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RVR Energy Technology MICROMAT EC 45 Instruction For Usage, Installation & Commissioning

Wall mounted ultra high efficiency gas boilers 45kw, 62kw, 76kw
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Summary of Contents for RVR Energy Technology MICROMAT EC 45

  • Page 3 index Page Section User Instructions General Notes Product Description Product Description (contd) Technical Data & Dimensions Delivery Consignment/Unpacking The Boiler Boiler Location Installation Clearances Wall Mounting Gas Connection Gas Conversion 10.0 System Flow & Return Connections 11.0 Condensate Connection 11.0 Condensate Connection (contd) 12.0 Flue Combustion Air Connection - General...

  • Page 4: User Instructions

    1.0 user instructions for the micromat boiler appliance Boiler Switch Panel ECO/ECO ON/OFF Display Water Pressure Plus Switch Switch RESET Button ENGINEERS TEST Button Button Before operating the boiler: Check that the boiler has been installed in strict accordance with the instructions contained in this manual. Non compliance with the instructions may result in injury and/or damage to property.

  • Page 5: Test Button

    1.0 user instructions for the micromat boiler appliance Functions of the Control Panel Buttons and Dials Reset Button This button has two functions 1. Resetting of fault conditions: - When the display text is flashing on and off, a boiler fault is indicated. The type of fault is displayed on the screen.

  • Page 6: General Notes

    2.0 general notes These instructions are intended to assist the installer, commissioning engineer, maintenance engineer and user with the installation, maintenance and usage of MICROMAT EC,45, 62 and 76 models gas fired condensing boilers. Please read this manual fully before commencing the installation of the appliance. The MICROMAT EC must only be installed by persons deemed to be competent.

  • Page 7: Energy Saving

    3.0 product description energy saving In addition to the extremely efficient burner and heat exchanger system employed in the MICROMAT EC each appliance includes a modulating speed boiler primary pump. This feature allows the boiler to self-maintain a 20°C ∆t across the heat exchanger, optimising the heat exchanger efficiency and reducing also the electrical consumption of the pump motors.
  • Page 8 4.0 technical data & dimensions MODEL MICROMAT EC Nominal Heat Input Nett (max) Nominal Heat Output 80/60°C 41.3 55.8 70.6 Nominal Heat Output 50/30°C 45.2 60.4 76.0 m 3 /h Input Rate Nat Gas (max) 6.01 Minimum/Maximum Gas Pressure mbar 15/60 15/60 15/60...

  • Page 9: Unpacking The Boiler

    5.0 delivery consignment unpacking the boiler The boiler is delivered as a consignment of a carton containing the boiler and associated fittings, plus any other optional ancillary flue or control components in separate cartons. The boiler carton contains • Assembled Boiler •...

  • Page 10: Wall Mounting

    8.0 wall mounting The MICROMAT EC boiler mounts to the wall via a wall mounting bracket which interlocks to a rail on the rear of the boiler. The wall mounting bracket should be firmly fixed to the wall using suitable fixings with a countersunk head.

  • Page 11: Gas Conversion

    • Re-tighten the flange joint. Do not forget the O-rings. • Check for Leakage. • On the MICROMAT EC 45 H/62 H/76 H, when converting to LPG, the front bore on both gas/air mixing chambers must be closed using the black ø10mm plugs supplied in the conversion kit.

  • Page 12: Condensate Connection

    10.0 system flow & return connections Note The MICROMAT EC boiler must only be installed on sealed and pressurised systems. The maximum working pressure of the boiler = 3 bar. A safety valve set to 3.0 bar is supplied with the boiler and must be installed onto the flow pipe adjacent to the boiler.

  • Page 13: Multiple Boilers

    11.0 condensate connection If any part of the condensate pipe is to be run external to the building or is at risk of freezing, then the pipe must be suitably insulated to protect from freezing. If a suitable drain for accepting the condensate is not available nearby to, and below the boiler (e.g. boiler installed in a basement below ground level location), then a suitable condensate sump receptacle with a discharge pump should be installed below the boiler to remove the condensate to a remote drain.

