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INSPIRED EFFICIENCY
ETHOS 70, 90, 110 & 130
Wall mounted gas fired
condensing boilers
TECHNICAL
DOCUMENTATION
Issue 05/08
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TABLE OF CONTENTS
Technical Data
1
Dimensions
2
1. Safety guidelines
Conditions
General guidelines
Service
General restrictions
3
2. Description
General
Application features
Main components
Boiler control
Safety aspects
4
3. Delivery & transport
Delivery
Transport
8
4. Installation
Regulations
Installation area
General
Installation
Ventilation
Connections
Gas connection
Electrical connections
Wiring diagram
Internal controls breakdown
Controls & options
Water connections
Flue connections
Flue gas outlet and air inlet pipe
Flue
Flue parameters
Condense connection
Hydraulic system
Flow and resistance
Pump characteristics
9
2
Technical Documentation
4
5
6
7
10
11
12
13
14
15
16
17
Shut-off valves
Valves
Water flow protection device
Water pressure
System expansion vessel
Water pressure protection device
Water temperature
Water quality
Water hardness
5. Operating Instructions
Operation
Controls
Boiler module
Boiler operation
Adjusting the room temperature setpoint
Heating curve
Boiler temperature setting
Display information
Manual operation
Programming
User levels
List of displays
Error codes
Maintenance codes
Special operation codes
Switching on the appliance
Switching off the appliance
Warnings
6. Commissioning
General
Commissioning
18
19
20
21
22
23
24
25
26
28
30
31
32
7. Maintenance
Safety
General
Removal of parts
35
8. Boiler parts
40
9. Conversion formulae and factors
42
36
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TECHNICAL DATA
* With this resistance valuetheheat output will remain within the specifications indicated on the dataplate;
if the resistance is higher, the heat output will drop,
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DIMENSIONS
Type
70
90
110
130
B1
mm
120
140
140
140
B2
mm
260
260
260
260
D
mm
80
100
100
100
D1
mm
80
100
100
100
R 3/4”
R 3/4”
R 3/4”
R 3/4”
G
L
mm
475
475
660
660
L1
mm
90
90
90
90
R 1 1/4”
R 1 1/4”
R 1 1/4”
R 1 1/4”
W
(We reserve the right to make changes without prior notification)
The data may deviate slightly due to fabrication tolerances.
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SAFETY GUIDELINES
Conditions
Mikrofill Systems Ltd. shall not be liable for any damages caused by non-compliance with this manual
instructions. Only original ETHOS parts must be used for service purposes.
General Guidelines
It is a statutory requirement that all gas appliances are installed in accordance with the manufactures instructions
and all current regulations in force, all instructions should be fully read before installing or using the appliance.
All installations should be carried out by competent persons as described in the Gas Safety (Installation & Use)
Regulations. i.e. CORGI registered and holding current certification.
The Manufacturers instructions MUST NOT be taken in any way as overriding statutory obligations.
This boiler has been tested and certified to comply with all necessary European directives, latest building
regulations and efficiency requirements, is CE marked and complies with;
90/396/EEC Gas Appliance Directive
93/68/EEC Low Voltage Directive (was 73/23)
92/31/EEC Electromagnetic Compatibility Directive
The boiler should be installed in compliance with
The building regulations (Scotland-consolidated)
The Health and safety at work act
Gas safety (installation & use) regulations
Building Regulations (Northern Ireland)
Building Regulations
Water fittings regulations or water bylaws in Scotland
Local water company bylaws
The boiler should not be modified in any way. Any modifications will invalidate the gas approval and invalidate
the warranty.
ATTENTION: High Voltage
Before opening the boiler casing for maintenance or servicing the 230VAC main supply to the boiler must
be disconnected!!
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SAFETY GUIDELINES
Service
Should you require any assistance during installation or in the unlikely event of a product failure please do not
hesitate to contact our technical service department on 08452 606020
General restrictions
Mikrofill products should always be used, installed and maintained in accordance with the statutory requirements,
specifications and standards applicable to these installations. Mikrofill cannot be held responsible for any losses or
damage whether direct or consequential that have arisen as a result of incorrect or poor installation.
Warning!
Particular attention must be given to the safety guidelines in section 1 as non compliance will
render the warranty void and may constitute an illegal installation.
DESCRIPTION
General
The Mikrofill Ethos wall mounted boilers are environmentally friendly gas fired heating boilers with a
modulation range between approximately 15% and 100% of their maximum output. The appliances have
low NOx and CO emission, which satisfy the most stringent environmental requirements.
The Ethos range has received CE Approval for all relevant European countries and has
been registered under the Product Identification Number
The boilers may be used on both open (type B23) as well as room sealed (type C13, C33,
C43, C53, C63 or C83) systems.
The boiler is delivered fully wired, fully assembled, tested and preset complete with emissions report.
Working principle and design
Air is drawn in as required, via a variable speed fan. The gas valve measures the negative pressure
(draught) in the venturi and modulates the gas valve in response. The gas/air is then thoroughly mixed in the correct
ratio in the fan housing and fired directly into the burner.
The boiler management system compares the actual water flow temperature to the required water
temperature. The management system computes the load required and adjusts the fan speed.
This is a continual process during operation.
The heat transfer takes place in a stainless steel double heat exchanger block. The burner fires into the primary heat
exchanger whilst the second heat exchanger ( condenser) is connected downstream in such a manner that the condense water cannot enter the primary heat exchanger, both heat exchangers consist of several smooth pipes in the
form of a coil and are connected using stainless steel water distribution manifolds.
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DESCRIPTION
The design of the boiler incorporates the following:Full operation and fault diagnostics via LCD.
Control / high limit sensors
Integral boiler shunt pump
Integral safety relief
Integral weather compensation ( optional external sensor required )
Integral advanced seven day timebase
Two stage frost protection.
Pressure readout
Compatible with most external BMS options including BUS systems
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DESCRIPTION
Main components
1.
2.
3.
4.
5.
6.
7.
8.
9.
