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Celtic dus
Room Sealed Fanned Balanced Flue
Combination Boiler
GAS SAFETY (INSTALLATION AND USE) REGULATIONS.
It is the law that al1 gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. G20)
G.C. No
from serial number 994 225 395 - 3
47 980 07
1
Installation and
Servicing Instructions
(leave these instructions with the user)
Looking Good.Heating Better
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Supplied By www.heating spares.co Tel. 0161 620 6677
CONTENTS
Page No.
Health and Safety Information
1.
2. INSTALLATION REQUIREMENTS
INTRODUCTION
1.
1.1.
1.2.
1.3.
1.4.
1.4.1.
1.4.2.
1.4.3.
1.5.
1.6.
1.6.1.
1.6.2.
1.6.3.
1.6.4.
1.6.5.
1.6.6.
1.6.7.
General description, special features, guarantee
Dimensions Fig. 1
Technical Data
Clearances
Wall thickness
Rear flue outlet Fig. 2
Side flue outlet Fig. 3, Fig. 3a, Fig. 3b
Other flue arrangements Horizontal Fig. 3c
Description of components and location Fig. 4
Description of operation
Central heating Fig. 5
Hot water Fig. 6
Gas (also see 2.7)
Functional flow diagram Fig. 7,
Safety controls
Functional flow wiring diagram Fig. 8
Illustrated tiiring diagram Fig. 9
1
2
2
3
3
3
4
4
4
5
6
6
6
7
7
7
8
8
3.
2. 1. General
2.2. Location
2.3.
2.4. Siting the flue terminal Fig. 10
2.5. Air supply
2.6. Electrical supply
2.7. Gas supply
SYSTEM GUIDANCE
3.1.
3.2
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.9.1.
3.9.2.
3.10
3.11
3.12
3.13
3.14
Water circulation system
General
System controls
Pump Fig. 11
Expansion vessel
Mains water connection
Filling and recharging Fig. 12, Fig. 13 (page 12)
Make up system
Pipework
Domestic expansion vessel
Boiler replacement
Existing systems
Cylinder
Inhibitors and water conditioners
Add on devices
Heating and hot water systems Fig. 14, Fig. 15, Fig. 16, Fig. 17
Shower application Fig. 17a
9
9
9
9
10
10
10
10
11
11
11
11
11
11
11
11
12
12
12
12
12
13
14
(9
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CONTENTS (cant)
Page No.
4.
5.
INSTALLING THE BOILER
General information
4.1.
4.2.
4.3.
4.4
4.5.
4.6.
47
4.8.
4.9.
4.10.
4.11.
4.12
4.13.
EXTERNAL CONTROLS
5.1.
5.2.
5.3.
Positioning the boiler Fig. 18
Rear outlet flue Fig. 19
Side outlet flue Fig. 20
Jig plate Fig. 21
Gas and water connections Fig. 22
Water connections
Gas connection
Fitting the boiler Fig. 23
Fitting the safety valve Fig. 24
Fitting the flue (up to 700 mm long) Fig. 25
Fitting the flue (over 700 mm long)
Connection the pressure switch Fig. 26
Electrical connections Fig. 27
Time clock - Time clock and room stat Flg. 28 19
Time clock and zone valves (spring return) Fig. 29 19
Programmer and zone valves Fig. 30 20
15
15
15
16
16
16
16
16
17
17
17
18
18
18
5.4. Honeywell & Satchwell controlled zones Fig. 3 I 20
5.5.
Frost thermostat Fig. 32
20
6.
7.
COMMISSIONING
6.1.
6.2.
6.3.
Hot water circuits, filling Fig. 33
Central heating circuits, filling, Fig. 34 21
Lighting the boiler Fig. 35
6.4. Gas rate adjustment Fig. 36, Fig. 37, Fig. 38
6.5.
6.6.
D.H.W. flow rate adjustment (see also 6.7, Fig. 39a)
Adjusting the heating system by-pass Fig. 39
6.7. D.H.W. flow rate adjustment Fig. 39a
6.8.
6.9.
ROUTINE SERVICING
Pump switching adjustment Fig. 39b
Fitting the casing Fig. 40
General requirements
7.1.
7.2.
7.3
7.4.
7.5.
7.6.
7.7.
To remove front casing Fig.4 1
To remove combustion chamber Fig.42
To remove burner assembly Fig.43
To remove pilot Fig.44
To clean heating return filter Fig.45
Cleaning and replacement of parts
To check operation of safety valve Fig.46
21
21
22
23
23
23
23
24
25
25
25
26
26
26
27
27
(ii)
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CONTENTS (COW
Page.
8.
REPLACEMENT OF PARTS
8.1. To remove thermocouple Fig. 47, Fig. 48
8.2. To replace electrode and lead assembly Fig. 49
8.3. To replace overheat thermostat Fig. 50
8.4.
8.5.
8.6.
8.7.
8.8.
To replace ignition microswitch Fig. 5 1
To replace C.O.V. microswitch Fig. 52
To replace flow switch assembly Fig. 53
To replace venturi Fig. 54
To replace primary heat exchanger Fig. 55
28
28
28
29
29
29
30
30
8.9. To remove electrical control box Fig. 56, Fig. 56a (page 33) 30
8.10. To replace pump head Fig. 57 31
8.11. To replace change over valve Fig. 58, Fig. 58a (page 34) 31
8.12. To replace secondary heat exchanger Fig. 59 32
8.13. To replace air separator Fig. 59a
32
8.14. To replace boiler thermostat Fig. 60 33
8.15.
8.16.
8.17. To replace spark generator Fig.63
8.18.
8.19.
8.20.
8.21.
8.22.
8.23.
8.24.
8.25.
8.26.
8.27.
8.28.
8.29.
8.30.
8.31.
8.32.
8.33.
8.34.
To replace boiler limit thermostat Fig. 61 33
To replace D.H.W. thermostat Fig. 62 33
34
To replace P.C.B. Fig. 64 Electrical box layout Fig. 65
To replace therm0 electric valve Fig. 66
To replace solenoid valves Fig. 67
To replace heating body linings Fig. 68
To replace fan assembly Fig. 69
To replace pressure switch Fig. 70
To re-pressurise expansion vessel Fig. 7 1
To replace pressure gauge Fig. 72
To replace the domestic expansion vessel Fig. 73
To replace main burner Fig. 74
To replace burner manifold assembly Fig. 75
To replace pilot injection Fig. 76
To replace expansion vessel Fig. 77
To replace viewing window Fig .78
To replace main gas valve body Fig. 79
To replace the thermometer Fig. 80
To replace safety valve Fig. 8 1
34
35
35
35
35
36
36
36
37
37
37
38
38
38
39
39
39
9.
FAULT FINDING
9.1.
9.2.
9.3.
Logic sequence
Central heating operation
Domestic hot water operation
9.4. Fault finding tabular chart
SHORT SPARE PARTS LIST
(iii)
40
41
42
43
Rear cover
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CONTROL OF SUBSTANCES HARMFUL TO HEALTH
IMPORTANT
To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to
provide information on the following substance that is contained in this appliance.
Descriution
Material
Precaution8
Combustion Chamber Lining
Alumino Silicone Fibre
During servicing, keep the dust generation to a minimum and avoid
inhaling any dust and contact with the skin and eyes. Normal handling
and use will not present any discomfort, although some people with a
history of skin complaints may be susceptible to irritation.
When disposing of the lining ensure that it is securely wrapped and
wash hands after contact.
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1. INTRODUCTION
The Celtic plus is a wall mounted, low water content
fanned balanced flue appliance suitable for central heating
and hot water via a non storage water to water heat
exchanger. The maximum output is 23 kW (78480 Btti).
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, electric
connection box, and domestic expansion vessel.
The standard flue assembly supplied with the boiler is
100 mm (4 in) dia pipe, can be directed to the rear or to the
lett 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,
3c).
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.
- Water flow switch to protect appliance.
- Suitable for showers with compatible mixer valves.
Guarantee
The manufacturer’s guarantee on this appliance is for 12 months from the date of purchase. The guarantee is void, if the
appliance is not installed in accordance with the recommendations made herein.
1.1 DIMENSIONS
B
1 i
1-1
Mains water in. 15 mm
b
f
REAR OUTLET
FLUE
/ T’
--
F
SIDE OUTLET
FLUE
mm
A
B
C
D
E
F
G
H
J
K
L 150.0
M
N
P
R
S
T
820.5
391.0
365.0
100.0
169.5
654.5
43.0
50.0
75.0
260.0
972.5
13.0
61.0
30.0
152.0
112.0
in
32.3
15.4
14.4
4.0
6.7
25.7
1.7
2.0
3.0
10.2
6.0
38.3
0.5
2.4
1.2
6.0
4.4
Fig. 1
2
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1.2 Technical Data
Hot water
Input ...........................................
Output.. ......................................
Water flow raised
45 “C (81
Water flow raised
35 OC (63 OF) ..............................
Water ffow raised
30 ‘C (54 OF).
Maximum
Maximum
Minimum working pressure..
Gas rate..
Burner pressure..
Central heating
Maximum input..
Maximum output..
Gas rate (maximum).
Burner pressure..
Minimum input..
Minimum
Gas rate (miniium)
Burner pressure..
Minimum
Maximum
Manifold injectors 14 of..
Pilot injector..
Gas section restrictors 2/3 valves
OF). .............................
.............................
temperature.. .............
pressure.. ...................
......
....................................
........................
........................
......................
..................
........................
........ . ................
output.. .......................
...................
........................
flow rate .....................
pressure.. ................... 2.5 bar
............
..............................
l/3 valve..
