Chaffoteaux & Maury Calydra 80 Owner's manual

COMBINATION BOILER
Heating and lnstantane~us DomesticHot
eater with TSS@
Fanned Flue system
Installation and
Calydra 80 Calydra 100
Operating instructions

These instructions are suitable for the following boilers :
Calydra 80
Calydra 100

CUSTOMER CARE
Chaffoteaux et Maury Ltd ,as a leading manufacturer of domestic and commercial water heating appliances, as well as domestic unvented direct and indirect
storage cylinders, is committed to providing high quality products and a first class after sales service. If it is necessary to contact an engineer, then telephone your
local Chaffoteaux Service Centre. The number can be obtained from the leaflet enclosed with your appliance or by telephoning the Chaffoteaux Customer Services
Department at Telford
Advice on installation or servicing can also
CUSTOMER SERVICES DEPARTMENT
be contacting the Chaffoteaux Customer Services Department
Tel [phone]
Fax [phone]
GUARANTEE
The manufacturer’s guarantee against faulty manufacture or materials for the cylinder and secondary heat exchanger is 5 years, from the date of purchase. For the
boiler, electrical components, thermal controls and safety valves it Is for 12 months. from the date ot purchase.
The guarantee will be rnvalrdated if the factory frtted DHW pressure relief valve is tampered with or removed The Manufacturer or Distributors cannot be held
responsible for any damage howsoever caused and which is a consequence of the removal or tampering
The guarantee may also be invaltdated if the appkance 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, modified in any way, subjected to frost, misuse or neglect and that factory fitted parts have
had unauthorised repairs or replacemenfs carned out Evidence of purchase and the date ot supply must be made available at the time of any claim. The guarantee
is only vakd for appkances installed in the UK
To asstst us In providing you with an efficient after sales service, please return the guarantee registration card enclosed with the cylinder without delay.
STATUTORY REQUIREMENTS
The mstallatton of this appliance must be carried out by a CORGI Registered person or other competent person and in accordance with the requirements of the Gas
Safely (Installatron and Use) Regulations.
In addrtion, the installahon must also comply with the current byelaws of Local Water Undertakings, Building Regulations, IEE Wiring Regulations, Local Authority
Building Standards (Scotland) Regulations and the Safety Document 635 The Electricity at work Regulation,
It should also be carried out in accordance with current editions of the following British Standards Codes of practice: BS 6891, BS 5440 parts I and 2, BS 5449 part
1, BS 7593, BS 6798, BS 5546, BS 4814, BS 7074 part 1 and 2, BS 7671 and BG DM2
Ifthere is a possibility of the incoming mains water pressure exceeding 7 bar then a suitable pressure limiting valve must be fitted.
Precautions During servicing, keep the 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 irntation. When disposing of the lining, ensure that it is
securely wrapped and wash hands after contact
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Page
CUSTOMER CARE.. .................................................................... 3
Guarantee.. .................................................................................. 3
Statutory Requirements.. ............................................................. 3
Contents.. ..................................................................................... 4
INTRODUCTION.. ........................................................................ 5
DESCRIPTION.. ........................................................................... 6
LOCATION OF COMPONENTS .................................................. 6
SPECIFICATIONS.. ...................................................................... 8
DIMENSIONS.. ............................................................................. 10
OPERATION ............................................................................... .12
DOMESTIC HOT WATER MODE ............................................... .12
CENTRAL HEATING MODE.. ..................................................... .I4
INSTALLATION .......................................................................... .15
PLANNING .................................................................................. .15
LOCATION ................................................................................. ..15
INSTALLING THE CALYDRA .................................................... .15
INSTALLATION ........................................................................... .15
POSITIONING THE BOILER ON THE WALL.. ............................ 15
CONNECTING THE BOILER TO THE SYSTEM.. ...................... .18
FITTING THE HORIZONTAL FLUE.. .......................................... .17
MAKING THE ELECTRICAL CONNECTIONS ........................... .18
PRE-COMMISSIONING.. ............................................................ .20
Electrical Adjustments ........................................................... .20
1. Room thermostat options.. ................................................ .20
2. Pump Speed Adjustment.. ................................................ .20
3. Burner operating modes :.................................................. .20
COMMISSIONING.. ..................................................................... .22
DHW.. .................................................................................... .22
Central Heating ..................................................................... .22
Page
LIGHTING THE BOILER ............................................................. .22
POST COMMISSIONING.. ........................................................... 23
HANDING OVER TO THE HOUSEHOLDER.. ............................ .23
SYSTEM GUIDANCE.. ................................................................ .24
FLUE ........................................................................................... .24
VENTILATION.. ........................................................................... .25
GAS SUPPLY.. ............................................................................ .25
ELECTRICAL SUPPLY.. ............................................................. .25
FLUSHING AND WATER TREATMENT ...................................... 26
SYSTEM CONTROLS ..................................................................26
BY PASS AND PUMP ................................................................. .27
EXPANSION VESSEL.. ............................................................... .28
FILLING POINT.. ......................................................................... .28
MAINTENANCE.. ......................................................................... 28
USER’S INSTRUCTIONS ........................................................... .29
Control panel ............................................................................... .29
Isolating Taps .............................................................................. .29
SWITCHING ON.. ........................................................................ .30
Hot Water .................................................................................... .30
Heating and Hot Water.. .............................................................. .30
Heating Only.. .............................................................................. .30
To Turn Boiler Off Completely.. ................................................... .30
INSTRUCTIONS FOR SETTING THE BUILT IN CLOCK.. ........ .31
MECHANICAL TIMER.. ............................................................... .31
1. General Layout.. ...................................................................... .31
2. To Set the Time.. ..................................................................... .31
3. To Set the “On” and “Oft” Times.. ............................................ .31
4. To Select Function MODE ........................................................31

