Table of Contents
Related Manuals for MHS Boilers Ultramax 73
Summary of Contents for MHS Boilers Ultramax 73
- Page 1 Ultramax Floor Standing 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.MHSBOILERS.COM L???
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Page 2: Table Of Contents
MHS Boilers Ltd © 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... - Page 3 MHS Boilers Ltd © 5.3.5.2 Chimney 5.3.6 Condensate discharge 5.4 Hydraulic system 5.4.1 General 5.4.2 Water flow 5.4.2.1 Flow rate and resistance 5.4.2.2 Pump characteristics 5.4.2.3 Isolating valves 5.4.2.4 Valves 5.4.2.5 Water flow protection 5.4.3 Water pressure 5.4.3.1 Operating pressure 5.4.3.2 Boiler expansion tank...
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Page 4: Ultramax Technical Data
MHS Boilers Ltd © Ultramax Technical Data. Type Nominal heat output Nominal heat input (nett. CV) Minimum heat input Gas consumption natural gas H ( 10.9 kWh/m 6.79 8.35 11.10 13.49 17.80 22.29 26.51 propane ( 12.8 kWh/kg kg/h 5.78 7.11... - Page 5 MHS Boilers Ltd © Type ⁄ " ⁄ " ⁄ " ⁄ " R 1" ⁄ " ⁄ " ⁄ " ⁄ " ⁄ " ⁄ " R 2" R 2" R 2" Conditions applicable to table above: - Nominal capacity measured at: 60 - 80°C.
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Page 6: Introduction
1.2 Supplier MHS Boilers Ltd are proud to supply and technically support the Ultramax Range of boilers throughout the United Kingdom. For advice or more information please contact your local sales representative or our head office via 01268 591010. -
Page 7: General Restrictions
(legal or otherwise), specifications and standards applicable to such installations. All data, information and suggestions provided by MHS Boilers Ltd. in relation to its products are based on careful investigation. Nevertheless, neither MHS Boilers Ltd. nor any other organisation connected with MHS Boilers Ltd. - Page 8 MHS Boilers Ltd © flow rate is ensured by the presence of an integral water flow switch. Application possibilities Because of its construction, the R300 unit is suitable for use in heating systems: - With a constant supply temperature - With a weather dependent heating demand...
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Page 9: Main Components
MHS Boilers Ltd © 2.2 Main components 1 Casing 17 Frame 2 Air pressure switch 18 Filling/drainage valve 3 Control panel 19 Return connection 4 Burner 20 Water flow switch 5 Combustion chamber 21 Water headers 6 First heat exchanger... -
Page 10: Description Of Principal Components
MHS Boilers Ltd © 2.2.1 Description of principal components The boiler is constructed from the following principal components: Fan [26] The DC fan, which is equipped with a speed feedback, draws in the combustion air and increases the air pressure. The speed feedback signal is relayed to the regulator, which adjusts the speed if need be. -
Page 11: Boiler Control
MHS Boilers Ltd © Frame [17] The frame is constructed from steel profile sections and is fitted with vibration absorbing adjusting feet [16]. Casing [1] The casing consists of easy-to-remove panels. Once the cover has been opened (using tools), all other panels can be removed without using tools. - Page 12 MHS Boilers Ltd © The appliance must be installed by a recognised installer in accordance with the applicable national and local regulations. The installation may only be used for heating systems up to a maximum water temperature of 90°C. It is expressly stated that these installation instructions must be seen as a supplement to the above mentioned standards and regulations and that these standards and regulations must take precedence over any information included in this technical manual.
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Page 13: Delivery And Transport
MHS Boilers Ltd © Installation The appliance must be installed by an authorised installer in accordance with the applicable national and local specifications and regulations. Carefully follow all the safety instructions. Operation In the event of a gas leak, switch off the unit and close the gas supply valve. Open doors and windows and warn the appropriate authorities. -
Page 14: Installation
The appliance must be installed by a recognised installer in accordance with the applicable national and local specifications and regulations. Commissioning should be carried out by the Technical Service Department of MHS Boilers Ltd, who can also determine the composition and quality of the system water. -
Page 15: Electrical Connection
MHS Boilers Ltd © national and local standards and regulations. The gas connection is made at the rear of the boiler. The pressure of the gas supplied to the unit must be reduced to 20 mbar for natural or 37 mbar for propane with the use of a gas pressure regulator. - Page 16 MHS Boilers Ltd © At the exits from the boiler room. In the event of a calamity, the power supply to the unit can be switched off. In order to prevent malfunctions occurring as a result of inductive or high frequency signals, or static electricity, screened cables must be employed for all low voltage and control signals between the boiler and externally connected units.
