Chaffoteaux & Maury Britony FIexiFIue User guide

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Britony FIexiFIue
Room Sealed Balanced Flue
MULTI POINT WATER HEAm
GAS SAFETY (INSTALLATION AND USE) REGUIATIONS.
It is the law that all gas appliances are installed by a competant person
in accordance with the above regulations.
(For use on natural gas only G20)
G.C. N” 52 980 22
from serial number 8942 16759-04
fastallatfon
and servicing instructfons
(leave these instructions with the aser)
The model number and serial number of this heater are on the data badge which is found inside rear
case at lower IeA hand side.
These numbers should be used when ordering replacement parts.
CONFORMSWIIHEUROPEANSTANDARDEN.26
Looking Good.Heating Better

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I
CONTROL OF SUBSTANCES HARMFUL TO HEALTH
IMPORTANT
To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to provide infor-
mation on the following substance that is contained in this appliance.
Description Combustion Chamber Lining
Material Alumino Silicone Fibre
Precadons 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 wil not present any discomfort,
although some people with a history of skin complaints may be susceptible to irritation.,
When disposing of the lining ensure that it is securely wrapped and wash hands after.

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L. GENERAL
The Britony Fle.xiFlue is a room sealed, fanned balanced ffue, multipoint water heater. The flue which is
100 mm (4”) diameter pipe, can be directed to the rear or to either side. The maximum recommended iIue
length is 3 metres for straight application and 1.6 metres total when using a bend.
The appliance is for connection to a mains cold water supply having a minimum working pressure of 1 bar.
A permanent electrical connection is required and should be provided by use of a fused spur. The external
electrical supply should be via a double pole switch having 3 mm. contact separation in both poles. If the
appliance is installed in a bathroom the fused spur must be external to the bathroom.
When on pilot only the fan runs at “low speed” increasing to normal speed when there is a demand for hot
water. Included is a pressure switch, which operates if the fan stalls or if the flues is obstructed and a low tem-
perature sensor which will turn off the fan when the appliance is running on pilot only (fan low speed) in the
event of low air temperatures likely to cause freezing in the appliance.
Note : Gas Safety Installation and Use Reg 1984. It is the law that all gas appliances are installed by C.O.R.G.1
registered persons in accordande with the above regulations. Failure to install appliances correctly could lead
to prosecution. It is in your own interest and that of safety to ensure compliance with the law.
1.1 Guarantee
The guarantee on this appliance is void if it is not installed in accordance with the recommendations made
herein or in a manner approved by the manufacturer.
3
1.2 Dimensions
mm Ins.
A
655 25.9
B 395 15.5
C 270 10.6
D 100 4.0
E 40 1.6
F 385 15.15
G 438 17.25
H 775 30.6
J 728 28.6
K 53 2.1
L 55 2.15
M 98 3.8
N 70 2.75
P 285 11.22
S 105 4.13
T 199 7.8
v 290 11.4
W 95 3.54
X a70 34.14
3

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..
. Technical Data
Heat input nomimaf ..........................................
Heat output nominal .........................................
Gas rate (maximum) :
. Natural gas (G20) 35,9 MJ/ms - 20 mbar .....
with manifold restrictor.. ...............................
Butane (G30) 45,6 MJ/Kg -. 28-30 mbar.. ....
Propane (G31) 46,4 MJ/Kg - 37 mbar .........
Main burner injectors :
G20 ..............................................................
. G30 - G31 .....................................................
Pilot injector marking G20.. ...............................
G30 - G31.......................
Water flow rate - raised 50°C (90°F) .................
Water flow rate - raised 25°C (45°F) .................
Min. water pressure selector closed ..................
Min. water pressure selector open ....................
Max. water pressure .........................................
Electrical supply ...............................................
fused 3 A
25,2 kW 85966 Btu/h
22,7 kW 77452 Btu/h
2,67 msih
6,l mm diam.
1,99 kg/h
1,96 kg/h
94,29 fix/h
1,28 mm diam.
0,74 mm diam.
26
15
3,2 to 6,5 Enin
6,5 to 13 Rnin
05 bar
1,0 bar
10 bar
240V-50Hz
0,7 to 1,43 gpm
1,43 to 2,8 gpm
16,5 A (7,5 psi)
33,0 ft (15 psi)
150 psi.
The rninimum water pressure is for the correct operation of the appliance only. An additional aJlowance
must be made for the resistance of pipework and fittings particularly where showers and washing
machines are used. This should be equivalent to 2 m. (6,5 A) head.
Water inlet (Compression type fittings) ..............
Water outlet (Compression type fittings). ...........
Gas (Compression type fittings) ........................
Height (iclud.ing ffue bend) ..............................
Width ................................................................
Depth ................................................................
Weight - Cartoned .............................................
Weight - Lift .......................................................
Minimum clearances - top (above flue) .............
- bottom (below case) .....
- sides. .............................
- front ..............................
Hole for the air inlet duct ..................................
Right hand connection 15 mm Copper
Left hand connection 15 mm Copper
Centre connection 15 mm Copper
778 mm 30,6 in
395 ml-n 15,5 in
270 mm 10,6 in
24,3 kg. 53,6 lbs.
15 kg. 33.1 lbs.
50 mm 2in
178 mm 7in
25 mm 1il-l
600 mm 24 in
102 mm diam. 4.2 in. diam.
The Britony FlexiFlue is supplied in one carton.

