Chaffoteaux & Maury 1F G.C. 51 980 39, Celt Star B, 2F G.C. 51 980 40 Installation And Servicing Instrucnions

Celt Star B

Flueless Single Point Water Heater

GAS SAFETY (INSTALLATION AND USE) REGULATIONS.

It is the law that all gas appliances are installed by a competent person

in accordance with the above regulations

(For use on natural gas only. G20)

from

Model 1F G.C. 51 980

2F G.C. 51 980

serial numbers 1F: 195023764 -

39

40

2F: 195020615

Celt

The model no. and serial no. of this heater are on the data badge which is found

hanging at the rear left hand side beneath the appliance. These numbers should be used

CC

BIF

Star

\

Installation and

Servicing Instructions

(leave these instructions with the user)

when ordering replacement parts.

CONFORMS WITH EUROPEAN STANDARD EN 26

Looking Good.Heating Better

CONTROL OF SUBSTANCES HARMFUL TO HEALTH
MPORTANT
o comply with the Control of Substances Harmful to Health Regulation 1988 we are required to provide information on

le following substance that is contained in this appliance.
lescriution Combustion Chamber Lining

1.0

1.1

Laterial

‘kecatltions During servicing, keep the dust generation to a minimum and avoid

Alumino Silicone Fibre

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 complatnts may be susceptible to irritation.

When disposing of the lining ensure that it is securely wrapped and wash hands

after contact.

GENERAL

The CELT STAR B is a gas fired instantaneous water heater.
It is designed to deliver hot water through a swivel spout or a hot water tap at a sink or basin (1 F). A

remote model is also available (2 F). This model is for use directly off the mains supply.
The appliance features an atmosphere sensing device which will turn off the gas supply to the pilot and

burner, when the oxygen in the atmosphere in the locality of the heater becomes diminished and is
unable to support safe combustion. It also protects the user if the heat exchanger fins become blocked.

Also included in the appliance is a scale reducer.
Two models are available :
Spout model 1F

Remote model 2F

Guarantee

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

- 12 months’from date of installation.

GC N” 51980 39
GC N” 51980 40

Dimensions

D

Fig. 1

Remote outlet

2

Celt Star B Installation & servicing instructions Erratum page 3 - passage h I’indice a

1.2

Technical Data

NATURAL GAS

Heat input Nominal ..............................................................

Heat output Nominal
Gas rate (maximum)
Burner pressure

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

PiIot injector marking ...........................................................

Restrictor .............................................................................

water flow raised 50 ’ C (90 ’ F) .........................................

water flow rate raised 25 o C (47 ’

Minimum operating water pressure ......................................

Maximum operating water pressure .....................................

Air flue supply for combustion .............................................

Note : The minimum water pressure is for the correct operation of the heater only. An additional allowance must
be made for the resistance of the pipework and fittings.

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

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

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

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

F)

TABLE 1

10.5 kw

8.7 kw

1.1 m%

5.1 mbar

1.28

26-40

2.7 mm

5.5 h-lin

5.0 hlin

0.5 bar

10.0 bar

21.5 m3ih

35,810 Btdh
29,670 Btdh

39,2 wh

2.0 in wg

0.55 gpm

1.1 gpm

8.05 psi
145 psi

760 WI-I

1.4

1.5

Connections

Water inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum clearance required for fnstallatton and servicing :

Top .............................................................................

Bottom .......................................................................

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

Sides

Front ...........................................................................

This

appliance is for use on Natural gas and must not be used on any other Gas.

1F MODEL

2F MODEL

15 mm copper
1 Fmodel:

Swivel Spout and / or

15 mm copper.

2 F model :

15 mm copper
15 mm copper

8.2 kg

600 mm

50 mm 2ins
75 mm 3 ins

250 mm 10 ins

18.1 lb

24 ins

This heater is designed for installation over the sink
to deliver hot water either through a swivel spout or
to a hot water tap at a sink or basin.

NEITHER MODEL IS SUITABLE FOR SHOWER APPLICATION.

3

The remote model is designed for direct connection
to the tap. These heaters must NOT be connected to
a bath hot water draw off, or be connected to hot water
outlets located in different rooms to where the appliance
is installed.

