The CP-M+ range. High Efficiency Gas Fired Condensing Boilers Installation, Commissioning & Maintenance Instructions. Models:

Transcription

1 The CP-M+ range High Efficiency Gas Fired Cndensing Bilers Installatin, Cmmissining & Maintenance Instructins Mdels: CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 INS0034 Issue N 5 Nvember

2 Table f Cntents 1.0 INTRODUCTION PRINCIPAL PARTS TECHNICAL DATA GENERAL REQUIREMENTS RELATED DOCUMENTS WATER QUALITY WATER CHEMISTRY AIR/DIRT SEPARATION WATER PRESSURE LOCATION PLANT ROOM REQUIREMENTS GENERAL REQUIREMENTS CLEARANCES MOUNTING THE BOILER MOUNTING THE BOILER ON A FRAME MOUNTING THE BOILER ON THE WALL CONDENSATE DRAIN FILLING THE CONDENSATE TRAP GAS SUPPLY SERVICE PIPES METERS GAS SUPPLY PIPES BOOSTED GAS SUPPLIES PLANT-ROOM CONTROL VALVE EQUIPMENT GAS SYSTEM LEAK CHECK FLUE SYSTEM FLUE TERMINAL LOCATIONS APPROVED FLUE SYSTEM TYPE B23P FLUE GAS SYSTEMS INSTALLATION PRECAUTIONS MAXIMUM LENGTH CONCENTRIC FLUE WORKED EXAMPLE CONCENTRIC FLUE MAXIMUM LENGTH CONVENTIONAL/TWIN-PIPE FLUE WORKED EXAMPLE CONVENTIONAL FLUE WORKED EXAMPLE TWIN-PIPE FLUE FLUE DISCHARGE FLUE TERMINAL INSTALLATION TYPE B23 (CONVENTIONAL FLUE) TYPE C13 (HORIZONTAL BALANCED FLUE) TYPE C33 (VERTICAL BALANCED FLUE) TYPE C TYPE C53 (TWIN PIPE FLUE) COMMON FLUE SYSTEMS FLUE TERMINAL GUARDING CONDENSATE DRAIN AIR SUPPLY COMBUSTION VENTILATION COOLING VENTILATION MECHANICAL VENTILATION WORKED EXAMPLE MECHANICAL INLET/NATURAL DISCHARGE WORKED EXAMPLE MECHANICAL INLET/MECHANICAL DISCHARGE (MINIMUM COMBUSTION AIR FLOW RATE) WORKED EXAMPLE MECHANICAL INLET/MECHANICAL DISCHARGE (ALTERNATE COMBUSTION AIR FLOW RATE): WATER CONNECTIONS FLOW/RETURN CONNECTIONS OPEN VENTED SYSTEM ARRANGEMENT SEALED SYSTEM ARRANGEMENT EXPANSION VESSEL SIZING CIRCULATING PUMPS DIRT SEPARATOR/STRAINER AIR SEPARATOR ROOF-TOP INSTALLATION INSTALLATION SCHEMATIC DRAWINGS ELECTRICAL SUPPLY CONNECTOR STRIP ARC WELDING PRECAUTIONS ANCILLARY EQUIPMENT OUTSIDE TEMPERATURE SENSOR SAFETY CIRCUIT CASCADE CONTROL CASCADE WIRING CASCADE SENSOR TIME, TEMPERATURE AND ZONE CONTROL CP-M+ WIRING DIAGRAM

3 12.0 CONTROL INTERFACE CONTROL PANEL / DISPLAY UNIT CONTROL PANEL MENU STRUCTURE DISPLAY DURING OPERATION MONITOR SCREENS SERVICE FUNCTION SCHORNSTEINFEGER FUNCTION SETTING THE TIME & DATE SETPOINTS SETTING THE TIMER PROGRAMS OUTSIDE TEMPERATURE COMPENSATION MAIN PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE ADDITIONAL PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE SETTING OUTSIDE TEMPERATURE COMPENSATION CHECKING THE OPERATING HISTORY CHECKING THE FAULT HISTORY SETTING THE MAINTENANCE SPECIFICATIONS SETTING THE USER LOCK PARAMETERS SETTING THE PARAMETERS WITH THE DISPLAY MENU COMMISSIONING AND TESTING ELECTRICAL INSTALLATION GAS INSTALLATION WATER CONNECTIONS COMMISSIONING THE EQUIPMENT GENERAL CHECKS PRIOR TO LIGHTING EQUIPMENT CHECKS PRIOR TO LIGHTING PROCEDURE FOR INITIAL LIGHTING GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS TEMPERATURE ADJUSTMENT PROCEDURE INSTALLATION NOISE LPG FUEL RELATED DOCUMENTS CONVERSION AND COMMISSIONING PROCEDURE MAINTENANCE GENERAL BURNER INSPECTION BURNER REMOVAL CLEANING THE HEAT EXCHANGER DRAINING THE BOILER SYSTEM DRAINING AN INDIVIDUAL BOILER DRAINING THE COMPLETE SYSTEM REFILLING THE SYSTEM OTHER CHECKS RELIEF VALVES (IF FITTED) FLUE SYSTEM SETTING A REPLACEMENT GAS VALVE TROUBLESHOOTING LOCK-OUT CODES BLOCKING CODES IMPORTANT MESSAGES USER INSTRUCTIONS

4 1.0 INTRODUCTION The Lchinvar CP-M+ range is a wall hung gas-fired cndensing biler. The equipment cmprises f stainless steel radial burner assembly and heat exchanger that permits fully cndensing peratin. The burner is initiated by a full electrnic ignitin sequence cntrl that incrprates a spark ignitin and a flame rectificatin device fr supervisin f the flame. The utput frm the biler is regulated by a variable speed cmbustin fan and gas/air rati cntrls t maintain the crrect cmbustin at all levels f mdulatin. This cnfiguratin allws mdulatin dwn t 25% f the rated utput. This equipment is intended fr use n Grup H Natural Gas (2 nd Family) and LPG prpane (3 rd Family). The infrmatin relating t prpane firing is t be fund in Sectin 15: LPG FUEL. This equipment MUST NOT use gas ther than that fr which it has been designed and adjusted. This equipment must be installed by a cmpetent persn, registered with a H.S.E. apprved bdy. All installatins must cnfrm t the relevant Gas Safety and Building Regulatins. Health & Safety requirements must als be taken int accunt when installing any equipment. Failure t cmply with the abve may lead t prsecutin. If the equipment is t be cnnected t an unvented (pressurised) system, care must be taken t ensure all extra safety requirements are satisfied shuld a high r lw-pressure cnditin ccur in the system. The equipment is designed fr direct cnnectin t a flue system. Ancillary Optins: Item Descriptin Part Number 1 Biler Munting Frame E Biler Munting Frame E Biler Munting Frame E Biler Munting Frame E Biler Gas/Flw/Return Maniflds CP-M+60 CP-M+120 (R 1 ½ ) E Biler Gas/Flw/Return Maniflds CP-M+60 CP-M+120 (DN65) E Biler Gas/Flw/Return Maniflds CP-M+60 CP-M+120 (DN80) E Biler Gas/Flw/Return Maniflds CP-M+150 CP-M+180 (DN65) E Biler Gas/Flw/Return Maniflds CP-M+150 CP-M+180 (DN80) E Biler Gas/Flw/Return Maniflds CP-M+150 CP-M+180 (DN100) E Intercnnecting Pipewrk: CP-M+60 CP-M+120 E CP-M+150 CP-M+180 E Lw Velcity Header: (R 1 ½ ) E (DN65) E (DN80) E (DN100) E Calrifier Temperature Sensr E Cascade Flw Sensr (Required fr cascade installatins) E Outside Temperature Sensr E Pressurisatin Unit Flr standing single pump LPU9000 Flr standing twin pump LPU9001 Wall munted single pump CHCWM1 Wall munted twin pump CHCWM2 Cndensate Neutralisatin Kit KIT2000 Time, Temperature and Zne Cntrl Refer t Sectin 11: ELECTRICAL SUPPLY Flue System Cmpnents Cntact Lchinvar Limited 4

5 2.0 PRINCIPAL PARTS FIGURE 2.1 REMOVABLE COMPONENTS CP-M+60 5

6 FIGURE 2.2 REMOVABLE COMPONENTS CP-M+60 (CONTINUED) 6

7 Item Descriptin Item Descriptin 1 L/H side panel with insulatin 29 Flw pipe 2 Frnt panel with insulatin 30 Pump 3 Ignitin cable 31 Pump gasket 1½" 4 Ignitin electrde with gasket and screws 32 Return pipe part 1 5 Heat exchanger rear wall insulatin 33 Heat exchanger cnnectin pipe gasket 6 Burner dr gasket 34 Heat exchanger cnnectin pipe 7 Burner dr insulatin 35 Heat exchanger cnnectin pipe retaining clip 8 Burner dr 36 Heat exchanger cnnectin pipe O-ring 9 Burner dr retaining nut 37 Flw / return temperature sensr 10 Burner 38 Return pipe part 2 11 Burner / gas-air mixing pipe gasket 39 High limit thermstat 12 Gas-air mixing pipe retaining screws 40 Autmatic air vent 13 Gas-air mixing pipe 41 Cndensate drain hse air supply duct 14 Cmbustin fan / gas-air mixing pipe gasket 42 Wall bracket 15 Cmbustin fan 43 Flue gas utlet pipe / flue spigt gasket 16 Gas-air mixing bx 44 Flue gas utlet pipe 17 Gas valve utlet pipe 45 Heat exchanger / flue gas utlet pipe gasket 18 Gas valve inlet pipe 46 Flue gas temperature sensr 19 Gas inlet cnnectr 47 Cndensate drain hse heat exchanger 20 Gas valve 48 Air pressure switch 21 Replacement fuses 49 Air pressure switch hse 22 Biler cntrl PCB 50 R/H side panel with insulatin 23 Display PCB 51 Cndensate water trap 24 PC cnnectin cver 52 Cndensate water trap drain hse 25 Terminal strip cver 53 N/A 26 Heat exchanger 54 Cable gland 27 Pressure sensr 55 Rubber grmmet 28 Pressure sensr gasket TABLE 2.1 REMOVABLE COMPONENTS CP-M+60 7

8 FIGURE 2.3 REMOVABLE COMPONENTS CP-M+80 CP-M+100 8

9 FIGURE 2.4 REMOVABLE COMPONENTS CP-M+80 CP-M+100 (CONTINUED) 9

10 Item Descriptin Item Descriptin 1 L/H side panel with insulatin 27 Pressure sensr 2 Frnt panel with insulatin 28 Pressure sensr gasket 3 Ignitin cable 29 Pump gasket 1½" 4 Ignitin electrde with gasket and screws 30 Flw pipe part 2 5 Heat exchanger rear wall insulatin 31 Pump 6 Burner dr gasket 32 Heat exchanger cnnectin pipe retaining clip 7 Burner dr insulatin 33 Heat exchanger cnnectin pipe 8 Burner dr 34 Heat exchanger cnnectin pipe O-ring 9 Burner dr retaining nut 35 High limit thermstat 10 Burner 36 Flw / return temperature sensr 11 Burner / gas-air mixing pipe gasket 37 Flue gas temperature sensr 12 Gas-air mixing pipe retaining screws 38 Heat exchanger utlet / flue spigt gasket 13 Gas-air mixing pipe 39 Autmatic air vent 14 Cmbustin fan / gas-air mixing pipe gasket 40 Cndensate drain hse air supply duct 15 Cmbustin fan 41 Wall bracket 16 Gas-air mixing bx 42 Heat exchanger rear wall thermstat 17 Gas valve cnnectin O-ring 43 Air pressure switch 18 Gas valve 44 Cndensate drain hse heat exchanger 19 Replacement fuses 45 Air pressure switch hse 20 Biler cntrl PCB 46 Cndensate water trap 21 Display PCB 47 R/H side panel with insulatin 22 PC cnnectin cver 48 Cndensate water trap drain hse 23 Terminal strip cver 49 N/A 24 Heat exchanger 50 Cable gland 25 Return pipe part 2 51 Rubber grmmet 26 Flw pipe part 3 TABLE 2.2 REMOVABLE COMPONENTS CP-M+80 CP-M

11 FIGURE 2.5 REMOVABLE COMPONENTS CP-M

12 FIGURE 2.6 REMOVABLE COMPONENTS CP-M+120 (CONTINUED) 12

13 Item Descriptin Item Descriptin 1 L/H side panel with insulatin 28 Flw pipe part 3 2 Frnt panel with insulatin 29 Pressure sensr 3 Ignitin cable 30 Pressure sensr gasket 4 Ignitin electrde with gasket and screws 31 Pump gasket 1½" 5 Heat exchanger rear wall insulatin 32 Flw pipe part 2 6 Burner dr gasket 33 Pump 7 Burner dr insulatin 34 Heat exchanger cnnectin pipe retaining clip 8 Burner dr 35 Heat exchanger cnnectin pipe 9 Burner dr retaining nut 36 Heat exchanger cnnectin pipe O-ring 10 Burner 37 High limit thermstat 11 Burner / gas-air mixing pipe gasket 38 Flw / return temperature sensr 12 Gas-air mixing pipe retaining screws 39 Flue gas temperature sensr 13 Gas-air mixing pipe 40 Heat exchanger utlet / flue spigt gasket 14 Cmbustin fan / gas-air mixing pipe gasket 41 Autmatic air vent 15 Cmbustin fan 42 Cndensate drain hse air supply duct 16 Gas-air mixing bx 43 Wall bracket 17 N/A 44 Heat exchanger rear wall thermstat 18 Gas inlet / utlet manifld gasket 45 Air pressure switch 19 Gas valve 46 Cndensate drain hse heat exchanger 20 Gas valve cnnectin O-ring 47 Air pressure switch hse 21 Replacement fuses 48 Cndensate water trap 22 Biler cntrl PCB 49 R/H side panel with insulatin 23 Display PCB 50 Cndensate water trap drain hse 24 PC cnnectin cver 51 N/A 25 Terminal strip cver 52 Cable gland 26 Heat exchanger 53 Rubber grmmet 27 Return pipe part 2 TABLE 2.3 REMOVABLE COMPONENTS CP-M

14 FIGURE 2.7 REMOVABLE COMPONENTS CP-M+150 CP-M

15 FIGURE 2.8 REMOVABLE COMPONENTS CP-M+150 CP-M+180 (CONTINUED) 15

16 Item Descriptin Item Descriptin 1 L/H side panel with insulatin 27 Flw pipe part 3 2 Frnt panel with insulatin 28 Pressure sensr gasket 3 Ignitin cable 29 Pressure sensr 4 Ignitin electrde with gasket and screws 30 Pump gasket 2" 5 Heat exchanger rear wall insulatin 31 Flw pipe part 2 6 Burner dr gasket 32 Heat exchanger cnnectin pipe retaining clip 7 Burner dr insulatin 33 Heat exchanger cnnectin pipe 8 Burner dr 34 Heat exchanger cnnectin pipe O-ring 9 Burner dr retaining nut 35 Pump 10 Burner 36 High limit thermstat 11 Burner / gas-air mixing pipe gasket 37 Flw / return temperature sensr 12 Gas-air mixing pipe retaining screws 38 Flue gas temperature sensr 13 Gas-air mixing pipe 39 Heat exchanger utlet / flue spigt gasket 14 Cmbustin fan / gas-air mixing pipe gasket 40 Autmatic air vent 15 Cmbustin fan 41 Cndensate drain hse air supply duct 16 Gas-air mixing bx 42 Wall bracket 17 Gas inlet manifld gasket 43 Heat exchanger rear wall thermstat 18 Gas valve 44 Air pressure switch 19 Gas valve utlet cnnectin O-ring 45 Cndensate drain hse heat exchanger 20 Replacement fuses 46 Air pressure switch hse 21 Biler cntrl PCB 47 Cndensate water trap 22 Display PCB 48 R/H side panel with insulatin 23 PC cnnectin cver 49 Cndensate water trap drain hse 24 Terminal strip cver 50 N/A 25 Heat exchanger 51 Cable gland 26 Return pipe part 2 52 Rubber grmmet TABLE 2.4 REMOVABLE COMPONENTS CP-M+150 CP-M+180 A replacement parts list is available t dwnlad frm Lchinvar s website; please visit 16

17 3.0 TECHNICAL DATA Mdel Number CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 GENERAL DATA Input G20 (grss) kw Input G31 (grss) kw Input (net) kw Output kw (50º/30º) Output kw (80º/60º) Seasnal Efficiency % Shipping Weight kg NOX Class 5 GAS DATA G20 Nminal gas inlet pressure mbar 20.0 Maximum gas inlet pressure mbar 25.0 Minimum gas inlet pressure mbar 17.5 Gas flw rate m 3 /hr Flue gas mass rate g/sec (@ 9.0% CO2) Gas inlet cnnectin size BSP ¾ 1 GAS DATA G31 Nminal gas inlet pressure mbar 37.0 Maximum gas inlet pressure mbar 45.0 Minimum gas inlet pressure mbar 25.0 Gas flw rate m 3 /hr Flue gas mass rate g/sec (@ 10.0% CO2) Gas inlet cnnectin size BSP ¾ 1 WATER DATA Water cntent litres Water cnnectins (F & R) BSP 1 ¼ 1 ½ Max. water pressure (PMS) bar 4.0 Min. water pressure bar 1.0 Test pressure bar 9.0 Maximum water temperature C 85 FLUE DATA TYPE B23 Nminal flue diameter mm Maximum flue gas temp. C 120 Flue gas temperature C Flue draught requirements mbar t -0.1 FLUE DATA TYPE C13 & C33 Nminal flue diameter mm 80/ /150 Maximum flue gas temp. C 120 FLUE DATA TYPE C43 & C53 Nminal flue diameter mm Average flue gas temp. C (80/60 Flw/Return) 80 Maximum flue gas temp. C 120 TABLE 3.1 TECHNICAL DATA 17

18 Twin pipe Cncentric Cnnectins CP-M+ 80 CP-M+ 100 CP-M+ 120 CP-M+ 60 CP-M+ 80 CP-M+ 100 CP-M+ 120 AI Air Inlet Ø80 Ø100 Ø100 Ø125 Ø125 Ø150 Ø150 FG Flue Gas Ø80 Ø100 Ø100 Ø80 Ø80 Ø100 Ø100 F Flw R 1 ¼ (male) C Cndensate Flexible hse Ø 25/21 x 750 mm R Return R 1 ¼ (male) G Gas R ¾ (male) Dimensin A Dimensin B FIGURE 3.1 DIMENSIONS CP-M+60, 80, 100 &

19 Twin pipe Cncentric Cnnectins CP-M+ 150 CP-M+ 180 CP-M+ 150 CP-M+ 180 AI Air Inlet Ø130 Ø130 Ø150 Ø150 FG Flue Gas Ø130 Ø130 Ø100 Ø100 F Flw R 1 ½ (male) C Cndensate Flexible hse Ø 25/21 x 750 mm R Return R 1 ½ (male) G Gas R 1 (male) FIGURE 3.2 DIMENSIONS CP-M+150 &

