Home

Installation and Operating Manual for the ProCon 16, 27, 47, 75 & 77

Contents

1. Es an i 1 Heating 1 Heating 1 sa li i LN ii Circuit 1 ll Circuit 2 6 ET 1 7 BE 1 FA 1 EUN iij TH pii pain un it 31 3 SSS I i do Lll a a Pressure av L NRV Vi P PX cmt Strainer N 7 N Flow T 8 M A mg L uU Jj Y ZN Return 2 High Recovery L Electrical Connections Single Unit Option 8 QAA73 Room Unit Use Only One Type of Room Temperature Control Low Volt Free Enable Room Thermostat BRIS Voltage QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation QAZ36 Hot Water sensor or Volt Free Enable Hot Water Charging Pump or 3 Way Valve 7 internal Valve on HS Models Procon 45 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output Only connect flow sensor Procen4s 75 amp 77 External Heating Circuit Pump fesses M ProCon 16 amp 27 Internal Boiler Pump bu L 1 0111010 Circuit 2 Pump Output 230V 1 Amp Max Heating Circuit 2 Mixing Valve gt Output 230V 1Amp Max Perminent 230 Volt Power Supply Fused at 7 Amps AGU 2 500 Heating Circuit Mixing Valve Clip Mounted onto LMU64 Controller Parameters Description Default Proposed
2. MHG Heating Ltd 8 14 Hydraulic Design Single Unit Option 12 00 Outside meneame RVA47 Cascade Manager Communication Fitted in Boiler RVA63 Zone Controllers Clips Fitted 3 ERA 0 7 in Boilers ED E SS EI gt E LE a a 3 1 Room Units Can Be Applied To Enhance Control i f E X yi 1 1 Heating Heating Heating l Heating H t 3 Circuit 1 1 Circuit 21 17 1 Circuit 3 a 1 Circuit 4L3 p A Fa 0 1 7 LL adim Era P ML E IN MAA AA pen Tox tx X 1 2i NY KY ie 1 X31 1 SPRY NRV NRY 3 i Strainer 0 gt Strainer Flow Sensor Return Hm se Sensor High Recovery Return 4 Calorifier NA y Electrical Connections Single Unit Option 12 Boiler Mounted Cascade Manager M Boiler Control Is Managed by the 5 4 RVA47 Cascade Manager Via the Voltage PD aac 3 nsor or 620 Ohm Substitute pP M 1 ne itor OCIA20 Communication Clip 0 2 le JOAD 21 FI L itag m fol ol E JOAD 21 Return Sensor Em ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt Volt Free Enable 0 10 Volt Control Input iiu E ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp d m IE Per Output gt 3
3. 70 Nominal Room Temperature Set Poit 00350 71 SetPoint Of Room Temperature 00350 SwtemFowTemperatueSetPont omw 5 Available in Cascade 0 NE Lead Moguel in Cascade 00 1 16 3 7 To WEEN _ 95 Heating Pump Output HKP Output Functions roo Of Weather Conpenston ce a 101 Gain Factor Room Influence 6 1 0 Active 1 Inactive Room Temperature Switching Differential 0 5 4 pe Minimum System Flow Temperature es 8 Maximum System Flow Temperature 105 Building Construction Type 0 1 1 0 Heavy 1 Light Adaptation of Heat Curve 0 Inactive 107 Optimum Start Time Maximum Forward Shift 00 06 00 00 AN 108 Optimum Stop Time Maximum Forward Shift 00 00 06 00 00 00 Heating Zone Quick Setback Constant Pi Feat Poison testno ae o L9 ie rome Preston Tempersus RE 119 HWS Pump Operation Function Stored Flow Temp 0 2 0 Off 1 Always On 2 Only On When Boiler is Interlocked Off Via 17023 Uo Reduced HWS Temperature SetPom 870 w 121 HWS Time Control 0 2 2 0 24 Hours per Day 1 As Heating Time Switch Settings 2 As HWS Time Switch Settings 0 1 1 HWS Pump Control 0 Heating Time Switch Setting Apply 1 HWS Time Switch Settings Apply 57 010108 MHG Heating Ltd HWS Control in Cascade System 0 Controlled Via Master RVA47 Manager 1 Controlled Via All RVA47 Managers
4. MHG Heating Ltd SIMPLY BETTER Installation and Operating Manual for the ProCon 16 27 47 75 amp 77 Wall Mounted Condensing Boiler Range MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR 0845 6448802 Telephone 0845 6448803 Fax Email info mhgheating co uk Website www mhgheating co uk 010108 MHG Heating Ltd Setin page tt Appliance Type 1 4 ProCon HS 2 0 Installation Regulations and Requirements 4 30 Dimensions 16 27847 6 32 Dimensions 77 33 bimensonsKompat Forimormatononl 9 Delivery and Mobility TT Delivery and Mobility 40 UJ 60 Pressure Relief Valve 80 Hydraulic and Wiring Guide Single Unit Option 1 Heating Only Low Resistance Circuit 20 84 Hydraulic and Wiring Guide Single Unit Option 5 Heating amp HWS High Resistance Circuit 24 85 Hydraulic and Wiring Guide Single Unit Option 6 Heating amp HWS Two Heating Circuits HS 25 O 8 6 25 Hydraulic and Wiring Guide Single Unit Option 7 Heating amp HWS Two Heating Circuits 26 Hydraulic and Wiring Guide Single Unit Option 8 Heating amp HWS Two Heating Circuits Mixing HS Hydraulic and Wiring Guide Single Unit Option 9 Heating amp HWS Two Heating Circuits Mixing 89 Hydraulic and Wiring Guide Single Unit Option 10 Heating amp HWS Two Heating Circuit RVAG3 2 90 BM
5. e ProCon 45 75 amp 77 External Heating Circuit Pump x DEB ui ProCon 16 amp 27 Internal Boiler Pump EIE CBS Heating Circuit Pump Output 230 2 Amy m 1 High It 7 4 Iu I Water Charging Pump Output 230V 2 Amp Max Perminent 230 Volt Power Supply Fused at 7 Amps EL LPB Communication Terminals Polarity Sensitive Cabling Required OCIA20 LPB Communication Clip Mounted onto The LUM64 Controller Please refer to System Options 10 and 11 for RVA47 and RVA63 controller wiring information Boiler Parameter Alterations Parameters Description Default Proposed Change H516 summer Winter Automatic Changeover Temperature H552 Appliance Hydraulic Configuration 66 67 70 80 80 81 H605 LPB Communication Appliances Address Maximum 12 Boilers RVA47 Manager Alterations Parameters Description Default Proposed Change 18 summer Winter Automatic Changeover Temperature RVA63 Controller Alterations Parameters Description Default Proposed Change DO Summer Winter Automatic Changeover Temperature 18 30 80 Boiler Control Type LPB On Off Hi Low 10 LPB Controller Appliance Communication Device L 0 sa LPB Controller Appliance Communication Segment 010108 MHG Heating Ltd 9 0 BMS Interface Clip Installation and Parameter Alteration Following the installation of the AGU2 511 communication clip
6. 87 Degree Elbow Straight Length 295 545 1000 2000 230 480 935 1935 10 6 Dimensions of Available Flue Components MHG Heating Ltd MHG Heating Ltd 10 7 Balanced Flue Terminal Positions For Boilers Below and Above 70kW Net Input All measurements are in mm and are minimum clearances Terminal Location Boilers with a rated Input lt 7OkW Net Boilers with a rated Ge gt 70kW Net A Below and opening window etc Below gutter soil pipes etc MS E Below eaves ao pO Below balconies or car port roof BE F From internal or odd qu 800 300 300 Above ground or balcony level 2000 where people have general access From a surface facing the 2000 2000 terminal From a terminal facing the 2000 2000 terminal E NI z J From opening In a carport into a 1200 N A dwelling K Vertically from a terminal on the 1500 1500 same wall Horizontally from a terminal on the same wall um Above an opening window etc 20 to an opening 300 window etc Above a level roof base of 500 500 terminal From an adjacent wall edge of 500 500 terminal EN From TN window 1000 1000 S From any other flue terminal 600 Positions not recommended Groups of appliances of 150kW gross input 136kW net input and above must comply with the Clean Air Act with respect to the chimney discharge height The t
7. MHG Heating Ltd MHG Heating Ltd 24 0 Exploded Spares Diagram 75 010108 80 MHG Heating Ltd 25 0 Exploded Spares Diagram 77 Exploded diagram To Follow Please contact our Spares Department 010108 81 MHG Heating Ltd 010108 Notes
8. line 50 where the generated fault code can be reviewed In either case the fault code should be noted for future reference If the fault is related to a specific appliance the unit can be reset by pressing the Lockout Reset Button If the fault is related to a RVA controller or the LPB communication network the fault code will clear automatically following the rectification of the fault This is also applicable following the rectification of any appliance fault This can take up to 10 minutes EG Notmorbegded Em RetmmWaterSemorfaut NotDeteded Ea System Return Water Sensor Fault Not Detected TT 010108 MHG Heating Ltd mn aulty Room Sensor aulty Room Sensor Incorrect Room Unit Connected Air Pressure Sensor Not Detected Not Used Water Pressure Sensor Defective Not Used LPB Short Circuit Boiler Cascade Wiring LPB Address Conflict Boiler Cascade Settings Short Circuit on PPS Connection Not Used in ProCon Configuration EEPROM Hardware Malfunction Conflict Between Time of Day Master Control Boiler QAA70 RVA47 Annual Service of Unit is Due QAA73 Service Tool Required to reset timer See Section 16 0 Module Water Temperature Overheat Module Temperature Too High Auto Resetting Flue Gas Temperature overheat Not Used High System Water Pressure Sensor Not Used Low System Water Pressure Sensor Not Used System Water Pressure Switch Activated Below 0 8 bar Module Temperature
9. 300mm min 50mm min 50mm 010108 MHG Heating Ltd 3 5 Mounting Clearances 75 Boiler 150 130 643 010108 MHG Heating Ltd 3 6 Installation and Service Clearances 77 Boiler E 465 is pore l l l IE l 9 9 S des min 50 mm min 50 mm 14 010108 15 MHG Heating Ltd 3 6 Mounting Clearances 77 Boiler Please contact our Technical department for Guidance 010108 MHG Heating Ltd 4 0 Delivery and Mobility All ProCons are supplied fully tested and therefore may contain residual test water The test water utilised contains additives that will help prevent the pump from sticking and other metals from oxidising To maintain the structural integrity of the appliance the internal components should not be used during the lifting and positioning of the unit onto the wall bracket All packaging materials should be disposed of in an environmentally way 4 1 Case Removal To remove the case insert a flat blade screwdriver or similar into the black latch slots and turn through 90 Pull the base of the cover forward and up to release the hooks at the top Ensure that the earth cable is removed prior to lifting the cover clear The lower case housing the display panel can be hinged down to all greater access to all internal components The lower case is secured on either side by thumb nuts located on the return edge on the s
10. Change Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 1 E10 Error signal when outside air sensor is not installed H558 2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 0 1 E50 Error signal when sensor is not used Second Heating Circuit Installed without 3 Way Valve and Sensor H554 b5 Mixed Flow Sensor Present 1 No Mixed Flow sensor Present 0 E26 Error signal when sensor is not used Second Heating Circuit Installed with 3 Way Valve and Sensor aae No Alterations Required 27 010108 MHG Heating Ltd 8 8 Hydraulic Design Single Unit Option 9 Outside Air Sensor AGU 2 500 Heating Circuit 2 Clip Fitted In Boiler Room Units Can Be Applied to Both c Heating Zones To Enhance Control 1 Dee n MEG GS 0 1 l gee 27 i gt Hy C EE nn M Lu 7 Pressure vessel HNI i I Il ji ee ee p Lin Circuit 1 Circuit 2 EE Fg 4 1 8 In 7 l Im XL 3 im ce c ecce d ET n I EE ESE N Las Es Pressure Relief ys juny Valve av _ o T V L Fi Strainer a Flo E Return High Recovery 2 Calorifier Electrical
