MHG Heating ProCon MCS 320 User manual

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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Installation and Operating Manual for the
ProCon MCS 320 -2150kW
Floor Standing Gas Condensing Boilers

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Section
Page
Appliance Type
3
ProCon MCSS
4
Installation Regulations and Requirements
5
Appliance Warranties Supplied Components
6
Dimensions
7
Installation Clearances and Mounting Information
10
Delivery and Mobility
11
Case Removal
11
Technical Data
12
Load Loss on Water Input Side Curve (DT=20)
15
Pressure Relief Valve
17
Electrical Connections
18
Internal Wiring Diagram
19
Wiring Diagram Legend
24
Hydraulic and Wiring Guide Single Unit Option 1 (Heating Only)
25
Two Boiler Cascade Option 2 (heating Only)
26
Hydraulic and Wiring Guide Single Unit Option 3 (Heating & HWS)
27
Hydraulic and Wiring Guide Single Unit Option 4 (Heating Multi Zone & HWS)
28
Three Boiler Cascade Hidro Units Option 1 (Heating Only)
29
Three Boiler Cascade Hidro Units Option 2 (Heating & HWS)
30
Three Boiler Cascade Hidro Units Option 3 (Heating Multi Zone & HWS)
31
Theta Cascade Manager
32
Theta Electrical Connections
33
Fluing Options
34
Single Unit Flue Options (Internal/External)
35
Ventilation and Flue Terminal Positioning Guide (BS5440-1:2008, BS5440-2:2009, BS6644:2011 & IGE/UP/10 (ed3))
36
Filling The System
39
Expansion Vessel
40
Appliance Controls
42
Appliance Fault Codes
43
NG/LPG –LPG/NG Conversion Procedure
44
Commissioning The Appliance
45
Combustion System Commissioning
46
Routine Inspection and Servicing
48
Weather Compensation Slope
51
Programing a Replacement GFA Module Controller
52
User Information
56
Operational Diagram
57
Sensor Resistance Tables
61
Exploded Spares Diagram
62

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Appliance Type
There are currently Five base boiler models in the range which are combined in cascades to provide a
further seventeen boilers within the ProCon MCS range.
ProCon MCS 210
ProCon MCS 260
ProCon MCS 320
ProCon MCS 400
ProCon MCS 535
Cascade Unit (Hidro)
ProCon MCS 580 Hidro
ProCon MCS 670 Hidro
ProCon MCS 740 Hidro
ProCon MCS 800 Hidro
ProCon MCS 850 Hidro
ProCon MCS 940 Hidro
ProCon MCS 1000 Hidro
ProCon MCS 1250 Hidro
ProCon MCS 1320 Hidro
ProCon MCS 1380 Hidro
ProCon MCS 1450 Hidro
ProCon MCS 1600 Hidro
ProCon MCS 1800 Hidro
ProCon MCS 1850 Hidro
ProCon MCS 1920 Hidro
ProCon MCS 2000 Hidro
ProCon MCS 2150 Hidro
The ProCon MCS range is designed to be applied to systems requiring direct on boiler weather
compensated heating and priority hot water production via a separate high recovery calorifier/cylinder.
The ProCon MCS range is supplied complete with weather proofed casings, allowing the units to be
located externally to the building without the need for a purpose built structure
Dedicated cascade controllers, communication adapters, hydraulic kits form part of the Hidro units.

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ProCon MCS Configuration. (210-535)
1
Stainless Steel Double Heat Exchanger
2
Manometer
3
Pressure Switch Maximum
4
Pump Differential Pressure Switch
5
Return Pipework
6
6bar Pressure Relief Valve.
7
Pressure Switch Minimum
8
High Head Pump
9
Thermometer
10
Flow Pipework
11
Limit Thermostat
12
Gas Pipework
13
Condensate Discharge Pipework
14
Low NOx Premix Burner
15
Weather Proof Casing.
ProCon MCS Hidro Configuration. (580-2150)
1
Stainless Steel Double Heat Exchanger
2
Pump Differential Pressure Switch
3
High Head Pump
4
6bar Pressure Relief Valve.
5
Common Flow Pipework DN150 PN6
6
Common Return Pipework DN150 PN6
7
Common Gas Pipework DN65 PN16
8
Common Condensate Discharge Pipework DN50
9
Limit Thermostat
10
Thermometer
11
Manometer
12
Pressure Switch Maximum
13
Pressure Switch Minimum
14
Low NOx Premix Burner
15
Weather Proof Casing.

