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MHG Heating ProCon HT 225 Installation And Operating Manual

Floor standing condensing boiler range
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Installation and Operating Manual for the
ProCon HT 150 & 225
Floor Standing Condensing Boiler Range.
MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth,
Surrey, KT20 5LR
0845 6448802 Telephone. 0845 6448803 Fax.
Email
info@mhgheating.co.uk
Website www.mhgheating.co.uk

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Summary of Contents for MHG Heating ProCon HT 225

  • Page 1 Installation and Operating Manual for the ProCon HT 150 & 225 Floor Standing Condensing Boiler Range. MHG Heating Ltd, Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR 0845 6448802 Telephone. 0845 6448803 Fax. Email info@mhgheating.co.uk Website www.mhgheating.co.uk...

  • Page 2: Table Of Contents

    © MHG Heating Ltd Contents. Section Page # Appliance Type Single Unit Cascade Manager Cascade Slave Installation Regulations and Requirements Appliance Warranties Dimensions Installation Clearances Delivery and Mobility Case Removal Technical Data Pressure Relief Valve Electrical Connections Hydraulic Design Single Unit...

  • Page 3: Appliance Type

    © MHG Heating Ltd 1.0 Appliance Type. There are three build types within the ProCon HT range. Please ensure you have the correct unit for the application and where required located correctly within the cascade prior to beginning the installation.

  • Page 4: Cascade Manager

    © MHG Heating Ltd 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.

  • Page 5: Cascade Slave

    © MHG Heating Ltd 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.

  • Page 6: Installation Regulations And Requirements

    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.

  • Page 7: Dimensions

    © MHG Heating Ltd 3.0 Dimensions. 010108...

  • Page 8: Installation Clearances

    © MHG Heating Ltd 3.1 Installation / Service Clearances Dimension [Minimum mm Clearance ] 1000 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.

  • Page 9: 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.
  • Page 10 © MHG Heating Ltd 5. (1)Swing the Control Panel to the right 6. (1) Swing the control panel back (2) Slide panel A to the right and remove. into its rest position, (2) slid panel B up and remove. 7. (1) Lift the top panel up, (2) push to the rear 8.

  • Page 11: Technical Data

    © MHG Heating Ltd 5.0 Technical Data Technical Data Nominal Heat Input Net Min/Max 15.0/149.2 15.0/216.0 Nominal Heat Output Min/Max 16.0/155.0 16.0/225.0 (50ºC/30ºC) Nominal Heat Output Min/Max 14.5/143.2 14.5/206.0 (80ºC/60ºC) Operating Efficiency (40ºC/30ºC) 109.5 109.5 Design Water Flow Rate Ltr/sec 2.66...

  • Page 12: Pressure Relief Valve

    © MHG Heating Ltd 6.0 Pressure (Safety) Relief Valve 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;...

  • Page 13: Hydraulic Design Single Unit

    © MHG Heating Ltd 8.0 Hydraulic Design Single Unit 8.1 Electrical Connections Single Unit If Direct On Boiler Weather Compensation is not required a 620 Ohm Resistor must be applied to the AF terminals to remove the E10 Error Code from the RVA47 Cascade Manager LPB Network.

  • Page 14: Hydraulic Design Cascade Units

    © MHG Heating Ltd 8.2 Hydraulic Design Cascade Units Legend Outside Air Sensor (QAC32) Heating Circuit Pump Hot Water Sensor(QAZ21) or VF Thermostat System Pressure Manager Hot Water Primary Pump Room Unit (QAA), BMS etc System Filling (Approved) Flow Sensor Return Sensor 8.3 Electrical Connections Cascade Units...

  • Page 15: Fluing Options

    © MHG Heating Ltd 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...
  • Page 16 © MHG Heating Ltd 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.
  • Page 17 © MHG Heating Ltd 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.

  • Page 18: Filling The System

    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...

  • Page 19: System Water Quality

    © MHG Heating Ltd 11.0 System Water Quality Water Treatment, System Cleaning (BS 7592: 2006) 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.

  • Page 20: Appliance Controls

    © MHG Heating Ltd 12.0 Appliance Controls 12.1 Control Panel 12.2 RVA47 Cascade Manager Legend Room Temperature Set Point Adjuster. Assumed Room Temperature if no Room Unit Fitted Parameter Setting Buttons - / + Parameter Line Selection Buttons Down / Up Display Screen Mode Selection Buttons.

