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Hamworthy Wessex Modumax 100 series User Manual

Hamworthy Wessex Modumax 100 series
60 pages
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IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
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
I
2H

Table of Contents

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Hamworthy Wessex Modumax 100 series Specifications

General IconGeneral
BrandHamworthy
ModelWessex Modumax 100 series
CategoryBoiler
LanguageEnglish

Summary

Introduction

Boiler Variations

Details variations of Wessex ModuMax boilers by model and kW output.

1.9 Options

Discusses optional features for Wessex ModuMax boilers, including kits and controls.

Site Location and Preparation

4.1 Site Location

Specifies requirements for the floor or plinth and plantroom space for boiler installation.

4.2 Gas Supply

Outlines regulations and requirements for gas supply installation and connection to the boiler.

4.3 Flueing

Details flue termination, routing, construction, and material requirements for safe operation.

4.4 Water Supply

Covers requirements for feed, expansion, cold feed, open vent, and pressurised systems.

4.5 Condensate Connections

Specifies provision for condensate removal, pipework material, and discharge methods.

4.6 Electrical Supply

Details electrical safety, wiring, isolation, and supply requirements for the appliance.

Boiler Assembly

5.2 Water Connections

Lists and describes the water connections provided on each boiler module.

5.3 Electrical Connections

Lists the electrical connections available on each boiler module.

Pre-Commissioning

6.1 Gas Supply

Ensures gas installation pipework is tested, purged, and certificates are available.

6.2 Ventilation

Confirms correct ventilation and air supply to the plantroom.

6.3 Pipework, Valves and Pump

Checks pipework, valves, pump installation, system filling, and isolation.

6.4 Flue

Verifies the flue system is correctly designed, installed, and clear.

6.5 Electrical

Ensures electrical connections are correct, isolatable, and external controls are operational.

Checks Prior to Lighting

7.1 Boiler Gas System Leak Check

Details the procedure for checking the gas system for leaks before initial lighting.

Initial Lighting

8.1 Carry out the following procedure to fire up the boiler

Provides a step-by-step guide for safely firing up the boiler for the first time.

Controls Operation

8.2.1 - Info button

Explains how to access and display information via the Info button.

8.2.1.1 - Fascia Label Legend

Identifies and explains the symbols and labels on the boiler's fascia control panel.

8.2.2 - Screen Legend

Describes the meaning of different characters and symbols displayed on the boiler's screen.

8.2.3 - Default Display

Shows the standard display layout and how the screen returns to it.

8.2.4 - Lockout Display

Explains how lockout codes are displayed and how to interpret them.

8.2.5 - Adjusting the heating circuit setpoint temperature

Details how to adjust the heating circuit setpoint temperature using the control panel.

8.2.6 - Parameter settings for the Enduser

Guides on modifying default settings to suit individual user needs.

8.2.7 - Start-up / initialisation

Describes the setpoint initialization process on startup or after a lockout reset.

8.2.8 - FUNCTIONS

Introduces special functions available for boiler operation and measurement.

8.2.8.1 - Chimney Sweep function

Explains the chimney sweep function for boiler startup and measurement.

8.2.8.2 - Controller Stop function

Details the controller stop function for manual adjustment of heat output.

8.2.8.3 - Time of day function

Emphasizes correct time setting for function operation.

8.2.9 - Heating circuit operating modes

Outlines the four different heating circuit operating modes selectable for the boiler.

8.2.10 - Error code display

Lists fault codes, their potential causes, and corresponding groups for diagnostics.

Ignition Controller Check

8.3 Ignition Controller Check.

Describes how to check the ignition controller's operation and flame signal.

8.4 Gas Supply Pressure Check.

Details checking the gas supply pressure after boiler module checks.

8.5 Combustion Checks

Outlines site checks for confirming correct boiler performance and flue gas analysis.

Fault Finding

9.1 Temperature Limit Thermostat

Explains how the limit thermostat functions, trips, and potential causes of overheating.

9.2 Ignition Controller

Discusses issues related to the burner ignition controller and flame detection.

Servicing

10.1 Regular servicing

Recommends regular servicing for trouble-free operation and checks controls/safety features.

10.2 Annual Service

Details the procedure for annual servicing, including isolation and component checks.

