C&M Britony FlexiFlu User guide

Britony FlexiFlue
Room Sealed Balanced Flue
MULTI POINT WATER HEATER
GGAASSSSAAFFEETTYY((IINNSSTTAALLLLAATTIIOONNAANNDDUUSSEE))RREEGGUULLAATTIIOONNSS..
It is the law that all gas appliances are installed by a competant person
in accordance with the above regulations.
Nat G.C. N° 52 980 08
LPG G.C. N° 52 980 10
from serial number 894216759-04
IInnssttaallllaattiioonn
aannddSSeerrvviicciinnggIInnssttrruuccttiioonnss
((lleeaavveetthheesseeiinnssttrruuccttiioonnsswwiitthhtthheeuusseerr))
The model number and serial number of this heater are on the data badge which is found inside rear
case at lower left hand side.
These numbers should be used when ordering replacement parts.
CCOONNFFOORRMMSSWWIITTHHEEUURROOPPEEAANNSSTTAANNDDAARRDDEENN..2266
c
c

2
11..GGEENNEERRAALL
The Britony FlexiFlue is a room sealed, fanned balanced flue, multipoint water heater. The flue which is
100 mm (4”) diameter pipe, can be directed to the rear or to either side. The maximum recommended flue
length is 3 metres for straight application and 1,6 metres total when using a bend.
The appliance is for connection to a mains cold water supply having a minimum working pressure of 1 bar.
A permanent electrical connection is required and should be provided by use of a fused spur. The external
electrical supply should be via a double pole switch having 3 mm. contact separation in both poles. If the
appliance is installed in a bathroom the fused spur must be external to the bathroom.
When on pilot only the fan runs at “low speed” increasing to normal speed when there is a demand for hot
water. Included is a pressure switch, which operates if the fan stalls or if the flues is obstructed and a low tem-
perature sensor which will turn off the fan when the appliance is running on pilot only (fan low speed) in the
event of low air temperatures likely to cause freezing in the appliance.
NNoottee::Gas Safety Installation and Use Reg 1984. It is the law that all gas appliances are installed by C.O.R.G.I
registered persons in accordande 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.
11..11GGuuaarraanntteeee
The guarantee on this appliance is void if it is not installed in accordance with the recommendations made
herein or in a manner approved by the manufacturer.
A
B
C
D
E
F
G
H
J
K
L
M
N
P
S
T
V
W
X
mm
655
395
270
100
40
385
438
775
728
53
55
98
70
285
105
199
290
95
870
ins.
25.78
15.5
10.6
4.0
1.6
15.15
17.25
30.45
28.6
2.1
2.15
3.8
2.75
11.22
4.13
7.8
11.4
3.73
34.22
11..22DDiimmeennssiioonnss
A
F
W
G
J
K
H
X
V
B
T
P
M
L
S
cable entry
C
N
ED Ø
WATER
OUTLET
GAS WATER
INTLET

3
11..33TTeecchhnniiccaallDDaattaa
Heat input nomimal .......................................... 25,2 kW 85966 Btu/h
Heat output nominal ......................................... 22,7 kW 77452 Btu/h
Gas rate (maximum) :
. Natural gas (G20) 35,9 MJ/m3- 20 mbar ..... 2,67 m3/h 94,29 ft3/h
with manifold restrictor ................................. 6,1 mm diam.
. Butane (G30) 45,6 MJ/Kg - 28-30 mbar...... 1,99 kg/h
. Propane (G31) 46,4 MJ/Kg - 37 mbar ......... 1,96 kg/h
Main burner injectors :
. G20 .............................................................. 1,28 mm diam.
. G30 - G31..................................................... 0,74 mm diam.
Pilot injector marking G20................................. 26
G30 - G31....................... 15
Water flow rate - raised 50°C (90°F) ................. 3,2 to 6,5 l/min 0,7 to 1,43 gpm
Water flow rate - raised 25°C (45°F) ................. 6,5 to 13 l/min 1,43 to 2,8 gpm
Min. water pressure selector closed .................. 0,5 bar 16,5 ft (7,5 psi)
Min. water pressure selector open .................... 1,0 bar 33,0 ft (15 psi)
Max. water pressure ......................................... 10 bar 150 psi.
Electrical supply ............................................... 240 V - 50 Hz
fused 3 A
The minimum water pressure is for the correct operation of the appliance only. An additional allowance
must be made for the resistance of pipework and fittings particularly where showers and washing
machines are used. This should be equivalent to 2 m. (6,5 ft) head.
Water inlet (Compression type fittings) .............. Right hand connection 15 mm Copper
Water outlet (Compression type fittings) ............ Left hand connection 15 mm Copper
Gas (Compression type fittings) ........................ Centre connection 15 mm Copper
Height (including flue bend) .............................. 778 mm 30,6 in
Width ................................................................ 395 mm 15,5 in
Depth................................................................ 270 mm 10,6 in
Weight - Cartoned ............................................. 24,3 kg. 53,6 lbs.
Weight - Lift....................................................... 15 kg. 33,1 lbs.
Minimum clearances - top (above flue)............. 50 mm 2 in
- bottom (below case) ..... 178 mm 7 in
- sides.............................. 25 mm 1 in
- front .............................. 600 mm 24 in
Hole for the air inlet duct .................................. 102 mm diam. 4,2 in. diam.
The Britony FlexiFlue is supplied in one carton.
Compartment ventilation not required.

