andrews MAXXflo EVO Manual

Andrews. Built to perform.
Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference.
M9373
MAXXfl o EVO
High effi ciency condensing stainless steel storage water heater
CWH 90/302, CWH 120/302
INSTALLATION AND MAINTENANCE MANUAL

General 2 MAXXfl o EVO
Blank Page

General 3 MAXXfl o EVO
Table of Contents
Ref Subject Page
1.0 General & Safety Information
1.1 Description of heater ...............................................................................
1.2 For whom is this manual intended? ........................................................
1.3 Symbols used in this guide .....................................................................
2.0 Safety
2.1 Usage and competency ..........................................................................
2.2 General safety .........................................................................................
2.3 Regulations and standards ......................................................................
2.4 CE Marking .............................................................................................
3.0 Technical Data
3.1 Technical data .........................................................................................
3.2 Product Fiche ..........................................................................................
3.3 Performance data ...................................................................................
3.4 General dimensions and connections .....................................................
3.5 System Schematic examples ..................................................................
3.6 Wiring diagrams ......................................................................................
4.0 Installation
4.1 Locating the heater .................................................................................
4.2 Removing the door and inner cover ........................................................
4.3 Cold water supply ...................................................................................
4.4 Unvented design .....................................................................................
4.5 Secondary return design (DHW circulation pump) .................................
4.6 Condensate disposal ...............................................................................
4.7 Flue systems and ventilation ...................................................................
4.8 Maximum fl ue lengths .............................................................................
4.9 Gas connections ......................................................................................
4.10 Electrical & communication connections .................................................
5.0 Commissioning
5.1 Filling and removal of air .........................................................................
5.2 Commissioning of heat engine ................................................................
5.3 Conversion to LPG .................................................................................
5.4 Frost protection and Legionella ...............................................................
5.5 Final checks and user handover ..............................................................
5.6 Fault fi nding .............................................................................................
6.0 Maintenance
6.1 Routine Inspection intervals & requirements ............................................
6.2 Removing and changing components .....................................................
6.3 Flushing / Descaling the heat exchangers .............................................
6.4 Component parts illustrations ....... ..........................................................
6.5 Recommended spares requirements ......................................................
6.6 Error codes ...............................................................................................
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18
20
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26
35
36
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46
48
50
51
52
59
69
70
78
79

General 4 MAXXfl o EVO
1.1 DESCRIPTION OF HEATER
This Andrews Water Heaters MAXXfl o EVO is a gas fi red, low NOx, twin heat engine, cascading, direct fi red
water heater, with an integrated stainless steel tank.
Fully automatic electronic controls are integrated into the heater, with a wide range of control and sensor
options available. The controls also provides voltage free outputs for Enable, Burner On and fault indication.
Full BMS integration is available through the use of Modbus and optional protocol devices.
Access to the controls of the heater via the internet and/or mobile phone app, is possible through an optional
web server device available from Andrews Water Heaters.
Each heat engine module consists of a stainless steel combustion chamber, premix burner, modulating fan,
gas valve, ignition and fl ame detection electrodes, water pressure sensor and a NTC fl ue sensor for safety
supervision.
Each heat engine module is equipped with NTC sensors for precise temperature control on fl ow and return
manifolds. Fully premixed, radiating, modulating burner, integrated with gas valve to deliver precise gas/air
mixture throughout the full modulation range.
Common combustion air intake manifold, takes air from boiler room (type B23 fl ue) or directly from outside
via a combined fl ue system (C13, C33, C53 & C63).
The safety and operation functions of each heat engine are managed by micro processor controlled circuit
boards, one for each heat engine. The upper controller also acts as the cascade master controller, modu-
lating the heat engines according to the demand, based on data from the systems sensors. Control is per-
formed using comparison parameters between the requested temperature and the global fl ow temperature.
C L:
When a demand is started (the sensor of the DHW tank is less than the set point of the DHW tank - Hyster-
esis), the heat engine is ignited quickly (in the case of the MAXXfl o EVO 90 & 120 the second heat engine
starts approximately 60 seconds after the fi rst heat engine ignition). The controls calculate the charge set-
point (factory standard is the setpoint of the DHW tank + 3OC) and the heat engine (s) modulate the pump (s)
and burner (s) so that the charge temperature in the tank does not exceed the charge set point.
When the temperature at B3 sensor equals the set point of the DHW tank, the burner (s) are switched off
during operation and the control elements remain in stand-by until the heat demand is restored.
If the temperature of the DHW tank (B3 sensor) is less than the DHW setpoint - DHW hysteresis, the de-
mand will be restarted and the operation as described above will start again.
1.2 FOR WHOM IS THIS MANUAL INTENDED?
This manual is intended for the heating specialist who installs commercial/industrial heating plant and equip-
ment.
1.0 GENERAL & SAFETY INFORMATION

