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Potterton Eurocondense Plus Installation Manual

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INSTALLATION MANUAL
General Safety Precautions
Installation of System:
Electrical installation
Gas connection:
Important notes:
Important: The boiler must be commissioned following completion of
installation. Operation of an uncommissioned appliance may cause injury
to personnel and damage to the boiler/burner unit and could invalidate the
manufactures warranties.
Commissioning must only be carried out by personnel approved and
competent to do so. This facility is available from Potterton Commercial
Service Offices.
Important: The boiler/burner unit is supplied in accordance with Potterton
commercial quality assurance plan registered to meet the requirements of
BSN ISO 9002. A condition of the supply of the appliance for compliance
with this is the return of the appliance commisioning report.
The work must be carried out by a qualified Electrician.
Gas connection as well as commissioning, servicing and
maintenance must be carried out by an approved Gas Installer
(Corgi Registered). For use with natural Gas (G20) only Gas
supply pressure 20 mbar (LPG options available).
Important notes for installation, operation, adjustment and
service are indicated by this symbol.
EUROCONDENSE
(with BMU 64... > SW 2.08)
Plus

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Summary of Contents for Potterton Eurocondense Plus

  • Page 1 Commissioning must only be carried out by personnel approved and competent to do so. This facility is available from Potterton Commercial Service Offices. Important: The boiler/burner unit is supplied in accordance with Potterton commercial quality assurance plan registered to meet the requirements of BSN ISO 9002.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page General ................3 Corrosion protection .

  • Page 3: General

    For high energy utilisation condensing boilers should be operated at a low return temperature. However the Eurocondense Plus will also work at designed temperatures of 70/50 °C in the condensing mode as the return temperature is under the dew point. (dew point is 53 °C at 8.5 % CO2).

  • Page 4: Installation

    INSTALLATION / DIMENSIONS Installation Before starting work a risk assessment should be carried out in the boiler house and its access to ensure a safe installation and working environment. Any person installing or working on the boiler must be qualified and attention is drawn to the mandatory requirements of C.O.R.G.I.

  • Page 5: Dimensions And Connections

    DIMENSIONS AND CONNECTIONS Clearances Special consideration must be given to the exhaust gas flue when selecting the position of the boiler. Sufficient space should be left at the front so that service work can be carried out. The minimum boiler room clearance for access, erection and maintenance are as follows:- REAR - 500 mm ·...

  • Page 6: Gas Connection / Electrical Connection

    GAS CONNECTION / ELECTRICAL CONNECTION Boiler siting and base A level non-combustible floor capable of supporting the weight of the boiler filled with water, see Table 11, together with any additional weight bearing down on the base from connections, etc. must be provided. This will typically be a 50mm concrete plinth with an area equal to that plan of the boiler.
  • Page 7 GAS CONNECTION / ELECTRICAL CONNECTION Table 2 Maximum Flue Lengths (in metres) for Systems including Fittings Boiler Nominal Flue Size Number of fittings Size 1 Bend* 2 Bends* 3 Bends* 4 Bends* * Bends: 90° Flue connection Typically a flue system must be constructed in 316 grade stainless steel with gasketed joints.

  • Page 8: Central Heating Connection / Exhaust Gas Connection

    CENTRAL HEATING CONNECTION / EXHAUST GAS CONNECTION Boiler siting and base A level non-combustible floor capable of supporting the weight of the boiler filled with water, see Table 9, together with any additional weight bearing down on the base from connections, etc. must be provided. This will typically be a 50mm concrete plinth with an area equal to that plan of the boiler.
  • Page 9 GAS CONNECTION / ELECTRICAL CONNECTION Electrical Supply A 230V 50Hz AC single phase electrical supply is required. The incoming mains supply should be terminated via a double pole fused isolator to the boiler, see Fig. 17 for wiring details. A fused supply is required. The Boiler has a 6,3 A internal fuse.

  • Page 10: Control Panel

    (see Table 13). Reset button (7) The Eurocondense Plus can be reset with the Reset button (7) and the burner is then ready for a new start attempt. After a number of unsuccessful start attempts, inform a heating engineer depending on the error code present (Table 13).
  • Page 11 Adjustment should be accomplished at maximum and minimum nominal heat input, called full load and minimum load below. Changing over from LPG to The type of gas for the Eurocondense Plus boiler should be changed only by natural gas or vice versa an authorised gas installer.
  • Page 12 COMMISSIONING Full load setting on gas valve Then set the gas valve to full load (adjustment screw for full load, Fig. 3) (see guide value for CO in table 3). Minimum load setting To adjust the minimum boiler load momentarily press the "Chimney sweep" button (12).

