Celtic
FF
ROOM SEALED FANNED BALANCED FLUE
COMBINATION BOILER
G.C.
No.
47 980
01
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
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
_-
F
SIDE OUTLET
-
A
B
C
D
E
F
c
H
J
K
1
M
N
P
R
S
T
-
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
2
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.
3
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
FM
Celtic and subtract 37 mm (this will give required
wall face
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
I
*j -_--- )--
“--P,
--t-l-f-
firmly pushed together.
1
- Cut same amount off aluminium flue duct (plain
L-&L- 7
end).
Flue extension accessory
L
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.
min.
Fig. 3
SIDE OUTLET ASSEMBLY
cut off
from this end
ci
I-
_ - _I
<- 7,
\
I I
\
a-
L
:
-----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
1.
Distance from internal corner 300 mm without
kit, 150 mm with kit no. 76216 (GC No, 264 833).
OE
WI
L”E
? 5
OE
L”E
f
1
\
2
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.
4
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.
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.
5)
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 :
1.
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
Id
6
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
1 Switch 1 1
S$Toff
1 \siq
S!!h 1
Pressure
over
Switch on
Valve
,r
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.
7
I
OR.
ORANGE
GN. GREEN YELLOW
B.
BLUE
I
R. RED
I
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 -
r
u WATER FLOW 1
24V
1 e)L- xwITCH Or E Bk
’ ‘Ll
Bk
FAN
CAPACITOR/
PRESSURE SWITCH
I 3
BOILER THERMOSTAT
HEATING
Fig. 9
ILLUSTRATED WIRING DIAGRAM
L
8
2
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
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.
D)
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.
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.
10
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.
1
2
3 4
5
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 :
I)
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.
11
heating system
f\
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
L
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
I
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 :
1)
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.
12
Heating & stored hot
water - spring return
1 1
valves only
Heating & stored hot
water using flow share
relay required
Fig. 15
1
Remote by-pass
Celtic
remote by pass
with L/S valve
hot water
3.13 Heating and hot water systems
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 constraints associated with mul-
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).
13
4.
INSTALLING THE BOILER
A
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 :
I)
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
a)
Select the location for the boiler referring to the
dimensions shown in 1.1 and 1.3 terminal location
positions (2.4 - fig. IO).
b)
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)
d)
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.
b)
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
d)
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.
f)
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.
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