Chaffoteaux & Maury Britony DUO 55 Supplement

System Plus
c
CJ
Duo 55
Installation and Operating
Instruction Manual
Including User Instructions

Chaffoteaux et Maury Ltd.,as a leading manufacturer of Advice on installation or servicing can also be obtained
domestic and commercial water heatingappliances, as by contacting the Chaffoteaux Customer Services
well as domestic unvented direct and indirect storage Department.
cylinders, iscommitted to providinghighquality products
and a first class after sales service. If it is necessary to
contact an engineer, then telephone your local
Chaffoteaux Service Centre.
LOCAL CHAFFOTEAUX SERVICE CENTRE
Tel: [phone]
CUSTOMER SERVICES DEPARTMENT
Tel: [phone] / Fax: [phone]
The manufacturer’s guarantee against faulty
manufacture or materials for the cylinder is 5years and
fortheelectricalcomponents,thermalcontrolsandsafety
valves is for 12 months, from the date of purchase.
The guarantee will be invalidated if the factory fitted
temperature and pressure relief valve is tampered with
or removed. The Manufacturer or Distributors cannot
be held responsible for any damage howsoever caused
andwhich isa consequence of the removalortampering.
The guarantee may also be invalidated if the appliance
is not installed by a competent person in accordance
with the recommendations made herein, current
standards, regulations or in a manner not approved by
the manufacturer,modifiedinanyway,subjectedto frost,
misuse or neglect, and that factory fitted parts have had
unauthorised repairs or replacements carried out.
Evidence of purchase and the date of supply must be
made available at the time of any claim.
To assist us in providing you with an efficient after
sales service, please return the guarantee
registration card enclosed with the cylinderwithout
delay.

The installation of this appliance must be carried out by
a licenced installer and who is a CORGI Registered
person or other competent person and in accordance
with the requirements of the Gas Safety (Installation and
Use) Regulations and the Building RegulationApproved
Document G3.
In addition, the installation must also comply with the
current byelaws of Local Water Undertakings, Building
Regulations, IEE Wiring Regulations, Local Authority
BuildingStandards(Scotland)RegulationsandtheSafety
Document 635 The Electricity at work Regulation.
It should also be carried out in accordance with the
current editions of the following British StandardsCodes
of practice: BS 6981, BS 5440 parts 1 and 2, BS 5449
part 1, BS 7593, BS 6789, BS 5546, BS 4814, BS 7074
parts 1and 2, BS 7671 and BG DM2.
Precautions: Duringservicing, keepthe dust generation
to a minimum and avoid inhaling any dust and contact
with the skin and eyes. Normal handling and use will
not present any discomfort, although some people with
a history of skin complaints may be susceptible to
irritation. When disposing of the lining, ensure that it is
securely wrapped and wash hands after contact.
Installation must becarried out byasuitably qualified
installer and in accordance with current regulations
and codes of practice.
Only the safety valves supplied with the DUO 55
cylinder should be used.
The DUO 55 cylinder must not be used without the
safety valves and expansion vessel.
The boiler, cylinder and ancillary controls must be
adequately maintained.
The installation must have a sufficient and constant
supply of mains fed cold water.
l Novalveshouldbefitted betweentheexpansionrelief
valve and the storage cylinder.
l The discharge pipe must be terminated where it is
visible and will not cause danger to people in the
vicinity of the discharge.
Note: The discharge could consist of scalding water and
steam.
l OnlyChaffoteauxapprovedreplacementpartsshould
be used.

