Chaffoteaux & Maury Celtic FF User guide

Celtic FF
ROOM SEALED FANNED BALANCED FLUE
COMBINATION BOILER
G.C. No. 47980 01
FROM SERIAL N” 391061863
This appliance has been tested and certificated by British Gas
(For use on natural gas only)
.
I lil Ill
Installation and
Servicing Instructions
(leave these instructions with the user)
Looking Good. Heating Better

The CELTIC FFis a wall mounted, low water content fan-
ned balanced flue appliance suitable for central heating
and hot water via a non storage wapr to water heat
exchanger. The maximum out pufis24.0 kW (81,900 Btu/h).
The boiler is designed for sealed systems only and inclu-
ded in the appliance isthe expansion vessel, circulating
pump, temperature and pressure gauges, safety valve
and electric connection box.
The flue which is 100 mm (4 in) dia pipe, can be directed
to the rear or to the left or right and can be extented to a
maximum length of 3 m, or 1.6metres horizontally using the
available 90” bend (see sections 1.4.1, 1.4.2 and 1.4.3
figures 2.3.3a. 3b, 3~).
Special features include :
-Output to central heating fully range rated between
l/3 and full output.
- High efficiency.
-Special jig plate enabling all pipework to be installed
before installing appliance.
- Independent control over central heating flow tempe-
rature and hot water.
- Fully adjustable central heating flow temperature.
- regulation between 50” C and 82” C.
- High limit thermostat for both boiler and hot water.
- Integral frost thermostats to protect appliance.
-Water flow switch to protect appliance.
-Suitable for showers with mixer valves which are com-
patible with water heaters.
Guarantee
The manufacturer’s guarantee on this appliance isfor 12months from the date of installation. The guarantee isvoid ; if the
appliance isnot installed in accordance with the recommendations made herein.
1.1 DIMENSIONS
1 I
’ I
REAR OUTLET
/T
_-
F
SIDE OUTLET
-
- A
B
C
D
E
F
c
H
J
K
1
M
N
P
R
S
T
-
mm in
820.5 32.3
391.0 15.4
365.0 14.4
100.0 4.0
169.5 6.7
654.5 25.7
43.0 1.7
50.0 2.0
75.0 3.0
260.0 10.2
150.0 6.0
972.5 38.3
13.0 0.5
61.0 2.4
30.0 1.2
152.0 6.0
112.0 4.4
2

1.2 Technical Data
Hot water
Input .......................
output .....................
Water flow rate raised
45” C(81” F) ................
Water flow rate raised
30” C(54” F) ................
Maximum temperature .......
Maximum pressure ..........
Minimum working pressure. ...
Gasrate ....................
Burner pressure .............
Central heating
Maximum input. .............
Maximum output ............
Gasrate (maximum) ..........
Burner pressure .............
Minimum input ..............
Minimum output .............
Gasrate (minimum) ..........
Burner pressure .............
Minimum flow rate ...........
Maximum pressure ..........
Manifold injectors 14 off ......
Pilot injector ................
Manifold restrictors 213valve
l/3 valve.
28.41 kW j6.940 Btulh
24.0 kW II ,900 Btu/h
7.6 L/min 1.7 gal/min
11.4 L/min 2.5 gal/min
60” C 140” F
10 bar 150 psi
1 bar 15 psi
2.7 m3/h 95.35 ft3/h
12.5 mbar 5.0 in wg
28.41 kW ,6.940 Btu/h
24.0 kW II ,900 Btu/h
2.7 m3/h 95.35 ft3/h
12.5 mbar 5.0 in wg
11.6kW 39580Btulh
8.0 kW 17.300Btu/h
1.Om3/h 35.31 ft3/h
1.5Tbar 0.6 in wg
300 L/h 1.I gal/min
3.0 bar 44 psi
Natural gas
1.28 mm 0.05 in
0.3 mm 0.01 in
4.5 mm 0.18 in
2.3 mm 0.09 in
1.3 Minimum clearances around Boiler
Top above air duct 50 mm (2 in)
Bottom below case 200 mm (8 in)
Sides 100 mm (4 in)
Front 600 mm (24 in)
1.4 Wall Thicknesses
Connections
Gas .._.............. 22 mm copper
Heating flow 22 mm copper
Heating return ..__. _............ 22 mm copper
Mainscold water inlet 15 mm copper
Hot water outlet 15 mm copper
Electrical supply 240 V - 50 Hz,fused at 3A.
Electrical input 195 watts
Internally fused, two at F2A(BS4265)
Weight .._. _..........
Watercapacity _......... _.......... I ,“iiZs I 1;::
Ignition - Anstoss continuous spark generator
Electrode - Chaffoteaux Ltd. spark gap 5 mm
Boiler thermostat - EGO(82” C)
Boiler limit thermostat - Sopac(85” C)
Hot water limit thermostat - Sopac(57” C+ 3” C)
Safety overheat thermostat Tokoswitch - (105” C)
Frost thermostats Elmwood - (3” Cand 11” C)
Gas valve - AEMF
Fan motor - SEL
Pressure switch - Dungs
Pump head -Grundfos UP15/60
Expansion vessel initial charge pressure - 0.65 bar (9.6 PSI)
The standard flue assembly can accomodate the following thicknesses.
Rear :from 55 mm to 576 mm
Side :from 55 mm to 392 mm
(Thisallows for a minimum clearance of 100mm between the appliance and the side wall. As this dimension
increases, so the maximum side wall thickness available decreases).
Extention flue assemblies are available to accomodate wall thicknesses of :
Rear :from 577 mm to 2876 mm
Side :from 393 mm to 2692 mm
See figs. 2 and 3 for details of number of extensions required.
IMPORTANT NOTE :The extension ducts supplied, up to a maximum of 3,will in fact permit a greater length than
indicated to be covered. Theducts MUSTbe cut sothat the maximum length from the centre line of the flue turret
to the outermost point of the air duct DOESNOTEXCEED3 metres. Greater length must not be used.
3

