How it Works
chaffotteaux
Loading...
Challenger 50 FF
User guide
24 pgs2 Mb0
Table of contents
Loading...

chaffotteaux Challenger 30 FF, Challenger 50 FF User guide

Download
CHALLENGER
Fanned Flue Boilers
30 FF
(GCN"41.980.74)
50 FF
(GCN"41.980.77)
installation
and servicing instructions
(these instructions are to be left with the User or adjacent to the Gas meter)
1.2
30
FF
OUTPUT
INPUT HOT BURNER PRESSURE
GAS RATE
1.3
kW
Max
Min
50
Max
Min
FF
8.79
4.4
kW
14.65
7.33
DIMENSIONS
I I
Gas connection
Water connection
Minimum flow rate Maximum static
Minimum static head Electrical connection
Btu/h
30,000 15,000
OUTPUT
Btu/h
50,000 25,000
(Casing)
3OFF&5OFF
.......................
.....................
....................
head
Max
Min
Max
Min
.................
..................
..................
Weight ..............................
Watercapacity
Burner Injector Size
Pilot injector
Ignition ..............................
.......................
...................
.........................
Electrode ............................
Boiler thermostat
High iimit thermostat
.....................
.................
Thermocouple and thermoelectric valve
Fanmotor Pressureswitch
...........................
......................
kW Btu/h m-bar
11.02 37,600 5.8
5.83 19,900 1.3
INPUT HOT BURNER PRESSURE
kW
18.6 63,500 7.9
9.9 33,750 1.5
1
I
Btu/h
m.bar
15 mm O.D. compression 22 mm O.D. compression fittings 30
FF 504
It/h (1.85 gpm)
50 30 m (98 ft) 150 mm (6 ins) - See figs 7.12 240 V single phase 50 hz supply fused 3 amp
30
FF - 24.77
30
FF
kg (54.5 lb)
- 0.5 lit. (0.11 gals)
1.18 mm (0.046 in) - marked 118
0.3 mm (0.011 in) - marked 030 Continuous spark - spark generator ANSTOSS Chaffoteaux - spark gap 5.0 mm Chaffoteaux - Electronic Ranco LM5 Chaffoteaux AEC DUNGS
ins.w.g. m3/h
2.3 1.03 36.4
0.5 0.54 19.2
GAS RATE
ins-w-g. m3/h ft3/h
3.2 1.74 61.4
0.6 0.94 32.6
CLEARANCES
mm in
Sides
TOP
Bottom
Front
FF 841
It/h (3.08 gpm)
50
FF - 25.9
50
FF
- 0.7 lit. (0.15 gals)
5 l/4
150 150 300
kg (57 Ibs)
ft3/h
6 6
12
1.4
HYDRAULIC RESISTANCE The hydraulic resistance of the boilers vary with the
water flow. The graph indicates resistance at va­rious flow rates for both models.
The minimum flow rates are :
30
FF
504 It/h (1.85 gpm)
50 FF 841 It/h (3.08 gpm)
The minimum flow rate is equivalent to a tempera­ture rise of 15’ C (27’ F).
Fig.
3
-
water2flow
1
2
400 600 800 1000
water
flow
per minute
gaily
- ri per hour
4 5
1.6 Description of operation
Minimum Wall Thickness 76 mm (3 in) - Max Wall thickness 3 m (9’10”)
The flue must be installed in accordance with BS 5440 Pt 1 1978
1
Pressing the igniter (ON) button disconnects the power supply to the pump, opens the thermoelectric valve and causes a continuous pilot ignition spark to be generated.
When a demand is indicated by a time clock, program­mer, thermostat etc. the pump starts, the fan changes from low speed to high speed and is proved by the pres­sure switch before the 50 % fixed gas valve opens. After 3 seconds the second 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 approaches the set temperature the main variable gas valve is closed and the boiler continues
to fire on 50 % fixed gas valve. When the set temperatu­re is reached the boiler switches off. If flow temperature
reduces the 50 % valve opens followed by the 100 % val-
ve. At the end of the ‘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 fan returns
to operation at the low speed. The high limit thermostat breaks the thermocouple cir-
cuit which extinguishes the pilot releasing the thermo­electric valve and closes the gas valve to the burner. Ma-
nual re-setting is required (See Section 5.4).
GENERATOR
FUNCTIONAL FLOW DIAGRAM
THERMISTOR
POTENTIOMETER
TEMP. SELECTOR
COMPARITOR
FAN PROVING
PRES!WRE SWITCH
2.
2.1
INSTALLATION REQUIREMENTS General
The installation of the boiler must be in accordance with the Gas Safety (Installation and Use) Regulations 1984, Building Regulations, current I.E.E. Wiring Regulations and the Byelaws of the local Water Undertaking. It should be in accordance also with the BS Codes of Prac­tice and the British Gas Specifications for Domestic Wet Central Heating Systems and any relevant requirements of the local Gas Region and Local Authority.
Detailed recommendations are stated in the following British Standard Codes of Practice : CP 331.3 1974, BS
5376:2 1970, BS 5440 1979, BS 544O:l 1978 and 2 1976, BS 5449:l 1977.
Note : Gas Safety Installation and Use Regs 1984 It is the law that all gas appliances are installed by competant 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.
across at all times. The minimum acceptable spacings from the terminal to obstructions and ventilation ope-
