Page 1
Moduloflame 140
Wall Hung Gas Boiler Designed
Modular Commercial Use
INSTALLATION AND SERVICING MANUAL
For
Page 2
chaffoteaux
et Ibury
CHAFFOTEAux ET MAURY Umited.
Trench lock, Trench,
Telford, Shropshire TFI 4SZ
Telephone. : Telford (0952) 222727
T&fax : (0952) 243493
Ref. : 92220-141 - 09/9E
Moduloflame 140
cat. II 2H 3P
STATUTORY REQUIREMENTS
The installation of this appliance must be carried out by a CORGI Registered
person or other competent person and in accordance with the requirements of the
current editions of the Gas Safety (Installation and Use)Regulations, the IEE Wiring
Regulations and local Water Authority By-Laws. It should also comply with the
following documents:
The Building Regulation:
-The Gas Safety (Installation and Use) Regulations
-The Public Health Act -1936
-British Gas Publications - Flues for Commercial and Industrial Gas Fired Boilers
and Air Heaters (1979) IM/l 1
British Standards:
Codes of Practice
-BS CP 331: Part 3 - “Gas supplies to appliances”
-BS CP 341 300 - 307 Central Heating by low pressure hot water
-BS CP 342 - Centralised hot water supply:
-Part 1- Individual dwellings
-Part 2 - Buildings other than Individual dwellings
-BS 6759 Safety Valves
-BS 4076 Specifications for steel chimneys
-BS 6891, BS 5440 parts 1 and 2, BS 5449 part 1, BS 7593, BS 6798, BS 5546,
BS 4814, BS 7074 part 1 and 2, BS 7671 and BG DM2.
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
within the 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.
GUARANTEE
The manufacturer’s guarantee is for 12 months from the date of purchase. The
guarantee is voidable if the appliance is not installed in accordance with the
recommendations made herein or in a manner not approved by the manufacturer.
CUSTOMER CARE
Chaffoteaux et Maury Ltd., as a leading manufacturer of domestic and commercial
water heating appliances, is committed to providing high quality products and a
high quality after sales service. If it is necessary to contact an engineer, then
telephone your local Chaffoteaux Service Centre The number can be obtained from
the leaflet enclosed in the customer care pack with your boiler or by telephoning
the Chaffoteaux Customer Services Department at Telford.
Advice on installation or servicing can also be obtained by contacting the
Chaffoteaux Customer Services Department at Telford.
CUSTOMER SERVICES DEPARTMENT
Tel: 01952 222288
Fax: 01952 260915
Page 3
CONTENTS
Statutory
Guarantee
Customer care
Introduction
Description
Technical data
Dimensions
Installation and Operation
Installation Requirements
System Guidance
Installing the Boiler
Commissioning
Routine Servicing
Suggested Sequence for Servicing
Replacing Components
Fault Finding Chart
Schematic Wiring Diagram
Short Parts List.
Component Recognition Chart
requirements
Operation
Location
Flue
Ventilation
Gas supply
Flushing and water treatment
System controls
Pump
Water connections
Gas connections
Electrical connections
Pre-commissioning
Filling and purging
Lighting the boiler
Setting the gas rate
Post commissionning
Handing over to user
Preliminary checks
Service schedule
Additional procedures
Heat exchanger
Burner manifold
Burner
Ionisation and ignition electrodes
Gas solenoids
Pump
Fuses
Printed circuit board
Spark generator
Thermostat
Thermistor
Overheat thermostat
Spillage detector
2
2
2
4
4
5
5
6
6
6
6
6
6
6
6
6
6
7
7
7
7
7
7
7
7
7
8
8
8
8
8
8
9
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9
9
9
9
9
9
9
9
9
9
9
9
10
10
IO
11
11
11
3
Page 4
Installation Instructions
INTRODUCTION
The MODULOFLAME 140 is a wall mounted, low water content open flued boiler. The boiler is rated between 13.1 kW (45,000
Btu/h) and 35 kW (120,000 Btu/h) outputs. The boiler is designed for use with Natural Gas and L.P.G. when a convertion kit is
fitted.
