Chaffoteaux & Maury Celtic FF Installation And Servicing Instrucnions

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Page 1

Celtic

ROOM SEALED FANNED BALANCED FLUE

COMBINATION BOILER

G.C.

No.

47 980

FROM SERIAL N” 391061863

This appliance has been tested and certificated by British Gas

(For use on natural gas only)

I lil Ill

Installation and

Servicing Instructions

(leave these instructions with the user)

Looking Good. Heating Better

Page 2

The CELTIC FF is a wall mounted, low water content fan-

ned balanced flue appliance suitable for central heating and hot water via a non storage wapr to water heat exchanger. The maximum out pufis24.0 kW (81,900 Btu/h).

The boiler is designed for sealed systems only and included in the appliance is the expansion vessel, circulating

pump, temperature and pressure gauges, safety valve

and electric connection box. The flue which is 100 mm (4 in) dia pipe, can be directed to the rear or to the left or right and can be extented to a

maximum length of 3 m, or 1.6 metres horizontally using the

available 90” bend (see sections 1.4.1, 1.4.2 and 1.4.3

figures 2.3.3a. 3b, 3~).

Special features include :

-Output to central heating fully range rated between l/3 and full output.

- High efficiency.

-Special jig plate enabling all pipework to be installed before installing appliance.

- Independent control over central heating flow temperature and hot water.

- Fully adjustable central heating flow temperature.

- regulation between 50” C and 82” C.

- High limit thermostat for both boiler and hot water.

- Integral frost thermostats to protect appliance.

-Water flow switch to protect appliance.

-Suitable for showers with mixer valves which are compatible with water heaters.

Guarantee

The manufacturer’s guarantee on this appliance is for 12 months from the date of installation. The guarantee is void ; if the appliance is not installed in accordance with the recommendations made herein.

1.1

DIMENSIONS

1 I ’ I

REAR OUTLET

/ T

SIDE OUTLET

B C D

F c

mm in

820.5

32.3

391.0

15.4

365.0

14.4

100.0 4.0

169.5 6.7

654.5 25.7

43.0 1.7

50.0 2.0

75.0

3.0

260.0 10.2

150.0 6.0

972.5

38.3

13.0 0.5

61.0 2.4

30.0 1.2

152.0

6.0

112.0

4.4

Page 3

1.2 Technical Data

Hot water

Input

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

output

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

Water flow rate raised 45” C (81” F)

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

Water flow rate raised 30” C (54” F)

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

Maximum temperature

.......

Maximum pressure

..........

Minimum working pressure.

...

Gas rate

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

Burner pressure

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

Central heating

Maximum input.

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

Maximum output

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

Gas rate (maximum)

..........

Burner pressure

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

Minimum input

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

Minimum output

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

Gas rate (minimum)

..........

Burner pressure

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

Minimum flow rate

...........

Maximum pressure

..........

Manifold injectors 14 off

......

Pilot injector

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

Manifold restrictors 213 valve

l/3 valve.

28.41 kW

j6.940 Btulh

24.0 kW

II ,900 Btu/h

7.6 L/min

1.7 gal/min

11.4 L/min

2.5 gal/min

60” C

140” F

10 bar

150 psi

1 bar

15 psi

2.7 m3/h

95.35 ft3/h

12.5 mbar

5.0 in wg

28.41 kW

,6.940 Btu/h

24.0 kW

II ,900 Btu/h

2.7 m3/h

95.35 ft3/h

12.5 mbar

5.0 in wg

11.6 kW

39580Btulh

8.0 kW

17.300 Btu/h

1 .O m3/h

35.31 ft3/h

1.5Tbar 0.6 in wg 300 L/h

1 .I gal/min

3.0 bar

44 psi

Natural gas

1.28 mm

0.05 in

0.3 mm

0.01 in

4.5 mm

0.18 in

2.3 mm

0.09 in

1.3

Minimum clearances around Boiler

Top above air duct 50 mm (2 in) Bottom below case 200 mm (8 in) Sides

100 mm (4 in)

Front 600 mm (24 in)

1.4

Wall Thicknesses

Connections

Gas .._..............

22 mm copper

Heating flow

22 mm copper

Heating return ..__. _............

22 mm copper

Mains cold water inlet

15 mm copper

Hot water outlet

15 mm copper

Electrical supply 240 V - 50 Hz, fused at 3A. Electrical input

195 watts

Internally fused, two at F2A (BS 4265)

Weight .._. _..........

Watercapacity _......... _..........

I ,“iiZs I 1;::

Ignition

- Anstoss continuous spark generator

Electrode

- Chaffoteaux Ltd. spark gap 5 mm

Boiler thermostat -

EGO (82” C)

Boiler limit thermostat -

Sopac (85” C)

Hot water limit thermostat -

Sopac (57” C + 3” C)

Safety overheat thermostat Tokoswitch -

(105” C)

Frost thermostats Elmwood

- (3” C and 11” C)

Gas valve

- AEMF

Fan motor -

SEL

Pressure switch

- Dungs

Pump head

-Grundfos UP 15/60

Expansion vessel initial charge pressure

- 0.65 bar (9.6 PSI)

The standard flue assembly can accomodate the following thicknesses.

Rear : from 55 mm to 576 mm Side : from 55 mm to 392 mm (This allows for a minimum clearance of 100 mm between the appliance and the side wall. As this dimension increases, so the maximum side wall thickness available decreases). Extention flue assemblies are available to accomodate wall thicknesses of :

Rear : from 577 mm to 2876 mm Side : from 393 mm to 2692 mm

See figs. 2 and 3 for details of number of extensions required.

IMPORTANT NOTE

: The extension ducts supplied, up to a maximum of 3, will in fact permit a greater length than

indicated to be covered. The ducts MUST be cut so that the maximum length from the centre line of the flue turret

to the outermost point of the air duct DOES NOT EXCEED 3 metres. Greater length must not be used.

Page 4

1.4.1

1.4.2

Side Flue Outlet

To cut flue assembly to length

- Measure from external wall face to centre line of

external

internal

Celtic and subtract 37 mm (this will give required

wall face

length ‘I”).

IL) L 50

- Cut off surplus from plastic air duct (plain end).

mm,

N-6. If extension sections are used ensure these are

.-I 1

*j -_--- )--

“--P,

--t-l-f-

firmly pushed together.

- Cut same amount off aluminium flue duct (plain

L-&L- 7

end).

Flue extension accessory

Par-t NO. 61061

700 mm max. (standard length)

(I metre length)

q 1 1

13mm

-I /y/q-

55 mm 1

9 I

r--

295 ’ mm

min

min.

Fig. 3

SIDE OUTLET ASSEMBLY

cut off

from this end

I-

_ - _I

<- 7,

I I

-----c

standard 2 part flue duct

Fig. 3a

PLASTIC AIR DUCT ALUMINIUM FLUE DUCT Fig. 3b

1.4.3

Other flue arrangements

Rear Flue Outlet

To cut flue assembly to length

- Measure wall thickness (T).

- Add 74 mm, this will give required length CL).

- Mark plastic air duct for length (L) and cut off surplus (from plain end).

N.B.

If extension sections are used ensure these are

firmly pushed together, see figs. 3b and 3c.

- Cut off same amount from aluminium flue duct (plain end).

Flue extension accessory Part No. 61061

(I metre length)

Fig. 2

REAR OUTLET ASSEMBLY

Distance from internal corner 300 mm without

kit, 150 mm with kit no. 76216 (GC No, 264 833).

L”E

? 5

OE L”E

Fig. 3c

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 horizontally.

Page 5

1.5 Description

Fig. 4

The appliance is mounted in a steel case which has a white epoxy resin paivt finish.

1. Chassis :

The chassis is a rigid plated mild steel pressing on which all components are mounted.

2. Flue hood :

Is an aluminium alloy casting onto which the two speed fan is mounted.

3. Combustion chamber :

This is assembled from a number of components mounted onto the chassis. The front panel is simply removed for servicing complete with the expansion vessel, hooks are fitted below the appliance to accept and retain the

panel during servicing.

4. Expansion vessel :

The expansion vessel has a capacity of 5,4 litres (1.19 gal) and is sized for a normal system water content where the-load is equivalent to the maximum output of the boiler. The charge pressure is 0.65 bar.

5. Pilot security

is by thermocouple flame failure :

6. Multigas burner cbmprising

: stainless steel blades

(14) and a manifold with injectors (14).

7. Gas section

including thermoelectric valve and two

stage valves.

8. Secondary heat exchanger :

The secondary heat exchanger is a plate type heat exchanger. A thermostat is fitted on the pipework limiting the domestic hot water temperature to a maximum of

5733” c.

9. Change over valve :

The valve is activated by a demand for domestic hot water, closes the heating circuits, and directs water to the secondary heat exchanger.

10. Electricial box containing :

Mains connection Fuses Printed circuit board Connections for external controls Connections for fan, pressure switch and Flow Switch Connections for pump

11. Solenoid valve :

Block on which 3 valves are mounted : l/3 valve - 1st stage valve-heating and hot water (blue)

2/3 valve - full output to hot water (black) 2/3 valve - (variable valve) central heating (orange).

12. Grundfos pump motor

13. Air separator and vent

directly connected to the

pump inlet (not illustrated).

14. Regulation screw

to adjust output to heating (2/3

valve).

15. Heating body comprising :

Copper finned tube heat exchanger protected with silicone resin paint. Combustion chamber in aluminium coated steel. Combustion chamber lining - ceramic fibre panels.

16. High limit thermostat.

17. Water service tap

(not illustrated)

18. Flow isolating valve

- heating (not illustrated).

19. Gas service tap

(not illustrated).

20. Domestic hot water outlet

(not illustrated).

21. Safety valve with drain tap

(not illustrated)

22. Heating return isolating valve

with filter (not illus-

trated).

23. Ignition button.

24. Thermometer

indicating boiler flow temperature

25. Temperature selector

for domestic hot Water

26.

Selector switch

- hot water only/OFF/heating and

hot water.

27. Thermostat to regulate heating

flow temperature.

28. Pressure gauge.

29. Pressure switch.

30. Integral frost thermostats.

31. Water flow switch.

Page 6

1.6 Description of Operation 1.6.3 Hot Water

(see

fig. 6)

1.6.1

The Celtic FF is a dual purpose or combination boiler providing central heating and hot water. Hot water is provided on a demand basis. For the duration of the demand for hot water the central heating is interrupted.

The appliance operates in two modes. A hot water only setting where it operates only on hot water demand and a hot water + central heating setting providing central heating and switching to hot water on demand.

