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
15/06/12 - 300022160-001-01 1

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
15/06/12 - 300022160-001-01 2

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
15/06/12 - 300022160-001-01 3

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
15/06/12 - 300022160-001-01 4

15/06/12 - 300022160-001-01 5

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

2 Safety instructions and
recommendations
2.1 Safety instructions
DANGER
If you smell gas:
1. Do not use a naked flame, do not smoke, do not
operate electrical contacts or switches ( doorbell,
light, motor, lift, etc..).
2. Shut off the gas supply.
3. Open the windows.
4. Trace possible leaks and seal them immediately.
5. If the gas leak is before the gas meter, contact the
gas supplier.
DANGER
If you smell flue gases:
1. Switch the appliance off.
2. Open the windows.
3. Trace possible leaks and seal them immediately.
2.2 Recommendations
WARNING
4Installation and maintenance of the boiler must be
carried out by a qualified professional in compliance
with prevailing local and national regulations.
4When working on the boiler, always disconnect the
boiler from the mains and close the main gas inlet
valve.
4After maintenance or repair work, check all
installations to ensure that there are no leaks.
CAUTION
The boiler must be installed in a frost-free environment.
Keep this document close to the place where the boiler is
installed.
Casing components
MCA 35 2. Safety instructions and recommendations
15/06/12 - 300022160-001-01 9

Only remove the casing for maintenance and repair operations. Put
the casing back in place after maintenance and repair operations.
Instructions stickers
The instructions and warnings affixed to the appliance must never be
removed or covered and must remain legible during the entire lifespan
of the appliance. Immediately replace damaged or illegible
instructions and warning stickers.
Modifications
Modifications may only be made to the boiler after the written
permission of De Dietrich Thermique to do so.
2. Safety instructions and recommendations MCA 35
10 15/06/12 - 300022160-001-01

3 Technical description
3.1 General description
Wall-hung gas condensing boilers
4High efficiency heating.
4Low pollutant emissions.
4Top of the range electronic DIEMATIC iSystem control panel
4Installation and connection facilitated by the mounting frame
delivered with the appliance.
4Flue gas discharge via a forced flue, chimney, bi-flow or 3CE type
connection.
4MCA 35: Heating only (Production of domestic hot water can be
ensured by a separate hot water calorifier).
3.2 Main parts
1Flue gas discharge pipe
2Casing/air box
3Flue gas measuring point
4Mixer pipe
5Heating flow hose
6Air intake silencer
7Box for the control PCBs
8Combined venturi and gas valve unit
9Flow end hydroblock
10 Safety valve outlet pipe
11 Siphon
12 Control panel
13 Shunt pump
14 Return end hydroblock
15 3-way valve
16 Condensate receiver tank
17 Fan
18 Heat exchanger (Heating circuit)
19 Ignition/ionization electrode
20 Air intake
T001964-D
2
14
15
13
16
17
18
19
3
4
5
6
7
8
9
10
11
12
1 20
MCA 35 3. Technical description
15/06/12 - 300022160-001-01 11

3.3 Operating principle
3.3.1. Skeleton Diagrams
1Heat exchanger (Heating circuit)
2Heating flow
3Heating flow (Secondary circuit)
4Heating return (Secondary circuit)
5Heating return
63-way valve
7Shunt pump (Heating circuit)
3.3.2. Shunt pump
The boiler is equipped with a circulating pump. This energy-efficient,
modulating circulating pump is controlled by the control unit based on
ΔT. The graph shows the manometric height at various outputs.
HManometric height central heating circuit
QWater flow
The parameters MIN.PUMP SPEED and MAX.PUMP SPEED are
used to modify the pump settings. If flow noise can be heard in the
system, it is possible to reduce the maximum pump speed with the
parameter MAX.PUMP SPEED (First of all, vent the heating
system). If circulation in the radiators is too low or the radiators do not
fully heat up, increase the minimum pump speed with the parameter
MIN.PUMP SPEED.
¼ See chapter: "Professional settings", page 81.
T002885-A
1
7
6
2 3 4 5
T001965-A
0 250 500 750 1000 1250
0
100
200
300
400
500
700
H (mbar)
Q (l/h)
600 20 kW
25 kW
30 kW
35 kW
835 12521038
1465
573
520
445
358
3. Technical description MCA 35
12 15/06/12 - 300022160-001-01

3.3.3. Water flow rate
The boiler's modulating control system limits the maximum difference
in temperature between the heating flow and return and the maximum
speed at which the flow temperature increases. In this way, the boiler
does not require a minimum water flow rate.
Δp Pressure drop
QWater flow (max = 2460 l/h)
3.4 Technical specifications
Boiler type MCA 35
General
Flow rate setting Adjustable Modulating, Start/Stop, 0 - 10 V
Nominal output (Pn)
Heating System (80/60 °C)
minimum-maximum kW 6,3 - 33,7
Factory setting kW 33,7
Nominal output (Pn)
Heating System (50/30 °C)
minimum-maximum kW 7,0 - 35,6
Factory setting kW 35,6
Nominal input (Qn)
Heating System (Hi)
minimum-maximum kW 6,5 - 34,8
Factory setting kW 34,8
Nominal input(Qn)
Heating System (Hs)
minimum-maximum kW 7,2 - 38,7
Factory setting kW 38,7
Heating efficiency under full load (Hi) (80/60 °C) - % 96,9
Heating efficiency under full load (Hi) (50/30 °C) - % 102,2
Heating efficiency under partial load (Hi) (Return temperature
60°C) - % 96,3
Heating efficiency under partial load (EN 92/42) (Return
temperature 30°C) - % 108,2
Data on the gases and combustion gases
Gas consumption - Natural gas H (G20) minimum-maximum m3/h 0,69 - 3,71
Gas consumption - Natural gas L (G25) minimum-maximum m3/h 0,80 - 4,32
Gas consumption - Propane G31 minimum-maximum m3/h 0,27 - 1,44
NOx-Emission per year (n =1) mg/kWh 42
Mass flue gas flow rate minimum-maximum kg/h 11,1 - 57,3
Flue gas temperature minimum-maximum °C 30 - 75
Maximum counter pressure Pa 140
Characteristics of the heating circuit
Water content l 2,3
Water operating pressure minimum kPa (bar) 80 (0,8)
Water operating pressure (PMS) maximum kPa (bar) 300 (3,0)
Water temperature maximum °C 110
Operating temperature maximum °C 90
(1) Front panel removed
T001749-B
0
100
200
300
400
500
600
0500
1043 1252 1465835
15001000 2000 2500
∆p [mbar]
Q [l/h]
∆T = 20K
20 kW
25 kW
30 kW
35 kW
MCA 35 3. Technical description
15/06/12 - 300022160-001-01 13

Boiler type MCA 35
Manometric height central heating circuit (∆T = 20K) mbar 358
Electrical characteristics
Power supply voltage VAC 230
Power consumption - Full load maximum W 173
Factory setting W 151
Power consumption - Part load maximum W 68
Power consumption - Standby maximum W 4
Electrical protection index IPX4D
Other characteristics
Weight (empty) Total kg 39
Mounting(1) kg 32
Acoustic level at 1 metre at full load dB(A) 45
(1) Front panel removed
3.4.1. Sensor characteristics
Outside sensor
Temperature in °C -20 -16 -12 -8 -4 0 4 8 12 16 20 24
Resistance in Ω 2392 2088 1811 1562 1342 1149 984 842 720 616 528 454
Outlet sensor circuit B+C
Domestic hot water sensor
System sensor
Flow sensor - Return sensor NTC
Temperature in °C 0 10 20 25 30 40 50 60 70 80 90
Resistance in Ω 32014 19691 12474 10000 8080 5372 3661 2535 1794 1290 941
3. Technical description MCA 35
14 15/06/12 - 300022160-001-01

4 Installation
4.1 Regulations governing installation
WARNING
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
4.2 Package list
4.2.1. Standard delivery
The delivery includes:
4The boiler, fitted with a connection cable
4Mounting frame
4Mounting template
4Connection kit
4Run-off collector for siphon and safety valve
4Outside sensor
4Installation and Service Manual
4User Guide
4.2.2. Accessories
Various options are available depending on the configuration of the
installation:
Boiler options Control system options
Description package Description package
Stand-off frame HR39 RX12 cable AD134
Pipework kit for stand-off frame HR40 TELCOM 2 voice remote monitoring module AD152
Pipe cover HR42 Flow sensor AD199
Flue gas thermostat HR43 DHW sensor AD212
adapter 80/125 HR38 Optional PCB for 3-way valve AD249
adapter 80-80 HR46 Hot water storage tank sensor AD250
Exchanger cleaning kit HR44 Outside radio-controlled temperature sensor AD251
Boiler body cleaning kit HR45 Boiler radio module AD252
DHW tank BS60 EE54 Radio remote control AD253
Kit for connection between MCA and BS60 EA138 Interactive remote control AD254
MCA 35 4. Installation
15/06/12 - 300022160-001-01 15

Boiler options Control system options
Description package Description package
DHW tank SR130 EE22 Room sensor FM52
Kit for connection between MCA and SR130 EA137
4.3 Choice of the location
4.3.1. Data plate
The data plate located on top of the boiler provides important
information on the appliance: serial number, model, gas category, etc.
T001539-B
4. Installation MCA 35
16 15/06/12 - 300022160-001-01

4.3.2. Location of the boiler
4Before mounting the boiler, decide on the ideal position for
mounting, bearing the Directives and the dimensions of the
appliance in mind.
4When choosing the position for mounting the boiler, bear in mind
the authorised position of the combustion gas discharge outlets
and the air intake opening.
4To ensure adequate accessibility to the appliance and facilitate
maintenance, leave enough space around the boiler.
WARNING
4Fix the appliance to a solid wall capable of bearing
the weight of the appliance when full of water and fully
equipped.
4It is forbidden to store inflammable products and
materials in the boiler room or close to the boiler,
even temporarily.
CAUTION
4The boiler must be installed in a frost-free
environment.
4A connection to the mains drainage system for the
discharge of condensate must be available close to
the boiler.
4.3.3. Ventilation
(1) Distance between the front of the boiler and the internal
wall of the casing box.
(2) Distance to allow on either side of the boiler.
If the boiler is installed in a closed casing, respect the minimum
dimensions given in the diagram opposite. Also allow openings to
obviate the following hazards:
4Accumulation of gas
4Heating of the box
Minimum cross section of the openings: S1 + S2 = 150 cm2
T001583-A
450
min.1000 450
min.
250
min.
250
690
T001584-A
min. 550
min.550
min. 250
50 (2)
min. 250
100
min. (1)
MCA 35 4. Installation
15/06/12 - 300022160-001-01 17

4.3.4. Main dimensions
iConnection of the combustion gas exhaust pipe Ø 60 mm
hConnection of the air intake pipe Ø 100 mm
êSafety valve outlet pipe Ø 25 mm
jCondensates discharge Ø 25 mm
zHeating circuit return (Primary circuit) G¾"
xHeating circuit return (Secondary circuit) G½"
Gas /
Gaz
Gas connection G½"
yHeating circuit flow (Secondary circuit) G½"
{Heating circuit flow (Primary circuit) G¾"
T001116-B
67
195
265
132
199
266
331
690
450 450
225
140
140
150
257,5
4. Installation MCA 35
18 15/06/12 - 300022160-001-01