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Installation Regulations and Requirements
The installation of ProCon MCS 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: 2008 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: 2009 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: 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.

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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 within 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 authorized supplier. Only 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.
Supplied Components
All MCS units are test fired prior to dispatch.
Due to shipping/handling issues the Hidro units are dismantled prior to shipping.
The interconnecting power and cascade wirings and plugs are shipped within the master unit packaging.
The Theta Cascade Controller is supplied with the following sensors:
Common Flow sensor * Must be installed*
Outside air sensor (Optional, required to activate direct on boiler weather compensation)
HWS Sensor (Optional, A volt free enable can be used.)(A parameter adjustment will be
required.)
Mixed Zone 1 Flow Sensor (Optional)
Mixed Zone 2 Flow Sensor (Optional)

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Dimensions
ProCon MCS 320 (210 & 260 for use in Hidro Cascade units only)
Manifold Connection Dimensions
1
System Delivery
G 2”1/2 Male
2
System Return MCS 210
G 2”1/2 Male
3
System Return MCS 260
G 2”1/2 Male
4
System Return MCS 320
G 2”1/2 Male
5
Gas Inlet 210/260
G 1”1/2 Male
6
Gas Inlet320
G 1”1/2 Male
7
3 Way Water Outlet Valve
G 1”1/2 Male
8
Condensate Discharge
Ø25
9
Relief Valve Discharge
G1”1/2 Male
10
Fume Discharge
Ø=150 Female
ProCon MCS 400 and 535
Manifold Connection Dimensions
1
System Delivery
G 2”1/2 Male
2
System Return MCS 400
G 2”1/2 Male
3
System Return MCS 535
G 2”1/2 Male
4
Gas Inlet
G 1”1/2 Male
5
3 Way Water Outlet Valve
G 1”1/2 Male
6
Condensate Discharge
Ø25
7
Relief Valve Discharge
G1”1/2 Male
8
Fume Discharge
Ø=180 Female

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ProCon MCS Hidro Units
ProCon MCS 320 Hidro (210 & 260 for use in Hidro Cascade units only)
ProCon MCS 400 and 535 Hidro
Item
Description
MI
Flow Header Connection
RI
Return Header Connection
SC
Condensate Water Connection
SF
Flue Gas Spigot

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ProCon MCS Hidro Layouts
A = 400kW and 535kW units B = 210kW, 260kW and 320kW Units

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Installation and Service Clearances
ProCon MC 210, 260, 320, 400 & 535
ProCon MCS Hidro All models
If these clearances cannot be achieved please contact MHG’s technical department for guidance.

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Delivery and Mobility
All ProCon MCS’s are supplied fully tested and therefore may contain residual test water.
The test water utilised contains additives that will help prevent the pump 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.
All packaging materials should be disposed of in an environmentally way.
Case Removal
The MCS front case is removable and secured in place by four screw tight swizzle lugs.
The MCS Hidro front case is hinged at the top and secured in place by four screw tight swizzle lugs.
The Theta cascade controller is mounted in a clear fronted housing secured on the left or right of the
unit.
All other casing panels are secured in place with screw tight swizzle lugs.
Weather Proof Casing
Craning the Boiler.
If the boiler is to be raised in to position via a crane, it is essential that the base of the unit and the
components immediate inside are protected from damage by using correctly located strops please
contact MHG’s technical department for guidance.

