Max. operating pressure C/H circuit: 2.5 bar
Expansion vessel net capacity: 5.44 l
Cal. comfort 100 : 12.5 to 28,2 kW
Expansion vessel initial pressure: 0.7 bar
Electrical consumption: 150 w
Voltage: 230 v
Electrical protection index: IP44
Fuses : 2 A and 1.25 A
Nominal gas f ow rate at 15°C and 1013 mbarCalydra. comfort 80Calydra. comfort 100
Maximum Minimum Maximum Minimum
power 25,9 kWpower 9.5 kWpower 31,1 kWpower 9,5 kW
- Natural gas ( G 20) at 20 mbar2.74 m3/h1.00 m3/h3.29 m3/h1.00 m3/h
- Butane gas ( G 30) at 28 mbar2.04 kg/h0.74 kg/h2.45 kg/h0.74 kg/h
- Propane gas ( G 31) at 37 mbar2.00 kg/h0.72 kg/h2.42 kg/h0.72 kg/h
DHW flow rate at @ AT 30 K Cal. comfort 80 : 12.1 l/min
Cal. comfort 100 : 14.1 l/min
DHW flow rate at @ AT 35 K Cal. comfort 80 : 10.4 l/min
Cal. comfort 100 : 12.1 l/min
Minimum DHW operating flow rat:2.00 l/min
Minimum DHW working pressure:0.5 bar
Maximum DHW working pressure:10 bar
Gas category: II 2H 3+
Injectors and gas valves seat diameterCalydra. comfort 80Calydra. comfort 100
- Solenoid restrictor diameter2.60 mm 1.75 mm2.90 mm 2.00 mm
Natural gas Butane or PropaneNatural gas Butane or Propane
- Gas valve restrictor diameter6.70 mm 4.90 mm
- Manifold injectors (16)1.23 mm 0.70 mm 1.28 mm 0.76 mm
no resrictor required6.70 mm
Page 2
Supplied By www.heating spares.co Tel. 0161 620 6677
Pump and expanssion vessel characteristics
0
4
3
2
1
5
6
100
200800
700
600
500
400
300
900
1000
1100
1200
l/h
mCE
Débit mini (robinets thermostatiques fermés)
Pression disponible
20 40 60 80 100 120Pf140 160 180 200 220 240
0,7
0,8
0,9
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
80°C
70°C
60°C
50°C
40°C
260
Pression à froid pour le circuit chauffage (en bar)
Head available / fl w
21. DHW pressure relief valve
34. Heating Flow isolating valve
35. DHW outlet
Pressure
Note : The system initial pressure should be over the following value :
System static height (in metre) + 0.7 = Initial pressure (in bar)
Components location
36. Gas service tap
37. Water service tap
38. CH Return isolating valve
System capacity chart
Liters
10
34
35
36
37
Fig. 2
1. Air Pressure switch
2. Steel chassis complete with expan
sion vessel
3. Fan
4. Main heat exchanger
5. Combustion chamber made of aluminium coated steel with 4 ceramic fibre
panels to provide heat insulation
Supplied By www.heating spares.co Tel. 0161 620 6677
FUNCTIONING
I
reset
3
6
14
15
13
55
17
12
52
Switching on
1) Check that the gas service tap is opened at the gasmeter and
1
main power is on.
2) Check that pressure in central heating system is above 0.7 bar
and below 1.5 bar with the pressure gauge 31.
3) Open the gas tap 36.
4) The boiler is now ready to use.
2
5) Turn main switch 23 to position I . The green "power on" indicator 27will light.
4
Hot Water
1) Turn the DHW temperature control knob clockwise 24. The
11
DHW indicator will light 32.
2) Turn on a hot water tap, the orange "burner on" indicator
5
will light 28 and the water will become hot..
Heating
20
1)Turn the CH thermostat control knob clockwise 25 The CH
indicator will light 33.
2) If the room thermostat (if fitted), the boiler temperature control
9
and the clock (if fitted) are all calling for heat, the orange
"burner on" indicator
will light and the heating will be on.
