DeDietrich INNOVENS PRO MCA 160 User manual

The INNOVENS PRO MCA 160 boiler can be supplied with a choice of either
of the following two control panels:
- DIEMATIC EVOLUTION: according to the options connected, this enables
command and control of up to 3 heating circuits according to the outside
temperature + 1 DHW circuit. It also allows optimised management of
combined systems and the control of 2 to 8 boilers in cascade configuration
(see page 5) when combined with boilers with the IniControl 2 panel (or
DIEMATIC EVOLUTION).
- IniControl 2: for operation via a 0-10V input, supplied with this panel
as standard. It is used as a secondary boiler as part of an installation in
cascade configuration, actuated by a boiler equipped with the DIEMATIC
EVOLUTION panel or in a cascade system where each boiler is controlled
via a 0-10V input.
Different air-flue gas connection configurations are possible; we offer
connection solutions using a horizontal or vertical forced flue, on a chimney
or bi-flow. MCA 160 units can be fitted in cascade only, or in combination
with MCA 45-115 boilers.
Complete hydraulic systems for connection of a cascade of 2 to 8 boilers
are available.
Operating cOnditiOns
Maximum operating pressure: 4 bar
Maximum operating temperature: 90°C
Safety thermostat; 110°C
Power supply: 230 V/50 Hz
International Protection marking: IP X1B
apprOval
B23 - B23P/B33 - C13x - C33x - C93x - C53 - C63 - C83
gas categOry
Equipped and preconfigured to operate using natural gas and propane
(with conversion kit)
NOx class: 6 (EN 15502-1)
WALL-MOUNTED GAS CONDENSING BOILER
MCA 160: from 34.7 to 161.6 kW for heating only
Heating and domestic hot
water using an independent
tank
Condensation
All natural gases
Propane
CE identification no.:
0063CQ3781
MCA 160 MCA 160 installed in cascade
INNOVENS PRO MCA 160
PROJECT
SUSTAINABLE COMFORT ®

2
PRESENTATION OF THE RANGE
MODELS AVAILABLE
Boiler Control
panel
INNOVENS PRO
model
Power range (kW)
at 50/30°C at 80/60°C
MCA_Q0200
For heating only
(option to connect a
domestic hot water
tank*)
DIEMATIC EVOLUTION
MCA 160 DIEMATIC EVOLUTION
34.7 to 161 .6 31.5 to 152.1
IniControl 2
MCA 160 IniControl 2
*Only in combination with the DIEMATIC EVOLUTION control panel
MCA_Q0211MCA_Q0212
enhanced perfOrmance
- Efficiency up to 108.5%
- NOx class 6, in line with EN 15502-1
- Low pollutant emissions: NOx < 39 mg/kWh.
advantages
- Compact packaged heating body made from
aluminium/silicium alloy with a large heat exchange surface
area and moderate pressure losses, providing high resistance
to corrosion and only requiring a very low irrigation flow rate
(except for a flow temperature > 75°C) thanks to the burner
regulator device which manages the transition phases within
the installation which are the source of the very low flow rates
in the boiler. The front access facilitates maintenance,
- Stainless premix burner with braided metal fibre surface,
modulating the output from 18 to 100% to ensure the comfort
level meets requirements, equipped with an air intake silencer.
Low CO and NOx emissions, enabling optimum protection of
the environment,
- Gas line with non-return valve,
Operates using natural gas and propane with conversion
kit
- The INNOVENS PRO MCA 160 boiler can be supplied with
either of the following two control panels:
• DIEMATIC EVOLUTION: suitable for all installation situations,
even the most complex; in its original configuration, it can
be used to control and regulate 2 direct circuits and up to 2
circuits with mixing valve (by adding 2 optional flow sensors).
Add a PCB + sensor to enable a third circuit with mixing
valve to be actuated. A DHW sensor can be fitted to enable
regulation with the DHW circuit prioritised. It is specially
designed to allow optimisation of combined systems.
This control panel can also be used to control an installation
in cascade configuration, where just the first boiler will be
equipped with this panel, and "slave" boilers will be equipped
with an IniControl 2 control panel. To connect more than
the 3 circuits available on the master boiler, it is possible to
insert 1 (or several) additional boiler(s) with the DIEMATIC
EVOLUTION panel into the cascade
• IniControl 2: this is mainly used in installations (cascade or
non-cascade) with an external control cabinet to control all
of the secondary circuits via a 0-10V input, which this panel is
fitted with as part of its original equipment,
- A range of equipment such as an automatic air vent, PPS
flue gas pipes, air-flue gas connection parts with measuring
ports, mains connection cable, internal lighting, heating pump
connector and signalling connector, wall mounting bracket, and
a siphon for draining the condensates,
- Complete cascade hydraulic systems for 2 and up to
8 boilers for installations between 300 and 1216 kW; see
page 12,
- Complete cascade hydraulic systems combining MCA
45/115 and MCA 160 units are also available; see page 17.
- Multiple options to ensure these boilers are as easy to
operate as possible:
• hydraulic connection kit comprising the flow/return valves, the
gas valve, the safety valve, and the filling valve
• primary pump, low-loss header, condensate neutralisation
tray, etc.
- Air-flue gas connection possible via horizontal or vertical
forced flue, on a chimney or bi-flow (see page 22).
The INNOVENS PRO MCA 160 gas condensing boiler is a new
high-power wall-mounted boiler. It boasts an innovative design and
a new aesthetic, with a sleek finish. Exceptionally compact (602 x
600 x 1 112 mm for 160 kW), is its very easy to install and maintain.
It is supplied assembled and factory-tested.

