CHAFFOTEAUX Celt Star Series User guide

Celt Star
Celt Star 1F HP
Model 1F HP GC N” 51.980.29
1F LP GC. N” 51.980.30
2 F HP GC. N” 51.980.31
2 F LP GC. N” 51.980.32
installation and
servicing instructions
(leave these instructions with the User)
The model no. and serial no. of this heater are on the data badge which is found
hanging at the rear left hand side beneath the appliance. These numbers should be used
when ordering replacement parts.
chaffoteau%
Looking Good. Heating Better

1.0 GENERAL
The CELTSTARisa gasfired instantaneous water heater.
It is designed to deliver hot water through a swivel spout or to a hot water tap at a sink or basin (I F).A remote
model is also available(2 F).A high pressure model is for use directly off the mains, a low pressure model is sup-
plied for use off a tank supply.
The appliance features an atmosphere sensing device which will turn off the gas supply to the pilot and burner,
when the oxygen in the atmosphere in the locality of the heater becomes diminished and is unable to support
safe combustion. It also protects the user if the heat exchanger fins become blocked.
Also included inthe appliance isa scalereducer.
Four models are available:
Spout model Highpressure IF HP GCN”. 51 980 29
Spout model Lowpressure IF LP GCN”. 51 980 30
Remote model Highpressure 2F HP GCN”. 51 980 31
Remote model Low pressure 2F LP GCN”. 51 980 32
1.1
GUaratltee 12 months’ from date of installation.
The guarantee on this appliance isvoid if it is not installed in accordance with the recommendations made herein
or in a manner approved by the manufacturer.
Dimensions Fig. 1
Bracket e-l
Fixing Screw 1
J
D
Remote outlet
2

1.2
1.3
/
1.4
Technical Data
NATURAL GAS TABLE 1
Heat input Nominal
Heatoutput Nominal ., . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasrate (maximum)
Burner pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mainburner injectors marking
Pilot injector marking
Restrictor . . . . . . . . . . . . .
Water flow raised 50 “C (90 “F)
Water flow rate raised 25 “C (47 “F)
Minimum operating head for high pressure (HP)models
Maximum operating head for high pressure (HP)models
Minimum operating head for low pressure (LP)models.
Maximum operating head for low pressure (LPImodels
11.6 kW
8.7 kW
1.095 m3/h
5.1 mbar
1.28
26
2.7 mm
2.5 Vmin
5.0 L/min
0.50 bar
10.0 bar
1.0 m
25 m
39,580 Btu/h
29,600 Btu/h
38.67 ft3/h
2.0 in wg
0.55 gpm
1.1 gpm
7.25 psi
145 psi
3.28 ft
82 ft
Note : The minimum water pressure isfor the correct operation of the heater only. An additional allowance must
be made for the resistance of the pipework and fittings.
Connections
Water inlet.
Water outlet
Gas
Weight
15 mm copper
SwivelSpout
(IF model)and/or
15 mm copper
remote (2Fmodel)
15 mm copper
8.2 kg 18.1 lb
Minimum clearance required for installation and servicing :
Top.. ........................
Bottom ......................
Sides.........................
Front ........................
600 mm 24 in
50 mm 2 in
75 mm 3 in
250 mm 10 in
1.5
This appliance is for use on Natural gas and must not be used on any other Gas.
IF MODEL 2F MODEL
This heater is designed for installation over the sink
to deliver hot water either through a swivel spout or The remote model is designed for direct connection
to the tap These heaters must NOTbe connected to
to a hot water tap at a sink or basin. a bath hot water draw off.
3