8
Flue outlet connection
Air inlet connection
Gas connection
Flow connection
Automatic air vent
Return connection
Flue gas temperature sensor
Combustion fan
Automatic burner controller
Technical Documentation
10.
11.
12.
13.
14.
15.
16.
17.
18.
Condense Trap
Condense outlet
Boiler pump
Safety valve
Heat exchanger and burner package
Air intake duct
Air intake drain trap
Ignition transformer
Gas valve and venturi
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DESCRIPTION
Boiler control
If there is a heat demand, if all necessary conditions have been fulfiled and all safety devices are satisfied the
boiler will start. This heat requirement will arise if:
- The flow temperature of the boiler is less than the required flow temperature
- The manual option has been selected using the selector switch.
- The frost protection has been triggered independently of the operating conditions.
The boiler control unit adjusts the boiler output by changing the fan speed such that the desired temperature
is attained and maintained.The actual flow temperature is controlled within 4°C of the target temperature.
Safety aspects
The following safety devices are installed on the boiler:
- Temperature monitoring system
- High limit temperature monitoring system
- Limit temperature monitoring system
- Frost protection system
- Using an external sensor, if the external temperature falls below 0°C
- Based on the flow temperature, if this is below 5°C and/or the domestic hot water temperature
is below 10°C
- Flame monitoring by means of ionisation measurement
- Fan speed monitoring
- Flue gas temperature monitoring
- Flow monitoring using a combination of flow water temperature and flue gas sensor readings
If one of these safety systems is activated, the boiler will go to an interlocking or lockout condition and
will be switched off. Lockout conditions can only be reset by pressing the reset button, after rectifying
the fault.
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DELIVERY & TRANSPORT
Delivery
The boiler is delivered fully assembled, tested, and packed.
- Check the boiler for damage after receipt.
- Check whether the items delivered are correct and in accordance with the items ordered.
Transport
The packing should only be removed after transportation.
Moving
Each boiler is packed in its own carton which has hand holes at both sides for lifting purposes. Refer to the
technical data for dimensions and weights in order to work safely within the Health and Safety guidelines when
handling these products.
Access requirements
The dimensions of the boiler are such that all Ethos wall mounted boilers can be transported through a
standard doorway (600mm).
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INSTALLATION
Regulations
The appliance should be installed by a competent installer in accordance with the applicable national and local
standard rules and regulations. Please refer to safety guidelines Section 1.1.
Installation area
General
- Due to the low noise level, there is no need for additional sound insulation of the room
- Due to its compact design, very little installation space is required see clearance dimensions below
- The location options for the boiler are increased because it is suitable for both open flued and room
sealed operation.
Mounting
Solid Walls (brick or block)
Fix the mounting bracket with the bolts provided using a spirit level and ensuring that there is sufficient clearance
around the boiler to allow for access and flue installation.
Non Load Bearing Walls ( Studding or lightweight partitions )
We recommend the use of a purpose designed mounting frame which are available from Mikrofill
Systems Ltd., alternatively we can supply drawings for site construction of the same.
Installation
The following guidelines should be complied with;
- The device should be installed in a frost free room due to the risk of freezing of the condensate drain.
The built-in protection system is activated when the temperature of the central heating water falls below 5°C
- Ensure that there is sufficient room around the device for maintenance and the replacement of
components if necessary
The recommended minimum clearance is as follows:
- 750 mm to the front (free space for movement);
- 400 mm above;
- 250 mm below;
- 100 mm sides;
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INSTALLATION
Ventilation
The ventilation of the installation room should conform to current gas regulations.
Connections
Gas connection
The gas connection should be installed by a competent installer in accordance with applicable national standards.
The gas connection is located on the bottom of the appliance.
A suitable isolation valve should be installed for each boiler and should be in an accessible position. Care should be
taken when sizing the pipework to ensure the supply is sufficient for maximum load operation of the boiler.
The pressure on the inlet side of the appliance should be reduced to 20 mbar for natural gas and no more than
50 mbar for propane. Under full load conditions the measured gas pressure at the gas valve should be no less than
17 mbar for natural gas(G20) and 30 mbar for propane(G31).
Electrical connection
The electrical connections should be installed by a competent installer in accordance with applicable national
standards.
The appliance is fully wired in accordance with the electrical diagrams delivered with the appliance.
The electrical terminal connections are located at the base of the boiler and are protected by a metal enclosure.
Access to the terminals is gained by removing the boiler front door and unscrewing the lid from the enclosure.
Suitable cable entry points are supplied in the form of cable glands.
The appliance is suitable for a 230 V 50Hz power supply with live/neutral/earth. The appliance is polarity sensitive.
The installer should use a local 2 pole main isolating switch with a contact opening of at least 3mm in the 240 volt
supply circuit to the boiler, a permanent earth must also be installed. In order to prevent problems due to
electromagnetic radiation screened cable should be used for all control wiring between the boiler and external
management systems. The screening should be earthed on both sides in accordance with current EMC directives.
Wiring diagram
*240
volt output to supply or motorised valve.
Terminal 9
240 volt output in no DHW load condition.
Fault relay
240 volt output in fault condition.
Boiler enable
link if no external control are used.
Mains
power
supply
Boiler
Outside DHW
Enable
Sensor Sensor
Volt free (optional)
12 Technical Documentation
DHW
Output*
Fault
Relay
Safety
interlock
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INSTALLATION
Internal controls breakdown
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INSTALLATION
Controls and options
The boilers feature an automatic fully modulating control system and as such can be used as “stand alone”
appliances.
The standard controls include;
- Full seven day time control
- Optimum start facility
- Weather compensation ( optional sensor required)
- Domestic hot water priority control ( optional sensor required )
- 2 stage frost protection
- Shunt pump over run timer
- High and low pressure cut out
- Condense trap blockage cut out
Further external controls are available including cascade and zone control. The boiler is also compatible with
most current “BMS” systems for further information please see our “ Controls Manual”.
Water connections
The boiler is designed for sealed systems only and should not be used for open vented systems.
