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Navien NCM-1130HH Installation Instructions Manual

Gas fired waa mounted stirling engine m-chp
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Summary of Contents for Navien NCM-1130HH

  • Page 1 Country of destination : GB...
  • Page 2 Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION Used without the safety alert symbol indicates a potential hazardous situation which, if not avoided, could result in property damage. 2 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 3 Ventilate the location. properly. In such cases, first contact the Close all doors leading to lining spaces. person in charge of filling the tank. Do not operate electrical switches. 3 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 4: Table Of Contents

    4.9.2 Appliance Loom Schematic Diagram ..............35 4.9.3 Accessing the Controller Assembly ..............42 4.9.4 Accessing All the Electricity Connections .............. 43 4.9.5 KD NAVIEN external control options ..............45 4.9.6 Connecting external valve and sensors ..............47 5.0 COMMISSIONING AND TESTING ................49 5.1 E...
  • Page 5 7.11 R ....................84 COMMISSIONING 7.12 F ......................84 INAL HECKS 8.0 SHORT SPARE PARTS ....................85 8.1 G ......................... 85 ENERAL 8.2 S ..................... 86 HORT PARE ARTS 5 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 6: General Information

    Incorrect use of this product constitutes a safety hazard. The product must at all times be operated in accordance with these and the KD NAVIEN NCM- 1130HH User Instructions as well as any subsequent instructions issued by KD NAVIEN.

  • Page 7: Certification Details

    6. Confirm head temperature by selecting ‘Head Limit Temperature’ and read temperature from display and note value ° 7. Both readings should be within 50 C of each other 7 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 8: Control Of Substances Hazardous To Health

    Note the following information on substances hazardous to health. Adhesives and Sealants The NCM-1130HH product employs a range of adhesives and sealants in its construction. These substances are fully cured and give no known hazard in this state. Insulation Pads, Fire Insulation Refectory ceramic and ceramic fibre insulation is used in a number of places within the product.

  • Page 9: Technical Specifications

    Diameter Gas Inlet Connection Inch PT 3/4 Condendate connection Physical dimensions (Width x Depth x Height) 480 x 430 x 1000 Weight Table 1. Performance data and General specifications 9 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 10: Minimum Installation And Service Clearances

    Diagram 2.1 Product dimensions 2.2 Minimum installation and service clearances The product must not be installed in compartments or cupboards. 10 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 11: Flue System Specifications

    2m flue extension, for example if two 90 elbows are used in the flue run then the total straight flue run must not exceed 6.5m. 11 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 12: Vertical Flue Systems

    Note: 45° bends = of a metre flue connector to the underside of the resistance terminal = 10.5m Diagram 2.3 Optional vertical flue systems available for use with the appliance 12 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 13 Diagram 2.4 Optional separate flue systems available for use with the appliance Diameter of Max Flue Reduced Flue Length [m] Pipe [mm] Length [m] 45° Ø 80/100 10.5 90° 45° Ø 80/80 90° Table 2. Reduction table 13 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 14: Kd Navien Appliance Internals

    2.4 KD NAVIEN appliance internals Diagram 2.5 Product Internals 14 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 15: Installation Requirements

    BS EN 7478 • BS EN 7593 Treatment of water in domestic hot water central heating systems • Manufacturer’s instructions must NOT be taken in any way as overriding statutory obligations. 15 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 16: Product Position

    The product must be installed on a flat vertical wall, which is capable of supporting the weight of the product and any ancillary equipment. It is not necessary to provide an air vent in the room in which the KD NAVIEN product is installed g) Do not position the appliance above an area likely to be occupied by a kettle or toaster.
  • Page 17 For vertical flue pipes, the terminal must not be within 60 cm of any openings 17 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 18: Central Heating System

    To help manage the level of operating noise of the installation it is recommended to thoroughly purge air from the system, position pump in appropriate location, support pipe work effectively, always firmly secure cover on casing. 18 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 19 Vessel charge and initial system pressure (bar) Total water content of system (litres) Vessel Volume 11.7 10.9 15.6 10.4 13.6 19.5 12.5 16.3 23.4 Table 4a: Expansion vessel table 19 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 20: Hydraulic Resistance

    A minimum of 22mm diameter pipework is required to within 1 metre of the product and a pressure drop of no more than 1 millibar is permissible c) Before any gas work commences, the gas pipework shall be tested for soundness. 20 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 21: Electricity Supply

    Condensate should be discharged into the internal household draining system. If this is not possible, external pipework is acceptable, see section 4.4 for more details. 21 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 22: Installation Procedure

    The product will come in a wooden package. Unpack and check the contents against the Installation Preparation Checklist provided. A copy of which is shown overleaf Any damage noticed to equipment shall be reported immediately to KD NAVIEN (82-2- 3489-2326) The appliance may be damaged if it is not properly transported.