By combining their modern highly efficient low water content fanned
TSS@‘Temperature Stabilised System”, Chaffoteaux et Maury have flue combination boiler concept
created a whole new concept.
CALYDRA
and the brand new
This unique combination is able to provide the user with hot water immediately at the outlet of the appliance
temperatures at both extremely low flow rates or when several taps are opened together. and stable
The TSS@ is a 5 litres, independently controlled mini unvented storage cylinder, powered by a 3 kW coil. It works in conjunction
with the Chaffoteaux et Maury low pressure instantaneous domestic hot water system.
The CALYDRA, as well as providing hot water, provides central heating. The boiler is designed for sealed systems only. A two
speed circulating pump, diverter valve, expansion vessel as well as a pressure gauge and safety valve are included within the
boiler.
The CALYDRA provides the advantages of mains pressure hot water to taps and showers. Supplied directly
water supply the CALYDRA does not need a separate feed cistern or vent pipe in the loft space.
The CALYDRA has been tested and approved by the WRc as meeting
The boiler has been tested and approved to carry the CE mark. with the requirements of the water by-laws scheme.
The CALYDRA can be installed with the standard horizontal flue, raised horizontal,
arrangements. Adapters, bends and other accessories are available on request.
The boiler is packed in TWO cartons:
1. The boiler.
2. The flue assembly and fixing kit.
concentric vertical, twin pipe flue or seduct
from the main

Location of components
1. Flue hood with fan
2. Sealed chamber
3. Gas valve assembly
4. Electrical box
5. Pump
6. Automatic air separator and automatic vent
7. Multi-gas burner assembly comprising ignition and ionisation
electrodes
8. Combustion chamber
9. Main heat exchanger
10. Steel chassis complete with expansion VE
11. Air pressure switch
12. Overheat thermostat
13. TSS @J(mini cylinder)
14. Central heating control thermistor
15. Three way valve
16. Expansion vessel connecting tube
17. By pass adjustment screw
18. By pass
19. CH Flow isolating valve
20. Domestic hot water outlet
21. Gas service tap
22. Water service tap
23. CH Return isolating valve
25. Pressure relief valve
27. DHW pressure relief valve
28. TSS@ control thermistor Fig.1

