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Commissioning

MAXXﬂ o EVO 150/302

5.1.2 FILLING THE CONDENSATE TRAPS

Before operating the burners it is ﬁ rst necessary to ensure that both condensation traps are ﬁ lled with water.
This is best done before the ﬁ nal connection is made to the condensate drain. The following actions are sug-
gested:

1. Rotate the elbow of the condensate trap so that it is facing upward (see photo below).

2. If the condensate pipe is already installed, disconnect the elbow and move pipe away from conden-

sate trap (see photo below).

3. Pour approximately 500ml of water into the trap and replace / reposition pipes.

4. Proceed with the commissioning of the heat engines

Summary of Contents for 7800597

Page 1: ...erstand these instructions before commencing installation and leave this manual with the customer for future reference M10419 MAXXﬂo EVO High eﬃciency condensing stainless steel storage water heater CWH 150 302 INSTALLATION AND MAINTENANCE MANUAL ...

Page 2: ...General 2 MAXXﬂo EVO 150 302 Blank Page ...

Page 3: ...upply 4 4 Unvented design 4 5 Secondary return design DHW circulation pump 4 6 Condensate disposal 4 7 Flue systems and ventilation 4 8 Maximum ﬂue lengths 4 9 Gas connections 4 10 Electrical communication connections 5 0 Commissioning 5 1 Filling and removal of air 5 2 Commissioning of heat engine 5 3 Conversion to LPG 5 4 Frost protection and Legionella 5 5 Final checks and user handover 5 6 Fau...

Page 4: ...m C13 C33 C53 C63 The safety and operation functions of each heat engine are managed by micro processor controlled circuit boards one for each heat engine The upper controller also acts as the cascade master controller modu lating the heat engines according to the demand based on data from the systems sensors Control is per formed using comparison parameters between the requested temperature and t...

Page 5: ...ger from electricity to personal safety and life WARNING Very hot water can cause severe burns and in extreme cases death CAUTION Indicates a potentially dangerous situation for the heater and the environment INFORMATION Suggestions to assist the user in implementing instructions in this guide ADDITIONAL READING Reference to additional information in other documents ...

Page 6: ...tallation adjustment servicing of this heater must be carried out by a competent person and installed in accordance with current standards and regulations Failure to correctly install or maintain this heater could cause injury to persons or damage to property The manufacturer shall not be held liable for any such injury and or damage DANGER Do not store or use explosive or easily inﬂammable materi...

Page 7: ... Ireland BS 7671 Requirements for electrical installations IET wiring regulations BS 6644 Speciﬁcation for the installation of Gas ﬁred hot water boilers for rated inputs between 70kW net and 1 8 MW BS 7074 2 Applications selection and Installation of expansion vessels and ancillary equipment for sealed water systems BS 6880 1 Code of practice for low temperature hot water heating systems of outpu...

Page 8: ...UK Ltd Coventry Road Warwick UK CV34 4LL M10120A 0558 22 2 3 UKCA CE MARKING There is one data plate located on the heater This is mounted on the outside of the heater left hand side The UKCA marking documents of this heater conﬁrms compliance with the essential requirements of the following Regulations Regulation EU 2016 426 on appliances burning gaseous fuel as brought into UK law Ecodesign for ...

Page 9: ...k smart kWh Weekly electricity consumption with smart controls Q elec week smart kWh Weekly fuel consumption without smart controls Q fuel week kWh Weekly electricity consumption without smart controls Q elec week kWh Storage volume V l 300 Mixed water at 40 C V40 l Harmonised standards applied Specific precautions that shall be taken when the water heater is assembled installed or maintained EN 1...

Page 10: ...ndoors dB 66 Ability to off peak hours functioning 3 Yes Enabled smart control settings 4 1 Electricity 2 Fuel 3 If applicable Annual energy consumption Other load profiles for which the water heater is suitable to use and corresponding water heating efficiency and annual electricity consumption 3 4 If smart control setting value is 1 the water heating energy efficiency and annual electricity fuel...

Page 11: ...Water return connection BSP 1 ELECTRICAL Electrical supply voltage Hz V Hz 220 240 50 Fuse rating on mains supply A 5 Insulation protection rating IP 20 Power consumption standby W 5 5 Power consumption maximum W 359 FLUE Flue connection single mm 130 Flue connection concentric mm 130 200 Flue systems permitted type B23 C13 C33 C53 C63 Max ﬂue equivalent length open B23 m 44 Max ﬂue equivalent len...

