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
4.

INSTALLING THE BOILER

A vertical flat incombustible area is required for installation of the boiler as follows : CHALLENGER 30 FF 445 mm wide x 955 mm high (17 l/2 in x 37 l/2 in) CHALLENGER 50 FF 445 mm wide x 955 mm high (17 l/2 in x 37 l/2 in)
The above dimensions include the necessary clearances around the boilers for case removal, air movement and installation and servicing.
The CHALLENGER FF and Flue assembly (standard length) are supplied in one carton in which there are 3 compartments.
1. Assembled boiler
2. Air inlet duct and flue duct
3. i) Flue turret assembled with pressure switch ii) Box containing :
- 2 nuts and olives 22 mm
- 1 nut and olive 15 mm
- 1 gas service cock
- 1 filter washer
- 1 mounting bracket
- 4 wood screws and washers
- 1 cable clamp and screws
iii) Plastic bag containing :
- 1 locking ring
- 1 ‘0’ ring
- 1 cork gasket
- 1 channelled neoprene gasket
- 4 fixing screws for flue turret
- 2 screws for turret cover
iv) Plastic bag containing :
- external wall plate with adhesive mastic
v) Plastic flue turret cover.
4.1
- Remove boiler from carton
- Release the front case by unscrewing the three fixing screws and washers positioned two at the top and one at the bottom and two screws securing the case to the control box. NB: one washer is paint cutting to maintain electrical bond. (Front of appliance covered by glass drop down door. See 7.1).
- Remove the case by easing it forward at the bottom and lifting it clear of the top locating lugs.
- Set out and drill hole for flue using a 4 in core drill or metric equivalent.
- Using dimensions on page 2 drill and plug the wall and fit bracket to the wall using screws and washers provi­ded. Check and ensure bracket is level.
- Temporarily hang the boiler on the bracket.
- Mark two fixings at the bottom of the boiler, remove
the boiler and drill and plug the wall.
-Rehang and screw the boiler to the wall using the screws and washers provided.
9
4.2
- Measure the wall thickness and cut the flue duct and air inlet duct to length - see 1.5 ANY SURPLUS LENGTH MUST BE CUT FROM PLAIN END.
NB : If cold the duct material becomes brittle-warm be­fore cutting.
- Peel off protective paper from the adhesive side of the cork gasket A and place on mating surface of flue turret B lining up screw holes. Press down.
- Fit a channelled gasket E to products outlet on top
of boiler.
- Assemble flue duct onto flue tube section.
- Fit locking ring C and ‘0’ ring over air duct as shown.
- Assemble the flue duct through the air duct so that it engages the terminal.
- Abutt the ‘0’ ring up to the turret and engage the loc­king ring over the lugs by turning in an anti-clockwise.
- Remove cable connection for pressure switch which in
transit is tucked into top of casing.
- Pass assembled flue through the wall so that the ter-
minal extends not less than 13 mm (l/2 in) beyond ex­ternal wall surface.
- Seat the turret onto the flue outlet ensuring that gas-
kets A & E are in position.
- Check that the flue assembly is level.
- Secure with the 4 screws provided.
- Where necessary make good external wall and fit wall
plate D with mastic sealant onto external surface. Make good internal wall.
NB : Do not fit turret cover or front case until gas and electrical connections have been made and tested.
4.3
4.4
RETURN
Making the gas connection a) Remove the plastic cover from the gas inlet which is
situated centre bottom of the boiler.
b) Fit the gas service cock together with the filter was-
her packed in the accessory box.
c) Fit the union nut and olive on the 15 mm gas supply
pipe, and tighten.
d) The gas supply pipe size should be sufficient to ensu-
re that there is 20mbar (8 in.w.g.1 pressure at the service tap, with the boiler working
NB : If space beneath boiler is restricted it is possible to fit a 3/4 BSP M & F elbow to the appliances. The gas ser­vice cock fits to the male thread.
Making the water connections a) Remove the plastic covers protecting the flow and re-
turn connection.
b) Fit the union nuts and olives supplied in the accessory
box on to flow and return pipes.
c) Tighten compression fitting whilst holding connection
inside case.
