DeDietrich Innovens MCA 35 Manual

Innovens EN
Wall-hung gas condensing boilers
MCA 35
Installation and
Service Manual
300022160-001-01

EG declaration of conformity
The device complies with the standard type described in the EG
declaration of conformity. It was manufactured and commissioned in
accordance with European directives.
The original of the declaration of compliance is available from the
manufacturer.
R000300-A
EG - VERKLARING VAN OVEREENSTEMMING
EC - DECLARATION OF CONFORMITY
EG - KONFORMITÄTSERKLÄRUNG
DÉCLARATION DE CONFORMITÉ CE
Fabrikant/Manufacturer/Hersteller/Fabricant : Remeha B.V.
Adres/Address/Adresse : Kanaal Zuid 110
Stad,Land/City,Country/Land,Ort/Ville, pays : Postbus 32, NL-7300 AA Apeldoorn
verklaart hiermede dat de toestel(len) : MCA ../.. (MI) (BIC)
this is to declare that the following product(s) :
erklärt hiermit das die Produk(te) :
déclare ici que les produit(s) suivant(s) :
op de markt gebracht door : De Dietrich Thermique
distributor : 57, rue de la Gare, F-67580
Vertreiber :
Commercialisé (s) par :
voldoet/voldoen aan de bepalingen van de onderstaande EEG-richtlijnen:
is/are in conformity with the following EEC-directives:
den Bestimmungen der nachfolgenden EG-Richtlinien entspricht/entsprechen:
répond/répondent aux directives CEE suivantes:
EEG-Richtlijn: 2009/142/EC toegepaste normen:
EEC-Directive: 2009/142/EC tested and examined tothe following norms:
EG-Richtlinie: 2009/142/EG verwendete Normen, normes appliquées:
CEE-Directive: 2009/142/CE EN 297
(1994*) , 483 (1999*) , 677 (1998*)
92/42/EEG
92/42/EEC
92/42/EWG
92/42/CEE
2006/95/EEG
EN 50165 (1997*), EN 60335-1 (1994*)
2006/95/EEC EN 60335-2-102
(2004*) 08
2006/95/EWG
2006/95/CEE
2004/108/EEG
EN 50165 (1997*)
2004/108/EEC EN 55014-2
(1997*), EN 55014-1 (2000*),
2004/108/EWG EN 61000-3-2
(2000*) , 61000-3-3 (1995*)
2004/108/CEE
97/23/EEG (art. 3, lid 3)
97/23/EEC (article 3, sub 3)
97/23/EWG (Art. 3, Abzats 3)
97/23/CEE (art.3 section 3)
*) inclusief (eventuele) aanvulling, including (if any) completion
einschließlich (falls vorhanden) Vervollständigung, y compris (le cas échéant) complément
Apeldoorn
, february 2010
W.F. Tijhuis
Approval manager
703/2012/02/232