Customer Care ............................................... .I
Guarantee ...................................................... .I
Statutory Requirements .................................. .2
Safety Notice .................................................. .2
Contents ......................................................... .3
Specifications ................................................. .4
Britony System Plus 60 ....................................... .4
DUO 55 Cylinder ................................................. .4
Weights ............................................................... .4
Minimum Clearances ........................................... 4
Outer Case Dimensions for Cylinder & Boiler ......4
Dimensions .................................................... .5
Location of Components ............................. 6-7
The Cylinder.. ....................................................... 6
Location of Components ...................................... 6
The Safety Controls Pack.. ................................... 7
Introduction .................................................... .8
Operation .................................................... 8-9
Installing the Boiler ....................................... .I0
Planning ............................................................. 10
Location ............................................................. 10
Safety Notice ...................................................... 10
Installation ............................................... 1O-14
Positioning the Boiler & Cylinder on the Wall.. .... 10
The Boiler.. ......................................................... 10
The Cylinder ........................................................ 11
Making the Electrical Connections ..................... 13
Safety Valves ..................................................... 14
Fitting the Horizontal Flue................................... 15
Refitting the Outer Cases ................................... 15
Commissioning ........................................ 16-l 7
DHW .................................................................. 16
Central Heating .................................................. 16
Lighting the Boiler............................................... 17
Post Commissioning .................................... .I7
System Guidance .................................... 18-20
Flue .................................................................... 18
Ventilation ........................................................... 18
Gas Supply.. ....................................................... 18
Electrical Supply ................................................. 18
System Pressure ................................................ 19
Flushing & Water Treatment .............................. 19
System Controls ................................................. 19
Bypass & Pump.. ................................................ 19
Expansion Vessel ............................................... 20
Filling Point.. ....................................................... 20
Maintenance.. ............................................... .21
Routine Maintenance ......................................... 21
User’s Instructions.. ................................. 21-22
Switching On ...................................................... 22
Heating............................................................... 22
Hot Water.. ......................................................... 22
ToTurn Boiler Off Completely ............................ 22
Operational Faults ................................... 23-24
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BRITONY SYSTEM PLUS 60
Appliance category .................................... Cat II2H3+
Heat input C/H & DHW
Maximum in kW.. ................................ 20.22
Maximum in Btu/h ............................... 69005
Heat output C/H & DHW
Maximum in kW.. ................................ 18
Maximum in Btu/h ............................... 61428
C/H circuit pressures
Min operating in bar 0.7
in ib/in*
Max operating in bar :p5
in ib/in2 36.6
Safety discharge
in bar................................................... 3
in ib/in3................................................ 43.5
Expansion vessel
Pre-charge pressure in bar.. ............... 0.7
Pre-charge pressure in lb/in2.............. 9.4
Net capacity at 3 bar in litre ................ 5.44
NATURAL GAS G20
Gas rate
Maximum in m3/h................................ 2.14
Maximum in ff/h ................................. 76
Inlet pressure
Nominal in mbar ................................. 20
Nominal in inwg ................................. 8
Burner pressure
Nominal in mbar ................................. 6.7
Nominal in inwg ................................. 2.7
Burner injector diameter
Natural gas G20 in mm.. ..................... 1.23
PROPANE L.P.G. G31
Gas rate
Maximum in kg/h ................................ 1.55
Maximum in fRh ................................. 3.42
Inlet pressure
Nominal in mbar ................................. 37
Nominal in inwg ................................. 14.8
Burner pressure
Nominal in mbar ................................. 21.O
Nominal in inwg ................................. 8.4
BUTANE L.P.G. G30
Gas rate
Maximum in kg/h ................................ 1.58
Maximum in Lbs/h .............................. 3.48
Inlet pressure
Nominal mbar ..................................... 28
Nominal in inwg ................................. 11.2
Burner pressure
Nominal in mbar .................................
Nominal in inwg .................................