General 5 MAXXfl o EVO
1.3 SYMBOLS USED IN THIS GUIDE
DANGER!
Indicates serious danger to personal safety and life
DANGER of electric shock!
Indicates serious danger from electricity to personal safety and life
WARNING!
Very hot water can cause severe burns and in extreme cases death
CAUTION!
Indicates a potentially dangerous situation for the heater and the
environment
INFORMATION
Suggestions to assist the user in implementing instructions in this
guide
ADDITIONAL READING
Reference to additional information in other documents

Safety 6 MAXXfl o EVO
2.1 USAGE AND COMPETENCY
2.1.1 IMPROPER USE
This Andrews Water Heaters product has been designed and manufactured to comply with
current European standards of safety. However, following an improper use, dangers could arise
concerning the safety and life of the user or of other people, or damage could be caused to the
heater or other objects. This heater is designed to be used in a domestic hot water supply and
storage system. Any other use of this heater will be considered improper. Andrews Water Heat-
ers declines any responsibility for any damage or injuries caused by an improper use. In order
to use the heater according to its designed scope, it is essential to carefully follow the instruc-
tions given in this guide.
2.1.2 USER COMPETENCY
This heater is not intended for use by persons with reduced physical, sensory or mental capa-
bilities, or lack of experience and knowledge, unless they are given supervision or Instruction
concerning the use of it by a person responsible for their safety. Children under the age of 12
years should not be permitted to use the heater.
2.1.3 ENGINEER COMPETENCY
The installation, adjustment & servicing of this heater must be carried out by a competent
person and installed in accordance with current standards and regulations. Failure to correctly
install or maintain this heater could cause injury to persons or damage to property. The manu-
facturer shall not be held liable for any such injury and/or damage.
2.2 GENERAL SAFETY
2.2.1 SMELL OF GAS
If you smell gas - follow these safety instructions:
- Do NOT turn off or on any electrical switches (including light switches)
- Do NOT smoke
- Do NOT use the telephone
- DO evacuate persons away from the source of the gas smell
- DO close the main gas shutoff valve
- DO open all the windows and doors where the gas leakage has occurred
- DO inform the gas authority or a competent specialist as soon as possible
2.2.2 FLAMMABLE SUBSTANCES
Do not store or use explosive or easily inflammable material (such as petrol, paint or
paper) in the same room where this heater has been installed.
2.2.3 VERY HOT WATER
Water temperature over 50OC can cause burns and in severe cases injury or death. Children,
the elderly and the physically or mentally disabled are most at risk from scald injury. Feel water
before bathing and showering. Temperature limiting devices such as mixing valves should be
installed whenever possible to ensure safe temperatures at outlets
2.0 SAFETY

Safety 7 MAXXfl o EVO
2.2.4 HEATER INSTALLATION AND MAINTENANCE
This heater has been designed for use with G20 (natural gas) and G31 (liquefi ed propane gas) and
is manufactured to give an effi cient, safe and long service life. To ensure continued trouble-free op-
eration of this heater at maximum effi ciency, it is essential that correct installation, commissioning,
operation and service procedures are carried out strictly in accordance with the instructions given
in this manual.
Only original parts and accessories from the manufacturer may be used on this heater. Using non-
approved parts may compromise the safety of the heater and invalidate any warranty.
In the event of failure and/or suspected faulty functioning of the heater. Switch off the heater and
contact a suitable qualifi ed technician. Do not attempt to make any repairs yourself, unless you are
suitably qualifi ed and competent to do so.
2.3 REGULATIONS AND STANDARDS
This heater must be installed in accordance with relevant Standard Specifi cations, Codes of Practice and cur-
rent Building Regulations, together with any special regional requirements of the Local Authorities, Gas under-
taking and Insurance Regulations for the Electrical Equipment of Buildings. The installation of this heater must
be in accordance with the relevant requirements of:
• Health and safety at work act 1974
• Building regulations 2010
• Electricity at work regulations 1989
• Management of health and safety at work regulations 1998
• Manual handling regulations 1992
• Model water byelaws 1986
• BS 7671 - Requirements for electrical installations, IEE wiring, regulations
• BS 6644 - Specifi cation for the installation of Gas fi red hot water boilers for rated inputs between 70kW
(net) and 1.8 MW
• BS 7074-2 - Applications selection and Installation of expansion vessels and ancillary equipment for sealed
water systems.
• BS 6880:1 Code of practice for low temperature hot water heating systems of output greater than 45kW.
• BS 6880:2 Code of practice for low temperature hot water heating systems of output greater than 45kW.
• BS 6880:3 Code of practice for low temperature hot water heating systems of output greater than 45kW.
• CP 342:2 Code of practice for centralised hot water supply. Buildings other than individual dwellings.
• IM/11 - Flues for commercial and Industrial Gas Fired Boilers and Air Heaters
• IGE/UP/1 - Soundness Testing and Purging Procedure for Non Domestic Installations
• IGE/UP/2 - Gas Installation Pipe work, Boosters and Compressors for Industrial and Commercial Premises
• IGE/UP/10 - Installation of fl ued gas appliances in industrial and commercial premises.
• IGE/UP/16 - Design for Natural Gas installations on industrial and commercial premises with respect to
hazardous area classifi cation and preparation of risk assessments
These manufacturer’s notes must not be taken in any way as over-riding statutory
obligations.

