Chaffoteaux & Maury Calydra green 24 Manual

MAINTENANCE AND
SERVICE GUIDE
Fanned Flue Condensing
Combination Boiler
Heating and Storage Domestic Hot
Water with TSS®
Dimensions
Flue types:
C 13: - C 33 - C 53
C
54 54 54 54
JKLMN I
88
JK
L
MN
232
235
32
Safety valve
center line
All dimensions in mm
Outer case dimensions :
- Width : 440 (minimum space required 450)
- Height : 850
- Depth : 24 kw : 380 30 kW : 405
212
360
67
737
850
50
ISafety valve outlet
JHeating flow
K D.H.W. flow
LGas supply
MCold water inlet
N Heating return
24 kW : 380
30 kW : 405
Technical data
Natural gas G20
Gas rate C.H. max .................. 2.64 m3/h 3.01 m3/h
Gas rate D.H.W. max .............. 2.64 m3/h 3.01 m3/h
Gas rate C.H. & D.H.W. min ... 0.87 m3/h 1 m3/h
Gas valve restrictor diameter .. without without
Propane L.P.G G31
Gas rate C.H. max. ................. 1.94 kg/h 2.21 kg/h
Gas rate D.H.W. max. ............. 1.94 kg/h 2.21 kg/h
Gas rate C.H. & D.H.W. min ... 0.64 kg/h 0.73 kg/h
Gas valve restrictor diameter .. 4.40 mm 4.8 mm
24 kW 30 kW 24 kW 30 kW
Heat gross input C.H. max ............................ 9.2-27.8 kW 10.4-31.6 kW
Heat gross input D.H.W. max........................ 9.2-27.8 kW 10.4-31.6 kW
Heat output C.H. 50°/30° max....................... 9-26 kW 10-30 kW
Heat output C.H. 80°/60° max....................... 8-24 kW 9-28 kW
Heat output DHW maxi ................................. 8-24 kW 9-30 kW
C.H. operating temperature........................... 80°C max 80°C max
C.H. circuit pressures Min operating ............. 0.7 bar 0.7 bar
C.H. circuit pressures Max operating ............ 2.5 bar 2.5 bar
D.H.W. flow rates 30°C ................................. 12.5 l/min 14.5 l/min
D.H.W. flow rates 35°C ................................ 10.7 l/min 12.4 l/min
Cold water mains pressures Min operating... 0.5 bar 0.5 bar
Cold water mains pressures Max operating.. 10 bar 10 bar
Flow limiter rate............................................. 8 l/min 10 l/min
Safety discharge ........................................... 3 bar 3 bar
Expansion vessel - Pre-charge pressure ...... 0.7 bar 0.7 bar
Net capacity at 3 bar in litres......................... 5.44 5.44
Supply ........................................................... 230 v 230 v
Consumption ................................................. 150 w 150 w
Protection ...................................................... IP 44 IP 44
Fuse F1/F2/F3/F4 ......................................... 2 A/1.25 A/0.315 A/0.250 A
External controls ........................................... 24 v 24 v

2
Pump and expansion vessel characteristics
Components location
Note : The system initial pressure should be over the following value :
System static height (in metre) + 0.7 = Initial pressure (in bar)
10
GV F= high speed by-pass closed
GVO = high speed by-pass open
PV F= low speed by-pass closed
PVO = low speed by-pass open
20 40 60 80 100 120
Pf
140 160 180 200 220 240
0,7
0,8
0,9
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
C
80°C
70°C
60°C
50°C
40°C
260
Pression à froid pour le circuit chauffage (en bar)
C liter
System capacity chart
Central heating initial pressure when cold (in bar)
0
4
3
2
1
5
6
100 200 800
700
600
500
400
300 900 10001100 l/h
mCE Débit mini (robinets thermostatiques fermés)
Hauteur manométrique
GVF
GVO
PVF
PVO
Pump head available
Minimum flow rate (with all heating thermostatic valves closed)
bar
0
13
4
42 43 44
41
40 45
46
47
1
2
3
4
5
6
8
11
12
13 14
7
15
10
9
16
1.- Steel chassis complete with expansion vessel
2.- Sealed chamber
3.- Burner and heat exchanger assembly
4.- Air / gas connection
5.- 24 V modulating fan
6.- Gas valve
7.- Ignition electrode
8.- Ionisation probe
9.- Ignitor
10.- Combustion products manifold
11.- 24 V transformer
12.- Siphon
13.- Electrical box
14.- Pump
15.- Secondary heat exchanger
16.- Pressure gauge
17.- Three way valve
18.- Automatic air separator and automatic vent
19 - Central heating flowswitch
20.- Domestic hot water flowswitch
21.- Central heating control thermistor
22.- Hot water control thermistor
23.- TSS Control thermistor
24 - Overheat sensor
25 - TSS ®(mini cylinder)
26 - DHW pressure relief valve.
40.- Central heating flow isolating valve
41.- Domestic Hot Water outlet
42.- Gas service tap
43.- Water service tap
44.- Central heating return isolating valve
45.- Central heating pressure relief valve
46.- User’s guide
47.- Connecting tails (x 5)
48.- Adjustable by-pass
49 - Silencer
20
21
17
19
22
23
24
25
26
18
49
48

