MHG Heating EcoStar 500 User manual

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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Installation and Operating Manual for the
EcoStar 500 Oil Condensing Floor Standing Range
Output Range 15.5 – 28.4 kW

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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Section
1.0 Appliance Type
1.1 ECOSTAR 500 Standard
1.2 ECOSTAR 500 Enhanced
2.0 Installation Regulations and Requirements
2.1 Appliance Warranties
3.0 Dimensions ECOSTAR 500
3.4 Dimensions and Connections
3.6 Installation Clearances
4.0 Delivery and Mobility
5.0 Technical Data
6.0 Pressure Relief Valve
7.0 Electrical Connections
7.1 Internal Wiring Diagrams
8.0 Hydraulic Configurations
8.1 Hydraulic Single Unit
8.2 Hydraulic Cascade Unit
9.0 Filling The System
9.1 Pressure Vessel
10.0 System Water Quality
11.0 Appliance Controls
12.0 Appliance Fault Codes
13.0 Commissioning
13.1 Pre-Commissioning Checks.
13.2 Combustion System Commissioning
14.0 Routine Inspection and Servicing
14.1 Routine Service Inspection
14.2 Routine Cleaning and Maintenance
15.0 Weather Compensation Slope Graph and Sensor Curves
16.0 Optional System Controls (QAA73, RVA47, RVA 63, RVA46, QAA70, QAA50, QAA10)
17.0 Exploded Spares Diagrams
18.0 Parts List
18.0 Installer / End Users Note

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.0 Appliance Type
There are four versions within the EcoStar 500 range. Each unit can be supplied with or without a
cascade controller.
Please ensure you have the correct unit for the application and where required located correctly
within the cascade prior to beginning the installation.
1.1 The EcoStar 500 Standard unit without cascade controller appliances are designed to be applied to
systems where the cascade control is undertaken via a remote system manager or a building
management system. Either control system must be capable of providing a volt free enable per applied
boiler.
1.2 The EcoStar 500 Enhanced unit with cascade controller appliances are designed to be applied to
systems where the cascade control is undertaken by the lead boiler. Control of the system is enhanced
by the addition of a dedicated room unit.
The product codes for the standard range are:
Product Name Product Code
EcoStar 515
Blue Flame Oil
94.10000-5750
EcoStar 518 Blue Flame Oil 94.10000-5751
EcoStar 522 Blue Flame Oil 94.10000-5752
EcoStar 527 Blue Flame Oil 94.10000-5753

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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2.0 Installation Regulations and Requirements
The installation of EcoStar 500 boilers must be in accordance with the relevant requirements of Gas
Safety (Installation & Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE
Regulations, Construction (Design & Management) Regulations 1994, Local Authority Bye-Laws,
National, Fire Regulations and Insurance Company requirements.
The following Codes of Practice are also applicable:-
BS 5440-1: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70
kW net (1st, 2nd and 3rd family gases).
Part 1: Specification for the installation of flues.
BS 5440-2: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70
kW net (1st, 2nd and 3rd family gases).
Part 2: Specification for installation and maintenance of ventilation for gas appliances.
BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic
premises.
BS 6644: 2005 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and
1.8MW(net) (2nd and 3rd family gases).
BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input not exceeding
60 kW.
BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater than
45kW. Parts 1, 2 & 3.
BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in
domestic premises (2nd family gases)
BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises
IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1: Flued
appliances.
And any addition prevailing regulation and or code of practice not detailed above.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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2.1 Appliance Warranties
All MHG appliances enjoy a full 36 month warranty as detailed in our terms and conditions.
The guarantee period shall begin on the day of commissioning, or at latest 3 months after delivery has
been made.
The customer shall only be able to claim against MHG under guarantee if the commissioning of the
object of delivery has been carried out by MHG staff or the authorised supplier, if the customer has
followed MHG's instructions relating to the treatment and maintenance of the object of delivery, and
if no replacement parts of outside origin have been fitted.
Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the guarantee.”
In addition to the above warranties, the Primary Heat Exchangers carry a 60 month guarantee against
manufacturing or material defect.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.0 Dimensions. ECOSTAR 500 Boilers
3.4 Dimension and Connection Dimension

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.6 Installation and Service Clearances

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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4.0 Delivery and Mobility
All ECOSTAR 500s are supplied fully tested and therefore may contain residual test water.
The test water utilised contains additives that will help prevent associated pumps from sticking and
other metals from oxidising.
To maintain the structural integrity of the appliance the internal components should not be used
during the lifting and positioning of the unit.
Place the primary heat exchanger assembly on the calorifier, boiler base or purpose made plinth.

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Once correctly positioned install the baffles 1-3 as indicated above.
Mount the door as indicated above. Ensure that the insulation is not damaged.

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Mount the Blue Flame Rocket Burner as Indicated.
Install the Burner/ Boiler wiring and control panel.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Install the thermostat probes as indicated.

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Connect the remote RESET wiring. Connect the Boiler controller. Connect the field wiring loom.
Connect the controller wiring HMI. Connect the Boiler Flow Sensor.
Flue Gas Temperature Thermostat
Install the flue gas thermostat assembly and route the cable to the controller in insert wires in place of
the link wire in SK1 and SK2.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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To programm the unit a QAA 75 must be connected to the control unit.
This can be hard wired or if required plugged in to the boilers control facia.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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An alternative to hard wiring the QAA75 room unit is to utilise a wireless QAA78 unit.
A transducer must be connected to the boiler unit.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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All packaging materials should be disposed of in an environmentally aware way.
The unit illustrated below includes the option pump assemblies.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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© MHG Heating Ltd
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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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5.0 Technical Data
Technical Data Units ECOSTAR
515
ECOSTAR
518
ECOSTAR
522
ECOSTAR
527
Number of Sections 2 3 4 4
Nominal Heat Input Net Max kW 15.7 17.9 22.1 26.4
Nominal Heat Output Max kW 16.1 18.4 22.5 26.9
Flow and Return Connections 1.5” 1.5” 1.5” 1.5”
Flue Gas Temperature OC 80 80 80 80
Minimum Water Pressure bar 0.5 0.5 0.5 0.5
Max Water Pressure bar 3 3 3 3
Power Supply (230 V / 50 Hz) Amps Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Max Power Consumption Watts Burner
Dependant
Burner
Dependant
Burner
Dependant
Burner
Dependant
Limit Temperature OC 110 110 110 110
Maximum Flow Temperature OC 90 90 90 90
Water Content Ltrs 23 23 23 23
Minimum Flow Rate Kg/S 0.55 0.63 0.79 0.96
Lift Weight (Dry) kg 110 115 119 119
*ECOSTAR 5008-69/ECOSTAR 5008-90

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0845 6448802 Telephone. [phone] Fax. Email [email protected] Website www.mhgheating.co.uk
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Fluing Options
The appliance must be flued in accordance with prevailing regulations.
An extensive range for rigid and flexible flue components are available from MHG.
The diagrams indicated below are for illustrative purposes only.
Flexible flue installation.

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Lined flue Stack installation.

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The overall length of the flue system must be calculated with reference to the respective burner
manual.
The addition of every 870Bend reduces the overall potential length by 1m.