The MODULOFLAME 140 is intended for the larger domestic installations, swimming pools, commercial and 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. It has electronic ignition and flame supervision, a fully adjustable electrical thermostat
which operates the boiler pump and thermistor control for the flow temperature.
The MODULOFLAME 140 is supplied in one carton. The 54 mm monotube should be fitted to the flow and return connections
to he boiler as shown in the picture below.
DESCRIPTION
1. Outer case
2. Built in down draught diverter
3. Spillage detector
4. Heating body containing a copper
finned heat exchanger
5. Patented twenty four blade stainless
steel multigas burner
6. Steel chassis
7. Thermistor
8. Support bracket for the valves
9. Electrical box
IO. Grundfos pump
11. Gas solenoid assembly
12. Gas rate adjusting screw
13. Ignition and ionisation electrodes
14. Manually resettable overheat
thermostat (not visible)
15. Temperature gauge
16. System temperature adjustment
17. Reset button
18. Red bulb (lock out)
19. Orange bulb (burner “on”)
20. Green bulb (Power “on”)
21. Main switch
4
22. Fuses
23. Two stage thermostat adjustment
24. Pressure gauge
25. Water pressure switch
26. Flow valve to isolate heating body
27. Monotube thermostat phial
28. Gas service tap
29. Return valve to isolate heating
body
Page 5
TECHNICAL DATA
Type Bl 1 BS
Suitable only for natural gas and conversion to L.P.G.
Heat Input
Heat output
Burner manifold injectors
Minimum air supply required
Combustion products rate
Average flue gas temperature
Maximum flow temperature
Minimum return temperature
Maximum system pressure
Minimum system pressure
Water capacity
Electrical supply
Power consumption
Weight excluding packaging
Weight including packaging
Burner pressure G20 (natural gas) @ 20 mbar
Burner pressure G31 (propane L.P.G.) @ 37 mbar
Gas rate (15 “C -1013 mbar)
Gas type
G20
G31
Burner injectors
Natural gas (Restrictor diameter : 0 2.8 mm & 6.0 mm) :
Propane gas (Restrictor diameter : o 1.9 mm & 4.0 mm) :
Pressure Net C.V.
20 mbar
37 mbar
230 V single phase - 50 Hz
35,9 MJ/m3
46,4 MJ/kg 3.09 kg/h
1.28 mm
0.74 mm
Modtdoffame 140
38.8 kW
13.1 - 35 kW
24
85 m3/h
32
g/l
120 “C
85°C
50°C
6 bar
0.6 bar
2 litres
9ow
51 kg
54 kg
8 mbar
24.8 mbar
Gas rate
4.21 m3/h
DIMENSIONS
A
0
0
7
Fig. 6
Clearances
Side
Top
Bottom
Front
NB. When boilers are installed side by side there should be at least 300mm
clearance between them.
i
150mm (6 ins)
1 OOmm (4 ins)
150mm (6 ins)
1000 mm (39 ins)
mm
A
B
C 365 14.3
D
E
F
G 95
H
J
K 44
L
M
N
P
925
600
174
150
65
820
390
45
165
260
95
ins
36.4
24.0
6.9
6.0
2.5
3.75
32.25
15.3
2.0
2.0
6.5
10.6
3.75
5
Page 6
INSTALLATION & OPERATION
OPERATION
When the external controls are calling
for heat,and the temperature in the
monotube is below the temperature set
on the thermostat, the pump will run.
Once the flow through the boiler is
established and the temperature in the
boiler is below the one set on the boiler
thermostat, the water pressure switch
will allow the grey safety solenoid and
the blue first stage solenoid to open.