2

Iinstallation Requirements

2.4 Gas Supply

2.1 Related Documents

The installation of the heater must be in accordance with the
relevant requirements of the Gas Safety (Installation and Use)
Regulations, Building Regulations and the Byelaws of the
local Water Undertaking. It should be in accordance also with
any relevant requirements of British Gas and local authority,
and the relevant recommendations of the following current
British Standard Codes of Practice :

BS 6891 :

BS 5546 :

BS 5440 :

Specification for installation of low pressure
gas pipework up to 28 mm (RI) in domestic
premises (2nd family gases).

Installation of gas hot water supplies for
domestic purposes (second family gases).

Flues and air supply for gas appliances of
rated input not exceeding 60 kW (lst, 2nd
and 3rd family gases).
Part 1 Flues
Part 2 Air Supply

2.3 Air Supply

IMPORTANT : This heater should be used in a well ventilated
room. An air vent direct to outside is required where the
room volume is less that 20 m3 size in accordance with the
foIlowing table. In addition an openable window is required.
This heater must not be installed in a space less than 5 m3 in
total volume.

An adequate sized gas meter must be connected to the
service pipe. Where necessary British Gas will arrange for the
existing meter to be checked or for a suitable meter to be
installed. On no account must any work be carried out on
the gas meter other than by British Gas or their specifically
authorised contractor.

Installation pipes should be fitted in accordance with BS

6891: Pipework from the meter must be of adequate size.
Pipes of a smaller size than the gas connection should be
not used,

The complete installation must be tested for gas soundness

and purged in accordance with BS 689 1.

In addition to any other gas appliance installed in the
premises, the meter should be capable of passing : 40 cu,

it/h of natural gas.

2.5

Description of Operation of Special

Components

2.5.1 Atmospherk Sensing Device

The thermoelectric circuit is fitted with a thermal switch

located on the front of the combustion chamber of the

heater. When the oxygen in the atmosphere in the locality of

the heater becomes diminished and is unable to support

safe combustion, the products of combustion pass through

an oriiice in the front panel and the increase in temperature

is detected by the thermal switch. When the switch is

activated it interrupts the thermoelectric circuit and the pilot

and main burner are extinguished.

Room

Volume

0-5m3

5m3-10m3 100 cm2

11 m3-20m3

over 20 m3

This water heater is fitted with an atmospheric sensing

device which will turn off the gas supply to the pilot and

burner, when the oxygen in the atmosphere in the locality of

the heater is diminished and will not support safe
combustion. It also protects the user if the heat exchanger
fins become blocked.
It is therefore important that the heater is not located over a

cooker or in a position where the air supply is restricted or
contaminated.
The location must also permit space for servicing and air

circulation around the appliance.

Permanent

Air vent

Installation

not permitted

50

cm2 YES

NIL YES

Openable

Window

YES

4

2.5.2 Scale Reducer

I

The scale reducer is a diaphragm vessel forming part of the

water section. At the termination of a demand cycle the

contens of the heat exchanger are displaced into the vessel
and replaced with cold water.

2.6 Flue

These appliances are ffueless. Protection is provided in the
form of the atmospheric sensing device (see Section 2.5.1).

They must not be operated continuously for more than fnre
minutes.

3.0 INSTALLING THE APPLIANCE

A vertical flat area of 1065 (42”) x 396 mm (14
If the heater is to be fitted to a wall likely to be affected by heat the

materiel which will not reverberate.
When selecting a position for the appliance there must be a minimum clearance of 600 mm (24 ins) between the top of

the appliance and a ceiling.

3.1 Packaging

he carton contains the following :
I) 1 x heater
>) 1 x set of knobs
:) 1 x set of fittings, consisting of:

- 318 ” nut, cap, blanking disc and washer,

-

318

“ nut and 15 mm bend for remote connection (2 F models only),

- 112 “ nut, metal I rubber washer, 15 mm bend for gas connection,

- 112 ” water service cock, 15 mm bend, 112 ‘I,

- 4 x HEX head screws for case fting,

- 2 x Spire clips,

- 2 ” No, 12 wood screw and metal washer, mounting bracket.

114

“) is required for the appliance.

- See Short List Diagram on page 20

water fdter, nut and fibre washer,

wall MUST

be protected by a sheet of incombustible

I) 1 xcase
!) 1 x 10 “ (250 mm) spout and washer.