28.90 kW 98612 Btu/h
23.00 kW 78480 Btu/h
7.4 Ymin
9.5 Ymin
11.1 Ymin
50 OC 140 OF
10 bar
.6 bar
2.743 m%-r
11.8 mbar
27.64 kW 94313 Btulh
22.00 kW 75068 Btu/h
2.63’m3/h 92.98 f&h
11.2 mbar 4.5 in wg
10.85 kW 37020 Btu/h
7.64 kW
1 .O m?h 35.31
1.5 mbar
3OOK-l
1.28 mm
0.3 mm 0.01 in
4.4 mm 0.17in
2.3 mm 0.09 in
1.7 gaI/min
2.1 gaifmin
2.5 gallmin
150 psi
9 psi
96.87
4.7 in wg
26062 Btu/h
0.6 in wg
1.1 gai/min
36.5 psi
Natural gas
0.05 in
ft3fh
ft3lh
Connections
Gas.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating
Heating return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains cold water inlet . . . . . . . . . . . . . .._..................
Hot water outlet ._........................... . . . . . . . . . . . . . .
Electricai supply 240 V - 50 Hz, fused at 3A.
Electrical
Internally fused, two at 2A (BS 4265)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition - Anstoss continuous spark generator
Electrode - Chaffoteaux et Maury Ltd, spark gap 5 mm
Boiler thermostat - EGO (82’C)
Boiler limit thermostat - SOPAC /JAEGER (85X)
Hot
Safety overheat thermostat (Tokoswitch - ( lOSaC)
Gas valve - AEMF
Fan motor - SEL.
Pressure switch - DUNGS 102 Pa / 55 Pa
Pump head - GRUNDFOS UP 15160
C.H. expansion vessel initial charge piessore - 0.65 bar (9.6 psi)
Domestic expansion vessel initii charge pn?ssure - 2 bar (30 psi)
flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
water
fim?t thermostat - SOPAC /JAEGER (57°C + 3°C)
(Eimwood - (105°C)
22 mm copper
22 mm copper
22 mm copper
15 mm copper
15 mm copper
195 watts
42 kg
4 litres
92.4 lb
7 pints
1.3
1.4
Minimum Clearances around Boiler
Top above air duct . . . . .
Bottom below case. __ __. _. _.
. . . . .
Sides
Front. .
I
50 mm (2 in)
150mm (6in)
100mm (4ir-l)
6GOmm(24in)
Wall Thicknesses
The standard flue assembly can accomodate the foliowing 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 waii. As this dimension
increases. so the maximum side wail thickness available decreases).
Extension flue assemblies are available to accomodate wali 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, wili 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 horizontal. Greater length must not be used.
See sections 1.4.1. 1.4.2. 1.4.3.
3
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1.4.1
1.4.2
Rear Flue Outlet Horizontal
REAR OUTLET ASSEMBLY
Fig. 2
Side Flue Outlet Hohontaf
To cut flue assembly to length
- Measure wall thickness (I).
- Add 74 mm, tthis will give required Ientgh Q.
- Mark plastic air duct for length (L) and cut off
surplus (from plain end).
N.B. If extension sections are used ensure these are
fumly pushed together, see figs. 3b and 3c and a fall of 5
mm per metre length should be provided (see section
4.3).
- Cut off same amount from aluminium flue duct
(plain end).
To cat flue assembly to length
- Measure from external wall face to centre line of
Ceftk
plus and substract 37 mm (this will give
required length “L”) .
- Cut off surplus t?om plastic air duct (plain end).
N.B. If extension sections are used ensure these are
firmly pushed together, see figs. 36 and 3c and a fall of 5
mm per metre length should be provided (see section
1.4.3
Fig. 3
Fig. 3a
SIDE OUTLET ASSEMBLY
standard air duct
PLASTIC AIR DUCT
Other ffue Arrangements Horizontal
Fig. 3c
Flue extension accessory
Part No. 62823.00
1. Distance from internal corner 300 mm without
kit,107 mm with kit No 76216 (GC No 264 833).
2. Distance below balconies or eaves 200 mm
without kit, 107 mm with kit No 76216 (GC No
264 833).
3.
Appliance is normally supplied packed with
standard 650 mm staight flue section. Additional
straight extension lengths of 1 metre, part No
62823 (GC No 264 459). can be use 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 + 12 should not exceed 1.6 metres
horizontally.
- Cut off same amount from
4
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Description of Components and Location
5
6
2i 2i 2b
Fig. 4
The appliance is mounted in a steel case which has a
white epoxy resin paint fmish.
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,
a hook is 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 ffame failure.
6. Multigas burner comptisig: stainless steel blades (14)
and a manifold with injectors (14).
7. Gas section including thermoelectric valve and two
stage solenoid valves.
31 19 17 18
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 57
f3O c.
9. Change over vsfve :
The valve is activated by a demand for domestic hot
water, closes the heating circuits, and directs water to the
secondary heat exchanger.
IO.EIectriciaf box containing :
Mains connection
Fuses
Priited circuit board
Connections for external controls
Connections for fan, pressure switch and flow switch
Connections for pump
Connections for change over valve and for gas solenoid
valve
11. Solenoid valve :
Block on which 3 valves are mounted :
l/3 valve -1st stage valve-heating and hot water (blue)
Z/3 valve - full output to hot water (black)
2/3 valve - (variable valve) central heating (orange)
12. Grandfos pump motor
13. Air separtor 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 tinned tube heat exchanger protected with silicone
resin paint. Combustion chamber in aluminium coated
steel. Combustion chamber lining - ceramic fibre panels.
16. Hirgh Emit thermostat (manual reset).
17. Water service tap (not illustrated).
18. Flow irsofating valve - heating (not illustrated).
19. Gas service tap (not illustrated).
20. Domestic hot water outlet with regulator (not
illustrated).
21. Safety valve with drain tap (not illustrated).
22. Heating return isolating valve with filter (not
illustrated).
23. Ignition button.
24. Thermometer indicating boiler flow temperature.
25.
Fuses.
26. Selector stitch - hot water only/OFF/heating and hot
water.
27. Thermostat to regulate heating ffow temperature.
28.
Pressure gauge.
29. Pressure switch (not illustrated).
30. Domestic expansion vessel (not illustrated).
31. Water flow switch (not illustrated).
32. Data badge position.
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1.6 Description of Operation
The Celtic plus is 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.
1.6.1 Central Heattng
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 passes through an
air separator and air purger (17). The return water
passes through the heat exchanger (2) where it is hea-
ted. It then passes through the change over valve (19)
which in heating mode is in its rest position 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 (11)
and variable solenoid valve (IO).
The liiit thermostat (16) set to 85” C closes both sole-
noids valves in the event of its set temperature beiig
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 pilot. If the high limit thermostat ope-
rates it is necessary to manually re-establish the pilot.
An expansion vessel (13) is fitted in the primary circuit.
(see
fig. 5)
1.6.2 Hot Water
When there is a demand water flows in from the cold
mains supply (26) through the water section part (35) of
the change over valve (19). The inclusion of a venturi (24)
produces high pressure under the diaphragm (23) 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.
Thii 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 iixed temperature thermostat
(32) which operates on the 2/3 faed solenoid (12).
The D.H.W. flow rate is adjustable by a restrictor (25) and
a limiting thermostat (32) reduces the gas rate when the
domestic hot water reaches 57°C by interrupting the
electrical supply to the hot water solenoid (12).
If the primary circuit reaches 85OC the limit thermostat (16)
closes both solenoids valves.
A domestic expansion vessel is fitted in the D.H.W. circuit
(36).
(see
fig.
6)
Central Heating
13
m
Hot Water
4
15
16
27
Fig. 5
6
_----.
Fig. 6
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1.6.3
Gas (see figs. 5 and 6)
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 ot 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.
1.6.4 FUNCTIONAL FLOW DIAGRAM
When the ignitor button is slowly released gas is admitted
to the underside of the solenoid valves (10.11 and 12).
There are 3 solenoid valves: the centre (blue) valve (11)
frxed at l/3 of max rated output the right hand hot water
(black) valve (12) f=ed at 2/3 of maximum rated output,
the left hand central heating (orange) valve (10) which is
variable up top 2/3 maximum rated output. The gas
admitted by the orange valve is varied by adjuster (6) (see
section 6.4).
Fig. 7
1.6.6 Safety Controls
In addition to the normal safety controls the
incorporates the following feature.
Celtic
plus
Should the central heating water flow reduce to below 300
l/h (1 ,l gavmin) the gas supply to the burner is turned off,
see fig. 4 (31) and figs. S&6 (37).
7
t
Domestic ’
Water 57°C
Thermostat
Fixed 85°C Fixed 85°C
Limit -
Thermostat
I
T
Limit
Thermostat
t
Boiler 82°C
Control
Thermostat
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1.6.f
FUNCTIONAL FLOW
WIRING DIAGRAM
1.6.7
PRINTED CIRCUI
ILLUSTRATED WIRING DIAGRAM
ALL CABLES ARE 240V EXEPT WHERE THEY ARE INDICATED 24V
T BOARD
CHANGE OVER VALVE
SOLENOID VALVE
2l3c l/3 2l3s
V
W
GR
L
ORANGE
BLUE
BLACK
BROWN
RED
VIOLET
WHITE
GREY
PRINTED CIRCUIT
SELECTOR SWITCH 1
-
B 7
--
SPARK GENERATOR u
WATER FLOW
SWITCH
8
- LIMITSTAT
SOILER TH HOT WATER
--~“I -
IGNITION BUTON
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2
2.1
2.2
INSTALLATION REQUIREMENTS
General
The installation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations,
Building Regulations and current Byelaws of the Local
Water Undertaking. It should be in accordance also
with the current B.S. Codes of Practice and the British
Gas Specifications for Domestic Wet Central Heating
Systems and any relevant requirements of the local
Gas Region, Local Authority Building Standards
(Scotland) Regulations, and the Safety Document 635,
The Electricity at work Regulation.