The ignition sequence begins. A
continuous, high speed stream of
sparks ignites the gas. Once the
ionisation circuit detects the flame the
orange secondary solenoid opens to
allow the full, or set, gas rate to the
burner. If a flame is not detected within
8 - 10 seconds the security solenoid
will close and shut off the gas. The red
lockout indicator bulb will light. The
temperature of the primary circuit is
sensed by the thermostat in the
monotube and the flow temperature of
the boiler is detected by the thermistor
in the flow pipe. These two thermostats
interact with each other and the boiler
thermostat must always be set above
the monotube temperature.
INSTALLATION REQUIREMENTS
Location
The Moduloflame 140 is wall mounted
and the position chosen should allow
adequate space for servicing and for
sufficient air flow around the boiler.
The location must permit the
satisfactory routing and termination of
the flue. The surface should be flat and
non combustible and able to
adequately support the weight of the
boiler and ancillary controls.
For guidance, a wall area of:
900 mm (36 ins) wide and 1185 mm
(47 ins) high would provide the
necessary clearances for case removal
and for air movement.
As it is an open flued appliance certain
locations are banned, for example
bedroom, bedsitting rooms, private
garages or rooms containing a bath or
a shower. A cupboard or compartment
used to house the boiler must have
been designed and constructed, or
modified, specifically for the purpose.
Refer to BS 6798 for further guidance.
Flue
The following notes are for general
detailed
guidance
recommendations refer to BS 5440:
pt 1.
There should be at least 600 mm of
vertical flue after the boiler before the
use of any bends. The flue must take
the most direct route practicable. The
number of bends must be kept to a
minimum. Long external runs and
Horizontal or slightly inclining runs
must be avoided.
Ventilation
The following notes are for general
guidance
recommendations refer to BS 5440:
pt 2.
The boiler must have a permanent air
supply. This may come from an
adjacent room or internal space which
must also have permanent ventilation
to outside or direct from outside. If the
supply is from another internal space
or room, that room must have a
permanent air supply at least the size
as required for the boiler. If installed in
a room, the boiler requires a vent with
175 cm2 free air space.
Where the boiler is installed in a
compartment, the air is supplied
through vents at high and low level as
shown in the chart below:
Note: both vents should communicate
with the same room, internal space or
be on the same wall to outside air.
If there is an extractor fan is installed
on the premises, a spillage test must
be carried out with the fan operating.
Position of air
vent
Gas Supply
Do not use pipe smaller than the boiler
gas connection which is 314” BSP. The
gas installation should comply with BS
6891. The meter and pipework must be
of sufficient capacity to supply the
boiler and other gas appliances. The
completed installation must be tested
for soundness in accordance with the
requirements of BS 6891.
only.
only.
For
For
Air from
room or
internal
space
350 cm2
700 cm2
detailed
Air direct
from
outside
175 cm*
350 cm*
--I
Electrical Supply
The boiler requires an earthed 230V 50 Hz single phase supply. It must be
possible to completely isolate the
appliance electrically. Connection
should be via a 3 amp fused double-
pole isolating or a fused three pin plug
and an unswitched shuttered socket
outlet. Either method must be in
accordance with the current I.E.E.
regulations. It should be readily
accessible and only supply the
appliance.
SYSTEM GUIDANCE
Flushing and Water Treatment
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 impair the
performance of the boiler and its
controls. Refer to BS 7593 (1992).
Consideration should also be given to
the treatment of the system water and
advice can be sought from the
manufacturers of water treatment
products such as
Betz Dearbon Ltd
Foundry Lane
Widnes
Cheshire
WA8 8UD
Tel: 0151 424 5351
Fernox Manufacturing
Britannica Works
Clavering
Essex
CBI1 4QZ
Tel: 01799 550811
If the boilers are being installed on an
existing system, a sump and drain
should be fitted on the heating return at
the lowest point. It is essential that the
system is fully flushed to remove any
sludge and debris before the boiler is
connected.
System Controls
The Moduloflame 140 is electrically
controlled and so most normal pumped
primary control systems can be used.
