CHAFFOTEAUX Corvec SH12 Release note

chaffsteaux ltd.
chaffoteaux
et Maury m
SHE!
installati
servicinginstructions

contents
Page3 :TECHNICAL DATA
Pages4 and 5 :INSTALLATION
Pages6 and 7 : SERVICING INSTRUCTIONS
Pages8 and 9 : FAULT FINDING CHART FOR
SH 12 SHOWER HEATER
Page 10 : SHORT LIST
GENERAL
The CORVEC SH 12 is a.balanced-flued instantaneous gas fired shower heater. It has been specifi-
cally designed to be used with a shower, and be connected directly to the mains cold water supply.
No purpose provided ventilation is required for the SH 12. It should be installed adjacent to the
proposed shower location providing that the terminal is positioned as recommended in the appro-
priate section of these instructions.
The installation of the shower heater must be in accordance with the relevant requirements of the
Gas Safety Regulations, Building Regulations and the Byelaws of the local Water Undertaking. It
should be in accordance also with any relevant requirements of the local gasregion and local autho-
rity, and the relevant recommendations of the following British Standard Codes of Practice :
CP 33 1 Installation of pipes and meters for town gas
Part 3 Low pressure installation pipes
CP 333 Selection and installation of town gashot water supplies
Part 1 Domestic premises
BS 5440 Flues and air supply for gas appliances of rated input not exceeding 60 kW (1st and 2nd
family gases)
Part 1 Flues
2

technicaldata
NATURAL GAS TABLE 1
Heat input ............................... 11.3 kW 38,600 Btu/h
Heat output .............................. 8.5 kW 29,000 Btu/h
Gasrate ................................ 1.08 m3/h 38.14 ft3/h
Burner pressure ........................... 12.7 mbar 5.1 inswg.
Main burner injectors marking .................. 113 113
Pilot burner injectors marking .................. 25 25
Waterflowrate-raised20oC(360F) ............ 380 l/h 1.39 gpm.
Waterflowrate-raised35oC(63oF) ............ 215 l/h 0.79 g-pm.
Minimum water pressure(heater only) ............ 0.5 bar 7.5 lb/in2
Maximum water pressure ..................... 10 bar 150 lb/in2
Note : The minimum water pressure is for the correct operation of the heater only. An additional allowance
must be made for the resistance of the shower and associatedpipework and fittings. This should be apprM-
mately O-2bar (3 1b/in2).
Water j.&$ ................. 1............ Right hand 15 mm copper
connection
Water outlet ............................. Left hand 15 mm copper
connection
Gas ................................... Centre 15 mm copper
connection
Height 23.6 ius
................................. 600 mm
Width.............-......-..-.-.....- 10.5 ins
.. 267 mm
Depth .................................. 210 mm 8.25 ins
Weight 10.7 kg 23.5 lbs .................................
Spacefor fixing Top 100 mm 4.0 ins
........................
Spacefor fixing Bottom 152mm 6.0 ins
......................
SpaceforfixingSides ....................... NIL NIL
SpaceforfigFront 130mm 5.1 ins
.......................
HOLE FOR WALL LINER
Width..........-...................-.-.
Height ................................. 240mm 9.5 ins
4.9 ins
125 mm
WALL THICKNESS
Standard flue set .......................... 75-355 mm 3-14 ins
Extra available 75610 mm 3-24 ins
............................
3
3