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2. INSTALLATION REQUIREMENTS
2.1 Related Documents
The installation of the heater must be in accordance
with the relevant requirements of the Gas Safety
(Installation and Use) Regulations. Building
Regulations and the current Byelaws of the local
water undertaking. It should be in accordance with
the current British Standard Codes of Practices Local
Authority Building standard (Scotland) regulations,
and the safety document 635, the electricity at work
regulation. Detailed recommendations are contained
in the following British Standard Codes of Practice :
BS6400:BS5546:BS5440:F't.l:andPQ:BS7671-BSOM2.
2.2 Location
The location chosen for the appliance must permit
the provision of a satisfactory fIue termination The
location must also permit adequate space for servi-
cing and air circulation around the appliance.
The appliance may be installed in any room or inter-
nal space although particular attention is drawn to
the requirements of the current BS 7671 and, in
Scotland, the electrical provisions of the Building
Standards applicable in Scotland, with respect to the
installation of a heater i a room or internal space
containing a bath or shower.
Where a room sealed appliance is installed in a
room containing a bath or shower, any electrical
switch or appliance control, utilising mains electrici-
ty should be so situated that is cannot be touched by
a person using the bath or shower.
Where the installation of the appliance will be in an
unusual location special procedures may be neces-
sary and BS 5546 gives detailed guidance on this
aspect.
A compartment used to enclose the appliance must
be designed and constructed specifically for this pur-
pose. An existing cupboard or compartment may be
used provided that it is modified for the purpose.
Details of essential features of cupboardcompart-
ment design are given in BS 5546.
2.3 Gas Supply
An adequately sized gas meter must be connected
to the service pipe. Where necessary the local Gas
Region of British Gas will arrange for the existing
meter to be checked or for a suitable meter to be
installed. On no account must any work be carried
out on the gas meter other than by BRITlSH GAS or
their specifically authorised contractor.
Installation pipes should be fitted in accordance with
BS 689 1. Pipework from the meter must be of ade-
quate size. Pipes of a smaller size than the gas
connection should not be used. Gas supply pipes in
excess of 3 metres use 22 mm pipe.
The complete installation must be tested for gas
soundness and purged in accordance with BS 689 1.
2.4 Siting the Flue Terminal
The ffue must be installed in accordance with
BS 5440 : Pt. 1.
The following notes are intended to give general gui-
dance.
The standard ffue set is suitable for walls having a
thickness of 75 mm (3 in.) to 612.5 mm (24 in.) for
rear outlet lluing or up to 500 mm (19,5 in.) for side
outlet ffuing. Other ffue options are available to a
maximum of 3 m (9 ft. 8 in.) to special order.
-
-
A
B
C
D
E
F
G
H
J
K
L
-
The appliance must be installed so that the ffue ter-
minal exposed to external air. The appliance must
NOT be installed so that the terminal discharges into
another room space such as an outhouse or lean-to.
It is important that the position of the terminal
allows a free passage of an across it all times. The
minimum acceptable spacings from the terminal to
obstructions and ventilation openings are specified
in the following chart. Also see Section 3.4.
Termhl poshions Mirn clearances
Directly below an opening, windows etc
or adjacent to an opening 300 mm
Below gutters soil pipes or drain pipes
75 mm
Below eaves 200 mm*
Below balconies or car port roof 200 mm*
From a vertical drain pipe or soil pipe 75 mm
From an internal or external comer 300 mm*
Above ground roof or balcony level 300 mm
From a surface facing the terminal 600 mm
From an opening in the car port
(e.g. door or window) into dwelling 1200 mm
Vertically from a terminal on the same
Wd
1500 rnm
Horizontally from a terminal on the
same wall
* (107 mm) minimum clearance using kit N” 76216.00 (G.C. 264 833)
Note - Where the terminal is fitted within 850 mm
(34 in.) of a plastic or painted gutter or 450 mm
(180 in.) of 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 adjoins the wall in which the terminal is situa-
ted must be protected by a guard of durable mate-
rial (a terminal guard is available from Quinnel
Barrett & Quinnel. 0171 639.1357 (GC No 381.
782)
The air inlet/products outlet duct and the terminal of
the appliance must not be closer than 25 mm (1 in.)
to any combustible material. Detailed recommenda-
tions on the protection of combustible material are
given in BS 5440 Pt. 1.
IMPORTANT NOTICE : TIMBER FRAMED
HOUSES. If the appliance is to be fitted in a timber
framed building it should be fitted in accordance
with the British Gas publication <<Guide for Gas
Installations in Timber Framed Housing, reference
DM2. If in doubt advice must be sought from British
Gas.
2.5 Wall Mounting
The appliance should be installed on a flat non-com-
bustible material which not reverberate. What ever
the thickness of the wall a hole 107 mm (4.2 in.) in
diameter will be required for the appliance ffue
assembly. It is recommended that a core drill be
used to form this hole.
For dimensions are clearances see sections 1.2 and 1.3.

