Chaffoteaux & Maury STERLING PP, Installation And Servicing Instructions

Page 1: ...t person in accordance with the above regulations For use on natural gas only GZO G C No 47 980 07 from serial number 495 089 010 32 CC Installation and Servicing Instructions leave these instructions with the user Looking Good Heating Better U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 2: ...U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 3: ...TS 2 1 General 2 2 Location 23 Watercirculationsystem 2 4 Siting theflue terminalFig 10 2 5 Air suppiy 2 6 Elecaicai supply 2 7 Gassupply 3 SYSTEM GUIDANCE 3 1 General 32 Systemcontrols 3 3 BumpFig 11 3 4 Expansionvessel 3 5 Mainswaterconnection 3 6 Fiig andrechargingFig 12 Fig 13 page12 3 7 Makeupsystem 3 8 Pipzwork 3 9 Domesticexpansionvessel 39 1 Boiler replacement 3 9 2 Existing systems 3 10 C...

Page 4: ...32 20 6 COMMISSIONING 6 1 Hot watercircuits filing Fig 33 21 62 Centralheatingcircuits filling Fig 34 21 6 3 Lighting theboilerFig 35 21 6 4 GasrateadjustmentFig 36 Fig 37 Fig 38 22 6 5 D H W flow rateadjustment seealso6 7 Fig 39a 23 6 6 Adjustingtheheatingsystemby passFig 39 23 6 7 D H W flow rateadjustmentFig 39a 23 6 8 PumpswitchingadjustmentFig 39b 23 6 9 Fitting thecasingFig 40 24 7 ROUTINE S...

Page 5: ...generator Fig 63 To replaceP C B Fig 64Electricalbox layoutFig 65 To replacetherm0electricvaiveFig 66 To replacesolenoidvalvesFig 67 To replaceheatingbodyliningsFig 68 To replacefanassemblyFig 69 To replacepressure switchFig 70 To m pressurise expansionvesselFig 71 To replacepressure gaugeFig 72 To replacethedomesticexpansionvesselFig 73 To repiacemainburnerFig 74 To replaceburnermanifoldassemblyF...

Page 6: ...U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 7: ...ring servicing keep the dust generation to a minimum and avoid inhaling any dustand contact with the skin andeyes Normal handling and use will not presentany discomfort although some people with a historyof skin complaintsmay be susceptibleto imitation When disposing of the lining ensure that it is securely wrapped and washhandsaftercontact 1 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O...

Page 8: ...en l 3 and fuil output High efficiency Specialjig plate enabling all pipework io be instai led before instailing appliance Independent control over central heating Bow tem perature and hot water Fully adjustable central heating flow temperature Regulation between 50 Cand 62 C High limit thermostat for both boiler and hot water Water flow switch to protect appliance Suitable for showers with compat...

Page 9: ...k gap 5 mm Bofla thamosmt EGO lMlT 82 C Boila iknit thermostat SOPAC JAEGER 85 C Hot wata fitnit thermostat SOPAC JAEGER 57 C t 3 C Safety overheat thertnosmt Tokoswitch 105 C l klmwood 105 O Guvahw AEMF Fan motor SEL Pressure switch DUNGS 102 Pai 55 Pa Pump head GRUNDFOSUP 15160 c Eexpa n initial gep1wsm 0 6Sbar 9 6psi Domestic a nvess ithfch gcprarmr 2bar 30psi 1 3 lvIfaimrrm Clearances around B...

Page 10: ...nsure these are fitmiy pushed together see figs 3b and 3c and a tXI of 5 mm per metre length should be provided see section Flue extension accessory Cut off same amount from Pefl No 62623 00 akuninium flue duct plain end GC 264459 1meuelength Other flue Arrangements Horhontal OE E 9 OE 1 2 Fig 3c 1 Distance from internal comer 300 mm without kit 107 mm with kit No 76216 GCNo 264 833 2 Distance beI...

Page 11: ... lO EIairidal box containing Mains connection Fuses Printed circuit board Conneaions for extemal controts Connections for fan pressure switch and flow switch Connections for pump Connections for change over valve and for gas solenoid Wve 11 Solenoid v e I Blcck on which 3 valves are mounted l 3 valve 1st stage valve heating and hot water blue 5 e full output to hot water black 2 3 valve i ariablev...

