISSIONING

5.1

Putting into Service

51.1. Open the gas and water service cocks beneath the appliance, purge the gas supply (BS 6891 : 1988). Turn on an adjacent tap and purge the water side of the installation.

Test for water soundness at all appliance and external

pipework connections.

Switch on electrical supply, fan will run at low speed.

5.1.3. To light the pilot temporarily fit the gas control knob (A) and light the pilot byturning the knob 90” anticlockwise. It may be necessary to purge the pilot gas supply, if so, wait a few minutes, return the gas control knob to the OFF position and repeat. (The pilot supply will only purge when the gas control knob has been turned 90” anti-klockwise).

5.1.4. When the pilot is lit turn the control knob (A) fully anti-clockwise as shown in the diagram. Test for gas soundness using leak detection fluid on all gas connections

5.1.5. Check the operation of the flame supervision device by blowing out the pilot light, the flow of gas to the pilot will cease and the thermoelectric valve should drop out with an audible ‘click” within approximately 30 seconds.

5.1.6. Re-light pilot and check gas pressures see Section 5.2.

5.1.7. Remove gas control knob (A).

5.1.8. Switch off electrical supply.

5.1.9. Fit front case by locating bottom first and ensuring top of case locates over bracket. Secure with 4 screws and washers previously removed.

- The centre screw and plastic washer retains the fascia mounting bracket.

- Replace the control fascia plate by sliding down

onto the support bracket.

- Fit bottom trim by sliding onto rails.

- Fit the gas control knob (A) and the temperature

selector knob (B). The temperature selector knob should be pushed onto the spline until it locates. Turn fully clockwise to (+), reposition knob as required, so that indicator dot is opposite the (+) sign.

5.1.10. Switch on electricial supply.

- Light the pilot and turn gas control knob (A) fully anticockwise to, the main gas position.

- If the pilot is now extinguished for any reason return the gas control knob to the OFF position and wait approximately 30 seconds for the safety interlock to reset before repeating.

5.1.11. Perform operations as detailed in sections 5.3

to 5.7.

Page 13

Gas Pressures

- Turn on an adjacent hot water draw off, the appliance will now light and the fan will change to high speed.

- Check burner setting pressure at test point A see Section 1.3. technical data.

- If the burner setting pressure is not correct, check that the pressure at the gas service cock, test point B is 20

mbar (8 in.w.g.) with the appliance operating. If the inlet pressure is not correct, check for any possible blockage or restriction in the pipework to the appliance. If the inlet supply pressure cannot be corrected contact your local gas region. The heat input to the appliance is pre-set and non-ajustable.

5.3

5.4

Slow Ignition

- Check burner ignition which should be smooth and quiet (not explosive).

- If slow ignition requires adjustment proceed as in Section 6.1 to remove front case.

Adjust slow ignition device l/4 turn at a time. Refit front case and recheck operation.

NOTE : Turning screw A clockwise delays ignition.

Microswitch

NOTE: During Commissioning it is important that the correct operation of the microswitch on the side of the gas section is checked.

Whilst the microswitch is factory set, it may require adjustment. When the appliance is at rest the fan runs continuously at low speed. Check operation as follows - set temperature selector to Othen open draw-off. The fan should now come to high speed before the burner ignites. On closing draw-off, the burner should extinguish before the fan resumes at low speed. If fan/burner operational sequence is NOT as described see Section 7.13.

5.5

The Pressure Switch

Check the operation of the pressure switch as follows : Open draw off, fan comes to high speed and the burner ignites. Close draw off, burner extinguishes and when fan resumes at low speed listen for the ‘click’ as the relay changes over. This should be followed within 15 seconds by a lighter ‘click’ as the pressure switch changes over. If the time separation is greater than 15 seconds or if the pilot extinguishes it suggests that the pressure switch is incorrectly set. See Section 7.11,

Page 14

5.6

Thermoelectric Circuit

The Thermocouple Circuit is fitted with an interrupter so that if the air flow is not proved on high speed the circuit is

incomplete and the flame supervision device will operate. In the case of intermittant pilot failure or permanent pilot

failure the termocouple circuit can be checked with a British Gas Multimeter or suitable Millivolt Meter to determine

if the pilot failure is due to poorthermocouple output, high resistance through Relay-l contact orfaultythermoelectric

valve. (See Section 2.9 Fig. 1). The thermocouple output measured at the Printed Circuit Board terminals should be greater than 12 millivolts.