3
FUNCTIONING
Control panel
38
33 27 32 30
28
37
31
36 39
3435 29
27 - Display
28.- Domestic Hot water switch
29.- Green indicator – Domestic Hot Water mode ON
30.- D.H.W. temperature reducing key
31.- D.H.W. temperature increasing key DHW mode indicator
32.- Central Heating switch
33.- Green indicator – Central Heating mode ON
34.- Central Heating temperature reducing key
35.- Central Heating temperature increasing key
36.- Green indicator – Power ON
37.- Orange indicator - Burner ON
38.- Red indicator - Lock out / flame failure
39.- Reset key
Switching on
1. Check that the pressure in the Central Heating system is above 0.7 bar and below 1.5 bar with the pressure gauge 16.
2. Check that the gas service tap is opened at the gas meter and the main power is on. Green indicator Power ON 36.
3. Open the gas tap 42.
The boiler is now ready to use.
Attention ! If the boiler remains off for a prolonged period of time, air may collect in the gas pipes and can hinder the boilers initial
attempts to light. (please refer to section 18 Incorrect Function)
Switching on the Central Heating
Press key 29 , the green indicator 33 will light and the display will show the Heating
flow temperature.
Keys 34 and 35 allow the adjustment of the temperature required in the Central Heating
system depending on the weather conditions.
• press to increase temperature when the weather is cold
• press to reduce temperature when the weather is fair
During the temperature setting operation the display will flash.
If the room thermostat is calling for heat, a dot will be displayed at the bottom of the 3rd digit

4
Switching on the Domestic Hot water and Central Heating together
Press key 29 the green indicator 33 will light.
Press key 28 the green indicator 32 will light.
If there is no water demand the display will show the heating flow temperature
If the tank is heating up
the digit will move clockwise on the display
In case of draw off a square made of 4 digits will move clockwise on the display
Turn off the boiler
- Press keys 29 and 28 , to switch off both D.H.W. and C.H. mode. The green indicators 33 and 32 will stop
- Switch off the main electrical supply
- Shut off the gas service tap 42
Note : In this condition, the anti-freeze system is inoperative
Stand by mode A fixed digit at the centre of the display and the green indicator 36 on
Putting the boiler in stand by mode and anti-freeze system. :
Press keys 29 and 28 , to switch off both DHW and CH mode. The green indicators 33 and 32 will stop.
During the duration of the stand-by mode, an automatic anti-sticking system will switch on the pump for 1 minute and
make a movement of the 3 way valve every 23 hours.
The stand-by mode will disable the anti-freeze function of the room thermostat (if fitted). To leave the room thermo-
stat anti-freeze system operative, please leave the Central Heating mode on.
The boiler is equipped with an automatic anti-freeze system which is permanently on.
If the Central Heating temperature decreases below 7°C, the pump will start.
If the Central Heating temperature decreases below 4°C, the pump and the burner will start.
Switching on the Domestic Hot Water
Press key 28 , the green indicator 32 will light :
If there is no water demand
the display will show the following graphic
If the tank is heating up
the digit will move clockwise on the display
In case of draw off
a square made of 4 digits will move clockwise on the display
Keys 30 and 31 allow the adjustment of the temperature required for the Domestic Hot Water flow. During the tempera-
ture setting operation the display will flash.
Note : The configuration of the C.H. system can generate some gravity effect when the boiler is set in D.H.W. mode only. It may
result in a temperature rise of the heating pipes close to the boiler (or eventually a radiator). To avoid this, it is possible to close dur-
ing the summer period (Central Heating switched off) the heating flow isolating tap (40). Don’t forget to open it before switching on
the Central Heating mode again.