  • Page 21: Module Controller

    © MHG Heating Ltd 12.3 Module Controller Legend Module Power Isolator Infrared Output to Flue Gas Analyser Optional Extra. Module Numerical Indicator Temporary Connection Port For QAA73 for LMU 64 Configuration. Indication of System Pressure (Not Used) Indication of Module Over Temperature...

  • Page 22: Accessing Module Parameters

    © MHG Heating Ltd 12.5 Accessing Module Parameters 1. Press the display mode button (10) to choose display level «P» (keep button depressed). 2. Press the display mode button (10) to choose the required parameter (press button briefly). 3. Adjust the value: Changing parameters: (only P0...P6)

  • Page 23: Module Operating Codes

    © MHG Heating Ltd 12.6 Module Operating Codes 010108...

  • Page 24: Appliance Error Codes

    © MHG Heating Ltd 13.0 Appliance Error Codes If a fault is encountered within the appliance or Cascade LPB network, a fault code will be generated and displayed by the failing module and all LPB networked RVA47 Cascade Managers. If a fault is encountered by a module the respective code will be displayed along with a flashing LED.
  • Page 25 © MHG Heating Ltd 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...

  • Page 26: Control Parameter Defaults

    There are two levels of access available, as follows. If you cannot access a particular parameter line, please consult with MHG’s Technical Department for further assistance. Level One Open The Hinged Flap.
  • Page 27 © MHG Heating Ltd Description Range 150 & 225 150 & 225 Single Cascade Master End User Level Time of Day 00:00-24:00 As Required As Required Weekday As Required As Required Date 00:00 As Required As Required Year 1900-3000 As Required...
  • Page 28 © MHG Heating Ltd Description Range 150 & 225 150 & 225 Single Cascade Master System Flow Temperature Set Point 0-140 Modules Available in Cascade 00.1/16.3 Lead Module in Cascade 00.1/16.3 Hour of Operation Until Sequence Change 0.990 Heating Pump Output (HKP) Output Functions Displacement Of Weather Compensation Curve -4.5 - +4.5...
  • Page 29 © MHG Heating Ltd Description Range 150 & 225 150 & 225 Single Cascade Master Changeover Sequence Program 0. No Exemptions 1. The First Module is Exempt 2. The Last Module is Exempt 3. The First and Last Modules are Exempt Module Designated as Fixed Lead Unit 00.1-16.3...
  • Page 30 © MHG Heating Ltd Description Range 150 & 225 150 & 225 Single Cascade Master Maximum Temperature Set Point Via H1 (170 = 4) 5-130 Operating Action of H1 control contacts. 0. The contact is Normally Closed. 1. The contact is Normally Open.
  • Page 31 LMU64 module controller. Via the X10:01 Terminal. There are two 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 Press &...
  • Page 32 © MHG Heating Ltd 150 & 225 150 & 225 150 & 225 Cascade QAA73 # Description Range Single Cascade Slave Master Defaults Defaults Defaults Maximum speed at maximum output in heating H536 0 ... 9950 rpm 7000 7000 7000...
  • Page 33 © MHG Heating Ltd 150 & 225 150 & 225 150 & 225 Cascade QAA73 # Description Range Single Cascade Slave Master Defaults Defaults Defaults Maximum value of heat demand with external H622 5 ... 130 °C predefined temperature setpoint (5 °C<...
  • Page 34 © MHG Heating Ltd 150 & 225 150 & 225 150 & 225 Cascade QAA73 # Description Range Single Cascade Slave Master Defaults Defaults Defaults H729 2nd Historical Fault – ALBATROS Error Code H730 3rd Historical Fault – ALBATROS Error Code H731 4th Historical Fault –...

  • Page 35: Commissioning

    © MHG Heating Ltd 15.0 Commissioning The Appliance 15.1 Pre-Commissioning Checks Prior to undertaking the commissioning of the unit please ensure that the system water has been cleansed and treated with a suitable inhibitor as detailed in Filling the system and system water quality.
  • Page 36 © MHG Heating Ltd Whilst the module is operating under the control of the Chimney Sweep Button (with adjustment) the gas valve can be adjusted to give correct flue gas analysis readings. Each module is equipped with a modulating gas valve.
  • Page 37 © MHG Heating Ltd Each module must be set to the following combustion figures. Gas Type Injector Size High Fire Low Fire Natural Gas (G20) 15mm 8.5% C0 9.0% CO (Exploded Part #79) LPG (G31) 10mm 11.0% CO 11.0% CO (Exploded Part #79) 15.3 Conversion of the Appliance to Operate on LPG (G31).

