Chaffoteaux & Maury Celtic FF Installation And Servicing Instrucnions Download

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Summary of Contents for Celtic FF

Page 1: ... BOILER G C No 47 980 01 FROM SERIAL N 391061863 This appliance has been tested and certificated by British Gas For use on natural gas only I lil Ill Installation and Servicing Instructions leave these instructions with the user Looking Good Heating Better ...

Page 2: ...t High efficiency Special jig plate enabling all pipework to be installed before installing appliance Independent control over central heating flow tempe rature and hot water Fully adjustable central heating flow temperature regulation between 50 C and 82 C High limit thermostat for both boiler and hot water Integral frost thermostats to protect appliance Water flow switch to protect appliance Sui...

Page 3: ...ater outlet 15 mm copper Electrical supply 240 V 50 Hz fused at 3A Electrical input 195 watts Internally fused two at F2A BS4265 Weight _ _ Watercapacity _ _ I iiZs I 1 Ignition Anstoss continuous spark generator Electrode Chaffoteaux Ltd spark gap 5 mm Boiler thermostat EGO 82 C Boiler limit thermostat Sopac 85 C Hot water limit thermostat Sopac 57 C 3 C Safety overheat thermostat Tokoswitch 105 ...

Page 4: ...length Measure wall thickness T Add 74 mm this will give required length CL Mark plastic air duct for length L and cut off sur plus from plain end N B If extension sections are used ensure these are firmly pushed together see figs 3b and 3c Cut off same amount from aluminium flue duct plainend Flue extension accessory Part No 61061 I metre length Fig 2 REAROUTLET ASSEMBLY 1 Distance from internal ...

Page 5: ...tic hot wa ter closes the heating circuits and directs water to the secondary heat exchanger 10 Electricial box containing Mainsconnection Fuses Printed circuit board Connections for external controls Connections for fan pressureswitch and FlowSwitch Connections for pump 11 Solenoid valve Block on which 3 valves are mounted l 3 valve 1st stage valve heating and hot water blue 2 3 valve full output...

Page 6: ...The boiler is protected by a high limit thermostat 4 the operation of which interrupts the thermocouple and extinguishes the pllot If the high limit thermo stat operates it is necessary to manually re establish the oilot When there is a demand water flows through the water section part 35 of the change over valve 19 The inclusion of a venturi 24 produces high pressure under the diaphragm 231 causi...

Page 7: ...alves IO 11 and 12 There are 3 solenoid valves I the centre blue valve 11 fixed at l 3 of max rated output 2 the right hand hot water black valve 12 fixed at 213of maxi mum rated output 3 the left hand central heating orange valve IO which is variable up top 2 3 maxi mum rated output The gas admitted by the orange valve is varied by ad juster 6 FUNCTIONAL FLOW DIAGRAM 1 1 Switch 1 1 S Toff 1 siq S...

Page 8: ... v VIOLET BR BROWN W WHITE BOILER TH HOT WATER 8 BK 213 240V 1 I 1 III 2 EXTERNAL CONTROL PRINTED CIRCUIT B R B 240 V SELECTOR SWITCH r 4 I r u WATER FLOW 1 24V 1 e L xwITCH Or E Bk Ll Bk FAN CAPACITOR PRESSURE SWITCH I 3 BOILER THERMOSTAT HEATING Fig 9 ILLUSTRATED WIRING DIAGRAM L 8 ...

Page 9: ...re the installation of the boiler will be in an unusual location special procedures may be necessary and BS 5546 givesdetailed guidanceon this aspect A compartment used to enclose the heater must be designed and constructed specificallyfor this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose Details of essential features of cupboard compart ment...

Page 10: ...8 SYSTEM GUIDANCE General The low water content CELTICFFdual purpose boiler includes the expansion vessel safety overheat ther mostat temperature and pressure gauges and safe ty valve The thermostat is adjustable and on its maximum setting gives a nominal 82 C 180 F flow tempera ture Detailed recommendations for water circulation are given in BS5546 1990 Whilstthe boiler provides hot water there m...

Page 11: ...xpansion vessel is not a vent point At the design flow temperature and the initial system pressures quoted the maximum allowable system volume is75litres 3 5 3 6 3 7 3 8 If the water volume is not known and cannot be accurately assessed from manufacturers data the following volumes may be used to give a conservative estimate of the systemvolume Boiler 4 litres 0 8gals Smallbore pipework 0 3litres ...

