Chaffoteaux & Maury CHALLENGER 30 BF, CHALLENGER 40 BF Installation And Servicing Instructions

CHALLENGER

Balanced Flue Boilers

30 BF

40 BF

(GCN"41.980.71)

(GCN"41.980.75)

installation

and servicing instructions

(leave these instructions adjacent to the gas meter)

CHALLENGER BF are low water content gas fired boilers.

CHALLENGER

30 is rated between 4.35 kW (15,000

Btu/h) and 8.7 kW (30,000 Btu/h).

CHALLENGER

40 is rated between 5.8 kW (20,000 Btu/h)

and 11.6 kW (40,000 Btu/h).
The boiler is designed for use on Natural Gas, unless

otherwise stated. It is suitable for open systems and sea­led systems.

The boiler is designed for fully pumped systems only with
a number features incorporated.

- Fully adjustable electronic temperature regulation bet­ween 60 “C and 82 “C.

- Automatic alternation high flame/low flame.

- Pump overrun.

- Low resistance.

- High limit thermostat.

1

Guarantee

The manufacturer’s guarantee on the appliance is for 24 months from

the date of

installation. The guarantee is voidable if it is

not installed in accordance with the recommendations made herein or in a manner approved by the manufacturer.

1.1 TECHNICAL DATA

return *; ~ Tflow

F

J

c

Cl

-

­A
6
C
D

E

F
G
H

J
K

L
M
N
0

LLENGEI

mm

R3

l-

‘OBF ’

ins

610 24
330

13
270 10.6
350

13.77
224 8.8
120 5.0

80

3.1
200 7.8
215 8.5
300 12
660 26
260 10.25

30

1.2

45

1.7

A

B
C

D

E
F

G

H
J
K

L
M
N
0

R4 LLENGEI

mm

10 BF

ins

655 25.78
395

15.55

260

10.25

320

12.6

225 8.9

120 5.00
250 9.8
200

7.87

210

8.26
300 12.00
700

27.5

260 10.23

35 1.37
50

1.96

.

1

2

1.2

1.3

1.4

30 BF

Max

Min

40 BF

Max

Min

OUTPUT

kW Btdh

8.7

30,000

4.35

15,000

OUTPUT

kW

Btu/h

11.6

40,000

5.8

20,000

Max

Min

Max

Min

INPUT

BURNER PRESSURE (HOT)

GAS RATE

kW Btu/h mbar ins.w.g. m3/h ft3/h

10.9 37,500 6.4

2.56 1.02 36.26

5.66 19,480 1.15

0.45 0.53 18.83

INPUT

BURNER PRESSURE (HOT)

GAS RATE

kW

Btu/h mbar ins.w.g. m3/h ft3/h

14.5 50,000 12.0

4.72 1.37 48.54

7.55 26,000 3.5

1.37 0.71 25.24

NB : For intermediate settings see graph page 13

Sides

TOP

Bottom

Front

CLEARANCES

mm ins

5 0.25

76 3

127 5

500 20

BalanceFlue ..___.

Flue set requires a hole in the wall 205 mm highx305 mm wide (8 inxl2 in)

Gas connection

15 mm compression fitting

Waterconnection

22 mm compression fittings

Minimum flow rate see 1.4
Maximum static head 30

m (98 ft)

Minimum static head 150

mm (6 ins) - See page 7.

Electrical connection

240 V single phase 50 Hz supply fused 3 amp

Weight

30 BF - 18.18

kg (40 Ibs)

40

BF - 20

kg (44 Ibs).

Watercapacity .._.......

0.5 lit. (0.11 gals.)

Manifold Injector Size

30 BF

1.18 mm (0.046 ins.)

40

BF

1.08 mm 0.042 ins

Pilot injector 0.3

mm (0.011 ins.)

Ignition

Continuous spark -spark generator ANSTOSS

Electrode ..___......... ,.,.,

Chaffoteaux - spark gap 5.0 mm

Boiler thermostat

Electronic - Chaffoteaux Ltd

High Limit thermostat

Ranco LM5

Thermocouple and thermoelectric valve

Chaffoteaux Ltd

water flow-gallons per minute

HYDRAULIC RESISTANCE

The hydraulic resistance of the boiler varies with
the water flow. The graph (Fig. 2) indicates resistan­ce at various flow rates.

3

The minimum flow rate is equivalent to a tempera-

a

ture rise of 15” C :

z

2:

.c

30 BF

f

9
B

504

I/h

1.85 gpm

673

I/h

.%?

1

Minimum water flow rate

0.1

I I

w I

I

I I

100 300 500

700 900

1100

13bo

200

400 600

800

1000 1200 1400

water flow - litres per hour

3

1.5 Description of Operation

Pressing the ignitor (on) button disconnects the supply
to the pump, opens the therm0 electric valve and causes
a continuous pilot ignition spark to be generated and the
pilot is lit.

If there is a demand the pump will start when the (( ON ))
button is released. The burner will commence after a 30
second delay when the 50 % fixed gas valve opens. After
3 seconds the 2nd (variable output) valve opens.

Temperature control is by means of a temperature sen­sing thermistor and potentiometer. These signals are
fed to a comparitor.

When the flow temperature approaches the set tempe­rature the main gas valve is closed and the bo’iler

continues to fire on 50 % fixed gas valve. When the set
temperature is reached the boiler switches off. If flow
temperature reduces the 50 % fixed gas valve opens fol­lowed by the variable valve.

At the end of an ‘on’ cycle under the control of a time

clock or programmer or when the cylinder and room
thermostat are satisfied the boiler switches off but the
pump continues to run for 15 seconds.