11. Diverter Valve BW K3 Neutral Terminal for Hot Water Diverter Valve or Charging Pump 230 Volt Output For Hot Water Diverter Valve or Charging Pump Max 1Amp 230 Volt Output For Heating Circuit Pump ProCon 16 47 Boiler Pump ProCon 75 amp 77 Max 1Amp Neutral Terminal for Pump yd ME Terminal forheatingiBollBump 230 Volt Output For Boiler Pump ProCon 16 47 Heating Circuit Pump ProCon 75 amp 77 Max 1Amp E B Earth Terminal N 19 Switched Fused Permanent Neutral 18 010108 MHG Heating Ltd Enhanced electrical connection for ProCon HM Units supplied with an integral Cascade manager Legend High Voltage Output Terminals 230 Volts Neutral Terminal for Hot Water Charging Pump BW Earth Terminal for Hot Water Charging Pump 230 Volt Output For Hot Water Charging Pump Max 1Amp Neutral Terminal for Heating Circuit Pump Earth Terminal for heating Circuit Pump 230 Volt Output For Heating Circuit Pump Max 1Amp Low Voltage Control terminals lt 25 Volts 44 H1 Ground Terminal Controller Operating Input Volt free Enable 0 10 Volt Control Mode Alteration System Return Sensor QAD 21 Terminal Not Polarity Sensitive lt 25 Volts System Flow Sensor QAD 21 Terminal Not Polarity Sensitive 25 Volts Hot Water Sensor QAZ36 or Hot Water Volt Free Enable Thermostat BMS BW 9 Not Polarity Sensitive gt 24Vol
12. Sensor A Room Unit or Room Thermostat can be Applied to Enhance Control Pressure AT Relief Valve X X1 v High Recovery m NRV Calorifier Strainer X Flow Return Electrical Connections Single Unit Option 2 QAAT3 Room Unit Use Only One Type of Room Temperature Contral Volt Free Enable Room Thermostat BMS Low Voltage 3 QAC34 Outside Air Sensor Required to Activate dE Direct On Boiler Weather Compensation 35 Hot Water sensor or Volt Free Enable Hot Water Charging Pump or 3 Way Valve 9 Internal Valve on HS Models x ProCon 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output a Procon4s 75 amp 77 External Heating Circuit Pump ProCon 16 amp 27 Internal Boiler Pump Perminent 230 Volt Power Supply Fused at 7 Amps Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 E10 Error signal when outside air sensor is not installed H558 b2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 E50 Error signal when sensor is not used 010108 MHG Heating Ltd 8 3 Hydraulic Design Single Unit Option 4 Outside Air Sensor Room Unit Heating Circuit ar Thermostat 1 5 a l PN vessel sl ee l l l L ERK l sA ML EL mW sae E 8 Pressure at
13. Thermostat ad Room Unit Or i can be Applied to Enhance Control ieee Thermostat 2 i Heating Circuit ae a EE U 7 A 3 7 a d Fes AU Three Way Spring L Ai rx x Return Valve IT Ll cl 7 Pressure Relief poe Valve T High Recovery 1 NRV nm ua m Flow Return es 0 Calorifier Strainer Electrical Connections Single Unit Option 2 QAA73 Room Unit Use Only One Type of Room Temperature Control Volt Free Enable Room Thermostat EMS Low Voltage QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation QAZ36 Hot Water sensor or Volt Free Enable ET Hot Water Charging Pump or 3 Way Valve Internal Valve on HS Models 75 amp 77 Internal Boiler Pump 230 Volt P ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output y ProCon 45 75 amp 77 External Heating Circuit Pump Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 E10 Error signal when outside air sensor is not installed H558 b2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 E50 Error signal when sensor is not used 010108 MHG Heating Ltd 8 2 Hydraulic Design Single Unit Option 3 Outside Air
14. Too High Auto Resetting Flame Extinguished During Operation LMU Version D Air Supply Error Fan not operating at correct speed LMU Version D Flue Temperature Too High Auto Resetting Fault With Burner External Safety Interlock Activated Open Circuit No Flame Detected After Final Ignition Attempt Flame Extinguished During Operation LMU Version C Air Supply Error Fan not operating at correct speed LMU Version C LPB Segment Address Not Recognized Boiler Cascade Settings LPB Missing Partner Boiler Cascade Settings Wrong Device Connected to PPS Circuit Not Used in ProCon Configuration Unrecognized Plant Configuration Burner Modules Not Connected PPS Circuit Not Used in ProCon Configuration LPB Interface Not Configured Boiler Cascade Settings General Boiler Fault Module LMU64 Controller Malfunction Module LMU64 Controller Parameter Programming Error Module Control Interlocked Module Operating Outside of Predefined Parameters System Hydraulic Error Fan Not Reaching Set Point Module Combustion Fan Speed Too High Air Pressure Switch Fault Not Used Flow Switch Pressure Switch Open Not Used Air Pressure Switch Fault Not Used Module Operating in Chimney Mode 100 Output Module Operating in Commissioning Mode Module Controller QAA73 Room Unit in Parameter Setting Mode n 47 010108 E 61 E 62 E 81 E 82 E 91 E 92 E 100 E 105 E 110 E 111 E 113 E 117 E 118 E 119 E 124 E 128 E 1
15. terminal 10 1 Single ProCon Balanced Flued Through The Wall Termination 1 r130mm Diameter Hole 210mm 146 5mm 1 s HL n ap 146 5mm Defail X 36 010108 37 MHG Heating Ltd 10 2 Single ProCon Balanced Flued Vertical Termination 10 3 Single ProCon Open Flued Through The Wall Termination Suitably Sized High amp Low Ventilation In Accordance with Prevailing British Standards 010108 38 Up MHG Heating Ltd 10 4 Single ProCon Open Flued Vertical Termination Suitably Sized High amp Low Ventilation In Accordance with Prevailing British Standards 10 5 Cascaded Appliance Fluing Installation Open Flued E TE Zh eus ii NS EX iin II KE HHHH L Er rm LI i 1 CH LI I 1 LH L L nm T i H 1 00000001 EL HH HHIHHHHHH 010108 010108 39 Solid To Flexible Base Elbow Flexible Flue Inspection Opening Vertical Terminal 1050 Ventilated Plate Wall Cower Plate Flue Way Cap Flexible Flue Flexible Flue Centralizing Bracket 6 gt 30 Degree Elbow Condensate Drain 0 109 45 Degree Elbow Inspection Opening
16. x i if On gek i bu Ti x hy f Heating T T Y 1 dee Circuit p ji FI a 1 Ea V i 1 F 5 i fez I h ihe i i w ww PRV Ww 7 PRV l NRV 1 HE i E x Strainer D Strainer pa po L Flow Sensor Flow IA m i Return Return a T Uy Sensor 4 High Recovery a A Calorifier Electrical Connections Single Unit Option 11 Boiler Mounted Cascade Manager Boiler Control Managed by the RVA47 Cascade Manager Via the Voltage OCIA20 Communication Clip CAM 70 70710 Raam Unit 0 32 ude Air Sancor or 620 Ohm Substitute Resistor DAT 21 Hot Water Sensor or Volt Free Enable aA 21 Flow Sensor Low Voltage ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output ProCon 45 75 amp 77 External Heating Circuit Pump Heating Crreunt Pump Cuit 2120V 2 Aap ProCon 16 amp 27 Internal Boiler Pump i High Voltage IE Hot Water Charging Pump Output 230 2 Amp Max Perminent 230 Volt Power Supply Fused at 7 Amps LPB Communication Terminals Polarity Sensitive Screened Cabling Required 08 MB DB Data ts FA Mil Ground cus 9 i 061420 LPB Communication Clip Mounted onto The LUM64 Controlle
17. 0 Modulating Limited Function Room Unit One unit per zone This modulating limited function room unit offers the heating user reduced remote access to operating mode and temperature functions that effect the provision of heat to the respective zone QAA10 Modulating Tamper proof Room Sensor One Unit per zone E This modulating tamper proof room unit offers room temperature feedback from the heated space that effects the provision of heat to the respective zone 66 010108 67 BM BDT MM MHG Heating Ltd 21 0 Internal Wiring The internal wiring configurations of the ProCon differ dependant upon the model H HS S and HM 21 1 Internal Wiring Diagram 16 27 H HS amp S F OW sensor Return Sensor j Display Panel HWS Flow Switch 5 Only System Water Pressure Swi tch m ET Li Wi c mo 1 LA 5 5 2 ia n zu ar 8 e E o LA 9 d my j Em B EF E MM q ss ka m 3 e EE PS EV gom une ang ome as e Internal Boiler Pump K1 e Internal 3 Way Valv HS amp 5 Only 83 EO kg 3 LMU 64016C180 ge Fa ru EP d 5 gt FO n 7 lt i Ca 29 2 OD A 2 5 e
18. 0108 MHG Heating Ltd RVA47 Cascade Manager Wiring Terminals Housing Housing designed for use with additional RVA46 Zone controller RVA46 TO BE INSTALLED THIS SIDE ON LY Blanking plates are available if an RVA46 is not being used RVA47 TO BE INSTALLED THIS SIDE ONLY Permanent RVA46 Heating Zone Connections RVA47 Cascade Manager Connections Power Supply Connections Terminal Designation LPB Data connected in parallel to boiler mounted 001420 Clips DE a LPB Ground connected in parallel to boiler mounted 001420 Clips QAA70 50 10 Room Unit PPS Data MD 25V QAA70 50 10 Room Unit PPS Ground B9 25V Outside Air Sensor QAC31 32 or 6202 Substitute Resistor 1C Mounted on North Facing Wall M 25V Ground Connection for all Sensors Inputs 0810 lt 25V System Flow Sensor QAD21 To be positioned on system side of system Low Loss Header BB lt 25V Hot Water Sensor QAZ21 Volt Free Enable via Calorifier Thermostat BMS Parameter alteration required if Volt Free Enable Used B70 lt 25V System Return Sensor QAD21 B4 To be positioned on boiler side of system Low Loss Header 81 lt 25V 0 10 Volt Input via BMS Volt Free Enable via Room Thermostat BMS Qi 23V Heating Pump Output aaa N 230V Permanent Neutral PE Permanent Earth All M Terminals are Internally Linked 33 010108
19. 29 E 130 E 131 E 132 E 133 E 134 E 135 E 140 E 142 E 145 E 146 E 147 E 148 E 150 E 151 E 152 E 153 E 154 E 160 E 161 E 162 E 164 E 166 E 180 E 181 E 183 Nea SE 6 MHG Heating Ltd 14 1 Enhanced Fault Diagnosis Codes LMU Internal Software Diagnostic Codes If required a more detailed fault diagnosis code can be viewed This will assist where a definitive cause for a repeated operational error cannot be found The enhanced fault diagnosis code is displayed at bO within the second INFO level Access to this level is detailed on page 49 The table below indicates a limited number of enhanced fault codes If the exact number indicated by the appliance is not detailed below please call our Technical Department or guidance Fault Code Fault Description Combustion Fan Not Reaching Pre Purge Speed Flame Rectification Signal Detected When Burner Off ME aal OS 8 Flame Signal Lost During Operation EE NEM Flame Signal Lost During Operation Flame Signal Lost During Operation Flame Signal Not Detected Following Last Ignition Attempt 2 Flame Signal Not Detected Following Last Ignition Attempt The Reset Button is being Continually Depressed Possible Display Module Mounting Error 259 The Reset Button Has Been Pressed When No Error Has Been Displayed E153 Generator Combustion Fan Not Reaching Correct Speed SE cw AL CON