20 4.0 GENERAL REQUIREMENTS The Lchinvar CP-M+ cndensing biler has been designed t perate truble free fr many years. These instructins shuld be fllwed clsely t btain the maximum usage and efficiency f the equipment. PLEASE read the instructins fully befre installing r using the appliance. 4.1 RELATED DOCUMENTS It is law that all gas appliances are installed by cmpetent persns, in accrdance with The Gas Safety (Installatin and Use) Regulatins Failure t install appliances crrectly culd lead t prsecutin. It is in yur wn interest, and that f safety, t ensure that this law is cmplied with. The installatin f the equipment MUST be in accrdance with the relevant requirements f the Gas Safety Regulatins, Building Regulatins, I.E.E. Regulatins and the bylaws f the lcal water undertaking. The installatin shuld als be in accrdance with any relevant requirements f the lcal gas distributr and lcal authrity. In additin the installatin shuld fllw the relevant guidance ffered in the fllwing dcuments. It is nt practical t list all relevant infrmatin but emphasis is placed n the fllwing dcuments, as failure t cmply with the guidance given will almst certainly result in an unsatisfactry installatin: BS EN 1858: 2003 BS 4814: 1990 BS : 2008 BS : 2009 BS 6644: 2011 BS 6700: 2006 BS 6880: 1988 Parts 1, 2 and 3 BS 7074: 1989 Parts 1and 2 BS 7671: 2008 CP 342: Part IGE/UP/1: Editin 2 IGE/UP/2: Editin 2 IGE/UP/4: Editin 2 Chimneys. Cmpnents. Cncrete flue blcks Specificatin fr expansin vessels using an internal diaphragm, fr sealed ht water heating systems Installatin and maintenance f flues and ventilatin fr gas appliances f rated input nt exceeding 70kW net (1st, 2nd and 3rd family gases) Part 1: Specificatin fr installatin and maintenance f flues Installatin and maintenance f flues and ventilatin fr gas appliances f rated input nt exceeding 70kW net (1st, 2nd and 3rd family gases) Part 2: Specificatin fr installatin and maintenance f ventilatin fr gas appliances Specificatin fr the installatin and maintenance f gas-fired ht water bilers f rated inputs between 70kW (net) and 1.8MW (net) (2 nd and 3 rd family gasses) Design, installatin, testing and maintenance f services supplying water fr dmestic use within buildings and their curtilages Cde f practice fr lw temperature ht water systems f utput greater than 45kW Applicatin, selectin and installatin f expansin vessels and ancillary equipment fr sealed systems Requirements fr electrical installatins, I.E.E. wiring regulatins seventeenth editin Cde f practice fr centralised ht water supply-buildings ther than dwellings Installatin pipewrk n industrial and cmmercial premises Gas installatin pipewrk, bsters and cmpressrs n industrial and cmmercial premises Cmmissining f gas fired plant n industrial and cmmercial premises 20

21 IGE/UP/10: Editin 3 Installatin f flued gas appliances in industrial and cmmercial premises Gas Safety (Installatin and Use) Regulatins 1998 (England, Sctland & Wales) CIBSE: Guide parts A, B and C CIBSE Cmmissining Cde B: CIBSE Cmmissining Cde W: BISRIA AG1/2001.1: H.S.E. guidance nte PM5: Bilers Water Distributin Systems Pre-cmmissin cleaning f pipewrk systems Autmatically cntrlled steam and ht water bilers Third editin f the 1956 Clean Air Act Memrandum n Chimney Heights Manufacturer's ntes must nt be taken in any way as verriding statutry bligatins. 5.0 WATER QUALITY 5.1 WATER CHEMISTRY In hard water areas, scale frmatin can ccur in ht water systems. The situatin can intensify where higher temperatures r demands exist. The ph value f the water must be between 7.5 and 9.5. Water hardness must be between 50 ppm CaCO3 and 150 ppm CaCO3 The Aluminium cntent f the TDS (Ttal Disslved Slids) shuld nt exceed 8.5 ppm. If the abve requirements cannt be satisfied, a water treatment specialist must be cnsulted. Details f cmpanies that prvide such a service can be btained frm Lchinvar Limited. 5.2 AIR/DIRT SEPARATION Precautins must be taken t remve air and dirt frm the heating system. The system shuld be fully flushed with an air separatr and dirt separatr fitted t fully prtect against cntaminatin f the heat exchanger. If there is any dubt f the water staying free f any kind f debris/cntaminatin in the perid after installing, a plate heat exchanger shuld be installed t separate the biler circuit frm the heating circuit. 5.3 WATER PRESSURE The CP-M+ biler has an in-built water pressure sensr, with this sensr the minimum water pressure in the biler is 0.8 bar and the maximum pressure is 4.0 bar (sensr values). The recmmended water pressure is between 1.5 and 2.0 bar. The pressure sensr will stp the biler frm firing when the water pressure drps belw 0.8 bar, and start the biler firing again when the water pressure reaches abve the 1.0 bar. If pressures higher than 4.0 bar are required within the heating system, it is recmmended that the system is separated frm the biler by means f a plate heat exchanger. This will allw the biler pressure t be under 4.0 bar and the biler cntrl remains as described abve. If this is nt pssible, a water pressure switch must be fitted t the biler instead f the water pressure sensr - the maximum allwed value in the biler nw is 6.0 bar and the biler cntrl needs t be adjusted. 21

22 6.0 LOCATION 6.1 PLANT ROOM REQUIREMENTS The Lchinvar CP-M+ may nly be installed in a rm that cmplies with the apprpriate ventilatin requirements. The Lchinvar CP-M+ can be used as a type C13, C33 C43, C53 r C83 appliance. Due t its rm sealed design, ventilatin allwances fr cmbustin air are nt necessary. If the appliance is t be installed in a cmpartment r a ht envirnment, ventilatin fr cling purpses must be fitted. Fr further guidance, please refer t Sectin 9 AIR SUPPLY r t BS6644. The Lchinvar CP-M+ can als be used as a type B23 appliance. If such a cnfiguratin is t be used, then apprpriate ventilatin fr cling and cmbustin must be prvided. Fr further details, please refer t Sectin 9 AIR SUPPLY r t BS GENERAL REQUIREMENTS Crrsin f the heat exchanger and flue system may ccur if air fr cmbustin cntains certain chemical vapurs. Such crrsin may result in pr cmbustin and create a risk f severe persnal injury r substantial prperty damage. Aersl prpellants, cleaning slvents, refrigeratr and air cnditining refrigerants, swimming pl chemicals, calcium and sdium chlride, waxes and prcess chemicals are crrsive. Prducts f this srt shuld nt be stred near the biler r utside by the air intake (if applicable). The fitting f this equipment in a situatin where aersls r ther chemicals may be entrained int the cmbustin air will invalidate the warranty. When using the biler munting frame, the equipment must be installed n a level surface that is capable f adequately supprting the weight f the biler(s), frame and any ancillary equipment. The peratin f the equipment must nt cause the temperature f any cmbustible material in the vicinity f the equipment and its flue t exceed 65 C. If such a situatin is unavidable, apprpriate insulatin shuld be prvided. When munting the biler n a wall, investigatins shuld be made as t whether the wall is strng enugh t supprt the full weight f the biler and ancillary equipment. Lcate the equipment s that if the appliance r any cnnecting pipewrk shuld leak, water damage will nt ccur. When such lcatins cannt be avided it is recmmended that a suitable drain pan be installed under the equipment. The pan shuld be adequately drained but must nt restrict the cmbustin r ventilatin airflw. 6.3 CLEARANCES The lcatin chsen fr the equipment must permit the prvisin fr a satisfactry flue system and, where necessary, an adequate air supply. The lcatin must als prvide adequate space fr servicing and air circulatin arund each unit. This includes any electrical trunking laid acrss the flr and t the appliance. See Figure 3.1 r Figure 3.2 fr dimensins/clearances. Further details regarding lcatins are given in BS MOUNTING THE BOILER NOTE: The munting bracket fr the biler is part f the shipping crate MOUNTING THE BOILER ON A FRAME NOTE: Munting frames are available fr the suspensin f ne, tw, three r fur bilers. When utilising the munting frame, the assembly instructins supplied with the frame shuld be used. A munting bracket is supplied with the munting frame. The lcking plate shuld be remved and the frame psitined and levelled in its required lcatin befre lifting any biler in t place. With the biler suspended n the frame, the lcking plate shuld be refitted and the biler levelled using the blts n the back f the appliance (see Figure 6.1) MOUNTING THE BOILER ON THE WALL A template is prvided with the biler shwing the lcatins fr the hles necessary fr the munting bracket. It is essential that the munting bracket is installed level using fixings that are strng enugh t supprt the biler and its ancillary equipment. 22

23 Once the munting bracket is installed, the lcking plate shuld be remved and the biler shuld be fitted by lifting and tilting the tp rear edge back and hking the munting lip ver the munting bracket. With the biler suspended, the lcking plate shuld be refitted and the biler levelled using the blts n the back f the appliance (see Figure 6.1). FIGURE 6.1 LOCKING AND LEVELLING THE APPLIANCE 6.5 CONDENSATE DRAIN The cndensate drain is lcated in the centre f the biler underside. The clean ut bwl is supplied in a separate bx within the heater packaging; this must be fitted and the cndensate water trap filled befre the appliance is fired. The cndensate trap is fitted with a ¾ flexible hse that shuld be cnnected t an apprpriate cndensate drain, slping cntinuusly away frm the biler at an angle f at least 3 (50mm per metre). The Water Resurces Act requires that trade effluent is discharged t municipal sewers between ph 6.5 and If it is determined that these levels cannt be achieved, an in-line cndensate neutralisatin kit is available as an ancillary ptin frm Lchinvar Limited. This unit is capable f neutralising 4000 litres f cndensate t a ph f 7.0 befre releasing it t a drain. 6.6 FILLING THE CONDENSATE TRAP Prir t the appliance being put in t peratin, the cndensate water trap must be filled t prevent the escape f cmbustin prducts. T fill the water trap, the bwl shuld be unscrewed frm the biler underside and filled with water t the tp befre reinstalling. FIGURE 6.2 FILLING THE CONDENSATE TRAP 7.0 GAS SUPPLY The Lchinvar CP-M+ range is suitable fr use n secnd and third family gasses 2H - G20-20mbar and 3P - G31-37mbar. Details relating t Natural Gas (2H) appear belw; fr details relating t Prpane (3P) please refer t Sectin 15: LPG FUEL. 7.1 SERVICE PIPES The lcal gas distributr must be cnsulted at the installatin planning stage in rder t establish the availability f an adequate supply f gas. An existing service pipe must nt be used withut prir cnsultatin with the lcal gas distributr. 23

24 7.2 METERS A new gas meter will be cnnected t the service pipe by the lcal gas distributr cntractr. An existing gas meter shuld be checked, preferably by the gas distributr, t ensure that it is adequate t deal with the rate f gas supply required. 7.3 GAS SUPPLY PIPES Supply pipes must be fitted in accrdance with IGE/UP/2. Pipewrk frm the meter t the equipment must be f adequate size. The cmplete installatin must be purged and tested as described in IGE/UP/1. Refer t Sectin 15: LPG FUEL fr infrmatin n LPG pipewrk installatin guidance. 7.4 BOOSTED GAS SUPPLIES Where it is necessary t emply a gas pressure bster, the cntrls must include a lw-pressure cut-ff switch at the bster inlet. The lcal gas distributr must be cnsulted befre a gas pressure bster is fitted. 7.5 PLANT-ROOM CONTROL VALVE A manual valve fr plant-rm islatin must be fitted in the gas supply line. It must be clearly identified and readily accessible fr peratin, preferably by an exit. 7.6 EQUIPMENT GAS SYSTEM LEAK CHECK An apprved gas inlet appliance islating valve and unin shuld be installed fr each unit in a cnvenient and safe psitin and be clearly marked. Ensure that the gas inlet appliance islating valve is in the OFF psitin. Althugh the equipment receives a gas leak check and gas train cmpnent integrity check prir t leaving the factry, transit and installatin may cause disturbance t unins, fittings and cmpnents. During cmmissining a further test fr tightness shuld be carried ut n the equipment gas pipewrk and cmpnents. Care must be taken nt t allw leak detectin fluid n r near any electrical parts r cnnectins. 8.0 FLUE SYSTEM 8.1 FLUE TERMINAL LOCATIONS FIGURE 8.1: FLUE TERMINAL POSITIONS 24

25 Lcatin Descriptin CP-M+60 CP-M+80 CP-M+180 A Directly belw an pening, air brick, pening windws etc B Abve an pening, air brick, pening windws etc C Hrizntally t an pening, air brick, pening windws etc D Belw a gutter r sanitary pipewrk E Belw the eaves F Belw a balcny r car prt rf G Frm a vertical drain r sil pipe H Frm an internal r external crner I Abve grund, rf r balcny level * J Frm a surface facing the terminal K Frm a terminal facing the terminal L Frm an pening in the car prt (e.g. dr, windw) int the dwelling M Vertically frm a terminal n the same wall N Hrizntally frm a terminal n the same wall P Frm a vertical structure n the rf Q Abve intersectin with the rf TABLE 8.1 FLUE TERMINAL MINIMUM DISTANCES * Any terminatin f a rm sealed appliance shall be in such a psitin as will nt cause a hazard t the health f persns wh may be nearby r a nuisance t ther persns beynd the curtilage. The height t the centreline f the terminal shall nt be less than 2m frm ccupied external areas. Detailed recmmendatins fr the flue system are given in BS fr equipment f rated input nt exceeding 70kW net, BS6644 fr equipment abve 70kW net and IGE/UP/10 fr equipment f rated input abve 54kW net. The fllwing ntes are intended t give general guidance nly. 8.2 APPROVED FLUE SYSTEM The apprved flue system is nt suitable fr use external t the building. If external rutes cannt be avided, a flue system manufacturer shuld be cnsulted t supply a suitable alternative. CP-M+60 CP-M+120 bilers are supplied fr cnnectin t a cncentric flue system. If twin pipe r cnventinal flue is used, a cnversin kit will be required. Cntact Lchinvar Limited fr further details. CP-M+150 & CP-M+180 bilers are supplied fr cnnectin t a twin pipe r cnventinal flue system. If cncentric flue is t be used, a cnversin kit will be required. Cntact Lchinvar Limited fr further details. When used as a Type C (Balanced Flued) appliance, the apprved, purpse designed adaptive flue system shuld be used. Cncentric and twin-pipe ptins are available, fr further details please cntact Lchinvar Limited. When used as a Type B (Cnventinal Flued) appliance, a suitable flue system cnstructed f Stainless Steel r Plyprpylene with a temperature rating in excess f 120 C shuld be used. Aluminium flue pipe must nt be used n this appliance as it may lead t a premature failure f the heat exchanger that wuld nt be cvered by the warranty. Flue kits are supplied separately, please cntact Lchinvar Limited fr further details TYPE B23P FLUE GAS SYSTEMS The CP-M+ biler is suitable fr use n B23P flue gas systems; this allws the flue t run under a psitive pressure reducing the required flue diameter. Fr verpressure flue gas systems the minimum requirements f the flue gas material fr can be determined in a designatin string accrding t the EN1443 (see table). CE string flue gas material (B23P) Eurpean Standard Temperature Class Pressure Class Resistance t Cndensate Crrsin Resistance Class Metal: Liner Specificatins St Fire Resistance Class Distance t Plastics: Cmbustible Material Lcatin Plastics: Fire Behaviur Plastics: Enclsure Min. Requirement PPs EN T120 P1 W 1 O 30 I r E C/E L Min. Requirement St S EN T120 P1 W 1 L20040 O 40 TABLE 8.2 TYPE B23P FLUE MATERIAL REQUIREMENTS 25

26 When selecting flue gas systems, it is essential that the minimum requirements are met therefre nly flue gas materials having the same r better prperties than this table shall be used. 8.3 INSTALLATION PRECAUTIONS The apprved flue system is rated t 120 C max. The biler must nt be perated unless the cmplete flue system is installed. This includes the biler cnnectins, twinpipe cnversin kit (if required) flue pipes, air ducts (if required) and terminals. If discharging at lw level, a suitable flue guard must be installed. During assembly f the flue system, precautin shuld be taken t ensure that the internal sealing ring is seated crrectly. Due t the clse tlerances in the flue system, it may be necessary t use a twisting actin t fit the jints tgether. N lubricatin ther than water shuld be used. 8.4 MAXIMUM LENGTH CONCENTRIC FLUE The maximum length f the flue system is determined by the resistance f the cmpnents within the flue. The resistance must nt exceed 200 Pa. CP-M+60 (80/125) CP-M+80 (80/125) CP-M+100 (100/150) CP-M+120 (100/150) CP-M+150 (100/150) CP-M+180 (100/150) Wall terminal Rf terminal Straight tube (m) Elbw Elbw TABLE 8.3 CONCENTRIC FLUE COMPONENT RESISTANCES (Pa) WORKED EXAMPLE CONCENTRIC FLUE CP-M+100 biler terminating vertically with a flue run f 6 metres plus 2 x 90 elbws. Item Quantity Resistance Ttal Rf terminal Straight tube (m) Elbw Ttal Resistance (Pa) 109 TABLE 8.4 WORKED EXAMPLE CONCENTRIC FLUE The ttal resistance f 109 Pa is less than the 200 Pa maximum value therefre this is acceptable. 8.5 MAXIMUM LENGTH CONVENTIONAL/TWIN-PIPE FLUE The maximum length f the flue system is determined by the resistance f the cmpnents within the flue. The resistance must nt exceed 200 Pa. The fllwing resistances are fr single biler flue systems nly; cmmn flue systems will require specialist design. 26

27 Item Size Resistance (Pa) (mm) CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 Straight tube (per metre) X X X X Straight tube (per metre) X X Straight tube (per metre) Elbw X X X X 45 Elbw X X 45 Elbw Elbw X X X X 90 Elbw X X 90 Elbw Vertical inlet cap X X X X Vertical inlet cap X X Vertical inlet cap TABLE 8.5 AIR INLET COMPONENT RESISTANCES (Pa) Item Size Resistance (Pa) (mm) CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 Straight tube (per metre) X X X X Straight tube (per metre) X X Straight tube (per metre) Elbw X X X X 45 Elbw X X 45 Elbw Elbw X X X X 90 Elbw X X 90 Elbw Vertical exhaust cap X X X X Vertical exhaust cap X X Vertical exhaust cap TABLE 8.6 EXHAUST COMPONENT RESISTANCES (Pa) When a cnventinal flue is t be used, the maximum length f the flue system is limited by the resistance f the exhaust flue cmpnents as detailed in Table 8.6. When a twin-pipe flue is t be used, the maximum length f the flue system is limited by the cmbined resistance f the inlet and exhaust flue cmpnents as detailed in Table 8.5 and Table WORKED EXAMPLE CONVENTIONAL FLUE CP-M+80 biler with a flue run f 24 metres plus 3 x 90 elbws Optin 1 80mm Flue Cmpnents TABLE 8.7 Item Quantity Resistance Ttal Straight tube (m) Elbw Ttal Resistance (Pa) 216 WORKED EXAMPLE CONVENTIONAL FLUE 80mm COMPONENTS Using 80mm flue cmpnents, the ttal resistance f 216 Pa is mre than the 200 Pa maximum value therefre this is unacceptable. Optin 2 100mm Flue Cmpnents TABLE 8.8 Item Quantity Resistance Ttal Straight tube (m) Elbw Ttal Resistance (Pa) 94.5 WORKED EXAMPLE CONVENTIONAL FLUE 100mm COMPONENTS By using 100mm cmpnents, the ttal resistance f the flue system is reduced t 94.5 Pa. As this is belw the 200 Pa limit, this is the flue system that shuld be used. 27

