DeDietrich MCA 45 - 65 - 90 - 115 Manual

Ireland
Innovens Pro EN
Wall-hung gas condensing boilers
MCA 45 - 65 - 90 - 115
Installation and
Service Manual
300024755-001-A

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.
R000040-A

Contents
1 Introduction ................................................................................................6
1.1 Used symbols .......................................................6
1.2 Abbreviations ........................................................6
1.3 General ..................................................................7
1.3.1 Manufacturer's liability .............................................7
1.3.2 Installer's liability .....................................................7
1.3.3 User's liability ..........................................................7
1.4 Homologations ......................................................8
1.4.1 Certifications ...........................................................8
1.4.2 Equipment categories .............................................8
1.4.3 Additional Directives ................................................8
1.4.4 Factory test .............................................................9
2Safety instructions and recommendations ............................................10
2.1 Safety instructions .............................................10
2.2 Recommendations ..............................................10
3 Technical description ..............................................................................12
3.1 General description ............................................12
3.2 Main parts ............................................................12
3.3 Operating principle .............................................12
3.3.1 Shunt pump ...........................................................12
3.3.2 System in cascade ................................................13
3.3.3 Calorifier connection .............................................13
3.3.4 Water flow rate ......................................................13
3.4 Technical characteristics ...................................13
3.4.1 Sensor characteristics ...........................................15
4 Installation ................................................................................................16
4.1 Regulations governing installation ...................16
4.2 Package list .........................................................16
4.2.1 Standard delivery ..................................................16
4.2.2 Accessories ...........................................................16
4.3 Choice of the location ........................................18
4.3.1 Data plate ..............................................................18
4.3.2 Location of the appliance ......................................18
4.3.3 Ventilation .............................................................19
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4.3.4 Main dimensions ...................................................20
4.4 Positioning the boiler .........................................21
4.5 Hydraulic connections .......................................21
4.5.1 Flushing the system ..............................................21
4.5.2 Connection of the heating circuit ...........................22
4.5.3 Connecting the expansion vessel .........................23
4.5.4 Connecting the condensate discharge pipe ..........24
4.6 Gas connection ...................................................24
4.7 Flue gas system connections ............................25
4.7.1 Classification .........................................................25
4.7.2 Lengths of the air/flue gas pipes ...........................26
4.8 Installing the outside sensor .............................27
4.8.1 Choice of the location ............................................27
4.8.2 Installing the outside sensor ..................................28
4.9 Electrical connections ........................................28
4.9.1 Control unit ............................................................28
4.9.2 Recommendations ................................................29
4.9.3 Fitting and connecting the control panel ...............30
4.9.4 Position of the PCBs .............................................30
4.9.5 Accessing the connection terminal blocks ............31
4.9.6 Connecting the pump ............................................32
4.9.7 Connecting a direct heating circuit ........................34
4.9.8 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................35
4.9.9 Connecting two circuits and a domestic hot water tank
after the mixing tank ..............................................36
4.9.10 Hot water storage tank connection ........................38
4.9.11 Pool connection .....................................................44
4.9.12 Connecting a mixed tank .......................................46
4.9.13 Connecting the options .........................................47
4.9.14 Connection in cascade ..........................................49
4.10 Electrical diagram ...............................................51
4.11 Filling the system ...............................................52
4.11.1 Water treatment ....................................................52
4.11.2 Filling the siphon ...................................................53
4.11.3 Filling the system ..................................................53
5 Start-up - DIEMATIC iSystem ..................................................................54
5.1 Control panel .......................................................54
5.1.1 Description of the keys ..........................................54
5.1.2 Description of the display ......................................55
5.1.3 Access to the various browsing levels ..................57
5.1.4 Browsing in the menus ..........................................58
5.2 Check points before commissioning ................59