3
TECHNICAL SPECIFICATIONS
descriptiOn
Flow temperature sensor
Gas line with non-return valve
Air-flue gas connection
with measuring port
(not visible)
Ionisation/ignition electrode
Flame inspection
window
Exchanger temperature
sensor
Packaged heating body made
from aluminium/silicium alloy
Control panel
- DIEMATIC EVOLUTION: see p. 7
- IniControl 2: see p. 9
Return temperature sensor
Fan
Differential pressure switch (air)
Intake silencer
Condensate manifold
Operating unit
Automatic air vent
(not visible)
Gas valve block
MCA_Q0011
Detail of the boiler internal
lighting
View of the boiler from underneath
MCA_F0088
MCA_F0088
Heating flow and return
Gas inlet
Location for
siphon connection
Heat exchanger inspection hatch
Water pressure sensor
Ignition transformer
MCA_Q0210

4
TECHNICAL SPECIFICATIONS
the technical specificatiOns
Generator type: heating only
Boiler type: condensing
NOx class: 6
Burner: premix burner
Energy used:
natural gas or propane
Combustion evacuation:
chimney or sealed
Average operating temperature:
- OpT_max: 85°C
- OpT_min: 25°C
“CE certificate” ref.: CE 0063CQ3781
Boiler
Boiler type MCA 160
Useful output - nominal determined at Qnom (1) kW 15 2 .1
- intermediate at 30% Qnom (1) kW 50.8
Nominal output Pn at 50/30°C kW 161 . 6
Efficiency in % LHV, load...%
and water temp.... °C
- 100% Pn at av. temp. 70°C %9 7. 5
- 30% Pn at return temp. 30°C % 108.5
Useful efficiency at …%
of the rated heat output (2)
- at 30 Eta 1 %9 7. 8
- at 100% Eta 4 %8 7. 8
Nominal water flow rate at Pn and ∆t = 20 K m3/h 6.5
Stand-by losses at ∆t = 30 K W191
Electrical output of auxiliaries at Pn_gen W275
Electrical output of auxiliaries in standby W 5
Useful output at 50/30°C min./max. kW 34.7-161 .6
Useful output at 80/60°C min./max. kW 31 .5-152.1
Flue gas mass flow rate min./max. kg/h 57/277
Flue gas temperature min./max. °C 32/66
Pressure available at boiler outlet Pa 200
Water content l17
Minimum required water flow rate * m3/h 0.4
Water side pressure drop at ∆t = 20 K mbar 170
Max. gas flow rate
(15°C-1013 mbar)
- natural gas H/L m3/h 16.5/19.6
- propane m3/h 6.3
Weight (empty) kg 147
* for operation at > 75°C, the minimum flow rate must be calculated at ∆t = 45 K
(1) Q nom = nominal heat output
main dimensiOns (in mm and inches)
5 6
200
5050
5050
100 100 229 46
80
1045
602
226
175 110185
300
600
130
1112
214
305152 143
4
12
4
3
5 6
200
5050
5050
100 100 229 46
80
1045
602
226
175 110185
300
600
130
1112
214
305152 143
4
12
4
3
Heating return R 1" 1/4
Heating flow R 1" 1/4
Gas inlet R 1"
Condensate discharge (siphon
supplied)
Air supply pipe Ø 150 mm
Combustion product discharge
Ø 150 mm
MCA_F0225

5
SELECTING THE CONTROL PANEL
The control panel is selected based on the installation to be created:
installatiOn with 1 single bOiler
installatiOn Of 2 tO 8 bOilers in cascade
Two types of panel are possible
With IniControl 2 control panels
With DIEMATIC EVOLUTION control panel for the 1st boiler in the cascade (master boiler)
and 1 IniControl 2 panel for each of the secondary boilers
- For installations with 0-10 V control cabinet in a boiler room.
All the boilers will be connected via a 0-10 V input to a control cabinet in the boiler room
which will manage all the secondary circuits (see p. 22).
- For control of one circuit:
- For control of one circuit:
M
MM M M M M M M M MM M
PICTO_CIRCUITS
M
MM M M M M M M M MM M
PICTO_CIRCUITS
2 x direct
M
M
M M M
M M M M M MM M
PICTO_CIRCUITS
valve
M
M
M
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 1 valve
M
MM M M M
M M
M M MM M
PICTO_CIRCUITS
2 x valve
M
MM
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 2 x with valve
M
MM M M M M M M M
MM M
PICTO_CIRCUITS
3 x with valve
Options:
standard 1 flow sen-
sor AD199
1 flow
sensor
AD199
2 flow
sensors
AD199
1 flow sensor AD199
+ 1 PCB AD249
2 flow sensors
AD199
+ 1 PCB AD249
M
MM M M M M M M M MM M
PICTO_CIRCUITS
M
MM M M M M M M M MM M
PICTO_CIRCUITS
2 x direct
M
M
M M M
M M M M M MM M
PICTO_CIRCUITS
valve
M
M
M
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 1 valve
M
MM M M M
M M
M M MM M
PICTO_CIRCUITS
2 x valve
M
MM
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 2 x with valve
M
MM M M M M M M M
MM M
PICTO_CIRCUITS
3 x with valve
Options:
standard 1 flow sen-
sor AD199
1 flow
sensor
AD199
2 flow
sensors
AD199
1 flow sensor AD199
+ 1 PCB AD249
2 flow sensors
AD199
+ 1 PCB AD249
IniControl 2
IniControl 2
DIEMATIC Evolution
DIEMATIC Evolution
MCA 160
IniControl 2
MCA 160
IniControl 2
MCA 160
IniControl 2
Boiler 1
MCA 160 DIEMATIC EVOLUTION
(master)
Boilers 2 to 8
MCA 160 IniControl 2
(secondary)
0-10 V
- No additional secondary circuit may be connected to the IniControl 2 panel.
MCA 160…
BUS
or