Contents
1 Introduction ................................................................................................6
1.1 Symbols used .......................................................6
1.2 Abbreviations ........................................................6
1.3 General ..................................................................7
1.3.1 Manufacturer's liability .............................................7
1.3.2 Installer's liability .....................................................7
1.4 Homologations ......................................................7
1.4.1 Certifications ...........................................................7
1.4.2 Equipment categories .............................................8
1.4.3 Additional Directives ................................................8
1.4.4 Factory test .............................................................8
2Safety instructions and recommendations ..............................................9
2.1 Safety instructions ...............................................9
2.2 Recommendations ................................................9
3Technical description ..............................................................................11
3.1 General description ............................................11
3.2 Main parts ............................................................11
3.3 Operating principle .............................................12
3.3.1 Skeleton Diagrams ................................................12
3.3.2 Shunt pump ...........................................................12
3.3.3 Water flow rate ......................................................13
3.4 Technical specifications ....................................13
3.4.1 Sensor characteristics ...........................................14
4 Installation ................................................................................................15
4.1 Regulations governing installation ...................15
4.2 Package list .........................................................15
4.2.1 Standard delivery ..................................................15
4.2.2 Accessories ...........................................................15
4.3 Choice of the location ........................................16
4.3.1 Data plate ..............................................................16
4.3.2 Location of the boiler .............................................17
4.3.3 Ventilation .............................................................17
4.3.4 Main dimensions ...................................................18
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4.4 Installing the mounting frame ...........................19
4.5 Positioning the boiler .........................................19
4.6 Hydraulic connections .......................................20
4.6.1 Flushing the system ..............................................20
4.6.2 Connection of the heating circuit ...........................21
4.6.3 Connecting the expansion vessel .........................22
4.6.4 Connecting the condensate discharge pipe ..........22
4.7 Gas connection ...................................................23
4.8 Flue gas system connections ............................24
4.8.1 Classification .........................................................24
4.8.2 Lengths of the air/flue gas pipes ...........................25
4.8.3 Additional Directives ..............................................26
4.9 Installing the outside sensor .............................27
4.9.1 Choice of the location ............................................27
4.9.2 Connecting the outside sensor ..............................27
4.10 Electrical connections ........................................28
4.10.1 Control unit ............................................................28
4.10.2 Recommendations ................................................29
4.10.3 Position of the PCBs .............................................30
4.10.4 Accessing the connection terminal blocks ............31
4.10.5 Connecting a direct heating circuit ........................33
4.10.6 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................34
4.10.7 Connecting two circuits and a domestic hot water
tank .......................................................................36
4.10.8 Hot water storage tank connection ........................39
4.10.9 Pool connection .....................................................45
4.10.10 Connecting a mixed tank .......................................47
4.10.11 Connecting the options .........................................48
4.10.12 Connection in cascade ..........................................50
4.11 Electrical diagram ...............................................53
4.12 Filling the system ...............................................54
4.12.1 Water treatment ....................................................54
4.12.2 Filling the siphon ...................................................55
4.12.3 Filling the system ..................................................55
5 Commissioning ........................................................................................57
5.1 Control panel .......................................................57
5.1.1 Description of the keys ..........................................57
5.1.2 Description of the display ......................................58
5.1.3 Access to the various browsing levels ..................61
5.1.4 Browsing in the menus ..........................................62
5.2 Check points before commissioning ................63
5.2.1 Preparing the boiler for commissioning .................63
5.2.2 Gas circuit .............................................................64
5.2.3 Hydraulic circuit .....................................................64
5.2.4 Electrical connections ...........................................64
Contents
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5.3 Commissioning the boiler ..................................64
5.4 Gas settings ........................................................65
5.4.1 Adapting to another gas type ................................65
5.4.2 Setting the air/gas ratio (Full load) ........................66
5.4.3 Setting the air/gas ratio (Part load) ......................67
5.4.4 Basic setting for the gas/air ratio ...........................69
5.5 Checks and adjustments after
commissioning ...................................................69
5.5.1 Displaying the parameters in extended
mode .....................................................................69
5.5.2 Setting the parameters specific to the
installation .............................................................70
5.5.3 Naming the circuits and generators ......................74
5.5.4 Setting the heating curve ......................................75
5.5.5 Finalizing work ......................................................77
5.6 Reading out measured values ...........................78
5.7 Changing the settings ........................................79
5.7.1 Language selection ...............................................79
5.7.2 Calibrating the sensors .........................................79
5.7.3 Professional settings .............................................81
5.7.4 Configuring the network ........................................88
5.7.5 Return to the factory settings ................................91
6 Switching off the boiler ............................................................................93
6.1 Installation shutdown .........................................93
6.2 Frost protection ..................................................93
7 Checking and maintenance .....................................................................94
7.1 General instructions ...........................................94
7.2 Chimney sweep instructions .............................94
7.3 Customising maintenance .................................95
7.3.1 Maintenance message ..........................................95
7.3.2 Contact details of the professional for After Sales
Support ..................................................................96
7.4 Standard inspection and maintenance
operations ...........................................................96
7.4.1 Checking the hydraulic pressure ...........................97
7.4.2 Checking the ionization current .............................97
7.4.3 Checking the tightness of the flue gas evacuation and
air inlet connections ..............................................97
7.4.4 Checking combustion ............................................97
7.4.5 Checking the automatic air vent ............................98
7.4.6 Checking the safety valve .....................................98
7.4.7 Checking the siphon ..............................................98
7.4.8 Checking the burner and cleaning the heat
exchanger .............................................................99
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7.5 Specific maintenance operations ....................100
7.5.1 Replacing the ionization/ignition electrode ..........100
7.5.2 Replacing the 3-way valve ..................................101
7.5.3 Replacing the non-return valve ...........................102
7.5.4 Assembling the boiler ..........................................103
8 Troubleshooting .....................................................................................104
8.1 Anti-hunting ......................................................104
8.2 Messages (Code type Bxx or Mxx) ..................104
8.3 Message history ................................................107
8.4 Faults (Code type Lxx or Dxx) .........................107
8.4.1 Deletion of sensors from the memory in the
PCB .....................................................................116
8.5 Failure history ...................................................116
8.6 Parameter and input/output check (mode
tests) ..................................................................117
8.6.1 Control system sequence ....................................120
9 Spare parts ..............................................................................................121
9.1 General ..............................................................121
9.2 Spare parts ........................................................121
9.2.1 Casing .................................................................122
9.2.2 Heat exchanger and burner ................................123
9.2.3 Fan ......................................................................124
9.2.4 Control panel .......................................................125
9.2.5 Connecting pipes ................................................126
9.2.6 Spare parts list ....................................................127
Contents
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1 Introduction
1.1 Symbols used
In these instructions, various danger levels are employed to draw the
user's attention to particular information. In so doing, we wish to
safeguard the user's safety, obviate hazards and guarantee correct
operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of a dangerous situation causing slight physical
injury.
CAUTION
Risk of material damage.
Signals important information.
¼ Signals a referral to other instructions or other pages in the
instructions.
1.2 Abbreviations
43CE: Collective conduit for sealed boiler
4DHW: Domestic hot water
4Hi: Lower heating value LHV (Nett)
4Hs: Higher heating value HHV (Gross)
4PPS: Polypropylene hardly inflammable
4PCU: Primary Control Unit - PCB for managing burner operation
4PSU: Parameter Storage Unit - Parameter storage for PCBs
PCU and SU
4SCU: Secondary Control Unit - control panel PCB
4SU: Safety Unit - Safety PCB
43WV: 3-way valve
1. Introduction MCA 35
615/06/12 - 300022160-001-01

