Chaffoteaux & Maury Celtic plus User guide

Supplied By www.heating spares.co Tel. 0161 620 6677

Celtic dus

Room SealedFannedBalanced Flue

Combination Boiler

GAS SAFETY (INSTALLATION AND USE) REGULATIONS.

It is the law that al1gas appliances are installed by a competant person

in accordance with the above regulations

(For use on natural gas only. G20)

G.C. No

47 980 07

from serial number 994 225 395 - 3

Installation and

Servicing Instructions

(leave these instructions with the user)

Looking Good.Heating Better

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CONTENTS

PageNo.

HealthandSafetyInformation 1

1. INTRODUCTION

1.1.

1.2.

1.3.

1.4.

1.4.1.

1.4.2.

1.4.3.

1.5.

1.6.

1.6.1.

1.6.2.

1.6.3.

1.6.4.

1.6.5.

1.6.6.

1.6.7.

Generaldescription,specialfeatures,guarantee

DimensionsFig. 1

TechnicalData

Clearances

Wall thickness

RearflueoutletFig. 2

Sideflue outletFig. 3,Fig. 3a,Fig. 3b

Otherflue arrangementsHorizontalFig. 3c

Descriptionof componentsandlocationFig.4

Descriptionof operation

CentralheatingFig. 5

Hot waterFig. 6

Gas(alsosee2.7)

Functionalflow diagramFig.7,

Safetycontrols

Functionalflow wiring diagramFig. 8

Illustratedtiiring diagramFig.9

2. INSTALLATION REQUIREMENTS

2. 1. General

2.2. Location

2.3. Watercirculationsystem

2.4. Sitingtheflue terminalFig. 10

2.5. Air supply

2.6. Electricalsupply

2.7. Gassupply

3. SYSTEM GUIDANCE

3.1. General

3.2 Systemcontrols

3.3. PumpFig. 11

3.4. Expansionvessel

3.5. Mainswaterconnection

3.6. Filling andrechargingFig. 12,Fig. 13(page12)

3.7. Makeupsystem

3.8. Pipework

3.9. Domesticexpansionvessel

3.9.1. Boilerreplacement

3.9.2. Existing systems

3.10 Cylinder

3.11 Inhibitorsandwaterconditioners

3.12 Add ondevices

3.13 HeatingandhotwatersystemsFig. 14,Fig. 15,Fig. 16,Fig. 17

3.14 ShowerapplicationFig. 17a

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CONTENTS (cant)

PageNo.

4. INSTALLING THE BOILER

4.1.

4.2.

4.3.

4.4

4.5.

4.6.

4.8.

4.9.

4.10.

4.11.

4.12

4.13.

Generalinformation

PositioningtheboilerFig. 18

RearoutletflueFig. 19

SideoutletflueFig. 20

Jig plateFig. 21

GasandwaterconnectionsFig.22

Waterconnections

Gasconnection

Fitting theboilerFig.23

Fitting thesafetyvalveFig.24

Fitting theflue (upto700mmlong)Fig.25

Fitting theflue (over700mmlong)

ConnectionthepressureswitchFig.26

ElectricalconnectionsFig.27

EXTERNAL CONTROLS

5.1. Time clock - TimeclockandroomstatFlg. 28 19

5.2. Time clock andzonevalves(springreturn)Fig. 29 19

5.3. ProgrammerandzonevalvesFig.30 20

5.4. Honeywell& SatchwellcontrolledzonesFig.3I 20

5.5. FrostthermostatFig. 32 20

6. COMMISSIONING

6.1. Hot watercircuits,filling Fig.33 21

6.2. 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. Adjusting theheatingsystemby-passFig.39 23

6.7. D.H.W. flow rateadjustmentFig. 39a 23

6.8. PumpswitchingadjustmentFig.39b 23

6.9. Fitting thecasingFig.40 24

ROUTINE SERVICING

7.1.

7.2.

7.3

7.4.

7.5.

7.6.

7.7.

Generalrequirements 25

To removefrontcasingFig.41 25

To removecombustionchamberFig.42 25

To removeburnerassemblyFig.43 26

To removepilot Fig.44 26

To cleanheatingreturnfilter Fig.45 26

Cleaningandreplacementof parts 27

To checkoperationof safetyvalveFig.46 27

(ii)

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CONTENTS(COW

Page.

