Alfalaval Micro Manual

DOC-1355, 3rd June 2014
Installation and service instruction Alfa Laval Micro
Heating & domestic hot water substation for apartments and single family houses

Alfa Laval Micro
Installation and service instruction
3
Contents
1General ..................................................................................................................................6
Product overview AquaMicro.....................................................................................................................61.1 Product overview Micro DPC ....................................................................................................................71.2 Product overview Micro RTC.....................................................................................................................81.3 Product overview Micro STC.....................................................................................................................91.4 Product overview Micro STC2................................................................................................................ 101.5 Product overview Micro HTC.................................................................................................................. 111.6 Symbols on the first fix-jig ...................................................................................................................... 111.7
2Installation...........................................................................................................................12
Unpacking............................................................................................................................................... 122.1 Preparation............................................................................................................................................. 122.2 Mounting................................................................................................................................................. 122.3 Mounting options general....................................................................................................................... 132.4 Mounting options Micro RTC............................................................................................................. 13
2.4.1 Mounting options Micro STC............................................................................................................. 142.4.2
Adjustments and setting general............................................................................................................ 152.5 Commissioning advice Micro RTC and Micro STC................................................................................ 152.6 Dismantlement........................................................................................................................................ 152.7 User instruction HTC hot water actuator................................................................................................ 152.8 Measure sketch...................................................................................................................................... 162.9
3Installing the room thermostat CM737 ..............................................................................17
General................................................................................................................................................... 173.1 Installing the room thermostat................................................................................................................ 183.2 Installing the outdoor temperature sensor (option) ................................................................................ 203.3 Starting up and component control of the room thermostat CM737 ...................................................... 203.4 Configure the room thermostat after installation.................................................................................... 203.5 Setting the time....................................................................................................................................... 203.6 Setting the time....................................................................................................................................... 213.7
4Installing the CM721 wireless system...............................................................................22
General................................................................................................................................................... 224.1 Room thermostat CM721....................................................................................................................... 224.2 Relay box BDR91................................................................................................................................... 234.3 Installation information ........................................................................................................................... 234.4 Installing the relay box............................................................................................................................ 244.5 Preparing the room thermostat............................................................................................................... 254.6 Installing the batteries ....................................................................................................................... 254.6.1 Setting the Date................................................................................................................................. 254.6.2 Setting the time ................................................................................................................................. 254.6.3
RF Communication check (test mode)................................................................................................... 264.7 Signal strength test............................................................................................................................ 274.7.1 Locating and mounting the room thermostat .................................................................................... 274.7.2
System check......................................................................................................................................... 284.8
5Binding/rebinding the CM721.............................................................................................29
6Basic operation of the system CM721...............................................................................31
Setting one temperature for the whole day............................................................................................ 316.1 Automatic operation ............................................................................................................................... 316.2 Temporary manual override................................................................................................................... 316.3 Communications loss ............................................................................................................................. 316.4
7Special functions for CM721..............................................................................................32
Service indicator..................................................................................................................................... 327.1 BDR91 relay box fail safe mode setup................................................................................................... 327.2
8Activation of installer parameters......................................................................................33
Entering the installer set-up mode ......................................................................................................... 338.1 CM737-Installer parameters table.......................................................................................................... 348.2 CM737-Category 1: Room Thermostat Settings............................................................................... 348.2.1