Detailed recommendations are stated in the following
British Standard Codes of Practice:
B.S. 6891. B.S. 6798, B.S. 5440 : 1 and 2, B.S. 5449: 1,
B.S. 7593, BS 5546 B.G.DM2, B.S. 4814, B.S. 7074 1
e 2,
B.S. 7671.
Note : Gas Safety Installation and Use Reg. It
law that aII gas appliances are installed by competant
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.
is the
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 B.S. 7671 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 intemaI 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 boiler 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.
2.3
2.4
Water Circulation System
The Celtic plots is suitable for SEALED SYSTEMS
ONLY and should be installed in accordance with the
relevant recommendations given in BS 6798. 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 boiler must NOT be
installed so that the terminal discharges into another
room or space e.g. outhouse or closed in lean-to. It is
important that the position of the terminal allows a
free passage of air across at aII times. The minimum
acceptable clearances from the terminal to
obstructions and ventilation openings are specified
below (fig. 10).
Horizontal Flue
Terminal positions
A - Directly below an opening, windows etc
or adjacent to an opening . . . . . . . . . . . . . . . . . . . . . .
B - Below gutters soil pipes or drain pipes . . .
C - Below eaves . . . . . . . .
D - Below balconies or car port roof. . . . . . . . . . 200 mm*
E - From a vertical drain pipe or soil pipe . .
F - From an internal or external corner . . . . . . . . 300 mm*
G - Above ground roof or balcony level. . . . 300 mm
H - From a surface facing the terminal. . . . . . . . . 600 mm
J - From an opening in the car port
(e.g. door or window) into dwelling.. . . . . .1200 mm
K - Vertically from a terminal on the same
wall . . . . . . . . . . .._ . . . . . . . . . . . . . . . . . . . .1500 mm
L - HorizontaIIy from a terminal on the
same wall . _.... . .._... . . .._. . . . . . . . . . . . . . . . . . . . . .
* (107 mm)
kit No. 76216.00 (G.C. 264 833).
minimum clearance using
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Win clearances
300 mm
75 mm
200
mm*
75 mm
300 mm
Fig. 10
9
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2.5
2.6
BUILDING REGULATIONS 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 IX 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).
Quinnef Barret & Quinnel Wiieworks
Old Kent Road
London SE15 INL Tel. 081-639-1357
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.
IMPORTANT NOTICE : TIMRER FRAMED HOUSES
IF THE APPLIANCE IS TO BE FITTED IN A TIMBER
FRAMED BUILDING IT SHOULD BE FITTED IN
ACCORDANCE WITH THE BRITISH GAS
PUBLICATION - “GUIDE FOR GAS INSTALIATIONS IN
TlMBER FRAMED HOUSING” reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCAL REGION OF BRITISH GAS OR C.O.R.G.I.
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.
Air
direct
from
Air
Position
High level 261 an2 (40 in2)
Low level 261 cm2 (40 in2)
of vents
km mom
130 a-t-12 (20 in2)
130 cm2 (20 in2)
outside
Electrical Supply
- This appliance must be earthed.
- AU wiring external to the appIiance must conform to
the current B.S. 7671.
- The Celtic plus requires a 240 V - 50 Hz suppIy.
- 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. AltemativeIy,
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 mm2 (24 x 0.2 mm)
three core to BS 6500 Table 16.
2.7 Gas Sapply
The Celtic plus requires:
2.743 m3/h (96.87 ft3fh) gas flow.
The meter and supply pipes should be capable of
delivering 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 desaibed in BS 6891.
SYSTEM
GUIDANCE
General
The low water content
expansion vessels, safety overheat thermostat,
temperature and pressure gauges, and safety valve.
The flow temperature is adjustable and gives a
nominal 82 “C (180” F) on its maximum setting.
Detailed recommendations for water circulation are
given in BS 5546. Whilst the boiIer 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 is given
in section 3.13. Thermostatic control should be used
in the heating circuits and the cylinder if one is titted.
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 boiIers.
The appliance has two separate functions, to provide
heating and hot water on demand. It can have a thiid
which is to supply hot water high demand through the
use of an indirect cylinder, where there is more than
one bathroom or if the standard and appointments of
the property, such as basins in al1 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 simukaneous demand outlets bathrooms etc, whilst the benefits of high efficiency in
generally small quantities of hot water. can be fulIy
utilised in kitchens, cloakrooms and so on.
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 ffow
share or priority pattern.
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 tail, smaII diameter cyIinder.
See section 5 for possible wiring arrangements.
A domestic expansion vessel is Mted to the boiler with
a capacity of 0,16 litres, prior to the secondary heat
exchanger which enables the boiler to be connected
to a cold main water supply containing a non-return
valve or any device containing a non-return valve.
Celtic
pltls boiler includes the
10
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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 plus 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 nonreturn valve should be less than 1 m (3 A) above the
top of the appliance and idealIy should be as close as
possible to the hot water outlet.
3.2 System controls
The boiler is electrically controlled and is suitable for
most control schemes currently available including
thermostatic radiator valves and motorised valves.
When using motorised valves the controls should be
arranged to switch off the boiler when circuits are
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.
(see
fig. 17).
3.3 Pump
The boiler is fitted with a Grundfos UP.15/60 pump
head. The graph (fig. 11) indicates the residual head
available for the system.
flow rate in g.p.m.
1
2 3 4
At the design fIow temperature and the initial system
pressures quoted the maximum allowable system
volume is 75 litres.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.
4
. . . . . . . . . . . . .._.................................
Boiler
Small bore pipework... . . . . . . . ._ . . . . . . ..0.3 litres (0.07 gals)
Microbore pipework. . . . . . . . . . . . . . . . . . . . . . . . . .7 litres (1.5 gals)
Steel panel radiators . . . . . . . . . . . . . . . . . . . . ..2.3 litres (0.5 gals)
per 0.292 kW (1000 Btti) of system output
Hot water cylinder . . . . . . . . . . . ..___........ 2
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
litres (0.8 gals)
per 0.292 kW
litres (0.44 gals)
3.5 Mdns 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 (see
Byelaw No. 14 and figs. 12 and 13).
3.6
5
mg pdnt (see B.S. 5449)
Filling and recharging can be done :
1) Through a temporary hose connection to mains
water.
A stop-valve should be fitted to the service main outlet
and a double check valve assembly and stop-valve
should be fitted to the system side of the temporary
hose (see fig. 12).
2) A cistern used for no other purpose connected to
the mains water.
The static head provided by the cistern must be
sufficient to satisfy the designed initial system
pressure. The supply pipe from the cistern should
3.7
include the double check valve assembly and
stopcock (see fig. 13).
3.8
Fig. 11
B
z H
H
z
flow rate in Lre”s/hLF
8888
:
r
8
s!
3.9
3.4 Expansion vessel
The expansion vessel which is fitted on the front of
the combustion chamber 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
(9.7 p.s.i.).
THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHARGING AND NOT A
VENT POINT.
11
Make ap 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
filliig point (see section 3.6).
Plpework
Pipework can be of copper or suitable plastic, small
bore or microbore with capillary or compression
jointing to a high standard, leak sealant must not be
used in the system.
Domestic expansion vessel
The expansion vessel which is fitted on the cold water
supply to the secondary heat exchanger accomodates
domestic hot water expansion. The vessel has a
capacity of 0.16 litres (0.035 gals) and is charged to a
pressure of 2 bars (30 p.s.i.); it has a maximum
working pressure of 10 bars with an allowable
pressure peak of 14 bars.
Supplied By www.heating spares.co Tel. 0161 620 6677
Air inlet Air inlet
valve valve
iose
Double check
Heating circuit / valve assembly 1 r u”io”s~
valve
(a) Non-automatic filling and make-up. Temporary hose filling loop avaible, Pt.No.CHL112
valve assembly
Test cock
Hose
,,,io”;~-J
P
I’
I’
g---_?:
Temporary
Overflow
Mains
water
;I
supply
Mains
Double check
valve assembly
Test cock
(b) Automatic filling and make-up.
Fig. 13
3.9.1 Boiler replacement (retrofit)
In an old system where the boiler is beiig replaced,
we recommend the use of a strainer, fitted with a
drain tap on the heating return, designed to retain
scale particles and other soIid debris It is good 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.
(see BS 7593).
3.9.2 Existing systems
Valves and joints should be carefuky 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 Cyhder
Where a domestic hot water cylinder is used with the
Celtic
plus it MUST be of the indirect and high
recovery type to BS 1566 Pt 1 Single feed cylinders
are not suitable for use with this appliance. Flow and
return pipework to the cylinder should be in 22 mm
pipe.
3.11 InMbitors and water conditioners
(see BS 7593)
Chaffoteaux et Maury generaIIy recommend the use
lA LA
above highest
hA
stop
valve
of inhibitors in systems using the
The following are the appliance manufacturer’s
recommendations :
I) Use only a British Gas or simiIar approved inhibitor,
These manufacturers can assist with the selection.
Grace Dearbon Ltd - Widnes - Cheshire WA8 8 UD
Tel: 051 424 5351.
Fernox Manufacturing Company Limited Britannica
Works. Clavering, Essex CBI1 4QZ
Tel: 0799 085811.
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 fmally refiuig the system.
5) In-line water conditioners both of chemical and
magnetic tyre are suitable for use with the Celtic plus.
point in the
system and
satisfy the
designed initial
system pressure
3.12 Add-on devices
It is important that no external control devices e.g.
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 void and also
infriige the Gas Safety (Installation & Use) Regulations.
Celtic
pIus boiler.