3.2 Preparing and fitting the appliance

Fit spire clips ; 2 bottom rear and 2 top rear.

a)

Fit the bottom bracket to rear of chassis where the gas and water section spacer bracket is attached to the chassis.

b)

Remove the two screws securing the spacer bracket and replace securing also the bottom bracket.
Select a suitable position for the heater.

4

Using dimensions in Section 1.2 mark the fling position for the bracket. Note: Check that the minimum clearances are

4

maintained see 1.4.
Drill and plug the wall and attach the fting bracket using the screw and large metal washer provided.

4

Attach gas and water connection fittings to the heater before hanging it on the wall bracket and connecting to the

4

supplies.
Note : The bracket referred to in “b” above can be f=ed to the wall to increase the stab&y of the appliance should this

be necessary. Use fxed bracket as a template to mark position of ftings, drill and plug wall.

5

Gas connection

Fig. 2

The heater is provided with a gas inlet bend (spigotted)
suitable for connecting to 15 mm copper pipe and can be
used with either capillary or compression Wings.

(See fig. 2).
Ensure that the pipe is clean before connecting to the
heater. A gas service cock is provided fitted to the
appliance. Fasten the gas bend to the gas service cock
using the washer provided. The union nut on the gas
service cock should be checked and tightened in case of
disturbance during the fitting of the gas bend.

Test the complete installation for gas soundness and purge
in accordance with BS 689 1.

3.4

Water connection

Fig. 3

Fig.4 a

Fig. 4 b

The water inlet is suitable for connection to a 15 mm
copper supply pipe and can be used with either capillary or
compression fittings. The models must be connected to the
cold mains supply.

The connection to the water section is made as shown.
Place the water filter and use the fibre washer when
connecting the copper bend to the water service cock (See
fig. 3).

The plastic plug should be removed from the inlet water
connection before fitting the water cock.

1Fmodel: Fit the blanking cap to the remote outlet

bend connection using the cap blanking
disc and washer provided (fig. 4a).

2Fmodel: Fit the remote outlet bend using the fibre

washer provided (fig. 4b).

The distance from the heater to the remote outlet should
not exceed 20 feet. The outlet must be located in the same
room as the appliance.

Note : A remote bend is available, but not supplied as
standard, with the 1 F model. This bend is fitted in place of
the blanking disc (fig. 4a).

This enables the heater to feed a remote tap in addition to
the spout.

Ensure that all water connections are fully tightened.
Test pipework for soundness.
A check should be made of all stop cocks in the incoming

supply and it should be ensured that they are of the fured

jumper pattern. Loose jumpers can be pinned or soldered

into position.
If the appliance is installed on a supply or distribution pipe

containing a non-return valve, combinations of check valve,
or any equipment containing such devices, then provision
must be made to accomodate an expansion of at least 4 %
of the volume of water contained within the installation.

Expansion vessels must be fitted on the supply pipe
between the non-return valve, combination check vaIve, or
any equipment containing such devices, and the appliance.

3.5

spout (1 F model only)

Fit the standard 250 mm (10 ins) spout to the base of
water section using the washer supplied.
ADDITIONAL SPOUTS ARE AVAILABLE FROM YOUR
STOCKISTS

150 mm (6 ins) G.C. No. 262927 Pt.No. 41936-00
450 rnm (18 ins) G.C. No. 262929 Pt.No. 41938-00
600 mm (24 ins) G.C. No. 263279 Pt.No. 41939-00

6

4.

COMMISSIONING

Fig. 5

4.1

Open the gas and mter service taps (see fig. 6a). Purge
the gas and water supplies. Check for gas and water
soundness.

Fit the gas and water control knobs and light the pilot by
turning 90” anti-clockwise (See Users Instructions). It may
be necessary to wait for the pilot to purge, if so, wait a
few moments then turn to the off position and repeat.

When the pilot is alight wait 10 seconds then turn the gas
control fully anti-clockwise to the main gas position.

Turn on the hot tap, the heater will now light.
Check for gas soundness on appliance gas carrying com-

ponents. Turn off the gas control knob.

Check the burner pressure by removing the screw from

.the pressure test point (A) (iig. 5) on the end of the burner

manifold. Attach a suitable pressure gauge. Light the

appliance and check the pressure. The correct pressure is
given in table 1, page 3. If the pressure is not correct,
check the pressure at the meter. The gas installation
should be examined for any possible blockage if the pres­sure is not correct. The heat input is pre-set and non­adjustable.

