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CHAFFOTEAUX LIMITED BRITONY II FF G.C. No 52.980.21 This appliance has been tested and certificated by British Gas For use on natural gas only) installation and servicing instructions (leave these instructions adjacent‘to the gas meter)

Boiler Servicing Manual

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Boiler Servicing Manual d

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CHAFFOTEAUXLIMITED BRITONYIIFF G.C. No 52.980.21 This appliance has been testedand certificatedby British Gas Foruse on naturalgas only) installationand servicinginstructions (leave theseinstructionsadjacenttothegas meter) 1.GENERAL The BRITONYII FF is a fanneddraught,balanced fluedinstantaneousmultipointappliance. The flueis suitable for rearoutlet,or toeitherside. The maximumrecommendedfluelengthis 3 m. straight. The appliance is forconnectiontoa mains cold watersupply only. A permanentelectricalconnectionis requiredand shouldbeprovidedbyuse ofa fusedspur. The externalelec- tricalsupply shouldbe via a doublepole switchhaving3 mm.contactseparationin bothpoles. If theappliance is installed in a bathroomthefusedspur mustbe externaltothebathroom. When on pilotonly thefanruns atlow speed increasing tonormalspeed when thereis a demandforhotwater. Included are a pressureswitch,which operatesif thefanstalls oriftheflueis obstructed,and a low temperature sensor whichwill turnoffthefanwhen theappliance is runningonpilotonly (fanlow speed) in theeventoflow air temperatureslikely tocause freezingin theappliance. 1.1 1.2Dimensions Guarantee I The guaranteeon thisappliance is void ifitis notinstalledin accordancewiththerecommendationsmade herein or in a mannerapprovedby themanufacturer. - - A B C D E F G H J K 1 M N P S T v W X - mmins. 65825.9 39515.5 27010.6 1004.0 401.6 38515.15 43817.25 77830.6 72828.6 532.1 552.15 983.8 702.75 28511.22 1054.13 1997.8 29011.4 903.54 86834.14 - X - 2 1.3 L TechnicalData Waterinlet (Compression tYpe fittings).. Wateroutlet(Compression typefittings) Gas (Compression typefittings). Height (including fluebend) .. . . Width.. . . . . . . . . . . . . . . . . . . . . . . . . . . Depth.... . . . . . . . . . . . . . . . . . . . . . . . . Weight.............................. Space forfixing-top(above flue) -bottom(below case) -sides. . . . . . . . . . . . . -front... Hole fortheair inlet duct... The BRITONYII FF is supplied in one carton. 97583Btu/h 76000Btu/h 94.3 ft3/h 4.4 in.w.g. 2 0.4 in.w.g. Heat inputnominal..28.6 kW Heat outputnominal... . .. . . . .. .22.4 kW Gas rate(maximum).....2.67 ms/h Burnerpressure. . . . . . . . . . . . . . . . . . . ... .10.9 mbar Burnerpressure tolerance.2 1 .O mbar Main burnerinjectors.... .. .1.23 mm (stamped1.23) Pilot injectors. .. .. . . . . . . . . . .. .0.23 mm (stamped231 Waterflowrate- raised 50 C (90 F) .. .6.3 I/min1.4 gpm Waterflowrate- raised 30 C (54 F).. ..10.9 I/min2.4 gpm Minimum operatinghead. . . . . . . . ..7.5 m.25 ft(10 psi) Maximumoperatinghead.. . . ..... .100m.328 ft(I 50 psi) Electrical Connections- 240 V50 Hz supply fused3 A. The minimumwaterpressureis forthecorrectoperationoftheappliance only. An additionalallowance mustbe madefortheresistanceofpipeworkandfittingsparticularlywhereshowersandwashingmachinesareused. This should be equivalentto2 m. (6.5 ft)head. . . . . . . . . . . . . . . . . . . . . . . . 15 mmCopper 15 mm Copper 15 mmCopper Right hand connection Lefthand connection Centreconnection 778 mm (30.6 in) 395 mm (15.5 in) 270 mm (IO.6 in) 20 kg. (42 lb) 50 mm (2 in) 178 mm (7 in) 25 mm (1 in) 600 mm (24 in) 107 mm (4 in)0 (diameter) 1.4FlueLengthMinimum Wall Thickness 3 in (75 mm) RearOutletWallthicknessUpto 612.5mm Deliveredwith appliance Flueductlength= wallthickness+ 25 mm Airinletductlength= wallthickness+ 25 mm Over612.5mm Extensionavailable ptN61061 I SideOutlet EM= Wallthickness DM = Distancefromwailto Rue AirinletductlengthEM + DM+ 130 mm 2.INSTALLATIONREQUIREMENTS 2.1RelatedDocuments The installationoftheheatermustbe in accordance with therelevantrequirementsoftheGas Safety(Installation andUse) Regulations1984,Building Regulations, thecur- rentIEE WiringRegulationsandtheByelaws ofthelocal waterundertaking.Itshouldalsobeinaccordancewith anyrelevantrequirementsinBritishStandardCodes of Practice.Detailedrecommendationsarecontainedin the followingBritishStandardCodes ofPractice : CP 331 :Pt.3 :1974..BS 5546 :1979,BS 5440 :Pt.1 : 1978 and BS 5440: Pt. 2 : 1976. 2.2Location Thelocationchosenfortheappliancemustpermitthe provisionofa satisfactoryfluetermination.The location mustalso permitadequatespace forservicing and air cir- culationaroundtheappliance. Theappliancemaybeinstalledinanyroomorinternal space althoughparticularattentionis drawntotherequi- rementsoftheIEE WiringRegulationsand,inScotland, theelectricalprovisionsoftheBuilding Standards applica- ble in Scotland, withrespecttotheinstallationofa heater in a roomorinternalspace containinga bathor shower. Wherearoomsealedapplianceisinstalledinaroom containinga bathorshower,anyelectricalswitchorap- pliance control,utilisingmains electricityshouldbeso si- tuatedthatitcannotbe touchedbyapersonusingthe bathorshower. Wheretheinstallationoftheappliancewillbeinan unusuallocationspecialproceduresmaybenecessary and BS 5546 gives detailedguidance on thisaspect. Acompartmentusedtoenclosetheappliancemustbe designed and constructedspecifically forthispurpose. An existingcupboardorcompartmentmay be used provided thatitis modifiedforthepurpose. Detailsofessentialfeaturesofcupboard/compartment design are givenin BS 5546. 