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Hamworthy Wessex ModuMax mk3 WM116/116H, Installation, Commissioning And Servicing Instructions

The Hamworthy Wessex ModuMax mk3 WM116/116H is an innovative heating system that ensures optimum efficiency and reliability. To ensure seamless installation, commissioning, and servicing, we provide comprehensive and easy-to-follow instructions in our user manual. Download it for free from our website for hassle-free maintenance of this exceptional product.

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HAMWORTHY HEATING LTD 

 

35 

Wessex ModuMax

 

mk3

 

Boilers 

 

500001308/C 

 

 

12.0 RECOMMENDED SPARES 

 

Please  Note:-

  To  ensure  the  correct  spare  parts  are  despatched  by  our  spares  department,  it  is  imperative  that  the 

complete Boiler/Module/Control Panel Serial Numbers are given.  The Boiler and Module Serial Numbers are located on 
the Data Plates affixed to the combustion chamber front panel. The Electrical Serial Number is located inside the Control 
panel on the maximum power rating label. These numbers 

MUST

 be quoted when ordering spare parts. 

SPARES ITEM 

PART No.

 

ELECTRICAL ITEMS

 

Navistem controller - 97  .................................................................................................................................................... 533901756 
Navistem  controller-  116  ................................................................................................................................................ 533901758 
Navistem  controller - 147  ................................................................................................................................................ 533901760 
Navistem controller - 196   ................................................................................................................................................ 533901762 
Navistem controller -  254   ............................................................................................................................................... 533901764 
Navistem control panel ...................................................................................................................................................... 533901691 
Ignition  Transformer  ......................................................................................................................................................... 533901441 
Flow / Return Sensor ......................................................................................................................................................... 533901431 
Temperature Limiter ........................................................................................................................................................... 531040016 
Hot Surface Igniter ............................................................................................................................................................. 563801019 
Flame Sensing Probe ........................................................................................................................................................ 533805021 
Clip in Module -  AGU2.511A109 ..................................................................................................................................... 533901776 
Clip in Module - LPB Bus communication - OCI345.06/101 ......................................................................................... 533901777

 

T1A Fuse 5x20 ................................................................................................................................................................... 533922013

 

MECHANICAL ITEMS

 

Burner Fabrication - 97 & 116 ........................................................................................................................................... 533301019 
Burner Fabrication - 147 .................................................................................................................................................... 533301020 
Burner Fabrication - 196 .................................................................................................................................................... 533301021 
Burner Fabrication - 254 .................................................................................................................................................... 533301024 
Gas Control Valve - 97/116/147 ....................................................................................................................................... 533903044 
Gas Control Valve - 196/254... ........................................................................................................................................ 533903036 
Combustion Fan - 97/116/147 .......................................................................................................................................... 533704014 
Combustion Fan - 196/254 ............................................................................................................................................... 533704003 
Venturi - 97/116/147 .......................................................................................................................................................... 532418007 
Venturi - 196/254 ................................................................................................................................................................ 532418001 
Low Gas Pressure Switch - 97/116/147 .......................................................................................................................... 533901497 
Low Gas Pressure Switch - 196/254 ............................................................................................................................... 533925004 
Gas Orifice (LPG models 196/254 only) .......................................................................................................................... 531101013 
Air Pressure Switch ............................................................................................................................................................ 532496004 
Descale Kit  (condensing models) .................................................................................................................................... 563605560 
Gasket - Burner to heat exchanger .................................................................................................................................. 531201078 
Gasket—Fan to burner ...................................................................................................................................................... 531201071 
Gasket—View port ............................................................................................................................................................. 531201066 
View Port Sight Glass ........................................................................................................................................................ 539907001 
Air Filter Media .................................................................................................................................................................... 532812016 
For service or spares please contact :- ................................................................................................................................................  

Hamworthy Heating Limited  

Phone Number.................................................................................. 01202 662500

 

Wessex House 

Fax Number ....................................................................................... 01202 662522

 

New Fields Business Park

 

Service ................................................................................................ 01202 662555

 

Stinsford Road 

Spares................................................................................................. 01202 662525 

Poole, Dorset BH17 0NF 

Technical ............................................................................................ 01202 662505

 

Summary of Contents for Wessex ModuMax mk3 WM116/116H

Page 1: ...s 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 ...

