DeDietrich Innovens MCA 25/28 BIC, Innovens MCA 35 Installation And Service Manual

Innovens

Wall-hung gas condensing boilers

MCA 25/28 BIC

Installation and Service Manual

300022159-001-01

EG declaration of conformity

R000300-A

EG - VERKLARING VAN OVEREENSTEMMING EC - DECLARATION OF CONFORMITY EG - KONFORMITÄTSERKLÄRUNG DÉCLARATION DE CONFORMITÉ CE

Fabrikant/Manufacturer/Hersteller/Fabricant : Remeha B.V. Adres/Address /Adresse : Kanaal Zuid 110 Stad,Land/City,Country/Land,Ort/Ville, pays : Postbus 32, NL-7300 AA Apeldoorn

verklaart hiermede dat de toestel(len) : MCA ../.. (MI) (BIC) this is to declare that the following product(s) : erklärt hiermit das die Produk(te) : déclare ici que les produit(s) suivant(s) :

op de markt gebracht door : De Dietrich Thermique distributor : 57, rue de la Gare, F-67580 Vertreiber : Commercialisé (s) par :

voldoet/voldoen aan de bepalingen van de onderstaande EEG-richtlijnen: is/are in conformity with the following EEC-directives: den Bestimmungen der nachfolgenden EG-Richtlinien entspricht/entsprechen: répond/répondent aux directives CEE suivantes:

EEG-Richtlijn: 2009/142/EC toegepaste normen: EEC-Directive: 2009/142/EC tested and examined tothe following norms: EG-Richtlinie: 2009/142/EG verwendete Normen, normes appliquées: CEE-Directive: 2009/142/CE EN 297

(1994*)

, 483

(1999*)

, 677

(1998*)

92/42/EEG 92/42/EEC 92/42/EWG 92/42/CEE

2006/95/EEG

EN 50165

(1997*),

EN 60335-1

(1994*)

2006/95/EEC EN 60335-2-102

(2004*)

08 2006/95/EWG 2006/95/CEE

2004/108/EEG

EN 50165

(1997*)

2004/108/EEC EN 55014-2

(1997*),

EN 55014-1

(2000*),

2004/108/EWG EN 61000-3-2

(2000*)

, 61000-3-3

(1995*)

2004/108/CEE

97/23/EEG (art. 3, lid 3)

97/23/EEC (article 3, sub 3) 97/23/EWG (Art. 3, Abzats 3) 97/23/CEE (art.3 section 3)

*) inclusief (eventuele) aanvulling, including (if any) completion

einschließlich (falls vorhanden) Vervollständigung, y compris (le cas échéant) complément

Apeldoorn

, february 2010

W.F. Tijhuis Approval manager

703/2012/02/232

The device complies with the standard type described in the EG declaration of conformity. It was manufactured and commissioned in accordance with European directives.

The original of the declaration of compliance is available from the manufacturer.