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Technical Data
ProCon MCS
210 (Used in Hidro Cascade)
260 (Used in Hidro Cascade)
Nominal Heating Capacity
kW
20-200
25-250
Nominal Thermal Power (80/60°C)
kW
19.52-195.2
24.45- 244.5
Nominal Thermal Power (50/30°C)
kW
21.3-213.0
26.63-266.3
Thermal Efficiency at Max Output (80/60°C)
%
97.6
97.8
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.52
NOx Class
5
5
Gas Consumption G20
m3/h
2.12-21.16
2.65-26.46
Gas Consumption G30
Kg/h
1.58-15.77
1.97-19.72
Gas Consumption G31
Kg/h
1.55-15.54
1.94-19.42
Min/Max Working Pressure
Bar
1/6
1/6
Number of Burners
#
2
2
Water Content of Individual Heat X
L
22
26
Water Content of Unit
L
26.6
31.6
Equipment Type
B23
B23
Power Supply/Power
230V/1400
230V/1500
Empty Weight
Kg
275
306
Dimension WxDxH
Mm
775x1150x1552
775x1150x1552
Flue Gas Mass Flow
Kg/h
33.7-337.2
42.1-421.4
Filled Weight
Kg
320
351
Residual Flue Pressure
Pa
100
100
Carbon Dioxide Concentration
%
9.0
9.0
ProCon MCS
320
400
535
580 Hidro
Nominal Heating Capacity
kW
30-300
38-380
50-500
25-550
Nominal Thermal Power (80/60°C)
kW
29.39-293.9
37.3-373
49.1-491
24.45-538.4
Nominal Thermal Power (50/30°C)
kW
31.95-319.5
40.47-404.7
53.25-532.5
24.45-585.8
Thermal Efficiency at Max Output (80/60°C)
%
98.0
98.2
98.2
97.89
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.5
106.5
105.51
NOx Class
5
5
5
5
Gas Consumption G20
m3/h
3.17-31.75
4.02-4021
5.29-52.91
2.65-58.21
Gas Consumption G30
Kg/h
3.37-23.66
3.00-29.97
3.94-39.43
1.97-43.38
Gas Consumption G31
Kg/h
2.33-23.31
2.95-29.52
3.88-38.84
1.94-42.73
Min/Max Working Pressure
Bar
1/6
1/6
1/6
1/6
Number of Burners
#
2
2
2
4
Water Content of Individual Heat X
L
30
39
55
56
Water Content of Unit
L
36.7
46.7
63.8
132.3
Equipment Type
B23
B23
B23
B23
Power Supply/Power
230V/1750
230V/1900
230V/2000
230V/3250
Empty Weight
Kg
361
366
409
1000
Dimension WxDxH
Mm
775x1150x1552
775x1150x1552
775x1150x1552
1550x1150x1552
Flue Gas Mass Flow
Kg/h
50.6-505.7
64.1-640.6
84.3-842.9
42.1-927.1
Filled Weight
Kg
361
366
409
1000
Residual Flue Pressure
Pa
100
100
100
100
Carbon Dioxide Concentration
%
9.0
9.0
9.0
9.0