It is recommended that manually operated valves should be installed between the water connections and
the installation.
It is recommended that the flow and return pipes are securely fixed with brackets. This prevents damage and
makes maintenance easier.
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INSTALLATION
Flue connection
During installation, a choice can be made between a ‘room sealed’ or ‘openflued’ system. The standard two
pipe (eccentric) connections can be easily converted using the Mikrofill adaptor.
The flue gas discharge outlet and air intake system should be installed by a competent installer according to
applicable national and local standard and specifications. When using multiple boilers on a single application
care should be taken to ensure compliance with the Clean Air Act.
• Type B23: Open type appliance without draught stabiliser, air supply from the room, flue gas discharge
outlet above the roof.
• Type C13: Room sealed appliance, connected to a concentric air supply / flue discharge through the wall.
• Type C33: Room sealed appliance, connected to a concentric air supply / flue discharge through the roof.
• Type C43: Room sealed appliances in cascade, connected to a common concentric air supply / flue discharge
at the appliance.
• Type C53: Room sealed appliance, connected to a separate air supply and flue discharge pipe, opening into
different pressure areas.
• Type C63: Room sealed appliance, sold without related connecting and/or discharge fittings
• Type C83: Room sealed appliances in cascade, connected to separate air supplies but common flue discharge
through the roof.
Flue gas outlet and air inlet pipe
The air inlet and flue gas outlet pipes may be single wall, smooth or flexible, and be made of:
• plastic
• aluminium
• stainless steel
Always consider the large resistance when using flexible material.
Always consider condensate formation due to the suction of cold air.
Type
Ethos 70
Ethos 90
Ethos 110
Ethos 130
Diameter of air inlet D1 (mm) Diameter of Flue gas outlet D (mm)
80
100
100
100
80
100
100
100
Table 3. Diameter of air inlet and flue gas outlet.
The connection for the air supply is on the top of the boiler.
The air supply pipe should be airtight. This is to prevent the suction of ‘false air’. Horizontal components in the air
supply should be installed sloping in the direction of the supply opening.
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INSTALLATION
The flue gas outlet is located on the top of the appliance and is designed for direct connection to a
corrosion resistant fluepipe.
The flue gas discharge pipe to be used should be airtight and watertight at the joints and connections,
or should be seamless. Horizontal components in the fluepipe should be installed sloping
in the direction of the appliance (minimum 25 mm per meter).
Care should be taken when making joints to ensure that the seals are not damaged and the joints
should be sited to enable access wherever possible.
A direct connection to a brick chimney is not permissible unless a suitable liner is installed.
The following table gives the flue gas data for all the types
Type
Maximum flue gas
Quantity of flue gas
temperature at full load
at full load
m3/h
kg/s
ºC
Ethos 70
Ethos 90
Ethos 110
Ethos 130
70
70
70
70
113
149
168
209
Maximum permissible
flue resistance
ºC
0.031
0.041
0.046
0.058
140
140
140
200
Table 5. Flue gas data / Load 100% / Flow temperature 80ºc / Return temperature 0ºc
Flue
Flue length
Since the boiler is equipped with a “premix burner ”with a fan, an over pressure is created in the boiler.
This over pressure is sufficient to overcome the resistance of the burner, the heat exchanger, and the chimney.
The back pressure outside the boiler depends on:
- The resistance of the flue pipe
- The degree of cooling of the combustion gases
- The resistance of the discharge outlet
The degree of cooling of the combustion gases depends on the following:
- The insulation value of the flue
- The ambient temperature
- The flue system and outlet
There is a maximum over pressure of around 1.4 mbar (140 pa) for the types 70,90,110 and
2.0 mbar (200 pa) for the type 130 in the boiler for the flue gas discharge system.
Calculation of diameter and length
For the calculation and control of the inner diameter of a discharge system with mechanical discharge,
please refer to the applicable national and local standards and regulations.
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INSTALLATION
Ethos resistance table
By using either concentric or the 2 pipe system different flue lengths can be achieved
In case a concentric system is used, its length should not exceed 12 metres.
Table 3. Flue discharge resistance
Example of calculation,
boiler type: Ethos 70
Concentric pipe 80/125 mm vertical 3m + horizontal 1m = total 4m concentric straight pipe
1x Concentric 90° bend;
2x Concentric 45° bend;
Vertical terminal 80/125.
Resistance
27.9 Pa
Concentric pipe 80/125:
3m
3 x 9.3
14.7 Pa
Concentric 90° bends:
1 pieces
1 x 14.7
24.2 Pa
Concentric 45° bends:
2 pieces
2 x 12.1
65 Pa
Vertical terminal 80/125*
138.6 Pa
Total resistance
Total resistance is 138.6 Pa, so the boiler output is not changed by the resistance ( lower than 140 Pa) and total concentric length is less
than maximum allowed 12 metres. *Vertical terminal includes 1 metre length.
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INSTALLATION
Condense Connections
The boiler includes an anti syphon condense trap enabling the condense pipework to be taken directly to drain.
The condense water is slightly acidic (PH3-4) and should be run in a standard drain pipe material, e.g. polyvinyl
chloride (PVC), unplasticized polyvinyl chloride (PVC-U), acrylonitrile-butadiene-styrene (ABS), polypropylene
(PP) or cross- linked polyvinyl chloride (PVC-C). The condensate pipe should, ideally, run and terminate internally
to a soil stack or a waste pipe. Alternatively, the condensate can be discharged into the rainwater system or a
purpose-made soakaway. All connecting drainage pipework should have a fall of at least 2,5° to the horizontal,
or approximately 25mm per metre of pipe run. If the drainage pipe has an external run it should be kept to a
minimum length with a minimum diameter of 22mm and insulate in order to minimize the effects of freezing.
It should be noted that connection of a condensate pipe to a drain may be subject to building controls.
Safety Valve Connection
The discharge pipe from the safety valve shall be self draining and shall terminate in a visible position where the
discharge cannot result in hazard to any person or to the plant. The size of the discharge pipe shall be no less than
the nominal size of the valve outlet.
