Page 1
Flexiflame 140
OPEN FLUE BOILER
GAS SAFETY (INSTALLATION AND USE) REGULATIONS
It is the law that all gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. G20)
G.C. No 41 980 64
FROM SERIAL N”
Installation and Servicing
Instructions
(Leave these instructions with the user)
Page 2
CONTENTS
Health and Safety Information
Page No
1
1.
INTRODUCTION
1.
General description, Special features, Guarantee
1.1
Dimensions
2.
TECHNICAL DATA
2.1
Input, Output, Burner setting pressure, Gas rate
2.2
Clearances
2.3
Flue connection
2.4
Gas connection
2.5
Water connection
2.6
Water flow rates and static head
2.7
Electrical connections
2.8
Weight
2.9
Water capacity
2.10
Injector sizes
2.11
Piezo ignitor
2.12
Electrode
2.13
Gas pressure test point
2.14
Boiler thermostat
2.15
Thermocouple and thermoelectric valve
3.
INSTALLATION REQUIREMENTS
3.1
General information
3.2
Location
3.3
Gas supply
3.4
Flueing
3.5
Air supply
3.5. I
Room or internal space air supply
3.5.2 Cupboard or compartment air supply
35.3 Effect of extractor fan
3.6
Water circulation systems
3.7
Electrical supply
4.
INSTALLATION OF BOILER
4.1
General
4.2
Control schemes Figs.
1, 2,
3,4,5,6,7
4.3
Boiler packaging
4.4
Mounting the boiler
4.5
Water connections
4.6
Gas connections and pipe sizes
4.7
Electrical connections
5.
WATER CIRCULATING SYSTEM
5.1
General
5.1. I
Strainers
5.2
Control schemes
5.3
Isolating valves
5.3.1
Electrical components Fig. 8, Fig. 9,
Fig. 10
5.3.2
Pump positions Fig. 11, Fig. 12, Fig.
13, Fig. 14
5.3.3
Air separator Fig. 15
5.4
Circulating pump
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
Page 3
5.5 Inhibitors
5.6 Automatic air separator
5.7 Open systems
5.7.1 Cold feeds and open vents
5.7.2 Hot water storage cylinder
5.7.3 Feed and expansion tank
5.8 Sealed system Fig. 15A
5.8.1 Safety valve
5.8.2 Pressure gauge
5.8.3 Hot water storage cylinder
5.8.4 Make-up system
5.8.5 Mains connection
5.8.6 Filling point
5.8.7 Pipework
6.
COMMISSIONING AND TESTING
6.1 Electrical installation
6.2 Gas installation
6.3 Water circulation system
6.3.1 Open system
6.3.2 Sealed system Fig. 16
6.4 Lighting the boiler
6.5 Gas rate adjustment
6.6 Flushing
6.7 Fitting the casting Fig.
18, Fig.
19, Fig. 20 (Page
9)
6.8 Thermostat adjustment
6.9 To drain boiler
6.10 Users instructions
7.
ROUTINE SERVICING
General
7.1
Remove casing
7.2 Annual service
7.2.1 To clean the burner Fig. 2 1
7.2.2 To clean the heating body
7.2.3 To clean the pilot assembly
7.2.4 To remove the gas section Fig. 22 (Page 10)
7.2.5 To clean and grease bearing plate spindle Fig. 23
7.2.6 To clean thermocouple and electrode Fig. 24
7.3 General service
7.3.1 To clean burner, heating body, pilot assembly and thermocouple
7.3.2 To remove electrical control module
7.3.3 To replace diahragm
7.3.4 To clean gas valve
8.
8.1
8.2
8.3
8.4
8.5
8.6
8.7
REPLACING COMPONANTS
To replace thermoelectric valve
To replace overheat thermostat
To replace piezo unit
To replace pump
To replace pump and volute
To replace heat exchanger
To replace boiler thermostat
7
7
7
7
7
7
7
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
8
9
9
9
9
9
9
9
9
9
9
10
10
10
10
10
10
10
10
10
10
10
10
11
11
12
13
9.
FAULT FINDING
10.
SHORT SPARE PART LIST
i i
Page 4
CONTROL OF SUBSTANCES HARMFUL TO HEALTH
Important
To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to provide information on the
following substance that is contained in this appliance.
Description
Combustion Chamber Lining.
Material
Alumino Silicone Fibre.
Precautions
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.
1
Page 5
1 Introduction
The FLEXIFLAME 140 is a wall mounted, low water content open flued boiler. The boiler is rated between 20.5 kW
70,000 Btu/h) and 4 1 kW (140,000 Btu/h) outputs.
f he boiler is designed for use with Natural Gas only.
The FLEXIFLAME 140 is intended for the larger domestic
installations, swimming pools and for commercial or industrial applications. The boiler is suitable for open vented or
sealed water systems.
A pump must be installed in the water circulation system
irrespective of whether the system is of the open or sealed
type. The pump incorporated in the boiler is sufficient only
to overcome the resistance of the boiler, the boiler has a fully
adjustable electric thermostat which operates the boiler
w-w.
The FLEXIFLAME 140 is supplied in one carton, it is essential that the monotube is fitted (the monotube is the 54 mm
horizontal tube at the base of the appliance).