20. Connections Single Unit Option 9 QAA73 Room Unit Use Only One Type of Room Temperature Control ue Volt Free Enable Room Thermostat 5 Lowy Voltage CT QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation OAZ36 Hot Water sensor or Volt Free Enable mal iv 14 nu re ZT 3 3 3 ETTTOT Hot Water Charging Pump or 3 Way Valve mad 7 Internal Valve on HS Models gt ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Flow Sensor Per Output Only connect af Ow nso gt ProCon 45 75 amp 77 External Heating Circuit Pump ifamixng ProCon 16 amp 27 Internal Boiler Pump valve is being JE ised Ma Connection ETET g Court 2 71 ul 230V 1 Amp Ma LST OLN 3 DI 3 0 291 sting Circuit 2 Mixing Valve Output Aon AE ST L Perminent 230 Volt Power Supply Fused at 7 Amps AGU 2 500 Heating Circuit Mixing Valve Clip Mounted onto LMU64 Controller oT Parameters Description Default Proposed Change H554 b3 Weather Compensation 1 Constant Flow Temperature Operation 1 0 E10 Error signal when outside air sensor is not installed H558 b2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 0 013 E50 Error signal when sensor is not used Second Heating Circuit Installed without 3 Way Valve and Sensor H554 5 Mix
21. H554 b5 Mixed Flow Sensor Present 1 No Mixed Flow sensor Present 0 a 0 N E26 Error signal when sensor is not used Second Heating Circuit Installed with 3 Way Valve and Sensor i No Alterations Required 1 1 1 25 010108 MHG Heating Ltd 8 6 Hydraulic Design Single Unit Option 7 Outside Air Sensor AGU 2 500 Heating Circuit 2 Clip Er EN I 0 m Fitted In Boiler HE ZEF m Room Units Can Be Applied to Both 1 Ta Heating Zones To Enhance Control 1 8 2 a p 4 ME SEE 1 2 PS l essel Heating Heating Circuit 1L 3r L Circuit 2 Relief MR NN Strainer lh 1 2 High Recovery Calorifier Electrical Connections Single Unit Option 7 OAAT3 Room Unit Use Only One Type of Room Er ie Control Volt Free Enable Room Thermostat BMS Low Voltage QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation QAZ36 Hot Water sensor or Volt Free Enable Hot Water Charging Pump or 3 Way Valve internal Valve on HS Models m ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt Mains Connection n Mh me mu M Via 3 11 3 ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp z V
22. ProCon boiler is being retro fitted into an old existing system as system silt or magnetite can be very damaging to the new boiler Following cleaning and flushing the system MUST be dosed with a good quality water treatment to prevent corrosion and the formation of scale FAILURE TO OBSERVE THESE REQUIREMENTS WILL RENDER THE WARRANTEE ON THE APPLIANCE VOID Cleaning flushing and water treatment must be carried out in accordance with the requirements of BS 7593 1992 prior to commissioning the boiler Repeated draining and refilling of the system without replenishment of water treatment must be avoided as this is very damaging to the boiler The boiler must not operate without the system water being correctly and adequately treated and maintained with an appropriate level of corrosion inhibitor For specific guidance on water treatment direct contact is advisable with Betz Dearborn Limited Alpha Fry Technologies Fernox Sentiel Cookson Electronics Foundry Lane Forsyth Road Widnes Sheerwater Cheshire Woking WA8 8UD Surrey Tel 0151 424 5351 GU21 5RZ Fax 0151 420 5447 Tel 0208 665 6666 Fax 0208 665 4695 12 1 Care With The Use of Solder Flux The ProCon HT range has heat exchangers fabricated from 316L Stainless Steel It is most important that the compatibility of any flux is checked with the supplier before use and that any flux manufactures recommendations are strictly followed with regards to use in conjunction with
23. QAAT3 Room Unit Use Only One Type of Room Temperature Contral Volt Free Enable Room Thermostat BMS Low QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation Hot Water sensor or Volt Free Enable 35 i 3 Hot Water Charging Pump or 3 Way Valve Internal Valve on HS Models ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output External Heating Circuit Pump 77 amp 75 45 ProCon 16 amp 27 Internal Boiler Pump Perminent 230 Volt Power Supply Fused at 7 Amps Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 E10 Error signal when outside air sensor is not installed H558 b2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 E50 Error signal when sensor is not used 24 010108 MHG Heating Ltd 8 5 Hydraulic Design Single Unit Option 6 Outside Air Sensor AGU 2 500 Heating Circuit 2 Clip E Fitted In Boiler HER Room Units Can Be Applied to Both Heating Zones To Enhance Control 8 1 dg l AN a Ee cc KA Pressure vesse B Heating Heating 1 Circuit 1 Circuit 2 Sinan 9 0 1 dg 5 AE 8 7 o o oo V gt a High Recovery Calorifier Electrical Connections Sin
24. Relief Valve Y Y y MR Strainer AAV Flow T E E Return 3 Electrical Connections Single Unit Option 4 m P1 QAA73 Room Unit Use Only One Type of Room Temperature Control 7 Volt Free Enable Room Thermostat BMS Low L IL Voltage D gt TT QAC34 Outside Air Sensor Required to Activate m Direct On Boiler Weather Compensation mi Im fol EE Ie ProCon 45 75 amp 77 Internal Boiler 230 Volt NJ ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp m I Per Output E e ProCon 45 75 amp 77 External Heating Circuit Pump HE ProCon 16 amp 27 Internal Boiler Pump m IG Perminent 230 Volt Power Supply Fused at 7 Amps SL Parameters Description Default Proposed Change Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 E10 Error signal when outside air sensor is not installed 010108 MHG Heating Ltd 8 4 Hydraulic Design Single Unit Option 5 Outside Air Sensor A Room Unit or Room Thermostat can be Applied to Enhance Control Heating Circuit OS Pi Pressure vessel 1 l l l Eee Pressure Relief 4 NA Valve 7 ri m Flow Return m X Electrical Connections Sinale Unit Option 5
25. S Interface Installation and Parameter Alteration 8 10 5 Cascaded Open Flue Vertical Termination 38 107 Balanced Flue Terminal Positions For Boilers below and Above 70kW Net Input 40 14 0 Appliance Fault Codes 6 141 Enhanced Appliance Fault Codes 48 54 54 61 61 61 63 65 20 0 Optional System Controls QAA73 RVA47 RVA 63 RVA46 QAA70 0 5 0 10 68 21 2 Internal Wiring Diagrams 47H amp S 68 21 3 Internal Wiring Diagrams 75877 25 0 Exploded Spares 92968887 8 010108 MHG Heating Ltd 1 0 Appliance Type There are four build types and four outputs within the ProCon range Please ensure you have the correct unit for the application and where required located correctly within the cascade prior to beginning the installation ProCon 16H amp 16HS ProCon 27H 27S amp 27HS ProCon 47H amp 47S ProCon 75H amp 75HM 1 1 The ProCon H range of appliances is designed to be applied to systems requiring direct on boiler weather compensated heating and priority hot water production via a separate high recovery calorifier cylinder 1 2 The ProCon S range of appliances is designed to be applied to systems requiring direct on boiler weather compensated heating and priority on demand hot water production via an internal late heat exchanger 1 3 The ProCon HS range of appliances are designed to be applied to systems requiring direct on boiler weather compe
26. Stainless Steel 42 010108 MHG Heating Ltd 13 0 Appliance Controls All appliance operational mode adjustments and settings are undertaken via the unit control fascia Legend Defaults EEN EE EN Hot water storage temperature adjustment He ER NG Only possible is a HWS sensor is used 7 HEATING CIRCUIT Heating flow temperature adjustment 50 90 80 C T5 FLOW Or TEMPERATURE Assumed room temperature adjustment 10 35 219C SETPOINT PROGRAM DOWN Access to program accessing In reverse PROGRAMUP UP Access to program De ne in sequential KEN N PROGRAM PLUS Alteration of program settings positively PROGRAM MINUS Alteration of program settings negatively T10 INFORMATION Access to operational information and saving altered program settings 010108 If outside air sensor installed Time of day time switches operational settings Indication Boiler Flow Temperature Stored HWS Operation Mode Outside Air Temperature 43 MHG Heating Ltd Display Legend Function WATER PRESSURE INDICATOR Not used In ProCon Ranges MAIN DISPLAY Flow Temperature or Selected Parameter Setting Commissioning Mode Indicator Full Power no COMMISSIONING MODE adjustment Engineers Mode full adjustment via Program Up amp Down Buttons SPECIFIC OPERATIONAL MODE INDICATOR The Display Reflects the Operational Mode Dependent Upon Inputs TIME OF DA
27. T 1 46 Boiler Flow Temperature Rising to Above Maximum Limit Temperature When Burner On Boiler Flow Temperature Rising to Above Maximum Limit Temperature When Burner Is Off System Hydraulic Error AT between Flow and Return Too High Repeatedly System Hydraulic Error AT between Flow and Return Too High Repeatedly System Hydraulic Error AT between Flow and Return Too High Repeatedly 1 1 1 282 4 4 4 422 433 4 0 0 0 8 0 0 0 2 3 3 3 48 010108 MHG Heating Ltd 15 0 Accessing Boiler Parameters Control Parameter Default Settings All Units are preset for correct operation However if alterations are required to enhance the operation of the unit following the application of optional control the procedure is detailed below The following Pages detail the parameters of the LMU64 controllers For your assistance the Standard Factory settings are indicated Please note the installer commissioning engineer may have changed some of these settings to suit the system installed To access the parameters detailed below the boiler s control panel must be used Only boilers supplied prior to 2003 will require a QAA73 Room Unit to access the control parameters The unit must be connected to the RU terminals or directly to the LMU64 controller via the X10 01 terminal There are three levels of access available as follows If you cannot access a particular parameter line please consult with MHG H
28. VERRIDE BUTTON AND N INDICATOR Manual Operation On Off COMPUTER ACCESS PORT Specialist Equipment Required 54 010108 MHG Heating Ltd 16 1 RVA47 Cascade Manager Settings The Single and Cascade Master units are preset for correct operation The following Pages detail the parameters of the RVA47 Cascade Manager and the Standard Factory settings please note the installer commissioning engineer may have changed some of these settings to suit the system installed There are two levels of access available as follows If you cannot access a particular parameter line please consult with MHG s Technical Department for further assistance Level One Open The Hinged Flap End User Use either of the V Z Program Buttons to access the desired parameter line Parameter Line range 0 50 Use the H LE gt Buttons to alter the required parameter Once all alterations have been completed press the AUTO button to exist this level Level Two Open The Hinged Flap Installer Press amp Hold the Program Buttons simultaneously for more than 3 seconds until Parameter 51 appears Use either of the N Program Buttons to access the desired parameter line Parameter Line range 51 173 Use the H LZ Buttons to alter the required parameter Once all alterations have been completed press the AUTO button to exist this level Level Three Open The Hinged Flap OEM Press amp Hold the Program Buttons simul
