Varmeteknikk MB 35 Operation manual

Installation - operating - servicing
MB – boilers
35 – 45 – 60 – 75 – 90
105 - 120 - 140 -150kW

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T e c h n i c a l d a t a
Model
MB 35
MB 45
MB 60
MB 75
MB 90
Power 35kW 45kW 0kW 75kW 90kW
Nominal supply voltage
Power circuit 3 x 400V 3 x 400V 3 x 400V 3 x 400V 3 x 400V
Control circuit 1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
Amps 51A 5A 87A 108A 130A
Number of elements 4 4 7 7 7
Temp.controller (steps) 7 7 7 7 7
Temp. range 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C
Water contents (liters) 75 75 75 75 75
Tube connections
Outlet/inlet DN 5/1 DN 5/1 DN 5/1 DN 5/1 DN 5/1
Expansion/drain 1" 1" 1" 1" 1"
Water circulation Δt=20 °C
(m³/h) 1,5 1,9 2, 3,2 3,9
Pressure drop(Wc) 2 3 5 7 10
Water speed(m/s) 0,11 0,14 0,19 0,23 0,28
Max. working pressure bar bar bar bar bar
Min. working pressure 1bar 1bar 1bar 1bar 1bar
Dime
nsions size
cm)
Height 128 128 128 128 128
Width 38 38 38 38 38
Depth 9 9 9 9 9
Weight empty, (kg) 130 130 135 135 140

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T e c h n i c a l d a t a
Model
MB 105
MB 120
MB 140
MB 150
Power 105kW 120kW 140kW 150kW
Nominal supply voltage
Power circuit 3 x 400V 3 x 400V 3 x 400V 3 x 400V
Control circuit 1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
1 x 230V
50/ 0Hz
Amps 152A 173A 202A 217A
Number of elements 7 7 7 8
Temp.controller (steps) 7 7 7 7
Temp. range 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C
Water contents (liters) 75 75 75 75
Tube connections
Outlet/inlet DN 5/1 DN 5/1 DN 5/1 DN 5/1
Expansion/drain 1" 1" 1" 1"
Water circulation Δt=20 °C
(m³/h) 4,5 5,2 ,0 ,5
Pressure drop(Wc) 14 18 24 28
Water speed(m/s) 0,33 0,37 0,43 0,47
Max. working pressure bar bar bar bar
Min. working pressure 1bar 1bar 1bar 1bar
Dimensions(cm)
Height 128 128 128 128
Width 38 38 38 38
Depth 9 9 9 9
Weight empty, (kg) 145 150 150 155

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MB 35 - 150kW
5 0
6 0
NB! Fri høyde over kjel,
ca. 100cm
1
2
3
4
5
6
7
8
10
1. Temp. controller
2. Safety temp .limiter
3. ON/OFF –switch
4. Contactors
5. F ses/circ it breakers
6. B s bars for connecting
S pply cables
7. Drain
8. Ret rn
9. Flow
10. Expansion

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Technical data 2
General information
Installation 6
Pressure safety valve 6
onnection 6
ontrol voltage 6
Commissioning
Start up 7
Temperature controller 7
Settings 8
Additional functions 9
Remote control
Boiler Start/stop 10
Temperature control 10
Power control 10
Monitoring
Operation signal 11
Failure signal 11
Output signals 0-10V 11
Terminal block 11
Menus 12
Maintenance 13
Troubleshooting 14
Circuit diagrams
ontrol circuit 15
Power circuit 16
Temp. controller
Terminals 17
Spare parts 18
Content