Guarantee
The manufactures guarantee on this appliance is for 12
months from this date of purchase. The guarantee is void if
the appliance is not installed in accordance with the
recommendations made herein.
1 .I Dimensions
LIB
L
mm
(ins1
A
925
(36.4 )
B
600
(24.0 )
C
365
114.3 b
D
174
( 6.9 1
E
150
(
6.0 )
F 65
( 2.5 b
G
95
( 3.75)
H
820 (32.25)
J
390
(15.3 )
K 54
( 2.0 )
L 45
( 2.0 1
M 165
( 6.5 ‘)
N 260
(IO.6 1
P
95 ( 3.75)
2. Technical data
2.1
Heat Output
Heat Input
Burner setting Pressure
Gas Rate
kW
(Btu/h)
kW
(Btu/h)
mbar
(ins. w.g.) m3/h
(ft3/h)
20.5 ( 70 000)
27.0 ( 91
100)
3.4
(1.4) 2.5
( 89,43)
41.00 (140 000)
51.9 (177
200)
12.8
(5.1) 4.65
(164,25)
2.2 Clearance for installation and servicing
2.7 Electrical connections
Side . . . . . . . . . . . . . . . . . . . . . . 150 mm (6 ins)
Top . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (4 ins)
Bottom.. . . . . . . . . . . . . . . . . . . . . . 150 mm (6 ins)
Front . . . . . . . . . . . . . . . . . . .
1000 mm (3ft. 3 ins)
2.3 Flue connection
240 V single phase 50 hz
supply
fused I amp
2.8 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
kg (1 14 lb)
2.9 Water capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 litre (0.22 gals)
2.10 Iqjector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner
1.18 mm
(.046 in)
Pilot 0.30 mm (.O 11 in)
A nominal 1.50 mm (6 ins) lightweight flue is required. The
draught diverter is integral. It is not necessary to fit a split
collar.
2.1 I Piezo ignitor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vernitron 60065
1. I2 Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Gap 5 mm (. 196 in)
2.4 (;as connection. . . . R 3/4 . . . . . .
(3/4” BSP male)
2.5 Water connection
2.13 Pressure test points
Gas inlet and left hand burner manifold
Flow. . . . -. . . . . . . . . . . . . . . . .
54 mm copper (socket)
Return. . . . . . . .
54 mm copper (socket)
2.6 Water flow rates
Minimum flow rate . . . . . . . . . . . . . . 2209 I/h (8.1 g.p.m.)
Maximum flow rate . . . . . . . . . 3 18.7 I/h (I 1.66 g.p.m.1
Minimum static head.. . . . . . . . . . . . . . .
3 m (10 ft)
-~ Maximum static head . . . . . . . . . . . . . . , .
30 m (100 ft)
2.14 Koiler thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sopac AE 350 A
2.15 Thermocouple and thermaelectric valve (Chat’foteaux et Maury)
The 24 blade stainless steel Chaffoteaux burner is fitted with
1.18
mm
injectors. The non-adjustable permanent pilot is
manually ignited by a piezo igniter. The boiler is controlled
by an adjustable thermostat which is fitted into the return side
of the monotube. The flow temperature measured on the flow
side of the monotube will vary relative to the mass flow rate
through the monotube but within the range 82” C T 4” C
( 180°F 7 7” F) with a temperature differential between 1 I “C
min and 20°C max.
2
Page 6
it to have a permanent air vent. This vent must be either
direct to outside air or to an adjacent room or internal space
which must itself have a permanent air vent of at least the
same size direct to outside air.
The minimum effective area of the permanent air vent(s)
related to the maximum rated input of the boiler and shou
be 202 cm2 (30.5 in2).
3. Installation requirements
3.1 General
The installation of the boiler must be in accordance with the
Gas Safety installation and use Regulations, relevant
Building Regulations, the Byelaws of the Local Water
Undertacking, the Safety Document 635, the Electricity at
work Regulations BS 767 I. It should also be in accordance
with thecfollowing British Standard Codes of Practice - BS
689l.BS7953.BS7074: I :2.BS5449: l.BSS440: I :2.
3.2 Location
The position chosen for the boiler must permit the provision
of a satisfactory flue termination and also provide adequate
space for servicing and air circulation around the boiler.
The boiler must not be installed in a room or internal space
containing a bath or a shower. En a bedroom area, a bed-sitting room, or a private garage.
Where installation will be in an unusual position, special
procedures may be necessary, and BS 6798, gives detailed
guidance on this aspect.
A cupboard or compartment used to enclose the boiler must
be designed and constructed specifically for this purpose. An
existing cupboard or compartment may be used provided
that it is modified for the purpose.
Details of essential features of cupboard/compartment
design, including airing cupboard installations are given in
BS 6798.
3.3 Gas supply
The gas installation should be in accordance with BS 689 1.
The meter to be used must be of adequate capacity to meet
the total gas load. i.e. boiler plus other gas appliances.
Ensure that the pipework from the meter to the boiler is of
adequate size. Do not use pipes of a smaller size than the
boiler gas connection.
The complete installation must be tested for soundness as
described in the above standard.
3.4 Flueing
Detailed recommendations for flueing are given in BS 5440 :
Part 1.
The following notes are for general guidance only : -
3.4.1 The boiler should be sited such that the maximum possible length of the flue system can be contained within the
building and that the route of the flue rises continuously to
the terminal and is as direct as practicable.