4
22..IINNSSTTAALLLLAATTIIOONNRREEQQUUIIRREEMMEENNTTSS
22..11RReellaatteeddDDooccuummeennttss
The installation of the heater must be in accordance
with the relevant requirements of the Gas Safety
(Installation and Use) Regulations. Building
Regulations and the current Byelaws of the local
water undertaking. It should be in accordance with
the current British Standard Codes of Practices Local
Authority Building standard (Scotland) regulations,
and the safety document 635, the electricity at work
regulation. Detailed recommendations are contained
in the following British Standard Codes of Practice :
BS 6400 : BS 5546 : BS 5440 : Pt. 1 : and Pt2 : BS 7671 - BS OM2.
22..22LLooccaattiioonn
The location chosen for the appliance must permit
the provision of a satisfactory flue termination The
location must also permit adequate space for servi-
cing and air circulation around the appliance.
The appliance may be installed in any room or inter-
nal space although particular attention is drawn to
the requirements of the current BS 7671 and, in
Scotland, the electrical provisions of the Building
Standards applicable in Scotland, with respect to the
installation of a heater i a room or internal space
containing a bath or shower.
Where a room sealed appliance is installed in a
room containing a bath or shower, any electrical
switch or appliance control, utilising mains electrici-
ty should be so situated that is cannot be touched by
a person using the bath or shower.
Where the installation of the appliance will be in an
unusual location special procedures may be neces-
sary and BS 5546 gives detailed guidance on this
aspect.
22..33GGaassSSuuppppllyy
An adequately sized gas meter must be connected
to the service pipe. Where necessary the local Gas
Region of British Gas will arrange for the existing
meter to be checked or for a suitable meter to be
installed. On no account must any work be carried
out on the gas meter other than by BRITISH GAS or
their specifically authorised contractor.
Installation pipes should be fitted in accordance with
BS 6891. Pipework from the meter must be of ade-
quate size. Pipes of a smaller size than the gas
connection should not be used. Gas supply pipes in
excess of 3 metres use 22 mm pipe.
The complete installation must be tested for gas
soundness and purged in accordance with BS 6891.
22..44SSiittiinnggtthheeFFlluueeTTeerrmmiinnaall
The flue must be installed in accordance with
BS 5440 : Pt. 1.
The following notes are intended to give general gui-
dance.
The standard flue set is suitable for walls having a
thickness of 75 mm (3 in.) to 612,5 mm (24 in.) for
rear outlet fluing or up to 500 mm (19,5 in.) for side
outlet fluing. Other flue options are available to a
maximum of 3 m (9 ft. 8 in.) to special order.
The appliance must be installed so that the flue ter-
minal exposed to external air. The appliance must
NOT be installed so that the terminal discharges into
another room space such as an outhouse or lean-to.
It is important that the position of the terminal
allows a free passage of an across it all times.
The minimum acceptable spacings from the termi-
nal to obstructions and ventilation openings are spe-
cified in the following chart. Also see Section 3.4.
T
Te er rm mi in na al lp po os si it ti io on ns sM Mi in nc cl le ea ar ra an nc ce es s
A Directly below an opening, windows etc
or adjacent to an opening 300 mm
B Below gutters soil pipes or drain pipes 75 mm
C Below eaves 200 mm*
DBelow balconies or car port roof 200 mm*
E From a vertical drain pipe or soil pipe 75 mm
F From an internal or external corner 300 mm*
G Above ground roof or balcony level 300 mm
H From a surface facing the terminal 600 mm
J From an opening in the car port
(e.g. door or window) into dwelling 1200 mm
K Vertically from a terminal on the same
wall 1500 mm
L Horizontally from a terminal on the
same wall
* (107 mm) minimum clearance using kit N° 76216.00 (G.C. 264 833)
NNoottee--Where the terminal is fitted within 850 mm
(34 in.) of a plastic or painted gutter or 450 mm
(180 in.) of 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 situa-
ted must be protected by a guard of durable mate-
rial (a terminal guard is available from Quinnel
Barrett & Quinnel. 0171 639.1357 (GC No 381.
782)
The air inlet/products outlet duct and the terminal of
the appliance must not be closer than 25 mm (1 in.)
to any combustible material. Detailed recommenda-
tions on the protection of combustible material are
given in BS 5440 Pt. 1.
IIMMPPOORRTTAANNTTNNOOTTIICCEE::TIMBER FRAMED
HOUSES. If the appliance is to be fitted in a timber
framed building it should be fitted 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 British
Gas.
22..55WWaallllMMoouunnttiinngg
The appliance should be installed on a flat non-com-
bustible material which not reverberate. What ever
the thickness of the wall a hole 107 mm (4.2 in.) in
diameter will be required for the appliance flue
assembly. It is recommended that a core drill be
used to form this hole.
For dimensions are clearances see sections 1.2 and 1.3.

5
22..66FFlluueeTTeerrmmiinnaallAAsssseemmbbllyy
The flue may be fitted from inside or outside of the
building. If fitting from inside the flue duct should be
assembled into the air intlet duct and the assembly
passed trough the hole in the wall. The outside dia-
meter of the terminal is the same as outside diame-
ter of the air inlet duct.
22..77AAiirrssuuppppllyy
The appliance does not require any purpose provi-
ded ventilation.
22..88EElleeccttrriiccaallCCoonnnneeccttiioonnss
The appliances must be earthed.
The installation should be undertaken by a compe-
tent electrician and should be in accordance with the
current edition of B.S 7671.
Particular attention should be paid to cross bonding.
The appliance must be provided with a means of
isolation. If installed in a bathroom the means of iso-
lation must be external to the bathroom or a double
pole cord switch fitted.
Acceptable methods of connection are :
1. A switched, double pole fused spur with 3 mm
contact separation on all poles.
2. A double pole switch where the supply must be
suitably fused 3 A.
3. An un-switched socket outlet compling with
BS 1363.
The method of connecting the plug brown wire to
live (L) blue wire to neutral (N) and green/yellow
to earth ( ), see fig. 3.
A three core cable should be used and a heat resis-
ting cable of 0.75 mm2(24 x 0,2 mm) is considered
suitable.
The cable should be passed through the gland on
the top of appliance and the clamp tightened to
secure the cable. Ensure current carrying conductors
become taught before earthing conductor should
cable slip from the cord anchorage. Connection to
the appliance should be made in accordance with
diagram (see section 3, 8, 2).
22..99DDeessccrriippttiioonnooffOOppeerraattiioonn
Read in conjunction with figs 1, 2 and 4).
The controls on the Britony FlexiFlue comprise of a
range of thermal, electric and electronic switches.
Broadly, the thermal controls are for the pilot flame
supervision, the electrical controls are functional
switching and the electronic controls act as a securi-
ty for the functional controls.
The circuit is designed so that, under normal condi-
tions, the fan runs continuously at low speed and
automatically changes to high speed when the gas
valve opens. If, however, the incoming air tempera-
ture approaches 0°C the integral frost protection
thermostat interrupts the low fan speed signal.
Under this condition, if there is a demand for hot
water, then the fan recommences at high speed.
There is an in-built delay circuit to prevent the safe-
ty devices operating prematurely.
The pilot can only be established under the control
of the thermocouple flame failure circuit after the
mains electricity connection is made since it is
dependent upon the energising of relay-RL1.
If the air flow is not proved on high speed the flame
supervision device will operate by interrupting the ther-
mocouple as a result of the de-energising relay-RL1.
ELECTRIC SUPPLY
FROST
THERMOSTAT FAN PRESSURE
SWITCH
MICRO SWITCH RELAY
RL2
RELAY
RL1
GAS VALVE
THERMOCOUPLE
THERMO
ELECTRIC
VALVE
FFUUNNCCTTIIOONNAALLFFLLOOWWDDIIAAGGRRAAMM

