MHG Heating 15 Instruction Manual

Procon
RVR.ie
Ireland’s Online Heating Suppliers
Instructions for Installing, Servicing and
Using Procon , ,  and  Boilers

Procon
T  C
. General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Product Description (cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Technical Data & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Delivery Consignment / Unpacking The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Water Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Condensate Waste Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Conventional Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Modular Conventional Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Room Sealed Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Installation of a Horizontal Wall Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Flue Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Calculating the Flue Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Flue Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Hydraulic System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Low Water Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Water Treatment, System Cleaning (BS : ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Care With The Use of Solder Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Inclusion of Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Pressure (Safety) Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Internal Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Low Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Outside Air Sensor QAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Optional Extra Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. QAA Room Unit Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. AGU. Clip-In Module Extra Heating Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. AGU. Clip-In Module BMS Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. OCI Clip-In Module LPB Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. RVA Cascade Controller (Grey) & Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. RVA Zone Controller (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. RVA Zone Controller (Grey) & Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Congurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. System Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Pre-commissioning Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. LPG Conversion Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Boiler LMU Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Level One Parameters Review and Alternation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. LMU Controller, Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Reviewing LMU Operating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Reviewing LMU Operating Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. LMU Operating Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Boiler Operating Sequence Numeric Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. First Firing / Burner Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Setting the Boiler to Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Routine Cleaning & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Full Parameters List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Exploded Views & Short Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Procon ,  &  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
. Procon  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Procon
. G N
These instructions are intended to assist the installer, commissioning and maintenance technicians and the
user with the application and use of the Procon , ,  &  gas red condensing boilers.
Please read this manual fully before commencing the installation of the appliance. The Procon boilers must
be installed by competent persons as dened by local, national and European regulations.
This manual must be handed to the appliance user following completion of the installation. The appliance
must not be left to operate with the outer casing removed.
Conformity Statement
Procon , ,  &  boilers are manufactured to the highest standards of quality, performance and safety,
in accordance with EC standards and carry the CE mark.
Installation Requirements
All gas appliances must be installed by a competent and qualied person, in accordance with relevant clauses
of applicable standards and recommendations. These include but may not be limited to the following:
• I.S.  Domestic Gas Installations
• I.S,  Non-Domestic Gas Installations
• All relevant Building Regulations.
• Local Water Bye Laws
• IEE Wiring Regulations
• Health & Safety legislation
Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety
to ensure that the law is complied with.
Manufacturer’s instructions must NOT be taken in anyway as over-riding statutory obligations.


Procon
. P D
The Procon , ,  &  wall mounted gas red condensing boilers are state of the art appliances, which
include a comprehensive range of features.
The appliance must only be used on a sealed and pressurized system. System design must take into account
that the boiler operates on a °C Δt.
Wall mounted with compact dimensions
At  mm High,  mm Deep, and  mm Wide for the Procon ,  &  boilers, and  mm Wide for
the Procon  boiler, these provide maximum heat output from minimum dimensions without compromising
serviceability.
Fully modulating heat output
The output of the boiler is fully variable, sliding between (approx.)  to , which automatically and
instantly adjusts to match the needs of the system.The percentage of power at any given time can be dictated
by either outside air temperature, ow temperature, return temperature, stored domestic hot water temperature,
room temperature, or a combination of the aforementioned.
Fully condensing stainless steel heat exchanger
The Procon , ,  &  boilers are designed with extended heat exchanger surface area and is fabricated
from corrosion resistant long-life L stainless steel.The unique Spiranox heat exchanger will return operating
eciencies up to .  gross (  net) at °C return temperature.
Extremely low harmful emissions
The Procon , ,  &  boiler utilizes  pre-mix gas/air fed at positive pressure to the metal bre
sheathed radiant burner. The combustion system incorporates pre-mixed fuel/air control, returning ultra low
emissions to satisfy the most stringent emission regulations in the world currently.
That is: <mg/kWh NOx ( ppm DAF) and <mg/kWh CO ( ppm DAF). The fully modulating nature of
the appliance also reduces emissions by avoiding repeated start/stops and the associated increase in emissions,
which occurs with burner ON/OFF cycling.
Accurate variable burner output control
The pre-mix burner fan has a direct current drive motor with pulse relay counting.This system allows precise
control over fan speed / combustion air volumes. Coupled with a gas valve system set to provide proportionately
measured volumes of fuel to air, this allows extremely accurate and instant variable burner output control to
be achieved.
Natural Gas or LPG
Appliances can be supplied for use with Natural Gas (G) or Liqueed Petroleum Gas (G). Conversion Kits
are available from RVR Limited.


