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MHS Boilers Ultramax WM 100, Operating & Maintenance Manual, Page: 2 / 50

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MHS Boilers Ultramax WM 100 Operating & Maintenance Manual Download Page 2

MHS Boilers Ltd © 

 

191007 

2

 

Contents 

 

Section 

 

Page # 

 

WM Technical data 

4 

 

WM Dimensions  

5 

1 

1 Introduction 

6 

1.1 

General 

6 

1.2 

The supplier 

6 

1.3 

This document 

6 

1.4 

Service  

 

7 

1.5 

General restrictions 

7 

2 

Description 

7 

2.1 

General 

7 

2.2 

Main components 

9 

2.21 

Case Removal 

9 

2.2.2 

Description of principal components 

10 

2.3 

Boiler control  

11 

2.4 

Safety aspects 

11 

3 

Safety 

12 

4 

Delivery and transport 

13 

4.1 

Delivery 

13 

4.2 

Packaging 

13 

4.3 

Transport 

13 

5 

Installation 

14 

5.1 

Regulations 

14 

5.2 

Installation area 

14 

5.2.1 

General 

14 

5.2.2 

Installation 

14 

5.2.3 

Ventilation 

14 

5.3 

Connections 

15 

5.3.1 

Gas connection 

15 

5.3.2 

Electrical connections 

15 

5.3.3 

Water connections 

26 

5.3.4 

Flue gas outlet and air inlet 

26 

5.3.4.1  Connection possibilities 

26 

5.3.4.2  Air inlet pipe 

27 

5.3.4.3  Flue gas outlet 

27 

5.3.4.4  Flue 

28 

5.3.5 

Condensate drain 

30 

5.4 

Hydraulic system 

30 

Summary of Contents for Ultramax WM 100

Page 1: ...ll Mounted Condensing Boiler Operating Maintenance Manual For Models 45 65 85 100 120 MHS Boilers Ltd 3 Juniper West Fenton Way Basildon Essex SS15 6SJ 01268 546700 Telephone 01268 888250 Fax WWW MHSBOILERS COM L282 ...

Page 2: ... 11 2 4 Safety aspects 11 3 Safety 12 4 Delivery and transport 13 4 1 Delivery 13 4 2 Packaging 13 4 3 Transport 13 5 Installation 14 5 1 Regulations 14 5 2 Installation area 14 5 2 1 General 14 5 2 2 Installation 14 5 2 3 Ventilation 14 5 3 Connections 15 5 3 1 Gas connection 15 5 3 2 Electrical connections 15 5 3 3 Water connections 26 5 3 4 Flue gas outlet and air inlet 26 5 3 4 1 Connection po...

Page 3: ... quality 33 6 Operating instructions 35 6 1 Operation 35 6 2 Controls 35 6 3 Boiler module KM628 35 6 4 Fault signals 37 6 5 Setting into operation 39 6 6 Switching off the appliance 39 6 7 Warnings 39 7 Commissioning 40 7 1 General 40 7 2 Commissioning 40 7 3 Fuel Conversion NG LPG LGP NG 42 8 Maintenance 42 8 1 Safety 42 8 2 General 42 8 3 Procedure 43 8 4 Cleaning the burner and the heat exchan...

Page 4: ... 30 50 30 50 30 50 30 50 Maximum water temperature of central C 90 90 90 90 90 heating system Maximum operating pressure bar 6 6 6 6 6 Water content litre 5 1 6 6 8 4 10 3 12 0 Water resistance T 20 C kPa 14 20 25 28 30 Excess head of the boiler pump T 20 C kPa 26 29 15 24 12 Connection for flue outlet D mm 80 80 100 100 100 Connection for air inlet D1 mm 80 80 100 100 100 Gas connection G R3 4 R3...