29. Y AUTO RESETTING ERROR Time of Day Alternating with Automatic Resetting Error Codes ER 2807 INDICATOR Indicator of M Circuit Operating 90 9 9 970 2 7 Indication of E Water Production If required an enhanced operational review level can be accessed The table on the following page indicates the level of information that is available To access these parameters the following sequence must be undertaken Press and release the INFO Press 8 Hold the SZ ZA Program Buttons simultaneously for at least 3 second The display will indicate 0 Use the ILE Button to access the various b level parameters Use the V or amp to access the other parameter levels C amp d Use the I gt Button to access the required levels within the desired parameter level To leave the enhanced operational review level press INFO or wait 8 minutes for automatic refresh 44 010108 MHG Heating Ltd 13 1 Module Operating Codes Display level Name of LMU Description Variable Temperatures service level pO DiagnoseCode LMU internal software diagnostic code Flue gas temperature Flow temperature AGU2 500 Process values service level lonization current C2 63 Gebl_ PWM AusAk RelModLevel Pump setpoint PWM Control differential Setpoints service level Setpoint of 2 position or modulating controller PID TkSoll Current boiler temperature setpoint Hoom temperature setpoint D h w temperature setpoint Maxi
30. a BMS Volt Free Enable via Room Thermostat BMS Zone 1 Mixing Valve Opening Output max2 amp Boiler Sensor Not Used 0 Boiler Sensor Not Used Used Power Input for Zone 1 Valve Outputs To be linked to Live Input Hot Water Sensor QAZ21 Volt Free Enable via Calorifier Thermostat BMS Q3 Y3 Hot 0 UD Way Parameter alteration required if Volt Free Enable Used j Outside Air sensor EN Power Input for Hot Water Pump Valve Output 6204 Substitute Resistor 1C To be linked to Live Input Mounted on North Facing Wall Zone 1 QAA70 50 10 Room Unit PPS Ground Burner Enable Output Stage 2 Not Used Zone 1 QAA70 50 10 Room Unit PPS Data E Power Input Burner Enable Stage 2 Not Used Boiler Communication LPB Ground connected in parallel to boiler K4 Burner Enable Stage 1 Not Used mounted 001420 Clip or RVA47 Manager Boiler Communication LPB Data connected in parallel to boiler mounted Power Input Burner Enable Stage 1 Not Used 001420 Clip or RVA47 Manager Permanent Live max Amp O N Permanent Neutral 30 010108 MHG Heating Ltd 8 11 Hydraulic Design Single Unit Option 11 Outside Air Sensor A 20 Communication Clips Fitted In Boilers FEES EJ ENER ELE 1 H A Ronm une Can HE Applied RVA47 Mounted 3 To Enhance Control In Cascade enne 7 Master Boiler Le 122 2
31. ally Open The RVA47 will operate according to its internal time switches and presets If a remote BMS is controlling the RVA47 via a Volt Free switch across H1 0 should be inserted This will allow the boilers operate when the Volt Free switch N UJ is made and stopped Blocked when the switch is opened If you are controlling the lead master RVA Boiler via a volt free switch across H1 all slave modules should be left with 1 as the input This will allow the AUTO light and the OFF light to indicate their operational mode dictated by the lead master RVA Boiler 59 010108 MHG Heating Ltd OEM Level 2 Maximum Module Temperature 8 120 82 RS Pump Run On Time et Minimum System Return Temperature 895 o Room Influence Gain Factor Lm 3 Boost Room Temperature Set Point 0 20 Room Sensor Dependant QAA10 50 70 Increase Heat Up Time Reduced Decrease Heat Up Time Increased Frost Protection 0 Frost Protection Program Disabled i 1 Frost Protection Program Enabled T Heat Gains 2 4 Increase If Heat Gains are High Decrease If Heat Gains are Low 0 Sensitivity 1 ma N EN N EEN EE Adaptation Sensitivity 2 OE e EI E aa rr TA 41 HWS Switching 20 QAZ21 Sensor Only 020 J 20 EN Legionella Function 0 Off 1 On ER Cascade Strategy 1 6 1 3 Automatic 51 Minimum Output reached Prior to Switching Off a Module In 5 ERI EN m t
32. ascade manager has the capability to control up to twelve appliances one CT circuit and one HWS primary circuit The RVA47 cascade manager communicates with the RVA63 amp 46 zone controllers via LPB offering enhanced communication zone and module temperature control A dedicated housing is also available to ease the installation process _ RVA63 Dual Zone Controller This dual zone controller has the capability to control up to two independent CT VT or a mixture of both The RVA63 dual zone controller communicates with the master boiler mounted RVA47 Cascade Manager via LPB offering enhanced communication zone and module temperature control A dedicated housing is also available to ease the installation process RVA46 Single Zone Controller This single zone controller has the capability to control one CT VT zone The RVA46 single zone controller communicates with the master boiler mounted RVA47 Cascade Manager via LPB offering enhanced communication zone and module temperature control A dedicated housing is also available to ease the installation process QAA70 Modulating Full Function Room Unit One unit per zone lA This modulating full function room unit offers the heating user full remote access to the all functions that effect the provision of heat to the respective zone The unit also displays information from all attached temperature sensors Boiler Hot water Outside and remote tamperproof room unit QAW 44 QAA5
33. ating Error Code Ma H703 2nd Historical Fault Number of Occurrences N 010108 MHG Heating Ltd 16 amp 27 H 27 5 75 amp 77 HM Descripti ON escription Range 16 amp 27 HS 47 S 45 75 77 H Cascade slave ENE ao ll ENE LI DL 7T j j j MEE 927 RM EE mm 0079 ANN Q SES f p i Ln ww wn I 1 4 T 1l 1 oe eee eee 1 T1 uw NN HM Sth Historical Fault Operating Error Code Historical Fault Operating Error Code Sth Historical Fault Operating Error Code Occurrences wn6 Current Historical Fault Operating Phase BEES Current Historical Fault Operating Error Code H719 Hours run heating mode 131070 rs 0 po o o is Nu SES ENE aa EE 200 aS 1 H732 Sth Historical Fault ALBATROS Error Code ma ME H732 Current Historical Fault ALBATROS Error Code H755 Measured value of ionization current mr mad 53 010108 MHG Heating Ltd 16 0 RVA47 Cascade Manager ProCon 75 HM amp 77 HM 1 1 NS 1 1 da i 8 Legend Function Assumed Room Temperature if no Room Unit Fitted 4 DISPLAY SCREEN Operational Status Indicator d ki Automatic Operation MODE SELECTION BUTTONS OPERATING IS continuous Operation On Off MODE INDICATION Standby O FAHWS On Off MANUAL O
34. ation of flues BS 5440 2 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net 1st 2nd and 3rd family gases Part 2 Specification for installation and maintenance of ventilation for gas appliances 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 7OkW 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 amp 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 a
35. ble d Disconnect the earth lead HT cap and Lead from the ignition electrodes e Remove the Circlip securing the gas injector into the fan inlet bracket and extract the gas valve and injector assembly Inspect and clean both the injector and gas valve assembly f Disassemble the burner by removing the six M6 nuts around the burner door using a 10mm Spanner Pull the burner forward and remove from the heat exchanger Gently put to one side 9 Once access has been gained to the combustion chamber and front section of the heat exchanger visually inspect the heat exchanger coils It is usually only necessary to clean the front section of the heat exchanger If server deposits are found the rear section of the heat exchanger should also be checked and cleaned which will necessitate the removal of the heat exchanger from the boiler If any coils appear to be significantly dis coloured then a blockage of either scale magnetite or general system debris has occurred which will have allowed excessive overheating to have occurred within the coil 64 010108 MHG Heating Ltd If dis colouration has occurred then specialist de scaling of the heat exchanger will be required however stress cracking may have occurred and the heat exchanger may become porous following the de scale works If the heat exchanger has not suffered from dis colouration as Item g above then a Standard Service can be undertaken Using a natural bristle
36. ce should be removed and the inner metal surface should be washed and cleaned A BRUSH OF ANY KIND MUST NOT BE USED TO CLEAN THE BURNER SURFACE If damage has occurred to the burner surface the burner MUST be replaced Check the combustion fan blades for debris build up Remove any debris with a soft bristle brush or preferably compressed air DO NOT TOUCH OR SPIN THE FAN BLADES WITH YOUR FINGERS AS THIS COULD AFFECT THE BALANCING OF THE FAN BLADES Re fit the Burners in the reverse order of dismantling ensure that all electrical connections are correctly and securely connected Inspect all water joints Any joints found to be leaking MUST be replaced It is also advisable when replacing water joints to also change any adjacent joints at the same time Inspect all gas joints with a suitable leak detection method Any joints found to be leaking MUST be replaced It is also advisable when replacing gas joints to also change any adjacent joints at the same time Inspect and clean the condensate neutralising tank replenishing the neutralising granules as required Granules available from MHG Heating Ltd Spares Department With the use of a suitable Flue Gas Analyser check and adjust the combustion settings as detailed in Section 15 2 Inspect the general condition of the flue system including the termination repair as necessary or advise on any remedial action as required Following the satisfactory completion of the above service procedure t
37. complete with base mounted wiring connection onto the front of the LMU64 controller a number of operational parameters within the unit must be altered to ensure the clips operates as required LMU64 Pictured above with AGU2 511 and OCI420 communication clips J SIEMENS Landis amp LM T LM 0 30 Volt Control input A number of parameters will require altering within the LMU64 controller from their standard default setting to rrectly allow the AGU2 511 communication clip to operate co Access is gained to the H parameters by pressing the PROG M ZN buttons simultaneously for 3 seconds unit H 90 appears on the screen The required H parameters can then be reached by using the PROG 2 or amp buttons Once at the required H parameter the required setting is achieved by using the TIE buttons To save the alteration in the controller the INFO button must be pressed Default New Setting 4 Predefined Temperature set point 5 Predefined Boiler Output 6 Low Loss Header Sensor 0 Hydraulic Diagram Derived 1 LPG SSOV Output 2 Boiler Fault Output 3 Boiler Operating Output 4 12 Non Supported Output 0 Hydraulic Diagram Derived 1 LPG SSOV Output 2 Boiler Fault Output 3 Boiler Operating Output 4 12 Non Supported Output 0 Hydraulic Diagram Derived 1 LPG SSOV Output 2 Boiler Fault Output 3 Boiler Operating Output 4 12 Non S