Procon
. P D (’)
Comprehensive microprocessor control
The Procon , ,  &  boiler control panel includes a user friendly microprocessor control centre which
manages the entire function of the appliance and encompasses:
) Management of the essential safety functions of burner ignition and ame monitoring.
) Water high temperature and ue gas high temperature safety cut out.
) Modulation of the burner output in conjunction with operating temperature control.
) Large LCD display screen with clear graphical notations which continuously display operation or fault
status.
) In built weather compensation to provide direct-on-boiler VT ow temperature (if required).
) Remote stored hot water temperature control.
) In built  stage boiler frost protection program.
) In built pump exercise program to avoid standstill seizure.
) Range rate adjustment which allows the power to be set to accurately match the maximum needs of
the system, with the facility to set dierent ring rates for heating and hot water generation.
) Facility to connect optional matched control components which allow the boiler to control;
• A hot water priority system using a  port valve or primary charging pump, and hot water sensor at-
tached to a stored hot water cylinder.
• An additional heating circuit pump and -port VT valve (if required).
• A multi functional room temperature controller with separate heating and hot water time controls, night
setback, frost protection, and remote interrogation of the boilers’set-points and function modes.
Room Sealed Option
Utilizing a concentric ue system / mm ∅(Air duct / Flue duct), the Procon , ,  &  can be installed
to take combustion air directly from outside the building. Horizontal and Vertical terminals sets are available.
Inherent safety is achieved by the negative pressure within the boiler case, which in the event of incorrect seal-
ing of the boiler case would result in safe inward air leakage only.
Alternatively the Procon , ,  &  may be installed as a conventional ue, exhaust only, using an  mm
∅ OD Polypropylene ue gas tube and ttings to exhaust the appliance to a suitable ue terminal location,
either vertical or horizontal.
Extended ue pipe lengths
The excess pressure from the combustion system at maximum output is in the order of  Pa. This allows
for the Procon , ,  &  to be ued over considerable distances providing a great deal of exibility in po-
sitioning the boiler.
Designed for ease of maintenance
The Procon , ,  &  has been engineered for ease of maintenance, even the most major of service
operations being able to be completed easily and quickly without the need for specialist tools.
Guarantee
The warranties available on the Procon , ,  &  range of boilers is as follows;
Supply Only
Parts OnlyWarranty, against manufacturing or material defects for a period of  months from the
date for delivery.
Supply and Commissioned (By an RVR Engineer)
Parts and Labour Warranty, against manufacturing or material defects for a period of up to 
months from the date for delivery. In addition to the above warranties, the Primary Heat Exchanger
carriers a ve year guarantee against manufacturing or material defect.


Procon
. T D  D
H H H H
Nominal Heat Input Net Min/Max kW ./. ./. ./. ./.
Nominal Heat Input Gross Min/Max kW ./. ./. ./. ./.
Carbon Emissions G kg/kW.h . . . .
 of Max Output G kg/kW.h . . . .
Carbon Emissions G kg/kW.h . . . .
 of Max Output G kg/kW.h . . . .
Nominal Heat Output
(ºC/ºC) Min/Max kW ./. ./. ./. ./.
Design Flow Rate (ºC/ºC) l/s . . . .
Heat Exchanger Resistance
(ºC/ºC) mHO N/A N/A N/A .
Nominal Heat Output
(ºC/ºC) Min/Max kW ./. ./. ./. ./.
Design Flow Rate
(ºC/ºC) l/s . . . .
Heat Exchanger Resistance
(°C/°C) mHO N/A N/A N/A .
Residual Head from In-Built
Pump mHO . . . N/A
Maximum Input Gas Rate G m/h . . . .
Maximum Input Gas Rate G m/h . . . .
Gas Inlet Pressure Min/Max mbar ./. ./. ./. ./.
Maximum Flue Gas Volume (Hot) m/h . . . .
Available Fan Pressure Pa    
Maximum Water Pressure (Hot) bar . . . .
Minimum Water Pressure (Cold) bar . . . .
Maximum Flow Temperature ºC    
Power Supply (V /  Hz) A
Max Power Consumption W    
Water Content l . . . .
Weight (Dry) kg . . . .
Connections
HTG Primary Flow (A)  mm  mm  mm  ¼"BSP
HTG Primary Return (B)  mm  mm  mm  ¼"BSP
Gas C)  mm  mm  mm ¾"BSP
Condensate Outlet (D) Plastic ¾"BSP ¾"BSP ¾"BSP ¾"BSP
Condensate Trap Cleaning Point (E) ¾"BSP ¾"BSP ¾"BSP ¾"BSP
Electrical Cable Glands (F)  ×  mm  ×  mm  ×  mm  ×  mm
DHW Primary Return (Optional Extra) (G)  mm  mm  mm N/A
DHW Primary Flow (Optional Extra) (H)  mm  mm  mm N/A
Fig .a – Underside View ,  &  Only Fig .a – Underside View ,  &  Only