The high temperature cut out breaks the thermocouple
circuit which extinguishes the Pilot and closes the gas
supply to the burner. Manual re-setting is reauired. (See
section 4.11)

FUNCTIONAL FLOW DIAGRAM

ON n

THERM0 ELECTRIC

VALVE

L

L

PILOT

r

SPARK GENERATOR

r

IGNITOR

A

HIGH LIMIT

T

THERMOSTAT

THERMOCOUPLE

L
r

THERMISTOR

1

FLOW SENSOR

I

1

VARIABLE
lDD%GAS

rh

SOLENOID

VALVE

COMPARITOR

POTENTIOMETER

TEMPERATURE

L

I

TIME DELAY

.2SI FPrl-m

r

I

Fig. 1

L

. TIME DELAY PUMP

.

OVER RUN

r

PUMP

2. INSTALLATION REQUIREMENTS

2.1 General

The installation of the boiler must be in accordance with
the Gas Safety Regulations, Building Regulations, I.E.E.
Regulations and the Byelaws of the local Water Underta­king. It should be in accordance also with BS Codes of
Practice and the British Gas Specifications for Domestic
Wet Central Heating Systems and any relevant reauire­ments of the local Gas Region and Local Authority.
Detailed recommendations are stated in the following
British Standard Codes of Practice : CP 331:3, BS 5376:2,

BS 5546, BS 544011 and 2, BS 5449:l.

Note

: Gas safety (Installation and Use) regulations 1984 :

It is the law that all gas appliances are installed by com­petent persons in accordance with the above regula­tions Failure to install appliances correctly could lead to
prosecution. It is in your own interest and that of safety
to ensure compliance with the law.

2.2

Location

The position chosen for the boiler should permit the pro­vision of a satisfactory flue termination. The position
should also provide adequate space for servicing and air
circulation around the boiler. (See Section 4).

Where installation will be in an unusual position, special

procedures may be necessary, and BS 5376:2 gives de-

tailed guidance on this aspect.
A cupboard or 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 5376:2.

2.3

Water Circulation Systems

2.5

Open or sealed type central heating systems (see Section

5) should be in accordance with the relevant recommen­dations given in BS 5376:2, BS 5449:l (for smallbore or
microbore systems) and the British Gas Specifications
for Domestic Wet Central Heating Systems,

Hot water systems should be in accordance with the re­levant recommendations given in CP 34211 and the abo­ve mentioned British Gas publication and BS 5546.

2.4 Air supply - Balanced Flue Boiler

2.6

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 and
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
room or must both be on the same wall to outside air.

2

7

.

This free area may be halved if the ventilation is provi­ded directly from outside.

30 BF cupboard or compartment air supply

Position of Air from

Air direct

air vents

room

from outside

40

BF

Position of

air vents

Air from

room

Air direct

from outside

Electrical Supply

This appliance must be earthed. All wiring must conform
to the I.E.E. Regulations. The CHALLENGER 30 requires a
240 V, single phase, 50 Hz supply. A means of isolation
must be provided adjacent to the boiler, this should pre­ferably be an unswitched plug and socket. Alternatively,
a double pole isolator having a contact separation of at
least 3 mm at both poles must be used. The fuse rating
should be 3 amp The

supply

cord must be 0.75 mm2

three core heat resisting cable.

Gas Supply

The CHALLENGER 30 requires 1.1 m3/h (37 fts/h). CHAL­LENGER 40 requires 1.4 m3/h (49 ft3/h) of natural gas.
The meter and supply pipes must 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 described in CP 331:3

Flueing

Detailed recommendations for flueing are given in BS 544O:l.
The following notes are for general guidance only.
The boiler must be installed so that the flue terminal dis­charges directly into the external air.
Termination should be on a clear expanse of wall ; the
terminal being preferably not less than 600 mm (2 ft)
from a corner or recess.
Where the terminal is less than 2 m (6.6. ft) above the le­vel of any ground, balcony, flat roof or place to which
people have access, the terminal must be protected by a
guard of suitable material.
Where a terminal guard has not been supplied (optional
extra) with the boiler, one may be obtained from Chaf­foteaux Limited or from Tower Flue Components Ltd.
Tonbridge 351555.
The air inlet/products outlet duct and the terminal
should be no closer than 25 mm (I in) to combustible
material. Detailed recommendations on protection of
combustible material are given in BS 544O:l.
The distance of any surface facing the terminal should
be greater than 600 mm (24 ins).
If the terminal is fitted within 850 mm of a plastic gutter

or within 450 mm of painted caves or a painted gutter,
an aluminium shield at least 750 mm long should be fit­ted to the underside of the gutter or painted surface.

Fig. 2

BALANCED FLUES

E PROJECTION

SPLITTER

(Zft)

NOT TO EXTEND
MORE THAN
DEPTH OF
TERMINAL

NE 1. TERMINALS MUST NOT BE FITTED

IN SHADED AREAS

2. IF LESSTHAN 1,606 mm l6ftl ABOVE GROUND LEVEL
FIT TERMINAL GUARD

3. If 3OOmm (1 ft) BELOW EAVE FIT DEFLECTOR TO
SOFFIT 600mm (2 h) ON EITHER SIDE OF TERMINAL
& EXTENDING TO INCLUDE PLASTIC GUTTER

5

3.

3.1

3.2

3.3

3.4

3.5

3.6

SYSTEM GUIDANCE

(Chaffoteaux Ltd. recommendations).

