Chaffoteaux & Maury celtic plus User guide

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Celtic dus
Room SealedFannedBalanced Flue
Combination Boiler
GAS SAFETY (INSTALLATION AND USE) REGULATIONS.
It is the law that al1gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. G20)
G.C. No 47 980 07
from serial number 994 225 395 - 3 1
Installation and
Servicing Instructions
(leave these instructions with the user)
Looking Good.Heating Better

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CONTENTS
PageNo.
HealthandSafetyInformation 1
1. INTRODUCTION
1.
1.1.
1.2.
1.3.
1.4.
1.4.1.
1.4.2.
1.4.3.
1.5.
1.6.
1.6.1.
1.6.2.
1.6.3.
1.6.4.
1.6.5.
1.6.6.
1.6.7.
Generaldescription,specialfeatures,guarantee
DimensionsFig. 1
TechnicalData
Clearances
Wall thickness
RearflueoutletFig. 2
Sideflue outletFig. 3,Fig. 3a,Fig. 3b
Otherflue arrangementsHorizontalFig. 3c
Descriptionof componentsandlocationFig.4
Descriptionof operation
CentralheatingFig. 5
Hot waterFig. 6
Gas(alsosee2.7)
Functionalflow diagramFig.7,
Safetycontrols
Functionalflow wiring diagramFig. 8
Illustratedtiiring diagramFig.9
2. INSTALLATION REQUIREMENTS
2. 1. General
2.2. Location
2.3. Watercirculationsystem
2.4. Sitingtheflue terminalFig. 10
2.5. Air supply
2.6. Electricalsupply
2.7. Gassupply
3. SYSTEM GUIDANCE
3.1. General
3.2 Systemcontrols
3.3. PumpFig. 11
3.4. Expansionvessel
3.5. Mainswaterconnection
3.6. Filling andrechargingFig. 12,Fig. 13(page12)
3.7. Makeupsystem
3.8. Pipework
3.9. Domesticexpansionvessel
3.9.1. Boilerreplacement
3.9.2. Existing systems
3.10 Cylinder
3.11 Inhibitorsandwaterconditioners
3.12 Add ondevices
3.13 HeatingandhotwatersystemsFig. 14,Fig. 15,Fig. 16,Fig. 17
3.14 ShowerapplicationFig. 17a
2
2
3
3
3
4
4
4
5
6
6
6
7
7
7
8
8
9
9
9
9
10
10
10
10
11
11
11
11
11
11
11
11
12
12
12
12
12
13
14
(9

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CONTENTS (cant)
PageNo.
4. INSTALLING THE BOILER
4.1.
4.2.
4.3.
4.4
4.5.
4.6.
47
4.8.
4.9.
4.10.
4.11.
4.12
4.13.
Generalinformation
PositioningtheboilerFig. 18
RearoutletflueFig. 19
SideoutletflueFig. 20
Jig plateFig. 21
GasandwaterconnectionsFig.22
Waterconnections
Gasconnection
Fitting theboilerFig.23
Fitting thesafetyvalveFig.24
Fitting theflue (upto700mmlong)Fig.25
Fitting theflue (over700mmlong)
ConnectionthepressureswitchFig.26
ElectricalconnectionsFig.27
5. EXTERNAL CONTROLS
5.1. Time clock - TimeclockandroomstatFlg. 28 19
5.2. Time clock andzonevalves(springreturn)Fig. 29 19
5.3. ProgrammerandzonevalvesFig.30 20
5.4. Honeywell& SatchwellcontrolledzonesFig.3I 20
5.5. FrostthermostatFig. 32 20
6. COMMISSIONING
6.1. Hot watercircuits,filling Fig.33 21
6.2. Centralheatingcircuits,filling, Fig.34 21
6.3. Lighting theboilerFig. 35 21
6.4. GasrateadjustmentFig.36,Fig. 37,Fig.38 22
6.5. D.H.W. flow rateadjustment(seealso6.7,Fig. 39a) 23
6.6. Adjusting theheatingsystemby-passFig.39 23
6.7. D.H.W. flow rateadjustmentFig. 39a 23
6.8. PumpswitchingadjustmentFig.39b 23
6.9. Fitting thecasingFig.40 24
7. ROUTINE SERVICING
7.1.
7.2.
7.3
7.4.
7.5.
7.6.
7.7.
Generalrequirements 25
To removefrontcasingFig.41 25
To removecombustionchamberFig.42 25
To removeburnerassemblyFig.43 26
To removepilot Fig.44 26
To cleanheatingreturnfilter Fig.45 26
Cleaningandreplacementof parts 27
To checkoperationof safetyvalveFig.46 27
15
15
15
16
16
16
16
16
17
17
17
18
18
18
(ii)