installation
The SH 12 is supplied in two cartons, one containing the
heater, the other containing the flue set and shower fittings.
INSTALLING THE BALANCED FLUE
The standard flue set is suitable for walls having athickness
of 75 mm (3 in) to 355 mm (14 in). A flue set for wall
thicknesses up to 610 mm (24 in) is available to special
order.
Detailed recommendations for flueing are given in BS
5440 : 1. The following notes are intended to give general
guidance.
The shower heater must be installed so that the flue ter-
minal is exposed to the external air.
Termination should be on a clear expanse of wall ; the
terminal being preferably not lessthan 600 mm (2 ft) away
from a corner, recessor projection.
DO NOT install the terminal :
a) within 300 mm (1 ft), measured vertically, from the
bottom of an openable window, air vent or any other
ventilation opening.
b) within 300 mm (1 ft) above adjacent ground level.
C) within 600 mm (2 ft) of any surface facing the terminal.
d) immediately beneath eavesor abalcony.
Where the lowest part of the terminal is less than 2 m
(6.6 ft) above the level of any ground, balcony, flat roof or
place to which any person hasaccessand which adjoins the
wall in which the terminal is situated, the terminal must be
protected by aguard of durable material. (A terminal guard
may be obtained from Chaffoteaux Limited).
The air inlet, products outlet duct and the terminal of the
heater must be not closer than 50 mm (2 in) to combustible
material. Detailed recommendations on protection of
combustible material aregiven in BS 5440 : 1.
Preparing the Wall
The heater should be installed on a wah of flat noncom-
bustible material that will not reverberate. Whatever the
thickness of the wall, make a hole 240 mm (9.5 ins)
wide x 125 mm (4.9 ins) high. If the hole is cut accurately
there is no need to line it, since the wall liner will seal
off the cavity.
A II$&N,M clearance of 75 mm (3.0 in) should be left
above the top of the wall opening. No allowance is neces-
sary at the side of the heater. For dimensions see Dia-
gramPage2.
Slide the wall liner through the wall ensuring that it is
horizontal and that the flanged end is flush with the face of
the wall. Trim to length if necessary, so that the outer end
of the liner is level with the face of the outside wall. Make
good around the wall liner (fig. 1).
FITTING THE TERMINAL
The terminal is fitted from the outside of the building by
fixing the two spring loaded chains over the hooks on the
inside of the wall liner (fig. 2). If the chains can not be
fitted to the hooks, fit them into the slots on the flue
bend brackets. Turn the hook through 900 if necessary.
If access to the outside of the building is difficult, the
terminal can be raised on a length of string and the chains
attached from the inside. If this procedure is adopted, it
must be ensured that there is no risk of damage to the
terminal, the building, or danger to persons in or about
the building.
INSTALLING THE HEATER
The heater is attached to the wall by 2 studs at the top and
2 screws at the bottom. These are supplied with the gas
service tap and foam gasket, and packed in abox placed in
the flue outlet.
Remove the front case, place the heater in position and
mark the fixing holes. Drill and plug the wall, and fasten
the wall studs in position. These studs can be screwedin the
wall by fast locking two nuts together on the parallel
thread and then use a spanner. Attach the self adhesive
foam gasket to the flat surface of the heater around the air
inlet spigot on the heater. Pull off the protective paper
while sticking down the gasket. Lift the heater into position
on the wall, locating on the studs and the air inlet spigot
into the wall liner. Securethe heater to the wall using the
nuts, washers and wood screws supplied. Unscrew the
screws A (frg. 3), then lift off the flue bend. Slide the flue
duct through the rectangular hole in the wall box and
engage it into the terminal by at least 25 mm (1 in), and
onto the flue bend as far as it will go. The duct must be
cut to length where necessary(fig. 4). Replace the screws
securing the flue bend.
GAS CONNECTION
The gas service tap supplied should be fitted to the centre
connection below the heater using the “filter washer”. A
15 mm dia. copper tail is also provided for direct fixing to
the gassupply
Fig. I
4
Fig. 2