  • Page 23: Preparing The Wall For Installation

    Ensure that during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. 6) It is absolutely essential that the KD NAVIEN appliance is installed vertically. If the wall is bowed or not plum, then spacers must be inserted between the back plate and the wall such that the back plate is accurately vertical.
  • Page 24 Diagram 4.1 Diagram showing cut away wall with m-CHP mounted 7) The Fischer Rawl bolts currently supplied by KD NAVIEN to secure the wall mounting bracket to the wall must be used in all cases 8) Set drill stop at depth of 90mm 9) Drill an 8mm diameter hole into the wall, using rotary hammer drill in conjunction with SDS drill bit.

  • Page 25: Mounting The Appliance

    - Ensure that balance is being sustained when carrying 4.3.1.1 Use of Lifting Gear This process describes removing an NCM-1130HH appliance from a packaging box to the wall. 1) When you lift the appliance, do not get rid of the EPP bottom base.

  • Page 26: Condensate Drain

    At a condensate absorption point (soakaway). The external pipe length should not be more than 3m g) The disposal of condensate liquid must comply with local Water Authority rules and regulations. 26 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 27 2.5° (i.e. 45mm for every metre length). The diagrams below show acceptable means of condensate drain connection Diagram 4.2a Internal termination of condensate drain to internal stack 27 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 28 Diagram 4.2b External termination of condensate drain via internal discharge branch (i.e sinks) and condensate siphon 28 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 29: Gas Connection

    2. Check for gas leaks. 3. Valve kit for external connections. Each boiler is supplied with an Navien Valve Kit for each external connection. Please refer to the installation instructions within the valve kit packaging. 29 of 88...

  • Page 30: Heating System Connection

    The flow connection is situated at the bottom side of the unit. The return connection is situated to the right of the flow connection. Refer to Diagram 4.4 Diagram 4.4: Flow and Return connections 30 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 31: Pressure Reilef Valve

    The exhaust gas ducts must not come in to contact with or be located close to combustible materials and must not pass through building structures or walls made of combustible materials. When replacing an old appliance, the flue system must be changed. 31 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 32 Take care to ensure that the water is only poured into the flue outlet and does not spill into the product casing. Diagram 4.5 Flue Assembly 32 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 33: Electrical Connection

    4.9 Electrical Connection 4.9.1 General The product must be installed by a competent KD NAVIEN trained electrician. 1) The fuse rating of the securable isolator shall be 13A 2) A mains supply of 230 V ~ 50 Hz is required.
  • Page 34 NAVIEN appliance Bi-directional Meter Electricity 1.5mm CSA flexible Consumer unit cord conductor Customer’ DNO’s s Wiring Wiring Diagram 4.7 KD NAVIEN product connection through a radial final circuit 34 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 35: Appliance Loom Schematic Diagram

    4.9.2 Appliance Loom Schematic Diagram Diagram 4.8a: NCM-1130HH Loom Schematic Diagram 35 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 36 Diagram 4.8b: NCM-1130HH Loom Schematic Diagram 36 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 37 37 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 38 Input Programmer (230 V) Phase AC 230 V Phase AC 230 V Input Programmer (230 V) Input Programmer (230 V) Phase AC 230 V Phase AC 230 V 38 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...
  • Page 39 X204 Supply Sensor U12V (or 5V) X204 Signal GND X204 Signal Input H3 (Water pressure or Flow Switch X204 Spool Valve Feedback U X204 Spool Valve Feedback R X204 39 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 40 BSB Power supply 12 V X600 BSB data X600 BSB ground X600 BSB Service Ident Pin X600 BSB GND (HMI) BSB Signal BSB Supply 12 VDC BSB Service Ident BSB n.c. 40 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 41 Condensate Ref. Condensate Signal Flow OH, Combi OH Ref. Flow OH, Combi OH Signal Flue OH Ref. Flue OH Signal Ionisation GND Ionisation Signal Diagram 4.8c: NCM-1130HH Loom Schematic Diagram 41 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 42: Accessing The Controller Assembly

    PCB by hand. Push the connector away from the PCB edge to release it. sliding it off the PCB by hand. Push the connector away from the PCB edge to release it. 42 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...