2.
2.1
INSTALLATION REQUIREMENTS
Related Documents 2.5 Description of Operation
The installation of the heater must be in accordance with
the relevant requirements of the GasSafety (Installation
and Use) Regulations, Building Regulations and the Bye-
lawsof the localWater Undertaking. It should be in accor-
dance also with any relevant requirements of the local
gas region and local authority, and the relevant recom-
of Special components
2.5.1 Atmosphere Sensitive Pilot
The primary air for the pilot is entrained via a tube from
the combustion chamber. When the oxygen in the atmos-
mendations of the following British Standard Codes of phere in the locality of the heater becomes diminished
Practice : and isunable to support safe combustion it causesthe pi-
CP331 Installation of pipesand meters for town gas
Part 3 Low pressure installation pipes lot to change shape, Under these conditions the thermo-
couple is in a cooler part of the flame the millivolt output
isreduced causingthe thermoelectric valve to drop out.
BS5546 Installation of gas hot water suppliesfor domes-
tic purposes (secondfamily gases) 2.5.2 Scale Reducer
BS5440 Fluesand air supply for gas appliances of rated
input not exceeding 60 kW (1st and 2nd family
gases)
Part 1 Flues
Part 2 Air Supply
The scale reducer ISa diaphragm vessel forming part of
the water section. At the termination of a demand cycle
the contents of the heat exchanger are displaced into the
vessel.
2.3 Air Supply 2.6 Flue
important : This heater should be used in a well ventila- These appliances are flueless. Protection is provided in
ted room. An air vent direct to outside is required of not the form of the atmosphere sensitive pilot (see Section
less than 35 cm* free area, plus an openable window in 2.5.1.).
the room or internal space in which it is installed. These
heaters must NOTbe fitted in a spacewhere the total vo- They must not be operated continuously for more than
five minutes.
lume islessthan 6 m3.
This water heater is fitted with an atmospheric sensing
device which will turn off the gas supply to the pilot and
burner, when the oxygen in the atmosphere in the locali-
ty of the heater is diminished and will not supr crt safe
combustion. It also protects the user if the heat I xchan-
ger fins become blocked.
It is therefore important that the heater is not located
over a cooker or in a position where the air supply is res-
tricted or contaminated.
The location must also permit space for servicing and air
circulation around the appliance.
2.4 Gas Supply
An adequate sized gas meter must be connected to the
service pipe. Where necessarythe localGasRegionwill ar-
range for the existing meter to be checked or for a suita-
ble meter to be installed. On no account must any work
be carried out on the gas meter other than by the local
GasRegionor their specifically authorised contractor.
Installation pipes should be fitted in accordance with
CP,331:3.Pipework from the meter must be of adequate
size. Pipes of a smaller size than the gas connection
should be not used.
The complete installation must be tested for gas sound-
nessand purged in accordance with CP,331:3.
In addition to any other gas appliance installed in the pre-
mises, the meter should be capable of passing : 40 cu,
ft/h of natural gas.
support safe
exchan-

3.0
3.1
3.2
INSTALLING THE APPLIANCE
A vertical flat area of 1065 mm (42”) x 396 mm (14 1/4”)is required for the appliance.
If the heater isto be fitted to a wall likely to be affected by heat the wall MUSTbe protected by a sheet of incom-
bustible materiel which will not reverberate.
When selecting a position for the appliance there must be a minimum clearance of 600 mm 124in) between the
top of the appliance and a ceiling.
Packaging - See Short List Diagram on page 20
The carton contains the following :
a) 1x heater
bl 1x set of knobs
c) 1x set of fittings, consisting of :
- 3/8” nut, cap, blanking discand washer,
- 3/8” nut and 15 mm bend for remote connection (2 F models only),
- 112”nut, gasservice cock, metal/rubber washer, 15 mm bend for gas connection,
- 1/2”water service cock, 15 mm bend, I/*” nut and fibre washer,
- 4 x HEXhead screws for casefixing, mounting bracket,
- 2 x spire clips.
2” x No, 12 wood screw and metal washer.
d) 1x pack containing front and side panels,
e) 1x IO” (250 mm) soout and washer.
Preparing and fitting the appliance
a) Selecta suitable position for the heater.
b) Usingthe dimensions in Section 1.2 mark the fixing position for the bracket.
Note : Checkthat the minimum clearancesare maintained see 1.4
c) Drilland plug the wall and attach the fixing bracket using the screw and large metal washer provided.
d) Attach the gas and water connection fittings to the heater before hanging it on the wall bracket and connec-
ting to the supplies.