The first 600 mm (2 ft) of flue pipe should rise vertically from
the draught diverter connection before the use of any bends
or elbows.
Horizontal or shallow angle runs, right angled bends and
mitred elbows should be avoided.
Where an existing brick chimney is to be used it should be
swept thoroughly before connection of the new boiler, and
the chimney should be lined. The boiler can be used with
fanned or fan diluted flues.
An approved British Gas terminal must be fitted and the
terminal sited at not less than 600 mm (2 ft) above the roof
edge, and, where possible, above the ridge line. The flue must
not be terminated at or adjacent to a wall face (except for fan
diluted flues).
3.5 Air supply
Detailed recommendations for air supply are given in BS
5440: 2.
The following notes are intended to give general guidance.
3.5.1 Room or internal space air supply
Where the boiler is to be installed in a room or internal space,
the boiler requires the room or internal space containing
3.5.2 Cupboard or compartment air supply
Where the boiler is to be installed in a cupboard or compart-
ment permanent air vents are required (for combustion, flue
dilution and cooling purposes) in the cupboard or compart-
ment at high and low level. These air vents must either
communicate with a room or internal space or be direct to
outside air.
The minimum effective areas of the permanent air vents
required in the cupboard or compartment are specified below
and are related to the maximum rated heat input of the
boiler.
POSITION
AIR VENT AREAS
AIR OVFENTS
Air from room Air direct from
or internal space
outside
High
Level
468 cm’ (72.5 in’) 234 cm’ (36 in’)
Low
Level
936 cm? (14.5 in’) 468 cm’ (72.5 ir
Note : Both air vents must communicate with the same room
or internal space or must both be on the same wall to outside air.
Where cupboard or compartment air vents communicate
with a room or internal space, the room or internal space
must itself have a permanent air vent(s) as specified above
(3.5. I).
3.5.3 Effect of an extract fan
If there is any type of extract fan fitted in the premises, there
is a possibility that if adequate air inlet area from outside is
not provided, spillage of the products from the boiler flue
could occur, when the extract fan is in operation. Where such
installations occur, a spillage test as detailed in BS 5440 : I :
must be carried out and ventilation requirement to BS
5440 : 2.
3.6 Water circulation systems
Open or sealed type central heating systems should be in
accordance with the relevant recommendations given in BS
5376 : 2, BS 5449 : 1 (for small bore or microbore systeme‘
Hot water systems should be in accordance with the relev.
recommendations given in BS 5449 and BS 5546.
3.7 Electrical supply
This appliance must be earthed. All wiring must conform to
the BS 7671. The Flexiflame 140 requires a 240 V, single
phase, 50 Hz supply. The boiler should be connected to the
mains via a fused double pole switch or via a 13 amp.
socket outlet in conjunction with a fused plug. The fuse rating
should be 3 amp.
The point of connection to the mains should be readily acces-
sible and adjacent to the boiler.
The supply chord must be 0.75 mm2 three core heat resisting
cable.
4. Installation of boiler
4.1 General
The wall on which the boiler is sited must be capable of
adequately supporting the weight of the boiler and any ancillary equipment and should be non-combustible.
A vertical flat area is required for the boiler as follows :
Wide 900 mm
36 ins
High 1185mm
47 ins.
Above dimensions include the necessary clearances around
the boiler for case removal and for air movement.
3
Page 7
4.2 Control schemes
Most normal pumped primary control schemes can
be used, including non-electrical heating and hot
water controls.
Hot Water Only, Pump, Time Clock and Cylinder,
Thermostat
Heating Only, Pump, Time clock and Room Thermostat
Hot Water and Heating, Pump, Programmer,
Room/Cylinder Thermostat and Flow Share Valve.
Hot Water and Heating, Pump, Programmer,
Room/Cylinders and two motorised valves.
.Hot Water and Heating, Pump, Time Clock and
Non-Electrical Hot Water and Heating Controls.
riot Water and Heating, Pump, Time Clock, NonElectrical Hot Water Control and Electrical
Heating Control.
Hot Water and Heating, Pump, Time Clock, NonElectrical Heating Control and Electrical Hot
Water Control.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
The following diagrams show typical control schemes using
electrical controls only.
The following diagrams show typical control schemes using
electrical/non-electrical controls.
It is not normally possible to use full programming facilities
when using a mixture of electrical and non-electrical
controls, but some non-electrical hot water controls are now
available with an external micro-switch which would allow
the scheme as in fig. 6 to be fully programmed.
Where a mechanical type cylinder thermostat is considered
the three port type with by pass must be used.
Where thermostatic radiator valves are used a system by pass
will be necessary to maintain a flow rate in the monotube of
not less than 8.1 g.p. m. required to prevent recirculation in
the monotube due to the action of the boiler pump.
4
Page 8
4.3 Boiler packaging
Each boiler is delivered in a protective carton.
Remove packing pieces before lifting out boiler.
Remove boiler from carton. DO NOT stand or support the
boiler on the draught diverter or the bottom chassis carrying
the isolating valves.
4.4 Mounting the boiler
- Using dimensions shown on Page 2 lit the wall mounting
plate to the wall using the screws provided.
- Hang boiler on the plate.
