Chaffoteaux & Maury 280, 420 Installation Instructions Manual

Supplied By www.heating spares.co Tel. [phone]

Cha&teaux

et Maury

MODULOFLAME 280 & 420

COMMERCIAL OPEN FLUED BOILER RANGE

INSTALLATION INSTRUCTIONS

Supplied By www.heating spares.co Tel. [phone]

cfwRmE4tJxETMAuwLLrred
Trencn lock. Trencn.
Telford. Shmosnrre TFl 4SZ
Telephone. : Telford [phone]
Teiegx : [phone]

Ref. : 92220-142 - 02196

STATUTORY REQUlREFulENTS

The tnstallation of this appliance must be canted out by a CORGI Reg(stered
person or other competent arson and In accoraance wrth the requirements of the
current eamons of the Gas .8

Beguiatrons and local Water Authorrty By-Laws. It should also comply wtth the

followrng aocuments:

The Building Regulation:

-The Gas Safety (Installation and Use) Regulations

-The Pubfic Heafth Act -1936

-British Gas Publications - flues for Commercial and lndustnal Gas Fired Boifers
and Air Heaters (1979) ILlI1 1

British Standards:

-8s 4505: Part 1 - Flanges and Bolting for pipes. valves and fittings

-tti g6.44 installation of gas-fired hot water boilers of rated inputs between 60kW

afety (lnstallatfon ana Use)Regulatfons. the iEE Wiring

ModuIofIame2808c420

cat. II 2H 3P

Codes of Practfce

-BS CP 331: Part 3 - “Gas supplies to appliances”

-BS CP 341 300 - 307 Central Heaung by low pressure hot water

-8s CP 342 - Centralised hot water supply:

-Part 1 - Individual dwefiings

-Part 2 - Buildings other than Individual dweiiings

-BS 6759 Safety Valves

-8s 4076 Specifications for steel chimneys

To comply with the Control of Substances Harmful to Health Regulation 1988 we
are re uired to provide informatron on the following substance that is contained

9,

within t e appliance.

Descnption: Combustion Chamoer fining
Material: Alumino Silicone Fibre

Precautions: During servicing, keep the dust generation to a minimum and avoid
inhaling any dust and contact wrth the skin ana eyes. Normal handling and use wiil
not present any discomfort. althou h some peopie wtth a history of skin complaints
may be susceptible to irrftation.
securely wrapped and wash hanos after contact

GUARANTEE
The manufacturer’s guarantee is for 12 months from the date of purchase. The

guarantee IS voidable if the appliance is not mstalled in accordance with the
recommenaations made herein or in a manner not approved by the manUfactUrer.

R hen disposmg of the lining, ensure that it is

CUSTOMER CARE

Chaffoteaux et Maury Ltd.. as a leading manufacturer of domestic and commercial
water heattng appliances. is commnted to providing high quakty products and a

hi B h quality after sales service. If it is necessary to contact an engineer. then
te ephone your local Chaffoteaux Service Centre The number can be ootamed from
the leaflet enclosed in the customer care pack wrth
the Chaffoteaux Customer Servrces Depanment at

Advice on rnstallation or servtcing can also be obtained by contacting the

Chaffoteaux Customer Services Oeoartment at Teifora.

CUSTOMER SERVICES DEPARTMENT

Tel: [phone]

Fax: [phone]

2

our borfer or by telephoning

Te ford. r

Supplied By www.heating spares.co Tel. [phone]

CONTENTS

Statutory requirements

Guarentee

Customer care

lntroductlon

Description

Technical data

Dlmensions

Installation and operation

Operation
System design
Fkrw rates
Operating pressures
Assembly
Accessories
layout
Positionning
Connecting to system
Electrical connecuons
Controlling modules or multiple borlers using external controls

2

2

2

4

4

5

5

6:. a
6
6
6
6
6
6
6
6
7
7
7

Commissioning

Routine servicing

Replacing components

Fault finding charts

Wiring diagram

Short part tist.

Filling and purgmg

Bringing into operation
Gas rate adjustment
Post commissionnmg
Handing over to

Suggested sequence for servicing

Preliminary checks

user

9
9
9

9

10

11

11

Supplied By www.heating spares.co Tel. [phone]

Installation Instructions

INTRODUCTlON
The Moduloflame 280 and Moduloflarne~ 420 are low water content floor standing open flue boilers. They are intended for

commercrai appficatrons and are suitablaior both open vented of sealed systems. Each boiler comprises two or three modules,
each module havrng its own water circulating pump, gas valve. burner and heat exchanger assemblies. The modules e&t have
an output of 40 kW and are mounted vertically one above the other providing a high output to floor area ratio. The boilers are of
a lightwerght ~~nstn~ction and so provide a high output to weight ratio. The Moduloflame 280 and 420 models are supplied with
flanged connections to albw for the simple connectron to system pipework or to other Moduloflame boilers of the same sire to
make up banks of boilers and thereby multiples of the output of each boiler. Each boiler has an integral flue duct and is
contained in a pre-assembled case with a single door that can be reversed to enable easy access for installation and
mantenance. Each module can be turned off and serviced independantly and all components are accessible and removeable
from the front. Optional side panels are available as accessories.