Contents

1 Introduction ................................................................................................6

1.1 Symbols used .......................................................6

1.2 Abbreviations ........................................................6

1.3 General ..................................................................7

1.3.1 Manufacturer's liability .............................................7

1.3.2 Installer's liability .....................................................7

1.4 Homologations ......................................................7

1.4.1 Certifications ...........................................................7

1.4.2 Equipment categories .............................................8

1.4.3 Additional Directives ................................................8

1.4.4 Factory test .............................................................8

2 Safety instructions and recommendations ..............................................9

2.1 Safety instructions ...............................................9

2.2 Recommendations ................................................9

3 Technical description ..............................................................................11

3.1 General description ............................................11

3.2 Main parts ............................................................11

3.3 Operating principle .............................................12

3.3.1 Skeleton Diagrams ................................................12

3.3.2 Shunt pump ...........................................................12

3.3.3 Water flow rate ......................................................13

3.4 Technical specifications ....................................13

3.4.1 Sensor characteristics ...........................................14

4 Installation ................................................................................................15

4.1 Regulations governing installation ...................15

4.2 Package list .........................................................15

4.2.1 Standard delivery ..................................................15

4.2.2 Accessories ...........................................................15

15/06/12 - 300022159-001-01

4.3 Choice of the location ........................................16

4.3.1 Data plate ..............................................................16

4.3.2 Location of the boiler .............................................16

4.3.3 Ventilation .............................................................17

4.3.4 Main dimensions ...................................................18

Contents

4.4 Installing the mounting frame ...........................19

4.5 Positioning the boiler .........................................19

4.6 Hydraulic connections .......................................20

4.6.1 Flushing the system ..............................................20

4.6.2 Connection of the heating circuit ...........................21

4.6.3 Connection of the water circuit for domestic

use ........................................................................21

4.6.4 Connecting the expansion vessel .........................22

4.6.5 Connecting the condensate discharge pipe ..........23

4.7 Gas connection ...................................................23

4.8 Flue gas system connections ............................24

4.8.1 Classification .........................................................24

4.8.2 Lengths of the air/flue gas pipes ...........................25

4.8.3 Additional Directives ..............................................26

4.9 Installing the outside sensor .............................27

4.9.1 Choice of the location ............................................27

4.9.2 Connecting the outside sensor ..............................27

4.10 Electrical connections ........................................28

4.10.1 Control unit ............................................................28

4.10.2 Recommendations ................................................29

4.10.3 Position of the PCBs .............................................30

4.10.4 Accessing the connection terminal blocks ............31

4.10.5 Connecting a direct heating circuit ........................33

4.10.6 Connecting two heating circuits ............................34

4.10.7 Hot water storage tank connection (Type

PS) ........................................................................35

4.10.8 Pool connection .....................................................37

4.10.9 Connecting the options .........................................38

4.11 Electrical diagram ...............................................40

4.12 Filling the system ...............................................41

4.12.1 Water treatment ....................................................41

4.12.2 Filling the siphon ...................................................42

4.12.3 Filling the system ..................................................42

5 Commissioning ........................................................................................44

5.1 Control panel .......................................................44

5.1.1 Description of the keys ..........................................44

5.1.2 Description of the display ......................................45

5.1.3 Access to the various browsing levels ..................48

5.1.4 Browsing in the menus ..........................................49

15/06/12 - 300022159-001-01

5.2 Check points before commissioning ................50

5.2.1 Preparing the boiler for commissioning .................50

5.2.2 Gas circuit .............................................................51

5.2.3 Hydraulic circuit .....................................................51

5.2.4 Electrical connections ...........................................51

5.3 Commissioning the boiler ..................................51

5.4 Gas settings ........................................................52

5.4.1 Adapting to another gas type ................................52

5.4.2 Setting the air/gas ratio (Full load) ........................53

5.4.3 Setting the air/gas ratio (Part load) ......................54

5.4.4 Basic setting for the gas/air ratio ...........................56

5.5 Checks and adjustments after

commissioning ...................................................56

5.5.1 Displaying the parameters in extended

mode .....................................................................56

5.5.2 Setting the parameters specific to the

installation .............................................................57

5.5.3 Naming the circuits and generators ......................61

5.5.4 Setting the heating curve ......................................62

5.5.5 Finalizing work ......................................................64

5.6 Reading out measured values ...........................65

5.7 Changing the settings ........................................66

5.7.1 Language selection ...............................................66

5.7.2 Calibrating the sensors .........................................66

5.7.3 Professional settings .............................................68

5.7.4 Configuring the network ........................................75

5.7.5 Return to the factory settings ................................78

6 Switching off the boiler ............................................................................80

6.1 Installation shutdown .........................................80

6.2 Frost protection ..................................................80

7 Checking and maintenance .....................................................................81

7.1 General instructions ...........................................81

7.2 Chimney sweep instructions .............................81

7.3 Customising maintenance .................................82

7.3.1 Maintenance message ..........................................82

7.3.2 Contact details of the professional for After Sales

Support ..................................................................83

7.4 Standard inspection and maintenance

operations ...........................................................83

7.4.1 Checking the hydraulic pressure ...........................84

7.4.2 Checking the expansion vessel .............................84

7.4.3 Checking the ionization current .............................84

7.4.4 Checking the transfer capacity ..............................84

7.4.5 Checking the tightness of the flue gas evacuation and

air inlet connections ..............................................84

7.4.6 Checking combustion ............................................85

7.4.7 Checking the automatic air vent ............................86

7.4.8 Checking the safety valve .....................................86

7.4.9 Checking the siphon ..............................................86

15/06/12 - 300022159-001-01

Contents

7.4.10 Checking the burner and cleaning the heat

exchanger .............................................................87

7.5 Specific maintenance operations ......................88

7.5.1 Replacing the ionization/ignition electrode ............88

7.5.2 Cleaning the plate exchanger ...............................89

7.5.3 Replacing the boiler tanks .....................................90

7.5.4 Replacing the 3-way valve ....................................91

7.5.5 Replacing the non-return valve .............................92

7.5.6 Assembling the boiler ............................................93

8 Troubleshooting .......................................................................................94

8.1 Anti-hunting ........................................................94

8.2 Messages (Code type Bxx or Mxx) ....................94

8.3 Message history ..................................................97

8.4 Faults (Code type Lxx or Dxx) ...........................97

8.4.1 Deletion of sensors from the memory in the

PCB .....................................................................106

8.5 Failure history ...................................................106

8.6 Parameter and input/output check (mode

tests) ..................................................................107

8.6.1 Control system sequence ....................................110

9 Spare parts ..............................................................................................111

9.1 General ..............................................................111

9.2 Spare parts ........................................................111

9.2.1 Casing .................................................................112

9.2.2 Heat exchanger and burner ................................113

9.2.3 Fan ......................................................................114

9.2.4 Control panel .......................................................115

9.2.5 Connecting pipes ................................................116

9.2.6 Spare parts list ....................................................117

15/06/12 - 300022159-001-01

1. Introduction

1 Introduction

1.1 Symbols used

MCA 25/28 BIC

In these instructions, various danger levels are employed to draw the user's attention to particular information. In so doing, we wish to safeguard the user's safety, obviate hazards and guarantee correct operation of the appliance.