Turn off at the gas control knob, remove pressure gauge,
replace the test point screw, relight and check for gas

soundness around the screw.
Remove screw on left hand side of combustion chamber

to allow the data badge to suspend freely. Replace screw.

Fig. 6

4.2

TO

fit

CaSing (fig.6)

a) Remove protective film and packaging.
b) Remove the control knobs and fit plastic spacer tube

over temperature selector spindle.
c) Offer up casing slightly springing sides to locate.
d) Fix with screw. two at top (A) and two at bottom (B)

(See fig.
e) Fit plastic facia plate by pressing fim-rly into position

insuring plastic catches locate around gas control and

temperature selector holes.

REPLACE THE GAS CONTROL KNOB, AND WATER TAP KNOBS. THE
TEMPERATURE SELECTOR SPINDLE SHOULD BE SCREWED FULLY

CLOCKWISE, THE KNOB PUSHED ON WITH THE INDICATOR AT THE +
POSITION.

6).

Fig.6 a

Gas service tap

Water service tap

7

4.3 Flame supervision device

Check the operation of the ffame failure device :
a) By blowing out the pilot. The flow of gas to the

pilot will cease and the thermoelectric valve should
drop out with an audible click, within approx 30
seconds.

b) - Ensure that the room is well ventilated and the
heater is cold (having been off for a minimum of 15
minutes)

- Light the pilot then turn the gas control knob to

the main gas position.

- Place a plate, as shown in figure 7a, over the

deflector and then open the hot water tap.

- The safety device should turn off the pilot and

main gas within 90 seconds.

Fig. 7

Fig. 7a

IMPORTANT : If the burner is not extinguished after 90
seconds immediately turn off the appliance and seek
advice from CHAFFOTEAUX et MAURY.

4.4 To check the thermocouple (fig. 7)

Check with a BGC mutltimeter or suitable millivolt
meter to determine the thermocouple output under
two conditions :

a) When operating normally - output should be 3 mv.
or greater.

b) When- the deflector is masked the thermoelectric
valve should close at 1.1 mv. or greater.

4.5 Handing over

Hand the Instuctions for Use to the consumer and
instruct in the correct and safe operation of the heater.

Explain to the user or purchaser that if the appliance
is not used for long periods it is recommended that
the appliance is drained. This is particularly important

during the winter months (see servicing instructions

for procedure to drain appliance).

/

deflector

F------------

/

metal Plate

\

l-l

5.

Finally, advice the user or purchaser that, for

continued efficient and safe operation of the appliance
it is important that adequate servicing is carried out at

regular intervals.

Pilot

The pilot Rame is pre-set and non adjustable.

8

6. Servicing Instructfons

6.1

6.2

Heat input

It is a requirement of the Gas Safety (Installation and Use) Regulations that the burner pressure and gas rate are

checked each time the appliance is serviced, likewise the service engineer should satisfy himself with regard to gas
soundness and the adequacy of combustion and ventilation air if this is appropriate.

The heat input is pre-set and non-adjustable.
The heat input and burner pressure should be checked againts Technical Data.
If the heat input / burner pressure is not correct check the working pressure at the gas meter. The gas installation

should be examined for any possible blockage if the pressures are incorrect.

Routine servicing

To ensure continued efiicient 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 competent person, such as BritishGas, other
registered personnel or your local Chaffoteaux Service Centre, in accordance with the Gas Safety (Installation and Use)
Regulation. This routine service will normally be confined to :

1) Cleaning the burner, and pilot tube.

2) Cleaning the heat exchanger and thermocouple

3) Checking the gas controls.

4) Cleaning the water governor.

5) Check diaphragm and replace every three years.

The following shedules are recommended :

C.O.R.G.I

6.3

a) Before commencing any work turn off :

b) Clean or replace components as necessary.
c) Check the function of the appliance and burner pressure after allowing it to warm up throughly.

d) Observe the ffame picture. Check for flame lift or excessive yellow tips.

1) the gas at the service cock,

2) the water at the water service cock by turning clockwise l/4
turn and drain if necessan(. Check for gas escapes and water
leaks after reassembly.