1.6.2

Central Heating

(see

fig.

The pump (21) circulates water which returns to the

boiler via the return valve (31) which incorporates a filter

(30). Before reaching the pump it passesthrough an air separator and air purger (17). The return water passes through the heat exchanger (2) where it is heated. It then pcsses through the change over valve (19) which

in heating mode is in its rest position (fig. 3) and out via the flow valve (27) to the radiator circuits (34).

The boiler thermostat (8) controls the temperature of the circulation water between a minimum of 50” C approx and a nominal maximum of 82” C. The boiler thermostat also controls the opening of the l/3 (I I) and variable solenoid valve (IO).

The limit thermostat (16) set to 85” C closes both so-

lenoids valves in the event of its set temperature being reached as could occur under the low flow conditions.

The boiler is protected by a high limit thermostat (4) the operation of which interrupts the thermocouple

and extinguishes the pllot. If the high limit thermostat operates it is necessary to manually re-establish the oilot

When there is a demand water flows through the water section part (35) of the change over valve (19). The inclusion of a venturi (24) produces high pressure under the diaphragm (231 causing it to rise. This movement IS transmitted to the change over valve closing the heating port and opening the hot water port, as shown (20). The primary water heated by the boiler now passes through the water to water heat exchanger (18) where it flows through alternate plates indirectly heating the DHW.

The rising of the change over valve spindle causes :

The opening of a microswitch stopping the pump.

This circuit is remade by a second microswitch

making when the hot water port is fully open.

2. The by-passing of the boiler thermostat brings the boiler under control of a fixed temperature thei-mostat (32) which operates on the 2/3 fixed solenoid (12).

3. The selection-of the ‘l/3 valve and the fixed 213 valve.

The water temperature is under control of the user and the opening of the regulator (25) increases the flow of the water and thus reduces the temperature.

When the regulator is closed - hottest setting, lowest flow - a limiting thermostat (32) prevents the secondary hot water temperature exceeding 60” C by cycling the solenoid valve without interrupting the flow of water.

CENTRAL HEATING

‘I-1 1

Fig. 5 Ll

‘I-1 1

HOT WATER

:ig. 6

Page 7

1.6.4

Gas (see figs. 5 and 6)

1.6.5

When the main gas tap (33) is turned to the on position gas is admitted to the gas section (7). Pressing the ignitor button (9) operates a microswitch causing the commencement of a firing cycle. The fan changes from low to high speed and after a purge period of approx 14 seconds a continuous stream of sparks are delivered lighting the pilot gas (3). Simultaneously, the thermoelectric valve (14) is opened and after a further 5 seconds, sufficient energy is being produced by the thermocouple (5) for the thermoelectric valve to be retained in the open position.

When the ignitor button is slowly released gas is admitted to the underside of the solenoid valves (IO, 11 and 12).

There are 3 solenoid valves (I) the centre (blue) valve (11) fixed at l/3 of max rated output, (2) the right hand hot water (black) valve (12) fixed at 213 of maximum rated output, (3) the left hand central heating (orange) valve (IO) which is variable up top 2/3 maximum rated output.

The gas admitted by the orange valve is varied by ad-

juster (6).

FUNCTIONAL FLOW DIAGRAM

1 Switch 1 1

S$Toff

1 \siq

S!!h 1

Pressure

over

Switch on

Valve

11°C

- Frost Thermostat

Limit

Boiler 82°C

Control

Thermostat

113 C Blue

Solenoid

Fig. 7

1.6.6 Safety Controls

In addition to the normal safety controls the CELTIC FF incorporates the following features.

Should the central heating water flow reduce to below 300 L/h (1.1 gal/min) the gas supply to the burner is turned off, see figs 3 & 4 (36).

Built in boiler protection is provided by turning the burner and pump on if there is any risk of frost damage.

Page 8

OR.

ORANGE

GN. GREEN YELLOW

BLUE

R. RED

IGNITION BUTTON

SELENOID VALVE

BK.

BLACK

v. VIOLET

BR.

BROWN

W WHITE

BOILER TH. HOT

WATER

8. BK. 213

240V .1-I. 1

III 2

EXTERNAL

CONTROL

PRINTED CIRCUIT

B & R B’

240 V, -

SELECTOR SWITCH

r-4

I -

u WATER FLOW 1

24V

1 e)L- xwITCH Or E Bk

’ ‘Ll

FAN

CAPACITOR/

PRESSURE SWITCH

I 3

BOILER THERMOSTAT

HEATING

Fig. 9

ILLUSTRATED WIRING DIAGRAM

Page 9

INSTALLATION REQUIREMENTS

2.1 General

The installation of the boiler must be in accordance with Gas Safety (Installation and Use) Regulations 1984, Building Regulations, current I.E.E. Wiring Regulations and the Byelaws of the Local Water Undertaking. It should be in accordance also with the

BS Codes of Practice and the British Gas Specifications for Domestic Wet Central Heating Systems and any relevant requirements of the local Gas Region and Local Authority Building Standards (Scotland) Regulations.

Detailed recommendations are stated in the following

British Standard Codes of Practice : BS 6891 : 1988, BS

6798 1987, BS 5440 1979, BS 5440 : 1 1990 and 2 : 1989, BS

5449 : 1 1990.

Note : Gas Safety Installation and Use Reg 1984. It is

thelawthatallgasappliancesareinstalledbyC.0.R.G.I.

Registred 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.

2.2 Location

The boiler is not suitable for external installation. The position chosen for the boiler must permit the provision of a satisfactory flue termination. The location must also permit adequate space for servicing and air circulation around the boiler. The surface on which the boiler is mounted must be of non combustible material.

The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations and, in Scotland, the electrical provisions of the Building Regulations applicable to Scotland, with respect to the installation of a heater utilising mains electricity in a room or internal space containing a bath or shower.

Where the installation of the boiler will be in an unusual location special procedures may be necessary and BS 5546 gives detailed guidance on this aspect.

A compartment used to enclose the heater must be designed and constructed specifically for this purpose. An existing cupboard or compartment may be used provided that it is modified for the purpose.

Details of essential features of cupboard/compartment design are given in BS 6798: 1987.

2.3

2.4

Water Circulation System

The Celtic FF is suitable for SEALED SYSTEMS only and should be in accordance with the relevant recommendations given in BS 6798: 1987, BS 5449:l (for the smallbore or/and microbore systems) and the British Gas Specifications for Central Heating Systems.

Siting the Flue Terminal

Refer to section 1.4 for details of wall thicknesses which can be covered.

Detailed recommendations for flueing are given in BS 5440 Pt 1. The following notes are intended to give general guidance.

The boiler must be installed so that the flue terminal is exposed to external air. The boil& must NOT be installed so that the terminal discharges into another room or space as an outhouse or lean-to. It is impor-

tant that the position of the terminal allows a free

passage of air across at all times. The minimum acceptable spacings from the terminal to obstruc-

tions and ventilation openings are specified below

(fig. IO).

Terminal positions

Min spacings

A - Directly below an opening, windows

etc. .._ .__..., ,....,

B - Below gutters soil pipes or drain pipes C - Below eaves D - Below balconies or car port roof E - From a vertical drain pipe or soil pipe F - From an internal or external corner

G - Above ground roof or balcony level

H - From a surface facing the terminal

J - From a terminal on the same wall

K - Vertically from a terminal on the same

wall .._ ..__..,

L - Horizontally from a terminal on the

same wall

300 mm

75 mm 200 mm 200 mm

75 mm 300 mm 300 mm 600 mm

1200 mm 1500 mm

300 mm

Fig. 10

Page 10

Note

: The flue can be extended to clear a projection. BUILDING REGULATIONS 1985 excerpt. Approved document J Part B 1.4 (C) (D).

C) Protect with a terminal guard if it could come in contact with people near the building or be subjected to damage.

Designed so as to prevent the entry of any matter

which might restrict the flue.

(A terminal guard G.C. No 381 782 is available from). Quinnel Barret & Quinnel Wireworks

Old Kent Road London SE15 1NL Tel. 08 1-639-l 357

The air inlet/outlet duct and the terminal of the appliance must not be closer than 25 mm (1 in) to any combustible material Detailed recommendations on the protection of combustiable material are given in BS 5440 Pt 1 : 1990.

IMPORTANT NOTICE : TIMBER FRAMED HOUSES

IF THE APPLIANCE IS TO BE FITTED IN A TIMBER FRA-

MED BUILDING, IT SHOULD BE FITTED IN ACCORDANCE WITH THE BRITISH GAS PUBLICATION - “GUIDE FOR GAS INSTALLATIONS IN TIMBER FRAMED HOUSING”

reference DM2. IF IN DOUBT, ADVICE MUST BE SOUGHT FROM THE LOCAL REGION OF BRITISH GAS.

2.5 Air Supply

The room in which the boiler is installed does not require a purpose provided air vent.

If the boiler is installed in a cupboard or compartment

permanent air vents are required in the cupboard or compartment, one at high level and one at low level either direct to the outside air or to a room. Both

high and low level air vents must communicate with the same space.

2.6

Position of vents Air from room

Air direct from outside

High level

264 cm2 (40 in2)

132 cm2 (20 in2)

Low level

264 cm2 (40 in2)

132 cm2 (20 in2)

Electrical Supply

- This appliance must be earthed.

- All wiring external to the appliance must conform

to the current I.E.E. Regulations.

- The Celtic FF requires a 240 V + 50 Hz supply.

- Connection of the appliance and any system

controls to the mains supply must be through a

common isolator and must be fused at 3A maximum.

This should preferably be an unswitched shuttered

socket outlet and 3 pin plug to BS 1363. Alternatively,

a double pole isolating switch may be used, provided

it has a minimum contact separation of 3 mm in both poles. The isolator should be clearly marked showing its purpose, preferably positioned close to the appliance.

- Fuse the supply at 3A.

- The supply cord must be 0.75 mm* (24 x 0.2 mm) three core to BS 6500 Table 16.

2.7

3.1

Gas Supply

The Celtic FF requires :

2.7 m3/h (95.35 ft3/h) gas flow. The meter and supply pipes should be capable of deli-

vering this quantity of gas in addition to the demand from any other appliances in the house.

The complete installation must be tested for soundness

as described in BS 6891 : 1988

SYSTEM GUIDANCE General

The low water content CELTIC FF dual purpose boiler includes the expansion vessel, safety overheat thermostat, temperature and pressure gauges, and safety valve.