- Fit monotube to flow and return connections on boiler with
thermostat phial to the left of the boiler.
- Remove thermostat phial from rear of electrical control
module and insert phial in pocket, to the left of the monotube and secure with retaining pin.
4.5 Water connections
- Flow and return connections are made to the monotube at
the base of the boiler. The return connection is on the left
-the flow on the right (54 mm copper tube) viewed from
front.
4.6 Gas connections
- The gas service tap is fitted to the appliance.
- Fit gas inlet bend and filter-washer to inlet of gas service
tap.
- Gas connection is R 314 (3/4 in. BSP male) thread.
- The gas supply pipe should not be less than 22 mm and
should be connected direct on to meter. The pipe run
should not exceed 9 meters. If the gas run is greater than 9
meters (29.5 ft) in length consult the following table.
GAS PIPE SIZES IN MM-
Equivalent length of pipe including fittings
Metres . . .
3
6 9 12 15 20 25 30 40 50
Diameter. 22 22 22 28 28 28 28 28 35 35
- The gas supply pipe size should be sufficient to ensure that
there is 20 mbar (8 in.w.g.) pressure at the gas service tap
when the boiler is working.
4.7 Electrical connections (figs. 8,9 and 10)
- Withdraw fuses.
- Remove two screws on left hand side of electrical control
module cover and open left hand section.
- Enter 0.75 mm* flexible heat resisting cable from rear of
module. Pass under clamp and secure to their respective
terminal connections.
Note : The length of the earth wire between the cord
anchorage and the terminal must be such that the live and
neutral wires become taut before the earth wire if the supply
cord is pulled.
- For connection see wiring diagram.
- Tighten cable clamp.
- Secure door with two screws and replace fuses.
- Switch ON/OFF switch to OFF position.
5. Water circulating system
5.1 General
The Flexiflame 140 is a low water content boiler designed
only for use with fully pumped systems. It may be used with
open (vented) or sealed systems, all safety controls other than
the safety valve, being incorporated in the boiler. The thermostat is adjustable and on its maximum setting gives a nominal 82” C (180” F) flow f 4” C (7’ F) depending on flow
through monotube.
Thermostatic control should be fitted to the cylinder and
heating circuits.
Under normal circumstances the boiler should not be
operated other than with the monotube supplied.
51.1 Strainers
Where the Flexiflame 140 is used as a replacement for a
boiler on an existing system, the system should be
flushed and cleaned using a suitable chemical cleaner
following the manufacturer’s recommendations and fitted
with a strainer in the return before the boiler.
5.2 Control schemes
The boiler is electrically controlled. The tiring of the boiler is
initiated by the pump incorporated in the boiler. This pump
is for the boiler only and is not intented to act as a system
pump which must be supplied, correctly sized for the system
design, by the installer.
Most normal pumped primary control schemes can be used
including thermostatic radiator and cylinder valves. When
using motorised valves the controls should be so arranged to
switch off the boiler when circuits are satisfied.
For details of control schemes see 4.2. Chaffoteaux can be
consulted where technical assistance is required.
5.3 Isolating valves
Two isolating valves are fitted to the boiler to allow for COI,
plete isolation of the boiler for servicing.
5.3.1 Electrical comnonents
Boiler thermostat
red circuit board
‘nal thermostat can be fitted between terminals 6 and 7.
Fig. 8
5
Page 9
5.3.2 Pump positions
r
---
22mm
cold feed
4
Vlax. 156 rn=
(6 ins)
See fig. 15
22 mm open vent
---------- 7
Minimum
static head
t
3 metres
f -- -
@Qpl
r
L-l-
Lr;
22mm
cold feed
.------
22 mm open vent
--t
Static head
not less than
maximum head
developped by
pump P2 or 3 m.
whichever is
greater
1,
\Seefig. 15
Fig. 13
N.B. h = maximum head developed by pump P2
5.3.3 Air separator
I.
Air seperator or formed low velocity point
!
C
22 mm cold feed
---
I
Minimum
t
static head
--
3 metres h/3
\
whichever greater
\ See fig. 15
Fig. 12
I
tr
--
22
zld feed
.---------
!il
Pl
22 mm open vent
mm----
4
3 met reb
t
--
t
Static head not less
than maximum head
developed by pump
P2 or 3 m. whichever
is greater
Ye--
\ SG fig. 15
Fig. 14
c- 22 mm open vent
Id
\
‘T’ one size
rl
Fig. 15
6
Page 10
5.4 Circulation pump
The system circulating pump should be sized relative to the
resistance of the connected load and the system design At
selected. The mass flow rate through the manifold should not
be less than 8.1 g.p.m. (2209 litres/hour) and the temperature
difference across the manifold should not be greater than
18 ‘C. The boiler requires a minimum static head of 3 m.
(10 ft) irrespective of whether the pump is fitted on the flow or
the return.
Most pump manufacturers require a minimum static head on
the pump inlet to prevent cavitation. The boilers are designed for a system temperature drop of 18’ C on full load but
the monotube arrangement provides a built in by pass feature
for temperature differences of less than 18” C.
5.5 Inhibitors
Chaffoteaux Limited, generally, recommend the inclusion
of an inhibitor with heating and hot water systems
utilising FLEXIFLAME boilers.
The following are the appliance manufacturer recommendations.
