CHAFFOTEAUX BRITONY COMBI 80 100 Maintenance and Service GUIDE

-=G v AA MAINTENANCE AND SERVICE GUIDE CC Edition et COMLEC 4/95 combi 80 and 100 Fanned Flue Combination Boiler Heating and Instantaneous Domestic Hot Water Dimensions JKLMN I Boiler outer case dimensions : I Safety valve outlet ‘lue types: Height : 850 J Heating flow : 12 C 22 or C42: horizontal - Boiler width : 440 (minimum space required 450) K D.H.W. flow :32xx: - Depth : 380 vertical concentric L Gas supply M Cold water inlet N Heating return Technical data Heat input C/H & DHW Combi 80 : 11.73 to 28.70 kW DHW flow rate at @ 30°C Combi 80 : 11.1 I/min Combi 100 : 15.43 to 34.57 kW Combi 100 : 13.4 I/min Heat output C/H & DHW Combi 80 : 9.5 to 23.25 kW DHW flow rate at @ 35°C Combi 80 : 9.54 I/min Combi 100 : 12.5 to 28 kW Combi 100 : 11.5 I/min Max. operating pressure C/H circuit : 2.5 bar Minimum DHW operating flow rate : 2 I/min Expansion vessel net capacity : 5.4 I Minimum DHW working pressure : 0.1 bar Expansion vessel initial pressure : 0.7 bar Maximum DHW working pressure : 10 bar Electrical consumption : 15ow Gas category : II 2E+ 3+ Voltage 230 v Electrical protection index IP24 Fuses : 2Aand 1.25A Nominal gas flow rate at 15°C and 1013 mbar BRITONY Combi 80 BRITONY Combi 100 Maximum Minimum Maximum Minimum power 23.25 kW power 9.5 kW power 28.2 kW power 12.5 kW -Natural gas ( G 20) at 20 mbar 2.74 m3/h 1.22 m3/h 3.34 m3/h 1.57 m3/h -Butane gas ( G 30 ) at 28 mbar 2.04 kg/h 0.91 kg/h 2.45 kg/h 1.17 kg/h -Propane gas (G 31 ) at 37 mbar 2.00 kg/h 0.89 kg/h 2.42 kg/h 1.15 kg/h Injectors and gas valves seat diameter BRITONY Combi 80 BRITONY Combi 100 Natural qas Butane or Propane Natural qas 1 Butane or Propane -Blue solenoid restrictor diameter 2.40 mm 1.74 mm 2.80 mm 1.90 mm -Black solenoid restrictor diameter 4.25 mm 5.00 mm 5.20 mm 3.80 mm -Manifold injectors (16) 1.23 mm 0.72 mm 1.26 mm 0.76 mm

Pump and expanssion vessel characteristics bar Hauteurmanomemque m 13 5 I,7 1 13 3 2 I,3 1 1 ,I 0 DPbd 100 200 300 400 5OD 600 700 800 utl 03 0,7 1 = by-pass closed 20 50 100 150 200 250 c (I) 2 = by-pass open Note : The system initial pressure should be over the following value : Head available / flow System static height (in metre) + 0.7 = Initial pressure (in bar) 10 Components location 1. CH Flow isolating valve 2. DHW outlet 7. Pressure relief valve 3. Gas service tap 8. Chassis 4. Water service tap 9. Connecting tails (x 5) 5. CH Return isolating valve 8 3 4 95 7 10. Steel chassis complete with expansion 24. Multigas burner comprising: 39. Combustion chamber made of Jesse1 11. Sealed chamber -25. 16 burner head aluminium coated steel with 4 cera- 12. Expansion vessel (not visible) -26. Manifold mic fibre panels to insure heat insu- -27. 2 Ignition electrode lation 13. Overheat thermostat -28. lonization electrode 40. Copper main exchanger 14. Electrical box 29. Gas section comprising: 41. Stainless steel secondary plate 15.Three position selector switch 16. User’s guide -30. Security valve (grey) exchanger -31. l/3 gas stage (blue) 42. Three way valve 17. Heating flow temperature adjustment -32. 2/3 gas stage (black) 43. connecting bracket 18. CH pressure gauge 33. Right hydraulic assy 44. DHW flowstat 20. Green indicator - Power ON 34. Left hydraulic assy 45. Heating flowstat 21. Orange indicator - Burner ON 35. Single speed pump 46. Flue hood ?2. Red indicator - Lock out/flame failure 36. Air separator 47. Adjustable by-pass ?3. Reset button 37. Heating thermistor 49. Air Pressure switch 38. DHW thermistor 50. 45” elbow comprising venturi 51. Fan 2

