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Hamworthy Wessex Modumax 100 series Installation, Comissioning And Servicing Instructions

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Wessex ModuMax
100 Series Boilers
Non Condensing & Condensing
Fully Modulating, Pre-Mix, Gas Fired, Modular
Boilers for Heating and Domestic Hot Water
Installations
Installation, Commissioning
and Servicing Instructions
I
2H
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Summary of Contents for Hamworthy Wessex Modumax 100 series

  • Page 1 Wessex ModuMax 100 Series Boilers Non Condensing & Condensing Fully Modulating, Pre-Mix, Gas Fired, Modular Boilers for Heating and Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions NATURAL GAS IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT...
  • Page 2 01202 662555 Hamworthy offer a service of site assembly for many of our products in instances where plant room area 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 ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER. THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. PRODUCT IDENTIFICATION No. 87BQ008 PUBLICATION NO. 500001123 ISSUE ‘C’ OCTOBER 2005 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 4: Table Of Contents

    Ignition Controller Check Gas Supply Pressure Check Combustion Checks User Instructions FAULT FINDING ..........................33 Temperature Limit Thermostat Ignition Controller 10.0 SERVICING ............................. 35 10.1 Regular Servicing 10.2 Annual Service 10.3 Four Year Service HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 5 Altitude Gauge (Water Pressure Gauge) E1.6 Thermometer E1.7 Drain Valves E1.8 Circulating Pump E1.9 Minimum Water Flow Rates E1.10 Waterside Pressure Drop E1.11 Water Flow Controls E1.12 Frost Protection E1.13 Unvented Systems HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 6 Figure D1 Mechanical Ventilation Flow Rates Chart ................48 Figure E1 Water Data ........................... 49 Figure E1.3 Cold Feed and Vent Pipe Sizes Chart .................. 49 Figure E1.1.1 Typical Piping Layouts ......................50 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 7 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. HAMWORTHY HEATING LTD...
  • Page 8 The boiler must be kept upright during handling. Care must be exercised to avoid toppling the boiler as this will result in damage. Figure 2.2 - Boiler Positioning HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 9 Weight Wessex ModuMax 850mm 830mm 900mm 120Kg 110/220 120/240c Wessex ModuMax 850mm 830mm 900mm 160kg 110/330 120/360c Figure 2.4 - Reverse Header Kit (as supplied) Figure 2.5 - Header Kit Packaged Dimensions HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 10 3.0 SIZE AND SPACE REQUIREMENTS 3.1 The Wessex ModuMax 100 Series boiler range has been designed to utilise minimum floor space by stacking boiler modules, therefore it is important the plantroom has sufficient ceiling height to allow for installation and connection to the flue system.
  • Page 11 3.0 SIZE AND SPACE REQUIREMENTS 3.2 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. (Refer to the Installer’s Guide 500005117 for specific details on the manifold kit.)

  • Page 12: Site Location

    • Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit. Rp 1” Gas Connection Figure 4.2 – Gas Connection Point HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 13: Flueing

    The Wessex ModuMax 110/120 can be installed as a room sealed boiler using the flue • components supplied by Hamworthy Heating - refer to Appendix C for installation details. Wessex ModuMax 2 and 3 high stacked models must use the headers provided with the •...

  • Page 14: Water Supply

    Leaks in the system pipework should be fixed to prevent dilution of water treatment. • Maximum working water pressure is 10bar. • For minimum water pressure see Appendix ‘E’ - Water Data Water Connection Figure 4.4 – Water Connection Point HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 15: 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. Condense may be discharged to a standard drain subject to National or Local •...

  • Page 16: 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 5.3 & 9.3 Figure 4.6 - Siemens Electrical Connections HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 17: Flue Collector Box Assembly

    Return G1½” Male thread. Indicated by a blue dot on boiler. Gas R1” Male thread. Condense 32mm dia. Male plain. Offset and below return connection. Figure 5.2.1 - Rear Water Connections HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 18: 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 vent pipe it is open to atmosphere. Hamworthy Heating Ltd recommend using the safety valve connection provided on the boiler.