Page 2: ... operating safely and efficiently Service Contracts Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant reducing the risk of failure and improving performance and efficiency Service contracts enable you to plan and budget more efficiently Breakdown service repair replacement Hamworthy provide a rapid response breakdown repair or repl...

Page 3: ...HE RELEVANT INFORMATION WITHIN THIS DOCUMENT FOR EACH SPECIFIC GAS REQUIREMENT IS ADHERED TO PRIOR TO FIRING THE BOILER COUNTRY OF DESTINATION UNITED KINGDOM REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES PRODUCT IDENTIFICATION No 86CP58 PUBLICATION NO 500001308 ISSUE C May 2017 Wessex ModuMax mk3 Boilers Condensing Fully Modulating Pre Mix Gas Fired Modular Boilers...

Page 4: ...ITIAL LIGHTING 21 8 1 Pre Lighting up Checks 8 2 Controls Operation 8 3 Operating Phases 8 4 Ignition Controller Check 8 5 Gas Supply Pressure Check 8 6 Combustion Checks 8 7 User Instructions 9 0 FAULT FINDING 27 9 1 Temperature Limit Thermostat 9 2 Ignition Controller 9 3 Wiring Diagram 10 0 SERVICING 29 10 1 Regular Servicing 10 2 Annual Service 10 3 Four Year Service 11 0 REPLACEMENT OF FAILED...

Page 5: ...igure 4 6 Electrical Connections 14 Figure 5 1 Module Fixings 14 Figure 5 2 Flue Collector Box Pre Assembly 15 Figure 5 2 2 Flue Header Connection 16 Figure 5 3 1 Rear Water Connections 16 Figure 7 1 Boiler Gas System Leak Check Diagram 18 Figure 7 2 1 Gas Valve Position 19 Figure 7 2 2 Venturi Gas Valve 196 254 Boiler 20 Figure 7 2 3 Hot Surface Igniter Resistance Check 20 Figure 8 1 1 Gas Valve ...

Page 6: ...re C1 1 1 Equivalent Flue Resistance Data 42 Figure C1 1 2 Open Natural Draught B23 B23p Flue System 43 APPENDIX D VENTILATION 44 Figure D1 Mechanical Ventilation Flow Rates Chart 45 APPENDIX E WATER DATA 46 Figure E1 1 General Water Data 46 Figure E1 1 1 Typical Piping Layout 47 Figure E1 3 Cold Feed and Vent Pipe Sizes Table 48 Figure E1 3 1 Hydraulic Schematic 1 50 Figure E1 3 2 Hydraulic Schem...

Page 7: ...terface LCD display for accessing and changing boiler parameters 1 3 4 Each of the boiler models is designed for direct connection to a flue system The Technical Data for the various arrangements is given in Appendix C The flue outlets from more than one unit may be connected to a single chimney No draught diverter is fitted to the boiler nor is a fixed diverter required in the flue system However...

Page 8: ...254 508 254 762 These kits are free standing allowing installation to the system prior to installing the boiler and can incorporate all necessary valves inter connecting pipework and flexible flow and return connections Refer to individual kit instructions for details 1 9 2 Controls peripherals The Navistem boiler management system has the potential to accept the following control options 1 9 2 1 ...

Page 9: ...e plantroom Ensure the boiler is kept secure when handling to avoid it toppling as this will result in damage Each 2 and 3 high stacked Wessex ModuMax model is supplied with a flue collector manifold This is separately packaged in a dedicated cardboard box Single Wessex ModuMax boilers do not have an additional flue collector manifold NOTE Care must be taken as impacts will cause damage to the flu...

Page 10: ...ery please ensure that you have received the correct number of boilers and flue collector manifold to fulfil your order If any item is missing please contact our after sales service team Please provide details of your order number and contract number as well as a detailed description of the missing item ...

Page 11: ...mm 192kg Wessex ModuMax 147 441 196 588 254 762 1200mm 800mm 2060mm 233kg Figure 2 2 Header Kit Packaged Dimensions Figure 2 1 Reverse Header Kit Where reverse return header sets are used these are packaged separately from the boilers The packaging for each header set is defined in the table below Ancillary items such as isolation valves and flexible boiler connectors are packaged in a cardboard b...