8. REPLACEMENT OF PARTS

8.1. ToremovethermocoupleFig. 47,Fig.48 28

8.2. ToreplaceelectrodeandleadassemblyFig.49 28

8.3. ToreplaceoverheatthermostatFig.50 28

8.4. Toreplaceignition microswitchFig. 51 29

8.5. To replaceC.O.V. microswitchFig. 52 29

8.6. Toreplaceflow switchassemblyFig. 53 29

8.7. To replaceventuriFig. 54 30

8.8. ToreplaceprimaryheatexchangerFig. 55 30

8.9. ToremoveelectricalcontrolboxFig. 56,Fig.56a(page33) 30

8.10. ToreplacepumpheadFig. 57 31

8.11. ToreplacechangeovervalveFig. 58,Fig. 58a(page34) 31

8.12. ToreplacesecondaryheatexchangerFig. 59 32

8.13. Toreplaceair separatorFig. 59a 32

8.14. ToreplaceboilerthermostatFig. 60 33

8.15. Toreplaceboilerlimit thermostatFig.61 33

8.16. ToreplaceD.H.W. thermostatFig. 62 33

8.17. ToreplacesparkgeneratorFig.63 34

8.18. ToreplaceP.C.B.Fig. 64ElectricalboxlayoutFig. 65 34

8.19. Toreplacetherm0electricvalveFig.66 35

8.20. ToreplacesolenoidvalvesFig. 67 35

8.21. ToreplaceheatingbodyliningsFig. 68 35

8.22. ToreplacefanassemblyFig. 69 35

8.23. ToreplacepressureswitchFig. 70 36

8.24. Tore-pressuriseexpansionvesselFig.71 36

8.25. To replacepressuregaugeFig.72 36

8.26. ToreplacethedomesticexpansionvesselFig. 73 37

8.27. ToreplacemainburnerFig. 74 37

8.28. ToreplaceburnermanifoldassemblyFig. 75 37

8.29. Toreplacepilot injectionFig. 76 38

8.30. To replaceexpansionvesselFig.77 38

8.31. Toreplaceviewing windowFig .78 38

8.32. ToreplacemaingasvalvebodyFig. 79 39

8.33. ToreplacethethermometerFig. 80 39

8.34. ToreplacesafetyvalveFig. 81 39

FAULT FINDING

9.1. Logic sequence 40

9.2. Centralheatingoperation 41

9.3. Domestichotwateroperation 42

9.4. Faultfinding tabularchart 43

SHORT SPARE PARTS LIST

(iii)

Rearcover

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CONTROL OF SUBSTANCESHARMFUL TO HEALTH

IMPORTANT

To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to

provide information on the following substancethat is contained in this appliance.

Descriution

Combustion Chamber Lining

Material

Alumino Silicone Fibre

Precaution8

During servicing, keep the dust generation to a minimum and avoid

inhaling any dust and contact with the skin and eyes. Normal handling

and use will not present any discomfort, although some people with a

history of skin complaints may be susceptible to irritation.

When disposing of the lining ensure that it is securely wrapped and

wash hands after contact.

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1. INTRODUCTION

The Celtic plus is a wall mounted, low water content

fanned balanced flue appliance suitable for central heating

and hot water via a non storage water to water heat

exchanger. The maximum output is 23 kW (78480 Btti).

The boiler is designed for sealed systems only and included

in the appliance is the expansion vessel, circulating pump,

temperature and pressure gauges, safety valve, electric

connection box, and domestic expansion vessel.

The standard flue assembly supplied with the boiler is

100 mm (4 in) dia pipe, can be directed to the rear or to the

lett or right and can be extented to a maximum length of 3

m, or 1,6 metres horizontally using the available 90” bend

(see sections 1.4.1, 1.4.2 and 1.4.3 figures 2, 3, 3a, 3b,

3c).

Special features include :

- Output to central heating fully range rated between

l/3 and full output.

- High efficiency.

- Special jig plate enabling all pipework to be

installed before installing appliance.

.- Independent control over central heating flow

temperature and hot water.

- Fully adjustable central heating flow temperature.

- Regulation between 50” C and 82” C.

- High limit thermostat for both boiler and hot water.

- Water flow switch to protect appliance.

- Suitable for showers with compatible mixer valves.

Guarantee

The manufacturer’s guarantee on this appliance is for 12 months from the date of purchase. The guarantee is void, if the

appliance is not installed in accordance with the recommendations made herein.