nings are specified bevow :
Terminal position
1. Directly below an openable win­dow air vent or any other vantila­tion opening.
2. Below guttering, drain pipes or soil pipes.
3. Below balconies or eaves.
4. Above adjacent ground or balco­w
5. From vertical drain pipes or soil pipes
6. From internal or external corners 300 mm (12 in
7. From a surface facing the termi­nal.
8. From a terminal facing the termi­nal.
Minimum
spacing
300 mm (12 in
75 mm (3 in)
200 mm (8 in) 300 mm (12 in
75 mm (3 in)
600 mm (24 in
1200 mm (48 in
2.2
‘2.3
2.4
Location
The position chosen for the boiler must permit the provi­sion of a satisfactory flue termination. The location must also permit adequate space for servicing and air circula­tion around the boiler.
The boiler may be installed in any room or internal space although particular attention is drawn to the require-
ments of the IEE Wiring Regulations and, in Scotland, the electrical provisions of the Building Regulations applica­ble in Scotland, with respect to the installation of a hea­ter in a room or internal space containing a bath or sho­wer.
Where the installation of the boiler will be in an unusual
location special procedures may be necessary and BS
5376~2 give detailed guidance on this aspect. A compartment used to enclose the heater must be des-
igned 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.
Water Circulation Systems
Open or sealed type central heating systems should be in
accordance with the relevent recommendations given in
BS 5376~2, BS 5449:l (for smallbore or microbore sys-
tems) and the British Gas Specifications for Central Hea-
ting Systems.
Hot water systems should be in accordance with the re-
levant recommendations given in BS 5546 and the above
mentioned British Gas publication.
Siting the Flue Terminal
The flue installation must be in accordance with BS 5440
Pt 1 1978.
The standard flue set is suitable for walls having a thick-
ness of 76 mm - 612 mm for rear outlet and 76 mm -
500 mm for side outlets - See 1.5. Other flue options are available to a maximum of 3 m (9 ft 10 in) to special or­der. (See 1.5).
The boiler must be installed so that the flue terminal is exposed to external air. The boiler must NOT be installed so that the terminal discharges into another room or space such as an outhouse or lean to. It is important that the position of the terminal allows a free passage of air
Note : The flue can be extended 150 mm (6 in) to clear a
projection. Where the terminal is fitted within 850 mm (34 in) of a plastic gutter or 450 mm (18 in) from painted eaves, an aluminium shield of at least 750 mm (30 in)
long should be fitted to the underside of the gutter or
painted surface. Where the lowest part of the terminal is less than 2 m
(6.5 ft) above the level of any ground, balcony, flat roof or place to which any person has access and which ad­joins the wall in which the terminal is fitted the terminal
must be protected by a guard of durable material (A ter-
minal guard is available from Chaffoteaux Ltd) or from Tower Flue Components. Tonbridge 351555.
The air inlet/products outlet duct and the terminal of the appliance must not be closer than 25 mm (I”) to any
combustible material. Detailed recommendations on the
protection of combustible material are given in BS 5440
Pt.1 1978 (Sub Clause 20.1).
IMPORTANT NOTICE : TIMBER FRAMED HOUSES
IF THE BOILER IS TO BE FITTED IN A TIMBER FRAMED
BUILDING, IT SHOULD BE FITrED IN ACCORDANCE WITH THE BRITISH GAS PUBLICATION - (( GUIDE FOR GAS INS­TALLATIONS IN TIMBER FRAMED HOUSING )) reference
DM2. IF IN DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCAL REGION OF BRITISH GAS.
Air Supply (BS 5440:2)
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 or
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 spa-
ce.
Cupboard or compartment air supply
30 FF
II
low level
106 cm2 (16 in21
53 cm2 (8 inn)
5
50 FF
2.6
2.7
Position of
air vents room
High level 168 cm* (26 in*)
I
Low level 168 cm* (26 in*)
Electrical Supply
This boiler must be earthed All wiring must conform to the I.E.E. Wiring Regulations, The CHALLENGER FF requi­res a 240 V single phase, SC Hz supply. A means of isola­tion must be provided adjacent to the boiler, this should preferably be an unswitched plug and socket which on disconnection has a separation of at least 3 mm on ail poles. The supply cord must be 0.75 mm* three core heat resisting cable.
Gas Supply
The Challenger FF on Natural Gas requires : 30 FF 1.03 m3/h (36.4 ft3/h)
50 FF 1.74 ms/h (61.4 ft3/h)
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 and purged as described in CP 331~3.
Air from 1 Air Direct