2.3Gas Supply Anadequatesized gas metermustbeconnectedtothe service pipe. Where necessary thelocal Gas Region ofBri- tishGas will arrangefortheexistingmetertobe checked orforasuitablemetertobeinstalled.Onnoaccount mustanyworkbecarriedoutonthegasmeterother thanbythelocal Gas Region ortheirspecificallyauthori- sed contractor. Installationpipesshouldbe fittedinaccordancewithCP 331 :3.Pipeworkfromthemetermustbeofadequate size.Pipesofasmallersizethanthegasconnection should notbe used. The completeinstallationmustbe testedforgas sound- ness and purgedin accordance withCP 331 : 3. 2.4SitingtheFlueTerminal The fluemustbe installed in accordance withBS 5440 : Pt. 1.1978. Theflueissuitable forSTRAIGHTflueapplication only. The followingnotes are intentedtogive general guidance. Thestandardfluesetis suitableforwalls havinga thick- ness of75 mm(3 in.) to612.5mm(24 in.) forrearoutlet fluingorupto500mm(19,5in.) forsideoutletfluing. Otherflueoptionsareavailable toa maximumof3 m(9 ft.8 in.) tospecial order. 2.5WallMounting Theapplianceshouldbeinstalledonaflatnon- combustiblematerialwhichwillnotreverberate.What everthethicknessofthewall a hole100 mm(4 in.) in dia- meterwillbe requiredfortheapp!iance flueassembly.It isrecommendedthatacoredrillbeusedtoformthis hole. For dimensions and clearances see sections1.2 and 1.3. 2.6FlueTerminalAssembly The appliance mustbe installedso thattheflueterminal is exposed toexternalair. The appliance mustNOT be ins- talledso thattheterminaldischargesintoanotherroom orspace suchas anouthouseorlean-to.Itis important thatthepositionoftheterminalallows a freepassage of airacrossitall times.Theminimumacceptablespacings fromtheterminaltoobstructionsandventilationope- nings are specifiedin thefollowingchart. 1. II Diilybelowanopenablewindow,air vent or anyotherventilationopening. I 300mm(12in.) I II 2.1 Belowqutterinq,drainpipesor soilpipes.175mm(3iIL) 13.I Belowbalconiesor eaves.12OOmm(8ill.)1 4.Aboveadjacentgroundor balconylevel3OOmm(12in.) 5.Fromverticaldrainpipesor soilpipes.7.5mm(3 in.) 16.1 Fromintemalor externalcomers.13OOmm(12in)1 7.Froma surfacefacingtheterminal 8.Froma terminalfacingtheterminal 600mm(24in) 1200mm(46h.) Note-Wheretheterminalis fittedwithin850 mm(34 in.) ofa plasticorpaintedgutteror450 mm(18 in.) ofpain- tedeaves an aluminiumshield ofatleast750 mm(30 in.) longshouldbefittedtotheundersideofthegutteror paintedsurface. Wherethelowestpartoftheterminalis less than2 m. (6.5 ft)abovethelevel ofanyground,balcony,flatroof orplace towhich any person has access and which adjoins thewall in which theterminalis situatedmustbeprotec- tedbyaguardofdurablematerial(a terminalguardis available fromChaffoteauxLimited) or fromQuinnell Bar- rett& Quinnell. 01.639.1357.(GC No 381.782) The airinlet/productsoutletductand theterminalofthe appliancemustnotbecloserthan25 mm(Iin.) toany combustiblematerial.Detailedrecommendationsonthe protectionofcombustiblematerialaregiveninBS 5440 Pt. 1 : 1978 (Sub-clause 20.1). IMPORTANTNOTICE:TIMBER FRAMED HOUSES.Ifthe applianceistobefittedinatimberframedbuildingit shouldbe fittedin accordancewiththeBritishGas publi- cationGuide forGas Installationsin TimberFramedHou- singreferenceDM2. Ifin doubtadvicemustbesought fromthelocal Gas Region ofBritish Gas. The fluemaybe fittedfrominside oroutsideofthebuil- ding.Iffittingfrominside theflueductshould be assem- bled intotheair inlet ductand theassembly passed trough thehole in thewall. The outside diameteroftheterminalis thesame as outside diameteroftheair inlet duct. 4 2.7Airsupply Theappliancedoesnotrequireanypurposeprovided ventilationunless installed in a compartment.A compart- mentenclosingan appliancerequireshighandlowlevel openings.These openings musteithercommunicatewith aroomorinternalspace orbedirecttooutsideair.The minimumFREEarea oftheopeningmustbe : HighlevelLowlevel Airfrom mom or internalspace258cm2(40in2)258cm* (40irL2) Air directfromoutside129cm2(20in.2)129ails (20in*) 2.8ElectricalConnections The appliances mustbe earthed. Theinstallationshouldbeundertakenbyacompetent electricianandshould bein accordancewiththecurrent editionoftheIEEWiring Regulations. Particular attentionshould be paid tocross bonding. The appliance mustbe providedwitha means ofisolation. Ifinstalledin a bathroomthemeans ofisolationmustbe externaltothebathroomor a doublepole cordswitch fit- ted. Acceptablemethodsofconnectionare : 1.A switched,double pole fusedspur with3 mmcontact separationon all poles. 2.A doublepole switchwherethesupplymustbe suita- bly fused3 A. 3.Anun-switchedsocketoutletcomplingwithBS 1363. The methodofconnectingtheplug brownwiretolive (U bluewiretoneutral(N) andgreen/yellowtoearth(), see fig.3. A threecore cable should be used and a heatresistingca- ble of0.75 mm2 (24 x 0.2 mm) is consideredsuitable. 