Hydraulic system
Flow and resistance
The minimum required water circulation over the boiler should be maintained at all times (equivalent to Δt 25 K
at full load). The minimum required water circulation should not be adversely affected by the use of valves,
non-return valves, systems in which several boilers are connected to a common distribution pipe, etc.
The maximum water flow is achieved at Δt 15 K.
Type
◊t 20 K
Nominal
Boiler
flow rate resistance
Q
nom. flow
R
Pump data
Pump type
Grundfos
Pump
seed
Pump head Available Maximum*
at nom.
head at
Power
flow
nom. flow consumption
Q
Q
KPa
KPa
W
2
48
28
190
UPS 25-80
2
37
16
190
19
UPS 25-80
2
29
10
190
26
UPS 25-80
3
42
16
190
m3/h
KPa
Ethos 70
2.79
20
UPS 25-80
Ethos 90
3.64
21
Ethos 110
4.29
Ethos 130
5.14
Table 9. Water flow quantity and pump data for the Ethos
*Maximum power consumed is given in pump position 3
When using another Δt you can use the following formula for calculating the flow rate and resistance of the boiler.
After this you have to check the available head of the pump.
The boiler has a pump control circuit. When the boiler is enabled, the pump is switched on. If the boiler is disabled,
the pump will continue to run for a few minutes more. This run on time can be adjusted. The standard time is
2 minutes.
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INSTALLATION
Pump characteristics
UPS 25-80
180
1 x 230 V, 50 Hz
Pump characteristics
Shut-off valves
It is recommended that manual valves should be installed between the flow and return connections
to the installation.
Valves (boilers in cascade arrangement)
To prevent water flow through non firing boilers, and hence unnecessary heat loss, a spring loaded
non return valve may be installed on the return pipework external to the boiler.
Water flow protection device
The boiler is equipped with water flow protection devices.
The fl ow sensor and the flue gas sensor ensure that the protection device is triggered if the
water flow is too low.
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INSTALLATION
Water pressure
At a maximum flow temperature of 90°C and with the minimum water flow that occurs at at of 20K,
the minimum operating pressure should be at least 1.5 bar. The operating pressure should be measured when the
pump is switched off. If a lower operating pressure is required, it is necessary to adjust the maximum flow
temperature.
System expansion vessel
The size of the expansion vessel is determined by the water volume of the system. We recommend that the system
expansion vessel is installed on the return pipework in a suitable neutral pressure position.
Water pressure protection device
A 3 bar pressure relief valve is integral within the boiler casing . Should it be necessary to protect the
system at a lower pressure, an external safety valve will need to be fitted to the system.
Water temperature
The maximum permissible water flow temperature is 90°C. If the limit thermostat is triggered at 97°C, the boiler
will switch off and will automatically restart when the water temperature falls below the limit temperature that has
been set. The high limit thermostat is set to 100°C, if activated the boiler will switch off and will not automatically
restart when the water temperature falls.
Water quality
The composition and quality of the system water directly effects the performance of any hydronic (water filled)
heating system. The life of the boiler and associated equipment will depend on the correct use of water treatments
and (when required) deaerators, water filters and or air and dirt seperators. This is particularly important when
connecting the boiler into an existing older system.
Care should be taken to ensure that pipework is sound and leaks are eliminated thus reducing the need for fresh
‘top up’ water to a minimum.
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INSTALLATION
Water Hardness
Water hardness levels are caused by dissolved minerals in the water and vary geographically. The harder the water
the more likely that problems with precipitation (limescale deposits) will occur, causing permanent damage to the
boiler and associated equipment, this is a system fault and is not covered by warranty.
The water hardness is generally expressed in terms of “ppm” ( parts per million) and is sub-divided
as follows;
Very soft
Soft
Moderately Hard
Hard & very Hard
< 50 ppm
50-160 ppm
160-250 ppm
< 250 ppm
The system should contain soft to medium hard water, with a water hardness that does not exceed 250 ppm at a
flow temperature of 80°C and t 20 °C. Before supplying water, the hardness and chloride value of the system
water should always be determined.
The chloride value should never exceed 200 mg/l.
If the chloride value does exceed this value, the cause should be determined. Compare the chloride value of the
supply water and the central heating system water. If this content is much higher, and if no materials containing
chloride have been added, this indicates evaporation. If the chloride content is very high, the water is rendered more
aggressive (Can be caused by, amongst other things, improperly regenerated water softener). The system should be
flushed clean and filled with low chloride water.
In order to counter unnecessary wear and tear and blockages due to impurities present in the system, we
recommend the use of a filter system with a mesh size of 100 microns. Always place this in the return line of the
secondary part of the system. In order to guarantee a properly working system and long life, one should remove
suspended and corrosive particles by installing a suitable filter system.
A periodic inspection, including the analysis of the system water and the cleaning of the filters, should be performed.
Operating instructions
Operation
The fan, wh ich is modulated by the temperature controller, supplies the combustion air. Due to the resultant under
pressure in the venturi, the zero pressure controller in the gas valve mixes in the required quantity of gas. Gas and air
are completely mixed in the venturi. The gas-air mixture is then fi red directly in the burner. The fan also removes
the combustion gases. The boiler has no lower limit to the return water temperature. If this temperature is low,
condensate will be formed, which is removed via the discharge system.
Controls
Depending on the heat requirement of the system, the boiler output will automatically modulate between 14%
and 100% ( 7:1 Turn down ratio). Below 14% load, the boiler operates on/off, based on temperature.
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OPERATING INSTRUCTIONS
Boiler Module
DHW selection button
Heating selection button
Show information
Settings accept
Chimney sweep function
STB test
Quit setting
Service plug (BSB)
Manual mode
Adjust room comfort setpoint
Navigation and settings
Heating to Comfort setpoint
Info level activated
Heating to Reduced setpoint
Programming activated
Heating to frost protection setpoint
Heating temporarily
switched off
ECO function active
Process running - please wait
Holiday function active
Change battery
Reference to heating circuit
Burner operating
Maintenance / special operation
Error messages
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OPERATING INSTRUCTIONS
Boiler operation
Selecting heating module
This setting is used to switch between the different operating modes.
