MHG Heating ProCon 16 Unit installation

© MHG Heating Ltd
ProCon Streamline Hybrid Unit.
Installation and Operating Manual.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Section
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
Appliance Type
Installation Regulations and Requirements
Appliance Warranties
Dimensions Internal Unit
Dimensions External Unit
Installation Clearances
Delivery and Mounting
Technical Data Gas Boiler Module
Technical Data Heat Pump Module
Positioning the External Unit
Installing the Refrigerant Pipework
Electrical Connections
Internal Hydraulic Configuration
Hydraulic Configuration Single Heating Zone & Hot Water
Hydraulic Configuration Dual Heating Zone & Hot Water
Fluing Installation Options
Fluing Options
Balanced Flue Terminal Positions
Pressure (Safety) Relief Valve
Filling The Heating System
Expansion Vessel
System Water Quality
Appliance Controls
Default Controls
Appliance Fault Codes (Heat Pump Controller)
Appliance Fault Codes (Boiler Controller)
Fuel Gas Conversation Procedure
Boiler Controls
Boiler Controller Adjustment
Commissioning The Appliance
Pre-Commissioning Checks
Combustion System Commissioning
Routine Inspection & Servicing
Routine Service Inspection
Routine Cleaning and Maintenance (Boiler Module)
Routine Cleaning and Maintenance (Heat Pump)
Fault Codes (Boiler Module)
Weather Compensation Slope
Exploded Spares Diagram (Boiler Module)
Parts List
Notes
Page #
3
4
5
6
7
7
9
15
16
17
17
20
26
27
28
29
30
32
33
33
34
34
35
36
42
43
44
45
46
48
48
48
49
49
50
51
52
53
54
59
60
Additional Manuals
Heat Pump Controller Manual
Heat Pump External Unit Manual
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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1.0 Appliance Type
The ProCon Streamline Hybrid unit is supplied complete with a 3-10kW air to water heat pump (COP 4.4), 7.7-26.8kW
modulating condensing gas boiler and comprehensive controller.
The heat pump module is designed as a split system.
A suitably qualified F gas registered engineer is required to install and commission the interconnecting refrigerant
pipework.
The external unit is supplied with 3.2kg of R410A refrigerant which is sufficient for 10m (One way) of interconnecting
refrigerant pipework. (Model PUHZ-SW75VHA.UK)
The modulating gas condensing boiler can operate on either Natural Gas or LPG. (Conversion kit required).
Kit Name
Natural Gas
LPG conversion kit
External Unit
Product Code
18.60000-9300
96.34344-7207
PUHZ-SW75VHA.UK
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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2.0 Installation Regulations and Requirements
The installation of the Hybrid unit must be in accordance with the relevant requirements of Gas Safety (Installation &
Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE Regulations, Construction (Design &
Management) Regulations 1994, Local Authority Bye-Laws, National, Fire Regulations and Insurance Company
requirements.
The following Codes of Practice are also applicable:F Gas and ODS Regulations.
BS 5440-1: 2008 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd
and 3rd family gases).
Part 1: Specification for the installation of flues.
BS 5440-2: 2009 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd
and 3rd family gases).
Part 2: Specification for installation and maintenance of ventilation for gas appliances.
BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic premises.
BS 6644: 2011 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and 1.8MW(net) (2nd
and 3rd family gases).
BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input not exceeding 60 kW.
BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater than 45kW. Parts 1, 2
& 3.
BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in domestic premises
(2nd family gases)
BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises
IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1: Flued appliances.
And any addition prevailing regulation and or code of practice not detailed above.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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3.0 Appliance Warranties
All MHG appliances enjoy a full 36 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.
The customer shall only be able to claim against MHG under guarantee if the commissioning of the object of delivery
has been carried out by MHG staff or the authorized supplier, if the customer has followed MHG's instructions relating
to the treatment and maintenance of the object of delivery and if no replacement parts of outside origin have been fitted.
Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the guarantee.
In addition to the above warranties, the gas condensing boilers Primary Heat Exchangers carry a 60 month guarantee
against manufacturing or material defect.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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4.0 Dimensions Internal Unit. (H=910mm x W=780mm x D=300mm)
Legend
1
2
2.1
3
4
4.1
5
6
7
Refrigerant Line
Refrigerant Line
Electrical Inlet Route
Header Drain
Heating Flow
Condensate Outlet
Gas Inlet
Heating Return
Flue Spigot
16mm
10mm
3 Clips
½” BSP
1” BSP
¾” Flexible
½” BSP
1” BSP
Concentric 80/125
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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5.0 Dimensions Evaporator External Unit. (H=943mm x W=950mm x D=330mm) (PUHZ-SW75VHA.UK)
#
A
B
C
W
Dimension
330 mm
943 mm
950 mm
75 kg
6.0 Installation and Service Clearances
Internal Unit Front View
Internal Unit Top View
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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External Unit
#
A
B
C
D
E
Minimum Clearance
50mm
750mm
250mm
250mm
100mm
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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7.0 Delivery and Mounting
The hybrid unit is supplied on two pallets.
The cased internal hydraulic assembly and separate gas condensing boiler on one pallets and the external evaporator on
the other.
Please dispose of all packaging in an environmental way.
It is advisable to remove the casing from the internal units prior to installing.
The case is secured with 2 screws. The screws are located behind the blue door.
Rotate the MHG badge to expose a finger hole.
Once open the control panel and case fixing screws can be seen.
The left hand casing can be lifted clear of the unit once the screws have been removed. Followed by the interlocked right
hand casing.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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The hanging bracket measurements are detailed below. (A = Bracket)
Hang the two internal units onto the wall bracket and ensure the hydraulic connections 1 are secured with washers.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Install the 3/8” vent valve and ½” drain valve as indicated.
#13indicated below.
Legend
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Heat Pump Heat Meter (Optional)
Low Loss Header
Boiler Control Panel
Controller Display
Boiler PCB
Flow Switch
Common Flow Sensor
Unit Circulating Pump (Boiler/Header)
3 Way Diverting Valve (Heat Pump/Boiler)
Cable Entry Route
Heat Pump Circulating Pump
Heat Pump Return Sensor
Drain Cock
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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The following electrical connections must be made/checked for security.
#
1
2
Description
Common Flow Senor F8
Unit Circulating Pump
#
3
4
Description
HWS Enable from Heat Pump Control to the Boiler
Flow Switch
#
Description
Remove the Control Panel Securing screw to access the wiring Terminals for
the Outside Air Sensor and RT Boiler Enable
5
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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#
6
#
7
#
8
Description
Wiring Terminal X 4
RT Enable Terminals 6 & 7
Outside Air Sensor Terminals 8 & 9
(Fitted on a North or North East facing wall.)
Description
Route the RT Enable as shown.
Secure the control panel with the screw
Description
Connect the boilers power supply to terminals 27, 28 & 29
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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#
1
Description
In addition to the boilers outside air sensor the Heat Pump module must have
an outside air sensor fitted on a North or North East facing wall. Minimum
CSA 1.00 mm up to 20m. 1.5mm from 21-100m
Wired to F9 / M
Additional sensors can be wired to the sensor terminal rail depending upon the system design. (Bold indicates required.)