1.1 DIMENSIONS

Fig. 1

B b

1 i

1-1

REAR OUTLET

Mains water in. 15 mm

FLUE

F--

/T’

SIDE OUTLET

FLUE

A 820.5 32.3

391.0 15.4

365.0 14.4

100.0 4.0

169.5 6.7

654.5 25.7

43.0 1.7

50.0 2.0

75.0 3.0

260.0 10.2

L 150.0 6.0

972.5 38.3

13.0 0.5

61.0 2.4

30.0 1.2

152.0 6.0

112.0 4.4

mm in

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1.2 Technical Data

Hot water

Input ........................................... 28.90 kW 98612 Btu/h

Output.. ...................................... 23.00 kW 78480 Btu/h

Water flow raised

45 “C (81 OF).............................. 7.4 Ymin 1.7 gaI/min

Water flow raised

35 OC(63 OF).............................. 9.5 Ymin 2.1 gaifmin

Water ffow raised

30 ‘C (54 OF).

............................. 11.1 Ymin 2.5 gallmin

Maximum temperature.. ............. 50 OC 140 OF

Maximum pressure.. ................... 10 bar 150 psi

Minimum working pressure.. ...... .6 bar 9 psi

Gas rate.. .................................... 2.743 m%-r 96.87

ft3fh

Burner pressure.. ........................ 11.8 mbar 4.7 in wg

Central heating

Maximum input.. ........................ 27.64 kW 94313 Btulh

Maximum output.. ...................... 22.00 kW 75068 Btu/h

Gas rate (maximum). .................. 2.63’m3/h 92.98 f&h

Burner pressure.. ........................ 11.2 mbar 4.5 in wg

Minimum input.. ........ ................. 10.85 kW 37020 Btu/h

Minimum output.. ....................... 7.64 kW 26062 Btu/h

Gas rate (miniium) ................... 1.Om?h 35.31

ft3lh

Burner pressure.. ........................ 1.5 mbar 0.6 in wg

Minimum flow rate ..................... 3OOK-l 1.1 gai/min

Maximum pressure.. ................... 2.5 bar 36.5 psi

Natural gas

Manifold injectors 14 of.. ............ 1.28 mm 0.05 in

Pilot injector.. .............................. 0.3 mm 0.01 in

Gas section restrictors 2/3 valves 4.4 mm 0.17in

l/3 valve.. 2.3 mm 0.09 in

Connections

Gas.. ............................................................ 22 mm copper

Heating flow ................................................ 22 mm copper

Heating return. ............................................. 22 mm copper

Mains cold water inlet ..............._.................. 15 mm copper

Hot water outlet ._........................... .............. 15 mm copper

Electricai supply 240 V - 50 Hz, fused at 3A.

Electrical consumption ................................. 195 watts

Internally fused, two at 2A (BS 4265)

Weight ......................................................... 42 kg 92.4 lb

Water capacity ............................................. 4 litres 7 pints

Ignition - Anstoss continuous spark generator

Electrode - Chaffoteaux et Maury Ltd, spark gap 5 mm

Boiler thermostat - EGO (82’C)

Boiler limit thermostat - SOPAC /JAEGER (85X)

Hot

water

fim?t thermostat - SOPAC /JAEGER (57°C + 3°C)

Safety overheat thermostat (Tokoswitch - (lOSaC)

(Eimwood - (105°C)

Gas valve - AEMF

Fan motor - SEL.

Pressure switch - DUNGS 102 Pa / 55 Pa

Pump head - GRUNDFOS UP 15160

C.H. expansion vessel initial charge piessore - 0.65 bar (9.6 psi)

Domestic expansion vessel initii charge pn?ssure - 2 bar (30 psi)

1.3 Minimum Clearances around Boiler

Top above air duct .. ... 50 mm (2 in)

Bottom below case. ____._._. 150mm (6in)

Sides . . . . . 100mm (4ir-l)

Front. . 6GOmm(24in)

1.4 Wall Thicknesses

The standard flue assembly can accomodate the foliowing thicknesses.

Rear : from 55 mm to 576 mm

Side : from 55 mm to 392 mm

(this allows for a minimum clearance of 100 mm between the appliance and the side waii. As this dimension

increases. so the maximum side wail thickness available decreases).

Extension flue assemblies are available to accomodate wali thicknesses of:

Rear : from 577 mm to 2876 mm

Side : from 393 mm to 2692 mm

See figs. 2 and 3 for details of number of extensions required.

IMPORTANT NOTE : The extension ducts supplied, up to a maximum of 3, wili in fact permit a greater length than

indicated to be covered. The ducts MUST be cut so that the maximum length from the centre line of the flue turret to

the outermost point of the air duct DOES NOT EXCEED 3 metres horizontal. Greater length must not be used.

See sections 1.4.1. 1.4.2. 1.4.3.

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1.4.1

Rear Flue Outlet Horizontal

To cut flue assembly to length

- Measure wall thickness (I).

