Chaffoteaux & Maury Flexiflame 140 User guide

Flexiflame140
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 useon 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
PageNo
1
1. INTRODUCTION
1. General description, Special features, Guarantee
1.1 Dimensions
2. TECHNICAL DATA
2.1 Input, Output, Burner setting pressure,Gasrate
2.2 Clearances
2.3 Flue connection
2.4 Gasconnection
2.5 Water connection
2.6 Water flow ratesand 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 Gaspressuretest point
2.14 Boiler thermostat
2.15 Thermocouple andthermoelectric 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 spaceair 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 schemesFigs. 1,2, 3,4,5,6,7
4.3 Boiler packaging
4.4 Mounting the boiler
4.5 Water connections
4.6 Gasconnections andpipe 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 separatorFig. 15
5.4 Circulating pump
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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 storagecylinder
5.7.3 Feedandexpansion tank
5.8 Sealedsystem Fig. 15A
5.8.1 Safety valve
5.8.2 Pressuregauge
5.8.3 Hot water storagecylinder
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 Sealedsystem Fig. 16
6.4 Lighting the boiler
6.5 Gasrate adjustment
6.6 Flushing
6.7 Fitting the casting Fig. 18,Fig. 19,Fig. 20 (Page9)
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. 21
7.2.2 To clean the heating body
7.2.3 To clean the pilot assembly
7.2.4 To remove the gassection Fig. 22 (Page 10)
7.2.5 To clean andgreasebearing plate spindle Fig. 23
7.2.6 To clean thermocouple andelectrode Fig. 24
7.3 General service
7.3.1 To clean burner, heating body, pilot assembly andthermocouple
7.3.2 To remove electrical control module
7.3.3 To replacediahragm
7.3.4 To clean gasvalve
8.
8.1
8.2
8.3
8.4
8.5
8.6
8.7
REPLACING COMPONANTS
To replace thermoelectric valve
To replaceoverheat thermostat
To replace piezo unit
To replace pump
To replacepump andvolute
To replaceheatexchanger
To replaceboiler thermostat
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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 con-
tent open flued boiler. The boiler is rated between 20.5 kW
70,000 Btu/h) and 41kW (140,000 Btu/h) outputs.
f heboiler is designedfor usewith Natural Gas only.
The FLEXIFLAME 140 is intended for the larger domestic
installations, swimming pools and for commercial or indus-
trial applications. The boiler is suitable for open vented or
sealedwater 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 140is supplied in one carton, it is essen-
tial that the monotube is fitted (the monotube is the 54 mm
horizontal tube at the baseof 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 . .. . . . . . . . . . . . . . . . . . . . 150mm (6 ins)
Top . . . . . . . . . . . . . . . . . . . . . . . . 100mm (4 ins)
Bottom.. . . . . . . . . . . . . . . . . . . . . . 150mm (6 ins)
Front .. . . . . . . . . . . . . . . . . . 1000 mm (3ft. 3 ins)
2.3 Flue connection
240 V single phase50 hz supply fused I amp
2.8 Weight ...................................................... 52 kg (114 lb)
2.9 Water capacity ................................... 1litre (0.22 gals)
2.10 Iqjector ................................ Burner 1.18 mm (.046 in)
Pilot 0.30 mm (.O11in)
A nominal 1.50mm (6 ins) lightweight flue is required. The
draught diverter is integral. It is not necessary to fit a split
collar. 2.1I Piezo ignitor ...................................... Vernitron 60065
1.I2 Electrode ........................... Spark Gap 5 mm (.196 in)
2.4 (;as connection. . . . R 3/4 . . . . . . (3/4” BSPmale)
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 (8.1g.p.m.)
Maximum flow rate ... . .. . . . 318.7I/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 measuredon 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 1I“C
min and 20°C max.
2

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
samesizedirect 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 accordancewith 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 767I. 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
spacefor 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. Ena bedroom area, a bed-sit-
ting 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 gasconnection.
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 pos-
sible 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 asdirect aspracticable.
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 beavoided.
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 lessthan 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 spaceair 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 468cm’ (72.5in’) 234cm’ (36 in’)
Low
Level 936cm? (14.5in’) 468cm’ (72.5ir
Note : Both air vents must communicate with the sameroom
or internal space or must both be on the same wall to outsi-
de 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 asdetailed 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.
socketoutlet 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 ancil-
lary equipment and should be non-combustible.
A vertical flat area is required for the boiler asfollows :
Wide 900 mm 36 ins
High 1185mm 47 ins.
Above dimensions include the necessary clearances around
the boiler for caseremoval and for air movement.
3

