Chaffoteaux & Maury CHALLENGER 30 FF, Installation And Servicing Instructions

Page 1: ...CHALLENGER Fanned Flue Boilers 30 FF 50 FF GCN 41 980 74 GCN 41 980 77 installation and servicing instructions these instructions are to be left with the User or adjacent to the Gas meter ...

Page 2: ...ures Fullvadiustable electronic temperature regulation Guarantee The manufacturer s guarantee isto supply free of charge any defective part of a Challenger boiler for a period of 24 months from the date of purchase The guarantee isvoidable if it is not installed in accordance with the recommendations made herein or in a manner approved by the appiiance manufacturer 1 1 TECHNICAL DATA ii a a A A 71...

Page 3: ...otor Pressureswitch Sides TOP Bottom Front mm in 5 l 4 150 6 150 6 300 12 15 mm O D compression 22 mm O D compression fittings 30 FF 504 It h 1 85 gpm 50 FF 841 It h 3 08 gpm 30 m 98 ft 150 mm 6 ins Seefigs 7 12 240 Vsingle phase 50 hz supply fused 3 amp 30 FF 24 77 kg 54 5 lb 50 FF 25 9 kg 57 Ibs 30 FF 0 5 lit 0 11 gals 50 FF 0 7 lit 0 15 gals 1 18 mm 0 046 in marked 118 0 3 mm 0 011 in marked 03...

Page 4: ... is proved by the pres clock or programmer or when the cylinder and room sure switch before the 50 fixed gas valve opens After thermostat are satisfied the boiler switches off but the 3 secondsthe second gas valve variableoutput opens pump continues to run for 15 seconds The fan returns Temperature control is by means of a temperature sen to operation at the low speed sing thermistor and potentiom...

Page 5: ...12 mm for rear outlet and 76 mm 500 mm for side outlets See 1 5 Other flue options are available to a maximum of 3 m 9 ft 10 in to special or der See1 5 The boiler must be installed so that the flue terminal is exposed to external air The boiler must NOTbe installed so that the terminal discharges into another room or space such as an outhouse or leanto It is important that the position of the ter...

Page 6: ...at pumping over and cavitation or air entrainment are avoided see recommendations for various layouts on page 8 Chaffoteaux recommend that the 15 mm cold feed and 22 mm open vent are close coupled within 150 mm 6 on the low pressure side of the pump The connection should be so arranged that there is a low ve locitv point at the open vent junction with the system Page8 Fig 13 3 6 Automatic Air Sepa...

Page 7: ...lves are used a sys tem by pass will be necessary to maintain the minimum flow rate Seesection 1 4 NB All wiring to externai controis must be in accordan ce with the ICEWiring Regulations 7 Fully pumped system independant control of central hea ting and hot water using two spring return motorised val Fig 3 Ii i t I 6 N L onlofflonlaff CH HW LNNL56 PROGRAMMER PUMP BOILERTERMINALS 2 Fully pumped sys...

Page 8: ... z I A 43 2 Minimum Fe iFtead BS 5449 Part 1 1977 I 74 w fg see 3 4 I v Fig 11 LJ Air seperator or formed low velocity point b open vent cold feed AJ Fig 13 Minimum gta ead Fig 8 l l Minimum Tt t Head Fig 12 I J 1 Cold feed 15 mm 2 Open vent 22 mm 3 6 in maximum 4 See fig 13 5 By pass 15 mm 6 Regulating motorised valve 7 Combined cold feed and open vent 8 ...

Page 9: ...lled neoprene gasket 4 fixing screws for flue turret 2 screws for turret cover iv Plastic bag containing external wall plate with adhesive mastic v Plasticflue turret cover 4 1 Remove boiler from carton Releasethe front case by unscrewing the three fixing screws and washers positioned two at the top and one at the bottom and two screws securing the caseto the control box NB one washer is paint cut...

Page 10: ...s kets A Eare in position Checkthat the flue assembly is level Securewith the 4 screws provided Where necessary make good external wall and fit wall plate D with mastic sealant onto external surface Makegood internal wall NB Do not fit turret cover or front case until gas and electrical connections have been made and tested Making the gas connection a Remove the plastic cover from the gas inlet wh...

Page 11: ...and the earth on earth terminal e Connect ancillary controls across terminals marked 5 6 Seecontrols diagrams Figs2 6 and 14 16 f Clamp wires with cable clamp A g Replacecontrol box cover NB The length of the earth wire between the cord an chorage and the terminal must be such that the live and neutral wires become taut before the earth wire if the supply cord is pulled Connection of the pressure ...

Page 12: ...d repeat b 5 5 above h Check for gas soundness around the boiler gas com ponents using leak detection fluid i Checkand adjust gas rate as detailed in 5 5 5 4 Resetting the high limit thermostat a If for any reason the high limit thermostat operates the pilot will go off and the boiler will require manual re setting b Re establish the appliance by resetting the high limit thermostat by pressing the...

Page 13: ...k tions see Fig 7 13 for illustration of recommended system layouts The expansion vessel shall be capa ble of accepting water up to at least 62 5 of its vo lume without damage ii The nitrogen or air charge pressure of the expansion vessel shall not be less than the hydro static head height of the top point of the system above the ex pansionvessel iii The expansion vessel shall be sized in accordan...

Page 14: ...s should occur within 0 3 bar k4 3 Ibf irP of the preset lift pressure ie 3 bar 43 5 Ibf in2 Release water from the system until the initial system design pressure is attained taking into account any dif ference in height between the pressure gauge and the point at which the pressure vessel is connected Light the boiler as detailed in 5 3 The water system should be heated to maximum war king tempe...

Page 15: ...5Ol k Earth Solenoid Valves Orange and Blue Fan 240 V Printed Circuit Board Temperature Sequence Control Thermocouple External Controls Notlessthan8mv 111 Y W Pressure switch m I IThem or Comparitor TellIaerature a I 1 Fig 22 50 Blue Soienoid Gas Valve Variable Orange Solenoid Gas Valve 15 ...

Page 16: ...rs B securing front panel of combustion chamber b Remove panel complete with regulator plate by ea sing forward 50 FF a Remove six screws A and two nuts screws and was hers B securing front panel of combustion chamber b Remove panel by easing forward at bottom and di sengage Remove the burner assembly a Remove the screws A securing burner manifold to gas section bl Remove gasket and retain in safe...

Page 17: ...e at thermoelectric valve by unscrewing nut IO mm AF g Disconnect from high limit thermostat by pulling connections apart where high limit thermostat connects i Remove thermocouple and seating j Replacein reverse order taking care to locate thermo couple in positioning grooves in bracket k Replace seating in to casing and reposition electrode lead Replacing combustion chamber linings a Remove fron...

Page 18: ...x i To replace heat exchanger a Drain system b Remove front case 7 1 c Remove combustion chamber front panel A 7 2 d Remove burner assembiy B 7 3 e Remove high limit thermostat phia left hand side 0 f Withdraw thermostat temperature sensor right hand side D 8 13 g Unscrew nuts on flow and return connections E 30 mm AFL h Remove two screws securing combustion chamber to rear chassis FL i Drop assem...

Page 19: ...moelectric valve a Remove front case7 1 b Remove or displace as necessary the electrical box 8 7 c Remove thermocouple connection from thermoelec tric valve A d Remove nut securing securing thermoelectric valve nut size25 mm AFL e Withdraw thermoelectric valve f Replacein reverse order NB Care should be taken when replacing the nut secu ring the thermoelectric valve FINETHREADS To replace solenoid...

Page 20: ...remove spark electrode wire and earth wire from spark generator NB PCB is a wedge shape and it will be found easier to ease front corners first e Remove plugs from rear of electrical control box f Slideboard forward and remove g Replacein reverse orders h Checkfunction of controls Testing of FDDCircuit Closedcircuit Slide back insulation at plug in connection and attach millivolt meter using croco...

Page 21: ...t Gasfilterwasher Gasservicecock Olive15 mm NutV2inBSP Mountingbracket Thermistortemperaturesensor High limit thermostat Thermocouple Electrode and lead assembly Microswitch Printed circuit board Fuse 2amp Fanassembly Pressureswitch Sampletube 406327 45817 366678 64145 366677 64144 366553 64051 366558 47509 366559 47508 366564 65519 06 366715 66207 366565 27834 366714 45654 263 545 37309 366566 65...

Page 22: ...5 6 or are external control in demand mode Does fan run at high speed no Check fan and rectify Yes I Flue blocked I 1 I Rectify 1 I no Check for blocked pilot injector change if necessary I Replace pressure switch I no I Is plug on PCB I I Yes Does boiler fire b I Is there Replace valves supply to blue valve and plug I I correctly located I no 22 ...

Page 23: ...s limit thermostat I Is svstem vented In and water circulating IO 1 f Vent system 1 C I r limit stat continue to JImate ConsfZXItlv I I ye 1 r Is the pump wired to the boiler temperature sensor I Ghal I 23 ...

Page 24: ...Chaffoteaux Ltd Concord House Brighton Road Salfords Redhill Surrey RH15DX Telephone Horley 0293 772744 Telex 87378 39 41 A Imp C M R f 92220 l 29 9185 ESP021 ...