DESCRIPTION

1. Steel chassis

2. Common rear flue duct

3. Heatmg body containing a copper
finned heat exchanger

4. Electronc gas vaive

5. Water flow switch

6. Gas service tap

7. Flow and return valves to isolate
heating boay

8. Non return vaive

9. Grundfos pump
1 O-Patented twenty four blade

stainless steel multrgas burner

11. Manually resettable overheat

thermostat

12. lgnrtron and ionrsatron electrodes

13. Two stage thermostat

14. Built in down draugnt diverter

15. Reversible aoor. closea by two
latches

16. Optional left ana right hana sides
panels

17. Control panei

18. Insulated water manifold allowing
monotube connectlon

19. Waterflange PN16.22Ox115mm
4

20. Gas manifold allowing monotube
connection

21. Gas flange PNlO l85x77mm

22. Leveiling screw

23. Electrrcaf connections behind panel

24. Conduit for electmal cables

25. lonisatron control with manual reset

26. Draugnt diverter cover

27. Fuses

28. Main switches for each module
with indicator lamps

29. Overheat indicator lamps

Supplied By www.heating spares.co Tel. [phone]

TECHNICAL DATA

Type BllBS
Suitable only for natural gas and ccnverston to LP.G

Heat

Input

Heat output 80
Burner manifold injectors

Miniium air supply required
Combustton products rate 124 g/f
Average flue gas temperature 71 ‘C

Maximum flow temperature

Minimum return temperature

Maximum system pressure

Minimum system pressure
Water capacity 15 litres

Electrical suppfy

Power consumption 300 w

Weight exduding packaging

Weight including packaging 183kg

Burner pressure G20 (natural gas) @ 20 mbar 8.8 mcar

Burner pressure G31 (propane L.P.G.) @ 37 mbar

Modutoflam~

89.5 kW

kW

24

337 m31h

90°C
5o”c

6bar

1.5 bar

230 V single phase

145kg

328 moar

280

- 50

Hz

f&&doff

230 V single phase

ame

132kW
120 kW

24

420 ma/h

145 g/l
112%

90 OC
50 “C

6 bar

1.5 bar

18

litres

500 w

170 kg

210 kg

8.8 mbar

32.8 mbar

420

- 50 Hz

Gas rate (15 “C -1013 mbar)
Gas type Pressure
G20 20 mbar
G31

37 mbar

Net

C.V.

35.9 MJ/m3

46.4 MJlkg 3.41 kg/h

Burner injectors

Natural gas

Propane gas (Restrictor diameter : o 6.5) :

(Restrictor

diameter : o 6.4) :

DIMENSIONS

4Ul.~,~

1.29mm

0.74 mm

A

65

1 moaule 2 modules

4.65 ma/h

9.30 ma/h

6.82 kg/h

Moduloflamo

280 420

A 711 711

B 300 300

c 340 340

D 125 125
E

170

170

3 modules

13.95 ma/h

10.23

kg/h

level : rmvmum 8 mm

5

F 485 485
G 112 112
Ii

1155

I 1697 2200
J 8 mini 8 mini
L 610 610

lS58

Supplied By www.heating spares.co Tel. [phone]

INSTALLATION & OPERATION

OPERARON
When the ext&al controls or the holler

thermostat are calling for heat, the
pump wlii run. When the flow swnch
detects the flow it will allow the ignition
process to take place. The first stage
of the gas vafve opens and a stream of
sparks ignites the gas. After 10
seconds and if the ionisation circuit has
been proved. the second stage of the
gas valve opens and establishes the
set gas rate. The temperature is
controlled by a two stage thermostat.
The first stage controls the upper

module and the second stage controls

the lower module of the 280 and !he

lower two modules of the
end of a heating cycle the pump runs
on for three minutes. A non return

valve

prevents circulation within the

heating body when module is off.

420.

