Hamworthy Wessex ModuMax mk3 WM97/97H Installation, Commissioning And Servicing Instructions Download Page 1

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Wessex Modu

Max

mk3 Boilers

Condensing

Fully Modulating, Pre-Mix, Gas Fired,

Modular Boilers for Heating and

Domestic Hot Water Installations

Installation, Commissioning and Servicing

Instructions

Models– 97, 116,

147, 196 & 254

NATURAL GAS

LPG Propane

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Summary of Contents for Wessex ModuMax mk3 WM97/97H

Page 1: ...for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions Models 97 116 147 196 254 NATURAL GAS I2H LPG Propane I3P IMPORTANT NOTE THESE INSTRUCTIONS MUST...

Page 2: ...operating safely and efficiently Service Contracts Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant reducing the risk of failure and...

Page 3: ...E RELEVANT INFORMATION WITHIN THIS DOCUMENT FOR EACH SPECIFIC GAS REQUIREMENT IS ADHERED TO PRIOR TO FIRING THE BOILER COUNTRY OF DESTINATION UNITED KINGDOM REPUBLIC OF IRELAND THIS BOILER COMPLIES WI...

Page 4: ...TIAL LIGHTING 21 8 1 Pre Lighting up Checks 8 2 Controls Operation 8 3 Operating Phases 8 4 Ignition Controller Check 8 5 Gas Supply Pressure Check 8 6 Combustion Checks 8 7 User Instructions 9 0 FAUL...

Page 5: ...gure 4 6 Electrical Connections 14 Figure 5 1 Module Fixings 14 Figure 5 2 Flue Collector Box Pre Assembly 15 Figure 5 2 2 Flue Header Connection 16 Figure 5 3 1 Rear Water Connections 16 Figure 7 1 B...

Page 6: ...e C1 1 1 Equivalent Flue Resistance Data 42 Figure C1 1 2 Open Natural Draught B23 B23p Flue System 43 APPENDIX D VENTILATION 44 Figure D1 Mechanical Ventilation Flow Rates Chart 45 APPENDIX E WATER D...

Page 7: ...erface LCD display for accessing and changing boiler parameters 1 3 4 Each of the boiler models is designed for direct connection to a flue system The Technical Data for the various arrangements is gi...

Page 8: ...54 508 254 762 These kits are free standing allowing installation to the system prior to installing the boiler and can incorporate all necessary valves inter connecting pipework and flexible flow and...

Page 9: ...plantroom Ensure the boiler is kept secure when handling to avoid it toppling as this will result in damage Each 2 and 3 high stacked Wessex ModuMax model is supplied with a flue collector manifold T...

Page 10: ...ry 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...

Page 11: ...m 192kg Wessex ModuMax 147 441 196 588 254 762 1200mm 800mm 2060mm 233kg Figure 2 2 Header Kit Packaged Dimensions Figure 2 1 Reverse Header Kit Where reverse return header sets are used these are pac...

Page 12: ...0 568 717 1 102 815 836 3 583 2 FLUE 204 9 CONDENSE 1258 1798 9 2084 31 1543 41 54 5 GAS 44 RELIEF 291 66 FLUE CONDENSATE 350 54 723 1 CONDENSE O100 FLUE SOCKET 477 RETURN 303 FLOW 350 54 FLUE CONDENS...

Page 13: ...OW 610 RELIEF 666 GAS 92 FLOW RETURN G 2 1 2 MALE RETURN G 2 1 2 MALE FLOW O32 CONDENSE DRAIN 1 PER MODULE 286 RETURN 182 CONDENSE R3 4 RELIEF VALVE 1 PER MODULE NOT SUPPLIED 600 Rp 1 1 4 GAS SUPPLY 1...

Page 14: ...for specific details on the manifold kit suitable for 97 116 models Optional accessory kits to control shunt pumps and valves can be found on page 2 of this manual Safety Valve When using this kit it...

Page 15: ...4 models Optional accessory kits to control shunt pumps and valves can be found on page 2 of this manual Safety Valve When using this kit it is important that each boiler module is fitted with an indi...

Page 16: ...with BS 6644 The plantroom must have sufficient space for installation of boilers manifold kits pipework pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply...

Page 17: ...flue condensation Horizontal flue runs must be kept as short as possible and be inclined at minimum 2 towards the terminal The flue system must be designed acknowledging that there is a positive pres...

Page 18: ...as 180mg CaCO3 litre precautions such as water treatment are strongly recommended to prevent the build up of sludge and scale and also to control the system water pH to between 7 0 8 0 Leaks in the sy...

Page 19: ...ged to a standard drain subject to National or Local regulations Location of condense pipework should prevent freezing within tundish s traps and pipework The connection to the boiler condense drain a...

Page 20: ...t 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 using the conduits su...

