C&M BRITONY System II 80 Maintenance And Service Manual - User Manual

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MAINTENANCE AND

SERVICE GUIDE

System II 80 and 100

Central Heating

Fanned Flue Boiler

Dimensions

Technical data

Heat input C/H

System 80 :

11.73 to 28,70 kW

System 100 :

15.43 to 34.50 kW

Heat output C/H

System 80 :

9.50 to 24 kW

System 100 :

12.50 to 28 kW

Max. operating pressure C/H circuit :

2.5 bar

Expansion vessel net capacity

5.4 l

Expansion vessel initial pressure

0.7 bar

Electrical consumption

150 w

Voltage

230 v

Electrical protection index

IP24

Fuses

2 A and 1.25 A

Gas category

II 2E+ 3+

Nominal gas flow rate at 15°C and 1013 mbar

BRITONY System II 80

BRITONY System II 100

Maximum Minimum Maximum Minimum

power kW

-Natural gas ( G 20) at 20 mbar

2.74 m

1.22 m

3.34 m

1.57 m

-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 System II 80

BRITONY System II 100

Natural gas

Butane or Propane

Natural gas

Butane or Propane

-Blue solenoid restrictor diameter

2.60 mm

1.75 mm

2.90 mm

2.00 mm

-Gas valve restrictor diameter

6.70 mm

4.90 mm

no restrictor required

6.70 mm

-Manifold injectors (16)

1.23 mm

0.70 mm

1.26 mm

0.76 mm

Safety valve outlet

J Heating flow
L Gas supply
N Heating return

Sizes in mm

Flue types:
C 12 or 42: horizontal
C 32 xx:

vertical concentric

C 32 xy:

Twin flue

Boiler outer case dimensions :

- Height : 850
- Boiler width : 440 (minimum space required 450)
- Depth : 380

Pump and expanssion vessel characteristics

Pression disponible
Débit mini (robinets thermostatiques fermés)

Débit

1100

100

200

300

400

500

600

700

800

900

1000

l/h

m CE

Components location

bar

1. CH Flow isolating valve
3. Gas service tap
5. CH Return isolating valve

7. Pressure relief valve
8. Chassis
9. Connecting tails (x 3)

Note : The system initial pressure should be over the following value :

System static height (in metre) + 0.7 = Initial pressure (in bar)

1 = by-pass closed
2 = by-pass open

Head available / flow

10. Steel chassis complete with

expansion vessel

11. Sealed chamber
12. Expansion vessel (not visible)
13. Overheat thermostat
14. Electrical box
15. Two position selector switch
17. Heating flow temperature

adjustment

18. CH pressure gauge
20. Green indicator - Power ON
21. Orange indicator - Burner ON
22. Red indicator - Lock out / flame

failure

23. Reset button

24. Multigas burner comprising:

-25. 16 burner head
-26. Manifold
-27. 2 Ignition electrode
-28. Ionization electrode

29. Gas section comprising:

-30. Security valve (grey)
-31. 1/3 gas stage (blue)
-32. 2/3 gas stage (black)

33. Right hydraulic assy
34. Left hydraulic assy
35. Pump
36. Air separator
37. Heating thermistor

39. Combustion chamber made of

aluminium coated steel with 4
ceramic fibre panels to insure
heat insulation

40. Copper main exchanger
43. Connecting bracket
45. Heating flowstat
46. Flue hood
47. Adjustable by-pass
49. Air Pressure switch
50. 45° elbow including venturi
51. Fan
K. Flue kit fixing point (refer to kit

manual)

PUMP HEAD AVAILABLE

Minimum flow rate (with all heating thermostatic valves closed)

mCE

Flow

FUNCTIONING

COMPONENTS LOCATION

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

18.

3) Open the gas tap

3 by turning from right to left.

4) The boiler is now ready to use.

Central Heating

1) Turn selector switch 15 fully clockwise to position

The green

"power on" indicator

will light 20.

2) If the room thermostat (if fitted), the boiler temperature control

and the clock (if fitted) are all calling for heat, the orange

"burner on" indicator

21 will light and the heating will be on.

Note: If the boiler has been turned off for some time the first
attempt to light it may result in a lockout

22 If this happens

press the reset button 23 and the boiler will light.

Control panel

BRITONY SYSTEM FUNCTIONAL DIAGRAM

Central Heating

To be able to supply heating, the main switch 15 must be
turned fully clockwise to

position. This will be confirmed

by the green indicator light

20.

When there is a demand for heating (either from the room
thermostat or the external programmer) and the boiler tem-
perature control is calling for heat. The pump starts and at a
flow rate of 4 ltr/min the central heating flow switch operates
allowing the ignition sequence to begin.
The first stage solenoid 31 (blue) and security solenoid 30
(grey) open together to allow gas to the burner.
The ignition sequence begins and a continuous high speed
spark ignites the gas. As soon as a flame is detected the
orange indicator bulb

21 will light.