38. d brush ONLY remove the worst of the mineral debris build up With the use of the dissolved ProCon Combustion Chamber Cleaning Granules spray the solution onto the heat exchanger surface and leave for approximately 5 minutes This will help to remove any stubborn mineral deposits and clear the condensate drain connections Finally brush the heat exchanger whilst rinsing thoroughly with copious amounts of fresh water ProCon Combustion Chamber Cleaning Granules are available from MHG Heating Ltd Spares Department A STEEL OR PVC BRUSH MUST NOT BE USED TO CLEAN THE HEAT EXCHANGER Following the cleaning of the Heat Exchangers the condensate syphon must be flushed to ensure that all mineral deposits debris that has been washed from the heat exchanger surface is correctly removed Open the syphon cleaning point cap at the base of the boiler with a suitable receptacle directly below to collect the syphon contents Safely dispose of the contents of the syphon Replace the receptacle below the cleaning point and poor 2 litres of clean tap water into the heat exchanger which will drain through the cleaning point Refit the cleaning point cap and poor half a litre of clean tap water into the heat exchanger to ensure the syphon is re flooded Check the cleaning point cap for leaks Visually check the burner surface for signs of damage and debris build up Remove any debris build up with compressed air If excessive debris build up is identified the burner lan
39. dby Switching 0 0 Deactivated 1 Activated Clock Mode 0 3 2 0 Autonomous All Clocks Can Have Different Times 1 System Time Without Adjustment 2 System Time With Adjustment 3 System Clock Master There Can Only be One Master 149 Auto Time Adjustment Spring Date Month 25 03 MANN Ma 150 Auto Time Adjustment Autumn Date Month 25 10 170 Operation of H1 Terminal 0 Changeover of Operation When Volt Free Switch is Made HWS Stopped 1 Changeover of Operation When Volt Free Switch is Made HWS Unaffected 2 Minimum Flow Temperature Maintained When Volt Free Switch is Made Set at 171 3 Heat Generation Stopped When Volt Free Switch is Made Frost Active 4 0 10 Volt Control to Vary System Flow Temperature Curve set at 172 Terminal 1 0 10 volt Terminal 2 Ground If a 0 10 volt signal is the required heat generation control method for the RVA47 boiler installation this setting must be adjusted to 4 Alterations must also be made to parameter 17 The setting must be adjusted from 32 to on all RVA47s present in the boiler cascade installation This will result in the Auto On Off and Frost lights becoming inactive Possible alterations to parameter 172 may also be required Minimum Temperature Set Point Via H1 17022 8 w 172 Maximum Temperature Set Point Via H1 170 4 5 _ ENE Operating Action of H1 control contacts 0 The contact is Normally Closed 1 The contact is Norm
40. e Switch 3 First Off 00 00 24 00 pe Time Switch 3 Second On 00 00 24 00 N Time Switch 3 Second Off 00 00 24 00 pe Time Switch 3 Third On 00 00 24 00 Time Switch 3 Third Off 00 00 24 00 General Functions P45 Default Reset of Time Switch Setting 0 1 ff P516 Summer Winter Changeover Temperatures 8 30 20 P727 Detailed Diagnostic Code 50 010108 MHG Heating Ltd Level Two Engineer Parameters TE 16 amp 27 H 275 75 amp 77 HM 0682709 99 TT Reduced Temperature for 10 e e TvSmin lt TvSmax lt 90 C Summer winter changeover temperature 8 30 C S W changeover deactivated 0 0 5 5 1 8 3 3 2 H533 Heating curve slope heating circuit 2 1 1 H536 Maximum speed at 0 1 output in 08 9950 rom 5000 mode maximum speed limitation Maximum degree of modulation in heating mode 5000 7000 7000 6 100 6 15 15 ow DHW Production Control 0 1 1 0 Time control 1 Constant H93 DHW Production Control 0 Non Eco 1 Eco po o DHW Secondary Pump Control 0 As H91 1 As HWS Time Switch 0 1 K2 X2 03 H615 6 Minimum boiler setpoint temperature 20 90 2 2 2 2 Maximum boiler setpoint temperature 20 90 C TkSmin TkSmax 90 C Boiler setpoint at design outside temperature 20 90 C 8 Minimum flow setpoint temperature 20 90 C 2 25 25 2 20 C lt TvSmins Tvsmax H507 Maximum flow se
41. eating Ltd Technical Department for further assistance Level One Press and release one of the SZ or Program Buttons User The display will now indicate Use the Program Buttons to access the desired parameter line Use the Button to alter the displayed parameter to the required setting To save the adjusted parameter move to the adjacent parameter or press and release the INFO Button if you wish to exit this level To exit without saving any adjustment press and release the MODE Button Level Two Press amp Hold the S ZN Program Buttons simultaneously for at least 3 seconds Installer The display will indicate H90 Use the Program Buttons to access the desired parameter line Use the LE Button to alter the displayed parameter to the required setting To save the adjusted parameter move to the adjacent parameter or press and release the INFO Button if you wish to exit this level To exit without saving any adjustment press and release the MODE Button Level Three Press amp Hold the Z Program Buttons simultaneously for at least 9 seconds OEM The display will indicate A password IS required to access this level Please contact MHG prior to accessing this as parameter level Use the ZZ Program Buttons to access the desired parameter line Use the lt E gt Button to alter the displayed parameter to the required setting To save the adjusted parameter move to the adjacent parameter o
42. ection 34 Cap D Heating Flow 1 Va B Condensate Outlet 34 BSP Plastic E Gas Supply inlet 34 Heating Return 1 Va F Cable Entry Grommets 010108 MHG Heating Ltd 3 2 Dimensions 77 Boiler Legend Heating Return Top Connection Option 1 Va E Condensate Outlet 34 BSP Plastic B Heating Return Bottom Connection Option 1 Va F Condensate Cleanout Connection 34 Cap Heating Flow Top Connection Option 1 Va Cable Entry Grommets D Heating Flow Bottom Connection Option 1 Va H Gas Inlet 34 010108 MHG Heating Ltd 3 3 Dimensions HS Calorifier Below Additional information available from the website www mhgheating co uk Hot Water Primary Return 1 Hot Water Secondary Outlet 34 rs 120 Litre Calorifier Hot Water Secondary Return Va B Pipework Cover Cold Water Secondary Inlet 34 Hot Water Primary Return 4 Hot water Primary Flow 34 Hot Water Secondary Outlet 34 D 60 Litre Calorifier Cold Water Secondary Inlet 34 E Calorifier Cover Hot Water Secondary Return Va E Pipework Cover 010108 MHG Heating Ltd 3 4 Installation and Service Clearances 16 47 Boilers C 3 C o2 FT om Y U min 50 mm min 50 mm 10 010108 11 MHG Heating Ltd 010108 3 4 Mounting Information 16 47 Boilers 12 MHG Heating Ltd 3 5 Installation and Service Clearances 75 Boiler min
43. ed Internal Boiler Pump A j 0 LMU 640150180 Steckplatz 5 3 Amp Fuse Ignition Electrode Combustion Fan 230 V 0 8 Gas Valve 010108 010108 70 JOU 5 jaqexpuequie4 Doll 22992225 ofl 196000 os al 04 05 28181 35 eC 21145 spoag2s 3 uonius T f jaueg Aejdsig f sng ddl C SX 0 i E 027190 E ad GE ad el VA 68 o 105 038 UIMaH 205038 sec an 4 2311 6 31055210 515 AA 6 0 3u07 Ue 8 6 SED wy sy 9 Sy Sy ue 4 uonsnquio 3 5 20 6 G inlees N 7 AA TELER els LU 2001777 duing 121109 jeuiaqu 128515 2PE25E7 21 4 Internal Wiring Diagram 75 HM MHG Heating Ltd 71 MHG Heating Ltd 22 0 HM Appliances and Slave units equipped with 001420 Communication Clips Communication Operation Indications The RED LED on the 0 420 communication clip mounted on the front of each LMU64 module controller flashes to indicate the detected operational status of the module dictated by the LPB communication from the RVA47 Cascade Manager LED FLASH STATUS INTERPRETATION OPTIONS LED ON Constantly 001420 not configured to operate with LMU64 LED OFF Constantly 001420 Configured LPB Short Circuit No Power LED ON 93 OFF 7 001420 and LUM64 Not Compat
44. ed Flow Sensor Present 1 No Mixed Flow sensor Present 0 E26 Error signal when sensor is not used Second Heating Circuit Installed with 3 Way Valve and Sensor No Alterations Required 28 010108 MHG Heating Ltd 8 9 Hydraulic Design Single Unit Option 10 061420 Cascade RVA63 Dual Zone Controller Outside Air Sensor Communication clip 1 ie 2 Fitted in Boiler FE B Room Units Can Be Applied to Both Heating Zones To Enhance Control N V Heating A Circuit 2 Heating Circuit 1 Lag Li EE X E j High Recovery Calorifier Electrical Connections Single Unit Option 10 5 Boiler Control Managed by the 2 aie RVA63 Zone Controller Via the Voltage gt 5 5 E 001420 LPB Communication Clip E LPB Communication e Terminals Polarity m ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt 06 5 ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp basies zia lal Per Output Her 8 status indicator Procon 45 75 amp 77 External Heating Circuit Pump Aa ProCon 16 amp 27 Internal Boiler Pump m Perminent 230 Volt Power Supply Fused at 7 Amps 061420 LPB Communication Clip Mounted onto The LUM64 Controller Boiler Parameter Alterations Parameters Description Default Proposed Change 18 H516 Summer Winter Automatic Changeover Temp
45. erature RVA63 Controller Alterations Parameters Description Default Proposed Change Summer Winter Automatic Changeover Temperature BO Boiler Control Type LPB On Off Hi Low 2 0 10 LPB Controller Appliance Communication Device EE LPB Controller Appliance Communication Segment 29 010108 MHG Heating Ltd 8 10 RVA63 Zone Controller Wiring Terminals FREE 1 I Ws LS LAS LS LILAA LS le eL Low Vollage Torminaln 248 Volt Termiset C DIN Te BOETE om a 4 3 B5 3 0 f EN mr m Pn ra f IM Ue 7 Mr QD 2 Y x LL u Terminal Designation Low Voltage Terminals Terminal Designation 230 Volt Terminals Description Operation Function Description Operation Function Zone 2 QAA70 50 10 Room Unit eZ PPS Ground E Zone 2 Mixing Valve Closing Output max 2 Amp To be positioned on Zone side of 3 way mixing valve To be linked to Live Input M Ground Connection for all Sensors Inputs Q6 200662 Pump Output mm Flue Gas Sensor Not Used Volt Free Enable via Room Power In put for Zone Pumps Output Thermostat BMS KEET EN Zone 1 Flow Sensor Zone 1 Flow Sensor QAD21 26 OM Zone 1 Mixing Valve Closing Output max 2 amp To be Zone 1 Flow Sensor QAD21 26 on Zone side of 3 way mixing valve 0 10 Volt Input vi