  • Page 14: Flue Systems

    13.0 flue systems The MICROMAT EC has an excess pressure combustion system that allows the appliance to be exhausted over extended distances using small OD flue components. The flue gas temperature is extremely low (typically the same as the flow water temperature), which allows the use of easy to install PPS (polypropylene) flue pipe and fittings.
  • Page 15 13.0 flue systems Flue System Option No. 2 Vertical Balanced Flue System Using this system the air for combustion and the flue products are piped vertically to/from outside the space. The balanced flue may exit through both flat and pitched roofs. Suitable flashings are available for either case. The following components and options are available from RVR Limited: •70/125 concentric roof terminal set, complete with concentric pipes and terminal.
  • Page 16 13.0 flue systems 70mm Ø Grey PPS Pipe 250mm long Order Code 70mm Ø Grey SBA057 PPS Pipe 500mm long Order Code SBA058 70mm Ø Grey PPS Pipe 250mm long Order Code SBA059 Flue Products Sampling Tee Order Code SBA052 70mm Ø...
  • Page 17 14.0 calculating flue resistance The excess pressure available for overcoming the frictional resistance of a flue system is 100 Pa. The adjacent table of flue component resistances will assist the designer in calculating total flue system frictional loss. If the total installed flue system resistance exceeds 100 Pa., then the result will be a reduction in boiler output. Reference to the ‘Effect of Flue System Resistance On Boiler Output”, graphs will assist.

  • Page 18: Calculating Flue Resistance

    2 A MICROMAT EC 45 boiler is installed with a concentric flue system which takes a part horizontal, part vertical route to a roof terminal with rain cap.

  • Page 19: Flue Terminal Positions

    14.0 calculating flue resistance Minimum dimensions of flue terminal positions see fig 19 below. Dimension Terminal Position Balanced flue room sealed (mm) Non room sealed (mm) Directly below an opening, 300mm 300mm air brick, windows etc. Not Recommended. Below gutters, soil pipes or 75mm 75mm drain pipes...

  • Page 20: Ventilation Requirements

    Room Installation - Non Room Sealed Flue. Natural Ventilation Direct to Outside Air Boiler Model Ventilation Openings Free Area cm High Level Low Level MICROMAT EC 45 Position Not Dictated MICROMAT EC 62 MICROMAT EC 76 Table 2 Room Installation - Non Room Sealed Flue.
  • Page 21 Boiler Model Ventilation Openings Free Area cm High Level Low Level MICROMAT EC 45 With adjacent room ventilated at 196 cm direct to outside air. MICROMAT EC 62 & 76 Ventilation from adjacent room not permitted see table 4 for ventilation area direct to outside air.
  • Page 22 16.0 hydraulic system design The MICROMAT EC boiler can be operated to serve a heating load in a number of ways: 1. Constant flow temperature, with the option to set either high temperature (85°C), medium temperature (75°C) or low temperature (55°C). 2.

  • Page 23: Hydraulic System

    16.0 hydraulic system design system type 1 Typical Single MICROMAT EC boiler installation serving heating only where the boiler's own in-built circulating pumps are used to circulate the water around the system (used only where system index resistance <1 metre). Flow temperature may be fixed/constant or weather variable. AV's Micromat EC Boiler...

  • Page 24: System Type 2

    16.0 hydraulic system design system type 2 Typical Single MICROMAT EC boiler installation serving domestic hot water and heating where hot water has priority via a divertor valve. The in-built circulating pumps within the boiler are used to circulate the system (used only where system index resistance <1 metre).

  • Page 25: System Type 3

    16.0 hydraulic system design system type 3 Typical Single MICROMAT EC boiler installation serving heating only and using a low velocity mixing header where system index resistance exceeds 1 metre. Flow temperature may be fixed/constant or weather variable. AV's Micromat EC boiler PRO 1 Safety Valve...