General

The CHALLENGER is a low water content boiler designed

ONLY for use with fully pumped systems. It may be used

with open or sealed systems, all safety controls exclu-

ding the pressure relief valve being incorporated in the
boiler. The thermostat is adjustable and, on its maximum
setting, gives a nominal 82 “C (180 “F)i4 “C (7 “F).

Detailed recommendations for the water circulation are
given in BS 5376.2 1976, BS 5449.1 1977 and BS
5546:1979.

Thermostatic control should be fitted to the cylinder and

heating circuits.

Strainers

Where the CHALLENGER is used as a replacement for a

boiler on an existing system, ideally the system should

be flushed and cleaned using a suitable chemical cleaner
following the manufacturer’s recommendations and fit­ted with a strainer similar to that manufactured by Ho-

neywell.

Control Schemes

The boiler is electrically controlled. See section 3.11.

Most normal pumped primary control schemes can be
used including thermostatic radiator

and

cylinder valves.
When using motorised valves the controls should be so
arranged to switch off the boiler when circuits are satis­fied.

Chaffoteaux can be consulted where technical assistan­ce is required.

Circulation Pump

The system circulating pump should be sized relative to
the resistance of the connected load and the system de­sign selected. The water flow rate through the boiler
should not be less than shown in section 1.4. The pump
must be installed between isolating valves. Most pump
manufacturers require a minimum static head on the
pump inlet to prevent cavitation. For boiler resistance
see graph on page 3.

Cold feeds and open vents

The cold feed and open vent should be so positioned
that pumping over and sub-atmospheric pressures are
avoided see recommendations for various layouts on

page 7.

Automatic Air Separator

Chaffoteaux Limited strongly recommend the inclusion

of a British Gas accepted automatic air separator in the

system as shown in fig. 9.

The open vent pipe should rise continuously from the

system pipework.
It should not be entered horizontally into the system pi-

pework. The use of an enlarged T to create a low velocity
point is recommended. The preferred arrangement is
shown in fig. 9.

3.7 Cylinder

The domestic hot water cylinder used with the CHAL­LENGER must be of the indirect and high recovery type
to BS 1566 Pt. 1. Single feed cylinders are not suitable
for use with the appliance. Flow and return pipework to
the cylinder should be in 22 mm pipe.

3.8 Feed and Expansion Tank

The feed and expansion tank should be adequately sized
to accept the system water expansion, it should not be
mounted closer than 9 in. to a ceiling to allow access to

the ball valve.

3.9

Inhibitors

Chaffoteaux Limited do not generally recommend the
inclusion of an inhibitor with heating and hot water sys­tems, utilising CHAFFOTEAUX boilers. It is, however, ap­preciated that the use of a corrosion and limescale inhi­bitor may be desireable or specified.

The following are the appliance manufacturer recom­mendations :

Use only a British Gas or similar approved inhibitor
from the Fernox range manufactured by Industrial
(Anti-Corrosion) Services, Brittanica Works, Arkesdon
Road, Clabering, Nr Saffron Waldron.

Use only the quantities specified by the inhibitor
manufacturer.

Cleanse the system as may be required be the inhibi-

tor manufacturer.
Add inhibitor only after flushing when finally refilling

the system.

3.10 Add on devices

This appliance is approved by British Gas for safety and

performance. It is important that no external control de­vices - eg. flue dampers, economisers etc. - be directly
connected to this appliance unless covered by these lns­tallation Instructions or agreed by the Manufacturer in
writing.

Any direct connection of a control device not approved
by the manufacturer could invalidate British Gas appro­val and also infringe the Gas Safety Regulations.

6

Minimum
Static Head

150mm

Static Head

-----

----.

PREFERED

.

. . .

. . . . .

. . . . .

_----

Static Head

Static Head

Refer to
BS 5449
Part 1 1977

Air seperator or formed low velocity point

1. Cold feed 15 mm

2. Open vent 22 mm

3.11 Electrical Controls

(Chaffoteaux recommendations)

CHALLENGER can be used with most normal pumped pri­mary schemes including non-electrical heating and hot
water controls.

It is not normally possible to use full programming facili­ties when using a mixture of electrical and non-electrical
controls. However, some non-electrical controls are now
available with an external microswitch and these controls
are preferred.

Where the thermostatic radiator valves are used a sys­tem by pass will be necessary to maintain the minimum
flow rate - See section 1.4.

Important:

All external wiring to and from the boiler

must be in accordance with the current edition of the

I.E.E. wiring regulations

1. Fully pumped system independant control of central hea­ting and hot water using two spring return motorised val­ves.

PROGRAMMER

PUMP

BOILER TERMINALS

Fig. 10

2. Fully pumped systems independant control of central
heating and hot water using two motorised valves.

PROGRAMMER PUSP BOXER TERMINALS

Fig. 11

3. Drayton flow share valve system.

Fig. 12

4. Honeywell Sundial ‘Y’ plan.

PROGRAMMER PUMP

Fig. 13

5. Satchwell Duoflow system.

BOILER TERMNILS

TLX 2259

ROOM

SA 2451

CM 361

STAT

CYL STAT

C”OFLOW VALVE

PROGRAMMER

PUMP

BOILER TERMINALS

Fig. 14

4.

INSTALLING THE BOILER

A vertical flat area is required for the boiler as follows :
CHALLENGER 30 BF 340 mm wide x 813 mm high (13.4 ins x 32.0 ins)
CHALLENGER 40 BF 405 mm wide x 858 mm high (16.0 ins x 33.7 ins)
The above dimensions include the necessary clearances around the boilers for case removal and for air movement,

The standard flue set supplied with the boiler is suitable for walls having a thickness of 75 mm to 355 mm (3 ins to 14 ins). Ex­tension sets are available for walls up to 610 mm (24 ins). This can be extended to 610 mm (24 ins) using an extension kit or

alternatively a 610 mm (24 ins) complete assembly is available.