12
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Celtic plffs
Heating & stored hot
water - spring return
1
valves only
AAVT h
3.13 Heating and hot water systems
Figs. 14, 15, 16 and 17 indicate various layouts for
the production of hot water. It is recommended that
only a high recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special saturated heat exchanger in an indirect
stat.
cyIinder may be desirable.
instant hot
water low
demand
outlets
Fig. 14
water low
7g. 15
Celtic plus
I
1
Heating & stored hot
water using flow share
relay required
When replacing an exisiting cylinder storage system
with an instantaneous type system it is essential that
a11 redundant pipework is removed and dead legs
eliminated.
The consideration of heating systems using
thermostatic valves should ensure that the minimum
flow rate through the appliance is maintained at all
times and in this connection the remote by-pass is
preferred (see fig. 17).
Fig. 16
Celtic
plus
Remote by-pass
remote
by pass
with US valve
I
hot water
13
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3.14 Shower Application
The appliance can be used to supply hot water to separate. shower draw-off It must not be used to supply more than
one shower mixing valve.
The recommended pipework arrangement for a shower is shown below and the hot supply to the mixing valve should
be the first draw off.
Celtic plus
n
Valve
HOT WATER
HOT
COLD
Fig. 17 a
It is important to select a compatible shower for the Celtic plus The following manufacturers can assist with the
selection
a
1
COLD WATER
New Team Ltd Meynell Valves Ltd
Brunell Road
Earlstree industrial Estate Bushbury
Corby
Northants NN17 2LF West Midlands WV1 0 9LB
Tel.No.0536-62822
Aqualisa Products Ltd
Hortons Way
London Road
Westerham
Kent TN1 6 1 BT
Tel.No.0959-63240
Shaw Road
Wolverhampton
Tel.No.0902-28621
Barking Grohe
1 River Road
Barking
Essex IGll OHD
Tel.No.081-594-8898
Do not use the appliance with push on hand showers that tit over hot and cold taps.
14
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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 :
1) The chassis with aII functional parts attached.
2)
Casing comprising :
2 side panels
1 front panel
1 controls fascia cover
1 glass door complete with hinges
4.1
Zt)
Mounting
4) Plastic bag contaXing :
5) Box containing :
6) Box containing :
7) Flue assembly :
8)
Plastic bag containing :
N.B. (i) Flue accessories are not suppIied as standard, and must be ordered to suit (see section 1.4)
bracket comprising :
gas and water connections inc. 4 above.
control knobs
safety valve
wall plugs
screws and fixings.
flue turret with pressure differential switch and 1st flue duct section
plastic wall liner with terminal
flue duct
plastic turret cover
2nd flue section
flue lockiig ring
‘0’ ring
2 gaskets - one cork and one rubber
4 mounting screws with washers for flue turret
flueguide
top support plate
spacing strip
bottom support plate
plastic jig plate connection
gas ffiterlwasher
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. 10). 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. 10)
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.
‘ig. 18
4.2
‘ig. 19
15
Rear outlet ffae
a) Mark vertical centre line for boiler on wall.
b) Mark horizontal centre lie for 107 mm (4.2 in) dia
waII opening and one for upper bracket tixing screws
(A).
c) Using bracket as template mark 4 tixing points (A) and
(B).
d) Mark wall for flue opening using flue guide plate.
e) Drill the wail for the flue opening using a 107 mm (4.2
in) core drill.
f) Drill 4 fixing holes (A) and (B) 7.9 mm (5/16 in) and
Plug.
g) Fii 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.
Supplied By www.heating spares.co Tel. 0161 620 6677
4.3
Fig.
*
D (295 mm minimum)
Slope 5 mm. per metre
1700
2200 156,5
2700
2900
N.B. Dimension (A) decreases
increases due to the required decline of he of 5 mm
20
Per metre.
161
156
155
as
dimension (D)
Side outlet flue
Y
a) Mark vertical centre line for boiler on wall (see fig. 20).
b) Using bracket as a template mark 4 fixing slots (A) and
(B).
c) Mark horizontal lie through the fling slots (A) and
project to side wall.
d) Mark vertical axis of flue opening 112 mm (4.4 in) frorr
comer of wall.
e) Mark wall for centre of flue opening 169.5 mm above
the horizontal on side wall.
0 Drill the wall for the fiue opening using a 110 mm (4.:
in) core drill.
g) Drill 4 f&g holes (for (A) top of slot) and (for (B)
6) Fix bracket to wall using 6 mm x 50 mm wood screw:
provided.
N.B. Ensure bracket is square and plumb to vertical centre
lie before tightening.
4.4
4.5
Fig. 22
+++++
J K L M N
N.B. By using the plastic jig plate the piping system can bt
completed before the boiler is mounted.
a) Attach plastic jig plate to bottom bracket using 4.6 mn
x 10 hexagonal screws provided (fig. 21).
b) Fit copper tails and washers to jig plate, the main:
water inlet tail (M) is the shorter of the two 15 mm tails
c) All connections can either come from above or belou
using the standard tails provided.
N.B. IF THE GAS CONNECTION IS FROM ABOVE THI
PIPE WILL HAVE TO BE SET AROUND THE FLUE
OUTLET, IF THE OUTLET IS TO THE RBAR.
Gas and water
conne!ctions
J) Heating return
K) Hot water outlet domestic
L) Gas inlet
M) Mains water inlet domestic
N) Heating flow
Pipework
a) Copper tails are 22 mm and 15 mm to accep
staight connectors.
Tube dimeter
22 mm
15mm
22mm
15mm
22 mm
4.6
4.7
Water connections
a) Make connections to copper tails using either solder capillary fittings or compression type.
Gas connection
a) The gas connection is 22 mm diameter.
b) Make the gas connection using solder capillary fittings.
N.B. The gas supply pipe must not be less than 22 mm diameter
IMPORTANT #OTB :
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.
16
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4.8
Fig. 23
-ig. 24
d) Fit 14 mm tail drain bend using washer
Fiting the boiler
a) Before hanging the boiler, uncoil wiring harness
(connections to pressure switch) stored by
changeover valve, route through front of chassis and
up front of boiler, pIace into clips.
b) 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
boiier. Use the plain black 3/4 and 112 diameter graphited
fibre washers for water unions, and the white 314
fdter/washer for the gas union.
d) Connect water union using plain washers, working
from left to right.
e) Connect the gas union using the tilter/washer packed
separately either way round.
N.B. As an akemative to using the plastic jig plate the tails
can be fitted to the boiler before mounting, then
connected to the services.
provided.
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 directly over the 22 mm drain and
readiIy visible. A’ tundish arrangement is acceptable. The
connection must NOT be made by a capilary or
compression fitting directly between the 14 mm drain
bend and the 22 mm discharge pipe without a 2 mm air
gap (see fig. 24).
TRE 22 MM DISCHARGE PIPE MUST DISCHARGE TO TE
OUTSIDE OF THE BUILDING WHERE POSSIBLE OVER A
DRAIN. THE DISCHARGE MUST BE SUCH THAT IT WILL
NOT BE RAZARDOUS TO OCCUPANTS OR CAUSE DAMAGE
TO EXTERNAL ELECTRICAL COMPONENTS OR WIRING. TEE
PIPE SHOULD BE DIRECTED DOWNWARDS. IT MUST NOT
DISCHARGE ABOVE AN ENTRANCE OR WINDOW OR ANY
TYPE OF PUBLIC ACCESS AS THB TEMPERATURE OF THE
WATER BEING DISCHARGED MAY REACH 100’ C.
4.10
Fig. 25
Fitting the flue up to 700 mm long
a)
Cut plastic duct (G)
dimension (L)).
b) Cut same amount from aluminium ffue duct (H).
N.B. In very cold weather the plastic air duct becomes brittle,
warm before cutting.
to length required (see fig. 2 or 3
c) Remove plastic turret cover (D) from flue turret (B)
held by two screws.
d) Peel off protective paper from adhesive side of cork
gasket (A) place on mating side of flue turret (B) liniig
up with four clearance holes, press together.
e) Assemble second part of flue duct (H), push fit.
f) Slide lockiig ring (C) and ‘0’ ring over plastic air duct.
g) Slide air duct over ffue duct, engage end of flue duct
into terminal and locate air duct into. turret (B).
h) Slide ‘0’ ring along air duct (C), to contact with the face
of the turret (B). Locate lugs on locking ring (C)
between lugs on flue turret (B). Push together and
turn to lock.
j) Position square channelled rubber gasket (E) on the
flue hood outlet of the boiler, channel facing
downwards.
k) Pass the flue assembly through the wail and seat turret
(B), onto the flue outlet, secure with 4 screws
provided.
N.B. The terminal must extend 13 mm (0.5 in) past the
surface of the external wall.
I) Fit wall plate (F) provided with mastic sealing ring over
air duct to structure.
m) Make good internal wall face where the air/flue duct
assemblies exit the room.
n) Do not fit plastic turret cover ‘D’ until electrical
connections to the pressure switch have been made
(see fig.26).
17
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4.11
Httingthefiueover7OOmmfong
a) Assembly is precisely as detailed in section 4.10 using
the requisite number of extension flue and air ducts. In
particular note the following.
b) The standard ffue duct is always used (both sections)
at the appliance end (uncut).
c) The standard air duct is always used at the terminal
end (uncut).
d) 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.
E) If internal futures prevent the assembled ducts being
passed through the wall from the inside, the ducts
may be pushed through from outside (remove the
lockiig ring (C) and 0 ring ii&).
N.B. see also section 4.3
4.12
4.13
‘ig. 26
Fig. 27
COVER
/
caple retaining clip
L COM (P) RED
Connection to the pressure switch
a) The 3 wires on the harness must be connected.
b) Push spade terminals onto tags COM (P) No (1) and
No
(2)
c) Fit turret cover (D) (fig.25) ensuring that both the air
tube and cables are not trapped.
Ensure that the cable retaining clip is positionned
inside of the cover as shown, (see fig. 26).