  • Page 26: System Type 4

    16.0 hydraulic system design system type 4 Typical Single MICROMAT EC boiler installation serving heating & domestic hot water. Hot water is priority and is served via a divertor valve and the boiler's in built circulating pump where index loss through HWS primaries is less than 1 metre.

  • Page 27: System Type 5

    16.0 hydraulic system design system type 5 Typical Single MICROMAT EC boiler installation serving heating & domestic hot water with hot water priority. Hotwater & heating circuits both have index resistance exceeding 1 metre & are served by independent pumps from a low velocity mixing header. Heating flow temperature may be fixed/constant or weather variable. AV's Micromat EC Boiler...

  • Page 28: System Type 6

    16.0 hydraulic system design system type 6 Typical Multiple MICROMAT EC installation. Boilers controlled by modulating Kaskade manager which also has the facility to control heating & domestic hot water production. Heating flow temperature may be fixed/constant or weather variable. Hot water has priority. KKM 2 AV's Micromat...
  • Page 29 16.0 hydraulic system design system type 7 Typical Single MICROMAT EC boiler installation serving domestic hot water and radiator heating zone and an underfloor coil zone all via a low velocity mixing header. The HWS will always have priority. The 2Nr heating zones may operate independently via 2 Nr separate room units.

  • Page 30: System Type 8

    16.0 hydraulic system design system type 8 Typical Single MICROMAT EC boiler installation serving heating and domestic hotwater via a system pump and 2Nr 2Port motorised valves with conventional controls i.e. programmer, room stat & cylinder stat. NOTE: system temperature will be fixed constant and direct-on-boiler weather compensation is not possible. AV's Micromat EC Boiler...

  • Page 31: Electrical Connection

    16.1 water treatment system cleaning The entire system must be thoroughly cleansed and flushed to remove debris, flux residues etc before opening the boiler isolation valves & flooding the boiler. Particular care must be taken where the MICROMAT EC boiler is being retro-fitted into an old/existing system, as system silt or magenite can be very damaging to the new boiler.
  • Page 32 17.0 electrical connections plan of internal electrical connections Ltd. E n e r g y T e c h n o l o g y...
  • Page 33 17.0 electrical connections Typical electrical connection schematic to suit system type 1 Ltd. E n e r g y T e c h n o l o g y...
  • Page 34 17.0 electrical connections Typical electrical connection schematic to suit system type 2 Ltd. E n e r g y T e c h n o l o g y...
  • Page 35 17.0 electrical connections Typical electrical connection schematic to suit system type 3 Ltd. E n e r g y T e c h n o l o g y...
  • Page 36 17.0 electrical connections Typical electrical connection schematic to suit system type 4 Ltd. E n e r g y T e c h n o l o g y...
  • Page 37 17.0 electrical connections Typical electrical connection schematic to suit system type 5 Ltd. E n e r g y T e c h n o l o g y...
  • Page 38 17.0 electrical connections Typical electrical connection schematic to suit system type 6 Ltd. E n e r g y T e c h n o l o g y...
  • Page 39 17.0 electrical connections Typical electrical connection schematic to suit system type 7 Ltd. E n e r g y T e c h n o l o g y...
  • Page 40 17.0 electrical connections Typical electrical connection schematic to suit system type 8 = Weiland Plugs / Sockets = Control sockets on control panel. Not Used Boiler Dip Switch Settings Junction Box HW M/V & CH M/V = Typical spring return L N P System Pump type motorised valves...

  • Page 41: Electrical Connections

    17.0 electrical connections Remote Fault Indication The MICROMAT EC boiler includes a built in fault alarm relay with volt free contacts for interface with, if required a remote alarm indicator. The volt free contacts within the boiler control panel will close in the event that the boiler goes to a fault resulting in boiler lockout.