Page 12: ...80 568 717 1 102 815 836 3 583 2 FLUE 204 9 CONDENSE 1258 1798 9 2084 31 1543 41 54 5 GAS 44 RELIEF 291 66 FLUE CONDENSATE 350 54 723 1 CONDENSE O100 FLUE SOCKET 477 RETURN 303 FLOW 350 54 FLUE CONDENSATE 1264 CONDENSE 586 89 FLOW 610 2 RELIEF 666 2 GAS 91 FLOW RETURN G 1 1 2 MALE RETURN G 1 1 2 MALE FLOW O32 CONDENSE DRAIN 1 PER MODULE 285 51 RETURN 182 2 CONDENSE R3 4 RELIEF VALVE 1 PER MODULE N...

Page 13: ...LOW 610 RELIEF 666 GAS 92 FLOW RETURN G 2 1 2 MALE RETURN G 2 1 2 MALE FLOW O32 CONDENSE DRAIN 1 PER MODULE 286 RETURN 182 CONDENSE R3 4 RELIEF VALVE 1 PER MODULE NOT SUPPLIED 600 Rp 1 1 4 GAS SUPPLY 1 PER MODULE 278 FLUE CONDENSATE 750 CRS 704 SINGLE 1454 DOUBLE 2204 TRIPLE CASCADE WIDTH Minimum clearances 3 Modules High 2 Modules High 1 Modules High Minimum boiler to boiler stack spacing 230 CL ...

Page 14: ...7 for specific details on the manifold kit suitable for 97 116 models Optional accessory kits to control shunt pumps and valves can be found on page 2 of this manual Safety Valve When using this kit it is important that each boiler module is fitted with an individual safety valve using the connection provided on the back of each boiler This item is not supplied with the boiler Figure 3 2 1 2 Manif...

Page 15: ...54 models Optional accessory kits to control shunt pumps and valves can be found on page 2 of this manual Safety Valve When using this kit it is important that each boiler module is fitted with an individual safety valve using the connection provided on the back of each boiler This item is not supplied with the boiler 570 747 R EF 1057 180 541 586 541 541 280 5 5 N OM 690 Finished Floor Level R2 G...

Page 16: ...e with BS 6644 The plantroom must have sufficient space for installation of boilers manifold kits pipework pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply Gas supply pipes must be in accordance with BS 6891 or IGE UP 2 Gas supply connections to the boiler must not be smaller than the connection on the boiler Rp1 97 116 Rp11 4 147 196 254 Gas installati...

Page 17: ...e flue condensation Horizontal flue runs must be kept as short as possible and be inclined at minimum 2 towards the terminal The flue system must be designed acknowledging that there is a positive pressure generated by the boiler combustion fan Refer to Appendix C The flue system must be designed to limit the max suction cold to 30Pa negative measured at the connection to the boiler If the suction...

Page 18: ...eas 180mg CaCO3 litre precautions such as water treatment are strongly recommended to prevent the build up of sludge and scale and also to control the system water pH to between 7 0 8 0 Leaks in the system pipework should be fixed to prevent dilution of water treatment To monitor the volume of make up water entering the system a water meter must be fitted and readings recorded in a log book to be ...

Page 19: ...rged to a standard drain subject to National or Local regulations Location of condense pipework should prevent freezing within tundish s traps and pipework The connection to the boiler condense drain accepts a straight push fit coupling for 32mm i d plastic waste pipe Boiler Condensate Connection 32mm o d Figure 4 5 2 Boiler Condensate Connection Open Tundish Condense U Trap Minimum Fall 30mm m 1 ...

Page 20: ...ct separation of minimum 3mm in all poles Electrical isolators must be installed in readily accessible locations Electrical supplies to boiler modules should only serve the boiler using the conduits supplied High low voltage cables should be separated into individual conduits Where volt free contacts are used these too must be individually isolatable Time clock control should be via the boiler mod...

Page 21: ...ranged in banks of 2 or 3 high adjacent to each other it is advisable to fit the water and flue connections to each individual bank prior to fitting the connections to the adjacent bank s Figure 5 2 Flue Collector Box Assembly Modular Tee Closing plate with condense discharge 5 1 Site dis assembly The individual modules are secured by 4 x M8 bolts securing the boiler frames together see figures 5 ...