installation
“ATER CONNECTIONS
The installation of the water supply to the shower must be
in accordance with the relevant requirements of the Bye-
laws of the local Water Undertaking. The cold water con-
nection to the heater is on the right with the hot flow on
the left. The connections on the heater are 15 mm copper
tubing. Seediagram Page2.
The heater is supplied with the water outlet connection at
the bottom. This can be changed to a top outlet by remo-
ving the outlet bend and replacing it with the short bend
supplied in the accessory box (fjs. 5). The blanking disc
fitted to the top of the heater should be transferred to the
base and the sealing ring and disc transferred to the top.
A Water Council approved Servicetap must be fitted in the
cold mains water supply to the heater. It must be a type
having a fixed jumper washer. This tap is not supplied by
Chaffoteaux Limited.
&STALLING THE SHOWER
The shower set consists of :
- Handset
NOTE - In accordance with the requirements of Water
Byelaws, the installer of a shower which is supplied with
water direct from a water servicepipe and which incorpora-
tes a shower outlet with aflexible connection, must ensure
that the shower outlet cannot reach a level lower than
13 mm (l/2 in) above the spill-over level of the receptacle
that receivesthe water from the shower.
- Thread the flexible shower hosethrough the retainer and
attach at one end to the tap, and the other to the
handset.
PUTTING INTO SERVICE
- Open the gas and water service taps. Purge the gas and
water supplies. Check for gas and water soundness.
- Fit the gas control knob and light the pilot by turning
90° anti-clockwise. It may be necessaryto wait for the
pilot to purge, if so, wait a few moments then turn to
the “off” position and repeat.
- Turn the gas control fully anti-clockwise to the main
gasposition.
- Turn on the shower, the heater will now light.
- Handset holder and bracket
- Hose and washers
- Check for gas soundnessaround heater gas components
using senseof smell and leak detection fluid.
Check the burner pressure by fitting a gauge on to the
- Hoseretainer pressure test point on the end of the burner manifold.
- Control tap 15 mm compression x l/2” BSP
The correct pressure is given in Table 1, Page3. If the
pressure is not correct, check the pressure at the meter
outlet. This should be 20 mbar (8 ins wg.), the gas
installation should be examined for any possible
blockage if the pressure is not correct. If the pressure is
- Secure the control tap to the wall in a suitable position not correct, consult the local gasregion. The heat input
adjacent to the shower. Connect the pipe from the is preset and non-adjustable.
SH 12to thetap.
- Insert a screwdriver into the slot on the back of the
handset holder and twist to detach the bracket _ - Remove the gascontrol knob.
- Fix the bracket in the required position with the arrow - Replace the front case, gas control knob and water
pointing UP. temperature selector knob. The temperature selector
spindle should be screwed fully in, and the knob then
- Replace the handset holder onto the bracket, slide it
downward and snapinto position. positioned opposite the word “hot”.
- Hand the User’s Instructions to the consumer and
- Position the hose retainer in a similar manner. instruct in the safe operation of the shower heater.
Fig. 3 Fig. 4
5
Fig. 5
Water
INSTALLING

servicinginstructions
Turn off the gas at the gas inlet tap on the appliance and
water at the inlet water service tap commencing servicing.
1) Front Casing
- To remove, pull off the gas control and temperature
control knobs.
- Unscrew the centre fixing screwon the front of the case,
also the top and bottom fixing screws.
- Pull off the case taking care not to loose the rubber
spacerbehind the centre fixing point.
2) Burner (fig. 6).
- Unscrew the pilot tube clamping screw A. and remove
clamp and tube.
- Remove burner manifold by unscrewing fixing screwsB.
- Pull burner head assembly forward to remove, take care
not to trap the thermocouple or ignitor wires.
- The burner headscan be cleaned by brushing.
- Replace in reverse order, make sure that the gasket
between the manifold and the gassection is in place and
that the burner head assembly is correctly located on the
spigot at the rear.
3) Heating Body s/1,
- With the burner and flue bend removed, the heating
body can be inspected and cleaned in position.
- TO remove, drain the heater by unscrewing the water
governor A (fg. lo), collecting the water in a basin
below the heater.
- Remove the burner, seeSection 2.
- Remove the screw holding the bottom of the heating
body skirt to the rear case.
- Releasethe two union nuts joining the heating body legs
to the water section.
- Remove the heating body.
- Clean the heating body by brushing with hot water and
detergent.
- Reassemble in reverse order, do not forget to replace
the skirt fixing screw and reinforcing strip.
4) Pilot
- unscrew the pilot tube clamping screw A (fig. 7) and
remove the clamp and tube.
- Blow through the tube to remove any dust.
- Remove the burner, seesection 2.
- Unscrew the knurled pilot burner outer ring A (fig. 7).
- Unscrew the pilot body B with a 15 mm spanner. It may
be necessary to remove the heating body. Clean by
blowing or washing in water. Do not clean the holes
withawire.
- Blow any dust out of the gassection.
- Re-assemblein reverseorder.
5) Thermocouple (fig. 8).
- Remove the burner, seeSection 2.
- Remove the pilot, seeSection 4.
- Unscrew the thermocouple nut D from the thermo-
electric valve and remove it from the wire (fig. 6).
- With a 7 mm box spanner, unscrew the nut E holding
the thermocouple into the gassection.
- Thread the thermocouple and wire up through the gas
section.
- Replace in reverseorder.
6) Spark Electrode (fip .8).
- Remove the burner, seeSection 2.
- Remove the electrode fixing screw F with a screwdriver
placed inside the heating body skirt.
- Pull off the electrode cable from the piezo cartridge.
- Lift the electrode out of the gassection.
- Reassemble in reverse order, and note that the slot in
the connector on the end of the electrode cable is verti-
cal when pushed onto the cartridge.
7) Thermoelectric Vabe
- To replace, remove the thermocouple nut A (fii. 9).
- Unscrew cap 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 heater can not be relit until the
thermocouple cools down and the lighting sequence is
repeated.
Fig. 6 Fig. 7
6
Fig. 8

