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andrews MAXXflo EVO CWH 90/302 User Manual

andrews MAXXflo EVO CWH 90/302
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Andrews. Built to perform.
Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference.
M9373
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CWH 90/302, CWH 120/302
INSTALLATION AND MAINTENANCE MANUAL
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andrews MAXXflo EVO CWH 90/302 Specifications

General IconGeneral
CategoryWater Heater
ModelMAXXflo EVO CWH 90/302
Gas TypeNatural Gas
Max. Gross Heat Input (kW)90
ErP Water Heating Efficiency ClassA
Nox Class5
Voltage230
TypeCondensing
Water Tank Capacity (L)N/A (Continuous Flow)
PhaseSingle Phase
Protection RatingIPX5

Summary

GENERAL & SAFETY INFORMATION

1.1 DESCRIPTION OF HEATER

Details the MAXXflo EVO as a gas-fired, low NOx, twin heat engine water heater.

1.2 FOR WHOM IS THIS MANUAL INTENDED?

States the manual is for heating specialists installing commercial/industrial plant.

SYMBOLS USED IN THIS GUIDE

SAFETY

2.1 GENERAL SAFETY

Covers essential safety advice, including gas leaks, handling, and general precautions.

2.2 REGULATIONS AND STANDARDS

Lists relevant standards, codes of practice, and building regulations for installation.

2.3 UKCA & CE MARKING

Details the data plate information and compliance with directives/regulations.

TECHNICAL DATA

3.1 TECHNICAL DATA

Provides key technical specifications like electricity and fuel consumption, noise levels.

3.2 PRODUCT FICHE

Presents energy efficiency class, annual consumption, and thermostat settings.

3.3 PERFORMANCE DATA

Details heat input, output, gas consumption, flue data, and electrical specifications.

3.4 GENERAL DIMENSIONS & CONNECTIONS (300 LITRE MODELS)

Provides physical dimensions, connection types, and port details for the heater.

3.5 SYSTEM SCHEMATIC EXAMPLES

Shows schematic diagrams for single and parallel MAXXflo EVO installations.

3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Illustrates wiring and related settings for circulation pumps and sensors.

3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Depicts a schematic for MAXXflo EVO with a buffer tank.

3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Shows wiring and settings for MAXXflo EVO with a storage tank and expansion module.

3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Illustrates BMS (Building Management System) connections for the heater.

3.6 WIRING DIAGRAMS (MAXXflo EVO 90 & 120 KW MODELS)

Provides detailed wiring diagrams for the main control board (PCB1).

3.6 WIRING DIAGRAMS (MAXXflo EVO 90 & 120)

Shows wiring diagrams for the second control board (PCB2).

INSTALLATION

4.1 LOCATING THE HEATER

Guides on selecting a suitable location for the heater, considering flue, air, and access.

4.2 REMOVING THE DOOR AND INNER COVER

Step-by-step instructions for removing the heater's outer door and inner cover, including bracket removal.

4.3 COLD WATER SUPPLY

Details connections, system type, water quality, and anti-vacuum valve requirements.

4.4 UNVENTED DESIGN

Explains requirements for unvented systems, including the use of specific kits and components.

4.5 SECONDARY RETURN DESIGN (DHW CIRCULATION PUMP)

Details how to fit a secondary return circuit and maximum flow rates.

4.6 CONDENSATE DISPOSAL

Guides on condensate discharge pipework, material requirements, and trap filling.

4.7 FLUE SYSTEMS AND VENTILATION

Covers general requirements, suitable flue materials, and standards for flue systems.

4.7.3 GENERAL VENTILATION REQUIREMENTS (TYPE B23 CLASSIFICATION)

Specifies ventilation requirements for type B23 flue appliances in rooms and enclosures.

4.7.5 OPEN FLUE APPLIANCE IN A ENCLOSURE VENTILATED DIRECT TO OUTSIDE AIR

Details minimum vent free areas for enclosures ventilated directly to outside air.

4.7.7 FLUE TERMINAL POSITIONS - B23 TYPE (OPEN FLUE)

Provides minimum distance requirements for flue terminal positions based on location codes.

4.7.8 ROOM SEALED FLUE (C13 C33 C53 & C63) SYSTEM

Explains room sealed flue arrangements, terminal positions, and ventilation requirements.

4.7.10 ΜΑXXflo EVO 90 & 120 KW FLUE PARTS

Lists part numbers and descriptions for flue kits and optional flue parts.

4.7.11 ΜΑXXflo EVO FLUE SET UP

Illustrates horizontal, vertical, and alternative flue setup configurations.

4.7.12 ΜΑXXflo EVO 90 & 120 KW FLUE SYSTEM DIMENSIONS

Provides dimensions for various concentric flue components like terminals, traps, and elbows.

4.7.13 FLUE TERMINAL POSITIONS - C13 C33 C53 C63 TYPE (CONCENTRIC / TWIN)

Details minimum distance requirements for concentric/twin flue terminal positions.

4.8 MAXIMUM FLUE EQUIVALENT LENGTHS

Explains Flue Equivalent Length (FEL) and provides tables for calculating total FEL.

4.9 GAS CONNECTIONS

Covers gas supply requirements, meter types, and pressure specifications.

