Chaffoteaux & Maury 280 User 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
afety (lnstallatfon ana Use)Regulatfons. the iEE Wiring
Beguiatrons and local Water Authorrty By-Laws. It should also comply wtth the
followrng aocuments:
ModuIofIame2808c420
cat. II 2H 3P
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
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
within t e appliance.
9,
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. R hen disposmg of the lining, ensure that it is
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.
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
hiB 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 our borfer or by telephoning
the Chaffoteaux Customer Servrces Depanment at Te ford.r
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

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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
Commissioning Filling and purgmg
Bringing into operation
Gas rate adjustment
Post commissionnmg
Handing over to user
Routine servicing Suggested sequence for servicing
Preliminary checks
Replacing components
Fault finding charts
Wiring diagram
Short part tist.
2
2
2
4
4
5
5
6:. a
6
6
6
6
6
6
6
6
7
7
7
9
9
9
9
10
11
11

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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
1O-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

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TECHNICAL DATA
Type BllBS
Suitable only for natural gas and ccnverston to LP.G
Modutoflam~ 280 f&&doff
ame 420
Heat Input 89.5 kW
Heat output 80 kW
Burner manifold injectors 24
Miniium air supply required 337 m31h
Combustton products rate 124 g/f
Average flue gas temperature 71 ‘C
Maximum flow temperature 90°C
Minimum return temperature 5o”c
Maximum system pressure 6bar
Minimum system pressure 1.5 bar
Water capacity 15 litres
Electrical suppfy 230
V single phase - 50
Hz
Power consumption 300 w
Weight exduding packaging 145kg
Weight including packaging 183kg
Burner pressure G20 (natural gas) @ 20 mbar 8.8 mcar
Burner pressure G31 (propane L.P.G.) @ 37 mbar 328 moar
132kW
120 kW
24
420 ma/h
145 g/l
112%
90 OC
50 “C
6 bar
1.5 bar
18 litres
230 V single phase - 50 Hz
500 w
170 kg
210 kg
8.8 mbar
32.8 mbar
Gas rate (15 “C -1013 mbar) 1 moaule 2 modules 3 modules
Gas type Pressure
Net C.V.
G20 20 mbar 35.9 MJ/m3 4.65 ma/h 9.30 ma/h 13.95 ma/h
G31 37 mbar 46.4 MJlkg 3.41 kg/h 6.82 kg/h 10.23
kg/h
Burner injectors
Natural gas (Restrictor diameter : o 6.4) : 1.29mm
Propane gas (Restrictor diameter : o 6.5) : 0.74 mm
DIMENSIONS
A
Moduloflamo
280 420
A 711 711
B 300 300
4Ul.~,~ 65 c 340 340
D 125 125
E 170 170
F 485 485
G 112 112
Ii 1155 lS58
I 1697 2200
J 8 mini 8 mini
L 610 610
level:rmvmum 8 mm
5

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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 420. At 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.
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 I
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:
Moduloflame 280:
183 kg Inci. packaglng
145kg excl. packaglng
Moduloflame 420:
210 kg incl. packaging
17Okg excl. packaging
ACCESSORIES
Contained within the boilers
- 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 mm long leveiing
screws (adjusted using 8 mm key)
Optional Reference;
- Side panels kit 280 1003622
- Side panels kit 420 1003630
- Mating flanges kit 1008378
- Water f gas gasket kit 1000616
LAYOUT --“jp-
The boilers may be placed side by side
in order to form a single manifold. A
maximum of 5 boilers can be fitted on
one monotube. They can be ranged
along a wall or fitted back to ba& in a
central location. A minimum space of
0.8 metres should be allowed in front
for access for maintenance.
When considering the layout, albw for
the placement of the flue. Ffueing can
be achieved individually or grouped in
ducts. Natural draught, fan assisted or
fan dilution arrangements may be
used. Specialist advice on flueing
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 are
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.
6