The thermostat is adjustable and on its maximum setting gives a nominal 82” C (180” F) flow temperature. Detailed recommendations for water circulation are given in BS 5546 : 1990. Whilst the boiler provides

hot water, there may be occasions when a cylinder

will be used, for instance, if the property has two

bathrooms. Detailed recommendations of this application are given in sections 3.13 to 3.16 Thermostatic control should be used in the heating circuits and the cylinder if one is fitted.

It must be remembered that a combination appliance has a limited volume of hot water that can be supplied at any one time for a given temperature. Indeed in most respects it is equivalent to a multipoint water heater and many of the contraints associated with multipoints apply equally to combination boilers.

The appliance has two separate functions, to provide heating and hot water on demand. It can have a third which is to supply hot water high demand through the use of an indirect cylinder.

Such a course could recommend itself if, for instance, there is more than one bathroom or if the standard and appointments of the property, such as basins in all bedrooms and a large kitchen indicate a high usage of hot water.

Hot water produced indirectly through a cylinder can be used to satisfy high simultaneous demand outlets

- bathrooms etc. whilst the benefits of high efficiency in generally small quantities of hot water, can be fully utilised in kitchens, cloakrooms and so on.

Figs. 14, 15, 16 and 17 indicate various layouts for the production of hot water. It is recommended that only a high recovery cylinder is used and circumstanceS may from time to time dictate that a special saturated heat exchanger in an indirect cylinder may be desirable.

Separate time and temperature control over hot water generated in this way can be achieved by the use either of two port valves or three port valves of a flow share or priority pattern (see notes on drawing).

It is also possible, where the occupation of the house is

variable, to provide either for a small or large load. This

is best achieved with a tall, small diameter cylinder. See section 5 for possible wiring arrangements.

When using the hot water side of the appliance the

use of non-return valves and/or loose jumpered stop cocks is just as critical as with the conventional multipoint and should be avoided. If a non-return valve is fitted in the incoming water supply then an expansion vessel MUST be fitted in the domestic hot water circuit with a capacity of at least 0.16 litres.

Page 11

3.2

3.3

3.4

If the mains cold water supply is in excess of 10 bar (150 psi) a pressure limiter must be fitted to avoid excessive pressure being applied to the boiler.

When replacing an existing cylinder storage system with CELTIC FF it is essential that all redundant pipework is removed and dead legs eliminated.

In properties where there are multiple draw-off points on different levels consideration should be given to the use of non-return valves in the secondary hot water system to avoid “active dead legs”. No-non return valve should be less than 3 ft (I m) above the top of the appliance and ideally should be as close as

possible to the terminal fitting.

System controls

The boiler is electrically controlled and is suitable for

most control schemes currently available including thermostatic radiator valve and motorised valves. When using motorised valves the controls should be arranged to switch off the boiler when circuits Bre satisfield. The boiler requires a minimum flow rate of

300 L/h (1.1 gal/min) and consequently, if thermostatic radiator valves are fitted to all radiators, a by pass will be necessary. This will ensure that the boiler will operate correctly when all TRVs are closed.

Pump

The boiler is fitted with a Grundfos UP. 15/60 pump head.

The graph (fig. 11) indicatesthe residual head available

for the system.

flow rate in g.p.m.

3 4

Fig. 11

Expansion vessel

The expansion vessel which is fitted on-the front of the combustion chamber maintains pressure and accomodates system water expansion. The vessel has a capacity of 5.4 litres (1.19 gals) and is charged to a pressure of 0.65

bar.

The connection in the centre of the expansion vessel is not a vent point.

At the design flow temperature and the initial system pressures quoted the maximum allowable system volume is 75 litres.

3.5

3.6

3.7

3.8

If the water volume is not known and cannot be accurately assessed from manufacturers data the following volumes may be used to give a conservative estimate of the system volume.

Boiler

.4 litres (0,8 gals)

Small bore pipework .0.3 litres (0.07 gals)

per 0.292 kW

Microbore pipework

.7 litres (1.5 gals)

Steel panel radiators .2.3 litres (0.5 gals)

per 0.292 kW (1000 Btu/h) of system output

Hot water cylinder

.(0.44 gals)

If the volume exceeds 75 litres an additional vessel will be required fitted in the flow from the appliances. Refer to BS 7074 Pt. 1 or BS 5449 for details of sizing.

Mains Water Connection

There shall be no permanent connection to the

Heating System Pipework for filling or replenishing without the approval of the Local Water Authority.

Filling

point (see BS 6798: 1987 Appendix A)

Filling and recharging can be done :

Through a temporary hose connection from a draw off tap supplied from a service pipe under mains pressure provided that this is acceptable to the

Local Water Authority, see fig. 12).

2) Through a self contained unit comprising a cistern, pressure pump if required and if necessary a pressure reducing valve or flow restrictor, fig. 13.

3) Through a cistern, used for no other purpos-, permanently connected to a service pipe. The static head available must be sufficient to provide the designed initial system pressure.

Make up system

Provision must be made for replacing water lost from the system indicated by a reduction in pressure shown on the pressure gauge. Recharge through the filling point (see section 3.6).

Pipework should be of copper, small bore or microbore with capillary or compression jointing to a high standard, leak sealant must not be used in the system.

Page 12

heating system

anti-vacuum valve

this method may only be used if acceptable to the Local Water

complies with

BS 6798 appendix A, method A. 1.

stop

non-return valve

valve

test co&k

Fig. 12

heating system

overflow

cistern

Note : Cistern to be supplied

-1

1-1

through a temporary

complies with

BS 6798

-7-w

. connection from the

----,A/

service pipe or cold

appendix A

stop valve

reducing valve

pressure pump

water distributing pipe.

method A2

(if required)

Fig. 13

3.9.1 Boiler replacement (retrofit)

3.11 Inhibitors

In an old system where the boiler is being replaced, we recommend the use of a strainer, fitted with a drain tap on the heating return, designed to retain

scale particles and other solid debris. It is godd practice to use a chemical cleaner with a floctuating agent,

used as recommended by the cleanser manufacturer, to clean the system before the old boiler is removed.

Chaffoteaux

Ltd do not generally recommend the

use of inhibitors in systems using the Celtic FF boiler. It is however, appreciated that the use of a corrosion and limescale inhibitor may be desirable or specified.

The following are the appliance manufacturer’s

recommendations :

Use only a British Gas or similar approved inhibitor

from the Fernox Manufacturing Company Limited

3.9.2 Existing systems

Valves and joints should be carefully checked for leaks and the appropriate action should be taken either as a repair or replacement. The old open system has probably only been subjected to a pressure of 0.4 bar or less. When you change to a sealed system where the charge pressure will be 1.0 bar and the running pressure exceeding 1.5 bar, consideration should be given to the replacement of radiator valves with a pattern capable of sealing at the higher pressures.

3.10 Cylinder

Where a domestic hot water cylinder is used with the Celtic FF it MUST be of the Indirect and high recovery type to BS 1566:Pt I. Single feed cylinders are not suitable for use with this appliance. Flow and return

pipework to the cylinder should be in 22 mm copper pipe.

Britannica Works, Clavering,-Essex CBl 1 4QZ -

Tel : 0799 085811 ; Grace Service Cheminal, Grace

Dearbon Ltd - Widness - Cheshire WA8 8 UD

Tel : 051 424 5351 - Telex : 627 341 - Fax : 051 423 2722

2) Use only the quantities specified by the inhibitor manufacturer.

3) Cleanse the system as required by the inhibitor

manufacturer.

4) Add inhibitor only after flushing when finally

re-filling

the system.

3.12 Add-on devices

It is important that no external control devices eg.

economisers be directly fitted to

this appliance unless

covered by these installation instructions or agreed with the manufacturer in writing. Any direct connection of a control device not approved by the manufacturer could make the guarantee vaid and also infringe the

Gas Safety (Installation & Use) Regulations 1984.

Page 13

Heating & stored hot water - spring return

1 1

valves only

Heating & stored hot

water using flow share

relay required

Fig. 15

Remote by-pass

Celtic

remote by pass

with L/S valve

hot water

3.13 Heating and hot water systems

tipoints apply equally to the combination boilers. The appliance has two separate functions, to provide

heating and hot water on demand. It can have a third, which is to supply hot water high demand through the use of an indirect cylinder.

Such a course would recommend itself if for instance there is more than one bathroom. If the standard and appointments of the property such as basins in all bedrooms and a large kitchen indicate a high usage of hot water.

3.14

3.15

Hot water produced indirectly through a cylinder can

be used to satisfy high simultaneous demand outlets

- bathrooms etc. Whilst the benefits of the high effi-

ciency in generally small quantities of hot water, can

be fully utilised in kitchens, cloakrooms and so on.

Figs. 14, 15, 16 and 17 indicate various layouts for the production of hot water. It is recommended that only a high recovery cylinder is used and circumstances

may from time to time dictate that a special saturated

heat exchanger in an indirect cylinder may be desirable.

Separate time and temperature control over hot water generated in this way can be achieved by the

use either of two port valves or three port valves of a flow share or priority pattern (see notes on drawing).

It is also possible, where the occupation of the house

is variable, to provide either for a small or large load. This is best achieved with a tall, small diameter

cylinder (fig. 16, see sections 5 for possible wiring arrangements).

When using the instantaneous side of the appliance the use of non-return valves and/or loose jumpered

stop cocks is just as critical as with the conventional

multipoint and should be avoided. If a non-return valve is fitted in the incoming water supply then an

expansion vessel MUST be fitted in the domestic hot water circuit with a capacity of at least 0.16 litres

When replacing an exisiting cylinder storage system with an instantaneous type system it is essential that

all redundant pipework is removed and dead legs

eliminated.

In properties where there are multiple draw off

points on different level consideration should be given

to the use of non-return valves in the secondary hot

water system to avoid “active dead legs”. No non-

return valve should be less than 3 ft (I m) above the

top of the appliance and ideally should be as close as

possible to the terminal fitting

3.16

The consideration of heating systems using thermo-

static valves should ensure that the minimum flow

rate through the appliance is maintained and in this

connection the remote by-pass is preferred (see fig.

17).

Page 14

INSTALLING THE BOILER

vertical flat area is required for the boiler : 1122 mm high x 591 mm wide (44 in x 23.25 in). The surface on

which the boiler is mounted must be of a non reverberating and of a non combustible material.

The appliance is supplied in a single carton which contains :

The

chassis

with all functional parts attached.