5.2.1 Preparing the boiler for commissioning .................59
5.2.2 Gas circuit .............................................................60
5.2.3 Hydraulic circuit .....................................................60
Contents
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5.2.4 Electrical connections ...........................................60
5.3 Putting the appliance into operation ................60
5.4 Gas settings ........................................................62
5.4.1 Adapting to another gas type ................................62
5.4.2 Setting the air/gas ratio (Full load) ........................62
5.4.3 Setting the air/gas ratio (Part load) ......................64
5.5 Checks and adjustments after
commissioning ...................................................65
5.5.1 Displaying the parameters in extended
mode .....................................................................65
5.5.2 Setting the parameters specific to the
installation .............................................................66
5.5.3 Naming the circuits and generators ......................68
5.5.4 Setting the heating curve ......................................69
5.5.5 Finalizing work ......................................................71
5.6 Reading out measured values ...........................72
5.7 Changing the settings ........................................73
5.7.1 Language selection ...............................................73
5.7.2 Calibrating the sensors .........................................73
5.7.3 "Professional" settings ..........................................75
5.7.4 Configuring the network ........................................81
5.7.5 Return to the factory settings ................................87
6 Start-up - IniControl .................................................................................88
6.1 Control panel .......................................................88
6.1.1 Description of the keys ..........................................88
6.1.2 Description of the display ......................................89
6.2 Check points before commissioning ................90
6.2.1 Preparing the boiler for commissioning .................90
6.2.2 Gas circuit .............................................................91
6.2.3 Hydraulic circuit .....................................................91
6.2.4 Electrical connections ...........................................91
6.3 Putting the appliance into operation ................92
6.4 Gas settings ........................................................93
6.4.1 Adapting to another gas type ................................93
6.4.2 Setting the air/gas ratio (Full load) ........................93
6.4.3 Setting the air/gas ratio (Part load) ......................94
6.5 Checks and adjustments after
commissioning ...................................................95
6.5.1 Setting the heating curve ......................................95
6.5.2 Finalizing work ......................................................96
6.6 Reading out measured values ...........................97
6.6.1 Reading out measured values ..............................97
6.6.2 Readout from the hour counter and percentage of
successful starts ....................................................99
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6.6.3 Status and sub-status ...........................................99
6.7 Changing the settings ......................................100
6.7.1 Description of the parameters .............................100
6.7.2 Modification of the installer-level parameters ......103
6.7.3 Setting the maximum heat input for central heating
operation .............................................................104
6.7.4 Return to the factory settings "Reset Param" ......105
6.7.5 Carrying out an auto-detect .................................105
7 Switching off the appliance ...................................................................106
7.1 Installation shutdown .......................................106
7.2 Frost protection ................................................106
8 Checking and maintenance ...................................................................107
8.1 General instructions .........................................107
8.2 Chimney sweep instructions ...........................107
8.2.1 Control panel DIEMATIC iSystem .......................107
8.2.2 Control panel IniControl ......................................108
8.3 Customising maintenance ...............................108
8.3.1 Maintenance message ........................................109
8.3.2 Installer's contact details .....................................110
8.4 Standard inspection and maintenance
operations .........................................................110
8.4.1 Checking the hydraulic pressure .........................110
8.4.2 Checking the ionisation current ...........................111
8.4.3 Checking the tightness of the combusted gases
evacuation and air inlet connections ...................111
8.4.4 Checking combustion ..........................................111
8.4.5 Checking the automatic air vent ..........................112
8.4.6 Checking the siphon ............................................113
8.4.7 Checking the burner and cleaning the heat
exchanger ...........................................................114
8.5 Specific maintenance operations ....................115
8.5.1 Inspection of the ignition electrode ......................115
8.5.2 Replacing the non-return valve ...........................116
8.5.3 Assembling the boiler ..........................................117
9 Troubleshooting .....................................................................................118
9.1 Anti-hunting ......................................................118
9.2 Messages (Code type Bxx or Mxx) ..................118
9.3 Message history ................................................121