10.3 Four Year Service

Outlines the procedure for a four-year service, including heat exchanger cleaning.

Replacement of Failed Components

11.1 Hot Surface Igniter and Flame Probe Assembly

Provides instructions for replacing the igniter and flame probe, noting fragility.

11.2 Flow / Return sensor

Details the removal and replacement of flow/return sensors.

11.3 Temperature Limiter (Limit Stat)

Guides on replacing the temperature limiter and checking its setting.

11.4 Gas Valve

Recommends replacing the gas valve and provides isolation and removal instructions.

11.5 Combustion Fan

Explains how to replace the combustion fan and associated components.

11.6 Venturi

Details the replacement of the venturi, noting factory-set air inlet ring position.

11.7 Burner

Provides instructions for replacing the burner assembly and associated components.

11.8 Ignition Transformer

Guides on replacing the ignition transformer, noting electrical isolation.

11.9 Main Control - LMU

Details replacing the main control (LMU) unit, including electrical isolation.

11.10 Clip in Modules

Explains how to remove and replace clip-in modules for the LMU.

11.11 Display screen

Guides on replacing the display screen and its associated components.

11.12 Low Gas Pressure Switch

Details replacing the low gas pressure switch and checking connections.

11.13 Air Pressure Switch

Provides instructions for replacing the air pressure switch.

Recommended Spares

Appendix A - Gas Data

Appendix B - Electrical Connections and Controls

B1.1 Electrical Supply

Addresses earthing, isolation, wiring, and mains supply requirements for boilers.

Appendix C - Flue Data

C1.0 Flue System

Introduces flue system recommendations and compliance with standards.

C1.1 General Requirements

Details general requirements for natural draught and room sealed flue systems.

C1.2 Waste Gas Volume and Temperature

Recommends using specified waste gas volumes and temperatures for flue design.

C1.3 Materials

Outlines material requirements for flue systems, considering corrosion and freezing.

C1.4 Suction

Addresses flue system design acknowledging boiler fan pressure and recommending draught stabilizers.

C1.5 Disconnection

Advises on provisions for flue pipe disconnection for servicing.

C1.6 Flue Discharge

Ensures safe operation and dispersion of combustion products, considering terminal location.

C1.7 Surface Temperatures

Specifies maximum surface temperatures for combustible materials near the flue.

C1.8 Location

Advises on flue system placement to avoid accidental damage and ensure clarity.

C1.9 Condensate Discharge

Details condensate removal, pipework, and protection from freezing.

Appendix D - Ventilation

D1.1 Air Supply

Provides general guidance on air supply for combustion and ventilation.

D1.2 Air Supply by Natural Ventilation

Covers requirements for permanent air vents for boiler room ventilation.

D1.3 Air Supply by Mechanical Ventilation

Details requirements for mechanical ventilation systems and their interlocks.

Appendix E - Water Data

E1.1 Water Circulation System

Outlines requirements for water circulation systems, including indirect cylinders and insulation.

E1.2 Minimum System Water Pressure

Provides minimum system water pressure requirements based on boiler configuration.

E1.3 Pressure Relief Valve (Safety Valve)

Discusses the importance of safety valves and their capacity requirements.

E1.4 Open Vent and Cold Feed Pipe.

Specifies requirements for open vent and cold feed pipes, including bore and protection.

E1.5 Altitude Gauge (Water Pressure Gauge)

Recommends fitting an altitude gauge with an isolating valve.

E1.6 Thermometer

Advises fitting a thermometer to indicate water flow temperature.

E1.7 Drain Valves

Details the location and type of drain valves required for the boiler and system.

E1.8 Circulating Pump

Discusses pump requirements, performance checks, and system flushing.

E1.9 Minimum Water Flow Rates

States minimum water flow rates that must be maintained to prevent heat exchanger damage.

E1.10 Waterside Pressure Drop

Refers to table for waterside hydraulic resistance.

E1.11 Water Flow Controls

Emphasizes ensuring minimum flow rates and suggests flow switches.

E1.12 Frost Protection

Suggests fitting a frost thermostat for protection.

E1.13 Unvented Systems

Refers to layout for unvented systems and pressurisation unit sizing.

Useful User Information

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