DeDietrich MCA 45 - 65 - 90 - 115, Innovens Pro MCA 45, Innovens Pro MCA 65, Innovens Pro MCA 90, Innovens Pro MCA 115 Installation And Service Manual
Ireland
Innovens Pro
EN
Wall-hung gas condensing boilers
MCA 45 - 65 - 90 - 115
Installation and
Service Manual
300024755-001-A
EG declaration of conformity
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.
R000040-A
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
1.3.3 User's liability ..........................................................7
1.4 Homologations ......................................................8
1.4.1 Certifications ...........................................................8
1.4.2 Equipment categories .............................................8
1.4.3 Additional Directives ................................................8
1.4.4 Factory test .............................................................9
2 Safety instructions and recommendations ............................................10
2.1 Safety instructions .............................................10
2.2 Recommendations ..............................................10
3 Technical description ..............................................................................12
3.1 General description ............................................12
3.2 Main parts ............................................................12
3.3 Operating principle .............................................12
3.3.1 Shunt pump ...........................................................12
3.3.2 System in cascade ................................................13
3.3.3 Calorifier connection .............................................13
3.3.4 Water flow rate ......................................................13
3.4 Technical characteristics ...................................13
3.4.1 Sensor characteristics ...........................................15
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
4.3 Choice of the location ........................................18
4.3.1 Data plate ..............................................................18
4.3.2 Location of the appliance ......................................18
4.3.3 Ventilation .............................................................19
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4.3.4 Main dimensions ...................................................20
4.4 Positioning the boiler .........................................21
4.5 Hydraulic connections .......................................21
4.5.1
Flushing the system ..............................................21
4.5.2 Connection of the heating circuit ...........................22
4.5.3 Connecting the expansion vessel .........................23
4.5.4 Connecting the condensate discharge pipe ..........24
4.6 Gas connection ...................................................24
4.7 Flue gas system connections ............................25
4.7.1 Classification .........................................................25
4.7.2 Lengths of the air/flue gas pipes ...........................26
4.8 Installing the outside sensor .............................27
4.8.1 Choice of the location ............................................27
4.8.2 Installing the outside sensor ..................................28
4.9 Electrical connections ........................................28
4.9.1 Control unit ............................................................28
4.9.2 Recommendations ................................................29
4.9.3 Fitting and connecting the control panel ...............30
4.9.4 Position of the PCBs .............................................30
4.9.5 Accessing the connection terminal blocks ............31
4.9.6 Connecting the pump ............................................32
4.9.7 Connecting a direct heating circuit ........................34
4.9.8 Connecting a direct heating circuit and a domestic hot
water tank ..............................................................35
4.9.9 Connecting two circuits and a domestic hot water tank
after the mixing tank ..............................................36
4.9.10 Hot water storage tank connection ........................38
4.9.11 Pool connection .....................................................44
4.9.12 Connecting a mixed tank .......................................46
4.9.13 Connecting the options .........................................47
4.9.14 Connection in cascade ..........................................49
4.10 Electrical diagram ...............................................51
4.11 Filling the system ...............................................52
4.11.1 Water treatment ....................................................52
4.11.2 Filling the siphon ...................................................53
4.11.3 Filling the system ..................................................53
5 Start-up - DIEMATIC iSystem ..................................................................54
5.1 Control panel .......................................................54
5.1.1 Description of the keys ..........................................54
5.1.2 Description of the display ......................................55
5.1.3 Access to the various browsing levels ..................57
5.1.4 Browsing in the menus ..........................................58
5.2 Check points before commissioning ................59
5.2.1 Preparing the boiler for commissioning .................59
5.2.2 Gas circuit .............................................................60
5.2.3 Hydraulic circuit .....................................................60
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5.2.4 Electrical connections ...........................................60
5.3 Putting the appliance into operation ................60
5.4 Gas settings ........................................................62
5.4.1
Adapting to another gas type ................................62
5.4.2 Setting the air/gas ratio (Full load) ........................62
5.4.3 Setting the air/gas ratio (Part load) ......................64
5.5 Checks and adjustments after
commissioning ...................................................65
5.5.1 Displaying the parameters in extended
mode .....................................................................65
5.5.2 Setting the parameters specific to the
installation .............................................................66
5.5.3 Naming the circuits and generators ......................68
5.5.4 Setting the heating curve ......................................69
5.5.5 Finalizing work ......................................................71
5.6 Reading out measured values ...........................72
5.7 Changing the settings ........................................73
5.7.1 Language selection ...............................................73