WNCTIONING the gas service tap is opened at the gasmeter and 50 pressure in central heating system is above 0.7 bar and below 2.5 bar with the pressure gauge0 (8). 3) Open the gas tap (3) by turning from right to left. 0 4) The boiler is now ready to use. 1) Turn selector switch (15) to position flf . The green “power on” indicator 0 (20) will light. 2) Turn on a hot water tap, the orange “burner on” indicator @ (21) will light and the water will become hot. ‘9 0 ‘3 0 x3 Heating and Hot Water ‘3 ‘3 0 ,3 ‘3 1) Turn selector switch (15) to position 2 ‘1111. The green “power on” indicator 0 will light (20). 3) If the room thermostat (if fitted), the boiler temperature control ‘1111 and the clock (if fitted) are all calling for heat, the orange BRITONY COMBI FUNCTIONAL DIAGRAM 12 ____A 35 Hot water mode 3

“burner on” indicator 4 (21) will light and water temperature is controlled by the hot shuts off the gas. The red lockout indicate the heating will be on. water control thermistor 38 and the central bulb 0 22 will light. When there is a need for hot water while heating control thermistor (37). This SYS- The central heating flow temperature i: the heating is on, it is only necessary to turn tern anticipates the changes of temperatu- controlled by the central heating contra on a hot tap. The heating will be interrupted re in the secondary heat exchanger and thermistor (37). The boiler has been desi momentarily while the hot water is being ensures accurate temperature regulation. gned to minimise cycling and will not attemp delivered. The boiler will switch back auto- matically to heating when the tap is turned to relight for at least 3 minutes after the boi When the tap is closed the burner is extin- ler thermostat has been satisfied. When the Off. guished and the pump stops. The boiler room thermostat is satisfied the burner wil Note: If the boiler has been turned off for will now stay in the hot water mode for switch off and the pump will remain running some time the first attempt to light it may three minutes to maintain temperature to for a further 3 minutes before it too stops. result in a lockout @ (22) . If this happens ensure a fast response in the event of a press the reset button (23) and the boiler subsequent hot water demand. NB will light. It is possible to override the 3 minute dela! Priority will be given to a demand for hot by pressing the RESET button (23). Domestic Hot Water Mode water. This will interrupt the central hea- To be able to supply hot water, the selector ting for the duration of hot water delivery. Lock out procedure switch 15 must be in either on ,:’ or Flame disappearance : ‘1111 2 position. This will be confirmed by Central Heating Mode When the ionisation electrode (28) does no the green indicator light 0 (20) To be able to supply heating, the selector detect flame presence. The orange indicate switch (15) must be on ‘Ill1 c? position. lamp (21) extinguishes. A lighting cyck When a tap or shower is turned on, the flow This will be confirmed by the green indica- starts. If a flame is not detected before f of mains water, above 2 litres per min., will tor light 0 (20). seconds, the grey security solenoid (30) ark activate the DHW flow switch (44) and the blue i/3 solenoid (31) will close. The allow the 3 way valve (42) to move to the When there is a demand for heating lock out red indicator (22) lights, the pump DHW position. The pump can now circulate (either from the room thermostat or the (35) runs and the 3 way valve (42) stays ir Its position. primary water heated by the main heat clock) the pump starts. If the boiler tempe- exchanger through the secondary heat rature control is calling for heat and prima- After a few seconds, it will become possibk to reset the boiler by pressing the reset but exchanger. ry flow rate over 4 Itr/min, the central ton (23). heating flow switch operates ailowing the The first stage solenoid (31) (blue) and . Ignition sequence to begin. The first stage Overheat detection : security solenoid (30) (grey) open together to allow gas to the burner. The ignition solenoid (31) (blue) and security solenoid If an overheat is detected by the senso sequence begins and a continuous high (30) (grey) open together to allow gas to (13), the grey security solenoid (30) and the speed spark ignites the gas. As soon as a the burner. The ignition sequence begins blue i/3 (31) closes, the orange indicate flame is detected the orange indicator bulb and a continuous high speed spark ignites lamp (21) extinguishes. The ignitor is energi h (21) will light and the second stage sole- the gas. As soon as a flame is detected sed for 8 seconds and the red lockout indi noid (32) (black) opens to allow the full gas the orange indicator bulb b (21) will light. cator (22) ligths. If the burner cannot religh the boiler will go to lockout. rate. If a flame is not detected, after 8 After 45 seconds the second stage sole- seconds, the security solenoid closes and noid (32) (black) opens to allow the full shuts Off the gas. The red lockout indicator gas rate, lf a flame is not detected, after 8 bulb @ (22) will light. The domestic hot seconds, the security solenoid closes and WIRING rEiimiq Plug for main power and Room thermostat connection I 1 2 3 4 5 El 1. Neutral 2. Phase 3. Room thermostat live 4. Accelerator resistor 5. Common for Accelerator and room thermostat. 4