  • Page 42: Dip Switch Settings

    18.1 pre-commissioning checks a) Ensure system has been thoroughly cleansed and flushed, any strainers have been cleaned and that the appropriate water treatment has been added to the system to prevent corrosion, scale formation etc. b) Ensure the system and boiler has been properly and fully flooded and vented of air and the cold fill pressure at the boiler is at a minimum 0.5 Bar Check that the pumps within the boiler are free to rotate by removing the vent screw in the end of both pump motors and checking that the impeller shafts rotate freely when turned with an appropriate sized screwdriver.
  • Page 43 18.2 dipswitch settings Ltd. E n e r g y T e c h n o l o g y...

  • Page 44: First Firing

    18.3 first firing NOTES The MICROMAT EC boiler has 2Nr heat Exchange and Control Panel Burner Assemblies. The Lower Assembly is referred to as No 1 and the upper as No 2. There are two gas valves - one for each burner: the left hand gas valve serves the lower assembly (No 1), and the right hand gas valve serves the upper assembly (No2).
  • Page 45 18.3 first firing NOTE: Test period expires after 10 minutes - if this expires whilst commissioning is still in progress, press Engineers button twice to reset and carry on with necessary checks and adjustments. To exit “10 min Low’ test period - press Engineers button once, this will set controls to auto.

  • Page 46: Setting Weather Compensation

    18.4 setting weather compensation Ltd. E n e r g y T e c h n o l o g y...
  • Page 47 18.4 setting weather compensation Ltd. E n e r g y T e c h n o l o g y...

  • Page 48: Hot Water Temperature

    18.5 setting domestic hot water temperature A) With HWS sensor in/on DHW Calorifier • Set desired stored hotwater temperature by using the “green” potentiometer on the boiler control panel. This arrangement will give the potential to charge hot water continuously (24 hour/day) with priority over the heating demand.

  • Page 49: Setting The Boiler To Work

    18.6 service button/setting heating output pump speeds and minimum mixed flow temperature c) Setting minimum pump speed. If it is required to limit the minimum pump speed of the in built boiler pumps then this may be done by the following: Press “red”...

  • Page 50: Inspection

    20.0 servicing instruction GENERAL In general, maintenance/inspections should take place: a) When the display on the unit indicates that inspection is required (status shows [SERVICE]). b) At least every 18 months, before carrying out any maintenance the unit must be inspected. 20.1 inspection a) Ask the user about any problems with the boiler unit or any other comments.

  • Page 51: Maintenance

    20.2 maintenance Depending on the results of the inspection carry out any maintenance and if necessary any preventive maintenance. Possible actions include: at a) The remarks and comments of the client must be taken seriously and the cause(s) of any faults or problems must be found.
  • Page 52 21.0 screen display diagnosis of faults The control panel of the MICROMAT EC boiler has an LCD screen, displaying two lines of data. This screen provides information about the operation of the appliance; it shows operation messages (non flashing) and fault messages (flashing display).
  • Page 53 21.1 screen display diagnosis of faults STATUS MESSAGES (FLASHING DISPLAY) INDICATING A FAULT A flashing display indicates a fault and that the boiler has shutdown (lockout). The boiler will not attempt to operate until the red’ reset button is pressed. Any repetitive flashing fault message should be investigated, the cause found and corrective action taken.

  • Page 54: Corrective Action

    21.1 screen display diagnosis of faults DISPLAY MESSAGE FLASHING MEANING CAUSE NUMBER/S Fan 2 low Upper burner fan speed too low 9,10,11,14,18,29,31,33 during pre-purge Fan 2 oper Upper burner fan is detected as 4,11,29,31 operating when should be idle Flame 2 on/w Flame is detected at the upper burner 17,30 when there should be no flame...
  • Page 55 21.2 (possible) causes of fault &corrective action CAUSE No. REASON/ACTION Fan is defective / Replace fan There is no gas supply available / Investigate, restore gas supply Low gas pressure / Investigate and rectify Fuse defective / Check fuses and replace as necessary Gas valve min output setting is incorrect / Check and adjust min output C0 Poor ignition lead connection to electrode or damp connection or lead damaged and shorting to earth / Check and rectify...

This manual is also suitable for:

Micromat ec 62Micromat ec 76

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