andrews MAXXflo EVO CWH 90/302 Installation And Maintenance Manual Download Page 66

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Maintenance

MAXXflo EVO

• Remove the 6 heat exchanger door bolts and remove the whole burner assembly and put to one side.

• Unscrew the flow and return pipework from the heat exchanger.

• Unscrew the flow and return sensors form the heat exchanger and retain

• Disconnect the condense drain connection by releasing the jubilee clip and pulling the pipe off

• Remove the 6 screws of the heat exchanger retaining clamps and remove the clamps

CAuTION

Warning 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 quietly

Removed burner

assembly

Condense hose

Jubilee clip

Retaining clamp

Heat exchanger

connection

Summary of Contents for MAXXflo EVO CWH 90/302

Page 1: ...these instructions before commencing installation and leave this manual with the customer for future reference M9373 MAXXflo EVO High efficiency condensing stainless steel storage water heater CWH 90...

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

Page 3: ...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...

Page 4: ...53 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 con...

Page 5: ...rom 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 environm...

Page 6: ...lation 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 he...

Page 7: ...ion 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...

Page 8: ...lation 2016 426 Ecodesign Requirements for Energy Related Products ERP 2009 125 EC Electromagnetic Compatibility EMC Directive 2014 30 EU Low Voltage LVD Directive 2014 35 EU Boiler Efficiency BED Dir...

Page 9: ...ty 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 vo...

Page 10: ...lity to off peak hours functioning 3 Yes Yes Enabled smart control settings 4 1 Electricity 2 Fuel 3 If applicable 4 If smart control setting value is 1 the water heating energy efficiency and annual...

Page 11: ...connections BSP 1 1 2 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...

Page 12: ...72 300 391 128 91 301 91 DHW 1 5 BSP m SECONDARY RETURN 1 BSP m MCWS 1 5 BSP m INSPECTION HATCH SENSOR WELL CONCENTRIC FLUE AIR 30kW 60kW Models 80mm 125mm 90kW 120kW Models 130mm 200mm REMOVABLE AIR...

Page 13: ...AXXflo EVO EXAMPLE 1 Single MAXXflo EVO schematic EXAMPLE 2 Parallel MAXXflo EVO schematic Maximum ci Maximum circulation rate Q4 pump Model MAXXflo EVO 90 MAXXflo EVO 120 Flow m3 h 1 8 2 4 3 5 System...

Page 14: ...w off 1663 Circulation setpoint Standard setpoint is 45O C When the B39 sensor is installed the controller will monitor the DHW return temperature during the activation time of the pump Whenever the t...

Page 15: ...Technical Data 15 MAXXflo EVO EXAMPLE 3 MAXXflo EVO BUFFER SS300 10 schematic 3 5 System Schematic EXAMPLES Continued...

Page 16: ...K21 pump will be turned off 5572 Factory setting 3 0O C When 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 DH...

Page 17: ...XXflo EVO Example 4 BMS CONNECTIONS A B REF Enable Flame Burner 1 Fault Modbus Flame Burner 2 BMS Black Relay White Relay L N PE L N 1 2 3 4 9 NO NO CO CO 5 6 7 8 Black Relay NO CO 3 5 System Schemati...

Page 18: ...kW H2 M BX21 BX22 U M Module No1 L N QX23 QX22 QX21 N N Remote enable volt free Flame indicator 1 Q4 DHW pump Fault indicator Live Neutral Live Earth Neutral B39 DHW Return sensor kit Flame indicator...

Page 19: ...120 Wiring Diagram MAXXflo EVO Slave Models 90 120 kW ng diagram MAXXflo EVO ster Models 90 120 kW Remote enable volt free Flame indicator 1 Fault indicator Flame indicator 2 Black Relay White Relay u...

Page 20: ...e 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 angle...

Page 21: ...ve the four screws either side of the GUI display unit at high level Loosen the two screws at low level inside the case to remove the case retaining bracket Pull the inner cover forwards and remove co...

Page 22: ...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 l...