4.1

c

4.2

IMPORTANT NOTICE : TIMBER FRAMED HOUSES
If the appliance is to be fitted in a timber framed building it should be fitted in accordance with the British Gas Publica-

tion, “Guide for Gas Installations in Timber Framed Housing” reference DM2. If in doubt, advice must be sought from
the local Gas Region of British Gas.

4.3.1

4.3.2

Preparing the wall (traditional constructions)

a) Using dimension on page 2, or using boiler as templa-

te, cut hole for air duct.

b) If the hole is cut accurately, there will be no necessity

to line the hole since the air duct will make a satisfac­tory seal.

Assembling the balanced flue set
NB : For walls 355 mm (14”) or less use the air duct

body and cover supplied with the appliance. For walls
over 355 mm (14 ins) up to 600 mm (24 ins) a 24” flue
assembly is available alternatively the flue extension
kit may be used (See 4.3.2).

a) Remove air duct body (I) and cover (2) from car-

ton.

b) Measure and cut plain ends of air duct body and cover

to the wall thickness plus 5 mm (l/4 ins).
c) Place cover over body and engage tags.
d) Turn down tags in direction of flange (3).
e) Tape along length of joints with tape provided.
f) Using nut and bolt provided fit hooks (4) to air duct.

For walls in excess of 350 mm (14 ins)

tape

NB : Use either 600 mm (24 ins) assembly or flue exten­sion kit.

a) Proceed as a-f -4.3.1.
b) Assemble air duct extension.
c) Insert extention piece inside flanged section and ex-

tend to the wall thickness + 5 mm (l/4) leaving a mini-

mum of 50 mm (2 ins) overlap.
d) Trim extension piece to length as necessary.
e) Mark around inside of joint,
f) Remove from wall and reassemble to mark in (e) and

tape around outside of joint with tape provided.

9

4.4.1

4.4.2

4.5

46.1

46.2

Fitting the balanced flue set walls in excess of
100 mm (4 ins)

a) Fit air duct into hole with the flanged end flush with

the internal wall surface.

b) Make good and seal air duct into hole internally and

externally.

c) Pass terminal through hole and secure with springs

and chains on the hooks on the air duct.

NB : It is recommended that a length of card or string is
fixed to the terminal to prevent any risk of damage or
danger to persons in or about the building.

Fitting the balanced flue terminal walls 75 mm
(3 ins) to 100 mm (4 ins)
a) Proceed as 4.4.1 a and b.
b) Mount boiler see 4.5 and 4.6.

G) Transfer chains from the hooks to the slots in the flue

bend mounting bracket A.

d) Secure chain with nut and bolt B provided.

Preparing the boiler for fitting
a) Remove front casing by removing two screws (A) at

top and bottom and two screws (B) front lower Part

of boiler.

b) Remove the aluminium flue bend by removing screws

(C) on either side of bend.

c) Fit two brackets to top of boiler using screws provi-

ded A - 4.6.1.

d) Fit cable clamp bracket below boiler (A - 4.8) using

screws and paint cutting washers provided.

NB : Paint cutting washers must be used to maintain the
earth bond.

Fitting the boiler

30 BF

a) Measure down from base of the air duct (page I) for

bottom fixing. Mark, drill, rawplug and fix bottom
bracket.

b) Offer boiler to wall resting on bottom bracket and lo-

cating with air duct.
c) Mark, drill and rawplug wall.
d) Attach foam gasket around the air inlet spigot(c) (pull

off protective paper whilst sticking down gasket).
e) Lift boiler into position with the air inlet spigot loca-

ting into the air duct.
f) Secure boiler to the wall with the screws and washers

provided.

g) Secure boiler screwing through bottom bracket.
Fitting the boiler

40 BF

a) Offer boiler to the wall and mark top fixing bracket

and bottom fixing holes.

b) Drill and rawplug wall.
c) Attach foam gasket around the air inlet spigot (pull

off protective paper whilst sticking down gasket).

d) Lift boiler into position with the air inlet spigot loca-

ting into the air duct.

e) Secure boiler to the wall with the screws and washers

provided.

10

4.7

4.8

4.7-I Assembling the flue duct and bend (Walls
75 mm (3 ins1 to 100 mm (4 ins)

a) Cut flue duct to length, wall thickness plus 100 mm (4”).
b) Slide flue duct through the air duct and fully engage it

in the terminal.
c) Replace flue bend engaging the flue duct.
d) Ensure that the flue bend sits evenly and securely on

the heat exchanger secure flue bend with the two

screws previousty removed.
NB : It is advisable to reduce the tension from the termi-

nal securing chains before locating flue bend. Retension

after fixing bend securing chain with the nut and bolt

provided. See 4.4.2.

4.7.2

Assembling the flue duct and bend (walls

100 mm to 350 mm (4 ins to 14 ins)

a) The flue duct is telescopic and should be extended to a

length equal to tha wall thickness plus 100 mm (4 ins)

including an overlap of not less than 50 mm (2 ins).

b) Tape around the joint in flue duct.
c) Slide flue duct through the air duct and fully engage

in the terminal.
d) Replace the flue bend engaging the flue duct.
e) Ensure that the flue bend sits evenly and securely on

the heat exchanger, secure flue bend with the two

screws previously removed.

4.7.3

Assembling the flue duct and bend (walls

355 mm to 600 mm 14 to 24 ins) - 14 ins flue as­sembly plus extension kit.