5.7.2 Calibrating the sensors .........................................73
5.7.3 "Professional" settings ..........................................75
5.7.4 Configuring the network ........................................81
5.7.5 Return to the factory settings ................................87
6 Start-up - IniControl .................................................................................88
6.1 Control panel .......................................................88
6.1.1 Description of the keys ..........................................88
6.1.2 Description of the display ......................................89
6.2 Check points before commissioning ................90
6.2.1 Preparing the boiler for commissioning .................90
6.2.2 Gas circuit .............................................................91
6.2.3 Hydraulic circuit .....................................................91
6.2.4 Electrical connections ...........................................91
6.3 Putting the appliance into operation ................92
6.4 Gas settings ........................................................93
6.4.1 Adapting to another gas type ................................93
6.4.2 Setting the air/gas ratio (Full load) ........................93
6.4.3 Setting the air/gas ratio (Part load) ......................94
6.5 Checks and adjustments after
commissioning ...................................................95
6.5.1 Setting the heating curve ......................................95
6.5.2 Finalizing work ......................................................96
6.6 Reading out measured values ...........................97
6.6.1 Reading out measured values ..............................97
6.6.2 Readout from the hour counter and percentage of
successful starts ....................................................99
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6.6.3 Status and sub-status ...........................................99
6.7 Changing the settings ......................................100
6.7.1
Description of the parameters .............................100
6.7.2 Modification of the installer-level parameters ......103
6.7.3 Setting the maximum heat input for central heating
operation .............................................................104
6.7.4 Return to the factory settings "Reset Param" ......105
6.7.5 Carrying out an auto-detect .................................105
7 Switching off the appliance ...................................................................106
7.1 Installation shutdown .......................................106
7.2 Frost protection ................................................106
8 Checking and maintenance ...................................................................107
8.1 General instructions .........................................107
8.2 Chimney sweep instructions ...........................107
8.2.1 Control panel DIEMATIC iSystem .......................107
8.2.2 Control panel IniControl ......................................108
8.3 Customising maintenance ...............................108
8.3.1 Maintenance message ........................................109
8.3.2 Installer's contact details .....................................110
8.4 Standard inspection and maintenance
operations .........................................................110
8.4.1 Checking the hydraulic pressure .........................110
8.4.2 Checking the ionisation current ...........................111
8.4.3 Checking the tightness of the combusted gases
evacuation and air inlet connections ...................111
8.4.4 Checking combustion ..........................................111
8.4.5 Checking the automatic air vent ..........................112
8.4.6 Checking the siphon ............................................113
8.4.7 Checking the burner and cleaning the heat
exchanger ...........................................................114
8.5 Specific maintenance operations ....................115
8.5.1 Inspection of the ignition electrode ......................115
8.5.2 Replacing the non-return valve ...........................116
8.5.3 Assembling the boiler ..........................................117
9 Troubleshooting .....................................................................................118
9.1 Anti-hunting ......................................................118
9.2 Messages (Code type Bxx or Mxx) ..................118
9.3 Message history ................................................121
9.3.1 Control panel DIEMATIC iSystem .......................121
9.3.2 Control panel IniControl ......................................122
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9.4 Faults (Code type Lxx or Dxx) .........................123
9.4.1
Control panel DIEMATIC iSystem .......................124
9.4.2 Control panel IniControl ......................................124
9.4.3 List of errors ........................................................124
9.4.4 Deletion of sensors from the memory in the
PCB .....................................................................132
9.4.5 Deleting the IOBL 3WV modules from the memory in
the PCB ..............................................................133
9.5 Failure history ...................................................133
9.5.1 Control panel DIEMATIC iSystem .......................133
9.5.2 Control panel IniControl ......................................134
9.6 Parameter and input/output check (mode
tests) ..................................................................135
9.6.1 Control panel DIEMATIC iSystem .......................135
9.6.2 Control panel IniControl ......................................137
9.6.3 Control system sequence ....................................137
10 Spare parts ..............................................................................................139
10.1 General ..............................................................139
10.2 Spare parts ........................................................139
10.2.1 Casing .................................................................140
10.2.2 Heat exchanger and burner - MCA 45 ................141
10.2.3 Heat exchanger and burner - MCA 65 ................142
10.2.4 Heat exchanger and burner - MCA 90/115 .........143
10.2.5 Fan - MCA 45/65 .................................................144
10.2.6 Fan - MCA 90 ......................................................145
10.2.7 Fan - MCA 115 ....................................................146
10.2.8 Control panel .......................................................147
10.2.9 Spare parts list ....................................................148
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1 Introduction
1.1 Used symbols
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.