#
Sensor Function
Location
Voltage / Wire
41.0/F9
Outside Air Sensor (Required)
North/North East Facing Wall
<24 Volt / 4 Core / Screened
42.6/F8
Common Flow Sensor
Internal
<24 Volt / 2 Core / Screened
43.0/F6
Hot Water Sensor
External Calorifier
<24 Volt / 2 Core / Screened
40.1/F5
Heating Circuit 2 Flow Sensor
Heating System
(If a 3 port valve is used.)
<24 Volt / 2 Core / Screened
44.0/F3
Thermal Store Sensor (Upper)
External Buffer (Infrequently used)
<24 Volt / 2 Core / Screened
44.2/F2
Thermal Store Sensor (Middle)
External Buffer (Infrequently used)
<24 Volt / 2 Core / Screened
44.1/F1
Thermal Store Sensor (Lower)
External Buffer (Infrequently used)
<24 Volt / 2 Core / Screened
40.0/F11
Heating Circuit 1 Flow Sensor
Heating System
(If a 3 port valve is used.)
<24 Volt / 2 Core / Screened
43.1/F12
Hot Water Sensor (Lower)
Multifunctional Relay 2 (MF2)
<24 Volt / 2 Core / Screened
F/13
No Function Within Hybrid
Multifunctional Relay 3 (MF3)
45.0/F14
Solar Collector Sensor
Optional Solar Panel (MF4)
F15
No Function Within Hybrid
~
42.3/F17
Heat Pump Return Senor
Internal to Unit
<24 Volt / 2 Core / Screened
CAN
Communication Ports
~
<24 Volt / 4 Core / Screened
BM
Room Unit
Heated Space
<24 Volt / 4 Core / Screened
BMT
Heat Pump Controller
Internal
<24 Volt / 4 Core / Screened
<24 Volt / 2 Core / Screened
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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8.0 Technical Data
Gas Condensing Boiler Module
Description
Product Number
Weight
Dimensions
Primary Water Content
Unit
Kg
mm
L
Heat Exchanger Construction
Heating Flow & Return
Gas Supply Inlet
Flue Gas/Combustion Air
Nominal Input
Nominal Output 80/60°C
Nominal Output 50/30°C
Nominal Efficiency 80/60°C
Nominal Efficiency 50/30°C
Nominal Efficiency 40/30°C
Maximum Flow Temperature
Nominal Mass Flow Rate @20 ΔT
Maximum Operating Pressure
Maximum Inlet Gas pressure
Minimum Inlet Gas Pressure
Nominal Power Input
Installation Categories
Residual Flue Gas Pressure
Flue Gas Temperature @ 80/60°C
mm
mm
mm
kW
kW
kW
%
%
%
°C
L/h
bar
mbar
mbar
(Nat/LPG)
V / Hz
CE-0063AR3527
64
H 910mm x W 780mm x D 300mm
1.4
Copper Water Ways &
Aluminum Flue Ways
22
15
80/125
7.2 – 27.3
7.0 – 26.2
7.7 – 26.8
97.2 – 96.0
98.2 – 106.9
101.0 – 108.5
75
1160
3
50
18/35
230/50
B23, B33, C13X , C33X, C43X, C53X, C63X, C83X
Pa
°C
90
94
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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9.0 Technical Data
Heat Pump Module (PUHZ-SW75VHA.UK)
System
Air/Water
Model PUHZ-SW75VHA.UK
Heat output in 7 output levels
kW
Heat
7,2 (3,1-10,5)
Range of use for heating
°C
-20 to +24
Max. flow temperature for hot water
°C
60
Max. heat output / Compressor frequency at A10/W 35
kW / Hz / COP1)
10,5 / 99 / 4,4
Max. heat output / Compressor frequency at A7/W35
kW / Hz / COP1)
10 / 96 / 4,3
Max. heat output / Compressor frequency at A2/W35
kW / Hz / COP
1)
7,2 / 96 / 3,4
Max. heat output / Compressor frequency at A2/W35
kW / Hz / COP
1)
5,1 / 61 / 3,9
Max. heat output / Compressor frequency at A-7/W35
kW / Hz / COP1)
4,8 / 99 / 2,5
kW / Hz / COP
1)
3,8 / 99 / 1,9
kW / Hz / COP
1)
9,4 / 99 / 3,4
Max. heat output / Compressor frequency at A2/W45
kW / Hz / COP
1)
7,0 / 96 / 2,8
Max. heat output / Compressor frequency at A-7/W45
kW / Hz / COP1)
5,2 / 99 / 2,2
Max. heat output / Compressor frequency at A-15/W35
Max. heat output / Compressor frequency at A7/W45
kW / Hz / COP
1)
4,3 / 116 / 1,5
kW / Hz / COP
1)
10,4 / 94 / 3,0
Max. heat output / Compressor frequency at A7/W55
kW / Hz / COP
1)
7,9 / 89 / 2,5
Max. heat output / Compressor frequency at A-7/W55
Refrigerant / Base fill
kW / Hz / COP1)
3,1 / 95 / 1,1
-- / kg
R 410A2) / 3,2
Refrigerant, Additional volume 10-50m
g/m
60
Water volume flow at Δt 5K (level 6)
m³/h
1,2
Volume flow, air (exterior unit)
m³/h
3300
Max. operating pressure water
Bar
3,0
Hydraulic connection flow/return
BSP
1“ AG
Diameter of cooling lines, liquid
mm
10
Diameter of cooling lines, gas
mm
16
Max. single length
m
50
Max. difference in elevation
m
30
Max. heat output / Compressor frequency at A-15/W45
Max. heat output / Compressor frequency at A20/W 55
Sound pressure level (for exterior unit)
dB(A)
383)
Dimensions of interior unit (H x W x D)
mm
910x780x300
Dimensions of exterior unit (H x W x D)
mm
943x950x330
Weight of interior unit
kg
85
Weight of exterior unit
kg
75
V / Hz
1 NPE 230 V 50 Hz
A
16
Electricals internal unit
Power supply system
Fuse on site, Tripping characteristic B
Electricals external unit
Power supply system
V / Hz
1 NPE 230 V 50 Hz
Starting current max.
A
19
Operating current
A
9,74
kW
2,32
A
20
Rated power consumption
Fuse on site (exterior unit), Tripping characteristic C
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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10.0 Positioning the External Unit (PUHZ-SW75VHA.UK)
Please refer to the External Unit’s technical manual for complete guidance.
11.0 Installing the Refrigerant Pipework
Only a suitably qualified F Gas engineer shall undertake the installation and commissioning of the refrigerant pipework
between the internal and external units.
Failure to install and commission the refrigerant pipework correctly will invalidate the appliances warranty.
Additional guidance can be found in the External Unit’s manual.
The interconnecting pipework is 10mm and 16mm.
In order to connect the refrigerant line and the electrical cables to the exterior unit the wall must be breached. The
breach/hole must be a min. of Ø 70 mm and 10 mm gradient from inside to outside.
To avoid damage the breach/hole should be padded from within as detailed below and lined with a PVC pipe.
After assembly has been completed the wall breach/hole on site should be sealed with an appropriate sealing compound
in accordance with fire prevention regulations. Do not use substances containing cement or lime for this purpose.