servicinginstructions
Main Gasvaive
- To inspect and clean, remove burner.
- Disconnect the thermocouple and the ignitor lead.
- Remove the four fixing screwsfastening the top of the
gas section to the base B (fig. 9). Also the two screws
at the back holding it to the rear case.
- Lift the gassection top off the base.
- Remove the gasvalve spring.
- Lift out the gasvalve.
- Cleanthe valve seating.
- Replace the facing rubber if necessary.
- Replace in reverseorder.
“j Diaphragm (fii . 10).
- To replace, turn off the cold water supply and gas.
- Dram the heater by removing the water governor plug A
situated in the base of the water section.
- Unscrew the four water unions B on the water section.
- Unscrew the six screws C holding the water section to
the gassection.
- Remove the water section complete with the diaphragm
and bearing plate.
- Replace in reverseorder - NOTE - fit the water governor
last. It is easier if the cold water inlet connection is
partially engaged before ftiing the screws and re-
connecting the union nuts.
10) Water Governor
To clean, turn off the cold water supply to the heater.
- Remove the governor situated in the baseof the water
section.
- Cleanthe components with water.
- Check that the spring loaded piston moves freely.
- Replace in reverseorder.
Fig. 9
11) GasFilter (fg. 11).
A gas filter is fitted between the gas service tap and the
heater.
- To clean, turn off the gasat the servicetap.
- Unscrew the union nut attaching the tap to the heater.
- Lower the union nut and withdraw the filter which
also acts asa washer.
- Clean the filter by blowing or washing in water, do not
use solvents since the filter is made of nylon and may
disolve.
- Replace in reverseorder.
12) Heat Input
The heat input is preset and non-adjustable. The heat input
and burner pressure should be checked against Table 1. If
the heat input/burner pressure is not correct, check the
working pressure at the pressure test point on the gas
service tap. This should be 20 mbar (8 ins. wg.). The gas
installation should be examined for any possible blockage
if the pressureis incorrect.
RECOMMENDED SERVICING SCHEDULE
For efficient and trouble free operation, it is recommended
that this heater is serviced annually. The following work
should be carried out by a competent person.
1) Cleanthe burner.
2) Clean the heating body by brushing.
3) In hard water areasit may be necessaryto descalethe
heating body. Use a solution consisting of 5 parts water
to 1 part hydrochloric acid. The water should preferably
be hot - ADD ACID TO WATER, NOT WATER
TO ACID.
4) Clean the pilot and thermocouple.
5) Clean the gasfilter.
6) Clean the water governor.
7) Changethe diaphragm every three years.
Fig, 10
7
Fig. 11

FAULT FINDING CHART FOR SH12 SHOWER HEATER
PROBLEM CAUSE REMEDY
PILOTFLAME DOESNOT
LIGHT
i) Gasservice tap closed
i i) Air in pipe
i i i) Pilot injector blocked
-
Open servicetap
Purge line
Clean or change
POOR PILOT FLAME i) Pilot injector dirty/damaged
i i) Wrong injector
i i i) Pilot head blocked
i v) Faulty pilot tube
Clean or change
Changefor correct diameter
Clean
Clean or replace
PILOT WILL NOT
STAY ALIGHT i) Thermocouple not working i i) Thermoelectric valve faulty
i i i) Gaspressurelow/variable
i v) Terminal wrongly positioned
v) Badly assembledflue
v i) Gaspressuretoo high
v i i) Water rate too high
v i i i) Incorrect venturi
i xj No venturi fitted
Changethermocouple
Changevalve
Check at inlet to heater
Reposition heater
Refit - Check sealing
Check working pressureat meter
Check water governor
Replace
Fit
Mi4IN BURNER DOES NOT
LIGHT/MAIN BURNER i) Gasservice tap not open fully i i) Gaspressurelow
i i i) Water rate low
i v) Gasvalve push rod jammed
v) Diaphragm punctured
vi) Venturi blocked or loose
v i i) Gas control tap faulty
v i i i) Injector size
Open fully
Check at manifold and at inlet
with heater running
Check if water rate is sufficient (page 3)
Clean rod
Changediaphragm
Check venturi
Check operation of User’sgascontrol
tap
Check burner injectors are for natural
gas 1.13 mm diameter
EXPLOSIVE IGNITION i) Pilot Check length and clean injector
GAS TAP STIFF i) Greasedried Clean and regrease
i i) Operating mechanism replaced incorrect Refit
WATER TEMPERATURE LOW i) Water rate too high Check water regulator rate
i i) Insufficient gasflow Check rate and user’s
tap is open
i i i) Water governor sticking Remove and clean or replace
8

