COMBINATION BOILER Heating and lnstantane~us eater with TSS@ Domestic Hot Fanned Flue system Calydra 80 Installation and Operating instructions Calydra 100
These instructions are suitable for the following boilers : Calydra 80 Calydra 100
CUSTOMER CARE Chaffoteaux et Maury Ltd , as a leading manufacturer of domestic and commercial water heating appliances, as well as domestic unvented direct and indirect storage cylinders, is committed to providing high quality products and a first class after sales service. If it is necessary to contact an engineer, then telephone your local Chaffoteaux Service Centre.
Page Page CUSTOMER CARE.. .................................................................... Guarantee.. .................................................................................. Statutory Requirements.. ............................................................. Contents.. ..................................................................................... INTRODUCTION.. ........................................................................ 3 3 3 4 5 DESCRIPTION.. ......................
By combining their modern highly efficient low water content fanned flue combination boiler concept and the brand new TSS@‘Temperature Stabilised System”, Chaffoteaux et Maury have created a whole new concept. CALYDRA This unique combination is able to provide the user with hot water immediately at the outlet of the appliance and stable temperatures at both extremely low flow rates or when several taps are opened together.
Location of components 1. Flue hood with fan 2. Sealed chamber 3. Gas valve assembly 4. Electrical box 5. Pump 6. Automatic air separator and automatic vent 7. Multi-gas burner assembly comprising ignition and ionisation electrodes 8. Combustion chamber 9. Main heat exchanger 10. Steel chassis complete with expansion VE 11. Air pressure switch 12. Overheat thermostat 13. TSS @J(mini cylinder) 14. Central heating control thermistor 15. Three way valve 16. Expansion vessel connecting tube 17.
29. 30. 31. 32. 33. 34. 35. 36. Location of heating filter (not visible) DHW circuit flow switch Heating circuit flow switch Hot water control thermistor Secondary heat exchanger Four position selector switch User’s instruction panel. Domestic hot water temperature adjustment 37. 38. 39. 40. 41. 42. 43.
SPEClFlCATloNS CALYDRA Appliance 80 category C/H 81 DHW C/H circuit pressures Min operating Max operating CALYDRA Natural gas G20 Gas rate Maximum 25.9 kW 88392 Btuh 31.1 kW 106138 Btu4-1 23.25 kW 79347 Bhuh inlet pressure 28.0 kW Nominal 95558 lBu4-1 0.7 bar 10 lb/in2 0.7 bar 10 lb/in2 2.5 bar 36.3 lb/in2 2.5 bar 36.3 lb/in2 Burner pressure Nominal Burner injector and restrictor Natural gas G20 l/3 restrictor Z3 restrictor DHW specific flow rates for 10 min Q 30 deg C rise 11.5 Vmin 13.
80 CALYDRA BUTANE 100 Gas rate Maximum 2.04 kg/h 4.50 lb/h inlet pressure Nominal 11.2 in wg 28 mbar 11.2 in wg Burner pressure Nominal Burner injector and restrictor Butane LPG G30 l/3 restrictor 213 restrictor 26.7 mbar 10.7 in wg CALYDRA Safety discharge - Heating 2.45 kg/h 5.40 lb/h Safety discharge - DHW 28 mbar Expansion Pre-charge LPG G30 24 mbar 9.6 in wg vessel pressure Net capacity Adjustable 0.7 mm 1.75 mm 4.9 mm 0.76 mm 2.0 mm 100 2.5 bar 2.5 bar 36.25 iblin2 36.
Outer case dimensions : -Width : 440 (minimum space required 450) 850 - Height : - Depth : 380 Weights With packaging -Calydra 80 : Calydra 100 : : 49.0 kg 49.5 kg Without packaging -Calydra 80 : -Calydra 100 : : 46.5 kg 47.0 kg Liit weight : -Calydra 80 : -Calydra 100 : 41.5 kg 41 .O kg 1po Tails diameter - J Heating flow 022mm K D.H.W. flow 015mm L Gas supply 022mm M Cold water inlet 015mm N Heating return 022mm P Safety valve outlet 015mm a,: I : ‘. ji -.
