Hamworthy Wessex Modumax 100 series Installation, Comissioning And Servicing Instructions Download Page 1

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IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Wessex Modu

Max

100 Series Boilers

Non Condensing & Condensing

Fully Modulating, Pre-Mix, Gas Fired, Modular

Boilers for Heating and Domestic Hot Water

Installations

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

Summary of Contents for Wessex Modumax 100 series

Page 1: ...NG COMMISSIONING OPERATING OR SERVICING EQUIPMENT Wessex ModuMax 100 Series Boilers Non Condensing Condensing Fully Modulating Pre Mix Gas Fired Modular Boilers for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions NATURAL GAS I2H ...

Page 2: ...rating safely and efficiently Maintenance Agreements 01202 662555 Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant reducing the risk of failure and improving performance and efficiency Maintenance agreements enable our customers to plan and budget more efficiently Breakdown service repair replacement 01202 662555 Hamworthy provide...

Page 3: ...N GROUP H NATURAL GAS 2ND FAMILY I2H PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES PRODUCT IDENTIFICATION No 87BQ008 PUBLICATION NO 500001123 ISSUE C OCTOBER 2005 Wessex ModuMax 100 Series Boilers Non Condensing Condensing Fully Modulating Pre Mix Gas Fired Mo...

Page 4: ...r Box Assembly 5 2 Water Connections 5 3 Electrical Connections 6 0 PRE COMMISSIONING 13 6 1 Gas Supply 6 2 Ventilation 6 3 Pipework Valves and Pump 6 4 Flue 6 5 Electrical 7 0 CHECKS PRIOR TO LIGHTING 14 8 0 INITIAL LIGHTING 17 8 1 Pre Lighting up Checks 8 2 Controls Operation 8 3 Ignition Controller Check 8 4 Gas Supply Pressure Check 8 5 Combustion Checks 8 6 User Instructions 9 0 FAULT FINDING...

Page 5: ... FLUE DATA 44 C1 1 General Requirements C1 2 Waste Gas Volume and Temperature C1 3 Materials C1 4 Suction C1 5 Disconnection C1 6 Flue Discharge C1 7 Surface Temperatures C1 8 Location C1 9 Condense Discharge APPENDIX D VENTILATION 48 D1 1 Air Supply General Requirements D1 2 Air Supply by Natural Ventilation D1 3 Air Supply by Mechanical Ventilation APPENDIX E WATER DATA 49 E1 1 Water Circulation...

Page 6: ...a 18 Figure 8 1 6 General Overview of Controls 18 Figure 8 2 System Configuration of Boiler Control 19 Figure 8 2 1 1 Fascia Label Legend 19 Figure 8 2 1 2 Info Display Parameters 21 Figure 8 2 1 3 Operation and Display Philosophy 22 Figure 8 2 2 Screen Legend 23 Figure 8 2 3 1 Default Display 24 Figure 8 2 3 2 Display of Status Code 24 Figure 8 2 4 Display of Lockout Code 25 Figure 8 2 5 Heating ...

Page 7: ...terlocks will shut the boiler s off should a high or low pressure fault occur The pressurisation unit must also incorporate a low level water switch which protects the water pumps and will directly or indirectly shut down the boiler plant should a low water condition occur Consideration should also be given to the maximum working pressure of the boiler as given in Appendix E Consult Hamworthy Heat...

Page 8: ...t truck This allows the boiler to be manoeuvred into position without any pallets to remove Additionally the boiler is designed to pass through a standard doorway where access is restricted NOTE The boiler is packaged with cardboard corner protection and shrunk wrapped for basic protection during handling However when manoeuvring the boiler care must be taken to avoid damage to the casing The boil...

Page 9: ...x 110 330 Wessex ModuMax 120 360c 15kg x3 Figure 2 3 Boiler Packaged Dimensions Delivery Verification When taking delivery please ensure that you have received the correct number of boilers and flue collector manifold to fulfil your order If any item is missing please contact our after sales service team Please provide details of your order such as order number and contract number as well as a det...

Page 10: ...tem Also important is allowance for sufficient access at sides and rear of boiler for flue and pipework connections See Figure 3 1 below Figure 3 1 Dimensions and Clearances WM110 330 120 360c WM110 220 120 240c WM110 110 120 120c 700 240 1380 1920 2120 180 I D 1580 180 I D 1120 1030 840 750 crs 400 400 600 R FOR PRESSURE RELIEF VALVE NOTHHL SUPPLY 1 PER MODULE FLOW G1 MALE Rp1 GAS 1 PER MODULE 32...