Overlap 50 mm (2 ins)

a) The flue duct is telescopic and comprises 3 pieces it

should be extended to a length equal to the wall

thickness plus 100 mm (4”) including two overlaps of

not less than 50 mm (2 ins).

b) Proceed as 4.7.2 b to e.
NB : When a 24 ins flue assembly is supplied the flue

duct comprises 2 telescopic sections.

Making the gas connection
a) Fit the gas service tap (B) together with the filter was-

her 0.

b) The gas supply pipe size should be sufficient to ensu-

re that there is 20 mbar (8 in.w.g.) pressure at the

service tap, with the appliance working.

NB : The gas supply pipe size should not be less than the
gas inlet to the appliance.

Making the water connections
a) Remove sealing plugs.

b) Fit the nuts and olives supplied in the accessory box.
c) Enter the FLOW pipe into the RIGHT hand connection

and the RETURN goes to the LEFT hand connections.

d) Tighten compression fitting holding connection on in-

side of boiler.

11

Making Electrical Connections (See section 2 for
electrical supply requirements.)

a) Remove control box cover (see 8.10).
b) Three core heat resisting supply cable is passed

through clamp and through slot in casing, and into

rear of electrical box and connected to terminals on
connection block and the earth connection made to
earth terminal.

c) Connect pump cable to terminals @I and the earth on

earth terminal.

d) Connect ancillary controls across terminals marked 5

and 6. See controls diagrams, Pages 8 and 12.

e) Clamp wires with cable clamp.

f) Replace control box cover.

NOTE : The length of the earth wire between the cord
anchorage and the terminal must be such that the live
and neutral wires become taut before the earth wire if
the supply cord is pulled.

Maik

Pump

4.11

Resetting high limit thermostat

L

El@ reset

a) If for any reason the high limit thermostat operates

the pilot will go off and the boiler will require manual
re-setting.

b) Re-establish the appliance by re-setting the high limit

thermostat by pressing the red buttom in hole on
electrical panel.

c) Establish cause and rectify - see fault finding chart,

page 21.

In the event of an electrical fault after installation preliminary electrical system checks as described in the Multimeter
Instruction book should be carried out.

Checks to ensure electrical safety should be carried out by a competent person, i.e. earth continuity, polarity and resis-

tance to earth

3 Wire clock

4 Wire clock

Fig. 15

CHALLENGER -SIMPLE CONTROLS

Room thermostat only

f f R~~~~~~~ @

N N

Room thermostat and time clock

Fig. 16

6

I

Frost thermostat

Fig. 17

12

5.

5.1

COMMISSIONING -OPEN VENTED SYSTEMS
Gas Installation

5.5 Adjusting the by-pass

The whole of the gas installation, including the meter
should be inspected and tested for soundness and pur­ged in accordance with the recommendations of
CP 331 :3.

5.2

Water circulation system ­Open vented system only

The whole of the system should be filled and thoroughly

flushed out with cold water without the pump in posi-

tion. Ensure that all valves are open.
With the pump fitted the system should be filled and air

locks cleared. Vent all radiators and check for water
soundness.

Light the boiler as detailed in 5.3.

The water system should be heated to maximum wor-

king temperature and examined for water soundness.
Both gas and water should then be turned off and the

water system rapidly drained while still hot.
The system should again be filled, cleared of air locks and

examined for water soundness and inhibitor added to

the system if required in the specification (See section

3.9).

5.3 Lighting the boiler

a) Check that the gas service tap is open.

b) Switch controls to a demand mode, ensuring that

pump is running.

c) Push the button marked ‘on’ fully in and hold for 10

seconds.
d) Check that pilot is alight and release button slowly.
e) If the pilot extinguishes press red button and repeat

from (b). (The pilot should be about 13 mm (l/2”) long

and impinge on the tip of the thermocouple).
f) If the pilot extinguishes, wait 3 minutes and repeat b)

above.

g) After 30 seconds the main burner will light.
h) Check for gas soundness around the boiler gas corn-

ponents using sense of smell and leak detection fluid.

i) Check and adjust gas rate as detailled in 5.4.

5.4

Gas rate adjustment

(TO be carried out be-

fore adjusting by-pass.)
NB : The boiler is supplied rated at the highest output.

The boiler is fitted with a gas rate adjuster.
a) Switch boiler to off by pressing OFF button.

b) Remove the pressure test point screw C (8.5) and

connect a suitable pressure gauge.

c) Remove the hexagonal cap from gas volume adjuster,

D (7.5) exposing the adjustment screw.
d) Turn boiler on by pressing ON button (see lighting boi-

ler 5.3).

e) Adjust pressure after boiler has been running for 10

minutes and then check the gas rate. Setting pressu­res are given in graph relative to required output. The
pressure will be reduced by clockwise movement of

screw, increased by anti-clockwise movement.
f) Turn boiler to OFF and refit pressure test point screw

and volume regulator cap. Test for gas leakage
around pressure test point.

g) Mark the data badge to indicate output to which boi-

ler has been set.

h) Replace case. Particular attention must be given to

ensuring that the case seal is sound when the casing

is replaced.

NB : The by-pass valve should be of the lock shield pat­tern.

Set the pump to achieve the system requirements
but ensure that the minimum flow rate through the
boiler is achieved (See 1.4 - page 3). This is equivalent
to a temperature rise across the boi!er of 15” C. Set
boiler thermostat to maximum.

Fit the boiler with the by-pass fully closed and the
system on full load, i.e. central heating and domestic
hot water (indicator valve fully open).

Adjust the system to minimum load. This will normally
be central heating only with one radiator operating.