6
THERMOSTAT FAN
MICRO
SWITCH
LN
D3
D2
D1R1 RL1
Com
C1
Com
Nc
No
R2
RL2
C2
TC
2A
THERMOELECTRIC
VALVE
LOW FLOW
HIGH FLOW
PRESSURE SWITCH
FFiigg..11
CCIIRRCCUUIITTDDIIAAGGRRAAMM
E
NL
FU
G
V
P
PR Nc1
No2
Com
YG
BM
TC
W
Bk
O
SW
Br
Bl
R

FAN
Y-G
Bk
O
W

V
G
P

Bl
Br
R
FU Fuse (2 A)
TC Thermocouple
BM Thermo-electric Valve
SW Microswitch
PR Pressure Switch
Y-G Yellow - Green
Br Brown
Bl Blue
R Red
W White
O Orange
Bk Black
V Violet
G Grey
P Pink
L
N
fuse 3A
NB : IF APPLIANCE INSTALLED IN A BATHROOM
SPUR MUST BE EXTERNAL TO ROOM

live
neutral
earth
NB : IF APPLIANCE INSTALLED IN A BATHROOM
SWITCH TO BE OF PULL CORD TYPE
heater
L
N
fuse 3A
live
neutral
earth
heater
double pole
switch
WWIIRRIINNGGDDIIAAGGRRAAMMEELLEECCTTRRIICCAALL
CCOONNNNEECCTTIIOONN
FFiigg..22FFiigg..33

7
L
N
FROST THERMOSTAT
FAN
N
LOW
HIGH
HIGH
LOW
NO FLOW
WATERFLOW
MICRO-SWITCH
2A
PRESSURE SWITCH

N
RL1

N
RL2
PRINTED CIRCUIT BOARD
THERMOCOUPLE
THERMOELECTRIC
VALVE
OOPPEERRAATTIIOONNAALLDDIIAAGGRRAAMM
FFiigg..44
33..IINNSSTTAALLLLIINNGGTTHHEEAAPPPPLLIIAANNCCEE
A vertical flat area is required for the appliance : 1006 mm high x 445 mm wide (39.6 in x 17.5 in). The surface
on which the appliance is mounted must be of a non combustible material.
33..11PPaacckkaaggiinngg
The appliance is attached to the wall via the mounting bracket and two bottom screw fixings. The appliance is pac-
ked in a single carton. Remove contents from carton and check against list.
11))APPLIANCE - Assembled with trims.
22))FLUE ASSEMBLY : a) Air inlet duct complete with terminal.
b) 2nd section flue duct (inside air inlet duct).
c) Flue turret with 1st section flue duct fitted.
d) Plastic turret cover.
33))ACCESSORY BOX - containing : -mounting bracket
- flue locking ring and ‘0’ ring seal
- 2 gaskets
- 4 wall mounting screws
- 4 turret fixing screws
- 2 turret cover fixing screws
- 1 gas control knob
- 1 temperature selector knob
- gas service tap assy (not supplied with LPG models)
- water service tap assy

33..33FFlluueeLLeennggtthhMinimum Wall Thickness 3 in (75 mm)
8
FFiigg..66
33..22PPrreeppaarriinnggaannddffiittttiinnggtthheeaapppplliiaannccee
PPrreeppaarraattiioonn::
- Remove the bottom trim by pulling forwards.
- Slide the controls facia plate (P) upwards to disen-
gage from retaining bracket.
-Release the front case by removing the four fixing
screws and washers positioned at the top, bottom
and centre of appliance.
- Remove the front case by lifting off the top locating
lugs and pulling forward to clear the water section
at the base of the appliance.
NNOOTTEE::
A template is not supplied with this appliance.
Particular care is therefore necessary to ensure that
the appliance mounting bracket is fitted level and
positioned accurately. When using extended flues,
a fall fo 5 mm per metre length should be provi-
ded. (From turret to terminal) (see Fig. 5).
- Refer to the drawings opposite for rear and side flue
applications and/or to the dimensions given.
- Set out an drill hole 290 mm (11.4 in) accurately
mark position for bracket.
- Drill and plug the wall.
- Fix bracket to wall using No. 12 screws provided,
ensuring that the bracket is level. If necessary
adjust bracket, finally secure in position.
- Hang the appliance on the bracket, and re-check for
level. Mark bottom fixing holes, removes applian-
ce, drill and plug the wall to suit No 12 screws.
- Re-hang appliance and secure with screws provi-
ded.
Rear Outlet Wall thickness Up to 612.5 mm Over 612.5 mm
Delivered with Extension available
appliance Pt No 1008520
Flue duct length = wall thickness + 25 mm
Air inlet duct length = wall thickness + 25 mm
Pt No. 1008520
Side Outlet EM Up to 500 mm 1401 mm 2300 mm
+ DM 500 mm to 1400 to 2300 to 2787
Deliv.1 extern. 2 extern. 3 extern.
With Pt No 2 x 3 x
appliance 1008520 1008520 1008520
EM = Wal thickness Flue duct length EM + DM + 130 mm
DM = Distance from wall to case Air inlet duct length EM + DM + 130 mm
FFiigg..55
EM
90 mm
EM DM