  • Page 43: Accessing All The Electricity Connections

    2. Remove the black silicone tube “B” from the cable gland. 3. Insert wire “C” into cap “A” and the silicone tube “B”. 3. Insert wire “C” into cap “A” and the silicone tube “B”. 43 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...
  • Page 44 The main supply to the boiler must be connected through a double pole isolator situated ㆍ local to the appliance. The isolator must have a minimum contact separation of 3mm acros all poles. Diagram 4.10 Accessing the electricity Connections 44 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 45: Kd Navien External Control Options

    4.9.5 KD NAVIEN external control options The KD NAVIEN appliance may be configured for use with wired and wireless external controls which are manufactured by SIEMENS. The wired option requires connections to be made inside the appliance controls enclosure for each wired device.
  • Page 46 AVS14.390 which is powered from a power adapter AVS16.290. Diagram 4.10 Room thermostat conncetion 46 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 47: Connecting External Valve And Sensors

    DHW temperature sensor(Resistance of 12k sensor) to 2,n terminals of X300 terminal block. Check the fallowing parameters. 1) Parameter No. 5702 is ‘w-plan’ 2) Parameter No. 5773 is ‘3’ 47 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 48 Diagram 4.12: Connecting external valve and sensors 48 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 49: Commissioning And Testing

    Diagram 5.1 Two side transit bracket (one each side of engine) & one in front side transit bracket (one each side of engine) & one in front side transit bracket (one each side of engine) & one in front 49 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...

  • Page 50: Electrical Installation

    3) Complete any local or regulatory requirements such as ER G83/1 Commissioning pro- forma and submit on day of commissioning, an example is shown in table 5. 50 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 51 Recommendations G83/1. The SSEG installation complies with the relevant sections of BS 7671 and an installation test certificate is attached. Comments (continue of separate sheet if necessary). Name: Signature: Date: 51 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 52: Gas Installation

    (opened full bore to remove any installation debris prior to lighting the boiler). 7) Refill the heating system 52 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 53: Commissioning The Appliance

    5.5 Commissioning the appliance Photo 5.1 – Facia Control panel (Embedded in appliance front) 53 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 54: Starting The Appliance

    5) Turn on the appliance and use the commissioning function on the programmer. The flue gas sampling point is shown in diagram 5.3 Sampling point Diagram 5.3 Flue sampling point 54 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 55: Commissioning The Burners

    After 60 minutes, a time out will terminate the chimney sweeper function, it the function is not already terminated by pressing the chimney sweeper button. 1) Using a flue gas analyser, check the products of combustion and ensure they are within the limits stated below; 55 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 56: Adjusting Gas Valve For Combustion Specification

    6. The following mentioned items are done in conjunction with the checking and adjusting of the CO level. 6-1. prepare the water column meter or manometer like the figure on the left. 56 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 57 If the actual value deviates more than 0.5% from the above range, check the seals in the flue system. 9. Enter the actual values in the service report. Diagram 5.4 Adjusting the CO Value 57 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 58: Final Checks

    When venting the product using the air vent on supplementary heat exchanger ensure that suitable care is taken so that water does not fall onto the product or controls. d) Balance the system. 5) Complete the KD NAVIEN commissioning form 6) Finally, set the controls to the User’s requirements. 58 of 88...

  • Page 59: Product Programmer Unit Operation

    3) Room Unit QAA78 – This is the wireless option which carries out the same function as unit QAA75. To enable the wireless unit to be received by the KD NAVIEN, the appliance requires a radio module AVS71 connected to the appliance (see diagram 5.6.4)
  • Page 60 4) Wireless outside sensor AVS13.399 – In conjunction with the room unit an outside sensor can be utilised. If required a radio repeater AVS14.390 can be used to relay the signal. 60 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 61: Setting Time And Day

    Operating lines may be hidden, depending on the type of unit, the configuration and user • level Operation Display example Description The basic display is shown. basic display selected, press the ESC button. Press the OK button 61 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 62 You can continue to make other settings, or you press the operating mode button to return to the basic display. Now, you have returned to the basic display. 62 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 63: User Levels

    Press the Info button for 3 seconds. You are given a choice of user levels. Turn the setting knob until the required user level is reached. Press the OK button. 63 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 64 The example given here shows that certain user levels do not allow certain settings to be made. The example shows them highlighted. On the unit, they are hidden. Setting structure for ”Heating engineer“ 64 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 65: Programming The Appliance

    5.6.3.3 Programming the appliance Operation QAA7x QAA55 65 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 66: Selecting Heating Mode