2) Casing comprising

: 2 side panels

1 front panel 1 controls fascia cover 1 glass door complete with hinges

3) Mounting bracket comprising

: flue guide

top support plate

spacing strip bottom support plate plastic jig plate connection

4) Plastic bag containing

: gas filter/washer

5) Box containing

: gas and water connections inc.4 above.

6) Box containing

: controi knobs

safety valve wall plugs screws and fixings.

7) Flue assembly

: flue turret with pressure differential switch and 1st flue duct section

plastic wall liner with terminal flue duct plastic turret cover 2nd flue section

8) Plastic bag containing

: flue locking ring

‘0’ ring 2 gaskets - one cork and one rubber

4 mounting screws with washers for flue turret

N.B. (i)

Extension flue assemblies are not supplied as standard, and must be ordered to suit (see section 1.4)

4.1

4.2

Fig. 18

Positioning the boiler

Select the location for the boiler referring to the dimensions shown in 1.1 and 1.3 terminal location positions (2.4 - fig. IO).

Check flue length (see 1.4 - figs. 2 and 3).

c) Check clearance on external wall for flue terminal

position (see table 2.4 - fig. IO)

Assemble the mounting bracket made up from 4 pieces (fig. 18) using 4 thread forming screws.

e) If for rear flue installation, remember to include

the flue guide plate E, using 2 thread forming screws.

Rear outlet flue a)

Mark vertical centre line for boiler on wall.

Mark horizontal centre line for 107 mm (4.2 in) dia wall opening and one for upper bracket fixing screws (A).

c) Using bracket as template mark 4 fixing points (A)

and (BL

Mark wall for flue opening using flue guide plate.

e) Drill the wall for the flue opening using a 107 mm

(4.2 in) core drill.

Drill 4 fixing holes (A) and (B) 7.9 mm (5116 in) and plug.

g) Fix bracket to wall using 6 mm x 50 mm wood

screws provided.

Fig. 19

N.B.

Ensure bracket is square and plumb to vertical

centre line before tightening.

Page 15

4.3

295 mm minimum

Side outlet flue a)

Mark vertical centre line for boiler on wall (see fig.

20).

Using bracket as template mark 4 fixing slots (A) and (B).

169.5 1 -

- -------

c) Mark horizontal line through the fixing slots (A) and

project to side wall.

Fig. 20

4.4

Fig. 21

4.5

Fig. 22

4.6

Water connections

Make connections to copper tails using either solder capillary fittings or compression type.

4.7

Gas connection

Mark vertical axis of flue opening 112 mm (4.4 in) from corner of wall.

el Mark wall for centre of flue opening 169.5 mm

above the horizontal on side wall.

Drill the wall for the flue opening using a 107 mm

(4.2 in) core drill.

g) Drill 4 fixing holes (for (A) top of slot) and (for (B)

center of slotl.

Fix bracket to wall using 6 mm x 50 mm wood screws provided.

N.B.

Ensure bracket is square and plumb to vertical

centre line before tightening.

Jig plate N.B.

By using the plastic jig plate the piping system

can be completed before the boiler is mounted.

Attach plastic jig plate to bottom bracket using 4.6 mm x 10 hexagonal screws provided (fig. 21).

Fit copper tails and washers to jig plate, the mains water inlet tail (M) is the shorter of the two 15 mm tails (fig. 22).

c) The water can either come from above or below

using the standard tails provided. The gas must enter from below.

Gas and water

Tube Thread

connections diameter size Jl

Heating return 22 mm 3/4 in

Hot water outlet domestic

15mm l/2 in

1) Gas inlet

22 mm 3/4 in

Mains water inlet domestic

15 mm

l/2 in

N) Heating flow

22 mm 3/4 in

Pipework a)

Fit or cut pipework to connect with copper tails on jig plate.

a) The gas connection is 22 mm diameter.

Make the gas connection.

N.B.

The gas supply pipe must not be less than 22 mm diameter.

IMPORTANT NOTE :

At this stage the pipework can be completed and tested before the boiler is positioned. Having completed a Satisfactory test on the pipework the boiler can now be fitted or retained for fitting at a later date.

Page 16

4.8

Fitting the boiler al

Before hanging the boiler, uncoil wiring harness (connections to pressure switch) stored by

changeover valve, route through lower part of

chassis and up back of boiler, place into clips.

Remove plastic jig plate from bracket and retain screws.

c) Hang boiler on mounting bracket, ensure that it is

properly located.

N.B.

Insert washer into union nut and offer assembly to boiler. Use the plain black 3/4 and l/2 diameter graphited fibre washers for water unions, and the white 3/4 filter/washer for the gas union.

Connect water union using plain washers, working from left to right.

el Connect the gas union using the filter/washer

packed separately either way round.

Fig. 23

N.B.

As an alternative to using the plastic jig plate the tails can be fitted to the boiler before mounting, then connected to the services.

4.9

c) Fit 14 mm tail drain bend using washer provided.

Fit plastic tube from air separator to nipple on

14 mm tail.

N.B.

The drain must be 22 mm and the 14 mm drain bend from the safety valve must be installed so that discharge of water is readily visible. A tundish arrangement is acceptable. The connection must

NOT

be made by a capilary or compression fitting directly betweenthe mmdrain bendandthe22 mmdischarge pipe without an air gap. see fig. 24.

Fig. 24

Fit safety valve ,

The 22 mm discharge pipe must discharge to the

The safety valve is mounted below the

outside of the building where possible over a drain. The

heating return (J) (fig. 22) isolating valve.

discharge must be such that it will not be hazardous to

Ensure ‘0’ ring is in position within the

occupants or cause damage to external electrical

socket from heating return isolating

components or wiring. The pipe should be directed downwards. It must not discharge above an entrance or

Fit safety valve and secure with grub

window or any type of public access as the temperature

screw provides.

of the water being discharged may reach 100” C.

c) Remove plastic turret cover (D) from flue turret (B)

held by two screws.

Peel off protective paper from adhesive side of cork gasket (A) place on mating side of flue turret (B) lining up with four clearance holes, press together.

e) Assemble second part of flue duct CH), push fit.

Slide locking ring (C) and ‘0’ ring over plastic air duct.

g) Slide air duct over flue duct, engage end of flue duct

into terminal and locate air duct into turret (B).

Slide ‘0’ ring along air duct 0, to contact with the face of the turret (B). Locate lugs on locking ring CC) between lugs on flue turret (B). Push together and turn to lock.

Position square channelled rubber gasket (E) on the flue hood outlet of the boiler, channel facing downwards.

Pass the flue assembly through the wall and seat turret (B), onto the flue outlet, secure with 4 screws provided.

Fitting the flue up to 700 mm long a)

Cut plastic duct (G) to length required, see fig. 2 or 3 dimension CL).

Cut same amount from aluminium flue duct CH).

N.B.

In very cold weather the plastic air duct becomes

brittle, warm before cutting.

N.B.

The terminal must extend 13 mm (0.5 in) past the

surface of the external wall.

Fit wall plate (F) provided With mastic sealing ring over air duct to structure.

Make good internal wall face where the air/flue duct assemblies exit the room.

Do not fit plastic turret cover ‘D’ until electrical connections have been made.

Page 17

4.11

4.12

4.13

Fitting the flue over 700 mm long al

Assembly is precisely as detailed in section 4.10 using the requisite number of extension flue and air ducts. In particular note the following.

The standard flue duct is always used (both sections) at the appliance end (uncut).

c) The standard air duct is always used at the terminal

end (uncut).

When cutting, always cut one extension flue duct and the same amount from one extension air duct. Always cut the plain end

NOT

the socket end.

e) Full details of dimensions and assembly are given in

figs. 2 or 3 as applicable.

If internal fixtures prevent the assembled ducts being passed through the wall from the inside, the ducts may be pushed through from outside (remove the locking ring VJ and 0 ring first).

Connection to the pressure switch a)

The two wires on the harness must be connected.

Push spade terminals onto tags COM (P) and No (2)

-the common and normally open contacts - polarity immaterial.

c) Fitturretcove?(D) (fig.25)ensuringthatboththeair

tube and cables are not trapped, with the

cable

retaining clip

positioned as shown, see fig. 26,

within the cover.

N.B. NC

(1) Terminal is not used.

zig.

Making the electrical connection N.B.

See Section 2.6 for electrical supply requirements

THIS APPLIANCE MUST BE EARTHED.

Pull out fuses (A).

Remove two screws (B).

c) Open door to left hand side of electrical box.

Cut the cable entries to the size of the cable being used which should not be less than 0.75 mm2.

e) Remove cable clamp.

Connect permanent live to (L) (Ph) and neutral to N.

g) Connect earth to earth pillar ( & ).

Connect external controls - time clock room thermostat etc. across terminal 4 and 5, (sections

5.1-5.5).

i> Secure cables with cable clamp and locate flex

into clip on boiler chassis.

Close door and secure with two screws.

Replace fuses.

N-B.

The length of the earth wire between the cable

clamp and the terminal must be such that the live and

Fig. 27

neutral wires become taut before the earth wire if the supply cord is pulled.

In the event of an electrical fault after installation preliminary electrical system checks must be carried out. Checks to ensure electrical safety should be carried out by a competent person i.e earth continuity, polarity and resistance to earth.

Use only voltage free external control switching. No supply voltage should be connected to terminals 3,4 or 5.

Page 18

5.1

5.2

N.B. For additional information

contact Time Control Manufacturers

Terminal 3 is a neutral for acceleration if required.

Supply through :

1. Double pole fused switch spur

2. 13 amp unswitched plug and socket

; boiler terminal block ’ (terminals are not shown in

-----------

same order as on boiler follow notation).

remove link between terminals

and

Fig. 28

Time clock - Time clock and room stat

- The time clock contacts

must

be voltage free (remove external links).

-. The room stat accelerator should be connected if fitted.

- Supplv fuse valve 3 amp.

NB. I)

X in table indicates no earth connection in time clock.

2) * In table indicates that external links on time clock must be removed.

3) + in table indicates no ‘spare’ connection in time clock so a connector will be required.

room thermostat

cylinder thermostat

Honeywell T60 60B

Honeywell L6 41 A

240 V 50 Hz

fused 3

amp.

boiler terminals

(remove link4-5)

Fig. 29

Page 19

5.3

5.4

Programmer and zone valves

spring return

motorised valves

w.ith end switch.

I-

---

Fig. 30

room thermostat

boiler terminal

block

Honeywell Y plan, Satchwell flow share or Satchwell mini valves to control zones.