#
1
2
3
4
Description
Communication / Control Cable
10mm Refrigerant Pipe
Communication / Control Cable
16mm Refrigerant Pipe
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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The external unit is supplied with 3.5kg of R410A refrigerant which is sufficient for 10m (One Way) of interconnecting
pipework.
Refrigerant lines must be countersunk to avoid clipping particles
#
1
2
Description
Refrigerant Pipework
Countersink Tool
For connection to the exterior unit a flare border must be added to the copper pipe ends.
#
Description
3
Bordering Tool
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Please ensure that the correct border dimensions are adhered to.
Copper Pipe External Diameter
10mm
16mm
Border Dimensions
12.8 – 13.2 mm
19.3 – 19.7 mm
Ensure that the correct tightening Torque is used.
Diameter
3/8”
5/8”
Tightening Torque
32-40 Nm
65-75 Nm
If any brazing/welding work is undertaken on the refrigerant line, a protective gas (i.e. nitrogen) will need to be passed
through the pipe in order to prevent scale formation. Scale and other contamination can impair the proper operation of
the device leading to premature failure which will not be covered by the unit’s warranty.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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12.0 Electrical Connections
Both the internal and external units require suitably rated power supplies.
Electricals internal unit
Power supply system
Fuse on site, Tripping characteristic B
Electricals external unit
Power supply system
Starting current max.
Operating current
Rated power consumption
Fuse on site (exterior unit), Tripping characteristic C
V / Hz
1 Phase 230 V 50 Hz
A
16
V / Hz
1 Phase 230 V 50 Hz
A
19
A
9,74
kW
2,32
A
20
A 3 core and earth link from the internal unit to the external unit provides control and operational data feedback.
Please note that a power supply for the external unit is present within the internal unit
Please ensure that the power supplies to both the internal and external units are isolated prior to undertaking
work on either unit to prevent electrical shocks.
Internal Unit Power Connections
3=L, 6=N, 8=E.
Output to Heating
Pump
3 Core
230V
1 Amp
External Unit
LNE
Unit Power Supply.
3 Core
230V Single Phase
25 Amp Supply.
17=L, 18=N, 19=E.
Output to HWS Pump
3 Core
230V
1 Amp
23=S1, 24=S2,
25=S3, 22=Earth
Internal unit to
External unit
Control
3 Core + Earth
230V
5 Amp
32=L, 31=N, 30=E.
Unit Power Supply.
3 Core
230V Single Phase
10 Amp Supply.
S1, S2, S3. Earth
Internal unit to External unit Control
3 Core + Earth
230V
5 Amp
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Internal Wiring
Internal Wiring Diagram Heat Pump Module
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Internal Wiring Diagram Heat Pump Module
Main #
Sub #
Sub #
Description
X12
(TB141)
5/6
Compressor
Relay Heating Zone 1 Pump
X12
(TB142)
1/2
Compressor
A2
Relay Heating Zone 2 Pump
X11 (S1)
1/2
3 /4
Main Power Switch L
Main Power Switch N
A3
Relay Hot Water Pump
1
Compressor Operating Indicator Lamp
2
Indicator Lamp Neutral
1
Hand Mode Indicator Lamp
2
1
Indicator Lamp Neutral
Automatic Operation
2
Live in to Hand Auto Switch
3
Hand Operation
1 /2
Unit Fuse 6.3 A
1
2
3
4
5
6/7
8/9
10
11
12
13/14
15/16
17
18/19
20/21
22
Power Supply Company Control EU
Power Supply Company Control EU
Heating Zone 1 Power Output
Heating Zone 1 Valve Open Output
Heating Zone 1 Valve Close Output
Common Neutral
Common Earth
Heating Zone 2 Power Output
Heating Zone 2 Valve Open Output
Heating Zone 2 Valve Close Output
Common Neutral
Common Earth
Hot Water Pump Output
Common Neutral
Common Earth
External Unit Earth
S1 230Volt Communication to External
Unit
S2 Ground Communication to External
Unit
S3 24V Communication to External Unit
Neutral For Unit Pump
Neutral For Gas Condensing Boiler
230 V Power Supply to Gas Condensing
Boiler
Earth For Gas Condensing Boiler
Main Earth Input
Main 230V Neutral Input
Main 230V Live Input
A5
A6
A7
A8
A9
KR (X2)
Main #
A1
A4
X13
Description
Maximum output loading 1Amp per
output
Total loading 6.3 amp
Relay Heating Zone 2 Mixing Valve
Open
Relay Heating Zone 2 Mixing Valve
Close
Relay Heat Pump Enable
Relay Gas Boiler Enable
Relay Heating Zone 2 Mixing Valve
Open
Relay Heating Zone 2 Mixing Valve
Close
A10
Relay Heat Pump Pump
A12
E1
E2
1
2
3
4
5/6
7
8
4/5
6/7
8
9/10
Relay Unit Pump
Power Supply Company Control
Not Used
Not Used
Power Supply to Gas Boiler L
Power Supply 3 Way Valve L
Power Supply to Gas Boiler N
Not Used
Power Supply 3 Way Valve N
Power Supply 3 Way Valve L*
Not Used
Heating Enable (Volt Free)
Not Used
Hot Water Enable (Volt Free)
X11 (b1)
X11 (b2)
X11 (S2)
X11
(6.3AT)
X10
23
24
KR (X14)
11/12
Not Used
25
26
27
28
29
30
31
32
*Permanent Live for 3 Way Valve
Item
UV1
K6
K8
K3
K9
P1
P2
SW1
Description
3 Way Valve
Heat Pump Enabling Relay
Boiler Enabling Relay
Hot Water Control
Manual Override to Enable The Gas Boiler and Pump
Unit Pump
Heat Pump Pump
Flow Switch
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Internal Unit Sensor Terminals (All sensor/inputs are twin core with the second core connecting to the terminal below)
#
Sensor Function
Location
Voltage / Wire
41.0/F9/
Outside Air Sensor (Required)
North/North East Facing Wall
<24 Volt / 4 Core / Screened
42.6/F8
Common Flow Sensor
Internal
<24 Volt / 2 Core / Screened
43.0/F6
Hot Water Sensor
External Calorifier
<24 Volt / 2 Core / Screened
40.1/F5
Heating Circuit 2 Flow Sensor
Heating System
(If a 3 port valve is used.)
<24 Volt / 2 Core / Screened
44.0/F3
Volt Free Heating Enable*
Via a Volt Free Room Unit
<24 Volt / 2 Core / Screened
44.2/F2
Thermal Store Sensor (Middle)
External Buffer
<24 Volt / 2 Core / Screened
44.1/F1
Thermal Store Sensor (Lower)
External Buffer
<24 Volt / 2 Core / Screened
40.0/F11
Heating Circuit 1 Flow Sensor
Heating System
(If a 3 port valve is used.)