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Installation and service instruction
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CM737-Category 2: System Settings................................................................................................ 358.2.2 CM737-Category 3: Boiler Settings................................................................................................... 358.2.3 CM737-Category 4: Transparent Boiler Parameter .......................................................................... 368.2.4 CM737-Category 5: Fault History...................................................................................................... 368.2.5
CM721–Installer parameters table........................................................................................................ 378.3 CM721- Category 1: Room Thermostat Settings.............................................................................. 378.3.1 CM721- Category 2: System Settings............................................................................................... 388.3.2 Using the room thermostat for specific applications ......................................................................... 388.3.3
9Troubleshooting the CM737...............................................................................................39
Fault Codes on the CM737 .................................................................................................................... 409.1
10 Troubleshooting the CM721...............................................................................................41
Diagnostic mode, CM721....................................................................................................................... 4210.1
11 Differential pressure control valve, DPC...........................................................................43
Setting the DPC valve ............................................................................................................................ 4311.1 Flow rate graph of the DPC.................................................................................................................... 4311.2
12 Electrical circuit diagram ...................................................................................................44
13 Schematic diagram, main components.............................................................................46
AquaMicro .............................................................................................................................................. 4613.1 Micro DPC.............................................................................................................................................. 4613.2 Micro RTC .............................................................................................................................................. 4713.3 Micro STC............................................................................................................................................... 4713.4 Micro STC2............................................................................................................................................. 4813.5 Micro HTC .............................................................................................................................................. 4813.6
14 Service instructions............................................................................................................49
General service instructions................................................................................................................... 4914.1
A. Tap water temperature too low ......................................................................................................... 49
B. Tap water temperature too high........................................................................................................ 50
C. Hot water temperature unstable or too low....................................................................................... 50
D. Heating system temperature too high or too low .............................................................................. 51
E. No heating......................................................................................................................................... 51
F. Heating temperature unstable........................................................................................................... 51
STC service instructions......................................................................................................................... 5114.2
A. Heating system temperature too high or too low .............................................................................. 51
B. No heating......................................................................................................................................... 52
C. Disturbing noise from the circulation pump/ Noise in the radiator system........................................ 53
D. Heating temperature unstable........................................................................................................... 53
RTC service instructions ........................................................................................................................ 5314.3
A. Heating system temperature too high or too low .............................................................................. 53
B. No heating......................................................................................................................................... 54
HTC service instructions ........................................................................................................................ 5414.4
A. Tap water temperature too low/ hot water temperature unstable or too low..................................... 54
B. Heating system temperature too high or too low .............................................................................. 54
15 Maintenance and repairs....................................................................................................55
Change the hot water actuator and exchanger...................................................................................... 5515.1 Change the hot water valve.................................................................................................................... 5515.2 Change the heating actuator.................................................................................................................. 5615.3 Change the heating valve....................................................................................................................... 5615.4 Change the pump................................................................................................................................... 5615.5 Change the heating circuit supply temperature sensor.......................................................................... 5715.6 Change the outdoor temperature sensor ............................................................................................... 5715.7 Change the differential pressure control valve....................................................................................... 5715.8 Change the flow switch .......................................................................................................................... 5815.9
16 Options................................................................................................................................59
Under floor heating thermostat............................................................................................................... 5916.1 First fix-jig............................................................................................................................................... 5916.2
17 Declaration of conformity...................................................................................................60

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Installation and service instruction
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General warnings
The installation work must be carried out by an authorized installation contractor. Before the
system is taken into operation, it must be pressure tested in accordance with relevant
regulations.
The temperature and the pressure of the primary heating water are very high. Only qualified
technicians are allowed to work with the substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
If the hot water temperature is set too high, people may be scalded. If the hot water temperature
is set too low, unwanted bacteriological growth may occur in the hot water system. This can
result in serious personal injury.
Parts of the substation may get very hot and should not be touched.
When starting up the substation: To avoid the risk of scalding, make sure that no-one draws any
hot water until the hot water temperature has been adjusted.
Start heating circulation by first opening the valves in the primary heating supply and then return
lines, in order to avoid pollutions in the system. Open up the valves slowly to avoid pressure
surges.
Micro STC and Micro STC2 warnings
Before the substation is connected to the electrical supply, make sure that the heating system is
topped up with water. Starting up the system without water will damage the circulation pump.
The substation comes prepared with an electrical plug to be connected to the main supply. The
strain relief clips of the cable must be fitted so that there is no risk of damage. If necessary, the
plug-and-socket connection can be replaced with a permanent installation with an all-pole isolate
switch. This must be carried out by a qualified electrician.
Do not shut of the electrical supply to the room thermostat, this will damage the circulation pump,
valves, actuators etc.

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Installation and service instruction
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1 General
Product overview AquaMicro1.1
Picture 1
1
Heat exchanger and temperature
controller for hot water
9
Adapter for Hot water flow meter
2
Control valve for hot water
10
Heating network media, supply
3
Temperature sensor connection,
heating media supply
11
Heating network media, return
4
Filter for heating media
12
Cold water (cw)
5
Adapter for energy meter
13
Cold water outlet (cw)
6
Check valve for cold water
14
Hot water (hw)
7
Adapter for Cold water flow meter
30
First fix jig including shut-off valves (option)
8
Safety valve for domestic hot water