I ) Use only a British Gas or similar approved inhibitor from
the Femox range manufactured by Industrial (Anti
Con-o-’
sion) Services, Britannia House, Waltham Cross, Herts.
Telephone : 0799-085811 or Grace Dearbon Limited,
Widnes. Cheshire WA8 8UD - Telephone : 05 l-424-535 I.
2) Use only the quantities specified by the inhibitor manu-
facturer.
3) Cleanse the system, as may be required by the inhibitor
manufacturer.
system.
4) Add inhibitor only after flushing when finally refilling
5.6 Automatic air separator
Chaffoteaux Limited strongly recommend the inclusion of a
British Gas accepted automatic air separator in the system as
shown in fig. 15
The open vent pipe should rise continuously from the system
pipework.
It should not be entered horizontally into the system pipework.
The use of an enlarged T to create a low velocity point is
recommended. The preferred arrangement is shown in fig. 15
5.7 Open systems only
5.7.1 Cold feeds and open vents
The cold feed and open vent should be so positioned that
pumping over and sub-atmospheric pressures are avoiled.
Chaffoteaux recommend that a 22 mm cold feed is fitted on
the left and a 22 mm open vent on the flow to the right of the
boiler. The connection should be so arranged that there is a
low velocity point at the open vent junction with the system.
5.7.2 Hot water storage cylinder
The domestic hot water cylinder used with a Flexiflame
140 must be of the indirect coil and high recovery type
BS 1566 Pt. 1. Single feed cylinders are not suitable for u,
with this appliance. Flow and return pipework to the cylin-
der should be in 22 mm pipe.
5.7.3 Feed and expansion tank
The feed and expansion tank should be adequately sized to
accept the system water expansion, it should not be mounted
closer than 9 in. to a ceiling to allow access to the ball valve.
5.8 Sealed system only
5.8.1 Safety valve
A safety valve shall be fitted close to the appliance on the
flow pipe by a horizontal or a vertically upward connection.
Only safety valves set to operate at 3 bar (45 lbf/in2) shall be
used; they shall be so positioned, or any discharge pipe so
arranged. that discharge of water or steam from the valve
cannot create a hazard to occupants of the premises or cause
damage to electrical components and wiring.
1
5.8.2 Pressure gauge
A pressure gauge covering at least the range O-4 bar /
(O-60 lb/in*) shall be fitted to the system adjacent to, and u
visible from, the filling point. A temperature gauge should be
fitted.
5.8.3 Hot water storage cylinder
The hot water cylinder shall be the indirect coil type which is
suitable for the system pressure.
Provision shall be made for replacing water lost from the
5.8.4 Make-up system
system either :
(i) From a make-up vessel or tank mounted in a position higher than the top point of the system, and connected through
a non-return valve to the system on the return side of the hot
water cylinder or the return side of all heat emitters, or,
(ii) Where access to a make-up vessel would be difflcu!t, by
prepressurisation of the system (see also 5.8.6 Filling point).
5.8.5 Mains connection
There shall be no connection to the mains water supply or to
the water storage tank supplying domestic water, even
through a non-return valve without the approval of the local
water authority.
5.8.6 Filling point
The sytem should be fitted with a filling point at low level.
Methods of filling and marking up sealed systems T
described in BS 5376 : 2
Diagrams showing sealed system layout
1. Expansion vessel
2. Pressure gauge
3. Filling point
4. Drain cock
5. Air release point
6. Safety valve
7. Top up bottle
I
Pump on return Pump on flow
7
1
Fig. 15A
Page 11
5.8.7 Pipework
Pipework should be of copper ; small bore or microbore with
capillary or compression jointing to a high standard. Leak
sealant shall not be used in the system.
6. Commissioning and testing
6.1 Electrical installation
Checks to ensure electrical safety should be carried out by a
competent person i.e. earth continuity, polarity and resistance to earth. In the event of an electrical fault after installation of the appliance preliminary electrical system checks
shall be carried out.
6.2 Gas installation
The whole of the gas installation, including the meter, should
be inspected and tested for soundness and purged in accor-
dance with the recommendations of KS 6XY I
6.3 Water circulation system
6.3.1 Open system only
The whole of the system should be thoroughly flushed out
with cold water without the system circulating pump in position, Ensure that all valves are open.
With the pump fitted, the system should be filled and air
zks cleared. The boiler water section can be vented if neces-
fry by unscrewing the drain valve (see A fig. 16). Vent all ra-
diators and check for water soundness.
Light the boiler as detailed in 6.4
6.3.2
Sealed system only
The whole of the system should be filled and thoroughly
flushed out with cold water without the circulating pump in
position. Ensure that all valves are open. (The system must
be filled with water either from a sealed system filler pump
with a break tank, or by any other method approved by the
local Water Undertaking).
With the circulating pump fitted, the system should be filled
and air locks cleared until the pressure gauge registers 1.5 bar
(2 I .5 p.s.i.). (The boiler water section can be vented if
necessary by unscrewing the drain valve, see A fig. 16). Vent
all radiators and check for water soundness.
Manually raise the water pressure to ensure that the safety
valve lifts. This should occur at 2 0.5 bar ( i 7.2 p.s.i.)
on the max working pressure i.e. 3 bar (43.5 p.s.i. should
operate at 3.5 bar (50.75 p.s.i.).