  • Page 13: Guide Values For Injector Pressure

    GUIDE VALUES FOR INJECTOR PRESSURE Guide values for gas flow rate, The values given in Tables 3 are guide values. It is important that the gas injector pressure and CO content quantity is set via the injector pressure so that the CO value is within the specified values.

  • Page 14: Temperature Setting

    OPERATING MODES / MAINTENANCE Temperature setting There are various setting possibilities for the temperature, see table 4. Table 4 Operating modes (operation with outdoor temperature sensor) Room temperature Hot-water temperature Operation with setting setting Heating program Room control module RRG On room control module RRG On room control module RRG On room control module RRG Heating circuit module On heating circuit module HKM On heating circuit module HKM On EMS or DSU timer...

  • Page 15: Maintenance

    MAINTENANCE Cleaning Cleaning the heat exchanger and condensate sump. G Remove cleaning cover at the front bottom of the condensate sump G Clean with plastic or stainless steel brush and water using a normal detergent (e.g. washing up liquid). Finally rinse off with a gentle water jet. G Re-fit cleaning cover G Re-install burner after cleaning is completed G Check nominal heat load and exhaust gas values...

  • Page 16: Boiler Views

    BOILER VIEWS Fig. 5 Boiler views Eurocondense Plus Control (LMU) Regelung (LMU) Mixing chamber Mischkanal Gas valve Gasventil Gebläse Injector Gasdüse Flow temperature sensor (on the back side of the heat exchanger) Vorlauffühler (hintenliegend am Wärmetauscher) Sight glass Schauglas Sicherheitstemperatur-...

  • Page 17: Control Centre Program Sequence

    CONTROL CENTRE PROGRAM SEQUENCE Fig. 6 BMU control centre program sequence (Type LMU64.002/A100) (Continued on next page)
  • Page 18 CONTROL CENTRE PROGRAM SEQUENCE Time Min. [s] Max. [s] Reaction at end Designation 21,0 Fault position Burner shut-off delay 51,0 Fault position Open air pressure switch 51,0 Fault position Up to speed = 0 THL1 51,0 Fault position fan startup time THL2 51,0 Fault position...

  • Page 19: Hydraulic Circuits (Examples)

    HYDRAULIC CIRCUITS (EXAMPLES) Example 1a: 1 constant temperature heating circuit with room control RRG or with heating (Hydr. System “2”) module HKM and timmer EMS, including DHW tank temperature control HC 1 Legend: Main (CTC) Tank sensor QAZ 36 *) 230V AC N, N3( K4 ) Room control RRG *)
  • Page 20 HYDRAULIC CIRCUITS (EXAMPLES) Example 2a: 1 constant temperature heating circuit (CTC) an 1 variable temperature heating circuit (VTC) (Hydr. System “50”) with room control RRG and/or with heating module HKM and timer EMS, including DHW tank temperature control Alternatively: VTC with zone controller ZR EC 1/2 Gemischtes Heizsystem HK 1 HC 1...
  • Page 21 HYDRAULIC CIRCUITS (EXAMPLES) Example 3: 2 constant temperature heating circuit (CTC) with a mixer module CIM and room control RRG (Hydr. System “34”) and/or with heating module HKM and timer EMS, including DHW tank temperature control HC 1 HC 2 HK 1 HK 2 Mains...
  • Page 22 HYDRAULIC CIRCUITS (EXAMPLES) Example 5a: 1 variable temperature heating circuit (VTC) with CIM and room control RRG, (Hydr. System “50”) including DHW tank temperature control Alternative: VTC with zone controller ZR EC 1/2 HC 2 HK 2 Mains NETZ (VTC) 230V AC N, N4 Legend:...
  • Page 23 HYDRAULIC CIRCUITS (EXAMPLES) Example 6a: 1 CTC, 1 VTC with CIM and room control RRG and/or heating module HKM and timer EMS, (Hydr. System “66”) including DHW tank temperature control, 1 additional mixer circuit (VTC) with ZR EC 1/2 (up to 15 circuits possible) Alternatively: Both VTCs with zone controller ZR EC 2 Separate circuit Gemischtes Heizsystem...
  • Page 24 HYDRAULIC CIRCUITS (EXAMPLES) Example 6c: 1 CTC, 1 VTC with CIM and room control RRG and/or heating module HKM and time EMS, (Hydr. System “66”) including DHW tank temperature control, with primary loop. DHW tank in the secondary loop. 1 additional mixer circuit (VTC) with ZR EC 1/2 (up to 15 circuits possible) Separate circuit Gemischtes Heizsystem Getrennter Heizkreis...
  • Page 25 HYDRAULIC CIRCUITS (EXAMPLES) Example 9a: 1 VTC with CIM and room control RRG and/or heating module HKM and time EMS, (Hydr. System “66”) including DHW tank temperature control, 1 additional mixer circuit (VTC) with ZR EC 1/2 (up to 15 circuits possible) Alternatively: Both VTCs with zone controller ZR EC 2 HK 2 ZR EC bzw.
  • Page 26 HYDRAULIC CIRCUITS (EXAMPLES) Example 11: Boiler cascade with 2 EUROCONDENSE PLUS and BCA 2: 1 CTC and 1 VTC (Hydr. System “80”) (up to 15 circuits possible) including DHW tank temperature control (via BCA 2) Mains NETZ 230V AC Hydraulische Weiche, Sonderzubehör...
  • Page 27 HYDRAULIC CIRCUITS (EXAMPLES) Example 14: Mixed cascade with condensing and non condensing boilers (3 EUROCONDENSE PLUS and (Hydr. System “80”) 1 non condensing boiler) with 1 BCA 2 and 1 EUROCONTROL KK. 1 VTC (up to 15 possible), 1 CTC, including DHW tank temperature control:...
  • Page 28 EXPLANATIONS ON THE EXAMPLES Parameter Name Factory setting New setting Remarks Example 3 HydrSys KonfigHks Both circuits controlled by RRG (see table 10 for details) CTC controlled by HKM/EMS VTC controlled by RRG 506, 507 TvSMin, TvSMax 20/70 Set according to user’s needs (see table 7 for details) Example 4 HydrSys...