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2.6 Flue Terminal Assembly
3. An un-switched socket outlet compling with
The flue may be fitted from inside or outside of the
building. If fitting from inside the flue duct should be
assembled into the air intlet duct and the assembly
passed trough the hole in the wall. The outside dia-
meter of the terminal is the same as outside diame-
ter of the air inlet duct.
BS 1363.
The method of connecting the plug brown wire to
live (L) blue wire to neutral (N) and green/yellow
to earth ( f ), see fig. 3.
A three core cable should be used and a heat resis-
ting cable of 0.75 mm2 (24 x 0,2 mm) is considered
suitable.
2.7 hir supply
The appliance does not require any purpose provi-
ded ventilation unless installed in a compartment. A
compartment enclosing an appliance requires high
and low level openings. These openings must either
I communicate with a room or internal space or be
direct to outside air. The minimum FREE area of the
opening must be :
The cable should be passed through the gland on
the top of appliance and the clamp tightened to
secure the cable. Ensure current carrying conductors
become taught before earthing conductor should
cable slip from the cord anchorage. Connection to
the appliance should be made in accordance with
diagram (see section 3, 8, 2).
2.9 Description of Operation
Read in conjunction with iigs 1,2 and 4).
i,,,,,,,,.~
Air from roomor Internalspace
2.8 Electrical Connections
The appliances must be earthed.
The installation should be undertaken by a compe-
tent electrician and should be in accordance with the
current edition of B.S 7671.
Particular attention should be paid to cross bonding.
The appliance must be provided with a means of
isolation. If installed in a bathroom the means of iso-
lation must be external to the bathroom o; a double
pole cord switch fitted.
Acceptable methods of connection are :
1. A switched, double pole fused spur with 3 mm
contact separation on all poles.
2. A double pole switch where the supply must be
suitably fused 3 A.
The controls on the Britony FlexiFlue comprise of a
range of thermal, electric and electronic switches.
Broadly, the thermal controls are for the pilot flame
supervision, the electrical controls are functional
switching and the electronic controls act as a securi-
ty for the functional controls.
The circuit is designed so that. under normal condi-
tions, the fan r-t.& continuously at low speed and
automatically changes to high speed when the gas
valve opens. If, however, the incoming air tempera-
ture approaches 0°C the integral frost protection
thermostat interrupts the low fan speed signal.
Under this condition, if there is a demand for hot
water, then the fan recommences at high speed.
There is an in-built delay circuit to prevent the safe-
ty devices operating prematurely.
The pilot can only be established under the control
of the thermocouple ikrne failure circuit after the
mains electricity connection is made since it is
dependent upon the energisiig of relay-RLl .
If the air ffow is not proved on high speed the &me
supervision device will operate by interrupting the ther-
mocouple as a result of the de-energising relay-RLl .
ELECTRIC SUPPLY
FUNCTIONAL FLOW DIAGRRM
,
MlC& SWITCH RELAY RELAY THERM0 THERM0
+ RLZ h L
v RLl r m”pu -b ElJEclmc
b & VALVE
_

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CIRCUIT DIAGRAM
THERMOELECTRH
WIRING DIAGRAM
FU Fuse (2 A)
TC Thermocoupla
BM Thermc4ectrlc Valva
SW MIcromitch
PR Pressure Switch
Y-G Yellow - meen
Br Bruwn
BI Blue
R Red
W White
0 orange
Bk Black
v vldet
0 Orey
P Pink
LFig. 2
ELECTRICAL
CONNECTION
fuse 3 A heater
switched fused spur
NB : IF APPLIANCE INSTALLED IN A BATHROOM
SPUR MUST BE EXTERNAL TO ROOM
-----I--------------
NB : IF APPLIANCE INSTALLED IN A BATHROOM
SWITCH TO BE OF PULL CORD TYPE
heater
3 A. fuse do;ble&e -
Fig. 3
7

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OPERATIONAL DIAGRAM
‘E SWITCH
..---_.i
ii . ’ I II N
II
I
I
THERMOCOUPLE
II \
ii ii
I
IIII I
II
II I
IIII I
II
II I
IIII
L
I
II
II I
IIII
RL.RL.
PRINTED CIRCUIT BOAIPRINTED CIRCUIT BOAI
IL--- ---IL--- ---
--------------
ka
2 II
N
RD
.-_----11
-m-s----
Pig. 4
=
3. INSTALLING THE APPLIANCE
A vertical flat area is required for the appliance : 1006 mm high x 445 mm wide (39.6 in x 17.5 in). The surface
on which the appliance is mounted must be of a non combustible material.
3.1 Packaging
The appliance is attached to the wall via the mounting bracket and two bottom screw fixings. The appliance is pac-
ked in a single carton. Remove contents from carton and check against List.
1) APPLIANCE - Assembled with trims.
2) FLUE ASSEMBLY : a) Air inlet duct complete with terminal.
b) 2nd section flue duct (inside air inlet duct).
c) Hue turret with 1st section flue duct fitted.
d) Plastic turret cover.
3) ACCESSORY BOX - containing : -mounting bracket
- ffue locking ring and ‘0’ ring seal
- 2 gaskets
- 4 wall mounting screws
- 4 turret fixing screws
- 2 turret cover fixing screws
- 1 gas control knob
- 1 temperature selector knob
- gas service tap assy (not supplied with LPG models)
- water service tap assy
8