46. erminal s shall be guarded if it is less than 2000mm above the ground or in any position where it may cause injury to persons resulting from touching a hot surface Absolute guidance must be sought from the respective regulation 40 010108 MHG Heating Ltd 11 0 Filling The System The Initial filling of a sealed heating system and subsequent refilling must be by a method that has been approved by the Water Regulation Advisory Scheme WRAS for that type of heating system i e Domestic n House Fluid Category 3 C 3 Non Domestic Other than n House Fluid Category 4 C 4 For Category 3 systems the approved method of filling must comprise of the following components in the arrangement shown e Control Valve incorporating a Double Check Valve on the Mains Cold Water pipework Heating e Temporary Connecting Hose which must cy DCV Hose cvy System be disconnected after use e Control Valve on the heating system For Category 4 systems the approved method of filling must comprise of the following components in the arrangement shown e Control Valve Strainer RFF e Strainer e Verifiable Backflow Device with Reduced ORNE Heating Pressure Zone RPZ Valve Cy stem e Incorporating a Type BA Air Gap fr aus undish e Tundish e Control Valve Further more in accordance with BS 6644 2005 system with an input greater than 70kW nett an automatic water replenishment unit shall be installed to automa
47. gas the modules have been set to operate with Prior to firing the unit for the first time it is advisable to check the size of the gas injector The injectors are located on the outlet of module gas valves The table below indicates the size of injector for the respective fuel gas If the unit is required to operate on a fuel gas different from that to which it is currently set the following conversion procedure must be undertaken Isolate the fuel and electrical supplies at the appliances isolators Disconnect the electrical connection for the gas valves solenoid coils Disconnect the gas valve from the gas supply tubing at the union immediately prior to the gas valves inlet Remove the Circlip located at the outlet of the valve securing the injector to the fan inlet bracket Extract the gas valve and injector from the fan inlet bracket Install the correctly sized injector into the outlet of the gas valve ensuring to apply the sealing washer Reinstall the gas valve s complete with correct sized injector s in the reverse order Following completion of the re injectoring of all modules the units will require recommissioning as detailed in section 15 2 Gas Type ProCon 16 ProCon 27 ProCon 45 ProCon 75 amp 77 Natural Gas 620 PG 631 63 010108 MHG Heating Ltd 1 8 0 Routi ne Inspection a nd Se rvici ng A QAA73 Room Unit service tool is required to reset the modules service interval timer As with all Gas Applia
48. genee 52 Maximum 96 Output Reached Prior to Switching On a Module In 5 56 Time Spent By Module On Ignition Rate Prior to Modulation 0 1200 KAR N Minimum Temperature Difference Between Flow Return Sensor 0 20 2 2 Readings Prior to The Return sensor Becoming tead OO Display Default 0 Time of Day 1 System Flow Ep NE CA I RVA47 Manager Operating Hours 0 0 60 010108 MHG Heating Ltd 17 0 Commissioning The Appliance 17 1 Pre Commissioning Checks Prior to undertaking the commissioning of the unit please ensure that the system water has been cleansed and treated with a suitable inhibitor as detailed in Filling the system and system water quality Prior to applying power to the appliance its circulation pump should be bled and checked to ensure free rotation of the armature 17 2 Combustion System Commissioning The commissioning function enables the boiler to be started up in heating mode by pressing the Buttons simultaneously There are two levels of operation accessed via the commissioning mode Operation at Maximum Output With No Adjustment Pressing the BUTTONS for more than 3 seconds but less than 6 seconds places the appliance in High Fire mode To indicate that the module is operating under the control of the commissioning mode an arrow will appear on the display adjacent to the symbol The display will also indicate 100 This mode is maintained until the limi
49. gle Unit Option 6 QAA73 Room Unit Use Only One Type of Room Temperature Control mm Volt Free Enable Room Thermostat BMS eim Voltage gt QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensati on BE OAZ36 Hot Water sensor or Volt Free Enable rm e mis Hot Water Charging Pump or 3 Way Valve e SE Internal Valve on HS Models DE gt ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt fs ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp ml Per Output Su gt ProCon 45 75 amp 77 External Heating Circuit Pump ProCon 16 amp 27 Internal Boiler Pump m z E Perminent 230 Volt Power Supply Fused at 7 Amps usd r Mains Connection Via LMU X1 02 Flow Sensor Heating Circuit 2 Pump Only connect z Output 230V 1 Amp Mox flow sensor Heating Circuit 2 Mixing Valve Output 230V 1Amp Max 4 if mixing z valve i being AGU 2 500 Heating Circuit Mixing Valve Clip Mounted onto LMU64 Controller Parameters Description Default Proposed Change H554 b3 Weather Compensation 1 Constant Flow Temperature Operation 0 a 0 E10 Error signal when outside air sensor is not installed H558 b2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 0 1 E50 Error signal when sensor is not used Second Heating Circuit Installed without 3 Way Valve and Sensor LES
50. he internal Routine Service Control Timer needs to be reset Utilising the appliances fascia gain access to the Second Level Parameters as detailed in Section 14 2 and select Parameter Line H630 Bit 6 using the button adjust the value from 0 to 1 and press the INFO button to reset the Service Interval counter Weather Compensation Slope Flow Temperature MEEN VE Pad 5 5 Y NNW NND 3 YE WAGE YUYZED f Ed Z p amp Curve H532 en NS N S N ANN LASN N AN Proposed UR NS HAN AZ aL T ne ze MN TN M TN E 10 20 30 i 20 Proposed UE Cut re H532 2 Outside Air Temperature 0 65 010108 h 19 0 MHG Heating Ltd 20 0 Optional System Controls If required the following controls can be applied to the ProCon HT range to enhance boiler and system operational efficiency and longevity Further detailed guidance can be obtained from the respective controller manuals QAA73 Modulating Full Function Room Unit Single Boiler Applications Only as This modulating full function room unit offers the heating user full remote access to the all functions that effect the provision of heat to the respective zone The unit also displays information from all attached temperature sensors Boiler Hot water Outside Boiler Modulation and Operational Status RVA47 Cascade Manager This c
51. ia LMU 1 01 8 46 M Heating Circuit 2 Pump Per Output Only connect 230071 Aso Mas a flow sensor B gt 4 z ProCon45 75 amp 77 External Heating Circuit Pump amid ProCon 16 amp 27 Internal Boiler Pump valve is being ES Healing Circuit 2 Mixing Valve Output 230V 1Amp Max Perminent 230 Volt Power Supply Fused at 7 Amps AGU 2 500 Heating Circuit Mixing Valve Clip Mounted onto LMU64 Controller Parameters Description Default Proposed Change H554 b3 Weather Compensation 1 Constant Flow Temperature Operation 1 0 E10 Error signal when outside air sensor is not installed H558 2 Hot Water Storage Sensor 0 Hot Water Thermostat 1 0 013 E50 Error signal when sensor is not used ma Second Heating Circuit Installed without 3 Way Valve and 0 Sensor H554 5 Mixed Flow Sensor Present 1 No Mixed Flow sensor Present 0 E26 Error signal when sensor is not used Second Heating Circuit Installed with 3 Way Valve and Sensor e No Alterations Required 26 010108 MHG Heating Ltd 8 7 Hydraulic Design Single Unit Option 8 Calorifier Outside Air Sensor AGU 2 500 Heating Circuit 2 Clip BE Fitted In Boiler nU 7 ed Room Units Can Be Applied to Both Heating Zones To Enhance Control 8 EA aT E EE 1 2 ee 5 pn PSE M 255 B M 12 KA n i
52. ible LPB Address inadmissible LED ON 5 OFF 95 Boiler being controlled via LPB and required to be not operating LED ON 5 OFF 20 ON 5 OFF 70 Boiler being controlled via LPB and required to be operating 010108 010108 72 1 ie YS a T 3 C f tim rh E E 1 23 0 Exploded Spares Diagram 16 27 amp 47 MHG Heating Ltd MHG Heating Ltd 23 0 Exploded Spares Diagram 16 27 amp 47 77 i g bd p IMS Dy 39 Ce PES 28 7 ad 0 ut ER 38Y SEN aat 0 73 010108 74 010108 MEN 8 So 6 9 SY Ny PEER 6 ex se J LE a 0 Mei N N l 909690 E E m MHG Heating Ltd 23 0 Exploded Spares Diagram 16 27 amp 47 010108 75 e A wa s L fs ee af Ww 77 a ww a En Y 5 n T 23 0 Exploded Spares Diagram 16 27 amp 47 MHG Heating Ltd 010108 76 AV 6 FT i 1 ts E H EL Gee 23 0 Exploded Spares Diagram 16 27 amp 47 MHG Heating Ltd 727 MHG Heating Ltd 7 010108 Exploded Spares Diagram 16 27 amp 4 23 0 010108 78 24 0 Exploded Spares Diagram 75
53. ide case 16 010108 MHG Heating Ltd 5 0 Technical Data 27H amp 47 H amp 75 amp 77 HS amp S S H amp HM Carbon Emissions G20 kgC kWhr 0 061 0 061 0 061 0 060 100 Of max Output G31 kgC kWhr 0 078 0 078 0 078 0 077 Carbon Emissions G20 kgC kWhr 0 055 0 055 0 055 0 055 30 Of max Output G31 kgC kWhr 0 070 0 070 0 070 0 070 SEDBUK Rating 8 68 8 8 Operating Efficiency 40 C 30 C 1 1088 108 7 108 5 108 5 Nominal Heat Output 50 C 30 C 4 3 15 8 7 0 26 2 12 9 47 0 16 0 74 6 Design Flow Rate 50 C 30 C Ltr sec 0 188 0 312 0 560 0 880 Design Flow Rate 8000600 me 01 2 0288 0519 08 Hot Water Generation Output kW es us Hotwater flow rate DT 30 umn 9 Q9 Win Flow Rate For HAW Activation min G Minimum Fow Rate usec 0125 246 037 os Residual Head from inbuilt Pump mwe 37 13 os 05 G31 m3 hr 0 57 1 00 1 72 2 60 Maximum Flue Gas Volume 21 36 40 81 64 08 96 84 Available Fan Pressure Pa 40 40 400 40 Technical Data Units Minimum Water Pressure Cold bar 08 08 08 08 Maximum Flow Temperature C 90 290 90 90 Power Supply 230 V 50 HZ Amp 5 J 5 5 5 Max Power Consumption Watts 122 129 145 250 WaterContent les 4 52 52 82 bftWeightDy kg 430 430 17 010108 MHG Hea
54. in Segment 2 Controlled Via All RVA47 Managers In LPB System HWS Charging Cycles Per 24 Hour Period 0 1 1 0 One Per Day with 2 5 Hour Forward Shift from Heating Time Switch Setting 1 Several Per Day with 1 Hour Forwarding Shifting from Heating Time Switch Setting HWS Temperature Control 0 1 0 QAZ21 Sensor 1 Volt Free Enable via Thermostat 127 HWS Priority Shifting 0 3 1 0 Absolute Priority 1 Shifting Priority Heating Reduced to Increase HWS Recovery 2 No Priority HWS and Heating Operate in parallel 3 Shifting Absolute Heating Switched OFF Mixing Circuit Decreased RVA46 to Increase HWS Recovery Hours Of Operation Prior to Sequence Rotation 10 990 100 131 Changeover Sequence Program 0 3 0 No Exemptions 1 The First Module is Exempt 2 The Last Module is Exempt 3 The First 20 Last Mos are E SEG ME Cascade Enable Delay Time 1120 Anti Cycling Time Seconds 0 1800 140 LPB Control Address 0 16 1 1 Master RVA47 Manager 2 16 Slave RVA47s Operating From Master RVA47 Manager LPB Control Segment 0 14 0 Heat Generating Units RVA47s 1 14 Heat Consuming Units RVA46s mi EE LPB Power Supply 0 Off 1 On 145 Changeover Via LPB Connection 0 1 1 0 All Controllers in Same Segment 1 All Controllers in LPB System 0 1 0 Summer Winter Changeover Via LPB 0 Local Control Only 1 Entire Control Via LPB 58 010108 MHG Heating Ltd Central Stan
55. mum degree of modulation in heating mode T G NhzMax Maximum speed at maximum output in heating mode DI 27 a al Jes d d d d Tdi 4 p 98 5 E 45 010108 MHG Heating Ltd 14 0 Appliance Fault Codes The ProCon range has two levels of fault code indication Automatic Resetting Fault Code A small fault code alternating with the time of day The appliance will stop operating for a limited period until the error has been corrected Repeated occurrences of an Automatic Resetting Fault Codes will result in a Manual Reset Fault Code Manual Reset Fault Code A large fault code is displayed on the screen along with the fA symbol The appliance will stop operating until the error has been corrected and the RESET button has been pressed PLEASE NOTE If the RESET button is pressed when a small fault code is displayed or no fault code is displayed the unit will display a Manual Reset Fault Code of E153 will be displayed The RESET button must be pressed again to clear this code If a fault is encountered within the appliance or Cascade LPB network a fault code will be generated and displayed by the failing appliance and all LPB networked RVA and Opentherm units If a fault is encountered by a RVA controller or is communicated to a RVA controller via the LPB network ER will be generated on the display Opening the controllers flap and pressing the Down PROG button twice will gain access to parameter
56. n ue I o A ox i v EE Ignition Electrode Ds ormer I Transi 010108 MHG Heating Ltd 21 2 Internal Wiring Diagram 47 H amp S F OW sensor i Return sensor N Display Panel MW 5 FI OW 5 wi tc h 5 0 ni y System Water Pressure Switch m LL m c mo e e aoa Vi LM ome OW 2 ay a RI E LL Z Te o wi os m em da V ka m P un LE Paulum alien Ma AANT A T GT GE 1 mE BM E EJ BDT Internal Boiler Pump 8 fin 0 MM on ai e Internal 3 Way Valv HS amp 5 Only gt F 2t 2 A e m rr pem lt un e D e m T gl qi LE I an A o i WNW EV mr Ignition Electrode as 68 010108 MHG Heating Ltd 21 3 Internal Wiring Diagram 75 amp 77 H Return Sensor Flow Sencor Display Panel Flue Gas Sensor Combustion Fan System Water Pressure 7 zb V PWM Fan Control te 000 xn Steckplatz m
57. n 15 2 g Listen to the sound of the combustion fan Utilizing the appliances fascia review the units Operating Error Codes and note the recorded codes onto the Service Report H700 H722 h Undertake a System Water Analysis to check the concentration level of the Water Treatment and note the level onto the Service Report i Check the flue route including the terminal position for conformity with prevailing regulations and trim back any foliage that may be around the terminal j Check the plant room compartment ventilation system for conformity with prevailing regulations k Check the Pressure Safety Relief Valve size rating and orientation for conformity with prevailing regulations The results of the Inspections undertaken above must be acted upon and all discrepancies should be recorded on the Service Report and brought to the Client End User s attention Undertake any maintenance and if necessary any preventative maintenance that s required 18 2 Routine Cleaning amp Maintenance As part of the Routine Service Inspection certain areas of the boiler need to the checked and cleaned as necessary a Turn the boiler OFF at the ON OFF switch and electrically isolate the boiler by removing the plug or fuse from the boiler supply b Turn off the gas at the boiler isolation tap fitted by the installer adjacent to the appliance C Remove the electrical connections Two in the case of 45 75 amp 77 from the units fan assem
58. nces we would highly recommended that a competent heating engineer services the ProCon at least every 12 months This is assuming a normal daily usage of 8 10 hours If however the boiler is to be operated 24 hours a day 7 days we would recommend services every 6 months ProCon boilers will display an E105 Error Code when 12 months has lapsed indicating that the appliance requires a Routine Service Inspection This code will also be displayed on the RVA47 cascade manager and room unit if present If the Installer Commissioning Engineer is unable to undertake the Routine Service Inspection as detailed Section 16 1 please contact the MHG Technical Department who will be able to arrange the Routine Service Inspection to be undertaken 18 1 Routine Service Inspection Before commencing any service maintenance work the following tasks must be undertaken a Ask the end user about any problems with the operation of the boiler unit and note their comments b Check the water pressure of the installation c Remove the boiler casing and visually inspect all pipe and water joints for signs of leakage d Inspect the top of the casing and the top of the heat exchangers for signs of water leakage or ingress e Run the unit in Commissioning Mode HIGH FIRE with the use of a flue gas analyzer record the CO2 level See section 15 2 f Run the unit in Commissioning Mode LOW FIRE with the use of a flue gas analyzer record the CO2 level See sectio
59. nsated heating and priority hot water production via a separate high recovery Calorifier Cylinder where the diverter valve controlling the production of hot water is within the boiler case 1 4 The ProCon HS can be supplied complete with an integrated high recovery calorifier for simplified and attractive installation housed within and extended case The high recovery calorifer can be located beneath of adjacent to the boilers Further information available via the website www mhgheating co uk 1 5 The ProCon HM appliance is supplied complete with and integral RVA47 Cascade Manager capable of controlling an additional 11 ProCon boilers Each subsequent boiler must be fitted with an OCI420 Communication Clip The product codes for the entire range are 96 30000 7191 010108 MHG Heating Ltd 2 0 Installation Regulations and Requirements The installation of Procon HT boilers must be in accordance with the relevant requirements of Gas Safety Installation amp Use Regulations 1994 Health amp Safety at Work Act Building Regulations IEE Regulations Construction Design amp Management Regulations 1994 Local Authority Bye Laws National Fire Regulations and Insurance Company requirements The following Codes of Practice are also applicable BS 5440 1 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net 1st 2nd and 3rd family gases Part 1 Specification for the install
60. ppliances And any addition prevailing regulation and or code of practice not detailed above 010108 MHG Heating Ltd 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 010108 MHG Heating Ltd 3 0 Dimensions 16 47 Boilers Legend Hot Water Primary Return 22mm HS Models 3 72 EY Cold Water Inlet 22mm S Models Heating Fow 22mm All Models n Heating Return 22mm All Models Hot Water Primary Flow 22mm HS Models zm Hot Water Outlet 22mm S Models 7 Condensate Outlet 34 BSP Plastic 4 Gas Inlet 22mm Condensate Cleanout Connection 4 Cap 010108 MHG Heating Ltd 3 1 Dimensions 75 Boiler Legend Condensate Cleanout Conn
61. r Boiler Parameter Alterations Parameters Description Default Proposed Change H516 summer Winter Automatic Changeover Temperature H552 Appliance Hydraulic Configuration 66 67 70 80 80 81 H605 LPB Communication Appliances Address Maximum 12 Boilers RVA47 Manager Alterations Parameters Description Default Proposed Change 18 Summer Winter Automatic Changeover Temperature 31 010108 MHG Heating Ltd 8 12 Separately Housed RVA47 Cascade Manager 0 10 Volt Input via BMS Volt Free Enable via Room Thermostat BMS M terminal used to create circuit lt 25V System Return Sensor QAD21 To be positioned on boiler side of system Low Loss Header Ground Connection for all Sensors Inputs Hot Water Sensor QAZ21 Volt Free Enable via Calorifier Thermostat BMS Parameter alteration required if Volt Free Enable Used System Flow Sensor QAD21 To be positioned on system side of system Low Loss Header QAA70 50 10 Room Unit PPS Ground QAA70 50 10 Room Unit PPS Data LPB Ground connected in parallel to boiler mounted 001420 Clips LPB Data connected in parallel to boiler mounted OCIA20 Clips Hot Water Charging Pump 3 Way Valve Output max2 Amp Description Operation Function Outside Air Sensor QAC31 32 or 6200 Substitute Resistor 1 C Mounted on North Facing Wall Power Input for Heating and Hot Water Pump Outputs To be linked to Live Input N 230V Permanent Neutral 32 01
62. r press and release the INFO Button if you wish to exit this level To exit without saving any adjustment press and release the MODE Button 49 010108 MHG Heating Ltd Level One end User Parameters Time of Day 0 2359 P2 Day Of Week 1 Monday P5 Reduced Room Temperature Set Point If outside air sensor installed 5 34 Minimum Boiler Flow Temperature 20 80 Time Switch 1 Heating Zone 1 Set Points a Heating Circuit 1 Time Switch 1 Day Selection 1 2 1 5 1 7 1 7 Heating Circuit 1 Time Switch 1 First On 00 00 24 00 e Heating Circuit 1 Time Switch 1 First Off 00 00 24 00 Heating Circuit 1 Time Switch 1 Second On 00 00 24 00 Heating Circuit 1 Time Switch 1 Second Off 00 00 24 00 Heating Circuit 1 Time Switch 1 Third On 00 00 24 00 pe Heating Circuit 1 Time Switch 1 Third Off 00 00 24 00 Time Switch 2 Heating Zone 2 Set Points AGU2 500 Clip and QAD36 sensors required Heating Circuit 2 Time Switch 2 Day Selection 1 2 1 5 1 7 Heating Circuit 2 Time Switch 2 First On 00 00 24 00 N Heating Circuit 2 Time Switch 2 First Off 00 00 24 00 N N Heating Circuit 2 Time Switch 2 Second On 00 00 24 00 Heating Circuit 2 Time Switch 2 Second Off 00 00 24 00 Heating Circuit 2 Time Switch 2 Third On 00 00 24 00 pe Heating Circuit 2 Time Switch 2 Third Off 00 00 24 00 QAZ36 HWS Sensor Required Time Switch 3 Day Selection 1 2 1 5 1 7 Time Switch 3 First On 00 00 24 00 N Tim
63. t generation control method for the RVA47 boiler installation this setting must be adjusted to on all RVA47s present in the boiler cascade installation This will result in the Auto On Off and Frost lights becoming inactive Alteration to parameter 170 and 172 will also be required Actual Room Temperature Actual Outside Temperature 50 50 Pressing the amp buttons simultaneously until the display stops flashing will reset the averaged value 32 Hot Water Time Switch 2nd OnTime 00002800 35 HotWaterTmeSwih2zndOffTime 00002800 3i Hot Water Time Switch 3rd On Time 00002800 35 HotWaterTimeSwitch3rdOfftime 00002800 3 FeHCodeDspay O o 025 LL tet Output Test 0 Automatic control 1 All outputs off 2 HWS pump valve on 3 Circulating pump on 52 Input Test 0 Return Temperature 1 HWS Temperature 2 Flow Temperature 3 Outside Temperature 4 Room Temperature 5 0 10 Volt Required Temperature 56 010108 MHG Heating Ltd Plant Type etal Stem Flow Temperature ER Actual System Return Temperature ow 57 Actuel System HWS Temperature om 35 Attenuated Outside Air Temperature 504580 60 61 Composite Outside Air Temperature soso Outside Air Temperature Source ooma 66 Maximum System Flow Temperature 885 6 Maximum HWS Temperature J ss TT
