How it Works
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Challenger 30 OF
User guide
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chaffotteaux Challenger 30 OF, Challenger 50 OF User guide

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CHALLENGER
Open Flue Boilers
30 OF
(GCN"41.980.72)
50 OF
(GCN"41.980.76)
installation
and servicing instructions
(leave these instructions with the User or at the Gas Service meter)
1.2
30 OF
OUTPUT
INPUT BURNER PRESSURE (HOT)
GAS RATE
1.3
kW Btu/h
Max
Min
50 OF
Max
Min
DIMENSIONS
I
9. 30,375
4.14 14,150
OUTPUT
kW Btu/h
14.6 50,000
7.32 25,000
(Casing ex connections)
3OOF&5OOF
mm
I
Max 11.7 39,995 8.0 3.2
Min 5.63 19,226 1.47 0.5
Max 18.94 64,661 7.3 2.9
Min 9.95 33,800 1.9 0.08
NB
ins
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
kW Btu/h m.bar
INPUT BURNER PRESSURE (HOT)
kW Btu/h m-bar
: For mid position setting pressures see section 5.4
I
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
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)
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
ins.w.g.
ins.w.g.
Sides
TOP
Bottom
Front
OF
841 lit/hr (8.08 gpm) equivalent to
50
OF -
19.54 kg (43 Ibs)
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
CLEARANCES
mm ins
76 3
76 3 127 500 20
5
1.4
HYDRAULIC RESISTANCE
The hydraulic resistance of the boiler varies with the water flow. The graph (Fig. 2) indicates resistan­ce at various flow rates.
The minimum flow rate is equivalent to a tempera­ture rise of 15” C :
30
OF
505 I/h 1.85 gpm 841 I/h 3.08
Minimum water flow rate *
50
OF 9 a
gpm
water flow-gallons per minute
1
200 400 600 800 mob
3
2 3 4 5
water flow - litres per hour
1200 1400
3
1
2'
.I
B
d
1
1.5 Description of Operation
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
Fig. 1
THERM0 ELECTRIC
TIME DELAY PUMP
OVER RUN
SPARKGENERATOR
THERMOCOUPLE
TIME DELAY
GAS SOLENOID
L r
PUMP

INSTALLATION REQUIREMENTS

2.
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 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
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
2A.2
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 CHALLENGER 50 OF 53.73
21.15 cm2 (3.27 ins21 cm2 (8.32 ins?
Compartment air supply
If an open flued boiler is installed in a cupboard or com­partment permanent air vents are reauired in accordan­ce with the following table.
Note that both air vents must communicate with the same room or internal space. and must both be on the same wall to outside air.
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.
Cupboard or compartment air supply
30
OF
2.5
Flue System
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 pos-
sible, above the ridge line. The flue must not be termina-
ted 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 ope-
ning.
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.
2.6 Electrical Supply
This appliance must be earthed. All wiring must conform to the I.E.E. Regulations. The CHALLENGER requires a 240 V single phase, 50 Hz 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.
2.7 Gas Supply
The
CHALLENGER CHALLENGER
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
30 requires 1.09 m3/h 38.67 ft3/h. 50 requires 1.77 m3/h 62.53 ft3/h
supply.
A means of isolation
Low level
50
OF
Position of
air vents
211 cm2 106 cm2
32 ins2 16 ins2
Air from room Air direct
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.
Fig. 2
5
3.
3.1
3.2
3.3
3.4

SYSTEM GUIDANCE

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 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 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.
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.
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 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 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).
3.8
3.9
3.10
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.
3.5
3.6
3.7
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.
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.
Cylinder
The domestic hot water cylinder used with the CHALLENGER must be of the indirect and high recovery
6