29. Location of heating filter (not visible)
30. DHW circuit flow switch
31. Heating circuit flow switch
32. Hot water control thermistor
33. Secondary heat exchanger
34. Four position selector switch
35. User’s instruction panel.
36. Domestic hot water temperature adjustment
37. Heating flow temperature adjustment
38. Green indicator - Power ON
39. Orange indicator - Burner ON
40. Red indicator - Lock out / flame failure
41. Reset button
42. Mechanical clock
43. Pressure gauge

SPEClFlCATloNS
CALYDRA
Appliance category
Heat input C/H & DHW
Maximum
Heat output C/H 81DHW
Maximum
C/H circuit pressures
Min operating
Max operating
DHW specific flow rates for 10 min
Q 30 deg C rise
Q 35 cieg C rise
DHW circuit pressures
Min operating
Max operating
Flow limiter rate
Compartment ventilation
80 100 CALYDRA 80 100
Cat ii 2H 3+ Cat ii 2H 3+ Natural gas G20
Gas rate
25.9 kW 31.1 kW Maximum 2.74 m31h 3.29 m3/h
88392 Btuh 106138 Btu4-1 97 ft3lh 116ft31h
inlet pressure
23.25 kW 28.0 kW Nominal 20 mbar 20 mbar
79347 Bhuh 95558 lBu4-1 8inwg 8inwg
Burner pressure
0.7 bar 0.7 bar Nominal 11 mbar 12.8 mbar
10 lb/in2 10 lb/in2 4.4 in wg 5.12 in wg
2.5 bar 2.5 bar Burner injector and restrictor diameter
36.3 lb/in2 36.3 lb/in2 Natural gas G20 1.23 mm 1.28 mm
l/3 restrictor 2.60 mm 2.9 mm
11.5 Vmin 13.9 Vmin Z3 restrictor 6.7 mm no restrictor
2.54 gal/min 3.06 gai/min
9.86 Umin 11.91 Umin PROPANE LPG G31
2.17 gallmin 2.62 gailmin Gas rate
Maximum
0.1 bar 0.1 bar
1.45 lb/in2 1.45 lb/in2 inlet pressure
7 bar 7 bar Nominal
100 lb/in2 100 lb/in2
8 Vmin 10 Vmin Burner pressure
Nominal
not required
2.00 kg/h 2.42 kg/h
4.41 lb/l-u 5.34 Ib/hr
37 mbar
14.8 in wg 37 mbar 14.8 in wg
35 mbar
14 in wg 30.4 mbar 12.16 in wg

CALYDRA
BUTANE LPG G30
Gas rate
Maximum
inlet pressure
Nominal
11.2 in wg
Burner pressure
Nominal
Burner injector and restrictor diameter
Butane LPG G30
l/3 restrictor
213 restrictor
80
2.04 kg/h
4.50 lb/h
28 mbar
11.2 in wg
26.7 mbar
10.7 in wg
0.7 mm
1.75 mm
4.9 mm
100
2.45 kg/h
5.40 lb/h
28 mbar
24 mbar
9.6 in wg
0.76 mm
2.0 mm
6.7 mm
CALYDRA
Safety discharge - Heating
80 100
2.5 bar 2.5 bar
36.25 iblin2 36.25 lb/in2
Safety discharge - DHW 7 bar
100 lb/in2 7 bar
100 lb/in2
Expansion vessel
Pre-charge pressure
Net capacity at 2.5 bar
Adjustable by-pass
Minimum flow rate
Maximum flow rate
Electrical characteristics
SUPPlY
Consumption
Protection
Fuse no 1
Fuse no 2
External controls
0.7 bar 0.7 bar
9.4 lb/in2 9.4 lb/in2
5.44 itr 5.44 itr
150 i/h 150 i/h
0.55 gai/min 0.55 gai/min
480 i/h 480 iih
1.76 gai/min 1.76 gal lmin
23fiv5oi-k 23Ov5OHz
155w 155w
IP 44 iP44
2A 2A
1.25A 1.25A
24V 24V