54
Control panel
10
33
8
30
26
28
2729
19
32
18
Fig. 3
CALYDRA FUNCTIONAL DIAGRAM
7
Fig. 4
242531
3a
6
13
ac
b
16
17
52
1
4
5
6c
6d
14
12
18
15
10
19
8
23
53
9
Hot water mode
Fig. 5
Heating mode
3
20
34
35
50
36
37
38
7
21
51
Fig. 6
Page 4
Supplied By www.heating spares.co Tel. 0161 620 6677
When there is a need for hot water while
the heating is on, it is only necessary to
turn on a hot tap. The heating will be interrupted momentarily while the hot water is
being delivered. The boiler will switch
back automatically to heating when the
tap is turned off.
Note: If the boiler has been turned off for
some time the first attempt to light it may
result in a lockout
press the reset button 30 and the boiler
will light.
T
o Turn Boiler Off Completely
1) Turn the main switch 23 to the off position O.
2) Turn the gas tap 36 (f g.2) OFF.
Domestic Hot Water Mode
In order to supply hot water, the main
switch 23 (f g. 4) must be in ON position I.
This will be confirmed by the green indicator light 27 (f g. 4). Turn DHW temperature adjustment knob 24 clock wise to
establish the green DHW indicator 32 (fig
4).
The hot water temperature in the mini
cylinder can be adjusted between 40 and
0°C using control knob 24 (fig 4)
6
When a tap or shower is turned on, the
f ow of mains water, above 2 litres per
min., will activate the 3 way valve 17
4) to move to the DHW position. The
(f g.
pump will now circulate primary water
heated by the main heat exchanger
through the secondary heat exchanger.
The f rst stage solenoid a (f g. 6) and safety solenoid c (f g. 6) open together to allow
gas to the burner. The ignition sequence
begins and a continuous high speed spark
If this happens
ignites the gas. As soon as a flame is
detected the orange indicator bulb 28
g.4) will light and the second stage sole-
(f
noid b (f g. 6) opens to allow the full gas
rate. If a flame is not detected, after 8 seconds, the security solenoid closes and
shuts
off the gas. The red lockout indicator bulb29 (f g.4) will show. Over 2
l/min, the domestic hot water temperature
is controlled by the hot water control thermistor 9 (f
thermistor 16 (fig.6), but dependant upon
to the position of the DHW temperature
adjustment knob 24 (f g.4). This system
anticipates the changes of temperature in
the secondary heat exchanger and
ensures accurate temperature regulation.
When the tap is closed the burner is extinguished and the pump stops. (unless the
mini cylinder thermistor is calling for heat,
in which case the burner will remain on at
a low rate and the pump will continue running until the mini cylinder thermistor is
satisfied). The boiler will now stay in the
hot water mode for 30 seconds to be
ready for a subsequent draw off
Priority is given to a demand for hot water.
This will interrupt the central heating for
the duration of hot water delivery or recovery of the mini cylinder.
When the boiler has been in standby in
Hot Water Mode for some time or when
drawing DHW at flow rates of less than
2 l/min the temperature in the mini cylinder will eventually decrease and the
TSS®control thermistor 18 (f g.6) will call
for heat. Bringing the pump and burners to
operate, until the cylinder thermistoris satisfied. this is quite normal
g.6) and the heating control
Central Heating Mode
To be able to supply heating, the main
switch 23 (f g.4) must be in I position. This
will be confirmed by the green indicator
light 27 (f g.4.) Turn the temperature
control knob 25 clock wise to establish the
green heating indicator 33 (fig.4)
When there is a demand for heating
(either from the room thermostat or the
clock) and the boiler temperature control
is calling for heat. The pump starts allowing the ignition sequence to begin. The
f rst stage solenoid a (f
solenoid c (f g.6) open together to allow
gas to the burner. The ignition sequence
begins and a continuous high speed spark
ignites
the gas. As soon as a flame is
detected the orange indicator bulb 28
(f g.4) will light. After 45 seconds the second stage solenoid b (f g.6) opens to allow
the full gas rate. If a flame is not detected,
after 8 seconds, the security solenoid
closes and shuts off the gas. The red lockout indicator bulb 29 (f g.4) will show.
The central heating f ow temperature is
controlled by the central heating control
thermistor 16 (f g.6). The boiler has been
designed to minimise cycling and will not
attempt to relight for at least 3 minutes
after the boiler thermostat has been satisfied (it is possible to reduce the time to 30
s if necessary). When the room thermostat is satisfied the burner will switch off
and the pump will remain running for a further 4 minutes before it to stops.