  • Page 19: Gas Supply

    6.3 Pipework, Valves and Pump Ensure that; • Pipework and valve arrangement is installed to Hamworthy Heating recommendations. • Circulating system is full of water, vented and pressurised appropriately. • Circulation pump is fitted, working and interlocked where required.
  • Page 20 4) System may be considered sound if over a period of 2 minutes any drop in pressure is less than 0.5 mbar (0.2" wg.). Note:- Allow a manometer stabilisation period of approximately 1 minute before each 2 minute check period. Following soundness tests close valve B and remove manometer connections and tighten test points. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 21: Controls Operation

    The control thermostat is set using the display screen and buttons as detailed in section 8.2.6 - Controls Operation. Instrument Outlet Temperature Limiter / Reset Switch Fuse Holder Figure 7.2.2 - Boiler Controls Label HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 22 2 way connector. The reading should be between 70 and 110 ohms. Figure 7.2.4 - Ignition Check HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 23 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 100 SERIES 500001123/C...
  • Page 24 Air Pressure Switch Limit Thermostat LMU Control IEC Mains Outlet Socket Filter Clip in Module Vfc / 0~10v Display Screen Ignition Transformer 230v Mains Supply Keypad Figure 8.1.6 - General Overview of LMU HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 25 OCI /ACS Clip-in Auxiliary mod ules Service Tool 0.. 10 V 4.. 20 mA Figure 8.2 - System configuration of boiler control (LMU) & system peripherals Figure 8.2.1.1 - Fascia Label Legend HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 26 Adjustment of dhw temperature setpoint - not used Line selection (down / up) Selection of operating parameter Adjustment of settings Adjustment of parameter settings Information Select information display screens Enable Maintenance mode Press buttons simultaneously to select HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 27 Press Info button Press buttons for at least 3 seconds Press button twice Choose the relevant parameter with buttons Note after about 8 minutes, the display will automatically change to the default display. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 28 Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 29 Operating mode is, or changes to: Automatic Continuous ‘Normal’ operation Continuous ‘Reduced’ operation Standby Operating mode of dhw. On or Off - not used Time bar Display of time program of heating circuit HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 30 3 seconds. The internal error code will be displayed. Example “4975” Press the info button to return to the info display. Press to return to the default display. Figure 8.2.3.2 - Display of Status Code HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 31 The room temperature setpoint or boiler temperature setpoint will be changed depending on the plant’s configuration ( with or without outside sensor). If no button is pressed for about 8 minutes, the screen will automatically return to the default display. Changes will be stored. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 32 Time program HC1 switch-off time 2 period 00:00...24:00 hh:mm 10 min 24:00 Time program HC1 switch-on time 3 period 00:00...24:00 hh:mm 10 min 24:00 Time program HC1 switch-off time 3 period 00:00...24:00 hh:mm 10 min 24:00 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 33 - see figure 8.2.9 The operating modes are selected by pressing button On the LCD, a pointer below the respective symbol points to the selected heating circuit operating mode. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 34 Chimney sweep function active Special functions are active Controller stop function active Special functions are active Calibration during optimization of combustion active Special functions are active LMU... in parameter setting mode Special functions are active HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 35 PH_TN_2 Home run PH_TNB PH_TLO PH_TNN Lockout position (display of the current PH_STOER error code) Note: -If operating phases are passed very quickly or skipped, the relevant display code will not appear. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 36 Figure 8.2.11 - Operating phases HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 37: Ignition Controller Check

    NOTE: THIS DISTANCE MUST BE SET TO ENSURE ACCURATE ANALYSIS OF FLUE GASES. Figure 8.5.3 - Combustion Analyser Probe Setting 4. Insert probe horizontally into combustion chamber until depth stop is met. Figure 8.5.4 - Insertion of Analyser Probe HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 38: User Instructions

    CONTACT HAMWORTHY HEATING TECHNICAL DEPARTMENT FOR FURTHER DETAILS 7. Shut down the boiler and isolate from the electrical supply. Remove all instrumentation and replace any test points and plugs.