ELECTRICAL WIRING continuation I U” 13. 14. I4a. 14b. I4c. l4d. I4e. I4f. 149. 18. 27. 28. 30. 31. 32. 35. 37. 38. $2. $4. $5. 51. Designation Wiring colours -Overheat sensor Brown -Electrical box -Regulation PCB -Igniter Red, Black -Fuse 1.25 A -Fuse 2A -Power PCB -Room thermostat -Mains 230V 50 Hz -Pressure switch 2: Black P: Orange 1: White -Spark electrodes White -Ionisation probe White -Security solenoid (grey) Grey -2/3 gas stage solenoid (black) Black -l/3 gas stage solenoid (blue) Blue -Pump -C/H thermistor Violet -DHW thermistor Green -3 way valve White, Yellow, Orange -DHW flow switch Brown -C/H flow switch Red -Fan Brown. Blue REGULATION Temperature regulation for both C/H and DHW circuits are controlled by 2 thermistors. The C/H knob allows the adjustment Df temperature between 35 and 85°C. The DHW temperature is limited to 60°C. DHW and C/H thermistors are identical and interchangeable. Resistance value are -5000 Q at 25 “C -2631 Q at 40°C -620 52 at 80°C -255 Q at 11o”c FLOW SWITCHES Flow in both D.H.W. and Heating circuits are detected by 2 flow switches. A piston with a magnet at the top operates a REED switch. The piston is lifted by flow rates listed below : Flow rate threshold : D.H.W. 120 I/h ?20 I/h C/H 250 I/h *20 I/h AIR PRESSURE SWITCH The air flow rate is detected by a pressure differential created by a venturi located in the flue duct. ON threshold AP > 130 Pa OFF threshold AP < 100 Pa ADJUSTMENTS ON CONTROL The following adjustments are available on the regulation PCB. To gain access to them, pivot down electrical box, remove the rear cover and the rear panel of electrical box, unplug connectors from regulation PCB and pull it toward you. Heating output limitation : - Functioning without limitation plug C on “P MAX” - Functioning at l/3 gas rate only plug C on “P l/3” Burner functioning: - Regulation available 3/3, l/3, 0 - Functioning at full gas rate only plug D on “NOR” plug D on “TUR” I ROUTINE SERVICING To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation condition and usage, but in general, once a year should be adequate. It is the law that any service work must be carried out by a competent person such as your local Chaffoteaux Service Centre, British Gas or other CORGI registered personnel in accordance with the current Gas Safety (Installation and Use) Regulations. The service schedule should include the following operations: - Check the pressure in the system. - Check the correct operation of the appliance. - Check the correct operation of the gas controls. - Check the functions of the safety controls. - Check combustion chamber insulation panels for damage. - Clean the burner. - Clean the heat exchanger. - Check the burner manifold injectors. - Clean gas and water filters. - Check expansion vessel charge pressure. - Clean and check operation of safety valve. Additional Procedures that may be necessary: - Check burner pressure and gas flow rates. - Check that the fan blades are clean. - Check, clean and replace components as necessary. - Carry out combustion test utilising the tes points in the flue turret. SUGGESTED SEQUENCE for SERVI- CING Before disconnecting or removing any parts, isolate the gas and electricity supplies. Ensure that the appliance is cool. (for detail please see section on Parts Removal and Replacement) Preliminary Checks - Remove outer case - Check the system pressure is at least 0.7 bar cold - Check operation of l/3 and 2/3 solenoids - Check that the burner is extinguished full: when both solenoids are closed in both DHW and C/H modes. - Test ionisation functions and check that lockout occurs by turning off gas tap. -Whilst boiler is operating, check operatior of primary flow switch by closing heating flow valve and by pass screw (turn clockwi se) noting the number of turns so that it may be reset correctly. 5 1