The millivoltage drop through the relay (i.e. terminal to terminal) should not be greater than 4 millivolts.

5.7

Handing Over

Hand all instructions to the user or purchaser and instruct in the correct and safe operation of the appliance. Explain to the user or purchaser that if the appliance is not used for long periodsit is recommended thattheappliance

is drained, this is particulary important during the winter months (see servicing instructions for procedure to drain appliance).

Finally, advise the user or purchaser that, for continued efficient and safe operation of the appliance it is important that servicing is carried out annually to the manufactures recomendations by a C.O.R.G.I. registered person.

Page 15

SERVICING INSTRUCTIONS

Before commencing any service work :

1. Isolate electrical supply.

2. Remove bottom trim by sliding forward.

3. Turn off gas at gas service cock.

4. Turn off water at water service cock.

5. Drain the appliance by opening hot water outlet tap and removing drain plug in the water service cock

6.1

6.2

Front Casing

Burner

m .

il.Iz

To remove :

- Pull off gas control and temperature selector knobs.

- Remove controls facia plate by sliding upwards.

- Remove the four fixing screws which secure the front case (top, bottom and centre) taking care not to lose facia retaining bracket and washers.

- Remove the front case by lifting off the to locating

lugs and pulling forward to clear the water section

at the base of the appliance.

- Remove the combustion chamber front panel as follows.

- Remove two threaded screws which secure the front panel of the combustion chamber skirt to the flue hood (A) Section 6.4.

- Remove three self-tapping screws on either side of combustion chamber skirt (B) Section 6.4.

- Unscrew the pilot tube clamping screw (A) and remove the clamp and screw and pilot tube.

- Remove the burner manifold by unscrewing the two screws (B) and two screws and washers 0.

- Withdraw the burner head assembly taking care not to damage the pilot burnerielectrode assembly or the ignition lead

- The burner head should be turned upside down and cleaned by brushing.

- Replace in reverse order making sure that the gasket between the burner manifold and gas section is in place and is in good condition. If necessary replace gasket and ensure that the burner head assembly is correctly located on the two spigots at the rear.

6.3

Pilot

- Remove combustion chamber front panel, burner and pilot tube as in 6.2 if not already removed.

- Blow through the tube to remove any dust.

- Remove screw securing spark electrode. Lift out of ‘D’ slot and ease to one side.

- Unscrew the knurled pilot burner outer ring (A).

- Remove flame retention gauze.

- Unscrew the pilot body (B1 with a 15 mm spanner. Clean by brushing and blowing.

DO NOT CLEAN HOLES WITH A WIRE.

- Re-assemble in reverse order ensuring pilot body is screwed down tightly.

Page 16

6.4

Heating Body

a) The heat exhcanger can be examined in posi-

tion :

Remove combustion chamber front panel as in Section 6.2 if not already removed. Prior to cleaning the heat exchanger adequate precaution should be taken to protect the pilot burner/gas val-

ve assembly to prevent the ingress of dust etc.

If extensive cleaning is necessary, the heat exchan-

ger will need to be removed asfollows.

bl To remove heat exchanger

- Slide out combustion lining and retain.

Disconnect the unions on either side of the heat

exchanger.

Remove two screws securing the combustion chamber/heating body assembly to the rear panel.

Remove heat exchanger and combustion chamber.

Remove two screws at the rear of the combustion chamber securing the combustion chamber to the heat exchanger to seperate the components.

Care should be taken when handling the heating exchanger to ensure that the fins are not damaged.

- Replace in reverse order.