    The button is used to switch DHW heating mode on and off. The choice made is indicated by a bar which appears below the symbols. DHW mode • The DHW is heated according to the selected switching program. • No DHW heating, the protective function is active. 66 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 67: Adjusting The Room Temperature Set Point

    • The current selection is active until the next switching action according to the heating program occurs 5.6.3.7 Displaying information The Info button is used to display information. Certain information lines are hidden, depending on the type of unit, unit Available information 67 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 68 The default display of the operator unit shows the boiler (flow) temperature and the state of the burners. State burner: Both off Engine burner on Supplementary burner on Engine burner and supplementary burner on 68 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 69: Handing Over

    8) Explain the function of the product safety controls and how to reset them. Emphasise that if cut-out persists, the product should be turned off and a KD NAVIEN service engineer consulted. 9) Make sure all safety labels are correct and in place.

  • Page 70: Fault Finding

    6.0 Fault finding Any/all service work must be earned out by a KD NAVIEN trained Engineer. Electrical capacitors can remain charged for long periods after disconnection from the mains supply. Extreme caution must be exercised at all times when working on this product 6.1 General...
  • Page 71 In that case, press the Info button to obtain changed to special mode. In that case, more information. press the Info button to obtain more information. A list of possible displays is given in section 6.4 71 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 72 By pressing the Info button once again, the next display will display which type of Reset (User Reset or Service Reset) is required. A User Reset may be done on the operator unit. 72 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 73 Each 3 minutes, the credit will be increased by +1 up to the maximum of 5 credits. Service reset button Diagram 6.1 Service re-set button (remove controller casing first) 73 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 74: Error Codes

    I r r e p a r a b l e d a t a l o s s i n N R P N R P E E P R O M 74 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 75 . 75 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 76 - w h e n t h e l i m i t v a l u e w a s e x c e e d e d a f t e r 1 0 m i n u t e s 76 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 77 - t r a v e l s w i t c h e s h a v e b e e n a c t i v a t e d 77 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 78 E m S d l i m t h e r m o c o u p l e w a s d e t e c t e d . 78 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 79 3 0 ° C i n o n e m i n u t e b e f o r e g r i d c o n n e c t i o n . 79 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 80: Routine Servicing

    In general once a year should be adequate. Any service work must be carried out by qualified KD NAVIEN trained personnel only. The product incorporates a flue sampling point on top of the appliance. Do not forget to replace the screwed cap after use.

  • Page 81: General Inspections

    3) Ensure that the condensate trap is visually inspected to asses for any signs of blockage or build up of debris. 4) Replace cover. If in any doubt contact KD NAVIEN or your supplier. 7.4 Servicing Supplementary Burner 1) Turn OFF the mains power supply.
  • Page 82 2) If the burner is not correct, for example it is damaged, replace the burner. Diagram 7.2 Supplementary burner Supplementary burner packing and mix chamber gasket packing and mix chamber gasket 82 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...

  • Page 83: Checking & Adjusting The Ignition And Ionization Electrode

    83 of 88 Navien stirling engine m-CHP installation manual CHP installation manual Page No:...

  • Page 84: Engine Burner

    MEC Engine Operating Instructions (Doc ref PS-V1-01 MEC V1 Series LFPSE Micro CHP Integration OEM Manual and Instructions) The NCM-1130HH engines may require check and top up of Helium on a regular basis; this shall be carried out by competent trained personnel in accordance with KD NAVIEN & MEC procedures.

  • Page 85: Short Spare Parts

    8.0 Short Spare Parts 8.1 General When replacing any KD NAVIEN product component; 1) Isolate the electricity supply at the local securable isolator and at the 16A circuit breaker in the consumer unit 2) Turn off the gas supply to the product at the product gas cock.

  • Page 86: Short Spare Parts List

    8.2 Short Spare Parts List The following list comprises parts commonly required as replacements, due to damage or wear. 86 of 88 Navien stirling engine m-CHP installation manual Page No:...
  • Page 87 BHA4060100021 Controls Enclosure BHABOF000059 Sophisticated room unit BHABOF000060 Wireless sophisticated room unit BHABOF000062 Simple room unit BHABOF000063 Programmers (HMI) BHABOF000064 Wireless outdoor sensor Outdoor sensor BHABOF000065 Wireless transceiver BHABOF000066 87 of 88 Navien stirling engine m-CHP installation manual Page No:...

  • Page 88: Navien Stirling Engine M-Chp Installation Manual Page No: 4 Of

    88 of 88 Navien stirling engine m-CHP installation manual Page No:...

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