After 45 seconds the second stage solenoid 32 (black) opens
to allow the full gas rate.
If a flame is not detected, after 8 seconds, the security sole-
noid closes and shuts off the gas
The red lockout indicator bulb

22 Fig. 6 will light.

The central heating flow temperature is controlled by the cen-
tral heating control thermistor 37.

The boiler has been designed to minimise cycling and will not
attempt to relight for at least 3 minutes after the boiler ther-
mostat has been satisfied If used with a cylinder, the delay
must be set to 20 seconds (refer to adjustments on control
PCB).

When the room thermostat is satisfied the burner will switch
off and the pump will remain running for a further 3 minutes
before it too stops..

It is possible to override the 3 minute delay by pressing the
RESET button 23

Lock out procedure

Flame disappearance :
When the ionisation electrode 28 does not detect flame pres-
ence, the orange indicator lamp 21 extinguishes.
A lighting cycle starts.
If a flame is not detected before 8 seconds, the grey security
solenoid 30 and the blue 1/3 solenoid 31 will close.
The lock out red indicator 22 lights, the pump 35 runs.
After a few seconds, it will become possible to reset the boil-
er by pressing the reset button 23.

Overheat detection :
If an overheat is detected by the sensor 13, the grey security
solenoid 30 and the blue 1/3 31 closes, the orange indicator
lamp

21 extinguishes.

The ignitor is energised for 8 seconds (*) and the red lockout
indicator 22 lights.
(*) If the burner cannot relight the boiler will go to lockout.

Plug for main power and Room

thermostat connection

2 3

1. Neutral
2. Phase
3. Room thermostat live
4. Accelerator resistor
5. Common for Accelerator and room
thermostat.

WIRING

DIAGRAM

N°

Designation

Wiring colours

13.

-Overheat sensor

Brown

14.

-Electrical box

14a. -Regulation

PCB

14b.

-Ignitor

Red, Black

14c.

-Fuse 1.25 A

14d.

-Fuse 2A

14e.

-Power PCB

14f. -Room

thermostat

14g.

-Mains 230V 50 Hz

18.

-Pressure switch

2: Black P: Orange
1: White

27.

-Spark electrodes

White

28.

-Ionisation probe

White

30.

-Security solenoid (grey)

Grey

31.

-2/3 gas stage solenoid (black) Black

32.

-1/3 gas stage solenoid (blue)

Blue

35.

-Pump

37.

-C/H thermistor

Violet

45.

-C/H flow switch

Red

51.

-Fan

Brown, Blue

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 1/3 gas rate only

plug C on "P 1/3"

Burner functioning:
- Regulation available 3/3, 1/3, 0

plug D on "NOR"

- Functioning at full gas rate only

plug D on "TUR"

ELECTRICAL WIRING continuation

ADJUSTMENTS ON CONTROL PCB

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 appli-

ance.

- Check the correct operation of the gas

controls.

- Check the functions of the safety con-

trols.

- 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 pres-

sure.

- 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 test
points in the flue turret.

SUGGESTED SEQUENCE for SERVIC-
ING

Before disconnecting or removing any
parts, isolate the gas and electricity sup-
plies. 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 1/3 and 2/3 solenoids.
- Check that the burner is extinguished fully

when both solenoids.

- Test ionisation functions and check that

lockout occurs by turning off gas tap.

- Whilst boiler is operating, check operation

of primary flow switch by closing heating
flow valve and by pass screw (turn clock-
wise) noting the number of turns so that it
may be reset correctly.

Temperature regulation for C/H circuit is
controlled by a thermistor.
The C/H knob allows the adjustment of
temperature between 35 and 85°C.

Resistance value are
-5000

Ω

at 25

°C

-2631

Ω

at 40°C

-620

Ω

at 80°C

-255

Ω

at 110°C

REGULATION

Flow in Heating circuit is detected by a
flow switch.
A piston with a magnet at the top operates
a REED switch. The piston is lifted by flow
rates listed below :

Flow rate threshold :
- 250 l/h ±20 l/h

FLOW SWITCH

The air flow rate is detected by a pressure
differential created by a venturi located in
the flue duct.

ON threshold

∆

P > 130 Pa

OFF threshold

∆

P < 100 Pa

AIR PRESSURE SWITCH

5. Ignition Electrodes
Carry out steps 1 and 2 as above. Hinge
down electrical box by pressing retaining
tabs P on either side.
Remove wiring cover C. Disconnect leads

from spark generator. Loosen screws
securing the closure plate and remove.
Remove grommet from base of sealed
chamber. Remove screw securing elec-
trode bracket and lift clear easing spade
connectors through the grommet.
Reassemble in reverse order, twisted
together electrodes cable at least 10 times
to avoid electrical interference.

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 combus-
tion chamber rear panel.

Before removing appliance case, isolate
the gas and electrical supplies. Isolate boil-
er from the system and drain before
removing any component in the water-
ways. Ensure that the appliance is cool.