Page 22: ...fitting supplied Figure 5 2 2 Flue Header Connection 32mm condense trap fitted for connection to drain 5 3 Water Connections The following connections are provided on each boiler module Figure 5 3 1 Rear Water Connections Flow G1 Male thread 97 116 Flow G2 Male thread 147 196 254 Indicated by a red dot on boiler Safety valve R Male thread Adjacent to flow connection Capped when delivered Condense ...

Page 23: ...rth See Section 4 5 for details Optional Boiler Fault Alarm Normal Run Signal Output optional AGU clip in kit 0 10v Analogue Control Signal Input Remote on off Control Input Boiler Pump Output DHW pump output motorised valve output Safety Interlock Circuit Input Optional LPB Bus for use with Merley cascade control optional OCI clip in kit Master Slave sequencing 6 0 PRE COMMISSIONING The following...

Page 24: ...urbance to unions fittings and gas valve assemblies etc A procedure guide is given below Care must be taken not to allow leak detection fluid if used on or near any electrical parts or connections NOTE When testing 2 or 3 high stacked appliances the test detailed below must be carried out on each module Figure 7 1 Gas System Leak Check Diagram 6 4 Flue Ensure that Flue system is correctly designed...

Page 25: ...ource to the bulb Note take care not to damage the tension spring in removal and replacement Check the continuity with a meter If satisfactory refit the bulb and tension spring in the pocket and secure with the clip Ensure that all thermostat bulbs are fully inserted into their pockets The flow and return sensor bulbs are located at the rear of the boiler in the flow and return pipes 3 Check setti...

Page 26: ...e Igniter Check 196 254 shown with air filter removed Figure 7 2 2 Venturi Gas Valve 97 116 147 shown WARNING WHEN THE FRONT COVER AND AIR FILTER ARE REMOVED AND THE BOILER IS IN OPERATION IT IS POSSIBLE FOR ARTICLES OF CLOTHING OR LONG HAIR TO BE DRAWN INTO THE VENTURI FAN Venturi Air inlet Filter Gas Valve Fan ...

Page 27: ...tem manual HHL part no 500001310 5 If the above procedure occurs correctly open the gas isolating valve and the fault indication will extinguish The boiler will commence its ignition sequence as previously described This time when the gas valve is energised the burner will ignite 6 With the burner firing the flame signal displayed should be approximately 9 12µA but not less than 3µA Refer to separ...

Page 28: ... 2 1 General Overview of Panel Fascia Figure 8 2 2 General Overview of Controls Limit Thermostat IEC Mains Outlet Socket Navistem Control Panel Ignition Transformer Navistem Controller Air Pressure Switch Cable Strain Relief On Off button Display Screen Rotary Control Fuse ...

Page 29: ...ion manual HHL part no 500001310 which is supplied with each boiler A concise user instructions guide HHL part no 500001309 is supplied with each boiler This guide gives instruction on initial set up as well as a list of possible error codes The Navistem controller is located on the main control panel assembly which can be accessed after removal of the boiler front cover fig 8 2 2 Note Should reme...

Page 30: ...TNB THL1 THL1 A STOE SA F TNB TW1 STOE SA F TNB TW2 TVZ STOE SA F TNB STOE SA F TNB STOE TNB Duration 9500 9517 9519 9518 9519 9534 9540 9544 9540 9544 9652 120s 51s 51s 51s 51s 51s 51s 24h 51s 51s 51s THL1 THL1 THL1 TNB THL1 THL1 TNB TNB Fan speed Set point 9504 9504 9512 9512 9512 9512 9512 9512 9512 9524 9529 9524 9529 9524 9529 9524 9529 9504 9504 9524 9529 9512 9512 9651 Tolerance tim e 2 8 s...

Page 31: ...ne with all modules firing For Natural Gas a nominal gas inlet pressure of 20mbar measured at the rear of the boiler is required with a maximum inlet pressure of 25mbar For LPG a nominal gas inlet pressure of 37mbar measured at the rear of the boiler is required with a maximum inlet pressure of 45mbar 8 6 Combustion Checks The boiler modules are factory pre set but site checks must be done to conf...

Page 32: ...ncrease the CO2 level turn the adjustment clockwise Figure 8 6 5 Adjusting gas valve offset 97 116 147 97 116 147 196 254 196 254 If combustion is outside of the ranges defined below the factory sealed valves may be adjusted using the following procedure High Fire Target Nat Gas 9 0 0 25 CO2 LPG 10 6 0 25 CO2 If combustion level is outside of this range use the Cross Head Throttle Screw to adjust ...