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Installation and service instruction
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Product overview Micro DPC1.2
Picture 2
1
Heat exchanger and temperature
controller for hot water
10
Heating network media, supply
2
Control valve for hot water
11
Heating network media, return
3
Temperature sensor connection,
heating media supply
12
Cold water (cw)
4
Filter for heating media
13
Cold water outlet (cw)
5
Adapter for energy meter
14
Hot water (hw)
6
Check valve for cold water
15
Differential pressure controller
7
Adapter for Cold water flow meter
16
Heating circuit, return
8
Safety valve for domestic hot water
17
Heating circuit, supply
9
Adapter for Hot water flow meter
30
First fix jig including shut-off valves (option)

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Installation and service instruction
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Product overview Micro RTC1.3
Picture 3
1
Heat exchanger and temperature
controller for hot water
13
Cold water outlet (cw)
2
Control valve for hot water
14
Hot water (hw)
3
Temperature sensor connection,
heating media supply
15
Differential pressure controller
4
Filter for heating media
16
Heating circuit, return
5
Adapter for energy meter
17
Heating circuit, supply
6
Check valve for cold water
18
Flow switch for domestic hot water (option)
7
Adapter for Cold water flow meter
19
Control valve, heating circuit
8
Safety valve for domestic hot water
20
Actuator, heating circuit
9
Adapter for Hot water flow meter
21
Connection box for electric power and
sensors, heating circuit
10
Heating network media, supply
22
Room thermostat/control panel
11
Heating network media, return
30
First fix jig including shut-off valves (option)
12
Cold water (cw)

Alfa Laval Micro
Installation and service instruction
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Product overview Micro STC1.4
Picture 4
1
Heat exchanger and temperature
controller for hot water
15
Differential pressure controller
2
Control valve for hot water
16
Heating circuit, return
3
Temperature sensor connection,
heating media supply
17
Heating circuit, supply
4
Filter for heating media
18
Flow switch for domestic hot water (option)
5
Adapter for energy meter
19
Control valve, heating circuit
6
Check valve for cold water
20
Actuator, heating circuit
7
Adapter for Cold water flow meter
21
Connection box for electric power and
sensors, heating circuit
8
Safety valve for domestic hot water
22
Room thermostat/control panel
9
Adapter for Hot water flow meter
23
Outdoor temperature sensor (option)
10
Heating network media, supply
24
Check valve for heating circuit
11
Heating network media, return
25
Circulation pump, heating circuit
12
Cold water (cw)
26
Underfloor heating thermostat (option)
13
Cold water outlet (cw)
27
Supply temperature sensor, heating circuit
14
Hot water (hw)
30
First fix jig including shut-off valves (option)

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Installation and service instruction
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Product overview Micro STC21.5
Picture 5
1
Heat exchanger and temperature
controller for hot water
16
Heating circuit, return
2
Control valve for hot water
17
Heating circuit, supply
3
Temperature sensor connection,
heating media supply
19
Control valve, heating circuit
4
Filter for heating media
20
Actuator, heating circuit
5
Adapter for energy meter
21
Connection box for electric power and
sensors, heating circuit
6
Check valve for cold water
22
Room thermostat/control panel
7
Adapter for Cold water flow meter
23
Outdoor temperature sensor (option)
8
Safety valve for domestic hot water
24
Check valve for heating circuit
9
Adapter for Hot water flow meter
25
Circulation pump, heating circuit
10
Heating network media, supply
26
Underfloor heating thermostat (option)
11
Heating network media, return
27
Supply temperature sensor, heating circuit
12
Cold water (cw)
28
Heating circuit primary temp, return
13
Cold water outlet (cw)
29
Heating circuit primary temp, supply
14
Hot water (hw)
30
First fix jig including shut-off valves (option)
15
Differential pressure controller

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Installation and service instruction
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Product overview Micro HTC1.6
Picture 6
1
Heat exchanger and temperature
controller for hot water
11
Heating network media, return
2
Control valve for hot water
12
Cold water (cw)
3
Temperature sensor connection,
heating media supply
13
Cold water outlet (cw)
4
Filter for heating media
14
Hot water (hw)
5
Adapter for energy meter
15
Differential pressure controller
6
Check valve for cold water
16
Heating circuit, return
7
Adapter for Cold water flow meter
17
Heating circuit, supply
8
Safety valve for domestic hot water
19
Control valve, heating circuit
9
Adapter for Hot water flow meter
20
Actuator, heating circuit
10
Heating network media, supply
30
First fix jig including shut-off valves (option)
Symbols on the first fix-jig1.7
The first fix-jig has symbols that show which supply and return pipe that should connect to the different
connection points.
Picture 7
1
Heating circuit, return
2
Heating circuit, supply
3
Heating network media, supply
4
Heating network media, return
5
Hot water (hw)
6
Cold water outlet (cw)
7
Cold water (cw)