5
Domestic Hot Water Mode
To be able to supply hot water, the DHW
mode should be ON. Press on key 28
, the green indicator 32 will light.
If there is no water demand, the display
will show the following graphic if
the TSS®is cold, the burner
will light immediately. In case of draw off,
a square made of 4 digits will move
clockwise on the display .
Keys 30 and 31 allow the adjust-
ment of the temperature required for
D.H.W., flow. During the temperature
setting operation, the display will flash.
When a tap or a shower is turned on, the
flow of mains water, above 2 litres per
min., will activate the DHW flow switch
20 or if the TSS®thermistor is calling for
heat and allow the 3 way valve 17 to
move to the DHW position. The pump
can now circulate primary water heated
by the main exchanger through the sec-
ondary heat exchanger and TSS®coil.
The primary flow switch checks that this
flow rate is over 4lt./min. before allowing
the lighting sequence to begin.
The fan on the gas valve assembly starts
and when the lighting speed is reached
(detected by a hall effect sensor) the 2
safety solenoids 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 led 34
will light and the regulation system will
be able to adjust the gas rate regarding
the heat load. If the TSS®thermistor is
calling for heat, the burner will stay in
minimum output. If a flame is not detect-
ed, after 10 seconds, the security sole-
noids close together and shut off the
gas. The red lockout indicator led 38 will
light. Press the reset button to re-light
the burner.
For flow rates of less than 2 l/min, the
domestic hot water temperature is con-
trolled by TSS®thermistor 23 and heat-
ing thermistor 21. For flow rates over 2
l/min , the domestic hot water tempera-
ture is controlled by hot water control
thermistor 22 and the central heating
control thermistor 21. This system antici-
pates the changes of temperature in the
secondary heat exchanger and ensures
accurate temperature regulation.
When the tap is closed the burner may
stay alight until the TSS®cylinder is up
to temperature. Then the burner is extin-
guished and the pump stops. The boiler
will now stay in the hot water mode for 3
minutes to maintain temperature to
ensure a fast response in the event of a
subsequent hot water demand.
Priority will be given to a demand for hot
water or re-heating of the TSS®cylinder.
This will interrupt the central heating for
the duration of hot water supply.
Central Heating Mode
To be able to supply heating, the mode
should be switched ON. Press key 29
, the green indicator 33 will light, and
the display will show the Heating Flow
temperature.
Keys 34 and 35 allow the adjust-
ment of the temperature required for the
Central Heating system regarding the
weather conditions. During the setting
operation, the display will flash.
When there is a demand for heating,
(either from the room thermostat or the
clock) the pump starts. If the boiler tem-
perature control is calling for heat and
the primary flow rate is over 4 lt./min.,
the central heating flow switch operates,
allowing the ignition sequence to begin.
The fan on the gas valve assembly starts
and when the lighting speed is reached
(detected by a hall effect sensor) the 2
safety solenoids 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 LED 37
will light and the regulation system will
be able to adjust the gas rate regarding
the heat load. If a flame is not detected,
after 10 seconds, the security solenoids
close together and shut off the gas. The
red lockout indicator LED 38 will light.
Press the reset button to re-light the
burner.
The Central Heating flow temperature is
controlled by the Central Heating control
thermistor 21. The boiler has been
designed to minimise cycling and will not
attempt to re-light for at least 3 min. after
the boiler thermostat has been satisfied.
When the room thermostat is satisfied ,
the burner will switch off and the pump
will remain running for a further 3 min-
utes before it too stops.
Note: It is possible to override the 3
minute delay by pressing the Reset key
39.

6
Lockout procedure
Flame disappearance :
When the ionisation electrode 8does not
detect flame presence. The orange indi-
cator led 37 extinguishes. A lighting
cycle starts. If a flame is not detected,
before 10 seconds, the safety solenoids
will close. The lockout red indicator 38
lights and the display shows the error
code. The pump runs and the 3 way
valve 17 stays in its position. After a few
seconds, it will become possible to reset
the boiler by pressing the reset key 39.
Overheat detection :
If an overheat (over 100°C) is detected in
the primary circuit by the sensor 23, the
safety solenoids close and the fan stops.
The orange LED 37 extinguishes and the
pump remains running for 3 minutes.
The reset will only be possible once the
primary temperature has dropped below
76°C.
CALYDRA GREEN FUNCTIONAL DIAGRAM
17 18
19
20
21 23 24
26
27 28 29 30 31 33 32 34
36
37 38
39
1
2
3
4
5
6
78
9
10
11
12
13
14 15
16
22
25
35
17 18
19
20
21 23 24
26
27 28 29 30 31 33 32 34
36
37 38
39
1
2
3
4
5
6
78
9
10
11
12
13
14 15
16
22
25
35
Heating mode Hot Water mode
DIAGRAM
ELECTRICAL WIRING

7
5 ” Menu - 1 - Default register
Record the last 10 defaults
Section Digit 1 Digit 2 and 3
Last default occured 0•code from 01 to 99
Last but one default occurred 1•code from 01 to 99
... ... code from 01 to 99
Last default occurred before the previous one 9•code from 01 to 99
Menu - 2 - Boiler conditions
Indicates the conditions or the configurations of the boiler
Section Digit 1 Digit 2 and 3
Software version of display PCB 0•10 to 99
Flue type 2•1: FF
variable speed
Room thermostat is calling for heat 3•0: no
3•1: yes
Theoretical position of the 3 way valve 4•0: DHW
4•1: CH
DHW flow temperature in Celsius degrees 5•from 00 to 99
TSS®temperature in Celsius degrees 6•from 00 to 99
CH flow temperature in Celsius degrees 7•from 00 to 99
Software version of main PCB 9•10 to 99
DISPLAY
ACTION CONFIGURATION
once
x times
x times
Note -- is displayed if no default is recorded.