6
SELECTING THE CONTROL PANEL
installatiOn Of 2 tO 8 bOilers in cascade (cOntinued)
With a DIEMATIC EVOLUTION control panel for the first boiler in the cascade (master boiler)
and 1 or several DIEMATIC EVOLUTION panels for each of the secondary boilers
Boiler 1
MCA 160 DIEMATIC EVOLUTION
(master)
Boilers 3 to 8
MCA 160 IniControl 2 or
MCA 160 DIEMATIC EVOLUTION
if necessary (secondary)
- 1 or several DIEMATIC EVOLUTION panels according to the number of circuits to be
managed.
BUS
dhw prOductiOn
The DIEMATIC EVOLUTION control panel includes the “priority
DHW” function, and can therefore be completed with 1 or
2 DHW sensors - package AD212 for the control of one or
2 independent tanks.
To connect more than 3 heating circuits to a cascade installation,
one of the MCA 160 IniControl 2 boilers in the cascade must
be replaced with one (or several, depending on the number
of additional circuits to be managed) MCA 160 DIEMATIC
EVOLUTION boiler(s) (see example in the hydraulic diagram on
page 36).
Boiler 2
MCA 160 DIEMATIC EVOLUTION
(secondary)
- Management of circuits 4, 5 and 6, if applicable (see above).
DIEMATIC Evolution
DIEMATIC Evolution
- For control of one circuit:
M
MM M M M M M M M MM M
PICTO_CIRCUITS
M
MM M M M M M M M MM M
PICTO_CIRCUITS
2 x direct
M
M
M M M
M M M M M MM M
PICTO_CIRCUITS
valve
M
M
M
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 1 valve
M
MM M M M
M M
M M MM M
PICTO_CIRCUITS
2 x valve
M
MM
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 2 x with valve
M
MM M M M M M M M
MM M
PICTO_CIRCUITS
3 x with valve
Options:
standard 1 flow sen-
sor AD199
1 flow
sensor
AD199
2 flow
sensors
AD199
1 flow sensor AD199
+ 1 PCB AD249
2 flow sensors
AD199
+ 1 PCB AD249

7
THE DIEMATIC EVOLUTION CONTROL PANEL
presentatiOn Of the DIEMATIC EVOLUTION control panel
The DIEMATIC EVOLUTION control panel is a highly
advanced panel with new ergonomic controls, integrating a
programmable electronic control system which modulates the
boiler temperature by acting on the modulating burner, based
on the outside temperature (outside sensor delivered) and the
room temperature, where required, if an interactive remote
control (supplied as an option) is connected.
As standard, the DIEMATIC EVOLUTION is able to automatically
run a central heating system with a direct circuit without mixing
valve and 1 circuit with mixing valve (please note: the flow
sensor - package AD199 - must be ordered separately).
By simply adding 1 “PCB + sensor for 1 valve circuit” option
(package AD249), it will be possible to control up to 3 circuits
in total, with the option to equip each of these circuits with a
remote control (option).
The connection of a domestic hot water sensor enables the
programming and control of a DHW circuit (package AD212 -
option).
This control system has been specifically developed to enable
optimal management of systems combining different
heating generators (boiler + heat pump or + solar system…).
It allows the installer to configure the entire heating system, no
matter how complex.
For larger installations, it is also possible to connect 2 to
7 boilers in cascade configuration.
The DIEMATIC EVOLUTION panel will then be used as the
master for the installation, with the secondary boilers equipped
with the IniControl 2 control panel. To connect more than the
3 circuits available on the master boiler, a second boiler (or
several boilers) with DIEMATIC EVOLUTION can be included in
the cascade.
MCA_Q0211
the DIEMATIC EVOLUTION control panel options
8518Q022GT220_Q0002
Sensor for domestic hot water (length 5 m) - Package AD212
Flow sensor downstream of valve (length 2.5 m) - Package AD199
It allows regulation with temperature prioritised and
programming of domestic hot water production via
an independent tank.
This sensor is necessary for connecting the first
circuit with mixing valve on a boiler equipped with
the DIEMATIC EVOLUTION control panel.
Can be used as a cascade flow sensor.
Date and time
Button to return to
the previous
level or menu
Pictograms with info on the installation
(circuit temperature, outside air
temperature, circuits, etc.)
Button for
the main display
Socket for the
PC connection
Current menu display
Dialogue and
information fields
On/Off button
Status indicator LED:
- fixed green = normal operation
- flashing green = warning
- red = blockage
- continuous red = locked
Rotary/push button:
- turn to select a menu or parameter
- press to confirm the selection
MCA_Q0013
PCB + sensor for 1 mixing valve - Package AD249
It allows a mixing valve with an electromechanical
or electrothermal motor to be controlled. The PCB
is inserted in the DIEMATIC EVOLUTION panel and
is connected using plug-in connectors. DIEMATIC
EVOLUTION can house 1 “PCB + sensor” option,
enabling it to control 1 additional mixing valve.