<24 Volt / 2 Core / Screened
43.1/F12
Hot Water Sensor (Lower)
Multifunctional Relay 2 (MF2)
<24 Volt / 2 Core / Screened
F/13
No Function Within Hybrid
Multifunctional Relay 3 (MF3)
45.0/F14
Solar Collector Sensor
Optional Solar Panel (MF4)
F15
0-10 Volt Control Input
External Controller
42.3/F17
Heat Pump Return Senor
Internal to Unit
<24 Volt / 2 Core / Screened
CAN
Communication Ports
~
<24 Volt / 4 Core / Screened
BM
Room Unit
Heated Space
<24 Volt / 4 Core / Screened
BMT
Heat Pump Controller
Internal
<24 Volt / 4 Core / Screened
<24 Volt / 2 Core / Screened
*If a timed volt free enable is used, all heating time switches should be set to ON --:-- OFF --:--
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Internal Wiring Diagram Gas Condensing Boiler
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Gas Condensing Boiler Internal Wiring Diagram Legend
Item
AF
BpKR
DP
EA
EAW
GVZ
G
IZ
KR
NS
PC
RL
RT
UV1
VL
WS
DHW
X1
X2
X3
X4
X5
X6
X7
X14
ZES
Description
Outside Air Sensor
Common Earth Rail
Display Fascia
Common Earth Rail
Combustion/Heat Exchanger Chamber Earth
Connector
Gas Valve & Ignition Transformer/Rectification Unit
Combustion Fan
Ignition / Rectification Electrode
Controller PCB
Power Supply
Notebook Interface Connection
Return Sensor
Boiler Enable
3 Way Valve
Flow Sensor
Resistor 220 Ohm 5W
HWS Relay K3
Gas Valve and Ignition Output
3 Way Valve and Power In
Combustion Fan
External Sensor Input and Boiler Enable
PC Interface
No Function
Internal Sensor Input
Relay Interface Within Heat Pump Module
Ignition Electrode Cap 1k ohm
Associated Terminals.
Block X4 Terminals 8 & 9
~
~
~
~
~
~
~
~
Block 2 Terminals 2 L & 4 N
~
~
Block 4 Terminals 7 & 8
Block 2 Terminals 7 & 8
~
~
~
230 Volt
230 Volt
24 Volt
24 Volt
24 Volt
~
24 Volt
230 Volt / 24 Volt
~
Terminal X1
Terminal
1
2
3
4
--
Colour
Red
Black
Blue
Brown
Green / Yellow
Description
Rectification
Live
Gas Valve Neutral
Ignition Neutral
Protective Earth
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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13.0 Internal Hydraulic Configurations
Legend
#
1
2
3
4
5
6
F8
F17
K-VL
K-RL
SW1
Description
Gas Condensing Boiler
Hybrid Pump
3 Way Diverting Valve
Heat Pump Heat Exchanger
Heat Pump Pump
Heat Pump Low Loss Header
Hybrid Common Flow Senor
Heat Pump Return Senor
Hybrid Flow Pipe
Hybrid Return Pipe
Hybrid Flow Switch
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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14.0 Hydraulic Configuration
Single Heating Zone system with direct on Hybrid weather compensation and priority hot water.
Electrical Connections
Internal Unit Power.
Internal Unit Sensors
*If a timed volt free enable is used, all heating time switches should be set to ON --:-- OFF --:--
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15.0 Hydraulic Configuration
Dual Heating Zone system with direct on Hybrid weather compensation and priority hot water.
Electrical Connections
Internal Unit Power.
Internal Unit Sensors
*If a timed volt free enable is used, all heating time switches should be set to ON --:-- OFF --:-Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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16.0 Fluing Installation Options
When flues are installed with horizontal sections/portions a 3 0 fall back to the boiler must be maintained. This will not
only ensure condensate removal preventing premature seal failure, but also prevent nuisances dripping from the wall
terminal.
Please ensure that the flue adapter is installed prior to installing any addition flue components .
Concentric Wall Terminal Configuration
Concentric Roof Terminal Configuration
The boiler can also be installed open flued, taking air from the room. DN 80 Components are used in this configuration.
Flexible flues systems are also available with coils available up to 50M.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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17.0 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 operational faults.
80/125mm Concentric Flue Components
Wall Terminal
Vertical Terminal
955mm Flue Extension
500mm Flue Extension
255mm Flue Extension
87º Bend
45º Bend
30º Bend
Hybrid
(Pa Resistances)
5.0
5.0
4.0
2.0
1.5
4.0
2.0
1.5
80mmØ PPS Flue Components
Exhaust Pipe Terminal
Air Pipe Terminal
955mm Flue Extension
500mm Flue Extension
255mm Flue Extension
87º Bend
45º Bend
30º Bend
(Pa Resistances)
2.5
4.0
3.0
1.5
1.0
3.0
1.5
1.0
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18.0 Balanced Flue Terminal Positions For Boilers Below 70kW Net Input
(All measurements are in mm and are minimum clearances.)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S
Terminal Location
*Below and opening window etc.
Below gutter soil pipes etc.
Below Eaves.
*Below balconies or car port roof.
From vertical drain or soil pipe etc.
From internal or external corners.
Above ground or balcony level.
From a surface facing the terminal.
From a terminal facing the terminal.
*From opening in a carport into a dwelling.
Vertically from a terminal on the same wall.
Horizontally from a terminal on the same wall.
Above an opening, window etc.
*Horizontally to an opening, window etc.
Above a level roof (base of terminal.)
From an adjacent wall (edge of terminal.)
From adjacent opening, window etc.
From any other flue terminal.
Boilers with a rated Input < 70kW Net
300
75
200
200
150
300
300
2000
2000
1200
1500
300
500
300
500
500
1000
600
* Positions not recommended.
Groups of appliances of 150kW gross input (136kW net input) and above must comply with the Clean Air Act with respect to the chimney discharge
height.
The terminal/s shall be guarded if it is less than 2000mm above the ground or in any position where it may cause injury to persons resulting from
touching a hot surface. Absolute guidance must be sought from the respective regulation.
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19.0 Pressure (Safety) Relief Valve
In accordance with the prevailing British Standard 5440/6644, 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 units circulation pump, it is therefore
recommended to locate the Pressure (Safety) Relief Valve on the return pipe immediately adjacent to the heat generator;
furthermore, there must not be any means of isolation between the unit and the Pressure (Safety) Relief Valve.
To assist with the correct positioning of the pressure relief valve hydraulic connector kits are available as an optional
extra.
20.0 Filling The Heating System
The Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by
the Water Regulation Advisory Scheme (WRAS) for that type of heating system.
i.e. Domestic (In-House)
Non Domestic (Other than In-House)
Fluid Category 3 (C-3)
Fluid Category 4 (C-4)
For Category 3 systems, the approved method of filling must comprise of the following components in the arrangement
shown;
 Control Valve incorporating a Double Check
Valve on the Mains Cold Water pipework.
 Temporary Connecting Hose, which must be
disconnected after use.
 Control Valve, on the heating system.
For Category 4 systems, the approved method of filling must comprise of the following components in the arrangement
shown;

Control Valve.

Strainer.

Verifiable Backflow Device with Reduced
Pressure Zone (RPZ Valve).

Incorporating a ‘Type BA’ Air Gap.

Tundish.

Control Valve.
Furthermore, in accordance with BS 6644: 2005 system with an input greater than 70kW (nett), an automatic water
replenishment unit shall be installed to automatically replenish any lost or evaporated water.