Please note that when thermostatic
radiator, or zone valves are used, the
controls should be so arranged as to
turn off the boiler when they are
satisfied. A by-pass will be necessary
to maintain a minimum flow rate of
27.5 I/h (6.05 g/m) 1.65 m3/h through
the monotube.
6
Page 7
Pump
The system pump should be sized to
take into consideration the load and
design of the system. The integral
pump will overcome the resistance of
the heat exchanger and so for
calculation purposes the boiler can be
disregarded.
The temperature
difference across the monotube should
not exceed 18°C.
INSTALLING THE BOILER
The boiler is delivered in one carton.
Having removed the boiler do not
stand it on either the downdraught
diverter or the bottom chassis carrying
the isolating valves. Using the
dimensions in the diagram on page 5
mount the wall bracket and hang the
boiler on it. Fit the monotube ensuring
that the thermostat pocket is to the left
of the boiler. Remove the thermostat
phial from behind the electrical box and
insert in the thermostat pocket and
secure with a retaining pin.
i
Flow direction
likely to exceed 9 m (29.5 ft) then
consult the following table for
guidance.
Equivalent pipe
Pipe diameter.
length, including
1
Fittings, in metres.
9m
12m
15m
20 m
25 m
30 m
40 m
22 mm
28 mm
28 mm
28 mm
28 mm
28 mm
35 mm
The supply should be sufficient to
provide 20 mbar (8 in wg) pressure
with the boiler working.
Electrical Connections
Withdraw the fuses
Unclip the door on the front of the
electrical box to gain access to the
connections. Connect the live and
neutral wires to the connecting block
as shown in the picture below and the
earth wire to the pillar.The connections
must be made so that should the lead
be pulled from its anchorage, the
current carrying wires become taut
before the earth wire.
filling pressure remains constant.
Purge the installation of air.
It should not be necessary to vent the
boiler. If it is, the drain valve may be
used.
Sealed System
Ensure all valves are open
Fill the system slowly ensuring the
filling pressure remains constant.
Purge the installation of air.
It should not be necessary to vent the
boiler. If it is, the drain valve may be
used.
To check the operation of the safety
valve.
Raise the pressure in the system until
the safety valve starts to discharges.
This should happen at + 0.5 bar (+ 7.2
p.s.i.) of the maximum working
pressure which is 3.5 bar (50.75 p.s.i.).
Release water from the system until
the designed system pressure is
attained, taking into account the
difference in height between the
pressure gauge and the pressure
vessel.
Lighting the Boiler
Connect gas pressure gauge to test
point ( Fig. 8).
Turn on the gas supply and boiler gas
tap ( 28 page 4 ).
Ensure electrical supply is on.
Ensure all external controls are calling
for heat.
Turn selector switch ( 21 page 4 ) to
ON position . ‘1111
Turn the boiler thermostat to
maximum.
Pressure test point
Fig. 7
WaterConnections
Flow and return connections made to
the monontube are 54 mm copper.
Note that the flow is from left to right
when viewed from the front.
Gas Connections
The gas service tap is attached to the
boiler. An inlet bend and filter-washer
is provided. The gas connection is 314”
BSP. and the supply should not be less
than 22 mm and should be connected
directly to the meter. If the pipe run is
COMMISSIONING AND TESTING
Pre-commissioning
Ensure that the system has been
adequately flushed.
Purge gas supply and test for
soundness
Carry out final electrical tests to ensure
the correct polarity and earthing
continuity
Filling and Purging
Open System
Ensure all valves are open
Fill the system slowly ensuring the
7
The boiler will light.
Check for gas soundness.
Allow the boiler to heat system.
Check the inlet gas pressure is 20
mbar (8 in wg) with boiler operating.
Once up to temperature, re-flush the
system to remove any dissolved oils
and fluxes.
Recharge system pressure and
introduce any water treatment as
required.
Page 8
Setting The Gas Rate
Run boiler for IO mins to bring up to
temperature.
Switch the boiler off at the electrical
control box.