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ProCon MCS
670 Hidro
740 Hidro
800 Hidro
850 Hidro
Nominal Heating Capacity
kW
25-630
20-700
25-750
30-800
Nominal Thermal Power (80/60°C)
kW
24.45-617.5
19.52-686.2
24.45-735.5
29.39-784.9
Nominal Thermal Power (50/30°C)
kW
26.63-671
21.3-745.5
26.63-798.8
31.95-852
Thermal Efficiency at Max Output (80/60°C)
%
98.02
98.03
98.06
98.11
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.5
106.5
106.51
NOx Class
5
5
5
5
Gas Consumption G20
m3/h
2.65-66.67
2.12-74.07
2.65-79.37
3.17-84.66
Gas Consumption G30
Kg/h
1.97-49.69
1.58-55.2
1.97-59.15
2.37-63.09
Gas Consumption G31
Kg/h
1.94-48.94
1.55-54.38
1.94-58.26
2.33-62.15
Min/Max Working Pressure
Bar
1/6
1/6
1/6
1/6
Number of Burners
#
4
4
4
4
Water Content of Individual Heat X
L
65
77
81
85
Water Content of Unit
L
142.3
154.4
159.4
164.5
Equipment Type
B23
B23
B23
B23
Power Supply/Power
230V/3400
230V/3400
230V/3500
230V/3750
Empty Weight
Kg
1032
104
1075
1085
Dimension WxDxH
Mm
1550x1150x1552
1550x1150x1552
1550x1150x1552
1550x1150x1552
Flue Gas Mass Flow
Kg/h
42.1-1062
33.7-1180.1
42.1-1264.3
50.6-1348.6
Residual Flue Pressure
Pa
100
100
100
100
Carbon Dioxide Concentration
%
9.0
9.0
9.0
9.0
ProCon MCS
940 Hidro
1000 Hidro
1250 Hidro
1320 Hidro
Nominal Heating Capacity
kW
38-880
50-1000
25-1200
25-1250
Nominal Thermal Power (80/60°C)
kW
37.3-864
49.1-982
19.52-1177.2
24.45-12226.5
Nominal Thermal Power (50/30°C)
kW
40.47-937.2
53.25-1065
21.3-1278
26.63-1331.3
Thermal Efficiency at Max Output (80/60°C)
%
98.11
98.20
98.10
98.12
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.5
106.5
106.5
NOx Class
5
5
5
5
Gas Consumption G20
m3/h
4.02-93.12
5.29-105.82
2.12-126.98
2.65-132.28
Gas Consumption G30
Kg/h
3-69.4
3.94-78.86
1.58-94.63
1.97-98.58
Gas Consumption G31
Kg/h
2.98-68.36
3.88-77.68
1.55-93.22
1.94-97.1
Min/Max Working Pressure
Bar
1/6
1/6
1/6
1/6
Number of Burners
#
4
4
4
4
Water Content of Individual Heat X
L
94
110
132
136
Water Content of Unit
L
174.5
191.6
250.2
255.2
Equipment Type
B23
B23
B23
B23
Power Supply/Power
230V/3900
230V/4000
230V/5400
230V/5500
Empty Weight
Kg
1117
1160
1624
1655
Dimension WxDxH
Mm
1550x1150x1552
1550x1150x1552
1550x1150x1552
1550x1150x1552
Flue Gas Mass Flow
Kg/h
64.1-1483.5
84.3-1685.8
33.7-2023
42.1-2107.2
Residual Flue Pressure
Pa
100
100
100
100
Carbon Dioxide Concentration
%
9.0
9.0
9.0
9.0