10
Making Electrical Connection (see section 2.6 for elec-
trical supply requirements) a) Secure cable clamp A to the base of the appliance
using the screws and paint cutting washers provided. Paint cutting washers must be used to maintain
earthbond. b) Remove control box cover see 8.7. c) Three core heat resisting supply cable is passed
through clamp and through slot in casing, and into rear of control box. Secure with clamp on top of elec­trical box so that there is sufficient length of cable between the 2 clamps to allow displacement of the electrical box without imposing strain on the earth bond. Connected to terminals on connection block and the earth connection made to the terminal.
d) Connect pump cable to terminals and the earth on
earth terminal. e) Connect ancillary controls across terminals marked 5
& 6. See controls diagrams. Figs 2-6 and 14-16. f) Clamp wires with cable clamp A. g) Replace control box cover.
NB : 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.
4.6
Connection of the pressure switch a) Connect the violet wires in the wiring harness to ter-
minal COM (P) and NO (2) common and normally open
contacts.
L
In the event of an electrical fault after installation preliminary electrical system checks should be carried out. Checks to ensure electrical safety, earth continuity, polarity, and resistance to earth should be carried out by a compe-
tent person.
3 Wire clock
Time clock
CHALLENGER-SIMPLE CONTROLS
Room thermostat onlv
4 Wire clock
Fig. 14
Room thermostat and time clock
N
Fig. 15
11
Frost thermostat
N
Fig. 16
5

COMMISSIONING - OPEN VENTED SYSTEMS

5.1 Gas Installation
The whole of the gas installation, including the meter should be inspected and tested for soundness and pur­ged in accordance with the recommendations of CP 331:3.
5-2 Water circulation system -
Open vented systems 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 flushed and i 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 cock is open. b) Push the ON button fully in and hold for 10 seconds. c) Check that pilot is alight and release slowly. d) If the pilot extinguishes press red reset button and
repeat from (b). The pilot should be about 13 mm (I/2 in) long and impinge on the tip of the thermocouple.
e) Switch system controls to a demand mode, ensuring
that pump is running. f) After 30 seconds the main burner will light. g) If the pilot extinguishes, wait 3 minutes and repeat b)
above.
h) Check for gas soundness around the boiler gas com-
ponents using leak detection fluid.
i) Check and adjust gas rate as detailed in 5.5.
5.4 Resetting the 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 resetting the high limit
thermostat by pressing the red reset button.
c) Establish cause and rectify - See Fault Finding Chart,
rear cover.
NB : If the mains electrical supply is interupted the high limit thermostat may operate.
$ 3 B
h
2
Fig.
5.5
boiler output kW
/ I
10000
L
1
17
Gas rate adjustment
fore adjusting heating system by-pass). NB: The boiler is supplied rated at the highest output.
The boiler is fitted with a gas rate adjuster. a) Turn boiler to off by pressing OFF button. b) Remove the pressure test point screw (1) and
connect a suitable pressure gauge (fig. 17).
c) Remove the hexagonal cap from gas rate adjuster, (2)
exposing the adjustment screw (fig. 17).
d) Turn boiler on by pressing ON button (see lighting boi-
ler 5.3 above).
e) Adjust setting pressure. Setting pressures are given
in graph relative to required output. 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 gas rate adjuster cap and ensuring that a gas
tight seal is made. g) Mark the data badge to indicate output. h) Replace front case. Particular care must be given to
ensuring that the case seal is sound when the casing is replaced.
i) After boiler has been running for 10 mins check the
gas rate.
j) Fit the plastic turret cover threading the harness
through the slot provided.
k) Secure cover with the thread forming screws provi-
ded.
20000 30000 40000 50000
output Btu/h
(TO be carried
out
be-
12
5.6
6.
6.1
6.2
6.3
Adjusting the heating system by-
pass
NB : The by-pass valve should be of the lock shield pat­tern)
a) Fire the boiler with the by pass fully closed and the
system using the radiator lock shield valves to the system design temperature difference. Normally this will be 11” C (20” F).
b) Adjust the system to minimum load. This will general-
ly be central heating only with one radiator operating. Switch off radiators on the wheel head or thermosta-
tic valves. c) Switch boiler thermostat to maximum. d) Open by pass until minimum flow rate across the boi-
ler is achieved. This is equivalent to 15” C (27” F) tem­perature rise across the boiler.
e) Open all radiators and check the system design tem-
perature difference.