3.4
3.5
Spout (I F model only)
Gas connection
Fig. 2
The heater is provided with a gas inlet bend suitable
for connecting to 15 mm copper pipe and can be used
with either capillary or compression fittings,
Ensurethat the pipe is clean before connecting to the
heater. A gas service cock isprovided for fitting at the
rear of the heater. Fasten the gas bend to the gas
service cock using the metal/rubber washer.
Test the complete installation for gas soundness and
purge (CP331;3).
Water connection
Fig. 3
The water inlet is suitable for connection to a 15 mm
copper supply pipe and can be used with either capilla-
ry or compression fittings, The low pressure model
can be fed from atank. The high pressure model must
be connected to the mains supply.
The connection to the water section is made as
shown. Use the fibre washer when connecting the
copper bend to the water service cock (fig. 3).
1 F model : Fit the blanking cap to the remote outlet
bend connection using the cap blanking
discand washer provided (fig. 4a).
2 F model : Fit the remote outlet bend using the fibre
washer provided (fig. 4bL
The distance from the heater to the remote outlet
should not exceed 20 feet.
Fig. 4a
Note : When using the 1 F model it is possible in addi-
tion to the spout to supply a remote outlet. A remote
outlet bend is supplied and is fitted in place of the
blanking disc (fig. 4) however permission from the lo-
cal Water Authority must be obtained before connec-
ting the HPmodels of the heater to the main supply.
Ensurethat all water connections are fully tightened.
Test pipework for soundness.
Fig. 4b
Fit the spout to the base of the water section using
the washer supplied.
6

4. COMMISSIONING
Open the gas and water service taps (see fig. 6a). Purge
the gas and water supplies. Check for gas and water
soundness.
Fit the gas and water control knobs and light the pilot by
turning 90” anti-clockwise. It way be necessaryto wait for
the pilot to purge, if so,wait a few moments then turn to
the ‘off’ position and repeat.
When the pilot isalight wait 10 secondsthen turn the gas
control fully anti-clockwise to the main gas position.
Turn on the hot tap, the heater will now light.
Check for gas soundness on appliance gas carrying com-
ponents Turn off the gas control knob.
Check the burner pressure by removing the screw from
the pressure test point (A) (fig. 5) on the end of the bur-
ner manifold. Attach a suitable pressure gauge. Light the
appliance and check the pressure. The correct pressure is
given in table 1, page 2. If the pressure is not correct,
check the pressure at the meter. The gas installation
should be examined for any possible blockage if the pres-
sure is not correct. The heat input is pre-set and non-
adjustable.
Turn off at the gascontrol knob, remove pressure gauge,
replace the test point screw, relight and check for gas
soundness around the screw.
Remove screw on left hand side of combustion chamber
to allow the data badge to suspend freely. Replacescrew.
4.1 To fit casing (fig. 6)
a) Removethe control knobs.
b) Screw plastic spacer tube onto temperature selector
spindle guide.
c) Hang the side panels from the top deflector plate en-
suring they are engaged in the slots provided (A) (fig.
6).
d) Fasten the rear of each panel to the chassis at the
bottom (B)(fig. 6) using the screws provided and spire
clipsprovided (C).
e) Attach the front panel to the side panels in the same
manner.
Replacethe gas control knob, and water tap knobs. The
temperature selector spindle should be screwed fully
clockwise, the knob pushed on with the indicator at the +
position.
Fig. 5
Fig. 6
Fig. 6 a
Gas service tap
Water service tap
7

