Chaffoteaux & Maury Dua 120, Dua 150, Duo 200 Installation And Maintenance Instruction Manual

Supplied By www.heating spares.co Tel. [phone]

Installation and Maintenance

Instruction Manual

Including User Instructions

CaNI

CHAFFOTEAUX8Md”RY

Supplied By www.heating spares.co Tel. [phone]

Chaffoteaux & Maury Ltd., as a leading manufacturer of
domestic and commercial water heating appliances, as
well as domestic unvented direct and indirect storage
cylinders, is committed to providing high quality products
and a first class after sales service. If it is necessary to
contact an engineer, then telephone your local
Chaffoteaux Service Centre.

LOCAL CHAFFOTEAUX SERVICE CENTRE

Tel: [phone]

Advice on installation or servicing can also be obtained
by contacting the Chaffoteaux Customer Services
Department.

The guarantee will be invalidated if the factory fitted
temperature and pressure relief valve is tampered with
or removed. The Manufacturer or Distributors cannot
be held responsible for any damage howsoever caused
and which is a consequence of the removal or tampering.

The guarantee may also be invalidated if the appliance
is not installed by a competent person in accordance
with the recommendations made herein, current
standards, regulations or in a manner not approved by
the manufacturer, modified in any way, subjected to frost,
misuse or neglect and that factory fitted parts have had
unauthorised repairs or replacements carried out.

Evidence of purchase and the date of supply must be

made available at the time of any claim.

CUSTOMER SERVICES DEPARTMENT

Tel : [phone] Fax. [phone]

The manufacturer’s guarantee against faulty construction
or materials for the cylinder is 5 years and for the electrical
components, thermal controls and safety valves is for

12 months, from the date of purchase.

Installation must be carried out by a suitably qualified
installer and in accordance with current regulations
and codes of practice.

Only the safety valves supplied with the cylinder
should be used.

The cylinder must not be used without the safety

valves and expansion vessels.
The cylinder must not be used with a boiler without

thermostatic control.
The cylinder and ancillary controls must be adequately

maintained.

To assist us in providing you with an efficient after
sales service, please return the guarantee
registration card enclosed with the cylinder without
delay.

l

The installation must have a sufficient and constant
supply of mains fed cold water.

l

No valve should be fitted between the expansion relief

valve and the storage cylinder.

l

Only Chaffoteaux and Maury approved replacement
parts should be used.

l

The discharge pipe must be terminated where it is
visible and will not cause danger to people in the
vicinity of the discharge.

Note: The discharge could consist of scalding water and
steam.

1

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page

iwe

Customer Care and
Safety

Notice
Contents
Table

of Figures..

Introduction

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

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

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

Specifications
Dimensions

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

Location of Components

The Cylinder..

Installation

Planning ..............................................................

Installation
Fitting Safety Components

Discharge Pipes .................................................

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

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

Guarantee..

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

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

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

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

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

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

Wiring

.I

1

.2

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

Direct System
Indirect system
Britony System Plus Boiler
Britony System Boiler

.2

Commissioning..

.3
.3
.4

.5

.5

.7

7
7

.7

.7

Filling the Cylinder..
Check the operation of the safety valves
Direct Heating
Indirect Heating

Post Commissioning

Handing Over to the Householder..

Maintenance

Routine Maintenance

Fault Finding Charts
Spare Parts
Spare Parts Short List
User’s Instructions..

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

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

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

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

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

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

..........

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

Units

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

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

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

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

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

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

List.. ..........................................

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

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

.8

8
9

9

11

12

12
12
12
12

12

12

13

13

14

17
17

18

Fig. 1
Fig. 2
Fig. 3

Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Dimensions..
Combination safety control valves
Cylinder connected to System

Plus Boiler
Cylinder connected to System Boiler..
Discharge pipe arrangement

Discharge pipe sizing
Wiring for electrical element
Thermostat connections
Thermostat re-set button

Electrical box detail on boiler..

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

........... 5

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

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

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

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

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

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

................. 9

paw

4

5

..... 6

7
7
8
9
9

Fig. 11

Fig. 12
Fig. 13

Fig. 14
Fig. 15
Fig. 16
Fig. 17

paw

Hot water on constant and central
heating timed

Hot water and heating timed
Britony System boiler using

2 x two port valves 11
Deteriorating flow from taps
Cold water from taps
Discharge from expansion relief valve.. 15
Discharge from temperature and

pressure relief valve

10
10

14
14

16

2

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The Chaffoteaux & Maury DUO 120, 150 and 200 are
designed for use as unvented storage cylinders to be
heated indirectly by a sealed system boiler or directly
by the ceramic core electrical element included with
them. The cylinders are enamelled steel with a high
power coil. They are contained within a white case
insulated with CFC free polyurethane foam. There is a
magnesium anode to protect the cylinders against
corrosion.