Page 12: ... 1 5 BSP m SECONDARY RETURN 1 BSP m MULTIPLE CABLE ENTRY POINT DHW 1 5 BSP m 602 TANK INSPECTION HATCH CHECK VALVE 301 91 91 209 172 TANK SENSOR WELL ACCESS PANEL DATA LABEL 913 1983 264 602 203 97 CONDENSATE CONNECTION 41mm 60 259 300 391 128 GAS INLET 1 BSP 2x TP VALVES 28mm CONCENTRIC FLUE AIR 130mm 200mm REMOVABLE AIR DUCT SPIGOT PLATE CONDENSATE TRAP 2 PER UNIT 2008 REMOVABLE AIR DUCT SPIGOT ...

Page 13: ...150 302 EXAMPLE 1 SINGLE MAXXﬂo EVO SCHEMATIC EXAMPLE 2 PARALLEL MAXXﬂo EVO SCHEMATIC 3 5 SYSTEM SCHEMATIC EXAMPLES B39 Q4 MAXXﬂo EVO B39 Q4 MAXXﬂo EVO MAXXﬂo EVO Maximum circulation rate Q4 pump Model MAXXﬂo EVO 150 Flow m3 h 1 8 ...

Page 14: ...minutes then oﬀ for 20 minutes repeatedly Where B39 sensor has been installed this function will become active only once the circula tion setpoint has been achieved 1663 Circulation setpoint When B39 sensor is installed on the DHW distribution return pipe the heater controller will monitor the return temperature during the activation time of the circulation pump Q4 When ever the temperature acquir...

Page 15: ...Technical Data 15 MAXXﬂo EVO 150 302 EXAMPLE 3 MAXXﬂo EVO BUFFER SS300 10 SCHEMATIC 3 5 SYSTEM SCHEMATIC EXAMPLES CONTINUED Q4 ST1 K21 B39 AGU 2 5 MAXXﬂo EVO BUFFER SS300 10 ...

Page 16: ... BUFFER SS300 10 tank temperature is less than 2 0O C below MAXXﬂo EVO tank temperature K21 pump will be turned on 5573 Factory setting DHW sensor B3 5574 Factory setting Special temperature sensor 1 5575 Factory setting 30 seconds Represents the minimum time that K21 pump will be activated even if parameter 5571 conditions are met Related settings table in addition to example 1 table 3 5 SYSTEM S...

Page 17: ...Technical Data 17 MAXXﬂo EVO 150 302 EXAMPLE 4 BMS CONNECTIONS 3 5 SYSTEM SCHEMATIC EXAMPLES CONTINUED BMS 1 3 1 12 1 2 12 1 2 12 1 2 Modbus Enable Fault Flame top burner Flame bottom burner A B REF ...

Page 18: ...RING DIAGRAM MAXXﬂo EVO 150 kW MODEL PCB1 0 8 0 0RGXOH 1R 1 4 4 4 1 1 0RGEXV 5HPRWH HQDEOH YROW IUHH ODPH LQGLFDWRU 9 4 SXPS DXOW LQGLFDWRU 3 A B REF DB CL MB CL LYH 1HXWUDO LYH DUWK 1HXWUDO UHWXUQ WHPS ODPH LQGLFDWRU 1 3 1 12 1 2 12 1 2 12 1 2 ...

Page 19: ...Technical Data 19 MAXXﬂo EVO 150 302 PCB2 3 6 WIRING DIAGRAM MAXXﬂo EVO 150 kW MODEL ...

Page 20: ...be installed under the heater The drain tray must be no deeper than 38mm and must be 100mm wider and longer than the heater It should be piped to an adequate drain using 20mm 0 75in diameter pipe angled for proper drainage Access must be provided to the front of the heater with adequate clearance for servicing and operation See 3 3 The ﬂoor on which the heater is installed must be ﬂat level and of...

Page 21: ...Loosen the two screws E at low level inside the case to remove the case retaining bracket F Pull the inner cover forwards and remove completely Please note CWH 150kW models have two removable transit brackets G that will need to be removed and recycled prior to removing the inner cover for the ﬁrst time D E F G ...

Page 22: ...vice life of this appliance and all connected pipe work a sample of drinking water should be analysed before installation and compared against the following table If water sample readings are outside the limits given above corrective action should be taken For example the installation of a base exchange water treatment in areas of hard water CAUTION When installing Andrews Water Heaters in hard wa...