Making the electrical connection
N.B. See Section 2.6 for electrical supply requirements
THIS APPLIANCE MUST BE EARTHED.
a) Pull out fuses (A).
c) Open door to left hand side of electrical box.
d) 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.
f) Connect permanent live to L terminal (1) and neutral to
N terminal (2).
g) Connect earth to earth screw on the spade connector
block.
6) Connect external controls - room thermostat etc. across
terminals 3. 4 and 5, (see section 5, fig. 28).
j) Secure cables with cable clamp and locate flex into clip
on boiler chassis.
k) Close door
I) Replace fuses.
N.B. The length of the earth wire between the cable
clamp and the terminal must be such that the live and
neutral wires become taut before the earth wire if the
supply cord is pulled.
In the event of an electrical fault after installation prelimiiary 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 CONNECT-ED
TO TERMINALS 3.4 OR 5.
18
Supplied By www.heating spares.co Tel. 0161 620 6677
5.
EXTERNAL CONTROLS
5.1
Time clock - Tune clock and room stat
Fig. 28
I,
N
L
Supply through :
1. Double pole
fused switch spur
or
2.13A
unswitched plug
and socket
Fused at 3 A.
#k
-
5 l
-
4 m J remove link between terminals 4 and 5.
- N2
N.B. For additional information
contact Time Control Manufactures
boiler terminal blocks
(terminals are not shown in same order
1
as on boiler - follow notation).
Terminal 3 is a neutral for acceleration
if required.
5.2
- The time clock contact must be voltage free (remove external links) and connection between terminals 4 and 5.
the room stat accelerator should be connected if fitted to terminal 3.
Time clock and zone valves (Spring retam)
I
Mains
240 V 50 Hz
fused 3 A. double
pole fuse switched
spur or unswitched
plug and socket
room thermostat
honeywell T60 60B
cylinder thermostat
honeywell L6 41
A
Fig. 29
boiler terminals
(remove link 4-5)
19
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5.3
Programmer and zone valves
External programmer
\
L N tmt water heatiw
c
240
V - 50 Hz supply
0~10~~ ONIOFF
I
IQ
I
room thermostat
I
I-
------,
-
boiler termrnal
blocks
spring return
motorised valves
with end switch.
I-““““!
i
I
I
5.4
‘ig. 30
Eoneyweff Y plan, Satchwelf flow chart 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
5.5
Frostthermostat
It is advisable, if the appliance is fitted in a location
subject to adverse weather conditions, to protect
the system from frost damage by fitting an
additional remote kost thermostat which will over
ride the controls whilst the selector switch is set to
hot water + central heating.
frost thermostat
,--m-m--..----,
boiler terminal block
Fig. 31
Fig. 32
20
345
boiler terminal block
Supplied By www.heating spares.co Tel. 0161 620 6677
6.
6.1
COMMISSIONING
---_ --------------
Fig. 33
Hot water circuits - fiIfing
1) 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 instaIlation by opening taps and closing.
4) Check that “dead legs’ have been eliminated.
5) Check for water soundness and rectify if necessary.
6) Set D.H.W. flow rate as required by adjusting screw
(D) increase (anticlockwise) decrease (clockwise), see
section 6.7.
6.2
Fig. 34
Central heating circcdts - frIImg
1) Ensure that the isolating valves are open (fig. 34 B and
C). N.B. Vale (C) must be turned anti-clockwise by
the knurled sh& antU it dislocates from the thread
and then palled oat horiiontally to its extremity
(approximately 30 mm (1 l/4 ins)).
2) Fill system to charge condition, see section 3.
3) Vent radiators and any high points.
4) Vent air separator by loosening screw (fig. 34) (E) and
purging until no air is apparent N.B. : ensure screw E
is tightened.
5) Set system charge Pressure to design cold pressure.
For a new instaIIation 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.
7) Switch on electrical supply.
8) Manually check pump 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 (D).
9) Switch to HOT WATER + CENTRAL HEATING on
selector switch (A) (fig. 35) switch position (0).
10) Allow pump to run for ii&her lo-15 minutes. Switch
OFF.
11) Isolate water supply and drain boiler by
disconnecting fill system and opening the drain valve
(F). This is incorporated in the safety valve and is
achieved by screwing down the head until the valve
IiAs. Open aI1 low level drain cocks.
12) Remove filter in the return isolating valve (C) and
inspect for any installation debris (see section 7.5), to
clean and replace.
13) Retill system as above.
N.B. It is recommended that this is repeated after the
system has been operated up to temperature to ‘hot
flush’ to remove fluxes and remaining debris.
6.3
Fig. 35
Lighting the boiler
1) Purge gas supply. Switch on eledrical supply
2) Turn the lever on the gas service tap (fig. 34) (G) to the
left. In the open position the flame sign is to the front.
3) TemporariIy locate the two control ‘knobs’ one ther-
mostat knob, one ignition button extension.
4) Switch to HOT WATER + CENTRAL HEATlNG (II) on
the selector switch (A). The fan wiII run at low speed.
5) Press the ignition button (R) and hold in.
a) The fan will change to high speed to purge the combustion chamber. Gas is admitted to the pilot.
b) After approx 14 seconds the spark generator passes a
continuous stream of sparks to tight the pilot.
c) When the pilot is alight - viewed through the sight glass
wait for a further 5 seconds before slowly releasing the
button.
6) When the button is released, while the boiler is set to
heating and any ancillary controls are in demand position,
the boiier will fire.
7) Check for gas soundness using leak detection fluid or
gas detector.
8) Check and adjust gas pressure/gas rate, see Section 6.4
N.B. The thermocoupIe output should be checked at this
stage, should be greater than 12 mv.
21
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6.4
Gas rate aastment
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 (G 20).
The maximum gas rate on hot water is fored and is a
function of the restrictor size. The central heating variable
adjuster is factory set at 75 % i.e for an output of approx
16.5 kW (56248 Btu/h).
1) Switch boiler to the off (0) central position, see section
6.3 (fig. 35).
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 (C).
4) Switch the boiler to hot water and central heating (II)
and check that any fitted external controls are calIiig
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 hot
water regulator, see fig. 4 (20), to minimum and open
the largest volume draw-off tap. The gas pressure
should now be the maximum as indicated in Technical
Data.
6) Switch boiler off (0). Remove pressure gauge and
replace test point screw and gas rate adiuster 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.
3utput ki$
OutpuPOBtu/h ;I 03
Fig. 37
Input / Burner pressure
Input ft3;2
14
12
10
6
I I I I I I
Input m3/h
50
I ! I !
1.25
1.50
Fig. 38
70
60 90 100
I
1.75
/
I Y 9
! 1 !
200
2.25 2.50 2.75
! I
6
5
4
3
.2 .G
&I
22
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6.5
D.H.W flow rate amstment
This is set by the installer during commissioning.
See section 6.1 and 6.7.
6.6
6.7
hot water
Fig. 39
Celtic
plus
Remote by-pass
remote
by pass
with US valve
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 miniium flow requirement
of 300 Vh (1.1 gavmin).
1) Set boiler thermostat to maximum, switch boiler to
HOT WATER + CENTRAL HEATING (II).
2) Open all radiators and close the by-pass. Check the
temwrature rise accross the boiler which should not
be greater than 20” C (36 “F).
3) Adjust system to miniium load. This is normally done
I
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 l/h (1.1
galfmin) .
Hot water adjustment
A flow restrictor (A) is fitted on the domestic hot water
outlet. Adjustment of this restrictor enables regulation of
the flow rate of the D.H.W. to suit individual installation
conditions and requirements.
Adjustment is made by either turning the screw in a
clockwise direction to reduce the flow rate and increase
the temperature or by turning the saew anti-clockwise to
increase the flow rate and decrease the temperature.
Fig. 39 a
6.8
PUMP @
Fig. 39 b
23
Pump switc6mg adjffstment
The pump is set to turn ON/OFF via the room thermostat
along with the burner, when the central heating mode is
selected.
It is possible if required, to have the pump running
continuously by turning the switch 0 anti-clockwise, see
fig. 39 b. The room thermostat then only switching the
burner on and off.
Pump and burner
switched
Burner only
switched
Supplied By www.heating spares.co Tel. 0161 620 6677
6.9
Fitting the caskg
‘1) Take from the carton the controls cover (H), the glass
door (J) the top front panel 0 the side panels (A) and
the rubber grommets (I).
2) Remove control knobs used during testing and
commissioning and fit the four grommets into the holes
at the top of each side panel (I).
3) Fit side panels (A) and secure with screws at bottom
rear (B).
4) Put the control cover (H) in position and secure with
five screws.
5) Fit the front top panel over the pins at the top of the
boiler (C) and secure with two screws at the bottom (D)
6) Fit the central heating control knob.
7) To fit the glass door proceed as follows :
N.B. THE TIE ROD (G) MUST BE USED
a) Remove the nuts from the machine screws securing the
tie rod to the hinges.
b) Offer the door up vertically. Engage part (E) in the
protile of the right hand side panel . Fii assembly with
screw from beneath (F).
c) Pivot the left hand hinge and engage into profde of the
left hand side panel. Fix assembly with screw from
beneath.
HAND OVER THE USERS INSTRUCTIONS AND EXPLAIN THE BASIC FUNCTIONS OF OPERATING THE
APPLIANCE. LEAVE THE INSTALIATION AND SERVICING INSTRUCTIONS WITH THE USER.
IF THE ELECTRICITy SUPPLY IS INTERRUPTED THE PILOT MAY HAVE ESTlNGUISHED. WHEN THE SUPPLY IS
RESTORED RELIGHT THE PILOT SEE SECTION 6.3.
24
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7. ROUTINE SERVICING
To ensure continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will depend upon the particular installation condition and
usage, but in general once a year should be adequate.
It is the law that any service work must be carried out by a competant person, such as British Gas, other C.O.R.G.I.
registered personnel or your local Chaffoteaux Service Centre, in accordance with the Gas Safety (Installation and Use)
Regulations. This routine service will normally be confmed to :
1) Cleaning the burner.