The selection made is indicated by a bar which appears below the
respective symbol.
Automatic mode
Automatic mode controls the room temperature according to the time program.
Characteristics of automatic mode:
Heating mode according to the time program
Temperature setpoints according to heating program “Comfort setpoint“
Protective functions active
Automatic summer / winter changeover (ECO functions)
Continuous operation
or “Reduced setpoint“
or
Continuous operation or Continuous operation maintains the room temperature at the selected operating level.
Heating to Comfort setpoint
Heating to Reduced setpoint
Characteristics of continuous operation:
Heating mode with no time program
Protective functions active
Automatic summer / winter changeover (ECO functions)
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OPERATING INSTRUCTIONS
Protection
When using protection, the heating system is off. But it remains protected against frost
(frost protection temperature) provided there is no power failure.
Characteristics of Protection:
Heating off
Temperature according to frost protection
Protective functions active
Automatic summer / winter changeover (ECO functions) and automatic 24-hour heating limit active
Selecting DHW heating mode
The button is used to switch DHW heating mode on and off. The selection made is
indicated by a bar which appears below the respective symbol.
DHW heating
On
The DHW is heated according to the selected switching program.
Off
No DHW heating, the protective function is active.
Triggering is effected by keeping the DHW operating mode button on the
operator or room unit depressed for at least 3 seconds.
It can also be started when:
The operating mode is “Off“
Operating mode changeover acts via H1 or centrally (LPB)
All heating circuits use the holiday function
Adjusting the room temperature setpoint
Turn the setting knob to increase or decrease the Comfort setpoint
For the Reduced setpoint
Press OK
Select operating page “Heating circuit“ and
Adjust the “Reduced setpoint“
If no external sensors are connected, the boiler flow temperature will be determined by using the heating
curve with an external temperature of 0°C. Please see following graph for equivalent temperatures.
After each re-adjustment, wait at least 2 hours, allowing the room temperature to
adapt.
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OPERATING INSTRUCTIONS
Heating curve
The rate of change, with respect to weather compensation, is adjusted by the heating curve setpoint,
selection of a higher setpoint will result in a higher rate of temperature gain. Reducing the setpoint
will result in a lower rate of temperature gain.
Increase adjustment: Raises the flow temperature, especially when outside temperatures are low.
Decrease adjustment: Lowers the flow temperature, especially when outside temperatures are low.
Displacement of heating curve
Parallel displacement of the heating curve is used to change the flow temperature evenly across the entire outside
temperature range or, in other words, if the room temperature is always too high or too low, a readjustment must
be made with the help of parallel displacement.
Adaptation of the heating curve
Adaptation of the heating curve is used by the controller to automatically adapt the heating curve to the prevailing
conditions. In that case, a readjustment of the heating curve slope and parallel displacement is not required.
It can only be switched on or off.
Boiler Temperature setting
Comfort
Setpoint
Boiler
Temperature
Comfort
Setpoint
Boiler
Temperature
Above table based on a heat slope of 2.0 at 0°c outside air temperature
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OPERATING INSTRUCTIONS
Displaying information
Various data can be displayed by pressing the info button.
Possible displays
Depending on the type of unit, configuration and operating state, some of the info lines
listed below may not appear.
Display:
Possible error messages
Possible service messages
Possible special mode messages
Other displays:
Room temperature
State of DHW
State of boiler
Boiler temperature
Outside temperature
Date and time of day
DHW temp 1
State of heating circuit 1
Exception
In exceptional cases, the basic display shows one of the following symbols:
Error messages
If this symbol appears, an error in
the plant has occurred. Press the
info button and read further
information
26
Technical Documentation
Maintenance or special operation
If this symbol appears, a maintenance
alarm is delivered or the plant has
changed to special mode. Press the
info button and read further
information.
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OPERATING INSTRUCTIONS
Manual operation
When manual operation is active, the relays are no longer energized and deenergized according to the control state,
but are set to a predefined manual operation state depending on their function.
The burner relay energized in manual control can be deenergized by the electronic temperature controller (TR).
Setpoint adjustment in Manual control
After manual control has been activated, a change to the basic display must be made.
There, the maintenance / special mode symbol appears.
Press the info button to switch to info display “Manual mode“, where the setpoint can be adjusted.
Chimney sweep function
The chimney sweep function is activated by a short press (maximum 3 seconds) on the chimney sweep button.
This function produces the operating state required to make emission measurements (flue gas, maximum load only).
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OPERATING INSTRUCTIONS
Setting principle
Settings that cannot be made directly with the operating elements are made in the form of programming.
For this purpose, the individual settings are structured in the form of operating pages and operating lines, thus
forming practical groups of settings. The following example shows how to set the time of day and the date.
Example: “Setting the time of day“
Press ESC to go one step back at a time, readjusted values are not be adopted.
If no setting is made for 8 minutes, the display returns automatically to the basic display.
Operating lines may be hidden, depending on the type of controller, the configuration made
and the user level.
Basic display.
If the basic display is not shown,
press the ESC button to return to it.
Press OK.
The bottom section of the display
shows a number of operating pages.
Turn the setting knob until
operating page Time of day and
date appears.
Press OK to confirm.
In the bottom section of the display, the
first operating line of operating page
Time of day and date appears.
Turn the setting knob until operating line
Hours / minutes appears.
To confirm, press OK.
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OPERATING INSTRUCTIONS
The display shows the hours
flashing .
Turn the setting knob until the
hours of the time of day are
correct.
To confirm, press OK.
The display shows the minutes
flashing.
Turn the setting knob until the
minutes of the time of day are
correct.
To confirm, press OK.
The settings are saved and the
displays stops flashing.
Now, you can make further settings
or you press the operating mode
button to return to the basic
display.
