Hamworthy Wessex ModuMax mk3 WM97/97H Installation, Commissioning And Servicing Instructions
  1. Manuals
  2. Brands
  3. Hamworthy Manuals
  4. Boiler
  5. Wessex ModuMax mk3 WM97/97H
  6. Installation, commissioning and servicing instructions

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

Condensing fully modulating, pre-mix, gas fired, modular boilers for heating and domestic hot water installations, natural gas i2h, lpg propane i3p
Hide thumbs
Table of Contents

Advertisement

Quick Links

Max
Wessex Modu
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 I
2H
LPG Propane I
3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Wessex ModuMax mk3 WM97/97H and is the answer not in the manual?

Questions and answers

Related Manuals for Hamworthy Wessex ModuMax mk3 WM97/97H

Summary of Contents for Hamworthy Wessex ModuMax mk3 WM97/97H

  • Page 1 Wessex Modu 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 I LPG Propane I IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT...
  • Page 2 Site Assembly Hamworthy offer a service of site assembly for many of our products where plant room access is restricted. Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
  • Page 3 TO FIRING THE BOILER. COUNTRY OF DESTINATION : UNITED KINGDOM & REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. PRODUCT IDENTIFICATION No. 86CP58 PUBLICATION NO. 500001308 ISSUE ‘C’ May 2017 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 4: Table Of Contents

    Venturi 11.7 Burner 11.8 Ignition Transformer 11.9 Ignition Controller - LMS 11.10 Clip in Modules 11.11 Screen Display 11.12 Low Gas Pressure Switch 11.13 Air Pressure Switch 11.14 Ignition Transformer In-line Fuse HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 5 Wiring Diagram ........................28 Figure 10.2 Hot Surface Ignitor and Flame Probe Positions ..............30 Figure 11.4 Ignition Transformer In-line Fuse ..................34 Figure 11.4 Air Inlet Filter ......................... 34 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 6 Hydraulic Schematic 1 ......................50 Figure E1.3.2 Hydraulic Schematic 2 ......................51 Figure E1.3.3 Hydraulic Schematic 3 ......................52 Figure E1.3.4 Hydraulic Schematic 4 ......................53 Figure E1.3.5 Hydraulic Schematic 5 ......................54 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 7: Introduction

    1.4.2 Consideration should also be given to the maximum working pressure of the boiler as given in Appendix ’E’. Consult Hamworthy Heating Technical Department for help or assistance if in doubt. 1.5 The Wessex ModuMax boiler is not suitable for direct connection to domestic hot water supplies.
  • Page 8 BOILER VARIATIONS Wessex ModuMax mk3 WM97/97H - Single 97 kW unit Wessex ModuMax mk3 WM97/194V - Single 194 kW unit.( created by stacking 2 – 97 kW modules vertically ). Wessex ModuMax mk3 WM97/291V - Single 291 kW unit.( created by stacking 3 – 97 kW modules vertically ).

  • Page 9: Supply And Delivery

    Single Wessex ModuMax boilers do not have an additional flue collector manifold. NOTE: Care must be taken as impacts will cause damage to the flue collector manifold. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 10 If any item is missing please contact our after sales service team. Please provide details of your order number and contract number as well as a detailed description of the missing item. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers...
  • Page 11 Wessex ModuMax 97/291, 1200mm 800mm 2040mm 160kg 116/348. Wessex ModuMax 147/294, 1200mm 800mm 1520mm 192kg 196/392, 254/508 Wessex ModuMax 147/441 1200mm 800mm 2060mm 233kg 196/588, 254/762. Figure 2.2 - Header Kit Packaged Dimensions HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 12: Size And Space Requirements

    O 100 FLUE NOT SUPPLIED SOCKET G 1 1/2" MALE - FLOW G 1 1/2" MALE - RETURN O 32 CONDENSE DRAIN (1 PER MODULE) 415 CONDENSE 836.3 477 RETURN 204.9 CONDENSE HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 13 O 150 FLUE NOT SUPPLIED SOCKET G 2 1/2" MALE - FLOW G 2 1/2" MALE - RETURN O 32 CONDENSE DRAIN (1 PER MODULE) 415 CONDENSE 1082 477 RETURN 205 CONDENSE HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 14 3.2.1 The Hamworthy Heating Ltd water manifold kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections. There are two kits specific to individual models. (Refer to the Installer’s Guide 500005117 for specific details on the manifold kit.
  • Page 15 3.2.2 The Hamworthy Heating Ltd water manifold kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections. There are two kits specific to individual models. (Refer to the Installer’s Guide 500005119 for specific details on the manifold kit.