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3.2 Prepatig and fitting the appliance
Preparation :
- Remove the bottom trim by pulkng forwards.
- Slide the controls facla plate (P) upwards to disen-
gage from retaining bracket.
- Release the front case by removing the four Exing
screws and washers positioned at the top, bottom
and centre of appliance.
- Remove the front case by lifting off the top locating
lugs and pulling forward to clear the water section
at the base of the appliance.
NOTE : A template is not supplied with this applian-
ce. Particular care is therefore necessary to ensure
that the appliance mounting bracket is fitted level
and positioned accurately. When using extended
flues, a fall fo 5 mm per metre length should be
provided. (From turret to terminal) (see Fig. 5).
197,s mm minimum I
3
- Refer to the drawings opposite for rear and side flue
applications and/or to the dimensions given.
- Set out an drill hole 290 mm (11.4 in) accurately
it
i
mark position for bracket.
- Drill and plug the wall.
- Fii bracket to wall using No. 12 screws provided,
ensuring that the bracket is level. If necessary
adjust bracket, tinally secure in position.
- Hang the appliance on the bracket, and recheck for
level. Mark bottom iixing holes, removes applian-
ce, drill and plug the wall to suit No 12 screws.
- Re-hang appliance and secure with screws provi-
ded.
Pig. 5
3.3 Flue Length
Rear Outlet
Minimum Wall Thickness 3 in (75 mm)
Wall thickness Up to 612.5 mm Over 612.5 mm
Delivered with Extension available
appliance Pt No 62823
Flue duct length = wall thickness + 25 mm
Air inlet duct length = wall thickness + 25 mm
Pt No. 62623 = GC NO 264 469
Side Outlet
EM up to 500 mm 1401 mm 2300 mm
+DM 500 MM to 1400 to 2300 to 2787
Deliv. 1 extern. 2 extern. 3 extern.
With Pt No 2x 3x
appliance 62823 62823 62823
EM = Wal thickness Flue duct length EM + DM + 130 mm
DM = Distance from wall to case Air inlet duct length EM + DM + 130 mm
Ftg. 6

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3.4 Other ffue arrangements
l- Plan View
1. Distance from Internal comer 300 mm without
kit, 150 mm with kit no. 76216 (GC No. 264
833).
2. Distance below balconies or eaves 200 mm
without kit, 150 mm with no. 76216. (GC No.
264 833).
3. Appliance is nom&y supplied packed with stan-
dard 650 mm straight ffue section, Additional
straight extention lengths of 1 metre. Part No
62833 (GC No 264 459), can be used up to a
3- Plan View
total straight length of 3 metres. It is also possible
to incorporate one bend in the ffue using Part No.
65572 (GC No. 264 835). In this case the length
Ll + L2 should not exceed 1,6 metres horizon-
tally, (see iig. 7).
2- Side Elevation
Fig. 7
3.5 Fitting the he
Fig. 8
- Measure the wall thickness and cut ffue duct and
air inlet duct to required length, (see Section 1.4).
- Peel off protective paper from adhesive side of
cork gasket (A) and place on mating side of ffue
turret @) lining up screw holes and press down.
- Fit locking ring (C) and “0” ring over the air inlet
duct, (see iig. 8).
- Fit flue duct and turret so that it engages into the
terminal.
- Engage locking ring over lugs by turning in an
anticlockwise direction viewed from behind tur-
ret.
- Position square channeled rubber gasket (E) on
the ffue hood outlet of the heater, channel facing
downwards.
- Pass the assembled ffue through the wall.
- If long ffue sections are used (up to 3 metres) and
di&ulty is found, these can be assembled whil-
st being passed through the wall.
- Seat the turret onto the top of the appliance ensu-
ring the gaskets are in position.
- Secure with 4 saews provided.
- Do not fit plastic turret cover or the front case until
electrical connections have been made and the
appliance tested for gas and water soundness
(see section 5.1).
- A sealing ring (D) is supplied which can be used
to seal the air inlet duct to wall joint-extemally.
- Make good inside wall surface.
10