SEALED SYSTEMS Safety valve
A safety valve shall be fitted close to the appliance on
the flow pipe by a horizontal or vertically upward
connection. 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.
Pressure gauge
A pressure gauge covering at least the range O-4 bar (O-60 Ib/inz) shall be fitted to the system adjacent to, and visible from, the filling point.
Expansion vessel
(i) A diaphragm type expansion vessel shall be fitted by
a connection to the inlet side of the circulating pump,
in a manner laid down in the vessel maker’s instruc-
;afety valve
etting (bar)
lessel charge Iressure (bar)
nitial system lressure (bar)
'otal water :ontent If system
litres
25
50
75 100 125 150 175
200 250 300 350 400 450
500
orsystems olumes other Ian those given bove. multiply 0833 iesystem olume by the xtoracross
For the CHALLENGER FF boiler the above table should be multiplied by 0.8
3.0
0.5 1.0 1.5
0.5
1.0
1.5 2.0 1.0
Expansion Vessel Volume (litres)
1.5
2.0 1.5 2.0
- -
2.1 3.5 6.5 13.7 2.7
4.2 7.0 12.9 27.5 5.4
10.5
6.3 a.3
10.4 17.5
12.5 21.0
14.6 24.5
16.7 28.0
20.8 35.0
25.0 42.0
29.1 49.0
33.3 56.0
37.5 j3.0 $1.6 70.0
- -
- -
19.4 41.3 a.2
14.0
25.9 55.1 10.9
32.4 68.9 13.6
38.8 82.6 16.3
45.3 96.4 19.1
51.8 110.2 21.8
64.7 137.7 27.2
77.7 165.3 32.7
90.6 192.8 38.1
03.6 220.4 43.6 76.0 164.8 62.4 :6.5 247.9 49.0 15.5 185.4 70.2 !5.9 275.5 54.5 15.0 206.0 78.0
,140
259 0.551 0.109 .190 0.412 0.156
4.7 10.3 3.9
9.5 20.6 7.8
14.2 30.9 11.7
19.0 41.2 15.6
23.7 51.5 19.5
28.5 61.8 23.4
33.2 72.1 27.3
30.0 02.4 31.2
47.5 103.0 39.0
57.0 123.6 46.0
66.5 144.2 54.6
13
6
4
.
6.5
6.6
6.7
6.8
tions (see Fig. 7-13 for illustration of recommended
system layouts). The expansion vessel shall be capa­ble of accepting water up to at least 62.5 % of its vo­lume without damage.
(ii) The nitrogen or air charge pressure of the expansion
vessel shall not be less than the hydro-static head
(height of the top point of the system above the ex­pansion vessel).
(iii) The expansion vessel shall be sized in accordance
with the following table :
Hot water storage cylinder
The hot water cylinder shall be the indirect coil type which is suitable for the system pressure.
Make-up system
Provision shall be made for replacing water lost from the
system either :
0) From a make-up vessel or tank mounted in a position higher than the top point of the system and connec­ted through a non-return valve to the system on the return side of the hot water cylinder or the return side of all heat emitters, or -
(ii) Where access to make up vessel would be difficult, by
pressurisation of the system.
Mains connection
There shall be no connection to the mains supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the
local Water Authority.
Filling point
(see
8s
5376 Pt 2 Appendix A)
I) Through a temporary hose connection from a draw
off tap supplied from a service pipe under mains pressure, provided that this procedure is acceptable to the local Water Authority.
2) Through a self contained unit comprising a cistern, pressure booster pump if required and if necessary an automatic pressure reducing valve or flow restric­tor.
3) Through a cistern, used for no other purpose, perma­nently connected directly to a service pipe. The water distributing pipe. The static head available should be sufficient to provide the desired initial system design
pressure.
Pipework
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.