Page 12: ...d be carefully checked for leaks and the appropriate action should be taken either as a repair or replacement The old open system has probably only been subjected to a pressure of 0 4 bar or less When you change to a sealed system where the charge pressure will be 1 0 bar and the running pressure exceeding 1 5 bar consideration should be given to the replacement of radiator valves with a pattern c...

Page 13: ...hat a specialsaturated heat exchanger in an indirect cylindermay be desirable Separate time and temperature control over hot water generated in this way can be achieved by the use either of two port valves or three port valves of a flow share or priority pattern seenotes on drawing It is also possible where the occupation of the house is variable to provide either for a small or large load This is...

Page 14: ... mounting screws with washers for flue turret N B i Extension flue assembliesare not supplied as standard and must be ordered to suit seesection 1 4 4 1 4 2 Fig 18 Positioning the boiler a Select the location for the boiler referring to the dimensions shown in 1 1 and 1 3 terminal location positions 2 4 fig IO b Checkflue length see1 4 figs 2 and 3 c Check clearance on external wall for flue termi...

Page 15: ...sing the plastic jig plate the piping system can be completed before the boiler is mounted a Attach plastic jig plate to bottom bracket using 4 6 mm x 10 hexagonal screws provided fig 21 b Fit copper tails and washers to jig plate the mains water inlet tail M is the shorter of the two 15 mm tails fig 22 c The water can either come from above or below using the standard tails provided The gas must ...

Page 16: ...Ensure 0 ring is in position within the occupants or cause damage to external electrical socket from heating return isolating components or wiring The pipe should be directed downwards Itmust notdischarge above anentrance or b Fit safety valve and secure with grub window or any type of public access asthe temperature screw provides of the water being discharged may reach 100 C c Remove plastic tur...

Page 17: ...oned as shown see fig 26 within the cover N B NC 1 Terminal is not used zig 26 Making the electrical connection N B SeeSection 2 6 for electrical supply requirements THISAPPLIANCEMUSTBEEARTHED a Pullout fuses A b Remove two screws B c Opendoor to left hand side of electrical box d Cut the cable entries to the sizeof the cable being used which should not be lessthan 0 75 mm2 e Remove cable clamp f ...

Page 18: ...ig 28 Time clock Time clock and room stat The time clock contacts must be voltage free remove external links The room stat accelerator should be connected if fitted Supplvfuse valve 3 amp NB I X in table indicates no earth connection in time clock 2 Intable indicates that external links on time clock must be removed 3 in table indicates no spare connection in time clock so a connector will be requ...

Page 19: ...ure Live to re lay coil isthe wire in their literature which carries the si gnal to the boiler relay l 1 Jr boiler terminal block Fig 31 5 5 Frost thermostat The appliance is protected by integral frost thermostats It is advisable to protect the system from frost damage by fitting an additional remote frost ther mostat which will over ride the controls whilst the selector switch is set to hot wate...

Page 20: ... clean and replace N B Leave screw E in open position 13 Refill system as above lighting the boiler I Purge gas supply Switch on electrical supply 2 Turn the leveron the gasservicetap fig 34 0 to the left Inthe openpositionthe flame signisto the front 3 Temporarily locate the three blue control knobs one thermostat knob one ignition button extension and one temperature control knob 4 Switch to HOT...

Page 21: ... 5 Adjust Setting pressures are given in graph figs 37 and 38 The pressure will be reduced by clockwise movement of screw increased by anticlockwise movement Now select hot water only adjust temperature knob see fig 4 25 to minimum and open the largest volume draw off tap The gas pressure should now be the maximum as indicated in Technical Data Now reduce the water flow to minimum and check that t...

Page 22: ... 2 Remove control knobs used during testing and commissioning 3 Fit side panels A and secure with screws at bottom rear B 4 Put the control cover H in posrtion and secure with five screws 5 Fit the front top panel over the pins at the top of the boiler 0 and secure with two screws at the bottom D 6 Fit the various control knobs gas push button and domestic hot water temperature selector 7 To fit t...

Page 23: ...ted Isolate water supply and drain Appliance if required Remove front casing a Remove two screws A bottom rear of boiler b Remove screw B centre of lower front panel c Remove control knobs d Remove case by easing forward at bottom and lif ting off lugs at top If necessary remove the lower control cover 4 screws and lift off the upper front panel before removing case g 41 To remove combustion chamb...

