MHG Heating ProCon HT 150 User manual

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E:i[email protected].uk W: www.mhgheating.co.uk
010617
Installation and Operating Manual for the
ProCon HT& HTP 150 & 225
Floor Standing Condensing Boiler Range
**RVS Controlled**

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E:i[email protected].uk W: www.mhgheating.co.uk
010617
2
Contents
Section
Page #
1.0
Appliance Type
3
1.1
Single Unit
3
1.2
Cascade Manager
4
1.3
Cascade Slave
5
1.4
System Separation Plate Unit
6
2.0
Installation Regulations and Requirements
7
2.1
Appliance Warranties
8
3.0
Dimensions
9
3.1
Plate Heat Exchanger Hydraulic Resistance
10
3.2
Installation Clearances
10
4.0
Delivery and Mobility
10
4.1
Case Removal
11-12
5.0
Technical Data
13
5.1
Connection sizes
14
6.0
Pressure Relief Valve
15
7.0
Electrical Connections
15
8.0
Hydraulic Design Single Unit
16
8.1
Hydraulic Design Cascade Units
17
9.0-9.4
Fluing Options
18-20
10.0
Filling The System
21
10.1
Expansion Vessel
22
11.0
System Water Quality
23
11.1
Care With The Use Of Solder Flux
23
12.0
Appliance Controls
24
12.1
Control Panel
24
12.2
RVS43 143 Cascade Manager
24
12.3
Module Controller
25
12.4
Module Controller End User Settings
25
12.5
Accessing Module Parameters
26
12.6
Module Operating Codes
27
13.0
Appliance Error Codes
28-29
14.0
Control Parameter Defaults
30
14.1
RVS43 143Cascade Manager Defaults
31-55
14.2
Module LMU64 Controller (QAA73 Unit Required.)
56-59
15.0-15.2
Commissioning
59-61
15.3
NG/LPG –LPG/NG Conversion Procedure
62
16.0
Routine Inspection and Servicing
63
16.1
Routine Service Inspection
63
16.2
Routine Cleaning and Maintenance
64-65
17.0
Optional System Controls (RVA 63, RVA46, QAA70, QAA50, QAA10)
66
18.0
Module Operation Indication
67
18.1
Module BMS Fault Indication Clip Installation and Setting (AGU2.511 Clip)
68
18.2
Internal Wiring Diagram
69
19.0
Flue Components
70
20.0
Exploded Diagrams HT
71-74
21.0
Exploded Diagrams HTP
75
23.0
Note
76

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.0 Appliance Type
There are five build types within the ProCon HT & HTP range.
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 Single Units
(150 Product Code 96.30000-7182)
(225 Product Code 96.30000-7183)
The Single Unit is supplied with an integral low loss header.
This unit does not require the installation of a second low loss header remote from
the appliance.
The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected
(hydraulically) to the appliances flow and return connections.
The Single Unit is supplied complete with an integral RVS43 143 Single Unit Cascade
Manager wired to integral flow and return sensors.(QAZ36). An outside are sensor
(QAC34) is also supplied and located in the base of the unit.
Integral Low
Loss Header.
Complete with
Flow and Return
Sensors

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.2 Cascade Manager Units
(150Product Code 96.30000-7184)
(225 Product Code 96.30000-7185)
The Cascade Manager Unit is supplied without an integral low loss header.
A suitably sized low loss header must be installed within the system.
The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected
(hydraulically) to the external low loss header and not to the appliances flow and
return connections.
The Cascade Manager Unit is supplied complete with an integral RVS43 143multiple
unit Cascade Manager. Remote Flow and Return sensors (QAD36) must be mounted
as indicated in the hydraulic diagram section of manual and wired back the unit. An
outside are sensor (QAC34) is also supplied and located in the base of the unit.
Integral
Distribution
Header.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.3 Cascade Slave Units
(150 Product Code 96.30000-7186)
(225 Product Code 96.30000-7187)
The Cascade Slave Unit is supplied without an integral low loss header and should
only installed where a Cascade Manager is also installed
A suitably sized low loss header must be installed within the system.
The system’s (Secondary) circulating pumps (Heating / HWS) are to be connected
(hydraulically) to the external low loss header and not to the appliances flow and
return connections.
The Cascade Slave Unit is supplied without an integral RVS43 143 multiple unit
Cascade Manager and therefore relies on the presence of a Cascade Master Unit to
provide operational signals via the LPB communication wiring.
Integral
Distribution
Header.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.4 System Separation Plate Heat Exchanger Units
(150 Product Code 96.30000-7325)
(225 Product Code 96.30000-7326)
The System Separation Plate Heat Exchanger Unit are supplied with an integral plate
heat exchanger that maintains absolute separation of the boilers circuit from the
systems circuit.
These units may require the installation of a second low loss header remote from the
appliance. Alternatively the system’s (Secondary) circulating pumps (Heating / HWS)
can be connected (hydraulically) to the appliances flow and return connections.
The System Separation Plate Heat Exchanger Unit is supplied complete with an
integral RVS43 143 Single Unit Cascade Manager wired to integral flow and return
sensors (QAZ36). An outside are sensor (QAC34) is also supplied and located in the
base of the unit.
Integral System
Separation Plate
Heat Exchanger
Integral Pressure
Vessel