Checkthe operation of the flame failure device :
a) By blowing out the pilot The flow of gas to the pilot
will cease and the thermoelectric valve should drop
out with an audible click,within approx 30 seconds.
b) With the water running mask the top of the deflector
using a large pan or similar metal plate (fig. 7a).The pi-
lot and main gasshould extinguish within 15 seconds.
4.3 TOcheck the thermocouple (fig.7)
Check with a BGCmultimeter or suitable millivolt meter
to determine the thermocouple output under two condi-
tions :
4.2 Flame failure device I
a) When operating normally - output should be 14 mv or
greater.
b) When the deflector is obscured the thermoelectric
valve should closeat 5,5 mv.
4.4 Handing over
Hand the Instructions for Use to the consumer and ins-
truct inthe correct and safe operation of the heater.
Explain to the user or purchaser that if the appliance is
not used for long periods it is recommended that the ap-
pliance isdrained. This is particularly important during the
winter months (see servicing instructions for procedure
to drain appliance).
Finally, advise the user or purchaser that, for continued
efficient and safe operation of the appliance it is impor-
tant that adequate servicing is carried out at regular in-
tervals
Fig. 7
Fig. 7 a
/
deflector
metal Plate
-------------

6. SERVICING INSTRUCTIONS
6.1 1 Heat input
It isa requirement of the GasSafety (Installation and Use)Regulations 1984 that the burner pressure and gas rate
are checked eachtime the appliance isserviced, likewisethe service engineer should satisfy himself with regard to
gas soundness and the adequacy of combustion and ventilation air if this isappropriate.
The heat input ispreset and non-adjustable.
The heat input and burner pressure should be checked againts Table I.
If the heat input/burner pressure is not correct check the working pressure at the gas meter. The gas installation
should be examined for any possibleblockage if the pressures are incorrect.
Routine servicing
For efficient and trouble free operation it is important that the Celt Star receives annual maintenance. This routi-
ne service will normally be confined to :
a) Cleaningthe burner.
b) Cleaningthe heat exchanger fins.
c) Checking the gas controls.
d) Cleaningthe pilot tube and sampling tube.
e) Cleaningthe thermocouple and electrode.
f) Greasingthe gasvalve spindle.
g) Checkingthe heat input.
h) Checkingthe operation of the atmosphere sensing device.
The following schedulesare recommended :
a) Before commencing any work turn off : 1) the gasat the service cock,
2) the water at the water service cock by turning clockwise 1/4turn
and check for gas leaksafter reassembly.
b) Cleanor replace components as necessary.
c) Checkthe function of the appliance andburner pressure after allowing it to warm up throughly.
d) Observethe flame picture. Checkfor flame lift or excessiveyellow tips.
6.3 1 Cleaning
a) The burner can be cleaned by inverting and brushing with a soft brush. Inspect injectors, ensure they are
clear.
b) Cleanthe pilot and sampling tube by blowing through.
c) The heat exchanger flueways can be cleaned by thoroughly brushing the finned surface. After brushing ins-
pect to ensure that the flueways are completely clear.
d) The thermocouple can be wiped with a lint free cloth to remove any deposits. If the thermocouple tip appears
burnt or cracked, exchange to avoid a possible break at a later date.
e) Electrode :examine and cleanthe tip, if the tip appears damaged replace electrode and leadassembly.
f) Replaceall components in reverse order. The gasket between the gas section and the manifold must be cor-
rectly positioned upon reassembly.
1
I I
6.4 To remove the casing
a) Pulloff allthe knobs.
b) Remove the screws in the baseof the front panel and lift off panel.
c) Removethe screws at the bottom of the side panelsand lift off panels.
6

