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)
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
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
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
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
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