EM
90 mm
EM DM

3.5 ins

9
33..44OOtthheerrfflluueeaarrrraannggeemmeennttss
1. Distance from Internal corner 300 mm without
kit, 150 mm with kit no. 76216 (GC No. 264
833).
2. Distance below balconies or eaves 200 mm
without kit, 150 mm with no. 76216. (GC No.
264 833).
3. Appliance is normally supplied packed with stan-
dard 650 mm straight flue section. Additional
straight extention lengths of 1 metre. Part No
1008520 , can be used up to a total straight leng-
th of 3 metres. It is also possible to incorporate
one bend in the flue using Part No. 1008520. In
this case the length
L1 + L2 should not exceed 1,6 metres horizon-
tally, (see fig. 7).
33..55FFiittttiinnggtthheefflluuee
- Measure the wall thickness and cut flue duct and
air inlet duct to required length, (see Section 1.4).
- Peel off protective paper from adhesive side of
cork gasket (A) and place on mating side of flue
turret (B) lining up screw holes and press down.
- Fit locking ring (C) and “0” ring over the air inlet
duct, (see fig. 8).
- Fit flue duct and turret so that it engages into the
terminal.
- Engage locking ring over lugs by turning in an
anticlockwise direction viewed from behind tur-
ret.
- Position square channeled rubber gasket (E) on
the flue hood outlet of the heater, channel facing
downwards.
- Pass the assembled flue through the wall.
- If long flue sections are used (up to 3 metres) and
difficulty is found, these can be assembled whil-
st being passed through the wall.
- Seat the turret onto the top of the appliance ensu-
ring the gaskets are in position.
- Secure with 4 screws provided.
- Do not fit plastic turret cover or the front case until
electrical connections have been made and the
appliance tested for gas and water soundness
(see section 5.1).
- A sealing ring (D) is supplied which can be used
to seal the air inlet duct to wall joint-externally.
- Make good inside wall surface.
FFiigg..77
FFiigg..88
107 mm
107 mm
L2
L1
1- Plan View
3- Plan View
2- Side Elevation
D
C
E
A
B

10
33..66GGaassCCoonnnneeccttiioonn
- Fit the gas service cock provided using the fine fil-
ter/washer to seal the connection. Fit the nut and
olive onto the 15 mm gas supply pipe and tigh-
ten, (see fig. 9).
-Test the complete gas installation for soundness
and purge.
33..77WWaatteerrCCoonnnneeccttiioonnss
- Remove the plastic covers protecting the water
inlet and the water outlet connections.
- Fit the water service cock provided to the right hand
connection at the bottom of the appliance using the
coarse filter/washer to seal the connection, (see fig.
10).
- Fit the nuts and olives onto the supply and delivery
pipes.
- Connect the inlet supply to the water service cock and
tighten.
- The water service cock supplied with the appliance
incorporates a drain plug.
- Ensure that all water connections are fully tightened.
33..88EElleeccttrriiccaallccoonnnneeccttiioonnss
33..88..11PPrreessssuurreeSSwwiittcchh
- Connect the wires at the top of the appliance to
the pressure switch, (see fig. 11).
- The ggrreeyywire is connected to normally closed (NC
1) contact.
- The ppiinnkkwire to the normally open (NO 2)
contact.
- The vviioolleettwire to the common (P) contact.
- Fit the flue turret cover passing the wire through
one fo the slots provided and secure with the
screws provided.
- See figure.
33..88..22MMaaiinnssCCoonnnneeccttiioonn
- Pass 0.75 mm2heat resisting cable through cable
gland.
- The earth wire (open yellow) must be connected
to the earth pillar ( ) (see fig. 12).
- The live (brown) and neutral (blue) should be
connected as indicated into the terminal block.
- Check that component plugs are pushed home.
- Check for continuity, polarity and earthing.
FFiigg..99
FFiigg..1100
FFiigg..1111
FFiigg..1122
G
V
P