Please refer to BS 6644: 2005 for allowable water replenishment methods for use with sealed/pressurized heating
systems.
For information on a comprehensive range of pressurization units that comply with current British Standards and
WRAS Regulations, please contact MHG Heating Ltd Sales.
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21.0 Expansion Vessel
In accordance with BS 6644: 2005, WRAS Regulations, and Local Authority Water Regulations, as applicable, the
installer shall install a suitably sized, and approved, Expansion Vessel to ensure that the water capacity of the system has
ample expansion capacity.
The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service Valve, which
shall be locked in the OPEN position, to prevent accidental isolation.
Furthermore, a drain facility should be provided adjacent to the expansion vessel to aide the routine maintenance,
overhaul, of the vessels Air Pressure setting.
For information on a comprehensive range of expansion vessels that comply with current British Standards and
WRAS Regulations, please contact MHG Heating Ltd Sales.
22.0 System Water Quality
Water Treatment, System Cleaning (BS 7592: 2006)(Building Regulations Part L).
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. Particular care must be taken where the Hybrid boiler is being retrofitted into an old/existing system, as system silt or magnetite can be very damaging to the new unit.
Following cleaning and flushing the system MUST be dosed with a good quality water treatment to prevent corrosion
and the formation of scale. FAILURE TO OBSERVE THESE REQUIREMENTS WILL RENDER THE WARRANTEE
ON THE APPLIANCE VOID.
Cleaning, flushing and water treatment must be carried out in accordance with the requirements of BS 7592:2006, prior
to commissioning the boiler.
Repeated draining and refilling of the system, without replenishment of water treatment, must be avoided, as this is very
damaging to the boiler. The boiler must not operate without the system water being correctly and adequately treated, and
maintained, with an appropriate level of corrosion inhibitor.
For specific guidance on water treatment, direct contact is advisable with:Betz Dearborn Limited
(Sentiel)
Foundry Lane
Widnes
Cheshire
WA8 8UD
Tel: 0151 424 5351
Fax: 0151 420 5447
Alpha-Fry Technologies (Fernox)
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey
GU21 5RZ
Tel: 0208 665 6666
Fax: 0208 665 4695
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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23.0 Appliance Controls
Prior to activating the unit for the first time please ensure that all services, systems and sensors have been
installed, checked, flushed, all pumps & valves are bled and free to operate.
A self test mode is initiated by both the internal and external units. This may take up to 10 minutes.
Within this period the units will not operate.
When power is applied to the unit the controller will display END and OK.
END must be selected.
If OK is pressed the installation menu can be adjusted from the factory defaults. If alterations are made the unit
may not function as designed.
If no button is pressed within 5 Seconds the screen will refresh to the standard operating mode.
The Green Lamp must stop flashing before any programing can be undertaken.
The appliances control / display panel provides access to the majority of the units control settings.
A separate control panel is mounted on the gas condensing boiler. Once commissioned this panel should not need
adjusting. (Detail for this panel is provided later in this manual).
#
1
2
3
4
5
Description
Main Power Switch
Heat Pump Operation Indicator
Manual Override Button Commissioning Mode
Automatic / Manual Operation Switch
Main Fuse (6.3 Amp)
Adjustment of the controller is undertaken via the HOME BUTTON, the DISPLAY BUTTONS and the INFO WHEEL.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Controls
Function
Provides access to the setting parameters screen from a default screen.
Returns the screen to a default screen from a parameter setting screen.
Provides access to the second level information of the displayed value.
Selects a value to be altered by the INFO WHEEL. Stores the new value.
Changes the default display when more than four lines are available.
Changes the set value within the parameter setting mode.
Additional Controller information can be found in the Controller Manual at the rear of this manual.
24.0 Controller Defaults
The controller has been preset to allow the unit to operate and provide the optimum operating efficiency.
The operating mode of the unit can be adjusted by pressing the lower DISPLAY BUTTON, using the INFO WHEEL and
pressing the lower DISPLAY BUTTON to store the setting.
If the unit fails to operate please check the operation of all associated pumps, valves, enabling circuits prior to adjusting
any settings.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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End user parameterization
Key sequence: Home
 Controller  User
Description
System
Mode of operation
Language
LCD Contrast
LCD Brightness
Date and Time
Time Master
°C / °F
Range
Default
Off/On
Automatic 1
English
4
30
-20 to + 20
00-30
00:00-24:00 / 1-7
On / Off
Celsius, Fahrenheit
Warm Water (DHW)
1x Warm Water
T-DHW 1 Target
T-DHW 2 Target
T-DHW 3 Target
BoB-Value
Circ with DHW Prog
Anti-legionella
Off/On
10-70°C
10-70°C
10-70°C
0 K - 70 K
Off/On
Off/On
As Left
On
Celsius
Off
50°C
50°C
50°C
0K
Off
Off
Factory parameterization (HP) heating technician
Key sequence: Home
 Controller  Technician
Description
Range
Default
As Left
Heating circuit (HK) 1 / 2
Mode of operation
T-Room Target 1
T-Room Target 2
T-Room Target 3
T-Reduced
T-Absent
T-Room cool
Min TA cool
T-Flow Constant Target
T-Flow Constant Reduced
Standby, Automatic 1/2, Summer,
Heat, Reduced
Standby, Automatic 1/2, Summer,
Heat, Reduced
5-40°C
5-40°C
5-40°C
5-40°C
5-40°C
----, 20-40°C
----, 0-40°C
10-110°C
10-110°C
HK 1: ---HK 2: ---20°C
20°C
20°C
18°C
15°C
25°C
27°C
45°C
30°C
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Description
Heat limit day
Heat limit night
Heat curve
Rad adaption
Influence of room
Adjust Room Unit
Heat optimum
Max on-time
Low Optimum
PC Release
Configuration
Terminal
Change code
Controller Address
BUS-ID HK1
BUS-ID HK2
eBUS supply*
System selection
Control type
HS1 type
Gradient
HS BUS
HS2 type
HS2 reservoir
HS3 type
HS4 type
Buffer
Cooling operation (optional)**
F15 Function
E1 Function
E2 Function
Sensor
Heat source
Max T-HS1
Min T-HS1
Min T-HS2
Max T-Accumulator
Min T-Accumulator
Starting-load relief
Min limit
Hysteresis (or Hyst HS)
Hysteresis Time
Change of sequence
Clock inhibition
Hysteresis burner 2
Range
Default
----, -5°C to +40°C
----, -5°C to 40°C
0,00-3,00 (U/F=1.1. Rads=2.5)
OFF/ON
00-20
-5,0 to +5,0 K
Off, T-Reduced, T-Room
0:00-3:00 h
0:00-3:00 h
0000-9999
19°C
16°C
1.1
Off
0
0,0 K
Off
0:00 h
0:00 h
0
00-05
00-22
00-03
00-09
00-09
00, 01, 02
Off/On
00-08
00-03
00-03
1k / 5k Sensors
On
3000
1
1
2
Off
7
6
7
Off
5
1
0
1
0
0
Off
8
2
0
5k
30-110°C
10-80°C
10-80°C
30-110°C
10-80°C
10-85°C
00, 01, 02
5-20K
00-30 min.
00-800 h
00-30 min.