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Installation
THE BOILER MUST BE POSITIONED IN SUCH A WAY THAT IT DOES NOT PREVENT
PER ORMANCE O SERVICE AND MAINTENANCE.
Required free height a ove the oiler for disassem ly of heating elements is 1m. Front and at least
one side should e free in order to perform service and maintenance.
Pressure safety valves
The oiler must e equipped with pressure safety valves. The pressure safety valves should
e placed as close as possi le to oiler and it should not e any shutoff etween the valves
and the vessel. The opening pressure must not exceed maximum operating pressure of the
oiler. To avoid damage a pipe pointing down towards the floor, should e fixed to the pressure
safety valves.
Connection
NOTE! INSTALLATION MUST ONLY BE EXECUTED BY QUALI IED PERSONNEL
All applicable regulations must be observed when electrical and plumbing connections.
Sufficient provision must be made for expansion, in accordance with applicable regulations
Supply cables
Connect supply ca les to the us ars y using a ring terminal or suita le ca le clamps.
Two earth clamps is located in ottom of the switch gear for earth ca les.
Control voltage
220-230V control voltage is required. Connection to e done on F1 & F2 on the terminal lock
inside the oiler. See page 11.
E x p a n s io n
F lo w
R e tu r n
D ra in
C o n n e c ti ng
m a in p o w e r
C o n n e c ti ng
contro l v o lta g e
A9 5-3 0A9 5-3 0
Liftin g hoo k

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Commissioning
Note! BEFORE SWITCHING ON THE BOILER CHECK THE FOLLOWING:
- Check that the water system is completely fille with water. To prevent heating element break
own make sure there is no air pockets in plant.
- Switch on circulating pump an check water flow an irection.
- Hy raulic expansion system has to be controlle . Min. pressure, 1bar.
- Check for correct supply voltage
Note! Be ore start up, retighten all electrical connections.
This appliance is not intended or use by persons (including children) with reduced physical,
sensory or mental capabilities or lack o experience and knowledge, unless they have been
given supervision or instruction concerning use o the appliance by a person responsible or
their sa ety.
Children should be supervised to ensure that they do not play with the appliance.
Start up
Switch on the boiler by using the ON/Off-switch on the front panel. Display will after a few secon s
show actual water temp., preset temp. in brackets. The line below shows connecte power. Boiler
will now step by step increase power to obtain preset temperature.
The temperature is factory set at 80 °C, an step time is set to 40 sec. Unless corrections of preset
temperature or step time are require , no further a justments are nee e .
Note! I boiler is controlled by external signals, missing signal can prevent boiler rom
running.
Temperature controller
The boiler is equippe with a 7-steps electronic temperature controller locate in front of the boiler.
All settings can be one at the front. The controller has a proportional an integrating control an is
esigne to maintain constant boiler temperature. Temperature range is from 5 - 95°C in steps by
1 °C. 3 relays control the power contactors which are connecte in a binary or er. This gives a high
egree of reliability
If a failure occurs, an alarm io e starts flashing. Type of failure will be shown in isplay an coul
be:
Don’t switch on the boiler i there is a possibility that the
water in boiler
is rozen.
rozen

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Error temp: Temperature sensor is broken
Alarm net: Control voltage < 190
Alarm power: Power supply missing*
* Alarm power is activated if controller when reaching step 3, doesn’t measure any power. The
reason for this could be that main switch/circuit breaker on the switch board is OFF, security
temp. limiter (STB) released because of high temperature, heating element/fuse is broken, or
contactor is not connected.
Settings
Failure Menu button Enter button
Preset temperature:
Temperature range is from 30 – 95 °C. Preset temperature is factory set to 80 °C. If correction is
needed do the following:
Press + or – button to set desired temperature. Then press enter to save new value.
Step time:
Step time is adjustable between 20-250 sec. (factory setting is 40 sec.) and refer to connection of
power steps. When disconnecting power, step time is 5 sec. with step time below 60 sec., 10 sec
with step time above 60 sec. If correction is required do the following: Press menu button once to
enter step limitation mode. Then press + or – button. To enter step time mode press menu button.
With +/- button choose desired step time. Press E button to save new value.
Step 0( 7)
Step time 40s ► Step lim 0( 7
)
Step time 40s
Step lim 0( 7)
Step time 40s ►
Step 0( 7)
Step time 50s
To return to temp/power mode, press menu button.