  • Page 39: Temperature Limit Thermostat

    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 40 Figure 9.3.2 - Wiring Diagram HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...

  • Page 41: Regular Servicing

    10.1 Regular servicing is recommended, preferably 8) Check the burner and clean using a soft brush if by a Hamworthy appointed person, and at least required (if possible use compressed air to blow out the annually, to ensure trouble free operation.
  • Page 42 With the stainless steel springs and inserting the baffles beneath rear of the heat exchanger resting in the body of the it, then fitting the second spring. Remove the existing HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 43 11.1 Hot Surface Igniter and Flame Probe Assembly ensure safe, reliable operation of the boiler. Please refer to Hamworthy Heating Technical Department Part Nos. 563801019 & 533805019 before attempting to remove components from the gas Note:- The igniter and flame probe ceramics are valve.
  • Page 44 Also ensure that all other ensuring correct orientation. supplies, particularly to the volt free contact outputs, are also isolated. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 45 11.12 Low Gas Pressure Switch Part Number 533901420 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 100 SERIES 500001123/C...
  • Page 46 View Port Sight Glass ..............................539907001 For service or spares please contact :- Hamworthy Heating Limited Fleets Corner Poole Dorset BH17 0HH Phone Number.................01202 662500 Fax Number..................01202 665111 Service....................01202 662555 Spares ....................01202 662525 Technical...................01202 662566 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 47 Gas Supply Pressure Switch Setting mbar 12.5 11.9 / 23.8 / 35.7 / Gas Flow Rate (maximum) *12.7* *25.4* *38.1* Target CO % at High / Low fire ±0.1% 9.0 / 9.0 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 48 24V DC signal that can be fed through a volt free contact for operation. Refer to BS 6644 for further information on installing the electrical supply. NOTE: FOR BASIC TERMINATION DIAGRAM SEE PAGE 34 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 49 Figure B1.2 - External Control Wiring for Multiple Module Installation HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 50 Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who can supply a full flue design and installation service. The following points should be noted: Room Sealed Flue: Refer to Figures C1.1.2 &...
  • Page 51 A drain with an integral trap is fitted to the rear of each module suitable for connection to a 22mm plastic waste pipe (not Hamworthy Heating Ltd supply), which must be connected to a tundish (not Hamworthy Heating Ltd supply). Discharge piping from a tundish should be of synthetic material due to the mild acidity of the condensate (pH3-5), with all discharge piping having a minimum fall of 30mm/m away from the boiler.
  • Page 52 1000 long Ø1 00 R ef 45° Ben d Ø1 00 0 19 100 0 lon g Wall Clamp Ø100 Modu lar he ade r or e xisting flue system if suitable HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 53 Important - In fitting the HHL supplied 100mm dia. Ducts to a stainless steel flue system, the flue system must have it’s own condense drain. The system must not be allowed to drain back through the HHL supplied components. HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 54 Figure D1 Mechanical Ventilation Flow Rates Flow rate per 1000kW total rated heat input (Gross) Inlet air Atmospheric Extract air (Combustion Boilers (ventilation) ventilation) m³/s. m³/s. Volume 1.10 0.45 HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 55 Boiler Output Feed mm Vent mm 60 - 150kW 150 - 300 kW Figure E1.3 Cold Feed and Vent Pipe Sizes 300 - 600 kW HAMWORTHY HEATING LTD WESSEX MODUMAX 100 SERIES 500001123/C...
  • Page 56 Circulation pump (System) Hamworthy Modular Boilers Feed pipe Valve Circulation pump Drain (Primary l o op) valve VENTED SYSTEM: Primary loop, Hamworthy recom mended system. Pressure & Mains water Automatic Drai n Temperature Air Vent Automatic gauge s Safety Ai r Vent...
  • Page 57 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 58 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 59 Notes...
  • Page 60 Unit 2, Antrim Line Business Park, Sentry Lane, Newtownabbey BT36 8XX tel: 02890 849826 fax: 02890 847443 Website www.hamworthy-heating.com Associate Companies, Offices and Agents throughout the World. Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

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