Page 5: ... 4 Rp 1 R 11 4 Rp 1 R 11 4 Rp 1 R 11 4 Rp 1 R 11 4 Rp 1 Table 2 We reserve the right to make changes without prior notification The data may deviate slightly due to fabrication tolerances Conditions applicable to table 1 Gas consumption at 1013 mbar 15 C dry Gas category 22H3P Category of appliance B23 C13 C33 C43 C53 C63 C83 Service Clearances Minimum Front Above Below Left hand Side Right hand S...

Page 6: ...t your local sales representative or our head office via 01268 546700 or via our website www mhsboilers com 1 3 This document The present documentation has been prepared with the following target groups in mind The technical consultant The installer The maintenance technician The user MHS Boilers Ltd has opted to make the technical documentation as comprehensive as possible in the form of this boo...

Page 7: ...s have low NOx and CO emission which satisfy the most stringent environmental requirements The WM series has received CE Approval for all relevant European countries and has been registered under the Product Identification Number 0063BO3192 The boilers may be used on both open category B23 as well as room sealed category C13 C33 C43 C53 C63 or C83 systems As standard the boiler is delivered fully ...

Page 8: ...r temperature can be achieved It can be used without any return temperature protection The installed pump provides the water flow rate required This pump has three stage modulation types 45 65 and 85 Application possibilities The design of the WM boiler makes it suitable for use in heating systems with constant flow temperature weather dependent set point adjustment Only in combination with an opt...

Page 9: ...20 Boiler pump types 100 120 External 10 Pressure Gauge 21 Control panel 11 Automatic boiler controller 2 2 1 Case Removal Models produced post 01 01 07 To remove the case panels use a flat bladed screwdriver to loosen the two brass screws located at the base of the front sliding panel With the screws hanging from the base of the front panel slide the front panel up and disengage it from the unit ...

Page 10: ...e The other part functions as a condenser for the flue gases where the transfer of latent heat takes place Stainless steel water distribution manifolds ensure optimum water flow through the heat exchanger Water connections These consist of a flow connection 4 and a return connection 7 There is a water temperature sensor 16 on the flow connection which apart from controlling the burner load also mo...

Page 11: ...ature is reached and kept at a constant level Depending on the quantity of air displaced by the fan a specific quantity of gas will be added As a result the boiler capacity can be modulated seamlessly and the heat requirement can be accurately monitored If the flow temperature rises above the desired level together with any hysteresis the boiler will switch off The boiler will start again as soon ...

Page 12: ...the boiler Keep a safe distance from the hot water connection and the flue due to the danger of burns Before starting with any maintenance and service work shut off the electrical supply and close the gas valve to isolate the gas supply Check the entire installation for leakages after completing maintenance and service work Casing parts may only be removed for maintenance and service purposes Afte...

Page 13: ...livered in suitable cardboard packaging The types 45 65 85 and 100 can be stacked two high It s not allowed to stack up the type 120 4 3 Transport Regarding transportation refer to the technical data for dimensions and weights The packing should only be removed after transportation or remove the panels before transportation This is in order to prevent the panels from getting damaged Moving Each bo...

Page 14: ...drain The built in protection system is activated when the temperature of the central heating water falls below 5 C Pay attention to the location and temperature sensitivity of the boiler Ensure that there is sufficient room around the boiler for maintenance and the replacement of components if necessary The recommended minimum clearance is as follows 1000 mm to the front free space for movement 4...

Page 15: ...d in the gas pipeline The gas filter can be ordered as an option to be supplied with the boiler Install a gas isolating valve directly under the appliance 5 3 2 Electrical connections The electrical connections should be installed by a recognised installer in accordance with applicable national and local standards and specifications The appliance is fully wired in accordance with the electrical di...

Page 16: ...peratures If the voltage falls below 1 volt the boiler reverts to the set point set on parameter P1 A hot water priority circuit also forms part of the standard equipment an additional sensor is required Other options available on the boiler can be supplied to extend this Ultramax WM Boiler Range 0 5 Control Signal Interpretation Constant Temperature zone Controller P1 Temperature Set Point The th...