Burner injector diameter
LPG G30 and G31 in mm ................... 0.70
Adjustable by-pass
Minimum flow rate in I/h ...................... 100
Minimum flow rate in gal/min .............. 0.36
Maximum flow rate in I/h..................... 700
Maximum flow rate in gal/min ............. 2.56
Electrical characteristics
Supply.. ............................................. 230V - 50Hz
Consumption ............................................. 150W
Protection ........................................... IP44
Fuse no1 ............................................ 2A
Fuse no2 ............................................ 1.25A
External controls ................................. 24V
DUO 55 CYLINDER
Storage capacity in litre ............................. 55
Max water supply pressure to
pressure reducing valve ............................ 12 bar
Operating pressure ................................... 3 bar
Expansion vessel charge pressure ........... 3 bar
Expansion valve setting.. ........................... 6 bar
Maximum primary working pressure ......... 3.5 bar
Set opening pressure of combined
temperature and pressure relief valve.. ..... 90°C
....... 7 bar
Heating capacity of the primary heat
exchanger ................................................. 23 kW
Heating duration
(primarytemperature 90°C flow @
Im3/hr DHW temperature @ 15°C
raised to 65°C in mins) .............................17 min
Consumption per day to maintain
the temperature @ 65°C in kWhr/24hr ...... 0.04
70% reheat time ........................................ 13 min
WEIGHTS
Britony System Plus 60
With packaging.. ........................................ 43.2 kg
Without packaging.. ................................... 41.2 kg
Liftweight .................................................. 35.2 kg
Cylinder
Weight when empty.. ................................. 33 kg
Weight when full ........................................ 90 kg
MINIMUM CLEARANCES
Both sides ................................................. 5 mm
Above casing ............................................. 170 mm
Below casing ............................................. 200 mm
Front (for servicing) ................................... 500 mm
Front (in operation) .................................... 5 mm
OUTER CASE DIMENSIONS FOR CYLINDER &
BOILER
Width ......................................................... 440
(minimum space required 450)
Height.. ...................................................... 850
Depth.. ....................................................... 380
Minimum space required when cylinder
and boiler fitted side by side ...................... 895
4

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Heating flow 022mm
K H.W. flow 022mm
L Gas supply 022mm I I
N Heating return 022mm
0 Pressure relief outlet 015mm
The boiler is suitable for the 4 flue types: *type Cl2 or C42 l type C32 xx or C32 xy
TypeClZorC42 Type C 32 xx Type C 32 xy
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The Cylinder
The Chaffoteauxet MauryBRITONYDUO55isdesigned
for useas an unventedstorage cylinder heated indirectly
by a BRITONY SYSTEM PLUS 60 boiler. The cylinder
is supplied with a safety controls pack and expansion
vessel to allow itto beconnected to the main cold water
supply. The cylinder is stainless steel with a high power
coil. It is contained within a white case insulated with a
preformed polystyrenejacket.
Location of components
1. Air pressure switch
2. Steel chassis complete with expansion vessel
3. Main heat exchanger
4. Combustion chamber
5. Multi-gas burner assembly comprising ignition
and ionisation electrodes
6. Automatic air separator and automatic vent
7. Heating circuit flow switch
8. Pump
9. Electrical box
11. Overheat thermostat
12. Gas valve assembly
13. Sealed chamber
14. Flue hood with fan
16. Primary circuit control thermistor
17. Three way valve
18. CH Flow isolating valve
19. Two position selector switch
20. User’s instruction panel
21. Heating flow temperature adjustment
22. Green indicator - Power ON
23. Orange indicator - Burner ON
24. Red indicator - Lock out / flame failure
25. Reset button
26. Pressure gauge
27. Gas service tap
28. Hot water flow isolating valve
29. CH Return isolating valve
30. Pressure relief valve (boiler)
32. By pass
33. By pass adjustment screw
34. Location of central heating filter
35. Expansion relief valve also used for draining
cylinder
36. Pressure reducing valve
37. Discharge pipe to tundish
38. Cold water inlet
39. Return to boiler
40. Hot water outlet
41. Cylinder thermostat phial position
42. Flow to coil
.6
,7
8
27 29 30
6
m
--

44. Temperature selector
Flow and Return flexible pipes (not visible)
45. Temperature and pressure relief valve
46. Chassis
47. DHW expansion vessel
48. Cylinder
49. Pressure test point
The Safety Controls Pack
To enable the cylinder to comply with the current
regulations it is supplied with a safety controls pack.
This comprises:
Pressure regulator with integral strainer to ensure a
constant pressure to the hot water system
Check valve (non return valve) to prevent the back
feeding of hot water to the cold main.