9.3.1 Control panel DIEMATIC iSystem .......................121
9.3.2 Control panel IniControl ......................................122
Contents
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9.4 Faults (Code type Lxx or Dxx) .........................123
9.4.1 Control panel DIEMATIC iSystem .......................124
9.4.2 Control panel IniControl ......................................124
9.4.3 List of errors ........................................................124
9.4.4 Deletion of sensors from the memory in the
PCB .....................................................................132
9.4.5 Deleting the IOBL 3WV modules from the memory in
the PCB ..............................................................133
9.5 Failure history ...................................................133
9.5.1 Control panel DIEMATIC iSystem .......................133
9.5.2 Control panel IniControl ......................................134
9.6 Parameter and input/output check (mode
tests) ..................................................................135
9.6.1 Control panel DIEMATIC iSystem .......................135
9.6.2 Control panel IniControl ......................................137
9.6.3 Control system sequence ....................................137
10 Spare parts ..............................................................................................139
10.1 General ..............................................................139
10.2 Spare parts ........................................................139
10.2.1 Casing .................................................................140
10.2.2 Heat exchanger and burner - MCA 45 ................141
10.2.3 Heat exchanger and burner - MCA 65 ................142
10.2.4 Heat exchanger and burner - MCA 90/115 .........143
10.2.5 Fan - MCA 45/65 .................................................144
10.2.6 Fan - MCA 90 ......................................................145
10.2.7 Fan - MCA 115 ....................................................146
10.2.8 Control panel .......................................................147
10.2.9 Spare parts list ....................................................148
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1 Introduction
1.1 Used symbols
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
4Interscenario switch: Home automation switch that can be used
to centralise and control several scenarios
4IOBL: In One By Legrand - Carrier current home automation bus
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
1. Introduction MCA 45 - 65 - 90 - 115
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1.3 General
1.3.1. Manufacturer's liability
Our products are manufactured in compliance with the requirements
of the various european applicable 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.
1.3.3. User's liability
To guarantee optimum operation of the appliance, the user must
respect the following instructions:
4Read and abide by the instructions given in the user manual.
4Call on qualified professionals to carry out installation and initial
start up.
4Get your fitter to explain your installation to you.
4Have the required checks and services done.
4Keep the instruction manuals in good condition close to the
appliance.
MCA 45 - 65 - 90 - 115 1. Introduction
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This appliance is not intended to be used by persons (including
children) whose physcial, sensory or mental capacity is impaired or
persons with no experience or knowledge, unless they have the
benefit, through the intermediary of a person responsible for their
safety, of supervision or prior instructions regarding use of the
appliance. Care should be taken to ensure that children do not play
with the appliance.
1.4 Homologations
1.4.1. Certifications
CE identification no PIN 0063CL3333
NOx classification 5 (EN 297 pr A3, EN 656)
Type of connection Chimney: B23, B33
Flue gas outlet: C13, C33, C43, C53, C63, C83, C93
1.4.2. Equipment categories
Gas category Gas type Connection pressure (mbar)
II2H3P Natural gas H (G20) 20
Propane (G31) 37
The boiler is preset in the factory to operate on natural gas H (G20).
For operation on another group of gases:
4With DIEMATIC iSystem: ¼ "Adapting to another gas type",
page 62.
4With IniControl: ¼ "Adapting to another gas type", page
93.
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. Introduction MCA 45 - 65 - 90 - 115
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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
MCA 45 - 65 - 90 - 115 1. Introduction
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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. Isolate 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
2. Safety instructions and recommendations MCA 45 - 65 - 90 - 115
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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 boiler. 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.
MCA 45 - 65 - 90 - 115 2. Safety instructions and recommendations
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3 Technical description
3.1 General description
Wall-hung gas condensing boilers
4High efficiency heating (Production of domestic hot water can be
ensured by a separate hot water calorifier).
4Low pollutant emissions.
4DIEMATIC iSystem or IniControl electronic control panel.
4Flue gas evacuation by a forced flue, chimney or bi-flow type
connection.
4Very suitable for cascade systems with several boilers.
3.2 Main parts
1Flue gas outlet / Air intake
2Casing/air box
3Heat exchanger (Central heating)
4Outlet for measuring combustion gases
5Ignition/ionization electrode
6Mixer pipe
7Combined venturi and gas valve unit
8Áir intake silencer
9Instrument box
10 Siphon
11 Box for the control PCBs
12 Fan
13 Water flow pipe
3.3 Operating principle
3.3.1. Shunt pump
The boiler is supplied without a pump. When choosing a pump, take
account of the boiler resistance and system resistance.