Page 23: ... must not be used for any other purpose No ﬁtting should be installed be tween the expansion valve and the cylinder The cold water for services may be drawn from the 22mm com pression port up stream of the Pressure Reducing Valve The water pressure at this point will be similar to that available at the hot water outlet of the water heater If higher ﬂow rates are required for the cold water service...

Page 24: ...t exceed the heater maximum ﬂow rate An excessive ﬂow in the secondary circuit could result in a temperature mixing eﬀect in the heater storage vessel resulting in a stored water temperature less than set temperature See table below It is important that the heat losses from the return system are minimised through pipe insulation otherwise the heater may be operating for extended periods of time on...

Page 25: ...e outside should be run in a minimum of 40mm diameter External pipework should be insulated to a minimum of 13mm protection against frost and freezing tempera tures Insulation must be waterproof and UV resistant The end of the pipe must be cut at 45O and be insu lated to the tip of the pipe CAUTION The condensate trap must be ﬁlled with water before operating the heater see 5 1 2 for sugges tions ...

Page 26: ...ter may be vulnerable to accelerated corrosion from salty air e g Coastal installations Refer to the following standards and guidance notes before installing the ﬂue system BS6644 Speciﬁcation for the installation of gas ﬁred hot water boilers of rated inputs between 70kW net and 1 8MW net IGEM UP 10 Installation of ﬂued gas appliances in industrial and commercial premises 4 7 2 SUITABLE FLUE MATE...

Page 27: ...e internal space should not be part of a dwelling The ventilation system including mechanical ventilation shall be designed such as not to cause the installation space to be under suction to the extent that downdraft in the chimney system could lead to a reverse ﬂow of combustion products into the room or appliance When installing an appliance with a B23 ﬂue system it is recommended that a gas ala...

Page 28: ...relative to atmospheric conditions in the plant room The fans must be interlocked with the appliance Minimum ﬂow rate requirements are as follows 4 7 5 OPEN FLUE APPLIANCE IN A ENCLOSURE VENTILATED DIRECT TO OUTSIDE AIR Minimum free vent area Heater Model Low level High level MAXXﬂo EVO 150 1 485 cm2 810 cm2 4 7 6 OPEN FLUE APPLIANCE WITH MECHANICAL VENTILATION Minimum ﬂow rate with draught divert...

Page 29: ... G Above ground roof or balcony level 300 H From vertical drain or soil pipe 150 J From an internal or external corner to a ﬂue terminal alongside a boundary 300 K From a terminal facing a terminal 3 350 L Vertically from a terminal on the same wall 2500 M Horizontally from a terminal on the same wall 2 170 N From a surface or a boundary line facing a terminal 3 860 P From a opening in a carport e...

Page 30: ...ssembly it is recommended that a small quantity of petroleum jelly is used to lubricate each ﬂue seal before ﬁtting ﬂue sections together Any terminal must be ﬁtted with a guard if less than 2m above ground level or if it is in a position where it may cause harm to persons as a result of touching a hot surface Care must be taken to avoid long horizontal runs of ﬂue duct and continuous discharge of...

Page 31: ...cription 7620232 90 ELBOW C W CLAMP 130 200 7620233 FLUE CONDENSE TRAP PP 130 200 7726992 45 ELBOW C W CLAMP 130 200 7726994 1M FLUE CUTTABLE 130 200 7727001 FLUE CLAMP 200MM 7727003 FLUE SEAL 130MM E211 CONDENSATE BOTTLE PP H150 E217 FLAT ROOF PLATE E218 ANGLED ROOF PLATE E219 WALL CLAMP E261 CONDENSATE SYPHON CONNECTION E630 EXTENDED TERMINAL GUARD Alternative ﬂue Horizontal ﬂue Vertical ﬂue 4 7...

Page 32: ...between vertical terminals see item L section 4 7 13 Over 5 0m use ﬂue condense trap For maximum ﬂue lengths see section 4 8 For maximum ﬂue lengths see section 4 8 For maximum ﬂue lengths see section 4 8 FLAT ROOF FLASHING E217 ANGLED ROOF FLASHING E218 ...

