Chaffoteaux & Maury CHALLENGER 30 FF User guide

CHALLENGER
Fanned Flue Boilers
30 FF 50 FF
(GCN"41.980.74) (GCN"41.980.77)
installation
and servicing instructions
(these instructions are to be left with the User or adjacent to the Gas meter)

30 FF8.7 kW(30,000 Btu/h) to 4.4 kW(15,000 Btu/h) betheei50" Cand82" C.
- Pump overrun function.
50 FF14.6 kW(50,000 Btu/h) to 7.4 kW(25,000 Btu/h) - Lowresistance -water circulation.
The boiler is designed for use on Natural Gas, UnleSS
otherwise stated. It issuitable for open and sealedwater
systems, and is approved to Supplement 1 of BS 5258 :
Pt 1. FanPowered Appliances.
- Highlimit temperature protection.
- Rearor sideoutlet flue connection.
- Fluelengths up to 3 metres.
The CHALLENGER FF is a wall mounted low water
content gasfired boiler, There are 2 models inthe series,
each having a range rated output.
The boiler is designed for fully pumped systems only. It
hasa number of built in features.
- Fullvadiustable electronic temperature regulation
Guarantee
The manufacturer’s guarantee isto supply free of charge any defective part of a Challenger boiler for a period of 24 months
from the date of purchase. The guarantee isvoidable if it is not installed in accordance with the recommendations made herein
or in a manner approved by the appiiance manufacturer.
1.1 TECHNICALDATA
ii a ’a ’ AA
7171
r_-----~r_-----~
I+I+ flfl
L___---AL___---A
II
II
WW
!!
aa
II
i-” i”li-” i”l
II
w
7 T7 T
B
L
CHALLENGER30 - 50 FICHALLENGER30 - 50 FI
mmmm insins
AA 672672 26.526.5
BB 395395 15.5015.50
CC 275275 10.810.8
DD 100 4100 4
EE 807807 30.7530.75
FF 275275 10.7510.75
GG 219219 8.58.5
HH 445445 17.517.5
JJ 384384 15.015.0
KK 55 255 2
LL 270270 10.5010.50
MM 140140 5.505.50
NN 288288 11.2511.25
PP 7070 2.752.75
RR 4545 1.751.75
SS 2020 0.750.75
2

1.2
30 FF
Max
Min
50 FF
Max
Min
OUTPUT
kW Btu/h
8.79 30,000
4.4 15,000
OUTPUT
kW Btu/h
14.65 50,000
7.33 25,000
Max
Min
Max
Min
INPUT HOTBURNERPRESSURE GASRATE
kW Btu/h m-bar ins.w.g. m3/h ft3/h
11.02 37,600 5.8 2.3 1.03 36.4
5.83 19,900 1.3 0.5 0.54 19.2
INPUT HOTBURNERPRESSURE GASRATE
kW Btu/h m.bar ins-w-g. m3/h ft3/h
18.6 63,500 7.9 3.2 1.74 61.4
9.9 33,750 1.5 0.6 0.94 32.6
1.3
1.4
DIMENSIONS (Casing) 1 CLEARANCES
I I
3OFF&5OFF I
Gas connection .......................
Water connection .....................
Minimum flow rate ....................
Maximum static head .................
Minimum static head ..................
Electrical connection ..................
Weight ..............................
Watercapacity .......................
Burner Injector Size ...................
Pilot injector .........................
Ignition ..............................
Electrode ............................
Boiler thermostat .....................
High iimit thermostat .................
Thermocouple and thermoelectric valve
Fanmotor ...........................
Pressureswitch ......................
Sides
TOP
Bottom
Front
mm in
5 l/4
150 6
150 6
300 12
15 mm O.D.compression
22 mm O.D.compression fittings
30 FF 504 It/h (1.85 gpm) 50
FF 841 It/h (3.08 gpm)
30 m (98ft)
150 mm (6 ins)- Seefigs 7.12
240 Vsingle phase 50 hz supply fused 3 amp
30 FF - 24.77 kg (54.5 lb) 50
FF - 25.9 kg (57 Ibs)
30 FF - 0.5 lit. (0.11gals) 50
FF - 0.7 lit. (0.15 gals)
1.18 mm (0.046 in)- marked 118
0.3 mm (0.011 in)- marked 030
Continuous spark - spark generator ANSTOSS
Chaffoteaux - spark gap 5.0 mm
Chaffoteaux - Electronic
RancoLM5
Chaffoteaux
AEC
DUNGS
HYDRAULIC RESISTANCE
The hydraulic resistance of the boilers vary with the
water flow. The graph indicates resistance at va-
rious flow rates for both models.
The minimum flow rates are :
30 FF
504 It/h (1.85 gpm)
50 FF 841 It/h (3.08gpm)
The minimum flow rate is equivalent to a tempera-
ture rise of 15’ C(27’ F).
Fig. 2
water2flow
-
1
gaily per minute 4 5
400 600 800 1000
water flow -ri perhour
3