2) Cleaning the heat exchanger.
3)
Checking the gas controls.
4) Cleaning water filter, hoses and heating filter.
5) Check operation of safety valve.
The following schedules are recommended :
a) Check the function of appliance, burner pressure, gas flow rate and soundness.
b) Observe flame picture and undertake combustion test.
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.
7.1
7.2
To remove fkont casing
a) Remove two screws (A) bottom rear of boiler.
b) Remove screw (B) centre of lower front panel.
c) Remove thermostat knob and ignition push button.
d) Remove case by easing forward at bottom and lifting
off lugs at top. If necessary, remove the lower control
cover (4 screws) and lift off the upper front panel before
removing case.
Fig. 41
To remove sealed chamber front panel and combustion
chamber front panel to expose heat exchanger
(@nary)
a) Remove four screws (A) securing the combustion
chamber front panel.
b) Lit? 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.
- Remove 2 screws (Fl) and remove closure plate (see
section 7.3).
c) Remove 6 screws (C) and lit? off heating body front
panel with access panel (B).
d) Clean the heat exchanger after removing the burner,
see section 7.6.
- Replace in reverse order.
-ig. 42
25
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7.3
To nzmove burner assembly
a) Remove two screws (Fl) and remove closure plate by
withdrawing forward.
b) Remove two 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 one surface, leave alone as removal may damage
the gasket. Replace gasket if necessaq.
d) To clean burner (see section 7.6).
Fig. 43
To remove ptiot
a) Remove two screws (A) securing deflector plate and
pilot head. Lift off deflector plate (D) taking care not to
damage the electrode tip.
b) Remove pilot air filter (B).
c) Using a 7 mm spanner, remove pilot body (C) from
pilot burner base.
d) Check injector and clean the filter. N.B. The pilot
injector (F) is retained in the base of the body with an
‘0’ ring (G). If the injector is replaced it is fitted bright
side uppermost.
e) Ensure deflector plate (D) is correctly located on the
pilot.
7.5
Fig. 44
To clean heating return fdter
a) Close heating flow and return valves (B and C) and
drain through safety valve (F) #section 6.2).
b) 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.
d) Clean in warm water.
e) Replace in reverse order. Replace all components
removed in reverse order.
Fig. 45
26
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7.6
Cleaning and replacement of parts
a) The burner can be cleaned by inverting and brushing
with a soR brush, inspect injectors, ensure they are
clear.
b) The heat exchanger ilueways can be cleaned by
thoroughly brushing the finned surface . Alter brushii
inspect to ensure that the flueways are completely
clear.
d) The thermocouple can be wiped with a lint t?ee cloth
to remove any deposits. If the thermocouple tip
appears burnt or craked, exchange to avoid a possible
break at a later date - (see section 8.1).
d) Examiie electrode 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 ensuring that
the gasket between the gas section and the manifold is
correctly positioned upon reassembly.
f) Open all isolation valves and repressurise system if
necessary.
g) Recommission and check controls.
h) ARer the boiler is lit, check all gas connections for
soundess .
i) Allow the boiler to warm up thoroughly, then check the
burner pressure and adjust as necessary to that given
in the table for required output (see section 6.4).
j) Restore any sytem controls and clocks to their original
setting.
Fig. 46
I
To check operation of safety valve
Turn off the appliance by selecting the 0 position on the
Summer and Winter switch.
Engage the knurled ring (A) to the thread and turn it
clockwise until water can be seen to discharge from the
outlet (B). Turn the knurled ring (A) anti-clockwise until it
disengage from the thread.
Ensure that the pressure has not decreased below 1 bar
and repressurise if necessary (see section 6.2).
N.B. If the water does not discharge, replace valve (see
section 8.34).
27
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8.
REPLACEMENT OF PARTS
N.B. Before commencing ensure gas and electricity supplies are isolated.
8.1
Fig. 47
To remove thermocouple
a) Remove front case, see section 7.1.
b) Remove outer front panel, see section 7.2.
c) Remove burner, see section 7.3.
d) Remove high limit stat see section 8.3.
e) Remove thermocouple from thermoelectric valve
connection (F).
f) Loosen securing screw (G) two full turns to relieve
tension t&on-~ locking spring.
g) Remove thermocouple by sliding down through gas
section.
h) Remove grommet (E) from base of gas section.
j> Carefully form a 4 inch radius to thermocouple and
insert thermocouple through gas section.
k) Slide grommet (E) over the thermocouple.
I) 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.
n) Reposition grommet in base of gas section.
o) Form the new thermocouple and connect to
thermoelectric valve (F) _
p) Replace, high liiit thermostat.
8.2
8.3
Fig. 49
Fig. 49
NOTE : When replacing the thermocouple the conductor
may need manipulating - avoiding bending at acute
angles
To replace electrode and lead 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 (D), see section 7.4
e) Disconnect from electrical box by pulling off electrode
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.
6) Replace in reverse order locating electrode indeflector
plate (D), spark gap 5 mm.
To replace safety overheat thermostat
a) Remove front case, see section 7.1
c) Remove high limit stat and thermocouple see 8. 1.
d) Withdraw noting route.
e) Replace in reverse order. Use heat sink grease
between high liiit stat and bracket (B).
-ig. 50
28
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8.4
Fig. 51
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).
6) Remove the two screws (D) retaining gas section.
j) Slide out gas section (H) by pulling forwards
(comprises solenoid valves, gas valve, pilot assembly
electrode, etc)
k) Remove two screws (S) retaining microswitch.
m) Remove microswitch.
n)
Replace in reverse order.
8.5
8.6
Fig. 52
To replace change
a) Remove i?ont case see section 7.1
b) Undo saew (A) and remove miaoswitch box cover.
N.B. Upper microswitch operates for D, H, W mode.
Lower miaoswitch operates for C H mode.
c) Lift spring (B) and pull operating lever off mounting
pins.
d) Remove respective miaoswitch from mounting pins.
e) Note colour code and pull off electrical tags.
f) Replace in reverse order. When replacing box cover,
ensure that the lugs on the connector block are clamped
inside the box.
N.B. Refer to fig. 9 for colour codes.
To replace the flow switch assy.
a) Remove air separator see section 8.13.
b) Disconnect high pressure tube at union A.
c) Disconnect low pressure tube at union B.
d) Replace reverse order.
e) Check for leaks
wer
valve microswitch
Fig. 53
29
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8.7
Fig. 54
To replace vent&
a) Remove front case see section 7.1.
b) Isolate from cold mains water supply (A), open an hot
water outlet and drain down from valve (E).
c) Remove plug (C) from leff hand side of change over
valve.
d) Use small screw driver to gently push
ensure screw driver does not enter throat of venturi.
e) Replace in reverse order.
f) Ensure that valve E is closed, restore cold mains water
supply, check for leaks.
out
venturi
8.8
8.9
Fig. 55
Fig. 56
To replace primaly heat exchauger
a) Remove front case, see section 7.1.
b) Isolate appliance from svstem by closing heating ffow
and return valves (B and C), see fig. 34.
c) Drain boiler (primary side) through safety valve (P) (tig.
34).
d) Remove four screws securing the sealed chamber
t?ont panel and remove (see section 7.2).
e) Remove left and right hand side on chamber Panels by
pulling them carefully towards you.
f) Remove combustion chamber front panel, see section
7.2.
g) Remove burner, see section 7.3.
6) Remove four screws (A) securing heating body panels
to chassis.
f) Undo flow and return pipe unions (E), remove pipes
and slide primary heat exchanger forwards.
j) Replace in reverse order.
To remove electrical control box
a) Remove Front casing, see section 71.
b) Remove fuses by pulling fuse carrier (B) from electrical
box.
c) Remove 3 screws (C) lift electrical box cover away and
unplug from PCB.
d) Pull off plug from solenoid valves at PCB.
e) Unplug pump connector at PCB and earth wire.
f) Unplug connector to change over valve at PCB.
g) Unplug connector from fan at PCB.
h) Remove one saew (D) and two saews (E). (Electrical
box support bracket to lower chassis).
5) Carefully ease electrical box forward to allow access to
flow switch lead, also to electrode at bottom rear of
bOX.
j)
Disconnect lead from flow switch.
k) Disconnect electrode from rear of electrical box.
1) Carefully move the electrical box away from the
appliance and to the right whilst straightening the
capillary tube from boiler limit thermostat and
domestic hot water thermostat.
30
Supplied By www.heating spares.co Tel. 0161 620 6677
Fig. 56a
q) Continue moving electrical box until bottom support
bracket can be positioned on hook at bottom of
appliance (see fig. 56 a). To remove the electrical box
completely, continue in the following manner.
r) Isolate appliance from the system by closing valve A,
(see section 6.2 (Fig. 34)).
s) Drain secondary side by opening drain plug (H) (fig.
34).
u) Remove ciip and phial t?om DHW thermostat Rocket.
w) Unciip and remove limit boiler thermostat phiaf.
x) Remove box completeIy.
To replace electrical box in reverse order note :
a) Hang box on hook.
b) Capillaries must be routed behind any pipework .
8.10
8.11
To replace pump head
a) Remove front casesee section 7.1.
b) Isolate boiler from system by cIosing flow and return
valves (see section 6.2 (B and C)).
c) Drain boiler (primary side) through safety valve (see
section 6.2 (F)).
d) Open electrical box cover (B) and unplug pump
connection.
e) Remove four screws (A).
f) Remove pump head noting orientation.
g) Remove lead and transfer to new pump head.
II) Replace in reverse order.
j) Open flow and return valves Top up system if
necessarv.