  • Page 16: Site Location And Preparation

    Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit. Gas Connection with inlet pressure test point. Rp 1” (97 & 116) & Rp 1- (147/196/254) 1/4” Figure 4.2 – Gas Connection Point HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 17: Flueing

    If in doubt, refer to HHL Technical. Fan assist - the use of fan assist is not recommended as the boilers have sufficient • fan performance to drive the system. If in doubt, refer to HHL Technical. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 18: Water Supply

    • Maximum working water pressure is 10bar (1000 kPa). • For minimum water pressure see Appendix ‘E’ - Water Data Flue connection Water Connection Figure 4.4 – Water & Flue Connection Points HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 19: Condensate Connections

    Provision must be made for removal of condensate from the boiler and flue system. • Condense is mildly acidic, typically pH3 - pH5. • Condense pipework must be non-corrosive and not copper. Hamworthy recommend • 32mm dia. Plastic waste pipe. Typical volume of condensate produced is 15l/h per 100kW Condense may be discharged to a standard drain subject to National or Local •...

  • Page 20: Electrical Supply

    NOTE: The appliance must be isolated from the electrical supply if electric arc welding is carried out on connecting pipework. FOR DETAILED WIRING INSTRUCTIONS SEE SECTION 5.4 & 9.3 Figure 4.6 - Navistem Electrical Connections HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 21: Boiler Assembly

    3 high, adjacent to each other, it is advisable to fit Closing plate with condense discharge the water and flue connections to each individual bank prior to fitting the connections to the adjacent bank(s). Figure 5.2 - Flue Collector Box Assembly HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 22: Water Connections

    Return G1½” Male thread (97 & 116) Return G2½” Male thread (147/196/254). Indicated by a blue dot on boiler. Condense 32mm dia. Male plain. Offset and below return connection. Figure 5.3.1 - Rear Water Connections HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 23: Electrical Connections

    Boilers must not be capable of isolation from the safety valve. Valves between boiler and safety valve to be three way type such that when boiler is isolated from the safety valve it is open to atmosphere. Hamworthy Heating Ltd recommend using the safety valve connection provided on the boiler.

  • Page 24: Flue

    NOTE: When testing 2 or 3 high stacked appliances the test detailed below must be carried out on each module. Figure 7.1 - Gas System Leak Check Diagram HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 25 7. Ensure the heating system circulation / shunt pump is operational and that the pipework is free of air. 8. The flame ionisation signal generated whilst the boiler is firing, can be viewed directly from the display screen. The value is set to read dc μA. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 26 LONG HAIR TO BE DRAWN INTO THE VENTURI / FAN. Venturi Valve Air inlet Filter Figure 7.2.3 - Hot Surface Igniter Check (196/ 254 shown with air filter removed) Flame Signal Assessment HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 27: Initial Lighting

    DURING WHICH THE ABOVE PROCEDURES WILL BE REPEATED. AT THE END OF THE RESTART PROCEDURE, IF NO FLAME IS DETECTED AFTER THE FLAME PROVING PERIOD, THE BOILER WILL LOCKOUT. THE BOILER WILL NOT OPERATE UNTIL THE LOCKOUT HAS BEEN MANUALLY RESET. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 28 Figure 8.2.1 - General Overview of Panel Fascia Limit Thermostat Navistem Controller Navistem Control Cable Strain Panel Relief Fuse IEC Mains Outlet Socket Air Pressure Switch Ignition Transformer Figure 8.2.2 - General Overview of Controls HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 29: Controls Operation

    Note: Should remedial work be carried out on a module, then the non-firing module must be electrically isolated so as to prevent accidental operation in the event that the installation is required for ongoing heating requirements. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers...