Expansion vessel to take upthe expansion of thewater
when it is heated.
Expansion relief valve to prevent over expansion of
the water in the system (also used as drain-off for
cylinder).
Pressure relief valve to prevent over pressurisation of
the system.
Temperature relief valve to provide a safety outlet in
the event of overheating.
Cylinder thermostat to controlthe temperature ofwater
in the cylinder.
Tundish to collect and provide an air break for the
discharge pipesfrom thetemperatureandpressurerelief
valves. The discharge must be terminated in a safe
and visible location.
42
40 39 38 37 36
View from underneath cylinder
19 20 21 22 26
44
18 28 27 33 29
48 -
C
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The Chaffoteaux et Maury BRITONY DUO 55 is a
combination of an unvented stainless steel storage
cylinder heated indirectly by a fanned flued sealed
system boiler within matching outer cases. It benefits
from the high efficiency provided by the modern low
water content BRITONY System Plus 60 boiler and a
high power coil within the cylinder. A combination
providing very fast reheating of the hot water.
For greater flexibility of installation, the cylinder could
be fitted below, on the right or the left of the boiler or
separately from the boiler. Supplied directly from the
mainwater supply the cylinder does not needa separate
feed cistern or vent pipe in the loft space.
The BRITONY DUO 55 provides central heating aswell
as hotwater. The boiler is designed for sealed systems
only and a circulating pump, diverter valve, expansion
vessel, a pressure gauge and safety valve are included
within the boiler.
The cylinder has a capacity of 55 litres and provides the
advantages of mains pressure and greater volumes of
hot water to taps and showers. It is supplied complete
Domestic Hot Water Mode
To be able to supply hot water, the selector switch
(19 Fig. 1) must be in either in* or ‘11112 position.
This will confirmed by the green Indicator light 0 (22
Fig. 1).
The hot water temperature in the cylinder can be
adjusted between50°C and 70°C usingthe control knob
on the control panel of the cylinder (44 Fig. 2).
When the cylinder thermostat is calling for heat, it
switches the 3-way valve (17 Fig. 3) to the hot water
position. The hot water from the primary circuit is then
diverted through the cylinder coil to heat DHW.
The first stage solenoid (12a Fig. 3)and safety solenoid
(12~ Fig. 3) 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& (23 Fig. 1)will light
and the second stage solenoid (12b Fig. 3) opens to
allow the full gas rate.
If a flame is not detected, after eight seconds, the
security solenoid closes and shuts off the gas.
The red lockout indicator bulbjft (24 Fig. 1) will light.
Press the RESET button to attempt to relight.
The hot water flow temperature is controlled by the
primary circuit control thermistor (16 Fig. 3).
When the cylinder thermostat is satisfied, the burner is
extinguished and the pump stops.
with an expansion vessel, pressure reducer, strainer,
check valve, temperature and pressure relief valve,
expansion relief valve. The cylinder has been tested
and approved by the WRc as meeting with the
requirements of EN 60335 2.21 and EN 60529. The
boiler has been tested and approved to carry the CE
mark.
The BRITONY DUO 55 can be installed with the
standard horizontal flue, raised horizontal, concentric
vertical, twin pipe or SE duct flue arrangements.
Adapters, bends and other accessories are available
on request.
The DUO 55 is packed in four cartons:
1. The boiler
2. The flue assembly and fixing kit
3. The cylinder with the safety controls pack, fitting
template and instructions manual
4. Connections and plinth to close couple the boiler
and cylinder.
The boiler will now stay in the hot water mode for three
minutes (this can be set to 30 seconds if required. See
Commissioning section).
Priority will be given to a demand for reheating the
cylinder.
25
19 21 22 26
Fig. 1
44
Fig. 2

Central Heating Mode
Tobe able to supply central heating, the selector switch
(19 Fig. 1) must be in ‘~~~~3 position. This will be
confirmed by the green indicator light 0 (22 Fig. 1).