6.5

6.6

Descaling

PeriodIcally it may be necessary to remove scale deposits from the waterways of the appliance to ensure continued and efficient operation.

The frequency will depend largely on the hardness of the water in each specific area. If this is necessary contact your local water authority for advice.

Advice with regard to descaling is available from Chaffoteaux Ltd.

Main Gas Valve

To inspect and clean

Remove the burner (see Section 6.2)

- Disconnect the thermocouple at the PCB and ignitor lead from the piezo unit.

Remove the four screws and washers fastening the top of the gas section to the base and the two screws at the back holding it to the rear case.

Lift the gas section top off the base, taking care

not to damage the cork gasket.

Remove the hexagonal spring retainer (A) from the

top of the assembly (20 mm).

Remove the spring and gas valve and clean the Valve seating (B).

Renew facing rubber washer on the gas Valve if necessary.

- Grease spindle see Section 6.11

- Replace in reverse order,ensuringthatthe hexagonal

Spring

retaining nut is screwed fully down,

- DO not change the setting of the valve body

Page 17

6.7

spindle (see section 6.6)

6.8

Water Governor

Gas and Water Filters

To clean

-. Turn off the cold water supply to the appliance and drain into receptacle.

- Remove the governor situated in the base of the water section. (A)

- Clean the components with water and grease see Section 6.1 1

- Check that the spring loaded piston moves freely.

- Replace in reverse oder.

Gas and water inlet filters are fitted between the inlet service cocks and the appliance.

- To clean, turn off the gas supply at the meter and the service cocks, unscrew the union nuts attaching the cocks to the appliance and remove the filters.

- Clean the filters by blowing or washing in water. DO NOT USE ANY SOLVENTS.

- Replace ensuring that the coarse filter is fitted in

the water inlet and the fine filter in the gas inlet.

- Turn on the gas supply and open both water and gas service cocks.

- Test for soundness.

6.9

6.10

6.11

6.12

Microswitch

The microswitch operating mechanism is factory set and if the microswitch requires see Section 5.4 and proceed as in Section 7.12 and 7.13.

EplUCement

or adjustement

Pressure switch

The pressure switch is factory set and if the pressure switch requires adjustment or

and proceed as in Section 7.10 and 7.11.

replUCement.

See Section 5.5

Greasing of Components

Care should be taken during the annual service of an appliance to grease the gas valve spindle (see Section 6.6) water Govenor (see Section 6.7) and the bearing plate spindle (see Section 7.5). Use silicone grease.

Heat Input

It is a requirement of the Gas Safety (Installation and Use) Regulations 1984 that the burner pressure and gas rate are checked each time an appliance is serviced, likewise the service engineer should satisfy himself with regard to gas soundness and the adequacy of combustion and ventilation air if this IS appropriate.

The heat input is preset and non-adjustable. The heat input and burner pressure should be checked (See Section 1.3). If the heat input/burner pressure is not correct check the working pressure at the pressure test point on the gas

service cock. This should be 20 mbar (8 in wgl. The gas installation should be examined for any possible blockage if the pressure is incorrect.

Page 18

REPLACEMENT OF COMPONENTS

Remove the burner (see section 6.2)

Before commencing any work involving component replacement :

Isolate electrical supply.

?. Turn off gas at the gas service cock.

3. Turn off water at the water inlet cock.

4. Drain the applrance by opening hot water outlet tap and removing the drain plug in the water service cock

5. Remove the front casing (see Section 6.1).

7.2

Thermocouple

Spark Electrode

- Remove the burner (see Section 6.21.

- Remove the pilot (see Section 6.3).

- Trace the thermocouple and disconnect at the terminal on the PCB.

- With a 7 mm boxspanner, unscrew the nut (B) holding the thermocouple into the gas section.

- Thread the thermocouple and wire up through the gas section.

Replace in reverse order.

- Remove the burner (see Section 6.2).

Remove the electrode retaining screw (A)

- Pull off the electrode cable from the piezo cartridge.

- Lift the electrode out of the gas section.

