MHG Heating ProCon HT Bedienungsanleitung

Installation and Operating Manual for the

ProCon HT & HTP 150 & 225

Floor Standing Condensing Boiler Range.

**RVS Controlled**

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth,

Surrey, KT20 5LR

0845 6448802 Telephone. 0845 6448803 Fax.

Email [email protected] Website www.mhgheating.co.uk

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 2

Contents.

Section Page #

1.0 Appliance Type 3

1.1 Single Unit 3

1.2 Cascade Manager 4

1.3 Cascade Slave 5

1.4 System Separation Plate Unit 6

2.0 Installation Regulations and Requirements 7

2.1 Appliance Warranties 7

3.0 Dimensions 8

3.1 Plate Heat Exchanger Hydraulic Resistance 9

3.2 Installation Clearances 9

4.0 Delivery and Mobility 9

4.1 Case Removal 10

5.0 Technical Data 12

6.0 Pressure Relief Valve 13

7.0 Electrical Connections 13

8.0 Hydraulic Design Single Unit 14

8.1 Control Wiring Single Unit 14

8.2 Hydraulic Design Cascade Units 15

8.3 Control Wiring Cascade Units 15

9.0 Fluing Options 16

9.1 Single Unit Conventional Flue 16

9.2 Single Unit Balanced Flue 16

9.3 Cascade Conventional Flue 17

9.4 Cascade Balanced Flue 18

10.0 Filling The System 19

10.1 Expansion Vessel 19

11.0 System Water Quality 20

11.1 Care With The Use Of Solder Flux 20

12.0 Appliance Controls 21

12.1 Control Panel 21

12.2 RVS43 143 Cascade Manager 21

12.3 Module Controller 22

12.4 Module Controller End User Settings 22

12.5 Accessing Module Parameters 23

12.6 Module Operating Codes 25

13.0 Appliance Error Codes 24

14.0 Control Parameter Defaults 27

14.1 RVS43 143 Cascade Manager 27

14.1.1 RVS43 143 Cascade Manager Defaults 33

14.2 Module LMU64 Controller (QAA73 Unit Required.) 63

15.0 Commissioning 67

15.1 Pre-Commissioning Checks. 67

15.2 Combustion System Commissioning 67

15.3 NG/LPG – LPG/NG Conversion Procedure 68

16.0 Routine Inspection and Servicing 70

16.1 Routine Service Inspection 70

16.2 Routine Cleaning and Maintenance 70

16.3 QAA73 Room Unit/Service Tool 72

17.0 Optional System Controls (RVA 63, RVA46, QAA70, QAA50, QAA10) 74

18.0 Internal Wiring 75

18.1 Module Control Indication (OCI420 Communication Clip LED) 75

18.1.1 Module BMS Fault Indication Clip Installation and Setting (AGU2.511 Clip) 76

18.2 Internal Wiring Diagram 77

19.0 Flue Components 78

20.0 Exploded Diagrams 79

21.0 Spares Listings 83

22.0 HTP Exploded Diagram 87

23.0 Installer / End Users Note 88

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 3

1.0 Appliance Type.

There are five build types within the ProCon HT & HTP range.

Please ensure you have the correct unit for the application and where required located

correctly within the cascade prior to beginning the installation.

1.1 Single Units.

(150 Product Code 96.30000-7182)

(225 Product Code 96.30000-7183)

The Single Unit is supplied with an integral low loss header.

This unit does not require the installation of a second low loss header remote from the

appliance.

The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected

(hydraulically) to the appliances flow and return connections.

The Single Unit is supplied complete with an integral RVS43 143 Single Unit Cascade

Manager wired to integral flow and return sensors.(QAZ36). An outside are sensor

(QAC34) is also supplied and located in the base of the unit.

Integral Low

Loss Header.

Complete with

Flow and Return

Sensors

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 4

1.2 Cascade Manager Units

(150 Product Code 96.30000-7184)

(225 Product Code 96.30000-7185)

The Cascade Manager Unit is supplied without an integral low loss header.

A suitably sized low loss header must be installed within the system.

The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected

(hydraulically) to the external low loss header and not to the appliances flow and return

connections.

The Cascade Manager Unit is supplied complete with an integral RVS43 143 multiple unit

Cascade Manager. Remote Flow and Return sensors (QAD36) must be mounted as

indicated in the hydraulic diagram section of manual and wired back the unit. An

outside are sensor (QAC34) is also supplied and located in the base of the unit.

