Chaffoteaux & Maury CHALLENGER 30 OF User guide

CHALLENGER
Open Flue Boilers
30 OF 50 OF
(GCN"41.980.72) (GCN"41.980.76)
installation
and servicing instructions
(leave these instructions with the User or at the Gas Service meter)

CHALLENGEROFare low water content gasfired boilers.
CHALLENGER 30 is rated between 4.14 Kw (14,150
Btu/h) and 9 Kw(30,375 Btu/h).
CHALLENGER 50 is rated between 7.33 Kw (25,000
Btu/h) and 14.6 Kw(50,000 Btu/h).
The boiler is designed for use on Natural Gas, unless
otherwise stated. It is suitable for open systems and sea-
led systems.
The boiler isdesigned for fully pumped systems only with
a number of incorporated features.
- Fully adjustable electronic temperature regulation bet-
ween60°Cand82”C.
- Automatic alternation high flame/low flame.
- Pump overrun.
- Lowresistance.
- Highlimit thermostat.
Guarantee
The manufacturer’s guarantee on the appliance isfor 24 months from the date of installation. The guarantee isvoidable if it is
not installed in accordance with the recommendations made herein or in a manner approved by the manufacturer.
1. TECHNICAL DATA
A
V
+=++
-A- - _
I- i
-7-
-I+
F
A+ I --+-
-+-
I
E
I
CHA
-
-
A
B
C
D
E
F
ci
H
J
K
L
M
N
0
-
ENCER 3C
mm =-50
OF
ins
640 25.2
375 14.75
250 9.84
115 (int) 4.5
100 4.0
50 2.0
45 1.75
187 7.4
475 10.7
500 19.7
135 5.3
25 1.0
100 4.0
50 2.0
2

1.2
1.3
30 OF
Max
Min
50 OF
Max
Min
OUTPUT
kW Btu/h
9. 30,375
4.14 14,150
OUTPUT
kW Btu/h
14.6 50,000
7.32 25,000
INPUT BURNER PRESSURE(HOT)
kW Btu/h m.bar ins.w.g.
Max 11.7 39,995 8.0 3.2
Min 5.63 19,226 1.47 0.5
INPUT BURNER PRESSURE(HOT)
kW Btu/h m-bar ins.w.g.
Max 18.94 64,661 7.3 2.9
Min 9.95 33,800 1.9 0.08
NB : For mid position setting pressures see section 5.4
GAS RATE
m3/h ft3/h
1.09 38.67
0.52 18.59
GAS RATE
m3/h ft3/h
1.77 62.53
0.88 31.39
DIMENSIONS (Casingexconnections)
3OOF&5OOF
I
mm I ins I
Openflue . . . . . . . . . . . .
Gas connection .......................
Waterconnection .....................
Minimum flow rate ....................
Maximum static head .................
Minimum static head ..................
Electrical connection ..................
Weight ..............................
Water capacity .......................
Burner Injector Size ...................
Pilot injector .........................
Ignition ..............................
Electrode ............................
Boiler thermostat .....................
High Limit thermostat .................
Thermocouple and thermoelectric valve
CLEARANCES
Sides
TOP
Bottom
Front
mm ins
76 3
76 3
127 5
500 20
Requiresa nominal 100 mm (4 in)flue pipe. Draught diverter isintergral
and issuitable for flues to BS715. If flues to BS567 are used an adaptor
will be required
15 mm compression fitting
22 mm compression fittings
30 OF 505 IiWhr (I .85 gpm) 50 OF 841 lit/hr (8.08 gpm) equivalent to
15” C(27” F)temperature rise
30 m (98ft)
150 mm (Seepage 7)
240 Vsingle phase 50 hz supply fused 3 amp
30 OF - 18.63 kg (41 Ibs) 50
OF - 19.54 kg (43 Ibs)
0.5 lit. (0.11gals.)
30 OF 1.18 mm 50
OF 1.23 mm
0.3 mm (0.011 ins.)
Continuous spark-spark generator ANSTOSS
Chaffoteaux - spark gap 5.0 mm
Electronic - Chaffoteaux Ltd
RancoLM5
Chaffoteaux Ltd
water flow-gallons per minute
1.4 HYDRAULICRESISTANCE 1 2 3 4 5
The hydraulic resistance of the boiler varies with
the water flow. The graph (Fig.2) indicates resistan-
3
ce at various flow rates.
The minimum flow rate is equivalent to a tempera-
ture rise of 15” C : 1
2' .I
30 OF 50 OF 9a
B
505 I/h 1.85 gpm 841 I/h 3.08 gpm d
1
Minimum water flow rate *
200 400 600 800 mob 1200 1400
water flow - litres per hour
3

1.5 Description of Operation
2.
2.1
Pressing the ignitor (on) button disconnects the supply continues to fire on 50 % fixed gas valve. When the set
to the pump, opens the therm0 electric valve and causes temperature is reached the boiler switches off. If flow
a continuous pilot ignition spark to be generated and the temperature reduces the 50 %fixed gasvalve opens fol-
pilot isignited. lowed by the variable valve.
If there is a demand the pump will start when the on
button is released. The burner will commence after a 30
sec. delay when the 50 % valve opens. After 3 seconds
the 2nd gasvalve (variableoutput) opens.
Temperature control is by means of a temperature sen-
sing thermistor and potentiometer. These signals are
fed to a comparitor.
When the flow temperature approaches the set tempe-
rature the main gas valve is closed and the boiler
At the end of an ‘on’ cycle under the control of a time
clock or programmer or when the cylinder and room
thermostat are satisfied the boiler switches off but the
pump continues to run for 15 seconds.
The high temperature cut out breaks the thermocouple
circuit which extinguishes the pilot and closes the gas
supply to the burner. Manual re-setting is required. (See
section 4.7).
FUNCTIONALFLOW DIAGRAM
THERM0 ELECTRIC SPARKGENERATOR
THERMOCOUPLE
TIME DELAY
GAS SOLENOID
TIME DELAY PUMP
OVER RUN L
r
Fig. 1
PUMP
INSTALLATION REQUIREMENTS
General
The installation of the boiler must be in accordance with
the Gas Safety Regulations, Building Regulations, I.E.E.
Regulations and the Byelawsof the localWater Underta-
king. It should be in accordance also with BS Codes of
Practice and the British GasSpecifications for Domestic
Wet Central Heating Systems and any relevant require-
ments of the localGasRegionand LocalAuthority.
Detailed recommendations are stated in the following
British Standard Codesof Practice : CP331:3, BS5376:2,
BS5546, BS544O:l and 2, BS5449:l.
Note : Gassafety (Installation and Use)regulations 1984 :
It is the law that all gas appliances are installed by com-
petent persons in accordance with the above regula-
tions 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 position chosen for the boiler should permit the pro-
vision of a satisfactory flue termination. The position
should also provide adequate space for servicing and air
circulation around the boiler. (See1.3).
Where installation will be in an unusual position, special
procedures may be necessary, and BS 5376:2 gives de-
tailed guidance on this aspect.
A cupboard or compartment used to enclose the boiler
mtrst 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/compartment
design are given in BS5376:2.
4

2.3 Water Circulation Systems
2.5 Flue System
Openor sealedtype central heating systems (seeSection
5)should be in accordance with the relevant recommen-
dations given in BS 5376:2, BS 5449:l (for smallbore or
microbore systems) and the British Gas Specifications
for Domestic Wet Central Heating Systems.
Hot water systems should be in accordance with the re-
levant recommendations given in CP 342:l and the abo-
ve mentioned British Gaspublication and BS5546.
2.4 Air supply - Open Flue Version
2Al Room air supply
Where a boiler isto be installed in a room or internal spa-
ce, the boiler requires the room or internal space contai-
ning it to have a permanent air vent. This vent must be
either direct to outside air or to an adjacent room or in-
ternal spacewhich must itself have a permanent air vent
of at least the same sizedirect to outside air.
The minimum effective area of the permanent air
vent(s) is related to the maximum rated input of the boi-
ler and should be not lessthan :
CHALLENGER 30 OF 21.15 cm2(3.27 ins21
CHALLENGER 50 OF 53.73 cm2(8.32 ins?
2A.2 Compartment air supply
If an open flued boiler is installed in a cupboard or com-
partment permanent air vents are reauired in accordan-
The boiler should be sited such that the maximum possi-
ble length of the flue system can be contained within the
building and that the route of the flue rises continuously
to the terminal and isasdirect as practicable.
The first 600 mm (2ft) of flue pipe should rise vertically
from the draught diverter connection before the use of
any bends of elbows.
Horizontal or shallow angle runs, right angled bends or
mitred elbows should be avoided.
Where an existing brick chimney is to be used it should
be swept thoroughly before connection of the new boi-
ler, and the chimney should be lined.
An approved British Gasterminal must be fitted and the
terminal sited at the.adjacent roof edge and, where pos-
sible,above the ridge line. The flue must not be termina-
ted at or adjacent to a wall face.
The cross sectional area of the flue must not be less
than the area of the flue. outlet serving the boiler. The
point of termination must not be within 600 mm (2ft) of
an openable window, air vent or other ventilation ope-
ning.
Before installing the boiler to an existing flue system,
the flue system must be checked by applying a smoke
match to the opening at the baseof the flue system.
The flue pipe must not be closer than 25 mm (I ins) to
combustible material. For twin walled flue. pipe the
25 mm (I in)distance ismeasured from the internal pipe.
ce with the following table.
same room or internal space.and must both be on the
same wall to outside air.
Note that both air vents must communicate with the
Where cupboard or compartment vents communicate
with a room or internal spacethe room or internal space
must itself have a permanent air vent(s) as specified in
BS5440pt2.
An open flued appliance must not be installed in a
bathroom bedroom or bedsitting room or in a compart-
ment communicating with a bathroom, bedroom or bed
sitting room. An open flued boiler must not be installed
in a garage.
This appliance must be earthed. All wiring must conform
to the I.E.E.Regulations. The CHALLENGERrequires a
2.6 Electrical Supply
240 V single phase, 50 Hz supply. A means of isolation
must be provided adjacent to the boiler, this should pre-
ferably be an unswtiched plug and socket. Alternatively a
double pole isolator having a contact separation of at
least 3 mm on both poles must be used. The fuse rating
should be 3 amp. The supply cord must be 0.74 m2three
core heat resisting cable.
Cupboard or compartment air supply
30 OF
Low level
211 cm2 106 cm2
32 ins2 16 ins2
50 OF
Position of Air from room Air direct
air vents or internal space from outside
2A3 Effect of an extract fan
If there is any type of extract fan fitted in the premises
there is the possibility that if adequate air inlet area
from the outside is not provided, spillage of the pro-
ducts from the boiler flue could occur when the extract
fan is operating. Where such installations occur a spillage
test as detailed in BS5440:l must be carried out and any
necessaryaction taken.
2.7 GasSupply
The CHALLENGER 30 requires 1.09 m3/h 38.67 ft3/h.
CHALLENGER 50 requires 1.77 m3/h 62.53 ft3/h
of natural gas. The meter and supply pipes must be ca-
pable of delivering this quantity of gas in addition to the
demand from any other appliances inthe house.
The complete installation must be tested for soundness
asdescribed in CP331:3
Fig. 2
5

3.
SYSTEM GUIDANCE
3.1
General
The CHALLENGERis a low water content boiler designed
3.8
ONLYfor use with fully pumped systems. It may be used
with open or sealed systems, all safety controls exclu-
ding the pressure relief valve being incorporated in the
boiler. The thermostat isadjustable and, on its maximum
setting, gives a nominal 82 “C (180 “F)?4 “C (7 “F).
Detailed recommendations for the water circulation are 3.9
given in BS 5376.2 19876, BS 5449.1 1977 and BS
5546:1979.
Thermostatic control should be fitted to the cylinder and
heating circuits.
3.2 Strainers
Where the CHALLENGERis used as a replacement for a
boiler on an existing system, ideally the system should
be flushed and cleaned using a suitable chemical cleaner
following the manufacturer’s recommendations and fit-
ted with a strainer similar to that manufactured by
Honeywell.
3.3 Control Schemes
The boiler iselectrically controlled.
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-
3.10
fied.
Chaffoteaux can be consulted where technical assistan-
ce is required.
3.4 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 less than that stated in section 1.4. The
pump must be installed between isolating valves. Most
pump manufacturers require a minimum static head on
the pump inlet to prevent cavitation. For boiler resistan-
ce seegraph on page 3. (Sect. 1.4).
3.5
Cold feeds and open vents
The cold feed and open vent should be so positioned
that pumping over and sub-atmospheric pressures are
avoided. Recommendations for various layouts are given
on page 7.
The connection should be so arranged that there isa low
velocity point at the open vent junction with the system.
3.6
Automatic Air Separator
Chaffoteaux Limited strongly recommend the inclusion
of a British Gasaccepted automatic air separator in the
system asshown in fig. 9.
The open vent pipe should rise continuously from the
system pipework.
It should not be entered horizontally into the system pi-
pework. The use of an enlarged Tto create a low velocity
point is recommended. The preferred arrangement is
shown infig. 9.
3.7
Cylinder
The domestic hot water cylinder used with the
CHALLENGERmust be of the indirect and high recovery
6
type to BS1566 Pt. 1. Single.feed cylinders are not suita-
ble for use with the appliance. Flowand return pipework
to the cylinder should be in 22 mm pipe.
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 9 in. to a ceiling to allow accessto
the ballvalve.
Inhibitors
Chaffoteaux Limited do not generally recommend the
inclusion of an inhibitor with heating and hot water sys-
tems, utilising CHAFFOTEAUXboilers. It is, however, ap-
preciated that the use of a corrosion and limescale inhi-
bitor may be desireable or specified.
The following are the appliance manufacturer recom-
mendations :
Use only a British Gas or similar approved inhibitor
from the Fernox range manufactured by Industrial
(Anti-Corrosion) Services, Brittanica Works, Arkesdon
Road,Clabering, Nr Saffron Waldon.
Use only the quantities specified by the inhibitor
manufacturer.
Cleansethe system as may be required be the inhibi-
tor manufacturer.
Add inhibitor only after flushing when finally refilling
the system.
Add on devices
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 approved
by the manufacturer could invalidate British Gasappro-
val and also infringe the GasSafety Regulations.

ALTERNATIVE SYSTEM LAYOUTS
Minimum
Static Head
150mm
----- ----.
PREFERED
Syfi &Ad be
sQKWmospheric
. . . ..
Minimum
Static Head
Refer to
BS 5449
Part 1 1977
1. Cold feed 15 mm

3.11 Electrical Controls
Khaffoteaux recommendations)
CHALLENGERcan be used with most normal pumped pri-
mary schemes including non-electrical heating and hot
water controls.
It is not normally possible to use full programming facili-
ties where using a mixture of electrical and non-electrical
controls. However, some non-electrical controls are now
availablewith an external microswitch and these controls
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.
Important: All external wiring to and from the boiler
must be in accordance with the current edition of the
IEEWiring Regulations.
1. Fully pumped system independant control of central hea-
ting and hot water using two spring return motorised val-
ves.
SPRINGRETURN
CYLSTAT YALYED.H.W.
Fig. 10
2. Fully pumped systems independant control of central
heating and hot water using two motorised valves.
3. Drayton flow share valve system.
Fig. 12
4. Honeywell Sundial ‘Y’ plan.
Fig. 13
5. Satchwell Duoflow system.
TLX2259
ROOM SA 2457
PROGRAMMER PUMP
BOILER TERMINALS
Fig. 11 Fig. 14
PROGRAMMER PUMP RO,,.ER TERMINALS
a

4. INSTALLINGTHE BOILER
A vertical flat area isrequired for the boiler asfollows :
525 mm wide x 865 mm high (21 insx 34 ins)
The above dimensions includethe necessary clearancesaround the boilers for case removal and for air movement.
4.1
4.2
4.3
4.4
Position the boiler
- Using dimensions on page 2 mark position of fixings
for top wall bracket (A).
- ;I;,and plug wall and fix bracket using screw provi-
- Ensureapplaince issquare on wall.
- Mark bottom fixing holes (B). Drill and plug the wall
and fix appliance.
IMPORTANTNCTTJCE: Tl$ulBER~FRAMEDHOUSES
If the appliance isto be fitted in a timber framed building it shotid beWted in accordance with the British GasPublica-
tion ((Guidefor&s Installations in Timber Framed Housincja)reference DM2.lf in doubt. advice must be sought from
the local GasN&n of British Gas.
‘Fitting -the boiler
a) Removethe front case by
1. .Remov@g2 screws bottom rear of boiler (Al.
2. Removing 2 screws securing front casing to elec-
trical box CBI.
b) Remove case by putting out at the bottom and lifting
off locating hooks at the top of boiler.
Making the gas connection
a) Fit the gas service tap (Al together with the filter
washer.
b) The gas supply pipe.sizeshould be sufficient to ensu-
re that there is 20 mbar (8 in.w.g.) pressure. at the
service tap, with the appliance working.
n.b. The gas supply pipe.size should not be lessthan the
gas inlet to the appliance.
9

4.5
4.6
4.7
Making the water connections
RETURN
a) Fit the nuts and olives supplied inthe accessory box.
b) Enter the FLOWpipe into the RIGHThand connection,
the RETURNgoes to the LEFThand connection.
c) Tighten compression fitting holding connection on in-
side of boiler.
Making Electrical Connections
(Seesection 2 for electrical supply requirements)
a) Secure cable.clamp (D)to base of appliance using the
screws provided.
b) Remove control box cover.
c) Three core heat resisting cable is passedthrough the
clamp and through the slot in casing,and into the rear
of electrical box and connected to terminals on
connection block and the earth connection made to
earth terminal.
d) Connect pump cable to terminals @ and the earth
on earth terminal.
e) Connect ancillary controls across terminals marked 5
and 6. See-controls diagrams page 8.
f) Clampwires with cableclamp.
g) Replacecontrol box cover.
n.b. 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 ispulled.
Resetting 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-establishthe appliance by re-setting the high limit
thermostat by pressing the red button on the electri-
cal box.
--- c) Establish cause and rectify - see fault finding chart,
rear cover.
In the event of an electrical fault after installation preliminary electrical system checks as described in the Muiltimeter Ins-
truction book should be carried out.
Checksto ensure electrical safety should be carried out by a competent person, i.e. earth continuity, polarity and resistance
to earth.
3 Wire clock
CHALLENGER - SIMPLE CONTROLS
Room thermostatonly
4 Wire clock Room
thermostat and time clock
Fig. 15 Fig. 16 Fig. 17
10

5. COMMISSIONING
5.1 Gas Installation
5.2
The whole of the gas installation, including the meter,
should be inspected and tested for soundness and pur-
ged in accordance with the recommandations of CP
331:3.
Water circulation system -
Open system only
The whole.of the system should be filled and thoroughly
flushed out with cold water without the pump in posi-
tion Ensurethat allvalves are open.
With the pump fitted the system should be filled and air
locks cleared. Vent all radiators and check for water
soundness.
Light the boiler asdetailed in 5.3.
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 (Seesection
3.9).
5.3 Lighting the boiler
a) Checkthat the gasservice tap isopen.
b) Push the button marked ON fully in and hold for 10
seconds.
from (b).(The pilot should be about l/2” long and im-
pinge on the tip of the thermocouple).
c) Checkthat pilot isalight and release slowly.
d) If the pilot extinguishes press red button and repeat
boiler output kW
3 6 9 12
5
d P
I II I I I I I I I I I I
10000 20000 30000 40000 60000
output Btu/h
Fig. 1
e) After 30 secondsthe main burner will light.
f) If the pilot extinguishes, wait 3 minutes and repeat
from b)ahove..
n-b. The by-pass valve should be of the lock shield pat-
5.5 Adjusting the by-pass
tern.
a) Set the pump to achieve the system requirements
g) Switch controls to a demand mode, ensuring that
pump isrunning.
h) Check for gas soundness around the boiler gas com-
ponents using senseof smell and leakdetection fluid.
i) Checkand adjust gas rate asdetailed below.
but ensure that the. minimum flow rate through the
boiler is achieved (See1.4 - page 3).(Thisis equivalent
to a temperature. rise across the boiler of 15 ‘C
(27” F).(Setboiler thermostat to maximum.)
b) Fire the boiler with the by-pass fully closed and the
system on full load, i.e. central heating and domestic
5.4 Gas rate adjustment
(Tobe carried out before adjusting by-pass.)
n-b. The boiler is supplied rated at the highest output.
The boiler isfitted with a gas rate adjuster.
a) Switch boiler to off by pressing OFFbutton.
hot water.
c) Adjust the system to minimum load. This will normally
be central heating only with one radiator operating
d) Open the by-pass gradually until the boiler operates
quietly at all flow temperatures until the boiler ther-
mostat turns off the gas.
b) Remove the pressure test point screw (I) (fig. 18)and
connect a suitable.pressure gauge.
6. SEALEDSYSTEMS
c) Remove the hexagonal cap from gas volume adjuster,
(2)(fig. 18)exposing the adjustment screw.
6.1 Safety valve -
d) Turn boiler on by pressing ONbutton (seelighting boi-
ler - page 11 - 5.3).
e) Adjust pressure after boiler has been running for 10
minutes. Setting pressures are given in graph relative
to required output and then check the gas rate. The
pressure will be reduced by clockwise movement of
screw, increased by anti-clockwise-movement.
A safety valve shall be fitted close to the appliance on
the flow pipe. 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
the premises or cause damage to electrical components
and wiring.
f) Turn boiler to OFFand refit pressure test point screw
and volume regulator cap Test for gas leakage
6.2 Pressure Gauge
around pressure test point.
g) Mark the badge to indicate output to which boiler has
been set.
A pressure gauge covering at least the range O-4 bar
(O-60lb/in*) shallbe fitted to the system adjacent to, and
visible.from, the filling point.
11

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 makers’ instruc-
tions (seefig. 18 for illustration of recommended sys-
tem layouts). The expansion vessel shall be capable of
accepting water up to at least 62.5 % of its volume
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 vesselshall be sizedin accordance with
the following Table.
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. ofthe system volume‘:
Capacity 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 (I .5 gallons)
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.
;afety valve
Ming (bar)
lesselcharge
lressure(bar)
nitialsystem
lressure(bar)
.otalwater
:ontent
Ifsystem
litres
25
50
75
100
125
150
175
200
250
300
350
400
450
500
orsystems
oiumesother
lanthosegiven
!~ve,multiply
lesystem
olumebythe
uztoracmss
6.4 Hot Water storage Cylinder
The hot water cylinder shall be the indirect coil type
which issuitable.for the system pressure.
ExpansionVesselVolume(litres)
- - - - -
2.1 3.5 8.5 13.7 2.7
4.2 7.0 12.9 27.5 5.4
6.3 10.5 19.4 41.3 8.2
8.3 14.0 25.9 55.1 10.9
10.4 17.5 32.4 68.9 13.6
12.5 21.0 38.8 82.6 16.3
14.6 24.5 45.3 96.4 19.1
16.7 28.0 51.8 110.2 21.8
20.8 35.0 64.7 137.7 27.2
25.0 42.0 77.7 185.3 32.7
29.1 49.0 90.6 192.8 38.1
33.3 56.0 03.6 220.4 43.6
37.5 63.0 18.5 247.9 49.0
41.6 M.0 25.9 275.5 54.5
- - - - -
l.083:
-
0.140
-
0.109
-
4.7 10.3
9.5 20.6
14.2 30.9
19.0 41.2
23.7 51.5
28.5 81.8
33.2 72.1
38.0 82.4
47.5 103.0
57.0 123.6
66.5 144.2
76.0 164.8
85.5 185.4
95.0 206.0
3.9
7.8
11.7
15.6
19.5
23.4
27.3
31.2
39.0
46.8
54.6
62.4
70.2
78.0
-
0.190 0.412 0.156
-
-
Provision shall be made for replacing water lost from the
system either :
0)From a make-up vessel or 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
side of all heat emitters, or -
(ii)Where accessto make up vesselwould be difficult, by
pressurisation of the system.
~~:~I6.6 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.
I
6.7 Fihg Point
For the CHALLENGERboilers the above table should be
multiplied by 0.8
For the filling system see BS5376 Part 2 appendix A.
NB. A temporary hose connection is only permissible.if
acceptable.to the localWater Authority.
Pump on the return
8
Pump on the flow Diagrams showing
System layout
I- 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.

5.8 Pipework
Pipework should be of copper; small bore or microbore
with capillary or compression jointing to a high standard.
Leaksealant shallnot be used inthe system.
Where a vessel of the calculated size is not obtainable,
the next availablelarger sizeshould be used.
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 sealed system 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 airlocks cleared until the pressure gauge regis-
ters 1.5 bar (21.5 Ibf/in*).
Manually raise the water pressure to ensure that the sa-
fety valve lifts. This should occur within 2 0.3 bar (2 4.3
Ibf/in2) of the preset lift pressure, ie. 3 bar (43.5 Ibf/ir-?).
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 vessel isconnected.
Light the boiler asdetailed in 5.3.
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 whilst still hot.
The system should again be filled, add inhibitor to the
system, if required in the specification (see 3.9), cleared
of air locks and adjusted 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 adiust the oas rate and the svstem bv pass - See
Vent all radiators and check for water soundness. 5.4 and-5.5. -
1 Fig. 19
I
I ?=I
transformer n
rectifier
\I--
,?’ 4 36 4 1 U
iw a2
rc^
I 1 ” --- fuse
211 ;
I I
-1‘“1
I
43
C?
/
24VDC
S6
t I I
“5
L ---7
b i I
i
trump
-_--A
N2
- Nl
240 V. 50 Hz
+L
I r I 1
I I
orange solenoid
comparitor variable
thermistor
I I
emperature
sensor
782 ‘.R43 J2Z R23
c--i
I A
Fl4 D R24l
A-- ,
1.

CHALLENGERTESTPOINTS
SolenoidValves
Earth Orangeand Blue
24 V m k 5V m Thermistor
sensor
v- Microswitch
! ! ! [ ! ! 1 ilr in neutral side
I ’ L,. mainsvoltage circuit
I
Transformer Printed Circuit Board
1 (Temperature &SequenceControl)
Ignition
Electrode
Fuse2A
External Controls
&
Thermoelectric
Valve
240V 50Hz
Fig. 20
Thermistor
temperature sensor
LB
Thermocouple Electrode Solenoid valves
Blue
n
Thermo-electric
“/y////
Control box
valve roQ
Externalcontrol
high-limit
thermostat
Fig. 21
14

7. SERVICING
For efficient and trouble free operation it is important that the CHALLENGERreceives regular maintenance. The following
schedulesare recommended
Before commencing any work turn of the gas at the gas inlet tap (section 4.4). Ensurethat the electricity supply isdisconnec-
ted.
Important
: Always test for gassoundness after completing and service or exchange of gas carrying components.
7.2
7.3
7.4
Remove front casing
a) Remove screws (A) from front of boiler - securing
front caseto electrical control box.
b) Remove 2 screws (B)bottom rear of boiler.
c) Easebottom forward and lift off front case from re-
taining hooks situated top rear of boiler.
d) Replacein reverse.order.
Remove combustion chamber front panel
a) Remove six screws securing front panel of combus-
tion chamber.
b) Remove panel by easing forward at bottom and di-
sengage from draught diverter by pulling downwards.
c) Replacein reverse.order.
Remove burner assembly
a) Remove two screws securing burner manifold to gas
section (A)and 2 outer screws U (50 OFonly).
b) Remove gasket and retain in safe place.
c) Remove 2 screws (B) securing burner head to rear
chassis.
d) Replacein reverse order.
To remove pilot
a) Release thermocouple from bracket removing nut
and bolt (A) securing clamp. Move thermocouple to
the side.
b) Release.the electrode by loosening screw (B)on right
hand sideof assembly and rotating retaining clip.
c) Remove pilot gauze and filter by removing screw se-
curing gauze.to assembly.
d) Remove pilot by unscrewing (nut size 8 mm AF)using
set or adjustable spanner.
e) The pilot injector can be cleaned and should be repla-
ced bright sideuppermost.
f) Replacein reverse order.
15

Cleaning the parts
a) The burner can be cleaned by inverting and brushing with a soft brush.
b) The heat exchanger matrix can be cleaned by brushing. If deposits are too hard to remove by brushing, the matrix can be
removed -see section 8.7 page 17 and washed with hot water and detergent.
c) Any lint deposies in the burner ports should be removed using a suction cleaner and or washing.
d) The gasfilter (B - 4.4) can be cleaned using water and detergent. DO NOT USE SOLVENTS.
e) Replaceallcomponents in reverse order.
8. REPLACEMENTOF PARTS
Before proceeding - turn off gasand isolate electrical supply.
8.1
8.2
8.3
Replacing thermocouple
a) Remove front cover 7.1
b) Remove combustion chamber cover 7.2
c) Remove burner 7.3
d) Release thermocouple from thermocouple bracket
removing nuts and bolts securing clamp
e) Release at thermoelectric valve by unscrewing nut
IO mm.
f) Disconnect from overheat thermostat by pulling
connections apart.
g) Replacein reverse order.
Replace high limit thermostat
a) Remove front cover 7.1 and electrical control box
8.10.
b) Remove two screws (A)securing overheat assembly.
c) Disconnect at pin connectors by pulling apart.
d) Remove sensor from dry pocket first removing split
pin.
e) Replace in reverse order using a heat sink grease on
the sensing phial.
Replace electrode and lead
a) Remove front cover 7.1.
b) Remove combustion chamber cover 7.2.
c) Remove burner 7.3.
d) Remove thermostat knob and six screws from front
of electrical control box 8.10.
e) Remove plugs from rear of electrical controls box.
f) SlidePCBforward and remove spark lead.
g) Feedlead out through rear of control box.
h) Loosenscrew (A)securing clip retaining electrode and
turn clipthrough 90 *.
i) Withdraw electrode by slidingto the side..
j) Replacein reverse order taking care to locate electro-
de in locating groove..
n-b. Take care to replace plugs in rear of control box.
16

8.4
8.5
To replace thermoelectric valve
a) Remove front cover 7.1.
b) Removethermocouple connection.
c) Remove nut (A) securing thermoelectric
(25 mm).
d) Withdraw thermoelectric valve.
e) Replacein reverse order.
valve
To replace solenoid valves
a) Removefront cover 7.1.
b) Remove electrical control box 8.10.
c) Withdraw plug connection (A)(colour coded from sole-
noid valves.
d) Remove four screws (B) securing solenoid valve
mounting plate.
e) Remove mounting plate and solenoids (take care not
to misplacesprings).
f) Replacein reverse order.
8.6
8.7
8.8
To replace microswitch and lead assembly
a) Remove front cover 7.1.
b) Remove electrical control box 8.10.
c) Remove plug from microswitch.
d) Remove screws (B)retaining microswitch.
e) Replacein reverse order.
To replace heat exchanger
a) Drainsystem.
b) Removefront cover 7.1.
c) Remove combustion chamber front panel 7.2.
d) Remove burner manifold and burner 7.3.
e) Remove high limit thermostat phial - left hand side (E).
f) Withdraw thermostat phial (right hand side)(F).
g) Unscrew nuts on flow and return connection CC).
h) Loosenfour screws securing combustion chamber to
rear chassisCH).
i) Drop assembly and withdraw forwards.
j) Remove two screws from rear of assembly securing
heating body to combustion chamber.
k) Replacein reverse order.
To replace pilot injector
a) Proceed asfor cleaning (page 15 - 7.4).
b) Replaceinjector ensuring it isfitted bright side upper-
most
17

8.9
8.10
8.11
8.12
8.13
Rear Lining-
Replacing combustion chamber linings
a) Remove front cover 6.1.
B
u
7
b) Remove front panel combustion chamber 6.2.
\1
\
Pi-7
c) Remove burner 6.3.
\i
A+ d) Slideout side.liningsfirst followed by rear lining.
‘“4 (To remove rear lining ease upwards and withdraw by
b I=11 a downwards and forwards motion).
e) Replacein reverse order taking care that front lining
iscorrectly positioned.
Removal of electrical control box
a) Remove front cover 6.1.
b) Isolate electrical supply.
c) Remove six screws retaining electrical control box co-
ver.
d) Remove electrical connections from terminal strip
and earth.
e) Withdraw plugs from rear of box.
f) SlidePCBforward and disconnect spark lead.
g) Remove 2 screws securing control box to chassis.
h) Replacein reverse order taking care to replace plugs
in rear of control box.
n-b. Care should be taken to ensure correct location of
the ON,OFFand reset buttons.
To replace thermostat
a) Isolate.electrical supply.
b) Remove front cover 7.1.
c) Unscrew knurled ring (A) retaining thermostat phial
and remove phial.
d) Unplugfrom rear of control box.
e) Replace in reverse order using heat sink grease on
the sensing phial.
To replace fuse
a) Isolate electrical supply.
b) Remove front cover 7.1.
c) Remove cover on electrical control box 8.10.
d) Remove and replace fuse.
e) Reassemble.in reverse order.
To replace PCB
a) Isolate.electrical supply.
b) Remove front cover 7.1.
c) Remove cover on electrical control box 8.10.
d) Remove electrical connections from terminal strip
and the earth.
e) Withdraw plugs from rear of electrical control box.
f) Ease PCB forward and remove spark electrode. lead
and earth leadfrom the spark generator.
g) Slideboard forward and remove.
hl Replacein reverse order.
18

3.14
Testing the FFDcircuit
Closed circuit :
- Slide back insulation at plug in connection and attach
millivolt meter using crocodile clip connectors.
- Output should not be lessthan 3 mv.
Open circuit :
- Disconnect round pin connectors.
- Attach millivolt meter using crocodile clipsto the ther-
mocouple side - male connectors.
- Pressand hold ignitor button.
- Output with pilot on should not be lessthan 14 mv.
n-b. If closed circuit output is high and approaching the
open circuit voltage obtained, then suspect faulty
thermoelectric valve.
SHORTLIST
I=
Key No
3
4
7
IOa
IOb
20
21
26
30
31
32
34
35
36
37
43
109
118
119
163
186
IB
26
36 21
Description GC Number Part Number
Screw front case/electrical box securing ........................
Screwfrontcase/chassis ......................................
Temperatureselectorknob ...................................
Doorassembly30OF .........................................
Doorassembly50OF .........................................
Nut3/4”BSP ................................................
Olive(22 mm) ...............................................
Mountingbracket ............................................
Cableclampbracket ..........................................
Cableclamp .................................................
Screwscableclamp securing ...................................
Gasfilterwasher .............................................
Gasservicecock .............................................
Olive(15 mm) ...............................................
Nut1/2”BSP.. ..............................................
Thermistortemperaturesensor ...............................
Highlimit thermostat .........................................
Thermocouple ...............................................
Electrode and leadassembly ...................................
Printed circuit board .........................................
Fuse .......................................................
366 713 65622/01
366 311 39551103
366 553 64051
366 556 64147
366 625 64148
366 558 47509
366 559 47508
366 257 21720/10
366 564 65519
366 565 27834
366 714 45654/02
366 545 37309
366 566 65960
263 800 56489
366 642 56489
366 570 64153
366 636 65962
366 602 65961
366 593 63404
366 614 63176
264 446 44790
19

Pees main burner light ‘--
I
Change limit ~,a,
I Isthe pump wired “0
tothe boiler? I
between terminal 5
and terminal 6 in the boiler
n
Imp. C.M. - Ref. 92220-l 27 - 1185