64. t thermostat temperature is reached or the coommissioning buttons are pressed from more than 1 second Operation at Maximum or Minimum Output For Flue Gas Analysis and Gas Valve Adjustment Pressing the BUTTONS for more than 6 seconds places the appliance in High Fire mode To indicate that the module is operating under the control of the commissioning mode an arrow will appear adjacent to the symbol The display will also indicate 100 61 010108 MHG Heating Ltd The output of the appliance can be altered by using the vw buttons to move between 100 maximum outout and 0 minimum output Alterantaivley the output of the appliance can be altered by using the buttons to descrease or increase the output by 1 per press This mode is maintained until the limit thermostat temperature is reached or the coommissioning buttons are pressed from more than 1 second Whilst the appliance is operating under the control of the commissioning mode with adjustment the gas valve can be adjusted to give correct flue gas analysis readings The appliance is equipped with a modulating gas valve The modulating gas valve must be set at High Fire and Low Fire to ensure correct operation throughout its modulating range It is advisable to check the combustion figures on High and Low Fire prior to carrying out any adjustments Adjusting the High Fire has a marked effect on the Low Fire figures Where as adjusting the Low Fire has little effect on
65. taneously for up to 9 seconds until appears A password will be required to access this level Down Down Plus Minus Plus Use either of the SZ Z Program Buttons to access the desired parameter line Parameter Line range 2 92 Use the H LE gt Buttons to alter the required parameter Once all alterations have been completed press the AUTO button to exist this level Complete RVA47 Cascade Controller Parameter Settings The defaults indicated on the following pages are for standard systems If additional control features are required alteration will have to be made Please refer to the RVA47 manual for additional details Indicates where an input can be made if required Indicates where an input can not be made and a sensed attenuated figure is displayed OFF will be displayed if the buttons are used 55 010108 MHG Heating Ltd User Level 0 ER O eae TE Wese NEN 9 Be Reed Year 1900 3000 As requise psy ot We as Reauired 6 Heating Time Switch 1st On Time 00002400 0600 8 MHemingTimeSwichzndOnTime 00002400 3 Heating Time Switch 2nd OFF Tine wozo 10 HeatingTimeswithardontme 00002800 it HeatingTimeswith3rdOftime 00002400 13 Required HS Temperature 4060 so NEE E aee oreo eraa 13 39 Weather Compensation Curve If a 0 10 volt signal is the required hea
66. the High Fire figures The High fire adjustment is carried out via the 2 5mm Allen Key socket D The High Fire adjustment is a Gate type restrictor Therefore turning the screw clockwise will close the gate and thus restrict the quantity of gas passing through to the burner The Low fire adjustment is carried out via the 2 5mm Allen Key socket N The Low Fire adjustment is a diaphragm governor Therefore turning the screw clockwise will increase the pressure on the diaphragm and thus increase the quantity of gas passing through to the burner Legend Valve Inlet Gas Pressure Test Point Valve Outlet Gas Pressure Test Point High Fire Adjuster Gate Type Low Fire Adjuster Governor Type ZUW A flue gas analyser must be used to ensure that the correct combustion setting are achieved This is undertaken by inserting the analyser s probe in to plugged hole within the flue collector of the appliance or in the tapping in the flue immediately above the appliance if present 62 010108 MHG Heating Ltd The combustion setting required for all ProCon appliances are as detailed in the following table Gas Type High Fire Natural Gas G20 8 5 CO 9 0 CO LPG G31 11 0 CO 11 0 CO 17 3 Conversion of the Appliance to Operate on LPG G31 Unless specified at the time of ordering the appliance s will be supplied ready to operate on a Natural Gas G20 fuel supply The appliances data badge will indicate the type of fuel
67. tically replenish any lost or evaporated water Please refer to BS 6644 2005 for allowable water replenishment methods for use with sealed pressurized heating systems For information on a comprehensive range of pressurization units that comply with current British Standards and WRAS Regulations please contact MHG Heating Ltd Sales 11 1 Expansion Vessel In accordance with BS 6644 2005 WRAS Regulations and Local Authority Water Regulations as applicable the installer shall install a suitably sized and approved Expansion Vessel to ensure that the water capacity of the system has ample expansion capacity The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service Valve which shall be locked in the OPEN position to prevent accidental isolation Furthermore a drain facility should be provided adjacent to the expansion vessel to aide the routine maintenance overhaul of the vessels Air Pressure setting For information on a comprehensive range of expansion vessels that comply with current British Standards and WRAS Regulations please contact MHG Heating Ltd Sales 41 010108 MHG Heating Ltd 12 0 System Water Quality Water Treatment System Cleaning BS 7592 2006 The entire primary system MUST be thoroughly cleaned and flushed to remove debris flux residues etc before opening the boiler isolation valves amp flooding the boiler Particular care must be taken where the
68. ting Ltd 6 0 Pressure Safety Relief Valve In accordance with the prevailing British Standard 5440 6644 the installer shall install as suitably sized Pressure Safety Relief Valve The location of this valve is important with respect to the applied pressure of the boiler circulation pump it is therefore recommended to locate the Pressure Safety Relief Valve on the flow pipe immediately adjacent to the boiler furthermore there must not be any means of isolation between the boiler and the Pressure Safety Relief Valve 7 0 Electrical Connections Basic electrical connection for all types of ProCon 1213415617 BW Legend Low Voltage Control terminals lt 25 Volts QAA73 Room Unit Not Polarity Sensitive lt 24Volts Link terminals to activate second heating zone control Heating Circuit 1 Heating Circuit 1 Volt Free Enable Not Polarity Sensitive Room stat BMS lt 24 Volts Free Enable Not Heating Circuit 1 Volt Free Enable Not Polarity Sensitive Room stat BMS lt 24 Volts Sensitive Room stat BMS lt 24 Volts E Outside Air Sensor QAC34 Not Polarity Sensitive 24Volts Required to Activate Direct on Boiler Weather Compensation Hot Water Sensor QAZ36 or Hot Water Volt Free Enable Thermostat BMS d Not Polarity Sensitive gt 24Volts High Voltage Output and Input Terminals 230 Volts E 9 Common Earth Terminal Permanent 230 Volt Output for Motor Open Motor Close Hot Water
69. tpoint temperature 20 90 C w 5 5 5 2 5 6 LmodTL lt PhzMax lt LmodVL H542 Minimum boiler output in kW 75 0 9999 kw lower calorific value Maximum boiler output in kW 25 Overrun time of pumps ie 210 uu 0 255 min 10 10 10 10 setting 255 continuous operation of Q1 Minimum burner pause time heat demand dependent switching hysteresis 2 Constant for quick setback without room 0 0 2 2 2 gt influence b0 1 b0 1 b0 1 b0 1 100 15 Setting flags status code open circuit sensor for ANx channel suppressed not suppressed 51 010108 MHG Heating Ltd ae 16 amp 27H 275 75 45 75 77 H ascade slave E Description Range 16 amp 27 HS 47 S c 2 Setting flags Hs Setting flags Running time of actuator in heating circuit 2 30 873s 150 150 150 150 TimeOpening TimeClosing LPB device number of LMU HM or Master Boiler 2 then Slave units 3 12 m Progr input on clip in function module Md Function output1 clip in function module 21 Function output3 clip in function module cart a Maximum value of heat demand with H622 external predefined temperature setpoint 5 C lt TAnfoExtMax 130 C H630 Setting flags of maintenance alarms 7 0 255 66 Months interval since last service visit months H700 1st Historical Fault Number of Occurrences H701 1st Historical Fault Operating Phase H702 1st Historical Fault Oper
70. ts Outside Air Sensor QAC32 Not Polarity Sensitive gt 24 15 Required to Activate Direct On Boller Meat ier Compensation TS NEE Gr oe ay St X41 Terminal 2 Right OCI420 Communication Clip aa ue X41 Terminal 1 Left OCI420 Communication Clip 19 010108 MHG Heating Ltd 8 0 Hydraulic Design Single Unit Option 1 _ Room Unit or ma 2r mm Room Thermosat 106 LL OS 1 47 Pressure vessel E TT 2 I T 7 ut mad wol ad ea NN 4 ene E eee J TEN Pressure Relief Valve NRV Strainer Flow Return Electrical Connections Sinale Unit Option 1 QAAT3 Room Unit f Use Only One Type of Room Temperature Control Low Volt Free Enable Room Thermostat EMS i Voltage QAC34 Outside Air Sensor Required to Activate Direct On Boiler Weather Compensation ProCon 45 75 amp 77 Internal Boiler Pump 230 Volt ProCon 16 amp 27 External Heating Circuit Pump Max 1 Amp Per Output a ProCon45 75 amp 77 External Heating Circuit Pump ProCon 16 amp 27 Internal Boiler Pump Perminent 230 Volt Power Supply Fused at 7 Amps Weather Compensation 1 Constant Flow Temperature Operation H554 b3 0 E10 Error signal when outside air sensor is not installed 010108 MHG Heating Ltd 8 1 Hydraulic Design Single Unit Option 2 7 A Room Unit or Room
71. upported Output 35 Input control configuration upon control requirement 4 is recommended When H618 is set to 5 Left Terminal Live Right Terminal Neutral Output rated at 240 Volts 0 5 Amp Relay designation for Output from Clear Plug Left Terminal Live Middle Terminal Neutral Output rated at 240 Volts 0 5 Amp Relay designation for Output from Clear Plug Right Terminal Live Output rated at 240 Volts 0 5 Amp 010108 Input value interpretation affected by H622 or H623 Dependant Programmable Outputs Relay designation for Output from Orange Plug Programmable Inputs 1 5 H618 H622 Maximum Temperature Via X51 input 0 10 Volt 85 When 2618 is set to 4 5 Percentage level reached by input prior to boiler activation H623 H619 H620 H621 MHG Heating Ltd 10 0 Fluing Options Please note that excessive resistance within the flue and combustion air supply systems will lead to a reduction in the output of the appliance and induce operation faults 1 25 EE Exhaust Pipe Terminal o Z o 10 25 40 80 Air Pipe Terminal 2 0 4 0 7 0 15 0 955mm Flue Extension 15 30 50 90 87 Bend 1 0 2 5 45 Bend 30 Bend When flues are installed with horizontal sections portions a 3 fall back to the boiler must be maintained This will not only ensure condensate removal preventing premature seal failure but also prevent nuisances dripping from the wall

Download Pdf Manuals

Related Search

Related Contents

Z30497A / Z30497B  31295016605445    · 4.2.- ¿COMO LIMPIAR, ENGRASAR Y TENSAR LA CADENA  Saturn 100 User Manual  Installation Guide  english use and maintenance manual deutsch bedienungs  KOHLER K-3672-NA Installation Guide  und Strauchschere_Cover_LB1.indd  REllEnO dE hUECO óSEO OSTEOSET® XR  

Copyright © All rights reserved. Failed to retrieve file