‘elease water from the system until the initial system design
,ressure is attained, taking into account any difference in
height between the pressure
gauge and the point at which
the pressure vessel is connected.
Light the boiler as detailed in 6.4 and thoroughly full the
system again after the design temperature has been achievied.
6.4 Lighting the boiler
The following procedure should be followed :
a) Check that fuses have been replaced (see 4.7).
b) Open gas service tap by turning to 0 (see B fig. 16).
c) Press in pilot valve knob and light pilot using the ignition
button, continue to hold in the pilot valve knob for 30
seconds and release (n.b. the pilot should remain alight, it
may be necessary to wait a few moments for gas to reach
the pilot) (see C fig. 16).
d) If the pilot extinguishes for any reason wait 3 minutes
before relighting.
e) The boiler is now ready to operate and will light when
switched on at ON/OFF switch and thermostat is turned
to + which starts the pump (D and E fig. 19).
f) Test for gas soundness.
g) Check, and if necessary, adjust the gas rate as detailed in
6.5 ten minutes after lighting from cold.
6.5 Gas rate adjustment
Switch off the boiler at the electrical control box. Set the
system circulation pump in operation and open all system
control valves.
Remove the pressure test point screw from the left hand
end of the burner manifold and connect pressure gauge
suitable for measurement in the range O-20 mbar (O-8 in.w.g).
Remove the hexagonal cap from the front of the gas volume
governor to expose the adjusting screw (D fig. 16).
Turn on the boiler at the electrical control box and, after
running the boiler for ten minutes from cold adjust the
burner pressure to that shown in graph (fig. 17). The pressure
will be reduced for clockwise movement of the screw,
increased for anti-clockwise movement.
Turn off the boiler at the electrical control box, remove the
gauge and re-fit thC pressure test point screw and gas volume
governor cap. Test fdr gas soundness.
Mark the data badge against output to which the boiler has
been adjusted.
The data badge is situated at the bottom right hand side of
the chassis (fig. 16).
6.6 Hushing
The water system should then be heated to maximum
working temperature and examined for water soundness. Gas
electricity and water should then be turned off and the water
system rapidly drained whilst still hot.
The system should again be filled and cleared of air locks
sealed systems should be adjusted to the initial system design
pressure., any set pointer on the pressure gauge should be set
to coincide with the indicating pointer. Re-adjust controls to
appropriate setting. Examine for water soundness.
Add inhibitor to the system if required in the specification
(see 5.5).
6.7 To fit casing
- Fit side panels by hooking over pegs at top and securing
with screw bottom rear.
- Fit control module cover, secure with five screws two each
side and one in centre (F fig. 19).
- Fit front panel by hooking on pegs at top of boiler and
secure with three screws G along bottom (fig. 19).
I
I I
I
I I
I
70 80 90 100 110 120 130 140
outputBtu/hrxlOOO
Fig. 16
Fig. 17
6
Fig. 16
Page 12
- Fit control knob.
- Remove glass panel from carton.
- The hinges are held in position by a metal strap (fig. 19).
- Remove the screws securing the strap and set aside for
re-use both the strap and the screws.
- Slide the left hand side hinge from glass panel and slot into
left hand side vertical trim.
- Locate glass panel on to left hand side hinge with the panel
in a vertical position.
- Locate right hand side hinge into the right hand side
vertical trim.
- Using the screws removed re-fit the transit strap beneath
the glass panel.
- Finally secure hinges with screw from front of each hinge.
6.8 Adjust thermostat to system design requirements.
Set the boiler in operation and balance the system adjusting
thermostats, time clocks and other controls.
6.9 To drain boiler
Close the isolating valves on the holler by turning in a clock-
wise direction. Drain the boiler by unscrewing the drain
valve (A fig. 16).
6.10 Users instructions
Hand the user’s instructions to the user for retention
and
instruct in the safe operation of the boiler.
Advise the user of the precautions necessary to prevent
damage to the system and to the building in the event of the
svstem remaining inoperative during frost conditions.
ginallv advise the user that, for continued efficient and safe
operaiion of the boiler, it is important that adequate servicing
is carried out at regular intervals recommended b? the local
gas region, your local Chaffoteaux et Maury Service Centre
or other C.O.R.G.I. registered personnel in accordance
with the gas safety (installation and use) regulations.
7. Routine Servicing
To ensure continued afficient and safe 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 British Gas, other C.O.R.G.I.
registered personnel or your local Chaffoteaux Service
Centre, in accordance with the Gas Safety (Installation and
Use) Regulations. This routine service will normally be
cerfied to :
I) Cleaning the burner.
2) Cleaning the heat exchanger.
3) Cleaning the gas control.
4) Cleaning and greasing bearing pilot spindle.
5) Cleaning the diaphagm.
The following schedules are recommended.
a) Check the function of the appliance. burner pressure. gas
flow rate and soundness.
b) Observe tlame picture and undertake combution test.
c) Check,
clem
or replace components as necessary.
N.B. : Before commencing any work turn off gas at the gas
inlet tap, and ensure that the electricity supply is
disconnected. Inhale the flow and return, and train
appliance if required.
7.1 Remove casing
- Remove thermostat knob by pulling off.
- Remove two screws at bottom rear of side panels.