Cleaning

a) The burner can be cleaned by inverting and brushing with a soft brush. Inspect injectors, ensure they are clear.
b) Clean the pilot tube by blowing through.

c) The heat exchanger flueways can be cleaned by thoroughly brushing the iinned surface. After brushing inspect to

ensure that the flueways are completely clear.

d) The thermocouple can be wiped with a lint free cloth to remove any deposits. If the thermocouple tip appears

burnt or cracked, exchange to avoid a possible break at a later date.

e) Electrode : examine and clean the tip, if the tip appears damaged replace electrode and lead assembly.

9

Replace all components in reverse order. The gasket between the gas section and the manifold must be correctly

positioned upon reassembly.

To remove the casing.

\

a) Pull off all the knobs.
b) Remove the screws (4). Two top and two bottom (fig. 6A & B) and slide case off.

9

6.5

Burner

a) Remove the thermal switch (A) by pulling forwards from
its support bracket (see fig. 8).

7g. 8

A

D
D
B

b) Slacken screw (B) at the base of the pilot tube where the
pilot tube is joined onto the gas section. Remove tube by
pulling forwards.’

c) Remove the electrode lead from the piezo unit cartridge
by pulling off (C).

d) Remove the two screws (D) and the two screws (E)
securing the manifold.

Note : The pilot bracket is secured by the top centre screw
(D) on the burner manifold (G).

e) Remove the manifold (G)

9

Remove the two screws (F) which secure the burner to

the chassis.
g) Disconnect the thermocouple connection (H) at the gas

control and manoeuvre the pilot bracket outwards.
h) Lift the pilot bracket sufficient to withdraw the burner,

taking care not to loose the manifold gasket.

t) Upon completion of servicing replace in reverse order
making sure the gasket between the burner manifold and
the gas section is in place and in good condition. If
necessary replace the gasket.
Ensure that the burner head assembly is correctly located.

-.

6.6

Pilot assembly

Fig. 9

a) Withdraw the pilot bracket complete with the electrode
and thermocouple.

b) Clean the orifice (B) by brushing and blowing through
from the bracket end of the head assembly (see fig. 9).

c) Reassemble in reverse order ensuring that the pilot tube,
thermocouple are correctly located.

d) Reassemble in reverse order.

10

6.7

Gas valve

Fig. 10

a) Remove the four screws (A) fastening the burner base to
the gas section (see fig. 10).

b) Remove the burner base and spring, lift out the gas
valve.

c) Clean or replace the valve seating.
d) Replace in reverse order.
Note : The gasket should be inspected and replaced if

necessary.

6.8

6.9

Heat exchanger

Fig. 11

a) Remove the two screws (A) holding the deflector plate in

position (see fig. 11).
b) Remove the deflector plate by sliding forwards.

c) Disconnect joints at B by pulling off spring clips.
d) Lift and slide heating body forwards.
e) Reassemble in reverse order.

Descaling procedure

Periodically it may be necessary to remove scale deposits from the waterways of the appliance to ensure continued and
efficient operation. The frequency will depend largely on the hardness of the water.

Use a solution consisting of five parts water to one part hydrochloric acid. The water should preferably be hot, ADD ACID
TO WATER, NOT WATER TO ACID.

Advice with regard to descaling is available from Chaffoteaux et Maury Ltd.

11

6.10

a) Remove the governor (A) which is situated in the base of
the water section collecting the water in a receptacle (see
fig. 12).

b) Clean the components with water and regrease, using a
silicon based grease.

c) Check the spring loaded piston moves freely.
d) Replace in reverse order.

Fig. 12

6.11

6.12

Greasing of components

4!!!b

Replace burner (6.5) and outer casing

Care should be taken during the annual service of an
appliance to grease the diaphragmm spindle. Use silicon
grease.

a) Remove water section (six screws at base of gas section)
for additional information (see Section 7.5).
b) Remove diaphragm.
c) Remove diaphragm spindle.
d) Replace in reverse order.

12

7.

Replacement of components

Before commencing any work involving component replacement :

a) Turn off the gas at the gas service cock.
b) Turn off the water et the water service cock.

c) Remove the case (see Section 6.3)
d) If procedure involves breaking water connections then drains the appliances by opening an outlet tap and

removing the drain plug to the base of the water section.