Page 24: ... with an 0 ring 0 If the injector is replaced it is u fitted bright side uppermost e Ensure deflector plate CD is correctly located on the pilot Fig 44 To clean mains water inlet filter a Isolate from mains water and drain from valve A beneath the change over valve b Remove governor and filter B and C c Clean filter 0 grease governor spindle using a high temperature silicone grease N B Take care u...

Page 25: ... is lit check all gas connections for soundess j Allow the boiler to warm up thoroughly then check the burner pressure and adjust as necessary to that given inthetableforrequiredoutput seesection6 4 k Restore any sytem controls and clocks to their original setting The remove thermocouple a Remove front case see section 7 1 b Remove outer front panel see section 7 2 c Remove burner see section 7 3 ...

Page 26: ...tat and thermocouple see 8 1 d Withdraw noting route e Replace in reverse order Use heat sink grease between high limit stat and bracket B Fig 50 To replace ignition microswitch a Remove front case see section 7 1 b Remove outer front panel and combustion chamber front cover see section 7 2 c Remove burner see section 7 3 d Remove electrical control box see section 8 9 e Remove plugs from solenoid...

Page 27: ...witch assy a Remove air separator see section 8 13 b Disconnect high pressure tube at union A c Disconnect low pressure tube at union B d Undo retaining nut C e Remove assembly by lifting up and forward f Replace reverse order Fig 53 Fig 54 To replace venturi a Remove front case see section 7 I b Isolate from mains water and drain down from valve E c Undo union A at rear of change over valve d Loo...

Page 28: ...o change over valve h Unplug three leadsfrom ignition microswitch j Unplug connector of frost thermostat from PCB k Unplug connector from fan leadsat PCB I Remove one screw D andtwoscrews E Electrical box support bracket to lower chassis m Carefully ease electrical boxfotwardto allow access t0 flow switch lead alsoto electrode at bottom rear of box n Disconnect lead from flow switch 01 Disconnect ...

Page 29: ...heat thermostat h Remove flow pressure tube 2 from heat exchanger to flow switch i Remove tube 3 from C 0 V to return valve N B Swingmicroswitch box to giveaccessto union nuts j Remove rear tube 4 from C 0 V to secondary heat exchanger k Unscrewunion nut 5 of mainswater inlet to C 0 V I Unscrew heating return tube nut 6 from C 0 V m Unscrew union nut 7 of C 0 V to secondary heat exchanger n Remove...

Page 30: ...p 0 Liftout float Fig 59a p Clean float and inspect valve q Replace in reverse order Ensure that washer is replaced in lower union of separator r Open flow and return valves Re pressurisesystemif necessary To replace boiler thermostat a Remove front case see section 7 1 b Remove five screws A and remove electrical box cover Unplug from the PCBthe single connector for the switch c Remove clip retai...

Page 31: ...valve beneath the changeover valve seesection8 11fig 58CH d Remove clip which retains phial in wet pocket e Remove phialfrom pocket f Easethermostat off moulded pegs and pull of spa de connections g Feed capillary through the control box having re moved the split grommet h Replacein reverse order Polarity immaterial To replace spark generator a Remove front casesee section 7 1 b Remove electrical ...

Page 32: ... of PCB h Remove by pulling to the left and forward disen gage from guide centre bottom and top Fig 64 j PullPCBforward k Replacein reverse order Fig 65 3 4567 Ilg 1 15h6 Ik 1 Summer Winter Switch 7 D H W Thermostat Capillarv 13 Igniter 2 Pump 8 ChangeOver Valve 14 D H W Thermostat 3 Earth 9 Push Button Ignition 15 Boiler Thermostat 4 BolterThermostat Caplllarv IO Solenoid GasValves 16 Limit Therm...

Page 33: ...sel see section 7 2 A B Cand D1 c Remove burner see section 7 3 d First slide out side linings followed by rear which is removed by easing upwards and sliding out from bottom e Replacein reverse order Fig 68 To replace fan a Remove casesee section 7 1 b Remove outer front panel seesection 7 2 c Remove 7 screws right hand side of combustion chamber and lift off side panel d Pulloff 4 spadeconnectio...