Safety 8 MAXXfl o EVO
2.4 CE MARKING
There is one data plate located on the heater. This is mounted on the outside of the heater (left hand side)
The CE marking documents of this heater confi rms compliance with the essential requirements of the follow-
ing directives or Regulations:
• Gas Appliance (GAR) Regulation 2016/426
• Ecodesign Requirements for Energy Related Products (ERP) 2009/125/EC
• Electromagnetic Compatibility (EMC) Directive 2014/30/EU
• Low Voltage (LVD) Directive 2014/35/EU
• Boiler Effi ciency (BED) Directive 92/42/EEC
KEY
1 Type approval designation
2 Gas type and pressure
3 Model Name
4 Heat, gas fl ow & CO² data
5 Technical data
6 Serial number and year
This manual is an integral and indispensable part of the heater and it is suggested that
this manual is kept in a safe place for future reference.
1
2
3
4
5
6

Technical Data 9 MAXXfl o EVO
Product name CWH
90/302
CWH
120/302
Daily electricity consumption
Qelec kWh 0.223 0.246
Declared load profile XXL XXL Sound power level, indoors
LWA dB 62 65
Daily fuel consumption
Qfuel kWh 26.529 27.195
Emissions of nitrogen oxides
NO Xmg/kWh 39 39
Weekly fuel consumption with smart controls
Qfuel, week, smart kWh --
Weekly electricity consumption with smart controls
Qelec, week, smart kWh --
Weekly fuel consumption without smart controls
Qfuel, week kWh --
Weekly electricity consumption without smart controls
Qelec, week kWh --
Storage volume Vl300 300 Mixed water at 40 °C V40 l∞∞ Harmonised standards applied
Specific precautions that shall be taken when the water heater is assembled, installed or maintained:
EN: 13203-2
Before any assembly, installation or maintenance the
installation and operation manual has to be read
attentively and to be followed
MAXXflo EVO
3.0 TECHNICAL DATA
3.1 TECHNICAL DATA

Technical Data 10 MAXXfl o EVO
Product name CWH
90/302
CWH
120/302
Declared load profile XXL XXL Water heating energy efficiency class ---- ---- Water heating energy efficiency %91 90
kWh(1)
49 54
GJ (2) 21 21
Thermostat temperature setting ᵒC 60 60
Sound power level LWA indoors dB 62 65
Ability to off-peak hours functioning(3) Yes Yes
Enabled smart control settings(4) --
(1) Electricity (2) Fuel (3) If applicable
(4) If smart control setting value is "1", the water heating energy efficiency and annual electricity / fuel consumption only relate to enabled smart control settings
Annual energy consumption
Other load profiles for which the water heater is suitable to use and corresponding water heating efficiency and annual electricity consumption(3)
MAXXflo EVO
3.2 PRODUCT FICHE

