Chaffoteaux & Maury CHALLENGER 30 OF, CHALLENGER 50 OF Installation And Servicing Instructions

CHALLENGER

Open Flue Boilers

30 OF

50 OF

(GCN"41.980.72)

(GCN"41.980.76)

installation

and servicing instructions

(leave these instructions with the User or at the Gas Service meter)

CHALLENGER OF are low water content gas fired boilers.

CHALLENGER

30 is rated between 4.14 Kw (14,150

Btu/h) and 9 Kw (30,375 Btu/h).

CHALLENGER

50 is rated between 7.33 Kw (25,000

Btu/h) and 14.6 Kw (50,000 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 of incorporated features.

- Fully adjustable electronic temperature regulation bet­ween60°Cand82”C.

- Automatic alternation high flame/low flame.

- Pump overrun.

- Low resistance.

- High limit thermostat.

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.

TECHNICAL DATA

A

V

+=++

-A-

- _

I- i

-7-

-I+

F

A+ I --+-

-+-

I

E

I

CHA

-

-

A

B
C
D

E
F

ci

H

J

K

L

M

N
0

-

ENCER 3C

mm

=-50

OF

ins

640

25.2

375

14.75
250 9.84
115

(int)

4.5

100

4.0

50

2.0

45 1.75

187

7.4

475 10.7

500

19.7

135 5.3

25

1.0

100

4.0

50 2.0

2

1.2

1.3

30 OF

Max

Min

50 OF

Max

Min

OUTPUT

kW Btu/h

9. 30,375

4.14 14,150

OUTPUT

kW Btu/h

14.6 50,000

7.32 25,000

INPUT BURNER PRESSURE (HOT)

kW Btu/h m.bar

ins.w.g.

Max 11.7 39,995 8.0 3.2

Min 5.63 19,226 1.47 0.5

INPUT BURNER PRESSURE (HOT)

kW Btu/h m-bar

ins.w.g.

Max 18.94 64,661 7.3 2.9

Min 9.95 33,800 1.9 0.08

NB

: For mid position setting pressures see section 5.4

GAS RATE

m3/h ft3/h

1.09 38.67

0.52 18.59

GAS RATE

m3/h ft3/h

1.77 62.53

0.88 31.39

DIMENSIONS

(Casing ex connections)

3OOF&5OOF

I

mm

I

ins

I

Openflue . . . . . . . . . . . .

Gas connection .......................

Waterconnection .....................

Minimum flow rate ....................

Maximum static head .................

Minimum static head ..................

Electrical connection ..................

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

Water capacity .......................

Burner Injector Size ...................

Pilot injector .........................

Ignition ..............................

Electrode ............................

Boiler thermostat .....................

High Limit thermostat .................

Thermocouple and thermoelectric valve

CLEARANCES

Sides

TOP

Bottom

Front

mm ins

76 3
76 3

127

5

500 20

Requires a nominal 100 mm (4 in) flue pipe. Draught diverter is intergral
and is suitable for flues to BS 715. If flues to BS 567 are used an adaptor
will be required

15 mm compression fitting
22 mm compression fittings
30

OF

505 IiWhr (I .85 gpm) 50

OF

841 lit/hr (8.08 gpm) equivalent to

15” C (27” F) temperature rise
30 m (98 ft)
150 mm (See page 7)
240 V single phase 50 hz supply fused 3 amp
30

OF -

18.63 kg (41 Ibs)

50

OF -

19.54 kg (43 Ibs)

0.5 lit. (0.11 gals.)
30

OF

1.18 mm

50

OF

1.23 mm

0.3 mm (0.011 ins.)
Continuous spark-spark generator ANSTOSS
Chaffoteaux - spark gap 5.0 mm
Electronic - Chaffoteaux Ltd
Ranco LM5
Chaffoteaux Ltd

water flow-gallons per minute

1.4

HYDRAULIC RESISTANCE

1

2 3 4 5

The hydraulic resistance of the boiler varies with
the water flow. The graph (Fig. 2) indicates resistan-

3

ce at various flow rates.
The minimum flow rate is equivalent to a tempera-

ture rise of 15” C :

1

2'

.I

30

OF

50

OF 9 a

B

505 I/h 1.85 gpm 841 I/h 3.08

gpm

d

1

Minimum water flow rate *

200 400 600 800 mob

1200 1400

water flow - litres per hour

3

1.5 Description of Operation

2.

2.1

Pressing the ignitor (on) button disconnects the supply continues to fire on 50 % fixed gas valve. When the set
to the pump, opens the therm0 electric valve and causes temperature is reached the boiler switches off. If flow
a continuous pilot ignition spark to be generated and the temperature reduces the 50 % fixed gas valve opens fol­pilot is ignited. lowed by the variable valve.

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

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 required. (See
section 4.7).

FUNCTIONAL FLOW DIAGRAM

THERM0 ELECTRIC

SPARKGENERATOR

THERMOCOUPLE

TIME DELAY

GAS SOLENOID

TIME DELAY PUMP

OVER RUN

L
r

Fig. 1

PUMP

INSTALLATION REQUIREMENTS
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 Underta-

king. 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 require-

ments 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 544O:l 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 regula-

tions 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 pro-

vision of a satisfactory flue termination. The position
should also provide adequate space for servicing and air
circulation around the boiler. (See 1.3).