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Additional functions
The temp. controller has been provided ith a large number of other functions in addition to
several possibilities for remote control.
Remote boiler in/out
The temp. controller is equipped ith a potential free input for start/stop of the boiler. The
disconnecting signal can be either an “OFF” or an “ON” s itch. With a clamp on the PCB the
temp. controller can be adjusted to either type of signal (see page 30). If start signal is missing
display sho s:
Step S 0 ( 0)
Step time 40s
See page 11 for connecting start/stop signal.
Po er limitation
The maximum output of the boiler can easily be limited. It is only possible to limit the boiler on a hole
step base. Limitation can be done in the menu or on a potentiometer located on the PCB.
Limitation in menu:
Enter Step mode and press – button. Choose number of po er steps and then press E button to save
ne value.
Step lim 0(30
)
Step time 40s ►
Step lim 0(25)
Step time 40s
For limitation on the PCB, see page 17
Outdoor temperature compensator
The temp. controller is prepared for outdoor temperature compensation. If outdoor sensor is connected,
boiler ill calculate and set flo temperature depending on outdoor temperature. Both curve and
parallel are available for fine-tuning flo temperature. When outdoor sensor is connected, display
sho s:
TempU 47.0 (50)°C
Po er 60kW
Temperature in brackets is calculated flo temperature depending on outdoor temperature. It is
not possible to change calculated temperature hen outdoor sensor is connected.
Outdoor t. 24°C
Parallel 0°C
For further information, contact Varmeteknikk.

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Remote control by external signals
The boiler offers several possibilities for remote control. With a start/stop signal (potential free),
boiler can be connected/disconnected from running. Maximum output or preset temperature
can be controlled by a 0-10V DC signal.
Remote start/stop of boiler
Boiler can be s itched On/Off by an external signal. Before connecting signal, remove bridge on
terminal 1 & 2, see next page. If start/stop-signal is connected and boiler gets start signal, display
sho s:
Temp 47.0 (75 °C
Step 0 (30
Temperature control by 0-10V signal
Desired temperature can be controlled by a 0-10V DC signal. 0V = 20°C, 10 V = 120C°. Normal
temp. range is from 20 – 95°C, equivalent to 0 - 8,5V. Connection on terminal 30(-) and 31( +)
on PCB (see page 17). Signal must be activated in service menu, see page 12. "Temp IN" must
be set in ”ON” position. Press + button t ice and then E to enter ne value.
Temp IN
ON
Press menu button t ice to return to "Temp/Power" mode. When signal is activated display
sho s:
TempE 47.0(75 °C
Power 60kW
Note! When desired boiler temperature is controlled by a external 0-10V signal, internal set point
must be set as high as boiler should ork. Internal thermostat is no orking as a maximum
thermostat and limit the temperature. This must be done before signal is activaded.
Power control by 0-10V signal
Boiler output can be controlled by a 0 -10V DC signal. 0V = 0 step, 10V = all steps (15/30). Con-
nection on terminal 29(+) and 30(-) on PCB (see page 17). Signal must be activated in service
menu, see page 12. "Power IN" must be set in "ON" position. Press + button t ice and then
E to enter ne value.
Power IN
ON
Press menu button t ice to return to "Temp/Power" mode. When signal is activated display
sho s:
StepE 3 ( 7
Step time 40s
Temp 47.0 (75 °C
Step S 0 ( 0
If start signal is missing,
display sho s:

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Monitoring
Boiler is prepared for output digital signals to a central monitoring system. The signal contacts
are ired to a terminal block inside the boiler. The outlet signals are:
Operation signal: indicates boiler is ON connection on terminal 3 & 4.
Failure: indicates STB released, sensor broken or control voltage < 190V. Connection
on terminal 5 & 6. Type of error is sho n in display.
Output 0-10V DC signals:
External po er indication: 0V = 0kW, 10V = Max kW (terminal 36 & 39)
External temp.indication: 0V = 20 °C, 10V = 120°C (terminal 36 & 38)
External preset temperature: 0V = 20 °C, 10V = 120°C (terminal 36 & 37)
Connection diagram, see page 17.
Terminal block inside boiler
2
6
8
7
9
5
4
3
F2
F1 F1
F2
1
Transformer
Control voltage
On/off ext.
230V 50Hz, 10A
Styrespenning
Inn-/utkobling
Failure
6
8
9
7
Trafo
3
5
4
1
2
L2
L1
Operation
Driftsignal
Feilsignal