2-20 K
85°C
10°C
10°C
95°C
10°C
10°C
0
5K
00 min.
00 h
00 min.
2K
0000-9999
01-16
(00), 01-15
(00), 01-15
Off/On
----, 01-13
00-06
00-09
As Left
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Description
Gradient
Max lowering
Dynamic switch-off
HS Cool-Factor
T-WE start cool
Cascade
HS found
Power / step
HS1 step1
HS1 Step2
HS2 Step1
HS2 Step2
HS3 Step1
HS3 Step2
HS4 Step1
HS4 Step2
BUS Scan
min Mod cascade
DHW-HS
Error signal
Power nominal
Switching value
Remainder blocking time
Max T-HS
HS-Dynamic On
HS-Dynamic Off
Adjust time
Modgrad On
Modgrad Off
Min Modgrad
Modgrad DHW
HS sequence 1
HS sequence 2
Range
Default
On/Off
1-20 K
0,5-10 K/min.
Off/On
30-120°C
Off
10 K
2 K/min
Off
95°C
Display
00-9950 KW
00-9950 KW
00-9950 KW
00-9950 KW
00-9950 KW
00-9950 KW
00-9950 KW
00-9950 KW
On/Off
00-100%
10
--25
----------Off
0
0
Display
Display
Display
Display
90°C
250 K
75 K
50
100%
95%
0%
100%
1,2,3,4
4,3,2,1
Sequence change
Cycle lock
K
0-100%
(-99) - 0 - (99)
Rest [min]
50-110°C
20-500 K
20-500 K
5-500
50-100%
10-60%
0-60%
40-100%
WE sequence 1, WE sequence 2, periodic,
1/2 interchange, rotating, sorting
0-800 h
00-30 min.
Buffer
Load T-Buffer
T-PU night-load
Min T-B Puffer
40-90°C / OFF / Requirement
0-90°C
10-90°C
Requirement
Off
10°C
30-110°C
10-20°C
-20°C to +40°C
-30°C to +10°C
60°C
12°C
0°C
0°C
Sequence mode
Heat Pumps (HP)
Max T-RL HP
Min T-RL HP
Max TO HS
Min TO HS
As Left
1
0h
0 min.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Description
Range
Default
F15 Function*
E1 Function*
E2 Function*
RL Offset
Min T-DHW HS
Min T-PU HS
Max HS off-time
00-08
00-03
00-03
0-15 K
0-90°C
0-90°C
----, 10-210 min.
8
2
0
5K
51°C
10°C
Off
Cooling operation(optional)**
T-RL cool
Cooling off at DHW
Cooling with HP
5-25°C
00-01 (OFF, ON)
00-01 (OFF, ON)
18°C
1
1
0-10V I/O
SPG curve
curve 11-U1
curve 11-U2
curve 11-T1
curve 11-T2
curve 11-UA
00-11
0,00-10,00 V
0,00-10,00 V
00-120°C
00-120°C
0,00-10,00 V
11
1,80 V
10 V
10°C
100°C
1V
Floor
Floor
Floor program
Off/On
See Explanation!
Off
Standard
Off/On
Teilvorr DHW, Ein, Aus, PPL Alle
00-50 K
5-30 K
00-30 min.
Off/On
Off/On
Off/On
Off
Aus
10 K
5K
0 min.
Off
Off
Off
Warm water (DHW)
Load pump locking
PPL
T-HS DHW
Hysteresis DHW
DHW Trail
TH Input
Thermfct
Fully load
As Left
Heating circuit (HK) I/II
HC Function
Pump Operation
Mixer On (not for DHW-circuit)
Mixer On (not for DHW-circuit)
Max T-Flow
Min T-Flow
T-VL cool (optional)**
T-Antifreeze
T- External Verz
Curve dist
Force decline
Standard, T-Prov const, Pool,
DHW, Return
Standard, Heat limits, Time program only, Non
stop operation
5-25
5-25
10-110°C
10-110°C
OFF, CLOSED, 10-25°C
----; -15°C to +5°C
0:00-24:00
0-50 K
Off/On
Standard
Standard
18
12
85°C
10°C
18°C
3°C
00:00
0K
Off
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Description
Solar/MF1-4
MF1 Function
T-MF1- Target
MF1 Hyst
MF1 Hyst Off
MF2 Function
T-MF2 Target
MF2 Hyst
MF2 Hyst Off
MF3 Function
T-MF3 Target
MF3 Hyst
MF3 Hyst Off
MF4 Function
T-MF4 Target
MF4 Hyst
MF4 Hyst Off
Max T-Solar
Min T-Solar On
Min T-Solar Aus Off
T-Solar Protection
Return-cool diff
Max T-Reservoir DHW
Max T-Reservoir PU
Max T-Reservoir 3
Solar kick-duration
Solar kick-pause
Solar kick-gradient
Range
Default
00-34
10-90°C
2-10 K
2-10 K
00-34
10-90°C
2-10 K
2-10 K
00-34
10-90°C
2-10 K
2-10 K
00-34
10-90°C
2-10 K
2-10 K
80-180°C
-20°C to +95°C
-20°C to +95°C
80-180°C
0 K - 30 K
10-130°C
10-130°C
10-130°C
0-59 sec.
10-60 min.
01-05 min.
0
0
5
1
125°C
15°C
10°C
125°C
0K
60°C
85°C
30°C
0 sec.
60 min.
01 min.
As Left
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25.0 Appliance Fault Codes (Heat Pump Controller)
Error
Error description
E 54
E 81
Fault in heat pump. External Unit Not Functioning / Switched Off.
If the external unit is malfunctioning the PCB mounted RED and GREEN LED will
provide fault data. Please use the label located on the door of the external unit or the
manual attached to the end this manual.
EEPROM error. Controller Setting Error.
The invalid value has been replaced with the default value
Check parameter values!
Communication error
E 90
Addr. 0 and 1 on bus. Bus IDs 0 and 1 may not be used simultaneously.
E 91
Bus ID used. The set bus ID is already in use by another device.
E 200 – E207
Communication HS1 – HS7 (cascade)
E 220 – E235
Communication BM 0 – BM 15
E 240
Communication Manager
E 241
Communication HS (individual HS)
E 242
Communication Mixer
E 243
Communication Solar
Sensor defective (break/short circuit)
E 69
F5: Flow sensor HC2
E 70
F11: Flow sensor HC1, sensor multifunction1
E 71
F1: Buffer storage tank low sensor
E 72
F3: Buffer storage tank top sensor
E 75
F9: Outdoor sensor
E 76
F6: Storage tank sensor
E 78
F8: Boiler sensor / Collector sensor (cascade)
E 80
Room sensor HC1, F2: Buffer middle sensor
E 83
Room sensor HC2,
F15: Pool sensor (storage tank 3)
E 84
Fault in humidity sensor
E 135
F12: HW Storage tank low sensor,
Multifunction 2
E 136
F13 (PT1000): HS2, Solar Panel 2,
Multifunction 3
E 137
F14 (PT1000): Solar Panel 1, Multifunction 4
E 140
F17 Return flow sensor total (heat pumps/cooling)
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26.0 Appliance Fault Codes (Boiler Controller)
If the boiler encounters an operation fault a code will be displayed on the boiler’s control panel.