- Remove screw from centre of controls panel.
- Ease whole case forward and guide over piezo and pilot
operating plunger.
- Lift off turret fixings at top of appliance.
7.2 Annual service
7.2.1 To clean the burner (fig. 2 1)
Unscrew the pilot tube clamping screw A.
Remove the pilot tube by lifting out of bracket.
Remove six screws B which retain the burner manifold
(screws are different lengths).
Remove manifold gasket and pilot support bracket and
disconnect thermocouple at thermoelectric valve, pull off
connection on high limit thermostat, disconnect piezo
ignitor.
Remove two screws C at ends of rear of burner.
Unscrew nut D which secures manifold bend to gas sectif
Remove burner by moving to the left taking care to reta.-.
gasket.
Invert the burner head and clean by brushing.
Replace in reverse order, ensuring that the gasket between
the burner manifold and the gas section is in place.
7.2.2 To clean heating body. Remove case as described in 7.1
and the burner (7.2.1).
- Remove six screws and remove the front of the combustion
chamber.
- Clean the heat exchanger by brushing from below and
through the draught divertor openings. Do not attempt
to clean the internal waterways without consulting the
manufacturer.
- Replace in reverse order.
7.2.3 Clean the pilot assembly
7
Remove pilot clamp screw (A fig. 2 1)
Remove pilot tube. Blow through tube to remove dust.
Carefully unscrew the nut retaining the pilot injector (F
fig. 21) taking care not to lose the injector which is in t’
form of a small washer using a 8 mm or adjustable spannt.
Clean the injector by blowing also clean pilot filter.
Do not attempt to clean pilot injector by pushing wire
through the orifice.
,‘.2.4 Remove gas section
- With burner removed as described in 7.2.1
- Remove control panel as described in 7.3.2.
- Release two screws securing gas section to water section (A
fig. 22).
- Ease gas section forward and up.
Fig. 19
Fig. 20
Fig. 21
9
Page 13
7.2.5 Clean diaphragm spindle
With gas section removed (see fig. 23) start pump. The
bearing plate spindle A will rise. Whilst in this position
‘sari and apply coat of silicone grease.
.<e-assemble in reverse order.
7.2.6. To clean thermocouple and electrode
- Remove manifold as in 7.2.1
- Release thermocouple from thermoelectric valve (A
fig.
24).
- Pull off tab connectors from overheat thermostat.
- Pull off electrode cable from piezo ignitor.
- Slide thermocouple support bracket from slot in burner.
- Clean by brushing.
- Re-assemble in reverse order.
7.3 General service
7.3.1 Clean burner, heating body, pilot assembly and ther-
mocouple as detailed in 7.2.1. and 7.2.6.
7.3.2 To remove electrical control module (fig. 10)
- Isolate electrical supply.
- Withdraw fuses.
- Remove two screws left hand front of module and open the
left hand side front by pulling forward.
‘Jnplug pump from printed circuit board.
; ~Disconnect and remove mains input cable.
- Remove split pin and withdraw thermostat phial.
- Remove two screws on bracket at base.
- Pull off electrode lead from piezo unit.
- Remove two screws B either side of pilot valve knob.
- Remove nut from rear control box/control box bracket.
- Remove electrical control box by pulling forward.
7.3.3 To replace diaghragm
- Isolate boiler by turning off isolating valves.
- Slacken valve B in base of water section.
- Drain boiler.
- Remove control module as in 7.3.2.
- Disconnect high and low pressure tubes C from water
section.
- Slacken two screws between gas section and water section.
(Screw at front and at right hand side).
- Release nuts securing water section to chassis.
Remove water section complete with diaphragm.
,eparate the top and bottom halves of the water section by
removing screws E. Note the relative positions of the two
halves for correct re-assembly.
- Remove diaphragm and discard. Wash out water section.
- Replace diaphragm and reposition bearing plate on top of
diaphragm.
- Re-assemble in reverse order taking care to relocate upper
and lower sections in original position.
7.3.4 To clean the gas valve (fig. 22)
- Remove the burner as in 7.2.1
- Remove the four screws B fastening the top of the gas
section to the base.
n.b. it may be found easier if the combustion chamber front
cover is removed.
- Lift the gas section top off the base taking care not to lose
springs and valves (C).
- Lift off gas valves.
- Do not attempt to further dismantle the valve assembly.
- Clean the valve seating and replace the gas valve facing if
necessary.
- Replace in reverse order.
8. Replacing components
8.1 To replace the thermoelectric valve.
- Remove thermocouple nut.
- Unscrew valve (A fig. 24) from rear of gas section using a
35 mm or adjustable spanner.
- Withdraw thermoelectric valve.
- Replace in reverse order.
8.2 To replace the overheat thermostat
- Remove the two tab connectidns on the thermocouple
leads to the overheat assembly.
- Remove two screws retaining overheat thermostat.
- Replace thermostat - use heat sink grease for better
contact.
- Re-assembly in reverse order.
8.3 To replace piezo unit
- Remove earth tab from piezo. Pull off electrode lead.
- Unscrew plastic retainer from rear of control module.
- Withdraw piezo.
- Replace in reverse order.
8.4 To replace pump (fig. 24)
- Isolate electrical supply.
- Remove fuses and then the two screws securing the left
hand door of the electrical control box.