  • Page 38: Routine Inspection And Servicing

    If the Installer/Commissioning Engineer is unable to undertake the Routine Service Inspection, as detailed Section 16.1, please contact the MHG Technical Department, who will be able to arrange the Routine Service Inspection to be undertaken. 16.1 Routine Service Inspection Before commencing any service/maintenance work, the following tasks must be undertaken.
  • Page 39 Cleaning Granules are available from MHG Heating Ltd Spares Department. A STEEL OR PVC BRUSH MUST NOT BE USED TO CLEAN THE HEAT EXCHANGER. Following the cleaning of the Heat Exchangers, the condensate syphon must be flushed to ensure that all mineral deposits/debris that has been washed from the heat exchanger surface is correctly removed.

  • Page 40: Qaa73 Room Unit/Service Tool

    © MHG Heating Ltd 16.3 QAA73 Room Unit/Service Tool QAA73 Door Closed QAA73 Door Open QAA73 Mounting Plate/Terminals The QAA73 Room Unit/Service Tool must be connected to the X10:01 terminals (Not Polarity Sensitive) of the respective LMU64 controller to access the required fault history parameters and to reset the service interval timer as detailed in sections 16.1 and 16.2.

  • Page 41: Optional System Controls (Rva 63, Rva46, Qaa70, Qaa50, Qaa10)

    © MHG Heating Ltd 17.0 Optional System Controls. If required the following controls can be applied to the ProCon HT range to enhance boiler and system operational efficiency and longevity. (Further detailed guidance can be obtained from the respective controller manuals.) RVA63 Dual Zone Controller.

  • Page 42: Internal Wiring

    © MHG Heating Ltd 18.0 Internal Wiring The internal wiring configurations of the ProCon HT 150/225 differ dependant upon the model. Single/Cascade Manager/Cascade Slave. In all but the Cascade Slave units a RVA47 Cascade Manager is installed. The RVA47 Cascade Manager Communicates with the individual LMU64 module controllers via the LPB wiring loom.
  • Page 43 © MHG Heating Ltd 18.1.1 BMS Interface Clip Installation and Parameter Alteration Following the installation of the AGU2.511 communication clip (complete with base mounted wiring connection) onto the front of the LMU64 controller a number of operational parameters within the unit must be altered to ensure the clips operates as required.

  • Page 44: Internal Wiring Diagram

    © MHG Heating Ltd 18.2 Internal Wiring Diagram 010108...

  • Page 45: Exploded Diagrams

    © MHG Heating Ltd 19.0 Exploded Diagram 010108...
  • Page 46 © MHG Heating Ltd 010108...
  • Page 47 © MHG Heating Ltd 010108...
  • Page 48 © MHG Heating Ltd 010108...

  • Page 49: Spares Listings

    © MHG Heating Ltd 20.0 Spares Listings Cascade Cascade Cascade Cascade Description Part Number Single Single Master Slave Master Slave Base Tray 96.35460-7020 Base Tray Securing Bolts 94.15393-5001 Toothed Washer ; A5.3 On Request Hexagonal Nut ; M5 On Request Leveling Feet ;...
  • Page 50 © MHG Heating Ltd Cascade Cascade Cascade Cascade Description Part Number Single Single Master Slave Master Slave o.A. Flue Spigot Blanking Plug 96.36400-7006 44.6 Heat Exchanger Flue Seal 95.99287-0087 44.7 Appliance Flue Seal 95.99287-0092 44.13 Condensate Waste Elbows 96.36444-7001 44.15 Condensate Elbow Seal 96.36487-7004...
  • Page 51 © MHG Heating Ltd Cascade Cascade Cascade Cascade Description Part Number Single Single Master Slave Master Slave 66.19 Combustion Fan RG 148 96.34000-7006 Fan Outlet Mounting Screws On Request 66.20 On Request 66.21 Electrode Mounting Screws M4 66.22 Non Return Valve Base 96.34317-7001...
  • Page 52 © MHG Heating Ltd Cascade Cascade Cascade Cascade Description Part Number Single Single Master Slave Master Slave Mounting Post AD-510, On Request 4x12,5 Appliance Fuse Holder 96.39400-7001 Side Panel 96.35160-7002 Panel Spring Clips 94.15371-5001 Top & Lower Front Panel 96.35360-7025 Upper Front Panel 96.35360-7026...

  • Page 53: Installer / End Users Note

    © MHG Heating Ltd 21.0 Installer / End User Notes 010108...

This manual is also suitable for:

Procon ht 150

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