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Fig. 4
i ..
i‘2’
1
$ i
..--.-----A k Maang tlange
(aaessonesb
,-1.-.----e
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 water treatment
products such as
Grace Dearoon
Wines
Chesnire
WA8 8UD
Tel: [phone]
Fernox Manufacturing
Britannica Works
Cfavertng
Essex
CBll 402
Tel: [phone]
: safely
vaives
4
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. Also check the flow through
the system is adequate for the
boiier(s): at least 3ms/h for each 280
and 5.25mslh for each 420.
ELECTRICAL CONNECTIONS
The Moduloflame 280 and 420 boilers
require a single phase 230V - 50’Hr
earthed electrical supply. They should
be connected through a 2 Amp. fused
double pole switch which should be
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 the
correct polarity as reversing the
connections
Will cause a
malfunction.
exoanson
vessel
zr
Ii r
......
iI...
,..... .:....:.:.>::.,,,,:::-,,:..:.:.+:/;1:.;.::‘~.:.d:~:~::~:.~:~:
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 live
connection is maoe to terminal P, the
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.

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111~111~
L
To mam board
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.
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
Fig. 10
runs until the flame detection device
operates. If the flame is not detected
within IO seconds. the gas valve will
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.)
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.
-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.
,.,,,,,,,,,.,,,,.,.....,,---~--.
~~~~
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 how to regtster guarantee.
Leave Installation Manual, User’s
lnstructrons and all documentation with
the user.
COMMISSIONING

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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 wail depend upon
the particular installation condition and
usage, but in general. once a year
should be adequate.
It is the law that any service work must
be carried out by a competent person
such as your local Chaffoteaux Service
Centre, British Gas or other CORGI
registered personnel in accordance
with the current Gas Safety (Installation
and Use) Regulations.
The service schedule should include
the following operations:
-Check the pressure in the system.
-Check the correct operation of the
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.
SUGGESTED SEQUENCE for
SERVICING
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.
-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 the umon nuts between flow
and return pipes.
-Disconnect the overheat thermostat.
-Pull the exchanger towara you.
Pump
-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
-To remove the gas valve only,
unscrew the 4 screw located on both
sides of the platlc part. separate the 2
blocks and let hang the electronic
block. Disconnect the 2 unions on the
gas pipes. Pull the gas section toward
you.
Printed circuit board
-Unscrew the 4 screws of the
monotube cover.
-Unplug all connections to the board
and pull it from its support.
9

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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
chas mam mnrg. 230 v IS avadmm aI Inam cm-or.
Emvn the COT~OC+OO~UW. ConW~t that No~ral and EMh VOIIUIO~ l re WU~I. I
- sw*m tn. ..,ernal rsguuuon 10
000s ma l xcwnai
‘ON’
- Swdcn on mo moeub
cbuuorrepuodnaa8NlYl~. crluk oump spns tra or
fdbmlg Item : rwlsa I,
- Furr on tram Puuc
- BoilsIPCS 1 t
Pros* on me mm otnum 01 Ina I ooa km out
macafor
gas “al”. alIght 7
PI me mandoM?
Chaa 0, raOUCS
d
folbmng nem :
_ lonaauon emaroos
- EiecuonlcOIOCX01me gas valve
10

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Heating equipment short parts list
Key number : Description :
s-s A
Moduioflamc 280 ModuiofIam8 420
201
203
207
400
419
439
501
506
705
804
806
811
815
901
909
1002
I200
I202
I428
kcessories :
1501
5001
iO21
control unit 1008250 1008250
gas valve assembly 1007350 1007350
gas service tap 81214 81214
2E+ burner assembly (not shown) 1002667 1002667
ignition electrode 36899 36899
ionisation eiectrode 75773-l 0 75773-l 0
heat exchanger 1007557 1007557
over heat sensor 1008282 1008282
flue spillage sensor 1003959 1003959
printed circuit board 1009995 1009996
thermostat 1009766 1009766
thermostat knob 1004996 1004996
fuses 54442 54442
pump assembly 1010612 1010612
water isolating valve 81194 81194
non-return valve 54448 54448
flow switch 75709 75709
flow switch diaonragm 10419 10419
door iock assemoly 81478 81478
Water and gas gasket kit 1000616 1000616
Side panels kit 1003622 1003630
Water and gas connection kit 1008378 1008378
11

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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