1.4.1
1.4.2 Side Flue Outlet
To cut flue assembly to length
- Measure from external wall face to centre line of
external internal
FM
Celtic and subtract 37 mm (this will give required
wall face wall face length ‘I”).
IL) L 50
- Cut off surplus from plastic air duct (plainend).
mm,
N-6. If extension sections are used ensure these are
.-I 1 I
*j -_--- )--
“--P,
--t-l-f- firmly pushed together.
1 - Cut same amount off aluminium flue duct (plain
L-&L- 7 end).
Flueextension accessory
L Par-tNO.61061
700 mm max. (standard length) (I metre length)
q 1 1
13mm -I /y/q- 55 mm 1
9 I
r--
295 ’mm
min min. min.
Fig. 3 SIDEOUTLETASSEMBLY cut off
from this end ci
I-
_- _I <- 7, \
I I \
a-
L :
-----c
standard 2 part flue duct
Fig. 3a PLASTICAIRDUCT ALUMINIUMFLUEDUCT Fig. 3b
1.4.3
Other flue arrangements
Rear Flue Outlet
To cut flue assembly to length
- Measurewall thickness (T).
- Add 74 mm, this will give required length CL).
- Mark plastic air duct for length (L)and cut off sur-
plus (from plain end).
N.B. If extension sections are used ensure these are
firmly pushed together, seefigs. 3b and 3c.
- Cut off same amount from aluminium flue duct
(plainend).
Flue extension accessory
Part No. 61061
(I metre length)
Fig. 2 REAROUTLET ASSEMBLY
1. Distance from internal corner 300 mm without
kit, 150mm with kit no. 76216(GC No, 264833).
OE
WI
L”E
? 5
OE
L”E
f
1
\
2
Fig. 3c
2. Distance below balconies or eaves 200 mm
without kit, 150 mm with kit no. 76216 (GC No
264833).
3. Appliance is normally supplied packed with
standard 650 mm straight flue section. Addi-
tional straight extention lengths of 1 metre. Part
No. 62823 (GC No 264 459), can be used up to a
total straight length of 3 metres. It is also possible
to incorporate one bend in the flue using Part
No. 65572 (GC No. 264 835). In this case the
length Ll + L2 should not exceed 1,6 metres
horizontally.
4

1.5 Description
Fig. 4
The appliance is mounted in a steel case which has awhi-
te epoxy resin paivt finish.
1. Chassis :
The chassisis a rigid plated mild steel pressing on which
allcomponents are mounted.
2. Flue hood :
Is an aluminium alloy casting onto which the two speed
fan ismounted.
3. Combustion chamber :
This is assembled from a number of components moun-
ted onto the chassis.The front panel is simply removed
for servicing complete with the expansion vessel, hooks
are fitted below the appliance to accept and retain the
panelduring servicing.
4. Expansion vessel :
The expansion vessel has a capacity of 5,4 litres (1.19
gal)and is sizedfor a normal system water content whe-
re the-load is equivalent to the maximum output of the
boiler. The charge pressure is0.65 bar.
5. Pilot security is by thermocouple flame failure :
6. Multigas burner cbmprising : stainless steel blades
(14)and a manifold with injectors (14).
7. Gas section including thermoelectric valve and two
stage valves.
8. Secondary heat exchanger :
The secondary heat exchanger is a plate type heat ex-
changer. A thermostat is fitted on the pipework limiting
the domestic hot water temperature to a maximum of
5733” c.
9. Change over valve :
The valve isactivated by a demand for domestic hot wa-
ter, closes the heating circuits, and directs water to the
secondary heat exchanger.
10. Electricial box containing :
Mainsconnection
Fuses
Printed circuit board
Connections for external controls
Connections for fan, pressureswitch and FlowSwitch
Connections for pump
11. Solenoid valve :
Blockon which 3 valves are mounted :
l/3 valve - 1st stage valve-heating and hot water (blue)
2/3 valve - full output to hot water (black)
2/3 valve - (variablevalve) central heating (orange).
12. Grundfos pump motor
13. Air separator and vent directly connected to the
pump inlet (not illustrated).
14. Regulation screw to adjust output to heating (2/3
valve).
15. Heating body comprising :
Copper finned tube heat exchanger protected with sili-
cone resin paint.
Combustion chamber in aluminium coated steel.
Combustion chamber lining - ceramic fibre panels.
16. High limit thermostat.
17. Water service tap (not illustrated)
18. Flow isolating valve - heating (not illustrated).
19. Gas service tap (not illustrated).
20. Domestic hot water outlet (not illustrated).
21. Safety valve with drain tap (not illustrated)
22. Heating return isolating valve with filter (not illus-
trated).
23. Ignition button.
24. Thermometer indicating boiler flow temperature
25. Temperature selector for domestic hot Water
26. Selector switch - hot water only/OFF/heating and
hot water.
27. Thermostat to regulate heating flow temperature.
28. Pressure gauge.
29. Pressure switch.
30. Integral frost thermostats.
31. Water flow switch.

1.6 Description of Operation 1.6.3 Hot Water (see fig.6)
1.6.1 The Celtic FF is a dual purpose or combination boiler
providing central heating and hot water. Hot water is
provided on a demand basis. For the duration of the
demand for hot water the central heating is interrup-
ted.
The appliance operates in two modes. A hot water
only setting where it operates only on hot water de-
mand and a hot water + central heating setting
providing central heating and switching to hot water
on demand.
1.6.2 Central Heating
(see fig. 5)
The pump (21) circulates water which returns to the
boilervia the return valve (31)which incorporates afilter
(30).Before reaching the pump it passesthrough an air
separator and air purger (17). The return water passes
through the heat exchanger (2) where it isheated. It
then pcssesthrough the change over valve (19)which
in heating mode isin itsrestposition (fig. 3) and out via
the flow valve (27)to the radiator circuits (34).
The boiler thermostat (8) controls the temperature
of the circulation water between a minimum of 50” C
approx and a nominal maximum of 82” C. The boiler
thermostat also controls the opening of the l/3 (I I)
and variable solenoid valve (IO).
The limit thermostat (16)set to 85” C closes both so-
lenoids valves in the event of its set temperature
being reached as could occur under the low flow
conditions.
The boiler is protected by a high limit thermostat (4)
the operation of which interrupts the thermocouple
and extinguishes the pllot. If the high limit thermo-
stat operates it is necessary to manually re-establish
the oilot
When there is a demand water flows through the
water section part (35)of the change over valve (19).
The inclusion of a venturi (24)produces high pressure
under the diaphragm (231 causing it to rise. This
movement IStransmitted to the change over valve
closing the heating port and opening the hot water
port, as shown (20).The primary water heated by the
boiler now passes through the water to water heat
exchanger (18) where it flows through alternate pla-
tes indirectly heating the DHW.
The rising of the change over valve spindle causes:
1. The opening of a microswitch stopping the pump.
This circuit is remade by a second microswitch
making when the hot water port isfully open.
2. The by-passing of the boiler thermostat brings the
boiler under control of a fixed temperature thei-mo-
stat (32) which operates on the 2/3 fixed solenoid
(12).
3. The selection-of the ‘l/3 valve and the fixed 213
valve.
The water temperature is under control of the user
and the opening of the regulator (25) increases the
flow of the water and thus reduces the temperature.
When the regulator isclosed - hottest setting, lowest
flow - a limiting thermostat (32) prevents the
secondary hot water temperature exceeding 60” C
by cycling the solenoid valve without interrupting the
flow of water.
CENTRAL HEATING ‘I-1 1
Fig. 5 Ll
‘I-1 1
HOT WATER
:ig. 6 Id
6