11
44..AAPPPPLLIICCAATTIIOONNSSOOFF
TTHHEEBBRRIITTOONNYYFFLLEEXXIIFFLLUUEE
The appliance is designed to serve a variety of hot
water draw off points including washing machines
and showers. The appliance can be connected to all
hot water draw-off points in the installation. If more
than one outlet is open simultaneously the total flow
of water cannot exceed that quoted in the Technical
Data.
The appliance is comptatible with most current auto-
matic washing machines but care should be taken to
ensure that the machine is capable of accepting
water at the design flow of the appliance. Hot and
cold fill machines normally require a hot water tem-
perature of 60° C (140 °F), the appliance producing
approximately 6.5 l/min (1.44 gpm) at this tempera-
ture. The advice of the washing machine manufactu-
rers should be sought but generally it is only neces-
sary to remove the water flow restrictor (if fitted) in
the hot water inlet connection of the machine to
obtain a satisfactory appliance operation.
Do not use the appliance with push on hand showers
that fit over existing hot and cold water taps or with
mixer taps unless both supplied come from the
same source. Showers forming part of bath mixers
are not recommended for satisfactory operation of
the appliance.
44..11PPiippeewwoorrkk
The following notes are for general guidance only.
(i) The appliance performance may be affected if the
installation has old pipework forming dead-legs
or air reservoirs. Always ensure that any old pipe-
work is either removed or capped off immediate-
ly adjacent to the pipework that will be in use.
(ii) The size of the pipework between the
appliance and the various draw-off points should
be sized to ensure an adequate flow at draw-off
points when used individually.
(iii) A check should be made of all stop cocks in the
incoming supply and it should be ensured that
they are of the fixed jumper pattern. Loose jum-
pers can be pinned or soldered into the position.
Britony Flexiflue
HOT
COLD
HOT WATER
COLD WATER
Mixing Valve
The appliance can be used to supply hot water to a
separate shower draw-off. The appliance should not
be used to supply more than one shower mixing
valve. The recommended pipework arrangement for
a single shower head is shown above and the hot
supply to the mixing valve should be the first draw
off. Suitable shower mixing valves are manufactured
by :
C
Ca ar ra ad do on nM Mi ir ra aL Lt td dB Ba ar rk ki in ng gG Gr ro oh he e
Cromwell Road, 1 River Road
Cheltenham Barking
Gloucester GL52 5EP Essex IG11 OHD
Tel : [phone] Tel : [phone]
A
Aq qu ua al li is sa aP Pr ro od du uc ct ts sL Lt td dN Ne ew wT Te ea am mL Lt td d
Horton’s Way Brunell Road
London Road Earlstree Ind Estate,
Westerham Corby
Kent TN16 1 BT Northants NN17 2LF
Tel : [phone] Tel : [phone]
M
Me ey yn ne el ll lV Va al lv ve es sL LT TD D, ,
Shaw Road
Bushburv
Wolverhampton
West Midlands
WV10 9LB
Tel : [phone]
(iii) If the appliance is installed on a supply or distri-
bution pipe containing a non-return valve, combina-
tions of check valve, or any equipment containing
such devices, then provision must be hade to acco-
modate an expansion of at least 4 % of the volume
of water contained within the installation.
(V) Expansion vessels must be fitted on the supply
pipe between the non-return valve, combinations of
check valve, or any equipment containing such
devices and the appliance.

12
55..CCOOMMMMIISSSSIIOONNIINNGG
55..11..11..Open the gas and water service cocks benea-
th the appliance, purge the gas supply (BS 6891).
Turn on an adjacent tap and purge the water side of
the installation.
Test for water soundess at all appliance and exter-
nal pipework connections;
Switch on electrical supply, fan will run at low
speed.
55..11..22..Remove Protective Film from casing before
use.
55..11..33..TToolliigghhtttthheeppiilloott,temporality fit the gas
control knob (A) and light the pilot by turning the
knob 90° anti-clockwise in « » horizontal position
(see fig. 13). It may be necessary to purge the pilot
gas supply, if so, wait a few minutes, return the gas
control knob to the «I» vertical position and repeat.
(The pilot supply will only purge when the gas
control knob has been turned 90° anti-clockwise in
« » horizontal position).
55..11..44..When the pilot is lit, turn the control knob
(A) fully clockwise to the « » position as
shown in the diagram (see fig. 14). Test for gas
soundness using leak detection fluid on all gas
connections.
55..11..55..CChheecckktthheeooppeerraattiioonnoofftthheeffllaammee
ssuuppeerrvviissiioonnddeevviicceeby blowing out the pilot
light, the flow of gas to the pilot will cease
and the thermoelectric valve should drop out
with an audible «click» within approximately
30 seconds.
55..11..66..Re-light pilot and check gas pressures
see Section 5.2.
55..11..77..Remove gas control knob (A).
55..11..88..Switch off electrical supply.
55..11..99..Fit front case by location bottom first
and ensuring top of case locates over brac-
ket. Secure with 4 screws and washers pre-
viously removed.
- The centre screw and plastic washer retains
the fascia mounting bracket.
- Replace the control fascia plate by sliding
down onto the support bracket.
- Fit bottom trim by sliding onto rails.
- Fit the gas control knob (A) and the tempe-
rature selector knob (B). The temperature
selector knob should be pushed onto the
spline until it locates. Turn fully clockwise
to (+), reposition knob as required, so that
indicator dot is opposite the (+) sign.
55..11..1100..Switch on electricial supply.
- Light the pilot and turn gas control knob (A)
fully clockwise to the « » main gas posi-
tion.
55..11..1111..Perform operations as detailed in
sections 5.3 to 5.7.
55..11PPuuttttiinnggiinnttooSSeerrvviiccee
55..22GGaassPPrreessssuurree
FFiigg..1133
FFiigg..1144
FFiigg..1155
- Turn on an adjacent hot water draw off, the
appliance will now light and the fan will
change to high speed.
- Check burner setting pressure at test point A
see Section 1.3 technical data (see fig. 15).
- If the burner setting pressure is not correct,
check that the pressure at the gas service
cock, test point B is 20 mbar (8. in. w.g.)
with the appliance operating. If the inlet
pressure is not correct, check for any pos-
sible blockage or restriction in the pipe-
work to the appliance. If the inlet supply
pressure cannot be corrected contact your
local gas region. The heat input to the
appliance is pre-set and non-ajustable.
A
B
A
A