Page 33: ...0 ELBOW C W CLAMP PART No 7620232 45 ELBOW C W CLAMP PART No 7726992 FLUE CONDENSE TRAP PART No 7620233 VERTICAL FLUE TERMINAL C W CLAMP PART No 7620229 CONDENSE TRAP PART No E211 10 Ø130 Ø200 1780 570 Ø40 268 Ø32 300 300 670 970 Ø130 20 Ø200 MAINTAIN DIMENSION IF FLUE IS CUT ADJUSTABLE PLATE 220 220 Ø130 Ø198 199 Ø200 20 10 100 Ø130 Ø198 199 130 Ø200 10 180 Ø130 Ø198 199 ...

Page 34: ...ﬂue terminal alongside a boundary 300 K From a terminal facing a terminal 3 350 L Vertically from a terminal on the same wall 2 500 M Horizontally from a terminal on the same wall 1 100 N From a surface or a boundary line facing a terminal 3 860 P From a opening in a carport e g door windows into the building not recommended Q Above apex of a pitched roof 620 R From an adjacent wall edge of termin...

Page 35: ...ys check with the ﬂue supplier for exact values Example C33 A ﬂue system that uses six straight lengths three 90 bends and a horizontal terminal 6 x 1m straight lengths 6 0 m 3 x 90 bends 3 6 m 1 x Horizontal Terminal 1 0 m Total within 24m limit 10 6 m CAUTION Vertical sections should be secured using a support clamp every 2 5 m Horizontal sections should be secured using a support clamp every 1 ...

Page 36: ... and other appliances connected to the same gas supply operating at maximum load In order to ensure the gas isolation valve handle falls into the closed position it may be necessary to remove the handle and replace it 180o from its original position 4 9 2 GAS PIPE WORK Where this heater is installed in a plant room or purpose built compartment a manually operated valve must be ﬁtted The valve must...

Page 37: ...ater front door panel to reveal the electrical connections inside see illustration below 4 10 2 VOLT FREE CONNECTIONS This heater has volt free connections which can be used for a Building Management System or a remote indica tor panel These volt free connections are pre conﬁgured to perform the following functions Volt free Remote enable Closing this connection will activate the DHW system Volt F...

Page 38: ...r Settings Modbus 6651 Slave address If connecting more than one device to the Modbus network each appliance must have its own unique slave address 6652 Baud rate All devices in the Modbus network must have the same rate of transmission The higher the transmission rate the shorter the lines between the devices has to be doubling the baud rate halves the cable lengths Recommended baud rate with a c...

Page 39: ...After initial ﬁlling open each hot water draw oﬀ tap in succession and check that all the air is vented from the system 7 Check for leaks inside and outside of the heater 8 Turn on power to heater and operate the Q1 circulation pump by disconnecting the wiring from the front ﬂow sensor B2 of each heat exchanger This will automatically operate the pump 9 Continue to operate the pump s until the sou...

Page 40: ...nnection is made to the condensate drain The following actions are sug gested 1 Rotate the elbow of the condensate trap so that it is facing upward see photo below 2 If the condensate pipe is already installed disconnect the elbow and move pipe away from conden sate trap see photo below 3 Pour approximately 500ml of water into the trap and replace reposition pipes 4 Proceed with the commissioning ...

Page 41: ...nto its operating environment The commissioning process involves the operation of the individual heat engine s at the maximum possible heat load 5 2 2 TOP HEAT ENGINE COMMISSIONING Ensure that all the numbered points included in section 5 1 Commissioning General have been completed successfully before proceeding with the following NOTE A flue sample point is provided in the flue section immediatel...

Page 42: ...l allow at least three minutes for the heat engine to warm up fully before checking the combustion Ensure the Boiler temperature remains below 70O C during the commissioning process see above illustration if necessary open water outlets to introduce cold water into the tank keeping the boiler temperature down With the heater door open the CO2 combustion ﬁgure for G20 will be as follows If adjustme...

Page 43: ...n the ﬂue sample point Replace the throttle screw cover 5 2 3 BOTTOM HEAT ENGINE COMMISSIONING If the Commissioning Controller available from Andrews Water Heaters part code 7729664 is used the commissioning procedure for the top heat engine 5 2 2 should be followed to commission the bottom heat engine Special operations 1 3 Chimney sweep function Oﬀ Connection port The commissioning controller if...

Page 44: ...the clip at the end of the connector inwards towards the body of the connector then pull the connector from the fan Be careful not to pull on the wires The top heat engine will now go into fault when called upon to operate but this can be ignored during this stage of the commissioning process Turn the operation switch to ON or I then rotate the thumb wheel of the GUI and select the DHW tab Click t...