For the purpose of the above calculation, the volume of the system shall be determined as accurately as possible using manufacturers’ data as appropriate. Alternatively the volumes given below may be used to give a conser­vative estimate of the system volume :
Boiler . . . . .
Small bore pipework . . .
per 0.292 kW (1000 Btu/h) of system output
Microbore pipework . . . .
Steel panel radiators
per 0.292 kW (1000 Btu/h) of system output Hot water cylinder . . .
If a system is extended, an expansion vessel of increased volume may be required unless previous provision has been made for the extension.
0.5 litres (0.11 gallons)
0.3 litres (0.07 gallons) 7 litres (1.5 gallons)
2.3 litres (0.5 gallons) 2 litres (0.44 gallons)
Fig. 18
Pump on the return
H
Pump on the flow
Diagrams showing System layout
1 - Expansion vessel 2 - Pressure gauge 3 - Filling point 4 - Drain cock 5 - Air release point 6 - Safety valve 7 - Top-up bottle 8 - Temporary hose connection
or pressurisation make up.
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 air locks cleared until the pressure gauge regis­ters 1.5 bar (21.5 Ibs/irP). Vent all radiators and check for water soundness.
Manually raise the water pressure to ensure that the sa­fety valve lifts. This should occur within ? 0.3 bar (k4.3 Ibf/irP) of the preset lift pressure, ie. 3 bar (43.5 Ibf/in2).
Release water from the system until the initial system
Fan 1
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 war
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, and inhibitor added to
the system, if required in the specification (see 3.9). Clear all air locks and adjust 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 adjust gas rate and system by pass.
NB
: The boiler is supplied rated at highest output.
The boiler is fitted with a gas rate adjuster. (See 5.5 for adjustment procedure).
Red
Thermistor temperature
/ //
Fig. 20
Salenoid valves
,w 1 Control box
I
Fig. 21
CHALLENGER TEST POINTS
Thermocouple
Thermoelectric Valve
Miauswitch. 240 V
I
Solenoid Valves
Earth
Printed Circuit Board (Temperature & Sequence Control)
Notlessthan8mv (see sea 7.14)
Orange and Blue
Fan. 240 V
External Controls
240V 5Ol-k
Fig. 22
111,
,Y,W
Them-&or
I
TellIaerature
I!
Comparitor
a I
@ 50 % (Blue) Soienoid Gas Valve @ Variable (Orange) Solenoid Gas Valve
Pressure !switch
m,.
1
15

7. SERVICING

For efficient and trouble free operation it is important that the CHALLENGER FF boiler receives regular maintenance. The fol­lowing schedules are recommended. Check function of appliance and observe flame picture. Check clean or replace compo­nents as necessary.
Before commencing any work turn off the gas at the gas service cock (4.3 Page IO) Ensure that the electricity supply is isola-
ted. NB : Always test for gas soundness after completing any servicing or exchange of gas carrying components,
Remove front case a) Remove screws and washers (1) two at top and one at
bottom of boiler. (One washer paint cutting to main-
tain electrical bond). b) Remove two screws from lower front of case (2). cl Remove case by easing forward at the bottom and
lifting clear of the top locating lugs.
7.2
7.3
7.4
30
50
Remove combustion chamber front panel
FF
a) Remove four screws A and two nuts screws and was-
hers B securing front panel of combustion chamber.
b) Remove panel complete with regulator plate by ea-
sing forward.
FF
a) Remove six screws A and two nuts screws and was-
hers B securing front panel of combustion chamber.
b) Remove panel by easing forward at bottom and di-
sengage.
Remove the burner assembly a) Remove the screws A securing burner manifold to
gas section. bl Remove gasket and retain in safe place. c) Remove burner. NB : When replacing burner ensure that the lugs are lo-
cated to the rear bracket and the faces of the fixings on rear of burner are in cut outs provided taking care not to trap electrode lead.
To remove pilot a) Release thermocouple from bracket by removing
screw securing clamp (A) and removing clamp. Move
thermocouple to the side. b) Release the electrode by loosening screw on right
hand side of assembly and rotating clip (B).
c) Remove pilot gauze and filter by removing screw se-
curing gauze to assembly 0. d) Lift out pilot deflector plate. e) Remove pilot by unscrewing (nut size 8 mm AF). f) The pilot injector can be cleaned and should be repla-
ced bright side uppermost.