_ .6.5 Burner
a) Remove the screw (A)which holds the atmosphere
sampling tube onto the combustion chamber front
cover. Easetube out from the pilot head. Remove
tube by pulling from top of gassection.
b) Slackenscrew (B)at the baseof the pilot tube whe-
re the pilot tube isjoined onto the gas section. Re-
move tube by pulling forwards.
c) Remove the electrode lead from the piezo unit car-
tridge by pulling off CC).
d) Remove the two screws (D)and the two screws (E)
securing the manifold.
Note : The pilot bracket is secured by the top centre
screw(D) on the burner manifold 0.
e) Removethe manifold (G).
f) Remove the two screws (F)which secure the bur-
ner to the chassis.
g) Disconnect the thermocouple connection (H)at the
gas control and manceuvre the pilot bracket out-
wards.
h) Lift the pilot bracket sufficient to withdraw the
burner, taking care not to loose the manifold gas-
ket.
i) Upon completion of servicing replace in reverse or-
der making sure the gasket between the burner
manifold and the gas section is in place and in good
condition. If necessary replacethe gasket.
Ensure that the burner head assembly is correctly
located.
6.6 Pilot assembly
a) Withdraw the pilot bracket complete with the elec-
trode and thermocouple.
The flame retention ring is situated in the pilot
bracket.
b) Clean the retention ring (B) by brushing and blo-
wing through from the bracket end of the head as-
sembly.
c) Reassemblein reverse order ensuring that the pilot
tube, thermocouple are correctly located. Do not
fit to applianceat this stage.
10

6.8 Heat exchanger
6.9
Gas valve a) Remove the four screws (A) fastening the burner
baseto the gas section.
b) Remove the burner base and spring, lift out the
gasvalve.
c) Cleanor replace the valve seating.
d) Replacein reverse order.
Note : The gasket should be inspected and repla-
ced if necessary.
A
a) Remove the two screws (A) holding the deflector
plate in position.
b) Remove the deflector plate by slidingforwards.
c) Disconnect unions at junction where heating body
joins heating body legs (B).
d) Lift and slide heating body forwards,
e) Reassemblein reverse order.
Descaling procedure
Periodically it may be necessary to remove scaledeposits from the waterways of the appliance to ensure conti-
nued and efficient operation. The frequency will depend largely on the hardness of the water.
Usea solution consisting of five parts water to one part hydrochloric acid. The water should preferably be hot,
ADDACIDTOWATER,NOTWATERTOACID.
Advice with regard to descaling isavailablefrom Chaffoteaux Ltd (ServiceDepartment).
11

6.1(
6.1’
3 Water governor
a) Remove the governor iA) which is situated in the
base of the water section collecting the water in a
receotacle.
b) C:eanthe components with water and regrease.
c) Checkthe spring loaded piston moves freely.
d) Replacein reverse order.
Care should be taken during the annual service of an
appliance to grease the diaphragm spindle. Useeither
graphited or siliconegrease.
a) Rt)move water section (six screws at base of gas
section) for additional information (seeSection 7.5).
b) Removediaphragm.
c) Removediaphragm spindle.
d) Replacein reverse order.
6.12 Replace burner (6.5) and outer casing
12

7. REPLACEMENT OF COMPONENTS
Before commencing any work involving component replacement :
a) Turn off the gas at the gas service cock.
b) Turn off the water at the water service cock.
cl Re,%iovethe case(seeSecton 6.3).
d) If procedure involves breaking water connections then drain the appliance by opening an outlet tap and remo-
ving the drain plug to the baseof the water section.
Thermocouple
a) Disconnect from thermoelectric valve CD).
D
bl Remove pilot tube by loosening screw (A) and pul-
lingforwards.
c) Remove screw (B1top centre of burner manifold
and pull pilot assembly forwards.
d) Remove screw (C)securing thermocouple and re-
taining plate.
e) Replacein reverse order ensuring that the thermo-
couple is replaced in its purpose provided location.
7.2 Thermoelectric valve
B
a) Disconnect thermocouple from thermoelectric val-
ve (A).
b) Undo nut retaining the thermoelectric valve (B).
cl Lift out valve.
d) Replacein reverse order.
7.3 Spark electrode
a) Disconnect thermocouple from thermoelectric val-
ve CD).
b) Remove pilot tube by loosening screw (A - fig. 7.1)
and pulling forwards.
c) Remove the electrode in the pilot bracket by un-
doing and removing the screw (A) and sliding the
retaining plate (B1up from the bottom (screw end).
d) Disconnect leadfrom the piezounit cartridge 0.
e) Replacein reverse order.
Note : The slot in the conductor at the end of the
lead isvertical when pushed into the piezo unit car-
tridge.
Note : Sparkgap is 5 mm.
f) In replacing the pilot bracket ensure that the two
inside burners are correctly located into the brac-
ket.
13