2.9DescriptionofOperation The cable shouldbe passed throughthegland on thetop oftheapplianceandtheclamptightenedtosecurethe cable. Ensure currentcarryingconductorsbecome taught beforeearthingconductorshouldcableslipfromthe cordanchorage.Connectiontotheappliance shouldbe made in accordance withdiagram(see section 3,6,2). Read in conjunctionwithfigs1. 2 and 4). The controlsontheBRITONYII FF are comprised ofa ran- ge ofthermal,electric and electronic switches. Broadly, the thermalcontrolsareforthepilotflamesupervision, the electrical controlsare functionalswitching and theelectro- nic controlsact as a security forthe functional controls. Thecircuitis designedso that,undernormalconditions, thefanrunscontinuouslyatlow speed and automatically changestohighspeedwhenthegasvalveopens.If, however,theincomingairtemperatureapproaches0 C theintegralfrostprotectionthermostatinterruptsthe low fanspeed signal. Under thiscondition,if thereis a de- mandforhotwater,thenthefanrecommencesat.high speed.Thereisanin-builtdelaycircuittopreventthe safetydevices operatingprematurely. The pilotcan onlybe established underthecontrolofthe thermocoupleflamefailurecircuitafterthemains electri- cityconnectionismadesinceitis dependentuponthe energisingofrelay-RLI. If theair flowis notproved on high speed the flame failure device will operateby interruptingthethermocoupleas a resultofthefailureofthecircuitthroughrelay-RLI. Additionalsecurityisprovidedfortheconditionwhere, because thelinkage is mechanical, themain gas burneris initiatedbutthemicroswitchhas remainedin thelow fan speedposition.Iftheburnerissensedinthelowfan speed circuittheappliance fails safe. ELECTRICSUPPLY FUNCTIONALFLOWDIAGRAM . THERMOSTAT L r FAN 1r 17 AA I L r I THERM0 THERM0 MICROSWITCH RELAY -RL2 iRELAYL 7 RLl r COUPLE-tELECTRC VALVE SASVALVE I CIRCUITDIAGRAM L 2A Fig. 1* WIRING DIAGRAM Fig. 2 FUFura(2A) IElonkatlonelectrode TCThemlocouplr BMThemm4@cttlcValve SWMlcmswltch PRPressureSwitch Y-CYellow-Green BrBrown BIBlue RRed WWhlts 0onnos BkBlack vVI&t 0Grey PPlnk ELECTRICAL CONNECTION fuse3A heater switchedfusedspur NB:IFAPPLIANCEINSTALLEDIN ABATHROOM SPURMUSTBEEXTERNALTOROOM ---------I---------- NB:IFAPPLIANCEINSTALLEDINABATHROOM SWITCHTOBE OFPULLCORDTYPE heater neutral earth I9. !dii . 1.II*I i-.,.-.-ii-.-.i 3 A.fuseway doublepole switch Fig. 3 6MICRO-SWITCH WATERFLOW PREBSURESWITCH ,--w--w------- 11PRINTEDCIRCUITBOARD Fig. 4 3.INSTALLING THE APPLIANCE A verticalflatarea is requiredfortheappliance : 1006 mmhigh x 445mmwide(39.6 in x17.5 in). The surfaceon which theappliance is mountedmustbe ofa non combustiblematerial. 3.1Packaging The appliance is attachedtothewall via themountingbracketand twobottomscrew fixings.The appliance is packed in a single carton.Remove contentsfromcartonand check againstlist. I)APPLIANCE- Assembled withtrims. 21FLUEASSEMBLY:a)Air inlet ductcompletewithterminal. b)2nd section flueduct(inside air inlet duct). c)Flue turretwith1st section flueductfitted. d)Plastic turretcover. 3)ACCESSORYBOX - containing:-mountingbracket -gas and waterconnectionswithwashers, nutsand olives -fluelocking ring and 0ring seal -2 gaskets -4 wall mountingscrews -4 turretfixingscrews -2 turretcover fixingscrews -1 gas controlknob -1 temperatureselectorknob 7 -. 3.2PreparingandPreparation: fittingtheappliance y--- -Remove thebottomtrimby pulling forwards. -Slide thecontrolsfaciaplate(PI upwardstodisen- gage fromretainingbracket. -Release thefrontcase byremovingthefourfixing screwsand washerspositionedatthetop,bottom and centreofappliance. 11421:142j - --c 197.5mmminimum I 7 . --- !- rI I Ii -Remove thefrontcase byliftingoffthetoploca- tinglugsandpullingforwardtoclearthewater sectionat thebase oftheappliance. NOTE: A templateis notsupplied withthisappliance. Particularcareis thereforenecessary toensurethat theappliance mountingbracketis fittedlevel and po- sitionedaccurately,relativetotheflue. -Refertothedrawingsoppositeforrearandside flueapplicationsand/ortothedimensionsgivenin Section 1.4, referalso toSection 2.4 forfluetermi- nal siting. -Set outandrill hole forflueusing a100mm(4 in) core drill. -Using thedimension290mm(11.4in) accurately markpositionforbracket. -Drill and plug thewall. - FixbrackettowailusingNo.12screwsprovided, ensuringthatthebracketis level.Ifnecessaryad- justbracket,finallysecure in position. - Hang theapplianceonthebracket,andre-check forlevel.Markbottomfixingholes,removeap- pliance, drill and plug thewall tosuitNo. 12 screws. -Re-hangapplianceandsecurewithscrewsprovi- ded. 3.3 3.4 3.5 Fittingtheflue - Measure thewallthicknessandcutflueductand air inlet duct torequiredlength,(see Section 1.4). -Peeloffprotectivepaperfromadhesivesideof corkgasket(A) andplaceonmatingsideofflue turret(B)lining up screw holes and press down. -Fitlockingring(C) and0ringovertheairinlet duct. -Fit flueductand turretso thatitengages intothe terminal. D-Engage locking ringoverlugs by turningin an anti- clockwise directionviewed frombehind turret. - Pass theassembled fluethroughthewall. -Iflongfluesectionsareused (up to3 metres)and difficultyis found,thesecanbeassembledwhilst being passed throughthewall. -Seat theturretontothetopoftheappliance ensu- ring thegaskets are in position. -Secure with4 screws provided. -Do notfitplastic turretcoverorthefrontcase un- tilelectricalconnectionshavebeenmadeandthe appliance testedforgas and watersoundness (see Section 5.1). -Asealing