16
Cleaning the parts a) The burner can be cleaned by inverting and brushing with a soft brush.
b) The heat exchanger flueways can be cleaned by brushing. c) The gas filter in the gas service cock can be cleaned using soap and water - DO NOT USE SOLVENTS. d) Replace all components in reverse order. Particular attention should be given to ensuring that the case seal is sound when
the casing is replaced.
e) Recommission and check controls. Note burner pressures.

8. REPLACEMENT OF PARTS

To remove gas filter a) Remove nut A and remove filter B.
b) Replace in reverse order.
8.1
8.2
Replacing thermocouple
a) Remove front case 7.1
b) Remove combustion chamber front panel 7.2 c) Remove burner assembly 7.3
d) Release thermocouple from thermocouple bracket by
undoing screw A and removing clamp.
e) Release electrode lead from sealing gland.
f) Release at thermoelectric valve by unscrewing nut
IO mm AF.
g) Disconnect from high limit thermostat by pulling
connections apart where high limit thermostat connects.
i) Remove thermocouple and seating.
j) Replace in reverse order taking care to locate thermo-
couple in positioning grooves in bracket.
k) Replace seating in to casing and reposition electrode
lead.
Replacing combustion chamber linings a) Remove front case 7.1 b) Remove combustion chamber front panel 7.2 c) Remove burner assembly 7.3 d) Slide out side linings first followed by rear lining which
is removed by easing upwards and sliding out from the bottom.
e) Replace in reverse order taking care that front lining
IS corwoositloned
8.3
To replace fan a) Remove front case 7.1 b) Remove four screws -two on flue hood B and two on
the bracket - supporting the fan motor (A).
c) Turn to disengage from lug at rear and slide out as-
sembly.
d) Note position of electrical connections and pull off
spade connectors.
e) Replace in reverse order ensuring rear locking lug is
correctly engaged.
17
8.4
8.5
8.6
To replace pressure switch a) Remove two screws retaining plastic turret cover.
b) Note position of spaae connectors and remove.
c) Disconnect pessure sampling tube by pulling off nip-
pie. d) Remove two screws retaining pressure switch. e) Replace in reverse order. NB : See 4.6 -electrical connections.
Replace spark electrode and lead
a) Remove front case 7.1
b) Remove combustion chamber front panel 7.2
c) Remove burner assembly 7.3 d) Remove thermostat knob and six screws and screw
seats from the electrical control box.
e) Remove plugs from rear of electrical control box. f) Slide PCB forward and disconnect spark lead from 1
ignition generator. g) Feed lead out through rear of control box. hj Loosen screw securing clip retaining electrode and
turn clip through 90” C.
i) Slide electrode sideways complete with lead. Release
spark lead from sealing gland.
j) Replace in reverse order taking care to locate electrode
in locating ring and replace plugs in rear of control box.
To replace heat exchanger a) Drain system. b) Remove front case 7.1. c) Remove combustion chamber front panel (A; 7.2. d) Remove burner assembiy (B) 7.3 e) Remove high limit thermostat phia! - left hand side
0.
f) Withdraw thermostat temperature sensor - right
hand side (D) 8.13
g) Unscrew nuts on flow and return connections (E)
(30 mm AFL
h) Remove two screws securing combustion chamber to
rear chassis (FL
i) Drop assembly and withdraw forwards.
j) Remove two screws from rear of assembly retaining
heat exchanger to combustion chamber.
k) Repace in reverse order.
i
I
i
i I
I
i
i /
I
8.7
NB : Omit d & e above if the box is to be temporarily dis-
placed to gain access to another component.
18
To remove the electrical control box a) Remove front case 7.1.
b) Remove the boiler thermostat knob (A) by pulling off
the spindle.
c) Remove six screws and screw seats retaining the elec-
trical box cover (B) and remove cover taking care not to lose the red reset button.
d) Mark and remove the mains, pump and external
controls wiring.
e) Remove plugs at rear of electrical box and disconnect
earth. f) Ease PCB forward and remove spark electrode cable. g) Remove two screws in the rear of the box securing
box to chassis and remove box.
h) Replace in reverse order.