7.4 Venturi
a) Remove the right hand heating body leg from the
water section and remove the venturi by unscre-
wing. Cleanor replace as necessery.
b) Reassemblein reverse order ensuring washers are
in place.
Diaphragm
a) Disconnect from the water section the two water
connections of the heating body and the water ser-
vice tap
b) Unscrew the six screws which hold the water sec-
tion position to the gas section.
c) Remove the water section complete with dla-
phragm and the inlet water connection.
d) Carefully remove and inspect the plastic water sec-
tion top cover and ‘0’ ring seal.
e) Remove and grease diaphragm spindle.
f) Reassemblein reverse order.
Note : Fit the governor last. It is easier if the cold wa-
ter connection is partially engaged before fitting the
screws and connecting the union nuts. Replaceallwas-
hers.
7.6 Piezo unit cartridge
a) Disconnect the spark lead from the piezo unit car-
tnd,re.
b) Remove the two screws (A) holding the retaining
plate.
c) Remove the piezocartridge and renew.
Note : On rreassemblingensure that the locating pins
on each end of the spring are correctly engaged in
their location holes.
7.7 Tap washers
al Unscrew tap spindle guide using a 14 mm spanner
and remove.
b) Pullout the tap washer. The washer can be rever-
sed but it should be ensured that there are 2 mm
between the washer cup and the washer face.
c) Replacein reverse order.
14
tridge

7.8 Scale reducer
a) Removethe retaining spring clip (A)with pliers.
b) Pullout to the side.
c) Rt\placein reverse order
Note : It will be easier to first engage the long leg of
the retaining spring clip into the bottom hole then en-
gage the top hole before pushing home.
7.9 Diaphragm in scale reducer
a) Remove scalereducer (seeSection 7.8).
c b) Remove six screws (A) which retain cover to bot-
tom housing of scalereducer.
c) Lift out diaphragm (B).
d) Replacein reverse order.
Note 1 : When replacing the diaphragm care should be
taken positioning the portion which seals the tube
which connects the top and bottom sidesof the water
section.
Note 2 : Before replacing the scale reducer inspect
the two ‘0’ rings (0 and grease if necessary.
Note 3 : It will be easier to first engage the long leg of
the retaining spring clip into the bottom hole then en-
gage the top hole before pushing home.
Combustion chamber lining
a) Remove two screws (A) holding the deflector plate
in position.
b) Remove deflector plate by slidingforwards.
c) Disconnect unions at junction where heating body
joins heating body legs(B).
d) Remove heating body by lifting and sliding for-
wards.
e) Undo nuts securing heating body legsto water sec-
tion and remove legs.
f) Remove screw (0 which secures the atmosphere
sampling tube onto the combustion chamber front
cover.
g) Easesample tube from the pilot head.
h) Remove brackets (E)which are retained by screws
(F)onto burner manifold.
il Remove the four screws (D)which retain the com-
bustion chamber front cover.
j) Slideout combustion chamber side linings.
k) Remove the rear lining if necessary complete with
support bracket, then slideout of plate.
I) Replacein reverse order.
15
Replace

7.42 Burner
Heat exchanger
A
a) Remove the two screws (A) holding the deflector
plate in position.
b) Removethe deflector plate by slidingforwards.
cl Disconnect unions at junction where heating body
joins heating body legs (B).
d) Lift and slide heating body forwards.
e) Reassemblein reverse order.
a) Remove the screw (A)which holds the atmosphere
sampling tube onto the combustion chamber front
cover. Easetube out from the pilot head. Remove
tube by pulling from top of gas section.
b) Slackenscrew (B)at the baseof the pilot tube whe-
re the pilot tube isjoined onto the gas section. Re-
move tube by pulling forwards.
cl Remove the electrode lead from the piezo unit car-
tridge by pulling off CC).
dl Remove the two screws (D)and the two screws (E)
securing the manifold.
Note : The pilot bracket is secured by the top cen-
tre screw(D) on the burner manifold (G).
e) Removethe manifold (G).
f) Remove the two screws (F)which secure the bur-
ner to the chassis.
g) Disconnect the thermocouple connection (HIat the
gas control and manoeuvre the pilot bracket out-
wards.
h3 Lift the pilot bracket sufficient to withdraw the
burner, taking care not to loose the manifold gas-
ket.
i) Replace in reverse order making sure the gasket
between the burner manifold and the gas section is
in place and in good condition. If necessary replace
the gasket.
Ensure that the burner head assembly is correctly
located.
7.13 Pilot assembly
a) SeeSection 7.1-Removal of thermocouple.
b) Remove pilot tube by loosening screw (A)(fig. 7.1)and pulling.
c) Remove electrode (seeSection 7.3 c).
d) Replacein reverse order.
Gas valve
a) Remove main burner (seeSection 7.12)
b) Disconnect thermocouple.
c) Remove gasvalve (seeSection 6.7)
d) Reolacein reverse order,
16

7.15 Water governor
a) Remove the governor (A) which is situated in the
base of the water section collecting the water in a
receptacle.
bl Cleanthe components with water and regrease.
c) Checkthe spring loaded piston moves freely.
d) Replacein reverse order.
7.16 Burner manifold
a) Remove pilot tube by loosening screw (A)(fig. 7.1)and pulling.
b) Remove screws (E)and (D)(fig. 6.5)and remove injector manifold.
c) Replacein reverse order taking care that the manifold gasket iscorrectly positioned.
7.17 Atmosphere sensing device
The tube isreplaced asfollows :
a) Remove screw (Al (section 7.12)and pull off from casting.
b) Replacein reverse order.
17

8
FAULT FINDING CHART FOR CELT STAR
PROBLEM CAUSE REMEDY
8.1
Pilot flame does not light
automatically
i) Gasservice cock closed
ii) Alr in pipe
iii) Pilot injector blocked
iv) Incorrect spark gap at electrode
VI Nospark
vi) Pilot air tube obstructed
8.2
Poor pilot flame
i) Pilot injector dirty/damaged
iI) Wrong injector
iii) Pilot head blocked
iv) Faulty pilot tube
VI Pilot air tube obstructed
vi) Inadequate ventilation
8.3
Pilot will not stay alight
I) Thermocouple low output
ii) Thermoelectric valve faulty
iii) Gaspressure low/variable
iv) Gaspressure too high
v) Pilot flame incorrect
vi) Inadequate ventilation
vii) Looseconnection thermocouple/
thermoelectric valve
vii0 Heat exchanger fins blocked
ix) Pilot air tube obstructed
8.4.1
Main burner does not light
i) Gasservice tap not open fully Openfully
ii) Water rate low Check If water rate issufficient
(seepage 2)
iri) Gasvalve push rod jammed Cleanrod and regrease
iv) Diaphragm perforated Changediaphragm
v) Gascontrol tap faulty Checkoperation of User’sgas
control tap
vi) Injector size Checkburner injectors against Table 1
vii) Diaphragm scalereducer damaged Replace
8.4.2
Explosive ignition
i) Pilot
ii) Center burners misplaced
Openservice cock
Purge line
Cleanor change
Reposition to 5 mm
Replaceelectrode and leadat
piezo cartridge
Clean
Cleanor change
Changefor correct diameter
Clean
Cleanor replace
Clean
Remedy
Changethermocouple
Changevalve
Checkat meter
Check pressure at meter
Check injector and pilot air tube
for obstruction
Remedy
Tighten
Clean
Clean
Check length is 7 mm and clean injector
if necessary
Relocate into slots in pilot bracket.
18

8 FAULT FINDING CHART FOR CELT STAR
8.5
8.6
8.7
8.8
8.9
8.10
8.11
PROBLEM CAUSE REMEDY
Water temperature low i) Wate flow rate too high
ii) Insufficient gasflow
iii) Water governor sticking
iv) Heat exchanger blocked or scaled
v) Diaphragm scalereducer damaged
Checkgovernor
Checkgas rate and that the gas service
cock and user’s control are open
Remove and cleanor replace
Descaleor replace
Replace
Burner stays on
i) Air in draw off
ii) Gasvalve push rod jammed
iii) Gasvalve “letting by”
iv) Loosejumper on house stop cock
v) Deadleg on system
vi) Dirt in water section
Purge lineto eliminate dead leg
Cleanpush rod and grease
Changevalve facing
Replacewater stop cock
or pin down jumper
Vent or remove
Cleanwater section
Unstable flames i) Water in gas line
ii) Inlet pressure too high for governor Drainand purge
Check pressure at meter
Heating body noise i) Scale
ii) Overgassed Descaleheating body Check burner and meter pressures
Insufficient water flow
i) Water service tap partly closed
ii) Lowwater pressure
iii) Water governor faulty
iv) Water governor sticking
v) Foreign matter in water section
Check it isfully opened
Checkwater pressure (TableI)
Changegovernor
Remove and cleanor replace
Remove and clean
Heater smells when new i) Appliance newness Smellwill go within a short period of time
High water flow i) Water governor sticking Replaceor grease
19

short list
e 749
@-750
@
0
Cl
G,
703
7;8
202b 202a
aa
216
Key
No
201a
201b
202a
202b
203
206
209
210
211a
212
213
214
215
216
317
318
432
433
441
446
448
703
726
727
729
731
738
748
749
750
751
754
Description
Front case 1F.. .................................
Frontcase2F ...................................
Right hand side panel ............................
Left hand side panel .............................
Vertical trim ............. .1 .....................
Case fixing screws. ..............................
Temperature selector guide ......................
Gas controlknob ................................
Temperature selector knob (HPmodel) ............
Hotandcoldtapknobs(lF) ......................
Fixing bracket - Wall mounting plate ...............
Woodscrew ....................................
Washer ........................................
Spire clip for side panel ..........................
Thermocouple ..................................
Electrode and lead ..............................
Gasservicecock ................................
Washer between gas service cock and inlet pipe
Air sample tube lower part .......................
Gastube .......................................
Nut - Gastube ..................................
Diaphragm .....................................
Water tail ......................................
Nut ............................................
Washer ........................................
Waterservicecock ..............................
spout ..........................................
Nut ............................................
Blanking disc ...................................
Washer ........................................
Remote outlet bend ..............................
Tapwashers ....................................
NO. GC Maker’s
OFF number part number
1
1
1
1
2
4
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
264680
264681
264682
264683
264684
366716
264688
264689
264690
264692
264693
366 107
264694
264782
264701
264702
264725
366016
264729
264733
262744
263432
264754
262744
262509
264756
262928
263669
262503
263668
263655
263375
79028
79027
74396/06
74397/06
74909
66206
70493
74521
74811
74810
54606
25617/03
35378/03
72411
74432
75229
74427
22835116
70628
76058118
20747/38
25809/30
78864/08
20747/38
61855/14 L%
74425 .
6
22527/10
20476/20 2
7
1219 E
61854/10 :
39783 L
w.
Chaffoteaux Ltd, Concord House, Brighton Road, Salfords, Redhill, Surrey RHI 5DX. Telephone : Horley [phone]. Telex : 87378.
Warrington [phone]. E-P003