Remove the pressure test point
( Fig. 9 ) and connect pressure gauge.
Remove hexagonal cap ( Fig. IO ) to
expose the adjuster screw.
Adjust pressure to suit output as per
the graph below.
Note: The burner pressure is reduced
when the screw is turned clockwise
and increased when turned anti
clockwise.
Turn off boiler before removing the
pressure gauge.
Test pressure point for soundness.
04 I I I : I
14,00 17,SO 21,00 24,SO 28,OO 31,50 35,OO
kW kW kW kW kW kW kW
kW
Adjustment beneath cap
Assemble parts starting with the sides
panels as shown in the picture below
after located the grommets on their
support at the top of the chassis.
Hang the side panels and position the
two case fixing screws without
tightening.
- Position the control panel onto the
electrical box with the centre screw.
- Fix the control panel to the side
panels with four screws adjusting the
position before final tightening.
- Hang the front panel on the upper
supports and fix it to the control panel
with 3 screws.
- Fit the temperature adjustment knobs.
The glass door is fitted using the
hinges A and B and the tie bar C which
when unpacked is holding hinges A
and B to the door.
- Remove and discard the nuts
retaining the tie bar and screws. for
future use.
- Offer the door locating hinge B into
the aluminium profile on the right hand
side panel and fix in position with the
screw and tie bar as in the drawing
below.
- Hing door foward so that the hinge A
can be offered into position and fix
using screw and tie bar as in the
drawing below.
Post Commissioning
Ensure system pressure has been set
correctly.
Set boiler thermostat and controls.
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.
Explain how to register guarantee.
Leave Installation Manual, User’s
Instructions and all documentation with
the user.
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.
Assemble the casing
Remove the two side panels, the front
panel, the control panel and the glass
door from the packaging.
If it is necessary, please remove the
protective film on white panels.
Fig. 11
-
P&ion for case fixing screws
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.
SUGGESTED SEQUENCE for
SERVICING
Before disconnecting or removing any
parts, isolate the gas and electricity
supplies.
(for detail please see section on Parts
Removal and Replacement)
Preliminary Checks
Lift off outer case in one piece by
removing the four lower case fixing
screws, the screw in the centre of the
control panel and the temperature
adjustment knobs
On sealed system, check the system
pressure is at feast 1 bar cold.
Check operation of l/3 and 213
solenoids.
Check that the burner is extinguished
fully when both solenoids are closed.
Test ionisation functions and check
that lockout occurs by turning off gas
tap.
Fig. 12
Page 9
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 be
necessary:
Carry out combustion test.
Check, clean and replace components
as necessary.
Check burner pressure and gas flow
rates.
REPLACING COMPONENTS
Heat exchanger
- Isolate from the system and drain the
boiler
- Remove the front cover to the
combustion chamber
- Release the nuts connecting the heat
exchanger to the internal pipework
- Remove the four screws securing the
combustion chamber to the chassis
- Remove the combustion chamber
complete with the heat exchanger
- Remove two screws at the rear and
two screws at the front of the heat
exchanger
- Remove the heat exchanger
- Re-assemble in the reverse order
Burner manifold
- Remove the four screws securing the
manifold to the burner assembly. Pull it
toward you.
- Replace gasket on gas section before
re-assembly.
-To remove ionisation and ignition
electrodes without removing the burner
assembly, remove the front combustion
chamber panel.
- Unscrew retaining screws and lift free.
- Remove the fuses and screws
securing the front panel of the electrical
box
- Disconnect all plugs and noting the
positions.
- Re-assemble in reverse order.
Gas solenoids
- Pull the colour coded wires free.
- Remove the six retaining screws.
- The solenoids can be removed
complete with their base plate. Take
care not to lose springs and valves.
- Replace gasket on gas section before
re-assembly.