ALTERNATIVE SYSTEM LAYOUTS

Minimum Static Head
150mm
-----
PREFERED
Syfi &Ad be sQKWmospheric
. . . . .
Minimum Static Head Refer to BS 5449 Part 1 1977
----.
1. Cold feed 15 mm
3.11 Electrical Controls
Khaffoteaux recommendations)
CHALLENGER can be used with most normal pumped pri-
mary schemes including non-electrical heating and hot
water controls.
It is not normally possible to use full programming facili­ties where 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:
must be in accordance with the current edition of the
IEE Wiring Regulations.
1. Fully pumped system independant control of central hea­ting and hot water using two spring return motorised val­ves.
All external wiring to and from the boiler
CYL STAT YALYE D.H.W.
SPRING RETURN
3. Drayton flow share valve system.
Fig. 12
4. Honeywell Sundial ‘Y’ plan.
Fig. 10
2. Fully pumped systems independant control of central heating and hot water using two motorised valves.
PROGRAMMER
Fig. 11
PUMP
BOILER TERMINALS
Fig. 13
5. Satchwell Duoflow system. TLX 2259
ROOM
PROGRAMMER
Fig. 14
SA 2457
PUMP
RO,,.ER TERMINALS
a
4.5
4.6
RETURN
Making the water connections
a) Fit the nuts and olives supplied in the accessory box. b) Enter the FLOW pipe into the RIGHT hand connection,
the RETURN goes to the LEFT hand connection.
c) Tighten compression fitting holding connection on in-
side of boiler.
4.6
4.7
---
Making Electrical Connections
(See section 2 for electrical supply requirements) a) Secure cable. clamp (D) to base of appliance using the
screws provided. b) Remove control box cover. c) Three core heat resisting cable is passed through the
clamp and through the slot in casing, and into the rear
of electrical box and connected to terminals on
connection block and the earth connection made to
earth terminal. d) Connect pump cable to terminals @ and the earth
on earth terminal. e) Connect ancillary controls across terminals marked 5
and 6. See-controls diagrams page 8. f) Clamp wires with cable clamp. g) Replace control box cover.
n.b.
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.
Resetting high limit thermostat
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 button on the electri-
cal box.
c) Establish cause and rectify - see fault finding chart,
rear cover.
In the event of an electrical fault after installation preliminary electrical system checks as described in the Muiltimeter 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 resistance to earth.
CHALLENGER - SIMPLE CONTROLS
Room
thermostat only
Room
thermostat
and time clock
Fig. 17
10
Fig. 15
3
Wire clock
4 Wire clock
Fig. 16