Page 12: ...e diaphragm 23 causing it to rise This movement is transmitted to the change over valve dosing the heating port and opening the hot water port as shown 20 The primary water heated by the baiter now passes through the water to water heat exchanger 18 where it flows through alternate plates indiicUy heating the DHW A domestic exoansion vessel is fitted in the D H W circuit 36 The rising of the chang...

Page 13: ...pilot variable up top 2 3 maximum rated output The gas is 3 Simukaneouslv the thermoelectric vaive 14 is admitted by the orange valve is varied by adjuster 6 see opened and after a further 5 seconds sufficient energy is seaion 6 4 king produced by the thermocouple 5 for the thermo electric valve to be retained in the open position 1 6 4 FUNbIONAL FLOW DIAGRAM Fig 7 1 Generator Fan t hgh Soeed L SO...

Page 14: ...IED WIRING DIAGRAM i W AU CABLES ARE 240V EXCEPT WHERE THEY ARE INDICATED 24V GR FAN i m1 CHANGE OVER VALVE SOLENOID VALVE 213 li33 r f 8 SPARK GENERATOR IGNITION BUllON WATER FLOW SWITCH Fig 9 8 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 15: ... BS 5546 gives detailed guidanceon this aspect A compartment used to enclose the boiler must be designed and constructed specikaUy for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose Details of essential features of cupboardkompart ment design are given in BS6798 2 3 Water Ckulation System The appliance is suitable for SEXED SYSTEMSONLY and...

Page 16: ... demand from any other appiiances in the house The complete Installation must be tested for soundness as described in BS 6891 3 SYSTEM GUIDANCE 3 1 Gened The low water content appliance boiler inciudes the expansion vessels safety overheat thermostat temperature and pressure gauges and safety valve The fiow temperature is adjustable and gives a nominal 82 C 180 F on its maximum setting Detailed re...

Page 17: ... may be used to give a conservative estimate of the system volume Appliance 4 Iitres 0 8 gals Smaii bore pipework 0 3 iitres 0 07 gals per 0 292 kW Micro x e pipework 7 iitres 1 5 gals Steel panei radiators 2 3 litres 0 5 gals per 0 292 kW 1000 Btti of system output Hot water cyiinder 2 litres 0 44 gais If the volume exceeds 75 litres an additional vessel wiii be required fitted in the tlow from t...

Page 18: ...h recovery type to BS 1566 Pt 1 Single feed cylinders are not suitable for use with this appliance Flow and retum pipework to the nder should be in 22 mm pipe Inhibitor and water conditioners see Bs 7593 Chaffoteaux et Maury generally recommend the use of inhiirxs in systems using the appliance boiler 3 12 The following are the appliance manufacturer s recommendations I Use only a British Gasor si...

Page 19: ...ith an instantaneous type system it is essential that all redundant pipework is removed and dead legs eliminated Heating stored hot STERLINGPP water using flow share I relay required The consideration of heating systems using thermostatic v6alvesshould ensure that the minimum flow rate thrcr h the appliance is maintained at all times and in X znnection the remote by pass is preferred see fig 17 1F...

Page 20: ...facturers can assist with the seiection New Team Ltd Brunell Road Earlstree Industrial Estate bY Nolthants NNl7 2LF Meynell Valves Ltd Shaw Road Bushbury Wohrerhampton West Midlands WV1 0 9LB Tel No 56 32 40 Tei No 0902 28621 Aqualisa Products Ltd Hortons Way London Road Westerham Kent TN1 6 1BT Barking Grohe 1 River Road Barking Essex 1Gll OHD Tei No 0959 63240 Tel No 081 594 8898 Do not use the ...

Page 21: ... accessoriesare not supplied as standard and must be ordered to suit see section 1 4 4 1 4 2 PosSoning the boiler a Select the location for the boiIer referring to the dimensions shown in 1 1 and 1 3 terminal Iocation positions 2 4 fig 10 b Check flue length see 1 4 figs 2 and 3 c Check clearance on externai wail for flue terminal position see table 2 4 fg 10 d Assemble the mounting bracket made u...

Page 22: ...dedtneofffueof5mm N E Ensure bracket is square and plumb to vertical centi Fig 20 per line before tightening N B By using the plastic jii plate the piping system can bc compieted before the boiler is mounted a Attach plastic jig plate to bottom bracket using 4 6 mn x 10 hexagonal screws provided fig 211 b Fit copper tails and washers to jig plate the main inleCtail M ischesh ofthetwo 15mmtails e A...

Page 23: ...OVE AN ENTRANCE ox WINDOW OR ANY TIPEOPPUEUCACCESSASTEB TEMPER TUREOPTE d fitl4rnmtaildiainbendusingwasher Wm BEING DISCHHBCEDM Y BEACH loo C held by two screws 6 Peel off protective paper from adhesive side of cork gasket A place on mating side of flue turret B fining up with four dearance holes press together c Assemble second part of flue duct H push fit f SEdelocking ring 0 and 0 ring over pla...

Page 24: ...e fig 26 Iaddngtbeelec coMdoa N B See Section 2 6 for electrical supply requirements THISAPPLTANCE MUST BEEARTHED a Pull out fuses AI c Open door to left hand side of electrical box ecmr d Cut the cable entries to the size of the cable beiig used which should not be less than 0 75 mm e Remove cable damp f Connectpermanent Jiveto L terminal I and neutral to N terminal 2 g Connect earth to earth sae...

Page 25: ... mom stat accelerator should be connectedif ftited to terminal 3 5 2 Time clock and zone valves Spring retrun room thermostat honey l T60 6OE N 6 For additional information omact fime Control Manufactums connected cylinder mermosrat hcneywall L6 41 A tabs 40V50Hz tseU3 A double ale fuse sw tied wr or unswitched iganasccka ig 29 baler termmas remcwelink 4 5 19 U n i t 3 A T h o r n t o n R o a d I ...

Page 26: ...e which canies the signal to the Boiler relay boiler terminal block rg 31 ig 32 5 5 Frost thermostat Itisadvisable if the appliance is fitted in a location subject to adverse weather conditions to proted the system from frost damage by fitting an additional remote frost thermostat which will over ride the controls whilst the selector switch is set to hot water central heating for systems without z...

Page 27: ...upply and drain boiler by disconnecting iill system and opening the drain valve P This is incorporated in the safety valve and is achieved by screwing down the head until the valve liRs openaa1owleveidraincocks 12 Remove t iker in the return isolating valve C and inspect for any installation debris see section 7 5 to dean and replace 13 Re6Usystem as above N B It is recommended that this is repeat...

Page 28: ...lling for heat 5 Adjust Setting pressures are given in graph figs 37 and 38 The pressure will be reduced by clockwise movement of screw increased by anticfockwise movement Now select hot water only adjust hot water regulator see 6g 4 20 to minimum and open the largest volume draw off tap The gas pressure should now be the maximum as indicated in Technical Data 6 Switch boiler off 0 Remove pressure...

Page 29: ...tlow switch operates at approx 300 Vh 1 1 Fig 39 gUmin Hot water adjustmeat A tlow restrictor A is fitted on the domestic hot water outlet Adjustment of this restrictor enables regufationof the tlow fate of the D H W to suit individual instaUation conditions and requirements Adjustment is made by either turning the screw in a clockwise direction to reduce the 5ow tate and inuease the temperature o...

Page 30: ...a Remove the nuts om the machine screws securing tie rod to the hinges b Offer the door up vertically Engage part E in pro6le of the right hand side panei Fix assembiy T screwfrornben th0 c Pivot the left hand hinge and engage into profile of left hand side panel Fix assembly with screw ft beneath d Remove protective film before use Bass and and Ok torn with the 03 the the Nith the cml HAND OVER T...

Page 31: ... B Before commencing any work turn off gas at the gas iniet tap fig 34 item G and ensure that the edacity suppiy is discoMected koiate water suppiy and dtain appliance if required To remove front using a Remove two screws A bottom rear of boiier b Remove suew B centre of Iower front panel c Remove thermostat knob and ignition push button d Remove case by easing forward at bottom and lifting off lu...

Page 32: ...pilot body C from piiot burner base d Check injector and clean the filter N B The pilot injector F is retained in the base of the body with an 0 ring G If the injector is replaced it is fitted bright side uppermost t Ensure deflector plate D is correctly located on the piiot Fig 44 r To than heating rtturn fdttr a Close heating Bow and return valves B and Cl and drain throu4 safetyvalve F l sectio...

Page 33: ...and repressurise system if newsary g Recommksion and check controk 6 After the boiler is lit check all gas connections for soundess 1 Allow the boiler to warm up thorough y then chedr the burner pressure and adjust as necessary to that given in the table for required output see section 6 4 j Restore any sytem controk and docks to their orighai setting To thtck opuation of safttymh t Turn off the a...

Page 34: ...m oehxrric valve Fl p Replace high limit thermostat NOTE When replacing the thermocouple the conductor may need manipulating avoiding bending at acute gl Tortp tttItctnadttad feadossemhfy a Remove kont case seesection 7 1 b Remove outer front panel and combustion chamber fmntpafd seesection7 2 c Remove burner seesection 7 3 d Remove deflector plate D see section 7 4 t Disconnect from eiectrical bo...

Page 35: ...witch n Replacein reverse order To repkace change ovcrlI8fve miaondtch a Remove ont case see section 7 1 b Undo screw A and remove microswitch box cover N B Upper microswitch operates for D H W mode Lower microswitch operates for C H mode c Lift spring B and pull operating lever off mounting pUls i Rzmove respective microswitch from mounting pins c Note colour code and pull off electrical tags f R...

Page 36: ... heating body panels to chassis Fig 55 1 Undo flow and return pipe unions E remove pipes and slide primary heat exchanger forwards f Replacein reverse order io remove rhctrfuf contfd box a Remove kont casing seesection 71 b Remove fuses by pulling fuse carrier B from electrical box c Remove 3 screws C lift eiectricai box cover away and unplug from PCB d Pull off plug from solenoid vaives at PCB e ...

Page 37: ...ug pump connection c Remove four screws A f Remove pump head noting orientation g Remove lead and transfer to new pump head h Replacein reverse order J Open flow and return valves Top up system if Fig 57 N B For the Celtk phs the pump is a Grundfos UP 15 60 Fig 58 L To fcphu change over dve C 0 VI a Remove ont case seesection 7 I b Disconnect and remove electrical box see section8 9 c Tum off main...

Page 38: ...t exchanger to chassis g Remove bottom saew B and spacer h Remove secondary heat exchanger I Replacein reverse order N B Do not unscrew the four tie rods in the secondaty heat exchanger a 13 Fig 59 a To repbee air sepanttor a Remove front case see section 7 1 c Close heating flow and return valves B C see section 8 11 fg 58 a d Dram boiler down through safety valve F seesection 8 11 fg 58 a C DiSC...

Page 39: ...right hand lower side c Remove split pin from dry pocket on ffow pipe A d This thermostat is located on moulded pins ease forward and remove spade connectors e Feed cap q through the control box having removed the split grommet f Replacein reverse order polarity immaterial To repface domestic hot water theostat a Remove font case see section 7 1 b Remove electriozlbox Rant cover see section 8 9 c ...

Page 40: ...als 1 and 2 but A not the earth e Disconnect external controls if Wed from terminals 4 and 5 f Remove one screw A g Slide PCBslightiy upwwards to disengage guide h Pull PCB forward j Replacein reverseorder IFfg 64 I 16 17 1 11 13 9 4 6 14 1 Summer Winter Switch capillary 9 Push Button Ignition 14 D H W Thermostat 2 Pump 6 Water Flow Switch 10 Solenoid Gas Valve 15 Limit Thermostat 3 Earth 7 D H W ...

Page 41: ...and drain boiler through safety vaive see section 6 2 fig 34 0 c Remove protective cap and check pressure on schroeder valve with gauge N B The setting pressure is 0 65 bar 9 5 psi d To re pressurise use car foot pump or bicycle pump with adaptor c Close safety valve f Open heating flow and return valves g ReElIand commission boiler N RDonotuuahQhpreu Ene Fig 72 To fepiocc pressure gauge a Remove ...

Page 42: ... 2 c Remove burner see section 7 3 d Replace in reverse order ensuring that the gasket is cortect y positioned between the injector cover plate and the manifold Fig 74 Fig 75 F2 To rep e the burner manifo i assembly a Remove the front case see section 7 1 b Remove the combustion chamber front panel to expose the burner manifold see section 7 2 a to c c Remove the two saews FI and remove the closur...

Page 43: ...d loosen lower saew Slide out expansion vessel 0 Replace in reverse order engaging the thread of the flexibie pipe before screwing fully home screws B The vessel must be central on the Erontpanel 0 Re pressurise expansion vessel seesection 8 24 6 Open tlow and return valves If necessary repressurise sze n 6 2 Fig 77 To repka viewing window a Remove front case see section 7 1 b Remove combustion ch...

Page 44: ...1 b Undip and remove thermometer sensor from flow pipe A c Withdraw gauge B by compressing the two f ng lugs and pushing the gauge towards you Feed the sensor through the bracket d Replacein reverse order Fig 80 To rrpkce safety valve a Remove case see section 7 1 b se heating flow and return valves and drain the appliance through safety valve see section 6 2 fig 34 D and section 7 8 c Ensurethat ...

Page 45: ...1 fan high speed 1 no no time delay 5 sec max time delay 5 sec max 2nd stage soienoid opens 2nd stage soienold opens 40 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 46: ...ART 1 READ IN CONJUNCTION WITH SECTIONS 9 1 9 3 hhasun mdlivdl oumui al lhetrm elsdnc valv XV gmala than 12mV Ou uttoTCfbuihm12mV I U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 47: ...AD IN CONJUNCTION WITH SECTIONS 9 1 9 2 START T No t YeS t No Ensure alI1SOlP ltngvalves and Check dwhragm is OK Spindle OK Rsplaw d necas SW 42 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 ...

Page 48: ...4 10 6 Remove and refit correctiy see section 8 22 vi Combustion chamber front cover not sealing 6e Tighten 6b Replace sealing strip vii Heat exchanger fins blocked 7 Clean see section 7 2 and 7 7 viii Neoprma gasket in turret not conecay fitted 8 Fit or refit see se On 4 10 or missing 3 Central heating low Aow temperature i Boiler thermostat out of calibration 1 Replace see section 8 14 ii Limit ...

Page 49: ... Solenoids not operating 4 See section 9 2 flow chart 1 v Pressure switch hunting 5 Replace see section 8 23 vi Low inlet gas pressure 6 See section 6 4 vi9 Control stat out of calibration 7 Replace see section 8 16 i No main burner 9 Lack of water flow ii Pump jammed iii No water iv Flow switch not operating v Heating thermostat faulty CH only vi Pressure switch not operating 1 Checks valves are ...

Page 50: ...By pass if fitted not regulated 3 Adjust see section 6 5 iv Blocked heat exchanger 4 Clean or replace see section 6 8 I1 Fan on high speed i Defective printed circuit board 1 Replace see section 8 18 continuously ii Microswitch fault 2 Replace see section 8 5 12 Loss of pressure i Leak on system 1 Locate and rectify ii Leak on appiiance 2 Locate and rectify 13 Gain in pressure i Filling loop still...

Page 51: ...D 1011304 00 2214 AQUASTAT 57 C KIT 266060 100606 30 2215 HEATlNG THERMOSTAT 85 C 264849 56974 00 2245 REGULATING THERMOSTAT ASSY 277666 81426 00 6 2302 PRESSURE GAUGE ASSY 277591 8102i 00 z 2303 THERMOMETER ASSY 277592 al 022 00 0 2507 AQUASTAT KNOB 277670 1004996 00 f d 2509 SUCK BU ITON 277671 59600 10 ii 2909 PRESSURE REUEF VALVE 277770 76584 00 3001 277768 1009106 00 i5 FAN MOTOR ASSY 24OV 31...