Please note the fault code prior to resetting boiler.
Pressing the Reset button for 5 seconds resets the unit.
Fault Code
Display D
1
2
3
Fault Code
Display E
Description
Cause / Remedy
0
Flow Sensor S1 Fault
Return Sensor S2 Fault
Not Used
General Sensor Fault After Self Check
1
Temperature Too High
2
S1 or S2 Requires Replacing
4
No Flame Signal After 4 Ignition Attempts
5
Flame Out 4 Restarts
6
Flame Detected When Fan Off
7
8
F or h
Computer Connected to Controller
Fan Speed Incorrect
Internal Controller Fault
Check sensor and wiring
Check sensor and wiring
Not Used
Check wiring, replace sensors
Air in system, Strainer blocked, Pump
failure.
Check wiring, replace sensors
Gas supply Off, Gas pressure too low,
Gas Valve Faulty, Gas valve out of
adjustment, ignition electrode /cable
fault, Condensate drain blocked.
Gas pressure too low, Gas valve out of
adjustment, ignition electrode /cable
fault, Condensate drain blocked.
Ignition electrode /cable fault, Controller
fault.
Reset Unit
Fan fault, Fan wiring fault,
Reset Unit, Earthing fault
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27.0 Fuel Gas Conversion Procedure
Conversion of the gas setting ring
1. Switch off the electrical supply to the appliance.
2. Close the gas tap.
3. Remove the front cover of the appliance.
4. Disconnect the coupling (1) above the gas valve and turn the gas mixing pipe (2) backwards.
5. Replace the O-ring (3) and the gas setting ring (4) by the rings of the conversion set.
6. Reassemble in reverse order.
7. Open the gas tap.
8. Check the gas connections for tightness/ leaks.
9. Switch on the electrical supply to the appliance.
10. Change the parameters d and F to the values given in the table below.
11. Now check the setting of the gas/air ratio. (See below)
12. Attach a sticker of the set gas type over the existing sticker on the gas mixing pipe (2).
13. Apply a sticker of the set gas type at the appliance plate.
14. Refit the appliances case.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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28.0 Boiler Controls
The boiler utilized within the ProCon Streamline Hybrid is the ProCon Streamline.
The boiler is enabled via the Hybrids controller, however the boiler is equipped with its own controller which must be set
to provide the correct flow temperature for the system requirements.
All settings are made via the boilers control panel.
#
1
2
3
4
5
A
B
C
D
E
F
Description / Function
Power Mode Selector
Parameter Adjustment Selectors
Temperature Set Point Selector
Commissioning Mode Selector
Boiler Reset / Setting Store Selector
Power Indicator LED
Heating Mode Output Set Point Indicator LED
HWS Mode Output Set Point Indicator LED
Boiler Flow Set Point Temperature
Operating Mode Indication Display
Reset Required Indicator
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29.0 Controller Adjustment
The control panel can be used to set or review the operation parameters of the boiler. A number of the buttons have
dual/multiple functions dependent to the sequence of operation or function mode the unit is in.
1/A
Power Mode Selector/Indicator.
Pressing the button once will change to operating mode of the boiler.
If the LED is Red and the display is indicating -- the boiler is OFF and will not respond to an enabling signal.
If the LED is Green and the display is blank the boiler is ON and will respond to an enabling signal.
2 / 3 / B / C / D Boiler Flow Temperature Adjustment for Heating and HWS Operation.
Pressing button 3 will illuminate the heating mode LED B and display the respective target flow temperature on the
display D. This can be adjusted via the + & - buttons 2. The setting can be stored by pressing the Reset Button 5.
Pressing button 3 twice will illuminate the HWS mode LED C and display the respective target flow temperature on the
display D. This can be adjusted via the + & - buttons 2. The setting can be stored by pressing the Reset Button 5.
4 / E / 2 Commissioning Mode Selection
The commissioning mode can be activated by pressing the following buttons in the required sequence.
Required Function
Low Fire
Hire Fire Heating Mode
Highest Firing Mode
Exit Commissioning Mode
Buttons
Service Button 4 & Minus Temperature Button 2
Service Button 4 & Plus Temperature Button 2
Service Button 4 & Plus Temperature Button 2 Twice
Minus Temperature Button 2& Plus Temperature Button 2
Display
L
h
H
Normal Control
These operating mode must be used when commissioning the appliance and following any service interventions.
5 / F Reset / Storage Button
If the unit fails to operate correctly and the unit Locks-Out the F LED will be illuminated, a fault code will be displayed
on E and the Reset button must be pressed for up to 5 Seconds to reset the boiler. Prior to resetting the boiler the fault
code displayed on E should be noted.
Second Level Access and Alteration
A second level of operational parameters can be accessed and altered if required to suit the installation.
The second level is accessed as follows.
Switch Off the boiler by pressing button 1 so that the display E indicates -.
Press Service 4 and Reset 5 buttons simultaneously until the display E indicates – and the display D indicates 0.
Press the + button to change the Display D to 15. Press the Service 4 button to accept the password.
Access to the second level is now available.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Pressing the Service 4 buttons provides access to the different functions. The + & - buttons are used to alter the function.
The Reset 5 button is used to store the altered functions.
Function
0
1
Setting
Access Code
System Type
Required Setting
15
3
Description
Second Level Access Code
2
CH Pump Continuous
0
3
4
5
Set CH Power %
Set Max Power
Weather Comp Curve Min Flow Temp.
Weather Comp Curve Outside Air Max
Flow Temp.
Weather Comp Curve Outside Air Max
Temp.
CH Pump Over-run Time
CH Pump Over-run Time HWS Mode
Rest Position of 3 way valve or 2 Port
Valve Present
70
80
25
0 = Pump Overrun Only
1 = Pump Continuous
2 = CH Pump Continuously Active with
External MIT Switch
CH Output
HWS Output
Max Outside Air Temp For Min CH Flow Temp
-1
Min Outside Air Temp For Max CH Flow Temp
25
Max Outside Air Temp for CH Operation
1
1
C
Step Modulation
0
d
Minimum Output
30
0 -15 Minutes
0 – 15 Minutes
0 = Confirmed During CH Operation
1 = Confirmed During HWS Operation
0 = Step Modulation Off During CH Operation
1 = Step Modulation On During CH Operation
25%-40% Nat Gas
40% LPG
Requested Flow Temp Below Which the Boiler
Will Not Operate
40 – 99%
40 = 4000rpm 50 = 5000rpm
6
7
8
9
A
E
F
H
Min Flow Temp Requested by
Open-Therm Controller
Ignition Speed % of Max
Max Fan Speed
0
40
70
45
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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30.0 Commissioning The Appliance
We recommend that the unit is commissioned by a MHG engineer to maximize operational efficiency and longevity.
The refrigerant system must be commissioned in line with the guidance provided in the External Units technical manual.
31.0 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.
Prior to applying power to the appliance its circulation pumps should be bled and checked to ensure free rotation of the
armature.
32.0 Combustion System Commissioning
A flue gas analyser must be used to ensure that the correct combustion settings are achieved.
The appliance must be placed in the commissioning mode to check and set the combustion at Maximum and Minimum
outputs.
This is achieved as follows.