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3.6 Gas Connection
3.7 Water Connections
Pig. 10
3.8 Electrical connections
- Fit the gas service cock provided using the fine fit-
ter/washer to seal the connection. Fit the nut and
olive onto the 15 mm gas supply pipe and tigh-
ten, (see fig. 9).
- Test the complete gas installation for soundness
and purge.
- Remove the plastic covers protecting the water
inlet and the water outlet connections.
- Fit the water service cock provided to the right hand
connection at the bottom of the appliance using the
coarse filter/washer to seal the connection, (see Sg.
10).
- Fit the nuts and olives onto the supply and deltvery
HP=
- Connect the inlet supply to the water service cock and
tighten.
- The water service cock supplied with the appltance
incorporates a drain plug.
- Ensure that all water connections are fully tightened.
3.8.1 Pressure Switch
- Connect the wires at the top of the appliance to
the pressure switch, (see fig. 11).
- The grey wire is connected to normally closed (NC
1) contact.
- The pink wire to the normally open (NO 2)
contact.
- The violet wire to the common (P) contact.
- Fit the flue turret cover passing the wire through
one fo the slots provided and secure with the
screws provided.
- See figure.
3.8.2 Mains Connection
- Pass 0.75 mm2 heat resisting cable through cable
gland.
- The earth wire (open yellow) must be connected
to the earth pillar ( 4 >(see fig. 12).
- The live (brown) and neutral (blue) should be
connected as indicated into the tetial block.
- Check that component plugs are pushed home.
- Check for continuity, polarity and earthing.
11

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4. APPLICATIONS OF
THE BRITONY FLEXIFLUE
Do not use the appliance with push on hand showers
that fit over existing hot and cold water taps or with
mixer tans unless both sunnlied come from the
The appliance is designed to serve a variety of hot
water draw off points including washing machines
and showers. The appliance can be connected to all
hot water draw-off points in the installation. If more
than one outlet is open simultaneously the total ffow
of water cannot exceed that quoted in the Technical
Data.
The appliance is comptatible with most current auto-
matic washing machines but care should be taken to
ensure that the machine is capable of accepting
water at the design flow of the appliance. Hot and
cold fill machines normally require a hot water tem-
perature of 60” C (140 “F), the appliance producing
approximately 6.5 Enin (1.44 gpm) at this tempera-
ture. The advice of the washing machine manufactu-
rers should be sought but generally it is only neces-
sary to remove the water flow restrictor (if fitted) in
the hot water inlet connection of the machine to
obtain a satisfactory appliance operation.
same source. Showers fo&g part of bath mixers
are not recommended for satisfactory operation of
the appliance.
4.1 Pipework
The following notes are for general guidance only.
(i) The appliance performance may be affected if the
installation has old pipework forming dead-legs
or air reservoirs. Always ensure that any old pipe-
work is either removed or capped off immediate-
ly adjacent to the pipework that will be in use.
(ii) The-size of the pipework between the
appliance and the various draw-off points should
be sized to ensure an adequate ffow at draw-off
points when used individually.
(iii) A check should be made of all stop cocks in the
incoming supply and it should be ensured that
they are of the fixed jumper pattern. Loose jum-
pers can be pinned or soldered into the position.
Britony FlexiFlue
...............
................
................
................
................
................
.................................
................. T
.................
................
................. 3
................
................
................ I
................
................
................. s
................
.................
................
.................
................
................ -3
................
.................
,:.:.:.:.:.:.i;:.~.:.:.:.:.:.:.:, 8
Mixing Valve
................
.~.~.~.~.‘.‘.~.‘.~.~.~.~.~.~.~.~ 8
. . . . .1. ..... . . .
. . .... ... . .
...............................
HOT WATER
COLD WATER
HOT
COLD
The appliance can be used to supply hot water to a
d -- I. a **
SepaK3te SlIOWer ClraW-Off. lhe appliance should not
be used to supply more than one shower mixing
valve. The recommended pipework arrangement for
a single shower head is shown above and the hot
supply to the mixing valve should be the first draw
off. Suitable shower mixing valves are manufactured
by :
(ii) If the appliance is installed on a supply or distri-
bution pipe containing a non-return valve, combina-
tions of check valve, or any equipment containing
such devices, then provision must be hade to acco-
modate an expansion of at least 4 % of the volume
of water contained within the installation.
Caradon Mira Ltd Barking Grohe
Cromwell Road, 1 River Road
Cheltenham Barking
Gloucester GL52 5EP Essex IGl 1 OHD
Tel : [phone] Tel : [phone]
Aqualisa Products Ltd
Horton’s Way
London Road
Westerham
Kent TN16 1 BT
Tel : [phone]
Meynell Valves LTD,
Shaw Road
Bushburv
Wolverhampton
west Midlands
WV10 9LB
Ted: 01902-28621
New Team Ltd
Brunell Road
Earlstree Ind Estate,
Corby
Northants NN17 2L-F
Tel : [phone]
(V) Expansion vessels must be fitted on the supply
pipe between the non-return valve, combinations of
check valve, or any equipment containing such
devices and the appliance.
12
pipe between the non-return valve combinations of