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Installation and service instruction
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2 Installation
Unpacking2.1
Remove the transport packaging and check that the product has not been damaged in transit and that
the consignment agrees with the specifications.
When lifting the unit take care not to apply stress to pipes and heat exchanger as this may weaken
them. Avoid lifting the unit by holding the heat exchanger.
Note: Risk of injury lifting heavy objects.
Micro RTC:
Make sure that each individual room thermostat and its relay box are kept together. They are pre-
configured at the factory. If they are separated see 5 Binding/rebinding the CM721.
Preparation2.2
Choose a suitable installation area in accordance with official regulations.
The system may generate sounds during operation caused by pumps, regulators systems, flows etc.
This should be taken in consideration during installation of the unit so that possible operational sounds
affect the surroundings as little as possible. This means that the system should be installed on well-
insulated walls, such as outer walls or on concrete walls.
Check the applicable regulations of the primary heating supplier. The available differential pressure
should be for :
oAquaMicro: at least 50kPa and at most 600 kPa
oMicro DPC, RTC STC, STC2 and HTC at least 50 kPa and at most 400 kPa
Where the differential pressure is higher, a differential pressure controller should be added to the
installation.
Flush out the heating and hot water systems.
Mount the first fix-jig (option) to the connection points. Tighten with 45 Nm.
Carefully loosen the electrical plug from the insulation and attached it to the correct power cable.
See Picture 8. Make sure that the cable is fasten in the insulation
Picture 8
Mounting2.3
Mount the substation on the wall using four screws or bolts suitable for the material of the wall and for
the weight of the unit. The unit may be mounted at any height on the wall, but a distance of 1500 –
1800 mm from floor to keyhole fixing may be taken as a guide. The hole pattern for screws/bolts and
the piping connection measures is shown in 0

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Installation and service instruction
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Measure sketch.
Drainage pipe from the safety valve must be taken to floor gully.
Energy meters must be installed at a prepared location, replacing a gauge block, or following the
instructions of the energy supplier.
Retighten all connections, including those made at the factory. Tighten with 45 Nm. If connections need
retightening after the installation has been taken into service, the system should be depressurised
before retightening. If the system is not depressurised before retightening, gaskets will be damaged.
Connect the pipe work to the first fix-jig (option) connection points. Tighten with 45 Nm.
Bleed the heating system.
Start the heating circulation pump with the highest output setting. Let the heating system heat up and
bleed the system again.
Set the pump capacity of the heating circulation pump according to the pressure head diagram see the
manual Operating Instruction Alfa Laval Micro.
Use the lowest setting that manages the heating demand for best electrical efficiency.
Mounting options general2.4
If the substation is connected to a low temperature system, for example floor heating, a safety
thermostat must be mounted and activated before start up. See 16.1.
For more information; contact the supplier of the under floor heating system.
Install enclosed check valve for cold water in cold water pipe, see Picture 9.
Picture 9; Installation of check valve in cold water pipe.
Mounting options Micro RTC2.4.1
See 4

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Installation and service instruction
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Installing the CM721 wireless system.
Mounting options Micro STC2.4.2
See 3 Installing the room thermostat CM737.
Mount the outdoor temperature sensor (option) on the north side of the building, 2 metres above the
ground, or higher. See 3.3 Installing the outdoor temperature sensor (option).

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Installation and service instruction
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Adjustments and setting general2.5
Open up incoming cold water supply and fill the service water and heating circuits, bleeding off any
trapped air.
Check the operation and opening pressures of the safety valve.
Adjust the hot water temperature by having a hot water tap open at normal flow rate for a time.
Measure the temperature at the draw-off point with a thermometer.
The temperature should be approximately 50°C. It takes about 20 seconds to get stable tap water
temperature
50°C corresponds to a set point of approximately 1,5 on the actuator.
See chapter 14 Service instructions for adjusting hot water temperature.
With a Micro HTC:
Recommended set point for the actuator is 5 or 6.
Set point
2
3
4
5
6
7
°C (approx.)
20
30
40
50
60
70
Alfa Laval recommends that the tap water temperature is set to 10º less than the primary inlet
temperature. If a HTC the temperature must be 15º less than the primary inlet temperature.
NOTE: Make sure that no cold water is mixed with the hot water while making this adjustment.
The property owner must be instructed in the operation, setting and care of the unit. It is particularly
important to provide information about the safety systems and about hazards that may arise in relation
to the high pressure and temperature of the primary heating water.
Commissioning advice Micro RTC and Micro STC2.6
The room thermostat has been set at the factory. If any function needs tuning, values can be changed
see 8 Activation of installer parameters. Initially, the commissioning process should be carried out with the
factory settings.
Dismantlement2.7
When the time comes for the substation to be dismantled and scrapped it must be disposed of in the correct
manner in accordance with local or national regulations.
User instruction HTC hot water actuator2.8
Hot water temperature in apartments or one family houses can be set to about 50°C. If the temperature is set
too high, there is a risk of scalding. Setting the hot water temperature too low may result in unwanted
bacteriological growth in the hot water system.