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Menus
By pressing menu button, different modes appears
Start up:
EL 7 v0549
El 15: 7-steps controller
v0549: version
Main menu
Temp 60.0(80) C
Power 120kW
Step
1( 7)+
Step time 40s
Outdoor t.
-
15 C
Parallel 0 C
(appears only if outdoor sensor is
connected)
Settings in main menu:
- Desired temperature
- Number of po er steps
- Step time
Service menu
To get access to service menu,
press and hold menu button for
more than 5sec.
Temp 60.0(80) C
Power 120kW
Curre
nt lim
0,0(5,0)A
Current marg
1,0A
Power
factor
60kW/A
Curve 40 C
Curve min 20 C
(Appears only if outdoor sensor
is connected)
Test contactor 0
K1-4 0000 A1
Step time
Service 0
Power
IN
OFF
Temp IN
OFF
English
Node 0 Net 107

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Maintenance
NOTE!
BEFORE SERVICE AND MAINTENANCE, BE SURE SUPPLY CABLES ARE DEAD.
Always use an appropriate voltage detector to verify t at t ere is no voltage present.
After boiler as been in operation for some time, retig ten electrical connections. To prevent
breakdown, boiler s ould be c ecked annually. T is c eck s ould contain t e following points:
- Leakage control
Make a visual inspection of t e boiler c ecking for signs of water leakage. Remove top cover
and c eck on top of t e pressure vessel for leakage from eating elements.
- Power checking
C eck if circuit breakers ave tripped. C eck by resistance measurement if any eating elements
are broken.
- Contactors
C eck all individual contactors if t ey are in normal position. Undertake a visual inspection of
all wiring to t e contactors and c eck for signs of over eating or burning. Any noise from con-
tactor indicates wear and requires a t oroug c eck. Be aware t at burnt contactors may cause
major damage.
- Electrical connections
Retig ten all electrical connections on fuse olders, contactors and eating elements.
- Temp.controller
C eck if temp.controller connect or disconnect power steps w en adjusting preset temp. up and
down. By entering service menu connection of power groups/contactors can be c ecked.
- Safety temp.limiter
C eck safety temp.limiter. T is can be done by switc ing off circulation pump or close valves.
T e boiler will t en soon reac release temp. Safety temp. limiter must be manually reset.
Note!
SERVICE AND MAINTENANCE SHOULD ONLY BE CARRIED OUT BY QALIFIED PERSONNEL
Tig tening torques for contactors:
Contactor, type Connection screw Tig tening torque
AF9, AF12, AF 16 M3,5 1,5Nm
AF26, AF30, AF 38 M4 2,5Nm
AF40, AF52, AF 65 M6 4Nm
Tig tening torques for circuit breakers:
type Connection screw Tig tening torque
MS132/10 M3,5 1,2Nm
MS132/12 - 16 M4 1,5Nm
MS132/20 - 32 M4 2Nm
XT1 M6 6Nm
Tig tening torque for eating element: M4 - 1,2Nm
M12 - 15Nm

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Troubleshooting
NOTE! TROUBLESHOOTING MUST ONLY BE EXECUTED BY QUALIFIED PERSONNEL
FAILURE DISPLAY TEXT
POSSIBLE CAUSE OF TROUBLE
CONTROL /REPAIR
BOILER
”dead”
Control voltage missing Boiler needs separate
control voltage
Fuse s for control voltage broken Check fuses and replace if
required
NO POWER
Temp 30.0 (80) C
StepS 0 ( 0) External start signal missing Check external signal. (See
terminal 1& 2 on –X1)
Temp 30.0 (80) C
StepE 0 ( 0) External signal for power control
missing
Check external signal
TempE 20.0 (20) C
Power 0kW
External signal for temperature
control missing
Check external signal
Temp 0.0 (80) C
Error Temp Defect temp.sensor
Change temp.sensor and
Replace if required
BOILER
STOPS AT
STEP 3
(Alarm diode is
flashing)
Temp 30.0 (80) C
Alarm Power
Connecting box mounted on left
side without moving transformer
Transformer must be
mounted on same side as
connecting box
Temp 30.0 (80) C
Alarm Power
Safety temp.limiter has tripped Reset safety temp.limiter
(STB) on front panel
Temp 30.0 (80) C
Alarm Power
Main switch off or broken fuses Check switch board fuses
Replace if required
LITTLE HEAT
FROM BOILER
Temp 50.0 (80) C
Step 4 ( 4)
Maximum power limited
from outside
Check external signals from
a central monitoring system
TempU 30.0 (30) C
Power 0kW
Check if boiler is limited from
outdoor compensator
Check curves for outdoor
compensation
Defect heating elements,
fuses, contactors
Check heating elements,
fuses, contactors and
replace if required
STB, safety
temp.limiter
released
(Display shows
"Alarm Power")
Temp 30.0 (80) C
Alarm Power circulation in boiler Check pump valves
Burned contactor
Check contactors and
replace if required
LEAKAGE
Loose screws for heating element Tighten screws
Gasket for heating element Replace if required
Defect heating element Replace if required