Page 23: ...arrows marked on the components are pointing in the direction of flow that is towards the heater The relief valves fitted to this heater must not be used for any other purpose No fitting should be ins...

Page 24: ...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 t...

Page 25: ...fitted with a minimum of 40mm diameter External pipework should be insulated to protect against frost and freezing temperatures Use of 40mm plastic pipe with a drop of at least 30 mm for every metre...

Page 26: ...ay 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 in...

Page 27: ...pose of the internal space from which ventilation is provided The internal space should not be part of a dwelling The ventilation system including mechanical ventilation shall be designed such as not...

Page 28: ...ant room The fans must be interlocked with the appliance Minimum flow rate requirements as as follows 4 7 5 Open flue Appliance in a ENCLOSURE ventilated direct to outside air Minimum free vent area H...

Page 29: ...200 F Below a balcony or car port roof Not recommended G Above ground roof or balcony level 300 H From vertical drain or soil pipe 150 J From an internal or external corner to an alongside boundary 3...

Page 30: ...mmended 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 o...

Page 31: ...SATE 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 11 MAX...

Page 32: ...n 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...

Page 33: ...30 90 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 10 130 200 1780...

Page 34: ...m vertical drain or soil pipe 150 J From an internal or external corner to an alongside boundary 300 K From a terminal facing a terminal 2 270 2 810 L Vertically from a terminal on the same wall 2 500...

Page 35: ...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 Ho...

Page 36: ...nnected to the same gas supply operating at maximum load When replacing a MAXXflo with a MAXXflo EVO and reusing the existing gas isolation valve and fittings remove the new Gas Union MxF from the MAX...

Page 37: ...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 connect...

Page 38: ...ttings 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 ha...

Page 39: ...r 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 o...

Page 40: ...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 num...

Page 41: ...s 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...

Page 42: ...stops before continuing see Figure below Remove the gas analyser and replace the rubber bung in the flue sample point Replace the throttle screw cover 5 2 3 Bottom Heat engine COMMISSIONING If the Co...

Page 43: ...lip 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 calle...

Page 44: ...USTMENTS 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...

Page 45: ...r I and wait for both heat engines 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...

Page 46: ...press the spring clip holding the black air intake hose onto the venturi and remove the hose Undo and remove the 5 screws securing the venturi to the gas valve and fan Remove the venturi completely an...

Page 47: ...an two turns away from the initial adjustment setting to achieve ignition If this is the case ensure that the components are refitted correctly and also be aware that the gas carrying pipes may need p...

Page 48: ...mperature 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 eq...

Page 49: ...f 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 setpo...

Page 50: ...cleaning products A soft cloth used with soap and warm water should be sufficient to clean the casing 5 5 4 User Handover When commissioning is satisfactorily completed the user must be instructed on...

Page 51: ...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 FAULT...

Page 52: ...red 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...

Page 53: ...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...

Page 54: ...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...

Page 55: ...ater 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...

Page 56: ...ning 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 Withd...

Page 57: ...n to the heat exchanger and pipework for leaks 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...

Page 58: ...o that the hatch drops downwards and is held in place by the nut Remove the bolt and clamp and while holding the threaded shaft allow the hatch to drop down and then angle the hatch and remove it thro...

Page 59: ...enerator 7 Combustion fan 8 Gas valve 9 Electrode removal 10 Back flow prevention flue valve 11 Overheat thermostat 12 Air pressure switch The following items require isolation of water before removal...

Page 60: ...This is located 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 AVS37 GUI Display This is located in the cen...

Page 61: ...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...

Page 62: ...olts securing 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 th...

Page 63: ...e Operate the heat engine and check for gas leaks After five minutes check the rate and combustion is correct to the Data table page 11 Adjust using the throttle adjustment screw on the gas valve if n...

Page 64: ...spect 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...

Page 65: ...ty as possible Disconnect all electrical connections 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 th...

Page 66: ...clip and pulling the pipe off Remove the 6 screws of the heat exchanger retaining clamps and remove the clamps CAUTION Warning this item is heavy Before releasing the brackets ensure support is avail...