When there is a demand for heating (either from the
room thermostat or the external programmer) and the
boiler temperature control is calling for heat.
The pump starts and at a flow rate of 4ltr/min the central
heating flow switch operates allowing the ignition
sequence to begin.
The first stage solenoid (12a Fig. 3) and safety solenoid
(12~ Fig. 3) open together to allow gas to the burner. I&
The ignition sequence begins and a continuous high
speed spark ignites the gas. As soon as a flame is 11
detected the orange indicator bulb 0 (23 Fig. 1) will
light. After 45 seconds the second stage solenoid (12b
Fig. 3) opens to allow the full gas rate. -------4
If a flame is not detected, after eight seconds, the
security solenoid closes and shuts off the gas. The red 17
lockout indicator bulb f (24 Fig. 1)will light. Press the
RESET button to attempt to relight.
The central heating flow temperature is controlled by
the central heating control thermistor (16 Fig. 3).
The boiler has been designed to minimise cycling and
will not attempt to relight for at least 3 minutes after the
27
boiler thermostat has been satisfied (this can be set to
30 seconds if required, see maintenance and service
guide).
When the room thermostat is satisfied the burner will
switch off and the pump will remain running for afurther
3 minutes.
Fig. 3
Note: It is possible to override the 3 minute delay by
pressing the RESET button (25 Fig. 1).
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Planning
Please ensure that you are familiar with the installation
requirements as well as the relevant British Standards
and Statutory Regulations (see page 2) before
commencing work.
Location
The DUO 55 can be installed on any suitable internal
wall. Provision must bemadeto allowthe correct routing
of the flue and siting of the terminal to allow the safe
andefficient removalof theflue products. The appliance
may be installed in any room, although reference must
be made to the IEE regulations if it contains a bath or
shower. A compartment or cupboard may be used
provided that it has been purpose-built or modified for
the purpose. It is not necessary to provided permanent
ventilation for cooling purposes. Detailed
recommendations are given in BS 5440 pt. 2. If it is
proposed that it is installed in a timber framed building
then reference must be made to British Gas Document
DM2, or advice sought from CORGI.
Safety Notice
Installation must becarried out byasuitably qualified
installer and in accordance with current regulations
and codes of practice.
Only the safety valves supplied with the cylinder
should be used.
The cylinder must not be used without the safety
valves and expansion vessel.
The boiler, cylinder and ancillary controls must be
adequately maintained.
The installation must have a sufficient and constant
supply of mains fed cold water.
Novalveshould befitted betweentheexpansionrelief
valve and the storage cylinder.
The discharge pipe must be terminated where it is
visible and will not cause danger to people in the
vicinity of the discharge.
Note: The discharge could consist of scalding water and
steam.
l
OnlyChaffoteauxapprovedreplacementpartsshould
be used.
The installation kit comprises four cartons:
1. The Boiler
l
Installation and Maintenance Instructions (for
the boiler only)
l Accessory bag 1
t Safety valve discharge elbow
t Silicone tube
t Washers for connecting tails:
(2 x 22mm, 2 x 15mm, 1x gas washer)
l Accessory bag 2
+ Flue gasket and 4 x securing bolts
2. The Cylinder
l
Installationand Maintenance Instructions (cylinder
and boiler)
3. The Horizontal Flue Starter Pack
l Pre-piping fixing jig
l Hanging bracket
l
Connecting tails for the boiler
l Flue turret
l
600mm flue pipe including terminal
l Inner flue
l Rubber seal
l
Fixing screws and wallplugs
l Flue restrictor ring
l Water filter and washers:
(4 x 22mm, 1x gas washer)
l Paper template for the boiler only (showing the
dimensions of the boiler and the required 5mm
clearance on either side)
4. The Cylinder Installation Pack
l Paper template showing the fixing positions for
the boiler and cylinder
l Flexible connecting pipes
l Tundish
l Thermostat clip and ‘0’ ring
l Tee
Positioning the Boiler and Cylinder on the
Wall
Before commencing installation, decide if the cylinder
is to befitted to the right or left of the boiler. If it is to be
fitted beneath the boiler an additional pipe kit will be
required, OR the connections to the boiler can be made
in copper pipe by using the pre-piping kit supplied with
the flue starterpack.