¼ See chapter: "Technical characteristics", page 13.
T002036-B
8
7
4
55
6
2
3
9
11
10
12
13
1
3. Technical description MCA 45 - 65 - 90 - 115
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If possible, install the pump directly under the boiler on the return
connection.
¼ See chapter: "Connection of the heating circuit", page 22.
CAUTION
The pump may have a maximum input of 200 W. Use an
auxiliary relay for a pump with a larger input.
3.3.2. System in cascade
The boiler is ideally suited for a cascade system. There are a number
of standard solutions available. For example:
4Cascade sets (quick assembly) for the installation of 2 to 7 boilers
next to each other or 3 to 10 boilers mounted back to back on a
free-standing frame. When the boilers are mounted next to each
other, they can be mounted either on the wall or on a free-standing
frame.
Please contact us for further information.
3.3.3. Calorifier connection
A calorifier can be connected to the boiler. Our product range includes
various calorifiers.
Please contact us for further information.
The calorifier can be connected to the boiler in two ways:
4Using a three-way valve.
4Using a calorifier pump.
3.3.4. 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. For this reason the
boiler is, so to speak, insensitive to a flow which is too low.
In all cases, maintain a minimum water flow of 0,4 m3/h.
3.4 Technical characteristics
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Boiler type MCA 45 MCA 65 MCA 90 MCA 115
General
Flow rate setting Adjustable Modulating, Start/Stop, 0 - 10 V
Nominal output (Pn)
Heating System (80/60 °C)
minimum-maximum kW 8,0 - 40,0 12,0 - 61,0 14,1 - 84,2 16,6 - 107,0
Factory setting kW 40,0 61,0 84,2 107,0
Nominal output (Pn)
Heating System (50/30 °C)
minimum-maximum kW 8,9 - 43,0 13,3 - 65,0 15,8 - 89,5 18,4 - 114,0
Factory setting kW 43,0 65,0 89,5 114,0
Nominal input (Qn)
Heating System (Hi)
minimum-maximum kW 8,2 - 41,2 12,2 - 62,0 14,6 - 86,0 17,2 - 110,2
Factory setting kW 41,2 62,0 86,0 110,2
Nominal input(Qn)
Heating System (Hs)
minimum-maximum kW 9,1 - 45,7 13,6 - 68,8 16,2 - 95,5 19,1 - 122,4
Factory setting kW 45,7 68,8 95,5 122,4
Heating efficiency under full load (Hi)
(80/60 °C) - % 97,2 98,3 97,9 96,6
Heating efficiency under full load (Hi)
(50/30 °C) - % 102,9 104,6 104,1 102,5
Heating efficiency under partial load (Hi)
(Return temperature 60°C) - % 97,5 98,3 96,6 96,5
Heating efficiency under partial load (EN
92/42)(Return temperature 30°C) - % 107,7 108,9 108,1 107,1
Data on the gases and combustion gases
Gas consumption G20 (Natural gas H) minimum-maximum m3/h 0,9 - 4,4 1,3 - 6,6 1,5 - 9,1 1,8 - 11,7
Gas consumption G31 (Propane) minimum-maximum m3/h 0,3 - 1,7 0,5 - 2,5 0,6 - 3,5 0,6 - 4,7
NOx-Emission per year or (EN 483) mg/kWh 37 32 45 46
Mass flue gas flow rate minimum-maximum Kg/h 14 - 69 21 - 104 28 - 138 36 - 178
Flue gas temperature minimum-maximum °C 30 - 67 30 - 68 30 - 68 30 - 72
Maximum counter pressure Pa 150 100 160 220
Characteristics of the heating circuit
Water content l 5,5 6,5 7,5 7,5
Water operating pressure minimum kPa (bar) 80 (0,8) 80 (0,8) 80 (0,8) 80 (0,8)
Water operating pressure (PMS) maximum kPa (bar) 400 (4,0) 400 (4,0) 400 (4,0) 400 (4,0)
Water temperature maximum °C 110 110 110 110
Operating temperature maximum °C 90 90 90 90
Water resistance (∆T = 20K) mbar 90 130 140 250
Electrical characteristics
Power supply voltage V/Hz 230/50 230/50 230/50 230/50
Power consumption - Full load maximum W 68 88 125 199