1.6.4
Gas (seefigs. 5 and 6)
1.6.5
When the main gas tap (33) is turned to the on posi-
tion gas is admitted to the gas section (7). Pressing
the ignitor button (9)operates a microswitch causing
the commencement of a firing cycle. The fan chan-
ges from low to high speed and after a purge period
of approx 14 seconds a continuous stream of sparks
are delivered lighting the pilot gas (3).Simultaneously,
the thermoelectric valve (14) is opened and after a
further 5 seconds, sufficient energy is being produ-
ced by the thermocouple (5) for the thermoelectric
valve to be retained inthe open position.
When the ignitor button is slowly released gas is ad-
mitted to the underside of the solenoid valves (IO, 11
and 12).
There are 3 solenoid valves (I) the centre (blue)valve
(11) fixed at l/3 of max rated output, (2) the right
hand hot water (black)valve (12)fixed at 213of maxi-
mum rated output, (3) the left hand central heating
(orange) valve (IO) which is variable up top 2/3 maxi-
mum rated output.
The gas admitted by the orange valve isvaried by ad-
juster (6).
FUNCTIONAL FLOW DIAGRAM
1 1 Switch 1 1 S$Toff 1 \siq S!!h 1 Pressure over
Switch on Valve
,r 11°C
- Frost
Thermostat
Limit
Boiler 82°C
Control
Thermostat
113C Blue
Solenoid
Fig. 7
1.6.6 Safety Controls
In addition to the normal safety controls the CELTIC
FFincorporates the following features.
Should the central heating water flow reduce to be-
low 300 L/h (1.1 gal/min) the gas supply to the burner
isturned off, seefigs 3 & 4 (36).
Built in boiler protection is provided by turning the
burner and pump on if there is any risk of frost da-
mage.
7

I
OR. ORANGE GN. GREEN YELLOW
B. BLUE I R. RED I
IGNITION BUTTON
SELENOID VALVE
BK. BLACK v. VIOLET
BR. BROWN W WHITE
BOILER TH. HOT
* WATER
8. BK. 213
240V .1-I. 1 III 2
EXTERNAL
CONTROL
PRINTED CIRCUIT
= B & R B’
240 V, -
SELECTOR SWITCH -.
r-4
I -
r
u WATER FLOW 1
24V
1 e)L- xwITCH Or E Bk
’ ‘Ll
Bk
FAN
CAPACITOR/
PRESSURE SWITCH I 3
BOILER THERMOSTAT
HEATING
Fig. 9
ILLUSTRATED WIRING DIAGRAM
L
8

2 INSTALLATION REQUIREMENTS
2.1 General
The installation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations
1984, Building Regulations, current I.E.E. Wiring
Regulations and the Byelaws of the Local Water
Undertaking. It should be in accordance also with the
BS Codes of Practice and the British Gas Specifica-
tions for Domestic Wet Central Heating Systems and
any relevant requirements of the local Gas Region
and Local Authority Building Standards (Scotland)
Regulations.
Detailed recommendations are stated inthe following
BritishStandard Codes of Practice : BS6891 : 1988,BS
67981987,BS54401979,BS5440: 11990and 2 : 1989,BS
5449: 1 1990.
Note : Gas Safety Installation and UseReg 1984.It is
thelawthatallgasappliancesareinstalledbyC.0.R.G.I.
Registred persons in accordance with the above
regulations. Failure to install appliances correctly
could lead to prosecution. It is in your own interest
and that of safety to ensure compliance with the law.
2.2 Location
The boiler is not suitable for external installation. The
position chosen for the boiler must permit the provi-
sion of a satisfactory flue termination. The location
must also permit adequate spacefor servicing and air
circulation around the boiler. The surface on which
the boiler is mounted must be of non combustible
material.
The boiler may be installed in any room or internal
space although particular attention is drawn to the
requirements of the current I.E.E.Wiring Regulations
and, in Scotland, the electrical provisions of the Buil-
ding Regulations applicable to Scotland, with respect
to the installation of a heater utilising mains electricity
in a room or internal space containing a bath or
shower.
Where the installation of the boiler will be in an unusual
location special procedures may be necessary and BS
5546 givesdetailed guidanceon this aspect.
A compartment used to enclose the heater must be
designed and constructed specificallyfor this purpose.
An existing cupboard or compartment may be used
provided that it ismodified for the purpose.
Details of essential features of cupboard/compart-
ment design are given in BS6798: 1987.
2.3
2.4
Water Circulation System
The Celtic FFis suitable for SEALEDSYSTEMSonly and
should be in accordance with the relevant recommen-
dations given in BS 6798: 1987, BS 5449:l (for the
smallbore or/and microbore systems) and the British
GasSpecificationsfor Central Heating Systems.
Siting the Flue Terminal
Refer to section 1.4 for details of wall thicknesses
which can be covered.
Detailed recommendations for flueing are given in BS
5440 Pt 1. The following notes are intended to give
general guidance.
The boiler must be installed so that the flue terminal
is exposed to external air. The boil& must NOT be
installed so that the terminal discharges into another
room or space as an outhouse or lean-to. It is impor-
tant that the position of the terminal allows a free
passage of air across at all times. The minimum
acceptable spacings from the terminal to obstruc-
tions and ventilation openings are specified below
(fig. IO).
Terminal positions Min spacings
A - Directly below an opening, windows
etc. .._ .__..., ,....,
B - Belowgutters soil pipes or drain pipes
C - Below eaves
D - Below balconiesor car port roof
E - From a vertical drain pipe or soil pipe
F - From an internal or external corner
G - Above ground roof or balcony level
H - From a surface facing the terminal
J - From a terminal on the samewall
K - Vertically from a terminal on the same
wall .._ ..__..,
L - Horizontally from a terminal on the
same wall
300 mm
75 mm
200 mm
200 mm
75 mm
300 mm
300 mm
600 mm
1200 mm
1500 mm
300 mm
Fig. 10