Technical Data 11 MAXXfl o EVO
3.3 PERFORMANCE DATA
PERFORMANCE Unit 90/302 120/302
Q Maximum Heat Input net (gross) kW 84.0 (93.3) 112.0 (124.4)
Q Minimum Heat Input net (gross) kW 18 (19.5) 24 (26)
Output Max (Min) kW 91.6 (19.5) 122.1 (26)
V Maximum Gas Consumption G20 / G31 m3/h 8.7 / 3.5 11.6 / 4.7
Flue gas temperature max (75OC Anti-legionella) oC90
CO2 at max output G20 / G31 % 9.2 / 10.0 9.4 / 9.5
CO at max output ppm 100 120
NOx emission GCV mg/kWh 39.1 36.0
NOx Class class 6
Sound level (EN15036-1 Average @ 1m) LAeq 62 65
HOT WATER
Tank capacity litres 300
Thermal Standby losses kWh/day 2.26
Recovery rate through 50oC l/hr 1,440 1,920
Recovery rate through 56oC l/hr 1,284 1,712
Approximate Heat up time T = 50oCminutes 12 9
Approximate Heat up time T = 45oCminutes 10 8
PMS Inlet / Operating pressure max (min) bar 9.0 (0.8)
In / Out connections BSP 1 1/2”
Water return connection BSP 1”
ELECTRICAL
Electrical supply voltage / Hz V / Hz 220 - 240 / 50
Fuse rating on mains supply A 5
Insulation protection rating IP 20
Power consumption - standby W 5.5
Power consumption - maximum W 215 280
FLUE
Flue connection - single mm 130
Flue connection - concentric mm 130/200
Flue systems permitted type B23, C13, C33, C53, C63
Max fl ue equivalent length - open (B23) m 44
Max fl ue equivalent length - concentric (C13, C33) m 24
Max fl ue equivalent length - twin (C53) m 48
Flue gas volume @ minimum load kg/h 15.7 21.0
Flue gas volume @ nominal load kg/h 146.5 195.3
Maximum internal fl ue pressure @ 65OC Pa 120 160
Maximum condensation production l/h 12.0 16.0
OTHER CONNECTIONS
Gas BSP 3/4”
Condensate mm 41mm (Hunter type)
Tank drain mm 22mm
WEIGHTS & CLEARANCES
Shipping weight kg 265 280
Weight empty kg 195 210
Weight full kg 505 530
Service clearance - rear mm 20mm
Service clearance - right mm 25mm
Service clearance - top mm 300mm
Service clearance - left mm 300mm
Service clearance - front mm 800mm

Technical Data 12 MAXXfl o EVO
3.4 GENERAL DIMENSIONS & CONNECTIONS (300 LITRE MODELS)
1046
913
602
2008 - REMOVEABLE AIR DUCT SPIGOT FOR LOWER DOOR CLEARANCE
1980
671
602
GAS INLET
0.75" BSP
210
496
T&P VALVE EXIT
TANK DRAIN (INSIDE UNIT)
22mm ISOLATION VALVE
97
LH Side Front Door
Inner Cover
MULTIPLE CABLE
ENTRY POINT
395
CONDENSATE TRAP
41mm
718
209
172
300
391
128
91
301
91
DHW
1.5" BSP (m)
SECONDARY
RETURN
1" BSP (m)
MCWS
1.5" BSP (m)
INSPECTION
HATCH & SENSOR
WELL CONCENTRIC FLUE/AIR
30kW & 60kW Models - 80mm/125mm
90kW & 120kW Models - 130mm/200mm
REMOVABLE AIR DUCT
SPIGOT PLATE
REMOVABLE PLATE
FOR TANK CONNECTION
INSPECTION (INSIDE UNIT)
USER DISPLAY
POWER & RESET
SWITCHES
MANUAL
BLEED VENT
T&P VALVES - 28mm
30kW & 60kW Models - 1 fitted
90kW & 120kW Models - 2 fitted
Model Dimensions:
MAXXflo EVO CWH 30/301
MAXXflo EVO CWH 60/301
MAXXflo EVO CWH 90/302
MAXXflo EVO CWH 120/302
60
259
DATA PLATE
1998 - MINIMUM HEIGHT

Technical Data 13 MAXXfl o EVO
EXAMPLE 1: SINGLE MAXXfl o EVO (SCHEMATIC)
EXAMPLE 2: PARALLEL MAXXfl o EVO (SCHEMATIC)
Maximum ci
Maximum circulation rate Q4 pump
Model MAXXfl o
EVO 90
MAXXfl o
EVO 120
Flow m3/h 1.8 2.4
3.5 SYSTEM SCHEMATIC EXAMPLES