NB : It is possible to override the 3 minute
delay by pressing the RESET button 30
(f g. 4)
g.6) and safety
WIRING
DIAGRAM
4
Page 5
Supplied By www.heating spares.co Tel. 0161 620 6677
C10C10
C11C11
C38C38
J1J1
J2J2
J5J5
MV1MV1
R72R72
R73R73
R75R75
R76R76
1
2
HOR
P3
mini maxi
P3
P3
1/3
3/3
P3
1/3
JP3
ADJUSTMENTS ON CONTROL PCB
Adjustment on the PCB :
- P3 : potentiometer TAC (Temporisation Anti Cycle)
may now be adjusted between 30 seconds and 3
minutes (see detail) (factory set at 3 minutes).
- JP3 : the spade connector allows the gas rate to be
reduced to 1/3 performance by positionning
spade across pins as shown A
Full performance across pins as shown B.(factory
set)
After completling adjustments replace rubber cover and
refit outer casin
AB
REGULATION
Temperature regulation for both C/H and
DHW circuits are controlled by 2 thermistors. The C/H knob allows the adjustment
of temperature between 35 and 85°C. The
DHW temperature is limited to 60°C. DHW
and C/H thermistors are identical and
interchangeable.
Resistance value are
-5000 Ω at 25 °C
-2631 Ω at 40°C
-620 Ω at 80°C
-255 Ω at 110°C
AIR PRESSURE SWITCH
The air flow rate is detected by a pressur
differential created by a venturi located in
the flue duct
ON threshold∆P > 130 Pa
OFF threshold∆P < 100 Pa
P3
Detail
ROUTINE SERVICING
To ensure continued efficient operation o
the appliance, it is recommended that it is
checked and serviced as necessary at
regular intervals. The frequency of servicing will depend upon the particular installation condition and usage, but in general,
once a year should be adequate.
It is the law that any service work must be
carried out by a competent person such
as your local Chaffoteaux Service Centre,
British Gas or other CORGI registered
personnel in accordance with the current
Gas Safety (Installation and Use)
Regulations.
The service schedule should include
the following operations:
- Check the pressure in the system.
- Check the correct operation of the
appliance.
- Check the correct operation of the gas
controls.
- Check the functions of the safety controls.
- Check combustion chamber insulation
panels for damage.
- Clean the burner.
- Clean the heat exchanger.
- Check the burner manifold injectors.
- Clean gas and water filters
- Check expansion vessel charge pressure.
- Clean and check operation of safety
valve.
Additional Procedures that may be
necessary:
- Check that the fan blades are clean.
- Check, clean and replace components as
necessary.
- Carry out combustion test utilising the test
points in the flue turret
SUGGESTED SEQUENCE for SERVICING
Before disconnecting or removing any
parts, isolate the gas and electricity supplies. Ensure that the appliance is cool.
(for detail please see section on Parts
Removal and Replacement)
Preliminary Checks
- Remove outer case
- Check the system pressure is at least
0.8 bar cold
- Check operation of solenoids.
- Check that the burner is extinguished fully
when solenoids are closed in both DHW
and C/H modes.
- Test ionisation functions and check that
lockout occurs by turning off gas tap.
- Check burner pressure and gas f ow
rates.
5
Page 6
Supplied By www.heating spares.co Tel. 0161 620 6677
1
2
3
0
4
bar
REMOVAL AND REPLACEMENT OF PARTS
1
2
Before removing appliance case, isolate
the gas and electrical supplies. Isolate boiler from the system and drain before
removing any component in the waterways. Ensure that the appliance is cool.
1. Outer Case
Remove four screws in base of case and
A
A
A
A
lift free. When replacing, carefully locate on
lugs B on top edge of chassis.
B
B
5. Ignition Electrodes
Carry out steps 1 and 2 as above. remove
the wiring cover undo the power lead plug
open the electrical box 2 clips. Dicconnect
leads from spark generator on PCB. Loosen
screws securing the closure plate and
remove. Remove grommet from base of
sealed chamber. Remove screw securing
electrode bracket and lift clear easing
spade connectors through the grommet.