DANGER

Risk of a dangerous situation causing serious physical injury.

WARNING

Risk of a dangerous situation causing slight physical injury.

1.2 Abbreviations

CAUTION

Risk of material damage.

Signals important information.

¼ Signals a referral to other instructions or other pages in the instructions.

4 3CE: Collective conduit for sealed boiler 4 DHW: Domestic hot water 4 Hi: Lower heating value LHV (Nett) 4 Hs: Higher heating value HHV (Gross) 4 PPS: Polypropylene hardly inflammable 4 PCU: Primary Control Unit - PCB for managing burner operation 4 PSU: Parameter Storage Unit - Parameter storage for PCBs

PCU and SU

4 SCU: Secondary Control Unit - control panel PCB 4 SU: Safety Unit - Safety PCB 4 3WV: 3-way valve

15/06/12 - 300022159-001-01

MCA 25/28 BIC 1. Introduction

1.3 General

1.3.1. Manufacturer's liability

Our products are manufactured in compliance with the requirements of the various applicable European Directives. They are therefore

delivered with [ marking and all relevant documentation.

In the interest of customers, we are continuously endeavouring to make improvements in product quality. All the specifications stated in this document are therefore subject to change without notice.

Our liability as the manufacturer may not be invoked in the following cases:

4 Failure to abide by the instructions on using the appliance. 4 Faulty or insufficient maintenance of the appliance. 4 Failure to abide by the instructions on installing the appliance.

1.4 Homologations

1.3.2. Installer's liability

The installer is responsible for the installation and inital start up of the appliance. The installer must respect the following instructions:

4 Read and follow the instructions given in the manuals provided

with the appliance.

4 Carry out installation in compliance with the prevailing legislation

and standards.

4 Perform the initial start up and carry out any checks necessary. 4 Explain the installation to the user. 4 If a maintenance is necessary, warn the user of the obligation to

check the appliance and maintain it in good working order.

4 Give all the instruction manuals to the user.

1.4.1. Certifications

15/06/12 - 300022159-001-01

CE identification no NOx classification Type of connection

(1) IP20

PIN 0063BT3444

5 (EN 297 pr A3, EN 656)

83(x)

(1)

, C

Chimney: B23 Flue gas outlet: C

, C

63(x)

, B

13(x) 93(x)

23P

(1)

, C

, B

33(x)

, C

43(x)

, C53 ,

1. Introduction MCA 25/28 BIC

1.4.2. Equipment categories

Gas category Gas type Connection pressure (mbar)

2ESi3P

Natural gas H (G20) 20 Natural gas L (G25) 25 Propane (G31) 37

The boiler is preset in the factory to operate on natural gas H (G20).

¼ For operation on another type of gas, see chapter: "Adapting to another gas type", page 52.

1.4.3. Additional Directives

Apart from the legal provisions and Directives, the additional Directives described in these instructions must also be observed.

For all provisions and Directives referred to in these instructions, it is agreed that all addenda or subsequent provisions will apply at the time of installation.

WARNING

Installation of the appliance must be done by a qualified engineer in accordance with prevailing local and national regulations.

1.4.4. Factory test

Before leaving the factory, each boiler is set for optimum performance and tested to check the following items:

4 Electrical safety 4 Adjustment (CO2) 4 Water tightness 4 Gas tightness 4 Parameter settings

15/06/12 - 300022159-001-01

MCA 25/28 BIC

2 Safety instructions and

recommendations

2.1 Safety instructions

DANGER

If you smell gas:

1. Do not use a naked flame, do not smoke, do not operate electrical contacts or switches ( doorbell, light, motor, lift, etc..).

2. Shut off the gas supply.

3. Open the windows.

4. Trace possible leaks and seal them immediately.

5. If the gas leak is before the gas meter, contact the gas supplier.

2. Safety instructions and recommendations

2.2 Recommendations

DANGER

If you smell flue gases:

1. Switch the appliance off.

2. Open the windows.

3. Trace possible leaks and seal them immediately.

WARNING

4 Installation and maintenance of the boiler must be

carried out by a qualified professional in compliance with prevailing local and national regulations.