Integral

Distribution

Header.

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 5

1.3 Cascade Slave Units.

(150 Product Code 96.30000-7186)

(225 Product Code 96.30000-7187)

The Cascade Slave Unit is supplied without an integral low loss header and should only

installed where a Cascade Manager is also installed

A suitably sized low loss header must be installed within the system.

The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected

(hydraulically) to the external low loss header and not to the appliances flow and return

connections.

The Cascade Slave Unit is supplied without an integral RVS43 143 multiple unit Cascade

Manager and therefore relies on the presence of a Cascade Master Unit to provide

operational signals via the LPB communication wiring.

Integral

Distribution

Header.

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 6

1.4 System Separation Plate Heat Exchanger Units.

(150 Product Code 96.30000-7325)

(225 Product Code 96.30000-7326)

The System Separation Plate Heat Exchanger Unit are supplied with an integral plate

heat exchanger that maintains absolute separation of the boilers circuit from the

systems circuit.

These units may require the installation of a second low loss header remote from the

appliance. Alternatively the system’s (Secondary) circulating pumps (Heating / HWS) can

be connected (hydraulically) to the appliances flow and return connections.

The System Separation Plate Heat Exchanger Unit is supplied complete with an integral

RVS43 143 Single Unit Cascade Manager wired to integral flow and return

sensors.(QAZ36). An outside are sensor (QAC34) is also supplied and located in the base

of the unit.

Integral System

Separation Plate

Heat Exchanger .

Integral Pressure

Vessel.

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 7

2.0 Installation Regulations and Requirements

The installation of ProCon HT boilers must be in accordance with the relevant

requirements of Gas Safety (Installation & Use) Regulations 1994, Health & Safety at

Work Act, Building Regulations, IEE Regulations, Construction (Design & Management)

Regulations 1994, Local Authority Bye-Laws, National, Fire Regulations and Insurance

Company requirements.

The following Codes of Practice are also applicable:-

BS 5449: 1990 Specification for forced circulation hot water central heating systems for

domestic premises.

BS 6644: 2005 Specification for gas fired hot water boilers of rated inputs between

70kW (net) and 1.8MW(net) (2nd and 3rd family gases).

BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input

not exceeding 60 kW.

BS 6880: 1988 Code of Practice for low temperature hot water heating systems of

output greater than 45kW. Parts 1, 2 & 3.

BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm

(R1) in domestic premises (2nd family gases)

BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central

heating systems.

BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth

edition.

CISBE Guide reference sections B7, B11 and B13.

CP342 Part 2: 1974 Code of Practice for centralized hot water supply.

GE/UP/2 Gas installation pipework, boosters and compressors on industrial and

commercial premises.

IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises

IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1:

Flued appliances.

And any addition prevailing regulation and or code of practice not detailed above.

2.1 Appliance Warranties

All MHG appliances enjoy a full 24 month warranty as detailed in our terms and

conditions.

“The guarantee period shall begin on the day of commissioning, or at latest 3 months

after delivery has been made.

The customer shall only be able to claim against MHG under guarantee if the

commissioning of the object of delivery has been carried out by MHG staff or the

authorised supplier, if the customer has followed MHG's instructions relating to the

treatment and maintenance of the object of delivery, and if no replacement parts of

outside origin have been fitted.

Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the

guarantee.”

In addition to the above warranties, the Primary Heat Exchangers carry a 60 month

guarantee against manufacturing or material defect.

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 8

3.0 Dimensions.

Standard Unit System separation Plate Unit

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 9

3.1 Plate Heat Exchanger Hydraulic Resistance.

3.2 Installation / Service Clearances

Dimension [Minimum mm Clearance ]

A 500

B 1000

C 700

D 680

E 1050

4.0 Delivery And Mobility.

Each ProCon HT boiler is supplied with a manoeuvring tool. This is to be used to

facilitate the correct position of the unit.

MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR

P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk

011011 10

4.1 Case Removal

A 4.0mm Allen Key is required to initiate the removal of the appliances case.

1. Case In Place 2. (1) Turn the MHG Logo, (2) insert

Finger and open the cover to the right.

3. Locate the top sprung hinge pin 4. Using a 4mm Allen Key loosen

and pull down to release the cover. the two captive bolts.

Dieses Handbuch passt für folgende Modelle

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