8.8
Replace high limit thermostat a) Remove front case 7.1 and remove or displace as ne-
cessary electrical control box 8.7. b) Remove combustion chamber front panel. c) Remove two screws (A) securing high limit thermo-
stat.
d) Disconnect conductors at pin connectors by pulling
apart. e) Remove sensor from dry thermostat pocket first re-
moving split pin.
f) Unclip capillery.
g) Replace in reverse order using a heat sink grease on
the thermostat phial.
8.9
To replace microswitch and lead assembly a) Remove front case 7.1
b) Remove or displace as necessary the electrical control
box 8.7.
c) Pull off connector (A). d) Remove two screws retaining microswitch (B). e) Replace in reverse order.
To replace thermoelectric valve a) Remove front case 7.1
b) Remove or displace as necessary the electrical box
8.7.
c) Remove thermocouple connection from thermoelec-
tric valve (A).
d) Remove nut securing securing thermoelectric valve
(nut size 25 mm AFL
e) Withdraw thermoelectric valve. f) Replace in reverse order. NB : Care should be taken when replacing the nut secu-
ring the thermoelectric valve - FINE THREADS.
19
To replace solenoid valves a) Remove front case 7.1
b) Remove or displace as necessary the electrical control
box 8.7.
c) Disconnect plug connectors (A) from solenoid valves
(colour coded).
d) Remove four screws (B) securing solenoid valve
mounting plate.
e) Remove mounting plate and solenoids - take care
not to misplace valve springs or damage gasket.
f) Replace in reverse order using new gasket.
Replace pilot injector
a) Proceed as for servicing 7.4.
b) Replace injector ensuring it is fitted bright side upper-
most.
8.13
To replace boiler thermostat sensor and lead a) isolate electrical supply. b) Remove front case 7.1. c) Undo knurled ring retaining thermostat sensor phial
and remove phial. d) Unplug from rear of control box. e) Replace in reverse order using heat sink grease on
thermostat sensor phial.
al4
8.15
al6
To replace fuse a) Isolate electrical supply. b) Remove front case 7.1. c) Remove cover on electrical control box 8.7. d) Remove and replace fuse (2 amp). e) Replace in reverse order.
To replace PCB a) Isolate electrical supply. b) Remove front case 7.1. c) Remove cover on electrical control/box. d) Ease forward PCB and remove spark electrode wire
and earth wire from spark generator NB. PCB is a wedge shape and it will be found easier to ease front
corners first. e) Remove plugs from rear of electrical control box. f) Slide board forward and remove. g) Replace in reverse orders. h) Check function of controls.
Testing of FDD 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 ther­mocouple side male connectors.
- Press and hold igniter button.
- Output with pilot on should not be less than 14 mv.
NB : If closed circuit output is high and approaching the open circuit voltage obtained, then suspect faulty ther­moelectric valve.
20
Is link in 5-6 or are external
control in demand mode
Yes
4
Check ignitor lead and
connections microswitch
and electrode and replace
where necessarv
+
Is spark present ?
I
no*
Check for blocked pilot
injector change if necessary
yes
Does fan run at high speed
no
dyes J
,
]
- -
I - I
4
no+ I
Check fan and rectify
I
I
Flue blocked
Rectify
1
I
I
1
Yes
+
22
I
no
Is plug on PCB
I
Does boiler fire
I
supply to blue valve and plug
I
I
Is there
correctly located.
no
Replace pressure
switch
I
I
Yes
Replace valves
I
I
b
Does limit thermostat
I
Is svstem vented In
and water circulating
r
- limit stat, continue to
JImate
I
I
ConsfZXItlv
ye=
temperature sensor
I
IO
-
Vent system
1
f
1
1
Is the pump wired
C
to the boiler ?
r
I
Ghal
I
23
Chaffoteaux
Ltd, Concord
House,
Brighton
Road,
Salfords, Redhill, Surrey RH15DX. Telephone: Horley (0293) 772744. Telex: 87378.
39-41 A - Imp. C.M. - R&f. 92220-l 29 - 9185
ESP021
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use