Page 33: ...peatedly occurs contact Hamworthy Heating for assistance Do not continue to operate or use the boiler as this may cause damage to the controls 9 1 Safety Temperature Limiter Limit Thermostat 1 The electronic control thermostat has several safety levels built in such that a controlled shutdown should occur before the safety temperature limiter is activated Should these safety levels be overridden s...

Page 34: ...HAMWORTHY HEATING LTD 28 Wessex ModuMax mk3 Boilers 500001308 C Figure 9 3 Wiring Diagram ...

Page 35: ...ch 6 Remove the air inlet filter cassette Refer to section 11 15 7 Remove the 2 M8 burner retaining nuts and carefully withdraw the complete burner fan assembly from the heat exchanger Separate the burner fabrication from the fan venturi and gas control valve 8 Remove and inspect H S I and flame probe ensure they are free from debris or deposits Test resistance value of H S I if above 200 ohms col...

Page 36: ...mbly without cutting it Remove the 6 M10 nuts that retain the heat exchanger into the boiler module casing and with the front end supported slowly withdraw the heat exchanger until the rear of the stainless steel baffles are visible With the rear of the heat exchanger resting in the body of the boiler and the front supported by the lifting apparatus access is gained for removal of the stainless st...

Page 37: ...trode A typical flame current is 10µA high fire with the lockout threshold at 3µA Disconnect the flame probe lead earth lead remove the single socket cap head screw securing the probe to the burner flange and withdraw the probe When fitting the replacement carefully feed the probe through the mounting hole taking care not to damage the ceramic Note Do not remove both securing screws at the same ti...

Page 38: ... to the burner and remove the fan Fit the replacement in reverse order and if required replace any seals or gaskets Note After re making any gas or combustion circuit joint connection an integrity check is recommended to ensure safety 11 6 Venturi Part No 532418007 97 116 147 Part No 532418001 196 254 Ensure that the boiler module electrical power supply is isolated before removing the front cover...

Page 39: ...at the connector end of the clip in to allow the module to be hinged up and disengaged from the Navistem or control panel Assemble in reverse order 11 11 Display screen Part Number 533901691 Ensure that the boiler module electrical power supply is isolated before removing the front cover and gaining access to the controls Carefully disconnect the ribbon cable connecting the screen to the Navistem ...

Page 40: ...n has been diagnosed Fig 11 14 In line Fuse 11 15 Air Inlet Filter Replacement Filter Material Part No 532812016 The ModuMax mk3 is fitted with an air inlet filter which is accessed after removing the main front cover of the boiler The White filter material can be replaced at service intervals by ordering the part number above available from Hamworthy Heating Ltd spares department Remove the retai...

Page 41: ... Probe 533805021 Clip in Module AGU2 511A109 533901776 Clip in Module LPB Bus communication OCI345 06 101 533901777 T1A Fuse 5x20 533922013 MECHANICAL ITEMS Burner Fabrication 97 116 533301019 Burner Fabrication 147 533301020 Burner Fabrication 196 533301021 Burner Fabrication 254 533301024 Gas Control Valve 97 116 147 533903044 Gas Control Valve 196 254 533903036 Combustion Fan 97 116 147 5337040...

Page 42: ... 359 4 Boiler Output kW maximum condensing 50 30 C kW 116 2 116 2 232 5 232 5 348 7 348 7 Boiler Output kW maximum non condensing 80 60 C kW 115 2 115 2 230 4 230 4 345 6 345 6 Boiler Module Output minimum 80 60 C kW 23 5 Model Condensing 147 147 147 294 147 441 Nat Gas LPG Nat Gas LPG Nat Gas LPG Boiler Input maximum kW Gross 163 0 159 5 326 319 1 489 478 6 Boiler Input maximum kW Nett 146 8 146 ...