At the

SYSTEM DESIGN

The Moduloflame 280 and 420 are
designed for use on installations where

a

high output is required with limited
floor space.
The Moduloflame 280 provides the
equivalent of 206.4 kWlm2
The Moduloflame 420 provides the
equivalent of 304.4 kW/mz
Each module is provided with a pump
to overcome the resistance of its heat
exchanger. Together with the use of a

schematic diagram :

monotube type water manifold obviates
the need to include the boiler
resistance when pump sizing. The
modules are connected in parallei to a
single manrfold flanged at either end
for simple connection to the system or
to additional moduloflames.

FLOW RATES

The boiler is suitable for sealed or
open systems and must only be used
on indirect fully pumped systems.

Particular attention must be given to
achieving minimum flow rates. The
nominal flow rates througn the
manifold must be 3ms/h for each
Moduloflame 280 ano 5.25ms/h for

each

Moduloflame 420.

[ pi &stance of loao of coilector)

Thhs

numnws conospona to me numner

of W-Jiu msulltld

Fig.5

OPERATING PRESSURES
The system pressure water. measured

at the manifold. must not be iess than

1 .5 bar or exceed 6 bar.
ASSEMBLY
The boilers are supplied ready

assembled, covered in polythene and
secured in wooden crates. The units
are designed for ease of hanoling and
to be able to pass through door ways.lt
is recommended that the units are
stored vertically and sheltereo from
bad weather, particularly frost.
Do not lie the boiler on its back.

Weight:

ACCESSORIES
Contained within the

- A plastc bag contaming:
lx set of installation instructions.

guarantee registration card are
attached to the inside of the door.

- A carton containing

12xl6mmx70mmlongbolts
12x 16 mm nuts

4 x 16 mm x 50

screws

(adjusted using 8 mm key)

boilers

mm

long leveiing

Optional

Reference;

- Side panels kit 280

- Side panels kit 420

- Mating flanges kit

- Water f gas gasket kit

1003622
1003630
1008378
1000616

LAYOUT --“jp-

The boilers may be placed side
in order to form a single manifold. A
maximum of 5 boilers can be fitted on

one

monotube. They can be
along a wall or fitted back to ba& in a
central location. A minimum space of

0.8 metres should be allowed
for access for maintenance.

When considering the layout, albw
the placement of the flue. Ffueing can

I

be achieved individually or grouped in
ducts. Natural draught, fan assisted or
fan dilution arrangements
used. Specialist advice on
arrangements should be sought from
flue manufacturers.

POSlTlONlNG

A purpose made plinth is not

necessary. Ensure that the floor is
reasonably level and is strong enough

to take the weight of the boiler(s) and

ancillary controls. For multi boiler

installations, check that the UnffS
vertical and that the water and gas
flange faces are parallel using the

leveiling screws provided. The boilers
can then be bolted together USing the

intermediate gaskets and bolts

avallable as accessories.

by

side

ranged

in front

for

may be

flueing

are

Moduloflame 280:

183 kg Inci. packaglng
145kg excl. packaglng

Moduloflame 420:
210 kg incl. packaging

17Okg excl. packaging

6

Supplied By www.heating spares.co Tel. [phone]

Fig. 4

CONNECTING TO ME SYSTEM
Before connecting to the system, the

pipework should be chemically
cleansed to remove metal filings,
solder. machining oils and other fluxes
and greases which might impare the
performance of the boiler and its
controls. Consideration should also be
given to the treatment of the system

water

and advice can be sought from
the manufacturers of
products such as

water

treatment

i . .
i ‘2’

1

..--.-----A

,-1.-.----e

Grace Dearoon
Wines

Chesnire
WA8 8UD
Tel: [phone]

Fernox Manufacturing
Britannica Works
Cfavertng
Essex
CBll 402
Tel: [phone]

$ i

Maang tlange
(aaessonesb

k

If the boilers are being installed on an
existing system, a sump and
should be fitted on the heating
the lowest point. It is essential that the
system is fully flushed to remove any
sludge and debris before the

connected.

the system is adequate for the
boiier(s): at least 3ms/h for each 280
and 5.25mslh for each 420.

Also check the flow through

drain

return at

boiler is

ELECTRICAL CONNECTIONS

The Moduloflame 280 and 420 boilers
require a single phase 230V - 50’Hr
earthed electrical supply. They
be

connected

double pole switch which should
readily accessible and adjacent to the
boiler. All wiring must conform to the
LEE. Regulations. The electrical
supply is connected using the

removable connector strip (Fig 8)
accessible behind the upper panel

(Fg 6). It is important to observe
correct polarity as reversing
connections
malfunction.

. . . . . .

i I...

,.....