Now, you see the basic display again.
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OPERATING INSTRUCTIONS
User levels
The user levels only allow authorized user groups to change settings. To reach the required
user level, proceed as follows:
Basic display.
If the basic display is not shown,
press the ESC button to return to it.
Press OK.
You are on the user level Enduser.
Press the info button for 3
seconds.
You are now given a choice of user levels.
Turn the setting knob until the required
user level is reached.
Press OK.
You are now on the required
user level.
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OPERATING INSTRUCTIONS
Setting structure “Enduser”
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 ”Heating engineer“
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OPERATING INSTRUCTIONS
List of displays
Error code
Error Code
Description of maintenance
10
20
28
40
50
81
105
109
110
113
117
118
121
126
127
128
129
131
133
146
178
217
218
320
Outside temperature sensor error
Boiler temperature 1 sensor error
Flue gas temperature sensor error
Return temperature 1 sensor error
DHW temperature 1 sensor error
Short-circuit LPB
Maintenance message
Boiler temperature supervision
Lockout by SLT
Safety shutdown flue gas
Upper pressure limit (crossed)
Critical lower pressure limit (crossed)
Flow temperature 1 (HC1) supervision
DHW charging supervision
Legionella temperature not reached
Loss of flame in operation
Wrong air supply
Burner fault
Safety time exceeded
Configuration error common message
Temperature limiter heating circuit 1
Sensor error common message
Pressure supervision common message
DHW charging temperature sensor error
Maintenance code
Error Code
Description of maintenance
1
2
3
5
Burner hours run exceeded
Burner starts exceeded
Maintenance interval exceeded
Water pressure heating circuit too low
(dropped below lower pressure limit 1)
Water pressure 2 heating circuit too low
(dropped bel ow lower pressure limit 2)
Replace battery of outside sensor
Maximum flue gas temperature exceeded
Water pressure 3 too low
(dropped below lower pressure limit 3)
18
10
21
22
Special operation code
Error Code
Description of maintenance
301
302
303
309
310
314
Manual operation
SLT test
Chimney sweep function
Simulation outside temperature
Alternative energy operation
Economy mode
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OPERATING INSTRUCTIONS
Switching-on the appliance
1 Open the gas valve.
2 Switch on the boiler using the on/off switch on the control panel.
3 Set the type of operation to “automatic operation
” using the “heating selection” button.
Switching-off the appliance
The appliance can be switched off in three ways:
A The boiler remains available for hot water operation. Using the “heating selection” button,set the
type of operation to .
B The boiler is out of operation and only comes into operation due to the automatic frost protection
system. Using the “heating selection” button, set the type of operation to .
C Switch off the boiler completely.
1 Switch off the boiler using the on/off switch.
2 Close the gas valve.
Warnings
The appliance should be installed by a competent installer.
These operating instructions should be closely followed.
If the cause of the fault cannot be determined, contact the Service department. Never carry out repairs
on your own.
COMMISSIONING
General
The commissioning should only be carried out by qualified personnel. The guarantee may be void if this is not
adhered to.
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COMMISSIONING
Before operating the appliance, the following should be done:
- Switch off the electrical power supply of the appliance
- Remove the front door casing
- Check the leak-tightness of the gas connection
- Check whether the electrical connection including earthing have been correctly made.
Also check whether the phase (L) has been connected properly. The boiler is phase sensitive.
- Twist open the cap of the automatic air vent.
- Fill the appliance and the system with water.
- Fill the condensate bottle trap with water. The beaker on the bottom can be easily unscrewed
and filled.
- Check the flue gas discharge connection and, if present, the air supply connection.
- Open the gas valve and vent the gas pipe.
- Switch on the electrical power supply of the appliance.
- Check the built in pump.
- Check the boiler at maximum load.
Start the boiler. Allow the boiler to run at full load and stabilise (around 3 minutes). At full load, the
following settings should be checked and corrected if necessary:
Reference value for maximum load
Reference value for CO2
Ethos 70,90 & 110
Ethos 130
9.0% + 0.2 for natural gas
10.3% + 0.2 for propane
10.0% + 0.2 for propane
G20, G25
G31
G31
< 50 ppm for natural gas
< 70 ppm for propane
G20, G25
G31
Reference value for CO
Measure the gas pressure before the gas valve. At maximum load, this must be at least 17 mbar for natural gas and
30 mbar for propane. If there are several boilers, this pressure should be measured with all the boilers operating at
maximum load.
Check the water-side temperature difference (Δt) between the fl ow and return connections of the boiler.
The Δt should be between 15 and 25 K at full load.
- Check the boiler at minimum load.
Set the boiler back to minimum load. At minimum load, the following settings should be
checked and corrected if necessary:
Reference value for minimum load
Reference value for CO2
Ethos 70,90 & 110
Ethos 130
8.4% + 0.2 for natural gas
9.5% + 0.2 for propane
9.2% + 0.2 for propane
G20, G25
G31
G31
< 10 ppm for natural gas
< 10 ppm for propane
G20, G25
G31
Reference value for CO
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COMMISSIONING
Maximum load adjustment
Press and hold the ‘heating selection’ button until ‘controller stop function on’ appears on the display, the boiler
will then start to operate. The display will the show;
To adjust to maximum rate press the ‘OK’ button, the display will then flash, turn the dial clockwise to 100%
and press the ‘OK’ once more. The boiler will modulate to maximum load
Minimum load adjustment
Press and hold the ‘heating selection’ button until ‘controller stop function on’ appears on the display, the boiler
will then start to operate. The display will the show;
The boiler will modulate to minimum load. If the boiler is already operating at maximum load i.e. display showing
100%, Press the ‘OK’ button and turn the dial anti clockwise to 0%, press the ‘OK’ button once more and the boiler
will modulate to minimum load
To return to normal operation press and hold the ‘heating selection’ button until ‘controller stop function off ’
appears in the display.