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5.1 Putting into Service
5.1.4. When the pilot is lit turn the control knob
(A) fully anti-clockwise as shown in the dia-
gram. Test for gas soundness using leak detec-
tion ffuid on all gas connections (see fig. 14).
5.1.5. Check the operation of the flame
supervision device by blowing out the pilot
light, the flow of gas to the pilot will cease
and the thermoelectric valve should drop out
with an audible &i& within approximately
30 seconds.
5.1.8. Relight pilot and check gas pressures
see Section 5.2.
5.1.7; Remove gas control knob (A).
5.1.8. Switch off electrical supply.
5.1.9. Fit front case by locationg bottom iirst
and ensuring top of case locates over brac-
ket. Secure with 4 screws and washers pre-
viously removed.
- The centre screw and plastic washer retains
the fascia mounting bracket.
- Replace the control fascia plate by sliding
down onto the support bracket.
- Fit bottom trim by sliding onto rails.
Pig. 14
5.1.1. Open the gas and water service cocks beneath
the appliance, purge the gas supply (BS 689 1).
Turn on an adjacent tap and purge the water side of
the installation.
Test for water soundess at all appliance and external
pipework connections;
Switch on electrical supply, fan will run at low
speed.
5.1.2. Remove Protective Fii from casing before
use.
5.1.3. To fight the pilot temporality fit the gas
control knob (A) and light the pilot by turning the
knob 90” anti clockwise. It may be necessary to
purge the pilot gas supply, it so, wait a few minutes,
return the gas control knob to the OFF position and
repeat. (The pilot supply will only purge when the
gas control knob has been turned 90” anti-clockwi-
se), (see flg. 13).
- Fit the gas control knob (A) and the tempe-
rature selector knob (B). The temperature
selector knob should be pushed onto the
spline until it locates. Turn fully clockwise
to (+), reposition knob as required, so that
indicator dot is opposite the (+) sign.
5.1.10. Switch on electricial supply.
- Light the pilot and tum gas control knob (A)
fully anticockwise to, the main gas posi-
tion.
. If the pilot is now extinguished for only rea-
son return the gas control knob to the OFF
position and wait approwimately 30
seconds for the safety interlock to reset
before repeating.
5.1.11. Perform operations as detailed in
sections 5.3 to 5.7.
5.2 Gas Pressures
- Turn on an adjacent hot water draw off, the
appliance will now light and the fan will
change to high speed.
- Check burner setting pressure at test point A
see Section 1.3 technical data (see fig. 15).
- If the burner setting pressure is not correct,
check that the pressure at the gas service
cock, test point B is 20 mbar (8. in. w.g.)
with the appliance operating. If the inlet
pressure is not correct, check for any pos-
sible blockage or restriction in the pipe-
work to the appliance. If the inlet supply
pressure cannot be corrected contact your
local gas region. The heat input to the
appliance is pre-set and non-ajustable.
Pig. 15
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5.3 Slow Ignition
- Check burner ignition which should be smooth and
quiet (not explosive).
- If slow ignition requires adjustment proceed as in
Section 6.1 to remove front case.
- Adjust slow ignition device A (see iig. 16) l/4 turn
at a time. Reiit front case and recheck operation.
NOTE : Turning screw A clockwise delays ignition.
Pig. 16
5.4 Microswitch
NOTE : During Commisionning it is important that the correct operation of the microswitch on the side of the
gas section is checked.
Whilst the miaoswitch is factory set, it may require adjustment. When the appliance is at rest the fan runs conti-
nuously at low speed. Check operation as follows - set temperature selector to - then open draw-off. The fan
should now come to high speed before the burner ignites. On cloising draw-off, the burner should extinguish
before the fan resumes at low speed. If fanbumer operational sequence is NOT as described see Section 7.13.
5.5 The Pressure Switch
Check the operation of the pressure switch as follows : Open draw off, fan comes to high speed and the bur-
ner ignites. Close draw off,. burner extinguishes and when fan resumes at low speed listen for the “click” as the
relay changes over.This should be followed within 15 seconds by a lighter “click” as the pressure switck changes
over. If the time separation is greater than 15 seconds or if the pilot extinguishes it suggests that the pressure
switch is incorrectly set. (See Section 7.11).
5.6 Thermoelectric Ckuit
The Thermoelectric Circuit is &ted with an interrupter so that if the air flow is not proved on high speed the cir-
cuit is incomplete and the ffame supervision device will operate. In the case of intermittant pilot failure or per-
manent pilot failure the termocouple circuit can be checked with a British Gas Multimeter or suitable Millivolt
Meter to determine if the pilot failure is due to poor thermoucouple output, high resistance through Relay-l
contact or faulty themnoelectric valve. (See Section 2.9, iig. 1).
The thermocouple output measured at the Printed Circuit Board terminals should be greater than 12 millivofts.
The millivoltage drop through the relay (i.e. terminal to terminal) should not be greater than 4 millivolts.
5.7 Handing Over
Hand all instructions to the user or purchaser and instruct in the correct and safe operation of the appliance.
Explain to the user or purchaser that if the appliance is not used for long periods it is recommended that the
appliance is drained, this is particulary important during the winter months (see servicing instructions for pro-
cedure to drain appliance).
Finally, advice the user or purchaser that, for continued efiicient and safe operation of the appliance it is impor-
tant that servicing is carried out annually to the-manufactures recomendations by a C.O.R.G.I. registered person.
14