Page 43: ...9 0 87 4 At 30 nominal power and in 30 C return temperature regime P1 kW 29 1 36 0 44 1 58 8 76 2 N1 Gross 96 6 94 6 96 6 95 0 96 8 Auxiliary electricity consumption Under full load elmax kW 0 072 0 072 0 151 0 252 0 252 Under partial load elmin kW 0 043 0 043 0 045 0 151 0 151 In standby mode PSB kW 0 005 0 005 0 005 0 005 0 005 Other properties Heat Loss Pstby kW 0 19 0 19 0 22 0 22 0 22 Nitroge...

Page 44: ... in all poles 3 A mains isolator must be provided adjacent to the boiler in a readily accessible position The supply should only serve the boiler using the conduits supplied High and low voltage cables should be separated and routed along individual conduits 4 2 3 high stacked modules It is highly recommended that each boiler module is connected via its own mains isolator to facilitate servicing a...

Page 45: ...f electrical supply and control signals Signal cables must not be run in the same conduit as mains voltage cables Option 1 reference should be made to Building Regulations and CIBSE Guide Energy Efficiency in Buildings for controls requirements All modules must be sequenced Enable will give On Off control of the modules 0 10V will give modulation control of each module Option 2 provides modulation...

Page 46: ...m and discharge via horizontal vertical flue Fig C1 1 2 Type B23p Flue pressurised intake from ventilated plant room and discharge via horizontal vertical flue Fig C1 1 2 The connection to the boiler is suitable for 100mm flue duct 97 116 150mm flue duct 147 196 254 for connection to an open flue chimney system The resistance of the flue system components is detailed in Figure C1 1 1 The following...

Page 47: ...ure condition at the connection to the boiler is 150Pa positive In the event that the flue system when Hot does generate a suction the maximum suction is 100Pa Fan Dilution The design must provide for the use of balancing and trim dampers and their location and operation must be such that the constraints detailed above can be met Care must be taken to ensure that the fan performance is matched to ...

Page 48: ...freezing of condense water traps and pipework This must be avoided at all times by routing pipework within the building where possible In addition to the above the stacked module arrangement flue boxes are supplied with a trap terminating in a 32mm i d connection which should be connected in a similar manner to a drain Figure C1 1 1 Flue Resistance Model Flue Dia mm Max Flue Length m Equivalent Le...

Page 49: ...e Boiler Installations Adjustable Flashing Ø100 flue Ø100 flue Flat Roof Flashing Single Flue Single Flue 500 long Ø100 250 long Ø100 1000 long Ø100 Single Flue Vertical terminal Ø100 Flue Ø80 100 Eccentric Adaptor Wall Clamp Ø100 Single Flue 500 long Ø100 1000 long Ø100 Single Flue Single Flue 250 long Ø100 Wall Clamp Ø100 1000 long 45 Bend Ø100 1000 long 90 Bend Ø100 flue system if suitable Modu...

Page 50: ...oded or in any position adjacent to an extraction system which is carrying flammable vapour Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing the boiler Boiler house ventilation Low level inlet 4cm per kW of total rated input Net High level output 2cm per kW of total rated input Net Compartment ventilation Where the boiler is to be installe...

Page 51: ...fans D 1 4 Boiler House Temperatures The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows At floor level or 100mm above floor level 25 C At mid level 1 5m above floor level 32 C At ceiling level or 100mm below ceiling level 40 C D 1 5 General Requirements The air supply should be free from contamination such as buildi...

Page 52: ...al heating and hot water system the hot water storage vessel must be of the indirect cylinder or calorifier type The hot water storage vessel should be insulated preferably with not less than 75mm 3 thick mineral fibre or its thermal equivalent 2 Circulating pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing particularly wher...

Page 53: ...fitting of a safety valve not supplied BS 6644 provides comprehensive information for the selection and location of safety valves and attention is drawn to the higher capacity requirements of safety valves for pressurised hot water systems Figure E1 1 1 Typical Piping Layouts UNVENTED SYSTEM Primary loop Hamworthy recommended system VENTED SYSTEM Primary loop Hamworthy recommended system Circulati...

Page 54: ...rformance against the new boiler waterside pressure loss to ensure that the minimum flow rate can be obtained It is also important that the existing system be flushed through twice to remove any loose matter which may have accumulated If in any doubt regarding the cleanliness of the system a coarse filter should be fitted in the return pipework to the boilers If boilers are run off time clock cont...

Page 55: ... be used 3 Maximum flow temperature C 4 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 Normally manufacturers of vessels impose a limit of 0 5 This value must not be...