4.2 Control schemes
Most normal pumped primary control schemescan
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 Ther-
mostat
Hot Water and Heating, Pump, Programmer,
Room/Cylinder Thermostat and Flow ShareValve.
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, Non-
Electrical Hot Water Control and Electrical
Heating Control.
Hot Water and Heating, Pump, Time Clock, Non-
Electrical 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 schemesusing
electrical controls only.
The following diagrams show typical control schemesusing
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 schemeasin fig. 6 to be fully programmed.
Where a mechanical type cylinder thermostat is considered
the three port type with by passmust be used.
Where thermostatic radiator valves are useda 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

4.3 Boiler packaging
Each boiler is delivered in a protective carton.
Remove packing piecesbefore 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 Page2 lit the wall mounting
plate to the wall using the screwsprovided.
- 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 mono-
tube and securewith retaining pin.
4.5 Water connections
- Flow and return connections are made to the monotube at
the baseof 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 gasservice 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. BSPmale) 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 exceed9 meters. If the gasrun 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 gassupply 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 seewiring diagram.
- Tighten cable clamp.
- Securedoor with two screwsand 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 sealedsystems,all safety controls other than
the safety valve, being incorporated in the boiler. The ther-
mostat is adjustable and on its maximum setting gives a no-
minal 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 schemescan 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 see4.2. Chaffoteaux can be
consulted where technical assistanceis 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

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

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 massflow rate through the manifold should not
be lessthan 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 des-
igned for a system temperature drop of 18’ C on full load but
the monotube arrangement provides a built in by passfeature
for temperature differences of lessthan 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 recommenda-
tions.
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 : [phone] or Grace Dearbon Limited,
Widnes. Cheshire WA8 8UD - Telephone : 05l-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 enteredhorizontally into the systempipework.
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 feedsand openvents
The cold feed and open vent should be so positioned that
pumping over and sub-atmospheric pressuresare 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
140must 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 Feedand 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 accessto the ball valve.
5.8 Sealedsystem 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
damageto electrical components and wiring. 1
5.8.2 Pressure gauge
A pressure gauge covering at least the range O-4bar /
(O-60lb/in*) shall be fitted to the system adjacent to, and u
visible from, the filling point. A temperature gaugeshould be
fitted.
5.8.3 Hot water storage cylinder
The hot water cylinder shall be the indirect coil type which is
suitable for the systempressure.
Provision shall be made for replacing water lost from the
5.8.4 Make-up system
system either :
(i) From a make-up vesselor tank mounted in a position hi-
gher 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 accessto a make-up vesselwould be difflcu!t, by
prepressurisation of the system(seealso 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 BS5376 : 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

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 usedin 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 resis-
tance to earth. In the event of an electrical fault after installa-
tion of the appliance preliminary electrical system checks
shall be carried out.
6.2 Gas installation
The whole of the gasinstallation, including the meter, should
be inspected and tested for soundness and purged in accor-
dance with the recommendations of KS 6XYI
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 posi-
tion, Ensure that all valves are open.
With the pump fitted, the system should be filled and air
zkscleared. The boiler water section can be vented if neces-
fry by unscrewing the drain valve (seeA fig. 16).Vent all ra-
diators and check for water soundness.
Light the boiler asdetailed in 6.4
6.3.2 Sealedsystem 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 pressuregauge registers 1.5bar
(2 I .5 p.s.i.). (The boiler water section can be vented if
necessaryby unscrewing the drain valve, seeA 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 hasbeen achievied.
6.4 Lighting the boiler
The following procedure should be followed :
a) Check that fuses have been replaced (see4.7).
b) Open gasservice tap by turning to 0 (seeB fig. 16).
c) Pressin pilot valve knob and light pilot using the ignition
button, continue to hold in the pilot valve knob for 30
secondsand release(n.b. the pilot should remain alight, it
may be necessaryto wait a few moments for gasto reach
the pilot) (seeC 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 gassoundness.
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 rangeO-20mbar (O-8in.w.g).
Remove the hexagonal cap from the front of the gasvolume
governor to exposethe 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 pressureto 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
gaugeand re-fit thCpressuretest point screw and gasvolume
governor cap. Test fdr gassoundness.
Mark the data badge against output to which the boiler has
beenadjusted.
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
sealedsystemsshould be adjusted to the initial system design
pressure.,any set pointer on the pressure gaugeshould 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
(see5.5).
6.7 To fit casing
- Fit side panels by hooking over pegs at top and securing
with screwbottom rear.
- Fit control module cover, securewith five screwstwo each
sideand one in centre (F fig. 19).
- Fit front panel by hooking on pegs at top of boiler and
securewith three screwsG 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