- Withdraw plug from printed circuit board and earth tag.
- Remove four bolts B retaining pump head.
- Remove electrical cover from pump and remove lead n.b.
The motor/impeller can be replaced with a Grundfos UPS
18/60 motor/impeller and should be set on setting 2.
Should it be necessary to replace the pump during the
guarantee period it can be exchanged at any builder’s mer-
chants stocking Grundfos pumps.
- Replace in reverse order.
8.5 To remove pump and volute (fig. 24)
- Isolate boiler and drain water, see 7.3.3 disconnect electrical supply (see 8.4).
Fig. 22
Fig. 23
10
Fig. 24
Page 14
- Release nut C securing volute to leg from heating body.
- Release nut D from appliance side of isolating valve.
- Replace in reverse order.
8.6 To replace heat exchanger matrix (fig. 18)
- Disconnect electrical supply.
- Isolate boiler and drain water (see 8.3.3).
- Remove six screws and remove the front of the combustion
chamber.
- Release nuts A connecting heat exchanger matrix to
appliance internal pipework.
- Remove four screws B securing combustion chamber to
chassis (two on each side).
- Remove the combustion chamber complete with matrix.
- Unscrew the union nut and remove the left hand body leg.
- Remove two screws D at rear and two screws at front of
heat exchanger matrix.
- Remove heat exchanger matrix.
- Replace in reverse order. Taking care to ensure that the flat
locating bracket is in contact with heat exchanger skirt. In
this position the upper union can be tightened.
8.7 To replace boiler thermostat
- Isolate electrical supply.
- Remove casing (7.1).
- Remove fuses (E fig. 18).
- Remove live screws (F fig. 18) securing control box cover.
- Remove thermostat phial (G fig. 18) from monotube after
removing split pin.
- Remove thermostat with mounting plate from control box
(A fig. 10).
- Detach thermostat from plate.
- Replace in reverse order.
11
Page 15
9.
Fault finding chart
Fault
Pilot will not light
Pilot goes out
when gas knob is released
Main burner will not light
or lights at low flame
Complaints of noise
Excessively noisy burner
Frequent sooting
of heat exchanger and burners
Gas staying on after pump
is switched off
Possible cause
1) Gas supply not turned on.
2) Gas supply pipes not purged of air.
3) Blocked pilot filter or injector.
1) Gas control knob not fully held in before
releasing.
2) Thermocouple not in tip of pilot flame.
3) Pilot flame too soft.
4) Faulty thermocouple or union loose.
5) Main gas valve not purged.
6) Faulty thermoelectric valve.
)
7) Overheat failing.
8) Loose connection on overheat
thermostat.
1) Electricity not switched on to boiler.
2) Fuses missing or blown in control box.
3) Boiler thermostat at low setting.
4) Boiler thermostat faulty or not plugged
into control box.
5) Gas supply insufficient.
6) Lack of water in system.
7) Air in system.
8) Boiler pump faulty.
9) Water filter in return pipe blocked or
high presure and balancing tubes
blocked.
10) Bearing plate spindle bent or dry.
11) Diaphragm split or stretched.
12) Heat exchanger blocked.
1) Over-gassed.
2) Air in system.
3) Boiler thermostat wrongly set or faulty.
4) Water section sticking open.
5) Gas valve sticking open.
6) Dirt/swarfon gas valve facing.
7) Resistance to water flow.
8) Pump noise or vibrating.
9) Heat exchanger partially blocked.
1) Over-gassed.
2) Dirty burner bars.
3) Burr on injectors.
1) Linting.
2) Insufficient combustion air to room or
compartment.
3) Heat exchanger fins blocked.
4) Restriction in flue.
5) Wrong injectors fitted.
1) High pressure or balancing tubes blocked.
2) Gas valve sticking open.
3) Water section sticking open.
Remedy
Turn on.
Purge.
Clean or replace (7.2.3).
Press firmly before releasing.
Adjust (12 milli-volts min. required
measured at high limit thermostat).
Tighten pilot injector securing nut (7.2.3).
Replace or tighten.
Repeat ignition sequence.
Replace (8.1).
Replace (8.2).
Tighten.
Switch on.
Replace 1 amp.
Turn up fully.
Replace or check connection (8.7).
Check working pressure-8 in w.g.
required at inlet.
Fill.
Purge.
Clleck or replace (8.4).
Remove and clean.
Replace or grease (7.2.5).
Replace (7.3.3).
Descale or replace (8.6).
Check gas rate and adjust (6.5).
Purge.
Check flow temperature.
Check operation and grease (7.2.5).
Clean or grease (7.3.4).
Clean and reassemble (7.3.4).
Open valves.
Replace or refit (8.4).
Clean heat exchanger and check system
(8.6).
Check gas rate (see 6.5).
Clean (7.2.1).
Remove or replace.
Clean burner (7.2.1).
Check requirements (3.5.2).
Remove and wash throughly (7.2.2).
Check flue.
Check and replace (2.10)
Remove and clean.
Clean and grease (7.3.4).
Clean and grease (7.2.5).
12
Page 16
Chaffoteaux et Maw-y Limited,
Trench Lock, Trench, Telford, Shropshire TFl 4SZ
Telephone: (01952) 222727 Fax: (01952) 243493
13
ESP024
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