Refer to controls manufacturers literature. Live to relay coil is the wire in their literature which carries the signal to the boiler.

relay

---1

,&Jr

boiler terminal block

Fig. 31

5.5

Frost thermostat.

The appliance is protected by integral frost

thermostats.

It is advisable to protect the system from frost

damage by fitting an additional remote frost ther-

mostat which will over ride the controls whilst the selector switch is set to hot water + central hea-

trng (II).

frost thermostat

----

Fig. 32

Page 20

COMMISSIONING

6.1

6.2

6.3

Hot water circuits - filling I)

Check that stop cocks up stream of appliance are of a fixed jumper type.

2) Open mains cold water inlet valve (fig. 33) (A)

3) Vent installation by opening taps and closing.

4) Check that “dead legs”

have been eliminated

5) Check for water soundness and rectify if necessary,

Fig. 33

5) Set system charge pressure to design cold pressure. For a new installation we suggest 1.0 bar. For an old system see section (3, 9, 2) set to system static head or 0.8 bar which ever is the greater.

6) Check for water soundness and rectify any leaks.

71 Switch on electrical supply.

8) Manually check bump is free to rotate. Remove cap (fig. 35 D). Insert small electrical screwdriver (3 mm blade), locate in slot in pump shaft, rotate clockwise to ensure that pump is free replace cap CD).

Fig. 34

9) Switch to HOT WATER + CENTRAL HEATING on

Central heating circuits - filling

selector switch (A) (fig. 35) switch position (II).

Ensure that the isolating valves are open (fig. 34

101

Allow pump to run for further IO-15 minutes.

and C). N.B. Valve (C) must be turned anti-clockwise

Switch OFF.

by the knurled nut until it dislocates from the

11)

Isolate water supply and drain boiler by disconnecting

thread and then pulled out horizontally to its

fill system and opening the drain

valve (F). This is

extremity (approximately 30 mm (1 114 ins)).

incorporated in the safety valve and is achieved

2) Fill system to charge condition, see section 3.

by screwing down the head until the valve lifts.

3) Vent radiators and any high points.

Open all low level drain cocks.

4) Vent automatic air separator/air purger by loosening

12)

Remove filter in the return isolating valve (C) and

screw (fig. 35) (E) two complete turns from

inspect for any installation debris, see section

closed position.

(7.6) to clean and replace.

N.B. Leave screw (E) in open position.

13)

Refill system as above.

lighting the boiler I)

Purge gas supply. Switch on electrical supply.

2) Turn the lever on the gas service tap (fig. 34) 0 to the left. In the open position the flame sign is to the front.

3) Temporarily locate the three blue control ‘knobs’ -

one

thermostat knob, one ignition button

extension and one temperature control knob.

4) Switch to HOT WATER + CENTRAL HEATING (II) on

the selector switch (A). The fan will run at low speed.

5) Press the ignition button

(R)

and hold in.

The fan will change to high speed to purge the

combustion chamber. Gas is admitted to the pilot.

Fig. 35

After approx 14 seconds the spark generator passes a continuous stream of sparks to light the pilot.

ATTENTION :COMMlSSlONlNGINCOLDWEATHER

cl When the pilot is alight - viewed through the

This holler is protected by two m-built frost thermostats. During cold weather the boiler

sight glass, wait for a further 5 seconds before

may operate under the control of these thermostats.

slowly releasing the button.

Thus can happen under two conditions :

6) When the button is released, while the boiler is set

1. If the boiler temperature is less than 3’ C (e.g. the boiler has been stored under

to heating and any ancillary controls are in demand

very cold conditions) the fan will not run, the pump will operate continuously, It will

position, the boiler will fire.

still be possible to light the pilot but not the main burner.

7) Check for gas soundness using leak detection fluid.

Wait for a few mmutes to allow the heat of the pilot to reset the safety controls permitting the main burner to fire.

8) Check and adjust gas pressure/gas rate, see

Section 6.4

2. If the boiler temperature is between 3’ C and 11’ C the frost thermostat will override the external controls. This will cause the marn burner to fire for a few minutes

N.B. The thermocouple outp,ut should be checked at

and then turn off. Thus applies if the switch is rn posrtion I or II and is quite normal.

this stage, should be greater than 12 mv.

Page 21

6.4

Gas rate adjustment

N.B. Before adjustment check gas pressure on the inlet to the appliance, with the appliance working - this should be 20 m bar (8 in wg) for natural gas.

The maximum gas rate on hot water is fixed and is a function of the restrictor size. The central heating variable adjuster is factory set at 100 % i.e for an output of approx 24.0 kW (81.900 Btu/h).

Switch boiler to the off (0) central position, see section 6.3 (fig. 35).

Fig.36

2) Remove the pressure test point screw - (B) and connect a suitable pressure gauge.

3) Remove the hexagonal cap from gas rate adjuster exposing the adjusting screw (CL

4) Switch the boiler to hot water and central heating (II) and check that any fitted external controls are calling for heat.

5) Adjust. Setting pressures are given in graph figs. 37 and 38. The pressure will be reduced by clockwise movement of screw, increased by anticlockwise movement. Now select hot water only, adjust

temperature knob, see fig. 4 (25), to minimum and

open the largest volume draw-off tap. The gas pressure should now be the maximum as indicated in Technical Data. Now reduce the water flow to minimum and check that the burner reduces its output, this will take a short period of time.

6) Switch boiler off (0). Remove pressure gauge and replace test point screw and gas rate adjuster hexagon cap. Check for gas soundness around screw.

7) Mark the data badge, located on the front of the combustion chamber below the sight glass to indicate output to heating system.

Output/ Burner pressure

lnput/Burnerpressure

OutputkW

lnputft'/h

OutputBtdhx103

Fig. 37

UIO 125

1.50 1.75 2.00 2.25

2.50 2.75

Input m 3/h

Fig.38

Page 22

6.5

6.6

Remote by pass

Adjusting the heating system by-pass

Where a by-pass is fitted, see section 3.2, it is necessary to adjust to obtain the boiler minimum flow requirement of 300 I/h (I .I gal/min).

remote by pass

with L/S valve

Set boiler thermostat to maximum, switch boiler to HOT WATER + CENTRAL HEATING (11).

2) Open all radiators and close the by-pass. Check the temperature rise accross the boiler which should not be greater than 20” C (36” F).

3) Adjust system to minimum load. This is normally done by closing valves on all but two radiators.

4) Open by-pass gradually until the boiler operates quietly and the temperature rise is maintained.

N.B.

The by-pass valve should be of the lock shield pattern. The flow switch operates at approx 300 I/h (1 .I gal/min).

Fitting the casing I)

Take from the carton the controls cover CH), the glass door (J1 the top front panel (K) and the side panels (A).

2) Remove control knobs used during testing and

commissioning.

3) Fit side panels (A) and secure with screws at

bottom rear(B).

4) Put the control cover (H) in posrtion and secure

with five screws.

5) Fit the front top panel over the pins at the top of

the boiler (0 and secure with two screws at the bottom (D)

6) Fit the various control knobs, gas push button, and

domestic hot water temperature selector.

7) To fit the glass door proceed as follows :

N.B.

THE TIE ROD (G) MUST BE USED

Remove the nuts from the machine screws securing

the tie rod to the hinges.

Offer the door up vertically. Engage part (E) in the

profile of the right hand side panel. Fix assembly with screw from beneath (0.

c) Pivot the left hand hinge and engage into profile of

the left hand side panel. Fix assembly with screw from beneath.

6.7

HAND OVER THE USERS INSTRUCTIONSAND EXPLAIN THE BASIC FUNCTIONS OF OPERATING THE APPLIANCE. LEAVE THE INSTALLATION AND SERVICING INSTRUCTIONS ADJACENT TO THE GAS SERVICE METER. IF THE ELECTRICITY SUPPLY IS INTERRUPTED THE PILOT MAY HAVE EXTINGUISHED. WHEN THE SUPPLY IS

RESTORED RELIGHT THE PILOT SEE SECTION 6.3

Page 23

7.1

7.2

ROUTINE SERVICING

To ensure continued efficient and safe operation of the appliance it is recommended that it is checked and

serviced annually. It is the law that any service work must be carried out by a C.O.R.G.I. Registred person. This routine service will normally be confined to :

1) Cleaning the burner.

2) Cleaning the heat exchanger.

3) Checking the gas controls.

4) Cleaning water filters and hoses. The following schedules are recommended : a) Check the function of appliance, burner pressure and gas flow rate. b) Observe flame picture. c) Check, clean or replace components as necessary. N.B. Before commencing any work turn off gas at the gas inlet tap (fig. 34) item (G) and ensure that the electricity

supply is disconnected. Isolate water supply and drain Appliance if required.

Remove front casing a) Remove two screws (A) bottom rear of boiler. b) Remove screw (B) centre of lower front panel. c) Remove control knobs. d) Remove case by easing forward at bottom and lif-

ting off lugs at top.

If necessary,

remove the lower control cover (4 screws) and lift off the upper front panel before removing case.

?g. 41

To remove combustion chamber front panel and heating body panels to expose heat exchanger (primary)

a) Remove four screws (A) securing the combustion

chamber front panel.

b) Lift off front panel complete with expansion vessel

and hang on hooks provided below boiler through matching holes on top folded edge.

N.B. Alternatively support on worktop or floor to avoid damage to flexible tube.

c) Remove eight screws (C) and lift off heating body

front panel with access panel (B).

d) Cleantheheatexchangerafterremovingthe burner

and pilot, see section 7.7.

Fig. 42

Page 24

7.3

7.4

7.5

7.6

Remove burner assembly

Remove two screws (Fl) and remove closure plate by

withdrawing forward.

Remove four screws (F2) and remove burner by withdrawing forwards, taking care not to trap ignition electrode lead.

c) Remove gasket and retain in safe place,or if adhered

to onesutiace, leave alone as removal may damage the gasket.

To clean burner see action 7.7.

Fig. 43

To remove pilot a)

Remove two screws (A) securing deflector plate and pilot head. Lift off deflector plate (D) taking care not to damage the electrode tip.

Remove pilot air filter(B).

c) Using a 7 mm spanner, remove pilot body 03 from

pilot burner base.

ta-

Check injector and clean the filter.

N.B.

The pilot injector (F) is retained in the base of the

body with an ‘0’ ring 0. If the injector is replaced it is

fitted bright side uppermost. e) Ensure deflector plate CD) is correctly located on

the pilot.

Fig. 44

To clean mains water inlet filter a)

Isolate from mains water and drain from valve (A) beneath the change over valve.