Pump
- Remove the fuses and the screws
securing the door on the left side of the
front panel of the electrical box
- Unplug the pump supply leads and
earth connection
- Release the two union nuts on the
inlet and outlet of the pump volute
- Release the pressure sensing pipe
- Remove the stainless steel retaining
pin
- Remove the pump and volute
complete
- Re assemble in the reverse order
Fuses
-Fuses are accessible from the front
panel.
PCB
- Remove the fuses and screws
securing the front panel of the electrical
box
- Disconnect all plugs and noting the
positions, remove any loose wiring
- Remove the retaining screw
- Release the retaining clips and
remove the PCB
- Re-assemble in the reverse order
- Please note that the plugs cannot be
Retaining screw
placed in the wrong positions
Spark generator
The spark generator is located behind
the electrical box.
- Remove the electrical box retaining
screws as shown in the picture below.
- Pull the electrical box foward to gain
access to the spark generator.
- Remove screw and cover to gain
access to electrical connections.
- Lift the spark generator clear of
locating pins.
- Re-assemble in reverse order.
Two Two retaining screws retaining screws
‘-- =-- -I of gas tap
Fig. 14
Thermostat
The thermostat is located within the
electrical box at the bottom right hand
corner and sensing phial is located in
the monotube.
- Open the electrical box.
- Remove the wires
- Remove the thermostat and capillary ’
from the electrical box.
- Withdraw the retaining pin and pull
the phial free from monotube.
- Re-assembly in reverse order.
Thermistor
The thermistor is located in a dry
pocket on the flow pipe.
- Remove the wires from the thermistor.
- Unscrew the collar.
- Pull the thermistor free from the dry
pocket.
- Re-assembly in reverse order.
in front of gas tap
Burner
- Remove manifold as above.
- Unscrew and remove the two screws
securing the burner assembly to back
plate.
- To remove ionisation and ignition
electrode assemblies unscrew retaining
screws and lift free.
- Re-assemble in reverse order.
Ionisation and ignition electrodes
Fig. 13
-Retaining
9
clips -
Location of thermistor
Fig. 15
Page 10
Overheat thermostat
- Unplug the two connectors.
- Remove the 2 retaining screws and the
overheat sensor.
- Re-assembly in reverse order.
FAULT FINDING CHART
Prior to going through the flow chart, check the following items :
- System is fully vented
- All isolating taps are fully open
- Gas service taps is fully open
1
Ensure the correct polarity. Check that Neutral and Earth voltages are equal.
I
Check main voltage 230 V is available at main connector.
I
1
I
Spillage detector
- Unplug the two connectors.
- Remove the 2 retaining screws and the
spillage detector.
- Re-assembly in reverse order.
Switch the external controls to
‘ON”
Check and if necessary replace the
following items :
- Check main voltage
- Fuses on the PC8
- PCB
;T$ijg$
Check and If necessary replace the
- Monotube thermostat
- Thermistor
I
I
I-
m
4
Are the external
controls calling for heat
Rotate the 2 temperature control
knobs to maximum.
- Switch on the boiler
Does the pump run 7
?
Does the green
indicator light 7
lotes :
Check and if necessary replace the
following items :
- lonization electrode
- PC6
Press on the reset button of the
gas valve
The burner is alight (the orange indicator is alight)
4
and the boiler is operating.
Does the burner
liaht ?
Does the lock out
indicator light after 10
seconds ?
Does the orange
indicator light ?
I I
1 Yes 1
I
#
I
10
Page 11
SCHEMATIC WIRING DIAGRAM
n
Key
I ’
UO.
SHORT PARTS LIST
Description :
Part number :
c
c
.
H
@- 524
COMPONENT RECOGNITION CHART
2302
c
701
607
2101
2303
2214
11
o-2507
Page 12
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 omission in the information contained in this document.
0 Chaffoteaux et Mauty 1996
Chaffoteaux et Maury Ltd
Trench Lock
Trench
Telford
Shropshire
TFI 4SZ
Tel: 01952 222727
Fax: rO1952 243493
12
Looking Good.Heating Better g
ESP034
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