8
8801Q003
THE DIEMATIC EVOLUTION CONTROL PANEL
the DIEMATIC EVOLUTION control panel options
The BUS cable enables two boilers equipped with
the DIEMATIC EVOLUTION or IniControl 2 panel
to be connected as part of a cascade installation.
Wired programmable room thermostat - Package AD137
Wireless programmable room thermostat - Package AD200
Non-programmable room thermostat - Package AD140
AD137
AD200
Programmable thermostats provide weekly
programming and regulation of the heating by
activating the burner according to the various
operating modes: “Automatic” depending on the
programming, “Permanent” at a set temperature or
“Holiday”. The "wireless" version is delivered with
a receiver box to be mounted on the wall close to
the boiler.
The non-programmable thermostat is used to
regulate the room temperature based on the set
point, by activating the burner.
8518Q022
Sensor for buffer tank - Package AD250
Comprises 1 sensor for managing a buffer
tank with a boiler equipped with a DIEMATIC
EVOLUTION control panel.
Can be used as a cascade flow sensor.
AD140
S-BUS cable with plugs, 1.5 m - Package AD308
S-BUS cable with plugs, 12 m - Package AD309
S-BUS cable with plugs, 20 m - Package AD310
8801Q0028666Q120A
MCA_Q01149-MCA_Q01150-MCA_Q0151
AD308
AD309
AD310
VM_Q0009
DIEMATIC VM EVOLUTION control system (wall-mounted) - Package AD315
(Available first quarter 2018)
The DIEMATIC VM EVOLUTION electronic control
system, integrated into a wall unit, allows 3 heating
circuits and 2 DHW circuits to be controlled and
regulated; each of the heating circuits can be a
direct circuit or a circuit with a 3-way motorised
mixing valve.
It is possible to link together up to 8* DIEMATIC
VM EVOLUTION control systems and to thereby
create numerous combinations, regardless of the
type of installation:
- DIEMATIC VM EVOLUTION can be used in
relation with one or several generators equipped
with DIEMATIC EVOLUTION or IniControl 2.
- DIEMATIC VM EVOLUTION can be integrated
into a DIEMATIC iSystem via the Modbus as
supplementary only.
- DIEMATIC VM EVOLUTION can control a
cascade of boilers equipped with an IniControl 2
control panel.
* 1 “master” control system + 7 “slave” control
systems.

9
The IniControl 2 CONTROL PANEL
presentatiOn Of the IniControl 2 control panel
MCA_Q0212
The IniControl 2 control panel is used to manage the boiler
(without programming) via a configurable 0 - 10 V signal. For a
cascade installation, the IniControl 2 panel will be fitted to the
secondary boilers linked in series to the master boiler equipped
with the DIEMATIC EVOLUTION panel via the BUS cable
(option).
The boiler temperature, heating network pressure, and generator
operating status are displayed using alphanumeric codes and
symbols on a large screen integrating a flashing alarm function.
For monitoring the installation, there is an option to read the
fault log and the operating timer counters.
Keys:
- access to the various menus or parameters,
- setting, manual reset variant according to the selections
Digital display
(large format)
On/Off switch
Socket for the
PC connection
inicOntrOl 2 cOntrOl panel options
VM_Q00038227_Q020
ModBUS - OpenTherm interface - Package AD286
BUS connection cable (12 m) - Package AD314
As part of a “mixed” cascade, this interface must
be affixed to the wall close to the MCA 160 boiler,
enabling the MCA 45/115 boiler to be connected
to the MCA 160.
Enables a link to be created between 2 boilers
equipped with DIEMATIC iSystem and IniControl/
IniControl 2 panels.

10
THE BOILER OPTIONS
Hydraulic connection kit + gas valve - Package EH680
These kits comprise:
- 1 gas valve Rp 3/4,
- 1 heating return valve integrating the filling and
drain valve Rp 1 1/4,
- 1 heating flow valve with 3-bar safety valve and
port for connecting the expansion vessel Rp 1 1/4.
MCA_Q0206
Modulating primary heating pump (EEI < 0.23) - Package EH651
Specifications for the GRUNDFOS UPMXL 25-105 130 AUTO pump
3
MCA_F0501
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
0
2
4
6
8
10
12
14
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
0
40
80
120
160
200
240
Flow rate m3/h
Flow rate m3/h
Manometric height in mWG
Pump output in W
MCA_F0501
: Constant pressure
: Proportional pressure
3
MCA_F0501
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
0
2
4
6
8
10
12
14
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
0
40
80
120
160
200
240
Flow rate m3/h
Flow rate m3/h
Manometric height in mWGPump output in W
MCA_F0501
: Constant pressure
: Proportional pressure
MCA_F0501
MCA_Q0205
This kit comprises a diaphragm which must be
installed on the gas valve unit to enable operation
with propane.
Domestic hot water preparation
The De Dietrich independent tanks in the B…
series, with a capacity of 150 to 3000 litres,
enable the production of domestic hot water for
individual and collective housing and industrial
and commercial premises. The specifications and
performance of these tanks is given in the price
catalogue and respective technical brochures.
BLC_Q0001A
BLC
RSB_Q0004A BPB_Q0001A
BPB B…
Low-loss header, 120/80 - 2” - Package GV47
For any installations with several circuits or for
cascade installations, the use of a low-loss header
is strongly recommended.
The header is supplied with insulation and fitted
with a wall-mounting bracket and an accessories kit
comprising a plug, an air vent and a 1/2" drain valve.
MCA_Q0138 MCA_Q0204
Propane conversion kit - EH693
MCA_F0502
Type XXXX XX-XX XXX
XXXV ~
XX/XXHz
GFXXX
EuP Ready
I1/1(A) P1(W)
X.XX
X.XX
XX
XX
Max.
Min.
P/N:XXXXXXX
PC:XXXXXX
IP XX
TF XX
Max.X.XMPa
AHigh Efficiency
XX
EEI<0.23
Dimensions [mm] L1 L2 L3 B3 B4 B5 H1 H2 Connection
UPMXL 25-105130 22 131 117 50 64 27 112 G 1 1/2
MCA_F0502
Dimensions (mm) L1 L2 L3 B3 B4 B5 H1 H2 Connection
UPMXL 25-105 13 0 22 131 117 50 64 27 112 G 1 1/2

