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MHS Boilers Ultramax WM 45 Operating & Maintenance Manual

Wall mounted condensing boiler
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Ultramax WM Wall Mounted Condensing Boiler
Operating & Maintenance Manual
For Models 45, 65, 85, 100 & 120
MHS Boilers Ltd
3 Juniper West
Fenton Way
Basildon Essex
SS15 6SJ
01268 546700 Telephone 01268 888250 Fax
WWW.MHSBOILERS.COM
L282

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  • Page 1 Ultramax WM Wall Mounted Condensing Boiler Operating & Maintenance Manual For Models 45, 65, 85, 100 & 120 MHS Boilers Ltd 3 Juniper West Fenton Way Basildon Essex SS15 6SJ 01268 546700 Telephone 01268 888250 Fax WWW.MHSBOILERS.COM L282...

  • Page 2: Table Of Contents

    MHS Boilers Ltd © Contents Page # Section WM Technical data WM Dimensions 1 Introduction General The supplier This document Service General restrictions Description General Main components 2.21 Case Removal 2.2.2 Description of principal components Boiler control Safety aspects Safety...
  • Page 3 MHS Boilers Ltd © 5.4.1 Water flow 5.4.1.1 Flow and resistance 5.4.1.2 Pump characteristics 5.4.1.3 Shut-off valves 5.4.1.4 Valves 5.4.1.5 Water flow protection device 5.4.2 Water pressure 5.4.2.1 Operating pressure 5.4.2.2 Boiler expansion vessel 5.4.2.3 System expansion vessel 5.4.2.4 Water pressure protection device 5.4.3...

  • Page 4: Wm Technical Data

    MHS Boilers Ltd © WM Technical data Type WM/45 WM/65 WM/85 WM/100 WM/120 Nominal heat output (80/60 5.6-39.2 8.3-59.2 15.6-77.8 17.6-88.2 21.9-109.8 Nominal heat output (40/30 6.3-43.0 9.2-65.0 17.0-85.0 19.2-96.3 24.0-120.0 Heat input, gcv (H 6.4-44.4 9.5-67.4 17.7-88.8 19.9-99.9 25.0-124.8 Heat input, ncv (H 5.8-40.0...

  • Page 5: Wm Dimensions

    MHS Boilers Ltd © WM Dimensions WM/120 Type WM/45 WM/65 WM/85 WM/100 ⁄ " ⁄ " ⁄ " ⁄ " ⁄ " ⁄ "/Rp 1" ⁄ "/Rp 1" ⁄ "/Rp 1" ⁄ "/Rp 1" ⁄ "/Rp 1" Table 2 (We reserve the right to make changes without prior notification) The data may deviate slightly due to fabrication tolerances.

  • Page 6: 1 Introduction

    - Low noise level - Broad control range - Can be supplied in a wide range of models Through active and market oriented research, MHS Boilers Ltd is in a position to offer solutions for the most challenging heating requirements. 1.2 The supplier MHS Boilers Ltd are proud to supply and technically support the Ultramax WM Range of boilers throughout the United Kingdom.

  • Page 7: Service

    All the data, information and suggestions concerning its products provided by MHS Boilers Ltd are based on careful study. However, the use, installation and operation of the same are outside the control of MHS Boilers Ltd and neither MHS Boilers Ltd nor any other organisations associated with it, accept any liability for the same.
  • Page 8 MHS Boilers Ltd © (condenser). Both heat exchangers consist of several smooth pipes in the form of a coil. The two heat exchangers are connected to each other using water distribution manifolds. The water is circulated by the boiler pump. This pump will be in the boiler for types 45, 65 and 85 and external for the types 100 and 120 (supplied by the installer).

  • Page 9: Main Components

    MHS Boilers Ltd © 2.2 Main components 1 Flue outlet connection 12 On/off switch 2 Air inlet connection 13 Condensate drain 3 Gas connection 14 Frame 4 Flow connection 15 Burner/ heat exchanger package 5 Automatic air vent 16 Water flow temperature sensor...

  • Page 10: Description Of Principal Components

    MHS Boilers Ltd © 2.2.2 Description of principal components Fan [9] The fan pulls in and compresses the combustion air, drawn from inside the casing of the boiler. The fan is a DC current fan equipped with a speed feed-back signal. This speed feed-back signal is transmitted back to the controller, which makes the necessary corrections.

  • Page 11: Boiler Control

    MHS Boilers Ltd © Casing [6] The casing can be removed easily in 3 units. To do this, refer to the section 2.2.1. Electrical equipment This comprises of the control system and safety devices of the boiler. The connection terminals are installed in a fully sealed enclosure behind the control panel [21].

  • Page 12: Safety

    MHS Boilers Ltd © 3 Safety Installation specifications Read the specifications before commencing with installation. The equipment should be installed by a recognised installer in accordance with applicable national and local standards and specifications. The installation should only be used for heating systems with a maximum water temperature of 90°C.