The flue must be installed in accordance with BS5440 Pt 1 1978 1
Minimum WallThickness76 mm (3in)- MaxWallthickness 3 m (9’10”)
1.6 Description of operation
Pressing the igniter (ON)button disconnects the power to fire on 50 %fixed gasvalve. When the set temperatu-
supply to the pump, opens the thermoelectric valve and re isreached the boiler switches off. If flow temperature
causesa continuous pilot ignition spark to be generated. reduces the 50 %valve opens followed by the 100 %val-
When a demand is indicated by a time clock, program- ve.
mer, thermostat etc. the pump starts, the fan changes At the end of the ‘on’ cycle, under the control of a time
from low speed to high speed and is proved by the pres- clock or programmer or when the cylinder and room
sure switch before the 50 %fixed gas valve opens. After thermostat are satisfied, the boiler switches off but the
3 secondsthe second gasvalve (variableoutput) opens. pump continues to run for 15 seconds. The fan returns
Temperature control is by means of a temperature sen- to operation at the low speed.
sing thermistor and potentiometer. These signals are
fed to a comparitor. The high limit thermostat breaks the thermocouple cir-
cuit which extinguishes the pilot releasing the thermo-
When the flow approaches the set temperature the
main variable gas valve is closed and the boiler continues electric valve and closesthe gas valve to the burner. Ma-
nual re-setting isrequired (SeeSection 5.4).
GENERATOR
FUNCTIONALFLOWDIAGRAM
THERMISTOR
POTENTIOMETER
TEMP. SELECTOR
COMPARITOR FAN PROVING
PRES!WRE SWITCH

2.
2.1
2.2
‘2.3
2.4 Siting the Flue Terminal
INSTALLATION REQUIREMENTS
General
The installation of the boiler must be in accordance with
the GasSafety (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 BSCodesof Prac-
tice and the British GasSpecifications for Domestic Wet
Central Heating Systems and any relevant requirements
of the localGasRegionand LocalAuthority.
Detailed recommendations are stated in the following
British Standard Codes of Practice : CP 331.3 1974, BS
5376:2 1970, BS5440 1979, BS544O:l 1978 and 2 1976,
BS5449:l 1977.
Note : GasSafety Installation and UseRegs1984 It isthe
law that all gas appliances are installed by competant
persons in accordance with the above regulations. Failu-
re to install appliances correctly could lead to prosecu-
tion. It is in your own interest and that of safety to ensu-
re compliance with the law.
Location
The position chosen for the boiler must permit the provi-
sion of a satisfactory flue termination. The location must
also permit adequate space for servicing and air circula-
tion around the boiler.
The boiler may be installed in any room or internal space
although particular attention is drawn to the require-
ments of the IEEWiring Regulations and, in Scotland,the
electrical provisions of the Building Regulations applica-
ble in Scotland, with respect to the installation of a hea-
ter in a room or internal space containing a bath or sho-
wer.
Where the installation of the boiler will be in an unusual
location special procedures may be necessary and BS
5376~2give detailed guidance on this aspect.
A compartment used to enclose the heater must be des-
igned and constructed specifically for this purpose. An
existing cupboard or compartment may be used provi-
ded that it is modified for the purpose.
Details of essential features of cupboard/compartment
design are given in BS5376:2.
Water Circulation Systems
Openor sealedtype central heating systems should be in
accordance with the relevent recommendations given in
BS 5376~2,BS 5449:l (for smallbore or microbore sys-
tems) and the British GasSpecifications for Central Hea-
ting Systems.
Hot water systems should be in accordance with the re-
levant recommendations given in BS5546 and the above
mentioned British Gaspublication.
The flue installation must be in accordance with BS5440
Pt 1 1978.
The standard flue set is suitable for walls having a thick-
ness of 76 mm - 612 mm for rear outlet and 76 mm -
500 mm for side outlets - See 1.5.Other flue options are
available to a maximum of 3 m (9 ft 10 in)to specialor-
der. (See1.5).
The boiler must be installed so that the flue terminal is
exposed to external air. The boiler must NOTbe installed
so that the terminal discharges into another room or
spacesuch asan outhouse or leanto. It isimportant that
the position of the terminal allows a free passageof air
across at all times. The minimum acceptable spacings
from the terminal to obstructions and ventilation ope-
ningsare specified bevow :
Terminal position Minimum
spacing
1. Directly below an openable win- 300 mm (12 in
dow air vent or any other vantila-
tion opening.
2. Below guttering, drain pipes or 75 mm (3in)
soil pipes.
3. Below balconiesor eaves. 200 mm (8 in)
4. Above adjacent ground or balco- 300 mm (12 in
w
5. From vertical drain pipes or soil 75 mm (3 in)
pipes
6. From internal or external corners 300 mm (12 in
7. From a surface facing the termi- 600 mm (24 in
nal.
8. From aterminal facing the termi- 1200 mm (48 in
nal.
Note : The flue can be extended 150 mm (6 in)to clear a
projection. Where the terminal is fitted within 850 mm
(34 in)of a plastic gutter or 450 mm (18 in)from painted
eaves, an aluminium shield of at least 750 mm (30 in)
long should be fitted to the underside of the gutter or
painted surface.
Where the lowest part of the terminal is less than 2 m
(6.5 ft) above the level of any ground, balcony, flat roof
or place to which any person has access and which ad-
joins the wall in which the terminal is fitted the terminal
must be protected by a guard of durable material (Ater-
minal guard is available from Chaffoteaux Ltd) or from
Tower FlueComponents. Tonbridge 351555.
The air inlet/products outlet duct and the terminal of
the appliance must not be closer than 25 mm (I”) to any
combustible material. Detailed recommendations on the
protection of combustible material are given in BS5440
Pt.1 1978 (SubClause20.1).
IMPORTANTNOTICE: TIMBERFRAMEDHOUSES
IF THE BOILERISTO BE FITTEDIN A TIMBERFRAMED
BUILDING,IT SHOULDBE FITrED IN ACCORDANCEWITH
THE BRITISHGASPUBLICATION- ((GUIDEFORGASINS-
TALLATIONSIN TIMBER FRAMEDHOUSING)) reference
DM2. IF IN DOUBT,ADVICEMUST BESOUGHTFROMTHE
LOCALREGIONOFBRITISHGAS.
Air Supply (BS 5440:2)
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 ei-
ther direct to the outside air or to a room. Both high and
low level air vents must communicate with the same spa-
ce.
Cupboard or compartment air supply
30 FF
II
low level 106 cm2(16 in21 53 cm2(8 inn)
5

2.6 Electrical Supply
This boiler must be earthed All wiring must conform to
the I.E.E.Wiring Regulations,The CHALLENGERFF requi-
res a 240 V single phase, SCHzsupply. A means of isola-
tion must be provided adjacent to the boiler, this should
preferably be an unswitched plug and socket which on
disconnection has a separation of at least 3 mm on ail
poles. The supply cord must be 0.75 mm* three core
heat resisting cable.
2.7 Gas Supply
The Challenger FFon Natural Gasrequires :
30 FF1.03 m3/h (36.4ft3/h)
50 FF1.74 ms/h (61.4ft3/h)
The meter and supply pipes must be capable of delive-
ring this quantity of gas in addition to the demand from
any other appliancesinthe house.
The complete installation must be tested for soundness
and purged asdescribed in CP331~3.
3 SYSTEM GUIDANCE
3.1 General
The CHALLENGERFFboiler series are low water content
appliancesdesigned ONLYfor use with fully pumped sys-
tems. They may be used with open or sealedsystems, all
safety controls excluding the pressure relief valve being
incorporated in the boiler, The thermostat is adjustable
and, on its maximum setting, gives a nominal 82” C(180
F)flow temperature.
Detailed recommendations for water circulation are gi-
ven in BS 5376:2 1976, BS 5449:l 1977, BS 5446:1979.
Thermostatic control should be fitted to the hot water
storage cylinder and heating system.
3.2 Strainers
Where a CHALLENGERFFis used as a replacement for a
boiler on an existing system, ideally the water system
should be flushed and cleaned using a suitable chemical
cleaner following the manufacturer’s recommendations
and fitted with a strainer similar to that manufactured
by Honeywell (Code FY 30) in the return before the boi-
ler.
3.3
3.4
Control Systems
Most normal pumped primary control schemes can be
used including thermostatic radiator and cylinder valves.
When using motorised valves the controls should be so
arranged to switch off the boiler when circuits are satis-
fied.
Chaffoteaux can be consulted where technical assistan-
ce is required.
Circulation Pump
The system circulating pump should be sized relative to
the resistance of the connected load and the system de-
sign nt selected. The mass flow rate through the boiler
should not be lessthan :
CHALLENGER30 FF504 It/h (1.8 gpm)
CHALLENGER50 FF841 It/h (3.08 gpm)
50 FF
Position of Air from 1 Air Direct
air vents room from outside
I High level 168 cm* (26 in*) 84 cm* (13 in*)
Low level 168 cm* (26 in*) 84 cm* (I 3 in*)
3.5 Cold feeds and open vents (figs. 7-13)
The cold feed and open vent should be so positioned
that pumping over and cavitation or air entrainment are
avoided see recommendations for various layouts on
page 8. Chaffoteaux recommend that the 15 mm cold
feed and 22 mm open vent are closecoupled (within 150
mm (6”) on the low pressure side of the pump. The
connection should be so arranged that there is a low ve-
locitv point at the open vent junction with the system.
(Page8 - Fig.13).
3.6 Automatic Air Separator
Chaffoteaux strongly recommend the inclusion of a Bri-
tish Gasaccepted automatic air separator in the system
asshown infig. 13.
The open vent should rise continuously from the system
pipework.
It should not be entered horizontally into the system pi-
pework. The useof an enlarged T to create a low velocity
point is recommended. The preferred arrangements is
shown in fig. 13.
3.7 Cylinder
The domestic hot water cylinder used with the CHAL-
LENGERFF must be of the indirect and high recovery
type to BS1566 Pt. 1. Singlefeed cylinders are not suita-
blefor usewith this appliance. Flowand return to the cy-
linder must not be lessthan 22 mm pipe.
3.8 Feed and Expansion Tank
The feed and expansion tank should be adequately sized
to accept the system water expansion. It should not be
mounted closer than 230 mm (9”) to a ceilingto allow ac-
cessto the ballvalve.
3.9 Inhibitors
Chaffoteaux Limited do not generally recommend the
inclusion of an inhibitor with heating and hot water sys-
tems, utilising Challenger FF boilers. It is, however, ap-
preciated that the use of a corrosion and limescale inhi-
bitor may be desirable or specified.
The following are the appliance manufacturers recom-
mendations :
I) Use only a British Gas or similar approved inhibitor
from the Fernox range manufactured by Industrial
(Anti Corrosion) Services, Britannica Works, Arkesdon
Road,Clabering, Nr. Saffron Waldron.
2) Use only quantities specified by the inhibitor manu-
facturer.
3) Cleansethe system as required by the inhibitor ma-
nufacturer.
4) Add inhibitor only after flushing when finally refilling
the system.
3.10 Add on Devices
The pump must be installed between isolating valves si-
tuated as closeto the pump aspractical. Most pump ma-
nufacturers require a minimum static head on the pump
inlet to prevent cavitation. For boiler resistance, see
graph on page 3 - fig. 2.
This appliance is approved by British Gasfor safety and
performance. It is important that no external control de-
vices - eg. flue dampers, economisers etc. - be directly
connected to this appliance, unless covered by these Ins-
tallation Instructions or agreed by the Manufacturer in
writing. Any direct connection of a control device not ap-
proved by the manufacturer could invalidate British Gas
approval and also infringe the Gas Safety (Installation
and Use)Regulations 1984.
6

3.11 Electrical controls
(Chaffoteaux recommendations)
CHALLENGERFF boilers can be used with most normal
pumped primary schemes including non-electrical hea-
ting and hot water controls.
It is not normally possibleto use full programming facili-
ties when using a mixture of electrical and non-electrical
controls. However, some non-electrical controls are now
availablewith an external microswitch and these controis
are preferred.
Where the thermostatic radiator valves are used, a sys-
tem by-pass will be necessary to maintain the minimum
flow rate - Seesection 1.4.
NB: All wiring to externai controis must be in accordan-
cewith the ICEWiring Regulations.
7. Fully pumped system independant control of central hea-
ting and hot water using two spring return motorised val-
Fig. 3
Ii i t I 6
N L onlofflonlaff
CH (HW
LNNL56
PROGRAMMER PUMP BOILERTERMINALS
2. Fully pumped systems independant control of central
heating and hot water using two motorised valves.
PROGRAMMER PUMP BOILER
TERMlNALS
Fig. 4
3. Drayton flow share valve system.
PROGRAMMER PUMP BOILERTERMINALS
Fig. 5
4. Satchwell Duoflow svstem.
PROGRAMMER PUMP BOILERTERMINALS
Fig. 6
7

ALTERNATIVE SYSTEM LAYOUTS
Minimum
Static Head
150 mm
PREFERED
Fig. 7 I 1
-L
- - L-w-.
..... ‘1:’
..... ....
..... .... w
..... ....
..... ....
..... -----r-l .....
..... .....
Syfi buld be .....
. . .. .
. . .. .
sWAtmospheric
. . ... . .. . .
. . .. .
. . . . .
.__
Fig. 9
‘NOT RECOMMENDED1 -:-
Fig. 10
4I-l ...
.....
.
...
.....
.....
~rz~z----- -
I-A .....
..... .....
.....
.....
..... /=\ . ...
-43.:-2
.
Minimum
Fe;iFtead
BS 5449
Part 1 1977
I-
’
’ 74
<w fg
see 3.4
*I-- v
Fig. 11 LJ
Air seperator or formed low velocity point
b openvent
cold feed
AJ-
Fig. 13
Minimum
gta$;ead
Fig. 8 l-l
Minimum
Tt;t& Head
Fig. 12 I-J
1. Cold feed 15 mm
2. Open vent 22 mm
3. 6 in. maximum
4. See fig. 13
5. By pass 15 mm
6. Regulating motorised valve
7. Combined cold feed and
open vent
8

4. INSTALLING THE BOILER
A vertical flat incombustible area is required for installation of the boiler asfollows :
CHALLENGER30 FF445 mm wide x 955 mm high (17 l/2 in x 37 l/2 in)
CHALLENGER50 FF445 mm wide x 955 mm high (17 l/2 in x 37 l/2 in)
The above dimensions include the necessary clearances around the boilers for case removal, air movement and installation
and servicing.
The CHALLENGERFFand Flueassembly (standard length) are supplied in one carton in which there are 3 compartments.
1. Assembled boiler
2. Air inlet duct and flue duct
3. i) Flueturret assembled with pressure switch
ii) Box containing :
- 2 nuts and olives 22 mm
- 1 nut and olive 15 mm
- 1 gas service cock
- 1filter washer
- 1 mounting bracket
- 4 wood screws and washers
- 1 cable clamp and screws
iii) Plasticbag containing :
- 1 locking ring
- 1 ‘0’ ring
- 1 cork gasket
- 1 channelled neoprene gasket
- 4 fixing screws for flue turret
- 2 screws for turret cover
iv) Plasticbag containing :
- external wall plate with adhesive mastic
v) Plasticflue turret cover.
4.1
- Remove boiler from carton
- Releasethe front case by unscrewing the three fixing
screws and washers positioned two at the top and one
at the bottom and two screws securing the caseto the
control box.
NB: one washer is paint cutting to maintain electrical
bond. (Front of appliance covered by glass drop down
door. See7.1).
- Remove the case by easing it forward at the bottom
and lifting it clear of the top locating lugs.
- Set out and drill hole for flue using a 4 in core drill or
metric equivalent.
- Using dimensions on page 2 drill and plug the wall and
fit bracket to the wall using screws and washers provi-
ded. Checkand ensure bracket is level.
- Temporarily hangthe boiler on the bracket.
- Mark two fixings at the bottom of the boiler, remove
the boiler and drill and plug the wall.
-Rehang and screw the boiler to the wall using the
screws and washers provided.
9

4.2
4.3
4.4
- Measure the wall thickness and cut the flue duct and
air inlet duct to length - see 1.5 ANY SURPLUSLENGTH
MUSTBECUTFROMPLAINEND.
NB : If coldthe duct material becomes brittle-warm be-
fore cutting.
- Peel off protective paper from the adhesive side of
the cork gasket A and place on mating surface of flue
turret Blining up screw holes. Pressdown.
- Fit a channelled gasket E to products outlet on top
of boiler.
- Assemble flue duct onto flue tube section.
- Fit locking ring Cand ‘0’ ring over air duct asshown.
- Assemble the flue duct through the air duct so that it
engagesthe terminal.
- Abutt the ‘0’ ring up to the turret and engage the loc-
king ring over the lugs by turning inan anti-clockwise.
- Remove cable connection for pressure switch which in
transit istucked into top of casing.
- Passassembled flue through the wall so that the ter-
minal extends not lessthan 13 mm (l/2 in) beyond ex-
ternal wall surface.
- Seat the turret onto the flue outlet ensuring that gas-
kets A & Eare in position.
- Checkthat the flue assembly islevel.
- Securewith the 4 screws provided.
- Where necessary make good external wall and fit wall
plate D with mastic sealant onto external surface.
Makegood internal wall.
NB: Do not fit turret cover or front case until gas and
electrical connections have been made and tested.
Making the gas connection
a) Remove the plastic cover from the gas inlet which is
situated centre bottom of the boiler.
b) Fit the gas service cock together with the filter was-
her packed in the accessory box.
c) Fit the union nut and olive on the 15 mm gas supply
pipe,and tighten.
d) The gas supply pipe size should be sufficient to ensu-
re that there is 20mbar (8 in.w.g.1pressure at the
service tap, with the boiler working
NB : If space beneath boiler is restricted it is possible to
fit a 3/4 BSPM & Felbow to the appliances.The gas ser-
vice cock fits to the male thread.
Making the water connections
a) Removethe plastic covers protecting the flow and re-
turn connection.
b) Fit the union nuts and olives supplied in the accessory
box on to flow and return pipes.
RETURN
c) Tighten compression fitting whilst holding connection
insidecase.
10

4.6
Making Electrical Connection (see section 2.6 for elec-
trical supply requirements)
a) Secure cable clamp A to the base of the appliance
using the screws and paint cutting washers provided.
Paint cutting washers must be used to maintain
earthbond.
b) Remove control box cover see 8.7.
c) Three core heat resisting supply cable is passed
through clamp and through slot in casing, and into
rear of control box. Securewith clamp on top of elec-
trical box so that there is sufficient length of cable
between the 2 clamps to allow displacement of the
electrical box without imposing strain on the earth
bond. Connected to terminals on connection block
and the earth connection made to the terminal.
d) Connect pump cable to terminals and the earth on
earth terminal.
e) Connect ancillary controls across terminals marked 5
& 6. Seecontrols diagrams. Figs2-6 and 14-16.
f) Clampwires with cableclamp A.
g) Replacecontrol box cover.
NB : The length of the earth wire between the cord an-
chorage and the terminal must be such that the live and
neutral wires become taut before the earth wire if the
supply cord is pulled.
Connection of the pressure switch
a) Connect the violet wires in the wiring harness to ter-
minal COM(P)and NO(2) common and normally open
contacts.
L
Inthe event of an electrical fault after installation preliminary electrical system checks should be carried out.
Checksto ensure electrical safety, earth continuity, polarity, and resistance to earth should be carried out by a compe-
tent person.
3 Wire clock
Time clock
4 Wire clock
Fig. 14
CHALLENGER-SIMPLECONTROLS
Room thermostat onlv
N N
Room thermostat and time clock
Fig. 15
Frost thermostat
Fig. 16
11

5 COMMISSIONING- OPENVENTED SYSTEMS
5.1 GasInstallation
The whole of the gas installation, including the meter
should be inspected and tested for soundness and pur-
ged in accordance with the recommendations of CP
331:3.
boiler output kW
5-2 Water circulation system -
Open vented systems only
The whole of the system should be filled and thoroughly
flushed out with cold water without the pump in posi- $ 3 B
tion. Ensurethat allvalves are open. h
With the pump fitted the system should be flushed and i
air locks cleared. Vent all radiators and check for water
soundness. 2
Lightthe boiler asdetailed in 5.3
5.3 Lighting the boiler
The water system should be heated to maximum wor-
king temperature and examined for water soundness.
Both gas and water should then be turned off and the
water system rapidly drained while still hot.
The system should again be filled, cleared of air locksand
examined for water soundness and inhibitor added to
the system if required in the specification (see section
3.9).
a) Checkthat the gas service cock isopen.
b) Pushthe ONbutton fully in and hold for 10 seconds.
c) Checkthat pilot isalight and releaseslowly.
d) If the pilot extinguishes press red reset button and
repeat from (b).The pilot should be about 13 mm (I/2
in)long and impinge on the tip of the thermocouple.
e) Switch system controls to a demand mode, ensuring
that pump isrunning.
/ I
10000 20000 30000 40000 50000
output Btu/h
Fig.
L
1
17
f) After 30 secondsthe main burner will light.
g) If the pilot extinguishes, wait 3 minutes and repeat b)
5.5
above.
h) Check for gas soundness around the boiler gas com-
ponents using leak detection fluid.
i) Checkand adjust gas rate asdetailed in 5.5.
5.4 Resetting
the high limit thermostat
a) If for any reason the high limit thermostat operates
the pilot will go off and the boiler will require manual
re-setting.
b) Re-establish the appliance by resetting the high limit
thermostat by pressing the red reset button.
c) Establish cause and rectify - See Fault Finding Chart,
rear cover.
NB: If the mains electrical supply is interupted the high
limit thermostat may operate.
Gas rate adjustment (TObe carried out be-
fore adjusting heating system by-pass).
NB: The boiler is supplied rated at the highest output.
The boiler isfitted with a gas rate adjuster.
a) Turn boiler to off by pressing OFFbutton.
b) Remove the pressure test point screw (1) and
connect a suitable pressure gauge (fig. 17).
c) Remove the hexagonal cap from gas rate adjuster, (2)
exposing the adjustment screw (fig. 17).
d) Turn boiler on by pressing ONbutton (seelighting boi-
ler 5.3 above).
e) Adjust setting pressure. Setting pressures are given
in graph relative to required output. The pressure will
be reduced by clockwise movement of screw, increa-
sed by anti-clockwise movement.
f) Turn boiler to OFFand refit pressure test point screw
and gas rate adjuster cap and ensuring that a gas
tight sealis made.
g) Mark the data badge to indicate output.
h) Replace front case. Particular care must be given to
ensuring that the case seal is sound when the casing
isreplaced.
i) After boiler has been running for 10 mins check the
gas rate.
j) Fit the plastic turret cover threading the harness
through the slot provided.
k) Secure cover with the thread forming screws provi-
ded.
12

5.6
Adjusting the heating system by-
pass
NB : The by-pass valve should be of the lock shield pat-
tern)
a) Fire the boiler with the by pass fully closed and the
system using the radiator lock shield valves to the
system design temperature difference. Normally this
will be 11” C(20” F).
b) Adjust the system to minimum load. This will general-
ly be central heating only with one radiator operating.
Switch off radiators on the wheel head or thermosta-
tic valves. 6 .4
c) Switch boiler thermostat to maximum.
d) Open by passuntil minimum flow rate across the boi-
ler is achieved. This is equivalent to 15” C (27” F)tem-
perature rise across the boiler.
e) Open all radiators and check the system design tem-
6.5
perature difference.
6.
SEALEDSYSTEMS
6.1
Safety valve
A safety valve shall be fitted close to the appliance on
the flow pipe by a horizontal or vertically upward
connection. Only safety valves set to operate at 3 bar
shall be used ; they shall be so positioned or any dischar-
ge pipe so arranged, that discharge of water or steam
from the valve cannot create a hazard to occupants of
6.6
the premises or cause damage to electrical components
and wiring.
6.2
Pressure gauge
A pressure gauge covering at least the range O-4 bar
(O-60 Ib/inz) shall be fitted to the system adjacent to,
and visiblefrom, the filling point.
6.7
6.3
Expansion vessel
(i) A diaphragm type expansion vessel shall be fitted by
a connection to the inlet side of the circulating pump,
in a manner laid down in the vessel maker’s instruc-
;afety valve
etting(bar)
lesselcharge
Iressure(bar)
nitialsystem
lressure(bar)
'otal water
:ontent
If system
litres
25
50
75
100
125
150
175
200
250
300
350
400
450
500
3.0
0.5 1.0 1.5
0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0
ExpansionVesselVolume(litres)
- -
2.1 3.5 6.5 13.7 2.7 4.7 10.3 3.9
4.2 7.0 12.9 27.5 5.4 9.5 20.6 7.8
6.3 10.5 19.4 41.3 a.2 14.2 30.9 11.7
a.3 14.0 25.9 55.1 10.9 19.0 41.2 15.6
10.4 17.5 32.4 68.9 13.6 23.7 51.5 19.5
12.5 21.0 38.8 82.6 16.3 28.5 61.8 23.4
14.6 24.5 45.3 96.4 19.1 33.2 72.1 27.3
16.7 28.0 51.8 110.2 21.8 30.0 02.4 31.2
20.8 35.0 64.7 137.7 27.2 47.5 103.0 39.0
25.0 42.0 77.7 165.3 32.7 57.0 123.6 46.0
29.1 49.0 90.6 192.8 38.1 66.5 144.2 54.6
33.3 56.0 03.6 220.4 43.6 76.0 164.8 62.4
37.5 j3.0 :6.5 247.9 49.0 15.5 185.4 70.2
$1.6 70.0 !5.9 275.5 54.5 15.0 206.0 78.0
- -
orsystems
olumesother
Ian thosegiven
bove.multiply 0833 ,140 259 0.551 0.109 .190 0.412 0.156
iesystem
olumeby the
xtoracross - -
For the CHALLENGERFF boiler the above table
should be multiplied by 0.8
13
6.8
Pipework
tions (see Fig. 7-13 for illustration of recommended
system layouts). The expansion vessel shall be capa-
ble of accepting water up to at least 62.5 %of its vo-
lume without damage.
(ii) The nitrogen or air charge pressure of the expansion
vessel shall not be less than the hydro-static head
(height of the top point of the system above the ex-
pansionvessel).
(iii) The expansion vessel shall be sized in accordance
with the following table :
Hot water storage cylinder
The hot water cylinder shall be the indirect coil type
which issuitable for the system pressure.
Make-up system
Provision shallbe made for replacing water lost from the
system either :
0) From a make-up vesselor tank mounted in a position
higher than the top point of the system and connec-
ted through a non-return valve to the system on the
return side of the hot water cylinder or the return
sideof all heat emitters, or -
(ii) Where accessto make up vesselwould be difficult, by
pressurisation of the system.
Mains connection
There shall be no connection to the mains supply or to
the water storage tank supplying domestic water, even
through a non-return valve, without the approval of the
localWater Authority.
Filling point (see 8s 5376 Pt 2 Appendix A)
I) Through a temporary hose connection from a draw
off tap supplied from a service pipe under mains
pressure, provided that this procedure is acceptable
to the localWater Authority.
2) Through a self contained unit comprising a cistern,
pressure booster pump if required and if necessary
an automatic pressure reducing valve or flow restric-
tor.
3) Through a cistern, used for no other purpose, perma-
nently connected directly to a service pipe. The water
distributing pipe. The static head available should be
sufficient to provide the desired initial system design
pressure.
Pipework should be of copper ; small bore or microbore
with capillary or compression jointing to a high standard.
Leaksealant shall not be used inthe system.
Where a vessel of the calculated size is not obtainable,
the next available larger sizeshould be used.
For the purpose of the above calculation, the volume of
the system shall be determined as accurately as possible
using manufacturers’ data as appropriate. Alternatively
the volumes given below may be used to give a conser-
vative estimate of the system volume :
Boiler . . . . . 0.5 litres (0.11 gallons)
Smallbore pipework . . . 0.3 litres (0.07 gallons)
per 0.292 kW(1000 Btu/h) of system output
Microbore pipework . . . . 7 litres (1.5gallons)
Steel panel radiators 2.3 litres (0.5gallons)
per 0.292 kW(1000 Btu/h) of system output
Hot water cylinder . . . 2 litres (0.44gallons)
If a system isextended, an expansion vesselof increased
volume may be required unless previous provision has
been made for the extension.

Pump on the return
Fig. 18 H
Pump on the flow Diagrams showing
System layout
1 - Expansion vessel
2 - Pressure gauge
3 - Filling point
4 - Drain cock
5 - Air release point
6 - Safety valve
7 - Top-up bottle
8 - Temporary hose connection
or pressurisation make up.
6.9 Commissioning
Sealed System Only
The whole of the system should be filled and thoroughly
flushed out with cold water without the circulating pump
in position. Ensure that all valves are open. (The system
must be filled with water either from a sealedsystem fil-
ler pump with a break tank, or by any other method ap-
proved by the LocalWater Undertaking).
With the circulating pump fitted the system should be
filled and air locks cleared until the pressure gauge regis-
ters 1.5 bar (21.5 Ibs/irP).Vent all radiators and check for
water soundness.
Manually raise the water pressure to ensure that the sa-
fety valve lifts. This should occur within ? 0.3 bar (k4.3
Ibf/irP) of the preset lift pressure, ie.3 bar (43.5 Ibf/in2).
Releasewater from the system until the initial system
design pressure is attained, taking into account any dif-
ference in height between the pressure gauge and the
point at which the pressure vesselisconnected.
Light the boiler asdetailed in 5.3.
The water system should be heated to maximum war
king temperature and examined for water soundness.
Both gas and water should then be turned off and the
water system rapidly drained whilst still hot.
The system should again be filled, and inhibitor added to
the system, if required in the specification (see 3.9).
Clear all air locksand adjust to the initial design pressure.
Any set pointer on the pressure gauge should be set to
coincide with the indicating pointer. Examine for water
soundness. Now adjust gas rate and system by pass.
NB : The boiler issupplied rated at highest output.
The boiler isfitted with a gas rate adjuster. (See5.5
for adjustment procedure).
Fig. 20
Fan 1 Red
Thermistor temperature / //
Salenoid valves
,w 1Control box

I CHALLENGERTESTPOINTS
Miauswitch. 240 V
I
Fig. 21
Thermoelectric Valve (see sea 7.14) 240V 5Ol-k
Earth
Solenoid Valves
Orange and Blue Fan. 240 V
Printed Circuit Board
(Temperature & Sequence Control)
Thermocouple External Controls
Notlessthan8mv
111,
,Y,W
Pressure !switch m,.
I!
I
Them-&or Comparitor
TellIaerature a I 1
Fig. 22
@ 50 % (Blue) Soienoid Gas Valve
@ Variable (Orange) Solenoid Gas Valve
15

7. SERVICING
For efficient and trouble free operation it isimportant that the CHALLENGERFFboiler receives regular maintenance. The fol-
lowing schedules are recommended. Check function of appliance and observe flame picture. Check clean or replace compo-
nents asnecessary.
Before commencing any work turn off the gas at the gas service cock (4.3 Page IO) Ensurethat the electricity supply is isola-
ted.
NB : Alwaystest for gas soundness after completing any servicing or exchange of gascarrying components,
7.2
7.3
7.4
Remove front case
a) Remove screws and washers (1)two at top and one at
bottom of boiler. (Onewasher paint cutting to main-
tain electrical bond).
b) Remove two screws from lower front of case(2).
cl Remove case by easingforward at the bottom and
lifting clear of the top locating lugs.
Remove combustion chamber front panel
30 FF a) Remove four screws A and two nuts screws and was-
hers Bsecuring front panelof combustion chamber.
b) Remove panel complete with regulator plate by ea-
sing forward.
50 FF a) Remove six screws A and two nuts screws and was-
hers B securing front panel of combustion chamber.
b) Remove panel by easing forward at bottom and di-
sengage.
Remove the burner assembly
a) Remove the screws A securing burner manifold to
gas section.
bl Remove gasket and retain in safe place.
c) Remove burner.
NB : When replacing burner ensure that the lugs are lo-
cated to the rear bracket and the faces of the fixings on
rear of burner are in cut outs provided taking care not
to trap electrode lead.
To remove pilot
a) Release thermocouple from bracket by removing
screw securing clamp (A) and removing clamp. Move
thermocouple to the side.
b) Release the electrode by loosening screw on right
hand sideof assemblyand rotating clip(B).
c) Remove pilot gauze and filter by removing screw se-
curing gauze to assembly 0.
d) Lift out pilot deflector plate.
e) Remove pilot by unscrewing (nut size8 mm AF).
f) The pilot injector can be cleaned and should be repla-
ced bright side uppermost.
16

To remove gasfilter
a) Remove nut A and remove filter B.
b) Replacein reverse order.
Cleaning the parts
a) The burner can be cleaned by inverting and brushing with a soft brush.
b) The heat exchanger flueways can be cleaned by brushing.
c) The gas filter in the gas service cock can be cleanedusing soap and water - DONOTUSESOLVENTS.
d) Replaceallcomponents in reverse order. Particular attention should be given to ensuring that the casesealissound when
the casingis replaced.
e) Recommissionand check controls. Note burner pressures.
8. REPLACEMENTOF PARTS
8.1
8.2
8.3
Replacing thermocouple
a) Removefront case7.1
b) Removecombustion chamber front panel7.2
c) Removeburner assembly 7.3
d) Releasethermocouple from thermocouple bracket by
undoing screw A and removing clamp.
e) Releaseelectrode leadfrom sealinggland.
f) Release at thermoelectric valve by unscrewing nut
IO mm AF.
g) Disconnect from high limit thermostat by pulling
connections apart where high limit thermostat
connects.
i) Removethermocouple and seating.
j) Replacein reverse order taking care to locate thermo-
couple in positioning grooves in bracket.
k) Replaceseating in to casing and reposition electrode
lead.
Replacing combustion chamber linings
a) Removefront case7.1
b) Removecombustion chamber front panel7.2
c) Remove burner assembly 7.3
d) Slideout side liningsfirst followed by rear lining which
is removed by easing upwards and sliding out from
the bottom.
e) Replacein reverse order taking care that front lining
IScorwoositloned
To replace fan
a) Removefront case7.1
b) Removefour screws -two on flue hood Band two on
the bracket - supporting the fan motor (A).
c) Turn to disengage from lug at rear and slide out as-
sembly.
d) Note position of electrical connections and pull off
spadeconnectors.
e) Replace in reverse order ensuring rear locking lug is
correctly engaged.
17

8.4
8.5
8.6
8.7
To replace pressure switch
I
a) Removetwo screws retaining plasticturret cover.
b) Note position of spaae connectors and remove.
c) Disconnect pessure sampling tube by pulling off nip- i
pie.
d) Remove two screws retaining pressure switch.
e) Replacein reverse order. i
NB : See4.6 -electrical connections. I
I
Replace spark electrode and lead
a) Remove front case7.1
b) Remove combustion chamber front panel 7.2
c) Remove burner assembly 7.3
d) Remove thermostat knob and six screws and screw
seats from the electrical control box.
e) Remove plugsfrom rear of electrical control box. i
f) Slide PCB forward and disconnect spark lead from 1
ignition generator.
g) Feedleadout through rear of control box.
hj Loosen screw securing clip retaining electrode and
turn clipthrough 90” C. i
i) Slide electrode sideways complete with lead. Release /
spark leadfrom sealinggland.
j) Replacein reverse order taking care to locate electrode I
in locating ring and replace plugsin rear of control box. i
To replace heat exchanger
a) Drain system.
b) Remove front case7.1.
c) Remove combustion chamber front panel (A;7.2.
d) Remove burner assembiy (B)7.3
e) Remove high limit thermostat phia! - left hand side
0.
f) Withdraw thermostat temperature sensor - right
hand side (D)8.13
g) Unscrew nuts on flow and return connections (E)
(30 mm AFL
h) Remove two screws securing combustion chamber to
rear chassis(FL
i) Drop assembly and withdraw forwards.
j) Remove two screws from rear of assembly retaining
heat exchanger to combustion chamber.
k) Repacein reverse order.
NB : Omit d & e above if the box isto be temporarily dis-
placedto gain accessto another component.
To remove the electrical control box
a) Remove front case 7.1.
b) Remove the boiler thermostat knob (A) by pulling off
the spindle.
c) Remove six screws and screw seats retaining the elec-
trical box cover (B)and remove cover taking care not
to losethe red reset button.
d) Mark and remove the mains, pump and external
controls wiring.
e) Remove plugs at rear of electrical box and disconnect
earth.
f) EasePCBforward and remove spark electrode cable.
g) Remove two screws in the rear of the box securing
box to chassisand remove box.
h) Replacein reverse order.
18

8.8
Replace high limit thermostat
a) Remove front case 7.1 and remove or displaceas ne-
cessaryelectrical control box 8.7.
b) Remove combustion chamber front panel.
c) Remove two screws (A) securing high limit thermo-
stat.
d) Disconnect conductors at pin connectors by pulling
apart.
e) Remove sensor from dry thermostat pocket first re-
moving split pin.
f) Unclipcapillery.
g) Replace in reverse order using a heat sink grease on
the thermostat phial.
8.9
To replace microswitch and lead assembly
a) Removefront case7.1
b) Remove or displaceas necessarythe electrical control
box 8.7.
c) Pulloff connector (A).
d) Removetwo screws retaining microswitch (B).
e) Replacein reverse order.
To replace thermoelectric valve
a) Removefront case7.1
b) Remove or displace as necessary the electrical box
8.7.
c) Remove thermocouple connection from thermoelec-
tric valve (A).
d) Remove nut securing securing thermoelectric valve
(nut size25 mm AFL
e) Withdraw thermoelectric valve.
f) Replacein reverse order.
NB : Care should be taken when replacing the nut secu-
ring the thermoelectric valve - FINETHREADS.
To replace solenoid valves
a) Removefront case7.1
b) Remove or displaceas necessarythe electrical control
box 8.7.
c) Disconnect plug connectors (A) from solenoid valves
(colour coded).
d) Remove four screws (B) securing solenoid valve
mounting plate.
e) Remove mounting plate and solenoids - take care
not to misplace valve springs or damage gasket.
f) Replacein reverse order using new gasket.
Replace pilot injector
a) Proceedasfor servicing 7.4.
b) Replaceinjector ensuring it isfitted bright side upper-
most.
19

8.13
al4
8.15
al6
To replace boiler thermostat sensor and lead
a) isolate electrical supply.
b) Removefront case7.1.
c) Undo knurled ring retaining thermostat sensor phial
and remove phial.
d) Unplugfrom rear of control box.
e) Replace in reverse order using heat sink grease on
thermostat sensor phial.
To replace fuse
a) Isolate electrical supply.
b) Remove front case7.1.
c) Remove cover on electrical control box 8.7.
d) Remove and replace fuse (2amp).
e) Replacein reverse order.
To replace PCB
a) Isolate electrical supply.
b) Remove front case7.1.
c) Remove cover on electrical control/box.
d) Easeforward PCB and remove spark electrode wire
and earth wire from spark generator NB. PCB is a
wedge shape and it will be found easier to ease front
corners first.
e) Remove plugs from rear of electrical control box.
f) Slideboard forward and remove.
g) Replacein reverse orders.
h) Checkfunction of controls.
Testing of FDDCircuit
Closedcircuit
- Slide back insulation at plug in connection and attach
millivolt meter using crocodile clip connectors.
- Output should not be lessthan 3 mv.
Opencircuit
- Disconnect round pin connectors.
- Attach millivolt meter using crocodile clipsto the ther-
mocouple side male connectors.
- Pressand hold igniter button.
- Output with pilot on should not be lessthan 14 mv.
NB: If closed circuit output is high and approaching the
open circuit voltage obtained, then suspect faulty ther-
moelectric valve.
20