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6. ROUTINE SERVICING
To ensure continued efficient and sale operation of the appliance it is recommended that it is checked and serviced
as necessary at regular intervals. The frequency of servicing will depend upon the particular installation, condition
and usage, but in general once a year should be adequate.
It is the law that any service work must be carried out by a competant person, such as British Gas, other C.O.R.G.I.
registered personnel or your local Chaffoteaux Service Centre in accordance with the Gas Safety (Installation and
Use Regulations). This routine service will normally be confined to :
1) Cleaning the burner.
2) Cleaning the heat exchanger.
3) Checking the gas controls.
4) Cleaning water kilter, and water governor.
5) Check diaphragm and replace every three years.
The following schedules are recommended :
a) Check the function of appliance, burner pressure, gas ffow rate and soundness.
b) Observe flame picture and undertake combusion test.
c) Check clean or replace components as necessary.
6.1 Front Casing To
remove :
- Pull off gas control and temperature selector knobs.
- Remove controls facia plate by sliding upwards.
- Remove the four fixing saews which secure the front
case (top, bottom and centre) taking care not to lose
facia retaining bracket and washers.
- Remove to front case by lifting off the to locating lugs
and pulling forward to clear the water section at the
base of the appliance.
6.2 Burner
- Remove the combustion chamber front panel as fol-
lows.
- Remove two threaded saews which secure the front
panel of the combustion chamber skirt to the ilue
hood (A) Section 6.4.
- Remove three self-tapping saews on either side of
combustion chamber skirt (B) Section 6.4.
- Unscrew the pilot tube clamping screw (A) and remo-
ve the clamp and saew and pilot tube.
- Remove the burner manifold by unscrewing the two
screws and washers (C) (see fig. 17).
- Withdraw the burner head assembly taking care not
to damage the pilot burner/electrode assembly or the
ignition lead.
- The burner head should be turned upside down and
cleaned by brushing.
Pig. 17
6.3 Pilot
- Replace in reserve order making sure that the gasket
between the burner manifold and gas section is in
place and is in good condition. If necessary replace
gasket and ensure that the burner head assembly is
correctly located on the two spigots at the rear.
Pig. 18
A
- Remove combustion chamber front panel, burner
and pilot tube as in 6.2. if not already removed.
- Blow through the tube to remove any dust.
- Remove screw securing spark electrode. LiA out off
“D” slot and ease to one side.
- Unscrew the knurled pilot burner outer ring (A).
- Remove flame retention’gauze (see fig. 18).
- Unscrew the pilot body (B) with a 15 mm spanner.
Clean by brushing and blowing.
B
DO NOT CLEAN HOLES WITH A WIRE.
- Re-assemble in reverse order ensuring pilot body is
screwed down tightly.
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6.4 Heating Body
Rg. 19
a) The heat exchanger can be examked in position:
(see fig. 19)
- Remove combustion chamber front panel as in
Section 6.2. if not already removed. Prior to clea-
ning the heat exchanger adequate precaution
should be taken to protect the pilot burner/gas
valve assembly to prevent the ingress of dust etc.
- If extensive cleaning is necessary, the heat exchan-
ger will need to be removed as follows.
b) To remove heat exchanger
- Slide out combustion lining and retain.
- Disconnect the unions on either side of the heat
exchanger.
- Remove two screws securing the combustion
chamber/heating body assembly to the rear panel.
- Remove heat exchanger and combustion chamber.
- Remove two saews at the rear of the combustion
chamber securing the combustion chamber to the
heat exchanger to seperate the components.
Care should be taken when handling the heating
exchanger to ensure t&t the Bns are not damaged.
- Replace in reserve order.
6.5 Descalhg
Periodically it may be necessary to remove scale deposits from the waterways of the appliance to ensure conti-
nued and efficient operation.
The frequency will depend largely on the hardness of the water in each speciiic area. If this is necessary contact
your local water authority for advice.
Advice with regard to descaling is available from Chaffoteaux et Maury Ltd.
6.6 Main Gas Valve
To inspect and clean
- Remove the burner (see Section 6.2)
- Disconnect the thermocouple at the PCB and igni-
tor lead from the piezo unit.
- Remove the four saews and washers fastening the
top of the gas section to the base and the two
saews at the back holding it to the rear case.
- LiA the gas section top off the base, taking care not
to damage the cork gasket.
- Remove the hexagonal spring retainer (A) from the
top of the assembly (20 mm) (see fig. 20).
- Remove the spring and gas valve and clean the
valve seating (B).
- Renew facing rubber washer on the gas valve if
necessary.
- Grease spindle see Section 6.11.
Fig.20
- Replace in reverse order, ensuring that the hexago-
nal spring retaining nut is screwed fully down.
- Do not change the setting of the valve body.
16