- Page 17 MHS Boilers Ltd © for each group (BM). The boiler is then directly weather-dependently controlled. KKM option This is a boiler cascade manager permitting up to eight boilers to be switched in cascade. The KKM also has the same possibilities as the E6 option.
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Page 18: Water Connections
MHS Boilers Ltd © Calorifier temperature sensor*. After a suitable sensor has been connected it will 35 - 36 be automatically recognised when the power supply voltage is switched on. The terminals 35 - 36 must not be interconnected. The purpose of this function, in comparison with the calorifier thermostat, is to make possible a night time temperature reduction and an anti-legionella switching (only with BME, E6 or KKM). -
Page 19: General
MHS Boilers Ltd © 5.3.4.1 General Guide lines and installation instructions The flue gas discharge and the air supply systems must be installed by a recognised installer in accordance with the applicable national regulations. The total resistance of the air supply and the flue should not result in a pressure drop exceeding 1.8 mbar (types 73 and 90) or 1.0 mbar (types 115 to 287). - Page 20 MHS Boilers Ltd © Table 4 Air supply connection The connection to the air supply pipe is always mounted on the back of the unit. Multiple units may not be connected to the same air supply or flue pipe. To prevent snow entering, the air supply pipe must extend at least 300 mm above the roof and must be fitted with a rain cap.
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Page 21: The Flue System
MHS Boilers Ltd © 5.3.5 The Flue system 5.3.5.1 General The flue system must be installed by a recognised installer in accordance with the applicable national regulations. The flue pipe connection is at the back of the appliance and has been designed for direct connection to a corrosion resisting flue pipe. - Page 22 MHS Boilers Ltd © The degree of cooling of the flue gasses depends on: a the insulation value of the chimney b the local ambient temperature c the discharge system. The flue connection diameters of the units have been chosen such that the speed of the flue gas will always be approximately 5 m/s.
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Page 23: Condensate Discharge
MHS Boilers Ltd © Elbow 90° Elbow 90° Elbow 45° 90°Tee Type Diameter in R/D =0.5 R/D = 1 R/D=0.5 100* 100* 130* 150* 180* 200* 10.1 200* 10.1 Table 7 Chimney losses in metres of straight pipe * Connection at boiler. -
Page 24: Hydraulic System
MHS Boilers Ltd © Fig. 8 Condensate discharge 5.4 Hydraulic system 5.4.1 General Although it is not the intention to provide a complete handbook covering the most divergent hydraulic systems, the data is more extensive than would generally be provided in the case of conventional central heating boilers. - Page 25 MHS Boilers Ltd © Table 8 Water flow rate and pump data * The maximum power consumption of the pump is given for pump speed 3. The optimum operating point in relation to efficiency and minimum power consumption can be determined from the related pump curve ** 3-phase pump available.
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Page 26: Pump Characteristics
MHS Boilers Ltd © 5.4.2.2 Pump characteristics 011204... - Page 27 MHS Boilers Ltd © Type Pump speed P max I 1 x 240 V UPS 25-80 0.63 73 and 90 0.92 1.04 UPS 32-80 1.05 115 and 146 0.95 1.05 UPS 32-120F* 1.55 192 to 287 1.65 1.75 Table 9a Electrical pump data * 3-phase pump optionally available for types 5 - 7.