The Boiler
The template provides the fixing positions of the boiler
andthe cylinder when fitted to the rightof the boilerorto
the left of the boiler.

It can also be used to ensure the correct spacing of
kitchen cabinets etc.
The template is fixed to the wall and used to locate the
fixing holesfor the boilerhanging bracket, the pre-piping
bracket and the cylinder chassis. Itshould also be used
to locate the centre of the flue hole. There is space to
allow pipes to pass behind the boiler without the need
for an additional spacer.
Drill and plug the wall and secure the hanging bracket
using the screws provided.
Remove the boiler from its packaging as shown in Fig.4
and remove the outer case as shown in Fig. 5.
Hang the boiler on the bracket.
Note: If the pre-piping bracket has been used, it must
be removed before attempting to hang the boiler.
Connecting the Boiler to the System
To gain access to the valve connections, press tab (P
Fig. 6) to release the catch on either side of the boiler
and pivot the electrical box forward.
3x fibre washers for the cylinder flow, the C/H flow and
return connections.
1x rubber washer ‘R’ is for the gas connection.
Before making the connections to the boiler all the
system valves should be opened and the pipework
thoroughly flushed through with cold water to remove
any loose debris.
Using Fig 7 for reference, connect the gas and water
pipes to the valves using the tails and gaskets provided
with the flue starter pack and the cylinder.
There is 190mmspace, betweenthevalves onthe boiler
and the wall, to make these connections.
Provision must be made to fill and recharge the system
pressure. This can be achieved using a filling loop or
other methods approved by the Local Water Authority.
The Cylinder
The four fixing holes should have been pre-drilled while
the paper template was in position.
The cylinder must be unpacked and the outer case
removed as shown in Fig. 5. The cylinder can now be
lifted off the chassis.
To gain access to the fixing holes on the chassis,
disconnect and remove the expansion vessel by
releasing and removing both the locking nut and
retaining nut at the inlet. See Fig. 8, position A.
The chassis can now beoffered upto its position on the
wall and secured by the screws provided.
The expansion vessel and the cylinder can now be
remounted.
Fig. 4
ij”
Fig. 5
Fig. 6
Fig. 7
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Locate the thermostat phial in its sleeve using the clip
and rubber plug supplied. See Fig. 8.
Connecting the Cylinder
The main water supply should be carefully flushed
through, to clear any debris, before connecting to the
cylinder.
For cylinders fitted to the right of the boiler
Connect the long flexible tube (A Fig. 10) between the
hotwater isolating valve (32 Fig. 10)and the inlet of the
coil (42 Fig. 10) using the tail (D Fig. 10). The short
flexible pipe (B) is connected between the outlet of the
coil (39 Fig. 10)andthe central heating return pipe using
the tee supplied which must be soldered on to the return
tail (C Fig. 10).
Connect the cold water supply (EF) to the combination
safety valve (G Fig. 10) using the short tail. Use the
long tail to connect the hot water outlet (EC).
For cylinders fitted to the left of the boiler
Connect the short flexible pipe(B) betweenthe hotwater
flow isolating valve (32 Fig. 11)and the inlet of the coil
(42 Fig. 11)using tail (D Fig. 11). The long flexible pipe
(A Fig. 11) should be connected between the outlet of
the coil (39 Fig. 11)and the central heating return using
the tee, which must be soldered onto the return tail (35
Fig. 11). Connect the cold water supply (EF) to the
combination safety valve (G Fig. 11)using the short tail.
Use the long tail to connect to the hotwater outlet (EC).
Fig. 8
Fig. 9
Fig. 10
d
Fig. 11

Wiring
Making the electrical connections
Togain access to the electrical connections, press tabs
(P Fig 12) to release the catches on either side of the
boiler and pivot the electrical box forward.
