MHG Heating ProCon Boiler Controller User manual

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MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR
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ProCon Boiler Controller Commissioning Quick
Reference Guide
This sheet is intended as a quick reference guide and should be read in conjunction with the
operating and maintenance manual for the boiler supplied by MHG Heating Ltd.
Adjustment of the appliances controller can only be undertaken once power has been applied to
the boiler and it has passed through its internal system checks.
The level of parameter adjustment required will be dependent upon the age of the appliance and
the required system control.
All appliance operational mode adjustments and settings are undertaken via the unit control fascia.
Legend
Button Label Function Units Defaults
T1 RESET
Resets indicated large flashing fault codes. Places
the boiler into fault is no fault is present (E153) 0-200 N/A
T2 HOT WATER
(HWS)
Activates HWS generation capability. Indicated on
the screen by a dash beneath the icon. -
T3 MODE Adjusts the operating mode for the heating circuit.

☼

T4 HWS SETPOINT Hot water storage temperature adjustment.
Only possible is a HWS sensor is used. 20-60 55
o
C
T5
HEATING
CIRCUIT FLOW
TEMPERATURE
SETPOINT
Heating flow temperature adjustment.
Or
Assumed room temperature adjustment.
(If outside air sensor installed)
20 – 90
10 - 35
80
o
C
21
o
C

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T6 PROGRAM
DOWN
Access to program settings accessing in reverse
order.
Time of day/ time
switches/
operational settings.
-
T7 PROGRAM UP
Access to program settings accessing in sequential
order. - -
T8 PROGRAM +
PLUS Alteration of program settings positively. - -
T9 PROGRAM –
MINUS Alteration of program settings negatively. - -
T10 INFORMATION Access to operational information and saving
altered program settings.
Fault Indication/
Boiler Flow
Temperature/
Stored HWS/
Operation Mode/
Outside Air
Temperature.
-
Legend
Button Label Function
1 WATER PRESSURE INDICATOR Not used In ProCon Ranges
2 MAIN DISPLAY Flow Temperature or Selected Parameter Setting
3 COMMISSIONING MODE
Commissioning Mode Indicator Full Power (no
adjustment.)/Engineers Mode (full adjustment
via Program Up & Down Buttons.)
4 SPECIFIC OPERATIONAL MODE INDICATOR The Display Reflects the Operational Mode
Dependent Upon Inputs.
5 TIME OF DAY / AUTO RESETTING ERROR Time of Day Alternating with Automatic
Resetting Error Codes.
6 HEATING CIRCUIT MODE INDICATOR Indicator of Selected Heating Circuit Operating
Mode.
7 HOT WATER ACTIVATION INDICATOR Indication of Activation of Hot Water Production
Mode.

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If required an enhanced operational review level can be accessed.
The table on the following page indicates the level of information that is available.
To access these parameters the following sequence must be undertaken.
Press and release the INFO.
Press & Hold the Program Buttons simultaneously for at least 3 second.
The display will indicate b0
Use the Button to access the various b level parameters.
Use the or to access the other parameter levels C & d
Use the Button to access the required levels within the desired parameter level.
To leave the enhanced operational review level press INFO or wait 8 minutes for automatic refresh.

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The ProCon range has two levels of fault code indication.
Automatic Resetting Fault Code.
A small fault code alternating with the time of day.
The appliance will stop operating for a limited period/until the error has been corrected.
Repeated occurrences of an Automatic Resetting Fault Codes will result in a Manual Reset
Fault Code.
Manual Reset Fault Code.
A large fault code is displayed on the screen along with the symbol.
The appliance will stop operating until the error has been corrected and the RESET button
has been pressed.
PLEASE NOTE.
If the RESET button is pressed when a small fault code is displayed or no fault code is displayed the
unit will display a Manual Reset Fault Code of E153 will be displayed. The RESET button must be
pressed again to clear this code.
If a fault is encountered within the appliance or Cascade LPB network, a fault code will be
generated and displayed by the failing appliance and all LPB networked RVA and Opentherm units .
If a fault is encountered by a RVA controller or is communicated to a RVA controller via the LPB
network ER will be generated on the display.
Opening the controllers flap and pressing the Down PROG button twice will gain access to
parameter line 50 where the generated fault code can be reviewed.
In either case the fault code should be noted for future reference.
If the fault is related to a specific appliance the unit can be reset by pressing the Lockout Reset
Button.
If the fault is related to a RVA controller or the LPB communication network the fault code will
clear automatically following the rectification of the fault.
This is also applicable following the rectification of any appliance fault. This can take up to 10
minutes.
Fault Code Description
E-0 No Error Detected
E-10 Outside Air Sensor Fault / Not Detected
E-20 Flow Water Sensor Fault / Not Detected
E-26 System Flow Sensor Faulty / Not Detected
E-28 Flue Gas Sensor Fault / Not Detected
E-40 Return Water Sensor Fault / Not Detected
E-46 System Return Water Sensor Fault / Not Detected
E-50 HWS Sensor Short Circuit 1
E-52 HWS Sensor Short Circuit 2 (Not Used)