The unvented storage cylinders will provide the
advantages of mains pressure and higher flow rates to
taps and showers.

Supplied directly from the main water supply they do
not need a separate feed cistern or vent pipe in the loft

space. They can benefit from the high efficiency and
fast recovery provided by modern low water content
sealed system boilers and particularly when used in
conjunction with Chaffoteaux & Maury BRITONY
SYSTEM, SYSTEM PLUS, or COMBI BOILERS. A
better flow rate at main pressure can usually be achieved
when compared with vented or instantaneous systems.
The cylinders have been tested and approved by the
WRc as meeting with the requirements of EN 60335

2.21. EN 60529.
The cylinders should be stored and installed in an upright

position and be protected from extremes of temperature
and humidity at all times. They must never be lifted or
carried by the flow and return pipes or connections.

DUO Cylinders

Storage Capacity ltrs
Weight of unit when empty
Weight of unit when full

Maximum operating pressure
Expansion vessel charge pressure
Expansion relief valve setting
Maximum primary working pressure

Set opening pressure of temperature and pressure

relief valve

Set opening temperature of temperature and pressure

relief valve
Draw-off rate

Consumption per day to maintain 65°C in kW per 24h

Electrical protection index

Indirect System

Capacity of primary coil

Heating area primary coil
Heating duration (Domestic water raised from 15°C to 65°C)
Indirect heating power (primary flow temp. 82°C @ 900Vhr)

120 150

113 140
58kg

171kg 212kg
6bar 6bar
3bar 3bar
6bar 6bar

3.5bar 3.5bar

7bar 7bar

92°C 92°C
301tr 301tr

1.2

IPX3 IPX3

71tr 1 Oltr

0.83m2 1.15m2

18min 17min
21kW 27.2kW

72kg

1.55

200

190
83kg
273kg
6bar
3bar
6bar

3.5bar

7bar

92°C
301tr

1.75

IPX3

1 Oltr

1.15m2

22min

27.2kW

Direct System

Electrical power
Nominal current
Heating duration (Domestic water raised from 10°C to 65°C)
Efficiency

3kW 3kW

12.5A 12.5A

2h 45

0.89 0.91

3h 20

3kW

12.5A

4h 30

0.93

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Minimum clearance 500mm

Domestic hot water outlet M 3/4” G

c

f

nl

v

ll4

1

Cold water inlet M 3/4” G

Flow from heating boiler M 1” G

----.
t

280

-

J

1

Drain point M 3/4” G

\

-y--I---yq-q---

Minimum clearance
600mm

+0550-i

, 230 ,

.

Fig. 1 - Dimensions

A B

re and pressure
/ I= ‘2/J” G

C D
120 I
150 I 1150mm

200 I

960mm

1435mm

935mm
1125mm 300mm
1401mm

300mm

300mm

350mm
500mm
500mm

4

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The Cylinder

To enable the cylinder to comply with the current
regulations, it is supplied with a safety controls pack.
This comprises:

1. Cold water inlet

2. Pressure reducing valve with integral strainer

3. Check valve (non return valve)

4. Expansion relief valve

5. Cylinder thermostat and overheat thermostat
beneath cover

6. Temperature and pressure relief valve

7. Expansion vessel

8. Tundish

9. Drain valve

10. Two port motorized safety cut-off valve

11. Balanced cold water supply

12. Connecting pipe to expansion vessel

13. Cold water inlet pipe to cylinder

14. Hot water outlet pipe

15. Flow from boiler to cylinder coil

16. Return from coil to boiler

17. Electrical supply for direct element

18. Cover for electrical element and thermostat

19. Discharge pipe

20. Flow to central heating

21. Gas supply

22. Return from central heating

23. Electrical connection from cylinder thermostat to
boiler

24. Central heating zone valve

2

Fig. 2 - Combination safety control valves

4

Fig. 3 - Cylinder connected to System Plus Boiler

5

23

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Fig. 4 - Cylinder connected to System Boiler

Please note: the motorised two port safety cut off
valve is only necessary if the cylinders are linked to a
boiler other than the Britony System Plus Boiler.