Procon
. T D  D (’)
All dimensions are in Millimeters
Plain View ,  &  Only
Underside View ,  &  Only
Plain View  Only
Front View ,  &  Only Front View  Only
Underside View  Only


Procon
. D C / U T B
The boiler is delivered as a consignment of a palleted carton containing the boiler and associated ttings,
plus any other optional ancillary ue or control components in separate cartons.
The boiler carton contains:
• Assembled boiler.
• Wall mounting bracket and associated xings.
• Fittings bag including, condensate waste outlet, outside air sensor (QAC).
To unpack the boiler, the palleted carton should be laid on the oor. Carefully cut the nylon bands and lift
the breboard protective panel. Open the carton top and lift out wall hanging bracket and ttings bag. Remove
packing material and lift away bottomless carton. With  people, carefully lift the boiler from palleted carton
by holding the rear chassis only.
To remove the casing from the boiler, turn the two casing screws, on the blue casing strip above the control
panel, through °. This will release the casing latches. Pull casing slightly to the front and lift upwards to dis-
engage the casing from the top securing lip. The casing can then be removed.
. B L
The Procon , ,  &  boiler is not suitable for installation external to a building. The position chosen for
the boiler must be a structurally sound wall capable of supporting the weight of the boiler and any ancillaries.
The position should allow for access to a nearby foul water drain suitable to accept condensate water, an
alternative is to install a condensate sump receptacle and condense disposal pump which should remove the
condense water to a remote foul water drain suitable to accept condensate water.
The position of the boiler on the wall must be truly plumb vertical to ensure correct operation of the internal
gravity ow condense system. The position for the boiler must satisfy the requirements of BS :  or BS
:  as appropriate.
. I C
For ease of installation, commissioning, servicing and maintenance the following clearances should be
observed.
NOTE: These distances are MINIMUM and MUST NOT be reduced. Clearance Dimensions relate to ALL models. Dimensions in { } relate to
model 75 only.


Procon
. W M
The Procon , ,  &  boiler is mounted to the wall via a wall-mounting bracket, which interlocks to a rail
mounted on the rear of the boiler.
The wall-mounting bracket should be securely xed to the wall using suitable xings for the wall construc-
tion and boiler weight. The wall-mounting bracket positioning detail is shown in g . for Model ,  & ;
and g . for model  only.
The boiler should be carefully lifted by two people and oered up to the wall so that the rail on the rear of
the boiler is just above the mounting bracket. Gently lower the boiler to engage the bracket onto the rail.
Important Notice
When viewed from the side, the North/South axis of the boilers must be vertical. The appliance must not
incline out from the top. If necessary, adjust the position of the boiler at the bottom.
. G C
The gas connection is located at the base of the appliance in the centre, see g . for Models ,  & ; see
g . for model .
The pipe size used to supply the appliance must not be smaller than the gas connection size.The connection
to the appliance MUST include an isolation valve and a suitable method of disconnection, installed between
the isolation valve and the appliance.
The gas pipe used to supply the appliance must be installed in accordance with BS : , IGE/UP/, and
IGE/UP/ as applicable, and MUST NOT allow a dynamic pressure drop of greater than mbar from the meter
to the appliance with all gas appliances operational.
The nominal inlet working pressure measured at the appliance should be . mbar for Natural Gas (G),
or  mbar for Liqueed Petroleum Gas (G). The installer should provide a pressure test point adjacent to the
gas inlet connection between the isolation valve and the appliance.
Fig .a – Models ,  &  Illustrated Fig .b – Model  Illustrated
Fig .a – Models ,  &  Illustrated Fig .b – Models  Illustrated