1.4.2

1.4.3

- Add 74 mm, tthis will give required Ientgh Q.

- Mark plastic air duct for length (L) and cut off

surplus (from plain end).

N.B. If extension sections are used ensure these are

fumly pushed together, see figs. 3b and 3c and a fall of 5

mm per metre length should be provided (see section

4.3).

- Cut off same amount from aluminium flue duct

(plain end).

REAROUTLET ASSEMBLY

Fig. 2

Side Flue Outlet Hohontaf

To cat flue assembly to length

- Measure from external wall face to centre line of

Ceftk

plus and substract 37 mm (this will give

required length “L”).

- Cut off surplus t?om plastic air duct (plain end).

N.B. If extension sections are used ensure these are

firmly pushed together, see figs. 36 and 3c and a fall of 5

mm per metre length should be provided (see section

Flue extension accessory

- Cut off same amount from

Part No. 62823.00

Fig. 3 SIDEOUTLET ASSEMBLY

standard air duct

Fig. 3a

PLASTIC AIR DUCT

Other ffue Arrangements Horizontal

Fig. 3c

1. Distance from internal corner 300 mm without

kit,107 mm with kit No 76216 (GC No 264 833).

2. Distance below balconies or eaves 200 mm

without kit, 107 mm with kit No 76216 (GC No

264 833).

Appliance is normally supplied packed with

standard 650 mm staight flue section. Additional

straight extension lengths of 1 metre, part No

62823 (GC No 264 459). can be use up to a total

straight length of 3 metres. It is also possible to

incorporate one bend in the flue using part No

65572 (GC No 264 835). In this case the length

Ll + 12 should not exceed 1.6 metres

horizontally.

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Description of Components and Location

2i 2i 2b 31 19 17 18

Fig. 4

The appliance is mounted in a steel case which has a

white epoxy resin paint fmish.

1. Chassis:

The chassis is a rigid plated mild steel pressing on which

all components are mounted.

Flue hood:

Is an aluminium alloy casting onto which the two speed

fan is mounted.

3. Combustion chamber:

This is assembled from a number of components

mounted onto the chassis. The front panel is simply

removed for servicing complete with the expansion vessel,

a hook is fitted below the appliance to accept and retain

the panel during servicing.

4. Expansion vessel:

The expansion vessel has a capacity of 5.4 litres (1.19 gal)

and is sized for a .normal system water content where the

load is equivalent to the maximum output of the boiler.

The charge pressure is 0.65 bar.

5. Pilot security is by thermocouple ffame failure.

6. Multigas burner comptisig: stainless steel blades (14)

and a manifold with injectors (14).

7. Gas section including thermoelectric valve and two

stage solenoid valves.

8. Secondary heat exchanger :

The secondary heat exchanger is a plate type heat

exchanger. A thermostat is fitted on the pipework limiting

the domestic hot water temperature to a maximum of 57

f3O c.

9. Change over vsfve :

The valve is activated by a demand for domestic hot

water, closes the heating circuits, and directs water to the

secondary heat exchanger.

IO.EIectriciaf box containing :

Mains connection

Fuses

Priited circuit board

Connections for external controls

Connections for fan, pressure switch and flow switch

Connections for pump

Connections for change over valve and for gas solenoid

valve

11. Solenoid valve :

Block on which 3 valves are mounted :

l/3 valve -1st stage valve-heating and hot water (blue)

Z/3 valve - full output to hot water (black)

2/3 valve - (variable valve) central heating (orange)

12. Grandfos pump motor

13. Air separtor and vent directly connected to the pump

inlet (not illustrated).

14. Regulation screw to adjust output to heating (2/3

valve).

15. Heating body comprising :

Copper tinned tube heat exchanger protected with silicone

resin paint. Combustion chamber in aluminium coated

steel. Combustion chamber lining - ceramic fibre panels.

16. Hirgh Emit thermostat (manual reset).

17. Water service tap (not illustrated).

18. Flow irsofating valve - heating (not illustrated).

19. Gas service tap (not illustrated).

20. Domestic hot water outlet with regulator (not

illustrated).

21. Safety valve with drain tap (not illustrated).

22. Heating return isolating valve with filter (not

illustrated).

23. Ignition button.

24. Thermometer indicating boiler flow temperature.

25.

Fuses.

26. Selector stitch - hot water only/OFF/heating and hot

water.

27. Thermostat to regulate heating ffow temperature.

28.

Pressure gauge.

29. Pressure switch (not illustrated).

30. Domestic expansion vessel (not illustrated).

31. Water flow switch (not illustrated).

32. Data badge position.

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