DeDietrich Innovens MCA 15, Innovens MCA 25/28 MI, Innovens MCA 25 Installation And Service Manual
Innovens
Wall-hung gas condensing boilers
MCA 15 - MCA 25
MCA 25/28 MI
EN
Installation and
Service Manual
300022146-001-B
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: 90/396/EEG toegepaste normen:
EEC-Directive: 90/396/EEC tested and examined to the following norms:
EG-Richtlinie: 90/396/EWG verwendete Normen, normes appliquées:
CEE-Directive: 90/396/CEE 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) competion
einschließlich (falls vorhanden) Vervollständigung, y compris (le cas échéant) complément
Apeldoorn, decembre 2009
W.F. Tijhuis
Approval manager
703/2009/12/128
C002860-A
MCA 15 - MCA 25 MCA 25/28 MI
Declaration of conformity
The appliance complies with the standard model described in
declaration of compliance [. It is manufactured and distributed
pursuant to the requirements of european directives.
The original of the declaration of compliance is available from the
manufacturer.
Contents
1 Introduction ................................................................................................6
1.1 Used symbols .......................................................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 Gas 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 characteristics ...................................13
3.4.1 Sensor characteristics ...........................................14
4 Installation ................................................................................................16
4.1 Regulations governing installation ...................16
4.2 Package list .........................................................16
4.2.1 Standard delivery ..................................................16
4.2.2 Accessories ...........................................................16
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4.3 Choice of the location ........................................17
4.3.1 Data plate ..............................................................17
4.3.2 Location of the appliance ......................................18
4.3.3 Ventilation .............................................................18
4.3.4 Main dimensions ...................................................19
1
MCA 15 - MCA 25 MCA 25/28 MI
Contents
4.4 Installing the mounting frame ...........................20
4.5 Positioning the boiler .........................................21
4.6 Hydraulic connections .......................................22
4.6.1 Flushing the system ..............................................22
4.6.2 Connection of the heating circuit ...........................22
4.6.3 Hydraulic connection of the water circuit for domestic
use ........................................................................23
4.6.4 Connecting the expansion vessel .........................23
4.6.5 Connecting the condensate discharge pipe ..........24
4.6.6 Filling the siphon ...................................................24
4.7 Gas connection ...................................................25
4.8 Flue gas system connections ............................26
4.8.1 Classification .........................................................26
4.8.2 Lengths of the air/flue gas pipes ...........................27
4.9 Installing the outside sensor .............................28
4.9.1 Choice of the location ............................................28
4.9.2 Installing the outside sensor ..................................28
4.10 Electrical connections ........................................29
4.10.1 Control unit ............................................................29
4.10.2 Recommendations ................................................30
4.10.3 Position of the PCBs .............................................31
4.10.4 Accessing the connection terminal blocks ............32
4.10.5 Connecting a direct heating circuit ........................34
4.10.6 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................35
4.10.7 Connecting two circuits and a domestic hot water tank
before the mixing tank ...........................................37
4.10.8 Connecting two circuits and a domestic hot water tank
after the mixing tank ..............................................39
4.10.9 Hot water storage tank connection ........................41
4.10.10 Pool connection .....................................................46
4.10.11 Connecting a mixed tank .......................................48
4.10.12 Connecting the options .........................................49
4.10.13 Connection in cascade ..........................................50
4.11 Electrical diagram ...............................................53
4.12 Filling the system ...............................................54
4.12.1 Water treatment ....................................................54
4.12.2 Filling the system ..................................................56
5 Start-up ......................................................................................................57
5.1 Control panel .......................................................57
5.1.1 Description of the keys ..........................................57
5.1.2 Description of the display ......................................58
5.1.3 Access to the various browsing levels ..................60
5.1.4 Browsing in the menus ..........................................62
5.2 Check points before commissioning ................63
5.2.1 Preparing the boiler for commissioning .................63
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2
5.2.2 Gas circuit .............................................................64
5.2.3 Hydraulic circuit .....................................................64
5.2.4 Electrical connections ...........................................64
5.3 Putting the appliance into operation ................65
5.4 Gas settings ........................................................66
5.4.1 Adapting to another gas type ................................66
5.4.2 Setting the air/gas ratio (Full load) ........................67