- Fit control knob.
- Remove glasspanel from carton.
- The hingesare held in position by a metal strap (fig. 19).
- Remove the screws securing the strap and set aside for
re-useboth the strap and the screws.
- Slide the left hand side hinge from glasspanel and slot into
left hand sidevertical trim.
- Locate glasspanel 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 glasspanel.
- Finally securehingeswith 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 safeoperation 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
gasregion, your local Chaffoteaux et Maury Service Centre
or other C.O.R.G.I. registered personnel in accordance
with the gassafety (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 Removecasing
- Remove thermostat knob by pulling off.
- Remove two screwsat bottom rear of sidepanels.
- 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. 21)
Unscrew the pilot tube clamping screwA.
Remove the pilot tube by lifting out of bracket.
Remove six screws B which retain the burner manifold
(screwsare 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 screwsC at endsof rear of burner.
Unscrew nut D which securesmanifold bend to gassectif
Remove burner by moving to the left taking care to reta.-.
gasket.
Invert the burner headand clean by brushing.
Replace in reverse order, ensuring that the gasketbetween
the burner manifold and the gassection is in place.
7.2.2 To clean heating body. Removecaseasdescribed in 7.1
and the burner (7.2.1).
- Remove six screwsand 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 reverseorder.
7.2.3 Clean the pilot assembly
7
Remove pilot clamp screw (A fig. 21)
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 Removegassection
- With burner removed asdescribed in 7.2.1
- Remove control panel asdescribed in 7.3.2.
- Releasetwo screwssecuring gassection to water section (A
fig. 22).
- Easegassection forward and up.
Fig. 19 Fig. 20 Fig. 21
9

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-assemblein reverseorder.
7.2.6. To cleanthermocouple and electrode
- Remove manifold asin 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-assemblein reverseorder.
7.3 General service
7.3.1 Clean burner, heating body, pilot assembly and ther-
mocouple asdetailed 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 screwsleft hand front of module and open the
left hand sidefront by pulling forward.
‘Jnplugpump from printed circuit board.
; ~Disconnectand remove mains input cable.
- Remove split pin and withdraw thermostat phial.
- Remove two screwson bracket at base.
- Pull off electrode lead from piezo unit.
- Remove two screwsB either sideof 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 baseof water section.
- Drain boiler.
- Remove control module asin 7.3.2.
- Disconnect high and low pressure tubes C from water
section.
- Slacken two screwsbetween gassection and water section.
(Screw at front and at right hand side).
- Releasenuts 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 gasvalve (fig. 22)
- Remove the burner asin 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 gassection top off the basetaking care not to lose
springs and valves (C).
- Lift off gasvalves.
- Do not attempt to further dismantle the valve assembly.
- Clean the valve seating and replace the gasvalve facing if
necessary.
- Replace in reverseorder.
8. Replacing components
8.1 To replacethe thermoelectric valve.
- Remove thermocouple nut.
- Unscrew valve (A fig. 24) from rear of gassection using a
35 mm or adjustable spanner.
- Withdraw thermoelectric valve.
- Replace in reverseorder.
8.2 To replacethe overheat thermostat
- Remove the two tab connectidns on the thermocouple
leadsto the overheat assembly.
- Remove two screwsretaining overheat thermostat.
- Replace thermostat - use heat sink grease for better
contact.
- Re-assembly in reverseorder.
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 reverseorder.
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 exchangedat any builder’s mer-
chants stocking Grundfos pumps.
- Replace in reverseorder.
8.5 To remove pump and volute (fig. 24)
- Isolate boiler and drain water, see7.3.3 disconnect electri-
cal supply (see8.4).
Fig. 22 Fig. 23
10
Fig. 24

- Releasenut C securing volute to leg from heating body.
- Releasenut D from appliance sideof isolating valve.
- Replace in reverseorder.
8.6 To replace heat exchanger matrix (fig. 18)
- Disconnect electrical supply.
- Isolate boiler and drain water (see8.3.3).
- Remove six screwsand 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 eachside).
- 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 reverseorder. Taking careto ensurethat 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 reverseorder.
11

9.
Fault finding chart
Fault
Pilot will not light
Pilot goesout
when gasknob 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 gasvalve not purged.
6) Faulty thermoelectric valve. )
7) Overheat failing.
8) Loose connection on overheat
thermostat.
1) Electricity not switched on to boiler.
2) Fusesmissing 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 exchangerblocked.
1) Over-gassed.
2) Air in system.
3) Boiler thermostat wrongly setor faulty.
4) Water section sticking open.
5) Gas valve sticking open.
6) Dirt/swarfon gasvalve facing.
7) Resistanceto 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 pressureor balancing tubesblocked.
2) Gas valve sticking open.
3) Water section sticking open.
Remedy
Turn on.
Purge.
Clean or replace (7.2.3).
Pressfirmly before releasing.
Adjust (12 milli-volts min. required
measuredat 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 1amp.
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 gasrate 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 gasrate (see6.5).
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

Chaffoteaux et Maw-y Limited,
Trench Lock, Trench, Telford, Shropshire TFl 4SZ
Telephone: [phone] Fax: [phone]
13
ESP024