28 8.5.2 WORKED EXAMPLE TWIN-PIPE FLUE CP-M+150 biler with an inlet air duct f 8 metres, 3 x 90 elbws plus a vertical inlet cap and an exhaust duct f 12 metres plus 4 x 90 elbws. Item Quantity Resistance Ttal Straight tube (m) Elbw Vertical inlet cap Straight tube (m) Elbw Ttal Resistance (Pa) 83.1 TABLE 8.9 WORKED EXAMPLE TWIN-PIPE FLUE The cmbined resistance f the air inlet duct and exhaust duct give the flue system an verall resistance f 83.1 Pa. As this is belw the 200 Pa maximum limit, this is acceptable. 8.6 FLUE DISCHARGE The flue system must ensure safe and efficient peratin f the equipment t which it is attached, prtect the cmbustin prcess frm wind effects and disperse the prducts f cmbustin t pen external air. The flue must terminate in a freely expsed psitin and be s situated as t prevent the prducts f cmbustin entering any pening in a building. Fr further infrmatin n terminal lcatins, please refer t Figure FLUE TERMINAL INSTALLATION TYPE B23 (CONVENTIONAL FLUE) T cnvert the CP-M+60 CP-M+120 t cnventinal flued peratin, the apprved air intake grille shuld be fitted t the cncentric flue spigt. The grille will have an pening in the tp plate that allws the cnnectin f the flue system t the exhaust prt f the biler. FIGURE 8.2 FITTING AIR INLET GRILLE TO CP-M+60 CP-M+120 The CP-M+150 & CP-M+180 require an air inlet grille t be fitted t the air inlet spigt f the biler casing. Mdels Part Number CP-M+60, CP-M+80 M87927 CP-M+100, CP-M+120 M87957 CP-M+150, CP-M+180 M81660 TABLE 8.10 AIR INTAKE GRILLE PART NUMBERS 28

29 When the heater is installed as a Type B23 appliance, the flue system shuld be installed in accrdance with the flue manufacturer s specific instructins TYPE C13 (HORIZONTAL BALANCED FLUE) When the heater is installed as a Type C13 appliance, the flue system shuld be installed as fllws: 1. Determine the lcatin f the flue terminal, taking int accunt minimum distances as detailed in Figure 8.1, Table 8.1 and the relevant British Standards. 2. Taking care t prtect the appliance frm debris and dust, drill a hle in the desired lcatin. The diameter f the hle shuld be n mre than 10mm greater than the diameter f the air supply pipe f the terminal. 3. Determine the required length f the terminal and cut as necessary. NOTE: When determining the required length fr the flue terminal, the uter wall plate r rsette shuld be flush t the wall. (See Figure 8.3) NOTE: Once cut; remve all burrs and sharp edges. 4. Insert the terminal int the drilled hle. The terminal sectin shuld be installed level r with a fall t utside (Max. 10mm per metre) t prevent the ingress f water. NOTE: When inserting the terminal, ensure the air intake sectin is at the bttm. 5. Fill the vid between the terminal and wall with water resistant sealant. 6. Fit the wall plates r rsette using apprpriate fixings. 7. Install the remainder f the flue system wrking prgressively away frm the biler supprting the pipes as necessary. FIGURE 8.3 HORIZONTAL TERMINAL INSTALLATION TYPE C33 (VERTICAL BALANCED FLUE) When the heater is installed as a Type C33 appliance, the flue system shuld be installed as fllws: 1. Cnfirm that the rf flashing is crrect fr the type f rf thrugh which the terminal is t be installed. (See Figure 8.4) 2. Determine the desired lcatin fr the flue terminal, taking int accunt minimum distances as detailed in Figure 8.1, Table 8.1 and the relevant British Standards. 3. Taking care t prtect the appliance frm debris and dust, drill a hle in the desired lcatin. The diameter f the hle shuld be n mre than 10mm greater than the diameter f the air supply pipe f the terminal. NOTE: The hle shuld be drilled frm the utside t ensure that n damage is dne t the rfing material. Extra care shuld be taken t ensure that the hle is drilled vertically. 4. Install the rf flashing and secure as apprpriate. 5. Carefully insert the rf terminal thrugh the rf flashing and hle in the rf. NOTE: When inserting the rf terminal d nt supprt r turn the terminal using the cap. 6. Ensure the terminal is vertical using a spirit level. 7. Fit the supprt bracket arund the terminal and secure using apprpriate fixings. D nt tighten the supprt bracket. 8. Install the remainder f the flue system wrking prgressively away frm the biler supprting the pipes as necessary. 9. Once the flue system is fully installed, tighten the clamp t secure the terminal in place. 29

30 FIGURE 8.4 VERTICAL TERMINAL ROOF FLASHINGS FOR SYNTHETIC, FLAT AND TILED ROOFS FIGURE 8.5 INSTALLING TERMINAL THROUGH ROOF FLASHING TYPE C43 This appliance can perate n a U-Duct cmmn flue system. The maximum lengths fr the intercnnecting flue can be calculated using the infrmatin in Sectin 8.5: MAXIMUM LENGTH CONVENTIONAL/TWIN-PIPE FLUE Cncrete cmpnents f the U-Duct must meet the requirements f BS EN 1858 CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 Flue Gas Mass Rate (G20) 100% (g/sec) Flue Gas Mass Rate (G20) 25% (g/sec) Flue Gas Mass Rate (G31) 100% (g/sec) Flue Gas Mass Rate (G31) 25% (g/sec) TABLE 8.11 FLUE GAS MASS RATES TYPE C53 (TWIN PIPE FLUE) When installing the heater as a Type C53 appliance, it shuld be nted that the terminals must nt be installed n ppsite sides f the building. The details f hw t cnvert the appliance fr twin pipe flued peratin are cntained within the cnversin kit. T install a hrizntal Type C53 terminal r air inlet the prcedure fr a Type C13 terminal shuld be fllwed. T install a vertical Type C53 terminal r air inlet, the prcedure fr a Type C33 terminal shuld be fllwed. 8.8 COMMON FLUE SYSTEMS The CP-M+ biler can be installed n t a cmmn flue system if required. The cmmn flue system shuld be sized t perate under a negative pressure f t mbar. 30

31 If a psitive pressure cmmn flue system is t be used, a prprietary recirculatin preventin device must be installed at the flue spigt f each biler t prevent prducts f cmbustin frm re-entering the plant rm. A cascaded cmmn flue system which perates n a psitive pressure is available frm Lchinvar Limited. Further details can be fund in the Cascade Flue Systems guide, available frm FLUE TERMINAL GUARDING If a hrizntal flue terminal is t be fitted less than 2 metres frm grund level r in a lcatin where it can be tuched frm a windw, dr r balcny, a terminal guard must be fitted. The terminal guard shuld be psitined centrally arund the terminal and secured using apprpriate wall fixings. An apprved terminal guard is available; please cntact Lchinvar Limited fr further infrmatin CONDENSATE DRAIN Fr flue runs f less than 6 metres, prvided that the flue system rises at an angle f at least 3 (50mm per metre), n additinal cndensate drain will be required. Failure t prvide an adequate rise in the flue system may lead t pling f cndensate which may lead t premature failure f the flue system. If the flue run is greater than 6 metres, it is recmmended that an inline cndensate drain and trap be fitted. The cndensate trap shuld be cnnected t a suitable drainage system as described in Sectin 6.5: CONDENSATE DRAIN Where a cmmn flue is used, precautins shuld be taken t ensure that all cndensatin frmed in the flue system is nt drained thrugh ne biler. It is recmmended that a cndensate drain pint is installed in the cmmn flue header and cnnected t a suitable drainage system. 9.0 AIR SUPPLY The fllwing infrmatin is based n single biler installatins nly. If mre than ne biler is being used, BS6644 shuld be cnsulted t calculate the necessary requirements. 9.1 COMBUSTION VENTILATION When used as a Type C appliance, ventilatin fr cmbustin is nt necessary as the cmbustin air is ducted directly frm utside. When used as a Type B appliance, the cmbustin air requirements are as fllws: Grss Net Cmpartment Cmpartment Ventilatin Input Input (Direct t Outside) (T Internal Space) Mdel (Rm) (kw) (kw) (cm 2 ) High Lw High Lw (cm 2 ) (cm 2 ) (cm 2 ) (cm 2 ) CP-M TABLE 9.1 COMBUSTION VENTILATION REQUIREMENTS CP-M+60 Plant Rm Enclsure Mdel Grss Input Net Input Lw Summer Use Medium Summer Use High Summer Use Lw Summer Use Medium Summer Use High Summer Use (kw) (kw) High (cm 2 ) Lw (cm 2 ) High (cm 2 ) Lw (cm 2 ) High (cm 2 ) Lw (cm 2 ) High (cm 2 ) Lw (cm 2 ) High (cm 2 ) Lw (cm 2 ) High (cm 2 ) Lw (cm 2 ) CP-M CP-M CP-M CP-M CP-M TABLE 9.2 COMBUSTION VENTILATION REQUIREMENTS CP-M+80 CP-M

32 9.2 COOLING VENTILATION When used as a type C appliance, installed in a cmpartment r an enclsure, cling ventilatin shuld be prvided as fllws: Mdel Enclsure/Cmpartment Enclsure/Cmpartment Input Input Biler Rm (Direct t Outside) (T Internal Space) (Grss) (Net) kw kw High Lw High Lw High Lw (cm 2 ) (cm 2 ) (cm 2 ) (cm 2 ) (cm 2 ) (cm 2 ) CP-M N/A N/A CP-M CP-M CP-M CP-M CP-M TABLE 9.3 COOLING VENTILATION REQUIREMENTS When used as a type B appliance, prvisin fr cling ventilatin is included in the cmbustin ventilatin allwance. 9.3 MECHANICAL VENTILATION In situatins where cmbustin air cannt be prvided by the means f ventilatin grilles, it can be supplied by a fan. The minimum flw rate fr the fan shuld be in accrdance with Table 9.4. If required, extract air can als be thrugh the use f a fan. When sizing the extract fan, the extract flw rate shuld be calculated by subtracting the difference vlume (frm Table 9.4) frm the actual supplied vlume f inlet air. If therefre, a larger than required inlet vlume is prvided, the extract flw rate will need t be increased accrdingly. If the ventilatin discharge frm the plant rm is thrugh the means f simple penings relying n thermal effects, the minimum free areas f the penings and any assciated grilles shuld be as specified fr natural ventilatin (see Sectin 9.1: COMBUSTION VENTILATION). The ventilatin penings shall be at high level and the air supply shall be at lw level. NOTE: VENTILATION MUST NOT BE PROVIDED THROUGH NATURAL INLET AND MECHANICAL EXTRACT AS THIS WILL CAUSE A NEGATIVE PRESSURE WITHIN THE PLANT ROOM AND MAY LEAD TO THE PRODUCTS OF COMBUSTION BEING DRAWN INTO THE PLANT ROOM. Appliance Type Withut draught diverters. (with r withut draught stabilisers) TABLE 9.4 Flw rate per kw ttal rated net input (m 3 /h) Minimum Inlet Air (Cmbustin, Ventilatin) Difference between Inlet and Extract Air (Inlet minus Extract Ventilatin) ± 0.18 MECHANICAL VENTILATION FLOW RATES WORKED EXAMPLE MECHANICAL INLET/NATURAL DISCHARGE Lchinvar CP-M+100 Heat input (net): = 92.0 kw Minimum cmbustin air flw rate: = 92.0 x 2.6 m 3 /h = m 3 /h Ventilatin grille size (high level): = 184 cm 2 32

33 9.3.2 WORKED EXAMPLE MECHANICAL INLET/MECHANICAL DISCHARGE (MINIMUM COMBUSTION AIR FLOW RATE) Lchinvar CP-M+100 Heat input (net): = 92.0 kw Minimum cmbustin air flw rate: = 92.0 x 2.6 m 3 /h = m 3 /h Difference between inlet and extract air (maximum value): = 92.0 x ( ) m 3 /h = m 3 /h Difference between inlet and extract air (minimum value): = 92.0 x ( ) m 3 /h = m 3 /h Extract air (maximum value): = m3/h m 3 /h = m 3 /h Extract air (minimum value): = m3/h m 3 /h = m 3 /h WORKED EXAMPLE MECHANICAL INLET/MECHANICAL DISCHARGE (ALTERNATE COMBUSTION AIR FLOW RATE): Lchinvar CP-M+100 Heat input (net): = 92.0 kw Minimum cmbustin air flw rate: = 92.0 x 2.6 m 3 /h = m 3 /h Actual cmbustin air flw rate: = 92.0 x 3.15 m 3 /h = m 3 /h Difference between inlet and extract air (maximum value): = 92.0 x ( ) m 3 /h = m 3 /h Difference between inlet and extract air (minimum value): = 92.0 x ( ) m 3 /h = m 3 /h Extract air (maximum value): = m 3 /h m 3 /h = m 3 /h Extract air (minimum value): = m 3 /h m 3 /h = m 3 /h 10.0 WATER CONNECTIONS 10.1 FLOW/RETURN CONNECTIONS There are tw tee-pieces supplied with the biler, these are fr enlarging the flw/return cnnectins t the biler and fr installing a pressure relief valve (nt supplied) and a drain valve (nt supplied). It is recmmended that islatin valves are fitted t the biler flw and return cnnectins t allw the appliance t be islated frm the system when required. The biler has n internal relief valve; therefre a suitably sized pressure relief valve must be fitted t the biler flw cnnectin OPEN VENTED SYSTEM ARRANGEMENT The Lchinvar CP-M+ can be used in an pen vented arrangement prvided that a vent pipe in accrdance with CP 342 r BS6644 as apprpriate is fitted. The minimum static head requirement fr an pen vented system is 1.0 bar. The appliance is fitted with a water pressure sensr and requires a nminal system pressure f 1.0 bar. The burner cntrl will blck the biler frm perating if the system pressure drps belw a pressure f 0.8 bar; nce the system pressure rises abve 1.0 bar, the blck will be lifted. The maximum system pressure with the standard pressure sensr is 4.0 bar hwever, a pressure switch may be used if the static head exceeds this. Fr further details n the cnnectin f a water pressure switch, please refer t Sectin 11.0: ELECTRICAL SUPPLY 33

34 10.3 SEALED SYSTEM ARRANGEMENT If a sealed system arrangement is required, a suitable pressurisatin unit is available frm Lchinvar Limited n request. Sealed systems shuld incrprate a safety valve with a lift pressure n greater than the maximum pressure rating f any cmpnent in the heating system. The maximum wrking pressure f the biler is 6.0 bar. A suitably sized expansin vessel shuld als be fitted t the system in accrdance with BS4814. The appliance is fitted with a water pressure sensr and requires a nminal system pressure f 1.0 bar. The burner cntrl will blck the biler frm perating if the system pressure drps belw a pressure f 0.8 bar; nce the system pressure rises abve 1.0 bar, the blck will be lifted. The maximum system pressure with the standard pressure sensr is 4.0 bar hwever, a pressure switch may be used if the static head exceeds this. Fr further details n the cnnectin f a water pressure switch, please refer t Sectin 11.0: ELECTRICAL SUPPLY EXPANSION VESSEL SIZING The fllwing infrmatin is based n a static head f 3.5 bar. If a different cld fill pressure is t be used, please cnsult BS4814. V V = S V * e 0.45 Where: V V = Vessel Vlume S V = System Vlume e = Cefficient f Expansin (See Table 10.1) TABLE 10.1 Stred Temp. C e Stred Temp C e COEFFICIENT OF EXPANSION OF WATER AT 3.5 BAR COLD FILL PRESSURE 10.4 CIRCULATING PUMPS The CP-M+ biler has a built in circulating pump. This pump has a speed regulatr which has been adjusted t the maximum setting. T prevent peratinal issues, this setting must nt be altered. When there is a call fr heat, the pump is energised, nce the call fr heat expires, the pump verruns fr a perid f 3 minutes. The pump is als activated fr ne minute every 24 hurs after the biler pwer supply is cnnected in rder t prevent the pump seizing. 34

35 Head (meter WC) Head (meter WC) Hydraulic graph 60kW 8,0 ΔT=25K ΔT=20K 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 Water flw (m³/h) Resistance Biler Head Pump Head fr Installatin FIGURE 10.1 HYDRAULIC GRAPH CP-M+60 Hydraulic graph 80kW 8,0 ΔT=25K ΔT=20K 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 Water flw (m³/h) Resistance Biler Head Pump Head fr Installatin FIGURE 10.2 HYDRAULIC GRAPH CP-M+80 35

36 Head (meter WC) Head (meter WC) Hydraulic graph 100kW 8,0 ΔT=25K ΔT=20K 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 Water flw (m³/h) Resistance Biler Head Pump Head fr Installatin FIGURE 10.3 HYDRAULIC GRAPH CP-M+100 Hydraulic graph 120kW 8,0 ΔT=25K ΔT=20K 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 Water flw (m³/h) Resistance Biler Head Pump Head fr Installatin FIGURE 10.4 HYDRAULIC GRAPH CP-M

37 Head (meter WC) Head (meter WC) Hydraulic graph 150 kw ΔT=25K ΔT=20K Water flw (m³/h) resistance biler head pump s2 head fr installatin s2 head pump s3 head fr installatin s3 FIGURE 10.5 HYDRAULIC GRAPH CP-M+150 Hydraulic graph 180 kw ΔT=25K ΔT=20K Water flw (m³/h) Resistance Biler Head pump s2 Head fr installatin s2 Head pump s3 Head fr installatin s3 FIGURE 10.6 HYDRAULIC GRAPH CP-M

38 10.5 DIRT SEPARATOR/STRAINER Due t the high-efficiency, lw water cntent design f the heat exchanger, it is necessary t install a methd f remving dirt frm the system. A dirt separatr r strainer shuld be installed in the system return line and checked n a weekly basis t ensure an adequate flw is maintained whilst ensuring that the heat exchanger des nt get blcked. Where a strainer is used, it is recmmended that islatin valves are installed either side f the strainer and a bleed pint is installed t aid in the rutine maintenance. Blckage f the heat exchanger due t the ingress f debris frm the system is nt a manufacturing defect and is nt cvered by the warranty AIR SEPARATOR When a CP-M+ biler is installed n a heating system cntaining irn, xygen in the water can react t frm the mineral magnetite. Due t the highly magnetic nature f magnetite, the mineral can create flw restrictins in the heat exchanger, which may result in premature failure. When installing a CP-M+ biler the system must be fully flushed t remve all existing traces f magnetite and an air separatr shuld be fitted t prevent any further develpment. The air separatr shuld be installed in the httest part f the heating system, i.e. n the flw ut f the lw velcity header, and in accrdance with the item manufacturer s instructins ROOF-TOP INSTALLATION If the CP-M+ biler is t be psitined at the highest pint f the installatin, the system flw and return pipes must rise a minimum f 0.5m abve the tp f the biler, befre re-directing t the desired lcatins within the building t ensure a minimum water level is maintained within the biler. A lw-water level prtectin device shuld als be installed within the system INSTALLATION SCHEMATIC DRAWINGS The fllwing schematic drawings are fr guidance purpses nly. Alternate installatin schematic drawings are available; please visit 38

39 1. LOCKSHIELD VALVE 2. DRAIN VALVE 3. AIR SEPARATOR 4. DIRT SEPARATOR 5. AUTOMATIC AIR VENT 6. EXPANSION VESSEL 7. TEMPORARY FILL CONNECTION (REMOVE AFTER FILLING) 8. DOUBLE CHECK VALVE 9. LOW VELOCITY HEADER 10. NON RETURN VALVE 11. PRESSURE RELIEF VALVE 12. ISOLATION VALVE 13. MANUAL AIR VENT 14. STRAINER FIGURE 10.7 SINGLE BOILER INSTALLATION ON A SEALED SYSTEM 39