ring(D) is suppliedwhichcanbeused to seal theair inlet ducttowall joint-externally. - Make good inside wall surface. Gas Connection Fitthegasservicecockprovidedusingthefine c$ filter/washertoseal theconnection.Fit thenutand olive onto the15 mm gas supply pipe and tighten. andpurgeKP:331.3). Testthecompletegasinstallationforsoundness I Waterconnections - Remove theplastic coversprotectingthewaterin- let and thewateroutletconnections. - Fitthewaterservicecockprovidedtotheright handconnectionatthebottomoftheappliance using thecoarse filter/washertoseal theconnec- tion. - Fit thenutsand olives ontothesupply and delivery pipes. - Connecttheinletsupply tothewaterservice cock and tighten. - The waterservice cocksupplied withtheappliance incorporatesa drainplug. -Ensure thatall waterconnectionsarefullytighte- ned. 9 3.6 Electricalconnections3.6.1.PressureSwitch - Connectthewiresatthetopoftheapplianceto thepressureswitch. - The greywireis connectedtonormallyclosed (NC I)contact. -The pinkwire tothenormallyopen (NO 21contact. - The violetwire tothecommon(P) contact. -Fit theflueturretcoverpassing thewirethrough oneoftheslotsprovidedandsecurewiththe screws provided. -See figure. 3.6.2.Mains Connection - Pass 0.75mm2heatresistingcablethroughcable gland. - Theearthwire(greenyellow)mustbeconnected totheearthpillar ( &). - Thelive(brown)andneutral(blue)shouldbe connectedas indicatedinto theterminalblock. -Check thatcomponentplugs are pushedhome. - Check forcontinuity,polarityand earthing. L 10 10APPLICATIONSOF THE BRITONY II FF The appliance is designed toserve a varietvofhotwater drawoffPoints including washing machines and showers. The appliance can be connectedtoall hotwaterdraw-off pointsin theinstallation.Ifmorethanoneoutletis open simultaneouslvthetotalflowofwatercannotexceed thatquotedin theTechnical Data. The appliance is comptatibiewithmostcurrentautomatic washingmachinesbutcareshouldbetakentoensure thatthemachine is capable ofacceptingwaterat thede- sign flowoftheappliance. Hotand cold fillmachines nor- mallyrequirea hotwatertemperatureof60 C (140 F), theapplianceproducingapproximately6.5 Vmin Vl.44gpm)atthistemperature.Theadviceofthewas- hingmachinemanufacturersshould be soughtbutgene- rally itis onlynecessary toremovethewaterflowrestric- tor(if fitted)in thehotwaterinletconnectionofthema- chine toobtaina satisfactoryappliance operation. ContactChaffoteauxLimitedfordetailsofthosemachi- nes known tobe compatiblewiththeBRITONYII FF. Do notuse theappliance withpush on hand showers that fitoverexistinghotandcoldwatertapsorwithmixer tapsunlessbothsuppliescomefromthesamesource. Showers formingpartofbathmixersare notrecommen- ded forsatisfactoryoperationoftheappliance. 4.1Pipework The followingnotesare forgeneral guidance only. 0) Theapplianceperformancemaybeaffectedifthe installationhas oldpipeworkformingdead-legs orair reservoirs.Always ensure thatanyold pipeworkis ei- therremovedorcapped offimmediatelyadjacentto thepipeworkthatwill be in use. (ii) The size ofthepipework between theapplianceand the various draw-offpoints should be sized toensure an ade quate flow at all drawoffpoints when used indiiually. (iii) A checkshouldbe made ofall stopcocks in theinco- mingsupply and itshould be ensured thattheyareof thefixedjumperpattern.Loose jumperscan bepin- ned orsolderedintoposition. ...... ..-.*.*::.:::....... ......... ...... _*.-.~.~.~.~_~.~.~.:::::. HOTWATER TOCOLDTAPSDEREVEWATER ALTERNATIVE POSITION The appliance can be used tosupply hotwatertoa sepa- rateshowerdraw-off.The appliance shouldnotbe used tosupplymorethanoneshowermixingvalve.There- commendedpipeworkarrangementforasingle shower headis shownabove.Only thosefittingsdetailedshould beused withtheappliance.ChaffoteauxLimiteddonot supply thewatergovernororany showerfittings.For lo- cal suppliers oftheseplease contact: 4.2 A waterreservoiris providedon theoutletside ofthe heatexchangertolimit thewatertemperaturedue to ((afterheat)a. Watergovernor-Dereve (Flow Controls)Limited Park lane HANDSWORTH Birmingham821 8LE Tel :021 5537 021 ShowerAccessories-Caradon Mira Ltd. CromwellRoad, CHELTENHAM Gloucester GL 52 5EP Tel : 024227953 Aqualisa ProductsLimited HortonsWay, London Road, WESTERHAM,Kent, TN16 IBT Tel : 0959 63240 11 5. 5.1 COMMISSIONING PuttingintoService5.1.1.Open thegas and waterservice cocks beneath theappliance,purgethegassupply(CP331:3). Turn onanadjacenttapandpurgethewaterside ofthe installation. Testforwatersoundnessatall appliance andexter- nal pipeworkconnections. Switch on electricalsupplv, fanwill run at low speed. 5.1.3.Tolightthepilottemporarilyfitthegas controlknob(A)andlightthepilotbyturningthe knob 90anti-clockwise.It may be necessary topurge thepilotgas supply,ifso, waita fewminutes,return thegas controlknobtotheOFF positionand repeat. (The pilotsupplywill onlypurgewhenthegas control knob has been turned90anti-clockwide). 5.1.4.Whenthepilotis litturnthecontrolknob(A) fullyanti-clockwiseas shownin thediagram.Test for gassoundnessusingleakdetectionfluidonallgas connections. 5.1.5.Checktheoperationoftheflamefailu- redevicebyblowingoutthepilotlight,theflowof gas tothepilotwill cease and thethermoelectricval- veshoulddropoutwithanaudibleclick withinap- proximately30 seconds. 5.1.6.Remove gas controlknob (A). 