8
Menu - 3 - Boiler options
DISPLAY
ACTION CONFIGURATION
Section Digit Digit
1 2 and 3
Under floor heating system 0 0: no
1: yes
DHW Delay 5 0 to 5 mn by step 0.5mn
(time before CH relight after a DHW cycle)
DHW flow swith Delay 6 0 to 20 1/10 seconde
(time before DHW flow detection to
override pressure peak problem)
Factory
setting
once
x times
Menu - 4 - Boiler settings
Section Digit Digit
1 2 and 3
Room thermostat operation 0 0: Burner only
01: Burner and pump
Pump speed 1 0: High speed
11: Low speed
Pump post circulation duration 2 0.0 min
From 0 to 5 minutes by step of 0.5 min. 2 0,5 min
21.0 min
25.0 min
Maximum Central Heating flow temperature 4 50°C
480°C
C.H. anti-cycling delay 8 0.0 min
From 0 to 7 minutes by step of 0.5 min. 8 0.5 min
82.5 min
85.0 min
C.H. maximum output limitation
Model 24
From step 0 (P. min.) 8 kW Value from
to step 10 (P. max.) 24 kW 9 0 to 10
Model 30
From step 0 (P. min.) 9 kW Value from
to step 10 (P. max.) 28 kW 9 0 to 10
Factory
setting
DISPLAY
ACTION CONFIGURATION
once
x times

9
Menu - 5 - Combustion rate control mode
X X
X X
DISPLAY
ACTION CONFIGURATION
wait 5 ” Combustion rate control mode OFF
Switching on the combustion rate
control mode. Central heating out
put reaches the maximum power
set in menu 4 section 9.
Central heating temperature is dis-
played in celsius degrees.
The 3 dots indicate that the combus-
tion rate control is ON at maximum
output.
Switching the combustion rate
down to minimum power.
Central heating temperature is dis-
played in celsius degrees.
The dot indicates that the combus-
tion rate control is ON at minimum
output.
Switching on the combustion rate to
maximum output set in menu 4 sec-
tion 9.
Central heating temperature is dis-
played in celsius degrees.
The 3 dots indicate that the combus-
tion rate control is ON at maximum
output.
X X
Switching off the combustion rate
control mode.
press once
press once
press once
press once
press once
Effect Display
Locking conditions of the combustion rate control mode :
- boiler in stand by mode
- D.H.W. draw off
- room thermostat is not calling for heat
- room thermostat is calling for heat but the maximum temperature is reached
- boiler in lockout mode
- after a reset or if the main supply fails
- end of the mode if operator leave menu 5
- after 15 minutes if there is no actions on keyboard
Note : As soon as the combustion rate control mode is on, Central Heating and Domestic Hot Water keys
are inactive.

10
C.H. heat output setting :
If you would like to change the setting of the C.H. heat output, please proceed as follows:
(note: the factory setting is 18 kW and the following explanation refers to menu 4 section 9)
- Switch to installer mode, press key
and on DHW side for 5 sec-
onds.
The display shows :
-1- then 0•-- if there is no default in the
default register.
- press 3 times on menu key (on
C.H. side) to gain access to menu -4-,
The display shows :
-4- then the value set for section 0 ( 00
or 01 respectively Action on burner only
or pump and burner)
- change to section 9 (Adjustment of
C.H. heat output). Press key on
D.H.W. side 9 times.
The display shows:
906 (which corresponds to the 18 kW
which is the factory setting)
9= section 9 06 = 18 kW
- press setting key (on CH side)
once, the 2nd and 3rd digits flash
together. Then press the or
key on the D.H.W. side to change the
C.H. heat output step between 00 and
10.
Press the setting key to confirm the
value. The display stops flashing.
Setting procedure is finished.
To exit from setting mode, leave the
boiler for approx. 1 minute, the comput-
er will switch back to user mode.
After programming please close the
door P.
1
Display
2x 3
1
2
or
33x 9
44
5 ”