Page 21: ...anged in banks of 2 or 3 high adjacent to each other it is advisable to fit the water and flue connections to each individual bank prior to fitting the connections to the adjacent bank s Figure 5 2 Fl...

Page 22: ...itting supplied Figure 5 2 2 Flue Header Connection 32mm condense trap fitted for connection to drain 5 3 Water Connections The following connections are provided on each boiler module Figure 5 3 1 Re...

Page 23: ...th See Section 4 5 for details Optional Boiler Fault Alarm Normal Run Signal Output optional AGU clip in kit 0 10v Analogue Control Signal Input Remote on off Control Input Boiler Pump Output DHW pump...

Page 24: ...rbance to unions fittings and gas valve assemblies etc A procedure guide is given below Care must be taken not to allow leak detection fluid if used on or near any electrical parts or connections NOTE...

Page 25: ...ource to the bulb Note take care not to damage the tension spring in removal and replacement Check the continuity with a meter If satisfactory refit the bulb and tension spring in the pocket and secur...

Page 26: ...Igniter Check 196 254 shown with air filter removed Figure 7 2 2 Venturi Gas Valve 97 116 147 shown WARNING WHEN THE FRONT COVER AND AIR FILTER ARE REMOVED AND THE BOILER IS IN OPERATION IT IS POSSIB...

Page 27: ...em manual HHL part no 500001310 5 If the above procedure occurs correctly open the gas isolating valve and the fault indication will extinguish The boiler will commence its ignition sequence as previo...

Page 28: ...2 1 General Overview of Panel Fascia Figure 8 2 2 General Overview of Controls Limit Thermostat IEC Mains Outlet Socket Navistem Control Panel Ignition Transformer Navistem Controller Air Pressure Swi...

Page 29: ...on manual HHL part no 500001310 which is supplied with each boiler A concise user instructions guide HHL part no 500001309 is supplied with each boiler This guide gives instruction on initial set up a...

Page 30: ...NB THL1 THL1 A STOE SA F TNB TW1 STOE SA F TNB TW2 TVZ STOE SA F TNB STOE SA F TNB STOE TNB Duration 9500 9517 9519 9518 9519 9534 9540 9544 9540 9544 9652 120s 51s 51s 51s 51s 51s 51s 24h 51s 51s 51s...

Page 31: ...e with all modules firing For Natural Gas a nominal gas inlet pressure of 20mbar measured at the rear of the boiler is required with a maximum inlet pressure of 25mbar For LPG a nominal gas inlet pres...

Page 32: ...crease the CO2 level turn the adjustment clockwise Figure 8 6 5 Adjusting gas valve offset 97 116 147 97 116 147 196 254 196 254 If combustion is outside of the ranges defined below the factory sealed...

Page 33: ...eatedly occurs contact Hamworthy Heating for assistance Do not continue to operate or use the boiler as this may cause damage to the controls 9 1 Safety Temperature Limiter Limit Thermostat 1 The elec...

Page 34: ...HAMWORTHY HEATING LTD 28 Wessex ModuMax mk3 Boilers 500001308 C Figure 9 3 Wiring Diagram...

Page 35: ...h 6 Remove the air inlet filter cassette Refer to section 11 15 7 Remove the 2 M8 burner retaining nuts and carefully withdraw the complete burner fan assembly from the heat exchanger Separate the bur...

Page 36: ...bly without cutting it Remove the 6 M10 nuts that retain the heat exchanger into the boiler module casing and with the front end supported slowly withdraw the heat exchanger until the rear of the stai...

Page 37: ...rode A typical flame current is 10 A high fire with the lockout threshold at 3 A Disconnect the flame probe lead earth lead remove the single socket cap head screw securing the probe to the burner fla...

Page 38: ...to the burner and remove the fan Fit the replacement in reverse order and if required replace any seals or gaskets Note After re making any gas or combustion circuit joint connection an integrity chec...

Page 39: ...t the connector end of the clip in to allow the module to be hinged up and disengaged from the Navistem or control panel Assemble in reverse order 11 11 Display screen Part Number 533901691 Ensure tha...

Page 40: ...has been diagnosed Fig 11 14 In line Fuse 11 15 Air Inlet Filter Replacement Filter Material Part No 532812016 The ModuMax mk3 is fitted with an air inlet filter which is accessed after removing the...

Page 41: ...Probe 533805021 Clip in Module AGU2 511A109 533901776 Clip in Module LPB Bus communication OCI345 06 101 533901777 T1A Fuse 5x20 533922013 MECHANICAL ITEMS Burner Fabrication 97 116 533301019 Burner F...

Page 42: ...359 4 Boiler Output kW maximum condensing 50 30 C kW 116 2 116 2 232 5 232 5 348 7 348 7 Boiler Output kW maximum non condensing 80 60 C kW 115 2 115 2 230 4 230 4 345 6 345 6 Boiler Module Output min...