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COMMISSIONING
Setting the CO2 value for the Ethos Range
Any adjustments should only be carried out by competent persons
After adjustment of the gas valve the adjusters must be resealed
There is a setting screw on the gas valve with which the CO2 value can be set at maximum load. Set the boiler at
maximum load and check the CO2 value. If necessary, adjust with the fl at setting screw: clockwise gives less CO2,
anti-clockwise gives more CO2.
There is a torcx setting screw on the gas valve with which the CO2 value can be set at minimum load. Set the boiler
at minimum load and check the CO2 value. If necessary, readjust with the torcx setting screw: clockwise gives less
CO2, anti-clockwise gives more CO2 . After the CO2 values have been set, they should be checked once again and
corrected if necessary.
Ethos 70 - 110 Gas Valve
Ethos 130 Gas Valve
Maximum Load
Adjustment Screw
Minimum Load Adjustment
Screw Under Cap
Maximum Load
Adjustment Screw
Minimum Load
Adjustment
Screw Under
Cap
When setting the CO2 levels on the boiler the
readings can be taken from the flue gas
temperature sensor tapping. Disconnect the
electrical connection from the sensor. Unscrew the
sensor and remake the electrical connection.
Upon completion of tests replace the flue gas
temperature sensor in reverse order
Flue gas temperature
sensor tapping
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COMMISSIONING
- Conversion from natural gas to propane.
- For the Ethos range a throttle ring will be required for propane.
- This should be installed between the gas valve and venturi. After
the conversion, the CO 2 values should be set at full load and
minimum load.
- For the Ethos 130 it’s only necessary to change the gas volume
on the gas valve by using the setting screws.
- Remove the measuring equipment and re-fit the case
- The boiler is now ready for operation
Type
Ethos 70
Ethos 90
Ethos 110
Diameter of throttle ring
6.0mm
6.0mm
6.8mm
MAINTENANCE
Safety
Maintenance should only be carried out by competent persons. Always isolate the gas supply at the gas service valve
and isolate and disconnect the electrical supply prior to removal of any components. Ensure that all external controls
are isolated. After completion of maintenance or component replacement the following should be checked:
- Test for gas soundness
- Check the water system is correctly filled and free of air. Air in the boiler could cause damage to the heat
exchanger. For this reason the automatic air vent in the boiler must be left open.
- With the system hot check the boiler for signs of water leakage.
- Check the gas rate and measure the CO2 content to ensure it is within the specified range.Adjust if necessary
(see commissioning section page 32).
- Carry out functional tests.
- If in the unlikely event there is a component failure please refer to pages 36,37,38 & 39 for instructions on
removal of major components.
Servicing schedule
To ensure the safe and efficient operation of the appliance it is recommended that is checked at regular intervals and
maintained as necessary. The frequency of maintenance will depend upon the installation condition and usage but
should be carried out at least annually. Mikrofill systems limited does not accept liability resulting from the use of
unauthorised components or the repair and maintenance of appliances not out in the companies recommendations
and specifications.
- Light the boiler and carry out function checks, noting any operational faults.
- Run the system up to operating temperature then check the gas consumption rate. Refer to the commissioning
section (page 32) on how to operate the boiler at maximum rate.
- Connect a suitable flue gas analyser to the flue gas test point ( see commissioning section page 32) and check
the CO2 values are within those specified in the commissioning section, if values are correct and CO/CO2 ratio
is within legal limits, then no further action is required. If the values are incorrect remove and clean the burner
as described in the removal of components section.
- Inspect the heat exchanger, if there are signs of debris, vacuum heat exchanger and flush with water.
- Remove the condensate trap cap and flush through with water.
- Check that the flue terminal is unobstructed and that the flue system is sealed correctly.
- After completing maintenance carry out safety checks as above.
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MAINTENANCE
Removal of gas valve and venturi (Ethos 70,90 & 110 models)
- Isolate gas and electrical supplies to the boiler
- Remove 4 No. screws from flange on rear of gas valve (see diagram below (1))
- Remove electrical connection on gas valve
- Remove 2 No. screws from venturi/fan ( see diagram below (2))
- Remove gas valve/venturi assembly from boiler
- To separate gas valve and venturi remove 3 No. screws on gas valve/venturi assembly
(see diagram below (3))
- Replace in reverse order ensuring all seals/ gaskets are in good condition (renew if necessary)
.
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MAINTENANCE
Removal of gas valve and venturi (Ethos 130)
- Isolate gas and electrical supplies to the boiler
- Remove 4 No. screws from flange on rear of gas valve (see diagram below (1))
- Remove electrical connection on gas valve
- Remove 6 No. screws from venturi/fan (see diagram below (2))
- Remove gas valve/venturi from boiler
- To separate gas valve and venturi remove 4 No. screws on gas valve/venturi (see diagram below (3))
- Replace in reverse order ensuring all seals/ gaskets are in good condition
(renew if necessary)
.
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MAINTENANCE
Removal of fan and burner assembly
- Isolate the gas and electrical supplies to the boiler
- Remove plugs from ignition electrode and ionisation probe
- Remove gas valve and venturi as described on pages ? & ?
- Remove the two electrical connections from the fan
- Remove 6 no. nuts from burner (1)
- Extract the burner/fan assembly
- To separate the fan from the burner remove 4 No. screws from fan (2)
- Replace in reverse order ensuring all seals/gaskets are in good condition (renew if necessary)
.
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MAINTENANCE
Removal of pump/pump head
- Isolate gas and electrical supplies
- Isolate and drain water from boiler
- Disconnect electrical supplies from pump
- For complete pump removal unscrew pump unions (1) and extract pump
- For removal of pump head, remove 4 no. screws (2) from pump and separate pump head from base
- Replace in reverse order ensure all seals/gaskets are in good condition (renew if necessary)
.
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BOILER PARTS
No.
Part No.
Description
No.
Part No.