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CONTENTS(COW
Page.
8. REPLACEMENT OF PARTS
8.1. ToremovethermocoupleFig. 47,Fig.48 28
8.2. ToreplaceelectrodeandleadassemblyFig.49 28
8.3. ToreplaceoverheatthermostatFig.50 28
8.4. Toreplaceignition microswitchFig. 51 29
8.5. To replaceC.O.V. microswitchFig. 52 29
8.6. Toreplaceflow switchassemblyFig. 53 29
8.7. To replaceventuriFig. 54 30
8.8. ToreplaceprimaryheatexchangerFig. 55 30
8.9. ToremoveelectricalcontrolboxFig. 56,Fig.56a(page33) 30
8.10. ToreplacepumpheadFig. 57 31
8.11. ToreplacechangeovervalveFig. 58,Fig. 58a(page34) 31
8.12. ToreplacesecondaryheatexchangerFig. 59 32
8.13. Toreplaceair separatorFig. 59a 32
8.14. ToreplaceboilerthermostatFig. 60 33
8.15. Toreplaceboilerlimit thermostatFig.61 33
8.16. ToreplaceD.H.W. thermostatFig. 62 33
8.17. ToreplacesparkgeneratorFig.63 34
8.18. ToreplaceP.C.B.Fig. 64ElectricalboxlayoutFig. 65 34
8.19. Toreplacetherm0electricvalveFig.66 35
8.20. ToreplacesolenoidvalvesFig. 67 35
8.21. ToreplaceheatingbodyliningsFig. 68 35
8.22. ToreplacefanassemblyFig. 69 35
8.23. ToreplacepressureswitchFig. 70 36
8.24. Tore-pressuriseexpansionvesselFig.71 36
8.25. To replacepressuregaugeFig.72 36
8.26. ToreplacethedomesticexpansionvesselFig. 73 37
8.27. ToreplacemainburnerFig. 74 37
8.28. ToreplaceburnermanifoldassemblyFig. 75 37
8.29. Toreplacepilot injectionFig. 76 38
8.30. To replaceexpansionvesselFig.77 38
8.31. Toreplaceviewing windowFig .78 38
8.32. ToreplacemaingasvalvebodyFig. 79 39
8.33. ToreplacethethermometerFig. 80 39
8.34. ToreplacesafetyvalveFig. 81 39
9. FAULT FINDING
9.1. Logic sequence 40
9.2. Centralheatingoperation 41
9.3. Domestichotwateroperation 42
9.4. Faultfinding tabularchart 43
SHORT SPARE PARTS LIST
(iii)
Rearcover

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CONTROL OF SUBSTANCESHARMFUL TO HEALTH
IMPORTANT
To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to
provide information on the following substancethat is contained in this appliance.
Descriution
Combustion Chamber Lining
Material Alumino Silicone Fibre
Precaution8
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 irritation.
When disposing of the lining ensure that it is securely wrapped and
wash hands after contact.

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1. INTRODUCTION
The Celtic plus is a wall mounted, low water content
fanned balanced flue appliance suitable for central heating
and hot water via a non storage water to water heat
exchanger. The maximum output is 23 kW (78480 Btti).
The boiler is designed for sealed systems only and included
in the appliance is the expansion vessel, circulating pump,
temperature and pressure gauges, safety valve, electric
connection box, and domestic expansion vessel.
The standard flue assembly supplied with the boiler is
100 mm (4 in) dia pipe, can be directed to the rear or to the
lett or right and can be extented to a maximum length of 3
m, or 1,6 metres horizontally using the available 90” bend
(see sections 1.4.1, 1.4.2 and 1.4.3 figures 2, 3, 3a, 3b,
3c).
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
temperature 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.
- Water flow switch to protect appliance.
- Suitable for showers with compatible mixer valves.
Guarantee
The manufacturer’s guarantee on this appliance is for 12 months from the date of purchase. The guarantee is void, if the
appliance is not installed in accordance with the recommendations made herein.
1.1 DIMENSIONS
Fig. 1
B b
1 i
1-1
REAR OUTLET
Mains water in. 15 mm
FLUE
f
F--
/T’
SIDE OUTLET
FLUE
A 820.5 32.3
B
391.0 15.4
C
365.0 14.4
D
100.0 4.0
E
169.5 6.7
F
654.5 25.7
G
43.0 1.7
H
50.0 2.0
J
75.0 3.0
K
260.0 10.2
L 150.0 6.0
M
972.5 38.3
N
13.0 0.5
P
61.0 2.4
R
30.0 1.2
S
152.0 6.0
T
112.0 4.4
mm in
2