7.1

7.2

Thermocouple

Fig. 13

ThermoeIectric valve

a) Remove the thermal switch (c) by pulling forwards from
its support bracket (see section 7.8 fig. 20).
b) Disconnect from thermoelectric valve (D).
c) Remove pilot tube by loosening screw (A) and pulling
forwards.
d) Remove screw (B) top centre of burner manifold and
pull pilot assembly forwards (see fig. 13).
e) Remove screw (C) securing thermocouple and retaining
plate (see section 6.6 fig. 9).
f) Remove thermocouple assembly.
g) Replace in reverse order ensuring that the thermocouple
is replaced in its purpose provided location.

a) Disconnect thermocouple from thermoelectric valve (A)
(see fig. 14).
b) Undo nut retaining the thermoelectric valve (B).
c) Lift out valve.
d) Replace in reverse order.

7.3

Fig. 14

Spark electrode

a) Disconnect thermocouple from thermoelectric valve
(D) (see fig. 15).
b) Remove pilot tube by loosening screw (A - fig. 13) and
pulling forwards.
c) Remove the electrode in the pilot bracket by undoing
and removing the screw (A) and sliding the retaining plate
(B) out.
d) Disconnect lead from the piezo unit cartridge (C).
e) Replace in reverse order.

Note : The slot in the conductor at the end of the lead is

vertical when pushed into the piezo unit cartridge.

Note : Spark gap is 2,3 mm.

Fig. 15

13

Venturi

Fig. 16

a) Remove the right hand heating body leg from the water
section and remove the venturi by unscrewing. Clean or
replace as necessary (see iig. 16).

b) Reassemble in reverse order ensuring washers are in
place.

a) Disconnect from the water section the two water
connections of the heating body and the water service tap.
b) Unscrew the six screws (A) which hold the water section
position to the gas section (see fig. 17).
c) Remove the water section complete with diaphragm and
the inlet water connection.
d) Carefully remove and inspect the plastic water section
top cover and ‘0’ ring seal.
e) Remove and grease diaphragm spindle.
f) Reassemble in reverse order.

7.6

7.7

Fig. 17

Fig. 18

Tap washers

@

2mm4 I-

m

Note : Fit the governor last. It is easier if the cold water
connection is partially engaged before fitting the screws and
connecting the union nuts. Replace all washers.

a) Disconnect the spark lead from the piezo unit cartridge.
b) Remove the two screws (A) holding the retaining plate

(see fig. 18).
c) Remove the piezo cartridge and renew.
Note : On reassembling ensure that the locating pins on

each end of the spring are correctly engaged in their
location holes.

a) Unscrew tap spindle guide using a 14 mm spanner and
remove.

b) Pull out the tap washer. The washer can be reversed but
is should be ensured that there are 2 mm between the

washer cup and the washer face.

c) Replace in reverse order.

7.8

Scale reducer

a) Remove the retaining spring clip (A) with pliers (see fig.

19)

b) Pull out to the side.
c) Replace in reverse order.

Note : It will be easier to first engage the long leg of the
retaining spring clip into the bottom hole then engage the
top hole before pushing home.

Fig. 19

7.9

Combustion chamber fining

a) Remove two screws (A) holding the deflector plate in
position (see fig. 20).
b) Remove deffector plate by sliding forwards.
c) Disconnect joints at junction where heating body joins
heating body legs (B). (see 6.8).
d) Remove heating body by lifting and sliding forwards.
e) Undo nuts securing heating body legs to water section
and remove legs.
f) Remove the thermal switch (C) by pulling forwards from
its support bracket.
g) Ease sample tube from the pilot head.
h) Remove brackets (E) which are retained by screws (F)
onto burner manifold.

1) Remove the four screws (D) which retain the combustion
chamber front cover.

3) Slide out combustion chamber side linings.
k) Remove the rear lining if necessary complete with
support bracket, then slide out of plate.
I) Replace in reverse order.

Fig. 20

15

Heat exchanger

Fig. 21

a) Remove the two screw (A) holding the deflector plate in
position (see fig. 2 1).

A

b) Remove the deflector plate by sliding forwards.
c) Disconnect joints where heating body joins heating body
legs (B) (see 6.8)
d) Lift and slide heating body forwards.

e) Reassemble in reverse order.

7.11 Burner

Fig. 22

a) Remove the thermal switch (A) by pulling forwards from
its support bracket (see fig. 22).
b) Slacken screw (B) at the base of the pilot tube where the

A

r

6

pilot tube is joined onto the gas section. Remove tube by
pulling forwards.
c) Remove the electrode lead from the piezo unit cartridge
by pulling off (C)
d) Remove the two screws (D) and the two screws (E)
securing the manifold.