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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2.0 Installation Regulations and Requirements
The installation of ProCon HT 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 5449: 1990 Specification for forced circulation hot water central heating systems
for domestic premises.
BS 6644: 2011 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.
GE/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.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E:i[email protected].uk W: www.mhgheating.co.uk
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2.1 Appliance Warranties
All MHG appliances enjoy a full 24 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.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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010617
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3.0 Dimensions.
Standard Unit System separation Plate Unit

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.1 Plate Heat Exchanger Hydraulic Resistance
3.2 Installation / Service Clearances
Dimension
[Minimum mm Clearance ]
A
500
B
1000
C
700
D
680
E
1050
4.0 Delivery And Mobility.
Each ProCon HT boiler is supplied with a manoeuvring tool. This is to be used to
facilitate the correct position of the unit.

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4.1 Case Removal
A 4.0mm Allen Key is required to initiate the removal of the appliances case.
1. Case In Place
2. (1) Turn the MHG Logo, (2) insert
Finger and open the cover to the right.
3. Locate the top sprung hinge pin
4. Using a 4mm Allen
Key loosen and pull
down to release the
cover. The two captive
bolts.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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5. (5)Swing the Control Panel to the right 6. (5) Swing the control panel
back
(6) Slide panel A to the right and remove. into its rest position, (7) slid
panel B up and remove.
7. (8) Lift the top panel up, (8) push to the rear 8. (9) Pull the base of each side
of the unit and remove. panel to disengage it from the
press studs, (9) lift the panel
clear of the top pins.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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5.0 Technical Data
Technical Data
150 (150 Plate X)
225 (225 Plate X)
Nominal Heat Input Net
Min/Max
kW
15.0/149.2
15.0/216.0
Nominal Heat Output
(50ºC/30ºC)
Min/Max
kW
16.0/155.0
16.0/225.0
Nominal Heat Output
(80ºC/60ºC)
Min/Max
kW
14.5/143.2
14.5/206.0
Operating Efficiency (40ºC/30ºC)
%
109.5
109.5
Design Water Flow Rate
Ltr/sec
1.8
2.66
Residual Head from In-built Pumps
(Cascade version only)
kPa
15.0 (0)
15.0 (0)
Maximum Input Gas Rate
G20
G31
m³/hr
m³/hr
15.0
5.77
21.7
8.35
Gas Inlet Pressure
Min/Max
mbar
18.0/50.0
18.0/50.0
Maximum Flue Gas Mass
G20 (Hot)
Kg/hr
250.9
363.6
Maximum Flue Gas Mass
G31 (Hot)
Kg/hr
231.4
335.1
Residual Fan Pressure
Pa
200
200
Maximum Water Pressure
(Hot)
bar
3.0 (System 10)
3.0 (System 10)
Minimum Water Pressure
(Cold)
bar
1.0 (System 1)
1.0 (System 1)
Maximum Flow Temperature
ºC
90 (85)
90 (85)
Power Supply (240 V /50 Hz)
Amps
7
7
Max Power Consumption
Watts
690
800
Water Content
Ltrs
30
35
Lift Weight (Dry)
kg
250
270
Lift Weight (Wet)
kg
280
305
Efficiency @ Full Load Gross
%
86.48
85.67
Efficiency @ 30% of Full Load Gross
%
98.20
98.37
NOx emission @ 0% O2
Mg/kWh
26.7 (Class 5)
Flue Classification
B23, C33, C43, C53, C63, C83.
All Procon HT/HTP Boilers are fitted with ERP modulating pumps.