Weights
With packaging :
-Calydra 80 : 49.0 kg
Calydra 100 : 49.5 kg
Without packaging :
-Calydra 80 : 46.5 kg
-Calydra 100 : 47.0 kg
Liit weight :
-Calydra 80 : 41.5 kg
-Calydra 100 : 41.Okg
Tails diameter
J Heating flow 022mm
K D.H.W. flow 015mm
L Gas supply 022mm
M Cold water inlet 015mm
N Heating return 022mm
P Safety valve outlet 015mm
Outer case dimensions :
-Width : 440 (minimum space required 450)
- Height : 850
- Depth : 380
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All dimensions in mm
Fig. 4
66
Safety valve
center line

Minimum clearances :
- Both sides 5mm
- Above casing 170 mm
- Below casing 200 mm
- Front ( for servicing) 500 mm
- Front (in operation) 5 mm
TYPE C12, C42 or C22
T .<,::*.*.:
155 - y-m,.-+-----_-___-------
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...
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-
4
149
-_- -A-
*
l
Fig. 5 Dimensions in mm
The Calydra 80 and 100 are suitable for the 3 flue types :
l typeC12orC42
l type C 22
l typeC32xxorC32xy
TYPE C32 xx TYPE C32 xy
ini

Domestic Hot Water Mode
To be able to supply hot water, the selector switch (34 fig.
6) must be in either on ,,? or ‘1111,i position. This will be
confirmed by the green indicator light 0 (38 fig. 6).
The hot water temperature in the mini cylinder can be
adjusted between 40°C and 60°C using control knob (36
fig 6).
When a tap or shower is turned on and the flow of mains
water is above 2 litres per min., it will activate the DHW
flow switch 30 fig 7 and allow the 3 way valve (15 fig. 7)
to move to the DHW position. The pump can now
circulate primary water heated by the main heat
exchanger through the secondary heat exchanger.
The safety solenoid (3a fig. 7) and the first stage solenoid
(3b fig. 7) 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 0 (39 fig. 6) will light and the
second stage solenoid (3c fig. 7) opens to allow the full
gas rate. If a flame is not detected, after 8 seconds, the
safety solenoid and the first stage solenoids close and
shut off the gas. The red lockout indicator bulb 0 (40 fig.
6) will light.
Over 2 Vmin, the domestic hot water temperature is
controlled by the hot water control thermistor (32 fig. 7)
and the heating control thermistor (14 fig. 7), but
dependant upon to the position of the DHW temperature adjustment
knob (36 fig. 6). This system anticipates the changes of
temperature in the secondary heat exchanger and ensures accurate
temperature regulation.
When the tap is closed the burner is extinguished and the pump
runs on for 10 seconds (unless the mini cylinder thermistor is calling
for heat, in which case the burner will remain on at a low rate and
the pump will continue running until the mini cylinder thermistor is
satisfied). The boiler will now stay in the hot water mode for 30
seconds to be ready for a subsequent draw off (this can be set to 3
minutes if required. See Maintenance and Service Guide).
Priority is given to a demand for hot water. This will interrupt the
central heating for the duration of hot water delivery or recovery of
the mini cylinder.
When the boiler has been in standby in Hot Water Mode for some
time or when drawing DHW at flow rates of less than 2 Vmin the
temperature in the mini cylinder will eventually decrease and the