Technical Data 14 MAXXfl o EVO
EXAMPLES 1 & 2: SINGLE AND PARALLEL MAXXfl o EVO (SETUP)
Menu Parameter Settings
DHW 1660
Pump release
Set desired option for activation of the DHW circulation pump, normally either activated with
time program 4 (DHW) or independently of DHW via time program 5
1661
Pump cycling
When switched on, the circulation pump will cycle on and off during the activation period (on
for 10 minutes then off for 20 minutes repeatedly). This function is especially useful where
the heat losses on the return pipe work are high and the burner is operating continually for
long periods of time, with little or no DHW draw off .
1663
Circulation setpoint
Standard setpoint is 45OC. When the B39 sensor is installed, the controller will monitor the
DHW return temperature during the activation time of the pump. Whenever the temperature
acquired by the sensor falls below the circulation setpoint, the pump is kept running until the
setpoint is reached (minimum on time is 10 minutes). During a legionella cycle operation the
temperature at the sensor is used to adjust the dwell time, ensuring that the entire DHW sys-
tem reaches the legionella setpoint for the total dwell time length set. The dwell time counter
is not started until the temperature at the sensor reaches legionella setpoint.
Related settings table
3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)
/1
(
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:KLWH 5HOD\
/ 1 3( /1

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&2
12 1& &2
12 1& &2
12 1&

Technical Data 15 MAXXfl o EVO
EXAMPLE 3: MAXXfl o EVO & BUFFER SS300-10 (SCHEMATIC)
3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Technical Data 16 MAXXfl o EVO
EXAMPLE 3: MAXXFLO EVO & STORAGE TANK (SCHEMATIC)
Menu Parameter Settings
Confi guration 6020 Set function of extension module 1 to “Multifunctional”
6030 Set Relay Output QX21 module 1 to “dT controller 1 K21”
6041 Set sensor input BX22, module 1 to “Special temperature sensor 1”
General func-
tions
5570 Factory setting : Not used
5571 Factory setting: “- 1.5OC” - When BUFFER SS300-10 tank temperature is 0.5OC below
MAXXfl o EVO tank temperature K21 pump will be turned off .
5572 Factory setting: “3.0OC” - When BUFFER SS300-10 tank temperature is less than 2.0OC
below MAXXfl o EVO tank temperature K21 pump will be turned on.
5573 Factory setting : “DHW sensor B3”
5574 Factory setting : “Special temperature sensor 1”
5575 Factory setting : 30 seconds - Represents the minimum time that K21 pump will be activated
even if parameter 5571 conditions are met.
Related settings table (in addition to example 1 table)
3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)
(
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4;
4;
1
1
%U %H
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%H
/
1
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Technical Data 17 MAXXfl o EVO
EXAMPLE 4: BMS CONNECTIONS
A +
B -
REF
Enable
Flame Burner 1
Fault
Modbus
Flame Burner 2
BMS
Black Relay
White Relay
L N PE LN12349
NO
NO
COCO
5678
Black Relay
NO
CO
3.5 SYSTEM SCHEMATIC EXAMPLES (CONTINUED)

Technical Data 18 MAXXfl o EVO
3.6 WIRING DIAGRAMS (MAXXfl o EVO 90 & 120 KW MODELS)
PCB1
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8
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4;
1
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SXPS
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5HWXUQ
VHQVRU
NLW
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%ODFN 5HOD\
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REF
DB/CL+
MB/CL-
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Technical Data 19 MAXXfl o EVO
PCB2
3.6 WIRING DIAGRAMS (MAXXfl o EVO 90 & 120)

Installation 20 MAXXfl o EVO
The location selected for installation of the heater must allow the provision of a satisfactory fl ue, an ad-
equate air supply (for type B23), a drain and be well illuminated. A purpose built plant room or compartment is
strongly recommended.
If a purpose built plant room is not available, measures should be taken to protect the heater from damage
and prevent any extraneous matter from being stored on or around the heater. See BS 6644 Clauses 4, 5
and 6 for details.
There must be easy access to the plant room and heater at all times. The heater must be located in an area
where leakage from the tank, water connections or the combined temperature and pressure safety valve will
not result in damage to the area adjacent to it. When such locations cannot be avoided, a suitable drain tray
must be installed under the heater. The drain tray must be no deeper than 38mm and must be 100mm wider
and longer than the heater. It should be piped to an adequate drain using 20mm (0.75in) diameter pipe,
angled for proper drainage.
Access must be provided to the front of the heater with adequate clearance for servicing and operation
(See 3.3) The fl oor on which the heater is installed must be fl at, level and of suffi cient strength to withstand
the weight of it when fi lled with water, and should satisfy the requirements of the Local Authority & Building
Regulations.
Ensure that the heater is isolated from the power supply.
Remove the single screw on the left hand side of the door.
Release the two latches by pulling on the back of the latch and lifting outwards.
Open the door, and detach the case earthing lead near the upper hinge. Lift the door upwards and off its
hinges. Place the door carefully against a wall, ensuring that it cannot fall over.
4.1 LOCATING THE HEATER
4.2 REMOVING THE DOOR AND INNER COVER
4.0 INSTALLATION