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

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Summary of Contents for CHALLENGER 30 BF

Page 1: ...CHALLENGER Balanced Flue Boilers 30 BF 40 BF GCN 41 980 71 GCN 41 980 75 installation and servicing instructions leave these instructions adjacent to the gas meter ...

Page 2: ...ation high flame low flame Pump overrun Low resistance High limit thermostat 1 Guarantee The manufacturer s guarantee on the appliance isfor 24 months from the dateof installation The guarantee isvoidable if it is not installed in accordance with the recommendations made herein or in a manner approved by the manufacturer 1 1 TECHNICAL DATA return Tflow F J c Cl A 6 C D E F G H J K L M N 0 LLENGEI ...

Page 3: ...Minimum static head 150 mm 6 ins Seepage 7 Electrical connection 240 V single phase 50 Hzsupply fused 3 amp Weight 30 BF 18 18 kg 40 Ibs 40 BF 20 kg 44 Ibs Watercapacity _ 0 5 lit 0 11 gals Manifold Injector Size 30 BF 1 18 mm 0 046 ins 40 BF 1 08 mm 0 042 ins Pilot injector 0 3 mm 0 011 ins Ignition Continuous spark spark generator ANSTOSS Electrode ___ Chaffoteaux spark gap 5 0 mm Boiler thermos...

Page 4: ...OTENTIOMETER TEMPERATURE L I TIME DELAY 2SI FPrl m r I Fig 1 L TIME DELAY PUMP OVER RUN r PUMP 2 INSTALLATION REQUIREMENTS 2 1 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 f...

Page 5: ...NGER 30 requires 1 1 m3 h 37 fts h CHAL LENGER40 requires 1 4 m3 h 49 ft3 h of natural gas The meter and supply pipes must be capable of delive ring this quantity of gas in addition to the demand from any other appliances in the house The complete installation must be tested for soundness as described in CP331 3 Flueing Detailedrecommendationsfor flueing aregivenin BS544O l The following notes are...

Page 6: ...ic 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 recommended The preferred arrangement is shown in fig 9 3...

Page 7: ...Minimum Static Head 150mm Static Head PREFERED _ Static Head Static Head Refer to BS 5449 Part 1 1977 Air seperator or formed low velocity point 1 Cold feed 15 mm 2 Open vent 22 mm ...

Page 8: ...intain 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 I E E wiring regulations 1 Fully pumped system independant control of central hea ting and hot water using two spring return motorised val ves PROGRAMMER PUMP BOILER TERMINALS Fig 10 2 Fully pumped systems independant control of central heating and ...

Page 9: ...ing boiler as templa te cut hole for air duct b If the hole is cut accurately there will be no necessity to line the hole since the air duct will make a satisfac tory seal Assembling the balancedflue set NB For walls 355 mm 14 or less use the air duct body and cover supplied with the appliance For walls over 355 mm 14 ins up to 600 mm 24 ins a 24 flue assembly is available alternatively the flue e...

Page 10: ...bend c Fit two brackets to top of boiler using screws provi ded A 4 6 1 d Fit cable clamp bracket below boiler A 4 8 using screws and paint cutting washers provided NB Paint cutting washers must be used to maintain the earth bond Fitting the boiler 30 BF a Measure down from base of the air duct page I for bottom fixing Mark drill rawplug and fix bottom bracket b Offer boiler to wall resting on bot...

Page 11: ...t e Ensure that the flue bend sits evenly and securely on the heat exchanger secure flue bend with the two screws previously removed 4 7 3 Assembling the flue duct and bend walls 355 mm to 600 mm 14 to 24 ins 14 ins flue as sembly plus extension kit Overlap 50 mm 2 ins a The flue duct is telescopic and comprises 3 pieces it should be extended to a length equal to the wall thickness plus 100 mm 4 i...

Page 12: ...ome taut before the earth wire if the supply cord is pulled Maik Pump 4 11 Resetting high limit thermostat L El reset 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 re setting the high limit thermostat by pressing the red buttom in hole on electrical panel c Establish cause and rectify see f...

Page 13: ...ressu res 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 OFFand refit pressure test point screw and volume regulator cap Test for gas leakage around pressure test point g Mark the data badge to indicate output to which boi ler has been set h Replace case Particular attention must be gi...

Page 14: ...r than the top point of the system and connec ted 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 accessto make up vessel would be difficult by pressurisation of the system 6 6 Mains Connection There shall be no connection to the mains supply or to the water storage tank supplying domestic water even through ...

Page 15: ...essure vessel is connected 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 whilst still hot The system should again be filled and inhibitor added to the system if required in the specification see 3 9 clea red of air locks and adju...

Page 16: ...rature Sequence Control External Controls Thermoelectric 240V 50 Hz Fig 20 Valve Fig 2 Thermocouple Electrode Solenoid valves d v b7l I Thermistor temperature sensor White I I 4 22 Blue I I I I I I White Ignition JJ Red White I I I B Thermo elecrnc I I UM a 1 thermostst rol box control 16 ...

Page 17: ...ix screws securing front panel of combus tion chamber b Remove panel by easing forward at bottom and di sengage from flue hood by pulling downwards Remove burner assembly a Remove screws securing burner manifold to gas sec tion A 30 BFand screws A and B end of manifold in the 40 BF b Remove manifold and gasket and retain in a safe c Burner can now be removed To remove pilot a Release thermocouple ...

Page 18: ...rder taking care to replace rub ber seating BFonly Replace high limit thermostat a Remove front case7 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 a heat sink grease on the sensing phial Replace spark electrode and lead a Re...

Page 19: ...move burner manifold and burner 7 3 e Remove flue bend A f Remove overheat thermostat phial left hand side B g Withdraw thermostat temperature sensor right hand side 0 h Unscrew nuts on flow and return connections 0 Slackenfour screws securing combustion to rear chas sis j Drop assembly and withdraw forwards k Remove two screws from rear of assembly retaining heat exchanger to combustion chamber I...

Page 20: ...e a Isolate electrical supply b Remove front casing 7 1 c Remove cover on electrical control box 8 10 c d Remove and replace fuse e Reassemblein reverse order To replace PCB a Isolate electrical supply b Remove front casing 7 1 c Remove electrical control box cover see8 10 c d Remove plugs from rear of electrical control box e Easeforward PCB and remove spark electrode wire and earth wire from spa...

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Page 22: ...5 mm Nut1 2 BSP Fixing screw Bracket to case Thermistortemperaturesensor Foam gasket rearcase airinletduct Thermocouple assembly Electrode and lead assembly High limit thermostat assembly Printed circuit board Fuse 2amp 366713 65622 01 366688 64143 366649 64150 366553 64051 402327 45817 407715 34377 366035 13183 366558 47509 366559 47508 366250 40169 06 366 691 65485106 366564 65519106 366565 2783...

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