11
THE BOILER OPTIONS
The materials used for the condensate drain pipes
must be appropriate. Otherwise, the condensate
must be neutralised.
Principle: Acid condensates are conveyed via a
reservoir filled with granulates before being sent to
the wastewater network.
Mini
150 mm
MCA_F0086
3
2
1
MCA_F0090
EH692
MCA_F0086
MCA_F0090
flue system accessOries specific tO the innOvens prO mca 160 bOiler
FUMI_F0216
Concentric air-flue gas connection conversion kit - Package EH692
Ø 150 mm to Ø 200 mm adapter - Package EH645
Air filter - Package EH646
C330_Q0009
Granulate recharge for neutralisation station - Ref. 9422-5601 (10 kg)
Granulate recharge for neutralisation station - Package SA7 (25 kg)
An annual inspection of the system is required,
including a check of the effectiveness of the
granulates via a pH measurement. If necessary,
the granulates must be replaced.
C330_Q0006
SA4
SA3
C330_Q0005
C330_Q0008
DU15
Gravity flow condensate neutralisation station (up to 450 kW) - Package SA3
Condensate neutralisation station with lift pump:
- Package SA4 for boilers or cascades of boilers up to 300 kW
- Package DU15 for boilers or cascades of boilers up to 1300 kW
EH692
300 mbargas pressure regulator: - GDJ 20 - Package SA12
- GDJ 25 - Package AD245
- GDJ 50 - Package AD246
It is fitted on the gas inlet circuit. It is needed if the
gas is supplied at a pressure of 300 mbar.
C230_Q0002
Regulator Max. natural gas flow rate
in m3/h
Max power consumed
in kW
Connection
Ø
GDJ 20 24 240 Rp 3/4”
GDJ 25 70 700 Rp 1”
GDJ 50 14 0 1400 Rp 2”
EH645
EH646
MCA_Q0209
MCA_Q0203
FUMI_F0216
Condensate draining
Condensate neutralisation station
Siphon

12
MCA 160 CASCADE SYSTEMS
MCA 160 cascade systems are available in 3 versions:
- LW: for wall-mounted alignment of the constituent boilers,
- LV: for floor-mounted alignment of the constituent boilers,
- RG: for back-to-back floor-mounted alignment of the constituent
boilers.
These systems comprise:
- the low-loss header is available in 3 versions:
• < 350 kW: DN65,
• 350 to 460 kW: DN65 (with reduction plate),
• 460 kW to 1216 kW: DN100.
- the boiler connection manifold, comprising the heating return and
flow connecting pipes (DN 100 mm), the gas connecting pipes
(DN 65 mm),
- the modulating primary injection pumps (EEI < 0.23),
- the boiler connection kits with the return valve, the multifunction flow
valve (with the filling and drain valve, gate valve, non-return valve,
safety valve and port for connecting to an expansion vessel), and the
gas valve
- the wall mounting rail for the LW versions or the support uprights
for LV versions, with the boiler mounting frames.
- the flow sensor + pocket sensor and the BUS cables to connect
the boilers.
Note: the boilers must be ordered separately.
Below is a table with examples of “cascade” combinations
from 304 to 1216 kW, proposed based on the total output
required.
Important: other “cascade systems” are also possible: to help you
identify and enter these, an “Identifying cascades” tool can be
accessed on our website.
“lw” wall-mOunted alignment Of bOilers
30
100
2005
602
430
D
2005
676 30
55
480
D
MCA_F0085
Low-loss
header
Manifold
Boiler connection kit
Wall mounting rail
Alignment Number of
boilers
Output
(80/60°C)
kW
A
mm D mm
Water
DN
Gas
DN
Water flow
∆t = 20K
m3/h Description
WALL-MOUNTED
LW
2 304 1230 16 21 65 65 13 .10 LW.0304kW00002
3 456 1860 2591 65 65 19.65 LW.0456kW00003
4 608 2490 315 3 10 0 65 26.20 LW.0608kW00004
5760 312 0 3783 10 0 65 32.75 LW.0760kW00005
6912 3750 4 413 10 0 65 39.3 LW.0912kW00006
7 1064 4380 5043 10 0 65 45.85 LW.1064kW00007
81216 5 010 5673 10 0 65 52.4 LW.1216kW00008
Key:
Designation: LW 0304kW00002
Composition:
2 MCA 160 boilers
Type of alignment
(LW, LV or RG)
Total output (at 80/60°C)
Wall-mounted alignment of 2 to 8 boilers
MCA_F0085
MCA_F0093
2005
A
602
D