- Re-assemble in reverse order, and note that the slot in the connector on the end of the electrode cable is vertical when pushed onto the cartridge.

NOTE : Spark gap is 3-5 mm

7.3

Thermoelectric valve

To renew, remove the thermocouple conductor

lead nut (Al.

Unscrew cap (B) from the side of the gas section

and withdraw the thermoelectric valve.

NOTE - This heater is fitted with a safety interlock. When the pilot is turned off, the appliance cannot be

relit until the thermocouple cools down and the ligh-

ting sequence is repeated.

Page 19

Diaphragm

To renew ensure that the cold water supply and gas are turned off.

- Drain the appliance by removing the water governor plug situated in the base of the water section.

- Disconnect the two water connections at the water section.

- Unscrew the six screws (A) which hold the water section to the gas section.

- Remove the water section complete with the dia-

phragm. Remove bearing plate and spindle and grease, see

Section 6.11

- Carefully remove and inspect the plastic water section top cover.

- Re-assemble in reverse order Note,: Fit the water govenor last. It is easier if the

cold water inlet connection is partially engaged before fitting the screws and reconnecting the

union nuts.

7.6

Pie20 Unit Cartridge

Fan Assembly

EARTH

Y&W

- Green

BROWN (High Speed)

ed)

Disconnect the spark electrode lead from the piezo unit cartridge.

Remove the screw holding the gas control cam and remove the cam (A).

Remove the two screws (B) holding the retaining plate.

Remove the piezo cartridge and renew.

On reassembling ensure that the locating pins on each end of the spring are correctly engaged in

their location holes.

Disconnect electrical connectors from assembly. Note positions.

Remove the two screws and washers (A) securing the fan assembly to the flue hood.

Release wiring loom from support

Gently ease the fan assembly away from the flue hood disengaging lug at rear of fan assembly.

Re-assemble in reverse order.

NOTE : The dimension - back plate to front face of impellor is : - 57.5 mm + 0.5 mm - 0.0 mm

Clip.

Red

Page 20

7.8

To Replace Fuse or PCB

Isolate electrical supply. (A) FUSE : - Pull out fuse holder (A) from board and

(B) PCB

slide fuse out of holder.

: - Remove connections (fan, microswitch,

pressure switch)

Disconnect mains supply cable from terminals.

- Remove two nuts and washers (B) retaining thermocouple and conductor lead.

Remove fuse and ease board from plastic retaining clips.

Remove four screws and remove PCB.

- Re-assemble in reverse order.

7.10

7.11

To replace pressure switch

Isolate electrical supply.

Remove two screws securing

Pull off tag connectors from terminals.

Remove low pressure tube from pressure switch.

Remove two screws securing pressure switch to bracket.

PIaSk

turret cover.

Lift off pressure switch dis-engaging it from the high pressure tube.

Remove “0” ring fromspiggot on the underside of the pressure switch.

- Replace in reverse order referring to colour coding label on top of appliance.

Adjustment of pressure switch

a) If pilot extinction occurs within 10 seconds of turning the hot tap off, it is possible that the pressure switch is out

of adjustment, as if the pressure switch remains in the high flow position in excess of 10 seconds after the fan switches to low speed interruption of the current to the thermoelectric

It is possible to adjust the pressure switch to ensure a rapid return

Adjustment Sequence :

b) If main burner extinction occurs during hot water demand, it is possible that the pressure switch is out of ad-

justment. Screw adjusting screw (A) out until flush with top of moulding, then follow adjustment sequence above.

Adjusting the pressure switch.

Ensure the front case is on. Isolate electrical supply. Remove two screws securing plastic turret cover and

lift off cover. Remove terminal cover from pressure switch exposing

the adjusting screw (A) and remove securing paint.

- Set a multimeter to 240V scale and connect it

across the common and one other terminal of the switch.

Re-establish electrical supply and ensure that gas is

off at gas control.

Turn on a hot tap to give high fan speed.

Using a suitable screwdriver screw the adjusting screw (A) in until changeover of the pressure switch contacts are observed.