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I
6.7 Water Governor
A
-
To clean
- Turn off the cold water supply to the appliance and
drain into receptable.
- Remove the governor situated in the base of the
water section (A) (see fig. 21).
- Clean the components with water and grease see
Section 6.11.
- Check that the spring loaded piston moves freely.
- Replace in reverse oder.
pg.21
6.8 Gas and Water Pihers
Gas and water Met filters a~ fitted between the
inlet service cocks and the appliance.
- To clean, turn off the gas supply at the meter and
the service cocks, unsaew the union nuts atta-
ching the cocks to the appliance and remove the
tilters (see iig. 22).
- Clean the filters by blowing or washing in water, DO
NOT USE ANY SOLVENTS.
- Replace ensuring that the coarse filter is fitted in the
water inlet and the fine iilter in the gas inlet.
- Turn on the gas supply and open both water and
gas service cocks.
- Test for soundness.
6.9 Microswitch
The miaoswitch operating mechanism is factory set and if the miaoswitch requires replacement or adjustment
see Section 5.4. and proceed as in Section 7.12 and 7.13.
6.10 Pressrrre switch
The pressure switch is factory set and it the pressure switch requires adjustment or replacement, see Section 5.5.
and proceed as in Section 7.10 and 7.11.
6.11 Greasing of Components
Care should be taken during the annual service of an appliance to grease the gas valve spindle (see Section 6.6)
water Governor (see Section 6.7) and the bearing plate spindle (see Section 7.5). Use silicone grease.
6.12 Heat Input
It is a requirement of the Gas Safety (Installation and Use) Regulations 1984 that the burner pressure and gas
rate are checked each time an appliance is serviced, likewise the service engineer should satisfy himself with
regard to gas soundness and the adequacy of combustion and ventilation air if this is appropriate.
The heat input is preset and non-adjustable.
The heat input and burner pressure should be checked (see Section 1.3).
If the heat input/burner pressure is not correct check the working pressure at the pressure test point on the gas
service cock. This should be 20 mbar (8 in wg).
The gas installation should be examined for any possible blockage if the pressure is incorrect.
17

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Before commencing any work involving component replacement :
1. Isolate electrical supply.
2. Turn off gas at the gas service cock.
3. Turn off water at the water inlet cock.
4. Drain the appliance by opening hot water outlet tap and removing the drain plug in the water service cock.
5. Remove the front casing (see Section 6.1).
7.1 Thermocouple
Ftg. 23
Ftg. 24
- Remove the burner (see Section 6.2).
- Remove the pilot (see Section 6.3).
- Trace the thermocouple and disconnect at the ter-
minal on the PCB.
- Disconnect at thermoelectric valce by undoing nut
(A) (see iig. 23).
-With a 7 mm boxspanner, unscrew the nut (B) holding
the thermocouple into the gas section (see fig. 24).
- Thread the thermocouple and wire up through the
gas section.
- Replace in reverse order.
7.2 Spark Electrode
-
Fig. 25
- Remove the burner (see Section 6.2).
- “;“s;““” the electrode retaining screw (A) (see iig.
- Pull off the electrode cable from the piezo cartridge.
- Liil the electrode out of the gas section.
- Re-assemble in reverse order, and note that the slot
in the connector on the end of the electrode cable
is vertical when pushed onto the cartridge.
NOTE : Spark gap is 3-5 mm..
7.3 ThermoeIectric vaIve
Fig. 26
- To renew, remove the thermocouple conductor
lead nut (A) (see fig 26).
- Unscrew cap (B) from the side of the gas section
and withdraw the thermoelectric valve.
NOTE : This heater is fitted with a safety interlock.
When the pilot is turned off, the appliance cannot be
relit until the thermocouple cools down and the ligh-
ting sequence is repeated.
7.4 Water Section Ventufi
- Disconnect the right hand heating body leg from the
water section and remove the venturi (A) (see fig 27).
Clean or replace as necessary and the re-assemble
in reverse order.
Fig. 27 , 18

Supplied By www.heating spares.co Tel. [phone]
7.5 Diaphragm
- To renew ensure that the cold water supply and gas
are turned off.
- Drain the appliance by removing the water gover-
nor plug situated in the base of the water section
(see Section 6.7).
- Disconnect the two water connections at the water
section.
- Unscrew the six screws (A) which hold the water
section to the gas section (see fig. 28).
- Remove the water section complete with the dia-
phragm.
- Remove bearing plate and spindle and grease, (see
Section 6.11).
- Carefully remove and inspect the plastic water sec-
tion top cover.
- Re-assemble in reverse order.
Fig.28
NOTE : Fit the water governor last. It is easier if the
cold water inlet connection is partially engaged befo-
re iitting the screws and reconnecting the union nuts.
7.6 Piezo Unit Cartridge
- Disconnect the spark electrode lead from the piezo
unit cartridge.
- Remove the screw holding the gas control cam and
remove the cam (A) (see iig. 29).
- Remove the two screws (B) holding the retaining
plate.
- Remove the piezo cartridge and renew.
- On reassembling ensure that the locating pins on
each end of the spring are correctly engaged in
their location holes.
7.7 Fan Assembly
EARTH Yelbw - Green
UT Red
Rg.30
- Disconnect electrical connectors from assembly.
Note positions.
- Remove the two screws and washers (A) securing
the fan assembly to the ilue hood (see iig. 30).
- Release wiring loom from support clip.
- Gently ease the fan assembly away from the flue
hood disengaging lug at rear of fan assembly.
- Re-assemble in reverse order.
Note : The dimension - back plate to front face of
impeller is : -57.5 mm +0.5 mm -0.0 mm.
19