Remove governor and filter (B) and (C).

c) Clean filter 0 grease governor spindle, using a

high temperature silicone grease.

N.B.

Take care upon removal of governor and filter, a spring is situated between the spindle and the screwed section. Ensure this is correctly replaced.

Fig. 45

To clean heating return filter a)

Close heating flow and return valves (B and C) and

drain through safety valve (F) wsection 6.2).

Using spanner remove return valve spindle guide assembly (D).

N.B.

Take care not to damage the capillary tube right hand side.

c) Lift filter(E) off assembly.

Clean in warm water. e) Replace in reverse order. Replace all components removed in reverse order.

Fig. 46

Page 25

7.7

REPLACEMENT OF PARTS

N-6. Before commencing ensure gas and electricity supplies are isolated.

8.1

Cleaning and replacement of parts

a) The burner can be cleaned by inverting and brushing

with a soft brush. Inspect injectors, ensure they are clear.

The heat exchanger flueways can be cleaned by thoroughly brushing the finned surface. After brushing inspect to ensure that the flueways are completely clear.

c) The thermocouple can be wiped with a lint free

cloth to remove any deposits. If the thermocouple tip appears burnt or cracked, exchange to avoid a possible break at a later date - see section 8.1

d) Electrode : examine and clean, the tip, if the tip

appears damaged replace electrode and lead assembly - see section 8.2

e) Replace all components in reverse order noting

particularly that the deflector plate - see section

7.4 D is correctly located on the pilot jet. The gasket between the gas section and the manifold must be correctly positioned upon reassembly.

Open all isolation valves and repressurise system if necessary.

g) Recommission and check controls.

After the boiler is lit, check all gas connections for soundess.

j) Allow the boiler to warm up thoroughly, then check

the burner pressure and adjust as necessary to that given inthetableforrequiredoutput-seesection6.4

Restore any sytem controls and clocks to their

original setting.

The remove thermocouple a)

Remove front case, see section 7.1.

Remove outer front panel, see section 7.2.

c) Remove burner, see section 7.3.

Disconnect high limit stat see section 8.3.

e) Remove thermocouple from thermoelectric valve

connection (F).

Loosen securing screw (G) two full turns to relieve

tension from locking spring.

g) Remove thermocouple by sliding down through gas

section.

Fig. 47

Remove grommet (E) from base of combustion chamber.

j) Carefully form a 4 inch radius to thermocouple and

insert thermocouple into combustion chamber (pathx).

Slide grommet (E) over the thermocouple.

Continue feeding the thermocouple into its location until it is hard against the thermocouple stop H in the pilot head.

m) Tighten fixing screw (G), previously loosened.

Reposition grommet in baseofcombustion chamber.

o) Form the new thermocouple and connect to

thermoelectric valve (F).

Fig. 48

Reconnect high limit thermostat.

NOTE

: When replacing the thermocouple the conductor may need manipulating - avoiding bending at acute angles.

Page 26

8.2

8.3

8.4

To replace electrode and l&ad assembly a) Remove front case, see section 7.1 b)

Remove outer front panel and combustion

chamber front panel, see section 7.2 c) Remove burner, see section 7.3 d) Remove deflector plate CD), see section 7.4 e) Disconnect from electrical box by pulling off elec-

trode lead at lower left hand rear.

f) Feed cable up through gas section (H) removing

grommet (J).

g) Remove electrode by pulling upward from location

groove.

Fig. 49

h) Replace in reverse order locating electrode in-

deflector plate CD), spark gap 5 mm.

To replace safety overheat thermostat a)

Remove front case, see section 7.1

b) Remove two screws securing high limit thermostat

to bracket (BL c) Remove high limit stat and thermocouple see 8.1.

Withdraw noting route e) Replace in reverse order. Use heat sink grease

between high limit stat and bracket (B)

Fig. 50

To replace ignition microswitch

a) Remove front case, see section 7.1

b) Remove outer front panel and combustion

chamber front cover, see section 7.2 c) Remove burner see section 7.3 d) Remove electrical control box, see section 8.9 e) Remove plugs from solenoid valves (A), noting

colours.

f) Pull off three

tab connectors (C) from microswitch

noting their position

(blue top, red centre, black

bottom). Note : Microswitch connections must be made in

accordance with wiring diagram. (fig. 9)

g) Release gas union (B).

Fig. 51

h) Remove the two screws (D) retaining gas section.

j) Slide out gas section (H) by pulling forwards (com-

prises solenoid valves, gas valve, pilot assembly

electrode, etc). k) Remove two screws (S) retaining microswitch. m) Remove microswitch. n) Replace in reverse order.

Page 27

8.5

8.6

8.7

To replace change over valve microswitch a)

Remove front case, see section 7.1

Undo screw (A) and remove microswitch box cover.

N.B. Upper microswitch operates for D, H, W mode. Lower microswitch operates for C, H mode.

c) Lift spring (B) and pull operating lever off mounting

pins.

Remove respective microswitch from mounting

pins.

e) Note colour code and pull off electrical tags.

Replace in reverse order.

When replacing box cover, ensure tha the lugs on the connector block are clamped

inside

the box.

N.B.

Refer to fig. 9 for colour codes.

Fig. 52

To replace the flow switch assy a)

Remove air separator see section 8.13

Disconnect high pressure tube at union A. c) Disconnect low pressure tube at union B. d) Undo retaining nut C. e) Remove assembly by lifting up and forward.

Replace reverse order.

Fig. 53

Fig. 54

To replace venturi

a) Remove front case, see section 7. I

Isolate from mains water and drain down from

valve (E).

c) Undo union (A) at rear of change over valve.

Loosen union (B) on secondary heat exchanger and move pipe to one side.

e) Remove plug, spring and plastic valve (C) from right

hand side of change over valve.

Use small screw driver to gently push out venturi

ensure screw driver does not enter throat of ven-

turi.

N.B.

The venturi is contained within the union (A) and

can be removed using access at CD). g) Replace in reverse order.

Page 28

8.8

8.9

Fig. 55

To replace primary heat exchanger a) Remove front case, see section 7.1

Isolate appliance from system by closing heating flow and return valves (B and C), see fig. 34.

c) Drain boiler (primary side) through safety valve (F)

(fig. 34). d) Remove combustion chamber panels, see section 7.2 e) Remove burner, see section 7.3

Remove 14 screws holding left and right hand side combustion chamber panels.

g) Pull out lower split pin (D) and remove boiler

thermostat

sensing phial (C).

h) Remove four screws (A) secunng combustron

chamber to chassis.

Undo bottom flow and return pipe unions (E) and slide primary heat exchanger forwards with flow pipes and heating body (three sides) to remove.

N.B. To replace, the flow pipe unions need to be made

g!yz-

on to the heat exchanger before refitting. Check that bottom unions align correctly before continuing.

Fig. 56

Fig. 56a

Fig. 56b

To remove electrical control box a)

Remove front casing, see section 7.1

Remove fuses by pulling fuse carrier (B) from elec-

trical box. c) Remove five screws (C) lift electrical box cover

away and unplug from PCB.

d) Remove temperature gauge by easing off from by

pass tube see section 8.33

e) Pull off plug from solenoid valves (note cable co-

lours match solenoid case colours).

Unplug pump connector and earth wire from PCB.

g) Unplug connector to change over valve.

Unplug three leads from ignition microswitch.

Unplug connector of frost thermostat from PCB.

Unplug connector from fan leads at PCB.

I) Remove one screw(D) andtwoscrews (E). (Electrical

box

support bracket to lower chassis).

m) Carefully ease electrical boxfotwardto allow access

flow switch lead, also to electrode at bottom rear

of box.

n) Disconnect lead from flow switch.

01 Disconnect electrode from rear of electrical box.

p) Carefully move the electrical box away from the

appliance and to the right whilst straightening the

capillary tube from boiler control thermostat and

domestic hot water thermostat.

Contrnue moving electrical box until bottom

support bracket can be positioned on hook at bot-

tom of appliance, see fig. 56 B. To remove the electrical box completely, continue in the following manner :

Isolate appliance from the system by closing valves

A, B and C, see Section 6.2 (Fig. 34). s) Drain secondary side by opening drain plug (HI (fig. 34). t) Drain primary side through safety valve (F) (fig. 34). u) Remove clip and phial from boiler thermostat pocket. VI Remove clip and phial from DHW thermostat pocket. WI Remove split pin and phial from limit thermostat

pocket. x1 Remove box completely. To replace electrical box in reverse order note :

Hang box on hook.

Capillaries must be routed behind any pipework except the boiler control thermostat capillary

which must be routed behind the expansion vessel

pipe.

c) Connect three leads to ignition microswitch prior to

locating the electrical box.

Page 29

8.10

8.11

8.12

To replace pump head a)

Remove front case,see section 7.1

Remove electrical box see section 8.9

c) Isolate boiler from system by closing flow and re-

turn valves see section 6.2 (B and CL

Drain boiler (primary side) through safety valve see section 6.2 (F).

e) Remove four screws (A)

Remove pump head noting orientation.

g) Take off electrical connection cover by removing

screw.

Fig. 57

Remove lead and transfer to new pump head.

Replace in reverse order.

Open flow and return valves. Top up system if necessary.

To replace change over valve (C, 0, V) a)

Remove front case, see section 7.1

Disconnect and remove electrical box, see section 8.9

c) Turn off main water at valve see section 6.2 (A).

Turn off central heating flow and return valves see section 6 (B)

e) Drain secondary side by opening drain plug on

bottom of change over valve (H).

Unplug thermocouple connectors in cables to safety overheat thermostat.

g) Remove front tube (I) from change over valve

complete with safety overheat thermostat.

Remove flow pressure tube (2) from heat exchanger to flow switch.

Remove tube (3) from C, 0, V, to return valve.

N.B.

Swing microswitch box to give access to union nuts.

Remove rear tube (4) from C, 0, V, to secondary heat exchanger.

Unscrew union nut (5) of mains water inlet to C, 0, V.

Unscrew heating return tube nut (6) from C, 0, V.

Unscrew union nut (7) of C, 0, V, to secondary heat exchanger.

Remove C, 0, V.

Fig. 58a

01 To inspect diaphragm remove four screws (E)

securing valve to water section.

N.B.

Do not remove spring clips.

Clean or replace diaphragm.

Flush out water section.

t-1

Replace in reverse order.

s) Open flow and return valves. Top up system if

necessary.

To replace secondary heat exchanger a)

Remove front case, see section 7.1.