5.4.3 Setting the air/gas ratio (Part load) ......................69
5.4.4 Basic setting for the gas/air ratio ...........................71
5.5 Checks and adjustments after
commissioning ...................................................71
5.5.1 Displaying the parameters in extended
mode .....................................................................71
5.5.2 Setting the parameters specific to the
installation .............................................................72
5.5.3 Naming the circuits and generators ......................75
5.5.4 Setting the heating curve ......................................76
5.5.5 Finalizing work ......................................................78
5.6 Reading out measured values ...........................78
5.7 Changing the settings ........................................79
5.7.1 Language selection ...............................................80
5.7.2 Calibrating the sensors .........................................80
5.7.3 "Professional" settings ..........................................82
5.7.4 Configuring the network ........................................88
5.7.5 Returning to the factory settings ...........................96
6 Switching off the appliance .....................................................................97
6.1 Installation shutdown .........................................97
6.2 Frost protection ..................................................97
7 Checking and maintenance .....................................................................98
7.1 General instructions ...........................................98
7.2 Chimney sweep instructions .............................98
7.3 Customising maintenance .................................99
7.3.1 Maintenance message ..........................................99
7.3.2 Installer's contact details .....................................100
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7.4 Standard inspection and maintenance
operations .........................................................100
7.4.1 Checking the hydraulic pressure .........................101
7.4.2 Checking the opened expansion vessel ..............101
7.4.3 Checking the ionisation current ...........................101
7.4.4 Checking the transfer capacity ............................101
7.4.5 Checking the tightness of the combusted gases
evacuation and air inlet connections ...................101
7.4.6 Checking combustion ..........................................102
7.4.7 Checking the automatic air vent ..........................103
3
MCA 15 - MCA 25 MCA 25/28 MI
7.4.8 Checking the safety valve ...................................104
7.4.9 Checking the siphon ............................................104
7.4.10 Checking the burner and cleaning the heat
exchanger ...........................................................105
Contents
7.5 Specific maintenance operations ....................106
7.5.1 Replacing the ionisation/ignition electrode ..........106
7.5.2 Cleaning the plate exchanger (domestic hot water
end) and the water filter cartridge .......................106
7.5.3 Replacing the 3-way valve ..................................109
7.5.4 Replacing the non-return valve ...........................110
7.5.5 Assembling the boiler ..........................................111
8 Troubleshooting .....................................................................................112
8.1 Messages (Code type Bxx or Mxx) ..................112
8.2 Message history ................................................114
8.3 Faults (Code type Lxx or Dxx) .........................115
8.3.1 Deletion of sensors from the memory in the
PCB .....................................................................123
8.3.2 Deleting the IOBL 3WV modules from the memory in
the PCB ..............................................................123
8.4 Failure history ...................................................124
8.5 Parameter and input/output check (mode
tests) ..................................................................125
9 Spare parts ..............................................................................................129
9.1 General ..............................................................129
9.2 Spare parts ........................................................129
9.2.1 Casing .................................................................130
9.2.2 Heat exchanger and burner ................................131
9.2.3 Fan ......................................................................132
9.2.4 Control panel .......................................................133
9.2.5 Connecting pipes (MCA 15 - MCA 25) ................134
9.2.6 Connecting pipes (MCA 25/28 MI) ......................135
9.2.7 Spare parts list ....................................................136
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5
1. Introduction
1 Introduction
1.1 Used symbols
MCA 15 - MCA 25 MCA 25/28 MI
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 Interscenario switch: Home automation switch that can be used
to centralise and control several scenarios
4 Hi: Lower heating value LHV
4 Hs: Higher heating value HHV
4 IOBL: Carrier current home automation bus
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 - Diematic iSystem control panel
PCB
4 SU: Safety Unit - Safety PCB
4 3WV: 3-way valve
6
29/04/2010 - 300022146-001-B
MCA 15 - MCA 25 MCA 25/28 MI 1. Introduction
1.3 General
1.3.1. Manufacturer's liability
Our products are manufactured in compliance with the requirements
of the various european applicable 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 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
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CE identification no
NOx classification
Type of connection Chimney: B23 , B
PIN 0063BT3444
5 (EN 297 pr A3, EN 656)
Flue gas outlet: C13 , C33, C43, C53, C63, C83 , C
33
93
7
1. Introduction
MCA 15 - MCA 25 MCA 25/28 MI
1.4.2. Gas categories
Gas category Gas type Connection pressure (mbar)
II
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 66.