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E-58 HWS Volt Free Switch Fault / Not Detected
E-60 Faulty Room Sensor
E-61 Faulty Room Sensor
E-62 Incorrect Room Unit Connected
E-77 Air Pressure Sensor Not Detected (Not Used)
E-78 Water Pressure Sensor Defective (Not Used)
E-81 LPB Short Circuit (Boiler Cascade Wiring)
E-82 LPB Address Conflict (Boiler Cascade Settings)
E-86 Short Circuit on PPS Connection (Not Used in ProCon Configuration)
E-91 EEPROM
E-92 Hardware Malfunction
E-100 Conflict Between Time of Day Master Control (Boiler / QAA70 / RVA47)
E-105 Annual Service of Unit is Due. (QAA73 Service Tool Required to reset timer See Section 16.0)
E-110 Module Water Temperature Overheat
E-111 Module Temperature Too High (Auto Resetting)
E-113 Flue Gas Temperature overheat (Not Used)
E-117 High System Water Pressure Sensor (Not Used)
E-118 Low System Water Pressure Sensor (Not Used)
E-119 System Water Pressure Switch Activated (Below 0.8 bar)
E-124 Module Temperature Too High (Auto Resetting)
E-128 Flame Extinguished During Operation (LMU Version D)
E-129 Air Supply Error. Fan not operating at correct speed (LMU Version D)
E-130 Flue Temperature Too High (Auto Resetting)
E-131 Fault With Burner
E-132 External Safety Interlock Activated (Open Circuit)
E-133 No Flame Detected After Final Ignition Attempt
E-134 Flame Extinguished During Operation (LMU Version C)
E-135 Air Supply Error Fan not operating at correct speed (LMU Version C)
E-140 LPB Segment / Address Not Recognized (Boiler Cascade Settings)
E-142 LPB Missing Partner (Boiler Cascade Settings)
E-145 Wrong Device Connected to PPS Circuit (Not Used in ProCon Configuration)
E-146 Unrecognized Plant Configuration
E-147 Burner Modules Not Connected (PPS Circuit Not Used in ProCon Configuration )
E-148 LPB Interface Not Configured (Boiler Cascade Settings)
E-150 General Boiler Fault
E-151 Module LMU64 Controller Malfunction
E-152 Module LMU64 Controller Parameter Programming Error
E-153 Module Control Interlocked (The Reset button has been pressed when no fault code is present.)
E-154 Module Operating Outside of Predefined Parameters. (System Hydraulic Error.)
E-160 Fan Not Reaching Set Point
E-161 Module Combustion Fan Speed Too High
E-162 Air Pressure Switch Fault (Not Used)
E-164 Flow Switch / Pressure Switch Open (Not Used)
E-166 Air Pressure Switch Fault (Not Used)
E-180 Module Operating in Chimney Mode 100% Output
E-181 Module Operating in Commissioning Mode
E-183 Module Controller / QAA73 Room Unit in Parameter Setting Mode