13
55..33SSlloowwIIggnniittiioonn
-Check burner ignition which should be smooth and
quiet (not explosive).
- If slow ignition requires adjustment proceed as in
Section 6.1 to remove front case.
- Adjust slow ignition device A (see fig. 16) 1/4 turn
at a time. Refit front case and recheck operation.
NNOOTTEE::Turning screw A clockwise delays ignition.
55..44MMiiccrroosswwiittcchh
NNOOTTEE::During Commisionning it is important that the correct operation of the microswitch on the side of the
gas section is checked.
Whilst the microswitch is factory set, it may require adjustment. When the appliance is at rest the fan runs conti-
nuously at low speed. Check operation as follows - set temperature selector to - then open draw-off. The fan
should now come to high speed before the burner ignites. On closing draw-off, the burner should extinguish
before the fan resumes at low speed. If fan/burner operational sequence is NOT as described see Section 7.13.
55..55TThheePPrreessssuurreeSSwwiittcchh
Check the operation of the pressure switch as follows : Open draw off, fan comes to high speed and the bur-
ner ignites. Close draw off, burner extinguishes and when fan resumes at low speed listen for the “click” as the
relay changes over.This should be followed within 15 seconds by a lighter “click” as the pressure switck changes
over. If the time separation is greater than 15 seconds or if the pilot extinguishes it suggests that the pressure
switch is incorrectly set. (See Section 7.11).
55..66TThheerrmmooeelleeccttrriiccCCiirrccuuiitt
The Thermoelectric Circuit is fitted with an interrupter so that if the air flow is not proved on high speed the cir-
cuit is incomplete and the flame supervision device will operate. In the case of intermittant pilot faillure or per-
manent pilot failure the termocouple circuit can be checked with a British Gas Multimeter or suitable Millivolt
Meter to determine if the pilot failure is due to poor thermoucouple output, high resistance through Relay-1
contact or faulty thermoelectric valve. (See Section 2.9, fig. 1).
The thermocouple output measured at the Printed Circuit Board terminals should be greater than 12 millivolts.
The millivoltage drop through the relay (i.e. terminal to terminal) should not be greater than 4 millivolts.
55..77HHaannddiinnggOOvveerr
Hand all instructions to the user or purchaser and instruct in the correct and safe operation of the appliance.
Explain to the user or purchaser that if the appliance is not used for long periods it is recommended that the
appliance is drained, this is particulary important during the winter months (see servicing instructions for pro-
cedure to drain appliance).
Finally, advice the user or purchaser that, for continued efficient and safe operation of the appliance it is impor-
tant that servicing is carried out annually to the manufactures recomendations by a C.O.R.G.I. registered person.
FFiigg..1166
A

14
66..RROOUUTTIINNEESSEERRVVIICCIINNGG
To ensure continued efficient and sale operation of 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 competant person, such as British Gas, other C.O.R.G.I.
registered personnel or your local Chaffoteaux Service Centre in accordance with the Gas Safety (Installation and
Use Regulations). This routine service will normally be confined to :
1) Cleaning the burner.`
2) Cleaning the heat exchanger.
3) Checking the gas controls.
4) Cleaning water filter, and water governor.
5) Check diaphragm and replace every three years.
The following schedules are recommended :
a) Check the function of appliance, burner pressure, gas flow rate and soundness.
b) Observe flame picture and undertake combusion test.
c) Check clean or replace components as necessary.
66..11FFrroonnttCCaassiinngg
TToorreemmoovvee::
- Pull off gas control and temperature selector knobs.
- Remove controls facia plate by sliding upwards.
- Remove the four fixing screws which secure the front
case (top, bottom and centre) taking care not to lose
facia retaining bracket and washers.
- Remove to front case by lifting off the to locating lugs
and pulling forward to clear the water section at the
base of the appliance.
66..22BBuurrnneerr
- Remove the combustion chamber front panel as fol-
lows.
- Remove two threaded screws which secure the front
panel of the combustion chamber skirt to the flue
hood (A) Section 6.4.
- Remove three self-tapping screws on either side of
combustion chamber skirt (B) Section 6.4.
- Unscrew the pilot tube clamping screw (A) and remo-
ve the clamp and screw and pilot tube.
- Remove the burner manifold by unscrewing the two
screws and washers (C) (see fig. 17).
- Withdraw the burner head assembly taking care not
to damage the pilot burner/electrode assembly or the
ignition lead.
- The burner head should be turned upside down and
cleaned by brushing.
- Replace in reserve order making sure that the gasket
between the burner manifold and gas section is in
place and is in good condition. If necessary replace
gasket and ensure that the burner head assembly is
correctly located on the two spigots at the rear.
66..33PPiilloott
- Remove combustion chamber front panel, burner
and pilot tube as in 6.2. if not already removed.
- Blow through the tube to remove any dust.
- Remove screw securing spark electrode. Lift out off
“D” slot and ease to one side.
- Unscrew the knurled pilot burner outer ring (A).
- Remove flame retention gauze (see fig. 18).
- Unscrew the pilot body (B) with a 15 mm spanner.
Clean by brushing and blowing.
DO NOT CLEAN HOLES WITH A WIRE.
-Re-assemble in reverse order ensuring pilot body is
screwed down tightly.
FFiigg..1177
FFiigg..1188

15
66..44HHeeaattiinnggBBooddyy
aa))TThheehheeaatteexxcchhaannggeerrccaannbbeeeexxaammiinneeddiinnppoossiittiioonn::
(see fig. 19)
- Remove combustion chamber front panel as in
Section 6.2. if not already removed. Prior to clea-
ning the heat exchanger adequate precaution
should be taken to protect the pilot burner/gas
valve assembly to prevent the ingress of dust etc.
- If extensive cleaning is necessary, the heat exchan-
ger will need to be removed as follows.
bb))TToorreemmoovveehheeaatteexxcchhaannggeerr
- Slide out combustion lining and retain.
- Disconnect the unions on either side of the heat
exchanger.
- Remove two screws securing the combustion
chamber/heating body assembly to the rear panel.
- Remove heat exchanger and combustion chamber.
- Remove two screws at the rear of the combustion
chamber securing the combustion chamber to the
heat exchanger to seperate the components.
CCaarreesshhoouullddbbeettaakkeennwwhheennhhaannddlliinnggtthheehheeaattiinngg
eexxcchhaannggeerrttooeennssuurreetthhaatttthheeffiinnssaarreennoottddaammaaggeedd..
- Replace in reserve order.
FFiigg..1199
66..55DDeessccaalliinngg
Periodically it may be necessary to remove scale deposits from the waterways of the appliance to ensure conti-
nued and efficient operation.
The frequency will depend largely on the hardness of the water in each specific area. If this is necessary contact
your local water authority for advice.
Advice with regard to descaling is available from Chaffoteaux et Maury Ltd.
66..66MMaaiinnGGaassVVaallvveeTTooiinnssppeeccttaannddcclleeaann
- Remove the burner (see Section 6.2)
- Disconnect the thermocouple at the PCB and igni-
tor lead from the piezo unit.
- Remove the four screws and washers fastening the
top of the gas section to the base and the two
screws at the back holding it to the rear case.
- Lift the gas section top off the base, taking care not
to damage the cork gasket.
- Remove the hexagonal spring retainer (A) from the
top of the assembly (20 mm) (see fig. 20).
- Remove the spring and gas valve and clean the
valve seating (B).
- Renew facing rubber washer on the gas valve if
necessary.
- Grease spindle see Section 6.11.
- Replace in reverse order, ensuring that the hexago-
nal spring retaining nut is screwed fully down.
- Do not change the setting of the valve body.
FFiigg..2200