Page 56: ... Wessex ModuMax mk3 Boilers 500001308 C Figure E 1 3 1 Schematic 1 External Time Clock Enabled Boiler Hydraulic Schemes For Single Boiler Installations Figure E 1 3 2 Schematic 2 Two Heating Circuits with DHW Boiler Shunt Pump ...

Page 57: ...x ModuMax mk3 Boilers 500001308 C Figure E 1 3 3 Schematic 3 Master and Slave Sequence Control With Reverse Return Primary Hydraulic Schemes For Multiple Boiler Installations Figure E 1 3 4 Schematic 4 Reverse Return Primary Circuit ...

Page 58: ... 5 Schematic 5 Primary Circuit With Individual Boiler Shunt Pumps Hydraulic Schemes Figure E 1 3 6 Schematic 6 Reverse Return Primary Circuit with Individual Motorised Boiler Isolation Note Motorised valves can be either power open power close or power open spring return close ...

Page 59: ...ure E 1 3 7 Schematic 7 Single Pipe Primary Circuit Water meter Mains cold water Quick fill Safety valve Safety valve Safety valve Air separator Common flow sensor Primary Pump Dosing pot Low loss head er Expansion vessel Pressurisation Unit Boiler 1 Boiler 2 Boiler 3 Air dirt separator ...

Page 60: ...ompensation Legend E End user I Commissioning F Heating engineer Menu Operating Line User Level Function Setting LPB System 6600 F Device address 1 6630 F Cascade Master Automatically Heating Circuit 1 900 F Operating mode Changeover Automatic Configuration 5710 F Heating circuit 1 On 5977 F Function of input H5 HCS 5978 F Contact type H5 NC Heating Circuit 1 740 F Flow temp min set point 50 741 F...

Page 61: ...o their parameter setting as heating cir cuits 1 2 have pre defined outputs for each extension module as shown in the table below Boiler Parameter Settings Single Boiler Note To check operation of pumps mixing valves thermostats select engineer diagnostic consumers parameters 8730 to 8779 Optional extras required for this configuration 2x Heating circuit extension modules AGU2 55A109 Part number 5...

Page 62: ...cade pump Q25 5931 F Sensor input BX2 Boiler 1 Master Common flow sensor B10 Boilers additional set to none 6117 F Central compensation set up Boilers all set to 5 6200 F Save sensors Boilers all set to yes Internal time clock settings Settings must be programmed to master boiler Menu Operating Line User Level Function Setting Time program 500 E Mon sun Mon Fri As req Heating 501 E 1st period on C...

Page 63: ...modulation 5955 F Voltage value 2 H1 10 0v 5956 F Function valve 2 H1 1000 1000 100 modulation 5890 F Relay output QX1 Boiler pump Q1 BMS 0 10v Temperature Menu Operating Line User Level Function Setting LPB System 6600 F Device address 1 Configuration 5710 F Heating circuit 1 Off 5950 F Function input H1 Consumer req VK1 10v 5951 F Contact type H1 NO 5953 F Voltage value H1 0 5v 5954 F Function v...

Page 64: ...o 4 5 ect 6601 F Segment address Boilers all set to 0 6640 F Clock mode Boilers all set to Slave with remote setting Configuration 5710 F Heating Circuit 1 Boilers all set to off 6200 F Save sensors Boilers all yes 6117 F Central compensation set up Boilers all set to 5 Note Merley to be set up independently using the Merley O M 500001210 Optional extras required for this configuration Merley wall...

Page 65: ...HAMWORTHY HEATING LTD 59 Wessex ModuMax mk3 Boilers 500001308 C ...

Page 66: ...HAMWORTHY HEATING LTD 60 Wessex ModuMax mk3 Boilers 500001308 C INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION ...

Page 67: ......

Page 68: ...ales Service McDowall Modular Services 2 Penson Road Queenslie Industrial Estate Glasgow G33 4AG tel 0141 336 8795 fax 0141 336 8954 email MMS McDowallModularServices hamworthy heating com North East England Service Allison Heating Products 12 Sunnyside Lane Cleadon Village Sunderland SR6 7XB tel 0191 536 8833 fax 0191 536 9933 email allison heating gmail com Customer Service Centre Hamworthy Heat...

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Brand: Lamborghini Caloreclima Pages: 64

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