Page 45: ...river to adjust MAKE ADJUSTMENTS IN 1 8 TURN STAGES AND WAIT ONE MINUTE BETWEEN EACH ADJUSTMENT CAUTION If you are experiencing CO readings that exceed 200ppm after 20 minutes of burner operation please ﬁrst check that your gas analyser is functioning correctly and then contact Andrews Water Heaters on the customer support number given on the rear cover of this manual for advice When adjustments a...

Page 46: ... to ignite and operate at maximum output Keep the DHW tank temperature below 40O C by opening water outlets Check the total gas consumption ﬁgure using the following table The gas consumption must be within 5 of the gross kW input value of the data plate Turn oﬀ all taps and water draw oﬀs Change the DHW Set point to back to 60O C to 65O C as required by the user Heat engine commissioning is compl...

Page 47: ... the venturi and remove the hose Undo and remove all 5 screws securing the venturi to the gas valve and fan Remove the venturi completely If possible do not disturb the cork gasket if it is stuck to one of the two metal surfaces this will be helpful during re assembly Check the size of the LPG oriﬁce is correct refer to table overleaf and ﬁt the oriﬁce into the rubber seal that is located in the o...

Page 48: ...o EVO CWH 150 302 7800597 HEAT INPUT GROSS Q Hs 147 8kW HEAT INPUT NET Q Hi 136 0kW HEAT OUTPUT P 148 2kW CO2 MAX RATE 9 9 0 2 This appliance may only be installed in a room which complies with the appropriate ventilation requirements Read the technical instructions before installing this appliance CONDENSING APPLIANCE MAX WORKING PRESSURE 9 bar CAPACITY 300 Litres POWER SUPPLY 230V 50Hz IP20 359W...

Page 49: ...r temperature checks of outlets closest and furthest from the hot water tank To avoid stagnation introduce fresh water by ensuring that all outlets are used at least once per week This draw oﬀ must be equal to at least the total quantity of water in the complete system this includes all stored water in any appliance Clean and de scale shower heads every 3 months Inspect the DHW tank for signs of d...

Page 50: ...e If the legionella requirement was for a 70 C setpoint for 1 minute and the heat losses on the return system were 5 C The temperature leaving the tank would be at a maximum of 73 C anti legionella setpoint maximum boost and this would return to the tank at 68 C The anti legionella function would never be satisﬁed in this scenario and the controls would attempt to achieve the anti legionella setpo...

Page 51: ... controls 5 5 2 CHECKING THE DHW TANK SENSOR POSITION For optimum control of DHW tank temperature ensure that the tank sensor is touching the end of the sensor well The sensor and sensor well can be located behind an access panel A at low level on the left hand side of the heater Remove 2x ﬁxings that secure the access panel to the side panel Pull the sensor cable outwards a little above the P cli...

Page 52: ...that they should not be altered or interfered with in any way Explain that the DHW tank temperature should not be set below 60O C for any length of time as this can allow the growth of legionella bacteria Discuss what methods are in place or setting options to limit the formation of legionella bacteria see previous page Remind the user that in order to comply to the regulations in force the heater...

Page 53: ...one heat engine is in a lockout condition this should not aﬀect the other heat engine s ability to function and the heater should continue to operate as normal using the other heat engine 5 6 2 FAULTS AND LOCKOUTS If a heat engine is unable to ignite or detects a safety condition the control of that heat engine will lockout and will be prevented from ﬁring again without manual intervention The dis...

Page 54: ...istered personnel 6 1 1 RECOMMENDED MINIMUM SERVICING REQUIREMENTS ANNUALLY OR EVERY 4 000 HOURS Does not exclude annual gas safety checks required under Gas Safety Installation and Use Regulations 1998 1 Inspect and clean the following by removing the burner Burner tube Vapour seal Rope Gasket Combustion chamber Spark electrode Ionisation electrode 2 Check condition of condensate pipework and emp...

Page 55: ...late heater from the electrical supply Open the outer heater cover door by removing the screws on the left hand side and opening the door of the heater Disconnect the electrical connections to the fan Disconnect the venturi from the fan by removing the two cap head screws Remember to retain the cork gasket for re assembly Disconnect the spark and Ionisation leads Undo the six burner door nuts Pull...

Page 56: ... are any signs of damage and in any case replacement of the silicone gasket every two years is recommended Inspect the burner tube for signs of damage Replace if any damage or burnt areas are found Inspect the inside of the heat exchanger for signs of carbon build up or blockages between the tubes The heat exchanger can be cleaned using a nylon nonmetallic brush and vacuum cleaner to re move loose...