Open the by-pass gradually until the boiler operates
quietly at all flow temperatures and the boiler ther­mostat turns off the gas.

6

SEALED SYSTEMS

6.1

Safety valve

A safety valve shall be fitted close to the appliance on
the flow pipe. Only safety valves set to operate at 3 bar
shall be used ; they shall be so positioned or any dischar­ge pipe so arranged, that discharge of water or steam
from the valve cannot create a hazard to occupants of
the premises or cause damage to electrical components
and wiring.

6.2 Pressure Gauge

A pressure gauge covering the range O-4 bar (O-60 Ib/in2)
shall be fitted to the system adjacent to, and visible
from, the filling point.

6.3 Expansion vessel

0) A diaphragm type expansion vessel shall be fitted by
a connection to the inlet side of the circulating pump,
in a manner laid down in the vessel makers’ instruc­tions (see page 14 for illustration of recommended
system layouts). The expansion vessel shall be capable
of accepting water up to at least 62.5 % of its volume
without damage.

(ii) The nitrogen or air charge pressure of the expansion

vessel shall not be less than the hydro-static head
(height of the top point of the system above the ex­pansion vessel).

(iii) The expansion vessel shall be sized in accordance with

the Table on page 14.

3

boil: output kW

9 ?

51 I I I I I I I I

i

5

40 E.F

5

I

B

e

30 BF

-6 t

=,

m
E

outputBtu/h

13

Safetvvalvesetting (bar)

3.0

I

Vessel charge pressure (bar)
Initial system pressure (bar)
Total water content of svstem Expansion Vessel Volume (litres)

For systems volumes other than
those given above, multiply the system
volume bv the factor across

litres

25
50

75
100
125
150
175

200
250
300
350
400
450
500

0.5

1.0

1.5

0.5 1.0 1.5

2.0 1.0

1.5 2.0 1.5 2.0

2.1

3.5 6.5

13.7 2.7 4.7 10.3

3.9 8.3

4.2

7.0

12.9 27.5 5.4 9.5 20.6

7.8

16.5

6.3 10.5 19.4

41.3

8.2 14.2 30.9 11.7 24.8

8.3 14.0 25.9 55.1 10.9 19.0 41.2 15.6 33.1

10.4

17.5

32.4

68.9

13.6 23.7 51.5

19.5 41.3

12.5

21.0

38.8 82.6 16.3 28.5 61.8 23.4

49.6

14.6 24.5 45.3 96.4 19.1 33.2 72.1 27.3

57.9

16.7 28.0 51.8 110.2 21.8 38.0 82.4 31.2

66.2

20.8 35.0 64.7 137.7 27.2 47.5 103.0 39.0 82.7

25.0 42.0 77.7 165.3 32.7 57.0 123.6 46.8 99.3

29.1 49.0 90.6 192.8 38.1 66.5 144.2 54.6 115.8

33.3 56.0 103.6 220.4 43.6 76.0 164.8 62.4 132.4

37.5 63.0 116.5 247.9 49.0 85.5 185.4 70.2 148.9

41.6 70.0 125.9 275.5 54.5 95.0 206.0 78.0 165.5

0.0833 0.140 0.259 0.551 0.109

0.190 0.412 0.156 0.331

For the Challenger boilers the volume found from the

rat-y hose connection is only permissable if acceptable to

above table shall be multiplied by 0.80

the local Water Authority.

6.4 Hot Water storage Cylinder

6.8

Pipework

The hot water cylinder shall be the indirect coil type
which is suitable for the system pressure.

6.5 Make-up system

Provision shall be made for replacing water lost from the
system either :

(0 From a make-up vessel or tank mounted in a position

higher than the top point of the system and connec­ted through a non-return valve to the system on the
return side of the hot water cylinder or the return
side of all heat emitters, or -

(ii) Where access to make up vessel would be difficult, by

pressurisation of the system.

6.6 Mains Connection

There shall be no connection to the mains supply or to
the water storage tank supplying domestic water, even
through a non-return valve, without the approval of the
local Water Authority.

6.7 Filling Point

For filling system see BS 5376 Pt2 appendix A. A tempo-

Pipework should be of copper; small bore or microbore

with capillary or compression jointing to a high standard.

Leak sealant shall not be used in the system.

Where a vessel of the calculated size is not obtainable,
the next available larger size should be used.

For the purpose of the above calculation, the volume of

the system shall be determined as accurately as possible

using manufacturers’ data as appropriate. Alternatively
the volumes given below may be used to give a conser­vative estimate of the system volume :

Boiler 0.5 litres (0.11 gallons)

Small bore pipework 0.3 litres (0.07 gallons)

per 0.292 kW (1000 Btu/h) of system output
Microbore pipework 7 litres (1.5 gallons)
Steel panel radiators 2.3 litres (0.5 gallons)

per 0.292 kW (1000 Btu/h) of system outpu’
Hot water cyliner 2 litres (0.44 gallons)

If a system is extended, an expension vessel of increased

volume may be required unless previous provision has
been made for the extension.

Pump on the return Pump on the flow

Diagrams showing
System layout

1 - Expansion vessel
2 - Pressure gauge
3 - Filling point
4 - Drain cock
5 - Air release point
6 - Safety valve
7 - Top-up bottle
8 - Temporary hose connection

or pressurisation make up.

14

5.9

Commissioning
Sealed System Only

The whole of the system should be filled and thoroughly
flushed out with cold water without the circulating pump

in position. Ensure that all valves are open. (The system
must be filled with water either from a sealed system fil­ler pump with a break tank, or by any other method ap­proved by the Local Water Undertaking).