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5.1 Connection Sizes
Standard Unit Connections
HTG Primary Flow
PN6
DN 40
DN 40
HTG Primary Return
PN6
DN 40
DN 40
Gas
BSP
R1.25”
R1.25”
Flue Connection
DN 160
DN 160
Combustion Air Connection
The combustion air duct must have a
resistance no greater than 100Pa
DN 125
DN 125
Condensate Outlet
Plastic
20mm
20mm
Please note that the condensate disposal system must be installed in Plastic or
Stainless Steel. (Copper is not acceptable)
System Separation Plate Heat Exchanger Unit Connections
HTG Primary Flow
BSP
R1.25”
R1.25”
HTG Primary Return
BSP
R1.25”
R1.25”
Gas
BSP
R1.25”
R1.25”
Flue Connection
DN 160
DN 160
Combustion Air Connection
The combustion air duct must have a
resistance no greater than 100Pa
DN 125
DN 125
Condensate Outlet
Plastic
20mm
20mm

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6.0 Pressure (Safety) Relief Valve (Integral within the HTP)
In accordance with BS 6644: 2005, 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)
Relief Valve on the flow pipe immediately adjacent to the boiler; furthermore, there
must not be any means of isolation between the boiler and the Pressure (Safety)
Relief Valve.
7.0 Electrical Connections
Basic electrical connection for all types of ProCon HT/HTP
External Flow and return sensors (QAD36) are required for Cascade Manager Units
only. The sensors must be wired to the RL and VL terminals shown above.
(If internal sensors are in place please disconnect and install the remote sensors.)
Module Controller Mounted Safety Interlock Terminals (X10:03) (Low Voltage<25V)
If required each module can be connected to an external safety device. A relay must
be used to ensure separation of the voltages generated by each module controller.
(X10:03)
AVS75 Extension Module Mixing Clip Wiring Connections.

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8.0 Hydraulic Design Single Unit (HT and HTP)
Electrical Connections Single Unit
If Direct On Boiler Weather Compensation is not required a 3000 Ohm Resistor must be applied to the AF terminals to remove the E10 Error Code from the RVS43 143
Cascade Manager LPB Network.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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8.1 Hydraulic Design Cascade Units (HT Only)
(Additional Boiler circuit circulating pumps are required when using multiple HTP
units.)
Legend
AF Outside Air Sensor (QAC34) HK Heating Circuit Pump
BW Hot Water Sensor(QAZ36) or VF Thermostat PM System Pressure Manager
BW Hot Water Primary Pump RU Room Unit (QAA), BMS etc
FP System Filling (Approved) FS Flow Sensor
RS Return Sensor
Electrical Connections Cascade Units
If Direct On Boiler Weather Compensation is not required a 3000 Ohm Resistor must be applied to the AF terminals to remove the E10 Error Code from the RVS43 143
Cascade Manager LPB Network.
Addition control and hydraulic configurations are possible.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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9.0 Fluing Options
Please note that excessive resistance within the flue and combustion air supply
systems will lead to a reduction in the output of the appliance and induce operation
faults.
Boiler Type
Flue Outlet Size
Flue Size
Maximum Length
Flue and Combustion Air Ducts
CombinedMust Not Have a Resistance
of Greater Than 150Pa Max.
ProCon 150
DN 160
DN 160
28m
ProCon 225
DN 160
DN 160
23m
See section 19 for a full list of DN160 flue components
9.1 Single ProCon HT Conventionally Flued
9.2 Single ProCon HT Balanced Flued
Please note: The combustion air duct must have a resistance no greater than 100Pa

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9.3 Multiple Cascade ProCon HT’s Conventionally Flued
Preferred Method of Fluing Cascaded units
Conventional Flue Header Arrangement.
If this method is utilised the flue must be sized to prevent back pressure effecting
other appliances on the flue system.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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9.4 Multiple Cascade ProCon HT’s Balanced Flued
Preferred Method of Fluing Cascaded units
Please note: The combustion air duct must have a resistance no greater than 100Pa
Conventional Flue Header Arrangement.
If this method is utilised the flue must be sized to prevent back pressure effecting
associated appliances.
Please note: The combustion air duct must have a resistance no greater than 100Pa