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ProCon MCS
1380 Hidro
1450 Hidro
1600 Hidro
1800 Hidro
Nominal Heating Capacity
kW
30-1300
38-1380
50-1500
20-1700
Nominal Thermal Power (80/60°C)
kW
29.39-1275.9
37.3-1355
49.1-1473
1952.1668.2
Nominal Thermal Power (50/30°C)
kW
31.95-1384.5
40.47-1469.7
53.25-1597.5
21.3-1810.5
Thermal Efficiency at Max Output (80/60°C)
%
98.15
98.19
98.20
98.13
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.5
106.5
106.5
NOx Class
5
5
5
5
Gas Consumption G20
m3/h
3.17-137.57
4.02-146.03
5.29-158.73
2.12-179.89
Gas Consumption G30
Kg/h
3.37-102-52
3-108.83
3.94-118.29
1.58-134.06
Gas Consumption G31
Kg/h
2.33-100.89
2.95-107.2
3.88-116.52
1.55-132.06
Min/Max Working Pressure
Bar
1/6
1/6
1/6
1/6
Number of Burners
#
6
6
6
8
Water Content of Individual Heat X
L
140
149
165
187
Water Content of Unit
L
260.3
270.3
287.4
346
Equipment Type
B23
B23
B23
B23
Power Supply/Power
230V/5750
230V/5900
230V/6000
230V/7400
Empty Weight
Kg
1665
1697
1740
2204
Dimension WxDxH
Mm
2325x1500x1552
2325x1500x1552
2325x1500x1552
3100x1500x1552
Flue Gas Mass Flow
Kg/h
50.6-2191.5
64.1-2362.4
84.3-2528.7
33.7-2865.9
Residual Flue Pressure
Pa
100
100
100
100
Carbon Dioxide Concentration
%
9.0
9.0
9.0
9.0
ProCon MCS
1850 Hidro
1920 Hidro
2000 Hidro
2150 Hidro
Nominal Heating Capacity
kW
25-1750
30-1800
38-1880
50-2000
Nominal Thermal Power (80/60°C)
kW
24.45-1717.5
29.39-1766.9
37.3-1846
49.1-1964
Nominal Thermal Power (50/30°C)
kW
26.63-1863.8
31.95-1917
40.47-2002.2
53.25-2130
Thermal Efficiency at Max Output (80/60°C)
%
98.11
98.16
98.19
98.20
Thermal Efficiency at 30% Output (50/30°C)
%
105.3
105.3
105.3
105.3
Thermal Efficiency at Max Output (50/30°C)
%
106.5
106.5
106.5
106.5
NOx Class
5
5
5
5
Gas Consumption G20
m3/h
2.65-185.19
3.17-1+0.48
4.02-198.94
5.29-211.64
Gas Consumption G30
Kg/h
1.97-198.01
2.37-141.95
3-148.26
3.94-157.72
Gas Consumption G31
Kg/h
1.94-135.94
2.33-139.73
2.95-146.04
3.88-155.36
Min/Max Working Pressure
Bar
1/6
1/6
1/6
1/6
Number of Burners
#
8
8
8
8
Water Content of Individual Heat X
L
191
195
204
220
Water Content of Unit
L
351
356.1
366.1
383.2
Equipment Type
B23
B23
B23
B23
Power Supply/Power
230V/7500
230V/7750
230V/7900
230V/8000
Empty Weight
Kg
2235
2204
2277
2320
Dimension WxDxH
Mm
3100x1500x1552
3100x1500x1552
3100x1500x1552
3100x1500x1552
Flue Gas Mass Flow
Kg/h
42.1-2950.1
50.6-3034.4
64.1-3169.3
84.3-3371.6
Residual Flue Pressure
Pa
100
100
100
100
Carbon Dioxide Concentration
%
9.0
9.0
9.0
9.0

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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020315 Draft
Load Loss on Water Input Side Curve (DT=20C)
ProCon MCS210 (Hidro Use Only)
ProCon MCS260 (Hidro Use Only)
ProCon MCS320

© MHG Heating Ltd
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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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ProCon MCS400
ProCon MCS535

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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Pressure (Safety) Relief Valve
In accordance with the prevailing British Standard 5440/6644, 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.
A pressure Relief Valve has been supplied within the unit.
Setting: 5.4bar
Item # 60

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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Electrical Connections
Basic electrical connection for the ProCon MCS
Legend
Item
Description
Theta Cascade Manager
Providing Access to Each Modules Controller Data
Appliance and Module Power Isolators (Green)
Lockout Indicator (Red)
Providing central control of power to each appliance (pair of burners)
K3 Relay
Safety interlock relay
K11Relay
Cascade commination interlock relay
Module Fuses 10 Amp
Main Power Supply and transfer terminal rails
Sensor, E-Bus Cascade, RS485 Cascade & Module Power Supply Plugs
All power and communication leads are supplied reformed with colour coded plugs
and leads cut to the correct length.
All modules are assembled wired test fired then dismantle for shipping.

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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Module GFA Controller Wiring Diagram

© MHG Heating Ltd
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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR
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Theta Cascade Wiring Diagram