With the circulating pump fitted the system should be
filled and airlocks cleared until the pressure gauge regis­ters 1.5 bar (21.5 Ibf/in*).

Vent all radiators and check for water soundness.

Manually raise the water pressure to ensure that the sa-

fety valve lifts. This should occur within + 0.3 bar (t-

4.3 Ibf/in*) of the preset lift pressure, ie. 3 bar (43.5
Ibf/in*).

ference in height between the pressure gauge and the
point at which the pressure vessel is connected.

Light the boiler as detailed in 5.3.
The water system should be heated to maximum wor-

king temperature and examined for water soundness.
Both gas and water should then be turned off and the

water system rapidly drained whilst still hot.
The system should again be filled, and inhibitor added to

the system, if required in the specification (see 3.9). clea­red of air locks and adjusted to the initial design pressu­re. Any set pointer on the pressure gauge should be set
to coincide with the indicating pointer. Examine for wa­ter soundness. Now adjust the gas rate and the system
by-pass (See 5.4 and 5.5).

Release water from the system until the initial system

n.b.

The boiler is supplied rated at highest output.

design pressure is attained, taking into account any dif-

The boiler is fitted with a gas rate adjuster.

I

S6

’ 1

transformer

rectkier tld; a6ji

F1

n

1

2 amp. fuse

,L

5

pump

I

supply 24 V DC

I I

orange solenoid

comparltor

variable

*mistor

I

I

.-..-A..-- 1 1 I 1 I I

50

Hz

Fig. 19

CHALLENGER TEST POINTS

Earth

Solenoid Valves
Orange and Blue

Printed Circuit Board

(Temperature & Sequence Control)

External Controls

Thermoelectric

240V 50 Hz

Fig. 20

Valve

Fig. 2

Thermocouple

Electrode Solenoid valves

d/v b7l @!” I

Thermistor

temperature sensor

White

I I

4!22, Blue

I I-

/

I

I

I I

White

Ignition

JJ

Red

White

I I

* I :

B

Thermo- ’ ’ .

~elecrnc

I I/ UM/ ‘a

1

thermostst

:rol box

control

16

7.

SERVICING

7.1

7.2

For efficient and trouble free operation it is important that the CHALLENGER receives regular maintenance. The following
schedules are recommended

Before commencing any work turn off the gas at the gas inlet service 4.8 tap (Page 4). Ensure that the electricity

supply

is

disconnected.
NB : Always test for a gas soundness after completing any servicing or exchange of gas carrying components

Remove front casing

a) Remove screws (A) at top and bottom of boiler.

b) Remove two screws from lower front of case (B).
c) Remove case by pulling forward easing out bottom

first.

d) Replace in reverse order.

Remove combustion chamber front panel
a) Remove six screws securing front panel of combus-

tion chamber.

b) Remove panel by easing forward at bottom and di-

sengage from flue hood by pulling downwards.

Remove burner assembly
a) Remove screws securing burner manifold to gas sec-

tion (A). 30 BF and screws A and B (end of manifold in
the 40 BF).

b) Remove

manifold and gasket and

retain in a safe

c) Burner can now be removed.

To remove pilot
a) Release thermocouple from bracket retaining screw

and securing clamp (A). Move thermocouple to the
side.

b) Release the electrode by loosening screw (B) on right

hand side of assembly and rotating retaining clip.

c) Remove pilot gauze and filter by removing screw (0

securing gauze to assembly.

d) Remove pilot by unscrewing (nut size 8 mm AF) using

set or adjustable spanner.

e) The pilot injector can be cleaned and should be repla-

ced bright side uppermost.

f) Replace in reverse order.

17

Cleaning the parts
a) The burner can be cleaned by inverting and brushing with a soft brush.

b) The heat exchanger matrix can be cleaned by brushing. It may be an advantage to remove flue hood see 4.7. If deposits

are too hard to remove by brushing, the matrix can be removed - see section 8.7 page 19 and washed with hot water and
detergent.

c) The gas filter (see C 4.8) can be cleaned using water and detergent

- DO NOT USE SOLVENTS.

d) Replace all components in reverse order. NB : particular attention must be given to ensuring that the case seal is sound

when the casing is replaced.

8.

REPLACEMENT OF PARTS

8.1

8.2

8.3

8.4

Replacing thermocouple
a) Remove front case 7.1

b) Remove combustion chamber front panel 7.2
c) Remove burner 7.3
d) Release thermocouple from bracket securing clamp

(A).

e) Release at thermoelectric valve by unscrewing nut

10 mm.

f) Disconnect from overheat thermostat by pulling

connections apart.

g) Replace in reverse order (taking care to replace rub-

ber seating BF only).

Replace high limit thermostat

a) Remove front case 7.1 and electrical control box 8.10.

b) Remove two screws (A) securing overheat assembly.
c) Disconnect at pin connectors by pulling apart,

d) Remove sensor from dry pocket first removing split

pin.

e) Replace in reverse order using a heat sink grease on

the sensing phial.

Replace spark electrode and lead

a) Remove front case 7.1.
b) Remove combustion chamber front panel 7.2.
c) Remove burner 7.3.
d) Remove thermostat knob and six screws from front

of electrical control box.
e) Remove plugs from rear of electrical controls box.
f) Slide PCB forward and remove spark terminal.
g) Feed lead out through rear of control box.
h) Loosen screw securing clip - retain electrode and turn

clip through 90 ‘,
i) Withdraw electrode by sliding forward.

j) Replace in reverse order taking care to locate electro-

de in locating groove and to replace plugs in rear of

To replace thermoelectric valve
a) Remove front cover.

b) Remove thermocouple connection,

c) Remove nut securing thermoelectric
d) Withdraw thermoelectric valve.
e) Replace in reverse order.

valve (25 mm).