4.10 ELECTRICAL & COMMUNICATION CONNECTIONS

Guides on electrical connections, volt-free functions, and communication protocols.

COMMISSIONING

5.1 FILLING AND REMOVAL OF AIR

Provides a step-by-step guide for filling the DHW tank and system with water and removing air.

5.2 COMMISSIONING THE HEAT ENGINES

Details commissioning the heat engines, including important notes, top engine process, and bottom engine process.

5.2.4 HEAT ENGINE COMMISSIONING COMPLETION

Details final steps for heat engine commissioning, including refitting connectors and checking gas consumption.

5.3 CONVERSION FROM SECOND FAMILY (NATURAL GAS - G20) TO THIRD FAMILY OF GASES (PROPANE - G31)

Explains the procedure for converting the heater from natural gas to LPG.

5.4 FROST PROTECTION & LEGIONELLA

Covers frost protection, Legionella risks, and anti-legionella settings and controls.

5.5 FINAL CHECKS & USER HANDOVER

Covers setting time/date, checking sensor position, cleaning, and user handover procedures.

5.6 FAULT FINDING

Details operation sequences, faults, lockouts, and fault display examples.

MAINTENANCE

6.1 ROUTINE INSPECTION INTERVALS AND REQUIREMENTS

Recommends regular servicing intervals and lists minimum annual servicing requirements.

6.1.1.1 INSPECT AND CLEAN BURNER ASSEMBLY

Details steps to remove the heat exchanger, fan, and venturi for burner inspection and cleaning.

6.1.1.2 SPARK ELECTRODE AND IONISATION ELECTRODE

Recommends replacing electrodes every two years and provides inspection guidance.

6.1.1.3. CASE AIR & FLUE OUTLET SEALS

Advises on checking flue sections for firm connection and inspecting seals for leaks.

6.1.1.4. CONDENSATE PIPEWORK AND SYPHON TRAP

Guides on inspecting condensate pipework for leaks and cleaning the syphon trap.

6.1.1.5. GAS RATE & COMBUSTION

Details how to check and adjust gas rate and combustion by analyzing flue gas.

6.1.1.6 INSPECT AND FLUSH DHW STORAGE TANK

Provides procedures for inspecting, cleaning, and flushing the DHW storage tank.

6.2 REMOVING AND CHANGING COMPONENTS

Details procedures for removing and changing various heater components.

6.2.2 FLUE TEMPERATURE SENSOR (B8)

Explains the location and procedure for removing and replacing the flue temperature sensor.

6.2.3 COMMON FLOW TEMPERATURE SENSOR (B10)

Details the location and procedure for removing and replacing the common flow temperature sensor.

6.2.4 AVS37 GUI DISPLAY

Guides on removing and replacing the AVS37 GUI display unit.

6.2.5 LMS14 PCB MASTER & SLAVE REPLACEMENT

Provides instructions for replacing the Master and Slave control PCBs, emphasizing ESD precautions.

6.2.6 SPARK GENERATOR

Details how to remove and replace the spark generator, including power connections.

6.2.7 COMBUSTION FAN

Guides on removing and replacing the combustion fan, including venturi and gasket checks.

6.2.8 GAS VALVE

Provides instructions for removing and replacing the gas valve, including transfer of gasket and orifice.

6.2.8 ELECTRODE REMOVAL

Details how to remove spark and ionisation electrodes, ensuring gasket seal integrity.

6.2.10 BACK FLOW PREVENTION VALVE

Guides on inspecting and replacing the Back Flow Prevention Valve (BFPV) and air arm seal.

6.2.11 OVERHEAT THERMOSTAT

Details how to locate and replace the overheat thermostat.

6.2.12 AIR PRESSURE SWITCH

Guides on removing and replacing the air pressure switch, including air tube and connections.

6.2.13 HEAT EXCHANGER

Provides instructions for removing the heat exchanger, including draining water and disconnecting sensors.

6.2.14 CIRCULATION PUMP Q1

Details steps for removing and replacing the circulation pump Q1, including refilling and bleeding.

6.2.15 WATER PRESSURE SENSOR

Guides on removing and replacing the water pressure sensor, including connector and clip removal.

6.3 FLUSHING/DESCALING THE HEAT EXCHANGERS

Provides instructions for flushing and descaling heat exchangers, applicable when sensors/pipework are fitted.

6.4 COMPONENT ILLUSTRATIONS

Illustrates and lists part numbers for various components.

6.5 RECOMMENDED SPARES REQUIREMENTS

Lists essential first aid kit contents for maintaining heat engines in operation.

6.6 ERROR CODES

Lists error codes, descriptions, diagnostic codes, and notes for troubleshooting.

6.6 ERROR CODES (CONTINUED)

Lists error codes, descriptions, diagnostic codes, and notes for troubleshooting.

6.6 ERROR CODES (CONTINUED)

Lists error codes, descriptions, diagnostic codes, and notes for troubleshooting.

6.6 ERROR CODES (CONTINUED)

Lists error codes, descriptions, diagnostic codes, and notes for troubleshooting.

SENSOR RESISTANCE VALUES

Provides sensor resistance values for NTC 10K and 20K sensors.

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