Screw out adjusting screw (A) 3 turns to achieve the setting point.

Check operation of the pressure switch (see section 5.5).

Replace the plastic terminal cover on the pressure

switch.

Replace the plastic turret cover and fixing screws.

Valve OCCUIS.

from

high to

IOW flow.

Page 21

7.12

Replacement of Microswitch

- Isolate electrical supply.

- Part connector plug on leads to microswitch.

- Remove two lock nuts (4 mm) from microswitch retaining screws. (C)

- Remove screws securing microswitch.

- Remove switch together with plastic insulating plate.

- Renew microswitch and replace in reverse order.

7.13

7.14

Adjustment of Microswitch operating mechanism

- Re-establish electrical supply - leave gas cock and hot water taps off. Temperature selector can be set in any position.

- Slacken locking screw (6) see diagram in 7.2 - using 1,5mm hexagon key.

- Turn adjusting screw (A) anti-clockwise until high speed fan operation is obtained. The fan should now be at high speed.

- Turn adjusting screw clockwise slowly until low speed fan operation is obtained.

- Continue turning adjusting screw clockwise for a further 1 turn.

- Tighten locking screw.

- Check operation of microswitch (see section 5.4).

To replace the Gas and Water Section

Remove the burner see 6.2.

Disconnect microswitch by parting plug connector on leads.

Remove the conductor lead at thermoelectric valve (see Section 7.3).

Remove thermocouple lead at PCB.

Remove spark electrode lead from piezo cartridge (see Section 7.6).

Disconnect the gas union at rear of gas section.

- Disconnect the water connections from the water section these are the mains inlet and water SeCtOn to heating body.

- Remove the two screws securing the burner base to the rear chassis.

- Re-assemble in reverse order.

7.15

To replace Ceramic Liners in Heating Body

Remove the burner (see Section 6.2).

Remove two threaded screws (A) (Section 6.4). which secure the top front panel of the heating body to the

flue hood.

Remove six self tapping screws (B) (Section 6.4), from front panel of heating body.

Slide out front and side ceramic liners from locating channels.

Ease heat exchanger forward to allow rear ceramic liner to be lifted clear of lower channel.

Lift panel and withdraw lower edge first.

Re-assemble in reverse order.

Page 22

FAULT FINDING CHART

8.1.

8.2.

8.3.

8.4.

PROBLEM

Pilot does not light

Poor Pilot Flame

Pilot only

Pilot will not stay alight

CAUSE

i) Gas service cock closed

ii) Air in pipe

iii) Pilot injector blocked

iv) No ignition spark

i) Pilot injector dirty

ii) Wrong injector

iii) Pilot head blocked

iv) Faulty pilot tube

v) Pilot injector loose

i) Micro switch out of adjustment

i) Pilot flame poor

ii) Fan running at high speed

iii) Thermocouple not working

iv) Thermoelectric valve faulty

v) Gas pressure low/variable

vi) Terminal wrongly positioned

vii) Badly assembled flue

viii) Pressure switch out of adjustment

ix) Pressure switch faulty

x) Plugs loose on PCB

xi) PCB faulty

REMEDY

Open sewice cock Purge line Clean or change

Check electrode, lead and ignitor

Clean or change Change for correct diameter (0.23) Clean Clean or replace Tighten

a) Check micro switch high speed operation, see Section 5.4

b) Adjust micro switch, see Section 7.13

(See 8.2) Above (See 8.3) Above a)Check connection clean and tighten as necessary b) Replace it output less than 8 mv. Replace if drop out greater than 5 mv. Check at inlet to appliance (see 5.2) Re-position (see 2.4) Re-fit check sealing a) Check operation (see 5.5) b) Adjust (see 7.11) Replace (see 7.10) Secure Replace (see 7.8)

8.5.

8.6.