Minimum clearances : - Both sides 5mm - Above casing 170 mm - Below casing 200 mm - Front ( for servicing) 500 mm - Front (in operation) 5 mm TYPE C12, C42 or C22 T 155 * .<,: :*.*.: -----_-___------- y-m,.-+ '%.xx 4 .Z.S.2. .. 149 l -_- -A- r+% Fig.
Domestic Hot Water Mode To be able to supply hot water, the selector switch (34 fig. 6) must be in either on ,,? or ‘1111 ,i position. This will be confirmed by the green indicator light 0 (38 fig. 6). The hot water temperature in the mini cylinder can be adjusted between 40°C and 60°C using control knob (36 fig 6). When a tap or shower is turned on and the flow of mains water is above 2 litres per min., it will activate the DHW flow switch 30 fig 7 and allow the 3 way valve (15 fig.
TS@ control thermistor will call for heat. Bringing the pump and burners to operate, this is quite normal. The 3 way valve (15 fig. 7) will move to the domestic hot water position. The hot water from the primary circuit is then diverted to heat the mini cylinder via the coil and the secondary heat exchanger. 2 3c 7a 7b 3b 3a 10a 12 4 32 The safety solenoid (3a fig. 7) and the first stage solenoid (3b fig. 7) open together to allow a low rate of gas to the burner.
Central Heating Mode To be able to supply heating, the selector switch (34 fig. 6) must be in ‘1111 $ (heating and hot water position) or ‘fill (heating only position).This will be confirmed by the green indicator light 0 (38 fig. 6). When there is a demand for heating (either from a room thermostat, the built-in clock or an external programmer) and the boiler temperature control is calling for heat.
INSTALLING Planning Please ensure that you are familiar with the installation requirements as well as the relevant British Standards and Statutory Regulations (see page 3) before commencing work. Location The CALYDRA can be installed on any suitable internal wall. Provision must be made to allow the correct routing of the flue and siting of the terminal to allow the safe and efficient removal of the flue products.
Drill and plug the wall and secure the hanging bracket using the screws provided (refer to the paper template drawings). Remove the boiler from its packaging as shown in (fig. 8) and remove the outer case as shown in (fig. 9). Please note: If the pre-piping jig has been used it must be removed before attempting to hang the boiler. Place the boiler on the wall on the hanging bracket. Safetv Valves There are two pressure relief valves fitted to the CALYDRA.
so that it does not terminate over an entrance or window or where a discharge of heated water could endanger occupants or passers by. The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. Fig. 10 Heating flow 022mm K D.H.W. flow 015mm L Gas supply 022mm M Cold wafer inlet 015mm N Heating return 022mm P Safety valve outlet 015mm Q D.H.W.
Making the Electrical Connections Push in the tabs (P fig. 11) on either side of the boiler and pivot the electrical box forward to gain access to the electrical connections. Undo the two retaining screws (A fig. 1 l), remove cover (B fig. 11) and remove cable clamp. Connect the live and neutral wires to the multipin plug leaving sufficient earth wire to connect to the earthing point. (B fig.
Making the Electrical Connections (continued) t l i 3 amp. Mains q.
Pre-commissioning Ensure that the system has been adequately flushed. Purge gas supply of air and test for soundness. Carry out final electrical tests to ensure the correct polarity and earthing continuity. Electrical Adjustments There are three adjustments that can be made: 1. Room thermostat options 2. Pump speed 3. Burner operating modes : 1. Room thermostat options To gain access to the setting switch (1 fig. 13) pivot forward the electrical box cover and remove the cover (B fig.
3 min 3 min TUR Pmin 3. Burner operating modes : To gain access to the switches it is necessary to remove the facia: remove the main case pivot the electrical box forwards remove the pressure gauge clip noting its position replace elecrical box in its upright position remove the two screws and unclip the fascia from the electrical box remove the rubber grommet to gain access to the switches PCB adjustments (fig. 14) : Four switches are gathered together on the regulation PCB and labled SW4.
DHW Open the main cold feed valve. l Open all hot taps to purge DHW system. l Check for water soundness. l Central Heating Open flow and return valves on the boiler.(l9 and 23 fig. 15) l Open the automatic air vent (6 fig. 16) l Fill system and vent radiators. l Set system pressure and remove filling loop. l Check for leaks. l Manually check pump is free to turn. l Switch on electrical supply. l Turn selector switch (34 fig. 16) to heating only or heating and hot water position.
