Chaffoteaux & Maury CHALLENGER 30 OF Installation And Servicing Instructions Download | Manualshive

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Summary of Contents for CHALLENGER 30 OF

Page 1: ...CHALLENGER Open Flue Boilers 30 OF 50 OF GCN 41 980 72 GCN 41 980 76 installation and servicing instructions leave these instructions with the User or at the Gas Service meter ...

Page 2: ...y adjustable electronic temperature regulation bet ween60 Cand82 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 the date of installation The guarantee isvoidable if it is not installed in accordance with the recommendations made herein or in a manner approved by the manufac...

Page 3: ...6 3 127 5 500 20 Requiresa nominal 100 mm 4 in flue pipe Draught diverter is intergral and is suitable for flues to BS715 If flues to BS567 are used an adaptor will be required 15 mm compression fitting 22 mm compression fittings 30 OF 505 IiWhr I 85 gpm 50 OF 841 lit hr 8 08 gpm equivalent to 15 C 27 F temperature rise 30 m 98 ft 150 mm Seepage 7 240 V single phase 50 hz supply fused 3 amp 30 OF ...

Page 4: ...r Fig 1 PUMP INSTALLATION REQUIREMENTS General The installation of the boiler must be in accordance with the Gas Safety Regulations Building Regulations I E E Regulations and the Byelaws of the local Water Underta king It should be in accordance also with BS Codes of Practice and the British GasSpecifications for Domestic Wet Central Heating Systems and any relevant require ments of the localGasRe...

Page 5: ...m 2 ft of an openable window air vent or other ventilation ope ning Before installing the boiler to an existing flue system the flue system must be checked by applying a smoke match to the opening at the base of the flue system The flue pipe must not be closer than 25 mm I ins to combustible material For twin walled flue pipe the 25 mm I in distance is measured from the internal pipe ce with the f...

Page 6: ...int at the open vent junction with the system 3 6 Automatic Air Separator Chaffoteaux Limited strongly recommend the inclusion of a British Gasaccepted 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 pi pework The use of an enlarged T to create a low velocity point is ...

Page 7: ...ALTERNATIVE SYSTEM LAYOUTS Minimum Static Head 150mm PREFERED Syfi Ad be sQKWmospheric Minimum Static Head Refer to BS 5449 Part 1 1977 1 Cold feed 15 mm ...

Page 8: ...em by pass will be necessary to maintain the minimum flow rate Seesection 1 4 Important All external wiring to and from the boiler must be in accordance with the current edition of the IEEWiring Regulations 1 Fully pumped system independant control of central hea ting and hot water using two spring return motorised val ves SPRING RETURN CYL STAT YALYE D H W Fig 10 2 Fully pumped systems independan...

Page 9: ... framed building it shotid beWted in accordance with the British GasPublica tion Guidefor s Installations in Timber Framed Housincja reference DM2 lf in doubt advice must be sought from the local GasN n of British Gas Fitting the boiler a Remove the front case by 1 Remov g2 screws bottom rear of boiler Al 2 Removing 2 screws securing front casing to elec trical box CBI b Remove case by putting out...

Page 10: ...s page 8 f Clamp wires with cable clamp g Replacecontrol box cover n b The length of the earth wire between the cord an chorage and the terminal must be such that the live and neutral wires become taut before the earth wire if the supply cord is pulled Resetting 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 ...

Page 11: ...low but ensure that the minimum flow rate through the boiler is achieved See1 4 page 3 Thisis equivalent to a temperature rise across the boiler of 15 C 27 F Set boiler thermostat to maximum b Fire the boiler with the by pass fully closed and the system on full load i e central heating and domestic 5 4 Gas rate adjustment Tobe carried out before adjusting by pass n b The boiler is supplied rated a...

Page 12: ...ylinder shall be the indirect coil type which issuitable for the system pressure ExpansionVesselVolume litres 2 1 3 5 8 5 13 7 2 7 4 2 7 0 12 9 27 5 5 4 6 3 10 5 19 4 41 3 8 2 8 3 14 0 25 9 55 1 10 9 10 4 17 5 32 4 68 9 13 6 12 5 21 0 38 8 82 6 16 3 14 6 24 5 45 3 96 4 19 1 16 7 28 0 51 8 110 2 21 8 20 8 35 0 64 7 137 7 27 2 25 0 42 0 77 7 185 3 32 7 29 1 49 0 90 6 192 8 38 1 33 3 56 0 03 6 220 4 ...

Page 13: ...3 5 Ibf ir Release water from the system until the initial system design pressure is attained taking into account any dif ference in height between the pressure gauge and the point at which the pressure vessel isconnected Light the boiler asdetailed 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...

Page 14: ...insvoltage circuit I Transformer Printed Circuit Board 1 Temperature SequenceControl Ignition Electrode Fuse2A External Controls Thermoelectric Valve 240V 50Hz Fig 20 Thermistor temperature sensor LB Thermocouple Electrode Solenoid valves Blue n Thermo electric y Control box valve ro Q External control high limit thermostat Fig 21 14 ...

Page 15: ...ve six screws securing front panel of combus tion chamber b Remove panel by easing forward at bottom and di sengage from draught diverter by pulling downwards c Replacein reverse order Remove burner assembly a Remove two screws securing burner manifold to gas section A and 2 outer screws U 50 OFonly b Remove gasket and retain in safe place c Remove 2 screws B securing burner head to rear chassis d...

Page 16: ...ic valve by unscrewing nut IO mm f Disconnect from overheat thermostat by pulling connections apart g Replacein reverse order Replace high limit thermostat a Remove front cover 7 1 and electrical control box 8 10 b Remove two screws A securing overheat assembly c Disconnect at pin connectors by pulling apart d Remove sensor from dry pocket first removing split pin e Replace in reverse order using ...

Page 17: ... cover 7 1 b Remove electrical control box 8 10 c Remove plug from microswitch d Remove screws B retaining microswitch e Replacein reverse order To replace heat exchanger a Drain system b Remove front cover 7 1 c Remove combustion chamber front panel 7 2 d Remove burner manifold and burner 7 3 e Remove high limit thermostat phial left hand side E f Withdraw thermostat phial right hand side F g Uns...

Page 18: ... reverse order taking care to replace plugs in rear of control box n b Care should be taken to ensure correct location of the ON OFFand reset buttons To replace thermostat a Isolate electrical supply b Remove front cover 7 1 c Unscrew knurled ring A retaining thermostat phial and remove phial d Unplug from rear of control box e Replace in reverse order using heat sink grease on the sensing phial T...

Page 19: ...35 36 37 43 109 118 119 163 186 IB 26 36 21 Description GC Number Part Number Screw front case electrical box securing Screwfrontcase chassis Temperatureselectorknob Doorassembly30OF Doorassembly50OF Nut3 4 BSP Olive 22 mm Mountingbracket Cableclampbracket Cableclamp Screwscable clamp securing Gasfilterwasher Gasservicecock Olive 15 mm Nut1 2 BSP Thermistortemperaturesensor High limit thermostat T...

Page 20: ...Pees main burner light I Change limit a I Is the pump wired 0 tothe boiler I between terminal 5 and terminal 6 in the boiler n Imp C M Ref 92220 l 27 1185 ...

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