The Electrical Element

The cylinder contains an alternative source of power.
It is fitted with a 230~ 3 kW ceramic core element with
a factory set thermostat and a manually re-settable
thermal cut-out.

6

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Planning

The efficient operation of this appliance depends upon a
well-designed system and correct connection to the
boiler. Please familiarise yourself with these installation
instructions as well as the relevant British Standards and
Statutory Regulations. For example, please consult
current versions of the Building Regulations, The Building
Standards for Scotland, the IEE Regulations, the Model
Water Bylaws and the Health and Safety Document No.
635 (The Electricity at Work Regulations 1989) Approved
Document G3. The domestic hot water pipework must
be in accordance with BS 6700. All capillary joints must
be made using lead free solder.

Check that the kit of components is complete.

l

The cylinder must be installed vertically.

l

All pipe runs should be kept as short as possible for

economy.

l

Allow a minimum of 600 mm frontal clearance to allow
the removal of the electrical element and access to
the thermostat.

l

Allow 500 mm access to the top of the appliance to
allow the removal of the sacrificial anode.

l

Provision must be made for the positioning of the

safety valves, expansion vessel and discharge pipes.

l

Ensure that the floor is level and capable of supporting

the weight of the cylinder when full (see page 3).

l

Check that there is sufficient mains pressure and flow
to cater for the combined demands of hot and cold
water for the premises.

Water will only flow from the discharge pipe under
conditions of overheating or over-pressurisation. It is
important that the discharge is visible at the tundish or
termination point.

The discharge pipe from the tundish must be of metal

l

and positioned away from any electrical components.
There must be at least 300mm of vertical pipe after

l

the tundish before any bends or elbows.

l

The discharge pipe must be installed with a
continuous fall and terminate in a safe place where
there is no risk of scalding anyone.

The diameter of the discharge pipe can be calculated

l

from the table below.
The pressure relief valves cannot be used for any

l

external appliance or other purpose.

If unvented hot water storage systems are installed

l

where discharges from safety devices may not be
apparent, i.e. in dwellings occupied by blind, infirm
or disabled people, consideration should be given to
the installation of an electronically operated device
to warm when discharge takes place.

Note: The discharge will consist of scalding water and
steam. Asphalt, roofing felt and non-metallic rainwater
goods may be damaged by such discharges.

Discharge pipe
from temperature and
pressure relief valve

Safety de”lce e

g.

to tundish

I

Installation

To obtain the best performance from the Chaffoteaux &
Maury DUO, the lowest main working pressure (when
demand on the main supply is at its highest and with a
tap running) should not fall below 20 l/min at 1.5 bar.

Fitting Safety Components

The diagram should be used only for guidance for the
positioning of the safety components and controls.

Discharge Pipes

Please refer to the Building Regulations Approved
Document G3 for installation details.

Minimum size

Valve outlet size

Minimum size

of discharge

pipe

22 mm

of discharge

pipe from

tundish

28mm Up to 9m
35mm Up to 18m
42mm Up to 27m

Discharge pipe from
tundish with continuous fall

Fig. 5 - Discharge pipe arrangement

Maximum

resistance

allowed,

expressed as a

length of

Resistance

created by each

elbow or bend

straight pipe

(i.e. no elbows

or bends)

1 .Om

1.4m

1.7m

Fig. 6 - Discharge pipe sizing

7

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Direct System

All wiring must comply with the latest version of the IEE
Regulations. It must be possible to completely isolate
the appliance electrically. Connection should be via a
13 amp fused double pole isolating switch with contact
separation of at least 3mm on both poles. Alternatively,
a fused 13 amp, 3 pin plug and unswitched socket may
be used, provided it is not used in a room containing a
bath or shower. It should only supply the appliance and
be readily accessible and adjacent to the appliance.

l

Remove the front cover

l

Ensure that the supply voltage is correct for the
appliance

l

Connect the main electrical supply to the thermostat
as shown in the diagram (Fig. 7) using PVC insulated
cable of not less than 2,5 mm2

l

Ensure a good earth connection is made to the earth
terminal.

l

Ensure all electrical connections are well made to
avoid overheating.

l

Replace front cover.

l

Never fit the electrical element without its regulation
device.

CERAMIC

CORE ELEMENT

240V

50Hz

1

I

CYLlrJbER

EARTH PILLAR

Fig. 7 -Wiring for electrical element

8

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Indirect system

The Chaffoteaux & Maury DUO unvented cylinder is
suitable for connection to most gas or oil fired boilers
that are compatible with unvented systems. They must
have thermostatic control. CONTACT THE BOILER
MANUFACTURER IF YOU ARE ANY DOUBT.