Remove the two retainingscrews (Afig 12),liftthe cover
andturn over to revealan interface PCB andconnecting
block (Fig 13).
Connect the live and neutral wires to the connector (D
Fig 13)on the interface PCB leaving sufficient earth wire
to connect to the main earthing point.
The connectingcablefor the cylinderthermostat iscoiled
behind the temperature adjuster on the cylinder. This
cable is led through the cable clamp on the boiler
electrical box and is connected to connecting block (D)
as shown in Fig 13.
If a room thermostat is to be fitted, the link wire on the
main connector plug (C Fig 13) must be removed and
the room thermostat connected in its place. These
connections are for use with voltage free switching.
Fig. 12
/Connections Ra
Fig. 13
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Safety Valves
The DUO 55 has a pressure relief valve fitted to the
Discharge pipe
from temperature and
pressure relief valve
to tundish
boiler and a temperature and pressure reliefvalve fitted
to the cylinder. It is most important that they are
terminated below the boiler and over the tundish which
inturn shouldterminate safely outsidethe premises (see
Fig. 14). It is recommended that the tundish is installed
directly below the discharge pipe from the temperature
and pressure relief valve (37 Fig. 15). If necessary, the
pressure relief discharge pipe from the boiler may also
terminate over this tundish (Fig. 14a).
Safety device e.g.
;- Fixed grating
Discharge pipe from -
tundish with continuous fall
Fig. 14

Maximum
resistance
allowed,
expressed
Minimum as a length
Minimum size of of straight Resistance
size of discharge pipe (i.e. no created by
Valve outlet discharge pipe from elbows or each elbow
size pipe tundish bends) or bend
Gll2 15mm
22mm
28mm
35mm
Up to 9m 0.8m
Up to 18m l.Om
Up to 27m 1.4m
Fitting the Horizontal Flue
The standard horizontal flue kit is suitable for lengths
from 300mm up to 610mm. With extensions, the
maximum length is 3m. For rear flueing, the standard
pack will accommodate a maximum wall thickness of
490mm and for side flueing a maximum wall thickness
of 477mm. This takes into account the minimum side
clearance of 5mm.
The papertemplatewill providethe positionfor the centre
for drilling the flue hole with a core drill. If the flue is a
side exit installation, calculate the position of the hole
bydrawinga linefrom the centre positionon the template
to the corner of the wall (sloping downwards away from
the boiler at 5mm per IOOOmm). Then measure
horizontally 212mm. This will be the centre position of
the flue hole. For greater detail please refer to the
instructions enclosed with the flue kit.
The instructions for fitting the raised horizontal, vertical
concentric, twin pipe and SE duct flue options can be
found in the relevant flue starter packs.
Refitting the Outer Cases
The outer cases of the boiler and cylinder can now be
refitted. Before fully tightening the retaining screws, the
plinths can be placed in position using the keyhole slots
and then the screws tightened to hold the case and the
plinths in place.
Please Note: The cutaway sides of the plinth are to be
placedtogether (Fig. 16)so that the connecting pipework
and wiring may be hidden behind the plinth.
From boiler 3
pressure dzLP--:
relief valve ; and pressure
relief valve
:
‘: :’
~
iL =:
Fig. 14a
37
Fig. 15
Fig. 16
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DHW
Filling the Cylinder
l Ensure that all fittings and valves are correctly
installed and are water tight
l Flush all debris from the supply pipes before
connecting to the cylinder
l Open the furthest hot water tap from the DUO 55
cylinder
l Open the mains water inlet valve and allow the
cylinder to fill. Allow water to flow from the tap for a
few minutes to ensure any installation debris is
flushed through the system
l Open all other taps in turn to purge any remaining
air from the system
l Check all connections for leaks
Check the operation of the safety valves
l Manually open the temperature and pressure relief
valve (39 Fig. 17) for a few seconds.
l Check that the water flows away through the tundish
and discharge pipework and does not overflow.
l Ensure that the flow of water has stopped and that
the valve has reseated itself.
l Repeat the above check for the expansion relief
valve.
