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Commissioning

MAXXflo EVO

5.2.4 HEAT ENGINE COMMISSIONING COMPLETION

• Refit fan PWM connector onto the top heat exchanger, then press the RESET toggle switch for 1 second

to clear the control lockout.

• Once the lockout has been cleared from the display (bell symbol is not being displayed) close the door of

the heater and secure it with the two door clips.

•

urn the operation switch to ON or “I” and wait for both heat engines to ignite and operate at maximum

output.

• Keep the DHW tank temperature below 40

C (by opening water outlets). Check the total gas

consumption figure using the following table:

• The gas consumption must be within 5% of the gross kW input value of the data plate

• Turn off all taps and water draw offs.

• Change the DHW Set-point to back to 60

C to 65

C as required by the user

• Heat engine commissioning is complete

G20 GAS (38.8 MJ/m

)

Metric meter

Model

gross kW

input

Time taken to consume

0.1m

of gas

MAXXflo EVO 90

93.2

40s (+/- 2.0s)

MAXXflo EVO 120

124.3

30s (+/- 1.5s)

Содержание MAXXflo EVO CWH 90/302

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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