40 1. LOCKSHIELD VALVE 2. DRAIN VALVE 3. AIR SEPARATOR 4. DIRT SEPARATOR 5. AUTOMATIC AIR VENT 6. EXPANSION VESSEL 7. TEMPORARY FILL CONNECTION (REMOVE AFTER FILLING) 8. DOUBLE CHECK VALVE 9. LOW VELOCITY HEADER 10. NON RETURN VALVE 11. PRESSURE RELIEF VALVE 12. ISOLATION VALVE 13. MANUAL AIR VENT 14. STRAINER 15. CASCADE FLOW SENSOR FIGURE 10.8 MULTIPLE BOILER INSTALLATION ON A SEALED SYSTEM 40

41 OUTSIDE TEMPERATURE SENSOR CASCADE FLOW TEMPERATURE SENSOR CALORIFIER SENSOR OR THERMOSTAT GENERAL BLOCKING EMPTY EXTERNAL WATER PRESSURE SWITCH ROOM THERMOSTAT OR OPEN-THERM BUS CONTROLLER 0-10V DC CASCADE CONNECTION LOCK-OUT (N.O.) BURNER BURNING (N.O.) HEAT DEMAND (N.O.) CENTRAL HEATING SYSTEM PUMP (P3) CALORIFIER DIVERTER VALVE OR CALORIFIER PUMP (P2) 230 V ~ 1 Ph 50Hz SUPPLY 11.0 ELECTRICAL SUPPLY Wiring external t the equipment must be installed in accrdance with the I.E.E. Regulatins and any lcal regulatins that apply. Mdel Nrmal Supply Vltage External Fuse Rating Pwer Cnsumptin CP-M CP-M CP-M V AC Hz 6.0 Amps CP-M PH 370 CP-M CP-M TABLE 11.1 ELECTRICAL SUPPLY REQUIREMENTS WARNING: THIS APPLIANCE MUST BE EARTHED A suitably cmpetent persn MUST check wiring. Nrmal supply required is 230 vlts AC, single phase, 50 Hz. An islatr with a cntact separatin f at least 3mm in all ples shuld be sited clse t the equipment and must nly serve that equipment. The duble ple switch must be readily accessible under all cnditins CONNECTOR STRIP A B L N L1 N L2 L N PIN CONNECTION NOTES Outside Temperature Sensr Cascade Flw Temperature Sensr Calrifier Sensr r Thermstat General Blcking FIGURE 11.1 CONNECTOR STRIP When an utside temperature sensr is cnnected, the biler setpint will be cmpensated in relatin t the utside temperature. The additin f this sensr will reduce the flw temperature f the biler in warmer temperatures, increasing energy efficiency. A change in cntrl parameters will be required when this sensr is cnnected and the cntrl system shuld be cnfigured t functin as required. Fr further infrmatin, please refer t Sectin 12.10: OUTSIDE TEMPERATURE COMPENSATION. When a multiple biler cascade is used, the master biler requires a flw sensr t be fitted t the cmmn pipewrk in rder t cntrl the firing rate whilst acting as a lag biler. The sensr shuld be lcated n the system flw adjacent t the lw velcity header. N change in cntrl parameters will be required when this sensr is cnnected. Where a DHW calrifier is used, a ht water sensr r an n/ff thermstat can be cnnected. When a sensr is cnnected, the water temperature will be shwn n the display; when a thermstat is used the flw temperature t the indirect strage vessel will be shwn. Where an interlck with a safety system such as a flue fan r mechanical ventilatin system is required, the safety circuit shuld be wired t terminals 7 and 8. Where mre than ne safety system is used, each system shuld be wired in series. When the link n 7 and 8 is brken, all heat demands, including frst prtectin are blcked Empty N/A External Water Pressure Switch A water pressure sensr is munted in the biler with a maximum pressure f 4.0 bar. As an ptin, the sensr can be replaced by a water pressure switch, which can be wired t the terminals. When terminals are nt bridged, the biler will lck-ut. A change in cntrl parameters is required t activate this functin. 41

42 13-14 Rm Thermstat r Open-Therm Bus Cntrller When n time r temperature cntrl is required, these terminals shuld be linked. In this situatin, the biler flw temperature is set via the cntrl interface; if an utside temperature sensr is cnnected, the biler is cntrlled thrugh the heating curve. When an On/Off rm thermstat (with r withut timer) r a BMS enable cntact is cnnected, the biler will perate when the cntrller cntact is clsed. The flw temperature is cntrlled set via the cntrl interface (with r withut utside temperature cmpensatin). T prevent interference in the cntrl circuit, cabling t any cntrl switch shuld be kept away frm surces f electrmagnetic interference r suitable screened cable shuld be used. When cnfigured (see Sectin 13.1 SETTING THE PARAMETERS WITH THE DISPLAY MENU fr further infrmatin), terminals 7 and 8 can be used t switch the unit between nrmal and setback peratin mde. When an Open-Therm rm thermstat is cnnected, it shuld be cnnected t terminals 7 and 8 using screened cable. The biler is ready fr use with a multifunctinal rm cntrller (such as the Lchinvar RC Cntrller). Fr further infrmatin, please see the cntrller specific manual V DC N change in cntrl parameters will be required when this cnnectin is used. The biler setpint can r firing rate can be adjusted by an external cntrl, thrugh a 0V t 10V analgue signal. Fr Further infrmatin n 0-10 VDC cntrl, please refer t Sectin 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU Cascade Cnnectin Lck-Out Signal Burner Burning Signal Burner Demand Signal Central Heating System Pump Calrifier Diverter Valve r Calrifier Pump 230 V ~ 1 Ph 50 Hz Supply The + has t be cnnected t terminal 15, while the - has t be cnnected t the terminal 16. The Lchinvar CP-M+ has a built in cascade management system. When tw r mre bilers are cnnected in a cascade, each biler f the cascade has t be cnnected t the next biler using terminals 17 and 18. This cnnectin is plarity sensitive (all terminal 17s t be linked and all terminal 18s t be linked) and shuld be made using screened cable. One biler has t be appinted as a Master, while the ther biler(s) are the Slaves. All external cntrls such as calrifier sensr, utside temperature sensr, system pumps etc. are t be cnnected t the Master biler. Fr a cascade t wrk crrectly, it is essential that a flw temperature sensr is used. Each cnnected biler needs t be prgrammed with a different address thrugh the cntrl interface, see Sectin 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU fr further details. Terminals 19, and 20 are nrmally pen vlt free terminals that can be used t give status signals t a BMS panel in the event f a Lck-Out cnditin. N change in cntrl parameters will be required when these cnnectins are used. Terminals 21, and 22 are nrmally pen vlt free terminals that can be used t give status signals t a BMS panel when the burner is peratinal. The cntacts can als be cnfigured t clse when a specific firing rate is reached t enable a nn-cascaded biler. A change in cntrl parameters is required t activate this functin. Terminals 23 and 24 are nrmally pen vlt free terminals that can be used t give status signals t a BMS panel when a demand fr heat is present. A change in cntrl parameters is required t activate this functin. If required, a central heating system pump can be cnnected t terminals When a calrifier is cnnected t the biler (r t the Master, when a cascade system is installed), the system pump is switched ff when there is a DHW demand. If the pump has an electrical lading in excess f 250 watts, a relay shuld be used t energise the pump. Where a diverter valve is used t separate the CH circuit frm the DHW circuit, this can be cntrlled by the biler using terminals Where the DHW circuit is perated by an additinal pump, this can be enabled using terminals See Sectin 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU fr details n cnfiguring this utput. If the pump has an electrical lading in excess f 250 watts, a relay shuld be used t energise the pump. The 230 VAC 1PH 50Hz pwer supply shuld be cnnected t terminals Terminal 32 shuld be Live Terminal 33 shuld be Earth Terminal 34 shuld be Neutral. TABLE 11.2 CONNECTION TERMINAL DETAILS 42

43 11.2 ARC WELDING PRECAUTIONS The appliance must be islated frm the mains electricity supply in the event f electric arc welding being carried ut n any cnnecting pipewrk ANCILLARY EQUIPMENT OUTSIDE TEMPERATURE SENSOR When an utside temperature sensr is fitted t cmpensate the flw temperature f the biler, it shuld be lcated in an area where it is nt influenced by ther heat surces i.e. ut f direct sunlight (ideally n a nrth facing wall) and away frm flue terminals and heat extract fans SAFETY CIRCUIT Where additinal safety devices are used such as emergency stp cntrls, system pressurisatin units and fire cntrl systems, the safety circuits shuld be linked in series and cnnected t terminals 7 & 8 n the cnnectin strip. This will ensure that the appliance des nt fire in an unsafe situatin but maintains all f its prtectin features such as cmbustin pst-purge and pump ver-run CASCADE CONTROL CASCADE WIRING If the heaters are t be perated in a cascade, shielded 2-wire twisted pair cmmunicatin cable shuld be used. The shielding shuld be cnnected t a suitable earth pint and then all 17 terminals shuld be linked tgether and all 18 terminals shuld be linked tgether CASCADE SENSOR A strap-n pipe sensr is required fr the cascade cntrl t functin crrectly. This shuld be lcated as clse t the lw velcity header as practicably pssible n the system flw pipewrk TIME, TEMPERATURE AND ZONE CONTROL Lchinvar can supply time, temperature and zne cntrl ptins fr a variety f heating system installatins. Fr further details, please refer t the Systems and Cntrls Guide, available frm 43

44 Outdr sensr 12K External flw sensr 10K Calrifier sensr 10K Calrifier themstat water pressure switch OpenTherm/ pwer stealing thermstat Remte temperature setpint r burner input signal frm BMS Lck-ut N.O. Flame n N.O. Heat demand N.O. K10 K0 K4 K8 K1 K7 K3 Mdel 60 has n thermal fuse and n thermal switch. Bth cnnectins are bridged. K8 K8 K6 K4 K2 K8 K6 K2 K6 K2 K8 K6 K4 K6 K10 K5 K9 N.C. K9 K9 [clse] N K10 N.C. K Lck-Out NO Lck-Out NO Flame n NO Flame n NO Heat demand NO Heat demand NO Pump 1, L' Pump 1, N' Pump 2 / 3-way, L' (NO) [pen] 3-way, L' (NC) Pump 2 / 3-way, N' Gas Valve, N' Gas Valve, L' Pump 3, L' Pump 3, N' K8 Therm.stat 230v K8 Therm.stat 230v MAINS L' MAINS N' K K3 K6 fuse 2 fuse 1 K8 N.C CP-M+ WIRING DIAGRAM internal cnnectins inisatin and/r ignitin K10 siphn pressure switch (PSW) N.C. K7 display K7 K2 K2 clixn/maximum (S6/S7) water thermstat 24vdc fan cntrl flw sensr ntc (S1) 10K flue sensr ntc (S5) 10K FAN ref.1 K1 K1 fan Hall K0 K6 - K5 K5 K8 ut Gnd K0 K fan PWM +24Vdc K CN6 CN7 CN CN CN CN11 CN8 WIRING COLORS K0=white K6=blue K1=yellw K7=red K2=brwn K8=black K3=green K9=purple K4=grey K10=yellw/green K5=range CN3 CN CN F2 8 ignitin transfrmer incl. inisatin input. 9 F1 10 T2 CN4 CN nt used biler casing return sensr ntc (S2) 10K K3 K3 water pressure sensr (water pressure switch will be munted abve 4 Bar) (water pressure switch cnnectin) Nt used rear wall thermal fuse ut +5V Gnd K1 K1 + K2 K6 CN10 FAN burner dr thermal switch gas valve(s) K2 K6 biler pump (pump1) pump cnnectr K6 K2 K10 internal cnnectins ref.1 K2 K2 K6 K8 1 2 OUTDOOR SENSOR CALORIFIER EXTERNAL SENSOR FLOW r SENSOR THERMOSTAT GENERAL EMPTY EXTERNAL BLOCKING WPS On/Off Stat r OpenTherm Heating Circuit VDC A B CASCADE CONNECTION LOCK-OUT N.O BURNER HEAT BURNING DEMAND N.O. N.O L N CH System Pump P L1 N L2 Divertr Valve Calrifier by Calrifier Pump P L N Mains 230 VAC cnnectin examples wire bridge cnnectin examples External safety device: - External flw switch - Smke detectin - Gas detectin - Ventilatin fan - Flue gas fan - End switch mtr actuated flue gas valve - Gas leakage tester - etc t t master slave biler biler nly when unit is cascaded POWER SUPPLY FIGURE 11.2 WIRING DIAGRAM 44

45 12.0 CONTROL INTERFACE 12.1 CONTROL PANEL / DISPLAY UNIT CONTROL PANEL DISPLAY 2 rws / each 20 characters MENU ON/OFF RESET ENTER COMM. PORT SERVICE ON/OFF RESET ENTER Press and hld fr 6 secnds t switch biler n/ff. Is als used as RESET buttn and ENTER buttn when prgramming. Cnnectr fr cnnecting cmputer cable. COMM. PORT MENU Buttns can be pushed t pen menu. [ hld fr 1 secnd ] Buttns t tggle thrugh measured temperatures. These are als used fr navigating thrugh the menus and used fr changing values. SERVICE Buttn t activate service functin. [ hld fr 3 secnds ] Schrnsteinfeger functin (nly fr Germany). Light: will light up when cntrller sees gd flame signal. Lights when burner is burning. FIGURE 12.1 CONTROL INTERFACE 45

46 12.2 CONTROL PANEL MENU STRUCTURE BASE SCREEN : (what shws during peratin) H E A T I N G : S t a n d - b y > > > : C ( C ) press: MENU By pressing ( ) ne can tggle thugh the available menu's. CONFIRMATION CHANGE! When changes are being made in the menu's within this dashed rectangle, the user presses ENTER t cnfirm the changes. T prevent custmers making changes by accident the fllwing happens when changes are made: Step 1 : The user presses "ENTER" t cnfirm the change made. Step 2 : The display asks the user t be sure t make these changes. The user can cancel and cnfirm by using the left and right arrws. CANCEL = CONFIRM = "TIME/DATE/DAY" menu In this menu ne can set the time and the date. press: "MONITOR" screens One can tggle thrugh the measured values and status f the heater. Pressing "ON/OFF, RESET, ENTER" briefly will cause the display t g back t the base menu. When n buttn has been pressed fr 3 minues the display will autmatically g t the BASE DISPLAY. (This time perid can be set by a parameter) "SETPOINT" menu In this menu ne can change temperature settings withut the need fr a passwrd. - Heating setpint Flw set pint when cntrlling n/ff n set flw temp. - Heating reduced The amunt f degrees diff. relative t "Heating setpint" during night reductin. - Parallel shift +/- relative t utdr curve (als in utdr menu pssible) - Ht water setpint Calrifier r Water heater (depends n heater type) - Ht water reduced The amunt f degrees diff. relative t "Ht water setpint" during night reductin. press: press: Display shws 2x20 digit message fr 3 secnds Message can be set in parameters. example: Cmpany name City, Cuntry Display shws fr 3 secnds - Heater type - Time, date and day example: Z-FG :51 US(r EU) 06 / 01 / 2010 Wed After this message the display shws fr 3 secnds - Sftware versin and - Cascade designatin example: Firmware : Mk Adress : 0 "PROGRAM" menu In this menu ne can set the CH, DHW and Anti leginair prgram. "OUTDOOR" menu In this menu ne can set all Outdr relevant parameters. "OPERATING HISTORY" menu Shws burning hurs DHW, Heating, etc. "FAULT HISTORY" menu Reading last 15 faults (nly reading!). "MAINTENANCE" menu By pressing ( ) ne can set the fllwing ptins. - Maintenance reset - Maintenance Mde - All - Date - Ignitin cycles - Burning hurs - Mainten Off These three messages will als shw when: - Heater is cnnected t the pwer - When heater is turned ON - When heater is turned OFF sequence: The messages will shw frm TOP t BOTTOM each fr three secnds. "USER LOCK" menu In this menu ne can lck the menu fr users 0=UNLOCKED 1=LOCKED When un-lcked the user can enter the "MENU" by pressing the menu buttn and all sub menu's will shw. When lcked the user has t push the : MENU and simulatenusly press fr 6 secnds t get acces t all sub menu's. This is t prevent accidental changes! NOTE: The parameters sub menu can always be accessed. "PARAMETERS" menu In this menu ne can change parameters. The pssible access depends n the passwrd that is used. Enter passwrd: Passwrd "LEVEL 1" entered Passwrd "LEVEL 2" entered 3 secnd message cnfirming acces: "LEVEL 1" 3 secnd message cnfirming acces: "LEVEL 2" FIGURE 12.2 CONTROL MENU STRUCTURE 46

47 12.3 DISPLAY DURING OPERATION During nrmal peratin the text in the display shws the status f the biler. In the fllwing figures the pssble displays during nrmal peratin are explained. Display during HEATING DEMAND Heat demand type: Actual status: H E A T I N G : S T A N D - B Y > > > : C ( C ) Cascade Temperature Setpint Measured temperature at cntrl sensr Cmmunicatin Indicatr Can be turned ff by altering P5 BJ When heat is needed fr the calrifier the text "HEATING" changes int "HOTWATR". When there is n heat demand it always shws heating. Display during HOT WATER DEMAND Heat demand type: Actual status: H O T W A T R : S T A N D - B Y > > > : C ( C ) Cascade Temperature Setpint Measured temperature at cntrl sensr Cmmunicatin Thermstat = Cil Flw Temp. Indicatr Sensr = Water Setpint Temp. Can be turned ff by altering P5 BJ Actual status text descriptins Actual status: B i l e r f f The biler is turned ff at the cntrl interface. N d e m a n d N heat demand signal is received frm the rm thermstat r calrifier sensr/thermstat. S t a n d - b y Rm thermstat r calrifier sensr/thermstat heat demand present but setpint is reached. P r e - p u r g e The fan is purging the cmbustin chamber befre starting an ignitin cycle. P r e - i g n i t i n Ignitin prcess has started but the gas valve hasn't been pened. I g n i t i n The burner is attempting t ignite. P s t - p u r g e The fan is purging the cmbustin chamber after burner switches ff. B u r n i n g % The burner is firing at the indicated rate. Cascade Cmmunicatin Indicatr NO CASCADE COMMUNICATION > > > Screen 1 Display is fixed shwing Screen 1 CORRECT CASCADE COMMUNICATION > > Screen 1 > Screen 2 Display alternates between Screen 1 & Screen 2 at 1 secnd intervals FIGURE 12.3 OPERATION SCREEN 47