  • Page 29: Wiring Diagram

    WIRING DIAGRAM Fig. 7 EUROCONDENSE PLUS wiring diagram...
  • Page 30 CALL-UP AND PARAMETER VALUES Table 6 Call-up and parameter values for BMU control centre Note: Parameters in the groups "A, b, C and d" can only be called, parameters in group "P" can also be changed. Display Display Description Adjustment range [Units] Temperature General: Fault diagnosis code (system)
  • Page 31 CHECKING VALUES Calling parameter values Proceed as follows to obtain the various parameter values (see also Fig. 2 "Control panel"): Entering the Display mode The Display mode can be entered by pressing the Display mode button (10) for a longer period (> 3 sec.) (Display (13): "A.."). Continue to hold down the button to proceed to the various display levels b, C, d, P and then A again.
  • Page 32 ADJUSTEMENT TABLE FOR HEATING ENGINEERS Table 7 Setting system-dependent parameters in heating specialist level of control centre BMU (with RRG room control module or RRG service module). Procedure for changing parameters: G Press Info button. Then press + / M or + / L buttons until "Initialize BMU parameters" appears on the display (final user level, only parameters with "X"...
  • Page 33 ADJUSTEMENT TABLE FOR HEATING ENGINEERS Display on room control module RRG Function Basic setting BUM parameter final user level (set at factory) setting *) Program ZBreMinL Minimum running time for burner ZReglVerz Control delay after burner startup 60 s Constant for rapid reduction (without HydrSystem room influence) KonfigHks...

  • Page 34: Adjustment Table For Heating Engineers

    Display of actual ionization current value Display Other parameters displayed are not relevant for operation of EUROCONDENSE PLUS! *) Note: Any new settings to be recorded in manual! 1) These parameters should be optimized for adaptation to the specific heating system!

  • Page 35: Explanations On Adjustment Table For Heating Engineers

    EXPLANATIONS ON ADJUSTEMENT TABLE FOR HEATING ENGINEERS Explanations on heating The EUROCONDENSE PLUS boiler is factory-set for operation and specialist level requires no changes as a rule. However, a few parameters (see ) in the adjustment table for heating specialists), serve for adaptation to the specific heating system and should be optimized.
  • Page 36 ADJUSTMENT TABLE FOR HEATING ENGINEERS 520 (dTrAbsenk) The room temperature setting is reduced by the value set here by a connected Reduction of room temperature timer (e.g. EMS) in reduced/night mode. Adjustment range 0 to 10 K. setting The room temperature setting made here is included in calculating the boiler temperature setting when outdoor temperature control is used.
  • Page 37 (no function) and balancing the output when the cascade controller EUROCONTROL BCA 2 is used! 547 (ZReglVerz) The EUROCONDENSE PLUS is provided with a minimum pause time or Delay after burner startup startup disable of 3 min. to reduce the number of burner startups.