  • Page 13: Delivery And Transport

    MHS Boilers Ltd © Installation The appliance should be installed by a recognised installer in accordance with applicable national and local standards and specifications. Follow all the safety instructions precisely. Operation In case of a gas leakage: Prevent the boiler from operating and close the gas valve. Open doors and windows and notify the relevant authorities.

  • Page 14: Installation

    5.1 Regulations The appliance should be installed by a recognised installer in accordance with the applicable national and local standards rules and regulations. The commissioning should preferably be done by the Technical Services Department of MHS Boilers Ltd. 5.2 Installation area 5.2.1 General...

  • Page 15: Connections

    MHS Boilers Ltd © 5.3 Connections 5.3.1 Gas connection The gas connection should be installed by a recognised installer in accordance with applicable national and local standards and specifications. The gas connection is located on the bottom of the appliance.
  • Page 16 MHS Boilers Ltd © sensitive. The boiler can be switched on and off using the on/off switch on the control panel. The installer should use a 2-pole main isolating switch with a contact opening of at least 3 mm in the supply circuit to the boiler.
  • Page 17 MHS Boilers Ltd © - Calibration of the room sensor - Delay to flow temperature compensation due to external temperature up to a maximum of 3 hours - Holiday Programme - Frost protection system based on external temperature or room temperature...
  • Page 18 MHS Boilers Ltd © E8.1121 This is a control system for the weather dependent control of two secondary heating circuits. In addition, a hot water circuit can also be controlled at two different Set Points. All the settings can be made separately for each secondary circuit. This E8 controller can be further extended with an optimisation controller system for each secondary group (BM8).
  • Page 19 MHS Boilers Ltd © Terminal Designation Screened Cable Block Terminal #s Voltage Description/Operation/Function (Earthed Screening) 230V Permanent Neutral 2 & 3 230V Permanent Live Heating Zone 1 Pump 230V Output (Max 1 Amp) 230V Heating Zone 2 Pump 230V Output (Max 1 Amp)
  • Page 20 MHS Boilers Ltd © KKM8 This is a boiler cascade manager with which up to 8 boilers can be connected in cascade and an extra on/off boiler can be operated. The KKM8 also has the same functional features as the E8.1121.
  • Page 21 MHS Boilers Ltd © 230V Do Not Use (Not Used With Ultramax Boilers) Not Generally Used (Multifunctional Relay 3 230V Output/Secondary Circulating Pump Live Output) Not Generally Used (Solar Panel Transfer Pump 1 / 230V Multifunctional Relay 4 Output) Terminal Designation (Sensor and low voltage terminals)
  • Page 22 MHS Boilers Ltd © WM Connecting terminals The operation of the appliance can be influenced by externally generated signals applied to the appropriate terminals. Rear Of KM628 Boiler Controller Terminal Designation Screened Terminal #s Voltage Description/Operation/Function Cable (Earthed Screening) Do Not Use 6 &...
  • Page 23 MHS Boilers Ltd © Terminal: Description: Supply for the boiler should be installed with 6A fuse protection. If miniature L1-N-Earth circuit breakers are used, these should have C Rated characteristics. Lockout circuit (240 Vac from boiler, 1A). If the connection between the two terminals...
  • Page 24 MHS Boilers Ltd © Heating Pump Control Relay (SPDT). (To Enable Priority Hot Water Operation Without the Application of an E8 Zone Controller.) Rear Of KM628 Boiler Controller Terminal Designation Controller Relay Terminal Terminal Voltage Description/Operation/Function ST11 1 230V Hot Water Charging Pump 230V Neutral Output (Max 0.5 Amp)
  • Page 25 MHS Boilers Ltd © Ultramax BMS Run and Fault Indication Relays (Optional Extra) Terminal Designation (Boiler Run Indication Relay) Controller Relay Terminal Terminal Voltage Description/Operation/Function Relay Coil Live Input From Terminal ST11.4 ST11.4 230V Located on the rear of the KM628 boiler controller.

  • Page 26: Water Connections

    MHS Boilers Ltd © 5.3.3 Water connections It is recommended that the flow and return pipes are securely fixed with brackets. This prevents damage and makes maintenance easier. The boiler is deigned for use on sealed pre-pressurised systems only and is not suitable for use in open vented systems.

  • Page 27: Air Inlet Pipe

    MHS Boilers Ltd © • Type C83: Room Sealed appliances in cascade, connected to separate air supplies but common flue discharge through the roof. 5.3.4.2 Air inlet pipe The air supply pipe may be single wall, smooth or flexible, and be made of: •...

  • Page 28: Flue

    MHS Boilers Ltd © The flue gas discharge pipe to be used should be airtight and watertight at the joints and connections, or should be seamless. Horizontal components in the flue pipe should be installed sloping in the direction of the appliance (minimum 5 cm per meter).
  • Page 29 MHS Boilers Ltd © Calculation of diameter and length For the calculation and control of the inner diameter of a discharge system with mechanical discharge, please refer to the applicable national and local standards and regulations. Maximum Length of flue in m...