4 When working on the boiler, always disconnect the

boiler from the mains and close the main gas inlet valve.

4 After maintenance or repair work, check all

installations to ensure that there are no leaks.

CAUTION

15/06/12 - 300022159-001-01

The boiler must be installed in a frost-free environment.

Keep this document close to the place where the boiler is installed.

Casing components

2. Safety instructions and recommendations MCA 25/28 BIC

Only remove the casing for maintenance and repair operations. Put the casing back in place after maintenance and repair operations.

Instructions stickers

The instructions and warnings affixed to the appliance must never be removed or covered and must remain legible during the entire lifespan of the appliance. Immediately replace damaged or illegible instructions and warning stickers.

Modifications

Modifications may only be made to the boiler after the written permission of De Dietrich Thermique to do so.

15/06/12 - 300022159-001-01

T001961-D

14 13

MCA 25/28 BIC 3. Technical description

3 Technical description

3.1 General description

Wall-hung gas condensing boilers

4 High efficiency heating. 4 Low pollutant emissions. 4 Top of the range electronic DIEMATIC iSystem control panel. 4 Installation and connection facilitated by the mounting frame

delivered with the appliance.

4 Flue gas discharge via a forced flue, chimney, bi-flow or 3CE type

connection.

4 Heating and domestic hot water production with integrated DHW

tank.

3.2 Main parts

Flue gas discharge pipe

Casing/air box

Flue gas measuring point

Mixer pipe

Heating flow hose

Air intake silencer

Box for the control PCBs

Combined venturi and gas valve unit

Flow end hydroblock

Safety valve outlet pipe

Siphon

Control panel

Tank drainage valve

Expansion vessel (DHW circuit)

Tank hydroblock

Shunt pump (DHW circuit)

Shunt pump (Heating circuit)

Return end hydroblock

Plate heat exchanger (DHW circuit)

3-way valve

Condensate receiver tank

Fan

15/06/12 - 300022159-001-01

T001960-A

4 5 6 7

T002537-B

0 200 400 600 800 1000 1200

Q (l/h)

10 kW

15 kW

20 kW

25 kW

615

545

435

295

437 623 830 1037

100

200

300

400

500

700

H (mbar)

600

3. Technical description

MCA 25/28 BIC

3.3 Operating principle

Heat exchanger (Heating circuit)

Calorifier tank

Ignition/ionization electrode

Expansion vessel (Heating circuit)

Air intake

3.3.1. Skeleton Diagrams

Heat exchanger (Heating circuit)

Hydroblocks

Plate heat exchanger (DHW circuit)

Heating flow

Domestic hot water outlet

Domestic cold water inlet

Heating return

Shunt pump (DHW circuit)

Expansion vessel (DHW circuit)

3-way valve

Shunt pump (Heating circuit)

Calorifier tank

Expansion vessel (Heating circuit)

3.3.2. Shunt pump

The boiler is equipped with a circulating pump. This energy-efficient, modulating circulating pump is controlled by the control unit based on ΔT. The graph shows the manometric height at various outputs.

Manometric height central heating circuit

Water flow

The parameters MIN.PUMP SPEED and MAX.PUMP SPEED are used to modify the pump settings. If flow noise can be heard in the system, it is possible to reduce the maximum pump speed with the parameter MAX.PUMP SPEED (First of all, vent the heating system). If circulation in the radiators is too low or the radiators do not fully heat up, increase the minimum pump speed with the parameter MIN.PUMP SPEED.

15/06/12 - 300022159-001-01

MCA 25/28 BIC 3. Technical description

¼ See chapter: "Professional settings", page 68.

3.3.3. Water flow rate

The boiler's modulating control system limits the maximum difference in temperature between the heating flow and return and the maximum speed at which the flow temperature increases. In this way, the boiler does not require a minimum water flow rate.

3.4 Technical specifications

Boiler type

General

Flow rate setting Adjustable Nominal output (Pn)

Heating System (80/60 °C)

Nominal output (Pn) Heating System (50/30 °C)

Nominal output (Pn) DHW System

Nominal input (Qn) Heating System (Hi)

Nominal input(Qn) Heating System (Hs)

Nominal input (Qnw) DHW System (Hi)

Nominal input (Qnw) DHW System (Hs)

Heating efficiency under full load (Hi) (80/60 °C) - % 96,3 Heating efficiency under full load (Hi) (50/30 °C) - % 102,0 Heating efficiency under partial load (Hi) (Return temperature

60°C) Heating efficiency under partial load (EN 92/42) (Return

temperature 30°C)