Procon
. W C
The Procon , ,  &  boilers MUST only be installed on a sealed, pressurized heating system. The maxi-
mum working pressure of the boiler is  bar.
A safety valve set at . bar MUST be installed into the heating ow pipe adjacent to the appliance and
before any isolation valves. It is recommended that the nal working pressure (hot) of the system should not
exceed . bar.
The system that the boiler is installed onto will require an expansion vessel. The Procon  and  models
include an integral -litre expansion vessel.
Please contact RVR Sales Department for advice on the sizing of an expansion vessel suitable for the systems
requirements.
The ow and return connections should include isolation valves, a drain facility, and a suitable method of
disconnection between the isolation valves and the appliance.
The ow and return connections on the  model are ¼"BSP M (parallel), therefore it is recommended that a tting
with a tapered thread, such as a Tapered Union or Tapered Socket, be utilized for the connection onto the boiler.
. C W C
The condensate waste connection is located at the bottom of the appliance, see gs .a & .b.
The condense syphon cleaning point is factory tted with a heavy black plastic cap which MUST NOT BE
REMOVED apart from during routine maintenance when the syphon is cleaned and must be in place whenever
the appliance is in operation.
WARNING: operating the appliance with the cap removed will result in products of combustion being dis-
charged from the cleaning point.
The condensate waste connection is a ¾"BSP Male threaded stub fabricated from plastic. The installer
must connect to the stub, a condensate waste pipe fabricated from plastic tube & ttings (¾" or  mm ∅over-
ow pipe is considered suitable). Copper Tube is not acceptable.
The condense waste pipe must fall continuously from the appliance to a nearby foul water drain suitable for
accepting condense waste. If any part of the condensate waste pipe is to be run external to the building or is
at risk of freezing, then the pipe must be suitably insulated to protect against freezing.
If a suitable drain for accepting condense waste is not available nearby and below the boiler, (e.g. boiler
installed in a basement), then a suitable condense sump receptacle with a discharge pump should be installed
below the boiler to remove the condense waste to a suitable remote foul water drain. Available as an optional
extra, Contact RVR Sales Department for more information.
When making the connection to the condense waste pipe, do not use adhesives, it is recommended to
lightly apply a suitable jointing tape (PTFE or similar) and use only light pressure to connect the ttings to the
appliance to avoid damage to the condense waste outlet assembly. It is recommended that a suitable method
of disconnection be tted, and cleaning points be tted at regular intervals.
Fig .a – Models ,  &  Illustrated Fig .b – Models  Illustrated
Condense
Cleaning
Point.
mm ∅
Plastic
Condense
Outlet.
Condense
Cleaning
Point.
mm ∅
Plastic
Condense
Outlet.
Fig .a – Models ,  &  Illustrated Fig .b – Models  Illustrated
 mm
Heating
Flow
 mm
Heating
Return
 ¼" BSP
Heating
Flow
 ¼" BSP
Heating
Return


Procon
. F
The ue outlet and combustion air inlet connections to the appliance are located on the top of the appliance;
see g ..These connections are arranged concentrically with a Female  mm ∅ ue gas connection centrally
within a Male  mm ∅air connection.
There are two options for ueing the Procon boiler:
) Room Sealed, using either concentric / mm ∅ue components, or separate  mm ∅ue compo-
nents; where the air for combustion is taken from outside of the building. When using a room sealed
ue, ventilation to the boiler/s location may not be required, see section . for further guidance.
) Conventionally, using  mm ∅ue components for the combustion gases only and air for combustion
being taken from the room or compartment that the appliance is installed. The ventilation to the room
or compartment that the boiler/s are installed MUST be ventilated in accordance with the requirements
of IS , IS, BS or BS as appropriate, see section . for further guidance.
. C F
The Procon , ,  &  boilers have an excess pressure
combustion system, which coupled with very low ue gas tem-
peratures, allows the appliance to be ued over considerable
distances.
As standard the Procon , ,  &  boiler is supplied with
a concentric ue outlet on the top of the boiler and utilizes an
 mm ∅PPS polypropylene ue gas pipe within a  mm ∅
painted metal combustion air pipe, see g ..
To ue the boiler conventionally, i.e. exhaust only, only the
inner mm ∅PPS socket is used.
The gap between the  mm ∅PPS socket and the  mm
∅painted metal combustion air pipe is left open to allow the
air for combustion to enter the boiler from the room in which
the boiler is installed.
Any sections of the ue system that are to be installed horizontally MUST have at least a ° fall to the boiler
to allow any condensate which may form in the ue system to drain back into the boiler.
The ue system must be gas and water tight, and must be adequately supported over its entire length. Sup-
ports at  metre intervals are essential.
Care should be taken when selecting a position with a low level discharge, or discharges’ adjacent to win-
dows, doors, etc, as the ue terminal will plume heavily and the white water vapour discharged may cause a
visual nuisance.
The PPS ue components have push together spigot and socket joints, and have soft EPDM O-rings located
in the socket components.To aid assembly and assure that the joints have been fully pushed home, the sealing
EPDM O-rings and male ends of the tubes and ttings should be lightly lubricated with silicone grease.
A range of  mm ∅PPS ue components are available from RVR Boilers Ltd; and is listed on page .
. M C F
The Procon , ,  &  boilers can be connected onto common
conventional ue, in a modular arrangement; however, due to the
excess pressure combustion system, consideration must be given to
ensure that the excess pressure of a ring appliance/s is not applied to
any non-ring appliance/s.
Therefore, to ensure that the excess pressures are catered for, the
common ue system MUST be designed so that under partial load, the
resistance of the common riser MUST always be of a lesser resistance
than that of any boiler ue branch connecting to the common riser,
furthermore, the use of swept or shoed tee MUST be utilized.
The ue components used shall be pressure tight, and suitable for
a pressure in excess of  Pascal’s.
They shall also be of a suitable material for use with condensing
boilers, such as PPS Plastic, or L Stainless Steel, etc.
Fig . – Models ,  &  Illustrated
Fig .