48 12.4 MONITOR SCREENS During nrmal peratin and stand-by, the and buttns can be used t shw sme biler infrmatin, including measured temperatures, settings and data. The fllwing figure explains which values can be shwn in the display. When n buttn is activated fr 2 minutes the display will return t its status display. Pressing [ ] r [ ] when the display shws the "perating screen" tggles thrugh the screens belw. Pressing [ON/OFF, RESET, ENTER] r [MENU] at any time returns the display t the base menu. SCREEN: 1 T 1 F l w 1 2 3, 9 T 2 R e t u r n 1 2 3, 9 C Temperature measured by the internal flw sensr. C Temperature measured by the internal return sensr. O p e n Shwn when the cntrller des nt detect this sensr. S h r t e d Shwn when the sensr wires r the sensr itself is shrted. SCREEN: 2 T 3 E x t e r n a l 1 2 3, 9 T 4 C a l r i f i 1 2 3, 9 C Temperature measured by the external sensr. C Temperature measured by the calrifier sensr. O p e n Shwn when the cntrller des nt detect this sensr. S h r t e d Shwn when the sensr wires r the sensr itself is shrted. SCREEN: 3 T 5 O u t d r 1 2 3, 9 T 6 F l u e 1 2 3, 9 C Temperature measured by the utdr sensr. C Temperature measured by the flue gas sensr. O p e n Shwn when the cntrller des nt detect this sensr. S h r t e d Shwn when the sensr wires r the sensr itself is shrted. SCREEN: 4 d T F l w R e t u r n 1 2 3, 9 d T F l u e R e t u r n 1 2 3, 9 C Temperature difference between internal flw & internal return sensr. C Temperature difference between flue gas & internal return sensr. SCREEN: 5 d T E x t R e t u r n 1 2 3, 9 C Temperature difference between external & internal return (ΔT LLH). S i g n a l P w e r External supplied 0-10 Vlt dc signal. S e t p i "Pwer" = pwer utput cntrl r "Setpi" = temperature setpint cntrl. SCREEN: 6 F a n s p e e d r p m Actual fan speed in rpm. F a n s p e e d % Actual fan speed % f maximum allwable fan speed. SCREEN: 7 F l a m e s i g n a l μ A Flame signal given in μa. W a t e r P r e s s u r 1, 0 b a r Shws water pressure when sensr is cnnected. SCREEN: 8 P u m p 1 H e a t e r O f f Pump 1 (Internal pump) On r Off. P u m p 1 S i g n a l % Mdulating signal Pump 1 in (% ). SCREEN: 9 P u m p 2 C a l r i O f f Pump 2 (Calrifier pump) On r Off. 3 - w a y V a l v e H e a t i n g Signal t the 3-way valve: "HEATING" r "HOTWATER". SCREEN: 1 0 P u m p 3 S y s t e m O f f Pump 3 (System pump) On r Off. h h : m m D D / M M / Y Y Y Y D a y Time & Date: hh=hur; mm=minutes; DD=date; MM=mnth; YYYY=year; Day FIGURE 12.4 MONITOR SCREENS 48

49 SCREEN: 1 1 C a s c D e s i g n 0 Shws the cascade address f the biler 0 = MASTER, = SLAVES C a s I n f A B Displays number, pririty and state f cascade bilers. (See belw) SCREEN: 1 2 C a s c P w e r % % % heat demand f ttal (cascade) pwer available (% ). D u a l B u r n e r : N One heat exchanger equipped with tw burners: "Yes" r "N". SCREEN: 1 3 M a x T h e r m O p e n Status f the maximum thermstat: "Open" r "Clsed". G e n B l c k C l s e d Status f the general blcking cntact: "Open" r "Clsed". SCREEN: 1 4 S i p h n p r e s s C l s e d Status f the cndensate drain pressure switch: "Open" r "Clsed". N R V C n t a c t O p e n Status f the nn return valve cntact: "Open" r "Clsed". Screen 11 "CASCINF" Descriptin The CasInf screen shws the number f bilers cnnected with the Cascade. The Master/Lead biler is designated as 0. Slave/Lag bilers will be designated 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B. When a - is used instead f a number, than that biler is either nt cnnected, r in a lckut mde and nt available fr the Cascade. When an x is used instead f a number, than that biler is cnnected, but in lckut mde. When a d is used instead f a number, than that biler is handling a DHW demand. When the number is flashing, then that biler is prviding heat t the cascade. When the leading biler is changed accrding t the set pririty change time, then that biler s address will be shwn first in the rw f numbers. Example 1: " " There are six bilers present and number 3 biler has pririty. Example 2: "3 4 x d 1 2" There are six bilers present and number 3 biler has pririty. Biler 0 is heating up an indirect DHW tank. Biler 5 is present, but in a lckut. FIGURE 12.5 MONITOR SCREENS (ctd.) 49

50 12.5 SERVICE FUNCTION The fllwing figure describes hw t use the service functin. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [SERVICE] and hld fr 3 secnds. The burner will start and shw the display belw. Operating screen: H E A T I N G : S e r v i c e 2 6 % > > > C ( "HEATING": The appliance is perating as a heating biler. "Service": It is perating in the service mde. "26% ": The burner is firing at 26%. "90,0 C": Max. allwable water temp. during service. "60,0 C": Actual measured water temp. (when P5BJ active). C ) Press [SERVICE] t exit. The unit will g t the perating screen. Press [ON/OFF] fr 3 secnds t exit. The unit will be switched ff. Or By using the [ ] & [ ] buttns the burner firing rate % can be changed. Press [MENU] t access the main menu. Press [MENU] t return t the service menu. Use [ ] & [ ] buttns t brwse thrugh the mnitr screens. Press [MENU] t g t the peratin menu r the service mde. Press [SERVICE] t exit the service mde. The unit will return t the standard peratin display. FIGURE 12.6 SERVICE MODE Mdel CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180 Max. set pint* - (RPM) Max. actual** - (RPM) Margin n actual - (RPM) +/- 50 +/- 50 +/ / /- 50 +/- 50 TABLE 12.1 MAXIMUM COMBUSTION FAN SPEED * The maximum rpm that the cntrller is t use as a set pint. ** The maximum rpm that the fan is actual able t run. The maximum actual rpm can be lwer than the maximum rpm set pint. This is because the fan is nt able t reach the maximum rpm set pint, due t the unit s resistance. The tlerance varies accrding t the design f each specific unit. The relatin between the maximum rpm set pint and the maximum actual rpm is given in this table. This table applies als t the service and Schrnsteinfeger functin f the biler. 50

51 12.6 SCHORNSTEINFEGER FUNCTION The fllwing figure describes hw t use the Schrnsteinfeger functin. NOTE: This functin is nly required in Germany and can be activated by parameter (P5 BK). By default, this functin is disabled. "SCHORNSTEINFEGER" functin The purpse f this functin is t have an easy interface fr the "Schrsteinfegers" in Germany, t be able t d their required testing n the biler. This is a simplified functin similar t the nrmal service functin f the biler. When the "Schrnsteinfeger" buttn is pressed fr 3 secnds: The biler will fire at minimum firing rate (% ) In this state the display shws: F l u e s e r v i c e m d e P w e r : M i n i m u m When the buttn is pressed mmentarily again: The biler will fire at 50% firing rate In this state the display shws: F l u e s e r v i c e m d e P w e r : 5 0 % When the buttn is pressed mmentarily again: The biler will fire at maximum firing rate (% ) In this state the display shws: F l u e s e r v i c e m d e P w e r : M a x i m u m When the buttn is pressed mmentarily again: The biler will return t the nrmal peratin mde. The "Schrnsteinfeger" functin is switched ff. NOTES: When the heater is burning during Schrsteinfeger functin (when tp display line shws "Flue service mde") and n buttn is pressed fr 12 minutes the biler will return autmatically t the nrmal peratin mde. The "Schrsteinfeger functin" can be activated by altering parameter (P5 BK) All nrmal maximum temperature safeties remain active and the biler/water heater pump and the system pump are running. FIGURE 12.7 SCHORNSTEINFEGER FUNCTION 51

52 12.7 SETTING THE TIME & DATE The fllwing figure describes hw t prgram the time and date f the unit. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Main menu screen: M a i n M e n u C l c k The display shws "CLOCK" press [ENTER] Setting Time and Date: S e t t i m e / d a t e 0 8 : / 0 3 / T u e The day is nw flashing/selected and can be changed. Use [ ] & [ ] t change the value. Use [ ] & [ ] t select anther value. Press [ENTER] fr the cnfirmatin screen after all changes are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (display ges back t perating screen). Press [ ] t cnfirm the changes made. The time and day will start flashing fr a few secnds. After this, the display returns t its perating screen. FIGURE 12.8 SETTING THE DATE AND TIME 52

53 12.8 SETPOINTS The fllwing figure describes hw t prgram the heating and ht water set pints. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Setpints" using [ ] & [ ] M a i n M e n u S e t p i n t s Press [ENTER] By pressing [ ] & [ ] the fllwing screens can be selected. By pressing [ ] & [ ] the flashing values in the selected screen can be changed. Press [MENU] t exit. The unit will reset and return t the perating screen. Press [ENTER] fr cnfirmatin screen when all the changes are made. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The value set in the screen when pressing enter will be shwn fr a few secnds. After this the display returns t the nrmal perating screen. H e a t i n g s e t p i n t 8 0 C The flw temperature setpint that will be active during nrmal CH peratin perids. C H N i g h t s h i f t C The reductin relative t the nrmal setpint. This reductin is used utside the prgrammed CH perids. NOTE: This parameter shuld be a negative value r night time temperature will be increased relative t day time temperature. H e a t i n g P a r s h i f t 5 C Setting the parallel shift f the heating curve in relatin t the utdr temperature cntrl (Parameter P6 BB). D H W s e t p i n t 6 0 C This is the water temperature setpint that is active during the prgrammed DHW perids (Parameter P4 AA = 1/2). D H W R e d u c e 1 0 C The reductin f the DHW setpint relative t nrmal setpint. This reductin is used utside the prgrammed DHW perids (Parameter P4 AA = 1/2). FIGURE 12.9 SETTING SETPOINTS 53

54 12.9 SETTING THE TIMER PROGRAMS Three different prgrams can be set with the biler, these are: NOTE: Central Heating (CH) prgram Dmestic Ht Water (DHW) prgram Anti leginnaire s disease (pasteurisatin) prgram The anti leginnaire s disease (pasteurisatin) prgram can nly be used when the biler is set as an indirect biler cnfiguratin r a direct ht water biler cnfiguratin. If DHW is deactivated, the day and time prgram f the anti leginnaire s disease functin will be hidden. The default setting fr this functin is OFF. Three prgrammed time perids can be set each day. During these time perids the unit will use the nrmal CH and DHW setpints. Outside the prgrammed perid(s) the unit will use the reduced temperature setpints. If n time prgram is required, blanks shuld be left e.g. "Mn 3 --:-- ---:--". Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Timer" using [ ] & [ ] M a i n M e n u T i m e r Press [ENTER] P r g r a m C H M n : : 0 0 Press [ ] t brwse thrugh the values that can be set n the bttm line. The flashing value can be changed. Press [ ] & [ ] t change the selected (flashing) value. Press [ENTER] fr cnfirmatin screen when all settings are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The last alternatin will be flashing fr a few secnds and return t base menu. Press [MENU] t exit. The biler will reset and g t the perating screen. Press [ ] fr next SCREEN > > > Cntinued n next page < < < FIGURE SETTING THE TIMER PROGRAMS 54

55 > > > Frm previus page < < < Cpy prgrammed day fr CH: C p y f r m : C H M n C p y t : C H T u e Press [ ] t switch between "Cpy frm" and "Cpy t". The flashing day is selected and can be changed. Press [ ] & [ ] t change the selected (flashing) value. Press [ENTER] fr cnfirmatin screen when all settings are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The tw days will blink fr a mment. Press [MENU] t exit. The biler will reset and g t the perating screen. Press [ ] fr next SCREEN Setting DHW prgram times: P r g r a m D H W M n : : 0 0 Press [ ] t brwse thrugh the values that can be set n the bttm line. The flashing value can be changed. Press [ ] & [ ] t change the selected (flashing) value. Press [ENTER] fr cnfirmatin screen when all settings are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The last alternatin will be flashing fr a few secnds and return t base menu. Press [MENU] t exit. The biler will reset and g t the perating screen. Press [ ] fr next SCREEN > > > Cntinued n next page < < < FIGURE SETTING THE TIMER PROGRAMS (ctd.) 55

56 > > > Frm previus page < < < Cpy prgrammed day fr DHW: C p y f r m : D H W M n C p y t : D H W T u e Press [ ] t switch between "Cpy frm" and "Cpy t". The flashing day is selected and can be changed. Press [ ] & [ ] t change the selected (flashing) value. Press [ENTER] fr cnfirmatin screen when all settings are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The tw days will blink fr a mment. Press [MENU] t exit. The biler will reset and g t the perating screen. Press [ ] fr next SCREEN Setting leginella prgram (day and time): P r g r a m L e g i n e l l a M n 0 9 : 5 1 Press [ ] t brwse thrugh the values that can be set n the bttm line. The flashing value can be changed. Press [ ] & [ ] t change the selected (flashing) value. Press [ENTER] fr cnfirmatin screen when all settings are dne. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes. The last alternatin will be flashing fr a few secnds and return t base menu. Press [MENU] t exit. The biler will reset and g t the perating screen. Press [ ] fr next SCREEN FIGURE SETTING THE TIMER PROGRAMS (ctd.) 56

57 FLOW TEMPERATURE OUTSIDE TEMPERATURE COMPENSATION MAIN PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE HEATING CURVE - main settings P5 AD - Flw temp at utside temp lw P6 BC - Parallel shift P5 AF - Flw temp at utside temp high OUTSIDE TEMPERATURE P5 AC utside temp lw P5 AE utside temp high FIGURE COMPENSATED HEATING CURVE MAIN SETTINGS When using this functin the flw temperature is calculated based n the measured utdr temperature. The relatin between the utdr temperature and the flw temperature can be prgrammed with the fllwing parameters. This setting creates the s called heating curve. P5 AA Outside present Cnfig (1=n 0=ff) * T enable utside temperature cmpensatin, this parameter must be set t a value f 1 and an utside temperature sensr must be cnnected t the biler. When a cascade f CP-M+ bilers is used, these changes shuld be made t the master biler nly. P5 AC Heat curve minimum utside temperature C This sets the minimum utside temperature at which the maximum flw temperature that is set. P5 AD Heat curve flw temperature at minimum C This sets the desired maximum flw temperature at the set minimum utside temperature. P5 AE Heat curve maximum utside temperature C This sets the maximum utside temperature at which the minimum flw temperature that is set. P5 AF Heat curve flw temperature at maximum C This sets the desired minimum flw temperature at the set maximum utside temperature. P6 BC Heat curve Parallel Shift C This parameter defines actual parallel shift that is set by the user. The bandwidth f the shift allwed is limited by the cntrl sftware. 57

58 FLOW TEMPERATURE ADDITIONAL PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE HEATING CURVE - additinal settings P6 BA - max flw temp P6 BB - Heatcurve night shift P5 AH - Warm weather shutdwn P2 HA - Outdr sensr hysteresis 30 P5 AG - min flw temp OUTSIDE TEMPERATURE FIGURE COMPENSATED HEATING CURVE ADDITIONAL SETTINGS P5 AG Heat curve minimum flw temperature C The set pint will never be lwer than the flw temperature set in parameter P5AG. The minimum temperature is limited, even when the calculated set temperature shuld be lwer because f the heating curve. P5 AH Summer Outside temperature Central heating C When the utside temperature is higher than set in P5AH any central heating demand will be blcked. P2 HA Outdr sensr hysteresis C If the utdr temperature reaches the temperature set in P5 AH (warm weather shutdwn) all heating demands will be ignred. If the measured utdr temperature drps P5 AH minus P2 HA heating demands will resume. P6 BA CH User Setting C The setpint will never be higher than the flw temperature set in parameter P6BA. The maximum temperature is limited, even when the calculated set temperature shuld be higher because f the heating curve. P6 BB Heat curve night shift C The heating curve is set by the abve parameters. In additin t these settings, the end user has the ability t influence the flw temperature by ding a parallel shift setting. Parameter P6BB sets the margins within which the user can increase and decrease the calculated flw temperature relative t the calculated flw temperature by the heating curve that is set. 58

59 SETTING OUTSIDE TEMPERATURE COMPENSATION The fllwing figure describes hw t prgram the utside temperature cmpensatin curve. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Outdr" using [ ] & [ ] M a i n M e n u O u t d r Press [ENTER] Press [ ] & [ ] t brwse thrugh the screens that are shwn belw. Press [ ] [ ] t change the flashing value in the selected screen. Press [MENU] t exit. The unit will reset and g t the perating screen. Press [ENTER] fr cnfirmatin screen after all changes are made. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes made (unit will reset). Press [ ] t cnfirm the changes made. The time and day will start flashing fr a few secnds. After this, the display returns t its perating screen. 0 1 O u t s i d P r e s P5 AA H C m i n O u T m p P5 AC C 0 3 H C m i n F l T m p P5 AD 8 5 C 0 4 H C m a x O u T m p P5 AE 2 0 C 0 5 H C m a x F l T m p P5 AF 2 0 C 0 6 H C m i n F l L i m P5 AG 2 0 C 0 7 S u m S h D w n O u P5 AH 3 0 C 0 8 H C m a x F l L i m P6 BA 8 5 C 0 9 H C n g h t s h f t P6 BB C 0 A H C p a r a s h f t P6 BC 5 C 0 B O u t S 1 2 k 1 0 k P5 AR 0 FIGURE SETTING OUTDOOR TEMPERATURE COMPENSATION 59

60 12.11 CHECKING THE OPERATING HISTORY The fllwing figure describes hw t check the perating histry f the biler. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Operate" using [ ] & [ ] M a i n M e n u O p e r a t e Press [ENTER] Press [ ] & [ ] t brwse thrugh the 5 screens. Press [MENU] r [ENTER] t exit. The unit will return t the perating screen. SCREEN: 1 O p e r a t i n g h i s t r y P w e r O n h r s Tp line: Shws the perating histry menu is activated. Bttm line: Ttal number f hurs that the biler has been pwered n fr. SCREEN: 2 h r s C h T t h r s D h w T t Tp line: Ttal burner-n hurs fr central heating demand. Bttm line: Ttal burner-n hurs fr DHW demand. SCREEN: 3 h r s C h < 5 0 % h r s C h = > 5 0 % Tp line: Burner-n hurs fr central heating while the burner was firing at less than 50%. Bttm line: Burner-n hurs fr central heating while the burner was firing at equal t r mre than 50%. SCREEN: 4 h r s D h w < 5 0 % : h r s D h w = > 5 0 % : Tp line: Burner-n hurs fr DHW while the burner was firing at less than 50%. Bttm line: Burner-n hurs fr DHW while the burner was firing at equal t r mre than 50%. SCREEN: 5 T i a F i a S s l S s t Tp line: Tia = Ttal Ignitin Attempts Fia = Failed Ignitin Attempts Bttm line: Ssl = Sft Starts last Sst = Sft Starts Ttal FIGURE CHECKING THE OPERATING HISTORY 60

61 12.12 CHECKING THE FAULT HISTORY The fllwing figure describes hw t check the fault histry f the biler. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Faulthist" using [ ] & [ ] M a i n M e n u F a u l t h i s t Press [ENTER] F a u l t h i s t N / 0 4 / W e d 2 2 : 2 3 A flashing t S i p h n S w i t c h S v / C U M / R , 5 Press [ ] & [ ] t brwse thrugh the last 10 faults. Press [MENU] r [ENTER] t exit. The unit will return t the perating screen. The fault menu shws the last 10 faults. Fr each fault the display flashes between the tw screens shwn abve. The tp line f the first screen shws the fault number. The bttm line f the first screen shws the date, day and time that the fault ccurred. The tp line f the secnd screen shws the fault type. The bttm line shws the fllwing: SV: The number f this type f fault that has ccurred since the service histry was last erased (after service was dne). CUM: The ttal number f this type f fault that has ccurred. As this value cannt be erased after service, this shws the fault histry f the burner cntrl since the start f peratin. R: The elapsed time in hurs between the fault ccurring and it being reset. FIGURE CHECKING THE FAULT HISTORY 61