REMOVAL AND REPLACEMENT OF PARTS 1 efore removing appliance case, isolate 5. Ignition Electrodes e gas and electrical supplies. Isolate boi- Carry out steps 1 and 2 as above. Hinge r from the system and drain before remo- down electrical box by pressing retaining ng any component in the waterways. tabs P on either side. nsure that the appliance is cool. Remove wiring cover C. Disconnect leads front panel as in steps 1 and 2. Disconnec three pressure switch cables noting the1 positions. 1 = white cable connected to NC 2 = black cable connected to NO Outer Case and C t free. When replacing, carefully locate on gs (B) on top edge of chassis. Combustion Chamber iscrew four self tapping screws securing s sealed chamber front panel and lift er top corner locating lugs. Unscrew four If tapping screws to release combustion iamber front plate and lift clear. ?assemble in reverse order. Burner Manifold lrry out steps 1 and 2 as above. Remove o screws securing the closure plate and ? remaining four screws to release the mifold. Lift clear. Replace the manifold sket. Reassemble in reverse order. Ionisation Electrodes trry out steps 1 and 2 as above. Loosen rews securing the closure plate and nove. Disconnect the lead from the main ring loom. Remove screw securing elec- Ide to burner. Thread wire through grom- 9 and lift clear. Reassemble in reverse der. from spark generator. Loosen screws securing the closure plate and remove. Remove grommet from base of sealed chamber. Remove screw securing electrode bracket and lift clear easing spade connectors through the grommet. Reassemble in reverse order, twisted together electrodes cable at least IO times to avoid electrical interfe- rence. 6. Burner Assembly Carry out steps 1,2, disconnect electrodes as mentionned in section 4 and 5. Remove two screws securing burner assembly to the back panel of the boiler. Lift right hand back corner first. Reassemble in reverse order. 7. Gas Solenoids Disconnect colour coded leads. Remove six screws. The solenoids are attached to their base plate. Lift clear taking care not to lose the three plungers and springs. Reassemble in reverse order replacing the cork gasket. 8. Fan Assembly Remove outer case and sealed chamber front panel (See Steps 1 and 2). Disconnect spade connectors noting positions. Remove two screws securing the front of the fan assembly and loosen screw on flue outlet. Twist fan assembly anticlockwise to disen- gage from flue outlet and lift clear. Re-assemble in the reverse order ensuring that the wiring is re-connected correctly and the screw on the flue outlet tightened. 9. Flue Hood Carry out steps 1 and 2 as above. Remove fan assembly as in step 8. Remove the three screws securing the angled top of the hood to the chassis. Lift and remove taking care not to snag the pressure switch cables. Re-assemble in the reverse order ensuring that the hood is located behind the combustion chamber rear panel. 10. Pressure Switch Remove outer case and sealed chamber P = orange cable connected to C Remove screw securing the switch bracks to the chassis. Disconnect the samplin! tubes again noting their positioning (+ an -). Remove switch. Reassemble in revers order. 11. Pressure Switch Venturi Carry out steps 1, 2 and 8, as above Disconnect the sampling tubes and rema ve the screw securing the venturi to thl flue outlet. Remove venturi by the botton of the 45” elbow. Reassemble in revels order. 12. Drain down 5 drain points are located on the boiler (air sebarator) 1 = DHW circuit drain point 2 = Heating circuit drain point 13. Water filters ( DHW and Heating) The DHW filter ensures a seal between the connecting bracket and the pipe to the DHW flow switch. Drain the boiler as ir step 12. Unscrew the pipe nut and remove the clip on the hydraulic assy. Pull the pipe toward you and remove the water filter from its location. The C/H filter is located in the right hydrau lit assembly. Remove the return pipe a: described previously and withdraw the fit ter. Reassemble in reverse order.