  • Page 38: Function Sequence Following Burner Startup

    FUNCTION SEQUENCE FOLLOWING BURNER STARTUP Fig. 9 Function sequence following burner startup for heating operation Start- bzw. Startup or ignition output Zündleistung Leistung [ZReglVerz] Output [ZRegVerz] Minimum boiler output Kessel-Min.leistung Output according Leistung 10 s 60 s to heat nach Wärme- requirement anforderung...
  • Page 39 - RRG (heating curve 1 and TP 1) controls HC 1 (CTC) (plus EMS or. RT) - HKM (heating curve 2 of EUROCONDENSE PLUS 2) controls HC 2 (VTC) - RRG (heating curve 1 and TP 2) controls HC 1 (CTC) (plus EMS or.
  • Page 40 598 (LmodRgVerz) In program No. 598 (LmodRgVerz), the burner output can be set at which Output during controller the EUROCONDENSE PLUS operates during the delay time set in program No. 547 (ZreglVerz). delay time This output must never be changed!
  • Page 41 (KonfigAusgang) This output serves for control of an additional gas valve for operation with (Code 0 to 12) LPG. When heat is required from the EUROCONDENSE PLUS the signal - Program No. 558 output is actuated by the BMU. (primary pump) The signal output is not relevant for safety and is therefore not monitored.
  • Page 42 EXPLANATIONS ON ADJUSTEMENT TABLE FOR HEATING ENGINEERS Code 6 = Tank circulation pump M7 (Room control with software > 1.4) Pump runs according to timer program of romm control. Code 7 = Door veil function (Air heater) Pump M8 when door veil function activated Code 8 = Primary loop pump M6 (see example 1b).
  • Page 43 EXPLANATIONS ON ADJUSTEMENT TABLE FOR HEATING ENGINEERS 618 (KonfigEingangR) G No function: parm. 618 = “0” (Factory-preset) G Temperature setpoint (param. 618 = “4”) The temperature setpoint is given by an external analogue signal (0–10 V). The max. setpoint is set at param. 622. The setpoint can be between 5 and 100 °C (limited by the max.
  • Page 44 CONTROL STRATEGIES Hot-water control The hot-water requirement has priority over heat requirement. Automatic day heat limit The automatic day heat limit is effective only when the outdoor temperature sensor is connected. This is a rapid-acting economy function, which switches off the boiler when the mixed outdoor temperature is higher than the room temperature setting (standard or reduced).

  • Page 45: Heating Circuit Module Hkm

    CONTROL STRATEGIES Building frost protection The building is protected against frost in all operating modes: - Room control module RRG The frost protection room (with effective room sensor): temperature setpoint is effective in all modes. - Heating circuit module HKM with timer EMS/DSU or The building frost protection room control module RRG...
  • Page 46 HEATING CIRCUIT MODULE HKM AND ROOM CONTROL MODULE RRG (OPTIONAL EXTRA) Fig. 10 Heating circuit module HKM Installation location for EMS timer Central heating Hot water control Auto Automatic summer/winter switchover button Fig. 11 Room control module RRG (optional extra) Legend: Ž...
  • Page 47 - EUROCONDENSE PLUS switched off or no mains - Room control module defective - Room control module and EUROCONDENSE PLUS not compatible Display OFF: - EUROCONDENSE PLUS 2 not set to "Automatic mode" Display ---: No sensor present or sensor defective...
  • Page 48 TECHNICAL DATA Tab. 11 Technical Data EUROCONDENSE PLUS Model Product-ID CE 0085 BN 0577 Nominal Heat input range (net) Natural gas 31,5 - 90,0 42,0 - 120,0 56,0 - 160,0 70,0 - 200,0 87,5 - 250,0 Nominal Heat input range (gross)

  • Page 49: Diagnostic Flow Chart

    DIAGNOSTIC FLOW CHART Diagnostic flow chart Codes 0…22 refer to boiler operating phase; see tab. 6, MAINS OFF parameter A4 and table 5 Switch on Diagnostics 0 – Stand-by Water pressure > 0,5 bar “119“ flashing in display. (switch closed) Automatic reset when pressure rises.

  • Page 50: Fault Messages

    FAULT MESSAGES Table 12 Fault messages (display 13 flashing) Display Explanations flashing Description Possible causes and function sequence (Code-No.) Outdoor temperature sensor short circuit or discontinuity Check connection and outdoor temperature sensor Boiler flow sensor short circuit or open circuit Check connection Boiler return sensor short circuit or open circuit Check connection...
  • Page 52 Our service organisation covers the whole U.K. to look after your needs OFFICES for all Potterton Commercial Products. We are also able to offer our services for other manufacturers products. Service Hotline 08702 412759 Our service office offer a wide range of specialised services including:...

This manual is also suitable for:

Ec plus 90Ec plus 120Ec plus 160Ec plus 200Ec plus 250

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