Procon
. R S F
The Procon , ,  &  boilers have an excess pressure combustion system, which coupled with very low
ue gas temperatures, allows the appliance to be ued over considerable distances.
The Procon , ,  &  boilers are tted with a concentric ue outlet on the top of the boiler and uses a
female  mm ∅ PPS polypropylene ue gas pipe within a male  mm ∅ painted metal combustion air pipe, see
g .. To connect to the standard concentric ue components supplied by RVR a ue adaptor is required.
The ue system must be installed to have at least a ° fall to the boiler to allow any condensate which may
form in the ue system to drain back to the boiler.
The ue system must be gas and water tight, and must be adequately supported over its entire length. Sup-
ports at -metre intervals are essential.
Care should be taken when selecting a position with a low level
discharge, or discharges’ adjacent to windows, doors, etc, as the ue
terminal will plume heavily and the white water vapour discharged
may cause a visual nuisance.
The concentric ue components have push together spigot and sock-
et joints. Both the inner PPS ue gas tube, and the outer combustion air
tube have soft EPDM O-rings located in the socket components.
To aid assembly and assure that the joints have been fully pushed
home, the sealing EPDM O-rings and male ends of the tubes and ttings
should be lightly lubricated with silicone grease. A range of concentric
ue components are available from RVR Ltd; and is listed on page .
. I   H W
T
Rear Outlet Assembly Method
The following procedure applies to rear ue terminal position.
) With the boiler mounted in position, see section ., draw a horizontal line on
the wall  mm (,  &  models) above the top of the boiler. See g .a.
) Mark the center of the ue spigot on the wall, remove the boiler from its hang-
ing bracket and carefully position to one side. Draw a vertical line from the
center mark of the ue spigot to intersect the horizontal line. See g .a.
) At the intersection of the horizontal and vertical lines, cut a  mm ∅hole
with a core drill. See g .a.
) Measure the wall thickness‘W’in millimeters, add  mm (,  &  mod-
els), or  mm ( Model) to achieve total length‘TL’ of ue pipe required.
) Mark the Horizontal WallTerminal a distance of‘TL’from the outer edge of
the Air Pipe. Both tubes should be cut ush and square with each other,
and any burrs removed. See g .b.
) Re-position the boiler onto the hanging bracket, as detailed in section ..
) Fit the Flue Adaptor to the top of the boiler and lubricate the two seals
with silicone grease.
) Lubricate the male ends of the concentric bend and the ue adapter with
silicone grease; locate the ue adapter onto the ue outlet connection on
top of the boiler, and gently push home. Locate the bend on top of the
ue adapter, and gently push home.
) Locate the wall bezel plate onto the wall terminal assembly and position the
terminal through the previously prepared hole from outside the building.
) Locate the bezel plate onto the wall terminal for the inside face of the wall.
Lubricate the male ends of the concentric bend with silicone grease.
) Locate concentric tubes into bend and gently push fully home. Ensure
that the plain section of the external part of the air inlet tube is located
uppermost. See g .c.
) Fix internal and external wall bezel plates with xings provided. See g .c.
Fig . – Models ,  &  Illustrated
Fig .a
Fig .b
Fig .c