Disconnect and remove electrical box, see section 8.9

c) Remove change over valve, see section 8.11.

Unscrew union nut (8) at top of secondary heat exchanger.

Fig. 59

e) Unscrew bottom left hand union nut (9) of secondary

heat exchanger.

Slacken top screw (A) of heat exchanger to chassis.

g) Remove bottom screw (B) and spacer.

Remove secondary heat exchanger.

Replace in reverse order.

N.B.

Do not unscrew the four tierods in the secondary

heat exchanger.

Page 30

8.13

8.14

To replace air separator a)

Remove front case, see section 7.1 b) Remove electrical box see section 8.9 c) Close heating flow and return valves (B & C), see

section 8.11 (fig. 58 A).

Drain boiler down through safety valve (F), see sec-

tion 8.11 (fig. 56). e) Disconnect bleed pipe union from pump volute (E).

Pull off plastic drain tube (B).

g) Pull out spring clip (A) with pliers.

Disconnect flexible pipe union (D) at pump outlet.

Pull pump complete with volute forwards and remove.

Disconnect union nut at base of air separator.

Ease air separator forward and disengage integral

peg from chassis.

Remove four screws (C) retaining cap.

0) Lift out float.

Fig. 59a

Clean float and inspect valve.

Replace in reverse order. Ensure that washer is

replaced in lower union of separator.

r) Open flow and return valves. Re-pressurise system if

necessary.

To replace boiler thermostat

Remove front case see section 7.1.

Remove five screws (A) and remove electrical box cover. Unplug from the PCB the single connector for the switch.

c) Remove clip retaining thermostat phial see section

8.8 fig. 55 (D) in pocket-remove phial section 8.8 fig. 55 (C)

N.B.

Primary water must be drained from

appliance

Remove two screws (D) which secure boiler thermostat onto moulded pegs in electrical box.

e) Remove the spade connectors noting position, see

illustrated wiring diagram fig. 9.

0 Feed out capillary through electrical box having

removed the split grommet.

g) Replace in reverse order.

Fig. 60

Page 31

To replace boiler limit thermostat a)

Remove front case, see section 7.1

Remove electrical box, see section 8.9

N.B. Thermostat is situated to right top of electrical

box, sensor in pocket on flow pipe on right hand lower side.

c) Remove split pin from dry pocket on flow pipe (A).

This thermostat is located on moulded pins - ease forward and remove spade connectors.

e) Feed capillary through the control box having re-

moved the split grommet,

Replace in reverse order (polarity immaterial).

Fig. 61

Fig. 62

To replace domestic hot water thermostat a)

Remove front case see section 7.1

Remove electrical box front cover see section 8.9 cc).

c) Isolate mains water supplv - drain from valve beneath

the change over valve, see section 8.11 fig. 58 CH).

Remove clip which retains phial in wet pocket,

e) Remove phial from pocket.

Ease thermostat off moulded pegs and pull of spade connections.

g) Feed capillary through the control box, having re-

moved the split grommet.

Replace in reverse order. Polarity immaterial.

To replace spark generator a)

Remove front case see section 7.1

Remove electrical box cover see section 8.9 (0.

cl Remove PCB see section 8.18.

Remove insulating separator board (behind PCB).

e) Pull tab connections from spark generator noting

position.

Slacken bottom fixing screw and remove top screw from generator.

g) Lift up off bottom screw and pull forwards.

Replace in reverse order. (Connect leads before locating generator).

N.B.

Ensure earth is connected and when repositioning insulated separator board, wires must pass through cut outs.

Fig. 63

Page 32

8.18

To replace printed circuit board (PCB) a)

Remove front case, see section 7.1

Remove electrical box front cover see section 8.9 K3

c) Remove all plug-in connections (IO).

Disconnect mains input cable at terminals 1 and 2 but not the earth.

e) Disconnect external controls, if fitted, from

terminals 4 and 5.

Remove two screws (A)

gl Ease back plastic catches (B) at left and right side

of PCB.

Remove by pulling to the left and forward, disen-

gage from guide - centre bottom and top

Fig. 64

Pull PCB forward.

Replace in reverse order

Fig. 65

4567

Ilg

15h6

1 Summer/Winter Switch

7 D.H.W. Thermostat Capillarv

13 Igniter

2 Pump

8 Change Over Valve

D.H.W. Thermostat

3 Earth

9 Push Button Ignition

Boiler Thermostat

4 Bolter Thermostat Caplllarv

Solenoid Gas Valves

Limit Thermostat

5 C.H. Limit Thermostat

Fan

Fuse

6 Water Flow Switch

Frost Thermostat

Not Used

ELECTRICAL BOX SHOWING POSITION OF COMPONENTS

WITH LAYOUT OF PLUGS AND WIRING.

Page 33

8.19

8.20

8.21

8.22

To replace thermoelectric valve

Remove front case, see section 7.1

Remove thermocouple connection (B).

c) Remove nut (A) securing thermoelectric valve.

Withdraw thermoelectric valve.

e) Replace in reverse order.

N.B.

Care should be taken when replacing the nut

securing the thermoelectric valve - fine threads.

Fig. 66

To replace solenoid valves a)

Remove front case see section 7.1

Withdraw plugs - colour coded - from solenoids (B).

c) Remove four screws (A) securing valve mounting

plate.

Remove mounting plate and solenoids take care not to misplace valve springs and plungers.

e) Replace in reverse order using a NEW GASKET.

Fig. 6

To replace heating body linings a)

Remove case, see section 7.1

Remove combustion chamber front panel with expansion vessel, see section 7.2 (A, B, C and D1.

c) Remove burner, see section 7.3

First slide out side linings followed by rear which is removed by easing upwards and sliding out from bottom.

e) Replace in reverse order.

Fig. 68

To replace fan a)

Remove case see section 7.1

Remove outer front panel see section 7.2

c) Remove 7 screws right hand side of combustion

chamber and lift off side panel.

Pull off 4 spade connections from frost thermostats.

e) Pull off 4 spade connections from fan.

Remove four screws - two on flue hood (A) and two on support bracket(B).

g) Turn anti-clockwise 10’ to disengage lug from rear

and withdraw assembly.

Brown

h) I Remove three screws securing motor to bracket 0

EARTH Yellow-Green 2

leaving grommet in bracket.

j) Replace in reverse order using new gasket.

Capacitor

N.B.

Ensure frost stat leads are paired i.e mauve on

top white on bottom. Ensure correct location of fan

connectors and that the lug at the near is located correctly.

Fig. 69

Red

I I

Page 34

8.23

8.24

8.25

sampling

tube

Fig. 70

To replace pressure switch

Remove two screws (A) retaining plastic turret cover and remove terminal cover.

Note position of spade connectors and remove

(COM-P and No 2).

c) Disconnect pressure sampling tube by pulling off

nipple.

Remove two screws retaining pressure switch. B

e) Replace in reverse order.

N.B.

Ensure ‘0’ ring is position on rear of pressure switch to seal pressure switch - high pressure sample joint. Transfer 4 mm support screw (C) and nut onto the new switch.

Fig. 71

To re-pressurise expansion vessel a)

Remove case see section 7.1

Close heating flow

and

return valves and drain boi-

ler through safety valve, see section 6.2 fig. 34 (FL

c) Remove protective cap and check pressure on

Schroeder valve with gauge.

N.B.

The setting pressure is 0.65 bar (9.5 psi)

To re-pressurise use car foot pump or bicycle pump with adaptor.

e) Refill and commission boiler.

Fig. 72

Fig. 73

solenoid valves

To replace pressure gauge

Remove case see section 7.1

b) Close heating flow and return valves and drain boiler

through safety valve, see section 6.2 fig. 34 (FL

c) Pull off connectors noting colour on solenoid valves

to improve access.

Undo union nut (A) on pressure tube at rear of

gauge.

e) Undo locknut (B) and withdraw gauge, taking care

not to misplace washer.

Replace in reverse order.

g) Open flow and return valves. Re-pressurise system

if necessary.

Page 35

8.26

8.27

8.28

frost thermostats

Fig. 74

To replace frost themostats a)

Remove case, see section 7.1

Remove outer front panel, see section 7.2

c) Remove 7 screws securing right hand side panel

Remove leads from each thermostat.

e) Remove 2 screws securing each thermostat.

Replace in reverse order.

Fig. 75

To replace main burner al

Remove case, see section 7.1

Remove outer front panel, see section 7.2

c) Remove burner, see section 7.3 d) Replace in reverse order ensuring that the gasket

is correctly positioned between the injector cover plate and the manifold.

To replace the burner manifold assembly a)

Remove the front case, see section 7.1

Remove the combustion chamber front panel to expose the burner manifold see section 7.2 (a to c.)

c) Remove the two screws Fl and remove the closure

plate.

N.B.

When replacing the manifold it is advisable to

replace the gasket at the

same time.

d) Remove the two screws F2 and lift off from Burner

base.

e) Replace in reverse order.

Fig. 76

Page 36

8.29

8.30

8.31

To replace pilot injector, air filter, deflector plate/ burner head

Remove as detailed in section 7.4

Replace in reverse order.

Fig. 77

Fig. 78

To replace expansion vessel

Remove front case, see section 7.1

Isolate appliance from system by closing flow and return valves see section 6.2 fig. 34 (B et C).

c) Drain boiler (primary side) through safety valve

fig. 34 (F) and vent expansion vessel at (C). d) Remove flexible pipe from expansion vessel, AT (A). e) Loosen upper securing screw, (B) support and loosen

lower screw. Slide out expansion vessel. f) Replace in reverse order, engaging the thread of

the flexible pipe before screwing fully home screws

(B). The vessel

must

be central on the front panel. g) Re-pressurise expansion vessel see section 8.24. h) Open flow and return valves. If necessary, re-

pressurise system.

To replace viewing window a)

Remove front case, see section 7.1

Remove combustion chamber front panel (A), see section 7.2

c) Remove the screws (B) securing the sight glass

bracket 0. Take care not to loose the two nuts (D).

Replace in reverse order referring to diagram

opposite.

Fig. 79

Page 37

Fig. 80

To replace the main gas valve body a)

Remove front case, see section 7.1

Remove combustion chamber front panel, see section 7.2

c) Remove burner assembly, see section 7.3

Remove electrical control box, see section 8.9

e) Part thermocouple connections to high limit ther-

mostat.

Pull connectors off microswitch (MI noting colours.

g) Remove two screws (P) retaining bracket to gas

section and ease bracket down to clear gas section.

Slacken and undo the gas supply union (D) beneath gas section.