Note :Theflue can be extended to clear a projection.
BUILDINGREGULATIONS1985excerpt.
Approved document J Part B 1.4(C) (D).
C) Protect with a terminal guard if it could come in
contact with people near the building or be subjected
to damage.
D) Designed so as to prevent the entry of any matter
which might restrictthe flue.
(A terminal guard G.C. No 381782isavailable from).
Quinnel Barret& Quinnel Wireworks
Old Kent Road
London SE151NL Tel.081-639-l357
The air inlet/outlet duct and the terminal of the
appliance mustnot be closer than 25mm (1 in)to any
combustible material Detailed recommendations on
the protection of combustiable material are given in
BS5440Pt 1: 1990.
IMPORTANT NOTICE : TIMBER FRAMED HOUSES
IFTHEAPPLIANCEISTO BE FITTEDINA TIMBERFRA-
MEDBUILDING,ITSHOULDBEFITTEDINACCORDANCE
WITH THE BRITISHGAS PUBLICATION- “GUIDEFOR
GAS INSTALLATIONSIN TIMBER FRAMED HOUSING”
reference DM2. IF IN DOUBT, ADVICE MUST BE
SOUGHTFROMTHELOCALREGIONOFBRITISHGAS.
2.5 Air Supply
The room in which the boiler is installed does not re-
quire a purpose provided air vent.
If the boiler is installed in a cupboard or compartment
permanent air vents are required in the cupboard or
compartment, one at high level and one at low level
either direct to the outside air or to a room. Both
high and low level air vents must communicate with
the same space.
2.6
Position of vents Air from room Air direct from outside
Highlevel 264cm2(40in2) 132cm2(20in2)
Lowlevel 264cm2(40in2) 132cm2(20in2)
Electrical Supply
- Thisappliance must be earthed.
- All wiring external to the appliance must conform
to the current I.E.E.Regulations.
- The Celtic FFrequires a 240 V + 50 Hzsupply.
- Connection of the appliance and any system
controls to the mains supply must be through a
common isolator and must be fused at 3A maximum.
This should preferably be an unswitched shuttered
socket outlet and 3 pin plug to BS1363. Alternatively,
a double pole isolating switch may be used, provided
it has a minimum contact separation of 3 mm in both
poles. The isolator should be clearly marked showing
its purpose, preferably positioned close to the
appliance.
- Fusethe supply at 3A.
- The supply cord must be 0.75 mm* (24 x 0.2 mm)
three core to BS6500 Table 16.
2.7
3.
3.1
GasSupply
The Celtic FFrequires :
2.7 m3/h (95.35 ft3/h) gasflow.
The meter and supply pipes should be capableof deli-
vering this quantity of gas in addition to the demand
from any other appliances inthe house.
Thecomplete installation mustbe tested for soundness
asdescribed in BS6891: 1988
SYSTEM GUIDANCE
General
The low water content CELTICFFdual purpose boiler
includes the expansion vessel, safety overheat ther-
mostat, temperature and pressure gauges, and safe-
ty valve.
The thermostat is adjustable and on its maximum
setting gives a nominal 82” C (180” F)flow tempera-
ture. Detailed recommendations for water circulation
are given in BS5546 : 1990.Whilstthe boiler provides
hot water, there may be occasions when a cylinder
will be used, for instance, if the property has two
bathrooms. Detailed recommendations of this appli-
cation are given in sections 3.13to 3.16Thermostatic
control should be used in the heating circuits and the
cylinder if one isfitted.
It must be remembered that a combination appliance
has a limited volume of hot water that can be sup-
plied at any one time for a given temperature. Indeed
in most respects it is equivalent to a multipoint water
heater and many of the contraints associated with
multipoints apply equally to combination boilers.
The appliance has two separate functions, to provide
heating and hot water on demand. It can have a third
which is to supply hot water high demand through
the use of an indirect cylinder.
Sucha course could recommend itself if, for instance,
there is more than one bathroom or if the standard
and appointments of the property, such as basins in
all bedrooms and a large kitchen indicate a high usage
of hot water.
Hot water produced indirectly through a cylinder can
be used to satisfy high simultaneous demand outlets
- bathrooms etc. whilst the benefits of high efficien-
cy in generally small quantities of hot water, can be
fully utilised in kitchens, cloakrooms and so on.
Figs.14, 15, 16 and 17 indicate various layouts for the
production of hot water. It is recommended that only
a high recovery cylinder is used and circumstanceS
may from time to time dictate that a specialsaturated
heat exchanger in an indirect cylinder may be desira-
ble.
Separate time and temperature control over hot
water generated in this way can be achieved by the
use either of two port valves or three port valves of a
flow share or priority pattern (seenotes on drawing).
It isalso possible,where the occupation of the house is
variable,to provide either for a smallor large load.This
isbest achievedwith atall, smalldiameter cylinder. See
section 5for possiblewiring arrangements.
When using the hot water side of the appliance the
use of non-return valves and/or loosejumpered stop
cocks isjust as critical as with the conventional multi-
point and should be avoided. If a non-return valve is
fitted in the incoming water supply then an expan-
sion vessel MUSTbe fitted in the domestic hot water
circuit with a capacity of at least 0.16 litres.
10