N.B. ’
For the Celtic plus the pump is a Grundfos UP 15-60
To replace change over valve (C, 0, V)
a) Remove front case, see section 7.1.
b) Disconnect and remove electrical box, see section 8.9.
c) Turn off main water at valve see section 6.2 (A).
d) 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).
f) Remove safety overheat thermostat from tube and
carefuiiy position to one side.
g) Remove front tube (1) from change over valve unclip
thermometer sensor, uncIip high limit thermostat.
h) Remove flow pressure tube (2) from C, 0, V, to fiow
switch.
N.B. Swing miaoswitch box to give access to union nuts.
Supplied By www.heating spares.co Tel. 0161 620 6677
Fig. 58a
j) Remove rear tube (4) from C, 0, V, to secondary heat
exchanger.
k) Unscrew union nut (5)
I) Unscrew heating return tube nut (6) from C, 0, V.
m) Unscrew union nut (7) of C, 0, V, to secondary heat
exchanger.
n) Remove C, 0. V.
o) To inspect diaphragm remove eight screws (E)
securing valve to water section.
N.B. To service the C, 0, V, piston remove spring clips,
remove piston cIean and grease.
p) Clean or replace diaphragm.
q) Flush out water section.
r) Replace in reverse order.
s) Open flow and return valves. Top up system if
necessary
of
mains water inlet to C. 0. V.
8.12
8.13
To replace secondary heat exchanger
a) Remove front case, see section 7.1.
b) Disconnect and remove electrical box (see section 8.9).
c) Remove change over valve (see section 8.11).
d) Unscrew union nut (8) at top of secondary heat
exchanger.
e) Unscrew bottom left hand union nut (9) of secondary
heat exchanger.
f) Slacken top screw (A) of heat exchanger to chassis.
g) Remove bottom screw (B) and spacer.
h) Remove secondary heat exchanger.
1) Replace in reverse order.
N.B. Do not unscrew the four tie rods in the secondary
heat exchanger.
To replace air separator
a) Remove front case (see section 7.1).
c) Close heating flow and return valves (B & C) (see
section 8.11 (fig. 58 A)).
d) Drain boiler down through safety valve (F) (see section
8.11
(fig. 56)).
e) Disconnect bleed pipe union from pump volute (E).
f) Disconnect drain tube (B).
g) Pull out spring clip (A) with pliers.
h) Disconnect flexible pipe union (D) at pump outlet.
j) Pull pump complete with volute forwards and remove.
k) Disconnect union nut at base of air separator.
m) Ease air separator forward and disengage integral peg
from chassis,
q) 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.
Fig. 59 a
32
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8.14
To replace boiler thermostat
a) Remove front case (see section 7.1).
b) 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 .
d) Remove two screws (D) which secure boiler
thermostat to the electrical box cover.
e) Remove the spade connectors noting position, see
illustrated wiring diagram fig. 9.
f) Feed out capillary through electrical box having
removed the split grommet.
g) Replace in reverse order.
8.15
8.16
To replace boiler limit thermostat
A
a) Remove front case (see section 7.1).
b) 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).
d) This thermostat is located on moulded pins - ease
forward and remove spade connectors.
e) Feed capillary through the control box having removed
the split grommet.
f) Replace in reverse order (polarity immaterial).
To replace domestic hot water thermgstat
a) Remove front case (see section 7.1).
b) Remove electrical box front cover (see section 8.9.(c)).
c) Isolate mains water supply - drain from vaIve beneath
the change over valve (see section 8.11 fig. 58 (H)).
d) Remove clip which retains phial in wet pocket.
e) Remove phial from pocket.
fJ Ease thermostat off moulded pegs and pull of spade
connections.
g) Feed capillary through the control box, having
removed the split grommet.
6) Replace in reverse order. Polarity immaterial.
Fig.
62
33
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8.17
To replace spark generator
a) Remove front case (see section 7.1).
b) Remove electrical box cover (see section 8.9 (C)).
c) Remove PCB (see section 8.18).
d) Pull tab connections from spark generator noting
position.
e) Slacken bottom fxing screw and remove top screw
from generator.
f) Lift up off bottom screw and pull forwards.
g) Replace in reverse order. (Connect leads before
locating generator).
To replace printed circuit board (PCB)
a) Remove front case (see section 7.1).
b) Remove electrical box front cover (see section 8.9(C)).
c) Remove all plug-in connections (IO).
d) Disconnect mains input cable at terminals 1 and 2 but
not the earth.
e) Disconnect external controls, if fitted, from terminals 4
and 5.
f) Remove one screw (A).
g) Slide PCB slightly upwwards to disengage guide.
h) PuII PC B forward.
j) Replace in reverse order.
1 Summer/Winter Switch
2 Pump
3 Earth
4 Boiler Thermostat
5 Limit Thermostat
Fig. 65
ELECTRICAL BOX SHOWING POSITION OF COMPONENTS WITH LAYOUT OF PLUGS AND WIRING.
capillary
6 Water Flow Switch
7 D.H.W. Thermostat
Capillary
8 Change Over Valve
34
9 Push Button ignition
10 Solenoid Gas Valve
11 Fan connection
12 240V-50Hz connection
13 Igniter
14 D.H.W. Thermostat
15 Limit Thermostat
16
Fuse
17 Room thermostat
connection
Supplied By www.heating spares.co Tel. 0161 620 6677
8.19
Fig. 66
To replace
a)
Remove front case (see section 7.1).
b) Remove thermocouple connection (B).
c) Remove nut (A) securing thermoelectric valve.
d) Withdraw thermoelectric valve.
e) Replace in reverse order.
N.B. Care should be taken when replacing the nut
securing the thermoelectric valve - line threads.
thermoelectric valve
8.20
8.21
Rear lining
To replace solenoid valves
a)
Remove front case (see section 7.1).
b) Withdraw plugs - colour coded - t?om solenoids (B).
c) Remove four screws (A) securing valve mounting
plate.
d) Remove mounting plate and solenoids - take care not
to misplace valve springs and plungers.
e) Replace in reverse order using a NEW CASKET.
To rephw heating body linings
a) Remove case (see section 7.1).
b) Remove combustion chamber front panel with
expansion vessel (see section 7.2 (A, B. C and D)).
c) Remove burner (see section 7.3 (d)) Fist slide out side
Iinings followed by rear which is removed by easing
upwards and sliding out from bottom.
e) Replace in reverse order.
8.22
Fig. 68
EARTH Yellow-Green
Fig. 69
&---
35
To replace fan assembly
a) Remove case (see section 7.1).
b) Remove outer front pane1 (see section 7 2).
c) Remove right hand side combustion chamber pane1
(see
section
8.8).
e) PuII off 4 spade connections from fan.
4 Remove 2 screws - on flue hood (A).
g) Turn anti-clockwise 10’ to disengage lug from rear and
withdraw assembIy.
6) Replace in reverse order using new gasket,
N.B. &sure correct location of fan connectors and that
the lug at the rear is located correctly.
(0) : Red.
(1) : Brown.
(2) : Blue.
(E) : Yellow/Green.
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8.23
To replace pressure switch
a) Remove two screws (A) retaining plastic turret cover
and remove terminal cover.
b) Note position of spade connectors and remove (COM-
P. No 1 and No 2).
c) Disconnect pressure sampling tube by pulling off
nipple.
d) 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 if not supplied.
sampling tube
Fig. 70
8.24
8.25
To re-pressurise expansion vessel
a) Remove case (see section 7.1).
b) Close heating tIow and return valves and drain boiler
through safety valve (see section 6.2 fig. 34 (F)).
c) Remove protective cap and check pressure on
Schroeder valve with gauge.
N.B. The setting pressure is 0.65 bar (9.5 psi).
d) To re-pressurise use car foot pump or bicycle pump
with adaptor.
e) Close safety valve.
f) Open heating flow and return valves.
g) Refill and commission boiler.
N.B. Do not use a high pressure air fine.
Fig. 71
To replace pressure gauge
a) 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 (F)).
d) Undo union nut (A) on pressure tube at rear of gauge.
e) Withdraw gauge.
f) Replace in reverse order.
g) Open flow and return valves. Re-pressurise system ii
necessary.
1 Fig. 72
36
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8.26
8.27
To replace the domestic expansion vessel
a) Isolate cold water mains supply (see section 6.2).
b) Drain from valve beneath the change over valve see
section 8.11 (see fig. 58H).
c) Remove electrical control box (see section 8.9).
d) Undo connection (B) and remove domestic expansion
vessel.
Replace in reverse order.
Check for leaks.
Fig. 73
To replace main burner
a) Remove case (see section 7.1).
b) 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.
8.28
Fig. 74
To replace the burner manifold assembly
a) Remove the front case (see section 7.1).
6) Remove the combustion chamber front panel to
expose the burner manifold (see section 7.2 (a to c.)).
c) Remove the two screws FI 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. 75
37
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8.29
To replace pilot injector, air filter, deffector plate/
burner head
a) Remove as detailed in section 7.4.
b) Replace in reverse order.
N.B. Pilot injector fitted bright side uppermost.
ig. 76
8.30
8.31
To replace expanston vessel
a) Remove t?ont case (see section 7.1).
b) 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
(P) 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, repressurise
system.
(see section 6.2).
Fig. 77
To replace viewing window
a) Remove front case (see section 7.1).
b) Remove combustion chamber front panel (A) (see
section 7.2).
c) Remove the screws (B) securing the sight glass bracket
(C). Take care not to loose the two nuts (D).
d) Replace in reverse order referring to diagram opposite.
Fig. 78
38
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8.32
‘ig. 79
To replace the mah gas valve body
a) Remove iront case (see section 7.1).
b) Remove combustion chamber front panel (see section
7.2).
c) Remove burner assembly (see section 7.3).
d) Remove electrical control box (see section 8.9).
e) Part thermocouple connections to high limit
thermostat.
f) Pull connectors off miaoswitch (M) noting colours.
g) Remove two screws (P) retaining bracket to gas
section and ease bracket down to clear gas section.