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Enhanced Fault Diagnosis Codes (LMU Internal Software Diagnostic Codes)
If required a more detailed fault diagnosis code can be viewed. This will assist where a definitive
cause for a repeated operational error cannot be found.
The enhanced fault diagnosis code is displayed at b0 within the second INFO level.
Access to this level can is detailed on page three of this guide.
The table below indicates a limited number of enhanced fault codes. If the exact number indicated
by the appliance is not detailed below please call our Technical Department or guidance.
Fault Code Fault Description
83 Combustion Fan Not Reaching Ignition Speed
87 Combustion Fan Operating Beneath Minimum Setting
90 Combustion Fan Not Reaching Pre Purge Speed
96 Flame Rectification Signal Detected When Burner Off
97 Flame Rectification Signal Detected When Burner Off
98 Flame Signal Lost During Operation
99 Flame Signal Lost During Operation
100 Flame Signal Lost During Operation
101 Flame Signal Not Detected Following Last Ignition Attempt
102 Flame Signal Not Detected Following Last Ignition Attempt
170 The Reset Button is being Continually Depressed. (Possible Display Module Mounting Error.)
259 The Reset Button Has Been Pressed When No Error Has Been Displayed (E153 Generator.)
282 Combustion Fan Not Reaching Correct Speed
400 System Hydraulic Error. Return Temperature > Flow Temperature. (Repeatedly.)
401 System Hydraulic Error. Return Temperature > Flow Temperature. (Repeatedly.)
402 System Hydraulic Error. Return Temperature > Flow Temperature. (Repeatedly.)
403 System Hydraulic Error. Return Temperature > Flow Temperature. (Repeatedly.)
404 System Hydraulic Error. Return Temperature > Flow Temperature. (Repeatedly.)
406 Boiler Flow Temperature Rising to Above Maximum Limit Temperature When Burner Is On.
422 Boiler Flow Temperature Rising to Above Maximum Limit Temperature When Burner Is Off.
433 System Hydraulic Error. ΔT between Flow and Return Too High. (Repeatedly.)
434 System Hydraulic Error. ΔT between Flow and Return Too High. (Repeatedly.)
435 System Hydraulic Error. ΔT between Flow and Return Too High. (Repeatedly.)

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Accessing Boiler Parameters
Control Parameter Default Settings.
All Units are preset for correct operation.
However if alterations are required to enhance the operation of the unit following the application of optional
control the procedure is detailed below.
The following Pages detail the parameters of the LMU64 controllers, For your assistance the Standard Factory
settings are indicated.
(Please note, the installer/commissioning engineer may have changed some of these settings to suit the system
installed.)
To access the parameters detailed below the boiler’s control panel must be used. (Only boilers supplied prior to
2003 will require a QAA73 Room Unit to access the control parameters. The unit must be connected to the RU
terminals or directly to the LMU64 controller via the X10:01 terminal.)
There are three levels of access available, as follows. If you cannot access a particular parameter line, please
consult with MHG Heating Ltd Technical Department for further assistance.
Level One
(User)
- Press and release one of the or Program Buttons.
The display will now indicate
Use the Program Buttons to access the desired parameter line. Use the
Button to alter the displayed parameter to the required setting.
To save the adjusted parameter move to the adjacent parameter or press and
release the INFO Button if you wish to exit this level.
To exit without saving any adjustment press and release the MODE Button.
Level Two
(Installer)
- Press & Hold the Program Buttons simultaneously for at least 3 seconds.
The display will indicate H90
Use the Program Buttons to access the desired parameter line.
Use the Button to alter the displayed parameter to the required
setting.
To save the adjusted parameter move to the adjacent parameter or press and
release the INFO Button if you wish to exit this level.
To exit without saving any adjustment press and release the MODE Button.
Level Three
(OEM)
- Press & Hold the Program Buttons simultaneously for at least 9 seconds.
The display will indicate - - - - -
A password is required to access this level. (Please contact MHG prior to accessing this as parameter level)
Use the Program Buttons to access the desired parameter line. Use the
Button to alter the displayed parameter to the required setting.
To save the adjusted parameter move to the adjacent parameter or press and
release the INFO Button if you wish to exit this level.
To exit without saving any adjustment press and release the MODE Button.