Page 67: ...de screwdriver to lift the white tab before pulling each connector free Undo the unions at the top and bottom of the pump body and remove pump Fit the new pump seals Replacement is the reverse Refill...

Page 68: ...ter occurs Carefully remove wiring connector from the sensor using a small screwdriver to gently lift the tabs on each side in turn whilst at the same time gently pulling on the connector Pull out the...

Page 69: ...ease of water occurs Connect flushing apparatus to the drain flushing points For best results reverse the flow of the flushing apparatus When the operation is completed thoroughly flush the system to...

Page 70: ...ssion tee 7709367 104b 300 Litre access hatch assy inc o ring 7720064 105 Temp sensor DHW tank B3 7709329 106b 300 Litre tank 7617079 107 28mm obtuse comp elbow 7709372 108 option Castor assembly 7709...

Page 71: ...s INNER COVER DOOR SPARES Item No Description Part Number 200b Door for MAXXflo evo 300L 7725797 201 Door closing LATCH SET 7709375 202 Door hinge set 7709376 203b Door gasket MAXXflo evo 300L 7709378...

Page 72: ...k generator 7709314 302 Lead for spark electrode 7709313 303 Press sensor water H3 7709328 304 22mm rigid fan gas cock 7709371 305 Non return valve assy 7709287 306 Pump for MAXXflo evo 7709310 307 PU...

Page 73: ...ED 403 405 401 Drain components FLUE COMPONENTS Item No Description Part Number 401 Condensate system twin H E 7709359 403 Flue system twin H E MAXXflo evo 7709361 405 Flue seal set twin H E MAXXflo e...

Page 74: ...ance 74 MAXXflo EVO 6 4 COMPONENTS Illustrations CONTINUED 500 501 502 503 504 505 506a 506b 507 508 509a 509b 509c 510 511 512 514 515 516a 516b 517 518 519 520a 520b 520c 521 522 523 524 HEAT ENGINE...

Page 75: ...7709293 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 for MAXXflo ev...

Page 76: ...2 pack 7709324 605b wiring loom upper 90 120 MAXXflo evo 7709387 606 DIN rail terminal block 7709334 607 Temp limit thermostat 90 C 7709331 608 On Off switch 7709332 609 Reset switch 7709333 610 User...

Page 77: ...Pipe ALL UP H E CO RE AS 22 7709342 804 Pipe ALL UP H E CO FL AS 28 7709343 805a Pipe TWIN 90KW UP H E FLOW 90DEG 28 7709349 805b Pipe TWIN 120KW UP H E FLOW 90DEG 28 7709350 806 Pipe TWIN LOW H E FL...

Page 78: ...es 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 gas...

Page 79: ...dress of all control PCBs via parameter 6600 83 BSB short circuit Any No BSB communication or wires shorted Check operation of GUI or OZW672 if fitted 84 BSB address collision Any Two appliances conn...

Page 80: ...imit exceeded Check for overheating is sues and return sensor B7 performance 424 811 Return temperture reading error Temperature reading less than 0O C or greater than 124O C Check flow sensor B7 and...

Page 81: ...econds will also produce this lockout 848 849 Parameter update finished Press reset to apply changes 160 Fan speed threshold not reached Any Fan does not reach required speed setpoint via PWM control...

Page 82: ...to the AGU2 5 extension module 353 Cascade flow sensor B10 missing Any Check connections and configuration of common flow tempera ture sensor B10 which is located at the feed into the tank on the fron...

Page 83: ...90 10 19873 65 2084 15 15699 70 1753 20 12488 75 1481 25 10000 80 1256 30 8059 85 1070 35 6535 90 915 40 5330 95 786 50 3605 100 677 NTC 20K Sensors flue sensor only Temperature o C Resistance Ohms Te...

Page 84: ...perform BAXI HEATING COMMERCIAL BRANDS ALL TOGETHER BETTER Registered office address Baxi Heating UK Brooks House Coventry Road Warwick CV34 4LL June 2019 Sales 0345 070 1055 Technical 0345 070 1057 W...

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