Reassemble in reverse order, twisted
together electrodes cable at least 10 times
to avoid electrical interference.
6. Burner Assembly
Carry out steps 1,2, disconnect electrodes
as mentionned in section 4 and 5. Remove
two screws securing burner assembly to the
back panel of the boiler. Lift right hand back
corner first. Reassemble in reverse order
7. Gas Solenoids
Disconnect colour coded leads. Remove six
screws. The solenoids are attached to their
base plate. Lift clear taking care not to lose
the three plungers and springs.
Reassemble in reverse order replacing the
cork gasket.
Remove outer case and sealed chamber
front panel as in steps 1 and 2.
Disconnect three pressure switch cables
noting their positions.
1 = white cable connected to NC
2 = black cable connected to NO
P = orange cable connected to C
Remove screw securing the switch
bracket to the chassis. Disconnect the
sampling tubes again noting their positioning (+ and -).
Remove switch. Reassemble in reverse
order.
11. Pressure Switch Venturi
Carry out steps 1, 2 and 8, as above.
Disconnect the sampling tubes and
remove the screw securing the venturi to
the flue outlet. Remove venturi by the
bottom of the 45° elbow. Reassemble in
reverse order.
12. Drain down
2 drain
(air separator)
8. Fan Assembly
Remove outer case and sealed chamber
front panel (See Steps 1 and 2). Disconnect
spade connectors noting positions. Remove
two screws securing the front of the fan
assembly and loosen screw on flue outlet.
Twist fan assembly anticlockwise to disengage from flue outlet and lift clear
Re-assemble in the reverse order ensuring
that the wiring is re-connected correctly and
the screw on the flue outlet tightened
9. Flue Hood
Carry out steps 1 and 2 as above. Remove
fan assembly as in step 8. Remove the
2. Combustion Chamber
Unscrew four self tapping screws securing
the sealed chamber front panel and lift
over top corner locating lugs. Unscrew four
self tapping screws to release combustion
chamber front plate and lift clear.
three screws securing the angled top of the
hood to the chassis. Lift and remove taking
care not to snag the pressure switch cables.
Re-assemble in the reverse order ensuring
that the hood is located behind the combustion chamber rear panel.
Reassemble in reverse order.
10. Pressure Switch
3. Burner Manifold
Carry out steps 1 and 2 as above. Remove
two screws securing the closure plate and
2
1
the remaining four screws to release the
manifold. Lift clear. Replace the manifold
gasket. Reassemble in reverse order.
4. Ionisation Electrode
Carry out steps 1 and 2 as above. Loosen
screws securing the closure plate and
remove. Disconnect the lead from the main
wiring loom. Remove screw securing electrode to burner. Thread wire through grommet and lift clear. Reassemble in reverse
P
order.
6
2
1
points are located on the boiler.
1 = DHW circuit drain point
2 = Heating circuit drain point
(Pressure releave valve)
13. Water filter ( Heating and DHW)
The C/H filter ensures a seal between
the return tail and the tap 5 Fig. 2
unscrew the pipe nut and the tap nut.
Pull the tap toward you and remove the
C/H filter
The DHW filter is located in the DHW
command 37 Fig. 2 on the right hydraulic
assembly. Remove the clip and pull
toward you the DHW command remove
the plug and clean the filter. Reassemble
in reverse order.
DHW Flow switch
14.
Disconnect the electrical connections
undo the securing clip and remove the
microswitch reassemble in reverse
order.
15. Pressure relief valve
Drain the boiler f rst, unscrew the safety
valve head with a 24 mm spanner.
Reassemble in reverse order.
Page 7
Supplied By www.heating spares.co Tel. 0161 620 6677
16. 3-Way valve
Drain boiler as in step 12. Remove the 2
clips on the 3 way valve hydraulic motor
17 (fig. 6). Pull up the motor .Turn anticlockwise the 3 way valve body, rise it up
using a screw driver and remove it.
Reassemble in reverse order.
17. Secondary heat exchanger 20
20. Pump
Drain the boiler as in step 12. Open the
electrical box cover removing the 2
screws. Remove the main lead connection. Open the electrical box, 2 clips G
F
Drain both circuits of the boiler as in step
12. Unscrew the 2 fixing screws D and
remove the DHW exchanger from the
front. Prior to reassembly, check that the
4 gaskets are correctly positioned. The
heat exchanger is so designed that it
cannot be remounted incorrectly.