Page 57: ...an water until the condense pipe runs clear At the end of the cleaning process unscrew the condense trap bowl clean out and reﬁt Inspect the Ionisation and spark electrode assemblies for damage and wear Reassembly is the reverse When reﬁtting the venturi onto the fan inlet ensure that the cork gasket is in the correct position by using one of the screws to hold the gasket in place 5 0mm 0 5mm Scre...

Page 58: ... retaining the spark electrode in position and carefully withdraw Inspect for dam age and correct spark gap see illustration below 5 0mm 0 5mm Undo the two screws retaining the ﬂame sensing electrode Withdraw and inspect for wear or damage Replace electrode s if older than 24 months or if worn or damaged Assembly is the reverse ensure the gasket is undamaged and correctly placed 6 1 1 3 CASE AIR F...

Page 59: ... B for leaks The lower bowl of each condensate trap C should be unscrewed examined and cleaned see illustration below 6 1 1 5 GAS RATE COMBUSTION The gas rate and combustion ﬂue analysis must be carried out when the heater is operating at maximum loading See Section 5 2 for full details on how to check and adjust the CO2 To check re establish gas and electricity supply and then operate each heat e...

Page 60: ... so that the hatch drops downwards and is held in place by the nut Remove the nut and clamp and while holding the threaded shaft allow the hatch to drop down and then angle the hatch and remove it through the opening With the use of a torch it should be possible to see to the very bottom of the inside of the tank If the tank is clear of deposits then no further action is necessary and the hatch ca...

Page 61: ...t The following items require isolation of water before removal and bleeding air afterwards 12 Heat exchanger 13 Internal circulation pump 14 Water pressure sensor 6 2 1 DHW TANK TEMPERATURE SENSOR B3 Remove tank sensor access panel located at low level on LH side of heater refer to section 5 5 2 Gently remove and pull the cable sensor out of the sensor well whilst feeding it down through the P cl...

Page 62: ...ocated on the top left hand side of the case to the left of the top control PCB Unplug the sensor from the loom Squeeze the catch to release 6 2 4 GUI DISPLAY This is located in the centre of the heater inside the front cover Switch oﬀ electrical supply to heater Remove the 4 ﬁxing screws located at the rear of the screen Push oﬀ the wiring connector from the rear of the GUI Replacement is the rev...

Page 63: ... It is important that the correct PCB replacement is used Check that the model matches the replacement PCB Carefully push oﬀ all the connectors on the PCB be careful not to pull on the wires Release in turn all seven PCB support posts by squeezing together the end of the support and withdraw ing the board from each support one at a time Replacement is the reverse Master PCB PCB1 Slave PCB PCB2 Sup...

Page 64: ...ecuring the fan to the air arm Slide fan oﬀ venturi and remove Inspect both the venturi gasket and air arm gasket and replace if damaged Replacement is the reverse CAUTION Please ensure that the cork gasket between the fan and the venturi is correctly placed before ﬁxing the two venturi screws Place a screw through the venturi to hold the gasket in place when reﬁtting to fan Operate the heat engin...

Page 65: ... the rate and combustion is correct to the Data table page 11 Adjust using the throttle adjustment screw on the gas valve if necessary Turn clockwise to decrease CO2 anti clockwise to increase CO2 see 5 0 for details NB Valve Coil resistances are 2 8k and 1 6k ohms 6 2 8 ELECTRODE REMOVAL These are located on the front of the heat exchanger Carefully pull oﬀ the electrical connectors Undo the two ...

Page 66: ...the cover itself and can be slid out for inspection Inspect BFPV for damage and operation Replace if necessary Inspect air arm seal for damage Replace if necessary Assembly is the reverse 6 2 11 OVERHEAT THERMOSTAT Locate the overheat thermostat behind the GUI bridge see illustration below Remove the thermostat from the clip by pushing the assembly upwards Disconnect the two wires Assembly is the ...

Page 67: ...nections to the ﬂue ﬂow and return sensors Disconnect the ﬂue from the top of the heat exchanger by pushing the ﬂue section upwards so that it clears the heat exchanger Disconnect the electrical connections to the ionisation probe ignition probe fan and gas valve and place wiring to one side Remove the air intake from the venturi by squeezing the spring clip together and disconnect oﬀset tube Push...