Procon
. I   H W T (’)
Side Outlet Assembly Method
The following procedure applies to horizontal, side ue terminal position.
) With the boiler mounted in position, see section ., draw
a horizontal line along the wall  mm above the top of
the boiler. This line should rise at approximately ° from
the horizontal toward the terminal position to allow any
condensate to drain through the boiler. See g .d.
) On the adjacent sidewall, draw a vertical line  mm (,
 &  models), or  mm ( model) from the wall that
the boiler is mounted on. Continue the horizontal line
previously marked on the sidewall, See g .d
) At the intersection of the horizontal and vertical lines, cut
a  mm ∅hole with a core drill. See g .d.
) Measure the wall thickness‘W’in millimeters and the dis-
tance between the side of the boiler and the adjacent
sidewall (L).
For the ,  &  models, add  mm to the sum of Length
‘L + W’, to achieve total length‘TL’of ue piperequired.
For the  model, if ueing to the LEFT, add  mm to
the sum of Length‘L + W’, to achieve total length‘TL’ of
ue piperequired; If ueing to the RIGHT, add  mm
to the sum ofLength ‘L + W’, to achieve total length ‘TL’
of ue pipe required.
If‘TL’is greater than  mm , then additional ueex-
tensions will be required.
) Mark the Horizontal Wall Terminal, and ue extensions
if required, a distance of ‘TL’from the outer edge of the
Air Pipe. Both tubes should be cut ush and square with
each other, and any burrs removed. See g .e.
) Re-position the boiler onto the hanging bracket, as de-
tailed in section ..
) Fit the Flue Adaptor to the top of the boiler and lubricate
the two seals with silicone grease.
) Lubricate the male ends of the concentric bend and the
ue adapter with silicone grease, locate the ue adapter
onto the ue outlet connection on top of the boiler, and
gently push home. Locate the bend on top of the ue
adapter, and gently push home.
) Locate the wall bezel plate onto the wall terminal as-
sembly and position the terminal through the previously
prepared hole from outside the building.
) Locate the bezel plate onto the wall terminal for the in-
side face of the wall.
) Lubricate the male ends of the concentric bend with
silicone grease. Locate concentric tubes into bend and
gently push fully home. Ensure that the plain section of
the external part of the air inlet tube is located upper-
most. See g .f.
) Fix external wall bezel plate with xings provided (g .f).
Fig .d
Fig .e
Fig .f


Procon
. C  F P L
The excess pressure available from the boiler fan for overcoming the frictional resistance of the ue system is
 Pa.The adjacent table lists the resistances of the ue components, which will assist the designer in calculat-
ing the resistance of the total ue system.
As with all vertical ue systems, thermal up-draught is generated in the vertical sections of a ue, the graph
below (g .) shows the Thermal Up-draught generated, in Pa’s, which can then be deducted from the total
ue resistance.
If the resistance of the total ue system exceeds  Pa’s, this will result in a reduction of the boiler output.
The graph below (g .) shows the available maximum boiler output in relation to ue resistance.
15H 25H 45H 75H
Concentric Flue Components
Standard Wall Terminal . . . .
Vertical Discharge Wall Terminal . . . .
Vertical Terminal . . . .
 mm Flue Extension . . . .
 mm Flue Extension . . . .
° Bend . . . .
° Bend . . . .
 mm ∅PPS Flue Components
Concentric to Twin Pipe Adapter . . . .
Exhaust Pipe Terminal . . . .
Air Pipe Terminal . . . .
 mm Flue Extension . . . .
 mm Flue Extension . . . .
° Bend . . . .
° Bend . . . .
ermal Up-draught Graph Boiler Output / Flue Resistance Graph
Fig .a – Thermal Up-draught when ue gas
temperature ºC and outside temperature -° C.
A = Flue insulated or within the building.
B = Flue un-insulated and exterior to the
building.
Fig.b – Eect oftheuesystem
resistance on the boiler output.


Procon
. F T P
The ue terminal of the Procon , ,  &  boilers’will plume water vapour, heavily and care must be taken
when selecting the terminal position to ensure that a“nuisance situation” is not created.
Where the ue terminal discharges within 2 metres of ground or any upper part of the building where
people have general access, i.e. balcony level, etc., a terminal guard MUST be tted to prevent the terminal
from being touched.
Minimum Distance
All Dimensions are in millimeters, See Fig .
Dimension Description Minimum
Distance Dimension Description Minimum
Distance
ADirectly below an opening,
air brick, window, etc.  J From an opening, door,
window, etc., in a car port 
BBelow gutters, soil pipes,
drain pipes, etc.  K Vertically from a terminal on
the same wall. 
C Below eaves  L Horizontally from a terminal
on the same wall. 
DBelow balconies, car port
roof, etc.  MAbove an opening, window,
etc. 
EVertically from soil pipes,
drain pipes, etc.  NHorizontally to an opening,
window, etc. 
FFrom internal or external
corners.  P Above a level roof (base of
terminal). 
GAbove ground, intersecting
roof, balcony level, etc.  Q Q From adjacent wall (edge
of terminal). 
HFrom a surface facing the
terminal.  R From adjacent opening
window. 
IFrom a terminal facing the
terminal.  S From any other ue terminal. 
Note: Dimensions highlighted in BOLD are not recommended locations.
Fig . – Minimum Clearances