Britony System Plus Boiler

The DUO 120, 150 and 200 cylinders have been
designed to work in conjunction with the Britony System
Plus Boiler to provide the best possible combination of
performance and efficiency. They also utilize the boiler’s
built-in 3 port valve, which simplifies installation and
wiring.

Fig. 8 -Thermostat connections

Reset

button

Mains Thermostat

/

“-nnections

Fig. 9 - Thermostat re-set button

co

from Cylinder

J

Fig. 10 - Electrical box detail on boiler

9

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Option 1

Using a hot water priority system with the hot water on
constantly and the heating timed. Asimple time clock
can be use such as the Randall 103.

Timeclock

(for example Randall 103)

q

Interface PC

er

Fig. 11 - Hot water on constant and central heating timed

Option 2

Using hot water priority with a timed facility for both hot
water and central heating. A twin channel clock such
as the Horstman Channelplus Model H27 must be used.

Two Channel Programmer

For example

Horstman Channelplus

Model H27

Thermostat

IhJl

resistor

Fig. 12 - Hot water and heating timed

10

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Britony System Boiler

When the Britony System boiler (or a boiler from another
manufacturer) a two port safety cut off valve must be
used. This is supplied with the cylinder. It can be used
together with another two port valve, to provide timed
control over the heating and hot water circuits.

Fused
Spur

Fig. 13 - Britony System boiler using 2 x two port valves

Supplied By www.heating spares.co Tel. [phone]

Filling the Cylinder

l

Do not turn on electrical power to the immersion

heater without water in the cylinder.

l

Ensure that all fittings, valves and the immersion

heater are correctly installed and are watertight.

l

Flush all debris from the supply pipes before

connecting to the cylinder.

l

Open the furthest hot water tap from the cylinder.

l

Open the main valve and allow the cylinder to fill
steadily. Allow water to flow from the tap for a few
minutes to ensure any installation debris is flushed
through the system.

l

Open all other taps in turn to purge any remaining
air from the system.

l

Check all connections for leaks.

Check the operation of the safety valves

l

Manually open the temperature and pressure relief
valve (6 Fig. 3) for a few seconds.

l

Check that the water flows away through the tundish
and discharge pipework and does not overflow.

l

Ensure that the flow of water has stopped and that
the valve has reseated itself.

l

Repeat the above check for the expansion relief
valve.

Direct Heating Units

l

Carry out an electrical test for earth continuity, correct
polarity, short circuit and fuse continuity.

l

Turn on the electrical supply and allow the water to
heat up.

l

Check the correct operation of the cylinder
thermostat.

l

Check that water is not discharged from either the
expansion relief or the temperature and pressure
relief valves.

Indirect Heating

l

Refer to the boiler commissioning instructions.

l

Ensure that the cylinder heating coils are filled and

purged of air.

l

Light boiler and allow the cylinder to heat up.

l

Check the correct operation of the cylinder

thermostat.

l

Check that water is not discharged from either the

expansion relief or the temperature and pressure.

Handing Over to the Householder

l

Ensure system pressure has been set correctly

l

Set boiler and cylinder thermostat and controls

l

Demonstrate the lighting and operation of the boiler

l

Demonstrate how to maintain system pressure

l

Explain to the customer :

1. the operation of the appliance and safety
controls

2. things to look out for such as a continual leak of
water noticed at the tundish

3. Explain the necessity for annual maintenance

by a competent person

4. what to do in an emergency

l

Leave instruction manual with the customer

l

Fill out guarantee card and return to Chaffoteaux &

Maury Ltd.

12

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In order to ensure that the cylinder continues to operate
efficiently and safely, it is essential that it is serviced
and inspected annually. This may be timed to coincide
with the annual boiler maintenance.

l

Servicing and repairs should only be carried out by a
competent engineer.

l

Any part replaced should be genuine Chaffoteaux &

Maury spare parts.

Routine Maintenance

Before continuing with any maintenance, ensure
that the boiler has been turned off and that the
electrical supply has been isolated.

The anode is located at the top of the cylinder.
the cover. Disconnect the outlet pipe to from the T+P
valve. Unscrew 6 screws and lift the top plate clear.

When new the diameter of the anode is 26mm. If at
any point along its length the diameter has reduced to
half or less than half its original diameter, then it should
be replaced by unscrewing from the top plate.

Replace components in the reverse order using a new

gasket for the top plate.

Remove

3. Strainer

While the cylinder is partially drained the strainer can
be removed and cleaned.