CAUTION
Risk of material damage.
Signals important information.
¼ Signals a referral to other instructions or other pages in the
instructions.
1.2
Abbreviations
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 IOBL: In One By Legrand - 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 - control panel PCB
4 SU: Safety Unit - Safety PCB
1. Introduction MCA 45 - 65 - 90 - 115
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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.
1.3.2. 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.
1.3.3. User's liability
To guarantee optimum operation of the appliance, the user must
respect the following instructions:
4 Read and abide by the instructions given in the user manual.
4 Call on qualified professionals to carry out installation and initial
start up.
4 Get your fitter to explain your installation to you.
4 Have the required checks and services done.
4 Keep the instruction manuals in good condition close to the
appliance.
MCA 45 - 65 - 90 - 115 1. Introduction
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7
This appliance is not intended to be used by persons (including
children) whose physcial, sensory or mental capacity is impaired or
persons with no experience or knowledge, unless they have the
benefit, through the intermediary of a person responsible for their
safety, of supervision or prior instructions regarding use of the
appliance. Care should be taken to ensure that children do not play
with the appliance.
1.4
Homologations
1.4.1. Certifications
CE identification no
PIN 0063CL3333
NOx classification
5 (EN 297 pr A3, EN 656)
Type of connection Chimney: B23, B
33
Flue gas outlet: C13, C33, C43, C53, C63, C83, C
93
1.4.2. Equipment categories
Gas category Gas type Connection pressure (mbar)
II
2H3P
Natural gas H (G20) 20
Propane (G31) 37
The boiler is preset in the factory to operate on natural gas H (G20).
For operation on another group of gases:
4 With DIEMATIC iSystem: ¼ "Adapting to another gas type",
page 62.
4 With IniControl: ¼ "Adapting to another gas type", page
93.
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. Introduction MCA 45 - 65 - 90 - 115
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06/09/2010 - 300024755-001-A
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
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9
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.
DANGER
If you smell flue gases:
1.
Switch the appliance off.
2. Open the windows.
3. Trace possible leaks and seal them immediately.
2.2 Recommendations
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
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 45 - 65 - 90 - 115
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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.
MCA 45 - 65 - 90 - 115 2. Safety instructions and recommendations
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3 Technical description
3.1 General description
Wall-hung gas condensing boilers
4 High efficiency heating (Production of domestic hot water can be
ensured by a separate hot water calorifier).
4 Low pollutant emissions.
4 DIEMATIC iSystem or IniControl electronic control panel.
4 Flue gas evacuation by a forced flue, chimney or bi-flow type
connection.
