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MHS Boilers Ultramax 115, Operating & Maintenance Manual, Page: 2 / 46

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MHS Boilers Ultramax 115 Operating & Maintenance Manual Download Page 2

MHS Boilers Ltd © 

011204 

2

 

Contents 

 
Ultramax Technical Data  

 

 

 

 

 

 

 

 

 
Ultramax Dimensions   

 

 

 

 

 

 

 

 

 
1 

Introduction 

 

          

1.1 General 
1.2 Supplier 
1.3 This document 
1.4 Service 
1.5 General restrictions   

 

 

 

 

 

 

 

 

 
2 Description 

2.1 General 
2.2 Main components    

 

 

 

 

 

 

 

 

2.2.1 Description of principal components  

 

 

 

 

 

 

2.3 Boiler control  

 

 

 

 

 

 

 

 

 

2.4 Safety aspects 
 

3 Safety 
 
4 

Delivery 

and 

transport 

 

        

4.1 Delivery 
4.2 Packaging 
4 .3 Transport 
 

5 Installation    

 

 

 

 

 

 

 

 

 

5.1 Regulations 
5.2 Boiler room 
5.2.1 General 
5.2.2 Set up 
5.2.3 Ventilation 
5 .3 Connections  

 

 

 

 

 

 

 

 

 

5.3.1 Gas connection 
5.3.2 Electrical connection 
5.3.3 Water connections  

 

 

 

 

 

 

 

 

5.3.4 Combustion air supply  

 

 

 

 

 

 

 

 

5.3.4.1 General 
5.3.4.2 Air supply pipe    

 

 

 

 

 

 

 

 

5.3.5 The Flue system    

 

 

 

 

 

 

 

 

5.3.5.1 General 

Summary of Contents for Ultramax 115

Page 1: ...nding Condensing Boiler Operating Maintenance Manual For Models 73 287 MHS Boilers Ltd 35 Nobel Square Burnt Mills Industrial Estate Basildon Essex SS13 1LT 01268 591010 Telephone 01268 728202 Fax WWW...

Page 2: ...iption of principal components 2 3 Boiler control 2 4 Safety aspects 3 Safety 4 Delivery and transport 4 1 Delivery 4 2 Packaging 4 3 Transport 5 Installation 5 1 Regulations 5 2 Boiler room 5 2 1 Gen...

Page 3: ...tank 5 4 3 3 System expansion tank 5 4 3 4 Water pressure protection 5 4 4 Water temperature 5 4 5 Water quality 5 4 6 Examples of hydraulic systems 6 Operating instructions 6 1 Function 6 2 Regulati...

Page 4: ...0 17 50 30 50 17 50 30 50 17 50 30 50 17 50 30 50 17 50 30 50 Water capacity Max working pressure dm3 bar 13 6 15 6 17 6 19 6 36 6 39 6 42 6 Flue connection Air supply D D1 mm mm 100 100 100 100 130 1...

Page 5: ...537 H3 mm 943 943 921 921 921 921 921 L mm 685 685 685 685 895 895 895 L1 mm 50 50 50 50 85 85 85 L2 mm 160 160 160 160 160 160 160 L3 mm 80 80 90 90 100 100 100 L4 mm 445 445 445 445 655 655 655 L5...

Page 6: ...ocumentation has been written to aid the following target groups the consulting engineer the heating installer the service engineer the user Because these target groups require mostly similar informat...

Page 7: ...s are standard supplied as a standard category B23 or a room sealed categories C53 C33 or C63 appliance Working principle and construction Air is blown into the appliance as required by a speed contro...

Page 8: ...of its construction the R300 unit is suitable for use in heating systems With a constant supply temperature With a weather dependent heating demand With low temperature condenser systems With optimis...

Page 9: ...6 First heat exchanger 22 Ignition transformer 7 Second heat exchanger 23 Connecting terminals 8 Third heat exchanger 24 Distribution plate 9 Condensate receptacle 25 Gas valve unit 10 Flue attenuato...

Page 10: ...er is constructed of laser welded stainless steel finned pipes The third heat exchanger is constructed of smooth stainless steel pipes The second and third heat exchanger transfer the heat from the co...

Page 11: ...the water temperature falls below the frost protection temperature After the unit has started up the PID controller sends a signal to the fan thus controlling the fan speed Depending on the quantity o...

Page 12: ...ivities disconnect the electrical power supply and close the gas supply valve After completing any maintenance or service activity check the whole installation As a supplement to the information provi...

Page 13: ...a plate for the correct boiler type and gas supply pressure 4 2 Packaging The unit is supplied in cardboard packaging on a pallet For transport consult the technical details for dimensions and weight...

Page 14: ...id any difficulties the following rules apply to the boiler room a Install the appliance in a frost proof room b Pay particular attention to the positioning of the appliance to ensure protection from...

Page 15: ...ance The electrical connections the handling brackets and the boiler pump relay are located underneath the cover on the right hand side of the boiler You can unlock the cover using a 4 mm socket wrenc...

Page 16: ...3 phase pump available as an option Pumps supplied by others Control and options The appliances are fitted with a proportional regulation system This can be made temperature dependent with the aid of...