Page 68: ... pulling the pipe oﬀ Remove the 6 screws of the heat exchanger retaining clamps and remove the clamps CAUTION This item is heavy Before releasing the brackets ensure support is available Carefully lift out the heat exchanger Fitting is the reverse CAUTION After reﬁtting ensure no air is present in the heat exchanger by running the unit with the gas turned oﬀ until the heat exchanger is operating q...

Page 69: ...isconnecting the electrical connector from the heat exchanger front ﬂow sensor B2 When all sound of air has stopped reconnect B2 sensor and press the reset for around one second 6 2 14 WATER PRESSURE SENSOR Close both water shut oﬀ valves and use one of the drain points to drain down water until no further release of water occurs Carefully remove wiring connector from the sensor using a small scre...

Page 70: ...ower heat exchanger Q 13 Attach the ﬂushing device hoses G to the 22mm copper tails A using suitable ﬁttings not supplied 14 Flush and descale the heat exchanger using chemical and ﬂushing device suitable for potable water 15 When completed ﬂush with clean water and then remove ﬂushing connectors A and retain ﬁbre seals B 16 Inspect original ﬁbre seals for damage and replace if necessary with spar...

Page 71: ...SEMBLY 7709385 109 CONDENSATE TRAP 7617073 110 TEMPERATURE PRESSURE RELIEF VALVE 10 BAR 95 C 7727952 111b 1 GAS COCK C W TEST NIPPLE 150KW 7805970 112b 1 GAS UNION M F 150KW 7805971 113 OPTION ANTI VAC VALVE C W HATCH 7818123 114 ACCESS HATCH ASSY INC O RING G175 115 300 LITRE TANK WITH SIDE SENSOR WELL 7818124 116 CHECK VALVE ASSEMBLY 1 INCH 7818125 117 1 x 1 25 TUNDISH 5139811 113 100 105 115 10...

Page 72: ...ATIONS INNER COVER DOOR SPARES Item No Description Part Number 200 DOOR FOR MAXXﬂo EVO 150KW 7805974 201 DOOR CLOSING LATCH SET 7709375 202 DOOR HINGE SET 7709376 203 DOOR GASKET MAXXﬂo EVO 300L 7709378 204 INNER COVER MAXXﬂo EVO 300L 7709380 205 INNER COVER FIXING SCREWS 7709381 ...

Page 73: ...BLE GLAND 7709386 301 SPARK GENERATOR 7709314 302 LEAD FOR SPARK ELECTRODE 7709313 303 PRESS SENSOR WATER 7709328 304 22MM RIGID FAN GAS COCK 7709371 306 PUMP FOR MAXXﬂo EVO 7709310 307 PUMP NRV GASKET 7720039 308 TEMP SENSOR CASCADE B10 7709330 309 28MM COMPRESSION TEE 7709368 311 28MM ISOLATION VALVE 7709366 312 DRAIN VALVE 22MM 7727903 313 IONISATION ELECTRODE LEAD 5142139 ...

Page 74: ...ONTINUED 403 405 416 DRAIN COMPONENTS FLUE COMPONENTS Item No Description Part Number 403 FLUE SYSTEM TWIN H E MAXXﬂo EVO 7709361 405 FLUE SEAL SET TWIN H E MAXXﬂo EVO 7709363 415 REMOVABLE 200MM AIR DUCT PLATE ASSY 7776499 416 CONDENSATE SYSTEM TWIN H E 7818126 415 ...

Page 75: ...Maintenance 75 MAXXﬂo EVO 150 302 6 4 COMPONENTS ILLUSTRATIONS CONTINUED 500 501 502 503 504 505 506c 507 508 509d 510 511 512 514 515 516c 518 519b 520d 521 522 523 524 HEAT ENGINE SPARES ...

Page 76: ...ON GASKET 7720038 509d HEAT EXCHANGER 75KW 7805977 510 22X1 2 BSPM STRAIGHT CONN 7709369 511 H E BURNER DOOR INSULATION 7709296 512 IONIS ELECTRIC INC GASKET SCREWS 7709311 514 SPARKELECTR INC GASKET SCREWS 7709312 515 GAS VALVE 7709308 516c LPG KIT FOR MAXXﬂo EVO 150KW 7805978 518 FLUE BACKFLOW PREV DEVICE ASSY 7709315 519b AIR HOSE INC CLIP 150KW 7805979 520d VENTURI 150KW 7805980 521 VENTURI GA...