Procon
. V R
The room or space in which the Procon , ,  &  boiler is installed may need to be ventilated in accord-
ance with BS : Part :, or BS : , as appropriate.
The table below details the ventilation required for individual Procon , ,  &  boiler installations
ONLY.
Conventional Flue Installation H H H H (*)
Room Installation. Natural Ventilation direct
to outside. cm cm cm cm High,
cm Low Level
Room Installation. Natural ventilation from
adjacent room, which is directly ventilated to
outside.
cm cm cm N/A
Compartment Installation. Natural Ventilation
direct to outside.
cm High, cm
Low Level
cm High,
cm Low Level
cm High,
cm Low Level
cm High,
cm Low Level
Compartment Installation. Natural ventilation
from adjacent room, which is directly
ventilated to outside.
cm High,
cm Low Level
cm High,
cm Low Level
cm High,
cm Low Level N/A
Room H H H H (*)
Room Installation. (Consideration shall be
given to provide general ventilation for
cooling purposes).
NIL NIL NIL cm High & Low
Level
Compartment Installation, room sealed ue.
Natural ventilation direct to outside.
cm High & Low
Level
cm High & Low
Level
cm High & Low
Level
cm High & Low
Level
Compartment Installation. Natural ventilation
from adjacent room. Adjacent room similarly
ventilated direct to outside
cm High & Low
Level
cm High & Low
Level
cm High & Low
Level
cm High & Low
Level
Important Notice
The Ventilation Requirements detailed above are for guidance purposes and are relevant for single ap-
pliance installations ONLY.
For further information on dierent ventilation options/requirements, for single or multiple boiler instal-
lations, please refer to BS 5440: Part 2:2000 and BS 6644: 2005, as appropriate.
*1 – Consideration shall be given for the Summer Usage of the boiler, and the appropriate ventilational-
lowance applied, as detailed in BS 6644: 2005.
. H S D
The Procon , ,  &  boiler can be operated to serve a heating load as either;
• Constant Temperature, the option of adjusting the desired set-point temperature between  °C and  °C.
• Direct-On-Boiler weather compensated ow temperature.
• Hot Water Production, on a priority basis.
The Procon , ,  &  boilers are designed to operate
with a °C ∆T, the heating & hot water loads shall be designed
around a °C ∆T, operating the boiler on a reduced ∆T will result
in a reduced boiler output.
Where the system index circuit/s have a greater hydraulic re-
sistance than that of the residual head pressure available from
the internal boiler pump {, , }, or chosen boiler pump {},
then a low loss header must be used, with the boilers pump
delivering the water to the low loss header.
Where multiple boilers are to be installed, a low loss header
must be used, with the boiler primary pumps delivering the wa-
ter to the low loss header. Non-return valves MUST be tted to
each boiler to prevent short-circuiting. See . System Type .
Where the system has multiple pumped circuits that are pro-
posed to operating at the same time, then sub headers, both ow
and return, should be used with non-return valve being installed
directly after each pump to prevent re-circulation. See Fig .
Fig .