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Page 28: Isolating Valves
MHS Boilers Ltd © 5.4.2.3 Isolating valves It is recommended that manual valves be fitted between the flow and return connections and the installation. 5.4.2.4 Valves Mechanical non-return valve can be used. This is required so as to avoid short-circuiting the appliance on the water side. -
Page 29: Water Quality
MHS Boilers Ltd © 5.4.5 Water quality The composition and quality of the system water has a direct influence on the performance of the whole system and the life of the appliance. Unsuitable addition and use of chemicals, water softeners, oxygen binders, de-aerators, aerators, and water filters all increase the possibility of faults. -
Page 30: Examples Of Hydraulic Systems
MHS Boilers Ltd © The chloride concentration must not exceed 200 mg/l. If this level is exceeded, the cause must be located. Compare the chloride concentration of the additional water with that of the system water. If this concentration is higher, this indicates evaporation if no chloride containing materials have been added. - Page 31 MHS Boilers Ltd © Example of a low velocity header with isolating valves and an expansion tank. Mounting the low velocity header vertically has additional advantages: the upper section functions as an air separator and the lower section serves as a dirt separator.
- Page 32 MHS Boilers Ltd © Installations with weather dependent regulation and hot water priority switching The small water capacity of the boiler and the fast, accurate boiler temperature regulation makes the Ultramax unit ideal for use as a boiler with hot water priority switching.
- Page 33 MHS Boilers Ltd © Fig. 14 Installation with multiple appliances Hydraulic short-circuit In order to avoid a short circuit over a non-operating appliance, we advise the use of 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...
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Page 34: Operating Instructions
MHS Boilers Ltd © 6 Operating instructions 6 .1 Function When a heating demand is received and before the boiler starts up, the appliance must be prepurged. The fan supplies combustion air and has a modulating control. A zero controller in the gas valve determines the required quantity of gas. - Page 35 MHS Boilers Ltd © 6 operation mode 2 optical I/O night time reduction (no heating demand) 3 reset/programming push-button heating mode (heating demand) 4 alarm LED (flashing) burning 5 parameter/value selector 6 output status 7 current/desired parameter value 8 fault/parameter indication...
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Page 36: Fault Indications
MHS Boilers Ltd © Input indications: - Flame Ionisation detected SW Water flow switch in operating position DW Air Pressure Switch in operating position RT Boiler enabled by BMS Bus Data-bus detected. Output indications: - Power to Main Gas Valve... - Page 37 MHS Boilers Ltd © minutes active. The boiler can be nevertheless in operation. The high limit thermostat has operated. The boiler temperature has exceeded 100°C. Press the reset button. The interlocking input has been interrupted. Correct the external error and press reset.
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Page 38: Start-Up
Commissioning must be carried out by skilled personnel. Failure to observe this condition will invalidate the guarantee. Commissioning of the unit by MHS Boilers Ltd will not only ensure optimum operation of the unit but will enhance the warranty enjoyed by the unit. -
Page 39: Commissioning
MHS Boilers Ltd © 7.2 Commissioning Water and the hydraulic system The system water circulating around the boiler must be treated with a suitable / proprietary scale and corrosion inhibitor. Failure to comply with these requirements will invalidate the appliance warranty. - Page 40 A differential manometer is required for this process. Burner pressure = pressure above burner – fan pressure Pbb – Pvent Ultramax 73 - 90 1.5 + 0.5 mbar Pvent – Pbb Ultramax 115 – 287 1.0 + 0.5 mbar...
- Page 41 Run the boiler at full load and check the CO value. Adjust if necessary using the flat screw (Ultramax 73 - 90) or the inbus screw (Ultramax 115 – 287.) Run the boiler at minimum load and check the CO value.
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Page 42: Maintenance
MHS Boilers Ltd © For example: Pre-purging takes place when the appliance is enabled. The same pressure sampling point are used for his adjustment as used hen undertaking the monitoring of the burner pressure. Burner pressure = pressure above burner – fan pressure = Pbb – Pvent Once this measurement has been obtained the pressure switch must be set to a maximum of 80% (x0.8) of this value. -
Page 43: Procedure
The nominal rectification current is between 10 and 25 μA. The minimum rectification current is 2.8 μA. 8.7 Service For service and maintenance the Technical Service Department of MHS Boilers Ltd can be contacted on 01268 591010. 011204... - Page 44 MHS Boilers Ltd © 011204...