1. Electrical Element

Check the operation of the electrical element thermostat
by turning off the boiler and running off some hot water.
Allow the electrical element to reheat the water to its set
temperature. Check that no water is discharged from
the expansion or temperature relief valves. As the
electrical element is not indirect contact with the water,
it is not necessary to check it for scaling.

2. Sacrificial Anode

Drain the cylinder by turning off the main water inlet valve
and opening the lowest hot water tap to depressurise
the system. Open the drain valve (9 Fig. 3) and drain
approximately 5 litres.

4. Expansion Vessel

While there is no pressure in the system the pressure
in the expansion vessel can be checked against the
pressure on the data badge.

Refill and Re-pressurise the system as set out in the

commissioning instructions.

5. Safety Valves

Manually operate the temperature, pressure and
expansion relief valves. Check that water runs freely
through the tundish and at the discharge point without
overflowing. Check that the flow of water stops and that
the valves reseat satisfactorily.

13

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Deteriorating flow or

pressure at hot taps

I

Check incoming mains

pressure

I

Advise customer to

have sevice checked

by water suoolier

1

I I

I

Remove and clean

Fig. 14 - Deteriorating flow from taps

Cold water from hot taps

v

1 I

Check inline

stainer

I

Check operation of

pressure reducer

Re-adjust or replace

as necessary

I

Direct

System

r

Re-set thermal cut-out

on direct system

Check operation of

electrical thermostat

Check electrical

element and replace if

faulty

+

Boiler not operating

Reset or check

operation of boiler

thermostat

1

Check operation of

Boiler in conjunction

with boiler fault finding

chart

Indirect
System

1

Reset thermal cut-out

on indirect system

I

Check operation of
cylinder thermostat

I

Check operation of

Boiler 3 port valve

Fig. 15 - Cold water from taps

14

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Discharge from Expansion Relief Valve

Manually reset/reseat

valve.

Is discharge still

ocurring?

I

Yes

4

conditions?

4

Is the pressure

downstream of the

pressure regulator

I

correct?

Reset pressure

-I

Adjust or replace
faulty component

+ No

Service or replace
pressure regulator

Are the boiler and

cylinder thermostats

operating correctly?

Yes

I

Service or exchange

expansion relief valve

Please Note:

Use only genuine Chaffoteaux replacement parts

Fig. 16 - Discharge from expansion relief valve

m

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Discharge from Temperature Relief Valve

Manually reset/reseat

D

Is discharge still ocurring?

I

Yes

Is discharge water temperature

above 1 OOOC?

Yes

Check the operation/setting of

I

I

- No +

Reset or replace as

necessary

Adjust or replace as

necessary

t+

Yes

+

]]/ No -)

Please Note:

Use only genuine Chaffoteaux replacement parts

Checkoperation

I I

Discharge has stopped

e

Fig. 17 - Discharge from temperature and pressure relief valve

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9

10 -

11 -

12

6

17

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There are no user adjustable controls on the DUO. The
immersion heater thermostat will have been set on
installation. A suitably qualified engineer, installer or
electrician must carry out any adjustments or
maintenance.

If water is seen discharging from the DUO Safety
Valves

l

Turn off the electrical supply to the immersion heater

l

Turn off the boiler

l

Do not turn off the water supply

l

Contact the installer or other suitably qualified
engineer.

In order to ensure that the cylinder continues to operate
efficiently and safely, it is essential that it is serviced
and inspected annually. This may be timed to coincide
with the annual boiler maintenance.

l

Servicing and repairs should be carried out by a
competent engineer.

l

Any part replaced should be genuine Chaffoteaux &
Maury spare part.

If the thermal cut out is activated, it is necessary to reset
and check the operation of both thermostats fitted to
the cylinder (immersion heating and indirect heating
thermostats).

Chaffoteaux & Maury Ltd are continuously improving
their products and therefore reserve the right to change
specifications without prior notice and accept no liability
for any errors or omissions in the information contained
in this document.

18

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Chaffoteaux et Maury are contunuously improving their products and therefore reserve the right to change specifications without

prior notice and accepts no liability for any errors or omission in the information contained in this document.

0 Chaffoteaux & Maury Limited 1999

Chaffoteaux & Maury Limited, Trench Lock, Trench, Telford, Shropshire TFI 4SZ. 3

Technical Helpline: 01952 222288 /Technical Fax:[phone] In Warranty Service: 0870 2430224

Telephone: [phone] / Facsimile: 01952 243493 0

+