Data on the gases and combustion gases

Gas consumption - Natural gas H (G20) minimum-maximum

Gas consumption - Natural gas L (G25) minimum-maximum

Gas consumption - Propane G31 minimum-maximum

NOx-Emission per year (n =1) Mass flue gas flow rate minimum-maximum kg/h 8,9 - 49,3

Flue gas temperature minimum-maximum °C 30 - 85 Maximum counter pressure

Characteristics of the heating circuit

Water content Water operating pressure minimum kPa (bar) 80 (0,8) Water operating pressure (PMS) maximum kPa (bar) 300 (3,0) Water temperature maximum °C 110 Operating temperature maximum °C 90

(1) Front panel removed

minimum-maximum kW 5,0 - 24,1 Factory setting kW 19,4 minimum-maximum kW 5,6 - 25,5 Factory setting kW 20,5 minimum-maximum kW 5,0 - 29,9 Factory setting kW 29,9 minimum-maximum kW 5,2 - 25,0 Factory setting kW 20,1 minimum-maximum kW 5,8 - 27,8 Factory setting kW 22,3 minimum-maximum kW 5,2 - 29,3 Factory setting kW 29,3 minimum-maximum kW 5,8 - 32,6 Factory setting kW 32,6

- % 96,1

- % 108,0

m3/h

m3/h mg/kWh 38

Pa 130

l 1,8

MCA 25/28 BIC

Modulating, Start/Stop, 0 - 10 V

0,55 - 3,10

0,64 - 3,61

0,21 - 1,20

15/06/12 - 300022159-001-01

3. Technical description MCA 25/28 BIC

Boiler type

Manometric height central heating circuit (∆T = 20K)

Characteristics of the domestic hot water circuit

Specific hot water flow D (60 °C) Specific hot water flow D (30 °C) Domestic water resistance Water content Operating pressure (Pmw) maximum kPa (bar) 800 (8,0)

Electrical characteristics

Power supply voltage

Power consumption - Full load

Power consumption - Part load maximum W 21 Power consumption - Standby maximum W 4 Electrical protection index

Other characteristics

Weight (empty)

Acoustic level at 1 metre

(1) Front panel removed

maximum W 162 Factory setting W 72

mbar 295

l/min 7,5 l/min 20,0 mbar 20 l 40,5

VAC 230

Total kg 70 Mounting

(1)

kg 61 dB(A) 44

MCA 25/28 BIC

IPX4D

3.4.1. Sensor characteristics

Outside sensor

Temperature in °C -20 -16 -12 -8 -4 0 4 8 12 16 20 24 Resistance in Ω 2392 2088 1811 1562 1342 1149 984 842 720 616 528 454

Outlet sensor circuit B+C Domestic hot water sensor System sensor Flow sensor - Return sensor NTC

Temperature in °C 0 10 20 25 30 40 50 60 70 80 90 Resistance in Ω 32014 19691 12474 10000 8080 5372 3661 2535 1794 1290 941

15/06/12 - 300022159-001-01

MCA 25/28 BIC 4. Installation

4 Installation

4.1 Regulations governing installation

WARNING

Installation of the appliance must be done by a qualified engineer in accordance with prevailing local and national regulations.

4.2 Package list

4.2.1. Standard delivery

The delivery includes:

4 The boiler, fitted with a connection cable 4 Mounting frame 4 Mounting template 4 Connection kit 4 Run-off collector for siphon and safety valve 4 Outside sensor 4 Installation and Service Manual 4 User Guide

4.2.2. Accessories

Various options are available depending on the configuration of the installation:

Boiler options

Description package Description package

Stand-off frame HR39 RX12 cable AD134 Pipework kit for stand-off frame HR40 TELCOM 2 voice remote monitoring module AD152 Pipe cover HR42 Flow sensor AD199 Flue gas thermostat HR43 DHW sensor AD212 adapter 80/125 HR38 Optional PCB for 3-way valve AD249 adapter 80-80 HR46 Hot water storage tank sensor AD250 Exchanger cleaning kit HR44 Outside radio-controlled temperature sensor AD251 Boiler body cleaning kit HR45 Boiler radio module AD252

Control system options

Radio remote control AD253 Interactive remote control AD254 Room sensor FM52

15/06/12 - 300022159-001-01

T001539-B

T001898-C

600

min.1000

500

min. 250

900

4. Installation MCA 25/28 BIC

4.3 Choice of the location

4.3.1. Data plate

The data plate located on top of the boiler provides important information on the appliance: serial number, model, gas category, etc.

4.3.2. Location of the boiler

4 Before mounting the boiler, decide on the ideal position for

mounting, bearing the Directives and the dimensions of the appliance in mind.

4 When choosing the position for mounting the boiler, bear in mind

the authorised position of the combustion gas discharge outlets and the air intake opening.

4 To ensure adequate accessibility to the appliance and facilitate

maintenance, leave enough space around the boiler.