FAULT FINDING CHART FOR SH12 SHOWER HEATER
PROBLEM
BURNER STAYS ON
CAUSE
i) Air in hot pipe
i i) Gasvalve spindle jammed
i i i) Venturi blocked
i v) Gasvalve “letting by”
v) Loosejumper on house stop tap
v i) Dead-legon system
v i i) Dirt in water section
REMEDY
Purge line
Clean spindle
Remove and clean
Changevalvefacing
Replace water stop tap or pm down
jumper
Vent or remove
Cleanwater section
YELLOW FLAMES
SOOT FORMED i) Heating body fins blocked
i i) Primary air supply restricted
i i i) Wrong injectors
Remove heating body and clean
Check manifold
Check gastype and injector
UNSTABLE FLAMES
HEATING BODY NOISE
i) Water in gasline
i i) Faulty flue
i) Scale
i i) Excessivegas
Purge
Check terminal position and flue ducts
Des&e heating body
Check gaspressure
INSUFFICIENT WATER FLOW i) Water servicetap partly closed
i i) Blocked venturi
i ii) Low water pressure
i v) Water governor faulty
v) Water governor sticking
v i) Foreign matter m,water section
HEATER “SMELLS’ FROM
INSIDE BUILDING
HEATER “SMELLS’ FROM
OUTSIDE BUILDING AT
POINT OF TERMINATION
1HIGH WATER FLOW
i) Appliance newness
i i) Heater casenot fitted correctly
i i i) Defective sealingaround heater case
i) Gasrate too high
i i) Blocked flue
i i i) Insufficient aeration
i v) Delayed ignition due to poor pilot flame
v) Heater casenot fitted correctly
v i) Defective sealingaround heater case
i) Water governor sticking
Check it is fully opened
Remove and clean venturi
Check water pressure
Changegovernor
Remove and clean or replace
Remove and clean
Smell will go within a short period of
time
Fit casecorrectly
Replace sealingstrip
Adjust gasrate
Check and remove blockage
Check primary aeration
Seeremedy for “poor pilot flame”
Fit casecorrectly
Replace sealingstrip
Replace
9

Shortlist
61 77 76 75
126 122
KEY
No
1
16
17
61
69
70
71
72
73
74
75
76
77
78
122
126
166
G C No DESCRIPTION
263 487
263 488
263 489
366 096
366 160
263 545
366 152
263 365
387 251
387 252
262 544
Front CaseAssembly (not illustrated) ................
GasControl Knob .............................
Temperature Selector Knob .......................
GasketWallLmertoRearCase .....................
WallFixingScrew .............................
Wall Fixing Stud. ..............................
NutM7 ....................................
Washer .....................................
GasService Tap ...............................
GasFilter ...................................
Copper Tail ..................................
Nut .......................................
Washer .....................................
Adaptor Bend for Top Outlet ......................
Thermocouple Assembly .........................
Electrode & Lead Assembly. .......................
Diaphragm ..................................
No MARKERS
OFF PART No
1
38741
1 36246
1 36732
1 29091
2 25617
2 5787
2 29094
4 5369
1 31281
1 37309
1 20677
1 20747/ 14
1 22835114
1 26103
1 35087
1 34239
1 18197/30
CHAFFOTEAUX LIMITED
Concord House - Brighton Road
Salfords - Redhill
SURREY RH15 DX
TCl : 02934 - 72744

ESP002