14. Flow switches Drain boiler as in step 12. Disconnect the electrical plug, turn the top cover anticlockwise, remove the O-ring and the brass piston. Reassemble in reverse order. 15.3-Way valve Drain boiler as in step 12. Remove the 3 clips on the 3 way valve. Remove the clip on the exchanger flow pipe. Pull the pipe down then pull it out of the 3 way valve. Disconnect the plug from the motor. Unscrew the nut on the pipe between the connecting bracket and the 3 way valve and pull it toward you. Rotate the 3 way valve body anti-clockwise to unclip it from the left hydraulic assembly. 16. Secondary heat exchanger Drain both circuits of the boiler as in step 12. Unscrew the 2 fixing screws (D) and remove the DHW exchanger from the front. Prior to reassembly, check that the 4 gas- kets are correctly positioned. The heat exchanger is so designed that it cannot be remounted incorrectly. 17. Main heat exchanger Carry out steps 1 and 2 as above. Drain boiler as in step 12. Remove the 2 clips (E) located on return and flow pipes and pull them downwards. Pull the main exchanger toward you to remove. Reassemble in reverse order. H 18. Pump Drain boiler as in step 12. Pivot the electical box downwards. Open the electrical box cover removing the 2 screws. Remove the pump plug from the power board and earth plug from earth socket. Unscrew the nut (F) of the return pipe from the volute. Remove 22. Spark generator Carry out steps 1,2, and open the electrical box cover as mentionned in step 5. Undo the 4 screws of the electrical rear panel and remove it. Unplug electrodes wires, remove the ignitor connector from the PCB, remove earth plug from earth socket. Hang out the ignitor. Reassemble in reverse order. the clip (G) on the pump volute and pull pump toward you. Reassemble in reverse order. 19. Pressure relief valve The pressure relief valve can be serviced from the front of the appliance. Drain the boiler first, undo the retaining screw and pull out the valve.Reassemble in reverse order. 20. Thermistors Drain the boiler as step 12. Disconnect the plug, remove the retaining clip pull the thermistor out. Reassemble in reverse order. 38 = DHW thermistor 37 = Heating thermistor 38 37 21. Safety thermostat Remove the casing as step 1 and hinge down the electrical box as step 5. Disconnect the 2 cables, pull out the sensor with the clip (13). Reassemble in reverse order. 23. Power board Carry out steps 1, 2, and open the electrical box cover as mentionned in step 5. Undo the 4 screws of the electrical rear panel and remove it. Unplug all cables from the PCB, remove earth plug from earth socket. Hang out the power board. Reassemble in reverse order. 24. Control board Pull out plastic knob from the front panel and proceed as step 23. Reassemble in reverse order. 25. Expansion vessel Remove the casing as step 1 and drain the boiler as step 12 above. Unscrew the connecting tails nuts and lift out the boiler from the wall. Place it on a side on the floor. Remove the expansion vessel bracket retaining screws, disconnect the pipe from the vessel and pull ti toward you. Reassemble in reverse order. 7