5. COMMISSIONING

boiler output kW
3
6
9 12
5.1
5.2
Gas Installation
The whole of the gas installation, including the meter, should be inspected and tested for soundness and pur­ged in accordance with the recommandations of CP 331:3.
Water circulation system ­Open system only
The whole. of the system should be filled and thoroughly flushed out with cold water without the pump in posi­tion 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) Push the button marked ON fully in and hold for 10
seconds. c) Check that pilot is alight and release slowly. d) If the pilot extinguishes press red button and repeat
from (b). (The pilot should be about l/2”
pinge on the tip of the thermocouple).
e) After 30 seconds the main burner will light.
f) If the pilot extinguishes, wait 3 minutes and repeat
from b) a hove..
g) Switch controls to a demand mode, ensuring that
pump is running.
h) Check for gas soundness around the boiler gas com-
ponents using sense of smell and leak detection fluid.
i) Check and adjust gas rate as detailed below.
5.4 Gas rate adjustment
(To be carried out before adjusting by-pass.)
n-b.
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 (I) (fig. 18) and
connect a suitable. pressure gauge.
c) Remove the hexagonal cap from gas volume adjuster,
(2) (fig. 18) exposing the adjustment screw.
d) Turn boiler on by pressing ON button (see lighting boi-
ler - page 11 - 5.3).
e) Adjust pressure after boiler has been running for 10
minutes. Setting pressures are given in graph relative
to required output and then check the gas rate. 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 badge to indicate output to which boiler has
been set.
long
and im-
5
d
I II I I I I I I
10000
20000
30000
output Btu/h
Fig. 1
5.5 Adjusting the by-pass
n-b.
The by-pass valve should be of the lock shield pat-
tern. a) 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 boiler of 15 ‘C (27” F). (Set boiler thermostat to maximum.)
b) Fire the boiler with the by-pass fully closed and the
system on full load, i.e. central heating and domestic hot water.
c) Adjust the system to minimum load. This will normally
be central heating only with one radiator operating
d) Open the by-pass gradually until the boiler operates
quietly at all flow temperatures until the boiler ther-
mostat 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 at least the range O-4 bar (O-60 lb/in*) shall be fitted to the system adjacent to, and visible.from, the filling point.
P
I I I I
40000 60000
11
5.8 Pipework
1.
6.8
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.
6.9 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 sa­fety valve lifts. This should occur within 2 0.3 bar (2 4.3 Ibf/in2) of the preset lift pressure, ie. 3 bar (43.5 Ibf/ir-?).
Release water from the system until the initial system design pressure is attained, taking into account any dif­ference 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, add inhibitor 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 adiust the oas rate and the svstem bv pass - See
5.4 and-5.5. -
t I I
I
rectifier
a2
iw
43
rc^
C?
/
24VDC
I
r I 1
I
transformer
211 ;
\I--
,?’
4
I
-1
thermistor emperature
sensor
c--i
I A
A-- ,
I I
782 ‘.R43
36
4
‘“1
Fl4 D
comparitor
1 U
I
J2Z
R23
?=I
n
1 ” --- fuse
I
I
R24l
“5
b
-
+L
orange solenoid
I
S6
L
---7
i
trump
-_-- A
N2
Nl
240 V. 50 Hz
variable
I
I
i
1 Fig. 19

7. SERVICING

7.
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 of the gas at the gas inlet tap (section 4.4). Ensure that the electricity supply is disconnec-
ted.
Important
: Always test for gas soundness after completing and service or exchange of gas carrying components.
Remove front casing
a) Remove screws (A) from front of boiler - securing
front case to electrical control box. b) Remove 2 screws (B) bottom rear of boiler. c) Ease bottom forward and lift off front case from re-
taining hooks situated top rear of boiler.
d) Replace in reverse. order.
7.2
7.3
7.4
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 draught diverter by pulling downwards.
c) Replace in reverse. order.
Remove burner assembly
a) Remove two screws securing burner manifold to gas
section (A) and 2 outer screws U (50 OF only).
b) Remove gasket and retain in safe place. c) Remove 2 screws (B) securing burner head to rear
chassis.
d) Replace in reverse order.
To remove pilot
a) Release thermocouple from bracket removing nut
and bolt (A) securing clamp. 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 se-
curing 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.
15
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. If deposits are too hard to remove by brushing, the matrix can be
removed -see section 8.7 page 17 and washed with hot water and detergent. c) Any lint deposies in the burner ports should be removed using a suction cleaner and or washing. d) The gas filter (B - 4.4) can be cleaned using water and detergent.
e) Replace all components in reverse order.
DO NOT USE SOLVENTS.
8.
8.1
8.2