3.2
3.3
3.4
If the mains cold water supply is in excess of 10 bar
(150 psi) a pressure limiter must be fitted to avoid
excessive pressure being applied to the boiler.
When replacing an existing cylinder storage system
with CELTICFFit is essential that all redundant pipe-
work isremoved and dead legseliminated.
In properties where there are multiple draw-off points
on different levels consideration should be given
to the use of non-return valves in the secondary hot
water system to avoid “active dead legs”. No-non re-
turn valve should be less than 3 ft (I m) above the
top of the appliance and ideally should be as close as
possibleto the terminal fitting.
System controls
The boiler is electrically controlled and is suitable for
most control schemes currently available including
thermostatic radiator valve and motorised valves.
When using motorised valves the controls should be
arranged to switch off the boiler when circuits Bre
satisfield. The boiler requires a minimum flow rate of
300 L/h (1.1 gal/min) and consequently, if
thermostatic radiator valves are fitted to all radiators,
a by pass will be necessary. This will ensure that the
boiler will operate correctly when allTRVsare closed.
Pump
Theboilerisfitted with a GrundfosUP.15/60pump head.
Thegraph (fig. 11)indicatesthe residualhead available
for the system.
flow rate in g.p.m.
1
2 3 4
5
Fig. 11
Expansion vessel
Theexpansion vesselwhich isfitted on-the front of the
combustion chamber maintains pressure and
accomodates systemwater expansion. Thevesselhas
a capacity of 5.4 litres(1.19gals) and ischarged to a
pressureof 0.65 bar.
The connection in the centre of the expansion vessel is
not a vent point.
At the design flow temperature and the initial system
pressures quoted the maximum allowable system
volume is75litres.
3.5
3.6
3.7
3.8
If the water volume is not known and cannot be
accurately assessed from manufacturers data the
following volumes may be usedto give a conservative
estimate of the systemvolume.
Boiler .4litres(0,8gals)
Smallbore pipework .0.3litres(0.07gals)
per 0.292kW
Microbore pipework .7 litres(1.5gals)
Steelpanel radiators .2.3litres(0.5gals)
per 0.292kW(1000Btu/h) of systemoutput
Hotwater cylinder .(0.44gals)
Ifthe volume exceeds 75litresan additional vesselwill
be required fitted inthe flow from the appliances. Refer
to BS7074Pt. 1or BS5449for details of sizing.
Mains Water Connection
There shall be no permanent connection to the
Heating System Pipework for filling or replenishing
without the approval of the LocalWater Authority.
Filling point (see BS 6798: 1987 Appendix A)
Fillingand recharging can be done :
I) Through a temporary hose connection from a
draw off tap supplied from a service pipe under
mains pressure provided that this isacceptable to the
LocalWater Authority, seefig. 12).
2) Through a self contained unit comprising a cistern,
pressure pump if required and if necessarya pressure
reducing valve or flow restrictor, fig. 13.
3) Through a cistern, used for no other purpos-, per-
manently connected to a service pipe. The static head
available must be sufficient to provide the designed
initial system pressure.
Make up system
Provision must be made for replacing water lost from
the system indicated by a reduction in pressure
shown on the pressure gauge. Recharge through the
filling point (seesection 3.6).
Pipework should be of copper, smallbore or microbo-
re with capillary or compression jointing to a high
standard, leak sealant mustnot be used inthe system.
11

heating system
f\ anti-vacuum valve
this method may only
be used if acceptable
to the Local Water
complies with
BS6798
appendix A,
method A.1.
stop non-return valve
valve
test co&k
Fig. 12
heating system overflow
L
cistern Note :
Cistern to be supplied
-1 1-1
through a temporary
complies with
BS6798 \ -7-w
. connection from the
----,A/
service pipe or cold
appendix A stop valve I
reducing valve pressure pump water distributing pipe.
method A2
(if required)
Fig. 13
3.9.1 Boiler replacement (retrofit) 3.11 Inhibitors
In an old system where the boiler is being replaced,
we recommend the use of a strainer, fitted with a
drain tap on the heating return, designed to retain
scaleparticles and other soliddebris. It isgodd practice
to use a chemical cleaner with a floctuating agent,
used as recommended by the cleanser manufacturer,
to cleanthe system before the old boiler is removed.
Chaffoteaux Ltd do not generally recommend the use
of inhibitors in systems using the Celtic FF boiler. It is
however, appreciated that the use of a corrosion and
limescale inhibitor may be desirable or specified.
The following are the appliance manufacturer’s
recommendations :
1) Useonly a BritishGas or similar approved inhibitor
from the Fernox Manufacturing Company Limited
3.9.2 Existing systems
Valvesand joints should be carefully checked for leaks
and the appropriate action should be taken either
as a repair or replacement. The old open system has
probably only been subjected to a pressure of 0.4 bar
or less.When you change to a sealed system where
the charge pressure will be 1.0 bar and the running
pressure exceeding 1.5 bar, consideration should be
given to the replacement of radiator valves with a
pattern capableof sealingat the higher pressures.
3.10 Cylinder
Where a domestic hot water cylinder is used with the
Celtic FFit MUSTbe of the Indirect and high recovery
type to BS 1566:Pt I. Single feed cylinders are not
suitable for use with this appliance. Flow and return
pipework to the cylinder should be in 22 mm copper
pipe.
Britannica Works, Clavering,-Essex CBl 1 4QZ -
Tel : [phone]; Grace Service Cheminal, Grace
Dearbon Ltd - Widness- CheshireWA8 8 UD
Tel:[phone]- Telex:627341- Fax:[phone]
2) Use only the quantities specified by the inhibitor
manufacturer.
3) Cleanse the system as required by the inhibitor
manufacturer.
4) Add inhibitor only after flushing when finally re-filling
the system.
3.12 Add-on devices
It is important that no external control devices eg.
economisers be directly fitted to this appliance unless
covered by these installation instructions or agreed
with the manufacturer inwriting. Any direct connection
of a control device not approved by the manufacturer
could make the guarantee vaid and also infringe the
Gas Safety (Installation & Use) Regulations 1984.
12