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Level One end User Parameters
Line #
Description Range Defaults
P1 Time of Day 0…23.59 ---
P2 Day Of Week 1 = Monday ---
P5 Reduced Room Temperature Set Point (If outside air sensor installed)
Minimum Boiler Flow Temperature
5 - 34
20 - 80
16
20
Time Switch 1 Heating Zone 1 Set Points
P10 Heating Circuit 1 Time Switch 1 Day Selection 1..2, 1-5, 1-7 1-7
P11 Heating Circuit 1 Time Switch 1 First On 00:00 - 24:00 ---
P12 Heating Circuit 1 Time Switch 1 First Off 00:00 - 24:00 ---
P13 Heating Circuit 1 Time Switch 1 Second On 00:00 - 24:00 ---
P14 Heating Circuit 1 Time Switch 1 Second Off 00:00 - 24:00 ---
P15 Heating Circuit 1 Time Switch 1 Third On 00:00 - 24:00 ---
P16 Heating Circuit 1 Time Switch 1 Third Off 00:00 - 24:00 ---
Time Switch 2 Heating Zone 2 Set Points
(*AGU2.500 Clip and QAD36 sensors required )
P20* Heating Circuit 2 Time Switch 2 Day Selection 1..2, 1-5, 1-7 1-7
P21* Heating Circuit 2 Time Switch 2 First On 00:00 - 24:00 ---
P22* Heating Circuit 2 Time Switch 2 First Off 00:00 - 24:00 ---
P23* Heating Circuit 2 Time Switch 2 Second On 00:00 - 24:00 ---
P24* Heating Circuit 2 Time Switch 2 Second Off 00:00 - 24:00 ---
P25* Heating Circuit 2 Time Switch 2 Third On 00:00 - 24:00 ---
P26* Heating Circuit 2 Time Switch 2 Third Off 00:00 - 24:00 ---
Time Switch 3 HWS Set Points
(**QAZ36 HWS Sensor Required)
P30** Time Switch 3 Day Selection 1..2, 1-5, 1-7 1-7
P31** Time Switch 3 First On 00:00 - 24:00 ---
P32** Time Switch 3 First Off 00:00 - 24:00 ---
P33** Time Switch 3 Second On 00:00 - 24:00 ---
P34** Time Switch 3 Second Off 00:00 - 24:00 ---
P35** Time Switch 3 Third On 00:00 - 24:00 ---
P36** Time Switch 3 Third Off 00:00 - 24:00 ---
General Functions
P45 Default Reset of Time Switch Setting 0 / 1 0
P516 Summer / Winter Changeover Temperatures 8….30 20
P727 Detailed Diagnostic Code English ………. English

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Level Two Engineer Parameters
# Description Range
16 & 27 H
(16 & 27 HS)
27 S
[47 S] 45,75,77 H
75 & 77 HM
{Cascade Slave
Boilers}
H90 Reduced Temperature for DHW 8….60 10 10 10 10
H91 DHW Production Control
(0=Time control 1=Constant)
0…1 0 1 0 0
H93 DHW Production Control 0=Non Eco 1=Eco 0…1 0 0 0 0
H94
DHW Secondary Pump Control
(0= As H91. 1= As HWS Time Switch)
(K2, X2:03, H615:6)
0…1 0 0 0 0
H503
Minimum boiler setpoint temperature
(20 °C<=TkSmin<=TkSmax)
20 ... 90 °C 20 20 20 20
H504 Maximum boiler setpoint temperature
(TkSmin<=TkSmax<=90 °C)
20 ... 90 °C 90 90 90 90
H505 Boiler setpoint at design outside temperature 20 ... 90 °C 85 85 85 85
H506 Minimum flow setpoint temperature
(20 °C<=TvSmin<=TvSmax)
20 ... 90 °C 25 25 25 25
H507 Maximum flow setpoint temperature
(TvSmin<=TvSmax<=90 °C)
20 ... 90 °C 90 90 90 90
H516 Summer / winter changeover temperature
(30 °C: S / W changeover deactivated)
8 ... 30 °C 18 18 18 18
H532 Heating curve slope heating circuit 1 1 ... 40 32 32 32 32
H533 Heating curve slope heating circuit 2 1 ... 40 1 1 1 1
H536 Maximum speed at maximum output in heating
mode (maximum speed limitation)
0 ... 9950 rpm
5000 5000
[7000] 7000 7000
H541
Maximum degree of modulation in heating
mode
(LmodTL <= PhzMax <= LmodVL
)
0 ... 100 % 65 65
[100] 100 100
H542 Minimum boiler output in kW
(lower calorific value)
0 ... 9999 kW
6 6
[15] 15 15
H543 Maximum boiler output in kW
(lower calorific value)
0 ... 9999 kW
25 25
[75] 75 75
H544 Overrun time of pumps, max. 210 min
(setting 255: continuous operation of Q1)
0 ... 255 min 10 10 10 10
H545 Minimum burner pause time
(heat demand-dependent switching hysteresis)
0 ... 3600 s 300 300 300 300
H551 Constant for quick setback without room
influence 0 ... 20 2 2 2 2
H552 Hydraulic system adjustment 0 ... 255 67 70 66 80
554
Setting flags: status code open-circuit sensor
for ANx channel suppressed / not suppressed 0 ... 255
b0=1
b1=0
b2=1
b3=1
b4=0
b5=1
b6=0
b7=0
b0=1
b1=0
b2=1
b3=1
b4=0
b5=1
b6=0
b7=0
b0=1
b1=0
b2=1
b3=1
b4=0
b5=1
b6=0
b7=0
b0=1
b1=0
b2=1
b3=1
b4=0
b5=1
b6=0
b7=0