5.1.7.Switch offelectricalsupply. 5.1.8.Fit frontcase by locatingbottomfirstand en- suring topofcase locates overbracket.Secure with4 screws and washerspreviouslyremoved. -Thecentrescrewandplasticwasherretainsthe fasciamountingbracket. -Replacethecontrolfasciaplatebyslidingdown ontothesupportbracket. -Fit bottomtrimby sliding ontorails. - Fitthegascontrolknob(A) andthetemperature selectorknob(B). Thetemperatureselectorknob shouldbepushedontothesplineuntilitlocates. Turnfullyclockwise to(+I, repositionknob as requi- red, so thatindicatordotis oppositethe(+) sign. 5.1.9.Switch on electricalsupply. -Lightthepilotandturngascontrolknob(A) fully anti-cockwiseto,themain gas position. -Ifthepilotis nowextinguishedforanyreasonre- turnthegas controlknobtotheOFF positionand waitapproximately30secondsforthesafetyin- terlocktoresetbeforerepeating. 12 5.5.2Gas Pressure-Turnonanadjacenthotwaterdrawoff,theap- pliance will now lightand thefanwill change tohigh Speed. -Withthefrontcasefitted,checktheburnerset- tingpressureat thepressure testpointU. -If theburnersettingpressureis notcorrect,check thatthepressureatthegasservicecock,test pointis 20 mbar(8 in.w.g.) withtheappliance ope- rating.If theinletpressure is notcorrect,check for anypossible blockage orrestrictionin thepipework totheappliance. If theinlet supply pressure cannot becorrectedcontactyourlocalgasregion.The heatinputtotheapplianceispresetandnon- ajustable. .4Microswitch 5.5 SlowIgnition-Checkburnerignitionwhich should be smoothand quiet(notexplosive). -Ifslowignitionrequiresadjustmentproceedas in Section 6.1 toremovefrontcase. -Adjustslow ignitiondevice l/4turnata time.Refit frontcase and recheck operation. NOTE : Turningscrew A clockwise delays ignition. Themicroswitchis factorysetandshouldnotrequireadjustment.Whentheappliance is atrestthefanruns continuouslyatlowspeed.checkoperationas followssettemperatureselectorto+. opendrawoff.Thefan shouldnowcometohighspeed beforetheburnerignites.On closingdrawoffburnershould extinguishbefore thefanresumes at low speed. If fan/burneroperationalsequence is NOT as describedconsultor contactChaffo- teauxLtd (Service Department). ThePressureSwitch Check theoperationofthepressureswitchas follows: Open drawoff,fancomes tohigh speed and theburner ignites.Close drawoff,burnerextinguishesand whenfanresumesatlow speedlisten fortheclick as therelay changes over. This should be followedwithin15 seconds by a lighterclick as thepressure switch changes over.If thetimeseparationis greaterthan15 seconds orif thepilotextinguishesitsuggests thatthepressureswitchis incorrectlyset and should be referredtoChaffoteauxLtd (Sercice Department). 13 5.45.6ThermoelectricCircuit 5.7HandingOver The ThermocoupleCircuitis fittedwithan interrupterso thatiftheair flowis notprovedonhigh speed thecir- cuitis incompleteand theflamefailuredevice will operate.In thecase ofintermittantpilotfailureorpermanent pilotfailurethethermocouplecircuitcan be checkedwithaBritishGas MultimeterorsuitableMillivoltMeterto determineifthepilotfailureis duetopoorthermocoupleoutput,highresistancethroughRelay-lcontactor faultythermoelectricvalve. (See Section 2.9 Fig. I). Hand theUser instructionstotheuserorpurchaserandinstructin thecorrectandsafeoperationoftheap- pliance. Explain totheuser orpurchaserthatiftheappliance is notused forlongperiodsitis recommendedthattheap- pliance is drained, thisis particularlyimportantduringthewintermonths(see servicinginstructionsforprocedu- re todrain appliance). Finally, advise theuser orpurchaserthat,forcontinuedefficientand safeoperationoftheappliance itis impor- tantthatadequateservicing is carriedoutat regularintervals. 14 146.SERVICING INSTRUCTIONS 6.1 6.2 6.3 Beforecommencing any service work: 1.Isolate electrical supply. 2.Remove bottomtrimby sliding forward. 3.Turnoffgas at gas service cock. 4.Turnoffwaterat waterservice cock. 5.Drain theappliance by openinghotwateroutlettapand removingdrain plug in thewaterservice cock. FrontCasingTo remove: -Pull offgas control and temperatureselector knobs. -Remove controlsfaciaplateby sliding upwards. -Removethefourfixingscrewswhichsecurethe frontcase (top,bottomand centre)takingcare not toloose facia retainingbracketand washers. -Remove thefrontcase by liftingoffthetolocating lugs and pulling forwardtoclear thewatersection at thebase oftheappliance. Burner - Removethecombustionchamberfrontpanelas detailed below. -Removetwothreadedscrewswhichsecurethe frontpanel ofthecombustionchamberskirttothe fluehood (A) Section 6.4. -Remove threeself-tappingscrews on eitherside of combustionchamberskirt(B) Section 6.4. -Unscrew thepilottubeclampingscrew(A) andre- movetheclampandscrewandpilottube.Discon- nectthepressuretestpointtubefromtheleft hand end ofthemanifold. -Removetheburnermanifoldbyunscrewingthe twoscrews (B) and twoscrews and washers (0. -Unplug ionisation electrodeat theconnector. -Withdrawtheburnerheadassemblytakingcare nottodamage thepilotbvurner/electrodeassem- bly or theignitionleads. -Theburnerheadshouldbeturnedupsidedown and cleaned by brushing. -Replace in reverseordermakingsurethatthegas- ketbetweentheburnermanifoldand gas section is in place and is in good condition.If necessary replace gasket and ensure thattheburnerhead assembly is correctlylocated on thetwospigots at therear. Pilot-Removecombustionchamberfrontpanel, burner and pilot tubeas in 6.2 ifnotalreadyremoved. -Blow throughthetubetoremoveany dust. -Remove screw securingsparkelectrode.Liftoutof D slot and ease toone side, -Unscrew theknurledpilotburnerouterring (A). -Remove flameretentiongauze. -Unscrew thepilotbody(B) witha15 mmspanner. Clean by brushing and blowing. DO NOT CLEAN HOLESWITH A WIRE. -Re-assemble in reverseorderensuringpilotbody is screwed down tightly. 