62 12.13 SETTING THE MAINTENANCE SPECIFICATIONS The fllwing figures describe hw t check and prgram the maintenance settings. The standard factry setting fr this functin is OFF. MAINTENANCE SETTINGS The unit can be prgrammed in such a way that an autmatic maintenance message is displayed. There are three ptins that can be selected. A maintenance message appears after: * A prgrammed date is reached. * An amunt f burning hurs is reached. * An amunt f ignitin cycles is reached. A single ptin can be activated r all three ptins. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Maintenan" using [ ] & [ ] and press [ENTER] M a i n M e n u M a i n t e n a n Press [ENTER] M a i n t e n R e s e t Press [ ] t reset the: Cunter fr the ttal amunt f burning hurs. Cunter fr the ttal amunt f ignitin cycles. (The text will flash nce briefly after resetting). Operating screen: M a i n t e n M d e flashing secnd line. What is flashing at the secnd line (befre a selectin is made) is the active maintenance ptin. Press [ ] r [ ] t change the selected flashing ptin. Screen: Selecting f all maintenance ptins. M a i n t e n M d e A l l Press [ ] t set: The ptin that is flashing can be changed using by [ ] & [ ] * Date fr the Maintenance message. * Ttal amunt f burning hurs fr the Maintenance message. * Ttal amunt f ignitin cycles fr the Maintenance message. After selecting ne f these values the biler returns t the maintenance perating screen. Press [ENTER] t cnfirm the changes. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes r [ ] t cnfirm the changes. After the biler returns t perating screen. > > > Cntinued n next page < < < FIGURE SETTING MAINTENANCE ALERTS 62

63 > > > Frm previus page < < < Screen: Selecting message at certain date. M a i n t e n M d e D a t e Press [ ] t set: The date fr the maintenance message. Press [ ] t: Return t maintenance mde selectin. Press [ ] t brwse thrugh the values that can be set at the bttm line. The flashing value can be changed with [ ] & [ ] Press [ENTER] t cnfirm the changes. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes r [ ] t cnfirm the changes. After the biler returns t perating screen. Screen: Message after ttal amunt f ignitin cycles. M a i n t e n M d e I g n i t i n c y c l e s Press [ ] t set: The ttal amunt f ignitin cycles fr the Maintenance message. Press [ ] t: Return t maintenance mde selectin. The flashing value can be changed with [ ] & [ ] Press [ENTER] t cnfirm the changes. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes r [ ] t cnfirm the changes. After the biler returns t perating screen. > > > Cntinued n next page < < < FIGURE SETTING MAINTENANCE ALERTS (ctd.) 63

64 > > > Frm previus page < < < Screen: Message after ttal amunt f burning hurs. M a i n t e n M d e B u r n i n g h u r s Press [ ] t set: The ttal amunt f burning hurs fr the Maintenance message. Press [ ] t: Return t maintenance mde selectin. The flashing value can be changed with [ ] & [ ] Press [ENTER] t cnfirm the changes. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes r [ ] t cnfirm the changes. After the biler returns t perating screen. Screen: N maintenance message will be displayed. M a i n t e n M d e M a i n t e n O f f Press [ENTER] t cnfirm the changes. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes r [ ] t cnfirm the changes. After the biler returns t perating screen. Nte: The [MENU] buttn will return the display t the perating screen. FIGURE SETTING MAINTENANCE ALERTS (ctd.) NOTE: This maintenance reminder functin is disabled by default; it is a prgrammable functin t be used as a ntificatin that maintenance is required. Because the parameters are freely prgrammable, the functin cannt be used as a reasn t nt carry ut the required rutine maintenance r as an argument in warranty cases. The biler must be maintained in accrdance with Sectin 16.0: MAINTENANCE irrespective the settings/wrking f this functin. 64

65 12.14 SETTING THE USER LOCK When the user lck functin is activated, it prevents accidental changes being made t the perating characteristics f the biler. It shuld be nted that whilst access t the basic settings is disabled, the parameter menus can still be accessed using the required passwrds. Once the biler is lcked, the [MENU] buttn and [ ] buttn shuld be pressed simultaneusly and held fr 5 secnds. The fllwing figure describes hw t activate the user lck f the display. The standard factry setting fr this functin is OFF. Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Userlck" using [ ] & [ ] M a i n M e n u U s e r l c k Press [ENTER] S e t U s e r l c k = 0 0 The "0" is nw flashing/selected and can be changed. Use [ ] & [ ] t change the value. 0 = User lck functin OFF 1 = User lck functin ON Press [ENTER] fr the cnfirmatin screen after the selectin has been made. Cnfirmatin screen: A r e y u s u r e < C a n c e l ; > C n f i r m Press [ ] t cancel the changes (the unit will reset and the display returns t the perating screen). Press [ ] t cnfirm the changes. The changed value will be flashing fr a few secnds. After this, the display returns t the perating screen. NOTE: Pressing the [MENU] buttn during the User lck display, will reset the biler and the biler will return t the perating screen. Changes will be neglected in this case. FIGURE ACTIVATING THE USER LOCK 65

66 GENERAL CASCADE DHW HEATING 13.0 PARAMETERS 13.1 SETTING THE PARAMETERS WITH THE DISPLAY MENU The perating parameters f the biler are embedded in the burner cntrl system electrnics. Sme f the values and settings that are used t cntrl the biler peratin can be changed by mdifying these parameters in rder t cnfigure the appliance t meet the specific requirements f the installatin. Mdificatin shuld be carried ut by a trained service technician with the help f a cmputer, the crrect sftware and an interface cable. Certain parameters can be prgrammed n the unit itself, withut the use f a cmputer. The fllwing table gives a list f these parameters that can be prgrammed thrugh the user interface display. All parameters that are shwn in the display can be changed. MENU A RELATES PASSWORD: PASSWORD: TO 1342 XEPK SOFTW. LEVEL 1 LEVEL 2 DESCRIPTION UNITS DESCR. (display) PARAM Display Mdify Display Mdify 1 P5BE Step mdulatin (1=n 0=ff) - S t e p m d u l yes n yes yes 2 P5AO Blcking ffset flwtemperatur cntrl C H E s O f f 1 3 yes yes yes yes 3 P5AP Prprtinal range temperature cntrl C H E s P r b 1 3 yes n yes yes 4 P5AL Hysterese CH Flw temperatur cntrl C H E s c D i f 1 3 yes yes yes yes 5 P2IC Intergratin time temperature cntrl sec H E s I n t 1 3 yes n yes yes 6 P2MI Blcking ffset System CH temperatur cntrl C H E c O f f 3 yes yes yes yes 7 P2MJ Prprtinal range System CH temperature cntrl C H E c P r b 3 yes n yes yes 8 P2MK Intergratin time CH temperature cntrl sec H E c I n t 3 yes n yes yes 9 P5AB Timer Cntact (1=n) - T i m e r C n t yes yes yes yes B C D 1 P4AB DHW Pump Cnfig 0=Pump 1=TWV - D H i p m p / t w v yes yes yes yes 2 P5CB Flw temperature Dhw tank lw C D H i f l w L O yes yes yes yes 3 P5CK Flw temperature Dhw tank hi C D H i f l w H I yes yes yes yes 4 P5CL Lw Flwtemperature time Dhw min D H i L O t i m e yes yes yes yes 5 P5CD Leginella temperature C L e g i t e m p yes n yes yes 6 P5CI Leginella hyst Dhw tank temperatur C L e g i h y s t yes n yes yes 7 P5CJ Leginella hld time (0=ff) min L e g i h l d yes n yes yes 8 P2KI CH interrupt by Leginella (0=yes)(1=n) - L e g i i n t r yes n yes yes 9 P2LC Regulatin temperatur fset DHWd C D H d s c O f f 2 yes yes yes yes A P2LE Prprtinal range DHWd mdulatin C D H d s c P r b 2 3 yes n yes yes B P2LD Regulatin temperatur hysteres DHWd C D H d s c D i f 2 yes yes yes yes C P2LF Intergratin time DHWd mdulatin sec D H d s c I n t 2 3 yes n yes yes D P2ML Sys temp blcking fset DHW tank C D H d s c O f f 3 yes yes yes yes E P2MM Sys temp blcking hysteres DHW tank C D H d s c D i f 3 yes yes yes yes F P5CA Hysterese Dhw tank temperatur C D H i s c D i f 4 yes yes yes yes G P2KH Gradient heatdemand detect Dhw tank temperatur C D H i d e t g r a d yes yes yes yes 1 P2MA Max number extra bilers - M a x C a s c U n t yes n yes yes 2 P5DA Busdadres biler - B u s a d r e s s yes n yes yes 3 P5DC Dhw n entire cascade(0) nly master(1) - D H i c a s / m a s yes n yes yes 4 P5DE Extra Biler utput enable(1) - E x t r a u n i t yes yes yes yes 5 P5DF Cascade detectin (0=standalne 1=Leader) - C a s S i / M a yes n yes yes 6 P5BL Pwer ff ttal cascade (1) - P w r O f f T C a yes n yes yes 7 P5DB Number f bilers with cmmn flue 0=Nne - C m F l u N u m yes n yes yes 1 P5BB Analg input Cnfig (0=ff 1=temp 2=pwer) - A n I n p C n yes yes yes yes 2 P5AI Minimum Temperature 0-10V input C M i n T m p yes yes yes yes 3 P5BI Altitude (* 100 ft) ft/100 A l t * f t yes yes yes yes 4 P2LK Max cling time. min M a x C l T i m yes yes yes yes 5 P5BJ Temperature display 1=n - T e m p O n D i s p yes yes yes yes 6 P4AA DHW 0=ff 1=Indirect 2=Direct - D H W 1 = i 2 = d yes n yes yes TABLE 13.1 PARAMETERS The parameter table abve shws all f the parameters that can be set n the unit withut the use f a laptp/cmputer. In the fllwing sectin, a descriptin f each parameter is given and the prcedure fr mdifying it (if applicable) is given. NOTE: Sme parameters can be set, but are nt used when the cntrl is cnfigured t perate as a heating biler. Parameters P2CL, P2LD, P2ML, P2MM, P5BI may affect biler peratin and must therefre nt be changed. 66

67 Operating screen: H E A T I N G : S T A N D - B Y > > > : C ( C ) Press [MENU] Select "Parameter" using [ ] & [ ] M a i n M e n u P a r a m e t e r Press [ENTER] Parameter menu: I n s t a l l e r c d e Enter the 4-digit cde with the [ ] & [ ] and the [ ] & [ ] buttns and select [ENTER] The cde will blink a few secnds and when entered crrectly, the fllwing parameters will be displayed. NOTE: The tw cdes are user defined and give access t the parameters which can be viewed and mdified (as detailed in Table 13.1) Menu A: Heating A 1 S t e p m d u l 1 This parameter activates the step mdulatin feature. Step mdulatin hlds the firing f the appliance at defined rates fr pre-defied time perids. A value f 0 disables this functin, a value f 1 enables it. Menu A: Heating A 2 H E s f f C This parameter sets the CH ffset value. This is the value abve the setpint temperature that the biler can reach befre shutting dwn. Menu A: Heating A 3 H E s P r b C This parameter sets the CH prprtinal band. This is the temperature range belw the setpint temperature in which the biler will mdulate. Menu A: Heating A 4 H E s c D i f C This parameter sets the CH differential. This is the temperature belw the ffset temperature which the biler must reach befre the firing sequence will restart. Menu A: Heating A 5 H E s l n t S e c This parameter sets the CH integratin time. This is the time perid ver which an average temperature is recrded in rder t determine the firing rate. Menu A: Heating A 6 H E c O f f 3 4 C This parameter sets the Cascade CH ffset value. This is the value abve the setpint temperature that each biler in the cascade biler can reach befre shutting dwn. > > > Cntinued n next page < < < FIGURE 13.1 SETTING PARAMETERS 67

68 > > > Frm previus page < < < Menu A: Heating A 7 H E c P r b C This parameter sets the Cascade CH prprtinal band. This is the temperature range belw the setpint temperature in which each biler in the cascade biler will mdulate (as measured by the cascade sensr). Menu A: Heating A 8 H E c l n t S e c This parameter sets the cascade CH integratin time. This is the time perid ver which an average temperature is recrded in rder t determine the firing rate (as measured by the cascade sensr). Menu A: Heating A 9 T i m e r C n t 0 This parameter activates the external time cntrl feature. When enabled, a clsed cntact acrss terminals 13 & 14 runs the biler at daytime temperatures, an pen cntact runs the biler at night-time temperatures. A value f 0 disables this functin, a value f 1 enables it. Menu B: Ht water B 1 D H i p m p / t w v 1 This parameter sets hw DHW prductin is cntrlled. A value f 0 is used when a separate pump supplies the DHW vessel. A value f 1 is used when the DHW supply is cntrlled by a 3-way valve. Menu B: Ht water B 2 D H i f l w L O 2 5 C This parameter sets the 'lw level' indirect DHW flw temperature frm the biler during a DHW demand. Menu B: Ht water B 3 D H i f l w H I 8 5 C This parameter sets the 'high level' indirect DHW flw temperature frm the biler during a DHW demand. Menu B: Ht water B 4 D H i L O t i m e 1 M i n This parameter sets the time perid during which the DHW flw temperature will be at the 'lw level'. After this time perid expires, the setpint will autmatically switch t the 'high level. Menu B: Ht water B 5 L e g i t e m p 8 5 C This parameter sets the indirect DHW flw temperature frm the biler during a DHW pasteurisatin demand. Menu B: Ht water B 6 L e g i h y s t 2 C This parameter sets the differential during the pasteurisatin functin. This is the temperature belw the ffset temperature which the biler must reach befre the firing sequence will restart. > > > Cntinued n next page < < < FIGURE 13.2 SETTING PARAMETERS (ctd.) 68

69 > > > Frm previus page < < < Menu B: Ht water B 7 L e g i h l d 2 M i n This parameter sets the time perid that the pasteurisatin functin runs fr. Menu B: Ht water B 8 L e g i i n t r 0 This parameter determines whether a pasteurisatin demand takes pririty ver a CH demand ver the biler. A value f 0 gives pasteurisatin pririty, a value f 1 gives heating pririty. Menu B: Ht water B 9 D H d s c O f f 2 4 C This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B A D H d s c P r b C This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B B D H d s c D i f C This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B C D H d s c l n t S e c This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B D D H d s c O f f 3 4 C This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B E D H d s c D i f 3 8 C This functin is nt used n the CP-M+ biler and shuld nt be altered. Menu B: Ht water B F D H i s c D i f 4 5 C This parameter sets the differential used when the DHW vessel is cntrlled by a temperature sensr. This is the temperature belw the setpint temperature which the vessel must reach befre the firing sequence will restart. Menu B: Ht water B G D H i d e t g r a d 3 C This parameter is used when the DHW vessel is cntrlled by a temperature sensr. If the biler detects an accelerated ht water demand (e.g. a drp within 1 secnd) the firing sequence will start even if the differential temperature has nt been reached. > > > Cntinued n next page < < < FIGURE 13.3 SETTING PARAMETERS (ctd.) 69

70 > > > Frm previus page < < < Menu C: Cascade C 1 M a x C a s c U n t 1 1 This parameter sets the maximum number f slave bilers within a cascade. The maximum number is 11 therefre this parameter shuld nt be changed. Menu C: Cascade C 2 B u s a d r e s s 0 This parameter sets the cascade address f each appliance. The master biler shuld be set as 0 and each slave shall be independently addressed frm 1 t 11 Menu C: Cascade C 3 D H i c a s / m a s 0 This parameter determines whether all bilers in the cascade are used t meet a DHW demand r whether it is the master nly. A value f 0 will fire all bilers, a value f 1 will fire the master nly. Menu C: Cascade C 4 E x t r a u n i t 0 This parameter determines whether an additinal biler is cnnected t terminals 21 & 22 f the master biler. Once a pre-determined utput f the cascade is reached, a cntact in the burner cntrl will clse and an additinal nn-cascaded biler can be enabled. Menu C: Cascade C 5 C a s S i / M a 0 This parameter sets whether the biler perates as a standalne biler/slave biler r as a master biler. Each cascade shuld nly have ne master biler. A value f 0 sets the biler t act as a slave, a value f 1 sets the biler t act as a master. Menu C: Cascade C 6 P w r O f f T C a 0 This parameter sets whether the slave bilers cntinue t perate if the master biler is switched ff. A value f 0 sets the slave bilers t perate withut the master, a value f 1 sets the slave bilers t shut dwn when the master is nt present. Menu C: Cascade C 7 C m F l u N u m 0 This parameter sets hw many f the cascaded appliances perate n a cmmn flue system. Menu D: General D V c n t r 0 This parameter sets the functin f the 0-10 VDC input n terminals 15 & 16. A value f 0 disables the functin, a value f 1 relates the input vltage t setpint temperature and a value f 2 relates the input vltage t pwer utput. > > > Cntinued n next page < < < FIGURE 13.4 SETTING PARAMETERS (ctd.) 70

71 > > > Frm previus page < < < Menu D: General D M i n T m p 2 0 C When Parameter D1 set t '1' (temperature cntrl) this parameter sets the temperature required with a signal f 1 Vlt Menu D: General D 3 A l t * f 0 This functin is nt used n the CP-M+ biler and shuld nt be adjusted. Menu D: General D 4 M a x C l T i m 2 M i n This parameter sets the fan ver-run time and is used t cl the heat exchanger after a firing sequence. A value f 0 disables this functin. Menu D: General D 5 T e m p O n D i s p 1 This parameter sets whether the measured temperatures are displayed n the perating screen. Menu D: General D 6 D H W 1 = i 2 = d 1 This parameter sets hw a DHW demand is handled. A value f 0 sets the biler as heating nly (n DHW), a value f 1 sets the biler as heating and indirect DHW, a value f 2 sets the biler as direct DHW. A setting f 2 shuld nt be used n the CP-M+ biler. FIGURE 13.5 SETTING PARAMETERS (ctd.) 71

72 14.0 COMMISSIONING AND TESTING 14.1 ELECTRICAL INSTALLATION Ntes n the requirements fr electrical installatin are prvided in Sectin 11: ELECTRICAL SUPPLY. schematic drawing f the cntrl circuit is shwn in Figure 11.2 A 14.2 GAS INSTALLATION Fr design see Sectin 7: GAS SUPPLY. See Figure 3.1 r Figure 3.2 fr details n the psitin f the gas cnnectin WATER CONNECTIONS Fr design see Sectin 10: WATER CONNECTIONS The system shuld be thrughly flushed in accrdance with CIBSE Cmmissining Cdes B & W and BSRIA AG1/2001.1: Pre-cmmissin cleaning f pipewrk systems. Check the system fr leaks and repair as necessary. If the system is cnfigured in a sealed arrangement, check the expansin vessel cushin pressure and pressurisatin unit settings COMMISSIONING THE EQUIPMENT GENERAL CHECKS PRIOR TO LIGHTING A persn deemed cmpetent MUST be respnsible fr the cmmissining f this equipment. Befre attempting t cmmissin any equipment, ensure that persnnel invlved are aware f what actin is abut t be taken and begin by making the fllwing checks: 1. Flueway passages are clear. 2. Adequate ventilatin exists in the plant rm (if necessary) 3. The system is fully charged with water, ready t receive heat. All necessary valves are pen and all allied pumps are circulating water. 4. The gas supply pipewrk is clear f any lse matter, tested fr sundness and purged. 5. The cndensate drain is installed crrectly and the cndensate trap is filled with water. (see Sectin 6.6: FILLING THE CONDENSATE TRAP) NOTE: If the cndensate trap is nt filled with water befre use, prducts f cmbustin may escape and may cause severe persnal injury r death EQUIPMENT CHECKS PRIOR TO LIGHTING This unit has been designed fr a nminal gas inlet pressure f 20 mbar when used n natural gas. Infrmatin relating t prpane firing can be fund in Sectin 15: LPG FUEL 1. Gas supply is cnnected but turned t the ff psitin. Any unins r fittings are crrectly tightened, test pints are clsed and the ignitin electrde lead is cnnected crrectly. Ensure the ceramic sheath arund the ignitin electrde is nt cracked r brken. 2. Ensure electricity supply is cnnected. 3. Check that the heat exchanger is fully bled by pening the bleed autmatic air vent screw cap. 72