Page 11: ... it is important that each boiler module is fitted with an individual safety valve using the connection provided on the back of each boiler This item is not supplied with the boiler Figure 3 2 2 Manifold Dimensions for ModuMax 110 330 120 360c Figure 3 2 1 Manifold Dimensions for ModuMax 110 220 120 240c 199 844 1905 R EF 1593 541 541 280 541 541 232 175 76 NOM 753 NOM 753 NOM 40 5 40 5 672 541 54...

Page 12: ...tallation of boilers manifold kits pipework pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply Gas supply pipes must be in accordance with BS 6891 or IGE UP 2 Gas supply connections to the boiler must not be smaller than the connection on the boiler Rp1 Gas installation must be soundness tested to BS 6891 or IGE UP 1 IGE UP 1A Gas installation must be pur...

Page 13: ...ing and separable from the boiler for servicing requirements Due to the low flue gas temperature 50 C condensing 135 C non condensing condensation will occur in the flue flue materials must be non corrosive and utilise fully sealing joints Flue construction is recommended of a twin wall insulated type to maintain buoyancy within the flue Adequate facilities must be provided for draining the flue c...

Page 14: ...to comply with BS 7074 It is recommended that the system pipework is flushed twice before water treatment In hard water areas precautions such as water treatment should be implemented to prevent the build up of sludge and scale Leaks in the system pipework should be fixed to prevent dilution of water treatment Maximum working water pressure is 10bar For minimum water pressure see Appendix E Water ...

Page 15: ...system Condense is mildly acidic typically pH3 pH5 Condense pipework must be non corrosive and not copper Hamworthy recommend 32mm dia Plastic waste pipe Condense may be discharged to a standard drain subject to National or Local regulations Location of condense pipework should prevent freezing within tundishes traps and pipework The connection to the boiler condense drain accepts a straight push ...

Page 16: ...l isolation Electrical isolators must have contact separation of minimum 3mm in all poles Electrical isolators must be installed in readily accessible locations Electrical supplies to boiler modules should only serve the boiler Where volt free contacts are used these too must be individually isolatable Time clock control should be via the boiler modules stop start circuit 24V DC ADDITIONAL INFORMA...

Page 17: ... advisable to lubricate the seal located in the socket fittings to enable easy movement and adjustment 2 Fit and secure the bottom closing plate to the base of the duct assembly Do not fit the flue collector at this stage as it may restrict access to the other connections Note Should modules be arranged in banks of 2 or 3 high adjacent to each other it is advisable to fit the water and flue connec...

Page 18: ... Where using Hamworthy Heating Ltd pipework kits assembly of these is detailed in Operation and Maintenance manual 500005117 supplied with kit 5 3 Electrical Connections The following electrical connections are provided on each module Supply Live Neutral and Earth See Section 4 5 for details Supply Input for Boiler Fault and Normal Run Signals Boiler General Fault Alarm Signal Output Boiler Normal...

Page 19: ...installed to Hamworthy Heating recommendations Circulating system is full of water vented and pressurised appropriately Circulation pump is fitted working and interlocked where required Pipework connections to boiler are fitted correctly All necessary isolation valves are open Safety valve is correctly sized and located Condense connections on boiler and flue are connected and piped to drain Heat ...

Page 20: ...te check period Following soundness tests close valve B and remove manometer connections and tighten test points 7 0 Checks Prior to Lighting IMPORTANT BEFORE PROCEEDING ENSURE THAT THE PRE COMMISSIONING CHECKS ON PAGE 14 HAVE BEEN CARRIED OUT AND THE RESULTS SATISFACTORY 7 1 Boiler Gas System Leak Check Ensure that the appliance manual gas service valve is in the OFF position Although the boiler ...

Page 21: ... pocket in the front of the heat exchanger and carefully applying a heat source to the bulb The reset button should operate If satisfactory refit the bulb in the pocket and secure with the clip Ensure that all thermostat bulbs are fully inserted into the pocket The flow and return sensor bulbs are located at the rear of the boiler in the flow and return pipes 3 Check setting of both temperature li...

Page 22: ...ection 8 2 1 Controls Operation 5 To ensure correct ignition of the boiler it is recommended to check the resistance of the hot surface igniter This should be checked cold using a suitable ohmmeter by disconnecting the igniter from the control panel cable and measuring the resistance across the pins of the 2 way connector The reading should be between 70 and 110 ohms Flame Signal Assessment Figure...