15 6.4HeatingBody 6.5 6.6 a)Theheatexhcangercanbeexaminedinposi- tion: -Removecombustionchamberfrontpanelasin Section6.2ifnotalreadyremoved.Priortoclea- ningtheheatexchangeradequateprecaution should be takentoprotectthepilotburner/gasval- ve assembly topreventtheingress ofdustetc. -If extensivecleaning is necessary, theheatexchan- ger will need tobe removedasfollows. b)To removeheatexchanger -Slide outcombustionlining and retain. Disconnecttheunionsoneithersideoftheheat -exchanger. -Removetwoscrewssecuringthecombustion chamber/heatingbody assembly totherear panel. -Remove heat exchangerand combustionchamber. - Remove twoscrewsattherearofthecombustion chambersecuringthecombustionchambertothe heat exchanger toseperatethecomponents. Careshouldbetakenwhenhandlingtheheating exchangertoensurethatthefinsarenotdama- ged. -Replace in reverseorder. I ,DescalingProcedure Periodically itmay be necessary toremovescale depositsfromthewaterwaysoftheappliance toensure conti- nued and efficientoperation. The frequencywill dependlargely on thehardnessofthewaterin each specificarea. If thisis necessary COntaCt yourlocal waterauthorityforadvice. Advice withregard todescaling is available fromChaffoteauxLtd (Service Department). To inspectand clean - Remove theburner(see Section 6.2). -Disconnect thethermocoupleatthePCB and igni- torlead fromthepiezo unit. -Removethefourscrewsandwashersfastening thetopofthegas sectiontothebase and thetwo screws at theback holdingit totherear case. -Liftthegas sectiontopoffthebase, takingcare nottodamage thecorkgasket. -Remove thehexagonalspringretainer(A) fromthe topoftheassembly (20 mm). -Remove thespringand gas valveand clean theval- ve seating (IS). -Renew facingrubberwasheron thegas valve ifne- cessary. -Replace inreverseorder,ensuringthatthehexa- gonalspringretainingnutisscrewedfullydown and thewholeassemblyis screwedfullydowninto thegas section. 16 16WaterGovernor 6.10 6.11 To clean -Turnoffthecold watersupplvtotheappliance and drain intoreceptacle. -Removethegovernorsituatedinthebase ofthe watersection. -Clean thecomponentswithwater. -Check thatthespringloaded pistonmoves freely. -Replace in reverseoder. Gas andWaterFiltersGas andwaterinletfiltersarefittedbetweenthe inletservicecocks andtheappliance. -Toclean, turnofftheservicecocks,unscrewthe unionnutsattachingthecockstotheappliance and removethefilters. -Clean thefiltersby blowing or washing in water.DO NOT USEANY SOLVENTS. -Replace ensuringthatthecoarsefilteris fittedin thewaterinlet and thefinefilterin thegas inlet. 6.9Microswitch The microswitchoperatingmechanismis factorysetand ifthemicroswitchrequiresreplacementoradjustment proceed as in Section 7.12 and 7.13. Pressureswitch: The pressure switch is factoryset. To replace or adjustproceed as in Section 7.10 and 7.11 GreasingofComponents Care should be takenduringtheannual service ofan appliance togrease thegas valve spindle (see Section 6.6) and thediaphragmspindle tsee Section 7.5). Use eithergraphitedor silicone grease. HeatInput Itis a requirementoftheGas Safety(InstallationandUse) Regulations1984thattheburnerpressureand gas rateare checked each timean appliance is serviced,likewise theservice engineershould satisfyhimselfwithre- gard togas soundness and theadequacy ofcombustionand ventilationair if thisis appropriate. The heatinputis presetand non-adjustable. The heatinput and burnerpressureshould be checked against Table 1. If theheatinput/burnerpressureis notcorrectcheck theworkingpressure at thepressure testpointon thegas service cock. This should be 20 mbar(8 in wg). The gas installationshould be examinedforany possible blockage if thepressureis incorrect. 17 7REPLACEMENT OF COMPONENTS Beforecommencingany workinvolving componentreplacement: 1.Isolate electricalsupply. 2.Turn offgas at thegas service cock. 3.Turn offwaterat thewaterinlet cock. 4.Drain theappliance by opening hotwateroutlettapand removingthedrainplug in thewaterservlce cock. 5.Remove thefrontcasing (see Section 6.1). 7.1Thermocouple 7.2SparkElectrode Thermoelectricvalve 7.4WaterSectionVenturi - Remove theburner(see Section 6.2). - Remove thepilot(see Section 6.31. -Tracethethermocoupleand disconnectattheter- minal on thePCB. - Witha 7 mmboxspanner,unscrewthenut(B) hol- ding thethermocoupleinto thegas section. - Threadthethermocoupleand wireup throughthe gas section. - Replace in reverseorder. -Remove theburner(see Section 6.2). -Remove theelectroderetainingscrew (A). - Pull offtheelectrode cable fromthepiezo cartridge. -Lifttheelectrodeoutofthegas section. -Re-assemble in reverse order, and notethattheslot in theconnectoron theend oftheelectrode cable is verticalwhen pushed onto thecartridge. NOTE : Spark gap is 3-5 mm - Torenew,removethethermocoupleconductor lead nut(A). - Unscrewcap(B) fromtheside ofthegassection and withdrawthethermoelectricvalve. NOTE -Thisheateris fittedwithasafetyinterlock. When thepilotis turnedoff,theappliance cannotbe relituntilthethermocouplecools downand theligh- tingsequence is repeated. - Disconnecttherighthandheatingbodylegfrom thewatersection and removetheventuri(A). - Cleanorreplaceasnecessaryandre-assemblein reverseorder. 