Page 17: ...ing is removed if a fault has occurred more than 2 times within 6 minutes the fault code will appear in the display with a 3 or if a fault is longer than 6 minutes active 14 15 Control voltage for an...

Page 18: ...ppliance and is suitable only suitable for use with sealed pressurised systems providing the minimum pressure requirements as per table 10 The unit must be fitted with a boiler pump that guarantees th...

Page 19: ...115 to 287 Extreme care must be taken to limit the draught of the attached flue and air supply system to below 15Pa in all firing conditions 5 3 4 2 Air supply pipe The air supply pipe may be single w...

Page 20: ...d must be fitted with a rain cap The flue pipe opening must end at least 1000 mm above the roof assuming the roof to be flat Fig 6 Heights of air inlet and flue gas discharge The relative horizontal d...

Page 21: ...temperature at full capacity Flue gas quantity at full capacity Maximum permissible chimney resistance C m3 h kg s mbar 73 135 130 0 033 1 8 90 135 161 0 040 1 8 115 135 214 0 053 1 0 146 135 261 0 0...

Page 22: ...appliance flue connection of between 5 to 15 Pa Calculation of the diameter and length For calculating and checking the internal diameter of a flue system with mechanical discharge refer to the applic...

Page 23: ...ain If there is no direct connection to a drain present a water collection tank with a pump and a level switch may be used so that the condensate can be pumped into a drain The appliance is fitted wit...

Page 24: ...ceed 250 ppm with a supply temperature of 80 C see 5 4 5 Water quality 5 4 2 Water flow 5 4 2 1 Flow rate and resistance The rate of water flow through the appliance must never fall below the required...

Page 25: ...l is removed the pump will continue to run for several minutes This run on time is adjustable The standard time is two minutes When the system includes air heaters ventilation air treatment it is usua...

Page 26: ...MHS Boilers Ltd 011204 26 5 4 2 2 Pump characteristics...

Page 27: ...F 1 320 1 55 192 to 287 2 340 1 65 3 380 1 75 Table 9a Electrical pump data 3 phase pump optionally available for types 5 7 Type Pump speed P max I 1 x 240 V W A UPS 32 80B 1 145 1 05 73 to 146 2 220...

Page 28: ...be adjusted accordingly Minimum operating pressure Flow temperature in bar C 1 5 90 1 80 Table 10 minimum operating pressures at nominal flow rate 5 4 3 2 Boiler expansion tank If required It is poss...

Page 29: ...with a supply temperature of 80 C and T 20 K Before the water is topped up the hardness and the chloride content of the water must be determined During the construction of larger installations one of...

Page 30: ...osion producing particles must be removed with the aid of a well chosen and fitted filter system The analysis of system water and the cleaning of filters must form part of the periodic inspection proc...

Page 31: ...basis of the water flow through the secondary circuit Because the volume of the water in the secondary system is greater than that in the primary circuit boiler there will be a water circulation in th...

Page 32: ...mps on and off without the use of a building optimising system results in the temperature swings being too large and a boiler and pump that are switched too frequently This increases the chances of we...

Page 33: ...non return valves These may be either mechanically or electrically operated valves When two appliances are switched in cascade it is advisable to employ this system When appliances are controlled by a...

Page 34: ...mits for return water temperature If this temperature is low condensation will be formed which will then be removed via the drainage system 6 2 Regulation Depending on the heating demand the unit will...

Page 35: ...ct to a hot water demand service low capacity the boiler will run at low capacity adjusted by P17 service high capacity the boiler will run at full capacity adjusted by P19 Information mode With the c...

Page 36: ...ure has been reached Push the Reset Programming key the LED will go out Close the cover Setting the flow temperature for Domestic Hot Water cover open Open the lid Turn the rotational switch pos 5 clo...

Page 37: ...temp sensor is defective Correct fault 18 Header temp sensor is defective Correct fault 20 Error in the control of gas valve 1 After burner has stopped a flame has been detected for a period of 5 seco...

Page 38: ...nstalled by a recognised installer The operating instructions must be strictly observed If the source of the fault cannot be found the service organisation must be contacted Never repair the appliance...

Page 39: ...Operating pressures Check that there is a suitably sized by pass or a low velocity header fitted in the hydraulic system Check and bleed the pump Switch on the power supply to the boiler at the on of...

Page 40: ...alyser the combustion process must be adjusted to give the following readings Natural Gas G20 Propane G31 Butane G30 10 CO2 11 8 CO2 13 8 CO2 15 ppm CO 25 ppm CO 200 ppm CO Following the adjustment of...

Page 41: ...Natural Gas G20 Propane G31 Butane G30 9 2 CO2 11 0 CO2 13 0 CO2 15 ppm CO 25 ppm CO 180 ppm CO Following the adjustment of the combustion process to obtain the figures indicated above the burner pre...

Page 42: ...in respect of jewellery and loose clothing 8 2 General In order to ensure continued good and safe operation of the appliance this must be inspected at least once per year The following activities mus...

Page 43: ...Ensure that these are securely fastened and tighten the connection nuts if necessary Inspect the screws in the measuring nipples renew the measuring nipples if they have become damaged In order to mea...

Page 44: ...MHS Boilers Ltd 011204 44...

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