Description
1
301000
302000
303000
304000
301002
301001
304001
301003
304002
301004
301004
301004
301004
301011
301012
301010
301010
301017
301018
301016
301020
301015
301021
302021
303021
304021
Ethos 70 heat exchanger
Ethos 90 heat exchanger
Ethos 110 heat exchanger
Ethos 130 heat exchanger
Grundfos 25-80 Pump
Ethos 70-110 combustion fan
Ethos 130 combustion fan
Ethos 70-110 gas valve
Ethos 130 gas valve
Ethos 70 venturi
Ethos 90 venturi
Ethos 110 venturi
Ethos 130 venturi
Ignition electrode
Ionisation probe
Ignition electrode cap
Ionisation probe cap
Flow temperature sensor
Return temperature sensor
Flue gas temperature sensor
Automatic air vent
Pressure sensor
Ethos 70 Burner
Ethos 90 Burner
Ethos 110 Burner
Ethos 130 Burner
16
301022
302022
303022
304022
301023
301024
304024
301025
301019
301026
302026
303026
304026
301027
304027
301008
301028
304028
301009
301029
301030
Ethos 70 air/gas inlet tube
Ethos 90 air/gas inlet tube
Ethos 110 air/gas inlet tube
Ethos 130 air/gas inlet tube
Burner Gasket
Ethos 70-110 fan gasket
Ethos 130 fan gasket
Burner door mounting nuts
3/4” pressure relief valve
Ethos 70 gas inlet pipe
Ethos 90 gas inlet pipe
Ethos 110 gas inlet pipe
Ethos 130 gas inlet pipe
Ethos 70 - 110 sealed air inlet box
Ethos 130 sealed air inlet box
Sealed air inlet trap
Ethos 70 - 110 air inlet tube
Ethos 130 air inlet tube
Condense siphon
70 - 110 venturi gasket
Burner door insulation
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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17
18
19
20
21
22
23
24
25
26
27
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BOILER PARTS
No.
Part No.
Description
No.
Part No.
Description
1
301031
302031
303031
301032
303032
301033
301034
301035
301036
303036
Ethos 70 top casing
Ethos 90 top casing
Ethos 110 - 130 top casing
Ethos 70 - 90 right hand casing
Ethos 110 - 130 right hand casing
Back panel c/w fillets
Main control pcb
Ignition transformer
Ethos 70 - 90 left hand casing
Ethos 110 - 130 left hand casing
7
301037
303037
301038
301039
301040
301041
301042
Ethos 70 - 90 bottom casing
Ethos 110 - 130 bottom casing
Front door casing
Electrical isolation switch
Control fascia
Controls reset switch
Control panel casing
2
3
4
5
6
7
8
9
10
11
12
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CONVERSION FORMULAE & FACTORS
Formulae
CO2 =
20.9 - measured 02
x 11.7
20.9
O2 = 20.9 -
measured C02 x 20.9
11.7
11.7% CO2 is the maximum CO2 percentage that is generated by stoichiometric burning of G20
natural gas (H-gas).
Excess air N:
20.9
x 0.914
20.9 - measured O2
or
N = 1+
(
11.7
CO2 measured
(
N=
1 x 0.914
Conversion factors
For NOx (N=1):
1 ppm = 2.05 mg/m3 =1.759 mg/kWh = 0.498 mg/MJ
For CO (N=1):
1 ppm = 1.24 mg/m3 =1.064 mg/kWh = 0.298 mg/MJ
Example:
Measured values for an environmentally friendly unit:
NOx = 15 ppm
CO2 = 10%
What is the value for NOx according to the most usual standard in mg/kWh for N=1?
O2 = 20.9 -
10 x 20.9
11.7
= 3%
NOx (for N = 1) =
15.0 × 1.17 = 17.6 ppm
17.6 × 1.759 = 30.9 mg/kWh
W
1
1.163
0.293
Kcal/h
0.86
1
0.252
Table 13 Conversion factors
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Btu/h
3.41
3.97
1
N=
20.9
20.9 - 3
= 1.17
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CONVERSION FORMULAE & FACTORS
1 kcal = 4.187 kJ
1 kWh = 3.6 Mj
Efficiency at the flue gas side.
The difference between gross and nett calorifi c values is the heat of evaporation of the combustion
produced water. At 298.15 K (25°C), this is 2442.5 kJ/kg (583.38 kcal/kg).
For non-condensing boilers;
(
(
0.339
+ 0.008
CO2
no = 100 -
x ΔT
(
(
nb = 90 -
0.377
x 0.009
CO2
x ΔT
For condensing boilers;
As a result of condensation, the efficiency at the lower value increases.
(
(
0.339
+ 0.008
CO2
x ΔT + A
(
7.5 + 0.006 ΔT
(
nb = 90 -
no/ nb = 1.11
Δt = Difference in temperature between the flue gases and the environmental temperature (K)
nb = Fuel efficiency at the gross calorifi c value
no = Fuel efficiency at the nett calorifi c value
CO2 = The volume of CO2 in the flue gas (%)
O2 = The volume of O2 in the flue gas (%)
A = The quantity of condensed water in the appliance per m3 gas in kg (kg/ m3 gas).
meg/L ºdH
meg/1
ºdH
ºf
ºe
MgCaCO3/1
0.37
0.2
0.285
0.02
1
1
0.56
0.8
0.056
ºf
ºe
MgCaCO3/1
2.8
1.78
1
1.43
0.1
5
1.25
0.7
1
1.54
50
17.8
10
14.3
1
Table 14 Derivation of degree
1 degree English hardness (°e)
1 Grain/US Gallon
1 milligram equivalent per l (mval/l)
1 ppm (parts per million) CaCO3
= 65 mg CaCO3/imp. gallon
= 0.958 odH
= 2.8 odH
= 1 mg CaCO3/1
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MIKROFILL SYSTEMS LTD
WEST COURT
MERSE ROAD
NORTH MOONS MOAT
REDDITCH
WORCESTERSHIRE
B98 9HL
T: +44 (0)8452 60 60 20
F: +44 (0)8452 60 60 21
E: info@mikrofill.com
W: www.mikrofill.com
0087
MFS/PM1008