Page 17: ...y of KM628 functions with display of status operating hours number of starts degree of modulation and temperatures BM8 Room Unit Room Unit Mounting Plate Wiring Terminals Terminal Designation When connected to a Single Ultramax Boiler 2 Wire SCOM Terminal s Voltage Screened Cable Earthed Screening Description Operation Function 3 5 Polarity Sensitive 25V Yes SCOM Communication to boiler 3 5 3 6 No...

Page 18: ...ather dependent control of the boiler is done indirectly by the E8 1121 There are the following additional features to the BM8 The maximum flow temperature can be set for each heating circuit The compensation slope can be manipulated with a parallel displacement to the desired flow temperature of the boiler Time controlled hot water Secondary pump Pump exercise function DCF receiver for internal c...

Page 19: ...Used With Ultramax Boilers IX 4 Polarity Sensitive 25V Yes Control Communication BM8 E8 COCO2 For Boiler Control IX 3 Polarity Sensitive 25V Yes Control Communication BM8 E8 COCO2 For Boiler Control IX 2 Polarity Sensitive 25V Yes L Control Communication BM8 E8 COCO2 For Boiler Control IX 1 Polarity Sensitive 25V Yes H Control Communication BM8 E8 COCO2 For Boiler Control III 3 2 25V Yes Heating Z...

Page 20: ...2 3 230V Permanent Live II 4 A1 230V Heating Zone 1 Pump 230V Output Max 1 Amp II 5 A2 230V Heating Zone 2 Pump 230V Output Max 1 Amp II 6 A3 230V Hot water Charging Pump 230V Output Max 1 Amp II 7 A4 230V Heating Zone 2 Mixing Valve 230V Open Output Max 0 5 Amp II 8 A5 230V Heating Zone 2 Mixing Valve 230V Close Output Max 0 5 Amp II 9 10 230V Do Not Use Volt Free Stage One Burner Enable VI 1 2 2...

Page 21: ... III 3 F17 1 F15 25V Yes 0 10 Volt Control Input 3 1 Parameter alteration Required III 2 3 F17 25V Yes Heating Zone 2 Volt Free Enable 3 2 Ground VIII 2 F14 1 F13 25V Yes Not Generally Used Solar Panel Sensors Multifunctional Relays 3 4 inputs V 2 F12 25V Yes Not Generally Used Solar Vessel Panel Sensors Multifunctional Relay 2 input V 1 F11 25V Yes Heating Zone 1 Flow Sensor VFAS Multifunctional ...

Page 22: ... 230V Heating Volt Free Enable Via Time Switch Room Thermostat BMS 3 1 230V Safety Interlock Volt Free Enable For use with ventilation interlocks gas pressure switch etc 2 230V Switched Neutral 1 230V Switched Live N 230V Permanent Neutral L1 230V Permanent Live Max 5 Amp E 230V Common Permanent Earth ST2 1 2 25V Yes Outside Air Sensor AFS Mounted on North Facing Wall BM8 Required to activate weat...

Page 23: ... Vdc it will change over to the internal set flow temperature set at P1 10 11 Connection terminals for the 2 wire bus signal scom bus Pay attention to the polarity namely terminal 10 is earth and 11 is positive ST 1 1 1 2 An OK appliance healthy signal is available at these terminals 240 Vac from external 1A NO This circuit will be interrupted if more than 2 identical faults occur within 6 minutes...

Page 24: ...tage Description Operation Function ST11 1 A1 230V Hot Water Charging Pump 230V Neutral Output Max 0 5 Amp ST11 2 A2 230V Hot Water Charging Pump 230V Live Output Max 0 5 Amp ST11 3 N A 230V Boiler Pump 230V Neutral Output Max 0 5 Amp Heating Pump Neutral Output Max 0 5 Amp ST11 4 COM 230V Boiler Pump 230V Live Output Max 0 5 Amp Heating Pump Live Output Via Relay Max 0 5 Amp N A NC 230V Heating P...

Page 25: ...r Boiler Run Indication Relays Normally Closed Terminal of Single Pole Double Throw Relay Switch Terminal Designation Boiler Fault Indication Relay Controller Terminal s Relay Terminal s Voltage Description Operation Function ST1 2 A1 230V Relay Coil Live Input From Terminal ST1 2 Located on the rear of KM628 boiler controller Terminal ST1 1 Located on the rear of KM628 boiler controller must conn...

Page 26: ...by switching off the boiler via the enabling control circuit 5 3 4 Flue gas outlet and air inlet 5 3 4 1 Connection possibilities During installation a choice can still be made between a room sealed and an open version The standard eccentric connection can also be easily changed into a concentric connection The flue gas discharge outlet and air intake system should be installed by a recognised ins...

Page 27: ...r inlet The connection for the air supply is on the top of the boiler The air supply pipe should be airtight This is to prevent the suction of false air Horizontal components in the air supply should be installed sloping in the direction of the supply opening Fresh air opening 5 3 4 3 Flue gas outlet The flue gas components may be single wall smooth Rigid or flexible and be made of plastic stainle...

Page 28: ...kg s mbar WM 45 70 74 0 020 1 4 WM 65 70 113 0 031 1 4 WM 85 70 149 0 041 1 4 WM 100 70 168 0 046 1 4 WM 120 70 209 0 058 2 0 Table 5 flue gas data Load 100 Flow temperature 80 C Return temperature 60 C 5 3 4 4 Flue Flue length Since the boiler is equipped with a premix burner with a fan an overpressure is created in the boiler This overpressure is sufficient to overcome the resistance of the burn...

Page 29: ...or room sealed appliances these lengths apply to inlets and outlets combined Flue losses of various flue components expressed in meters of straight pipe The total loss should be subtracted from the maximum permissible flue length from the previous table Type Diameter in mm Pipe bend 90 R D 0 5 Pipe bend 90 R D 1 Pipe bend 45 R D 0 5 T piece WM 45 70 80 3 5 4 0 1 1 1 2 1 1 1 2 4 0 4 0 WM 65 80 90 1...

Page 30: ...In view of the acidity only plastic drainpipes should be used Fill the bottle trap with water after installation the bottle trap beaker on the bottom of the boiler can be easily removed to do so Ensure that there is an open connection between the drain system and the boiler bottle trap It is not permissible for condensate to be drained into guttering since the condensate may freeze 5 4 Hydraulic s...

Page 31: ...0 TOP S 30 7 3 42 12 195 Table 9 Water flow quantity and pump data for the WM Maximum power consumed is given in pump position 3 WM 100 120 Wilo pumps type shown for guidance equivalent or better pump can be utilised When using another t you can use the following formula for calculating the flow rate and resistance of the boiler After this you have to check the available head of the pump The boile...

Page 32: ... between the flow and return connections to the installation 5 4 1 4 Valves It is possible to install mechanical non return valves These valves are intended to prevent waterside short circuiting over the switched off boiler 5 4 1 5 Water flow protection device The boiler is equipped with a water flow protection device The flow sensor and the flue gas sensor ensure that the protection device gets t...

Page 33: ...ion device Install a pressure relief safety valve within 0 5 m of the appliance in the pipe between the appliance and the shut off valves if any in accordance with BS6759 The size of this safety valve should sized in accordance with the kW rating and system pressure 5 4 3 Water temperature The maximum permissible water flow temperature is 90 C If the limit thermostat is triggered at 97 C the boile...

Page 34: ...he supply water and the central heating system water If this content is much higher and if no materials containing chloride have been added this indicates evaporation If the chloride content is very high the water is rendered more aggressive Can be caused by amongst other things improperly regenerated water softener The system should be flushed clean and filled with low chloride water In order to ...

Page 35: ...oad the boiler operates on off based on temperature 6 3 Boiler module KM628 Lid closed Lid open Fig 6 Boiler module 1 Function 1 Parameter indication standby P1 current setting boiler supply temp automatic operation P2 current setting domestic hot water summer operation temperature service operation P3 desired temperature 2 Function selector Rotational Selector P5 current external temperature 3 fa...

Page 36: ...t unit There are 10 possibilities An arrow at the bottom of the LCD display will indicate which parameter has been selected The following parameters are readable Parameter P1 actual setting flow temperature P2 actual setting direct hot water temperature if used P3 set point temperature P3 set load in comb with KKM8 E8 P5 actual outside temperature if used P8 temperature at the low velocity header ...

Page 37: ...LED will go out The new value will now be active Close the lid 6 4 Fault signals In the case of the fault a flashing and an error code will constantly appear in the display In the case of a fault the cause should first be eliminated before the relevant safeguard is reset The OK signal will be lost if a fault occurs more than twice within 6 minutes the error code will be shown in the display with a...

Page 38: ...lue sensor ST3 3 and 21 24 Flue sensor ST3 4 14 Defective hot water sensor The resistance value measured by the hot water sensor lies outside the range of 39 and 110 C Repair the fault and press reset No hot water sensor present and desired value of P2 Set above zero 15 Defective external sensor The resistance value measured by the external sensor lies outside the range of 39 and 110 C Repair the ...

Page 39: ...Also see the operating instructions on the boiler 6 6 Switching off the appliance The appliance can be switched off in three ways A The boiler remains available for hot water operation Using the rotary selector switch set the type of operation to B The boiler is out of operation and only comes into operation due to the automatic frost protection system Using the rotary selector switch set the type...

Page 40: ...y Check the spark gap of the ignition electrode 4mm to the earth rod and 5mm to the burner Check the gap of the rectification electrode 10mm to the burner Switch on the electrical power supply of the appliance Check the built in pump for free and correct rotation Start the boiler Check the boiler at full load Allow the boiler to run at full load and stabilise around 3 minutes At full load the foll...

Page 41: ... 120 This adjuster is a non dynamic restrictor gate and therefore should be adjusted as follows To increase the gas throughput turn the adjuster counter clockwise To decrease the gas throughput turn the adjuster clockwise The Low fire adjustment 1 is made via a 40 Torques bit on all appliances This adjuster is a dynamic governor and therefore should be adjusted as follows To increase the gas throu...

Page 42: ...ns should be carried out for a more extensive description of these operations see 8 3 Replace the ignition and ionisation electrodes Clean the fan impeller Clean the primary heat exchanger with MHS Boilers Ltd WM heat exchanger cleaning granules Using only a natural bristle brush only Clean the burner assembly with compressed air only Do not brush the knitted material Clean the boiler condensate b...

Page 43: ...In the case of heavy contamination replace the filter Install the filter and tighten the cover in place Check for leakages Check the combustion Calibrated measuring equipment should be used to carry out gas air and flue gas measurements 8 4 Cleaning the burner and the heat exchanger Remove the burner door assembly to gain access to the primary heat exchanger Using a natural bristle brush remove th...

Page 44: ...ically from a terminal on the same wall 1500 1500 L Horizontally from a terminal on the same wall 300 600 M Above an opening window etc 500 600 N Horizontally to an opening window etc 300 600 P Above a level roof base of terminal 500 500 Q From an adjacent wall edge of terminal 500 500 R From adjacent opening window etc 1000 1000 S From any other flue terminal 600 600 Positions not recommended Gro...

Page 45: ...t 8 Gas Valve 1 Amp Control Fuse WM 120 Only 9 CXE Control Module 19 Boiler Power Isolator 21 DHW Sensor 22 Outside Air Sensor 23 Flue Gas Sensor 24 Boiler Flow Sensor 28 K1 K2 Relays Internal Control Interlocks 29 K4 K5 Relays Gas Valve Control Relays WM 120 Only 73 Combustion Fan Control Voltage Resistors 78 Combustion Fan 80 Boiler Pump Internal WM 45 85 External WM 100 120 93 Control System Tr...

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