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1.2 Technical Data
Hot water
Input ........................................... 28.90 kW 98612 Btu/h
Output.. ...................................... 23.00 kW 78480 Btu/h
Water flow raised
45 “C (81 OF).............................. 7.4 Ymin 1.7 gaI/min
Water flow raised
35 OC(63 OF).............................. 9.5 Ymin 2.1 gaifmin
Water ffow raised
30 ‘C (54 OF).
............................. 11.1 Ymin 2.5 gallmin
Maximum temperature.. ............. 50 OC 140 OF
Maximum pressure.. ................... 10 bar 150 psi
Minimum working pressure.. ...... .6 bar 9 psi
Gas rate.. .................................... 2.743 m%-r 96.87
ft3fh
Burner pressure.. ........................ 11.8 mbar 4.7 in wg
Central heating
Maximum input.. ........................ 27.64 kW 94313 Btulh
Maximum output.. ...................... 22.00 kW 75068 Btu/h
Gas rate (maximum). .................. 2.63’m3/h 92.98 f&h
Burner pressure.. ........................ 11.2 mbar 4.5 in wg
Minimum input.. ........ ................. 10.85 kW 37020 Btu/h
Minimum output.. ....................... 7.64 kW 26062 Btu/h
Gas rate (miniium) ................... 1.Om?h 35.31
ft3lh
Burner pressure.. ........................ 1.5 mbar 0.6 in wg
Minimum flow rate ..................... 3OOK-l 1.1 gai/min
Maximum pressure.. ................... 2.5 bar 36.5 psi
Natural gas
Manifold injectors 14 of.. ............ 1.28 mm 0.05 in
Pilot injector.. .............................. 0.3 mm 0.01 in
Gas section restrictors 2/3 valves 4.4 mm 0.17in
l/3 valve.. 2.3 mm 0.09 in
Connections
Gas.. ............................................................ 22 mm copper
Heating flow ................................................ 22 mm copper
Heating return. ............................................. 22 mm copper
Mains cold water inlet ..............._.................. 15 mm copper
Hot water outlet ._........................... .............. 15 mm copper
Electricai supply 240 V - 50 Hz, fused at 3A.
Electrical consumption ................................. 195 watts
Internally fused, two at 2A (BS 4265)
Weight ......................................................... 42 kg 92.4 lb
Water capacity ............................................. 4 litres 7 pints
Ignition - Anstoss continuous spark generator
Electrode - Chaffoteaux et Maury Ltd, spark gap 5 mm
Boiler thermostat - EGO (82’C)
Boiler limit thermostat - SOPAC /JAEGER (85X)
Hot water fim?t thermostat - SOPAC /JAEGER (57°C + 3°C)
Safety overheat thermostat (Tokoswitch - (lOSaC)
(Eimwood - (105°C)
Gas valve - AEMF
Fan motor - SEL.
Pressure switch - DUNGS 102 Pa / 55 Pa
Pump head - GRUNDFOS UP 15160
C.H. expansion vessel initial charge piessore - 0.65 bar (9.6 psi)
Domestic expansion vessel initii charge pn?ssure - 2 bar (30 psi)
1.3 Minimum Clearances around Boiler
Top above air duct .. ... 50 mm (2 in)
Bottom below case. ____._._. 150mm (6in)
Sides . . . . . 100mm (4ir-l)
Front. . 6GOmm(24in)
I
1.4 Wall Thicknesses
The standard flue assembly can accomodate the foliowing thicknesses.
Rear : from 55 mm to 576 mm
Side : from 55 mm to 392 mm
(this allows for a minimum clearance of 100 mm between the appliance and the side waii. As this dimension
increases. so the maximum side wail thickness available decreases).
Extension flue assemblies are available to accomodate wali 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, wili in fact permit a greater length than
indicated to be covered. The ducts MUST be cut so that the maximum length from the centre line of the flue turret to
the outermost point of the air duct DOES NOT EXCEED 3 metres horizontal. Greater length must not be used.
See sections 1.4.1. 1.4.2. 1.4.3.
3

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1.4.1 Rear Flue Outlet Horizontal
To cut flue assembly to length
- Measure wall thickness (I).
1.4.2
1.4.3
- Add 74 mm, tthis will give required Ientgh Q.
- Mark plastic air duct for length (L) and cut off
surplus (from plain end).
N.B. If extension sections are used ensure these are
fumly pushed together, see figs. 3b and 3c and a fall of 5
mm per metre length should be provided (see section
4.3).
- Cut off same amount from aluminium flue duct
(plain end).
REAROUTLET ASSEMBLY
Fig. 2
Side Flue Outlet Hohontaf
To cat flue assembly to length
- Measure from external wall face to centre line of
Ceftk plus and substract 37 mm (this will give
required length “L”).
- Cut off surplus t?om plastic air duct (plain end).
N.B. If extension sections are used ensure these are
firmly pushed together, see figs. 36 and 3c and a fall of 5
mm per metre length should be provided (see section
Flue extension accessory
- Cut off same amount from
Part No. 62823.00
Fig. 3 SIDEOUTLET ASSEMBLY
standard air duct
Fig. 3a
PLASTIC AIR DUCT
Other ffue Arrangements Horizontal
Fig. 3c
1. Distance from internal corner 300 mm without
kit,107 mm with kit No 76216 (GC No 264 833).
2. Distance below balconies or eaves 200 mm
without kit, 107 mm with kit No 76216 (GC No
264 833).
3. Appliance is normally supplied packed with
standard 650 mm staight flue section. Additional
straight extension lengths of 1 metre, part No
62823 (GC No 264 459). can be use 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 + 12 should not exceed 1.6 metres
horizontally.
4

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Description of Components and Location
5
6
2i 2i 2b 31 19 17 18
Fig. 4
The appliance is mounted in a steel case which has a
white epoxy resin paint fmish.
1. Chassis:
The chassis is a rigid plated mild steel pressing on which
all components are mounted.
2. Flue hood:
Is an aluminium alloy casting onto which the two speed
fan is mounted.
3. Combustion chamber:
This is assembled from a number of components
mounted onto the chassis. The front panel is simply
removed for servicing complete with the expansion vessel,
a hook is fitted below the appliance to accept and retain
the panel during servicing.
4. Expansion vessel:
The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is sized for a .normal system water content where the
load is equivalent to the maximum output of the boiler.
The charge pressure is 0.65 bar.
5. Pilot security is by thermocouple ffame failure.
6. Multigas burner comptisig: stainless steel blades (14)
and a manifold with injectors (14).
7. Gas section including thermoelectric valve and two
stage solenoid valves.
8. Secondary heat exchanger :
The secondary heat exchanger is a plate type heat
exchanger. A thermostat is fitted on the pipework limiting
the domestic hot water temperature to a maximum of 57
f3O c.
9. Change over vsfve :
The valve is activated by a demand for domestic hot
water, closes the heating circuits, and directs water to the
secondary heat exchanger.
IO.EIectriciaf box containing :
Mains connection
Fuses
Priited circuit board
Connections for external controls
Connections for fan, pressure switch and flow switch
Connections for pump
Connections for change over valve and for gas solenoid
valve
11. Solenoid valve :
Block on which 3 valves are mounted :
l/3 valve -1st stage valve-heating and hot water (blue)
Z/3 valve - full output to hot water (black)
2/3 valve - (variable valve) central heating (orange)
12. Grandfos pump motor
13. Air separtor 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 tinned tube heat exchanger protected with silicone
resin paint. Combustion chamber in aluminium coated
steel. Combustion chamber lining - ceramic fibre panels.
16. Hirgh Emit thermostat (manual reset).
17. Water service tap (not illustrated).
18. Flow irsofating valve - heating (not illustrated).
19. Gas service tap (not illustrated).
20. Domestic hot water outlet with regulator (not
illustrated).
21. Safety valve with drain tap (not illustrated).
22. Heating return isolating valve with filter (not
illustrated).
23. Ignition button.
24. Thermometer indicating boiler flow temperature.
25. Fuses.
26. Selector stitch - hot water only/OFF/heating and hot
water.
27. Thermostat to regulate heating ffow temperature.
28. Pressure gauge.
29. Pressure switch (not illustrated).
30. Domestic expansion vessel (not illustrated).
31. Water flow switch (not illustrated).
32. Data badge position.

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1.6 Description of Operation
The Celtic plus is 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 interrupted.
The appliance operates in two modes. A hot water only
setting where it operates only on hot water demand
and a hot water + central heating setting providing
central heating and switching to hot water on demand.
1.6.1 Central Heattng (see fig.5)
The pump (21) circulates water which returns to the
boiler via the return valve (31) which incorporates a fil-
ter (30). Before reaching the pump it passes through an
air separator and air purger (17). The return water
passes through the heat exchanger (2) where it is hea-
ted. It then passes through the change over valve (19)
which in heating mode is in its rest position 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 (11)
and variable solenoid valve (IO).
The liiit thermostat (16) set to 85” C closes both sole-
noids valves in the event of its set temperature beiig
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 pilot. If the high limit thermostat ope-
rates it is necessary to manually re-establish the pilot.
An expansion vessel (13) is fitted in the primary circuit.
Central Heating
13
m 4
15
16
Fig. 5
27
1.6.2 Hot Water (see fig. 6)
When there is a demand water flows in from the cold
mains supply (26) through the water section part (35) of
the change over valve (19). The inclusion of a venturi (24)
produces high pressure under the diaphragm (23) causing
it to rise. This movement is transmitted 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 plates
indirectly heating the DHW.
The rising of the change over valve spindle causes :
1. The opening of a microswitch stopping the pump.
Thii circuit is remade by a second microswitch making
when the hot water port is fully open.
2. The by-passing of the boiler thermostat brings the
boiler under control of a iixed temperature thermostat
(32) which operates on the 2/3 faed solenoid (12).
The D.H.W. flow rate is adjustable by a restrictor (25) and
a limiting thermostat (32) reduces the gas rate when the
domestic hot water reaches 57°C by interrupting the
electrical supply to the hot water solenoid (12).
If the primary circuit reaches 85OC the limit thermostat (16)
closes both solenoids valves.
A domestic expansion vessel is fitted in the D.H.W. circuit
(36).
Hot Water
_----.
Fig. 6
6

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1.6.3 Gas(see figs. 5 and 6)
When the main gas tap (33) is turned to the on position
gas is admitted to the gas section (7). Pressing the ignitor
button (9) operates a microswitch causing the commence-
ment of a firing cycle. The fan changes from low to high
speed and after a purge period of approx 14 seconds a
continuous stream ot 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 produced by the thermocouple (5) for the thermo-
electric valve to be retained in the open position.
When the ignitor button is slowly released gas is admitted
to the underside of the solenoid valves (10.11 and 12).
There are 3 solenoid valves: the centre (blue) valve (11)
frxed at l/3 of max rated output the right hand hot water
(black) valve (12) f=ed at 2/3 of maximum rated output,
the left hand central heating (orange) valve (10) which is
variable up top 2/3 maximum rated output. The gas
admitted by the orange valve is varied by adjuster (6) (see
section 6.4).
1.6.4 FUNCTIONAL FLOW DIAGRAM
Fixed 85°C Fixed 85°C
Limit - Limit
Thermostat T Thermostat
t
t
I Boiler 82°C
Domestic ’
Water 57°C
Thermostat
Control
Thermostat
Fig. 7
1.6.6 Safety Controls
In addition to the normal safety controls the Celtic plus
incorporates the following feature.
Should the central heating water flow reduce to below 300
l/h (1 ,l gavmin) the gas supply to the burner is turned off,
see fig. 4 (31) and figs. S&6 (37).
7

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1.6.f
1.6.7
FUNCTIONAL FLOW
WIRING DIAGRAM
PRINTEDCIRCUI
T BOARD
ILLUSTRATED WIRING DIAGRAM
V
L
W
ALL CABLES ARE 240V EXEPT WHERE THEY ARE INDICATED 24V
GR
ORANGE
BLUE
BLACK
BROWN
RED
VIOLET
WHITE
GREY
SELECTOR SWITCH 1 -
B 7
CHANGE OVER VALVE
SOLENOID VALVE
2l3c l/3 2l3s
PRINTEDCIRCUIT
- LIMITSTAT
--~“I -
SOILERTH HOTWATER
--
SPARK GENERATOR u IGNITION BUTON
WATER FLOW
SWITCH
8

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2 INSTALLATION REQUIREMENTS
2.1 General
2.2
The installation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations,
Building Regulations and current Byelaws of the Local
Water Undertaking. It should be in accordance also
with the current B.S. Codes of Practice and the British
Gas Specifications for Domestic Wet Central Heating
Systems and any relevant requirements of the local
Gas Region, Local Authority Building Standards
(Scotland) Regulations, and the Safety Document 635,
The Electricity at work Regulation.
Detailed recommendations are stated in the following
British Standard Codes of Practice:
B.S. 6891. B.S. 6798, B.S. 5440 : 1and 2, B.S. 5449: 1,
B.S. 7593, BS 5546 B.G.DM2, B.S. 4814, B.S. 7074 1
e 2, B.S. 7671.
Note : Gas Safety Installation and Use Reg. It is the
law that aII gas appliances are installed by competant
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.
Location
The boiler is not suitable for external installation. The
position chosen for the boiler must permit the
provision of a satisfactory flue termination. The
location must also permit adequate space for 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 B.S. 7671 and, in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland. with respect to the
installation of a heater utilising mains electricity in a
room or intemaI 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 gives detailed guidance on this aspect.
A compartment used to enclose the boiler must be
designed and constructed specifically for this purpose.
An existing cupboard or compartment may be used
provided that it is modified for the purpose.
Details of essential features of cupboard/compart-
ment design are given in BS 6798.
2.3 Water Circulation System
The Celtic plots is suitable for SEALED SYSTEMS
ONLY and should be installed in accordance with the
relevant recommendations given in BS 6798. BS
5449:l (for the smallbore or/and microbore systems)
and the British Gas Specifications for Central Heating
Systems.
2.4 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 boiler must NOT be
installed so that the terminal discharges into another
room or space e.g. outhouse or closed in lean-to. It is
important that the position of the terminal allows a
free passage of air across at aII times. The minimum
acceptable clearances from the terminal to
obstructions and ventilation openings are specified
below (fig. 10).
Horizontal Flue
Terminal positions Win clearances
A - Directly below an opening, windows etc
or adjacent to an opening ...................... 300 mm
B - Below gutters soil pipes or drain pipes ... 75 mm
C - Below eaves ........ .............................
200 mm*
D - Below balconies or car port roof. .. . ...... 200 mm*
E - From a vertical drain pipe or soil pipe .. 75 mm
F - From an internal or external corner ........ 300 mm*
G - Above ground roof or balcony level. ... 300 mm
H - From a surface facing the terminal. ........ 600 mm
J - From an opening in the car port
(e.g. door or window) into dwelling.. ... ..1200 mm
K - Vertically from a terminal on the same
wall .... . . . . .. .._...... .. ...... ......1500 mm
L - HorizontaIIy from a terminal on the
same wall . _......._... ...._. . ................... . 300 mm
* (107 mm) minimum clearance using
kit No. 76216.00 (G.C. 264 833).
Fig. 10
9

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BUILDING REGULATIONS excerpt.
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 IX subjected
to damage.
D) Designed so as to prevent the entry of any matter
which might restrict the flue.
(A terminal guard G.C. No 381 782 is available from).
Quinnef Barret & Quinnel Wiieworks
Old Kent Road
London SE15 INL Tel. [phone]
The air inlet/outlet duct and the terminal of the
appliance must not be closer than 25 mm (1 in) to
any combustible material . Detailed recommendations
on the protection of combustiable material are given
in BS 5440 Pt 1.
IMPORTANT NOTICE : TIMRER FRAMED HOUSES
IF THE APPLIANCE IS TO BE FITTED IN A TIMBER
FRAMED BUILDING IT SHOULD BE FITTED IN
ACCORDANCE WITH THE BRITISH GAS
PUBLICATION - “GUIDE FOR GAS INSTALIATIONS IN
TlMBER FRAMED HOUSING” reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCAL REGION OF BRITISH GAS OR C.O.R.G.I.
2.5 Air Supply
The room in which the boiler is installed does not
require 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.
Position of vents
Air km mom Air
direct from outside
High level 261 an2 (40 in2) 130 a-t-12(20 in2)
2.6
Low level 261 cm2 (40 in2) 130 cm2 (20 in2)
Electrical Supply
- This appliance must be earthed.
- AU wiring external to the appIiance must conform to
the current B.S. 7671.
- The Celtic plus requires a 240 V - 50 Hz suppIy.
- 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 BS 1363. AltemativeIy,
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.
-Fuse the supply at 3A.
-The supply cord must be 0.75 mm2 (24 x 0.2 mm)
three core to BS 6500 Table 16.
2.7 GasSapply
The Celtic plus requires:
2.743 m3/h (96.87 ft3fh) gas flow.
The meter and supply pipes should be capable of
delivering this quantity of gas in addition to the
demand from any other appliances in the house.
The complete Installation must be tested for
soundness as desaibed in BS 6891.
SYSTEM GUIDANCE
General
The low water content Celtic pltls boiler includes the
expansion vessels, safety overheat thermostat,
temperature and pressure gauges, and safety valve.
The flow temperature is adjustable and gives a
nominal 82 “C (180” F) on its maximum setting.
Detailed recommendations for water circulation are
given in BS 5546. Whilst the boiIer 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 application is given
in section 3.13. Thermostatic control should be used
in the heating circuits and the cylinder if one is titted.
It must be remembered that a combination appliance
has a limited volume of hot water that can be
supplied 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 boiIers.
The appliance has two separate functions, to provide
heating and hot water on demand. It can have a thiid
which is to supply hot water high demand through the
use of an indirect cylinder, where there is more than
one bathroom or if the standard and appointments of
the property, such as basins in al1 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 simukaneous demand outlets -
bathrooms etc, whilst the benefits of high efficiency in
generally small quantities of hot water. can be fulIy
utilised in kitchens, cloakrooms and so on.
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 ffow
share or priority pattern.
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 tail, smaII diameter cyIinder.
See section 5 for possible wiring arrangements.
A domestic expansion vessel is Mted to the boiler with
a capacity of 0,16 litres, prior to the secondary heat
exchanger which enables the boiler to be connected
to a cold main water supply containing a non-return
valve or any device containing a non-return valve.
10

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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 Celtic plus it is essential that all redundant
pipework is removed and dead legs eliminated,
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-
return valve should be less than 1 m (3 A) above the
top of the appliance and idealIy should be as close as
possible to the hot water outlet.
At the design fIow temperature and the initial system
pressures quoted the maximum allowable system
volume is 75 litres.If the water volume is not known
and cannot be accurately assessed from
manufacturers data the following volumes may be
used to give a conservative estimate of the system
volume.
Boiler .............._.................................
4 litres (0.8 gals)
Small bore pipework... ........_........0.3 litres (0.07 gals)
per 0.292 kW
Microbore pipework. .........................7 litres (1.5 gals)
Steel panel radiators ......................2.3 litres (0.5 gals)
3.2 System controls
The boiler is electrically controlled and is suitable for
most control schemes currently available including
thermostatic radiator valves and motorised valves.
When using motorised valves the controls should be
arranged to switch off the boiler when circuits are
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 all TRVs are closed.
(see fig. 17).
3.3 Pump
per 0.292 kW (1000 Btti) of system output
Hot water cylinder .............___........2 litres (0.44 gals)
If the volume exceeds 75 litres an additional vessel
will be required fitted in the flow from the appliances.
Refer to BS 7074 Pt. 1 or BS 5449 for details of sizing
3.5 Mdns water connection
3.6
There shall be no permanent connection to the
Heating System Pipework for filling or replenishing
without the approval of the Local Water Authority (see
Byelaw No. 14 and figs. 12 and 13).
mg pdnt (see B.S. 5449)
Filling and recharging can be done :
1) Through a temporary hose connection to mains
water.
The boiler is fitted with a Grundfos UP.15/60 pump
head. The graph (fig. 11) indicates the residual head
available for the system.
flow rate in g.p.m.
1
2 3 4 5
A stop-valve should be fitted to the service main outlet
and a double check valve assembly and stop-valve
should be fitted to the system side of the temporary
hose (see fig. 12).
2) A cistern used for no other purpose connected to
the mains water.
3.7
The static head provided by the cistern must be
sufficient to satisfy the designed initial system
pressure. The supply pipe from the cistern should
include the double check valve assembly and
stopcock (see fig. 13).
Make ap system
3.8
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
filliig point (see section 3.6).
Plpework
Hz z HB8888 : 8
flow rate in Lre”s/hLF r s!
Fig. 11 3.9
Pipework can be of copper or suitable plastic, small
bore or microbore with capillary or compression
jointing to a high standard, leak sealant must not be
used in the system.
3.4 Expansion vessel Domestic expansion vessel
The expansion vessel which is fitted on the front of
the combustion chamber accomodates system water
expansion. The vessel has a capacity of 5.4 litres
(1.19 gals) and is charged to a pressure of 0.65 bar
(9.7 p.s.i.).
THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHARGING AND NOT A
VENT POINT.
The expansion vessel which is fitted on the cold water
supply to the secondary heat exchanger accomodates
domestic hot water expansion. The vessel has a
capacity of 0.16 litres (0.035 gals) and is charged to a
pressure of 2 bars (30 p.s.i.); it has a maximum
working pressure of 10 bars with an allowable
pressure peak of 14 bars.
11

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Air inletAir inlet
valvevalve
iose
Heating circuit / valve assembly 1 r u”io”s~
Double check Hose
valve assembly ,,,io”;~-J
P
I’
valve I’ ;I
Test cock g---_?:
Temporary
Mains
water
supply
(a) Non-automatic filling and make-up. Temporary hose filling loop avaible, Pt.No.CHL112
Overflow Mains
Double check
valve assembly above highest
lA LA hA point in the
stop system and
valve satisfy the
designed initial
Test cock system pressure
Fig. 13
(b) Automatic filling and make-up.
3.9.1 Boiler replacement (retrofit)
In an old system where the boiler is beiig replaced,
we recommend the use of a strainer, fitted with a
drain tap on the heating return, designed to retain
scale particles and other soIid debris It is good practice
to use a chemical cleaner with a floctuating agent,
used as recommended by the cleanser manufacturer,
to clean the system before the old boiler is removed.
(see BS 7593).
3.9.2 Existing systems
Valves and joints should be carefuky 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 capable of sealing at the higher pressures.
3.10 Cyhder
Where a domestic hot water cylinder is used with the
Celtic plus it MUST be of the indirect and high
recovery type to BS 1566 Pt 1 Single feed cylinders
are not suitable for use with this appliance. Flow and
return pipework to the cylinder should be in 22 mm
pipe.
3.11 InMbitors and water conditioners
(see BS 7593)
Chaffoteaux et Maury generaIIy recommend the use
of inhibitors in systems using the Celtic pIus boiler.
The following are the appliance manufacturer’s
recommendations :
I) Use only a British Gas or simiIar approved inhibitor,
These manufacturers can assist with the selection.
Grace Dearbon Ltd - Widnes - Cheshire WA8 8 UD
Tel: [phone].
Fernox Manufacturing Company Limited Britannica
Works. Clavering, Essex CBI1 4QZ
Tel: [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 fmally re-
fiuig the system.
5) In-line water conditioners both of chemical and
magnetic tyre are suitable for use with the Celtic plus.
3.12 Add-on devices
It is important that no external control devices e.g.
economisers be directly fitted to this appliance unless
covered by these installation instructions or agreed
with the manufacturer in writing. Any direct
connection of a control device not approved by the
manufacturer could make the guarantee void and also
infriige the Gas Safety (Installation & Use) Regulations.
12

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instant hot
water low
demand
outlets
Fig. 14
Celtic plffs
1
Heating & stored hot
water - spring return
valves only
AAVT h
stat.
Heating & stored hot
Celtic plus
water using flow share
I 1
relay required
water low
7g. 15
Fig. 16
Celtic plus
hot water
Remote by-pass
remote by pass
with US valve I
3.13 Heating and hot water systems
Figs. 14, 15, 16 and 17 indicate various layouts for
the production of hot water. It is recommended that
only a high recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special saturated heat exchanger in an indirect
cyIinder may be desirable.
When replacing an exisiting cylinder storage system
with an instantaneous type system it is essential that
a11redundant pipework is removed and dead legs
eliminated.
The consideration of heating systems using
thermostatic valves should ensure that the minimum
flow rate through the appliance is maintained at all
times and in this connection the remote by-pass is
preferred (see fig. 17).
13

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3.14 Shower Application
The appliance can be used to supply hot water to separate. shower draw-off It must not be used to supply more than
one shower mixing valve.
The recommended pipework arrangement for a shower is shown below and the hot supply to the mixing valve should
be the first draw off.
HOT
COLD
Fig. 17 a
n
Celtic plus
HOT WATER
a COLD WATER
1
Valve
It is important to select a compatible shower for the Celtic plus The following manufacturers can assist with the
selection
New Team Ltd Meynell Valves Ltd
Brunell Road Shaw Road
Earlstree industrial Estate Bushbury
Corby Wolverhampton
Northants NN17 2LF West Midlands WV1 0 9LB
Tel.No.0536-62822 Tel.No.0902-28621
Aqualisa Products Ltd
Hortons Way
London Road
Westerham
Kent TN1 6 1BT
Barking Grohe
1 River Road
Barking
Essex IGll OHD
Tel.No.0959-63240 Tel.No.081-594-8898
Do not use the appliance with push on hand showers that tit over hot and cold taps.
14

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4 INSTALLING THE 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 is supplied in a single
carton which contains :
1) The chassis with aII functional parts attached.
2) Casing comprising : 2 side panels
1 front panel
1 controls fascia cover
1 glass door complete with hinges
Zt) Mounting bracket comprising : flueguide
top support plate
spacing strip
bottom support plate
plastic jig plate connection
4) Plastic bag contaXing : gas ffiterlwasher
5) Box containing : gas and water connections inc. 4 above.
6) Box containing : control knobs
safety valve
wall plugs
screws and 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 lockiig ring
‘0’ ring
2 gaskets - one cork and one rubber
4 mounting screws with washers for flue turret
N.B. (i) Flue accessories are not suppIied as standard, and must be ordered to suit (see section 1.4)
4.1
4.2
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. 10). b) Check flue length (see 1.4 -
figs. 2 and 3).
c) Check clearance on external wall for flue terminal
position (see table 2.4 - fig. 10)
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.
‘ig. 18
Rear outlet ffae
a) Mark vertical centre line for boiler on wall.
b) Mark horizontal centre lie for 107 mm (4.2 in) dia
waII opening and one for upper bracket tixing screws
(A).
c) Using bracket as template mark 4 tixing points (A) and
(B).
d) Mark wall for flue opening using flue guide plate.
e) Drill the wail for the flue opening using a 107 mm (4.2
in) core drill.
f) Drill 4 fixing holes (A) and (B) 7.9 mm (5/16 in) and
Plug.
g) Fii bracket to wall using 6 mm x 50 mm wood screws
provided.
‘ig. 19
N.B. Ensure bracket is square and plumb to vertical
centre line before tightening.
15