18 7.37.6 7.7 Diaphragm-Torenewensurethatthecoldwatersupplyand gas are turnedoff. -Drain theappliance byremovingthewatergover- norplug situatedin thebase ofthewatersection. -ys;;ectthetwowaterconnectionsat thewater -Unscrewthesixscrews(A) whichholdthewater sectiontothegas section. -Removethewatersectioncompletewiththedia- phragm. -Carefullyremoveand inspect theplastic watersec- tiontopcover. -Re-assemble in reverse order. NOTE : Fit thewatergovenorlast. It is easier ifthe cold waterinletconnectionis partiallyengagedbe- fourfittingthescrews and reconnectingtheunion -Disconnect thespark electrodelead fromthepiezo unitcartridge. -Remove thescrew holding thegas controlcam and removethecam (A). -Remove the two screws (8) holding the retaining plate. -Remove thepiezo cartridgeand renew. -Onreassemblingensurethatthelocatingpinson eachendofthespringarecorrectlyengagedin theirlocation holes. -Disconnectelectricalconnectorsfromassembly. Notepositions. -Removetwoscrewsand washers(B) securingsup- portbrackettofluehood. -Removethetwoscrews and washerssecuring the fanassembly tothefluehood. -Release wiringloom fromsupportclip. -Gentlyease thefanassembly awayfromtheflue hood disengaging lug at rear offanassembly. -Removetwoscrewsandwashers(A) holdingsup- portbrackettomotor. -Re-assemble in reverse order. NOTE :Thedimension-backplatetofrontfaceof impelloris : -57.5 mm + 0.5 mm -0.0 mm 19 7.8ToReplaceFuse orPCBIsolate electricalsupply. lA (A)FUSE :-Pull outfuseholder(A) fromboardand slide fuseoutofholder. (B) PCB:-Remove connections(fan.microswltch. pressureswitchandionisationlead completewithsleeve) -Disconnectmainssup~lvcablefrom termtnals. -Remove twonuts and washers (6) retai- ning thermocoupleand conductorlead. - Removefuseandeaseboardfrom plastic retainingclips. -Remove fourscrews and removePCB. -Re-assemble in reverseorder. 7.9 7.10 7.11 Toreplaceionisationprobe-Remove pilottube(see Section 6.3). - \.. -Remove combustionchamberfrontcover(see Sec- tion6.4 a). -Disconnect ionisationlead. -Remove screw (A) secunngprobe tobracket. -Pull outprobewhilstfeedinglead throughburner. -Replace in reverseorder. To replacepressureswitch - Isolate electricalsupply. -Remove twoscrews securingplastic turretcover. - Pull offtagconnectorsfromterminals. -Remove low pressuretubefrompressure switch. -Removetwoscrews securingpressureswitchto bracket. -Liftoffpressureswitch. -Remove0ringfromspiggotontheundersideof thepressureswitch. -Replace in reverseorderreferringtocolourcoding label on topofappliance. Adjustmentofpressureswitch a)If Pilot eXtinctiOn occurwithin5/10seconds ofturninghottapoff,it is possible thatthepressureswitchis out ofadjustment.If thepressure switchremains in thehigh flowpositionin excess ofS/IOseconds afterthefan switchingtolow speed interruptionofthethermoelectricalcurrenttotheflamefailurevalve occurs, Itis possible toadjustthepressureswitchtoensurea rapidreturnofthepressureswitchfromhightolow flow. AdjustmentSequence:-Adjustingthepressureswitch -Ensure thefrontcase is on. -Isolate electricalsupply. -Removetwoscrewssecuringplasticturretcover and liftoffcover. -Removeterminalcoverfrompressureswitchex- posing theadjustingscrew (A). -Set a multimeterto240 V scale and connect it across thecommon and one other terminal ofthe switch. -Re-establish electricalsupply and ensure thatgas is offat gas control. -Turnon a hottaptogive high fanspeed. -Usingasuitablescrewdriverscrewtheadjusting screw(A)inuntilchangeoverofthepressure switchcontactsare observed. -Screwoutadjustingscrew(A) 3turnstoachieve thesettingpoint. -Check operation of the pressureswitch (seesection 5.5). -Replace theplasticterminalcoveronthepressure switch. -Replace theplastic turretcover and fixingscrews. b)Ifmain burnerextinctionoccurs duringhotwaterdemand,itis possible thatthepressureswitchis outofad- justment.Screw adjustingscrew(A) outuntilflushwithtopofmoulding,thenfollowadjustmentsequence above. 20 7.12ReplacementofMicroswitch-Isolate electrical SUPPIY. -Part connectorplug on leads tomicroswitch. - Remove twolock nuts (4 mm) frommicroswitchre- taining screws. -Remove screws securingmicroswitch. -Remove switch togetherwithplastic insulating plate. - Renew microswitchand replace in reverseorder. 