13
MCA 160 CASCADE SYSTEMS
“lv” flOOr-mOunted alignment Of bOilers
30
100
2005
602
430
D
2005
676 30
55
480
D
MCA_F0085
Low-loss
header
Manifold
Boiler connection kit
Assembly frame
Support upright
MCA_F0085
Alignment Number of
boilers
Output
(80/60°C)
kW
A
mm D mm
Water
DN
Gas
DN
Water flow
∆t = 20K
m3/h Description
FLOOR-MOUNTED
LV
2 304 1310 16 71 65 65 13 .10 LV.0304kW00002
3 456 1940 2641 65 65 19.65 LV.0456kW00003
4 608 2570 3203 10 0 65 26.20 LV.0608kW00004
5760 3200 3833 10 0 65 32.75 LV.0760kW00005
6912 3830 4463 10 0 65 39.30 LV.0912kW00006
7 1064 4460 5093 10 0 65 45.85 LV.1064kW00007
81216 5090 5723 10 0 65 52.40 LV.1216kW00008
Key:
Designation: LV 0304kW00002
Composition:
2 MCA 160 boilers
Type of alignment
(LW, LV or RG)
Total output (at 80/60°C)
Floor-mounted alignment of 2 to 8 boilers
MCA_F0094
2005
A
676
D

14
MCA 160 CASCADE SYSTEMS
“rg” back-tO-back bOilers
Alignment Number of
boilers
Output
(80/60°C)
kW
A
mm D mm
Water
DN
Gas
DN
Water flow
∆t = 20K
m3/h Description
BACK-TO-BACK
RG
3 456 1310 2 011 65 65 19.65 RG.0456kW00003
4 608 1310 1943 10 0 65 26.20 RG.0608kW00004
5760 1940 2573 10 0 65 32.75 RG.0760kW00005
6912 1940 2573 10 0 65 39.30 RG.0912kW00006
7 1064 2570 3203 10 0 65 45.85 RG.1064kW00007
81216 2570 3203 10 0 65 52.40 RG.1216kW00008
Key:
Designation: RG 0456kW00003
Composition:
3 MCA 160 boilers
Type of alignment
(LW, LV or RG)
Total output (at 80/60°C)
Back-to-back alignment of 2 to 8 boilers
2005
1278
A
D
MCA_F0095

15
CASCADES WITH MCA 45/115 AND MCA 160
The INNOVENS PRO MCA 160 boiler can be fitted in a cascade
with INNOVENS PRO MCA 45/115 boilers or be added to an
existing cascade of MCA 45/115 boilers.
In these cascade systems, the master boiler will necessarily be the
MCA 45/115 equipped with the DIEMATIC iSystem control panel,
and the secondary boilers will be:
- MCA 45/115 IniControl boilers,
- MCA 160 IniControl 2 boilers.
selecting the cOntrOl panel
With DIEMATIC EVOLUTION control panel for the 1st boiler in the cascade (master boiler)
and 1 IniControl 2 panel for each of the secondary boilers
MCA 45/115 iSystem
(master)
Boiler 1
- No additional secondary circuit may be connected to the IniControl 2 panel
BUS
BUS
MCA 45/115 IniControl
(secondary)
Boiler 2 to 8
MCA 160 IniControl 2
(secondary)
Boiler 2 to 8
- No additional secondary circuit may be connected to the IniControl (1) panel
DIEMATIC iSystem
IniControl
IniControl 2
- For control of one circuit:
M
MM M M M M M M M MM M
PICTO_CIRCUITS
direct
M
M
M M M
M M M M M MM M
PICTO_CIRCUITS
valve
M
M
M
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 1 valve
M
MM M M M
M M
M M MM M
PICTO_CIRCUITS
2 x valve
M
MM
M M
M M M M M MM M
PICTO_CIRCUITS
direct
+ 2 x with valve
Options:
standard 1 flow sensor
AD199
1 flow sensor
AD199
1 flow sensor
AD199
+ 1 PCB
+ sensor AD249
1 flow sensor
AD199
+ 1 PCB
+ sensor AD249
MCA 160 boiler combined with a MCA 45/115 boiler or added to an existing cascade of MCA 45/115 boilers
(1) To connect more than 3 heating circuits on a cascade installation, one of the MCA
45/115 IniControl boilers in the cascade must be replaced with one MCA 45/115
iSystem boiler (or several of these boilers, depending on the number of additional
circuits to be managed).

