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
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