WARNING

4 Fix the appliance to a solid wall capable of bearing

the weight of the appliance when full of water and fully equipped.

4 It is forbidden to store inflammable products and

materials in the boiler room or close to the boiler, even temporarily.

CAUTION

4 The boiler must be installed in a frost-free

environment.

4 A connection to the mains drainage system for the

discharge of condensate must be available close to the boiler.

15/06/12 - 300022159-001-01

T001899-B

min. 700

min.600

50 (2)

min. 250

100 min. (1)

MCA 25/28 BIC 4. Installation

4.3.3. Ventilation

(1)

Distance between the front of the boiler and the internal wall of the casing box.

(2)

Distance to allow on either side of the boiler.

If the boiler is installed in a closed casing, respect the minimum dimensions given in the diagram opposite. Also allow openings to obviate the following hazards:

4 Accumulation of gas 4 Heating of the box

Minimum cross section of the openings: S1 + S2 = 150 cm

15/06/12 - 300022159-001-01

T001962-A

217

345

415

282

349

416

481

900

600

498

375

140

150

257,5

4. Installation MCA 25/28 BIC

4.3.4. Main dimensions

i h

j z x

Gas / Gaz

Connection of the combustion gas exhaust pipe Ø 60 mm

Connection of the air intake pipe Ø 100 mm

Safety valve outlet pipe Ø 25 mm

Condensates discharge Ø 25 mm

Heating circuit return G¾"

Domestic cold water inlet G½"

Gas connection G½"

y {

Domestic hot water outlet G½"

Heating circuit flow G¾"

15/06/12 - 300022159-001-01

T001869-A

T001870-A

MCA 25/28 BIC 4. Installation

4.4 Installing the mounting frame

The boiler is delivered with a mounting template.

1. Position the mounting template to the wall with adhesive tape.

CAUTION

Using a spirit level, check that the mounting axis is perfectly horizontal.

2. Drill 3 holes with a Ø of 10 mm.

Additional holes are provided in case one or other of the standard locating holes prevents the correct location of the plugs.

3. Put the plugs in place.

4. Secure the mounting frame to the wall using the 3 hexagonal headed screws provided for this purpose.

4.5 Positioning the boiler

1. Remove the protective caps from all of the hydraulic inlets and outlets on the boiler.

15/06/12 - 300022159-001-01

T001627-A

T001872-A

4. Installation

MCA 25/28 BIC

2. Fit a fibre gasket to each joint on the valve plate.

3. Position the boiler above the plumbing fixtures plate and locate it against the mounting frame. Gently lower the boiler.

4. Tighten the valve nuts on the boiler.

4.6 Hydraulic connections

4.6.1. Flushing the system

Installation must be carried out in accordance with the prevailing regulations, the codes of practice and the recommendations in these instructions.

Installing the boiler in new installations (installations less than 6 months old)

4 Clean the installation with a universal cleaner to eliminate debris

from the appliance (copper, hemp, flux).

4 Thoroughly flush the installation until the water runs clear and

shows no impurities.

Installing the boiler in existing installations

4 Remove sludge from the installation.

15/06/12 - 300022159-001-01

T001625-A

T001633-B

MCA 25/28 BIC

4. Installation

4 Flush the installation. 4 Clean the installation with a universal cleaner to eliminate debris

from the appliance (copper, hemp, flux).

4 Thoroughly flush the installation until the water runs clear and

shows no impurities.

4.6.2. Connection of the heating circuit

{ z

Connection by internal brazing ∅ 22 mm

1. Connect the heating water outlet pipe to the heating flow connection.

2. Connect the heating water return pipe to the heating return connection.

4 The boiler is factory fitted with a safety valve mounted

on the left hydroblock.

CAUTION

4 The heating pipe must be mounted in accordance

with prevailing provisions.

15/06/12 - 300022159-001-01

4.6.3. Connection of the water circuit for

domestic use

1. Connect the cold water inlet pipe to the domestic cold water connection.

2. Connect the domestic hot water outlet pipe to the domestic hot water connection.

T001626-B

4. Installation MCA 25/28 BIC

x y

Connection by internal brazing ∅ 16 mm

CAUTION

4 The domestic water pipes must be connected in

accordance with prevailing provisions.

4 If using synthetic pipes, follow the manufacturer's

(connection) instructions.

4.6.4. Connecting the expansion vessel

The boiler is fitted as standard with an 12-litre expansion vessel.

If the water volume is greater than 150 litres or the static height of the system exceeds 5 metres, an additional expansion vessel must be fitted. Refer to the table below to determine the expansion vessel required for the installation.