2
3c
3b
3a
12
7a
7b
10a
4
32
TS@ control thermistor will call for heat. Bringing the pump and
burners to operate, this is quite normal.
The 3 way valve (15 fig. 7) will move to the domestic hot water
position. The hot water from the primary circuit is then diverted
to heat the mini cylinder via the coil and the secondary heat
exchanger.
The safety solenoid (3a fig. 7) and the first stage solenoid (3b
fig. 7) open together to allow a low rate of 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 ID (39 fig. 6) will light and the burner will remain
on low rate until the TSS@ control thermistor (28 fig. 7) is
satisfied. If a flame is not detected, after 8 seconds, the security
and first stage solenoids close and shut off the gas.
The red lockout indicator bulb 9; (40 fig. 6) will light.
The hot water flow temperature is controlled by the primary
circuit control thermistor (14 fig. 7).
When the cylinder thermistor is satisfied, the burner is
extinguished and the pump remains running for 10 seconds at
low speed.
The boiler will now stay in the hot water mode for 30 sec. (this
can be set to 3 minutes if required. See Maintenance and
Service Guide).
Priority is given to a demand for hot water or reheating the mini
cylinder.

Central Heating Mode
To be able to supply heating, the selector switch (34 fig. 6)
must be in ‘1111$ (heating and hot water position) or ‘fill
(heating only position).This will be confirmed by the green
indicator light 0 (38 fig. 6).
When there is a demand for heating (either from a room
thermostat, the built-in clock or an external programmer) and
the boiler temperature control is calling for heat.
The pump starts and at a flow rate of 4 Itr/min the central
heating flow switch operates allowing the ignition sequence to
begin.
The safety solenoid (3a fig. 7) and the first stage solenoid (3b
fig. 7) 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 0
(39 fig. 6) will light.
After 45 seconds the second stage solenoid (3c fig. 7) opens
to allow the full gas rate.
If a flame is not detected, after 8 seconds, the security
solenoid closes and shuts off the gas.
The red lockout indicator bulb 0 (40 fig. 6) will light.
The central heating flow temperature is controlled by the
heating control thermistor (14 fig. 7).
The boiler has been designed to minimise cycling and will not
attempt to relight for at least 3 minutes after the heating
control thermistor has been satisfied (this can be set to 30
seconds if required. See Maintenance and Service Guide).
When the built-in clock, room thermostat and external
programmer are satisfied, the burner will switch off and the
pump will remain running for a further 3 minutes. (this can
also be set to 30 seconds if required. See Maintenance and
Service Guide).
NB It is possible to override
the RESET button (41 fig. 6). the 3 minute delay
by
pressing

