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Hamworthy Wessex ModuMax mk3 WM97/97H User Manual

Hamworthy Wessex ModuMax mk3 WM97/97H
68 pages
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Wessex ModuMax 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 I2H
LPG Propane I3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
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Hamworthy Wessex ModuMax mk3 WM97/97H Specifications

General IconGeneral
BrandHamworthy
ModelWessex ModuMax mk3 WM97/97H
CategoryBoiler
LanguageEnglish

Summary

1.0 Introduction

2.0 Supply and Delivery

3.0 Size and Space Requirements

3.1 Site Location.

Details requirements for boiler placement and necessary clearances for access.

4.0 Site Location and Preparation

4.1 Site Location.

Ensures correct alignment and stability of boilers and manifold kits.

4.2 Gas Supply.

Covers gas pipework standards, connections, pressure, and isolation valve.

4.3 Flueing

Details flue termination, routing, construction, and condensation management.

4.4 Water Supply

Specifies requirements for feed/expansion, pipework, flushing, and water pressure.

4.5 Condensate Connections

Addresses condensate removal from boiler and flue, material recommendations.

4.6 Electrical Supply

Outlines earthing, supply voltage, fuse ratings, wiring, and isolation requirements.

5.0 Boiler Assembly

5.1 Site dis-assembly

Instructions for safely dismantling and re-assembling boiler modules on site.

5.2 Boiler Assembly

Guidance on connecting flue collector ducts and positioning the assembly.

5.3 Water Connections:

Details the specific male thread connections for water flow and return.

5.4 Electrical Connections:

Lists electrical connections available on each module for various functions.

6.0 Pre-Commissioning

6.1 Gas Supply.

Ensures gas installation pipework and meter are tested and purged.

6.2 Ventilation

Confirms correct ventilation and air supply to the plant room.

6.3 Pipework, Valves and Pump

Checks system filling, venting, pressurization, pump operation, and valve status.

6.4 Flue

Verifies flue system design, installation, and clear passages.

6.5 Electrical

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

7.0 Checks Prior to Lighting

7.1 Boiler Gas System Leak Check

Procedure to check the boiler's gas system for leaks using a manometer.

8.0 Initial Lighting

8.2 Controls Operation

9.0 Fault Finding

9.1 Safety Temperature Limiter (Limit Thermostat)

Explains the function of the safety limiter and its reset mechanism.

9.2 Ignition Controller

Details the controller's supervision of the flame and restart procedures.

10.0 Servicing

10.1 Regular servicing

Recommends annual servicing for trouble-free operation and checks.

10.2 Annual Service

Outlines the procedure for servicing each module, including safety precautions.

11.0 Replacement of Failed Components

11.1 Hot Surface Igniter and Flame Probe Assembly

Instructions for replacing the igniter and flame probe ceramics.

11.2 Flow / Return sensor

Details how to remove and replace the flow and return sensors.

11.3 Temperature Limiter (Limit Stat)

Procedure for replacing the temperature limiter and checking connections.

11.4 Gas Valve

Provides guidance on replacing the gas valve assembly.

11.5 Combustion Fan

Steps for disconnecting and removing the combustion fan.

11.6 Venturi

Instructions for isolating the gas supply and removing the venturi.

11.7 Burner

Guidance on disconnecting the burner assembly and inspecting components.

11.8 Ignition Transformer

Procedure for unplugging and removing the ignition transformer.

11.9 Main Control - Navistem

Steps for removing and replacing the Navistem control PCB.

11.10 Clip in Modules

Instructions for disconnecting and removing clip-in modules from the Navistem.

11.11 Display screen

Procedure for disconnecting and removing the display screen.

11.12 Low Gas Pressure Switch

Details replacement of the low gas pressure switch.

11.13 Air Pressure Switch

Instructions for disconnecting and replacing the air pressure switch.

11.14 Ignition Transformer In-line Fuse

Guidance on checking the in-line fuse for the ignition transformer.

11.15 Air Inlet Filter

Instructions for replacing the air inlet filter material.

12.0 Recommended Spares

Useful User Information

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