REPLACEMENT OF PARTS

Before proceeding - turn off gas and isolate electrical supply.
Replacing thermocouple
a) Remove front cover 7.1
b) Remove combustion chamber cover 7.2 c) Remove burner 7.3
d) Release thermocouple from thermocouple bracket
removing nuts and bolts securing clamp
e) Release at thermoelectric valve by unscrewing nut
IO mm.
f) Disconnect from overheat thermostat by pulling
connections apart.
g) Replace in reverse order.
Replace high limit thermostat
a) Remove front cover 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.
8.3
Replace electrode and lead
a) Remove front cover 7.1.
b) Remove combustion chamber cover 7.2. c) Remove burner 7.3.
d) Remove thermostat knob and six screws from front
of electrical control box 8.10. e) Remove plugs from rear of electrical controls box. f) Slide PCB forward and remove spark lead. g) Feed lead out through rear of control box. h) Loosen screw (A) securing clip retaining electrode and
turn clip through 90 *. i) Withdraw electrode by sliding to the side..
j) Replace in reverse order taking care to locate electro-
de in locating groove..
n-b.
Take care to replace plugs in rear of control box.
16
8.9
Rear Lining-
B
u
\1
\i
A+
7
Pi-7
\
‘“4
b
I=11
Replacing combustion chamber linings
a) Remove front cover 6.1. b) Remove front panel combustion chamber 6.2. c) Remove burner 6.3. d) Slide out side.linings first followed by rear lining.
(To remove rear lining ease upwards and withdraw by a downwards and forwards motion).
e) Replace in reverse order taking care that front lining
is correctly positioned.
8.10
8.11
Removal of electrical control box
a) Remove front cover 6.1. b) Isolate electrical supply. c) Remove six screws retaining electrical control box co-
ver.
d) Remove electrical connections from terminal strip
and earth. e) Withdraw plugs from rear of box. f) Slide PCB forward and disconnect spark lead. g) Remove 2 screws securing control box to chassis. h) Replace in reverse order taking care to replace plugs
in rear of control box.
n-b.
Care should be taken to ensure correct location of
the ON, OFF and reset buttons.
To replace thermostat
a) Isolate. electrical supply. b) Remove front cover 7.1.
c) Unscrew 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.
8.12
8.13
To replace fuse
a) Isolate electrical supply.
b) Remove front cover 7.1. c) Remove cover on electrical control box 8.10. d) Remove and replace fuse. e) Reassemble. in reverse order.
To replace PCB
a) Isolate. electrical supply. b) Remove front cover 7.1. c) Remove cover on electrical control box 8.10. d) Remove electrical connections from terminal strip
and the earth. e) Withdraw plugs from rear of electrical control box. f) Ease PCB forward and remove spark electrode. lead
and earth lead from the spark generator. g) Slide board forward and remove. hl Replace in reverse order.
18
3.14
8.14
Testing the 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 ther-
mocouple side - male connectors.
- Press and hold ignitor button.
- Output with pilot on should not be less than 14 mv.
n-b.
If closed circuit output is high and approaching the open circuit voltage obtained, then suspect faulty
thermoelectric valve.

SHORT LIST

Key No
I=
3 4 7
IOa IOb 20 21 26
30
31
32
34
35
36
37 43
109 118 119 163 186
26
IB
36
Description
Screw front case/electrical box securing ........................
Screwfrontcase/chassis ......................................
Temperatureselectorknob ...................................
Doorassembly30OF .........................................
Doorassembly50OF
Nut3/4”BSP ................................................
Olive (22 mm) ...............................................
Mountingbracket
Cableclampbracket ..........................................
Cableclamp .................................................
Screws cable clamp securing ...................................
Gasfilterwasher .............................................
Gasservicecock
Olive (15 mm) ...............................................
Nut1/2”BSP..
Thermistortemperaturesensor ...............................
High limit thermostat .........................................
Thermocouple ...............................................
Electrode and lead assembly ...................................
Printed circuit board .........................................
Fuse .......................................................
.........................................
............................................
.............................................
..............................................
21
GC Number Part Number
366 713 65622/01 366 311 39551103 366 553 64051 366 556 366 625 64148 366 558 47509 366 559 47508 366 257 21720/10 366 564 65519 366 565 366 714 45654/02 366 545 37309 366 566 65960 263 800 56489 366 642 56489 366 570 64153 366 636 65962 366 602 65961 366 593 63404 366 614 63176 264 446 44790
64147
27834
19
n
Pees main burner light ‘--
I
between terminal 5
and terminal 6 in the boiler
Change limit ~,a,
I
Is the pump wired
tothe boiler?
“0
I
Imp. C.M. - Ref. 92220-l 27 -
1185
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