Ii

through a 2 Amp. fused

Will

r

.: . . . . :.:.>::. ,,,,: ::-, ,: . . :.:.+:/; 1:. ;. : :‘~.:.d:~:~::~:.~:~:

should

be

the

the

cause a

: safely

vaives

Fig. 6
CONTROLLING MODULES OR

MULITIPLE BOILERS USING
EXTERNAL CONTROLS

It is possible to control each module
using an external management system
by connecting the remote burner
control cables to terminals 1. 2, 3.
(Fig 8). It will also be necessary to
remove the links sl s2 s3 and making
a return connection from C to the
controller. To control each boiler rather
than each module. a permanent
connection is maoe to terminal

4

exoanson
vessel

zr

link sA is remove0 and replaced by the
boiler switching cable from the
controller. In eacn case. terminal N is

USed

to connect the neutrals.

P,

live

the

Supplied By www.heating spares.co Tel. [phone]

Fig. 10

COMMISSIONING

runs until the flame detection device
operates. If the flame is not detected
within IO seconds. the gas valve will

111~111~

L

5g. 8

COMk.: SSIONING

-Check that the stop valves on
individual modules are fully open.

-Check electrical suppiy to each boiler
for correct poiarity and earthing
continuity.

-Manually check pumps are rotating
freely.

To mam board

lock out. Press the red reset button
located on the front of the gas valve to
restart.
Check burner pressure and ensure all
connections are sound.
The burner pressure is factory set to
80% of maximum. If it is necessary, to
reset then refer to the gas rate
adjustment section.

-Check the correct operation of the
flue. The pressure drop at the down
draught divener must be at least 5 Pa
(0.5 ins w.g.)

-To check working pressure connect a
pressure gauge to test point ‘A’ In
figure XX and Tight the boiler. The
pressure should be 20 mbar.

-To check burner pressure mnnect a
pressure gauge to test point ‘8’ In
figure XX and light the boiler. The
maximum pressure should be

8.8 mbar. For the correct pressure
refer to gas rate adjustment chart.

To reset pressure:
Turn screw “C’ clockwise to increase
pressure and anti-clockwise to
decrease whilst observing.the pressure
gauge.

Filling and Purging
Water :

-Fill the system slowly ensuring the
filling pressure remains mnstant.

-Purge the installation of air.
To purge the boilers, run pumps by
switching main boiler switches to ‘on”.

Gas :

-Open the main gas valve.

-Open the gas valves for each module.

-Ensure the main control switches are
on. Attempting to light the burner will
purge the gas iine.

To Bring Into Operation

-Ensure main power is on.

-External controls calling for heat.

-Soiler thermostat turned to maximum.

-Main switches on the front panel are
turned to “on’.
The pump wiil run and when flow is
established switching the flow switch
the ignition sequence will begin. The
gas valve is opened and the ignitor

The thermostat (fig. 11 no. 13) can be
set between 28” and 85%.

Gas Rate Adjustment
The pressure test pomts are located on

the gas valve, to gain access to them,

it is necessary to remove the electricat
box from the gas valve.

Picture of the gas valve dismounted.