7.13 7.14 7.15 AdjustmentofMicroswitchoperatingmechanism -Re-establish electricalsupply -leave gas cock and hotwatertapsoff. -Set temperatureselectortof. -Slacken lock screw (B) using I,5mm hexagon socketscrew kev. -Check whetherfanis at high orlow speed. -If fanatlow speed screw outadjustmentscrew (A) untilhigh speed is obtained,thenscrew in untilhigh Speed k observedthena further3 fullturns. - If fanruns athigh speed screw in adjustmentscrew (A) untillow speed is observed thena further3 fullturns. -With thefannow atlow speed turnon a hottap. - Screw adjustmentscrew (A) outuntilhigh speed fanoperationis obtained. -Continueunscrewing adjustmentscrew (A) fora further1 turn. -Hold screw in position withscrewdriverand lock withhexagon socketscrew (8). -Check operationofmicroswitch(see Section 5.4). ToreplacetheGas andWaterSection -Remove theburnersee 6.2. -Disconnect microswitchbv partingplug connectoron leads. -Remove theconductorlead at thermoelectricvalve (see Section 7.31. -Remove thermocouplelead atPCB. -Remove spark electrodelead frompiezo cartridge(see Section 7.6). -Disconnect thegas union atrear ofgas section. - Disconnect thewaterconnectionsfromthewatersection. Mains inlet and watersection toheatingbodv. -Remove thetwoscrews securing theburnerbase totherear chassis. -Re-assemble in reverseorder. ToreplaceCeramicLinersinHeatingBody - Remove theburner(see Section 6.2). -Remove twothreadedscrews(A) (Section 6.4), whichsecurethetopfrontpanel oftheheatingbody tothe flue hood. -Remove six self tappingscrews (B) (Section 6.4). fromfrontpanel ofheatingbody. -Slide outfrontand side ceramic liners fromlocatingchannels. - Ease heatexchangerforwardtoallow rear ceramic liner tobe liftedclear oflower channel. -Liftpanel and withdrawlower edge first. -Re-assemble in reverseorder. 21 8 8.1 8.2 8.3 8.4.1 8.4.2 FAULT FINDING CHART FOR BRITONY II FF PROBLEM Pilotdoes notlight PoorPilotFlame Pilotwillnotstayalight Mainburnerdoes notlight Burnergoes out onhotwaterdemand CAUSE i)Gas service cock closed ii)Air in pipe iii)Pilot injectorblocked iv)No ignitionspark i)Pilot injectordirty ii) Wronginjector iii)Pilot head blocked iv)Faulty pilottube v)Pilot injectorloose i)Pilot flamepoor ii) Thermocouplenotworking iii) Thermoelectricvalve faulty iv)Gas pressurelow/variable v)Terminalwronglypositioned vi)Badly assembled flue vii)Pressure switchoutofadjustment /iii)Pressure switchfaultv ix)Plugs loose on PCB x1 PCB faulty i)Gas service cock notopen fully ii)Gas pressurelow iii) Waterratelow iv)Gas valve notopening v)Diaphragmpunctured vi)Venturiblocked orloose vii) Gas controltapfaulty /iii)Slow ignitiondevice screwed fullyhome i)Fan notswitchingtohigh speed ii)Pressure switchoutofadjustment iii)High pressuretubedetached iv)Flue blocked v)PCB faulty REMEDY Dpen service cock Purge line Clean orchange Check electrode,lead and ignitor Clean orchange Change forcorrectdiameter(0.23) Clean Clean orreplace Tighten See 8.2) Above a)Check connectionclean and tighten as necessary b)Replace ifoutputless than8 mv. Replace ifdropoutgreaterthan5 mv. Check atinlet toappliance (see 5.2) Re-position(see 2.4) Re-fitcheck sealing a)Check operation(see 5.5) b)Adjust(see 7.11) Replace (see 7.10) Secure Replace (see 7.8) Open fully Check atmanifoldand atinlet with theappliance running(see page 3 and 5.2) Check if waterrateis sufficient (see page 3) Check (v) and (vi) Change diaphragm(see Section 7.5) Check venturi Check operationofUsers gas controltap Adjust(see 5.3) a)Check micro-switchoperation(see 5.4) b)Adjustmicro-switch(see 7.13) c)Micro-switchdefective- replace (see 7.12) d)Fan defective- replace (see 7.7) a)Check pressureswitchoperation (see 5.5) b)Adjustpressureswitch(see 7.1 I) c)Pressure switchdefective- replace (see 7.10) Refix Check and clear Replace (see 7.8) 22 8 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 FAULT FINDING CHART FOR BRITONY II FF PROBLEMCAUSEREMEDY ExplosiveIgnitioni)Pilot toosmall ii)Slow ignitionnotadjusted Check pilottubeand injector Check and adjust(see 5.3) Gas controltapstiff (Users) i)Grease dried ii)Operatingmechanism replaced incorrectly Clean and regrease Refit LowWaterTemperaturei)Waterrate toohigh ii)Insufficientgas flow iii) Watergovernorsticking iv)incorrectventuri v)Main burnerinjectordirty Check watergovernor Check rateand if users tapis open Remove and clean orreplace (see 6.7) Replace (3.65 mm) (see Section 7.4) Clean orreplace (see Section 6.2) Burnerstaysoni)Air in pipework ii)Gas valve stays open iii)Dirton gas valve facing iv)Dirtor foreignmatter in watersection v)Loose jumperon house stockcock tap Check fordead legs Clean and grease gas spindle Stripand clean gas valve (see Section 6.6) Clean watersection Replace waterstoptaporpin down jumper YellowFlames - SootFormed i)Heating body finsblocked ii)Primary air supply restricted iii)Wronginjectors Remove heatingbody and clean (see 6.4) Check burnermanifoldand clean (see 6.2) Check injectorsizes UnstableFlamei)Waterin gas line ii)Faulty flue Drain and purge Check terminalposition and flue ducts (see Section 3.31 HeatingBodyNoisei)Scale ii)Excessive gas iii)Insufficientwaterflow Descale heatingbody Check gas pressure (see 1.3 and 5.2) See below Fan Noisyi)Fan remaining athigh speed ii)Fan outofbalance a)Check micro-switchoperation(see 5.4) b)Adjustmicro-switch(see 7.13) Replace (see 7.7) InsufficientWateri)Waterservice tapclosed ii)Blocked venturi iii)Low waterpressure iv)Watergovernorfaulty v)Watergovernorsticking vi)Foreign matterin watersection vii)Waterfilterblocked Check itis fullyopened (see 3.5) Remove and clean venturi(see 7.4) Check waterpressure (see Section 1.3) Change governor Remove and clean or replace (see 6.7) Remove and clean (see Sectlon 7.4) Remove and clean/replace(see 3.5) 23 ChaffoteauxLtd,Concord House, BrightonRoad, Salfords,Redhill, SurreyRHI5DX. Telephone: Harley(0293) 772744.Telex : 87378.4 E Warrington(0925) 830052.P ESP012