Page 23: ...ve procedure occurs correctly open the gas isolating valve Reset the lockout and the fault indication will extinguish The boiler will commence its ignition sequence as previously described This time when the gas valve is energised the burner will ignite 6 With the burner firing the flame signal displayed should be approximately 15 20µA but not less than 3µA Refer to Figure 8 2 1 2 of Controls Oper...

Page 24: ...01123 C Figure 8 1 5 General Overview of Panel Fascia Figure 8 1 6 General Overview of LMU Limit Thermostat IEC Mains Outlet Socket Display Screen 230v Mains Supply Clip in Module Vfc 0 10v Ignition Transformer LMU Control Keypad Air Pressure Switch Filter ...

Page 25: ...figuration of boiler control LMU system peripherals LMU QAC34 Roo m Thermostat Time Switch RVA47 Bu ilding Automation Remote Management Service Tool OCI420 AGU2 50 0 AGU2 51xx LPB Clip in Auxiliary modules 0 10 V 4 20 mA OCI ACS Figure 8 2 1 1 Fascia Label Legend 8 2 CONTROLS OPERATION ...

Page 26: ...utton refer to figure 8 2 1 1 A change on the information level can be made at any time by pressing the Info button Additional pushes of the Info button will deliver the following data sequence provided by the information level dhw temperature not used Water Pressure Operating phase refer to section 8 2 15 Outside temperature Error code refer to section 8 2 14 Boiler temperature Press one of these...

Page 27: ...rol PWM C 4 RelModLevel Relative output C 5 Pumpe_PWM Pump setpoint PWM Not used C 6 ek0 Control differential C 7 C8 C9 Reserved Setpoints Service level d 0 Reserved d 1 Tsoll Setpoint of 2 position or modulating controller PID d 2 TkSoll Current boiler temperature setpoint d 3 TsRaum Room temperature setpoint d 4 TbwSoll DHW temperature setpoint Not used d 5 PhzMax Maximum degree of modulation in...

Page 28: ...HAMWORTHY HEATING LTD 22 WESSEX MODUMAX 100 SERIES 500001123 C Figure 8 2 1 3 Operation and display philosophy ...

Page 29: ...Meaning of symbols Display of dhw temperature or dhw heating active not used Display of boiler or room temp set point or space heating active Display of outside temperature Operational level Normal Operational level Reduced Display of flame Display of fault 5 Display 1 4 x 7 small segments Display of time of day parameter settings or error code 6 Operating mode of heating circuit Operating mode is...

Page 30: ... Default display If no button is pressed for about 8 minutes the screen will automatically return to the default display Figure 8 2 3 2 Display of Status Code When a status code is displayed the display 1 shows alternatively the time of day and the error code Press the Info button for the display of the error code Press simultaneously both line selection buttons for 3 seconds The internal error co...

Page 31: ...fication of the fault press the reset button 0 6 seconds to reset the LMU Figure 8 2 4 Display of lockout code 304 7494z35 0202 8 2 5 Adjusting the heating circuit setpoint temperature Press the flow temperature button to adjust the heating circuit setpoint Press to adjust the required setpoint Press to return to the default value Changes will be stored Figure 8 2 5 Heating circuit setpoint temper...

Page 32: ...ed for about 8 minutes the screen will automatically return to the default display Changes will not be stored When switching to another level changes will be stored Line Function Range Unit Resolution Default value Time of day 1 Time of day 0 23 59 h min 1 min Setpoints 5 Reduced room temperature setpoint TrSollRed or reduced boiler temperature setpoint TvSollRed When using an additional room unit...

Page 33: ...ose the function press button 8 2 8 2 Controller Stop function The controller stop function enables the boiler s heat output to be adjusted manually in heating mode by pressing both buttons simultaneously for more than 6 seconds On the display the lower arrow of the maintenance function flashes and the currently selected temperature appears and the display shows the adjusted relative boiler output...

Page 34: ...5 Maintenance message System fault 110 STB has cut out Process fault 111 Limit thermostat has cut out Process fault 113 Flue gas supervision equipment has cut out Process fault 117 Water pressure too high Process fault 118 Water pressure too low Process fault 119 Water pressure switch has cut out Process fault 130 Flue gas limit temperature exceeded Process fault 132 Safety shutdown e g by gas pre...

Page 35: ...n PH_TI PH_MODULATION DHW mode 12 Parallel operation of space heating and DHW heating PH_TI PH_MODULATION Heating and DHW mode 20 Postpurging with the last control of operation PH_THL2_1 PH_TN_1 21 Postpurging with control of prepurging PH_THL2_2 PH_TN_2 22 Home run PH_TNB PH_TLO PH_TNN 99 Lockout position display of the current error code PH_STOER Note If operating phases are passed very quickly ...