Locate the flue gas sampling point on the flue adapter mounted directly above the boiler.
The commissioning mode can be activated by pressing the following buttons in the required sequence.
Required Function
Low Fire
Hire Fire Heating Mode
Highest Firing Mode
Exit Commissioning Mode
Buttons
Service Button 4 & Minus Temperature Button 2
Service Button 4 & Plus Temperature Button 2
Service Button 4 & Plus Temperature Button 2 Twice
Minus Temperature Button 2& Plus Temperature Button 2
Display
L
h
H
Normal Control
Insert your flue gas analyser in the sampling point and note the readings for the low and high outputs.
The High fire setting should always be set prior to adjusting the Low fire.
Adjust the unit to operate at High fire and adjust the gas valve B to obtain the correct CO2%.
Adjust the unit to operate at Low fire and adjust the gas valve B to obtain the correct CO2%.
Following the successful adjustment of both High and Low fire setting the boiler should be allowed
to pass through one ignition cycle prior to the settings being rechecked.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Gas Valve Adjustments
A = Dust Cap, B = High & Low Fire Adjustment, C = Off-Set pressure point, D = Inlet pressure point.
Required combustion settings
Setting
Low Fire CO2%
High Fire CO2%
Minimum Inlet Dynamic Gas Pressure Mbar
Outlet Restrictor Diameter mm
Minimum Fan Speed (Parameter d)
Minimum Ignition Speed (Parameter F)
Natural Gas (H) (G20)
8.9
9.1
18
7.05
25
70
LPG (P) (G31)
9.9
10.3
29
5.35
40
50
33.0 Routine Inspection and Servicing
As with all appliances, we would highly recommended that a competent heating engineer services the Hybrid unit, at least every 12
months. This is assuming a normal daily usage of 8 – 10 hours.
If however the unit is to be operated 24 hours a day, 7 days, we would recommend services every 6 months.
If the Installer/Commissioning Engineer is unable to undertake the Routine Service Inspection, as detailed in the following section for
the boiler and the respective section of the installed external evaporator manual, please contact the MHG Technical Department, who
will be able to arrange the Routine Service Inspection to be undertaken.
34.0 Routine Service Inspection
Before commencing any service/maintenance work, the following tasks must be undertaken.
a)
b)
c)
d)
e)
f)
g)
h)
i)
Ask the end user about any problems with the operation of the unit and note their comments.
Check the water pressure of the installation.
Remove the units casing and visually inspect all pipe and water joints for signs of leakage.
Inspect the appliance for signs of water leakage or ingress.
Run the Heat Pump section of the Hybrid. Visually inspect the external unit.
Run the unit in Commissioning Mode HIGH FIRE; with the use of a flue gas analyzer record the CO 2 level.
Run the unit in Commissioning Mode LOW FIRE; with the use of a flue gas analyzer record the CO2 level.
Listen to the sound of the combustion fan.
Undertake a System Water Analysis to check the concentration level of the Water
Treatment, and note the level onto the
Service Report.
j) Check the flue route including the terminal position for conformity with prevailing regulations, and trim back any foliage that
may be around the terminal.
k) Check the plant room/compartment ventilation system for conformity with prevailing regulations.
l) Check the Pressure (Safety) Relief Valve size, rating and orientation, for conformity with prevailing regulations.
The results of the Inspections undertaken above must be acted upon, and all discrepancies should be recorded on the Service Report
and brought to the Client / End User’s attention.
Undertake any maintenance, and if necessary any preventative maintenance, that’s required.
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35.0 Routine Cleaning & Maintenance (Boiler Module)
As part of the Routine Service Inspection, certain areas of the boiler need to the checked and cleaned as necessary.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Turn the boiler OFF at the ON/OFF switch and electrically isolate the boiler by removing the plug or fuse from the boiler
supply.
Turn off the fuel supply at the boiler isolation tap, fitted by the installer, adjacent to the appliance.
Remove the electrical connections from the boiler.
Remove the burner plate from the boiler.
Inspect the burner and clean with compressed air as required. Do not brush the burner. Ensure that the compressed air does not
damage the burner surface.
Brush the heat exchanger with a suitable soft bristled brush.
Adjust the ignition electrode as indicated in the image below.
Flush the heat exchanger with water.
Open the condensate trap and clean.
Refit the condensate trap and refill with water via the heat exchanger.
Refit the burner plate assembly.
Ensure that all electrical connections are correctly and securely connected.
Inspect all water joints. Any joints found to be leaking MUST be replaced. It is also advisable when replacing water joints to
also change any adjacent joints at the same time.
Inspect all fuel joints with a suitable leak detection method. Any joints found to be leaking MUST be replaced. It is also
advisable when replacing joints to also change any adjacent joints at the same time.
With the use of a suitable Flue Gas Analyser, check and adjust the combustion settings.
Inspect the general condition of the flue system, including the termination, repair as necessary or advice on any remedial action
as required.
Following the satisfactory completion of the above service procedure complete the required paperwork and leave the boiler as
found if possible.
Burner Plate Removal
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Ignition Electrode Adjustment
With the burner assembly removed set the ignition electrode to 27-29mm from the edge of the casing. This will ensure that the gap
will be 4.5 mm when the burner assembly is refitted.
36.0 Routine Cleaning & Maintenance (Heat Pump)
Please refer to the annual service data for the external unit provided in the specific manual at the rear of this manual.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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37.0 Fault Codes. (Gas Boiler Module)
If the boiler encounters an operation fault a code will be displayed on the boiler s control panel.
Please note the fault code prior to resetting boiler.
Pressing the Reset button for 5 seconds resets the unit.
Fault Code
Display D
1
2
3
Fault Code
Display E
Description
Cause / Remedy
0
Flow Sensor S1 Fault
Return Sensor S2 Fault
Not Used
General Sensor Fault After Self Check
1
Temperature Too High
2
S1 or S2 Requires Replacing
4
No Flame Signal After 4 Ignition Attempts
5
Flame Out 4 Restarts
6
Flame Detected When Fan Off
7
8
F or h
Computer Connected to Controller
Fan Speed Incorrect
Internal Controller Fault
Check sensor and wiring
Check sensor and wiring
Not Used
Check wiring, replace sensors
Air in system, Strainer blocked, Pump
failure.
Check wiring, replace sensors
Gas supply Off, Gas pressure too low,
Gas Valve Faulty, Gas valve out of
adjustment, ignition electrode /cable
fault, Condensate drain blocked.
Gas pressure too low, Gas valve out of
adjustment, ignition electrode /cable
fault, Condensate drain blocked.
Ignition electrode /cable fault, Controller
fault.
Reset Unit
Fan fault, Fan wiring fault,
Reset Unit, Earthing fault
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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38.0 Weather Compensation Slope
100
2
80
1,5
1,2
60
1
0,8
40
0,6
0,4
0,2
20
20
16
12
8
4
0
-4
-8
-12
-16
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39.0 Exploded Spares Diagram (Gas Boiler Module)
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Internal heat pump exploded diagram to follow.
Please refer to the external unit manual at the rear of this manual for the respective exploded diagram
40.0 Parts List
Please quote the respective bubble and page number when requesting replacement components.
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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Notes
Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey, KT20 5LR
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