1. Outer Case
Remove four screws in base of case and

lift free. When replacing, carefully locate on
lugs T on top edge of chassis.

2. Combustion Chamber
Unscrew four self tapping screws securing
the sealed chamber front panel and lift
over top corner locating lugs. Unscrew four
self tapping screws to release combustion
chamber front plate and lift clear.
Reassemble in reverse order.

3. Burner Manifold
Carry out steps 1 and 2 as above. Remove
two screws securing the closure plate and
the remaining four screws to release the
manifold. Lift clear. Replace the manifold
gasket. Reassemble in reverse order.

4. Ionisation Electrodes
Carry out steps 1 and 2 as above. Loosen
screws securing the closure plate and
remove. Disconnect the lead from the main
wiring loom. Remove screw securing elec-
trode to burner. Thread wire through grom-
met and lift clear. Reassemble in reverse
order.

10. Pressure Switch
Remove outer case and sealed chamber
front panel as in steps 1 and 2. Disconnect
three pressure switch cables noting their
positions.
1 = white cable connected to NC
2 = black cable connected to NO

P = orange cable connected to C
Remove screw securing the switch bracket
to the chassis. Disconnect the sampling
tubes again noting their positioning (+ and

-). Remove switch. Reassemble in reverse

order.

11. Pressure Switch Venturi
Carry out steps 1, 2 and 8, as above.
Disconnect the sampling tubes and
remove the screw securing the venturi to
the flue outlet. Remove venturi by the bot-
tom of the 45° elbow. Reassemble in
reverse order.

12. Drain down
2 drain points are located on the boiler.
H = Heating circuit drain point

13. Water filter
The C/H filter ensures a seal between the
connecting bracket and the pipe to the
flow switch. Drain the boiler as in 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.
Reassemble in reverse order.

REMOVAL AND REPLACEMENT OF PARTS

(air separator)

A A

14. Flow switch
Drain boiler as in step 12. Disconnect the
electrical plug, turn the top cover anti-
clockwise, remove the O-ring and the
brass piston. Reassemble in reverse order.

17. Heat exchanger
Carry out steps 1 and 2 as above. Drain
boiler as in step 12. Remove the 2 clips

located on return and flow pipes and pull

them downwards. Pull the main exchanger
toward you to remove. Reassemble in
reverse order.

18. Pump
Drain boiler as in step 12. Pivot the electi-
cal 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 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. Thermistor

Drain the boiler as step 12. Disconnect the plug, remove the retaining clip pull the
thermistor out. Reassemble in reverse order.
37 = Heating thermistor

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.

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.

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.

(

ile

ilt

lig

lli

lig

lly

ile

ïd

lig

ïd

ile

104

OVERHEAT THERMOSTAT 100°C

277783

1010572

110

IGNITION ELECTRODE ASSY

277788

1002801

111

IONIZATION ELECTRODE

277789

1002802

113

HEAT EXCHANGER

277790

1010017

HEAT EXCHANGER

E00606

1011136

206

FAN ASSY

1304720

FAN ASSY

1304721

216

AIR PRESSURE SWITCH KIT

1306697

AIR PRESSURE SWITCH KIT

1307335

402

SOLENOID VALVES KIT

E23494

81836

505

VALVE BLOCK ASSY

1010436

510

THERMISTOR TEMP. SENSOR

277834

1000733

514

JOINING PLATE

1010439

532

WATER THROTTLE

277846

81471

547

GAS FILTER

263545

37309

560

AIR SEPARATOR HEAD ASSEMBLY

277857

1002653

572

PUMP UP 15/50 230V

E11662

1010612

605

CONNECTOR

277872

1010349

606

PRESSURE GAUGE

1011046

607

IGNITER

379075

1002105.20

615

PRINTED CIRCUIT BOARD OF POW.

277880

1010592

616

PRINTED CIRCUIT BOARD OF REGU.

277881

1010047

627

FUSE 250V 2A - TEMPORIZED

277883

1003456

629

FUSE 250V 1.25A - TEMPORIZED

277884

1003635

805

PRESSURE GAUGE

1303158

636

KNOBS SET

1305158

938

PRESSURE RELIEF VALVE

1020933

Description

Key N°

Manf. Pt. N°

Type

G.C N°

100

FF FF

Manf. date

from to

SHORT LIST

113

216

110

104

505

514

572

402

547

607

616

605

938

560

805

615

627
629

510

206

532

111

606

636

Notes

Chaffoteaux & 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.

Manufacturer:

Chaffoteaux

Maury - France

Commercial subsidiary:

MTS (GB) Limited

MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT

Telephone: (01494)

755600

Fax: (01494)

459775

Internet: www.chaffoteaux.co.uk
E-mail: info@uk.mtsgroup.com

Technical Support Help Line: 0870 241 8180
Customer Service Help Desk:

0870 600 9888

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

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