Heating & stored hot
water - spring return
1 1 valves only
Heating & stored hot
water using flow share
relay required
Fig. 15
1
Remote by-pass
Celtic
remote by pass
with L/S valve
hot water
3.13 Heating and hot water systems
It must be remembered that a combination appliance
has a limited volume of hot water that can be sup-
plied at any one time for a given temperature. Indeed
in most respects it is equivalent to a multipoint water
heater and many of constraints associated with mul-
tipoints apply equally to the combination boilers.
The appliance has two separate functions, to provide
heating and hot water on demand. It can have a third,
which is to supply hot water high demand through
the use of an indirect cylinder.
Sucha course would recommend itself if for instance
there is more than one bathroom. If the standard
and appointments of the property such as basins in
all bedrooms and a large kitchen indicate a high usage
of hot water.
3.14
3.15
Hot water produced indirectly through a cylinder can
be used to satisfy high simultaneous demand outlets
- bathrooms etc. Whilst the benefits of the high effi-
ciency in generally small quantities of hot water, can
be fully utilised in kitchens, cloakrooms and so on.
Figs. 14, 15, 16 and 17 indicate various layouts for
the production of hot water. It is recommended that
only a high recovery cylinder isusedand circumstances
may from time to time dictate that a specialsaturated
heat exchangerin an indirect cylindermay be desirable.
Separate time and temperature control over hot
water generated in this way can be achieved by the
use either of two port valves or three port valves of a
flow share or priority pattern (seenotes on drawing).
It is also possible,where the occupation of the house
is variable, to provide either for a small or large load.
This is best achieved with a tall, small diameter
cylinder (fig. 16, see sections 5 for possible wiring
arrangements).
When using the instantaneous side of the appliance
the use of non-return valves and/or loose jumpered
stop cocks isjust as critical as with the conventional
multipoint and should be avoided. If a non-return
valve is fitted in the incoming water supply then an
expansion vessel MUSTbe fitted in the domestic hot
water circuit with a capacity of at least 0.16 litres
When replacing an exisiting cylinder storage system
with an instantaneous type system it is essential that
all redundant pipework is removed and dead legs
eliminated.
In properties where there are multiple draw off
points on different levelconsideration should be given
to the use of non-return valves in the secondary hot
water system to avoid “active dead legs”. No non-
return valve should be lessthan 3 ft (I m) above the
top of the appliance and ideally should be as close as
possibleto the terminal fitting
3.16 The consideration of heating systems using thermo-
static valves should ensure that the minimum flow
rate through the appliance is maintained and in this
connection the remote by-pass is preferred (see fig.
17).
13

4. INSTALLINGTHE BOILER
A vertical flat area is required for the boiler : 1122 mm high x 591 mm wide (44 in x 23.25 in). The surface on
which the boiler is mounted must be of a non reverberating and of a non combustible material.
The appliance issupplied in a single carton which contains :
I) The chassis with allfunctional parts attached.
2) Casing comprising : 2 side panels
1 front panel
1 controls fascia cover
1 glassdoor complete with hinges
3) Mounting bracket comprising : flue guide
top support plate
spacing strip
bottom support plate
plasticjig plate connection
4) Plastic bag containing : gas filter/washer
5) Box containing : gas and water connections inc.4 above.
6) Box containing : controi knobs
safety valve
wall plugs
screwsand fixings.
7) Flue assembly : flue turret with pressure differential switch and 1st flue duct section
plastic wall liner with terminal
flue duct
plastic turret cover
2nd flue section
8) Plastic bag containing : flue locking ring
‘0’ ring
2 gaskets - one cork and one rubber
4 mounting screws with washers for flue turret
N.B. (i) Extension flue assembliesare not supplied as standard, and must be ordered to suit (seesection 1.4)
4.1
4.2
Fig. 18
Positioning the boiler
a) Select the location for the boiler referring to the
dimensions shown in 1.1 and 1.3 terminal location
positions (2.4 - fig. IO).
b) Checkflue length (see1.4 - figs. 2 and 3).
c) Check clearance on external wall for flue terminal
position (seetable 2.4 - fig. IO)
d) Assemble the mounting bracket made up from 4
pieces(fig. 18) using 4 thread forming screws.
e) If for rear flue installation, remember to include
the flue guide plate E, using 2 thread forming
screws.
Rear outlet flue
a) Mark vertical centre linefor boiler on wall.
b) Mark horizontal centre line for 107 mm (4.2 in) dia
wall opening and one for upper bracket fixing
screws (A).
c) Using bracket as template mark 4 fixing points (A)
and (BL
d) Mark wall for flue opening using flue guide plate.
e) Drill the wall for the flue opening using a 107 mm
(4.2 in)core drill.
f) Drill 4 fixing holes (A) and (B)7.9 mm (5116 in) and
plug.
g) Fix bracket to wall using 6 mm x 50 mm wood
screws provided.
Fig. 19
N.B. Ensure bracket is square and plumb to vertical
centre line before tightening.

4.3
295 mm minimum 4
Side outlet flue
a) Mark vertical centre line for boiler on wall (seefig.
20).
IF
!
b) Using bracket as template mark 4 fixing slots (A)
and (B).
169.5 1 -
- -------
*
r
c) Mark horizontal line through the fixing slots (A)and
project to sidewall.
Fig. 20
4.4
Fig. 21
4.5
Fig. 22
4.6 Water connections
a) Makeconnections to copper tails using either solder capillary fittings or compression type.
4.7 Gasconnection
d) Mark vertical axis of flue opening 112 mm (4.4 in)
from corner of wall.
el Mark wall for centre of flue opening 169.5 mm
above the horizontal on sidewall.
f) Drill the wall for the flue opening using a 107 mm
(4.2 in)core drill.
g) Drill 4 fixing holes (for (A) top of slot) and (for (B)
center of slotl.
h) Fix bracket to wall using 6 mm x 50 mm wood
screws provided.
N.B. Ensure bracket is square and plumb to vertical
centre line before tightening.
Jig plate
N.B. By using the plastic jig plate the piping system
can be completed before the boiler ismounted.
a) Attach plasticjig plate to bottom bracket using 4.6
mm x 10 hexagonal screws provided (fig. 21).
b) Fit copper tails and washers to jig plate, the mains
water inlet tail (M)is the shorter of the two 15 mm
tails (fig. 22).
c) The water can either come from above or below
using the standard tails provided. The gas must en-
ter from below.
Gas and water Tube Thread
connections diameter size
Jl Heating return 22 mm 3/4 in
K) Hot water outlet domestic 15mm l/2 in
1) Gasinlet 22 mm 3/4 in
Ml Mainswater inlet domestic 15 mm l/2 in
N) Heating flow 22 mm 3/4 in
Pipework
a) Fit or cut pipework to connect with copper tails
on jig plate.
a) The gas connection is22 mm diameter.
b) Makethe gas connection.
N.B. The gas supply pipe must not be lessthan 22 mm diameter.
IMPORTANT NOTE :
At this stage the pipework can be completed and tested before the boiler is positioned. Havingcompleted a Satis-
factory test on the pipework the boiler can now be fitted or retained for fitting at a later date.
15