3 SYSTEM GUIDANCE

3.1
General
The CHALLENGER FF boiler series are low water content
appliances designed ONLY for use with fully pumped sys­tems. They 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) flow temperature.
Detailed recommendations for water circulation are gi-
ven in BS 5376:2 1976, BS 5449:l 1977, BS 5446:1979. Thermostatic control should be fitted to the hot water
storage cylinder and heating system.
3.2 Strainers
Where a CHALLENGER FF is used as a replacement for a
boiler on an existing system, ideally the water 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 (Code FY 30) in the return before the boi­ler.
3.3
3.4
Control Systems
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 : CHALLENGER 30 FF 504 It/h (1.8 gpm) CHALLENGER 50 FF 841 It/h (3.08 gpm)
from outside
84 cm* (13 in*)
84 cm* (I 3 in*)
The pump must be installed between isolating valves si­tuated as close to the pump as practical. Most pump ma­nufacturers require a minimum static head on the pump inlet to prevent cavitation. For boiler resistance, see graph on page 3 - fig. 2.
3.5 Cold feeds and open vents
The cold feed and open vent should be so positioned that pumping over and cavitation or air entrainment are avoided see recommendations for various layouts on page 8. Chaffoteaux recommend that the 15 mm cold feed and 22 mm open vent are close coupled (within 150 mm (6”) on the low pressure side of the pump. The connection should be so arranged that there is a low ve­locitv point at the open vent junction with the system. (Page 8 - Fig. 13).
3.6
Automatic Air Separator
Chaffoteaux strongly recommend the inclusion of a Bri­tish Gas accepted automatic air separator in the system as shown in fig. 13.
The open vent 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 arrangements is shown in fig. 13.
3.7 Cylinder
The domestic hot water cylinder used with the CHAL-
LENGER FF must be of the indirect and high recovery type to BS 1566 Pt. 1. Single feed cylinders are not suita­ble for use with this appliance. Flow and return to the cy­linder must not be less than 22 mm pipe.
3.8
3.9
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 230 mm (9”) 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 sys-
tems, utilising Challenger FF boilers. It is, however, ap-
preciated that the use of a corrosion and limescale inhi-
bitor may be desirable or specified. The following are the appliance manufacturers recom-
mendations :
I) Use only a British Gas or similar approved inhibitor
from the Fernox range manufactured by Industrial (Anti Corrosion) Services, Britannica Works, Arkesdon Road, Clabering, Nr. Saffron Waldron.
2) Use only quantities specified by the inhibitor manu­facturer.
3) Cleanse the system as required by the inhibitor ma­nufacturer.
4) 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 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 (Installation and Use) Regulations 1984.
(figs. 7-13)
6
3.11 Electrical controls
(Chaffoteaux recommendations) CHALLENGER FF boilers can be used with most normal
pumped primary schemes including non-electrical hea-
ting and hot water controls. It is not normally possible to use full programming facili-
ties when using a mixture of electrical and non-electrical controls. However, some non-electrical controls are now available with an external microswitch and these controis 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.
NB : All wiring to externai controis must be in accordan­ce with the ICE Wiring Regulations.
7.
Fully
pumped
ting and hot water using two spring return motorised val-
system independant control of central hea-
3. Drayton flow share valve system.
PROGRAMMER
Fig. 5
4. Satchwell Duoflow svstem.
PUMP
BOILER TERMINALS
Ii i
N L onlofflonlaff
CH (HW
PROGRAMMER PUMP BOILER TERMINALS
Fig. 3
2. Fully pumped systems independant control of central heating and hot water using two motorised valves.
t I
LNNL56
6
Fig. 6
PROGRAMMER
PUMP BOILER TERMINALS
Fig. 4
PROGRAMMER
PUMP
BOILER
TERMlNALS
7

ALTERNATIVE SYSTEM LAYOUTS

Minimum Static Head
150 mm
PREFERED
Fig. 7
.
. . .
. . . . .
. . . . .
. . . . .
~rz~z----- -
. . . . .
- - L-w -.
-L
Syfi buld be sWAtmospheric
. . . . .
Fig. 9
‘NOT RECOMMENDED1 -:-
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
----- r-l
/=\
I-A
‘1:’
4 I-l
. . . .
. . . .
. . . .
I 1
. . . . .
. . . . .
. . . . .
. . . .
.
-43 .:-2
. . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . .
. . . . .
. . . . .
. . . . .
. . . . .
.__
w
Fig. 8
Fig. 10
Minimum
gta$;ead
l-l
Minimum Tt;t& Head
Minimum
Fe;iFtead
BS 5449 Part 1 1977
<w fg
see 3.4
I-
*I-- v
’ 74
Fig. 11
Air seperator or formed low velocity point
LJ
b open vent
cold feed
AJ-
Fig. 13
’
Fig. 12
I-J
1. Cold feed 15 mm
2. Open vent 22 mm
3. 6 in. maximum
4. See fig. 13
5. By pass 15 mm
6. Regulating motorised valve
7. Combined cold feed and open vent
8
Loading...
+ 16 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use