6) Slacken and undo the gas supply union (D) beneath
gas section.
j) Remove two screws (R) retaining gas section to
combustion chamber base.
k) Remove gas section by pulling forward.
m) Reassemble in reverse order and check for gas
soundness.
8.33
8.34
To replace the thermometer
a) Remove the front case (see section 7.1).
b) Unclip and remove thermometer sensor from flow
pipe (A).
c) Withdraw gauge (B) by compressing the two fixing lugs
and pushing the gauge towards you. Feed the sensor
through the bracket.
d) Replace in reverse order.
Fig. 80
To replace safety valve
a) Remove case (see section 7.1).
b) Close heating flow and return valves and drain the
appliance through safety valve (see section 6.2 fig. 34 (f)
and section 7.8).
c) Ensure that the boiier is completely drained and the
pressure gauge is reading zero (0).
d) Undo the grub screw (A) and remove the complete
assembIy by carefuly pulling it in a downwards direction.
e) Replace in reverse order.
Q Ensure that the valve is in the close position and
repressurise system (see section 6.2).
g) Open heating flow and return valves.
h) Check for leaks.
Fig. 81
39
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9
9.
9.1
FAULT FINDING
Logic sequence
I
I
electrical supply
summer / winter
I
no
no
I
zero volts check
I
no
I
check low speed
+
( valve position )
zero volts
check
I I
,-enoid open
L
time delay 5 sec. max.
2nd
stage
solenoid opens
time delay
2nd stage solenoid opens
I
It
xl
5 sec. max.
no
1
40
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9.2
FAULT FINDING
CENTRAL HEATING OPERATION
SEQUENTIAL FLOW CHART 1
READ IN CONJUNCTION WITH SECTIONS (9.1 & 9.3)
START
Check
I) System water pressure .I bar
ii) Gas cock open gas lines pur-
ged
Iill Electrical supoly swtched on
Check electrode lead connected to
rear of electrical box. Check electro-
de and lead for physical damage.
Is 240V a.c
I) Inlet pressure 1s 20 mbar 18”
II) Inlet filter 1s clean
iii1 Pilot wxtor 1s clean
across red and blue
Set selector switch to central heating
and hot water.
t+
Is 240 V a.c. across red and brown
wires on fan connector on PCB.
Isolate supply IS there cont~ruty
lo pressure switch between red
and black leads at fan connector
on pnnted c~rwt board.
Check
i) E$;yl controls in demand
Check connections to main swtch.
Check continuity of switch
I
Check external fuse and/or rectify
I
seconds. Does
Check
i) Position of thermocouple
Ii) Pilot head
Iill Flame pattern
1
Measure millwolt outpl
electric valve ITEVI gre
t mV.
Output to TEV less than 12 mV.
Short out on high limit thermostat
IS output to TEV greater than 12 . L
mV?
‘- -“*-““o TEV less than 12 mV?
ut at thermo
!ater than 12
t
Rectify
Remove plugs from board and check
continuity across following :
al Black and orange wires to chan-
ge over valve
bl Water flow switch (black leads)
cl CH limit stat (black leads)
dl CH control stat lred and black
leads)
Is there continuity across all cornponents.
-:
I
I
“0
A
ves
41
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7.3
9.3
FAULT FINDING
DOMESTIC HOT WATER OPERATION
SEQUENTIAL FLOW CHART 2
READ IN CONJUNCTION WITH SIXTIONS (9.1 & 9.2)
START
7
1
END
q-yqzy-j
domestlc hot water thermostat ?
Ensure microswdch is made
Remove change over vatve
connection from pinted circuit
Ensure waler inlet pressure
greater than 0,6 bar.
Check venturi for blockage.
Ensure all isdating vahss and
Check diaphragm is OK
Spindle OK
Replace if necessary.
I
42
Supplied By www.heating spares.co Tel. 0161 620 6677
9.4 FAULT FINDING TABULAR CHART
PROBLEM
I) Explosive ignition
!) Unstable burner
CAUSE
i) Poor pilot flame
a) Inlet pressure low - should be 8” wg
(20 mbar) working pressure
b) Blocked gas filter
o) Pilot injector dirty
ii) l/3 valve not operating
a) 24 volts supply to valve
b) No voltage at solenoid
Crosslighting strip - missing/incorrectly
iii)
positioned
i) Incorrect injectors
ii)
Gas pressure at manifold
a) Too high
a) Too low
Terminal incorrectly positioned
iii)
Incorrectly assembled flue duct
iv)
v) Fan incorrectly located
REMEDY
la) Check meter and pipe sizing
see sections 2.7 and 4.7
lb) Clean
lc) Clean replace, see section 8.29
Za) Replace solenoids, see section 8.20
2b) Check plugs on printed circuit board
2c) Replace printed circuit board,
see sections 8.18
3) Replace or reposition
1) Replace manifold 1.28 mm injectors
for natural gas, see section 8.28
2a) Adjust, see section 6.4
2b) Check restrictors and inlet pressure,
see section 1.2
3) See section 2.4
4) Check and reassemble,
see section 4.10
5) Remove and refit correctly,
see section 8.22
3) Central heating
low flow
temperature
Combustion chamber front cover not sealing
vi)
Heat exchanger fins blocked
vii)
Neoprene gasket in turret not crrectly fitted
viii)
or missing
i) Boiler thermostat out of calibration
ii) Limit stat out of calibration
Insufficient gas pressure
iii)
iv) l/3 blue or 2/3 orange gas valve not opening
a) 24 volts at solenoid
b) No voltage at solenoid
Hot water valve in change over valve assembly
4
sticking
a) Dead leg on hot water system
b) Bent spindle in valve
By-pass, if fitted, incorrectly adjusted
vi)
Pressure switch hunting
vii)
System incorrectly balanced
viii)
6a) Tighten
6b) Replace sealing strip
3) Clean, see section 7.2 and 7.7
3) Fit or refit, see section 4.10
1) 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
4a) Replace solenoid, see section 8.20
4b) Replace print circuit board,
see section 8.18
5a) Eliminate
5b) Replace, see section 8.11
6) Adjust, see section 3.16
7) Replace, see section 8.23
8) Balance system.
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PROBLEM
CAUSE
REMEDY
4) Boiler noisy
5) Hot water does not i) Low inlet water pressure
operate over
temperature range
i) On heating only
a) Low flow rate as result of system resistance
b) Air in system
ii) On hot water and central heating
a) Low pressure in sealed system
b) Pump not running
iii) Blocked filter on heating return
iv) Gaz filter fitted to heating flow or return pipes
v) Heat exchanger scaled
vi) Overgassed
(vii)) isolating valves not fully open
ii)
Incorrect venturi fitted
iii) Hot water limit stat out of calibration
iv) Solenoids not operating
v) Pressure switch hunting
vi)
Low inlet gas pressure
la) Check and if omitted fit by-pass
see section 3.16
1 b) Purge by venting radiators
2a) Repressurise to 1 bar cold
see section 6.2 (5)
2b) Replace pump head, see section 8.10
3) Clean and replace see section 7.6
4) Remove and reposition see section 4.5
5a) Descale
5b) Replace, see section 8.8
6a) Check gas pressure and adjust, see
section 6.4
6b) Check restrictors. see section 1.2
7) Open fully see section 6.2
1) Ensure all down stream stop cocks
open
2) Replace with 5.4 mm diameter,
see section8.7
3) Replace, see section 8.16
4) See section 9.2. Flow chart 1
5) Replace, see section 8.23
6) See section 6.4
3) No main burner i) Lack of water flow
ii)
Pump jammed
iii) No water
iv) Flow switch not operating
v) Heating thermostat faulty (CH only)
vi) Pressure switch not operating
7) Safety valve
discharges
8) Pump noisy
i) System pressure too high
ii)
Not isolated from mains
iii) Vessel lost air charge 3) Recharge 0.65 bar, see section 8.24
iv) Secondary heat exchanger (water to water)
internal water leak
i) Air in system
ii) Air separator
iii) Debris in pump
iv) Water filter blocked
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
6) Replace, see section 8.23
1) Adjust 1 bar cold
2) Remove filling loop
4) Replace, see section 8.12
1) Vent radiators
2) Open vent on air separator,
see section 6.2 (4)
3) Clean and replace, see section 8.10
4) Clean and replace, see section 7.6
44
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PROBLEM
CAUSE
REMEDY
I) Excessive
temperature
rise across boiler
IO) Rapid cycling
high/low or
high/low/off
II) Fan on high speed
continuously
12) Loss of pressure
i) Return filter blocked
ii) Low water How rate
a) Pump defective
b) High system resistance
c) Gas filter inadvertantly fitted in flow
or return connection
iii) Gas rate too high
Low water flow rate
0
ii) Limit stat out of calibration
iii) By-pass, if fitted, not regulated
iv) Blocked heat exchanger
i) Defective printed circuit board 1) Replace, see section 8.18
Leak on system
i)
ii) Leak on appliance
1) Clean and replace, see section 7.6
2a) Replace, see section 8.10
2b) Fit by-pass, see section 3.16
2c) Remove and refit,
see sections 4.5
3) Adjust, see section 6.4
1) See System guidance’ section 3.3
2) Replace, see section 8.15
3) Adjust, see section 6.5
4) Clean or replace, see section 8.8
1) Locate and rectify
2) Locate and rectify
13) Gain in pressure
shown on gauge
i) Filling loop still fitted and letting by 1) 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
45
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Notes
Supplied By www.heating spares.co Tel. 0161 620 6677
Chaffeteaux et Maury Limited,
Trench Lock, Trench, Telford, Shropshire TFl 4SZ
Telephone: (01952) 222727 Fax: (01952) 243493
Looking Good. Heating Better
ESPOIG
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