  • Page 30: Condensate Drain

    MHS Boilers Ltd © Type Diameter in mm Maximum length of straight pipe in m Number of 90 ° pipe bends WM/45 WM/65 WM/85 WM/100 WM/120 Table 8 Maximum length of straight pipe 5.3.5 Condensate drain Condensate water is formed due to the condensation of flue gases, and this has to be drained from the boiler.
  • Page 31 MHS Boilers Ltd © Type ∆t 20 K Pump data Nominal Boiler Pump type Pump Pump Available Maximum* flow resistance WILO speed head at head at Power rate Q nom. flow (Equivalent or nom. nom. consumption better) flow Q flow Q WM/45 1.68...

  • Page 32: Pump Characteristics

    MHS Boilers Ltd © 5.4.1.2 Pump characteristics (Wilo curves shown for guidance. Equivalent or better pumps can be utilised.) Fig. 5 Pump characteristics 5.4.1.3 Shut-off valves It is recommended that manual valves should be installed between the flow and return connections to the installation.

  • Page 33: Water Pressure

    MHS Boilers Ltd © 5.4.2 Water pressure 5.4.2.1 Operating pressure At a maximum flow temperature of 90°C and with the minimum water flow that occurs at a ∆t of 20K, the minimum operating pressure should be at least 1.5 bar. The operating pressure should be measured when the pump is switched off.
  • Page 34 MHS Boilers Ltd © In connection with the hardness of the water, a distinction should be made between the following: a. Temporary hardness: This is also termed carbonate hardness. Deposits are formed at higher temperature and can be removed easily.

  • Page 35: Operating Instructions

    MHS Boilers Ltd © 6 Operating instructions 6.1 Operation The fan, which is modulated by the temperature controller, supplies the combustion air. Due to the resultant under pressure in the venturi, the zero pressure controller in the gas valve mixes in the required quantity of gas.
  • Page 36 MHS Boilers Ltd © Operating mode (cover closed) With the cover closed and by using the Rotational Selector (pos. No. 2) clockwise or anti-clockwise the boilers’ operating mode can be set. The operating modes are:- standby the boiler switched off but frost protection is active...

  • Page 37: Fault Signals

    MHS Boilers Ltd © Setting the required flow temperature for central heating system operation. Attention! This setting is not active if a KKM6/8, E6/8 or BME/BM8, or an external 0-5 V signal is connected. - Open the lid of the KM 628, and a black arrow will appear above P1.
  • Page 38 MHS Boilers Ltd © 6 Limit temperature monitoring system has been triggered The flow temperature has risen above the value set for the same, or the water flow is too low. 7 The maximum flue gas thermostat has been triggered The flue gas temperature has gone above 100°C.

  • Page 39: Setting Into Operation

    The appliance should be installed by a recognised installer. These operating instructions should be closely followed. If the cause of the fault cannot be determined, contact the MHS Boilers Ltd Technical Services Department. Never carry out repairs, unless qualified to do so.

  • Page 40: Commissioning

    MHS Boilers Ltd © 7 Commissioning 7.1 General The commissioning should only be done by qualified personnel. The guarantee will be void if this is not adhered to. 7.2 Commissioning Before operating the appliance, the following should be done: - Switch off the electrical power supply of the appliance - Remove the case.
  • Page 41 MHS Boilers Ltd © the boiler. The ∆t should be between 15 and 25 K at full load. - Check the boiler at minimum load. Set the boiler back to minimum load. At minimum load, the following settings should be...

  • Page 42: Fuel Conversion Ng-Lpg Lgp -Ng

    - Replace the ignition and ionisation electrodes - Clean the fan impeller - Clean the primary heat exchanger with MHS Boilers Ltd WM heat exchanger cleaning granules. (Using only a natural bristle brush only) - Clean the burner assembly with compressed air only. Do not brush the knitted material.

  • Page 43: Procedure

    The ionisation protection can be checked in this manner. The rated ionisation signal is from 6 to 25 µA. The minimum ionisation signal is 2.8 µA. 8.7 Service For service and maintenance the Technical Service Department of MHS Boilers Ltd can be contacted on 01268 546700 191007...

  • Page 44: Additional Information

    MHS Boilers Ltd © 9.0 Flue Terminal Positions All measurements are in mm and are minimum clearances. Terminal Location WM45 & WM65 WM85, WM 100 & WM120 *Below and opening window etc. Below gutter soil pipes etc. Below Eaves. *Below balconies or car port roof.

  • Page 45: Wiring Diagrams

    MHS Boilers Ltd © Legend to Wiring Diagrams Item # 45 – 120 Wiring Diagrams KM628 Boiler Controller Ignition Transformer Ignition Electrode Main Gas Valve Rectification Electrode BM8 Room Unit Gas Valve (1 Amp Control Fuse WM 120 Only) CXE Control Module...
  • Page 46 MHS Boilers Ltd © 191007...
  • Page 47 MHS Boilers Ltd © 191007...
  • Page 48 MHS Boilers Ltd © 191007...
  • Page 49 MHS Boilers Ltd © 191007...

  • Page 50: Notes

    MHS Boilers Ltd © Notes 191007...

This manual is also suitable for:

Ultramax wm 65Ultramax wm 85Ultramax wm 100Ultramax wm 120

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