Procon
. L W P P.
A low water pressure switch has been incorporated into the boiler and therefore an external unit is not re-
quired. The activation setting of the switch is . bar, with a . bar dierential; therefore the system pressure
must be in excess of . bar for the switch to activate and allow the appliance to function.
. W T  S C
The entire primary system MUST be thoroughly cleaned and ushed to remove debris, ux residues,
etc. before opening the boiler isolation valves & admitting water to the boiler.
Particular care must be taken where the Procon boiler is being retro-tted into an old/existing system,
as system silt or magnetite can be very damaging to the new boiler.
Following cleaning and ushing the system MUST be dosed with a good quality water treatment to
prevent corrosion and the formation of scale. A suitable corrosion inhibitor known as INIBAL is available
from RVR Limited.
FAILURE TO OBSERVE THESE REQUIREMENTS WILL RENDER THE WARRANTY ON THE APPLIANCE VOID.
Cleaning, ushing and water treatment must be carried out in accordance with the requirements of
BS :, prior to commissioning the boiler.
Repeated draining and relling of the system, without replenishment of water treatment, must be
avoided, as this is very damaging to the boiler.The boiler must not operate without the system water be-
ing correctly and adequately treated, and maintained, with an appropriate level of corrosion inhibitor.
. C W T U  S F
The Procon , ,  &  boiler has a heat exchanger fabricated from L Stainless Steel. It is
most important that the compatibility of any ux is checked with the supplier before use, and that any ux
manufactures recommendations are strictly followed with regards to use in conjunction with Stainless Steel.
. I  S
The return pipework MUST include some method of ltering or straining. The lter or strainer must be t-
ted with isolation valves to allow easy cleaning with the minimum amount of water loss and water replenish-
ment.
. P (S) R V
In accordance with BS :  and BS : , as applicable, the installer shall install as suitably sized
Pressure (Safety) Relief Valve.
The location of this valve is important with respect to the applied pressure of the boiler circulation pump, it
is therefore recommended to locate the Pressure (Safety) ReliefValve on the ow pipe i mm ediately adjacent to
the boiler; furthermore, there must not be any means of isolation between the boiler and the Pressure (Safety)
Relief Valve.


Procon
. F  S
The Initial lling of a sealed heating system, and subsequent relling, must be by a method that has been
approved by the local authority and complies with building regulations.
In general Water Regulation Advisory Scheme (WRAS) recommendations will be acceptable in Ireland.
Domestic (In-House) Fluid Category  (C-)
Non Domestic (Other than In-House) Fluid Category  (C-)
For Category  systems, the approved method of lling
must comprise of the following components in the arrange-
ment shown;
• ControlValve incorporating a Double Check Valve on
the Mains Cold Water pipework.
• Temporary Connecting Hose, which must be discon-
nected after use.
• Control Valve, on the heating system.
For Category  systems, the approved method of lling
must comprise of the following components in the arrange-
ment shown;
• Control Valve.
• Strainer.
• Veriable Backow Device with Reduced Pressure
Zone (RPZ Valve)
• Incorporating a‘Type BA’ Air Gap.
• Tundish.
• Control Valve.
Further more, in accordance with BS :  system with an input greater than kW (nett), an automatic
water replenishment unit shall be installed to automatically replenish any lost or evaporated water.
Please refer to BS :  for allowable water replenishment methods for use with sealed/pressurized
heating systems.
Please contact RVR Limited for more information.
. E V
In accordance with BS : , BS : , WRAS Regulations, and Local Authority Water Regulations,
as applicable, the installer shall install a suitably sized, and approved, Expansion Vessel to ensure that the water
capacity of the system has ample expansion capacity.
The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service
Valved, which shall be locked in the OPEN position, to prevent accidental isolation.
Furthermore, a drain facility should be provided adjacent to the expansion vessel to aide the routine main-
tenance, overhaul, of the vessels Air Pressure setting.
The Procon  &  boilers only, are supplied with an internal -litre expansion vessel. This vessel is suitable
for a system with a maximum capacity of  litres. This is based upon a Cold Fill Pressure of .bar, and a Final
Working Pressure (HOT) of .bar.
For information on a comprehensive range of expansion vessels that comply with current British
Standards and WRAS Regulations, please contact RVR Boiler Sales.
Fig .a
Fig .b


Procon
. E C.
In accordance with BS : , BS : , WRAS Regulations, and Local Authority Water Regulations,
as applicable, the installer shall install a suitably sized, and approved, Expansion Vessel to ensure that the water
capacity of the system has ample expansion capacity.
The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service
Valve which shall be locked in the OPEN position, to prevent accidental isolation.
Furthermore, a drain facility should be provided adjacent to the expansion vessel to aid the routine mainte-
nance, overhaul, of the vessel’s Air Pressure setting.
The Procon  &  boilers ONLY, are supplied with an internal -litre expansion vessel. This vessel is suitable
for a system with a maximum capacity of  litres. This is based upon a Cold Fill Pressure of .bar, and a Final
Working Pressure (HOT) of .bar.
For information on a comprehensive range of expansion vessels that comply with current Standards
and WRAS Regulations, please contact RVR Limited.
Fig .a – Connection Details for Models ,  & 
* – Parameter Change Required.
Fig .b – Connection Details for Model 
* – Parameter Change Required.


Procon
. I W D
Fig .a – Internal Wiring Diagram for Models ,  & 
Fig .b – Internal Wiring Diagram for Model 