Main burner does not light

Burner goes out on hot water demand

i) Gas service cock not open fully

ii) Gas pressure low

iii) Water flow rate low

iv) Gas valve not opening

v) Diaphragm punctured

vi) Venturi blocked or loose

vii) Gas control tap faulty

viii) Slow ignition device screwed

fully home

i) Fan not switching to high speed

ii) Pressure switch out of adjustment

iii) Low pressure tube detached

iv) High presssure tube blocked

v) Flue blocked

vi) PCB faulty

Open fully Check at manifold and at inlet with the apppliance running (see page 3 and 5.2) Check if water rate is sufficient (see page 3) Check (v) and (vi) Change diaphragm (see Section 7.5) Check venturi Check operation of User’s gas control tap

Adjust (see 5.3)

a) Check micro-operation (see 5.4) b) Adjust micro-switch (see 7.13) c) Micro-switch defective -

replace (see 7.12) d) Fan defective - replace (see 7.7) a) Check pressure switch operation (see 5.5) b) Adjust pressure switch (see 7.11) c) Pressure switch defective replace (see 7.10) Refit or replace (see 7.10) Check and clean (see 7.10) Check and clear, and ensure that the flue declines from appliance (see 3.2) Replace (see 7.8)

Page 23

FAULT FINDING CHART

8.7.

8.8.

8.9.

8.10.

PROBLEM

Explosive ignition

Gas control tap stiff

(User’s)

Low Water Temperature

Burner stays on

CAUSE REMEDY

i) Pilot too small

ii) Slow ignition not adjusted

i) Grease dried

ii) Operating mechanism replaced

incorrectly

i) Water rate too high

ii) Insufficient gas flow

iii) Water governor sticking

iv) Incorrect venturi

v) Main burner injector dirty

i) Air in pipework

ii) Gas valve stays open

iii) Dirt on gas valve facing

iv) Dirt or foreign matter

in water section

v) Loose jumper on house

stock cock tap

VI) Check-valve fitted on supply pipe

Check pilot tube and injector Check and adjust (see 5.3)

Clean and regrease Refit

Check water governor Check rate and if user’s tap is open Remove and clean or replace (see 6.7) Replace (3.65 mm) (see Section 7.4) Clean or replace (see Section 6.2)

Check for dead legs Clean and grease gas spindle Strip and clean gas valve (see Section 6.6)

Clean water section Replace water stop tap or pin down jumper See Section 4.1

8.11.

8.12.

8.13.

8.14.

8.15.

Yellow Flames Soot Formed

Unstable Flame

Heating Body Noise

Fan Noisy

Insufficient Water

i) Heating body fins blocked

ii) Primary air supply restricted

iii) Wrong injectors

i) Fan not switching to high speed

ii) Water in gas line

iii) Faulty flue

i) Scale

ii) Excessive gas

iii) Insufficient water flow

i) Fan remaining at high speed

ii) Fan out of balance

i) Water service tap closed

ii) Blocked venturi

iii) Low water pressure

iv) Water governor faulty

v) Water governor sticking

vi) Foreign matter in water section

vii) Water filter blocked

Remove heating body and clean (see 6.4) Check burner manifold and clean (see 6.2) Check injector sizes and gas rates (see Section 1.3) technical data

See section 8.6 Drain and purge Check terminal position and flue ducts (see Section 3.3)

Descale heating body Check gas pressure (see 1.3 and 5.2)

See Section 8.15

See Section 8.3

Replace (see 7.7)

Check it is fully opened (see 3.5) Remove and clean venturi (see 7.4) Check water pressure (see Section 1.3) Change governor Remove and clean or replace (see 6.7) Remove and clean (see Section 7.4) Remove and clean/replace (see 3.5)

Page 24

Ref. 91220-i 68a-02/92

Imp. SH

Chaffoteaux & Maury Britony FlexiFlue Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL

INSTALLATION REQUIREMENTS

INSTALLING THE APPLIANCE

APPLICATIONS OF THE BRITONY FLEXIFLUE

COMMISSIONING

SERVICING INSTRUCTIONS

REPLACEMENT OF COMPONENTS

FAULT FINDING CHART