Note : The pilot bracket is secured by the top centre screw
(D) on the burner manifold (G).

e) Remove the manifold (G).
f) Remove the two screws (F) which secure the burner to
the chassis.
g) Disconnect the thermocouple connection (H) at the gas
control and manoeuvre the pilot bracket outwards.
h) Lift the pilot bracket sufficient to withdraw the burner,
taking care not to loose the manifold gasket.
t) Replace in reverse order making sure the gasket between
the burner manifold and the gas section is in place and in
good condition. If necessary replace the gasket.
Ensure that the burner head assembly is correctly located.

7.12

7.13

Hot assembly

a) See Section 7.1 - Removal of thermocouple.
b) Remove pilot tube by loosening screw (A) (fig. 13) and pulling.
c) Remove electrode (see Section 7.3 C).
d) Replace in reverse order.

Gas valve

a) Remove main burner (see Section 7.11).

b) Disconnect thermocouple.
c) Remove gas valve (see Section 6.7)
d) Replace in reverse order.

16

ilow Ignition Device

Fig. 23

a) Unscrew the slow ignition device (A) anti-clockwise and
remove (see fig. 23).

b) Clean with water using a stiff brush (the ball move
freely).

c) Replace in reverse order.

7.15

Burner manifold

a) Remove pilot tube by loosing screw (A) (fig. 13) and pulling.
b) Remove screws (E) and (D) (see Section 6.5, fig. 8) and remove injector manifold.

c) Replace in reverse order taking care that the manifold gasket is correctly positioned.

7.16 Atmosphere sensing device

a) Remove thermocouple assembly (see Section 7.1)
b) Remove thermal switch by pulling forwards out of support bracket (A) (see Section 7.11)
c) Replace in reverse order.

7.17 Pilot injector

(THERMOCOUPLE ASSEMBLY)

r

a) Remove thermal switch (see Section 7.16).
b) Remove pilot tube (see Section 7.12).
c) Remove pilot injector by turning anti-clockwise with a 6 mm box spanner.
d) Replace in reverse order.
e) Ensure the flame pictures is correct (see Section 5.1)

17

8. FAULT FINDING CHART FOR CELT STAR B

8.1

8.2

8.3

PROBLEM

Pilot ffame does not

light automatically

Poor pilot flame

(see section 5.1)

Pilot will not stay

alight

CAUSE

1) Gas service cock closed
ti) Air in pipe
iii) Pilot injector blocked
iv) Incorrect spark gap at electrode
v) No spark

vt) Pilot air tube obstructed

1) Pilot injector dirty / damaged
if) Wrong injector

ti) Pilot head blocked
ti) Faulty pilot tube

v) Pilot air tube obstructed Clean
ti) Inadequate ventilation

t) Thermocouple low output
ti) thermoelectric valve faulty
ti) Gas pressue low / variable

hr) Gas pressure too high
v) Pilot flame incorrect

vt) Inadequate ventilation
vtl) Loose connection thermocouple /

thermoelectric valve
ti) Heat exchanger fins blocked
Ix) Pilot air tube obstructed
x) Thermal switch faulty

Open service
Purge line
Change
Change
Replace electrode and lead or
piezo cartridge
Clean

Change injector (See section 7.17)
Change for correct diameter

Clean
Clean or replace

Remedy

Change thermocouple assembly
Change valve
Check at meter

Check pressure at meter
Check injector and pilot air tube
For obstruction
Remedy

Tighten
Clean
Clean
Change thermocouple assembly

REMEDY

8.4.3

8.4.;

Main burner does
not light

Explosive ignition 1) Pilot Check pilot

1) Gas service tap not open fully
ti) water rate low

ti) Gas valve push rod jammed
?w) Diaphragm perforated
v) Gas contrrol tap faulty

VjI) Injector size

ti) Scale reducer damaged
ti) Slow ignition device stuck

18

Open fully
Check if water rate is sufficient
(see page 2)
Clean rod and regrease
Change diaphragm
Check operation of User’s gas

control tap
Check burner injectors against

Technical data
Replace
Clean or replace (see 7.14)

Relocate into slots in pilot bracket.