Conditions of validity of the table:

4 3-bar safety valve 4 Average water temperature: 70 °C

Supply temperature: 80 °C Return temperature: 60 °C

4 The filling pressure in the system is lower than or equal to the initial

pressure in the expansion vessel

Initial pressure of the expansion vessel

0.5 bar 4,8 6,0 7,2 8,4 9,6 12,0 14,4 Volume of the installation x 0,048 1 bar 8,0 10,0

1.5 bar 13,3 16,6 20,0 23,3 26,6 33,3 39,9 Volume of the installation x 0,133

(1) Factory configuration

Volume of the expansion vessel depending on the volume of the installation (in litres)

100 125 150 175 200 250 300 > 300

(1)

12,0

14,0 16,0 20,0 24,0 Volume of the installation x 0,080

It is possible to fit the boiler with an expansion vessel for DHW (package option HG77) under the integrated expansion vessel for heating.

15/06/12 - 300022159-001-01

T001873-C

T001621-A

MCA 25/28 BIC 4. Installation

4.6.5. Connecting the condensate discharge pipe

1. Mount a standard drainage pipe, Ø 32 mm or more, leading to the mains drainage system.

2. Mount the flow collector.

3. Into this, insert the condensate collector hose coming from the siphon j and the safety valve ê.

4. Into this, insert the discharge hose from the disconnector.

5. Mount a trap or a siphon in the discharge pipe.

CAUTION

Do not make a fixed connection owing to maintenance work on the siphon.

4 Do not plug the condensate discharge pipe. 4 Set the discharge pipe at a gradient of at least 30 mm

per metre, maximum horizontal length 5 metres.

4 Do not drain condensation water into a roof gutter at

any time.

4 Connect the condensate discharge pipe in

accordance with prevailing standards.

4.7 Gas connection

The diameters of the pipes must be defined in accordance with the standards in force in your country.

Connection by internal brazing ∅ 18 mm

1. Connect the gas inlet pipe.

WARNING

4 Close the main gas valve before starting work on the

gas pipes.

4 Before mounting, check that the gas meter has

sufficient capacity. To do this, you should keep in mind the consumption of all domestic appliances.

4 If the gas meter has too low a capacity, inform the

energy supply company.

CAUTION

4 Ensure that there is no dust in the gas pipe. Blow into

the pipe or shake it before mounting.

4 We recommend installing a gas filter on the gas pipe

to prevent clogging of the gas valve unit.

4 Connect the gas pipe in accordance with prevailing

standards and regulations.

15/06/12 - 300022159-001-01

6 8

33(x)

43(x)

83(x)

43(x)

13(x)

83(x)

33(x)

23P

93(x)

C002339-C

4. Installation MCA 25/28 BIC

4.8 Flue gas system connections

4.8.1. Classification

Configuration B

Connection to a collective pipe via a concentric pipe (combustive air taken from the boiler room) All of the pressurised parts of the appliance are surrounded by air.

Configuration B23 - B

23P

Connection to a chimney using a connection kit (combustive air taken from the boiler room)

Configuration C

13(x)

Air/flue gas connection by means of concentric pipes to a horizontal terminal (so-called forced flue)

Configuration C

33(x)

Air/flue gas connection by means of concentric pipes to a vertical terminal (roof outlet)

Configuration C

43(x)

Air/flue gas connection to a collective conduit for watertight boilers (3CE P system)

Configuration C

Air and flue gas connection separated by means of a bi-

flow adapter and single pipes (combustive air taken from outside)

Configuration C

83(x)

Flue gas connection to a collective conduit for sealed boilers. The air supply is individual via a terminal coming from outside the building.

15/06/12 - 300022159-001-01

MCA 25/28 BIC 4. Installation

Configuration C

93(x)

Air/flue gas connection by concentric pipes in the boiler room and single pipes in the chimney (combustive air in counter current in the chimney)

Configuration C

93(x)

Air/flue gas connection by concentric pipes in the boiler room and single flex in the chimney (combustive air in counter current in the chimney)

WARNING

4 Only factory components are authorised for

connecting the boiler and the terminal.

4 The clear section must comply with the

standard.

4 The chimney must be swept before the

installation of the evacuation conduit.