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Installation and service instruction
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Measure sketch2.9

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Installation and service instruction
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3 Installing the room thermostat CM737
General3.1
CM737 in Micro STC and Micro STC2 controls the supply temperature to the heating system. When connecting
the unit to the power supply, CM737 verifies the connected sensors and then automatically chooses to control
by room or outdoor temperature sensor or both.
Picture 10
1
LCD display
6
Temperature change buttons
11
Program buttons
2
Time display
7
Temperature enquiry button
12
Copy day button
3
Heating indicator
8
Operating mode buttons
13
Day select button
4
Day indicator
9
OK button, green
14
Time change buttons
5
Temperature display
10
Holiday function button
Micro STC and Micro STC2 with CM737 are supplied fully wired. The wiring conforms to the applicable rules for
CE marking and has undergone electrical safety tests testing and function tests.
OK-button (9)
When changing settings/values in CM737 the numbers in the display is flashing.
Confirm the new settings with the green OK-button (9) and the new setting will be confirmed.
Info-button (7)
Operating with outdoor compensation, target room temperature is shown on the display
Press the Info-button to review:
target room temperature
error code, if any
the text ext and measured outside temperature (if connected)
measured supply water temperature.
After ca. five seconds the display return to show measured room temperature.

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Installation and service instruction
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Installing the room thermostat3.2
Before installation make sure that the electrical power supply is disconnected.
Install the room thermostat in the living
space according to following:
A suitable installation is about
1.5 meters above floor and on
an inner wall.
The room thermostat must not
be combined with other
thermostats in the same control
zone.
Picture 11

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Installation and service instruction
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Picture 12

Alfa Laval Micro
Installation and service instruction
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Installing the outdoor temperature sensor (option)3.3
Connect the outdoor temperature sensor to the terminal strip in accordance with the electrical diagram, remove
any resistor.
If the outdoor temperature sensor is connected at a later time, for example in a construction period, the current
must be disconnected for a few minutes.
Set parameter 14 according to requested compensation; see 3.5 Configure the room thermostat after
installation.
Starting up and component control of the room thermostat CM7373.4
Note: The substation must be filled with water before starting the room thermostat, if not the pump can be
damage.
The room thermostat, CM737, controls the supply temperature to the heating system. When connecting the unit
to the power supply, the CM737 verifies the connected sensors and then automatically chooses to control by
room or outdoor temperature sensor.
1. Put the electrical cable from the control panel into a wall outlet.
2. Check the actuator and pump function. In start-up mode, the components manoeuvres by the following
schedule:
10s actuator closes
10s actuator opens
10s actuator closes
10s pump runs
150s actuator closes
After approximately another 4 minutes CM737 changes from start up to normal regulation.
3. Press the MAN (8) button for a fixed set point (no reduction) of the room temperature.
4. Adjust the room temperature with the increase/decrease buttons on the right (6).
By outdoor temperature compensation this change represents a standard parallel shift of the heat curve,
recalculated for room temperature. For more details see chapter Pump settings and pump performance in
the manual Operating Instruction Alfa Laval Micro.
Configure the room thermostat after installation3.5
CM737 can be configured in three different ways. All installation parameters can be found in the parameter list
under category 1, see 8.2.
Set parameter 14, under category 1, according to requested compensation.
Outdoor compensation, require a connected outdoor temperature sensor:
Set parameter 14 to 1
Room compensation: Set parameter 14 to 0.
Outdoor and room compensation, require a connected outdoor temperature sensor:
Set parameter 14 to 2.
Setting the time3.6
a) Press the DATE/DAY button to begin setting the date. When
you set the date for the first time after the batteries are inserted,
the display will show:
Press the or buttons to set the current day of the
month (e.g. d 01 = 1st day of the month) then press the green
button to confirm.