4 Very suitable for cascade systems with several boilers.
3.2 Main parts
1
Flue gas outlet / Air intake
2
Casing/air box
3
Heat exchanger (Central heating)
4
Outlet for measuring combustion gases
5
Ignition/ionization electrode
6
Mixer pipe
7
Combined venturi and gas valve unit
8
Áir intake silencer
9
Instrument box
10
Siphon
11
Box for the control PCBs
12
Fan
13
Water flow pipe
3.3 Operating principle
3.3.1. Shunt pump
The boiler is supplied without a pump. When choosing a pump, take
account of the boiler resistance and system resistance.
¼ See chapter: "Technical characteristics", page
13.
T002036-B
8
7
4
55
6
2
3
9
11
10
12
13
1
3. Technical description MCA 45 - 65 - 90 - 115
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If possible, install the pump directly under the boiler on the return
connection.
¼ See chapter: "Connection of the heating circuit", page
22.
CAUTION
The pump may have a maximum input of 200 W. Use an
auxiliary relay for a pump with a larger input.
3.3.2. System in cascade
The boiler is ideally suited for a cascade system. There are a number
of standard solutions available.
For example:
4 Cascade sets (quick assembly) for the installation of 2 to 7 boilers
next to each other or 3 to 10 boilers mounted back to back on a
free-standing frame. When the boilers are mounted next to each
other, they can be mounted either on the wall or on a free-standing
frame.
Please contact us for further information.
3.3.3. Calorifier connection
A calorifier can be connected to the boiler. Our product range includes
various calorifiers.
Please contact us for further information.
The calorifier can be connected to the boiler in two ways:
4 Using a three-way valve.
4 Using a calorifier pump.
3.3.4.
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. For this reason the
boiler is, so to speak, insensitive to a flow which is too low.
In all cases, maintain a minimum water flow of 0,4 m3/h.
3.4 Technical characteristics
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Boiler type
MCA 45 MCA 65 MCA 90 MCA 115
General
Flow rate setting Adjustable
Modulating, Start/Stop, 0 - 10 V
Nominal output (Pn)
Heating System (80/60 °C)
minimum-maximum kW 8,0 - 40,0 12,0 - 61,0 14,1 - 84,2 16,6 - 107,0
Factory setting kW 40,0 61,0 84,2 107,0
Nominal output (Pn)
Heating System (50/30 °C)
minimum-maximum kW 8,9 - 43,0 13,3 - 65,0 15,8 - 89,5 18,4 - 114,0
Factory setting kW 43,0 65,0 89,5 114,0
Nominal input (Qn)
Heating System (Hi)
minimum-maximum kW 8,2 - 41,2 12,2 - 62,0 14,6 - 86,0 17,2 - 110,2
Factory setting kW 41,2 62,0 86,0 110,2
Nominal input(Qn)
Heating System (Hs)
minimum-maximum kW 9,1 - 45,7 13,6 - 68,8 16,2 - 95,5 19,1 - 122,4
Factory setting kW 45,7 68,8 95,5 122,4
Heating efficiency under full load (Hi)
(80/60 °C)
- % 97,2 98,3 97,9 96,6
Heating efficiency under full load (Hi)
(50/30 °C)
- % 102,9 104,6 104,1 102,5
Heating efficiency under partial load (Hi)
(Return temperature 60
°C)
- % 97,5 98,3 96,6 96,5
Heating efficiency under partial load (EN
92/42)(Return temperature
30°C)
- % 107,7 108,9 108,1 107,1
Data on the gases and combustion gases
Gas consumption G20 (Natural gas H) minimum-maximum
m3/h
0,9 - 4,4 1,3 - 6,6 1,5 - 9,1 1,8 - 11,7
Gas consumption G31 (Propane) minimum-maximum
m3/h
0,3 - 1,7 0,5 - 2,5 0,6 - 3,5 0,6 - 4,7
NOx-Emission per year or (EN 483)
mg/kWh 37 32 45 46
Mass flue gas flow rate minimum-maximum Kg/h 14 - 69 21 - 104 28 - 138 36 - 178
Flue gas temperature minimum-maximum °C 30 - 67 30 - 68 30 - 68 30 - 72
Maximum counter pressure
Pa 150 100 160 220
Characteristics of the heating circuit
Water content
l 5,5 6,5 7,5 7,5
Water operating pressure minimum kPa (bar) 80 (0,8) 80 (0,8) 80 (0,8) 80 (0,8)