1.3 General
1.3.1. Manufacturer's liability
Our products are manufactured in compliance with the requirements
of the various applicable European Directives. They are therefore
delivered with [ marking and all relevant documentation.
In the interest of customers, we are continuously endeavouring to
make improvements in product quality. All the specifications stated in
this document are therefore subject to change without notice.
Our liability as the manufacturer may not be invoked in the following
cases:
4Failure to abide by the instructions on using the appliance.
4Faulty or insufficient maintenance of the appliance.
4Failure to abide by the instructions on installing the appliance.
1.3.2. Installer's liability
The installer is responsible for the installation and inital start up of the
appliance. The installer must respect the following instructions:
4Read and follow the instructions given in the manuals provided
with the appliance.
4Carry out installation in compliance with the prevailing legislation
and standards.
4Perform the initial start up and carry out any checks necessary.
4Explain the installation to the user.
4If a maintenance is necessary, warn the user of the obligation to
check the appliance and maintain it in good working order.
4Give all the instruction manuals to the user.
1.4 Homologations
1.4.1. Certifications
CE identification no PIN 0063BT3444
NOx classification 5 (EN 297 pr A3, EN 656)
Type of connection Chimney: B23 (1), B23P (1), B33
Flue gas outlet: C13(x) , C33(x) , C43(x) , C53 ,
C63(x) , C83(x) , C93(x)
(1) IP20
MCA 35 1. Introduction
15/06/12 - 300022160-001-01 7

1.4.2. Equipment categories
Gas category Gas type Connection pressure (mbar)
II2ESi3P Natural gas H (G20) 20
Natural gas L (G25) 25
Propane (G31) 37
The boiler is preset in the factory to operate on natural gas H (G20).
¼ For operation on another type of gas, see chapter: "Adapting
to another gas type", page 65.
1.4.3. Additional Directives
Apart from the legal provisions and Directives, the additional
Directives described in these instructions must also be observed.
For all provisions and Directives referred to in these instructions, it is
agreed that all addenda or subsequent provisions will apply at the
time of installation.
WARNING
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
1.4.4. Factory test
Before leaving the factory, each boiler is set for optimum performance
and tested to check the following items:
4Electrical safety
4Adjustment (CO2)
4Water tightness
4Gas tightness
4Parameter settings
1. Introduction MCA 35
815/06/12 - 300022160-001-01