Power consumption - Part load maximum W 18 23 20 45
Power consumption - Standby maximum W 5 6 4 7
Electrical protection index IP X4D X4D X4D X4D
Other characteristics
Weight (empty) Total kg 53 60 67 68
Mounting(1) kg 49 56 65 65
Acoustic level at 1 meter dBA 45 45 52 51
(1) Front panel removed
3. Technical description MCA 45 - 65 - 90 - 115
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3.4.1. Sensor characteristics
Outside sensor Outlet sensor circuit B+C
Domestic hot water sensor
Boiler sensor
Return sensor
-20 °C 2392 ¨ 0 °C 32014 ¨ -20 °C 98932 ¨
-16 °C 2088 ¨ 10 °C 19691 ¨ -10 °C 58879 ¨
-12 °C 1811 ¨ 20 °C 12474 ¨ 0 °C 36129 ¨
-8 °C 1562 ¨ 25 °C 10000 ¨ 10 °C 22804 ¨
-4 °C 1342 ¨ 30 °C 8080 ¨ 20 °C 14773 ¨
0 °C 1149 ¨ 40 °C 5372 ¨ 25 °C 12000 ¨
4 °C 984 ¨ 50 °C 3661 ¨ 30 °C 9804 ¨
8 °C 842 ¨ 60 °C 2535 ¨ 40 °C 6652 ¨
12 °C 720 ¨ 70 °C 1794 ¨ 50 °C 4607 ¨
16 °C 616 ¨ 80 °C 1290 ¨ 60 °C 3252 ¨
20 °C 528 ¨ 90 °C 941 ¨ 70 °C 2337 ¨
24 °C 454 ¨ 80 °C 1707 ¨
90 °C 1266 ¨
100 °C 952 ¨
110 °C 726 ¨
MCA 45 - 65 - 90 - 115 3. Technical description
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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 boiler is composed of 2 packages:
41 boiler package including:
-The boiler, fitted with a connection cable
-Mounting rail and mounting accessories for wall mounting
-Mounting template
-Installation and Service Manual
-User Guide
41 control panel package including:
-The DIEMATIC iSystem or IniControl control panel
-module assembly instructions
4.2.2. Accessories
Various options are available depending on the configuration of the
installation:
Boiler options
Description package
Hydraulic connection kit - MCA 45 HC137
Hydraulic connection kit - MCA 65 / 90 / 115 HC139
Right gas valve 3/4" HC158
3-speed heating pump - MCA 45 HC141
Electronic heating pump - MCA 45 HC142
3-speed heating pump - MCA 65 HC143
3-speed heating pump - MCA 90 HC145
Primary pump - MCA 45 / 65 / 90 HC147
3-way valve with motor 1" HC15
Low loss header HW PLUS 70 HC28
Low loss header HW 200 HC29
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Boiler options
Description package
Condensates neutralisation station HC33
Bracket for neutralisation station HC 33 HC34
2 kg refill of granulats to neutralisation station HC 33 HC35
Condensates neutralisation station (Boilers up to 120 kW) DU13
Condensates neutralisation station (Boilers from 120 to 350
kW)
DU14
Condensates neutralisation station (Boilers above 350 kW) DU15
Control system options
Description package
Optional PCB for 3-way valve Diematic iSystem AD249
System sensor AD250
Outside radio-controlled temperature sensor Diematic iSystem AD251
Boiler radio module AD252
Radio remote control Diematic iSystem AD253
Interactive remote control Diematic iSystem AD254
BUS connection cable (length 12 m) AD134
voice remote monitoring module AD152
Outlet sensor after 3-way valve AD199
A simplified remote control with room sensor FM52
Domestic hot water tank options
Description package
Heating / DHW inversion valve HC 134
Heating DHW reversal valve MCA 45 / 65 HC 135
Boiler/DHW tank connection kit BL / BP / BSC / DT EA 121
DHW sensor AD 212
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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.
4.3.2. Location of the appliance
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.
T001982-A
T002599-B
500
min.1000 500
min.
400
350
min.
250
750
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