16
CASCADES WITH MCA 45/115 AND MCA 160
In the cascade, the MCA 45/115 boilers are linked together
using the BUS cable - package AD134. The MCA 160 boiler or
boilers must equipped with the AD286 PCB (wall-mounted) to be
linked to other boilers via the BUS cable - package AD134 (see
illustration below).
cOnnecting the bOilers
MCA_F0550
IniControl 2
MCA 160
IniControl 2
MCA 160
AD286
BUS
AD134
BUS
AD134
BUS
AD134
BUS
+
+ +
... +
...
OT
AD286
OT
MCA 90/115 MCA 90/115
MCA_F0550
IniControlDIEMATIC
iSystem
MCA 45/115 MCA 160MCA 45/115 MCA 160

17
CASCADES WITH MCA 45/115 AND MCA 160
MCA 45/115/160 cascade systems are available in 3 versions:
- LW: for wall-mounted alignment of the constituent boilers,
- LV: for floor-mounted alignment of the constituent boilers,
- RG: for back-to-back floor-mounted alignment of the constituent
boilers.
These systems comprise:
- the low-loss header is available in 3 versions:
• < 350 kW: DN65;
• 350 to 460 kW: DN65 ;
• 460 kW to 1070 kW: DN100.
- The boiler connection manifold, comprising the heating return and
flow connecting pipes (DN 100 mm), the gas connecting pipes
(DN 65 mm),
- The modulating primary injection pumps (EEI < 0.23),
- The boiler connection kits with the return valve, the multifunction
flow valve (with the filling and drain valve, gate valve, non-return
valve, safety valve and port for connecting to an expansion
vessel), and the gas valve
- The wall mounting rail for the LW versions or the support uprights
for LV versions, with the boiler mounting frames.
- The flow sensor + pocket sensor and the BUS cables to connect
the boilers.
Note: the boilers must be ordered separately.
Important: To find out the composition of the various cascades
systems, an “Identifying cascades” tool is available on our
website.
“lw” wall-mOunted alignment Of bOilers
2005
D
A
80
MCA_F0091
2005
A
D
2005
A
D
80
80
80
Alignement 2 chaudières Puissance (80/60 °C)
kW
A
mm D mm
Eau
DN
Gaz
DN
Débit eau
Δt = 20K
m3/h Désignation
MURAL
LW
1 MCA 90 + 1 MCA 160 236 1180 1621
LW.0236kW.00101
1 MCA 115 + 1 MCA 160 260 1180 1621
LW.0260kW.00011
Alignement 3 chaudières Puissance (80/60 °C)
kW
A
mm D mm
Eau
DN
Gaz
DN
Débit eau
Δt = 20K
m3/h Désignation
MURAL
LW
1 MCA 90 + 2 MCA 160 388 1805 2591
LW.0388kW.00102
2 MCA 90 + 1 MCA 160 320 1670 2251
LW.0320kW.00201
1 MCA 115 + 2 MCA 160 411 1805 2591
LW.0411kW.00012
2 MCA 115 + 1 MCA 160 360 1670 2591
LW.0360kW.00021
Alignement 4 chaudières Puissance (80/60 °C)
kW
A
mm D mm
Eau
DN
Gaz
DN
Débit eau
Δt = 20K
m3/h Désignation
MURAL
LW
1 MCA 90 + 3 MCA 160 540 2440 3221
LW.0540kW.00103
2 MCA 90 + 2 MCA 160 472 2340 3221
LW.0472kW.00202
3 MCA 90 + 1 MCA 160 404 2240 3221
LW.0404kW.00301
1 MCA 115 + 3 MCA 160 563 2440 3221
LW.0563kW.00013
2 MCA 115 + 2 MCA 160 518 2340 3221
LW.0518kW.00022
3 MCA 115 + 1 MCA 160 473 2240 3221
LW.0473kW.00031
500
602
500
602
500
602
MCA_F0091
Wall-mounted alignment of 2 boilers
Alignment 2 to 8
boilers A mm D mm
WALL-MOUNTED
LW
1 MCA … + 1 MCA 160 118 0 16 21
1 MCA … + 2 MCA 160 1810 2591
1 MCA … + 3 MCA 160 2440 315 3
1 MCA … + 4 MCA 160 3070 3783
1 MCA … + 5 MCA 160 3700 4 413
1 MCA … + 6 MCA 160 4330 5043
1 MCA … + 7 MCA 160 4960 5673
Note: between 2 and 8 MCA 45 to 160 boilers can be fitted
in cascade in a wall-mounted alignment (LW). For the various
combinations of boiler in the cascade and the details of the
corresponding cascades systems, please consult the “Identifying
cascades” tool available on our website.

18
CASCADES WITH MCA 45/115 AND MCA 160
“lv” flOOr-mOunted alignment Of bOilers
Floor-mounted alignment of 2 boilers
2005
A
MCA_F0092
2005
A
2005
A
Alignement Chaudières Puissance (80/60 °C)
kW
A
mm D mm
Eau
DN
Gaz
DN
Débit eau
Δt = 20K
m
3
/h Désignation
AU SOL
LV
2 chaudières
1 MCA 90 + 1 MCA 160 236 1310 1623
LV.0236kW.00101
1 MCA 115 + 1 MCA 160 260 1310 1623
LV.0260kW.00011
3 chaudières
1 MCA 90 + 2 MCA 160 388 1940 2594
LV.0388kW.00102
2 MCA 90 + 1 MCA 160 320 1940 2253
LV.0320kW.00201
1 MCA 115 + 2 MCA 160 411 1940 2594
LV.0411kW.00012
2 MCA 115 + 1 MCA 160 360 1940 2594
LV.0360kW.00021
4 chaudières
1 MCA 90 + 3 MCA 160 540 2570 3153
LV.0540kW.00103
2 MCA 90 + 2 MCA 160 472 2570 3153
LV.0472kW.00202
3 MCA 90 + 1 MCA 160 404 2570 3153
LV.0404kW.00301
1 MCA 115 + 3 MCA 160 563 2570 3153
LV.0563kW.00013
2 MCA 115 + 2 MCA 160 518 2570 3153
LV.0518kW.00022
3 MCA 115 + 1 MCA 160 473 2570 3153
LV.0473kW.00031
80
80
574
D
676
574
D
676
574
D
676
MCA_F0092
Note: between 2 and 8 MCA 45 to 160 boilers can be fitted
in cascade in a wall-mounted alignment (LW). For the various
combinations of boiler in the cascade and the details of the
corresponding cascades systems, please consult the “Identifying
cascades” tool available on our website.
Alignment 2 to 8
boilers A mm D mm
ALIGNMENT
FLOOR-MOUNTED
LV
1 MCA … + 1 MCA 160 1310 16 71
1 MCA … + 2 MCA 160 1940 2641
1 MCA … + 3 MCA 160 2570 3203
1 MCA … + 4 MCA 160 3200 3833
1 MCA … + 5 MCA 160 3830 4463
1 MCA … + 6 MCA 160 4460 5093
1 MCA … + 7 MCA 160 5090 5723
“rg” back-tO-back bOilers
Back-to-back alignment of 3 boilers
D
602
500
500
602
A
2005
D
602
500
500
602
A
2005
MCA_F0096
Note: between 3 and 8 MCA 45 to 160 boilers can be fitted
in cascade in a wall-mounted alignment (LW). For the various
combinations of boiler in the cascade and the details of the
corresponding cascades systems, please consult the “Identifying
cascades” tool available on our website.
Alignment 3 to 8
boilers A mm D mm
BACK-TO-BACK
RG
1 MCA … + 2 MCA 160 1310 2 011
1 MCA … + 3 MCA 160 1310 2 011
1 MCA … + 4 MCA 160 1940 2573
1 MCA … + 5 MCA 160 1940 2573
1 MCA … + 6 MCA 160 2570 3203
1 MCA … + 7 MCA 160 2570 3203

19
MCA 160 CASCADE SYSTEMS
the OptiOns fOr cascade systems
MCA_Q0101
DN 65 gas filter for cascade systems from 160 to 600 kW - Package HC256
MCA_Q0104
Set of DN 65 90° elbows for cascade systems from 304 to 455 kW - Package HC209
Set of DN 100 90° elbows for cascade systems from 460 to 608 kW - Package HC210
Supplied with gaskets, nuts and bolts.
Enabling the low-loss header to be connected
perpendicular to the manifold.
MCA_Q0131
Set of DN 65 counterflanges for cascade systems from 304 to 455 kW - Package EH669
Set of DN 100 counterflanges for cascade systems from 460 to 608 kW - Package HC218
Contains 3 counterflanges: 2 for the installation side
of the pressure breaker (DN 65 or DN 100) and 1 for
the gas line (DN65); to be replaced with a gas pipe
to be welded, diam 65 mm).
Supplied with gaskets, nuts and bolts.
MCA_Q0126
Manifold insulation - Package EH647
It is necessary to order 1 insulation kit per boiler.
MCA_Q0112
Boiler hydraulic connection kit insulation - Package HC648
One lot of insulation is required per boiler
connection kit.
MCA_Q0113
90° elbow insulation - Package HC216
MCA_Q0127
Adjustable foot - Package HC219
This is used for “LV” in-line installations,
if the ground is not uniform.
Alignment in-line, “LV” floor-mounted
Number of boilers 2 3 4
Number of feet required 5 6 8
Low-loss header insulation - small model for output < 350 kW - Package HC224
- large model for output > 350 kW - Package HC215
MCA_Q0110MCA_Q0103
HC224 HC215
S-BUS cable with plugs, 1.5 m - Package AD308
S-BUS cable with plugs, 12 m - Package AD309
S-BUS cable with plugs, 20 m - Package AD310
Rear insulation for boiler connection kit - Package EH649
MCA_Q0208
DN 65 to DN 100 flange adapter insulation - Package EH650
MCA_Q0207
MCA_Q01149-MCA_Q01150-MCA_Q0151
AD308
AD309
AD310

20
IMPORTANT INFORMATION FOR INSTALLATION
statutOry guidelines fOr installatiOn and maintenance
Installation and maintenance of the appliance must be performed
by a qualified professional in accordance with the relevant statutory
guidelines and good industry practice.
pOsitiOn
The dimensions given are the minimum recommended (in mm) to
ensure sufficient access around the boiler.
Note: for installations with several boilers in cascade configuration,
these same dimensions must be observed for each boiler.
INNOVENS PRO MCA 160 boilers are installed in accordance with
the rules for installation in dedicated boiler rooms outside of the
inhabited area. The installation rules for the terminals (horizontal or
vertical) must also be observed - see page 29.
MCA_F0082
600 30
30
min. 1000
600
min.
500
min.
300
1045
min. 1000
MCA_F0082
In order to avoid damage to the boilers, it is necessary to prevent the contamination of combustion air by chlorine and/
or fluoride compounds, which are particularly corrosive.
These compounds are present, for example, in aerosol sprays, paints, solvents, cleaning products, washing products,
detergents, glues, road grit, etc.
The following must therefore be ensured:
- Preventing the intake of air expelled by premises using such products: hairdressing salons, dry cleaners, industrial premises (solvents),
premises containing refrigeration systems (risk of refrigerant leakage), etc.
- Preventing such products from being stored close to boilers.
We would like to underline that, should the boiler and/or peripheral equipment be corroded by chlorine and/or fluoride
compounds, the contractual guarantee will be invalidated.
Room ventilation
Comply with local regulations.