Page 77: ...1 604 CONTROL PCB FUSES 2 PACK 7709324 606 DIN RAIL TERMINAL BLOCK 7709334 607 TEMP LIMIT THERMOSTAT 90 C 7709331 608 ON OFF SWITCH 7709332 609 RESET SWITCH 7709333 610 GRAPHICAL USER INTERFACE 7709326 611c SLAVE CONTROL PCB MAXXﬂo EVO 150 7805982 613 OPTION WEB SERVER 7726955 614 WIRING LOOM UPPER MAXXﬂo EVO 7818127 615 WIRING LOOM LOWER MAXXﬂo EVO 7818128 6 4 COMPONENTS ILLUSTRATIONS CONTINUED 6...

Page 78: ...5KW H E GAS 22MM 7709355 808 PIPE TWIN LOW H E CO RE AS 28 7709340 809c PIPE TWIN 90KW LOW H E CO FL AS 28 7709344 812 PIPE TWIN H E RE MA AS 28MM 7709336 814 PIPE TANK CONN FLOW 28 7818129 815 PIPE ALL UP H E CO RE AS 22 7818130 816b PIPE UP H E CO FL AS 150KW 7818131 817c PIPE UPPER H E FLOW 28 150KW 7805984 818 PIPE TWIN LOW H E FL IV AS 28 7818132 819 PIPE TWIN UP H E RE IV PU 28 7818133 820 P...

Page 79: ...very abilities are retained Essential First Aid kit contents to maintain at least one heat engine in operation 1 x Gas valve 1 x Fan 1 x LMS14 PCB PCB1 1 x Q1 Pump 1 x Spark generator 1 x Ionisation electrode gasket 1 x Spark electrode gasket 1 x H3 Pressure sensor 1 x 10kΩ B2 Flow or B7 return temperature sensor 1 x 10kΩ B3 Tank temp sensor 1 x 20kΩ B8 Flue temp sensor Essential First Aid kit con...

Page 80: ... addresses of all Siemens controlled appliances via parameter 6600 83 BSB short circuit 595 No BSB communication or wires shorted Check operation of GUI or OZW672 if ﬁtted 84 BSB address collision 104 Two appliances connected through BSB e g OZW672 have the same allocation address Change one of the appliances address via parameter 6600 98 Extension module 1 error 605 Indicates that an expansion mo...

Page 81: ...w and return sensors are operating correctly 419 430 813 814 Flow temperature limit exceeded Check for overheating is sues and ﬂow sensor B2 performance 809 810 422 423 Flow temperature not plausible Reading less than 0O C or greater than 124O C Check ﬂow sensor B2 and replace if necessary 425 812 Return temperature limit exceeded Check for overheating issues and return sensor B7 performance 424 8...

Page 82: ...nnections Replace control PCB if no fault found 331 Error when opening ignition relay Check ignition generator and controls connections Replace control PCB if no fault found 332 Error when closing gas valve relay Check gas valve and con trols connections Replace control PCB if no fault found 333 Error when opening gas valve relay Check gas valve and con trols connections Replace control PCB if no ...

Page 83: ...below maximum levels Check that the appliance ﬂow is not restricted or blocked or the water isolator valves are shut oﬀ 323 Water press 3 too low Any Water pressure inside appliance is too low for safe operation Operation automatically resumes once water pressure is above 0 1 bar 324 Input BX same sensors 110 BX sensor duplicated Two sensor inputs have been deﬁned twice with the same sensor type e...

Page 84: ...e 374 383 384 Fan outside allowed speed tolerance during ignition phase 375 386 Fan outside allowed speed tolerance during min modulation phase 385 Fan outside allowed speed tolerance during max modulation phase 532 534 382 390 Fan outside allowed speed tolerance during post purge phase Other Check connections and wiring loom of the fan Replace fan if no fault found If necessary use parameter 9650...

Page 85: ...9 60 2 490 10 19 873 65 2 084 15 15 699 70 1 753 20 12 488 75 1 481 25 10 000 80 1 256 30 8 059 85 1 070 35 6 535 90 915 40 5 330 95 786 50 3 605 100 677 Temperature o C Resistance Ohms Temperature o C Resistance Ohms 0 67 650 90 1 845 10 40 491 100 1 377 20 25 099 110 1 043 25 20 000 120 801 30 16 057 130 624 40 10 569 140 491 50 7 140 150 392 60 4 938 160 315 70 3 489 170 256 80 2 515 180 210 ...

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Page 88: ...April 2022 FM00866 EMS514880 13755 M10419 Rev A April 2022 ...

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