18. Main heat exchanger
E
Carry out steps 1 and 2 as above. Drain
boiler as in step 12. Remove the 2 clips
E located on return and flow pipes and
pull them downwards. Pull the main
exchanger toward you to remove.
Reassemble in reverse order
19. Expansion vessel
Remove the casing as step 1 and drain
the boiler as step 12 above. Unscrew the
connecting nuts and lift out the boiler
from the wall. Place it on a side on the
floor. Remove the expansion vessel
bracket retaining screws, disconnect the
pipe from the vessel and pull it toward
you. Reassemble in reverse order.
G
D
Remove the pump plug from the control
board and earth plug from earth socket.
Pivot the electrical box downwards.
Unscrew the nut F of the flow pipe from
the volute. Remove the clip H on the
pump volute and pull pump toward you.
Remove the back clip.
Reassemble in reverse order.
21. Thermistors
Drain the boiler as step 12. Disconnect
the plug, remove the retaining clip pull
the thermistor out
Reassemble in reverse order.
Carry out step 1, open the electrical box
cover as mentionned in step 5. unplug all
cables from the PCB remove earth plug
from earth socket undo the screw f xing
the PCB. Hang out the control board.
Reassemble in reverse order.
23. Safety thermostat
Remove the casing as step 1 unscrew
four self tapping screws securing the
sealed chamber front panel. Disconnect
the 2 cables, pull out the sensor with the
clip 13. Reassemble in reverse order.
18
H
13
24. R2i mini cylinder
You have to remove the hydraulic bloc.
Carry out steps 1 and 2 as above.
Drain the cylinder by removing the drain
plug J. Remove the 3 way valve as in
step 16. Remove all the connections of
main wiring. Remove the lid of connections box K. Disconnect the pump from
10
electronic circuit. Remove the manometer. Unscrew the nut L of the pipe
between the pump and the primary heat
exchanger. Remove the gas pipe by
unscrewing the two nuts M.
Remove the gas block by removing the 4
screws. Unscrew the last nuts of connection from the pre-installation gig.
Remove the two fastening screws of the
hydraulic block from the frame.
Pull all the hydraulic block toward you by
inclining it slightly. Remove the two clips.
Unscrew the two nuts fixing the cylinder
Reassemble in reverse order.
JK
LM
7
Page 8
Supplied By www.heating spares.co Tel. 0161 620 6677
the next page
Please go to
Yes
Ok
PLEASE CHECK CAREFULLY FOLLOWING POINTS BEFORE
GOING THROUGH THE FAULT FINDING CHART
-Gas pressure
-Electric mains
-Minimal water pressure in the heating circuit (over 0.8 bar)
- All isolating valves opened
- Boiler air vented
-Minimal domestic hot water flow of 2 l/min at 0.5 ba
-Check that the heating filter is cleaned
- Put all buttons on OFF position (turn them anticlockwise)
Anytime the display can show an error code,
Please try to solve the problem and then press
Reset to make a new self test and start the boiler again
No
means a test or a choice
means an action
means a group of actions
No
Flashe?
Does the display
Ok
DHW on
mode on and turn
Switch the Domestic Hot water
Could you ear the
spark generation?
Yes
Does the fan run ?
Yes
with a flow of 3 l/min
Draw of Domestic Hot Water
Does the pump run ?
Check contact of
between P and 2
air pressure switch
No
The fan stops after 45s
- Check pressure probes or
- Check Flue duct condition or
- Replace pressure switch
The display flashes on 40/60/80
erator energize
Does the spark gen-
Yes
ignition electrods assembly
Replace spark generator or
No
switch
Check heating f ow
No
The display flashes on 60/70/80.
Replace heating flow switch, o
Check the plates exchanger
(Scaled)
Replace PCB
thermistor
Check the heating
No
50/70/80 or 50/60.
The display flashes on
Check contact of air
pressure switch between P
No
40/60/70.
The display flashes on
Replace the heating thermistor
Ok
and 1
Replace the air pressure switch.
No
and 1
Check if there is voltage
at between connectors P
No
Replace the PCB or the wiring
Check if there is
Yes
voltage at the fan
Replace the fan
FAULT FINDING CHART Part 1
Yes
alight ?