FAULT FINDING CHART Part 1 . -Check mains electrical connection -Check internal fuses -Check connection between the 2 PCBS Ok No Yes Does the red LED 1 No Ihght ? I - Ok Press the reset button Check or replace the DWH flow switch Does the pump run 1 Draw off Domestic Hot water 1 PLEASE CHECK THEFOLLOWING POINTS CAREFULLY BEFORE GOING Replace DHW flow Check DHW flow switch Does the pump run ? Does the fan run ? 1 switch operation I .I , , y&3& “-- Lot -Replace pressure swtch switch continuity \ J between P and 2 Check or replace main or secondary heat exchangers They could be _..“-. ~ ..“.. ,,. .,,- -.iler -Id 1 Replace spark generator or ignition electrods assembly a go~~~o~~~~o 1 1 11 fully scaled. I Release pump rotor THROUGH THEFAULT FINDING CHART -Gas pressure -Electric mains -Minimum water pressure in the heating circuit (over 0.8 bar) -All isolating valves have been opened -Boiler air vented -Minimumdomestic hot water flow of 2 I/min -Check that the heating filter is clear. Replace driver or control PCB Replace heating thermistor Check heating thermistor Replace pressure switch Ok Check air pressure switch continuity between P and 1 No Replace fan assembly I & No I Replace Driver or control PCB I

FAULT FINDING CHART Part 2 Does the orange LED light ? Does the DHW temperature rise ? Replace control PCB because orange LED is deffective Replace control or driver PCB Check if an overheat occur or replace overheat sensor No Does the red LED light 1 Yes Does overheat contact close ? Press the reset button Replace driver PCB Replace gas solenoids Do the gas solendids energise 1 Yes Is there a gas pressure at manifold ? Yes Replace electrode assembly Check the ionization electrode Ok I Replace driver PC6 I No F I Wait until the temperature becomes stable. Does DHW temperature rise over 7o”C? No Stop water draw off J Replace DHW thermistor Does the heating outlet pipe temperature we ? +Y Replace the DHW heat exchanger Replace control PCB Does the orange LED light ? + Yes Replace the 3 way valve cvi hot then rotate the heating control knob anticlockwise to minimum Replace control PCB Does the orange LED light ? I 1 No The boiler is OK co

SHORT LIST 104---B 411 572 505 811 39 805 607 938 532 615 560 627d 6294 (ey no Description BRITONY COMBI 80 BRITONY COMBI 100 GC N” 104 OVERHEAT THERMOSTAT 100°C 2;7$83 Manf. Pt. N” G.C. N” Manf. Pt. N” 1010572 277783 1010572 110 IGNITION ELECTRODE ASSY 277788 1002801 277788 1002801 111 IONIZATION ELECTRODE 277789 1002802 277789 1002802 113 HEAT EXCHANGER 277790 1010017 1011136 206 FAN ASSY 277804 1010212 1003011 216 PRESSURE SWITCH KIT 277808 81725 277808 81725 411 SOLENOID VALVE KIT 277812 81432 277812 81432 505 THREE-WAY VALVE 277833 1010000 277833 1010000 514 WATER/WATER HEAT EXCHANGER 277836 1002540 1011164 532 WATER THROTTLE HEAD ASSY 277846 81471 277846 81471 553 WATER FILTER 277854 1007727 277854 1007727 560 AIR SEPARATOR HEAD ASSY 277857 1002653 277857 1002653 572 PUMP 1 SPEED 240V 277862 1010774 277862 1010774 605 CONNECTOR 277872 1010349 277872 1010349 607 IGNITER 379075 1002105.20 379075 1002105.20 615 PRINTED CIRCUIT BOARD OF POWER 277880 1010592 277880 1010592 616 PRINTED CIRCUIT BOARD OF REGULATION 277881 1010047 277881 1010047 627 FUSE 250V 2A - TEMPORIZED 277883 1003456 277883 1003456 629 FUSE 250V 1.25A - TEMPORIZED 277884 1003635 277884 1003635 805 PRESSURE GAUGE 1012561 1012561 811 BLACK KNOB 1011699 1011699 922 TAP HEAD ASSY 366937 67704 366937 67704 938 PRESSURE RELIEF VALVE 277770 76584 277770 76584 Chaffoteaux et Maury are continuously improving their products and therefore reserve the right to change specifications without prior notice and accepts no liability for any errors or omission in the information contained in this document. 8 0 Chaffoteaux et Maury 1996 a: 6 W iz Chaffoteaux et Maury Ltd 2 Q Trench Lock Trench a Telford -7 Shropshire Ei TFI 4SZ : r: Tel: 01952 222727 Fax: 01952 243493

CHAFFOTEAUX BRITONY COMBI 80 100 Maintenance and Service GUIDE

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