73 PROCEDURE FOR INITIAL LIGHTING IF THE UNIT IS TO OPERATE ON LPG REFER TO SECTION 15.2 BEFORE PROCEEDING 1. Ensure that the gas-inlet appliance islating valve, prvided by the installer, is in the ff psitin. 2. Turn n the lcal electrical islatr, t bring the equipment n. 3. The biler will g thrugh a de-aeratin sequence f starting and stpping the integral pump three times. NOTE: If the system pressure is nt abve 1.0 bar during the deaeratin prcess, the biler will stp respnding and display the fllwing screen: Display message D e a i r a t i n Reasn 9 9 9, 5 h r s The deaeratin prcess has nt cmpleted due t insufficient system pressure. System pressure will need t be increased t abve 1.0 bar befre any further wrks can be carried ut. 4. Press and hld the service buttn fr three secnds t place the biler int service mde. 5. The cmbustin fan shuld ramp up t full speed t purge the cmbustin chamber and then drp back t half rate in rder t light. The spark generatr shuld create a spark, visible thrugh the burner sight glass. As the gas inlet appliance islating valve is clsed, the cntrls shuld g t a flame failure cnditin after fur ignitin attempts. 6. If the abve ccurs crrectly, pen the gas inlet appliance islating valve, reset the unit by depressing the buttn n the cntrl panel and place the biler back in t service mde. 7. The cmbustin fan will repeat the pre-purge prcedure and attempt t light. Once a flame is established, the display will change t indicate that the biler is in service mde and the firing rate. 8. Press the [ ] buttn nce t display the flw and return temperatures. If the difference between these values is belw 13 C r abve 25 C shut the biler dwn and check that there is sufficient water flw thrugh the biler. 9. If sufficient flw exists, press the n/ff/reset buttn fr 5 secnds t shut the biler dwn. Once this has been dne, check that the main flame has extinguished GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS CP-M+60 CP-M+80 & 100 CP-M+120 CP-M+150 & 180 FIGURE 14.1 GAS VALVES biler type lad G20 1 CO2 (%) O2 (%) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) 1 Cf. EN437 2 All values are measured withut biler dr. TABLE 14.1 COMBUSTION GAS READINGS 73

74 The mst effective way f setting the heat surce is thrugh the use f a CO2 measuring device such as a flue gas analyser. The prcedure is as fllws: 1. Put the biler int Service Mde. This is dne by depressing the service buttn fr three secnds. The display shuld shw: Display message H E A T I N G : S e r v i c e 2 6 % > > > Press the [ ] buttn until the display shws: C ( Reasn Biler is activated and perates at service mde at 26% (minimum). C ) Display message H E A T I N G : S e r v i c e % Reasn > > > C ( Biler is activated and perates at service mde at 100% (maximum). 3. Adjust screw 2 t give the CO2 utput as detailed in Table Turning the screw clckwise will reduce the CO2 level, turning anti-clckwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 4. Press the [ ] buttn until the display shws: C ) Display message H E A T I N G : S e r v i c e 2 6 % Reasn > > > C ( Biler is activated and perates at service mde at 26% (minimum). 5. Adjust screw 1 t give the CO2 utput as detailed in Table Turning the screw clckwise will increase the CO2 level, turning anti-clckwise will reduce the CO2 level. On the CP-M+120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 6. Using the [ ] and [ ] buttns, re-check the cmbustin reading at high and lw fire. Trim the gas valve settings as necessary. 7. Once the setting has been cmpleted, depress the service buttn fr 3 secnds t return the biler t its nrmal perating mde. 8. Recrd the cmbustin data and leave with the appliance fr future reference. C ) NOTE: The dust cap, nce reinstalled, shuld be marked with an anti-tamper indicatr. Cmbustin figures fr Prpane firing can be fund in Sectin 15: LPG FUEL TEMPERATURE ADJUSTMENT PROCEDURE Setpint temperatures are altered via the user cntrl system; refer t Sectin 12.8 SETPOINTS fr further infrmatin INSTALLATION NOISE If care has been taken t fllw the manufacturer s instructins there shuld be n discernible nise frm the equipment. The allied pump mtr may have a level f sund that culd lead t cnsideratin fr acustic insulatin, but care must be taken nt t impede ventilatin r airflw t the pump mtr. 74

75 15.0 LPG FUEL NOTE! IT IS STRONGLY RECOMMENDED THAT, ON LPG INSTALLATIONS, GAS DETECTION EQUIPMENT IS FITTED. THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE APPLIANCE AND AT LOW LEVEL. IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE APPLIANCE IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL. THIS APPLIANCE MUST NOT BE LOCATED BELOW GROUND E.G. IN A CELLAR 15.1 RELATED DOCUMENTS In additin t thse dcuments listed in Sectin 4.1: RELATED DOCUMENTS within the main bdy f the installer s guide the gas installatin shuld als cmply with the guidance ffered in the fllwing dcuments. BS : 2005 Part 1: Cde f practice fr dmestic butane and prpane gas burning installatins. Installatins at permanent dwellings, residential park hmes and cmmercial premises, with installatin pipewrk sizes nt exceeding dn25 fr steel and dn28 fr crrugated stainless steel r cpper. The peratin f the CP-M+ range n LPG-Prpane (3 rd Family) 3P is similar t that n Natural Gas (2 nd Family) 2H and the design and installatin details described in the main bdy f the installer s guide shuld be fllwed CONVERSION AND COMMISSIONING PROCEDURE This prcess must be carried ut in the rder stated when the biler is switched n fr the first time. Failure t fllw the fllwing prcedure may lead t nn-warrantable damage t the biler. Biler Type Number f Turns Open (Cunterclckwise) Prpane G31 CP-M CP-M CP-M CP-M+120 *1 CP-M+150 *1 CP-M+180 *2.25 * Bth gas valves must be pened this number f turns TABLE 15.1 PRE-ADJUSTMENT OF GAS VALVES TABLE 15.2 Biler Type p-ut Pressure at Gas Valve Prpane G31 CP-M t -2 Pa CP-M t -5 Pa CP-M t -5 Pa PRESSURE ADJUSTMENT OF LEFT GAS VALVE biler type lad G31 1 CO2 (%) CO2 (%) CP-M max. lad 10.3 (± 0.3) 10.3 (± 0.3) min. lad 9.3 (± 0.3) 9.3 (± 0.3) CP-M max. lad 10.4 (± 0.3) 10.4 (± 0.3) min. lad 9.3 (± 0.3) 9.3 (± 0.3) CP-M max. lad 10.5 (± 0.3) 10.5 (± 0.3) min. lad 9.3 (± 0.3) 9.3 (± 0.3) 1 Cf. EN437 2 All values are measured withut biler dr. TABLE 15.3 COMBUSTION GAS READINGS Due t the design f the biler, the cnversin t LPG-Prpane requires adjustment f the gas valve(s) nly (see Figure 15.1). The sequence is as fllws: 1. Turn screw 2 (Figure 15.1) clckwise until fully clsed. On mdels with tw gas valves, this shuld be dne t bth valves. 2. Turn screw 2 cunter clckwise in accrdance with Table On mdels with tw gas valves, this shuld be dne t bth valves. 75

76 3. On mdels CP-M+120, CP-M+150 & CP-M+180, remve the screw frm the utlet pressure test pint f the left hand gas valve (identified as screw 4 in Figure 15.1) and attach a manmeter. 4. Put the biler int Service Mde. This is dne by depressing the service buttn fr three secnds. 5. If the burner des nt light after three attempts, turn screw 2 thrugh ¼ turn cunter clckwise. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 6. Once the flame has established, press the [ ] buttn until the display shws: Display message H E A T I N G : S e r v i c e % Reasn > > > C ( Biler is activated and perates at service mde at 100% (maximum). 7. Adjust screw 2 t give the CO2 utput as detailed in Table Turning the screw clckwise will reduce the CO2 level, turning anti-clckwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 8. Press the [ ] buttn until the display shws: C ) Display message H E A T I N G : S e r v i c e 2 6 % Reasn > > > C ( Biler is activated and perates at service mde at 26% (minimum). 9. On mdels CP-M+120, CP-M+150 & CP-M+180 adjust Screw 1 f the left hand gas valve t give the required pressure as detailed in Table Adjust screw 1 (right hand gas valve nly n CP-M+120, CP-M+150 & CP-M+180) t give a CO2 utput as detailed in Table Turning the screw clckwise will increase the CO2 level, turning anticlckwise will reduce the CO2 level. 11. Using the [ ] and [ ] buttns, re-check the cmbustin reading at high and lw fire. Trim the gas valve settings as necessary. 12. Once the setting has been cmpleted, depress the service buttn fr 3 secnds t return the biler t its nrmal perating mde. 13. Remve the manmeter (if used) and replace all dust caps and test pint sealing screws, testing fr leaks as apprpriate. 14. Recrd the cmbustin data and leave with the appliance fr future reference. C ) NOTE: The dust cap, nce reinstalled, shuld be marked with an anti-tamper indicatr CP-M+60 CP-M+80 & 100 CP-M+120 CP-M+150 & 180 FIGURE 15.1 GAS VALVES 76

77 16.0 MAINTENANCE 16.1 GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS AND FLAMMABLE VAPOURS AND LIQUIDS. A cmpetent persn shuld check and ensure that the flue, its supprt and terminal, the ventilatin t the biler huse, safety valve, drain, pressure gauge etc. are in a serviceable and wrking cnditin and still cmply with the relevant standards and cdes f practice, as detailed in Sectin 4: GENERAL REQUIREMENTS. Servicing is recmmended at intervals n greater than 12 mnths t aid truble free peratin. Even if a maintenance schedule is determined t be less than annually, it is imprtant that all cntrls and safety features are checked fr crrect peratin n an annual basis. Measuring flue gas CO2 and flue gas temperatures will give an indicatin f the state f the flue and burner. Results f the flue gas analysis shuld be cmpared with previusly measured values t identify any changes in peratinal characteristics BURNER INSPECTION The heat exchanger has a sight glass fr inspectin f the flame picture. NOTE: If the appliance has been in recent peratin, this area may be ht. Apprpriate precautins shuld be taken t prevent persnal injury. T check the flame picture at high and lw fire, the fllwing prcedure shuld be used: 1. Put the biler int Service Mde. This is dne by depressing the service buttn fr three secnds. The display shuld shw: Display message H E A T I N G : S e r v i c e 2 6 % > > > Press the [ ] buttn until the display shws: C ( Reasn Biler is activated and perates at service mde at 26% (minimum). C ) Display message H E A T I N G : S e r v i c e % Reasn > > > Check the flame cnditin. 4. Press the [ ] buttn until the display shws: C ( Biler is activated and perates at service mde at 100% (maximum). C ) Display message H E A T I N G : S e r v i c e 2 6 % Reasn > > > C ( Biler is activated and perates at service mde at 26% (minimum). 5. Check the flame cnditin. 6. Depress the service buttn fr 3 secnds t return the biler t its nrmal perating mde. C ) 77

78 16.3 BURNER REMOVAL If it has been determined that the flame picture is unacceptable, the burner can be remved and cleaned using the fllwing prcedure: 1. Islate the electrical and gas supplies t the heater. 2. Allw the biler t cl dwn. 3. Discnnect the wiring cnnectins t the ignitin electrde. 4. Discnnect the pwer and cntrl cnnectin leads and earthing wire frm the cmbustin fan. 5. Apply a suitable release il t the 6 studs arund the edge f burner dr. 6. Remve the 6 retaining nuts arund the edge f the burner dr. NOTE: Once lsened, the nuts shuld be remved by hand. If any f the nuts seize, the nut shuld gently be re-tightened and additinal release il used. 7. Withdraw the heat exchanger frnt plate and burner assembly frm the heat exchanger cmplete with the cmbustin fan. 8. With the burner assembly away frm the biler, the burner can be gently cleaned with the brush attachment f a vacuum cleaner. The reassembly prcedure is the reverse f the abve taking care t ensure that the fr the heat exchanger frnt plate sealing gasket, the cmbustin fan cnnectin gasket, the burner dr insulatin and the cmbustin chamber rear wall insulatin are in gd cnditin r are replaced as necessary. When refitting the burner dr, the dr shuld be carefully lcated n the studs and pushed firmly in t place whilst all f the retaining nuts are tightened by hand. Once all nuts are hand tight, they shuld be tightened in the rder stated in Figure 16.1 t a trque f 8 Nm NOTE: PARTICULAR ATTENTION SHOULD BE PAID TO THE COMBUSTION CHAMBER REAR WALL INSULATION. IF ANY DETERIORATION IN THE INSULATING MATERIAL IS NOTED, THE INSULATION PANEL MUST BE REPLACED. FIGURE 16.1 BURNER DOOR RETAINING NUT TIGHTENING ORDER 78

79 16.4 CLEANING THE HEAT EXCHANGER T clean the heat exchanger, the fllwing prcedure shuld be carried ut: 1. Remve the burners as abve. 2. Use a vacuum cleaner t remve any accumulatin n the heating surfaces. 3. Inspect the heat exchanger t ensure that the 1 mm flueway is clear between all cils. 4. If any debris is still present, brush the heat exchanger with a nn-metallic brush taking care nt t damage the insulatin panel n the rear wall f the heat exchanger. NOTE: A kit f cmpnents t aid with cleaning the heat exchanger is available frm Lchinvar Limited. Fr mdels CP-M+60 CP-M+120 use part number KIT30063, fr mdels CP-M+150 & CP-M+180 use part number KIT NOTE: It is very imprtant t inspect and remve all depsits frm the heat exchanger. If all depsits cannt be remved frm the heat exchanger, cntact Lchinvar Limited fr further guidance. 5. Once the heat exchanger has been brushed it shuld be rinsed with fresh water t remve all residues. 6. Remve the cndensate water trap and clean ut any debris. 7. Refit the cndensate drain and fully recharge by puring 1 litre f water thrugh the heat exchanger cils. 8. Reinstall the burner. 9. Restart the biler as detailed in Sectin : PROCEDURE FOR INITIAL LIGHTING DRAINING THE BOILER SYSTEM The biler must be drained if it is t be shut dwn and expsed t freezing temperatures. Maintenance and service prcedures may als require draining the biler DRAINING AN INDIVIDUAL BOILER 1. Turn ff the biler electrical discnnect switch. 2. Turn ff the biler islatin valves. 3. Attach a hse t the biler drain valve and lcate the discharge in an area where ht water will nt cause any damage r injury. 4. Open the biler drain valve and the autmatic air vent plug t allw water t escape. 5. Once the biler is drained, clse the drain valve DRAINING THE COMPLETE SYSTEM 1. Turn ff the biler electrical discnnect switch. 2. Cnnect a hse t the system drain valve. 3. Lcate hse s discharge in an area where ht water will nt cause any damage r injury. 4. Clse the cld-water inlet valve frm the header tank r pressurisatin unit t biler system. 5. Open the drain valve. 6. Wrking systematically frm the highest pint in the heating system, pen bleed valves t allw the system t drain. 7. Clse all bleed valves 8. If the system is being drained fr an extended shutdwn, it is suggested the drain valve be left pen during this perid REFILLING THE SYSTEM 1. Clse the drain valve. 2. Open the cld-water inlet valve frm the header tank r pressurisatin unit t biler system. 3. Wrking systematically twards the highest pint in the system, pen all bleed valves and allw any trapped air t escape. 4. Fllw the lighting instructins as detailed in Sectin : PROCEDURE FOR INITIAL LIGHTING. 5. Check fr water leakage and airlcks, remedy as necessary. 79

80 16.7 OTHER CHECKS RELIEF VALVES (IF FITTED) At least nce a year, the pressure relief valve shuld be checked t ensure crrect peratin. T check the valve, lift the lever r turn the screw cap at the end f the valve several times. The valve shuld perate freely and seat prperly. If water des nt flw, remve and inspect fr bstructins r crrsin. Replace with a new valve f the recmmended size as necessary FLUE SYSTEM Examine the exhaust and air intake system at least nce a year. Pints f inspectin are as fllws: 1. Check fr bstructins and/r deteriratin f flue piping and terminal. Replace immediately where needed. 2. Check the terminal fr any freign material and remve as necessary. 3. Check all flue system cnnectins fr leakage and reseal as required. 4. Check that ventilatin grilles cmply with current regulatins. 80

81 16.8 SETTING A REPLACEMENT GAS VALVE When a replacement gas valve is fitted, the fllwing prcedure must be carried ut in the rder stated when the biler is switched n fr the first time. Failure t fllw the fllwing prcedure may lead t nn-warrantable damage t the biler. Biler Number f Turns Open (Cunterclckwise) Type Nat. Gas G20 Prpane G31 CP-M CP-M CP-M CP-M+120 *2.25 *1 CP-M+150 *2.25 *1 CP-M+180 *4.25 *2.25 * Bth gas valves must be pened this number f turns TABLE 16.1 PRE-ADJUSTMENT OF GAS VALVES Biler p-ut Pressure at Gas Valve Type Nat. Gas G20 Prpane G31 CP-M t 0 Pa -4 t -2 Pa CP-M t 0 Pa -7 t -5 Pa CP-M t 0 Pa -7 t -5 Pa TABLE 16.2 PRESSURE ADJUSTMENT OF LEFT GAS VALVE biler type lad G20 1 G31 1 CO2 (%) O2 (%) CO2 (%) O2 (%) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) 10.3 (± 0.3) 5.2 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) 9.3 (± 0.3) 6.7 (± 0.5) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) 10.4 (± 0.3) 5.0 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) 9.3 (± 0.3) 6.7 (± 0.5) CP-M max. lad 9.0 (± 0.3) 4.8 (± 0.5) 10.5 (± 0.3) 4.7 (± 0.5) min. lad 8.7 (± 0.3) 5.3 (± 0.5) 9.3 (± 0.3) 6.7 (± 0.5) 1 Cf. EN437 2 All values are measured withut biler dr. TABLE 16.3 COMBUSTION GAS READINGS CP-M+60 CP-M+80 & 100 CP-M+120 CP-M+150 & 180 FIGURE 16.1 GAS VALVES 1. Turn screw 2 (Figure 16.1) clckwise until fully clsed. On mdels with tw gas valves, this shuld be dne t bth valves. 2. Turn screw 2 cunter clckwise in accrdance with Table On mdels with tw gas valves, this shuld be dne t bth valves. 3. On mdels CP-M+120, CP-M+150 & CP-M+180, remve the screw frm the utlet pressure test pint f the left hand gas valve (identified as screw 4 in Figure 16.1) and attach a manmeter. 81