Post Commissioning l Ensure system pressure has been set correctly. l Set DHW temperature adjustment knob to required position l Set heating flow temperature adjustment knob to required temperature. l Set the built in clock or external programmer to householder’s requirements. l Set external controls. l Switch boiler to domestic hot water position and draw off hot water to allow TSS@ cylinder to heat up quickly. K6 Fig.
Flue The boiler must be installed so that the flue terminal is exposed to the free passage of external air at all times. It must not be allowed to discharge into another room or space such as an outhouse or closed lean-to. The minimum acceptable clearances are shown below: - A Directly below an opening, window, etc ... .. . . . .. 300 mm - B Below gutters soils pipes or drain pipes . .. . . .. . . .. . . 75 mm - C Below eaves . . .. . .. .. . .. .. . . .. . .. . . .. . .. . . .. . . .. .. .. . . . . .. . .
Ventilation The room in which the boiler is installed does not require specific ventilation. IF IT IS INSTALLED IN A CUPBOARD OR COMPARTMENT PERMANENT VENTILATION IS NOT REQUIRED FOR COOLING PURPOSES. If vents are installed, they must communicate with the same room or be on the same wall to outside air. Gas Supply The gas installation and soundness testing must be in accordance with the requirements of BS 6891 .
Flushing and Water Treatment The performance of the appliance could be impaired by system debris or the effects of corrosion. The system must be flushed thoroughly to remove metal filings, solder, machining oils and other fluxes and greases before connecting the boiler. An appropriate flushing and descaling agent should be used, particularly if it is an existing system. Refer to BS 7593 (1992) for guidance.
By pass and Pump The boiler is fitted with a pre-adjusted by pass. Although adjustment is not normally necessary, the by pass can be reset by turning screw (17 fig. 18) clockwise to open the bypass using the chart below for guidance. It is a l/4 turn from fully closed to fully open. If used on a system with thermostatic radiator valves, the flow rate, through the system, with the thermostatic valves closed should be at least 100 I/hr.
Expansion Vessel The expansion vessel is pre-charged to 0.7 bar (10 Iblin2). The vessel is suitable for systems up to 145 litres capacity. For systems of greater capacity an additional expansion vessel will be required. Refer to the chart below and BS 7074 pt 1 or BS 5449. Pressure 2,o 13 128 1.7 ’ System capacity Filling Point Provision must be made to be able to charge the system on commissioning and to make up any subsequent pressure loss.
Control panel 34. Four position Selector switch ‘Ii11 = Central heating only ( TSS@ not operational ) l = Switched OFF F = Hot water only ( including TSS@ ) z 9111 = Hot water ( including TSS@ ) + Central heating 35. User’s instruction panel. 36. &= Domestic hot water temperature adjustment 37. ‘Ill1 Heating 38. 0 Fig. 22 35 flow temperature adjustment Green indicator - Power ON 39. P Orange indicator - Burner ON 40. 0 Red indicator - Lock out I flame failure 41. “RESET” Reset button 42.
Switching on 1) Check that the gas service tap is opened at the gasmeter and main power is on. 2) Check that pressure in central heating system is above 0.7 bar and below 2.5 bar with the pressure gauge 0 (43 fig. 23). 3) Open the gas tap (21 fig. 23) by turning from right to left. 4) The boiler is now ready to use. Heating only 1) If heating is required without the need for TSS@ hot water storage, turn the selector switch (34 fig. 22) to position ‘1111.
MECHANICAL PROGRAMER 1. General layout The mechanical clock covers a 24 hour period. Each tappet represents 20 minutes (A fig. 25). An override switch is located on the right hand side of the clock (B fig 25). Fig. 24 2. To set the time To set the time of day, grasp the outer edge of the dial and turn slowly clockwise until the correct time is lined up with the arrow (C fig. 25). 3. To Set the “On” and “Off” times The clock uses a 24hours system. e.g. 8 =8.00 am and 18 = 6.00 pm.
-----a u 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.