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#
Description Range
16 & 27 H
(16 & 27 HS)
27 S
[47 S] 45,75,77 H
75 & 77 HM
{Cascade Slave
Boilers}
H555 Setting flags 0 ... 255
b0=0
b1=0
b2=0
b3=0
b4=1
b5=0
b6=0
b7=0
b0=0
b1=0
b2=0
b3=0
b4=1
b5=0
b6=0
b7=0
b0=0
b1=0
b2=0
b3=0
b4=1
b5=0
b6=0
b7=0
b0=0
b1=0
b2=0
b3=0
b4=1
b5=0
b6=0
b7=0
H558 Setting flags 0 ... 255
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=1
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=1
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=1
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=1
b7=0
H596 Running time of actuator in heating circuit 2
(TimeOpening / TimeClosing)
30 ... 873 s 150 150 150 150
H605 LPB device number of LMU (HM or Master Boiler 2 then Slave units 3…12) 0 ... 16* 1112
{3…12}
H606 LPB segment number of LMU 0 ... 14 0 0 0 0
H614 Program input LMU basis 0 ... 255 3 3 3 3
H615 Function programmable output K2 LMU 0 ... 255 0 0 0 0
H618 Progr input on clip-in function module 0 ... 255 0 0 0 0
H619 Function output1 clip-in function module 0 ... 255 0 0 0 0
H620 Function output2 clip-in function module 0 ... 255 0 0 0 0
H621 Function output3 clip-in function module 0 ... 255 0 0 0 0
H622
Maximum value of heat demand with
external predefined temperature setpoint
(5 °C< = TAnfoExtMax< = 130 °C)
5 ... 130 °C 85 85 85 85
H630 Setting flags of maintenance alarms 0 ... 255
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=0
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=0
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=0
b7=0
b0=1
b1=0
b2=0
b3=0
b4=0
b5=0
b6=0
b7=0
H636 Months (interval) since last service visit 0 ... 255
months 0 0 0 0
H700 1st Historical Fault – Number of Occurrences.
H701 1st Historical Fault – Operating Phase.
H702 1st Historical Fault – Operating Error Code
H703 2nd Historical Fault – Number of Occurrences.

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#
Description Range
16 & 27 H
(16 & 27 HS)
27 S
[47 S] 45,75,77 H
75 & 77 HM
{Cascade Slave
Boilers}
H704 2nd Historical Fault – Operating Phase.
H705 2nd Historical Fault – Operating Error Code
H706 3rd Historical Fault – Number of Occurrences.
H707 3rd Historical Fault – Operating Phase.
H708 3rd Historical Fault – Operating Error Code
H709 4th Historical Fault – Number of Occurrences.
H710 4th Historical Fault – Operating Phase.
H711 4th Historical Fault – Operating Error Code
H712 5th Historical Fault – Number of Occurrences.
H713 5th Historical Fault – Operating Phase.
H714 5th Historical Fault – Operating Error Code
H715 Current Historical Fault – Number of
Occurrences
H716 Current Historical Fault – Operating Phase.
H717 Current Historical Fault – Operating Error Code
H718 Hours run burner 0 ... 131070 hrs
0 0 0 0
H719 Hours run heating mode 0 ... 131070 hrs
0 0 0 0
H720 Hours run DHW heating 0 ... 131070 hrs
0 0 0 0
H721 Hours run zone 0 ... 131070 hrs
0 0 0 0
H722 Start counter 0 ... 327675 0 0 0 0
H727 Current Fault Code – ALBATROS Error Code 0 ... 583
H728 1st Historical Fault – ALBATROS Error Code
H729 2nd Historical Fault – ALBATROS Error Code
H730 3rd Historical Fault – ALBATROS Error Code
H731 4th Historical Fault – ALBATROS Error Code
H732 5th Historical Fault – ALBATROS Error Code
H732 Current Historical Fault – ALBATROS Error Code
H755 Measured value of ionization current -