Page 36: ...HAMWORTHY HEATING LTD 30 WESSEX MODUMAX 100 SERIES 500001123 C Figure 8 2 11 Operating phases ...

Page 37: ...uld be checked This should be done with all modules firing For Natural Gas the gas control valve zero governor control system is configured for a nominal gas inlet pressure of 20mbar measured at the rear of the boiler with a maximum inlet pressure of 25mbar 8 5 Combustion Checks The boiler modules are factory pre set however site checks must be undertaken to confirm correct performance 2 Use appro...

Page 38: ...Remove all instrumentation and replace any test points and plugs 8 Refer to section 8 2 Controls Operation to set the relevant boiler parameters and timings specific to the installation 8 6 User Instructions When the boiler is fully commissioned the owner or their representative should be made aware of the lighting up and operating instructions A practical demonstration should be given describing ...

Page 39: ...o section 8 2 4 Controls Operation the lockout code on the display does not extinguish and the boiler does not fire up it is possible that the limit thermostat will not reset because the boiler is still too hot 3 Always carry out an investigation to ascertain the reason for overheating The most common cause of overheating lack of water flow rate through the boiler possibly due to external pump pro...

Page 40: ...EEN Y ELLOW RE D B LUE RED RED BLUE BLU E BR OWN B ROWN BLU E RED BLU E B ROW N GR YE B LU E BLUE FLOW TEMP SENSOR RETURN T EMP SENSO R DC SERVO FAN 2 1 X30 AGU2 31A109 FASCIA DISPLAY KEYPAD MO DULE F LAME IONISATION PROBE 2 1 1 2 3 230V 220V 120V 0V 1 2 2 1 3 C 1 2 HSI PROBE GAS VALVE IGNITER T RANSFORMER SAFETY LIMIT THERMOSTAT 5 N L 4 3 2 1 DC SERVO FAN 5 4 3 BLU E BROW N BLA CK G REY B LACK P ...

Page 41: ...he 2 M8 burner retaining nuts and carefully withdraw the complete burner fan assembly from the heat exchanger Separate the burner fabrication from the fan venturi and gas control valve 7 Remove and inspect H S I and flame probe ensure they are free from debris or deposits Test resistance value of H S I if above 110 ohms cold replace with a lower resistance unit Check respective positions See Figur...

Page 42: ... front end supported slowly withdraw the heat exchanger until the rear of the stainless steel baffles are visible With the rear of the heat exchanger resting in the body of the boiler and the front supported by the lifting apparatus access is gained for removal of the stainless steel baffles Unhook the stainless steel springs and remove the baffle plates to expose the finned tube bank Wire brush b...

Page 43: ... the ceramic Note Do not remove both securing screws at the same time as the separate flange and Mica sight glass will become detached Ensure the positions of the igniter and probe are as recommended in Figure 10 2 11 2 Flow Return sensor Part No 533901431 The two identical sensors are located in pockets on the flow and return pipes at the rear of the boiler To remove the sensor unplug the sensor ...

Page 44: ...e weight of the assembly and put to one side on the flexible gas supply hose Remove the 3 M4 hex head screws nuts and washers fastening the venturi to the air inlet box ensuring correct orientation Fit the replacement in reverse order and if required replace any seals or gaskets Note the venture is supplied with an air inlet ring the position of which is factory set Do not adjust the position of t...

Page 45: ...ure that the boiler module electrical power supply is isolated before removing the front cover and gaining access to the controls Carefully disconnect the ribbon cable connecting the screen to the LMU control terminal X30 Remove the 4 screws securing the screen panel to the controls pod Remove the 4 nuts securing the screen to the front panel of the controls fascia and remove the display pcb Remov...

Page 46: ...533901437 Ignition Transformer 533901441 Flow Return Sensor 533901431 Temperature Limiter 533901179 Hot Surface Igniter 563801019 Flame Sensing Probe 533805019 Clip in Module vfc 0 10v AGU2 511A109 533901438 Clip in Module LPB Bus communication OCI420A109 533901456 MECHANICAL ITEMS Burner Fabrication 533301019 Gas Control Valve 533903037 Combustion Fan 533704007 Venturi 532418002 Low Gas Pressure ...

Page 47: ... Inlet Connection Pipe Thread Size R1 Nominal Gas Inlet Pressure mbar 20 Maximum Gas Inlet Pressure mbar 25 Gas Supply Pressure Switch Setting mbar 12 5 Gas Flow Rate maximum m3 h 11 9 12 7 23 8 25 4 35 7 38 1 Target CO2 at High Low fire 0 1 9 0 9 0 GENERAL DATA Wessex ModuMax M Series condensing BOILER MODEL Model 120 120c 120 240c 120 360c Boiler Input maximum kW Gross 133 266 399 Boiler Input m...

Page 48: ...ly The method of connection to the mains electricity supply must facilitate complete electrical isolation of the single boiler battery with a separation of at least 3mm in all poles 3 A mains isolator must be provided adjacent to the boiler in a readily accessible position The supply should only serve the boiler 4 2 3 high stacked modules It is highly recommended that each boiler module is connect...

Page 49: ...HAMWORTHY HEATING LTD 43 WESSEX MODUMAX 100 SERIES 500001123 C Figure B1 2 External Control Wiring for Multiple Module Installation ...

Page 50: ...mm flue duct for connection to an open flue chimney system maximum length 10m The resistance of the flue system components is detailed in Figure C1 1 1 The following points should be noted a Due to the high thermal efficiency of the boiler condensation in the flue will occur It is strongly recommended that twin wall or insulated flue pipe is used on all installations b Care should be taken to ensu...

Page 51: ...iameter a terminal must be fitted Where the flue is of a larger size consideration should be given to the fitting of a flue discharge terminal or grille to stop ingress of birds etc C1 7 Surface Temperatures Combustible materials in the vicinity of the boiler and flue shall not exceed 65 C during boiler operation The flue shall not be closer than 50mm to any combustible material except where it pa...

Page 52: ... drain Adjustable Flashing Ø100 flue 040 Ref 039 Ref Ø100 flue Flat Roof Flashing Ref 021 Ref 020 Single Flue Single Flue 500 long Ø100 250 long Ø100 Ref 022 1000 long Ø100 Single Flue Ref 026 Vertical terminal Ø100 Flue Ref 023 Ø80 100 Eccentric Adaptor Ref 017 Wall Clamp Ø100 Ref 022 021 Ref 020 Ref Single Flue 500 long Ø100 1000 long Ø100 Single Flue Single Flue 250 long Ø100 Ref 017 Wall Clamp...

Page 53: ...steel flue system the flue system must have it s own condense drain The system must not be allowed to drain back through the HHL supplied components Horizontal Inlet Terminal Ø100 Flue Ref 024 Ref Ref 022 Ref Ref Ref 019 018 020 021 90 Bend 1000 long Ø100 45 Bend 1000 long Ø100 Single Flue 1000 long Ø100 250 long Ø100 500 long Ø100 Single Flue Single Flue Inlet 10m max Outlet 10m max Outle t 10m m...

Page 54: ... for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows 1 At floor level or 100mm above floor level 25 C 2 At mid level 1 5m above floor level 32 C 3 At ceiling level or 100mm below ceiling level 40 C Where both low and high level openings are used the grilles shall have a total minimum free area of Low level inlet 540cm plus 4 5cm per ...

Page 55: ...nd hot water storage vessel 4 Each boiler module has G1 male flow indicated with a red spot and return indicated with a blue spot connections Boilers should be connected by flow and return headers Headers should be connected to the system in a reverse return arrangement the water flow in each header is in the same direction to ensure equal flow in each module or with a single pipe header system Fi...

Page 56: ...alve Air Vent Automatic Valve valve Drain Valve Module Hamworthy Modular Boilers Safety T valve Modu le 1 2 Drain 3 Module P gauge s Pressure Temperature T Automatic Air Vent Heating lo ad Lockshield valve fill line Temporary Double check valve vessel Expansion valve Lockshield Mains water valve Drain va lve Lockshield Primary loop System Circulation pump Valve Circulation pump Valve System Automa...

Page 57: ...pumps should be checked for performance against the new boiler waterside pressure loss to ensure that the minimum flow rate can be obtained It is also important that the existing system be flushed through twice to remove any loose matter which may have accumulated If in any doubt regarding the cleanliness of the system a coarse filter should be fitted in the return pipework to the boilers If boile...

Page 58: ...arameters given Hamworthy Heating can size the pressurisation unit and also the expansion vessel required Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded Normally manufacturers of vessels impose a limit of 0 5 This value must not be exceeded at any time during the operation of the boiler this includes the over pressure condition should a safety ...

Page 59: ...Notes ...

Page 60: ...hy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice Connect direct Direct Dial Telephone and Fax Numbers Direct Email Addresses Hamworthy Heating Accredited Agents Website www hamworthy heating com boilers controllers water heaters pressurisation sets North West England Gillies Modular Services 210 218 New Chester Road B...

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