CHALLENGER
Balanced Flue Boilers
30 BF
(GCN"41.980.71)
40 BF
(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.
Guarantee
The manufacturer’s guarantee on the appliance is for 24 months from
not installed in accordance with the recommendations made herein or in a manner approved by the manufacturer.
1.1 TECHNICAL DATA
return *; ~ Tflow
the date of
installation. The guarantee is voidable if it is
-
F
A
6
C
D
E
F
G
H
J
K
L
M
N
0
LLENGEI
Cl
mm
610 24
330
270 10.6
350
224 8.8
120 5.0
200 7.8
215 8.5
300 12
660 26
260 10.25
80
30
45
R3
‘OBF ’
l-
13
13.77
1
ins
3.1
1.2
1.7
.
R4 LLENGEI
10 BF
mm
A
655 25.78
B
395
C
260
D
320
E
J
c
F
G
H
J
K
L
M
N
0
225 8.9
120 5.00
250 9.8
200
210
300 12.00
700
260 10.23
35 1.37
50
ins
15.55
10.25
12.6
7.87
8.26
27.5
1.96
1
2
1.2
30 BF
OUTPUT
INPUT
BURNER PRESSURE (HOT)
GAS RATE
1.3
kW Btdh
Max
Min
40 BF
Max
Min
8.7
4.35
kW
11.6
5.8
30,000
15,000
OUTPUT
Btu/h
40,000
20,000
Max
Min
Max
Min
BalanceFlue ..___.
Gas connection
Waterconnection
kW Btu/h mbar ins.w.g. m3/h ft3/h
10.9 37,500 6.4
5.66 19,480 1.15
INPUT
kW
14.5 50,000 12.0
7.55 26,000 3.5
NB : For intermediate settings see graph page 13
Flue set requires a hole in the wall 205 mm highx305 mm wide (8 inxl2 in)
15 mm compression fitting
22 mm compression fittings
Minimum flow rate see 1.4
Maximum static head 30
m (98 ft)
Minimum static head 150
Electrical connection
Weight
Watercapacity .._.......
Manifold Injector Size
240 V single phase 50 Hz supply fused 3 amp
30 BF - 18.18
0.5 lit. (0.11 gals.)
30 BF
Pilot injector 0.3
Ignition
Electrode ..___......... ,.,.,
Boiler thermostat
High Limit thermostat
Thermocouple and thermoelectric valve
Continuous spark -spark generator ANSTOSS
Chaffoteaux - spark gap 5.0 mm
Electronic - Chaffoteaux Ltd
Ranco LM5
Chaffoteaux Ltd
2.56 1.02 36.26
0.45 0.53 18.83
BURNER PRESSURE (HOT)
Btu/h mbar ins.w.g. m3/h ft3/h
4.72 1.37 48.54
1.37 0.71 25.24
CLEARANCES
Sides
TOP
Bottom
Front
GAS RATE
mm ins
5 0.25
76 3
127 5
500 20
mm (6 ins) - See page 7.
kg (40 Ibs)
1.18 mm (0.046 ins.)
40
BF - 20
BF
kg (44 Ibs).
1.08 mm 0.042 ins
40
mm (0.011 ins.)
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 tempera-
ture rise of 15” C :
30 BF
504
I/h
1.85 gpm
673
I/h
Minimum water flow rate
3
a
0.1
I I
100 300 500
200
water flow-gallons per minute
w I
400 600
I
700 900
water flow - litres per hour
I I
800
1000 1200 1400
1100
13bo
3
2:
1
z
.c
f
9
B
.%?
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
ON n
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
Fig. 1
I
L
THERM0 ELECTRIC
VALVE
THERMISTOR
FLOW SENSOR
POTENTIOMETER
TEMPERATURE
.2SI FPrl-m
. TIME DELAY PUMP
OVER RUN
L
r
A
T
SPARK GENERATOR
HIGH LIMIT
THERMOSTAT
L
r
1
I
COMPARITOR
L
I
r
1
L
r
.
r
PILOT
IGNITOR
THERMOCOUPLE
VARIABLE
lDD%GAS
SOLENOID
VALVE
rh
TIME DELAY
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 detailed 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
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.
2.5
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
three core heat resisting cable.
supply
cord must be 0.75 mm2
2.4 Air supply - Balanced Flue Boiler
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.
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 vents
40
BF
Position of
air vents
Air from
room
room
Air direct
from outside
Air direct
from outside
2.6
Gas Supply
The CHALLENGER 30 requires 1.1 m3/h (37 fts/h). CHAL-
LENGER 40 requires 1.4 m3/h (49 ft3/h) of natural gas.
The meter and supply pipes must be capable of delive-
ring 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
2
7
.
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
SPLITTER
NOT TO EXTEND
MORE THAN
DEPTH OF
TERMINAL
BALANCED FLUES
(Zft)
E PROJECTION
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
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 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)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
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.
and
cylinder valves.
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.
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 inhibitor 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.
3.5
3.6
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 pipework. The use of an enlarged T to create a low velocity
point is recommended. The preferred arrangement is
shown in fig. 9.
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:
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.
All external wiring to and from the boiler
3. Drayton flow share valve system.
Fig. 12
4. Honeywell Sundial ‘Y’ plan.
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
PROGRAMMER PUMP
Fig. 13
5. Satchwell Duoflow system.
TLX 2259
ROOM
STAT
PROGRAMMER
SA 2451
CYL STAT
Fig. 14
PUMP
BOILER TERMNILS
CM 361
C”OFLOW VALVE
BOILER TERMINALS
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