8. FAULT FINDING CHART FOR CELT STAR B

8.5

8.6

PROBLEM CAUSE

Water temperature

Burner stays on

3) Water service flow rate too high
a) Insufiicient gas flow

M) Water governor sticking
iv) Heat exchanger blocked or scaled
v) Scale reducer damaged

1) Air in draw off
ti) Gas valve push rod jammed
ti) Gas valve “letting by”

iv) Loose jumper on house stop cock

v) Dead leg on system
vt) Dirt in water section

vtl) Slow ignition device stuck

REMEDY

Check governor
Check gas rate and that the gas
service cock and user’s control are
open
Remove and clean or replace
Descale or replace
Replace

Purge line to eliminate dead leg
Clean push rod and regrease
Change valve facing

Replace water stop cock or pin
down jumper
Vent or remove

Clean water section
Clean or replace (see 7.14)

8.7

8.8

8.9

8.10

Unstable flames

Heating body noise

Insufhdent water ffow

Heater smells when
new

1) Water in gas line
ti) Inlet pressure too high for governor

i) Scale
ti) Overgassed

1) Water service tap partly closed
ti) Low water pressure

ti) Water governor faulty
iv) Water governor sticking
v) Foreign matter in water section

i) Appliance newness Smell will go within a short period

Drain and purge
Check pressure at meter

Descale heating body

Check burner & meter pressures

Technical Data

Check it is fully opened
Check water pressure technical

data
Change governor
Remove and clean or replace
Remove and clean

of time

8.11

High water flow

t) Water governor sticking Replace or grease.

19

SHORT LIST

505

-901

- 907

-902

t

903

-909

0711

r908

Qr

725

502

911

I&

3

1034

0

1001

~1009

*lo10

"'O@-Jjp,,,

618

503

Ley N

THERMOCOUPLE.. ..................................................

502

ELECTRODE AND LEAD ASSEMBLY ........................

503

AIR SAMPLE TUBE ASSY.. .......................................

505

DIAPHRAGM

618

TAP WASHERS.. ......................................................

711

SPOUT.. ..................................................................

725

FRONTCASE.. ...........................................................

901

GAS CONTROL KNOB.. ............................................

902

COLD WATER KNOB.. ..............................................

903

HOT WATER KNOB.. ................................................

904

TEMPERATURE SELECTOR KNOB.. .........................

905

FRONT CASE TRIMS 1 F.. .........................................

307a

FRONT CASE TRIMS 2F.. .........................................

307b

SCREW HSZ D: 4.2-9.5.. ...........................................

908

TEMPERATURE SELECTOR GUIDE.. ........................

909

SPIRE CLIP .............................................................

911

WATER SERVICE TAP .............................................

IO01

WASHER D: 18.4-l 2.2-l .5.. .......................................

1002

NUT l/2”.

I003

WATER TAIL

I004

WATER FILTER ....................................................

1005

REMOTE CONNECTION WATER ..............................

I007

NUT 3/8”

I008

WASHER D: 14.8-11.5-l .5.. .......................................

I009

BLANKING DISC.. ....................................................

1010

GAS SERVICE COCK.. .............................................

1012

GASKET 314”

1013

GAS INLET BEND ....................................................

1014

WASHER D: 18.2-14-1.5 ...........................................

1015
1031
1032
1033
1034

MOUNTING BRACKET .............................................

WOOD SCREW.. ......................................................

WASHER D: 25-6.5-l .5 .............................................

SPACER BRACKET.. ................................................

Description

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

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

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

.................................................................. 262556

........................................................... 265086

“s

Type

G. C. NO.

264701
264702
265060
263432
263375
262928
265079
265043
265046
265045
265044
265082
265083
366716
264688
264782
264756
262509
262584
264754

263655
263668

262503
264725

265087
265088
264693
366017
264694
264780

MANF. PT. NO.
CELT STAR B

74432.00

81290.00

81320.00

25809.30

5579.00

22527.10

1001489.00

1001495.00

1001499.00

1001498.00

1001497.00

1001530.00

1001505.00

66206.00

70493.00

72411.00

1009433.00

61855.14

20747.38

78864.00

1003811 .OO

39783.00

20746.20

61854.10

1219.00

74427.00

1004025.00

76058.10

22835.16

54606.00

25617.03

35378.03

71707.00

Chaffoteaux et Maury Limited,

Trench Lock, Trench, Telford, Shropshire TFI 4SZ

Telephone : Telford [phone] - Telefax : [phone]

chaffoteaux

et Maury

Looking Good. Heating Better

ESP032