16
66..77WWaatteerrGGoovveerrnnoorr
TToocclleeaann
- Turn off the cold water supply to the appliance and
drain into receptable.
- Remove the governor situated in the base of the
water section (A) (see fig. 21).
- Clean the components with water and grease see
Section 6.11.
- Check that the spring loaded piston moves freely.
- Replace in reverse oder.
66..88GGaassaannddWWaatteerrFFiilltteerrssGGaassaannddwwaatteerriinnlleettffiilltteerrssaarreeffiitttteeddbbeettwweeeenntthhee
iinnlleettsseerrvviicceeccoocckkssaannddtthheeaapppplliiaannccee..
- To clean, turn off the gas supply at the meter and
the service cocks, unscrew the union nuts atta-
ching the cocks to the appliance and remove the
filters (see fig. 22).
- Clean the filters by blowing or washing in water, DO
NOT USE ANY SOLVENTS.
- Replace ensuring that the coarse filter is fitted in the
water inlet and the fine filter in the gas inlet.
- Turn on the gas supply and open both water and
gas service cocks.
- Test for soundness.
66..99MMiiccrroosswwiittcchh
The microswitch operating mechanism is factory set and if the microswitch requires replacement or adjustment
see Section 5.4. and proceed as in Section 7.12 and 7.13.
FFiigg..2211
FFiigg..2222
66..1100PPrreessssuurreesswwiittcchh
The pressure switch is factory set and it the pressure switch requires adjustment or replacement, see Section 5.5.
and proceed as in Section 7.10 and 7.11.
66..1111GGrreeaassiinnggooffCCoommppoonneennttss
Care should be taken during the annual service of an appliance to grease the gas valve spindle (see Section 6.6)
water Governor (see Section 6.7) and the bearing plate spindle (see Section 7.5). Use silicone grease.
66..1122HHeeaattIInnppuutt
It is a requirement of the Gas Safety (Installation and Use) Regulations 1984 that the burner pressure and gas
rate are checked each time an appliance is serviced, likewise the service engineer should satisfy himself with
regard to gas soundness and the adequacy of combustion and ventilation air if this is appropriate.
The heat input is preset and non-adjustable.
The heat input and burner pressure should be checked (see Section 1.3).
If the heat input/burner pressure is not correct check the working pressure at the pressure test point on the gas
service cock. This should be 20 mbar (8 in wg).
The gas installation should be examined for any possible blockage if the pressure is incorrect.

17
77..RREEPPLLAACCEEMMEENNTTOOFFCCOOMMPPOONNEENNTTSS
Before commencing any work involving component replacement :
11..Isolate electrical supply.
22..Turn off gas at the gas service cock.
33..Turn off water at the water inlet cock.
44..Drain the appliance by opening hot water outlet tap and removing the drain plug in the water service cock.
55..Remove the front casing (see Section 6.1).
77..11TThheerrmmooccoouuppllee-Remove the burner (see Section 6.2).
- Remove the pilot (see Section 6.3).
- Trace the thermocouple and disconnect at the ter-
minal on the PCB.
- Disconnect at thermoelectric valve by undoing nut
(A) (see fig. 23).
- With a 7 mm boxspanner, unscrew the nut (B) holding
the thermocouple into the gas section (see fig. 24).
- Thread the thermocouple and wire up through the
gas section.
- Replace in reverse order.
FFiigg..2233FFiigg..2244
77..22SSppaarrkkEElleeccttrrooddee
- Remove the burner (see Section 6.2).
- Remove the electrode retaining screw (A) (see fig.
25).
- Pull off the electrode cable from the piezo cartridge.
- Lift the electrode out of the gas section.
- Re-assemble in reverse order, and note that the slot
in the connector on the end of the electrode cable
is vertical when pushed onto the cartridge.
NNOOTTEE: Spark gap is 3-5 mm.
FFiigg..2255
77..33TThheerrmmooeelleeccttrriiccvvaallvvee
- To renew, remove the thermocouple conductor
lead nut (A) (see fig 26).
- Unscrew cap (B) from the side of the gas section
and withdraw the thermoelectric valve.
NNOOTTEE: This heater is fitted with a safety interlock.
When the pilot is turned off, the appliance cannot be
relit until the thermocouple cools down and the ligh-
ting sequence is repeated.
FFiigg..2266
77..44WWaatteerrSSeeccttiioonnVVeennttuurrii
·- Disconnect the right hand heating body leg from the
water section and remove the venturi (A) (see fig 27).
- Clean or replace as necessary and the re-assemble
in reverse order.
FFiigg..2277A