4.8
Fitting the boiler
al Before hanging the boiler, uncoil wiring harness
(connections to pressure switch) stored by
changeover valve, route through lower part of
chassisand up back of boiler, place into clips.
b) Remove plastic jig plate from bracket and retain
screws.
c) Hang boiler on mounting bracket, ensure that it is
properly located.
N.B. Insert washer into union nut and offer assembly
to boiler. Use the plain black 3/4 and l/2 diameter
graphited fibre washers for water unions, and the
white 3/4 filter/washer for the gas union.
d) Connect water union using plain washers, working
from left to right.
el Connect the gas union using the filter/washer
packed separately either way round.
Fig. 23
N.B. As an alternative to using the plastic jig plate the
tails can be fitted to the boiler before mounting, then
connected to the services.
4.9
c) Fit 14 mm tail drain bend using washer provided.
d) Fit plastic tube from air separator to nipple on
14 mm tail.
N.B. The drain must be 22 mm and the 14 mm drain
bend from the safety valve must be installed so
that discharge of water is readily visible. A tundish
arrangement is acceptable. The connection must NOT
be made by a capilary or compression fitting directly
betweenthe mmdrain bendandthe22 mmdischarge
pipe without an air gap. see fig. 24.
Fig. 24
Fit safety valve ,
The 22 mm discharge pipe must discharge to the
The safety valve is mounted below the outside ofthe building where possible over a drain. The
heating return (J) (fig. 22) isolating valve. discharge must be such that it will not be hazardous to
a) Ensure ‘0’ ring is in position within the occupants or cause damage to external electrical
socket from heating return isolating components or wiring. The pipe should be directed
downwards. Itmust notdischarge above anentrance or
b) Fit safety valve and secure with grub window orany type ofpublic access asthe temperature
screw provides. of the water being discharged may reach 100” C.
c) Remove plastic turret cover (D)from flue turret (B)
held by two screws.
d) Peeloff protective paper from adhesivesideof cork
gasket (A)place on mating side of flue turret (B)li-
ning up with four clearance holes,press together.
e) Assemble second part of flue duct CH),push fit.
f) Slidelockingring (C)and ‘0’ ring over plastic air duct.
g) Slideair duct over flue duct, engageend of flue duct
into terminal and locate air duct into turret (B).
h) Slide‘0’ ring along air duct 0, to contact with the
face of the turret (B). Locate lugs on locking ring
CC)between lugs on flue turret (B). Push together
and turn to lock.
jl Positionsquarechannelledrubber gasket(E)onthe flue
hoodoutlet of the boiler,channelfacingdownwards.
k) Passthe flue assembly through the wall and seat
turret (B), onto the flue outlet, secure with 4
screws provided.
Fitting the flue up to 700 mm long
a) Cut plastic duct (G)to length required, see fig. 2 or
3 dimension CL).
b) Cut same amount from aluminium flue duct CH).
N.B. In very cold weather the plastic air duct becomes
brittle, warm before cutting.
N.B. The terminal must extend 13 mm (0.5 in)past the
surface of the external wall.
I) Fit wall plate (F)provided With mastic sealing ring
over air duct to structure.
m) Make good internal wall face where the air/flue
duct assembliesexit the room.
n) Do not fit plastic turret cover ‘D’ until electrical
connections have been made.
16

4.11
4.12
4.13
Fitting the flue over 700 mm long
al Assembly is precisely as detailed in section 4.10
using the requisite number of extension flue and
air ducts. Inparticular note the following.
b) The standard flue duct is always used (both sec-
tions) at the applianceend (uncut).
c) The standard air duct isalways used at the terminal
end (uncut).
d) When cutting, always cut one extension flue duct
and the same amount from one extension air duct.
Always cut the plainend NOT the socket end.
e) Fulldetails of dimensions and assembly are given in
figs. 2 or 3 asapplicable.
f) If internal fixtures prevent the assembled ducts
being passedthrough the wall from the inside, the
ducts may be pushed through from outside (remo-
ve the locking ring VJ and 0 ring first).
Connection to the pressure switch
a) The two wires on the harness must be connected.
b) Pushspade terminals onto tags COM(P)and No (2)
-the common and normally open contacts - polari-
ty immaterial.
c) Fitturretcove?(D) (fig.25)ensuringthatboththeair
tube and cables are not trapped, with the cable
retaining clip positioned as shown, see fig. 26,
within the cover.
N.B. NC (1) Terminal is not used.
zig. 26
Making the electrical connection
N.B. SeeSection 2.6 for electrical supply requirements
THISAPPLIANCEMUSTBEEARTHED.
a) Pullout fuses (A).
b) Removetwo screws (B).
c) Opendoor to left hand side of electrical box.
d) Cut the cable entries to the sizeof the cable being
used which should not be lessthan 0.75 mm2.
e) Remove cableclamp.
f) Connect permanent liveto (L)(Ph)and neutral to N.
g) Connect earth to earth pillar ( & ).
h) Connect external controls - time clock room ther-
mostat etc. across terminal 4 and 5, (sections
5.1-5.5).
i> Secure cables with cable clamp and locate flex
into clip on boiler chassis.
k) Closedoor and secure with two screws.
I) Replacefuses.
N-B. The length of the earth wire between the cable
clamp and the terminal must be such that the live and
Fig. 27
neutral wires become taut before the earth wire if the
supply cord is pulled.
In the event of an electrical fault after installation preliminary electrical system checks must be carried out. Checks to
ensure electrical safety should be carried out by a competent person i.e earth continuity, polarity and resistance to
earth.
Useonly voltage free external control switching. Nosupply voltage should be connected to terminals 3,4 or 5.
17