18

8.5

8.6

8.7

8.8

8.9

To replace solenoid valves
al Remove front casing 7.1.

b) Remove electrical control box 8.10.
cl Withdraw plug connections (A) (colour coded from so-

lenoid valves.

d) Remove four screws (B) securing solenoid valve

mounting plate.

e) Remove mounting plate and solenoids -

take care

not to misplace springs.

f) Replace in reverse order.

To

replace microswitch

a) Remove front casing 7.1.
b) Remove electrical control box 8.10.
c) Remove plugs (A) from microswitch.
d) Remove two screws (B) retaining microswitch.
e) Replace in reverse order.

To

replace heat exchanger

a) Drain system.
b) Remove front casing 7.1.
c) Remove combustion chamber front panel 7.2.
d) Remove burner manifold and burner 7.3.
e) Remove flue bend (A).
f) Remove overheat thermostat phial - left hand side

(B).

g) Withdraw thermostat temperature sensor - right

hand side 0.
h) Unscrew nuts on flow and return connections.
0 Slacken four screws securing combustion to rear chas-

sis.

j) Drop assembly and withdraw forwards.

k) Remove two screws from rear of assembly retaining

heat exchanger to combustion chamber.
I) Replace in reverse order.

To replace pilot injector
a) Proceed as 7.4.

b) Replace injector ensuring it is fitted bright side

uppermost.

To

replace combustion chamber linings

a) Remove front casing 7.1.

b) Remove combustion chamber front panel 7.2.
c) Remove burner 7.3. Slide outside linings first followed by

rear lining which is removed by easing upwards and sli­ding out from bottom. Replace in reverse order taking
care that front lining is correctly positioned.

19

8.10

8.11

8.12

8.13

8.14

Pump

To replace electrical control box
a) Isolate electrical supply.

b) Remove front casing 7.1.
c) Remove six screws retaining electrical control box co-

ver

8.7

- F.
d) Withdraw plugs from rear of box.
e) Disconnect to terminal strip.
f) Slide PCB forward and disconnect spark electrode and

earth leads.
g) Remove 2 screws securing control box to chassis.
h) Replace in reverse order taking care to replace plugs

in rear of control box.
NB : Care should be taken to ensure correct location of

the ON, OFF and reset buttons.

L

A

-

To replace thermostat
a) Isolate electrical supply.

b) Remove front casing.
c) Undo knurled ring (A) retaining thermostat phial and

remove phial.
d) Unplug from rear of control box.
e) Replace in reverse order using heat sink grease on
the sensing phial.

To replace fuse
a) Isolate electrical supply.

b) Remove front casing 7.1.
c) Remove cover on electrical control box (8.10 c)
d) Remove and replace fuse.
e) Reassemble in reverse order.

To replace PCB
a) Isolate electrical supply.

b) Remove front casing 7.1.
c) Remove electrical control box cover (see 8.10 c).
d) Remove plugs from rear of electrical control box.
e) Ease forward PCB and remove spark electrode wire

and earth wire from spark generator.
f) Slide board forward and remove.
g) Replace in reverse order.

Testing of FFD Circuit

Closed circuit

- Slide back insulation at plug in connection and attach
millivolt meter using crocodile clip connectors.

- Output should not be less than 3 mv.

Open circuit

- Disconnect round pin connectors.

- Attach millivolt meter using crocodile clips to the ther­mocouple side - male connectors.

Press and hold ignitor button.

- Output with pilot on should not be less than 14 mv.

NB : If closed circuit output is high and approaching the
open circuit voltage obtained, then suspect faulty ther­moelectric valve.

20

I-

I

I

SHORT LIST

n I

(@I 46 @j 31

47

42

78

w

63a

Key No

Description

GC Number Part Number

5
7a
7b

17
19
20
21
30
31
33

38
41
42
43
44
45
46
47
49
63a
78

117
118
141
203
225

Screw M6 front cover/control box securing ......................

Door assembly (30 BF) ........................................

Door assembly (40 BF) ........................................

Temperatureselectorknob

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

Screw front case/rear case securing ............................

Plasticwasher.. .............................................

Serratedwasher.. ...........................................

Nut3/4..BSP ................................................

Olive(22mm) ...............................................

Top fixing bracket ...........................................

Bottom bracket 30 BF only ....................................

Cableclampbracket ..........................................

Cableclamp.. ...............................................

ScrewscableclamtYbracket ...................................

Gasfilterwasher .............................................

Gasservicecock .............................................

Olive (15 mm)

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

Nut1/2”BSP ................................................

Fixing screw - Bracket to case

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

Thermistortemperaturesensor ...............................

Foam gasket-rearcase/airinletduct ...........................

Thermocouple assembly ......................................

Electrode and lead assembly

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

High limit thermostat assembly ................................

Printed circuit board

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

Fuse(2amp) ................................................

366713 65622/01
366688 64143
366649 64150
366553 64051
402327 45817
407715 34377
366035

13183

366558

47509

366559

47508

366250 40169/06

366

691 65485106
366564 65519106
366565 27834
366714 45654
263 545

37309

366566

65960
263800 56489
366642 56490/01
366 546 66207/03
366570 64154
366662 56511
366667

65974
366593 63404
366636 65962
366614 63176
264446 44790

Chaffoteaux Ltd, Concord House, Brighton Road, Salfords, Redhill, Surrey RH15DX. Telephone: Horley (02934) 72744. Telex: 87378.

ESP023