11
REGULATION FLOW SWITCHES
Temperature regulation for both C.H., TSS®and D.H.W. circuits are con-
trolled by 3 thermistors. The C.H. knob allows the adjustment of temperature
between 35 and 85°C. The D.H.W. temperature is limited to 60°C. TSS®,
D.H.W. and C.H. thermistors are identical and interchangeable.
Resistance value are
- 5000 Ωat 25 °C
- 2631 Ωat 40°C
- 620 Ωat 80°C
- 255 Ωat 110°C
Flow in both D.H.W. and Heating cir-
cuits are detected by 2 flow switches. A
piston with a magnet at the top operates
a REED switch. The piston is lifted by
flow rates listed below :
Flow rate threshold :
D.H.W. 120 l/h ±20 l/h
C.H. 250 l/h ±20 l/h
ROUTINE SERVICING
To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at reg-
ulars 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 competent person such as your local Chaffoteaux Service Centre,
British Gas or other CORGI registered personnel in accordance with the current Gas Safety (Installation and Use) regulation.
Attention ! the air/gas connection pipe between the gas valve and the burner should never open. The seal can be checked only
in the factory.
The service schedule should include the following operations :
- Check the pressure in the system
- Check the correct operation of the appliance
- Check the correct operation of the gas controls
- Check the functions of safety controls
- Clean the electronic board of the fan located on the gas valve assembly and the different transformers in the sealed chamber.
- Check combustion chamber insulation panels for damage
- Check the lighting and ionisation electrodes condition
- Clean the burner (Never use a metallic brush as this can damage the stainless steel)
- Clean the heat exchanger (Never use a metallic brush as this can damage the stainless steel)
- Clean the siphon and pay attention to the acidity of its contents
- Check the correct seal of the drain system
- Clean gas and water filters
- Check expansion vessel charge pressure
- Clean and check the operation of the safety valve
- Check the correct seal of the flue system.
Additional procedures that may be necessary :
- Check the burner pressure and the gas flow rates
- Check, clean or replace components as necessary
- Carry out combustion test utilising the test points in the flue turret
Suggested sequence for servicing :
Before disconnecting or removing any part, isolate the gas and electricity supplies. Ensure that the appliance is cool, and take
care about the condensate products content in the siphon which are acid.
(For detail, please see section on Parts Removal and Replacement)
Preliminary checks
- Remove outer case
- Check the system pressure is at least 0.7 bar cold
- Check the modulation of the gas valve in DHW mode by reducing progressively the flow rate at a tap.
- Check that the burner is extinguished fully when both solenoids are closed and fan is off.
- Test ionisation functions and check that lockout occurs by turning off gas tap.
- Whilst the boiler is operating, check the operation of the primary flow switch by closing the Central Heating flow valve and by-
pass screw (turn clockwise ) noting the number of turns so that it may be reset correctly.
- Check the correct flood of condensate into the siphon which is transparent.

12
REMOVAL AND REPLACEMENT OF PARTS
Before removing the appliance case,
isolate the gas and electrical supplies.
Isolate the boiler from the system and
drain before removing any component in
the waterways. Ensure that the appli-
ance is cool.
1. Outer Case
Remove the four screws Ain the bottom
of the case and lift free. When replacing,
carefully locate on lugs Ton the top
edge of the chassis.
2. Sealed chamber front panel
Unscrew the four self tapping screws
securing the sealed chamber front panel
and lift over the top corner locating lugs.
Reassemble in reverse order.
3. Combustion Chamber front panel
and air/gas connection
Carry out steps 1 and 2 as above.
Unscrew the three screws securing the
air/gas connection pipe onto the gas
valve assembly. Disconnect the ionisa-
tion and lighting electrodes from their
wiring. Unscrew the six nuts to release
the combustion chamber front panel and
pull the assembly towards you.
Reassemble in reverse order.
4. Ionisation electrode
Carry out steps 1 and 2 as above.
Disconnect the ionisation electrode from
its wiring. Loosen the 2 screws and pull it
out from the combustion chamber front
panel. Replace the ionisation gasket
provided. Reassemble in reverse order.
5. Lighting electrode
Carry out steps 1 and 2. Disconnect the
lighting electrode from its wiring. Loosen
the 2 screws and pull it out from the
combustion chamber front panel.
Replace the ionisation gasket provided.
Reassemble in reverse order.
6. Burner
Carry out steps 1, 2 and 3. Remove the
4 Philips screw retaining the burner onto
the combustion chamber. Pull it out with
care to avoid any damage to the ceramic
panel protecting the combustion cham-
ber front panel. Replace the burner gas-
ket. Reassemble in reverse order.
7. Gas vale assembly
Carry out steps 1 and 2 Unscrew the
three screws securing the air/gas con-
nection pipe onto the gas valve assem-
bly. Disconnect the connectors from the
gas solenoids and fan. Loosen the gas
pipe nut. Unscrew the six nuts to
release the combustion chamber front
panel and pull the assembly towards
you. Replace the gas filter before fitting
the full assembly back into the boiler.
8. Fan assembly
Carry out all the operations mentioned in
step 7. Unscrew the three screws secur-
ing the air/gas connection pipe onto the
gas valve assembly. Separate the gas
valve assembly and the venturi from the
fan assembly by loosening the two
hexagonal head screws. Reassemble in
reverse order and replace all necessary
gaskets.
9. Gas section
Carry out all operations mentioned in
step 7. Unscrew the three screws secur-
ing the air/gas connection pipe onto the
gas valve assembly. Separate the gas
valve assembly and the venturi from the
fan assembly by loosening the two
hexagonal head screws. The venturi and
the gas section can be separated by
loosening the 2 screws located at the top
of the gas valve. Replace all necessary
gaskets before reassemble in reverse
order.
10. Venturi in the gas section
Carry out all operations mentioned in
step 7. Unscrew the three screws secur-
ing the air/gas connection pipe onto the
gas valve assembly. Separate the gas
valve assembly and the venturi from the
fan assembly by loosening the two
hexagonal head screws. The venturi and
the gas section can be separated by
loosening the 2 screws located at the top
of the gas valve. Replace all necessary
gaskets before reassembling in reverse
order.
11. Drain down
2 drain points are located on the boiler.
1 = DHW circuit drain point
2 = Heating circuit drain point
12. Water filters ( DHW and Heating)
The DHW filter ensures a seal between
the connecting bracket and the pipe to
the DHW flow switch. Drain the boiler as
in step 11. Unscrew the pipe nut and
remove the clip on the hydraulic assy.
Pull the pipe toward you and remove the
water filter from its location.
The C.H. filter is located in the right
hydraulic assembly. Remove the return
pipe as described previously and with-
draw the filter. Reassemble in reverse
order.
13. Flow switches
Drain boiler as in step 12. Disconnect
the electrical plug, turn the top cover
anti-clockwise, remove the O-ring and
the brass piston. Reassemble in reverse
order.
14. 3-Way valve
Drain boiler as in step 12. Remove the 3
clips on the 3 way valve. Remove the
clip on the exchanger flow pipe. Pull the
pipe down then pull it out of the 3 way
valve. Disconnect the plug from the
motor. Unscrew the nut on the pipe
between the connecting bracket and the
3 way valve and pull it toward you.
Rotate the 3 way valve body anti-clock-
wise to unclip it from the left hydraulic
assembly.
15. Secondary heat exchanger
Drain both circuits of the boiler as in step
12. Unscrew the 2 fixing screws Dand
remove the DHW exchanger from the
front. Prior to reassembly, check that the
4 gaskets are correctly positioned. The
heat exchanger is so designed that it
AAAA
TT
1
2
12
air separator
D

13
cannot be remounted incorrectly.
16. Main heat exchanger
Carry out steps 1 and 2. Drain down the
boiler as in step 12. Unscrew the three
screws securing the air/gas connection
pipe onto the gas valve assembly.
Disconnect the ionisation and lighting
electrodes from their wiring. Unscrew
the six nuts to release the combustion
chamber front panel and pull the assem-
bly towards you. Undo the two clips of
the pipes to the main exchanger and pull
down the pipes. Unscrew the three
screws located at the bottom, top left
and the right with the retaining system to
be able to pull the main heat exchanger
towards you.
Reassemble in reverse order taking care
about the location of the gasket on the
fumes collector and replace all neces-
sary gaskets.
17. Pump
Drain boiler as in step 12. Pivot the elec-
tical box downwards. Open the electrical
box cover removing the 2 screws.
Remove the pump plug from the power
board and the earth plug from the earth
socket. Unscrew the nut Fof the return
pipe from the volute. Remove the clip G
on the pump volute and pull the pump
toward you. Reassemble in reverse
order.
18. Pressure relief valve
The pressure relief valve can be ser-
viced from the front of the appliance.
Drain the boiler first, undo the retaining
screw and pull out the valve.
Reassemble in reverse order.
19. Thermistors
Drain the boiler as step 12. Disconnect
the plug, remove the retaining clip pull
the thermistor out. Reassemble in
reverse order.
22 = DHW thermistor
21 = Heating thermistor
20. Safety thermostat
Remove the casing as step 1 and hinge
down the electrical box as step 5.
Disconnect the 2 cables, pull out the
sensor with the clip (13). Reassemble in
reverse order.
21. Spark generator
Carry out steps 1 and 2. Unplug the con-
nector from the spark generator located
on the right hand side of the main heat
exchanger. Loosen the two screws to
remove the igniter. Reassemble in
reverse order.
22. Main control board
Carry out step 1 as above and hinge
down the electrical box by pressing the
retaining tabs Pon either side. Remove
wiring cover C. Undo the 4 screws of the
electrical rear panel and remove it.
Unplug all cables from the PCB, remove
the earth plug from the earth socket.
Hang out the main PCB. Reassemble in
reverse order.
23. Display PCB
Carry out step 1 and hinge down electri-
cal box by pressing the retaining tabs P
on either side. Remove the pressure
gauge clip. Rotate the electrical box
back into the upper position. Undo the 2
screws retaining the front panel, put your
two hands at the bottom of the front
panel and pull it down to release it from
the 2 clips. Hinge down again the electri-
cal box. Undo the 4 screws of the electri-
cal rear panel and remove it. Unplug the
display board cables from the main PCB.
Reassemble in reverse order.
24. Expansion vessel
Remove the casing as step 1 and drain
the boiler as step 12 above. Unscrew
the connecting tails nuts and lift out the
boiler from the wall. Place it on a side on
the floor. Remove the expansion vessel
bracket retaining screws, disconnect the
pipe from the vessel and pull it toward
you. Reassemble in reverse order.
25. Pressure gauge
Carry out step 1 and drain the boiler as
step 12. Hinge down the electrical box
by pressing the retaining tabs Pon either
side. Press on the clip to remove it and
pull it out. Remove the clip which holds
the connection of the capillary onto the
pump hose. Hang out the pressure
gauge with its capillary. Reassemble in
reverse order.
26. TSS®
Drain both circuits of the boiler as in
step 11. Unscrew all nuts from the con-
necting bracket and remove the gas pipe
from the gas section. Remove the main
exchanger flow pipe to the 3 way valve.
Remove the pump as in step 17. Unplug
all thermistors, 3 way valve, flow switch-
es. Unscrew the 2 retaining screws of
the hydraulic section to the chassis.
Pull the hydraulic assembly toward you.
Reassemble in reverse order and check
the gas section for soundness and the
water circuits for leakages.
F
G
21
22
24
P
P
C

14
FAULT FINDING CHART Part 1
Switch on the main electrical supply
Does the green LED
alight ?
- Check mains electrical
connection
- Check internal fuses
- Check connection between
the 2 PCBs
Replace control PCB or
display PCB
Replace control PCB
Replace DHW flow switch
Switch Domestic Hot Water
mode ON
Release pump rotor
Replace pump
Replace fan assembly
Replace heating flow switch
Does the red LED
light ?
Does the display
show a - XX code ?
Does the fan run ?
Check heating flow switch
Check voltage on
the fan
Check the 24 V at
the transformer
Press the reset button
Please refer to the list of error
codes and solve the problem
Does the pump run ?
Check that the
pump spins freely
Check voltage in the
pump electrical box
Replace control PCB
Could you see the
spark generation?
Does the spark
generator energize ?
Does the -24 error
display ?
Replace spark generator or
ignition electrods assembly
Replace transformer or the rel-
evant fuse
- Check pressure probes
or
- Check flue duct condition
or
- Replace pressure switch
Yes
Yes
Yes
Yes
No
No
No
No
Ok
Ok
No
Check or replace main or sec-
ondary heat exchangers. They
could be fully scaled.
Check flow in the
boiler primary circuit
Ok
No
Replace heating thermistor Check heating
thermistor
Ok
No
No
No
No
Yes
Yes
Yes
No
No
No
Ok
Ok
Ok
Ok
means a test or a choice means an action means a group of actions error code displayed
PLEASE CHECK THE FOLLOWING POINTS CAREFULLY BEFORE GOING THROUGH THE FAULT FINDING CHART -Gas pressure -Electric mains -Minimum water pressure in the heating circuit (over 0.8 bar) -All isolating valves have been opened -Boiler air vented -Minimum domestic hot water flow of 2 l/min -Check that the heating filter is clear. - Remove the front panel of the sealed chamber
-7
Yes
Check or replace the DHW fow
switch
Draw off Domestic Hot Water
at a tap
Does the pump run ?
No
Check DHW flow
switch operation
No No
Ok
-7
-7
-11
-12
Ok
Ok
No
No
-3
Wait for 4 seconds
-3
Error code Description
1Overheating LockOut 3No flame detection
5Anti-frost mode on 6Anti-frost mode on 7No water circulation 8Faulty water circulation in the primary circuit 9DHW thermistor faulty, Opened circuit
10 DHW thermistor faulty, Short circuit 11 Central heating thermistor faulty, Opened circuit 12 Central heating thermistor faulty, Short circuit 18 Ignition test 20 Faulty connexion 23 Low speed fan 24 Faulty control functionning fan 25 TSS®thermistor faulty opened circuit
26 TSS®thermistor faulty short circuit 29 3 ways valve locked in Heating position 31 Error communication with EEPROM 32 Error communication with the main PCB

15
FAULT FINDING CHART Part 2
Replace control PCB
Can you see the
flame on the burner ?
Replace gas section assembly
Do you feel air
drawing in at the air
Do the gas
solenoïds energise ?
Check that air inlet pipe, ven-
turi, fan, air/gas pipe or burner
are free of dust and not blocked
Purge the gas pipe and press
on reset button
Does the DHW tem-
perature rise?
Does the burner still
alight ?
Does the red LED
light and -3 displayed ?
Does the orange
LED light ?
Replace control PCB
Replace DHW thermistor
Replace control PCB
Replace display PCB or control the
connection between the 2 PCBs
- Adjust the DHW flow rate to
3 l/min at a tap. - Wait until the temperature becomes stable.
No
No
No
No
No
Yes
No No
Does the orange
LED light ?
No
Yes
Replace the DHW heat
exchanger
Yes
Yes
Yes
Yes
No
-3
Replace display PCB or control the
connection between the 2 PCBs
Is the combution
chamber full of conden-
sates ?
Yes
Check ionisation
probe
No
Ok
Drain and clean combustion cham-
ber, siphon and drain pipes
Yes
Replace the ionisation probe
No
Stop water draw off
Does DHW temper-
ature rise over 70°C ?
Check DHW ther-
mistor
No
Ok
- Press on DHW key to switch
off DHW mode. - Press on CH key to switch on CH mode and set CH tempera- ture to maximum. - Press the RESET button to cancel the 3 min. delay. - Ensure that external controls
are calling for heat.
Does the heating
outlet pipe temperature rise
?
Wait until the return pipe
become hot then reduce CH
temperature to minimum
Does the orange
LED light ?
Replace the 3 way valve
Replace control PCB
No
No
The boiler is OK
Yes
Does the heating
outlet pipe temperature
rise ?
Replace the 3 way valve
Yes
-29
No Yes
Yes
Yes
- Switch off the boiler.
- Draw off DHW at a tap until the temperature becomes cold. - Close the tap - Press on key 28
Does the orange
LED Alight
No
Check the TSS®
thermistor
Ok
Replace the TSS®thermistor
No 25 26
Boiler is OK
Yes

1311267d - 03/2003
Chaffoteaux & Maury are continuously improving their products and therefore reserve the right to change specifications without prior
notice and accepts no liability for any errors or omission in the information contained in this document.
Manufacturer: Chaffoteaux & Maury - France
Commercial subsidiary: MTS (GB) Limited
MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT
Telephone: [phone]
Fax: [phone]
internet: www.chaffoteaux.co.uk
E-mail: [e-mail]
Technical Support Help Line: [phone]
SHORT LIST
110 ELECTRODE KIT 1309624 ..
401 GAS VALVE (24 kW) 1308957 .. GAS VALVE (30 kW) 1310129
407 FAN ASSY 1307585 ..
505 THREE-WAY VALVE E23510 81839 ..
507 OVERHEAT THERMOSTAT 100°C 277783 1010572 ..
510 THERMISTANCE 277834 1000733 ..
514 WATER/WATER HEAT EXCHANGER 1302409 ..
532 WATER THROTTLE 277846 81471 ..
572 PUMP + AIR SEPARATOR 15/50 1301964 ..
PUMP + AIR SEPARATOR 15/60 1303461 ..
588 AIR SEPARATOR HEAD ASSEMBLY 1304608 ..
607 IGNITER 1002105.20 ..
615 PRINTED CIRCUIT BOARD 1310357 ..
627 FUSE 250V 2A - TEMPORIZED 277883 1003456 ..
628 FUSE 250V 1A - TEMPORIZED 1003634 ..
629 FUSE 250V 1.25A - TEMPORIZED 277884 1003635 ..
630 FUSE 250V 0.315A - TEMPORIZED 1307845 ..
640 TRANSFORMER 1308149 ..
805 PRESSURE GAUGE 1303158 ..
938 PRESSURE RELIEF VALVE 1020933 ..
DescriptionKey N°
Manf. Pt. N°
Type G.C N°
Manf. date
CALYDRA GREEN 24
CALYDRA GREEN 30
from to
110
407
401
532
505
640
514
510
507
R37
R31
J7
R102
1
+
+
+
8
C68
ST2
FT1A
Z11A
Z9A
R
DL1
TH1A
Z6A
R132
U5
Z5A
Z4A
TERRE1
TH1
C83
C78
C80
ST1
R87
Z9
Z6
Z5
Z4
Z3
Z2
Z11
Z1
U3
U10
U9
U7
U6
U4
TR1
TH2
TERRE
T8
T7
T5
T4
T3
T2
T6A
T6
T12
T11
T10
T1
SW1
RL8
RL7A
RL7
RL6
RL10
RL5A
RL5
RL4A RL4
RL3
RL2A
RL1A
RL9
RL1
RAD1
R118
R114
R113
R111
R112
R108
R107 R106
R105
R101
R97
R96
R95
R94 R93
R90 R88
R62
R58
R59
R57
R52
R53
R51
R55
R5
R78
R77
R4
R39
R35
R34
R3
R33 R32
R19
R2
R15
R25
R13
R131
C82
T14
T13
RL12
R76
R75
R71
R70
R67
R127
R116
R115
R119
R10
R1
Q1
P2
P1
MOV1
L1
J9
J10A
J8
J6
J4
J3
J2
J1 FT1
F3A
F3
F2A F2
F1A
D9
D7
D6
D5
D34
D31
D32
D4
D42
D41
D40
D39
D36
D43
D3
D29
D26
D23
D22
D20
D2
D19
D17
D15
D13
D12
D11
D1
CTP1
C8
C13
C49
R54
RL11
C35
C7
J5
C6
C52
C51
C77
C76
C75
C74
C72
C71
C70
C69
C5
C50
C48
C47 C46
C45
C43
C42
C4
C61
C60
C59
C22
C56
C55
C54
C31
C41
C39
C2
C29
C28
C27
C26
C
C11
C9
C3
C24
C23
C20
C18
C17
C14
C12
C1
K
M A
E E
K
1
1
1
1
1
EX
1
1
ROG A
K
K
KC
1
K
K
+5V
TR
COM
REP
8
0
N
628
627
629
630
607
805
938
615
588
572