Planning
Please ensure that you are familiar with the installation
requirements as well as the relevant British Standards and
Statutory Regulations (see page 3) before commencing work.
Location
The CALYDRA can be installed on any suitable internal wall.
Provision must be made to allow the correct routing of the flue
and siting of the terminal to allow the safe and efficient
removal of the flue 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 provide
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.
INSTALLING THE CALYDRA
Installation
The installation kit included with the flue components
comprise following items :
- Hanging bracket
- A paper template (showing the dimensions of the boiler with
5 mm side clearances and fitting instructions and on the
reverse, the fixing positions for the spacer bracket)
- Connection tails
- Screws and wall plugs
- Connection washers
- Pre-piping jig
- Installation and Operation manual
Positioning the boiler on the wall.
The paper template can be used to ensure the correct
positioning of kitchen cabinets etc.
The paper template is fixed to the wall and used to locate the
position of the hanging bracket, the centre for the flue hole
and, if required, the fixings for the pre-piping jig.
If there is a requirement to pass the piping behind the
boiler, it will be necessary to fit a spacing bracket. This is
available as an optional accessory. The standard paper
template shows the positions for the spacing bracket
fixing screws.
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Safetv Valves
Drill and plug the wall and secure the hanging bracket using
the screws provided (refer to the paper template drawings).
Remove the boiler from its packaging as shown in (fig. 8) and
remove the outer case as shown in (fig. 9).
Please note: If the pre-piping jig has been used it must be
removed before attempting to hang the boiler.
Place the boiler on the wall on the hanging bracket.
Connecting the boiler to the system
- Push in the tabs P (fig 10) on either side of the boiler and
pivot the electrical box forward to gain access to the valve
connections.
- Remove the yellow caps and connect the boiler to the taps
using washers provided in the plastic bag.
3 x fibre washers for the C/H flow and return and hot water
outlet connections
1 x fibre washer and mesh filter “F” for the cold water inlet.
1 x rubber washer “R” for gas connection.
Using (fig. 10) for reference, connect the gas and water pipes
to the valves located at the base of the appliance using the
tails provided. There is a 190 mm space between the valves
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.
There are two pressure relief valves fitted to the CALYDRA.
The DHW pressure relief valve connecting pipe is supplied
attached to.the valve and the CH pressure relief valve tube is
clear silicone and is packed with the boiler. They should
terminate together below the boiler over a tundish or a 28 mm
to 22 mm reducer (see P 17, fig 10) which should in turn
discharge safely outside the premises. Care should be taken
f
Fig. 8
Fig. 9
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so that it does not terminate over an entrance or window or
where a discharge of heated water could endanger occupants
or passers by.
The system should be carefully checked for leaks, as frequent
refilling could cause premature system corrosion or
unnecessary scaling of the heat exchanger.
J Heating flow 022mm
K D.H.W. flow 015mm
L Gas supply 022mm
M Cold wafer inlet 015mm
N Heating return 022mm
P Safety valve outlet 015mm
Q D.H.W. safety valve outlet 015mm
Fig. 10
Fitting the Horizontal Flue
The instructions for the installation of the elevated horizontal,
concentric vertical, biflux (twin pipe) and SE duct flue options
are included with the relevant adapter kits.
The horizontal standard flue supplied with the appliance is
suitable for lengths from 300 mm minimum to 610 mm
maximum. This means for rear flueing, the standard kit will
accommodate a maximum wall thickness of 490 mm, and for
side flueing a maximum wall thickness of 477 mm. This takes
into account the minimum appliance side clearances of 5 mm.
If the fixing is a rear exit flue, the template provides the
position of the centre for drilling the flue hole with a core drill.
If the flue is a side exit installation then calculate the position
of the hole with a slope, away from the boiler, of 5 mm / metre
to the terminal.

Making the Electrical Connections
Push in the tabs (P fig. 11) on either side of the boiler and pivot the
electrical box forward to gain access to the electrical connections.
Undo the two retaining screws (A fig. 1l), remove cover (B fig. 11)
and remove cable clamp.
Connect the live and neutral wires to the multipin plug leaving
sufficient earth wire to connect to the earthing point. (B fig. 12)
Note: The connections should be made so that should the lead be
pulled from its anchorage, the current carrying wires become taut
before the earth wire.
If using a room thermostat or other external control, they can be
connected in place of the link on the multipin plug. (fig. 12).C
Note: Use only controls designed for voltage free switching or 24V
supply. Do not connect to a 230V supply.
Connect multipin plug into the socket on the pcb (D fig. 12)
attached to the cover (B fig. 11). Secure the cable using the cable
clamp and replace the cover.
NB Any changes to the factory settings on the pcb can be
made before replacing the electrical box cover (see electrical
adjustments pages 20 and 21).
Fig. 11

Making the Electrical Connections (continued)
.
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Mains
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i
Room
l Thermostat

Pre-commissioning
Ensure that the system has been adequately flushed.
Purge gas supply of air and test for soundness.
Carry out final electrical tests to ensure the correct polarity and
earthing continuity.
Electrical Adjustments
There are three adjustments that can be made:
1. Room thermostat options
2. Pump speed
3. Burner operating modes :
1. Room thermostat options
To gain access to the setting switch (1 fig. 13) pivot forward the
electrical box cover and remove the cover (B fig. 11)
- move the switch to the left - (factory setting). When room
thermostat is satisfied the burner switches off and the pump over
runs for 3 min.
- move switch to the right - When room thermostat is satisfied the
burner switches off and the pump continues to run until the main
selector is turned from a heating position.
2. Pump Speed Adjustment
- move switch to the left (marked GV) - pump on high speed (factory
setting)
- move switch to the right (marked PV) - pump on low speed for use
on small systems