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
mtrst 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.

4

2.3 Water Circulation Systems

2.5

Flue System

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 342:l and the abo­ve mentioned British Gas publication and BS 5546.

2.4 Air supply - Open Flue Version

2Al

Room air supply

Where a boiler is to be installed in a room or internal spa­ce, the boiler requires the room or internal space contai­ning it to have a permanent air vent. This vent must be
either direct to outside air or to an adjacent room or in­ternal space which must itself have a permanent air vent
of at least the same size direct to outside air.

The minimum effective area of the permanent air
vent(s) is related to the maximum rated input of the boi­ler and should be not less than :

CHALLENGER 30 OF

21.15 cm2 (3.27 ins21

CHALLENGER 50 OF 53.73

cm2 (8.32 ins?

2A.2

Compartment air supply

If an open flued boiler is installed in a cupboard or com­partment permanent air vents are reauired in accordan-

The boiler should be sited such that the maximum possi­ble length of the flue system can be contained within the
building and that the route of the flue rises continuously
to the terminal and is as direct as practicable.

The first 600 mm (2ft) of flue pipe should rise vertically
from the draught diverter connection before the use of
any bends of elbows.

Horizontal or shallow angle runs, right angled bends or
mitred elbows should be avoided.

Where an existing brick chimney is to be used it should
be swept thoroughly before connection of the new boi­ler, and the chimney should be lined.

An approved British Gas terminal must be fitted and the
terminal sited at the.adjacent roof edge and, where pos­sible, above the ridge line. The flue must not be termina­ted at or adjacent to a wall face.

The cross sectional area of the flue must not be less
than the area of the flue. outlet serving the boiler. The
point of termination must not be within 600 mm (2 ft) of
an openable window, air vent or other ventilation ope­ning.

Before installing the boiler to an existing flue system,
the flue system must be checked by applying a smoke
match to the opening at the base of the flue system.
The flue pipe must not be closer than 25 mm (I ins) to
combustible material. For twin walled flue. pipe the
25 mm (I in) distance is measured from the internal pipe.

ce with the following table.
same room or internal space. and must both be on the

same wall to outside air.

Note that both air vents must communicate with the

Where cupboard or compartment vents communicate
with a room or internal space the room or internal space
must itself have a permanent air vent(s) as specified in
BS5440 pt2.

An open flued appliance must not be installed in a
bathroom bedroom or bedsitting room or in a compart­ment communicating with a bathroom, bedroom or bed
sitting room. An open flued boiler must not be installed
in a garage.

This appliance must be earthed. All wiring must conform
to the I.E.E. Regulations. The CHALLENGER requires a

2.6 Electrical Supply

240 V single phase, 50 Hz

supply.

A means of isolation
must be provided adjacent to the boiler, this should pre­ferably be an unswtiched plug and socket. Alternatively a
double pole isolator having a contact separation of at
least 3 mm on both poles must be used. The fuse rating
should be 3 amp. The supply cord must be 0.74 m2 three
core heat resisting cable.

Cupboard or compartment air supply

30

OF

Low level

211 cm2 106 cm2

32 ins2 16 ins2

50

OF

Position of

Air from room Air direct

air vents

or internal space from outside

2A3 Effect of an extract fan

If there is any type of extract fan fitted in the premises
there is the possibility that if adequate air inlet area
from the outside is not provided, spillage of the pro­ducts from the boiler flue could occur when the extract
fan is operating. Where such installations occur a spillage
test as detailed in BS5440:l must be carried out and any
necessary action taken.

2.7 Gas Supply

The

CHALLENGER

30 requires 1.09 m3/h 38.67 ft3/h.

CHALLENGER

50 requires 1.77 m3/h 62.53 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

Fig. 2

5

3.

SYSTEM GUIDANCE

3.1

General

The CHALLENGER is a low water content boiler designed

3.8

ONLY for use with fully pumped systems. It may be used
with open or sealed systems, all safety controls exclu­ding 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) ?4 “C (7 “F).

Detailed recommendations for the water circulation are

3.9
given in BS 5376.2 19876, BS 5449.1 1977 and BS
5546:1979.

Thermostatic control should be fitted to the cylinder and
heating circuits.

3.2

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
Honeywell.

3.3

Control Schemes

The boiler is electrically controlled.
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 satis-

3.10

fied.
Chaffoteaux can be consulted where technical assistan-

ce is required.

3.4

Circulation Pump

The system circulating pump should be sized relative to
the resistance of the connected load and the system de­sign nt selected. The mass flow rate through the boiler
should not be less than that stated 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. (Sect. 1.4).

3.5

Cold feeds and open vents

The cold feed and open vent should be so positioned
that pumping over and sub-atmospheric pressures are
avoided. Recommendations for various layouts are given
on page 7.

The connection should be so arranged that there is a low
velocity point at the open vent junction with the system.

3.6

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 pi­pework. 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

6

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.

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.

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 Waldon.

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.

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 Ins­tallation 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.