,.,,,,,,,,,.,,,,.,.....,,---~--.

~~~~

16.00 20.00 24.00 26.00 12.00 36.00 40.00
kW LW LW kW kW kW kW

Post Commissioning
Ensure system pressure has been set

correctly.

Set boiier thermostat and COntrOk.
Set external controls.

Handing Over to the User
Demonstrate the lighting and Operation

of the boiler.
Explain the benefits of annual
maintenance by a competent person.
Explatn
Leave Installation Manual, User’s
lnstructrons and all documentation with
the user.

how

to regtster guarantee.

Supplied By www.heating spares.co Tel. [phone]

ROUTINE SERVICING

To ensure continued efficient operation
of the

appliance.

that It is checked and serviced as
necessary at regular intervals. The
frequency of
the particular installation
usage, but in general. once a
should be adequate.

It is the law that any service work must
be carried out by a
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.

-Clean and check operation of safety
valve.

Additional Procedures that may

it is recommended

servicing

wail depend upon

competent person

condition

and

year

be

necessary:

-Carry out combustion test.

-ChecK. clean and replace components
as necessary.

-ChecK burner pressure and gas flow
rates.

SUGGESTED SEQUENCE
SERVICING

for

-Check operation of boiler thermostat
on each mooule wnile the boiler IS at Its
operating temperature.

REPLACING COMPONENTS

Door

SOmer manifold

Burner

lonlsatlon

and

Spark

electrodes

Control PC8

Gas Valve
Drain down

Flow switch

- Isolate the module with the 2 isolating

valves.

-Drain the boiler.

Pump
h4ain heat exchanger
Thermostat
Main PCB

Spillage detection
Fuses

Prior to any operation it is necessary to
disconnect the boiler from mains, turn
off the gas service tap. Before all
operation on hydraulic sections. the

module must be isolated and drained.

Burner

-Separate the gas section from the
manifold.

-Remove the 2 fixing screws of the
burner assembly located on the both

side of

it.

-Remove the 2 upper screws of
brackets between the manifold and the
front pannei of the combustion

chamber.

-Pull it toward you.
Heat exchanger

-Remove the front panel of the

mmbustlon chamber.

-Unscrew

and return pipes.

-Disconnect the overheat thermostat.

-Pull the exchanger towara you.

the umon nuts between flow

-To remove the gas valve only,
unscrew the 4 screw located on
sides of the platlc part. separate
blocks and let hang the electronic
block. Disconnect the 2 unions on

gas

pipes. Pull the gas section

both

the 2

the

toward

you.

Printed circuit

-Unscrew the 4 screws

board

of the

monotube cover.

-Unplug
and

all connections to the

pull it from its support.

board

Pump
Before disconnecting or removing any
parts. isolate the gas and electricity
supplies (for detail please see section
on Parts Removai and Replacement)

Preliminary Checks

-On sealed system, check the system
pressure IS at least 1 bar cold

-ChecK operailon of gas vaive .

-ChecK that tna burner is extinguished

fully wnen gas valve is closed.

-Test Ionisation functions and check
that lockout occurs by turning off gas
tap.

-ChecK operation of flow switch by
closing heating flow valve whilst boiier
is operating.

-Open the electrical box and disconnect

the pump cable.

-Disconnect unions with flow and return

pipes.

-Disconnect the pressure samoiing

pipe.

-Remove the pump clip.

-Pull the pump toward you.

Gas

valve

-To remove the complete block (gas

valve + electronic regulation) It is

necessary to disconnect the gas valve

from wiring. Remove the cover of

eiectricai part fixed by 1 screw at the

front. Unplug the cable. Then, unscrew

the 2 unions and remove the complete

block

9

Supplied By www.heating spares.co Tel. [phone]

Prior 10 90 rhrougn Ihe IIOW Cl-Ian check lhe lollowlng items :

- System IS fully vented

- All isohang tap3 are opened

- Gas SISIVIIX Ems are ooened

Emvn the COT~OC+ OO~UW. ConW~t that No~ral and EMh VOIIUIO~ l re WU~I.

- sw*m tn. ..,ernal rsguuuon 10

‘ON’

cbuuorrepuodnaa8NlYl~.
fdbmlg Item :

chas mam mnrg. 230 v IS avadmm aI Inam cm-or.

000s ma l xcwnai

- Swdcn on mo moeub

crluk oump spns tra or

rwlsa I,

- Furr on tram Puuc

- BoilsI PCS

Pros* on me mm otnum 01 Ina
gas “al”.

1

I

ooa km out

I

t

macafor

alIght 7

Chaa

0,

raOUCS

d

folbmng nem :
_ lonaauon emaroos

- Eiecuonlc OIOCX 01 me gas valve

10

PI

me mandoM?

Supplied By www.heating spares.co Tel. [phone]

Heating equipment short parts list

Key number :

201
203
207
400
419
439
501
506
705
804
806
811
815
901
909
1002

I200
I202
I428

kcessories :

1501
5001
iO21

Description :

control unit 1008250
gas valve assembly

gas

service tap 81214
2E+ burner assembly (not shown)
ignition electrode
ionisation eiectrode 75773-l 0
heat exchanger 1007557
over heat sensor
flue spillage sensor
printed circuit board
thermostat
thermostat knob
fuses 54442
pump assembly 1010612
water isolating valve
non-return valve
flow switch 75709
flow switch diaonragm 10419
door iock assemoly

Water and gas gasket kit
Side panels kit
Water and gas connection kit

Moduioflamc 280 ModuiofIam8 420

1007350 1007350

1002667

36899

1008282
1003959
1009995
1009766
1004996

81194
54448

81478

1000616
1003622
1008378

s-s

A

1008250

81214

1002667

36899

75773-l 0

1007557
1008282
1003959
1009996
1009766
1004996

54442

1010612

81194
54448

75709
10419

81478

1000616
1003630
1008378

11

Supplied By www.heating spares.co Tel. [phone]

Chaffoteaux et Maury are continuously improving their products and therefore reserves the right to change specifications

without prior notice and accepts no liability for any errors or omtssion in the informatlon contained in this document.

0 Chaffoteaux et Maury 1996

Chaffoteaux et Maury Ltd
Trencn LOCK ’
Trencn
Teffora
Shroosnire
TFl4SZ

Tel: [phone]
Fax: [phone]

12

ESP033