Remove two screws (R) retaining gas section to combustion chamber base.

Remove gas section by pulling forward.

Reassemble in reverse order and check for gas

soundness.

To replace the temperature gauge

Remove the front case, see section 7.1

The temperature gauge (A) is retained on the by

pass tube with a spring clip Carefully lever the gauge from the by pass tube using a suitable tool (B) whilst supporting from the front to prevent damage.

Fig. 81

Page 38

FAULT FINDING

9.1

logic sequence

electrical supply

summer I winter

1r 1r

yes L

yes

I‘

time delay purge

combustion chamber

spark

check low speed

Yes

zero volts check

1st stage solenoid open

time delay 5 sec. max.

2nd stage solenoid opens

Page 39

9.2

FAULT FINDING

CENTRAL HEATING OPERATION

SEQUENTIAL FLOW CHART 1

READ IN CONJUNCTION WITH SECTIONS (9.1 & 9.3)

Check

START

il System water pressure - 1 bar

ii) Gas cock open gas lines PUT-

w-d

set selector switch to central heating and hot water.

Check il External controls in demand

mode.

iii) Electrical supply switched on.

IS 240 V a.c. across red and brown wires on fan connector on PCB.

Check electrode lead connected to rear of electrical box. Check electrode and lead for physical damage. Is 240V a.~. across red and blue igniter connection on printed circuit board.

Isolate supply is there continuity to pressure switch between two

Check external fuse and/or rectify

Check connections to main switch.

iii) Pilot injector is clean

il Position of

ii, CA.-,+ kn-rl

Measure millivolt output at thermo

electric valve (TEV) greater than 12

limit thermostat

IS output to TN less than 12 mV?

diators valves open.

Rectify

Remove plugs from board and check

b) Water flow switch (black leads) cl CH limit stat (black leads)

dl CH control stat (red and black

leads)

Is there ContinuitV across all compo-

Page 40

9.3

FAULT FINDING

START

Open

I::

hot water

tap

DOMESTIC WATER OPERATION

SEQUENTIAL FLOW CHART 2

READ IN CONJUNCTION WITH SECTIONS (9.1 & 9.2)

END

Ensure microswitch is made.

yes

Is there continuity across domestic hot water thermostat ?

ii4L?l

Ensure water inlet pressure greater

Check inlet filter and venturi for

Ensure all isolating valves and stop

Check diaphragm is OK. Replace if necessary.

Page 41

9.4 FAULT FINDING TABULAR CHART

PROBLEM

CAUSE

REMEDY

1 Explosive ignition

Poor pilot flame a) Inlet pressure low - should be 8” wg

(20 mbar) working pressure

Blocked gas filter

c) Pilot injector dirty

ii)

l/3 valve not operating

24 volt supply to valve

No voltage at solenoid

la)

Check meter

and pipe sizing,

see sections 2.7 and 4.7.

lb)

Clean

ICI

Replace, see section 8.29

2al

Replace solenoids, see section 8.20

2b)

Check plugs on printed circuit board

2~) Replace printed circuit board,

see section 8.18

iii)

Crosslighting strip - missing/incorrectly positioned.

3a)

Replace or reposition.

!I Unstable burner

Incorrect injectors

Replace manifold 1.28 mm injectors for natural gas, see section 8.28

ii)

Gas pressure at manifold

Too high

Too low

2a)

Adjust, see section 6.4

2b)

Check restrictors and inlet pressure, see section 1.2

iii)

Terminal incorrectly positioned

iv)

Incorrectly assembled flue duct

See section 2.4

4) Check and reassemble, see section 4.10

VI Fan incorrectly located

5) Remove and refit correctly, see section 8.22

vi)

Combustion chamber front cover not sealing

6a)

Tighten

5b)

Replace sealing strip

vii)

Heat exchanger fins blocked

7) Clean, see section 7.2 et 7.7.

viii)

Neoprene gasket in turret not correctly fitted

8) Fit or refit, see section 4.10.

or missing

I) Central heating -

low flow

temperature

Boiler thermostat out of calibration

ii)

Limit stat out of calibration

iii)

Insufficient gas pressure

Replace, see section 8.14

2) Replace, see section 8.15

3) Check pressure at meter and pipe

sizing, see sections 2.7 and 4.7

iv)

I/3 blue or 2/3 orange gas valve not opening

24 volts at solenoid.

4a)

Replace solenoid, see section 8.20

No voltage at solenoid

4b)

Replace printed circuit board,

see section 8.18

VI Hot water valve in change over valve assembly

sticking

Dead leg on hot water system

5a)

Eliminate

Bent spindle in valve

5b)

Replace, see section 8.11

vi)

By-pass, if fitted, incorrectly adjusted

6) Adjust, see section 3.16

vii)

Pressure switch hunting

7) Replace, see section 8.23

Page 42

PROBLEM

CAUSE

REMEDY

I) Boiler noisy

i) On heating only

a) Low flow rate as result of system resistance

la)

Check and if omitted fit by-pass see section 3.16

Air in system

lb)

Purge by venting radiators

ii)

On hot water and central heating

Low pressure in sealed system

2a)

Repressurise tp 1 bar cold, see section 6.2 (5)

Pump not running

2bl Replace pump head, see section 8.10

iii)

Blocked filter on heating return

3) Clean and replace, see section 7.6

iv) GaS filter fitted t0 heating flow or

retUrn

pipes

4) Remove and

reposition,

see section 4.5

v) Heat exchanger scaled

5a)

Descale

5b)

Replace, see section 8.8

vi)

Overgassed

6al

Check gas pressure and adjust, see section 6.4

6b)

Check restrictors, see section I .2

(VII) Isolating valves not fully oper I

7) Open fully see section 6.2

5) Hot water does not

Water govenor sticking

Lubricate and replace,

operate over

see section 7.5

temperature range

ii)

Low inlet water pressure

2) Ensure all down stream stop cocks open

iii)

Inlet water filter blocked

3) Clean and replace, see section 7.5

iv)

Incorrect venturi fitted

4) Replace with 5.4 mm diameter, see section 8.7

v) Hot water limit stat out of calibration

5) Replace, see section 8.16

vi)

Solenoids not operating

6) See section 9.2. Flow chart 1

vii)

Pressure switch hunting

7) Replace, see section 8.23

viii)

Low inlet gas pressure

8) See section 6.4

5) No main burner

7) Safety valve discharges

i) Lack of water flow

ii) Pump jammed iii) No water iv)

Flow switch not operating

v) Heating thermostat faulty (CH only)

System pressure too high

ii)

Not isolated from mains

iii)

Vessel lost air charge

1) Checks valves are open, see sections 6.1 and 6.2

2) Manually check, see section 6.2 (8)

3) Fill system, see section 6.2

4) Replace switch, see section 8.34

5) Replace see section 8.14

Adjust to 1 bar cold

2) Remove filling loop

3) Recharge to 0.65 bar,

see section 8.24

iv) Secondary

heat exchanger (water to water).

Internal water leak.

4) Replace, see section 8.12

3) Pump noisy

Air in system

ii)

Air seperator not venting

Needle stuck

Float stuck

iii)

Debris in pump

iv)

Water filter blocked.

Vent radiators

2) Open vent on air separator,

see section 6.2 (4)

2a)

Release and lubricate

2b)

Release and lubricate

3) Clean and replace, see section 8.10

4) Clean

and replace, !ee section 7.6

Page 43

PROBLEM CAUSE REMEDY

9) Excessive temperature rise across boiler

i) Return filter blocked

ii)

Low water flow rate

Pump defective

High system resistance

c) Gas filter inadvertantly fitted in flow

or return connection

iii)

Gas rate too high

Clean and replace, see section 7.6

2a)

Replace, see section 8.10

2b)

Fit by-pass, see section 3.16

2~) Remove and refit, see section 4.5

3) Adjust, see section 6.4

10)

Rapid cycling high/low or high/low/off

Low water flow rate

ii)

Limit stat out of calibration

iii)

By-pass if fitted not regulated

iv)

Blocked heat exchanger

See ‘System guidance’ section 3.3

Replace, see section 8.15

Adjust, see section 6.5

Clean or replace, see section 8.8

11)

Fan on high speed

continuously

Defective printed circuit board

Replace, see section 8.18

12) Lossofpressure shown on gauge

Leak on system

ii)

Leak on appliance

Locate and rectify

2) Locate and rectify

13) Gain in pressure shown on gauge

Filling loop still fitted and letting by

Close stop cocks and remove

ii)

Blockage in expansion chamber flexible hose 2) Clear blockage

iii)

Secondary heat exchanger (water to water). 3)

Replace, see section 8.12

Internal water leak

Page 44

?O A 46

short list

380

283

78 & 267

- *’

0 0 68

Key

N”

26 27 40 42 46 55

68 78 82

120

138

165 229 263 267 275 283 291 380 396 429 430 451

Descridion

Boiler thermostat knob

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

Ignitor push button

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

Water temperature control knob

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

Burner head assembly

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

Manifold assembly with injectors

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

Manifold gasket

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

Solenoid valve assembly

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

Ignition micro-switch

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

Electrode and lead assembly

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

Thermocouple

and

Safety overheat thermostat assembly

Pump motor Grundfos 15/60

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

Change over valve micro-switch

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

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

Thermometer

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

Pressure relief valve

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

Printed circuit board

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

Domestic hot water thermostat 57°C

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

Heating thermostat 50” C - 82” C

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

Limit thermostat 85°C

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

Pressure gauge kit

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

Fan assembly

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

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

Pressure switch kit

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

Frost thermostat (ll” C)

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

Frost thermostat (3” C)

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

Flow switch

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

Chaffoteaux et Maury Limited,

number

366421 366846 264591 264592 264593 264477 366865 264793 264828 264602 383722 366897 366933 264630 264637 264547

264552 264649 264556 265121 264882 264663 264664 264666

Trench Lock, Trench, Telford, Shropshire TFl 4SZ

Telephone : Telford (0952) 222727 - Telefax : (0952) 243493

Maker’s

part number

44269.00

59600.00

44267.00

69106.00

81011.00

71226.00

81030.00

78989.00

70308.00

74723.00

1000772.00

1001156.00

44333.00

1001898.00

78867.00

100606.30

81420.00

56974.00

81180.00

56401.00

81054.00

71897.00

71896.00

1000658.00

ESP028

Chaffoteaux & Maury Celtic FF Installation And Servicing Instrucnions

Specifications and Main Features

Frequently Asked Questions

User Manual