MHG Heating ProCon HT User manual

© MHG Heating Ltd
Installation and Operating Manual for the
ProCon HT & HTP 150 & 225
Floor Standing Condensing Boiler Range.
**RVS Controlled**
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

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 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 7
3.0 Dimensions 8
3.1 Plate Heat Exchanger Hydraulic Resistance 9
3.2 Installation Clearances 9
4.0 Delivery and Mobility 9
4.1 Case Removal 10
5.0 Technical Data 12
6.0 Pressure Relief Valve 13
7.0 Electrical Connections 13
8.0 Hydraulic Design Single Unit 14
8.1 Control Wiring Single Unit 14
8.2 Hydraulic Design Cascade Units 15
8.3 Control Wiring Cascade Units 15
9.0 Fluing Options 16
9.1 Single Unit Conventional Flue 16
9.2 Single Unit Balanced Flue 16
9.3 Cascade Conventional Flue 17
9.4 Cascade Balanced Flue 18
10.0 Filling The System 19
10.1 Expansion Vessel 19
11.0 System Water Quality 20
11.1 Care With The Use Of Solder Flux 20
12.0 Appliance Controls 21
12.1 Control Panel 21
12.2 RVS43 143 Cascade Manager 21
12.3 Module Controller 22
12.4 Module Controller End User Settings 22
12.5 Accessing Module Parameters 23
12.6 Module Operating Codes 25
13.0 Appliance Error Codes 24
14.0 Control Parameter Defaults 27
14.1 RVS43 143 Cascade Manager 27
14.1.1 RVS43 143 Cascade Manager Defaults 33
14.2 Module LMU64 Controller (QAA73 Unit Required.) 63
15.0 Commissioning 67
15.1 Pre-Commissioning Checks. 67
15.2 Combustion System Commissioning 67
15.3 NG/LPG – LPG/NG Conversion Procedure 68
16.0 Routine Inspection and Servicing 70
16.1 Routine Service Inspection 70
16.2 Routine Cleaning and Maintenance 70
16.3 QAA73 Room Unit/Service Tool 72
17.0 Optional System Controls (RVA 63, RVA46, QAA70, QAA50, QAA10) 74
18.0 Internal Wiring 75
18.1 Module Control Indication (OCI420 Communication Clip LED) 75
18.1.1 Module BMS Fault Indication Clip Installation and Setting (AGU2.511 Clip) 76
18.2 Internal Wiring Diagram 77
19.0 Flue Components 78
20.0 Exploded Diagrams 79
21.0 Spares Listings 83
22.0 HTP Exploded Diagram 87
23.0 Installer / End Users Note 88

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 3
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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011011 4
1.2 Cascade Manager Units
(150 Product 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 143 multiple 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.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 5
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
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 6
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.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 7
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: 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.
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.
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
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 8
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
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 9
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.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 10
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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011011 11
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.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 12
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% O2Mg/kW
h
26.7 (Class 5)
Flue Classification B23, C33, C43, C53, C63, C83.
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

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 13
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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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 14
8.0 Hydraulic Design Single Unit . (HT and HTP)
8.1 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.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 15
8.2 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
8.3 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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011011 16
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
Combined Must 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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011011 17
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.

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MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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011011 18
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

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 19
10.0 Filling The System
The Initial filling of a sealed heating system, and subsequent refilling, must be by a
method that has been approved by the Water Regulation Advisory Scheme (WRAS) for
that type of heating system.
i.e. Domestic (
In-House ) Fluid Category 3 ( C-3 )
Non Domestic (Other than
In-House ) Fluid Category 4 ( C-4 )
For Category 3 systems, the approved method of filling must comprise of the following
components in the arrangement shown;
•Control Valve incorporating a Double
Check Valve on the Mains Cold Water
pipework.
•Temporary Connecting Hose, which must
be disconnected after use.
•Control Valve, on the heating system.
For Category 4 systems, the approved method of filling must comprise of the following
components in the arrangement shown;
•Control Valve.
•Strainer.
•Verifiable Backflow Device with Reduced
Pressure Zone (RPZ Valve)
•Incorporating a ‘Type BA’ Air Gap.
•Tundish.
•Control Valve.
Further more, in accordance with BS 6644: 2005 system with an input greater than 70kW
(nett), an automatic water replenishment unit shall be installed to automatically
replenish any lost or evaporated water.
Please refer to BS 6644: 2005 for allowable water replenishment methods for use with
sealed/pressurized heating systems.
For information on a comprehensive range of pressurization units that comply with
current British Standards and WRAS Regulations, please contact MHG Heating Ltd Sales.
10.1 Expansion Vessel
In accordance with BS 6644: 2005, 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
aide the routine maintenance, overhaul, of the vessels Air Pressure setting.
For information on a comprehensive range of expansion vessels that comply with
current British Standards and WRAS Regulations, please contact MHG Heating Ltd Sales.

© MHG Heating Ltd
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
P:0845 6448802 F:0845 6448803 E: [email protected]o.uk W: www.mhgheating.co.uk
011011 20
11.0 System Water Quality
Water Treatment, System Cleaning (BS 7592: 2006)(Part L2 Building Regulations)
The entire primary system MUST be thoroughly cleaned and flushed to remove debris,
flux residues, etc. before opening the boiler isolation valves & flooding the boiler.
Particular care must be taken where the ProCon boiler is being retro-fitted into an
old/existing system, as system silt or magnetite can be very damaging to the new boiler.
Following cleaning and flushing the system MUST be dosed with a good quality water
treatment to prevent corrosion and the formation of scale. FAILURE TO OBSERVE THESE
REQUIREMENTS WILL RENDER THE WARRANTEE ON THE APPLIANCE VOID.
Cleaning, flushing and water treatment must be carried out in accordance with the
requirements of BS 7593:1992, prior to commissioning the boiler.
Repeated draining and refilling 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 being correctly and adequately treated, and
maintained, with an appropriate level of corrosion inhibitor.
When utilizing HTP boilers system water treatment must be applied to the primary
circuit.
For specific guidance on water treatment, direct contact is advisable with:-
Betz Dearborn Limited
(Sentiel)
Foundry Lane
Widnes
Cheshire
WA8 8UD
Tel: [phone]
Fax: [phone]
Alpha-Fry Technologies
(Fernox)
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey
GU21 5RZ
Tel: [phone]
Fax: [phone]
11.1 Care With The Use of Solder Flux
The ProCon HT range has heat exchangers fabricated from 316L Stainless Steel. It is most
important that the compatibility of any flux is checked with the supplier before use, and
that any flux manufactures recommendations are strictly followed with regards to use in
conjunction with Stainless Steel.