Does the green LED
Put the main switch on 1
No
- Check mains inlet
alight ?
Does the red LED
Yes
Ok
No
connection
- Check internal fuses
- Check main switch on PCB
Yes
Ok
and solve the problem
Please refer to the error list
a new self test and reset
Press on reset button to make
Replace the PCB
No
f ow switch
Check the DHW
No
f ow switch
Replace the DHW
Ok
No
The display flashes on 50
No
Ok
f ow switch
Check heating
switch
Replace the heating f ow
Ok
Check that the
pump spins free
pump electrical box
Check voltage in the
No
Release pump rotor
Ok
Replace pump
Ok
Replace the PCB
8
Page 9
Supplied By www.heating spares.co Tel. 0161 620 6677
Stop to draw water at the tap
potentiometerto maximum position,
- Switch OFF the DHW mode,
- Rotate clockwise the heating
- Press on RESET button to cancel all delays.
Yes
LED alight ?
Does the orange
heat.
- Insure that external controls are calling for
Yes
outlet pipe
Does the heating
temperature rise ?
Yes
alight ?
Does heating LEDs
The boiler is OK
FAULT FINDING CHART Part 2
No
Yes
Does DHW
temperature over 50°C ?
DHWpotentiometer close
- Rotate counter to clockwise
becomes stable.
to the minimum.
3l/min on a tap.
- Adjust the DHW flow rate a
- Wait until the temperature
Yes
No
Does the DHW
temperature rise ?
Ok
thermistor
Check DHW
No
Replace DHW thermistor
No
Replace PCB
main exchanger
Replace the domestic hot
water heat exchanger or the
No
40/50/60/80
The display flashes on
No
valves
Replace PCB
Check or replace the 3 ways
Yes
No
LED alight ?
Does the orange
From the previous
page 8
No
Does the burner
alight more than 6 sec.?
Yes
Replace PCB
Does the red LED
No
Check the wire or
Yes
alight and 80 ?
Does the red LED
alight and 70/80 ?
No
Replace PCB
replace overheat sensor
Yes
reset button
Purge gas pipes and press on
9
Yes
Does safety gas
No
Is there a gas
solenoïds energized ?
No
Replace PCB
Replace gas solenoïds
Yes
pressure at manifold ?
Ok
electrod
check the ionization
No
assembly
assembly
Replace electrod
Replace PCB
Page 10
Supplied By www.heating spares.co Tel. 0161 620 6677
Incorrects functions is signalled by leds (rep 26) display flashing correspond with chart below
CODEFAULTINFORMATION
30 40 50 60 70 80
INCORRECT FUNCTION
mm mm mm mm mm ll
mm mm mm mm ll mm
mm mm mm mm ll ll
mm mm mm ll mm mm
mm mm mm ll mm ll
mm mm mm ll ll mm
mm mm mm ll ll ll
mm mm ll mm mm mm
mm mm ll mm mm ll
mm mm ll mm ll mm
mm mm ll mm ll ll
mm mm ll ll mm mm
mm ll mm ll mm ll
mm ll mm ll ll mm
mm ll ll mm mm ll
mm ll ll mm ll mm
mm ll ll ll mm ll
mm
LED off
=
ll
=
LED blinking
Overheating safety feature
Overheating defect without locking
Misfiring safety featur
Fire detection without burner working
Besides freezing pump
Besides freezing burnerr
Lack of water circulation.
Primary water circulation defect
Thermistor sanitary open
Thermistor sanitary bypassed.
Thermistor inlet heating open
Thermistor inlet heating bypassed
Extractor on and pressure regulator at rest
Extractor off and pressure regulator at rest
Thermistor cylinder open
Thermistor cylinder bypassed
Distribution valve stuck on heating
10
Page 11
Supplied By www.heating spares.co Tel. 0161 620 6677
Supplied By www.heating spares.co Tel. 0161 620 6677
This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.
Chaffoteaux & Maury are continuously improving their products and therefore reserve the right to change specifications without prior
notice and accepts no liability for any errors or omission in the information contained in this document.
Manufacturer:Chaffoteaux & Maury - France
Commercial subsidiary:MTS (GB) Limited
MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT