Chaffoteaux & Maury System plus 60 User manual

Heating boiler compatible
with indirect cylinder
Faned Flue system
SYSTEM PLUS BOILER
Installation and
System plus 40
Operating instructions
System plus 60 =~e~~~ v
u

These instructions are suitable for the following boilers :
BRITONY System plus 40
BRITONY System plus 60

CUSTOMER CARE
Chaffoteaux et Maury Ltd , as a leading manufacturer of domestic and commerctal water heating appliances, is committed to providing high quality products and a
high qualrty after sales service If it is necessary to contact an engineer, then telephone your local Chaffoteaux Service Centre The number can be obtained from
the leaflet enclosed in the customer care pack with your boiler or by telephoning the Chaffoteaux Customer Services Department at Telford.
Advrce on installatron or servicing can also be obtained by contacting the Chaffoteaux Customer Services Department at Telford
CUSTOMER SERVICES DEPARTMENT
Tel [phone]
Fax [phone]
GUARANTEE
The manuiacturer’s guarantee ISfor 12 months from the date of purchase. The guarantee is voidable if the appliance is not installed in accordance with the
recommendations made herem or in a manner not approved by the manufacturer To assist us in providing you with an efficient after sales service, please return the
guarantee regtstratron card enclosed with the boiler without delay
STATUTORY REQUIREMENTS
The installation of this appltance must be carried
Safety (Installatton and Use) Regulations out by a Registered or other competent person and in accordance requirements of the Gas
In addition, the installation must also comply with the current byelaws of Local Water Undertakings, Building Regulations, IEE Wiring Regulations, Local Authority
Building Standards (Scotland) Regulations and the Safety Document 635 The Electricity at work Regulation.
It should also be carried out in accordance with current editions of the following British Standards Codes of practice: BS 6891, BS 5440 parts 1 and 2, BS 5449 part
1. BS 7593, BS 6798, BS 5546, BS 4814, BS 7074 part 1 and 2, BS 7671 and BG DM2
If there ISa possibility of the incommg mains water pressure exceedtng IO bar then a suitable pressure limiting valve must be fitted
Precauttons. 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 dtscomfort, although some people with a history of skin complatnts may be susceptible to irritation. When disposing of the lining, ensure that it is
securely wrapped and wash hands after contact

CUSTOMER CARE ...............................................
Guarantee.. ............................................................
Statutory Requirements.. ......................................
Contents ................................................................
INTRODUCTION ...................................................
DESCRIPTION ......................................................
Location of components.. .......................................
TECHNICAL DATA.. ..............................................
DIMENSIONS.. ......................................................
OPERATION.. ........................................................
Domestic Hot Water Mode.. ...................................
Central Heating Mode.. ..........................................
INSTALLATION REQUIREMENTS.. .....................
Location .................................................................
Flue.. ......................................................................
Ventilation ..............................................................
Gas Supply ............................................................
Electrical Supply ....................................................
INSTALLING THE BOILER ...................................
Installation.. ............................................................
Fitting the horizontal flue.. ......................................
Making the electrical connections.. ........................
Page
3
3
3
4
5
6
6
8
10
12
12
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14
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15
15
15
16
16
17
19
COMMISSIONING AND TESTING ........................
Pre-commissioning ................................................
Domestic Hot Water.. .............................................
Central Heating.. ....................................................
Lighting the boiler ..................................................
Post Commissioning.. ............................................
Handing over to the Householder.. ........................
SYSTEM GUIDANCE.. ..........................................
Showers .................................................................
Flushing and Water Treatment ..............................
System Controls ....................................................
Bypass and pump.. ................................................
Expansion Vessel ..................................................
Filling Point ............................................................
USER’S INSTRUCTIONS.. ....................................
Control panel .........................................................
Isolating taps.. ........................................................
Switching on ..........................................................
Hot water ...............................................................
Heating and hot water.. ..........................................
Turn off the boiler.. .................................................
Page
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25
25
26
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26
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27
q
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The BRITONY SYSTEM PLUS is a fully automatic, wall mounted, low water content boiler. It is a room sealed, fan
assisted, balanced flued appliance . The appliance includes a diverter valve and so can provide central heating
and hot water flow for an indirect cylinder.
It has electronic ignition and is suitable for use with all modern electrical control systems. The boiler is designed for
sealed systems only and a circulating pump, expansion vessel together with a pressure gauge and safety valve
are included within the boiler.
The standard horizontal flue kit is suitable for lengths 300 mm minimum to 680 mm maximum and includes an
elbow adapter that can be rotated through 360”. The horizontal flue can be extended (refer to Flue Installation
Instructions), 45” and 90” flue bends are also available as accessories.
The BRITONY SYSTEM PLUS is also suitable for concentric vertical and twin pipe flueing. Adapters and
accessories are available.
The boiler is packed in three cartons:
1. the boiler,
2. the flue assembly and the pre installation kit,
3. additional accessories kit.

Location of components
1. Air pressure switch
1
2. Steel chassis complete with expansion vessel
3. Main heat exchanger
4. Combustion chamber
5. Multi- gas burner assembly comprising ignition and
ionisation electrodes
6. Automatic air separator and automatic vent
7. Heating circuit flow switch
8. Pump
9. Electrical box
11. Overheat thermostat
12. Gas valve assembly
13. Sealed chamber
14. Flue hood with fan
16. Primary circuit control thermistor
17. Three way valve
18. CH Flow isolating valve
19. Three position Selector switch
20. User’s instruction panel.
21. Heating flow temperature adjustment
22. Green indicator - Power ON
23. Orange indicator - Burner ON
24. Red indicator - Lock out /flame failure
11
9-
Fig.
- 4
- 5
-8

25 Reset button
26. Pressure gauge
27. Gas service tap
28. Hot water flow isolating valve
29. CH Return isolating valve
30. Pressure relief valve
32. By pass
33. By pass adjustment screw
34. Location of central heating filter
33

BRITONYSYSTEMPLUS type 40 60
Appliance category ..................... Cat II 2H3+ Cat II 2H3,
Heat input C/H & DHW
Maximum in kW .~....~.-........ 13.41 20.22
Maximum in Btulh ...._............ 45764 69005
Heat output C/H & DHW
Maximum in kW .................... 12 18
Maximum in Btu/h ................. 40952 61428
C/H circuit pressures
Min operating in bar 0.7 0.7
in lb/in* 10 IO
Max operating in bar 2.5 2.5
in lb/in’ 36.3 36.3
Compartment ventilation is not required
BRITONYSYSTEMPLUS type
40
Natural gas G20
Gas rate
Maximum in ma/h ................... 1.42
Maximum in ftVh .................... 50
inlet pressure
Nominal in mbar
.................... 20
Nominal in in wg.. .................. 8
Burner pressure
Nominal in mbar
.................... 2.9
Nominal in in wg .................... 1.2
Burner injector diameter
Natural gas G20 in mm ........ 1.18
PROPANE L.P.G. G31
Gas rate
Maximum in kg/h ................... 1.03
Maximum in ftVh.. .................. 2.27
Inlet pressure
Nominal in mbar .................... 37
Nominal in in wg.. .................. 14.8
Burner pressure
Nominal in mbar
.................... 9.2
Nominal in in wg.. .................. 3.7
60
2.14
76
20
8
6.7
2.7
1.23
1.55
3.42
37
14.8
21.0
8.4

BRITONYSYSTEMPLUS type 40
BUTANE L.P.G. G30
60
BRITONYSYSTEMPLUS type 40
Safety discharge
Gas rate inbar.. ................. 3
Maximum in kg/h.. 1.05 1.58 in lb/in* .................. 43.5 .................
Maximum in Lb&h.. ............... 2.32 3.48 Expansion vessel
Inlet pressure Pre-charge pressure in bar . 0.7
Nominal in mbar .................... 28 28 Pre-charge pressure in IbAn* 9.4
Nominal in in wg .................... 11.2 11.2 Net capacity at 3 bar in liter 5.44
Burner pressure Adjustable by-pass
Nominal in mbar .................... Minimum flow rate in I/h . . . 100
Nominal in in wg .................... Minimum flow rate in gal/min 0.36
Maximum flow rate in I/h . . . 700
Burner injector diameter Maximum flow rate in gal/min 2.56
LPG G30 and G31 in mm . . 0.70 0.70 Electrical characteristics
Compartment ventilation not required Supply . . . . . . . . . . . . . . . . . . 230 v
Consumption , , , . . . . . . . . . 150 w
Protection . . . . . . . . . . . . . . . IP 44
Fuse no1 . . . . . . . . . . . . . . . . 2A
Fuse no2 . . . . . . . . . . . . . . . . 1.25 A
External controls . . . . . . . . . 24 v
60
3
43.5
0.7
9.4
5.44
100
0.36
700
2.56
50Hz
15ow
IP 44
2A
1.25A
24v

Weights
With packaging :
- BRITONY SYSTEM PLUS 40 :
- BRITONY SYSTEM PLUS 60 :
Without packaging :
- BRITONY SYSTEM PLUS 40 :
- BRITONY SYSTEM PLUS 60 :
Lift weight :
- BRITONY SYSTEM PLUS 40 :
- BRITONY SYSTEM PLUS 60 :
43.2 kg
43.2 kg
41.2 kg
41.2 kg
35.2 kg
35.2 kg
Tails diameter
I Safety valve outlet 015mm
J Heating flow 022mm
K H.W. flow 022mm
L Gas supply 022mm
N Heating return 022mm
Outer case dimensions :
-Width 440 (minimum space required 450)
- Height 850
- Depth 380
6
:
cent& line
All dimensions in mm
Fig. 4

Minimum clearances :
- Both sides 5mm
- Above casing 170 mm
- Below casing 200 mm
- Front ( for servicing) 500 mm
- Front (in operation) 5 mm
TYPE Cl2 or C42
Fig. 5 Dimensions in mm
The boiler is suitable for the 3 flue types :
l typeC 12orC42
l type C 22
l tvoeC32xxorC32xv
TYPE C32 xx TYPE C32 xy

Domestic Hot Water Mode
To be able to supply hot water, the selector switch (19 fig.
6) must be in either in ,C or ‘1111,i position. This will be
confirmed by the green indicator light 0 (22 fig. 6).
When the cylinder thermostat is calling for heat, it
switches the 3 way valve (17 fig. 7) to hot water position.
Then the hot water from the primary circuit is diverted
through the cylinder coil to heat DHW.
The first stage solenoid (12a fig. 7) and safety solenoid
(12~ fig. 7) open together to allow gas to the burner.
The ignition sequence begins and a continuous high
speed spark ignites the gas. As soon as a flame is
detected the orange indicator bulb (4 (23 fig. 6) will light
and the second stage solenoid (12b fig. 7) opens to allow
the full gas rate.
If a flame is not detected, after 8 seconds, the security
solenoid closes and shuts off the gas.
The red lockout indicator bulb & (24 fig. 6) will light.
The hot water flow temperature is controlled by the
primary circuit control thermistor (16 fig. 7).
When the cylinder thermostat is satisfied, the burner is
extinguished and the pump stops.
25
Fig. 6 ‘20
The boiler will now stay in the hot water mode for three minutes.
Priority will be given to a demand for reheating the cylinder.
Central Heating Mode
To be able to supply central heating, the selector switch (19 fig. 6)
must be in ‘1111,i position. This will be confirmed by the green
indicator light 0 (22 fig. 6)

When there is a demand for heating (either from the room
thermostat or the external programmer) and the boiler
temperature control is calling for heat. The pump starts and at a
flow rate of 4 Itrlmin the central heating flow switch operates
allowing the ignition sequence to begin. The first stage solenoid
(12a fig. 7) and safety solenoid (12~ fig. 7) open together to
allow gas to the burner. The ignition sequence begins and a
continuous high speed spark ignites the gas. As soon as a
flame is detected the orange indicator bulb 4 (23 fig. 6) will
light. After 45 seconds the second stage solenoid (12b fig. 7)
opens to allow the full gas rate. If a flame is not detected, after 8
seconds, the security solenoid closes and shuts off the gas. The
red lockout indicator bulb 0 (24 fig. 6) will light.
The central heating flow temperature is controlled by the central
heating control thermistor (16 fig. 7). The boiler has been
designed to minimise cycling and will not attempt to relight for at
least 3 minutes after the boiler thermostat has been satisfied I
(this MTAC delay), can be set to 30 seconds if required, see
maintenance and service guide). When the room thermostat is
satisfied the burner will switch off and the pump will remain
running for a further 3 minutes.
NB
It is possible to override the TAC delay by pressing the RESET
button (25 fig. 6).

Location
The boiler can be installed on any suitable internal wall.
Provision must be made to allow the correct routing of the
flue and siting of the terminal to allow the safe and efficient
removal of the flue products. The appliance may be
installed in any room, although reference must be made to
the IEE regulations if it contains a bath or shower. A
compa~ment or cupboard may be used provided that it has
been purpose-built or modified for the purpose. It is not
necessary to provide permanent ventilation for cooling
purposes. Detailed recommendations are given in BS 5440
pt 2. If it is proposed that it is installed in a timber framed
building then reference must be made to British Gas
Document DM2, or advice sought from CORGI.
Flue
The boiler must be installed so that the flue terminal is
exposed to the free passage of external air at all times. It
must not be allowed to discharge into another room or
space such as an outhouse or closed lean-to. The
minimum acceptable clearances are shown below:
- A Directly below an opening, window, etc 300 mm
- B Below gutters soils pipes or drain pipes 75 mm
- C Below eaves 200mm
- 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
- I From another terminal facing the terminal 600 mm
- J From an opening into the dwelling when
under a car port 1200 mm
- K Vertically from a terminal on the same wall 1500 mm
- L Horizontally from a terminal on the same wall 300 mm
- M fixed by the flat roof ubbink rolux 4GM flue terminal
- N fixed by a pithed roof ubbink rolux 4GM flue terminal

-
--
It may be necessary to protect the terminal with a guard if it is
accessible and could be damaged. Reference should be made to
the Building Regulations for guidance. Suitable guards may be
obtained from the following maufacturer:
Quinnel Barret & Quinnel Wireworks
Old Kent Road
London SE15 1NL
Tel: [phone]
Ventilation
The room in which the boiler is installed does not require specific
ventilation. IF IT IS INSTALLED IN A CUPBOARD OR
COMPARTMENT PERMANENT VENTILATION IS NOT
REQUIRED FOR COOLING PURPOSES. If vents are installed,
they must communicate with the same room or be on the same
wall to outside air.
Gas Supply
The gas installation and soundness testing must be in
accordance with the requirements of BS 6891.The boiler
requires a 22 mm supply. Ensure that the pipe size is
adequate for the demand including other gas appliances on
the same supply.
Electrical Supply
The appliance requires an earthed 230V - 50 Hz supply and
must be in accordance with current I.E.E. It must also be
possible to be able to completely isolate the appliance
electrically. Connection should be via a 3 amp fused double-
pole isolating switch with contact separation of at least 3 mm
on both poles. Alternatively, a fused 3 Amp. 3 pin plug and
unswitched socket may be used, provided it is not used in a
room containing a bath or shower. It should only supply the
appliance.

Please check that you are familiar with the installation
requirements before commencing work.(section 6)
Installation
The installation kit included with the flue components
comprise following items :
- Hanging bracket
- A paper template (showing the dimensions of the boiler with
5 mm side clearances, fitting instructions and
commissioning instructions)
- Connection tails
- Screws and wall plugs
- Connection washers
- Pre-piping jig
- Installation manual
Also required is the additional accessories kit r-r” 1014574
contain 15 to 22 mm bush and tail.
Method of positionning the boiler on the wall.
The paper template can be used to ensure the correct
positioning of kitchen cabinets etc. It also details the
commissioning instructions.
The paper template has to be fixed to the wall and used to fix
the position of the hanging bracket, the centre for the flue hole
and, if required, the fixings for the pre-piping jig.
Drill and plug the wall and secure the hanging bracket using
the screws provided (refer to the paper template drawings).
Remove the boiler from its packaging as shown in fig. 13 and
remove the outer case as shown in fig.14. Place the boiler on
the wall on the hanging bracket after removing the pre-
installation jig.
If required, there is space for all piping to pass behind the
Fig. 13
Fig. 14

boiler. Using fig. 15 for reference, connect the gas and water
pipes to the valves located at the base of the appliance using
the tails provided. There is a 190 mm space between the
valves and the wall to make these connections.
Provision must be made to fill and recharge the system
Fig. 15
I Safety valve outlet 015mm
J Heating flow 022mm
K H.W. flow 022mm
L Gas supply 022mm
N Heating return 022mm
pressure. This can be achieved using a filling loop or other
methods approved by the local water authority.
The pressure relief should terminate below the boiler over a
tundish or 22 mm pipe (see I fig 15) which should in turn
discharge safely outside the premises. Care should be taken
that it does not terminate over an entrance or window or
where a discharge of heated water could endanger occupants
or passers by.
The system should be carefully checked for leaks, as frequent
refilling could cause premature system corrosion or
unnecessary scaling of the heat exchanger.
Fitting the Horizontal Flue
The instructions for the elevated horizontal, vertical and biflux
(twin pipe) flue options are included with the relevant adapter
kits,
The standard flue supplied with the appliance is suitable for
lengths from 300 mm minimum to 610 mm maximum. This
means for rear flueing, the standard kit will accommodate a
maximum wall thickness of 490 mm, and for side flueing a
maximum wail thickness of 477 mm. This takes into account
the minimum appliance side clearances of 5 mm. ”If the fixing is a rear exit flue, the template provides the
position of the centre for drilling the flue hole with a core drill.
If the flue is a side exit installation then calculate the position
of the hole with a slope of 5 mm / metre to the terminal.
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Connecting the boiler to the system
- Hinge down the electrical box to gain access to the valves
connections. Push in the tabs (P Fig 19) on either side of the
boiler and pivot the box forward.
- Remove the yellow caps from connecting pipes and connect
the boiler to the taps using gaskets provided in the plastic
bag.
Rubber washer “R” for gas connection.
Provision must be maid to reduce as much as possible the
distance A from the cylinder coil return to the boiler and B
should be greater than 200 mm to avoid gravity effects. Fig 16
I return
mini
heating return
Fig 17
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Making the Electrical Connections
Hinge down the electrical box to gain access to the
electrical connections. Push in the tabs (P fig 19) on
either side of the boiler and pivot the box forward.
Undo the two retaining screws (A fig 19), lift the cover
and turn over, and remove cable clamp (see fig. 19a).
Connect the live and neutral wires to the multipin plug
<CDS>(fig 20) of the PCB -Ea, leaving sufficient earth wire
to connect to the earthing point. (B fig 21)
Note: The connections should be made so that should
the lead be pulled from its anchorage, the current
carrying wires become taut before the earth wire.
Fig. 19
Fig. 19a

-
--
Earth pillar B
If using a room thermostat or other external control, they can
be connected in place of the link on the multipin plug -Ct>
(fig 20)
Note: Use only controls designed for voltage free
switching or 24V supply.
Socket for
connector C
Connect multipin plug c<Cbbonto into the socket on the power
board. Connect m&ipin plug <CDS)to the interface PCB
inside the cover (see fig. 20).
Secure the cables using the cable clamp and replace the
cover. To prevent damage, the cables should then be routed
through the cable support on the right hand side of the
chassis.
ALL
Fig. 21