Page 34: ...heating flow andreturn valves and drain boi ler through safety valve see section 6 2 fig 34 FL c Remove protective cap and check pressure on Schroeder valve with gauge N B The setting pressure is0 65 bar 9 5 psi d To re pressurise use car foot pump or bicycle pump with adaptor e Refill and commission boiler Fig 72 Fig 73 solenoid valves To replace pressure gauge a Remove casesee section 7 1 b Clos...

Page 35: ...ee section 7 2 c Remove burner see section 7 3 d Replace in reverse order ensuring that the gasket is correctly positioned between the injector cover plate and the manifold To replace the burner manifold assembly a Remove the front case see section 7 1 b Remove the combustion chamber front panel to expose the burner manifold see section 7 2 a to c c Remove the two screws Fl and remove the closure ...

Page 36: ...on vessel AT A e Loosenupper securingscrew B support and loosen lower screw Slideout expansion vessel f Replace in reverse order engaging the thread of the flexible pipe before screwing fully home screws B Thevesselmust be central on the front panel g Re pressuriseexpansion vesselsee section 8 24 h Open flow and return valves If necessary re pressurisesystem To replace viewing window a Remove fron...

Page 37: ...t to gas section and ease bracket down to clear gas section h Slackenand undo the gas supply union D beneath gas section j Remove two screws R retaining gas section to combustion chamber base k Remove gas section by pulling forward m Reassemble in reverse order and check for gas soundness To replace the temperature gauge a Remove the front case see section 7 1 b The temperature gauge A is retained...

Page 38: ...r 1r yes L LA yes 4 I no no time delay purge combustion chamber 1 spark I check low speed no no 1r no Yes zero volts check AL 1st stage solenoid open I 1st stage solenoid open I time delay 5 sec max time delay 5 sec max 2nd stage solenoid opens I 2nd stage solenoid opens I 38 ...

Page 39: ...box Check electro de and lead for physical damage Is 240V a across red and blue igniter connection on printed circuit board Isolate supply is there continuity to pressure switch between two Check external fuse and or rectify Check connections to main switch iii Pilot injector is clean il Position of ii CA kn rl Measure millivolt output at thermo electric valve TEV greater than 12 limit thermostat ...

Page 40: ...EAD IN CONJUNCTION WITH SECTIONS 9 1 9 2 1 END Ensure microswitch is made yes Is there continuity across domestic hot water thermostat ii4L l Ensure water inlet pressure greater Check inlet filter and venturi for Fl Ensure all isolating valves and stop Check diaphragm is OK Replace if necessary 40 ...

Page 41: ... Seesection 2 4 4 Check and reassemble see section 4 10 VI Fanincorrectly located 5 Remove and refit correctly see section 8 22 vi Combustion chamber front cover not sealing 6a Tighten 5b Replacesealing strip vii Heat exchanger fins blocked 7 Clean see section 7 2 et 7 7 viii Neoprene gasket in turret not correctly fitted 8 Fit or refit see section 4 10 or missing I Central heating low flow temper...

Page 42: ...tion 7 5 iv Incorrect venturi fitted 4 Replacewith 5 4 mm diameter see section 8 7 v Hot water limit stat out of calibration 5 Replace see section 8 16 vi Solenoidsnot operating 6 Seesection 9 2 Flowchart 1 vii Pressure switch hunting 7 Replace see section 8 23 viii Low inlet gas pressure 8 Seesection 6 4 5 No main burner 7 Safety valve discharges i Lack of water flow ii Pump jammed iii No water i...

Page 43: ... out of calibration iii By passif fitted not regulated iv Blocked heat exchanger I See System guidance section 3 3 2 Replace see section 8 15 3 Adjust see section 6 5 4 Cleanor replace see section 8 8 11 Fanon high speed continuously i Defective printed circuit board I Replace see section 8 18 12 Lossofpressure shown on gauge i Leakon system ii Leakon appliance I Locate and rectify 2 Locate and re...

Page 44: ...hot water thermostat 57 C Heating thermostat 50 C 82 C Limit thermostat 85 C Pressure gauge kit Fan assembly Pressure switch kit Frost thermostat ll C Frost thermostat 3 C Flow switch Chaffoteaux et Maury Limited GC number 366421 366846 264591 264592 264593 264477 366865 264793 264828 264602 383722 366897 366933 264630 264637 264547 264552 264649 264556 265121 264882 264663 264664 264666 Trench Lo...

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Chaffoteaux & Maury Celtic FF, Installation And Servicing Instrucnions

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