Page 43: ...0 87 4 At 30 nominal power and in 30 C return temperature regime P1 kW 29 1 36 0 44 1 58 8 76 2 N1 Gross 96 6 94 6 96 6 95 0 96 8 Auxiliary electricity consumption Under full load elmax kW 0 072 0 07...

Page 44: ...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 using the conduits supplied High and low voltage cables...

Page 45: ...electrical supply and control signals Signal cables must not be run in the same conduit as mains voltage cables Option 1 reference should be made to Building Regulations and CIBSE Guide Energy Effici...

Page 46: ...and discharge via horizontal vertical flue Fig C1 1 2 Type B23p Flue pressurised intake from ventilated plant room and discharge via horizontal vertical flue Fig C1 1 2 The connection to the boiler i...

Page 47: ...re condition at the connection to the boiler is 150Pa positive In the event that the flue system when Hot does generate a suction the maximum suction is 100Pa Fan Dilution The design must provide for...

Page 48: ...reezing of condense water traps and pipework This must be avoided at all times by routing pipework within the building where possible In addition to the above the stacked module arrangement flue boxes...

Page 49: ...ultiple Boiler Installations Adjustable Flashing 100 flue 100 flue Flat Roof Flashing Single Flue Single Flue 500 long 100 250 long 100 1000 long 100 Single Flue Vertical terminal 100 Flue 80 100 Ecce...

Page 50: ...ded or in any position adjacent to an extraction system which is carrying flammable vapour Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing t...

Page 51: ...ans D 1 4 Boiler House Temperatures The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows At floor level or 100mm above...

Page 52: ...ing and hot water system the hot water storage vessel must be of the indirect cylinder or calorifier type The hot water storage vessel should be insulated preferably with not less than 75mm 3 thick mi...

Page 53: ...itting of a safety valve not supplied BS 6644 provides comprehensive information for the selection and location of safety valves and attention is drawn to the higher capacity requirements of safety va...

Page 54: ...formance 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...

Page 55: ...be used 3 Maximum flow temperature C 4 Maximum system hot working pressure generally given in bar gauge From the parameters given Hamworthy Heating can size the pressurisation unit and also the expans...

Page 56: ...Wessex ModuMax mk3 Boilers 500001308 C Figure E 1 3 1 Schematic 1 External Time Clock Enabled Boiler Hydraulic Schemes For Single Boiler Installations Figure E 1 3 2 Schematic 2 Two Heating Circuits w...

Page 57: ...ModuMax mk3 Boilers 500001308 C Figure E 1 3 3 Schematic 3 Master and Slave Sequence Control With Reverse Return Primary Hydraulic Schemes For Multiple Boiler Installations Figure E 1 3 4 Schematic 4...

Page 58: ...5 Schematic 5 Primary Circuit With Individual Boiler Shunt Pumps Hydraulic Schemes Figure E 1 3 6 Schematic 6 Reverse Return Primary Circuit with Individual Motorised Boiler Isolation Note Motorised v...

Page 59: ...re E 1 3 7 Schematic 7 Single Pipe Primary Circuit Water meter Mains cold water Quick fill Safety valve Safety valve Safety valve Air separator Common flow sensor Primary Pump Dosing pot Low loss head...

Page 60: ...mpensation Legend E End user I Commissioning F Heating engineer Menu Operating Line User Level Function Setting LPB System 6600 F Device address 1 6630 F Cascade Master Automatically Heating Circuit 1...

Page 61: ...their parameter setting as heating cir cuits 1 2 have pre defined outputs for each extension module as shown in the table below Boiler Parameter Settings Single Boiler Note To check operation of pump...

Page 62: ...ade pump Q25 5931 F Sensor input BX2 Boiler 1 Master Common flow sensor B10 Boilers additional set to none 6117 F Central compensation set up Boilers all set to 5 6200 F Save sensors Boilers all set t...

Page 63: ...odulation 5955 F Voltage value 2 H1 10 0v 5956 F Function valve 2 H1 1000 1000 100 modulation 5890 F Relay output QX1 Boiler pump Q1 BMS 0 10v Temperature Menu Operating Line User Level Function Setti...

Page 64: ...4 5 ect 6601 F Segment address Boilers all set to 0 6640 F Clock mode Boilers all set to Slave with remote setting Configuration 5710 F Heating Circuit 1 Boilers all set to off 6200 F Save sensors Bo...

Page 65: ...HAMWORTHY HEATING LTD 59 Wessex ModuMax mk3 Boilers 500001308 C...

Page 66: ...HAMWORTHY HEATING LTD 60 Wessex ModuMax mk3 Boilers 500001308 C INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION...

Page 67: ......

Page 68: ...les Service McDowall Modular Services 2 Penson Road Queenslie Industrial Estate Glasgow G33 4AG tel 0141 336 8795 fax 0141 336 8954 email MMS McDowallModularServices hamworthy heating com North East E...

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