Central Heating
l Open flow and return valves on the boiler (28 & 29
Fig. 18)
l Open the automatic air vent (20 Fig. 19)
l Fill system and vent radiators
l Set system pressure and remove filling loop
l Check for leaks
l Manually check pump is free to turn
l Switch on electrical supply
l Turn selector switch (19 Fig. 20) to heating and hot
water position
l Allow pump to run for several minutes.
l Isolate electrical supply.
l Drain boiler and check water filter (34 Fig. 19) for
installation debris.
l Replace filter and recharge system.
Indirect Heating
l Ensure that the cylinder heating coils are filled and
purged of air.
Fig. 17
1% 28 27 29
Fig. 18
Fig. 19
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Lighting the Boiler
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Connect gas pressure gauge to set test point (43
Fig. 19).
Turn on the gas supply and boiler gas tap (27 Fig.
18).
Check all boiler connections for gas soundness.
Ensure electrical supply is on.
Ensure all external controls are calling for heat.
Turn selector switch (19 Fig. 20) to heating and hot
water position
Turn the boiler thermostat to maximum (21 Fig.20).
The boiler will light.
Allow the boiler to heat system.
Check that the inletgas pressure (working pressure)
whilethe boilerisoperating. (Refertotechnicaldata).
Check the operation of the boilercontrols and safety
devices. (See separate servicing leaflet for details).
Re-flush the system to remove any dissolved oils
and fluxes.
Recharge system pressure and introduce anywater
treatment as required.
49 \
Fig. 20
Handing Over to the Householder
l Ensure system pressure has been set correctly.
l Set the boiler and cylinder thermostat and controls.
l Demonstrate the lighting and operation of the boiler.
l Demonstrate how to maintain the system pressure.
l Explain to the customer:
1. the operation of the appliance and
safety controls
2. things to look out for such as continual leak
of water noticed at the tundish
3. Explain the necessity of annual maintenance
by a competent person
4. what to do in an emergency
l Leave users instructions, installation manual and all
other documentation with the householder.
l Fill out and register the guarantee card and send it
back to Chaffoteaux et Maury
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Flue
The boiler must be installed so that the flue terminal is
exposed to the free passage of external air at all times.
It must not be allowed to discharge into another room
or space such as an outhouse or closed lean-to.
The minimum acceptable clearances are shown below:
A Directly below an opening, window etc. 300 mm
B Below gutters soils pipes or drain pipes 75 mm
C Below eaves 200 mm
D Below 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 150 mm
G Above ground roof or balcony level 300 mm
H From a surface facing the terminal 600 mm
I From another terminal facing the terminal 600 mm
J From an opening into the dwelling when
undera car port 1200mm
K Vertically from a terminal on the
same wall 1500mm
L Horizontallyfrom a terminal on the
same wall 300 mm
M Fixed bythe flat roof ubbink rolux4GM flue terminal
N Fixed by a pithed roof ubbink rolux4GM flue
terminal
Fig. 21
It may be necessary to protect the terminal with a guard
if it is accessible and could be damaged. Reference
shouldbemadetothe BuildingRegulationsforguidance.
Suitable guards may be obtained from your local
merchant.
Ventilation
The room inwhich the boiler is installeddoes not require
specific ventilation. If it is installed in a cupboard or
compartment permanent ventilation is not required for
cooling purposes.
Gas Supply
The gas installation and soundness testing must be in
accordance with the requirements of BS 6891. The
boiler requires a 22mm supply. Ensure that the pipe
size is adequate for the demand including other gas
appliances on the same supply.
Electrical Supply
The appliance requires an earthed 230V - 50Hz supply
and must be in accordance with current I.E.E. It must
also be possible to be able to completely isolate the
applianceelectrically. Connection should bevia a 3 amp
fused double pole isolating switch with contact
separation of at least 3mm on both poles. Alternatively,
a fused 3 amp / 3 pin plug and unswitched socket may
be used, provided it is not used in a room containing a
bath or shower. It should only supply the appliance.
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