Water operating pressure (PMS) maximum kPa (bar) 400 (4,0) 400 (4,0) 400 (4,0) 400 (4,0)
Water temperature maximum °C 110 110 110 110
Operating temperature maximum °C 90 90 90 90
Water resistance (∆T = 20K)
mbar 90 130 140 250
Electrical characteristics
Power supply voltage
V/Hz 230/50 230/50 230/50 230/50
Power consumption - Full load maximum W 68 88 125 199
Power consumption - Part load maximum W 18 23 20 45
Power consumption - Standby maximum W 5 6 4 7
Electrical protection index
IP X4D X4D X4D X4D
Other characteristics
Weight (empty) Total kg 53 60 67 68
Mounting
(1)
kg 49 56 65 65
Acoustic level at 1 meter
dBA 45 45 52 51
(1) Front panel removed
3. Technical description MCA 45 - 65 - 90 - 115
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3.4.1. Sensor characteristics
Outside sensor Outlet sensor circuit B+C
Domestic hot water sensor
Boiler sensor
Return sensor
-20 °C
2392 ¨
0 °C
32014 ¨
-20 °C
98932 ¨
-16 °C
2088 ¨
10 °C
19691 ¨
-10 °C
58879 ¨
-12 °C
1811 ¨
20 °C
12474 ¨
0 °C
36129 ¨
-8 °C
1562 ¨
25 °C
10000 ¨
10 °C
22804 ¨
-4 °C
1342 ¨
30 °C
8080 ¨
20 °C
14773 ¨
0 °C
1149 ¨
40 °C
5372 ¨
25 °C
12000 ¨
4 °C
984 ¨
50 °C
3661 ¨
30 °C
9804 ¨
8 °C
842 ¨
60 °C
2535 ¨
40 °C
6652 ¨
12 °C
720 ¨
70 °C
1794 ¨
50 °C
4607 ¨
16 °C
616 ¨
80 °C
1290 ¨
60 °C
3252 ¨
20 °C
528 ¨
90 °C
941 ¨
70 °C
2337 ¨
24 °C
454 ¨
80 °C
1707 ¨
90 °C
1266 ¨
100 °C
952 ¨
110 °C
726 ¨
MCA 45 - 65 - 90 - 115 3. Technical description
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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 boiler is composed of 2 packages:
4 1 boiler package including:
- The boiler, fitted with a connection cable
- Mounting rail and mounting accessories for wall mounting
- Mounting template
- Installation and Service Manual
- User Guide
4 1 control panel package including:
- The DIEMATIC iSystem or IniControl control panel
- module assembly instructions
4.2.2.
Accessories
Various options are available depending on the configuration of the
installation:
Boiler options
Description package
Hydraulic connection kit - MCA 45 HC137
Hydraulic connection kit - MCA 65 / 90 / 115 HC139
Right gas valve 3/4" HC158
3-speed heating pump - MCA 45 HC141
Electronic heating pump - MCA 45 HC142
3-speed heating pump - MCA 65 HC143
3-speed heating pump - MCA 90 HC145
Primary pump - MCA 45 / 65 / 90 HC147
3-way valve with motor 1" HC15
Low loss header HW PLUS 70 HC28
Low loss header HW 200 HC29
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Boiler options
Description package
Condensates neutralisation station HC33
Bracket for neutralisation station HC 33 HC34
2 kg refill of granulats to neutralisation station HC 33 HC35
Condensates neutralisation station (Boilers up to 120 kW) DU13
Condensates neutralisation station (Boilers from 120 to 350
kW)
DU14
Condensates neutralisation station (Boilers above 350 kW) DU15
Control system options
Description package
Optional PCB for 3-way valve Diematic iSystem AD249
System sensor AD250
Outside radio-controlled temperature sensor Diematic iSystem AD251
Boiler radio module AD252
Radio remote control Diematic iSystem AD253
Interactive remote control Diematic iSystem AD254
BUS connection cable (length 12 m) AD134
voice remote monitoring module AD152
Outlet sensor after 3-way valve AD199
A simplified remote control with room sensor FM52
Domestic hot water tank options
Description package
Heating / DHW inversion valve HC 134
Heating DHW reversal valve MCA 45 / 65 HC 135
Boiler/DHW tank connection kit BL / BP / BSC / DT EA 121
DHW sensor AD 212
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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 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.
T001982-A
T002599-B
500
min.1000
500
min.
400
350
min.
250
750
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4.3.3. Ventilation
(1)
Distance between the front of the appliance and the
internal wall of the cupboard.
(2)
Distance to allow on either side of the appliance.
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
2
T002600-B
1000
min. (1)
530
15 (2)
min.1500
min.
400
min.
250
750
350
MCA 45 - 65 - 90 - 115 4. Installation
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4.3.4. Main dimensions
i
Connection of the combustion gas exhaust pipe ;
Ø 80 mm (≤ 45 kW) /
Ø 100 mm (≥ 65 kW)
h
Connection of the air intake pipe ;
Ø 125 mm (≤ 45 kW) / Ø
150 mm (≥ 65 kW)
â
Siphon connection bush
z
Heating circuit return ; 1 ¼" Male thread
Gas /
Gaz
Gas connection ; ¾" Male thread
{
Heating circuit flow ; 1 ¼" Male thread
T002614-C
191
500
750
500
100
50
50
130
191
365
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4.4 Positioning the boiler
The boiler is delivered with a mounting template.
A suspension clamp situated at the rear of the casing enables the
boiler to be directly suspended on the mounting bracket.
1.
Position the mounting template to the wall with adhesive tape.
CAUTION
4 Using a spirit level, check that the mounting axis is
perfectly horizontal.
4 During mounting, cover up the connection points for
the air supply and the combustion gas exhaust, to
protect
the boiler and its connections from dust. Only
remove this protection at the time when these
connections are made.
2. Drill 2 holes with a Ø of 10 mm.
3.
Insert the rawplugs with a Ø of 10 mm.
4. Attach the mounting bracket to the wall with the provided bolts with
a Ø of 10 mm.
5. Hang the boiler on the mounting bracket.
4.5 Hydraulic connections
4.5.1. Flushing the system
Installation must be carried out in accordance with the prevailing
regulations,
the codes of practice and the recommendations in these
instructions.
T001540-A
2
1
5
4
3
MCA 45 - 65 - 90 - 115 4. Installation
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21
n
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, flaxen thread, flux).
4 Thoroughly flush the installation until the water runs clear and
shows no impurities.
n
Installing the boiler in existing installations
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.
4.5.2.
Connection of the heating circuit
1. Remove the anti-dust plug located on the heating outlet
connection { under the boiler.
2.
Connect the heating water outlet pipe to the heating flow
connection.
3. Install a filling and drainage valve on the installation for filling and
draining the boiler.
T002856-C
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4. Remove the anti-dust button located on the heating return
connection z under the boiler.
5.
Connect the heating water return pipe to the heating return
connection.
6. Fit the pump in the return pipe.
¼
For the electrical connection of the pump, see chapter:
"Connecting the pump", page 32
To facilitate maintenance work, we recommend mounting
a shut off valve on the heating flow and return pipes.
CAUTION
4 The heating pipe must be mounted in accordance
with prevailing provisions.
4 If installing shut off valves, position the filling/
drainage valve and the expansion vessel between
the shut off valves and the boiler.
4.5.3. Connecting the expansion vessel
Install the expansion vessel on the heating return pipe z.
Refer to the table below to determine the opened expansion vessel
required for the installation.
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
Initial pressure of the
expansion vessel
Volume of the opened expansion vessel depending on the volume of the installation (in litres)
100 125 150 175 200 250 300 > 300
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
12,0
(1)
14,0 16,0 20,0 24,0 Volume of the installation x 0,080
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
T002857-B
MCA 45 - 65 - 90 - 115 4. Installation
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4.5.4. Connecting
the condensate discharge pipe
1. Fit
the condensate drain hose and the syphon of the boiler: these
are supplied separately.
2. Mount a standard drainage pipe, Ø 32 mm or more, leading to the
mains drainage system.
3.
Insert into this the hose of the condensate drain â.
4. 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 Gas connection
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 appliances.
4 If the gas meter has too low a capacity, inform the
energy supply company.
The diameters of the pipes must be defined in accordance with the
standards in force in your country.
1. Remove
the anti-dust plug from the GAS/GAZ gas inlet pipe under
the boiler.
2. Connect the gas inlet pipe.
3. Mount a gas isolation valve on this pipe, directly under the boiler.
4. Connect the gas pipe to the gas shut off valve.
CAUTION
4 Ensure that there is no dust in the gas pipe.
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.
T002858-B
T002859-C
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4.7 Flue gas system connections
4.7.1. Classification
6 3
4 2
2
2
1
5
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
C003034-A
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
93
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)
MCA 45 - 65 - 90 - 115 4. Installation
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4
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.
5
Configuration C
53
Air and flue gas connection separated by means of a biflow
adapter and single pipes (combustive air taken from
outside)
6
Configuration B
23
Connection to a chimney using a connection kit
(combustive air taken from the boiler room
)
4.7.2. Lengths of the air/flue gas pipes
Type of air/flue gas connection Diameter Maximum length
MCA 45 MCA 65 MCA 90 MCA 115
C13Concentric pipes connected to a horizontal terminal Alu or PPS 80/125 mm 16 m - - -
100/150 mm - 9 m 8 m 5,9 m
C33Concentric pipes connected to a vertical terminal aluminium 80/125 mm 14,5 m - - -
100/150 mm - 11,5 m 10 m 9,4 m
C93Concentric pipes in the boiler room
Single conduits in the chimney (combustive air in
counter-current)
aluminium 80/125 mm
80 mm
15 m - - -
80/125 mm
100 mm
11,5 m - - -
110/150 mm
110 mm
- 11 m 12,5 m 10 m
Concentric pipes in the boiler room
Single
flexible pipe in the chimney (combustive air in
counter-current)
PPS 80/125 mm
80 mm
12 m - - -
110/150 mm
110 mm
- 16,5 m 13,5 m 9,4 m
C53Bi-flow adapter and separate single air/flue gas ducts
(combustive air taken from outside)
aluminium 80/125 mm
2 x 80 mm
20,5 m - - -
100/150 mm
2 x 100 mm
- 23 m 17,5 m
11 m
(1)
5 m
(2)
B23Chimney (rigid or flexible duct in furnace flue,
combustive air taken from the premises)
PPS
80 mm
(3)
23,5 m - - -
110 mm
(3)
- 55 m 45 m 44 m
80 mm
(4)
21 m - - -
110 mm
(4)
- 29,5 m 24 m 17,5 m
(1) Air
(2)
Flue gases
(3) Rigid duct
(4) Flexible duct
4. Installation MCA 45 - 65 - 90 - 115
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06/09/2010 - 300024755-001-A
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.
4.8
Installing the outside sensor
4.8.1. 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
A
Recommended position
B
Possible position
H
Inhabited height controlled by the sensor
Z
Inhabited area controlled by the sensor
8800N001-C
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27
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.)
4.8.2. Installing the outside sensor
Mount the sensor using the screws and dowels provided.
A
CB wood screws diameter 4 + dowels
4.9 Electrical connections
4.9.1. 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 V AC/50 Hz
Rating of the main fuse F1(230 V AC) 6.3 AT
Fuse rating F2(230 V AC) 2 AT
Fan 230 V AC
CAUTION
Keep to the polarity shown on the terminals: phase (L),
neutral (N) and earth *.
8800N002-C
8800N003-B
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