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Circuit diagram MB 35 - 150kW

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Power circuit MB 35-150kW
Apparatplate
400V
MB 105kW 120kW 140kW
Apparatplate
400V
MB 60kW 75kW 90kW
Apparatplate
400V
MB 35kW 45kW
-E1
-E2 -E3
-E4
-E1
-E2
-E3
-E4
-E5
-E6
-E7
-E1
-E2
-E3
-E4
-E5
-E6
-E7
Apparatplate
400V
MB 150kW
-E1
-E2
-E3
-E4
-E5
-E6
-E7
-E8
Switch gear
Switch gear
Switch gear
Switch gear

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Temp.controller, terminals

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Spare parts MB 35 – 150kW
Number
Item
Article no.
35kW
45kW
60kW
75kW
90kW
105kW
120kW
140kW
150kW
Heating element 5kW 6613 0001- 1
Heating element 6kW 6613 0001-P 1
Heating element 7,5kW 6613 0001-AR 2
Heating element 9kW 6613 0001-N 5 1
Heating element 10kW 6672 0242-A 3 3 3 1
Heating element 12kW 6613 0001-G 2 3
Heating element 15kW 6672 0242-D 1 4 7 4
Heating element 20kW 6672 0242-G 3 7 7
Gasket 2152 0022-4 4 4 7 7 7 7 7 7 8
Temp.controller 7-steps 901 310 1 1 1 1 1 1 1 1 1
Sensor temp.controller 200 232 1 1 1 1 1 1 1 1 1
ON/OFF-switch 6672 0235-3 1 1 1 1 1 1 1 1 1
Safety temp.limiter (STB) 6672 0235-1 1 1 1 1 1 1 1 1 1
230V
400V
230V
400V
230V
400V
230V
400V
230V
400V
230V
400V
230V
400V
230V
400V
230V
400V
Contactor AF12 41 175 16 1 1
Contactor AF16 41 175 32 1 1 1 1 1 1
Contactor AF26 41 175 48 3 1 3 1 2 3 1 3 4 1 1 1 1 2
Contactor AF30 41 175 56 1 1 1 3 1
Contactor A50 41 147 56 1 3 2 3 3 3 3 3
Contactor A63 41 148 16 3
Contactor A75 41 148 46 3
Contactor A95 41 149 36 2
Contactor A110 41 150 26 2 2
Fuse control voltage 10A 6672 0235-27 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Circuit breaker MS132/10-16 43 640 80 1 2 1 1 1 1
Circuit breaker MS132/16-20 43 640 81 1
Circuit breaker MS132/20/25 43 640 82 1 1 1 1 1
Circuit breaker MS132/25-32 43 640 83 1 1 1 1 1
Circuit breaker XT1-32 067 411
Circuit breaker XT1-40 067 412 1 1 1 1 1
Circuit breaker XT1-50 067 413 1 1 1 3 1
Circuit breaker XT1-63 067 414 1 1 1 3 1 3 3
Circuit breaker XT1-80 067 415 1 1 1 3 1
Circuit breaker XT1-100 067 416 1 3
Circuit breaker XT1-125 067 417 1 3 3
Circuit breaker XT1-160 067 418 1
Transformer Natek 200 018 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Transformer 100/5A 6672 0235-50 1 1 1 1
Transformer 200/5A 6672 0235-51 1 1 1 1 1 1 1 1
Transformer 300/5A 6672 0235-53 1 1 1
Transformer 400/5A 6672 0235-54 1 1 1
Spare parts valid from 29
.2015