82 4. Put the biler int Service Mde. This is dne by depressing the service buttn fr three secnds. 5. If the burner des nt light after three attempts, turn screw 2 thrugh ¼ turn cunter clckwise. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 6. Once the flame has established, press the [ ] buttn until the display shws: Display message H E A T I N G : S e r v i c e % Reasn > > > C ( Biler is activated and perates at service mde at 100% (maximum). 7. Adjust screw 2 t give the CO2 utput as detailed in Table Turning the screw clckwise will reduce the CO2 level, turning anti-clckwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment shuld be made t the right hand gas valve nly. 8. Press the [ ] buttn until the display shws: C ) Display message H E A T I N G : S e r v i c e 2 6 % Reasn > > > C ( Biler is activated and perates at service mde at 26% (minimum). 9. On mdels CP-M+120, CP-M+150 & CP-M+180 adjust Screw 1 f the left hand gas valve t give the required pressure as detailed in Table Adjust screw 1 (right hand gas valve nly n CP-M+120, CP-M+150 & CP-M+180) t give a CO2 utput as detailed in Table Turning the screw clckwise will increase the CO2 level, turning anticlckwise will reduce the CO2 level. 11. Using the [ ] and [ ] buttns, re-check the cmbustin reading at high and lw fire. Trim the gas valve settings as necessary. 12. Once the setting has been cmpleted, depress the service buttn fr 3 secnds t return the biler t its nrmal perating mde. 13. Remve the manmeter (if used) and replace all dust caps and test pint sealing screws, testing fr leaks as apprpriate. 14. Recrd the cmbustin data and leave with the appliance fr future reference. C ) NOTE: The dust cap, nce reinstalled, shuld be marked with an anti-tamper indicatr CP-M+60 CP-M+80 & 100 CP-M+120 CP-M+150 & 180 FIGURE 16.1 GAS VALVES 82

83 17.0 TROUBLESHOOTING T avid electric shcks, discnnect electrical supply befre perfrming trubleshting. T avid burns, allw the unit t cl befre perfrming trubleshting. Be aware that a fault cde is an indicatin that the unit r the system needs attentin. When a fault ccurs repeatedly remedial wrk shuld be undertaken by a suitably qualified persn. The first step is t check if the unit is installed accrding t the instructins. If nt, first make sure the installatin cmplies with the installatin manual. Always check the fuses n the cntrl bard befre replacing any majr cmpnents. A blwn fuse can prevent the cntrller r ther cmpnents frm perating. Mst faults can als be caused by a bad wiring and/r cnnectins, even if it is nt specifically mentined. With every fault it is wise t check wiring and cnnectins (at bth ends) that cnnect t the safety device/cmpnent that generates the fault LOCK-OUT CODES If the biler lcks ut, it signifies that a serius situatin has ccurred and that the biler has shut dwn and will nt fire again until manually reset. Befre manually resetting the appliance crrective actin may need t be taken t prevent further ccurrences f the lck-ut situatin. When the biler is in lckut the backlight f the display flashes n and ff. When a lck-ut ccurs, the display will shw a descriptin f the fault in the tp line f the display; the bttm line f the display will shw the status f the pump when the fault ccurred and the time that has elapsed since the fault ccurred. Display message F l w s e n s r e r r r F0 p u m p n 9 9 9, 5 h r s Reasn: Flw sensr is nt detected. Faulty wiring r cnnectin in the flw sensr circuit. Crrective Actin: Check fr lse r damaged wiring and r cnnectins in the flw sensr circuit and repair as necessary. Defective temperature sensr causing a fault signal. Crrective Actin: Replace flw sensr. Display message F l w h i g h T e m p F1 p u m p n 9 9 9, 5 h r s Reasn: Flw temperature exceeds limitatin (lck-ut) value. The water flw thrugh the heat exchanger is restricted. Crrective Actin: Check the peratin f the pump. Check that all valves that might restrict the water flw thrugh the biler are pen. Check fr an external system pump that influences flw thrugh the biler. Check if the system resistance exceeds the spare capacity f the biler pump. 83

84 Display message R e t u r n h i g h T e m p F1 p u m p n 9 9 9, 5 h r s Reasn: Maximum return temperature exceeds limit value. An external heat surce (CHP, heat pump etc.) has heated the return temperature abve the maximum return temperature. Crrective Actin: Reduce pre heat temperature f external heat surce. The external heating cntrls suddenly clse causing excessive return water temperature. Crrective Actin: Dampen the reactin time f the external heating cntrl system t prevent sudden biler temperature rise. Display message L a c k f w a t e r F2 p u m p n 9 9 9, 5 h r s Reasn N temperature rise measured during firing. When the biler starts firing, the cntrl expects t measure a difference in temperature between inlet and utlet. If n temperature rise is detected, the burner cntrl assumes that there is n medium (water) present, t transfer heat frm cmbustin t the sensr and lcks ut t prevent damage. Crrective Actin: Ensure that the system if full f water and all air-lcks are remved. Display message R e t u r n s e n s r e r r r F3 p u m p n 9 9 9, 5 h r s Reasn Return sensr is nt detected Faulty wiring r cnnectin in the return sensr circuit. Crrective Actin: Check fr lse r damaged wiring and r cnnectins in the return sensr circuit and repair as necessary. Defective temperature sensr causing a fault signal. Crrective Actin: Replace the return sensr. Display message F l u e s e n s r e r r r F6 p u m p n 9 9 9, 5 h r s Reasn Flue sensr is nt detected Faulty wiring r cnnectin in the flue sensr circuit. Crrective Actin: Check fr lse r damaged wiring and r cnnectins in the flue sensr circuit and repair as necessary. Defective temperature sensr causing a fault signal. Crrective Actin: Replace the flue sensr. 84

85 Display message F l u e t e m p t h i g h F7 p u m p n 9 9 9, 5 h r s Reasn Flue gas temperature limitatin value exceeded 3 times within a preset time perid Heat exchanger plluted and nt able t effectively transfer heat t the system water. Crrective Actin: Check and clean the heat exchanger. Defective (partially shrted) flue gas sensr r sensr cnnectin. Crrective Actin: Check fr misture in the sensr cnnectins r replace sensr. There is n water in the unit while firing. Crrective Actin: Bleed all air frm the unit s the heat frm cmbustin can be transferred t the water and wn't leave thrugh the flue Heat exchanger failure. Crrective Actin: Cntact Lchinvar Limited fr further guidance. Display message F a i l e d b u r n e r s t a r t F8 p u m p n 9 9 9, 5 h r s Reasn Biler nt peratinal after 4 starting attempts. N spark. Crrective Actin: Check the cnditin f the ignitin electrde and clean/replace if necessary. Check the cnditin f the ceramic insulatr. Replace electrde if any sign f damage is present. Check the distance between the electrde pin, earth pin and burner. Check the cnditin f the ignitin cable and replace if necessary. Check the cnditin f the earth wire/cnnectin f the ignitin electrde and replace if necessary. Check the cnditin f the electrde cap and replace if necessary. Check the incming pwer supply. The supply vltage must be 230 VAC 50Hz 1Ph. Check fr crrect electrical earthing f the biler. Failed burner cntrl system. Change the burner cntrl PCB. Ignitin spark, but n flame. Crrective Actin: Ensure all islatin valves in the gas supply line are cmpletely pen. The nminal gas inlet pressure shuld be 20 mbar. Check that the gas supply pipewrk has been crrectly purged (start-up new systems). Check if the gas valve pens. When there is pwer supply t the gas valve, but the valve des nt pen, the gas valve must be replaced. Check if the gas valve settings are crrect and adjust if necessary. Check if the air supply t the biler is free frm bstructin. Flame, but nt enugh inisatin t establish the flame. Crrective Actin: Check the cnditin f the ignitin electrde and clean/replace if necessary. Check the cnditin f the ceramic insulatr. Replace electrde if any sign f damage is present. Check the distance between the electrde pin, earth pin and burner. Check the cnditin f the ignitin cable and replace if necessary. Check the cnditin f the earth wire/cnnectin f the ignitin electrde and replace if necessary. Check fr crrect electrical earthing f the biler. Check the incming pwer supply. The supply vltage must be 230 VAC 50Hz 1Ph. Check the cnditin f the electrde cap and replace if necessary. 85

86 Display message F l a m e l s t F9 p u m p n 9 9 9, 5 h r s Reasn Flame signal lst during peratin. Incrrect gas supply pressure. Crrective Actin: Be aware that the nminal gas inlet pressure must be met under all peratin cnditins. Check the incming gas supply pressure is crrect. Cntact the gas transprted if incrrect. Check if all gas valves in the supply line are cmpletely pen. Check if the gas supply pipewrk is crrectly sized. Check if the dirt filter mesh in the gas valve inlet is clean. Check that any external dirt filter in the gas supply line is nt blcked. Check if an external gas pressure regulatr is selected/installed crrectly. Incrrect gas valve settings. Crrective Actin: Check and set gas valve settings. Faulty gas valve. Crrective Actin: Replace gas valve. Faulty electrde/electrde wiring affecting the inisatin signal. Crrective Actin: Check inisatin signal. Check the cnditin f the ignitin electrde and clean/replace if necessary. Check the cnditin f the ceramic insulatr. Replace electrde if any sign f damage is present. Check the distance between the electrde pin, earth pin and burner. Check the cnditin f the ignitin cable and replace if necessary. Check the cnditin f the earth wire/cnnectin f the ignitin electrde and replace if necessary. Check fr crrect electrical earthing f the biler. Flue gas and/r air supply system fault. Crrective Actin: Check if the design f the flue gas and air supply system cmplies with the maximum cmbined resistance as specified. Check if the flue gas and air supply system is installed in accrdance with the relevant standards. Check all seals in the flue gas and air supply system. Display message F a l s e f l a m e s i g n a l F10 p u m p n 9 9 9, 5 h r s Reasn Flame signal detected, when n heat demand is present. The flame detectin circuit detects a flame which is nt suppsed t be present. Crrective Actin: Check the cnditin f the ignitin electrde and clean/replace if necessary. Check the incming pwer supply fr crrect plarity. Check the incming pwer supply fr incrrect frequency r vltage peaks. Check external wiring fr vltage feedback. Check the internal wiring fr bad cnnectins. Check if the gas valve is clsing crrectly. Replace the burner cntrl PCB. 86

87 Display message F a n s p e e d i n c r r e c t F11 p u m p n 9 9 9, 5 h r s Reasn Actual fan speed differs frm the unit rpm setpint. An incrrect fan speed is detected. Crrective Actin: Check the 4 wired fan cntrl wiring and cnnectins at the fan and at the main cntrl bard. Check the 3 wired pwer supply wiring and cnnectins at bth ends. Replace the fan. Replace the main cntrl bard. Display message p r g r a m m i n g e n d F12 p u m p n 9 9 9, 5 h r s Reasn Prgramming f the parameters cmpleted successfully. Prgramming f the parameters cmpleted successfully. Crrective Actin: This message ccurs t cnfirm the end f prgramming. Pressing RESET will return the unit in nrmal perating status. Display message P a r a m / H a r d w f a u l t F13 p u m p n 9 9 9, 5 h r s Reasn Failure during prgramming f the parameters. Prgramming f the parameters NOT successfully cmpleted. Crrective Actin: Unit was nt in stand-by mde when an attempt t prgram the parameters was made (fan must nt run during prgramming). Check the PC interface cable and cnnectins and try parameter prgramming again. Check if the sftware versin is crrect fr the burner cntrl PCB. Replace the PC interface cable. Replace the display PCB. Display message C l i x n F a u l t F15 p u m p n 9 9 9, 5 h r s Reasn: Heat exchanger fuse exceeded maximum value. The heat exchanger thermal fuse has pened permanently. Crrective Actin: Islate the electrical pwer and gas supply t the biler and cntact Lchinvar Limited fr further guidance. Display message W a t e r h i g h l i m i t F17 p u m p n 9 9 9, 5 h r s Reasn: High-temperature limit thermstat has exceeded the limitatin value. The water flw is restricted. Crrective Actin: Check fr crrect peratin f the integral pump. Check that all valves that may restrict the water flw thrugh the biler are fully pen. Ensure that any strainers installed in the primary circuit are free frm debris. Check fr an external system pump that influences the flw thrugh the unit. Check if the system resistance exceeds the spare capacity f the integral pump. 87

88 Display message S i p h n s w i t c h F19 p u m p n 9 9 9, 5 h r s Reasn: Siphn pressure switch detects high pressure in the flue/cndensate drain system. There is t much resistance in the flue system causing excessive pressure in the heat exchanger. Crrective Actin: Check if the flue system is blcked. Check the cnditin f the heat exchanger and clean if necessary. Check the flue gas system diameter & length cmplies with Sectin 8.4 r Sectin 8.5. The cndensate drain system is blcked causing the cndensate t build up abve the measuring pint f the pressure Crrective Actin: Check that the cndensate drain hse between the heat exchanger and the water trap is free frm blckages, ensuring the cndensate can flw freely t the trap. Check if the cndensate water trap is free f debris that might blck the cndensate flw and clean if necessary. Check the cndensate drain hse between the water trap and the cndensate drain pint in the external installatin fr blckages. Cndensate must be able t flw freely. Pressure fluctuatins in the building drainage system are affecting the heat exchanger. Crrective Actin: Make sure that there is an air-break between the cndensate drain hse and the drainage system f the building Blckage f the signal hse t the pressure switch. Crrective Actin: Check the signal hse and clean r replace it if necessary. Faulty pressure switch causing an incrrect signal. Crrective Actin: Replace the pressure switch. Bad wiring/cnnectin in the pressure switch circuit. Crrective Actin: Check fr lse wiring/cnnectins in the pressure switch circuit BLOCKING CODES Blcking cdes signify that a situatin is present under which the biler is nt safe t perate but nce the situatin clears, peratin can safely cntinue. When a blcking f the biler is active, the display is cnstantly illuminated. When a blcking ccurs, the display will shw a descriptin f the cnditin in the tp line f the display; the bttm line f the display will shw the time that has elapsed since the blcking ccurred. Display message F l w t e m p h i g h Reasn: 9 9 9, 5 h r s The flw temperature has exceeded the blcking temperature but nt the lck-ut The water flw is restricted Crrective Actin: Check the peratin f the integral pump. Check that all valves that may restrict the water flw thrugh the unit are fully pen. Check fr an external system pump that influences the flw thrugh the biler. Check if the system resistance exceeds the spare capacity f the integral pump. 88

89 Display message R e t u r n t e m p h i g h 9 9 9, 5 h r s Reasn The return temperature has exceeded the blcking temperature but nt the lck-ut temperature. An external heat surce (CHP, heat pump etc.) has heated the return temperature abve the blcking temperature. Crrective Actin: Reduce pre heat temperature f the external heat surce. The external heating cntrls suddenly clse causing excessive return water temperature. Crrective Actin: Dampen the reactin time f the external heating cntrl system t prevent sudden biler temperature rise. Display message F l u e t e m p h i g h 9 9 9, 5 h r s Reasn The flue gas temperature has exceeded the blcking temperature. Heat exchanger plluted and nt able t effectively transfer heat t the system water. Crrective Actin: Check and clean the heat exchanger. Defective (partially shrted) flue gas sensr r sensr cnnectin. Crrective Actin: Check fr misture in the sensr cnnectins r replace sensr. There is n water in the unit while firing. Crrective Actin: Bleed all air frm the unit s the heat frm cmbustin can be transferred t the water and wn't leave thrugh the flue Heat exchanger failure. Crrective Actin: Cntact Lchinvar Limited fr further guidance. Display message A n t i c y c l e t i m e 9 9 9, 5 h r s Reasn The cntrller received a new heat demand t sn after the last heat demand finished. System water temperature cling and causing a heat demand within the anti-cycling time perid. Crrective Actin: Dampen external heating system cntrls t slw dwn the cling time f the heating medium (water). Increase system vlume t act as a buffer between the biler circuit and heating circuit. Rapid pening and clsing f external thermstat Crrective Actin: Check switching differential f n/ff thermstat 89

90 Display message W a t e r p r e s s u r e f a u l t 9 9 9, 5 h r s Reasn System water pressure is t high r t lw. The water pressure in the system is t high. Crrective Actin: Check if the system pressure is t high after (re)filling. Check the settings f any autmatic pressurisatin unit attached t the system. Make sure that there is a pressure relief valve and expansin vessel installed in the system, accrding t the applicable standards. The water pressure in the system is t lw. Crrective Actin: Where fitted t an pen vented system, check t ensure that the header tank gives a static head f at least 1.0 bar. Check the heating system fr leaks and repair as necessary. Ensure that any external system pump cannt cause an under pressure situatin in the biler. Wherever pssible, a lwvelcity header shuld be used t separate the biler frm the system. Display message L i n e f a u l t p u m p n 9 9 9, 5 h r s Reasn Incrrect electrical pwer supply The electrical pwer supply des nt cmply with specificatins. Crrective Actin: Check if the pwer supply is cnnected crrectly t the unit. Refer t Sectin 11.0 f this dcument. Check the vltage and frequency. The electrical supply shuld be 230VAC 50Hz 1ph. Make sure there is n signal fuling r vltage peaks in the pwer supply. Display message O u t d r s e n s r f a i l 9 9 9, 5 h r s Reasn N utdr sensr detected. The biler is prgrammed t give utside temperature cmpensatin but des nt detect an utdr sensr. Crrective Actin: Check fr lse wiring/cnnectins in the utdr sensr circuit. Check the cnditin f the utdr sensr and replace if necessary. Display message H e a t e x c h a n g a t r i s k 9 9 9, 5 h r s Reasn The temperature difference between flw and return has exceeded the blcking temperature 3 times, causing the unit t run in reduced input mde. Lw water flw. Crrective Actin: Clean the water circuit f the heat exchanger. A partial blckage f the heat exchanger will increase the resistance causing the water flw t drp. Check the pump fr crrect peratin. Check that all valves that may restrict the water flw thrugh the unit are fully pen. Check fr an external system pump that influences the flw thrugh the biler. Check if the system resistance exceeds the spare capacity f the integral pump. 90

91 Display message G e n B l c k 9 9 9, 5 h r s Reasn The general blcking circuit is activated during peratin (after a flame was rectified). The circuit cnnected t the general blcking terminals is nt clsed. Crrective Actin: Check all external safety devices that are in the circuit cnnected t the general blcking terminals, and determine why the cntact is nt clsed during heat demand. Display message C a s c a d e B l c k 9 9 9, 5 h r s Reasn Cnnectin failure with ne f the bilers f the cascade. The unit is prgrammed in such a way that nne f the bilers in a cascade will fire, if ne has a lckut. One unit has a lckut and therefre the whle cascade is blcked. Crrective Actin: Trublesht the fault with the lcked-ut biler IMPORTANT MESSAGES The fllwing graphs describe the messages at the biler display. Depending n the selected and activated ptins fr the biler, it is pssible that sme messages will shw up at the display f the biler. Fr example a maintenance message after a certain prgrammed date has been reached. The biler will perate independently f these messages. Display message N e e d s M a i n t e n a n 0. 0 I g n i t i n c y c l e s h r s Reasn Maintenance ptin f ttal amunt f ignitin cycles has been reached. Display message N e e d s M a i n t e n a n 0. 0 D a t e h r s Reasn Maintenance ptin f the date has been reached. Display message N e e d s M a i n t e n a n 0. 0 B u r n i n g h u r s h r s Reasn Maintenance ptin f ttal amunt f burning hurs has been reached. Display message N e e d s M a i n t e n a n 0. 0 Reasn 18.0 USER INSTRUCTIONS A l l h r s One f the all selected maintenance ptins has been reached. Once the installatin and cmmissining is cmplete, the equipment wner r their representative shuld be made aware f the peratin f the appliance and its safety devices. A practical demnstratin shuld be given describing each functinal step. Incrrect use may result in injury and will als invalidate the warranty. The installers guide shuld be handed ver and kept in a safe place fr easy reference. It is strngly recmmended that the users read and understand the separate User Guide. 91

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