5.
5.1
5.2
N.B. For additional information
contact Time Control Manufacturers
Terminal 3 is a neutral for
acceleration if required.
Supply through :
1. Double pole fused
switch spur
2. 13 amp unswitched
plug and socket
; boiler terminal block
’ (terminals are not shown in
----------- same order as on boiler -
follow notation).
remove link between terminals
4 and 5.
Fig. 28
Time clock - Time clock and room stat
- The time clock contacts must be voltage free (remove external links).
-. The room stat accelerator should be connected if fitted.
- Supplvfuse valve 3 amp.
NB. I) X in table indicates no earth connection intime clock.
2) * Intable indicates that external links on time clock must be removed.
3) + in table indicates no ‘spare’ connection in time clock so a connector will be required.
room thermostat cylinder thermostat
Honeywell T60 60B Honeywell L6 41 A
240 V 50 Hz
fused3 amp.
boilerterminals
(remove link4-5)
Fig. 29
18

5.3
5.4
Programmer and zone valves
spring return
motorised valves
w.ith end switch.
I- --- 1
Fig. 30
room thermostat
boiler terminal
block
Honeywell Y plan, Satchwell flow share or Satchwell
mini valves to control zones.
Refer to controls manufacturers literature. Live to re-
laycoil isthe wire in their literature which carries the si-
gnalto the boiler.
relay
l- ---- 1
,&Jr
boiler terminal block
Fig. 31
5.5
Frost thermostat.
The appliance is protected by integral frost
thermostats.
It is advisable to protect the system from frost
damage by fitting an additional remote frost ther-
mostat which will over ride the controls whilst the
selector switch is set to hot water + central hea-
trng (II).
frost thermostat
r ----
1
Fig. 32
19

6. COMMISSIONING
6.1
6.2
6.3
Hot water circuits - filling
I) Check that stop cocks up stream of appliance are
of a fixed jumper type.
2) Openmains cold water inlet valve (fig. 33)(A)
3) Vent installation by opening taps and closing.
4) Check that “dead legs” have been eliminated
5) Check for water soundnessand rectify if necessary,
Fig. 33
5) Setsystem charge pressureto designcold pressure.
For a new installation we suggest 1.0 bar. For an
old system see section (3, 9, 2) set to system
static head or 0.8 bar which ever isthe greater.
6) Checkfor water soundness and rectify any leaks.
71 Switch on electrical supply.
8) Manually check bump is free to rotate. Remove
cap (fig. 35 D).
Insert small electrical screwdriver (3 mm blade),
locate in slot in pump shaft, rotate clockwise to
ensure that pump isfree replace cap CD).
Fig. 34
9) Switch to HOT WATER + CENTRALHEATINGon
Central heating circuits - filling
selector switch (A)(fig. 35) switch position (II).
1) Ensure that the isolating valves are open (fig. 34 B 101
Allow pump to run for further IO-15 minutes.
and C). N.B. Valve (C) must be turned anti-clockwise
Switch OFF.
by the knurled nut until it dislocates from the 11)
Isolatewater supplyanddrain boilerby disconnecting
thread and then pulled out horizontally to its fill system and opening the drain
valve (F).This is
extremity (approximately 30 mm (1 114 ins)).
incorporated in the safety valve and is achieved
2) Fill system to charge condition, see section 3.
by screwing down the head until the valve lifts.
3) Vent radiators and any high points.
Openall low leveldrain cocks.
4) Vent automatic air separator/air purger by loosening 12)
Remove filter in the return isolating valve (C)and
screw (fig. 35) (E) two complete turns from inspect for any installation debris, see section
closed position. (7.6) to clean and replace.
N.B. Leave screw (E) in open position. 13)
Refill system asabove.
lighting the boiler
I) Purge gas supply. Switch on electrical supply.
2) Turn the leveron the gasservicetap (fig. 34)0 to the
left. Inthe openpositionthe flame signisto the front.
3) Temporarily locate the three blue control ‘knobs’ -
one thermostat knob, one ignition button
extension and one temperature control knob.
4) Switch to HOTWATER+ CENTRALHEATING(II) on
the selector switch (A).Thefan will run at low speed.
5) Press the ignition button (R) and hold in.
a) The fan will change to high speed to purge the
combustion chamber. Gasisadmitted to the pilot.
Fig. 35 b)
After approx 14 secondsthe sparkgenerator pas-
sesacontinuousstream of sparksto lightthe pilot.
ATTENTION :COMMlSSlONlNGINCOLDWEATHER
cl When the pilot is alight - viewed through the
This holleris protectedby two m-builtfrost thermostats.Duringcoldweatherthe boiler
sight glass,wait for a further 5 seconds before
mayoperateunderthe controlof thesethermostats.
slowly releasingthe button.
Thuscan happenundertwo conditions:
6) When the button is released, while the boiler is set
1. If the boilertemperatureis less than 3’ C (e.g.the boilerhas beenstored under
to heating and any ancillary controls are in demand
very coldconditions)the fan will not run,the pumpwill operatecontinuously,It will position, the boiler will fire.
stillbepossibleto lightthe pilotbut notthe mainburner.
7) Checkfor gas soundness using leak detection fluid.
Wait for a few mmutesto allowthe heat of the pilotto resetthe safety controls
permittingthe mainburnerto fire.
8) Check and adjust gas pressure/gas rate, see
Section 6.4
2. If the boilertemperatureis between3’ Cand11’ Cthe frost thermostatwilloverri-
dethe externalcontrols.This will causethe marnburnerto fire for a few minutes
N.B. The thermocouple outp,ut should be checked at
andthenturn off. Thusappliesif the switch is rnposrtionI or IIandis quitenormal.
this stage, should be greater than 12 mv.
20