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 Domestic hot water mode (Only on models with domestic hot water
production)
4 Water tightness
4 Gas tightness
4 Parameter settings
8
29/04/2010 - 300022146-001-B
MCA 15 - MCA 25 MCA 25/28 MI
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. Isolate 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
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The boiler must be installed in a frost-free environment.
Keep this document close to the place where the boiler is
installed.
Casing components
9
2. Safety instructions and recommendations MCA 15 - MCA 25 MCA 25/28 MI
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 boiler. 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.
10
29/04/2010 - 300022146-001-B
T001867-C
2
15
14
13
16
17
18
19
20
21
3
4
5
6
7
8
9
10
11
12
1 22
MCA 15 - MCA 25 MCA 25/28 MI 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 MCA 15 - MCA 25: Heating only (Possibility of producing domestic
hot water via an independent tank which has been installed
separately).
4 MCA 25/28 MI: Heating and micro-storage domestic hot water
production.
3.2 Main parts
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Flue gas discharge pipe
Casing/air box
Outlet for measuring combustion gases
Mixer pipe
Heating flow hose
Áir intake silencer
Box for the control PCBs
Combined venturi and gas valve unit
Flow end hydrobloc
Safety valve outlet pipe
Siphon
Control panel
Shunt pump
Return end hydrobloc
Plate heat exchanger (DHW circuit) (Only on models with
domestic hot water production)
Inverter valve
Condensate receiver tank
Fan
Heat exchanger (Heating circuit)
29/04/2010 - 300022146-001-B
11
T001868-B
1
2
3
10
9
8
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
0
100
200
300
400
500
700
H (mbar)
600
3. Technical description
MCA 15 - MCA 25 MCA 25/28 MI
3.3 Operating principle
20
21
22
Expansion vessel
Ignition/ionization electrode
Air intake
3.3.1. Skeleton Diagrams
1
2
3
4
5
6
7
Heat exchanger (Heating circuit)
Hydrobloc
Plate heat exchanger (DHW circuit) (Only on models with
domestic hot water production)
Heating flow
Domestic hot water outlet
Domestic cold water inlet
Heating return
8
9
10
Inverter valve
Shunt pump (Heating circuit)
Expansion vessel
3.3.2. Shunt pump
H
Q
The boiler is fitted with a modulating pump which is regulated by the
control panel as a fuction of ΔT.
The graph shows the manometric height at various outputs. 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.
Manometric height central heating circuit
Water flow
12
¼ See chapter: ""Professional" settings", page 82.
29/04/2010 - 300022146-001-B
T001978-A
0
100
200
300
400
500
600
700
0 500
1037437
15001000 2000 2500
∆p [mbar]
Q [l/h]
623 830
∆T = 20K
10 kW
15 kW
20 kW
25 kW
MCA 15 - MCA 25 MCA 25/28 MI 3. Technical description
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.
Δp
Q
Pressure drop
Water flow (max = 1680 l/h)
3.4 Technical characteristics
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)
minimum-maximum kW 3,0 - 14,5 5,0 - 24,1 5,0 - 24,1
Factory setting kW 14,5 24,1 19,4
minimum-maximum kW 3,4 - 15,8 5,6 - 25,5 5,6 - 25,5
Factory setting kW 15,8 25,5 20,5
minimum-maximum kW - - 5,0 - 28,6
Factory setting kW - - 28,6
minimum-maximum kW 3,1 - 15,0 5,2 - 25,0 5,2 - 25,0
Factory setting kW 15,0 25,0 20,1
minimum-maximum kW 3,4 - 16,7 5,8 - 27,8 5,8 - 27,8
Factory setting kW 16,7 27,8 22,3
minimum-maximum kW - - 5,2 - 28,0
Factory setting kW - - 28,0
minimum-maximum kW - - 5,8 - 31,1
Factory setting kW - - 31,1
Heating efficiency under full load (Hi) (80/60 °C) - % 96,5 96,3 96,3
Heating efficiency under full load (Hi) (50/30 °C) - % 105,3 102,0 102,0
Heating efficiency under partial load (Hi) (Return
- % 94,9 96,1 96,1
temperature 60°C)
Heating efficiency under partial load (EN 92/42)
- % 108,5 108,0 108,0
(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 or (n =1)
m3/h
m3/h
m3/h
mg/kWh 33 38 38
Mass flue gas flow rate minimum-maximum kg/h 5,3 - 25,2 8,9 - 42,1 8,9 - 47,1
Flue gas temperature minimum-maximum °C 30 - 65 30 - 80 30 - 85
(1) Front panel removed
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MCA 15 MCA 25 MCA 25/28 MI
Modulating, Start/Stop, 0 - 10 V
0,33 - 1,59 0,55 - 2,65 0,55 - 2,96
0,38 - 1,85 0,64 - 3,08 0,64 - 3,45
0,13 - 0,61 0,21 - 1,02 0,21 - 1,15
13
3. Technical description MCA 15 - MCA 25 MCA 25/28 MI
Boiler type
Maximum counter pressure
Characteristics of the heating circuit
Water content
Water operating pressure minimum kPa (bar) 80 (0,8) 80 (0,8) 80 (0,8)
Water operating pressure (PMS) maximum kPa (bar) 300 (3,0) 300 (3,0) 300 (3,0)
Water temperature maximum °C 110 110 110
Operating temperature maximum °C 90 90 90
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 (40 °C)
Domestic water resistance
Flow rate threshold minimum l/min - - 1,2
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 25 25 25
Power consumption - Standby maximum W 4 4 4
Electrical protection index
Other characteristics
Weight (empty)
Acoustic level at 1 meter at high speed
(1) Front panel removed
maximum W 101 116 124
Factory setting W 63 76 76
Pa 80 120 130
l 1,7 1,7 1,7
mbar 545 295 295
l/min - - 8,2
l/min - - 13,7
mbar - - 490
l - - 0,33
VAC 230 230 230
Total kg 43 43 44
Mounting
(1)
kg 36 36 37
dBA 35 42 44
MCA 15 MCA 25 MCA 25/28 MI
IPX4D IPX4D IPX4D
3.4.1. Sensor characteristics
Outside sensor
-20 °C
-16 °C
-12 °C
-8 °C
-4 °C
0 °C
4 °C
8 °C
12 °C
16 °C
20 °C
24 °C
2392 ¨
2088 ¨
1811 ¨
1562 ¨
1342 ¨
1149 ¨
984 ¨
842 ¨
720 ¨
616 ¨
528 ¨
454 ¨
Outlet sensor circuit B+C
Domestic hot water sensor
0 °C
10 °C
20 °C
25 °C
30 °C
40 °C
50 °C
60 °C
70 °C
80 °C
90 °C
32014 ¨
19691 ¨
12474 ¨
10000 ¨
8080 ¨
5372 ¨
3661 ¨
2535 ¨
1794 ¨
1290 ¨
941 ¨
Boiler sensor
Return sensor
-20 °C
-10 °C
0 °C
10 °C
20 °C
25 °C
30 °C
40 °C
50 °C
60 °C
70 °C
80 °C
98932 ¨
58879 ¨
36129 ¨
22804 ¨
14773 ¨
12000 ¨
9804 ¨
6652 ¨
4607 ¨
3252 ¨
2337 ¨
1707 ¨
14
29/04/2010 - 300022146-001-B
MCA 15 - MCA 25 MCA 25/28 MI 3. Technical description
Outside sensor Outlet sensor circuit B+C
Domestic hot water sensor
Boiler sensor
Return sensor
90 °C
100 °C
110 °C
1266 ¨
952 ¨
726 ¨
29/04/2010 - 300022146-001-B
15
4. Installation MCA 15 - MCA 25 MCA 25/28 MI
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
DHW tank BS60 EE54 Radio remote control AD253
Kit for connection between MCA and BS60 EA138 Interactive remote control AD254
Control system options
16
29/04/2010 - 300022146-001-B
T001539-B
MCA 15 - MCA 25 MCA 25/28 MI 4. Installation
Boiler options Control system options
Description package Description package
DHW tank SR130 EE22 Room sensor FM52
Kit for connection between MCA and SR130 EA137
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.
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17
T001583-A
450
min.1000
450
min.
250
min.
250
690
T001584-A
min. 550
min.550
min. 250
50 (2)
min. 250
100
min. (1)
4. Installation
MCA 15 - MCA 25 MCA 25/28 MI
4.3.2. Location of the appliance
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.
4.3.3. Ventilation
(1)
(2)
If the boiler is installed in a closed box, 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
Distance between the front of the appliance and the
internal wall of the cupboard.
Distance to allow on either side of the appliance.
2
18
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T001116-B
67
195
265
132
199
266
331
690
450
450
225
140
140
150
257,5
MCA 15 - MCA 25 MCA 25/28 MI 4. Installation
4.3.4. Main dimensions
i
h
ê
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"
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y
{
Domestic hot water outlet G½"
Heating circuit flow G¾"
19
T001869-A
1
2
3
4
4. Installation MCA 15 - MCA 25 MCA 25/28 MI
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.
20
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T001870-A
T001627-A
T001872-A
MCA 15 - MCA 25 MCA 25/28 MI 4. Installation
4.5 Positioning the boiler
1. Remove the protective caps from all of the hydraulic inlets and
outlets on the boiler.
2. Fit a fibre gasket to each joint on the valve plate.
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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.
21
T001625-A
4. Installation MCA 15 - MCA 25 MCA 25/28 MI
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
n
less than 6 months old)
4 Clean the installation with a universal cleaner to eliminate debris
from the appliance (copper, flaxen thread, flux).
4 Thoroughly flush the installation until the water runs clear and
shows no impurities.
Installing the boiler in existing installations
n
4 Remove sludge from the installation.
4 Flush the installation.
4 Clean the installation with a universal cleaner to eliminate debris
from the appliance (copper, flaxen thread, flux).
4 Thoroughly flush the installation until the water runs clear and
shows no impurities.
4.6.2. Connection of the heating circuit
1. Connect the heating water outlet pipe to the heating flow
connection.
2. Connect the heating water inlet pipe to the heating return
connection.
{
z
Connection by internal brazing ∅ 22 mm
Connection by internal brazing ∅ 22 mm
22
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T001633-B
T001626-A
MCA 15 - MCA 25 MCA 25/28 MI
4. Installation
4 The boiler is factory fitted with a safety valve mounted
on the left hydrobloc.
CAUTION
4 The heating pipe must be mounted in accordance
with prevailing provisions.
4.6.3. Hydraulic 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.
x
y
Connection by internal brazing ∅ 16 mm
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 opened expansion
vessel required for the installation.
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Conditions of validity of the table:
4 3-bar safety valve
4 Average water temperature: 70 °C
Flow 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 opened expansion vessel
23
T001873-C
T001523-B
4. Installation MCA 15 - MCA 25 MCA 25/28 MI
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 opened 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
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.
4.6.6. Filling the siphon
1. Remove the siphon.
2. Fill the siphon with water. This must be filled up to the level
markers.
3. Re-assemble the siphon.
CAUTION
24
4 Fill the water siphon before starting the boiler to avoid
combustion products escaping from the boiler.
4 Mount the vent hose above the siphon.
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T001621-A
MCA 15 - MCA 25 MCA 25/28 MI 4. Installation
4.7 Gas connection
The diameters of the pipes must be defined in accordance
with the standards in force in your country.
g
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 bear 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.
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25
4
2
6
2
2
1
5
3
12
12
12
L1
L1
Lmax = L1+L2
Lmax =
L
1+L2
Lmax
Lmax
Lmax
Lmax
max
max
max
1m
1m
1m
Lmax
L2
L2
Lmax
Lmax
C
33
C
93
B
23
C
93
C
33
C
33
C
13
C
53
C
43
C
43
C
43
T000275-D
4. Installation MCA 15 - MCA 25 MCA 25/28 MI
4.8 Flue gas system connections
4.8.1. Classification
26
1
Configuration C
13
Air/flue gas connection by means of concentric pipes to a
horizontal terminal (so-called forced flue)
2
Configuration C
33
Air/flue gas connection by means of concentric pipes to a
vertical terminal (roof outlet)
3
Configuration C
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)
93
29/04/2010 - 300022146-001-B
MCA 15 - MCA 25 MCA 25/28 MI
4. Installation
4
5
6
12
Configuration C
93
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.
Configuration C
53
Air and flue gas connection separated by means of a biflow adapter and single pipes (combustive air taken from
outside)
Configuration B
23
Connection to a chimney using a connection kit
(combustive air taken from the boiler room)
Configuration C
43
Air/flue gas connection to a collective conduit for
watertight boilers (3CE system)
4.8.2. Lengths of the air/flue gas pipes
Type of air/flue gas connection
C13Concentric pipes connected to a horizontal terminal Alu or PPS 60/100 mm 12.0 3.5 4.2
C33Concentric pipes connected to a vertical terminal Alu or PPS 60/100 mm 13.0 4.9 5.5
C93Concentric pipes in the boiler room
Single conduits in the chimney (combustive air in
counter-current)
Concentric pipes in the boiler room
Flexible single conduit in the chimney
C53Bi-flow adapter and separate single air/flue gas ducts
(combustive air taken from outside)
B23Chimney (rigid or flexible duct in furnace flue,
combustive air taken from the premises)
Alu or PPS 60/100 mm
PPS 60/100 mm
Alu 60/100 mm
PPS 80 mm (Rigid duct) 50.0 50.0 50.0
Diameter Maximum length in metres
MCA 15 MCA 25 MCA 25/28
MI
80/125 mm 12.3 23.0 25.7
80/125 mm 10.7 21.0 23.6
15.0 8.1 9.1
60 mm (Rigid duct)
9.9 20.0 22.7
80 mm (Flexible
duct)
50.0 50.0 50.0
2 x 80 mm
80 mm (Flexible
duct)
45.0 45.0 45.0
29/04/2010 - 300022146-001-B
WARNING
Maximum length = lengths of the straight air/flue gas ducts
+ equivalent lengths of other components
For the list of flue gas system accessories and the equivalent lengths,
refer to the current price list.
27
8800N001-C
8800N002-C
4. Installation
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
MCA 15 - MCA 25 MCA 25/28 MI
A
B
H
Z
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.)
28
4.9.2. Installing the outside sensor
Mount the sensor using the screws and dowels provided.
29/04/2010 - 300022146-001-B
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