  • Page 30: Operating Phases

    Figure 8.3.1 - Operating phases HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 31: Ignition Controller Check

    NOTE: THIS DISTANCE MUST BE SET TO ENSURE ACCURATE ANALYSIS OF FLUE GASES. Figure 8.6.2 - Combustion Analyser Probe Setting 4. Insert probe horizontally into combustion chamber until depth stop is met. Figure 8.6.3 - Insertion of Analyser Probe HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 32 Torx Bit to make adjustments To increase the CO level, turn the adjustment clockwise. Figure 8.6.5—Adjusting gas valve offset (Note: Above readings taken with front cover removed and 200mm probe insertion CO = < 60 ppm*). HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 33: User Instructions

    Engineer. Should a fault code appear which cannot be reset, or a fault code repeatedly occurs, contact Hamworthy Heating for assistance. Do not continue to operate or use the boiler as this may cause damage to the controls.

  • Page 34: Wiring Diagram

    Figure 9.3- Wiring Diagram HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 35: Servicing

    See Figure 10.2. 10.1 Regular servicing is recommended, preferably Note:- The H.S.I. element is very fragile. by a Hamworthy appointed person, and at least annually, to ensure trouble free operation. 9) Check the burner and clean using a soft brush if...
  • Page 36 Re-assemble the baffle plates by fitting one of the stainless steel springs and inserting the baffles beneath Remove the 6 M10 nuts that retain the heat exchanger it, then fitting the second spring. When all the baffles are HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 37: Replacement Of Failed Components

    Please Unplug the igniter from the harness, remove the single refer to Hamworthy Heating Technical Department socket cap head screw securing the igniter to the burner before attempting to remove components from the gas flange and withdraw the igniter.

  • Page 38: Combustion Fan

    Note:- After re-making any gas or combustion circuit Ensure that the boiler module electrical power supply is joint/connection, an integrity check is recommended to isolated before removing the front cover and gaining ensure safety. access to the controls. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 39: Clip In Modules

    Navistem or control panel. Assemble in reverse order. 11.11 Display screen Part Number 533901691 Ensure that the boiler module electrical power supply is isolated before removing the front cover and gaining access to the controls. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 40: Ignition Transformer In-Line Fuse

    LMS malfunction has been intervals by ordering the part number above available diagnosed. from Hamworthy Heating Ltd spares department. Remove the retaining pin from the top corner of the filter and replace with the new, clean material. Re- place the retaining pin.

  • Page 41: Recommended Spares

    Gasket—View port ................................531201066 View Port Sight Glass ................................ 539907001 Air Filter Media ..................................532812016 For service or spares please contact :- ..............................Hamworthy Heating Limited Phone Number.................. 01202 662500 Wessex House Fax Number ..................01202 662522 New Fields Business Park Service ....................
  • Page 42 % at High / Low fire LPG ±0.25% 34.3 37.7 39.9 38.8 emission at 0% O (dry) Nat Gas mg/kWh 39.8 58.1 69.3 68.6 39.9 42.0 emission at 0% O (dry) LPG mg/kWh HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 43 0.043 0.043 0.045 0.151 0.151 In standby mode PSB kW 0.005 0.005 0.005 0.005 0.005 Other properties Heat Loss Pstby kW 0.19 0.19 0.22 0.22 0.22 Nitrogen oxide emissions Nox (Gross) mg/kWh HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 44: Electrical Connections

    NOTE: FOR ELECTRICAL CONNECTIONS TO BOILER SEE FIGURE 4.6 FOR BOILER WIRING SCHEMATIC SEE FIGURE 9.3.2 FOR MULTIPLE BOILER WIRING SEE FIGURE B1.2 FOR CONTROL WIRING SEE FIGURE E1.3.1 TO E1.3.3 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 45: External Control Wiring For Multiple Module Installations

    All modules must be sequenced. Enable - will give On/Off control of the modules 0~10V - will give modulation control of each module Option 2 provides modulation control of up to 16 modules. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 46: Flue Data

    Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who working in partnership with Midtherm Engineering Ltd can provide a comprehensive flue design and installation package.
  • Page 47 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 passes through such material with a non-combustible sleeve when the air gap may not be less than 25mm. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 48 Check that the flue and chimney are clear from any obstruction. Wessex ModuMax boilers are suitable for installation in a balanced compartment in accordance with the requirements of BS 6644. Consult Hamworthy Heating Technical Department for help or assistance if in doubt. C1.9. Condensate Discharge Due to the high thermal efficiency of the boiler, Figure C1.1.1 Flue Resistance...

  • Page 49: Open Natural Draught (B23/B23P) Flue System

    250 long Ø100 Single Flue 500 long Ø100 90° Bend Ø100 1000 long Single Flue 1000 long Ø100 45° Bend Ø100 1000 long Wall Clamp Ø100 Modular header or existing flue system if suitable HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 50: Ventilation

    Ventilation to a room or internal space - 10cm² per kW of total rated input (Net) Ventilation direct to outside - 5cm² per kW of total rated input (Net) HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 51 The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 52: Water Data

    ‘single pipe header system’. Figure E1.1.1 on the following page show typical layouts. 5)Ideally, individual valves should be fitted to each module to enable isolation from the system, however, the arrangement must comply with the requirements of BS 6644. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...

  • Page 53: Typical Piping Layout

    Module Circulation pump Heating load (System) Hamworthy Modular Boilers Feed pipe Valve Circulation pump Drain (Primary loop) valve VENTED SYSTEM: Primary loop, Hamworthy recommended system. Pressure & Mains water Automatic Drain Temperature Air Vent gauges Automatic Safety Air Vent valve...
  • Page 54 E1.7 Drain Valves Each boiler should have a 15mm NB drain valve (not Hamworthy Heating Ltd supply) fitted in the boiler return to drain the boiler only. The heating system in total should have drain valves as recommended by BS 6644. See Figure E1.1.1 for typical position.
  • Page 55 Maximum flow temperature (°C) Maximum system hot working pressure, generally given in bar gauge. From the parameters 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.
  • Page 56 Hydraulic Schemes: For Single Boiler Installations Figure E 1.3.1 - Schematic 1 - External Time Clock Enabled Boiler Figure E 1.3.2 - Schematic 2 - Two Heating Circuits with DHW & Boiler Shunt Pump HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 57 Hydraulic Schemes: For Multiple Boiler Installations Figure E 1.3.3 - Schematic 3 - Master and Slave Sequence Control With Reverse Return Primary Figure E 1.3.4 - Schematic 4 - Reverse Return Primary Circuit HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 58 Figure E 1.3.5 - Schematic 5 - Primary Circuit With Individual Boiler Shunt Pumps Figure E 1.3.6 - Schematic 6 - Reverse Return Primary Circuit with Individual Motorised Boiler Isolation Note: Motorised valves can be either power open/power close or power open/spring return close. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 59 Pressurisation Unit Boiler 1 Boiler 2 Boiler 3 Expansion vessel Water Quick fill meter Mains cold Air & dirt water separator Figure E 1.3.7 - Schematic 7 - Single Pipe Primary Circuit HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 60 Optional extras required for this configuration: External air sensor – QAC34 Part number 533901457 Room sensor choice – QAA55—Offset adjustable room sensor Part number 533901589 – QAA75—Programmable room sensor Part number 533901587 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 61 QX23—Switched live—Heating circuit pump (Contactor required for pump) BX21—Flow temperature sensor—Heating circuit H2—Heating circuit room thermostat—Basic type no/nc switch vfc (Only use if optional room sensor QAA55 or QAA75 are not specified) HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 62 Heating mode Auto symbol Hot water mode Optional extras required for this configuration: Heating sensor kit – QA236 Part number 563605674 LPB bus communication module OCI345—one per boiler module Part number 563605667 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 63 Function valve 2 H1 800 (800 = 80°C) 5890 Relay output QX1 Boiler pump Q1 Note: Use H1 wiring connection for 0-10V analog input from B.M.S. Optional extras required for this configuration: None HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 64 LPB bus communication module OCI345—one per boiler module Part number 563605667 Note: 2x LPB bus communications modules are supplied with each Merley boiler sequence controller, therefore addi- tional modules are only required for boiler module 3 upwards. HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 65 HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 66 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD Wessex ModuMax mk3 Boilers 500001308/C...
  • Page 68 Wessex House, New Fields Business Park, Stinsford Road, Poole, Dorset, BH17 0NF Telephone: 01202 662500 Fax: 01202 662522 Email: service@hamworthy-heating.com Website: www.hamworthy-heating.com Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

This manual is also suitable for:

Wessex modumax mk3 wm97/194vWessex modumax mk3 wm116/348vWessex modumax mk3 wm97/291vWessex modumax mk3 wm116/116hWessex modumax mk3 wm147/147hWessex modumax mk3 wm147/441v ... Show all

Table of Contents