18
77..55DDiiaapphhrraaggmm-To renew ensure that the cold water supply and gas
are turned off.
-Drain the appliance by removing the water gover-
nor plug situated in the base of the water section
(see Section 6.7).
- Disconnect the two water connections at the water
section.
- Unscrew the six screws (A) which hold the water
section to the gas section (see fig. 28).
- Remove the water section complete with the dia-
phragm.
- Remove bearing plate and spindle and grease, (see
Section 6.11).
- Carefully remove and inspect the plastic water sec-
tion top cover.
- Re-assemble in reverse order.
NNOOTTEE: Fit the water governor last. It is easier if the
cold water inlet connection is partially engaged befo-
re fitting the screws and reconnecting the union nuts.
FFiigg..2288
77..66PPiieezzooUUnniittCCaarrttrriiddggee- Disconnect the spark electrode lead from the piezo
unit cartridge.
- Remove the screw holding the gas control cam and
remove the cam (A) (see fig. 29).
- Remove the two screws (B) holding the retaining
plate.
- Remove the piezo cartridge and renew.
- On reassembling ensure that the locating pins on
each end of the spring are correctly engaged in
their location holes.
FFiigg..2299
77..77FFaannAAsssseemmbbllyy
- Disconnect electrical connectors from assembly.
Note positions.
- Remove the two screws and washers (A) securing
the fan assembly to the flue hood (see fig. 30).
- Release wiring loom from support clip.
- Gently ease the fan assembly away from the flue
hood disengaging lug at rear of fan assembly.
- Re-assemble in reverse order.
Note : The dimension - back plate to front face of
impellor is : -57.5 mm +0.5 mm -0.0 mm.
FFiigg..3300
A

19
77..88TTooRReeppllaacceeFFuusseeoorrPPCCBBIsolate electrical supply :
((AA))FFUUSSEE::- Pull out fuse holder (A) from board and
slide fuse out of holder (see fig. 31).
((BB))PPCCBB::-Remove connections (fan, microswitch,
pressure switch).
-Disconnect mains supply cable from ter-
minals.
-Remove two nuts and washers (B) retai-
ning thermocouple and conductor lead.
-Remove fuse and ease board from plas-
tic retaining clips.
- Remove four screws and remove PCB.
- Re-assemble in reverse order.
FFiigg..2277
77..1100TToorreeppllaacceepprreessssuurreesswwiittcchh
- Isolate electrical supply.
- Remove two screws securing plastic turret cover.
- Pull off tag connectors from terminals.
- Remove low pressure tube from pressure switch.
- Remove two screws securing pressure switch to
bracket.
- Lift off pressure switch dis-engaging it from the
high pressure tube.
- Remove “O” ring from spiggot on the underside of
the pressure switch.
- Replace in reverse order referring to colour coding
label on top of appliance.
77..1111AAddjjuussttmmeennttooffpprreessssuurreesswwiittcchh
aa))If a pilot extinction occurs within 10 seconds of turning the hot tap off, it is possible that the pressure switch is
out of adjustment, if the pressure switch remains in the high flow position in excess of 10 seconds after the fan
switches to low speed interruption of the current to the thermoelectric valve occurs.
It is possible to adjust the pressure switch to ensure a rapid return from high to low flow.
AAddjjuussttmmeennttSSeeqquueennccee::
- Adjusting the pressure switch.
- Ensure the front case is on.
- Isolate electrical supply.
- Remove two screws securing plastic turret cover
and lift off cover.
- Remove terminal cover from pressure switch expo-
sing the adjusting screw (A) and remove securing
paint (see fig.32).
- Set a multimeter to 240 V scale and connect it
across the common and one other terminal of the
switch.
- Re-establish electrical supply and ensure that gas is
off at gas control.
- Turn on a hot tap to give high fan speed.
- Using a suitable screwdriver screw the adjusting
screw (A) in until changeover of the pressure switch
contacts are observed.
- Screw out adjusting screw (A) 3 turns to achieve the
setting point.
- Check operation of the pressure switch (see section 5.5.).
- Replace the plastic terminal cover on the pressure
switch.
- Replace the plastic turret cover and fixing screws.
bb))If main burner extinction occurs during hot water demand, it is possible that the pressure switch is out of
adjustment. Screw adjusting screw (A) out until flush with top of moulding, then follow adjustment sequen-
ce above.
FFiigg..3322
A
A
B

20
77..1122RReeppllaacceemmeennttooffMMiiccrroosswwiittcchh
- Isolate electrical supply.
- Part connector plug on leads to microswitch.
- Remove two lock nuts (4 mm) from microswitch
retaining screws (C) (see fig. 33).
- Remove screws securing microswitch.
- Remove switch together with plastic insulating
plate.
- Renew microswitch and replace in reverse order.
NNOOTTEE::Microswitch is not available on its own.
Microswitch Assembly must be used therefore ins-
tructions not detail changing whole assembly.
FFiigg..3333
77..1133AAddjjuussttmmeennttooffMMiiccrroosswwiittcchhooppeerraattiinnggmmeecchhaanniissmm
- Re-establish electrical supply - leave gas cock and hot water taps off.
- Temperature selector can be set in any position.
- Slacken locking screw (B) see diagram in 7-12 - using 1,5 mm hexagon key.
- Turn adjusting screw (A) anti-clockwise until high speed fan operation is obtained.
- The fan should now be at high speed.
- Turn adjusting screw clockwise slowly until low speed fan operation is obtained
- Continue turning adjusting screw clockwise for a further 1/2 turn
- Tighten locking screw.
- Check operation of microswitch (see section 5.4).
77..1144TToorreeppllaacceetthheeGGaassaannddWWaatteerrSSeeccttiioonn
- Remove the burner (see Section 6.2).
- Disconnect microswitch by parting plug connector on leads.
- Remove the conductor lead at thermoelectric valve (see Section 7.3).
- Remove thermocouple lead at PCB.
- Remove spark electrode lead from piezo cartridge (see Section 7.6).
- Disconnect the gas union at rear of gas section.
- Disconnect the water connections from the water section these are the mains inlet and water section to hea-
ting body.
- Remove the two screws securing the burner base to the rear chassis.
- Re-assemble in reverse order.
77..1155TToorreeppllaacceeCCeerraammiiccLLiinneerrssiinnHHeeaattiinnggBBooddyy
- Remove the burner (see Section 6.2).
- Remove two threaded screws (A) (Section 6.4), which secure the top front panel of the heating body to the
flue hood.
- Remove six self tapping screws (B) (Section 6.4), from front panel of heating body.
- Slide out front and side ceramic liners from locating channels.
- Ease heat exchanger forward to allow rear ceramic liner to be lifted clear of lower channel.
- Lift panel and withdraw lower edge first.
- Re-assemble in reverse order.
C