4.8.2. Lengths of the air/flue gas pipes

For configurations B23 and C93, the lengths given in the table are valid for horizontal conduits with a maximum length of 1 metre. For each additional metre of horizontal conduit, subtract 1.2 m from the vertical length Lmax

Type of air/flue gas connection Diameter Maximum length in

metres

MCA 25/28 BIC

B B

Collective conduit To determine the dimensions of such a system, refer to the supplier of the

Chimney (rigid or flexible duct in

chimney, combustive air taken from the

23P

premises) Concentric pipes connected to a

13(x)

horizontal terminal

Concentric pipes connected to a vertical

33(x)

terminal

Collective conduit for sealed boiler (3

43(x)

CEP) Bi-flow adapter and separate single air/

flue gas ducts (combustive air taken from outside)

Collective conduit for sealed boiler To determine the dimensions of such a system, refer to the supplier of the

83(x)

Concentric pipes in the boiler room

93(x)

Single conduits in the chimney (combustive air in counter-current)

Concentric pipes in the boiler room Flexible single conduit in the chimney

collective conduit. PPS 80 mm (Rigid duct) 40.0

80 mm (Flexible duct) 40.0

Alu or PPS 60/100 mm 4.2

80/125 mm 20.0

Alu or PPS 60/100 mm 5.5

80/125 mm 20.0

To determine the size of such a system, consult the supplier of the 3 CEP conduit.

Alu 60/100 mm

2 x 80 mm

collective conduit. Alu or PPS 60/100 mm

60 mm (Rigid duct)

PPS 60/100 mm

80 mm (Flexible duct)

40.0

9.0

20.0

15/06/12 - 300022159-001-01

4. Installation

MCA 25/28 BIC

WARNING

Maximum length = lengths of the straight air/flue gas ducts + equivalent lengths of other components

The max length in the flue gas pipe (configurations C93, B

23P

) of the

elbow bracket at the outlet must not exceed:

4 30 m for rigid PPS 4 25 m for flexible PPS

If longer lengths are used, holding clamps must be added per sections of 25 or 30 metres.

For the list of flue gas system accessories and the equivalent lengths, refer to the current price list.

4.8.3. Additional Directives

4 Please refer to the manufacturer's instructions for the material in

question when installing the flue gas discharge and air supply materials. If the flue gas discharge and air supply materials are not installed according to the instructions (e.g. they are not leakproof, not clamped in place etc.), this may cause hazardous situations and/or result in bodily injury. After assembly, check at least all flue gas and air–carrying parts for tightness.

4 Connection of the combustion gas exhaust directly to the buildings

brick chimneys or flues is forbidden for condensation reasons.

4 Always clean the ducts thoroughly in cases where lining pipes are

used and/or a connection of the air-supply.

4 It must be possible to inspect the flue or chimney. 4 . 4 For long, aluminium, combustion-gas exhaust pipes it is initially

necessary to consider the relatively high quantity of corrosive products which are brought together with the condensate from the exhaust pipe. The siphon on the equipment requires regular cleaning or, preferably, an additional condensate collector can be installed above the equipment.

4 The combusted gas discharge pipe must be sufficiently inclined

towards the boiler (at least 50 mm per metre) and an adequate condensate collection tank and discharge system constructed (at least 1 m before the boiler opening). The elbows fitted must be at more than 90° to guarantee the provision of an adequate gradient and tightness on the lip rings.

15/06/12 - 300022159-001-01

8800N001-C

8800N002-C

MCA 25/28 BIC

4.9 Installing the outside sensor

4.9.1. Choice of the location

It is important to select a place that allows the sensor to measure the outside conditions correctly and effectively.

Advised positions:

4 on one face of the area to be heated, on the north if possible 4 half way up the wall in the room to be heated 4 under the influence of meteorological variations 4 protected from direct sunlight 4 easy to access

4. Installation

Recommended position

Possible position

Inhabited height controlled by the sensor

Inhabited area controlled by the sensor

Positions to be avoided:

4 masked by a building element (balcony, roof, etc.) 4 close to a disruptive heat source (sun, chimney, ventilation grid,

etc.)

15/06/12 - 300022159-001-01

4.9.2. Connecting the outside sensor

Mount the sensor using the screws and dowels provided.

8800N003-C

4. Installation MCA 25/28 BIC

4.10 Electrical connections

A Z

Inserts

Ø4 wood screw

¼ For the connection of the outside temperature sensor, refer to the chapter "Electrical Connections".

4.10.1. Control unit

The boiler is fully pre-wired. The mains supply is made via the cable C connected to the mains. All other external connections can be made to the connection connectors (low voltage). The main characteristics of the control unit are described in the table below.

Power supply voltage 230 VAC/50Hz Rating of the main fuse F1 (230 VAC) 6.3 AT Fuse rating F2 (230 VAC) 2 AT Fan-DC 27 VDC

CAUTION

Keep to the polarity shown on the terminals: phase (L), neutral (N) and earth *.

CAUTION

The following components of the appliance are at a voltage of 230 V:

4 Boiler pump (Heating circuit). 4 Boiler pump (DHW circuit). 4 Combined venturi and gas valve unit. 4 3-way valve. 4 The majority of components in the control panel and

the terminal box.

4 Power supply cable.

15/06/12 - 300022159-001-01

+ 94 hidden pages

DeDietrich Innovens MCA 25/28 BIC, Innovens MCA 35 Installation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual