Lochinvar CP-M, CP-M+120, CP-M+150, CP-M+60, CP-M+80 Maintenance Manual

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The CP-M+™ range

High Efficiency Gas Fired Condensing Boilers

Installation, Commissioning & Maintenance Instructions

Models:

CP-M+60 CP-M+80 CP-M+100 CP-M+120 CP-M+150 CP-M+180

INS0034 Issue No 5 | November 2013

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Table of Contents

1.0 INTRODUCTION ..................................................................................................................................................................................................................... 4

2.0 PRINCIPAL PARTS ................................................................................................................................................................................................................ 5

3.0 TECHNICAL DATA ............................................................................................................................................................................................................... 17

4.0 GENERAL REQUIREMENTS ............................................................................................................................................................................................... 20

4.1 RELATED DOCUMENTS .................................................................................................................................................................................................. 20

5.0 WATER QUALITY ................................................................................................................................................................................................................. 21

5.1 WATER CHEMISTRY ........................................................................................................................................................................................................ 21

5.2 AIR/DIRT SEPARATION ................................................................................................................................................................................................... 21

5.3 WATER PRESSURE ......................................................................................................................................................................................................... 21

6.0 LOCATION ............................................................................................................................................................................................................................ 22

6.1 PLANT ROOM REQUIREMENTS ..................................................................................................................................................................................... 22

6.2 GENERAL REQUIREMENTS ........................................................................................................................................................................................... 22

6.3 CLEARANCES .................................................................................................................................................................................................................. 22

6.4 MOUNTING THE BOILER ................................................................................................................................................................................................. 22

6.4.1 MOUNTING THE BOILER ON A FRAME ..................................................................................................................................................................... 22

6.4.2 MOUNTING THE BOILER ON THE WALL ................................................................................................................................................................... 22

6.5 CONDENSATE DRAIN...................................................................................................................................................................................................... 23

6.6 FILLING THE CONDENSATE TRAP ................................................................................................................................................................................ 23

7.0 GAS SUPPLY ........................................................................................................................................................................................................................ 23

7.1 SERVICE PIPES ............................................................................................................................................................................................................... 23

7.2 METERS ............................................................................................................................................................................................................................ 24

7.3 GAS SUPPLY PIPES ........................................................................................................................................................................................................ 24

7.4 BOOSTED GAS SUPPLIES .............................................................................................................................................................................................. 24

7.5 PLANT-ROOM CONTROL VALVE ................................................................................................................................................................................... 24

7.6 EQUIPMENT GAS SYSTEM LEAK CHECK ..................................................................................................................................................................... 24

8.0 FLUE SYSTEM ...................................................................................................................................................................................................................... 24

8.1 FLUE TERMINAL LOCATIONS ........................................................................................................................................................................................ 24

8.2 APPROVED FLUE SYSTEM ............................................................................................................................................................................................. 25

8.2.1 TYPE B

8.3 INSTALLATION PRECAUTIONS ...................................................................................................................................................................................... 26

8.4 MAXIMUM LENGTH – CONCENTRIC FLUE ................................................................................................................................................................... 26

8.4.1 WORKED EXAMPLE – CONCENTRIC FLUE .............................................................................................................................................................. 26

8.5 MAXIMUM LENGTH – CONVENTIONAL/TWIN-PIPE FLUE ........................................................................................................................................... 26

8.5.1 WORKED EXAMPLE – CONVENTIONAL FLUE ......................................................................................................................................................... 27

8.5.2 WORKED EXAMPLE – TWIN-PIPE FLUE ................................................................................................................................................................... 28

8.6 FLUE DISCHARGE ........................................................................................................................................................................................................... 28

8.7 FLUE TERMINAL INSTALLATION.................................................................................................................................................................................... 28

8.7.1 TYPE B23 (CONVENTIONAL FLUE) ............................................................................................................................................................................. 28

8.7.2 TYPE C13 (HORIZONTAL BALANCED FLUE) .............................................................................................................................................................. 29

8.7.3 TYPE C33 (VERTICAL BALANCED FLUE) ................................................................................................................................................................... 29

8.7.4 TYPE C43........................................................................................................................................................................................................................ 30

8.7.5 TYPE C53 (TWIN PIPE FLUE) ....................................................................................................................................................................................... 30

8.8 COMMON FLUE SYSTEMS ............................................................................................................................................................................................. 30

8.9 FLUE TERMINAL GUARDING .......................................................................................................................................................................................... 31

8.10 CONDENSATE DRAIN...................................................................................................................................................................................................... 31

9.0 AIR SUPPLY ......................................................................................................................................................................................................................... 31

9.1 COMBUSTION VENTILATION .......................................................................................................................................................................................... 31

9.2 COOLING VENTILATION ................................................................................................................................................................................................. 32

9.3 MECHANICAL VENTILATION .......................................................................................................................................................................................... 32

9.3.1 WORKED EXAMPLE – MECHANICAL INLET/NATURAL DISCHARGE ..................................................................................................................... 32

9.3.2 WORKED EXAMPLE – MECHANICAL INLET/MECHANICAL DISCHARGE (MINIMUM COMBUSTION AIR FLOW RATE) .................................. 33

9.3.3 WORKED EXAMPLE – MECHANICAL INLET/MECHANICAL DISCHARGE (ALTERNATE COMBUSTION AIR FLOW RATE): ............................ 33

10.0 WATER CONNECTIONS ...................................................................................................................................................................................................... 33

10.1 FLOW/RETURN CONNECTIONS..................................................................................................................................................................................... 33

10.2 OPEN VENTED SYSTEM ARRANGEMENT .................................................................................................................................................................... 33

10.3 SEALED SYSTEM ARRANGEMENT ............................................................................................................................................................................... 34

10.3.1 EXPANSION VESSEL SIZING ...................................................................................................................................................................................... 34

10.4 CIRCULATING PUMPS..................................................................................................................................................................................................... 34

10.5 DIRT SEPARATOR/STRAINER ........................................................................................................................................................................................ 38

10.6 AIR SEPARATOR .............................................................................................................................................................................................................. 38

10.7 ROOF-TOP INSTALLATION ............................................................................................................................................................................................. 38

10.8 INSTALLATION SCHEMATIC DRAWINGS ...................................................................................................................................................................... 38

11.0 ELECTRICAL SUPPLY ........................................................................................................................................................................................................ 41

11.1 CONNECTOR STRIP ........................................................................................................................................................................................................ 41

11.2 ARC WELDING PRECAUTIONS ...................................................................................................................................................................................... 43

11.3 ANCILLARY EQUIPMENT ................................................................................................................................................................................................ 43

11.3.1 OUTSIDE TEMPERATURE SENSOR .......................................................................................................................................................................... 43

11.3.2 SAFETY CIRCUIT ......................................................................................................................................................................................................... 43

11.4 CASCADE CONTROL ....................................................................................................................................................................................................... 43

11.4.1 CASCADE WIRING ....................................................................................................................................................................................................... 43

11.4.2 CASCADE SENSOR ..................................................................................................................................................................................................... 43

11.5 TIME, TEMPERATURE AND ZONE CONTROL .............................................................................................................................................................. 43

11.6 CP-M+ WIRING DIAGRAM ............................................................................................................................................................................................... 44

FLUE GAS SYSTEMS ................................................................................................................................................................................. 25

23P

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12.0 CONTROL INTERFACE ....................................................................................................................................................................................................... 45

12.1 CONTROL PANEL / DISPLAY UNIT ................................................................................................................................................................................ 45

12.2 CONTROL PANEL MENU STRUCTURE ......................................................................................................................................................................... 46

12.3 DISPLAY DURING OPERATION ...................................................................................................................................................................................... 47

12.4 MONITOR SCREENS ....................................................................................................................................................................................................... 48

12.5 SERVICE FUNCTION ....................................................................................................................................................................................................... 50

12.6 SCHORNSTEINFEGER FUNCTION ................................................................................................................................................................................ 51

12.7 SETTING THE TIME & DATE ........................................................................................................................................................................................... 52

12.8 SETPOINTS....................................................................................................................................................................................................................... 53

12.9 SETTING THE TIMER PROGRAMS ................................................................................................................................................................................ 54

12.10 OUTSIDE TEMPERATURE COMPENSATION ................................................................................................................................................................ 57

12.10.1 MAIN PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE ...................................................................................................... 57

12.10.1 ADDITIONAL PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE ......................................................................................... 58

12.10.2 SETTING OUTSIDE TEMPERATURE COMPENSATION ........................................................................................................................................... 59

12.11 CHECKING THE OPERATING HISTORY ........................................................................................................................................................................ 60

12.12 CHECKING THE FAULT HISTORY .................................................................................................................................................................................. 61

12.13 SETTING THE MAINTENANCE SPECIFICATIONS ........................................................................................................................................................ 62

12.14 SETTING THE USER LOCK ............................................................................................................................................................................................. 65

13.0 PARAMETERS ...................................................................................................................................................................................................................... 66

13.1 SETTING THE PARAMETERS WITH THE DISPLAY MENU .......................................................................................................................................... 66

14.0 COMMISSIONING AND TESTING ....................................................................................................................................................................................... 72

14.1 ELECTRICAL INSTALLATION .......................................................................................................................................................................................... 72

14.2 GAS INSTALLATION......................................................................................................................................................................................................... 72

14.3 WATER CONNECTIONS .................................................................................................................................................................................................. 72

14.4 COMMISSIONING THE EQUIPMENT .............................................................................................................................................................................. 72

14.4.1 GENERAL CHECKS PRIOR TO LIGHTING ................................................................................................................................................................. 72

14.4.2 EQUIPMENT CHECKS PRIOR TO LIGHTING ............................................................................................................................................................ 72

14.4.3 PROCEDURE FOR INITIAL LIGHTING ........................................................................................................................................................................ 73

14.4.4 GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS .............................................................................................................................. 73

14.5 TEMPERATURE ADJUSTMENT PROCEDURE .............................................................................................................................................................. 74

14.6 INSTALLATION NOISE ..................................................................................................................................................................................................... 74

15.0 LPG FUEL ............................................................................................................................................................................................................................. 75

15.1 RELATED DOCUMENTS .................................................................................................................................................................................................. 75

15.2 CONVERSION AND COMMISSIONING PROCEDURE .................................................................................................................................................. 75

16.0 MAINTENANCE .................................................................................................................................................................................................................... 77

16.1 GENERAL .......................................................................................................................................................................................................................... 77

16.2 BURNER INSPECTION..................................................................................................................................................................................................... 77

16.3 BURNER REMOVAL ......................................................................................................................................................................................................... 78

16.4 CLEANING THE HEAT EXCHANGER ............................................................................................................................................................................. 79

16.5 DRAINING THE BOILER SYSTEM ................................................................................................................................................................................... 79

16.5.1 DRAINING AN INDIVIDUAL BOILER ........................................................................................................................................................................... 79

16.5.2 DRAINING THE COMPLETE SYSTEM ........................................................................................................................................................................ 79

16.6 REFILLING THE SYSTEM ................................................................................................................................................................................................ 79

16.7 OTHER CHECKS .............................................................................................................................................................................................................. 80

16.7.1 RELIEF VALVES (IF FITTED) ....................................................................................................................................................................................... 80

16.7.2 FLUE SYSTEM .............................................................................................................................................................................................................. 80

16.8 SETTING A REPLACEMENT GAS VALVE ...................................................................................................................................................................... 81

17.0 TROUBLESHOOTING .......................................................................................................................................................................................................... 83

17.1 LOCK-OUT CODES .......................................................................................................................................................................................................... 83

17.2 BLOCKING CODES .......................................................................................................................................................................................................... 88

17.3 IMPORTANT MESSAGES ................................................................................................................................................................................................ 91

18.0 USER INSTRUCTIONS ......................................................................................................................................................................................................... 91

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1.0 INTRODUCTION

 The Lochinvar CP-M+™ range is a wall hung gas-fired condensing boiler. The equipment comprises of stainless steel

radial burner assembly and heat exchanger that permits fully condensing operation.

 The burner is initiated by a full electronic ignition sequence control that incorporates a spark ignition and a flame

rectification device for supervision of the flame.

 The output from the boiler is regulated by a variable speed combustion fan and gas/air ratio controls to maintain the correct

combustion at all levels of modulation. This configuration allows modulation down to 25% of the rated output.

 This equipment is intended for use on Group H Natural Gas (2

Family) and LPG propane (3rd Family). The information relating to propane firing is to be found in Section 15: LPG FUEL. This equipment MUST NOT use gas other than that for which it has been designed and adjusted.

 This equipment must be installed by a competent person, registered with a H.S.E. approved body. All installations must

conform to the relevant Gas Safety and Building Regulations. Health & Safety requirements must also be taken into account when installing any equipment. Failure to comply with the above may lead to prosecution.

 If the equipment is to be connected to an unvented (pressurised) system, care must be taken to ensure all extra safety

requirements are satisfied should a high or low-pressure condition occur in the system.

 The equipment is designed for direct connection to a flue system.

 Ancillary Options:

Item Description Part Number

1 Boiler Mounting Frame E00-000-158 2 Boiler Mounting Frame E00-000-159 3 Boiler Mounting Frame E00-000-160 4 Boiler Mounting Frame E00-000-116 2 Boiler Gas/Flow/Return Manifolds CP-M+60 – CP-M+120 (R 1 ½”) E00-000-152 3 Boiler Gas/Flow/Return Manifolds CP-M+60 – CP-M+120 (DN65) E00-000-186 4 Boiler Gas/Flow/Return Manifolds CP-M+60 – CP-M+120 (DN80) E00-000-154 2 Boiler Gas/Flow/Return Manifolds CP-M+150 – CP-M+180 (DN65) E00-000-155 3 Boiler Gas/Flow/Return Manifolds CP-M+150 – CP-M+180 (DN80) E00-000-156 4 Boiler Gas/Flow/Return Manifolds CP-M+150 – CP-M+180 (DN100) E00-000-157 Interconnecting Pipework:

CP-M+60 – CP-M+120 E00-000-162 CP-M+150 – CP-M+180 E00-000-163

Low Velocity Header:

(R 1 ½”) E00-000-164 (DN65) E00-000-165 (DN80) E00-000-166

(DN100) E00-000-167 Calorifier Temperature Sensor E04-016-303 Cascade Flow Sensor (Required for cascade installations) E04-016-304 Outside Temperature Sensor E04-016-585 Pressurisation Unit

Floor standing – single pump LPU9000

Floor standing – twin pump LPU9001

Wall mounted – single pump CHCWM1

Wall mounted – twin pump CHCWM2 Condensate Neutralisation Kit KIT2000 Time, Temperature and Zone Control Refer to Section 11: ELECTRICAL SUPPLY Flue System Components Contact Lochinvar Limited

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2.0 PRINCIPAL PARTS

FIGURE 2.1 REMOVABLE COMPONENTS – CP-M+60

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

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Item

Description

Item

Description

L/H side panel with insulation

Flow pipe

Front panel with insulation

Pump 3 Ignition cable

Pump gasket 1½"

Ignition electrode with gasket and screws

Return pipe – part 1

Heat exchanger rear wall insulation

Heat exchanger connection pipe gasket

Burner door gasket

Heat exchanger connection pipe

Burner door insulation

Heat exchanger connection pipe retaining clip

Burner door

Heat exchanger connection pipe O-ring

Burner door retaining nut

Flow / return temperature sensor

Burner

Return pipe – part 2

Burner / gas-air mixing pipe gasket

High limit thermostat

Gas-air mixing pipe retaining screws

Automatic air vent

Gas-air mixing pipe

Condensate drain hose – air supply duct

Combustion fan / gas-air mixing pipe gasket

Wall bracket

Combustion fan

Flue gas outlet pipe / flue spigot gasket

Gas-air mixing box

Flue gas outlet pipe

Gas valve outlet pipe

Heat exchanger / flue gas outlet pipe gasket

Gas valve inlet pipe

Flue gas temperature sensor

Gas inlet connector

Condensate drain hose – heat exchanger

Gas valve

Air pressure switch

Replacement fuses

Air pressure switch hose

Boiler control PCB

R/H side panel with insulation

Display PCB

Condensate water trap

PC connection cover

Condensate water trap drain hose

Terminal strip cover

N/A

Heat exchanger

Cable gland

Pressure sensor

Rubber grommet

Pressure sensor gasket

TABLE 2.1 REMOVABLE COMPONENTS – CP-M+60

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

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

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Item

Description

Item

Description

L/H side panel with insulation

Pressure sensor

Front panel with insulation

Pressure sensor gasket

Ignition cable

Pump gasket 1½"

Ignition electrode with gasket and screws

Flow pipe – part 2

Heat exchanger rear wall insulation

Pump

Burner door gasket

Heat exchanger connection pipe retaining clip

Burner door insulation

Heat exchanger connection pipe

Burner door

Heat exchanger connection pipe O-ring

Burner door retaining nut

High limit thermostat

Burner

Flow / return temperature sensor

Burner / gas-air mixing pipe gasket

Flue gas temperature sensor

Gas-air mixing pipe retaining screws

Heat exchanger outlet / flue spigot gasket

Gas-air mixing pipe

Automatic air vent

Combustion fan / gas-air mixing pipe gasket

Condensate drain hose – air supply duct

Combustion fan

Wall bracket

Gas-air mixing box

Heat exchanger rear wall thermostat

Gas valve connection O-ring

Air pressure switch

Gas valve

Condensate drain hose – heat exchanger

Replacement fuses

Air pressure switch hose

Boiler control PCB

Condensate water trap

Display PCB

R/H side panel with insulation

PC connection cover

Condensate water trap drain hose

Terminal strip cover

N/A

Heat exchanger

Cable gland

Return pipe – part 2

Rubber grommet

Flow pipe – part 3

TABLE 2.2 REMOVABLE COMPONENTS – CP-M+80 – CP-M+100

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FIGURE 2.5 REMOVABLE COMPONENTS – CP-M+120

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

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Item

Description

Item

Description

L/H side panel with insulation

Flow pipe – part 3

Front panel with insulation

Pressure sensor

Ignition cable

Pressure sensor gasket

Ignition electrode with gasket and screws

Pump gasket 1½"

Heat exchanger rear wall insulation

Flow pipe – part 2

Burner door gasket

Pump 7 Burner door insulation

Heat exchanger connection pipe retaining clip

Burner door

Heat exchanger connection pipe

Burner door retaining nut

Heat exchanger connection pipe O-ring

Burner

High limit thermostat

Burner / gas-air mixing pipe gasket

Flow / return temperature sensor

Gas-air mixing pipe retaining screws

Flue gas temperature sensor

Gas-air mixing pipe

Heat exchanger outlet / flue spigot gasket

Combustion fan / gas-air mixing pipe gasket

Automatic air vent

Combustion fan

Condensate drain hose – air supply duct

Gas-air mixing box

Wall bracket

N/A

Heat exchanger rear wall thermostat

Gas inlet / outlet manifold gasket

Air pressure switch

Gas valve

Condensate drain hose – heat exchanger

Gas valve connection O-ring

Air pressure switch hose

Replacement fuses

Condensate water trap

Boiler control PCB

R/H side panel with insulation

Display PCB

Condensate water trap drain hose

PC connection cover

N/A

Terminal strip cover

Cable gland

Heat exchanger

Rubber grommet

Return pipe – part 2

TABLE 2.3 REMOVABLE COMPONENTS – CP-M+120

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FIGURE 2.7 REMOVABLE COMPONENTS – CP-M+150 – CP-M+180

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

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Item

Description

Item

Description

L/H side panel with insulation

Flow pipe – part 3

Front panel with insulation

Pressure sensor gasket

Ignition cable

Pressure sensor

Ignition electrode with gasket and screws

Pump gasket 2"

Heat exchanger rear wall insulation

Flow pipe – part 2

Burner door gasket

Heat exchanger connection pipe retaining clip

Burner door insulation

Heat exchanger connection pipe

Burner door

Heat exchanger connection pipe O-ring

Burner door retaining nut

Pump

Burner

High limit thermostat

Burner / gas-air mixing pipe gasket

Flow / return temperature sensor

Gas-air mixing pipe retaining screws

Flue gas temperature sensor

Gas-air mixing pipe

Heat exchanger outlet / flue spigot gasket

Combustion fan / gas-air mixing pipe gasket

Automatic air vent

Combustion fan

Condensate drain hose – air supply duct

Gas-air mixing box

Wall bracket

Gas inlet manifold gasket

Heat exchanger rear wall thermostat

Gas valve

Air pressure switch

Gas valve outlet connection O-ring

Condensate drain hose – heat exchanger

Replacement fuses

Air pressure switch hose

Boiler control PCB

Condensate water trap

Display PCB

R/H side panel with insulation

PC connection cover

Condensate water trap drain hose

Terminal strip cover

N/A

Heat exchanger

Cable gland

Return pipe – part 2

Rubber grommet

TABLE 2.4 REMOVABLE COMPONENTS – CP-M+150 – CP-M+180

A replacement parts list is available to download from Lochinvar’s website; please visit www.lochinvar.ltd.uk

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Model Number

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

GENERAL DATA

Input – G20 – (gross) – kW

61.8

82.5

102.0

123.0

153.0

184.0

Input – G31 – (gross) – kW

60.4

80.8

100.0

121.0

150.0

180.0

Input (net) – kW

55.6

74.3

92.2

111.0

138.0

166.0

Output – kW (50º/30º)

57.4

77.5

96.2

116.0

144.0

175.0

Output – kW (80º/60º)

53.5

71.2

88.4

106.0

132.0

160.0

Seasonal Efficiency – %

94.9

95.1

95.2

Shipping Weight – kg

101

NOX Class

GAS DATA – G20

Nominal gas inlet pressure – mbar

20.0

Maximum gas inlet pressure – mbar

25.0

Minimum gas inlet pressure – mbar

17.5

Gas flow rate – m3/hr

5.88

7.86

9.76

11.75

14.60

17.57

Flue gas mass rate – g/sec (@ 9.0% CO2)

22.6

29.8

37.1

45.1

55.6

67.3

Gas inlet connection size – “ BSP

GAS DATA – G31

Nominal gas inlet pressure – mbar

37.0

Maximum gas inlet pressure – mbar

45.0

Minimum gas inlet pressure – mbar

25.0

Gas flow rate – m3/hr

2.27

3.04

3.77

4.54

5.65

6.79

Flue gas mass rate – g/sec (@ 10.0% CO2)

23.2

30.6

38.8

46.2

57.0

69.0

Gas inlet connection size – “ BSP

WATER DATA

Water content – litres

3.9

5.0

6.5

8.3

10.4

12.9

Water connections (F & R) – “ BSP

1 ¼

1 ½

Max. water pressure (PMS) – bar

4.0

Min. water pressure – bar

1.0

Test pressure – bar

9.0

Maximum water temperature – C

FLUE DATA TYPE B23

Nominal flue diameter – mm

100

130

Maximum flue gas temp. – C

120

Flue gas temperature – C

85 – 95

Flue draught requirements – mbar

-0.03 to -0.1

FLUE DATA TYPE C13 & C33

Nominal flue diameter – mm

80/125

100/150

Maximum flue gas temp. – C

120

FLUE DATA TYPE C43 & C53

Nominal flue diameter – mm

100

130

Average flue gas temp. – C (80/60 Flow/Return)

Maximum flue gas temp. – C

120

3.0 TECHNICAL DATA

TABLE 3.1 TECHNICAL DATA

Page 18

Connections

Twin pipe

Concentric

CP-M+

100

CP-M+

120

CP-M+

100

CP-M+

120

Air Inlet

Ø80

Ø100

Ø125

Ø150

Flue Gas

Ø80

Ø100

Ø80

Ø100

Ø100 F Flow

R 1 ¼” (male)

Condensate

Flexible hose Ø 25/21 x 750 mm

Return

R 1 ¼” (male)

Gas

R ¾” (male)

Dimension ‘A’

112

155

112

Dimension ‘B’

135

150

135

FIGURE 3.1 DIMENSIONS CP-M+60, 80, 100 & 120

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Connections

Twin pipe

Concentric

CP-M+

150

CP-M+

180

CP-M+

150

CP-M+

180

Air Inlet

Ø130

Ø150

Flue Gas

Ø130

Ø100

Ø100 F Flow

R 1 ½” (male)

Condensate

Flexible hose Ø 25/21 x 750 mm

Return

R 1 ½” (male)

Gas

R 1” (male)

FIGURE 3.2 DIMENSIONS CP-M+150 & 180

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4.0 GENERAL REQUIREMENTS

The Lochinvar CP-M+™ condensing boiler has been designed to operate trouble free for many years. These instructions should be followed closely to obtain the maximum usage and efficiency of the equipment. PLEASE read the instructions fully before installing or using the appliance.

4.1 RELATED DOCUMENTS

It is law that all gas appliances are installed by competent persons, in accordance with The Gas Safety (Installation and Use) Regulations 1998. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that this law is complied with.

The installation of the equipment MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, I.E.E. Regulations and the bylaws of the local water undertaking. The installation should also be in accordance with any relevant requirements of the local gas distributor and local authority.

In addition the installation should follow the relevant guidance offered in the following documents. It is not practical to list all relevant information but emphasis is placed on the following documents, as failure to comply with the guidance given will almost certainly result in an unsatisfactory installation:

BS EN 1858: 2003 Chimneys. Components. Concrete flue blocks

BS 4814: 1990 Specification for expansion vessels using an internal diaphragm, for sealed hot water heating

systems

BS 5440-1: 2008 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding

70kW net (1st, 2nd and 3rd family gases)

Part 1: Specification for installation and maintenance of flues

BS 5440-2: 2009 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding

70kW net (1st, 2nd and 3rd family gases)

Part 2: Specification for installation and maintenance of ventilation for gas appliances

BS 6644: 2011 Specification for the installation and maintenance of gas-fired hot water boilers of rated inputs

between 70kW (net) and 1.8MW (net) (2nd and 3rd family gasses)

BS 6700: 2006 Design, installation, testing and maintenance of services supplying water for domestic use within

buildings and their curtilages

BS 6880: 1988 Code of practice for low temperature hot water systems of output greater than 45kW Parts 1, 2 and 3

BS 7074: 1989 Application, selection and installation of expansion vessels and ancillary equipment for sealed Parts 1and 2 systems

BS 7671: 2008 Requirements for electrical installations, I.E.E. wiring regulations seventeenth edition

CP 342: Code of practice for centralised hot water supply-buildings other than dwellings Part 2 1974

IGE/UP/1: Installation pipework on industrial and commercial premises Edition 2

IGE/UP/2: Gas installation pipework, boosters and compressors on industrial and commercial Edition 2 premises

IGE/UP/4: Commissioning of gas fired plant on industrial and commercial premises Edition 2

Page 21

IGE/UP/10: Installation of flued gas appliances in industrial and commercial premises Edition 3

Gas Safety (Installation and Use) Regulations 1998 (England, Scotland & Wales)

CIBSE: Guide parts A, B and C

CIBSE Commissioning Code B: Boilers

CIBSE Commissioning Code W: Water Distribution Systems

BISRIA AG1/2001.1: Pre-commission cleaning of pipework systems

H.S.E. guidance Automatically controlled steam and hot water boilers note PM5:

Third edition of the 1956 Clean Air Act Memorandum on Chimney Heights

Manufacturer's notes must not be taken in any way as overriding statutory obligations.

5.0 WATER QUALITY

5.1 WATER CHEMISTRY

In hard water areas, scale formation can occur in hot water systems. The situation can intensify where higher temperatures or demands exist.

The pH value of the water must be between 7.5 and 9.5.

Water hardness must be between 50 ppm CaCO3 and 150 ppm CaCO

The Aluminium content of the TDS (Total Dissolved Solids) should not exceed 8.5 ppm.

If the above requirements cannot be satisfied, a water treatment specialist must be consulted. Details of companies that provide such a service can be obtained from Lochinvar Limited.

5.2 AIR/DIRT SEPARATION

Precautions must be taken to remove air and dirt from the heating system. The system should be fully flushed with an air separator and dirt separator fitted to fully protect against contamination of the heat exchanger. If there is any doubt of the water staying free of any kind of debris/contamination in the period after installing, a plate heat exchanger should be installed to separate the boiler circuit from the heating circuit.

5.3 WATER PRESSURE

The CP-M+ boiler has an in-built water pressure sensor, with this sensor the minimum water pressure in the boiler is 0.8 bar and the maximum pressure is 4.0 bar (sensor values). The recommended water pressure is between 1.5 and 2.0 bar. The pressure sensor will stop the boiler from firing when the water pressure drops below 0.8 bar, and start the boiler firing again when the water pressure reaches above the 1.0 bar.

If pressures higher than 4.0 bar are required within the heating system, it is recommended that the system is separated from the boiler by means of a plate heat exchanger. This will allow the boiler pressure to be under 4.0 bar and the boiler control remains as described above. If this is not possible, a water pressure switch must be fitted to the boiler instead of the water pressure sensor the maximum allowed value in the boiler now is 6.0 bar and the boiler control needs to be adjusted.

Page 22

6.0 LOCATION

6.1 PLANT ROOM REQUIREMENTS

The Lochinvar CP-M+ may only be installed in a room that complies with the appropriate ventilation requirements.

The Lochinvar CP-M+ can be used as a type C13, C33 C43, C53 or C83 appliance. Due to its room sealed design, ventilation allowances for combustion air are not necessary. If the appliance is to be installed in a compartment or a hot environment, ventilation for cooling purposes must be fitted. For further guidance, please refer to Section 9 AIR SUPPLY or to BS6644.

The Lochinvar CP-M+ can also be used as a type B23 appliance. If such a configuration is to be used, then appropriate ventilation for cooling and combustion must be provided. For further details, please refer to Section 9 AIR SUPPLY or to BS6644.

6.2 GENERAL REQUIREMENTS

Corrosion of the heat exchanger and flue system may occur if air for combustion contains certain chemical vapours. Such corrosion may result in poor combustion and create a risk of severe personal injury or substantial property damage. Aerosol propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals are corrosive. Products of this sort should not be stored near the boiler or outside by the air intake (if applicable). The fitting of this equipment in a situation where aerosols or other chemicals may be entrained into the combustion air will invalidate the warranty.

When using the boiler mounting frame, the equipment must be installed on a level surface that is capable of adequately supporting the weight of the boiler(s), frame and any ancillary equipment. The operation of the equipment must not cause the temperature of any combustible material in the vicinity of the equipment and its flue to exceed 65°C. If such a situation is unavoidable, appropriate insulation should be provided. When mounting the boiler on a wall, investigations should be made as to whether the wall is strong enough to support the full weight of the boiler and ancillary equipment.

Locate the equipment so that if the appliance or any connecting pipework should leak, water damage will not occur. When such locations cannot be avoided it is recommended that a suitable drain pan be installed under the equipment. The pan should be adequately drained but must not restrict the combustion or ventilation airflow.

6.3 CLEARANCES

The location chosen for the equipment must permit the provision for a satisfactory flue system and, where necessary, an adequate air supply. The location must also provide adequate space for servicing and air circulation around each unit. This includes any electrical trunking laid across the floor and to the appliance.

See Figure 3.1 or Figure 3.2 for dimensions/clearances. Further details regarding locations are given in BS6644.

6.4 MOUNTING THE BOILER

NOTE: The mounting bracket for the boiler is part of the shipping crate.

6.4.1 MOUNTING THE BOILER ON A FRAME

NOTE: Mounting frames are available for the suspension of one, two, three or four boilers.

When utilising the mounting frame, the assembly instructions supplied with the frame should be used.

A mounting bracket is supplied with the mounting frame. The locking plate should be removed and the frame positioned and levelled in its required location before lifting any boiler in to place. With the boiler suspended on the frame, the locking plate should be refitted and the boiler levelled using the bolts on the back of the appliance (see Figure 6.1).

6.4.2 MOUNTING THE BOILER ON THE WALL

A template is provided with the boiler showing the locations for the holes necessary for the mounting bracket. It is essential that the mounting bracket is installed level using fixings that are strong enough to support the boiler and its ancillary equipment.

Page 23

Once the mounting bracket is installed, the locking plate should be removed and the boiler should be fitted by lifting and tilting the top rear edge back and hooking the mounting lip over the mounting bracket. With the boiler suspended, the locking plate should be refitted and the boiler levelled using the bolts on the back of the appliance (see Figure 6.1).

FIGURE 6.1 LOCKING AND LEVELLING THE APPLIANCE

6.5 CONDENSATE DRAIN

The condensate drain is located in the centre of the boiler underside. The clean out bowl is supplied in a separate box within the heater packaging; this must be fitted and the condensate water trap filled before the appliance is fired. The condensate trap is fitted with a ¾” flexible hose that should be connected to an appropriate condensate drain, sloping continuously away from the boiler at an angle of at least 3 (50mm per metre).

The Water Resources Act requires that trade effluent is discharged to municipal sewers between pH 6.5 and 10.0. If it is determined that these levels cannot be achieved, an in-line condensate neutralisation kit is available as an ancillary option from Lochinvar Limited. This unit is capable of neutralising 4000 litres of condensate to a pH of 7.0 before releasing it to a drain.

6.6 FILLING THE CONDENSATE TRAP

Prior to the appliance being put in to operation, the condensate water trap must be filled to prevent the escape of combustion products. To fill the water trap, the bowl should be unscrewed from the boiler underside and filled with water to the top before reinstalling.

FIGURE 6.2 FILLING THE CONDENSATE TRAP

7.0 GAS SUPPLY

The Lochinvar CP-M+™ range is suitable for use on second and third family gasses 2H - G20 - 20mbar and 3P - G31 - 37mbar. Details relating to Natural Gas (2H) appear below; for details relating to Propane (3P) please refer to Section 15: LPG FUEL.

7.1 SERVICE PIPES

The local gas distributor must be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas. An existing service pipe must not be used without prior consultation with the local gas distributor.

Page 24

7.2 METERS

A new gas meter will be connected to the service pipe by the local gas distributor contractor. An existing gas meter should be checked, preferably by the gas distributor, to ensure that it is adequate to deal with the rate of gas supply required.

7.3 GAS SUPPLY PIPES

Supply pipes must be fitted in accordance with IGE/UP/2. Pipework from the meter to the equipment must be of adequate size. The complete installation must be purged and tested as described in IGE/UP/1. Refer to Section 15: LPG FUEL for information on LPG pipework installation guidance.

7.4 BOOSTED GAS SUPPLIES

Where it is necessary to employ a gas pressure booster, the controls must include a low-pressure cut-off switch at the booster inlet. The local gas distributor must be consulted before a gas pressure booster is fitted.

7.5 PLANT-ROOM CONTROL VALVE

A manual valve for plant-room isolation must be fitted in the gas supply line. It must be clearly identified and readily accessible for operation, preferably by an exit.

7.6 EQUIPMENT GAS SYSTEM LEAK CHECK

An approved gas inlet appliance isolating valve and union should be installed for each unit in a convenient and safe position and be clearly marked. Ensure that the gas inlet appliance isolating valve is in the OFF position. Although the equipment receives a gas leak check and gas train component integrity check prior to leaving the factory, transit and installation may cause disturbance to unions, fittings and components. During commissioning a further test for tightness should be carried out on the equipment gas pipework and components.

Care must be taken not to allow leak detection fluid on or near any electrical parts or connections.

8.0 FLUE SYSTEM

8.1 FLUE TERMINAL LOCATIONS

FIGURE 8.1: FLUE TERMINAL POSITIONS

Page 25

Location

Description

CP-M+60

CP-M+80 – CP-M+180

Directly below an opening, air brick, opening windows etc.

300

2000

Above an opening, air brick, opening windows etc.

300

1000

Horizontally to an opening, air brick, opening windows etc.

300

1000

Below a gutter or sanitary pipework

Below the eaves

200

Below a balcony or car port roof

200

From a vertical drain or soil pipe

150

From an internal or external corner

300

Above ground, roof or balcony level

300

300*

From a surface facing the terminal

600

1000

From a terminal facing the terminal

1200

2000

From an opening in the car port (e.g. door, window) into the dwelling

1200

Vertically from a terminal on the same wall

1500

Horizontally from a terminal on the same wall

300

600

From a vertical structure on the roof

300

Above intersection with the roof

300

CE string flue gas

material (B

23P

)

European Standard

Temperature

Class

Pressure

Class

Resistance

Condensate

Corrosion

Resistance

Class

Metal:

Liner

Specifications

Soot Fire

Resistance

Class

Distance to

Combustible

Material

Plastics:

Location

Plastics:

Fire

Behaviour

Plastics:

Enclosure

Min. Requirement PPs

EN 14471

T120

P1 W 1 O

I or E

C/E

Min. Requirement St S

EN 1856-1

T120

P1 W 1

L20040 O 40

TABLE 8.1 FLUE TERMINAL MINIMUM DISTANCES

* Any termination of a room sealed appliance shall be in such a position as will not cause a hazard to the health of persons who

may be nearby or a nuisance to other persons beyond the curtilage. The height to the centreline of the terminal shall not be less than 2m from occupied external areas.

Detailed recommendations for the flue system are given in BS5440-1 for equipment of rated input not exceeding 70kW net, BS6644 for equipment above 70kW net and IGE/UP/10 for equipment of rated input above 54kW net. The following notes are intended to give general guidance only.

8.2 APPROVED FLUE SYSTEM

The approved flue system is not suitable for use external to the building. If external routes cannot be avoided, a flue system manufacturer should be consulted to supply a suitable alternative.

CP-M+60 – CP-M+120 boilers are supplied for connection to a concentric flue system. If twin pipe or conventional flue is used, a conversion kit will be required. Contact Lochinvar Limited for further details.

CP-M+150 & CP-M+180 boilers are supplied for connection to a twin pipe or conventional flue system. If concentric flue is to be used, a conversion kit will be required. Contact Lochinvar Limited for further details.

When used as a Type C (Balanced Flued) appliance, the approved, purpose designed adaptive flue system should be used. Concentric and twin-pipe options are available, for further details please contact Lochinvar Limited.

When used as a Type B (Conventional Flued) appliance, a suitable flue system constructed of Stainless Steel or Polypropylene with a temperature rating in excess of 120C should be used. Aluminium flue pipe must not be used on this appliance as it

may lead to a premature failure of the heat exchanger that would not be covered by the warranty.

Flue kits are supplied separately, please contact Lochinvar Limited for further details.

8.2.1 TYPE B

FLUE GAS SYSTEMS

23P

The CP-M+ boiler is suitable for use on B

flue gas systems; this allows the flue to run under a positive pressure reducing the

23P

required flue diameter. For overpressure flue gas systems the minimum requirements of the flue gas material for can be determined in a designation string according to the EN1443 (see table).

TABLE 8.2 TYPE

FLUE MATERIAL REQUIREMENTS

B23P

Page 26

When selecting flue gas systems, it is essential that the minimum requirements are met therefore only flue gas materials having

CP-M+60

(80/125)

CP-M+80

(80/125)

CP-M+100

(100/150)

CP-M+120

(100/150)

CP-M+150

(100/150)

CP-M+180

(100/150)

Wall terminal

Roof terminal

Straight tube (m)

12 8 10

45° Elbow 5 7 8 9

90° Elbow 8 13

Item

Quantity

Resistance

Total

Roof terminal

Straight tube (m)

6 8 48

90° Elbow 2 11

Total Resistance (Pa)

109

the same or better properties than this table shall be used.

8.3 INSTALLATION PRECAUTIONS

 The approved flue system is rated to 120C max.  The boiler must not be operated unless the complete flue system is installed. This includes the boiler connections, twin-

pipe conversion kit (if required) flue pipes, air ducts (if required) and terminals. If discharging at low level, a suitable flue

guard must be installed.

 During assembly of the flue system, precaution should be taken to ensure that the internal sealing ring is seated

correctly.

 Due to the close tolerances in the flue system, it may be necessary to use a twisting action to fit the joints together. No

lubrication other than water should be used.

8.4 MAXIMUM LENGTH – CONCENTRIC FLUE

The maximum length of the flue system is determined by the resistance of the components within the flue. The resistance must not exceed 200 Pa.

TABLE 8.3 CONCENTRIC FLUE COMPONENT RESISTANCES (Pa)

8.4.1 WORKED EXAMPLE – CONCENTRIC FLUE

CP-M+100 boiler terminating vertically with a flue run of 6 metres plus 2 x 90° elbows.

TABLE 8.4 WORKED EXAMPLE – CONCENTRIC FLUE

The total resistance of 109 Pa is less than the 200 Pa maximum value therefore this is acceptable.

8.5 MAXIMUM LENGTH – CONVENTIONAL/TWIN-PIPE FLUE

The maximum length of the flue system is determined by the resistance of the components within the flue. The resistance must not exceed 200 Pa.

The following resistances are for single boiler flue systems only; common flue systems will require specialist design.

Page 27

Item

Size

(mm)

Resistance (Pa)

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

Straight tube (per metre)

4.0

7.5 X X X X

Straight tube (per metre)

100

1.2

3.0

3.5

4.0 X X

Straight tube (per metre)

130

0.4

0.7

0.8

1.1

1.2

2.0

45° Elbow

2.0

3.5 X X X X

45° Elbow

100

0.6

1.5

1.7

2.0 X X

45° Elbow

130

0.2

0.4

0.5

0.6

1.0

90° Elbow

4.0

7.0 X X X X

90° Elbow

100

1.2

3.0

3.5

4.0 X X

90° Elbow

130

0.3

0.7

0.8

1.1

1.2

2.0

Vertical inlet cap

10.4

18.1 X X X X

Vertical inlet cap

100

4.2

7.4

11.4

16.7 X X

Vertical inlet cap

130

1.5

2.6

4.0

5.8

9.1

13.1

Item

Size

(mm)

Resistance (Pa)

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

Straight tube (per metre)

5.0

8.0 X X X X

Straight tube (per metre)

100

2.0

3.5

4.0

6.5 X X

Straight tube (per metre)

130

0.5

0.8

1.2

1.8

3.8

6.0

45° Elbow

2.5 4 X X X

45° Elbow

100

1.0

1.7 2 3.2 X X

45° Elbow

130

0.2

0.4

0.6

0.8

1.9

3.0

90° Elbow

5.0

8.0 X X X X

90° Elbow

100

2.0

3.5

4.0

6.5 X X

90° Elbow

130

0.4

0.8

1.2

1.8

3.8

6.0

Vertical exhaust cap

13.8

24.0 X X X X

Vertical exhaust cap

100

5.6

9.8

15.2

22.1 X X

Vertical exhaust cap

130

2.0

3.5

5.3

7.8

12.0

17.3

Item

Quantity

Resistance

Total

Straight tube (m)

8.0

192.0

90° Elbow 3 8.0

24.0

Total Resistance (Pa)

216

Item

Quantity

Resistance

Total

Straight tube (m)

3.5

90° Elbow 3 3.5

10.5

Total Resistance (Pa)

94.5

TABLE 8.5 AIR INLET COMPONENT RESISTANCES (Pa)

TABLE 8.6 EXHAUST COMPONENT RESISTANCES (Pa)

When a conventional flue is to be used, the maximum length of the flue system is limited by the resistance of the exhaust flue components as detailed in Table 8.6.

When a twin-pipe flue is to be used, the maximum length of the flue system is limited by the combined resistance of the inlet and exhaust flue components as detailed in Table 8.5 and Table 8.6.

8.5.1 WORKED EXAMPLE – CONVENTIONAL FLUE

CP-M+80 boiler with a flue run of 24 metres plus 3 x 90° elbows

Option 1 80mm Flue Components

TABLE 8.7 WORKED EXAMPLE – CONVENTIONAL FLUE – 80mm COMPONENTS

Using 80mm flue components, the total resistance of 216 Pa is more than the 200 Pa maximum value therefore this is unacceptable.

Option 2 100mm Flue Components

By using 100mm components, the total resistance of the flue system is reduced to 94.5 Pa. As this is below the 200 Pa limit, this is the flue system that should be used.

TABLE 8.8 WORKED EXAMPLE – CONVENTIONAL FLUE – 100mm COMPONENTS

Page 28

8.5.2 WORKED EXAMPLE – TWIN-PIPE FLUE

Item

Quantity

Resistance

Total

Straight tube (m)

1.2

9.6

90° Elbow 3 1.2

3.6

Vertical inlet cap

9.1

Straight tube (m)

3.8

45.6

90° Elbow 4 3.8

15.2

Total Resistance (Pa)

83.1

Models

Part Number

CP-M+60, CP-M+80

M87927

CP-M+100, CP-M+120

M87957

CP-M+150, CP-M+180

M81660

CP-M+150 boiler with an inlet air duct of 8 metres, 3 x 90° elbows plus a vertical inlet cap and an exhaust duct of 12 metres plus 4 x 90° elbows.

TABLE 8.9 WORKED EXAMPLE – TWIN-PIPE FLUE

The combined resistance of the air inlet duct and exhaust duct give the flue system an overall resistance of 83.1 Pa. As this is below the 200 Pa maximum limit, this is acceptable.

8.6 FLUE DISCHARGE

The flue system must ensure safe and efficient operation of the equipment to which it is attached, protect the combustion process from wind effects and disperse the products of combustion to open external air.

The flue must terminate in a freely exposed position and be so situated as to prevent the products of combustion entering any opening in a building.

For further information on terminal locations, please refer to Figure 8.1.

8.7 FLUE TERMINAL INSTALLATION

8.7.1 TYPE B

(CONVENTIONAL FLUE)

To convert the CP-M+60 – CP-M+120 to conventional flued operation, the approved air intake grille should be fitted to the concentric flue spigot. The grille will have an opening in the top plate that allows the connection of the flue system to the exhaust port of the boiler.

The CP-M+150 & CP-M+180 require an air inlet grille to be fitted to the air inlet spigot of the boiler casing.

FIGURE 8.2 FITTING AIR INLET GRILLE TO CP-M+60 – CP-M+120

TABLE 8.10 AIR INTAKE GRILLE PART NUMBERS

Page 29

When the heater is installed as a Type B23 appliance, the flue system should be installed in accordance with the flue manufacturer’s specific instructions.

8.7.2 TYPE C

(HORIZONTAL BALANCED FLUE)

When the heater is installed as a Type C13 appliance, the flue system should be installed as follows:

1. Determine the location of the flue terminal, taking into account minimum distances as detailed in Figure 8.1, Table 8.1

and the relevant British Standards.

2. Taking care to protect the appliance from debris and dust, drill a hole in the desired location. The diameter of the hole

should be no more than 10mm greater than the diameter of the air supply pipe of the terminal.

3. Determine the required length of the terminal and cut as necessary.

NOTE: When determining the required length for the flue terminal, the outer wall plate or rosette should be flush to the

wall. (See Figure 8.3)

NOTE: Once cut; remove all burrs and sharp edges.

4. Insert the terminal into the drilled hole. The terminal section should be installed level or with a fall to outside (Max.

10mm per metre) to prevent the ingress of water.

NOTE: When inserting the terminal, ensure the air intake section is at the bottom.

5. Fill the void between the terminal and wall with water resistant sealant.

6. Fit the wall plates or rosette using appropriate fixings.

7. Install the remainder of the flue system working progressively away from the boiler supporting the pipes as necessary.

FIGURE 8.3 HORIZONTAL TERMINAL INSTALLATION

8.7.3 TYPE C

(VERTICAL BALANCED FLUE)

When the heater is installed as a Type C33 appliance, the flue system should be installed as follows:

1. Confirm that the roof flashing is correct for the type of roof through which the terminal is to be installed. (See Figure

8.4)

2. Determine the desired location for the flue terminal, taking into account minimum distances as detailed in Figure 8.1,

Table 8.1 and the relevant British Standards.

3. Taking care to protect the appliance from debris and dust, drill a hole in the desired location. The diameter of the hole

should be no more than 10mm greater than the diameter of the air supply pipe of the terminal.

NOTE: The hole should be drilled from the outside to ensure that no damage is done to the roofing material. Extra

care should be taken to ensure that the hole is drilled vertically.

4. Install the roof flashing and secure as appropriate.

5. Carefully insert the roof terminal through the roof flashing and hole in the roof.

NOTE: When inserting the roof terminal do not support or turn the terminal using the cap.

6. Ensure the terminal is vertical using a spirit level.

7. Fit the support bracket around the terminal and secure using appropriate fixings. Do not tighten the support bracket.

8. Install the remainder of the flue system working progressively away from the boiler supporting the pipes as necessary.

9. Once the flue system is fully installed, tighten the clamp to secure the terminal in place.

Page 30

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

Flue Gas Mass Rate (G20) 100% (g/sec)

22.6

29.8

37.1

45.1

55.6

67.3

Flue Gas Mass Rate (G20) 25% (g/sec)

5.7

7.5

9.3

11.3

13.9

16.8

Flue Gas Mass Rate (G31) 100% (g/sec)

23.2

30.6

38.8

46.2

57.0

69.0

Flue Gas Mass Rate (G31) 25% (g/sec)

5.8

7.7

9.7

11.6

14.3

17.3

FIGURE 8.4 VERTICAL TERMINAL ROOF FLASHINGS FOR SYNTHETIC, FLAT AND TILED ROOFS

FIGURE 8.5 INSTALLING TERMINAL THROUGH ROOF FLASHING

8.7.4 TYPE C

This appliance can operate on a U-Duct common flue system. The maximum lengths for the interconnecting flue can be calculated using the information in Section 8.5: MAXIMUM LENGTH – CONVENTIONAL/TWIN-PIPE FLUE

Concrete components of the U-Duct must meet the requirements of BS EN 1858

TABLE 8.11 FLUE GAS MASS RATES

8.7.5 TYPE C

(TWIN PIPE FLUE)

When installing the heater as a Type C53 appliance, it should be noted that the terminals must not be installed on opposite sides of the building.

The details of how to convert the appliance for twin pipe flued operation are contained within the conversion kit.

To install a horizontal Type C53 terminal or air inlet the procedure for a Type C13 terminal should be followed. To install a vertical Type C53 terminal or air inlet, the procedure for a Type C33 terminal should be followed.

8.8 COMMON FLUE SYSTEMS

The CP-M+ boiler can be installed on to a common flue system if required. The common flue system should be sized to operate under a negative pressure of -0.03 to -0.10 mbar.

Page 31

Model

Gross

Input (kW)

Net Input (kW)

Ventilation

(Room)

(cm2)

Compartment

(Direct to Outside)

(To Internal Space)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

CP-M+60

62.2

56.0

245

280

560

1120

Model

Gross

Input

(kW)

Net

Input

(kW)

Plant Room

Enclosure

Low

Summer Use

Medium

Summer Use

High

Summer Use

Low

Summer Use

Medium

Summer Use

High

Summer Use

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

CP-M+80

82.2

74.0

148

296

222

370

296

444

370

740

444

814

518

888

CP-M+100

102.2

92.0

184

368

276

460

368

552

460

920

552

1012

644

1104

CP-M+120

123.3

111.0

222

444

333

555

444

666

555

1110

666

1221

777

1332

CP-M+150

153.3

138.0

276

552

414

690

552

828

690

1380

828

1518

966

1656

CP-M+180

184.3

166.0

332

664

498

830

664

996

830

1660

996

1826

1162

1992

If a positive pressure common flue system is to be used, a proprietary recirculation prevention device must be installed at the flue spigot of each boiler to prevent products of combustion from re-entering the plant room.

A cascaded common flue system which operates on a positive pressure is available from Lochinvar Limited. Further details can be found in the Cascade Flue Systems guide, available from www.lochinvar.ltd.uk.

8.9 FLUE TERMINAL GUARDING

If a horizontal flue terminal is to be fitted less than 2 metres from ground level or in a location where it can be touched from a window, door or balcony, a terminal guard must be fitted. The terminal guard should be positioned centrally around the terminal and secured using appropriate wall fixings. An approved terminal guard is available; please contact Lochinvar Limited for further information.

8.10 CONDENSATE DRAIN

For flue runs of less than 6 metres, provided that the flue system rises at an angle of at least 3 (50mm per metre), no additional condensate drain will be required. Failure to provide an adequate rise in the flue system may lead to pooling of condensate which may lead to premature failure of the flue system.

If the flue run is greater than 6 metres, it is recommended that an inline condensate drain and trap be fitted. The condensate trap should be connected to a suitable drainage system as described in Section 6.5: CONDENSATE DRAIN

Where a common flue is used, precautions should be taken to ensure that all condensation formed in the flue system is not drained through one boiler. It is recommended that a condensate drain point is installed in the common flue header and connected to a suitable drainage system.

9.0 AIR SUPPLY

The following information is based on single boiler installations only. If more than one boiler is being used, BS6644 should be consulted to calculate the necessary requirements.

9.1 COMBUSTION VENTILATION

When used as a Type C appliance, ventilation for combustion is not necessary as the combustion air is ducted directly from outside.

When used as a Type B appliance, the combustion air requirements are as follows:

TABLE 9.1 COMBUSTION VENTILATION REQUIREMENTS – CP-M+60

TABLE 9.2 COMBUSTION VENTILATION REQUIREMENTS – CP-M+80 – CP-M+180

Page 32

9.2 COOLING VENTILATION

Model

Input

(Gross)

Input (Net)

Enclosure/Compartment

Boiler Room

(Direct to Outside)

(To Internal Space)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

High

(cm2)

Low

(cm2)

CP-M+60

62.2

56.0

280

560

N/A

CP-M+80

82.2

74.0

370

740

148

CP-M+100

102.2

92.0

460

920

184

CP-M+120

123.3

111.0

555

1110

222

CP-M+150

153.3

138.0

690

1380

276

CP-M+180

184.3

166.0

830

1660

332

Appliance Type

Flow rate per kW total rated net input (m3/h)

Minimum Inlet Air

(Combustion, Ventilation)

Difference between Inlet and Extract

Air

(Inlet minus Extract Ventilation)

Without draught diverters. (with or without draught stabilisers)

2.60

1.35 ± 0.18

When used as a type C appliance, installed in a compartment or an enclosure, cooling ventilation should be provided as follows:

TABLE 9.3 COOLING VENTILATION REQUIREMENTS

When used as a type B appliance, provision for cooling ventilation is included in the combustion ventilation allowance.

9.3 MECHANICAL VENTILATION

In situations where combustion air cannot be provided by the means of ventilation grilles, it can be supplied by a fan. The minimum flow rate for the fan should be in accordance with Table 9.4.

If required, extract air can also be through the use of a fan. When sizing the extract fan, the extract flow rate should be calculated by subtracting the difference volume (from Table 9.4) from the actual supplied volume of inlet air. If therefore, a larger than required inlet volume is provided, the extract flow rate will need to be increased accordingly.

If the ventilation discharge from the plant room is through the means of simple openings relying on thermal effects, the minimum free areas of the openings and any associated grilles should be as specified for natural ventilation (see Section 9.1:

COMBUSTION VENTILATION). The ventilation openings shall be at high level and the air supply shall be at low level.

NOTE: VENTILATION MUST NOT BE PROVIDED THROUGH NATURAL INLET AND MECHANICAL EXTRACT AS THIS

WILL CAUSE A NEGATIVE PRESSURE WITHIN THE PLANT ROOM AND MAY LEAD TO THE PRODUCTS OF COMBUSTION BEING DRAWN INTO THE PLANT ROOM.

9.3.1 WORKED EXAMPLE – MECHANICAL INLET/NATURAL DISCHARGE

Lochinvar CP-M+100

Heat input (net): = 92.0 kW

Minimum combustion air flow rate: = 92.0 x 2.6 m3/h = 239.2 m3/h

Ventilation grille size (high level): = 184 cm2

TABLE 9.4 MECHANICAL VENTILATION FLOW RATES

Page 33

9.3.2 WORKED EXAMPLE – MECHANICAL INLET/MECHANICAL DISCHARGE (MINIMUM COMBUSTION AIR

FLOW RATE)

Lochinvar CP-M+100

Heat input (net): = 92.0 kW

Minimum combustion air flow rate: = 92.0 x 2.6 m3/h = 239.2 m3/h

Difference between inlet and extract air (maximum value): = 92.0 x (1.35 + 0.18) m3/h = 140.76 m3/h

Difference between inlet and extract air (minimum value): = 92.0 x (1.35 - 0.18) m3/h = 107.64 m3/h

Extract air (maximum value): = 239.2 m3/h - 107.64 m3/h = 131.56 m3/h

Extract air (minimum value): = 239.2 m3/h - 140.76 m3/h = 98.44 m3/h

9.3.3 WORKED EXAMPLE – MECHANICAL INLET/MECHANICAL DISCHARGE (ALTERNATE COMBUSTION

AIR FLOW RATE):

Lochinvar CP-M+100

Heat input (net): = 92.0 kW

Minimum combustion air flow rate: = 92.0 x 2.6 m3/h = 239.2 m3/h

Actual combustion air flow rate: = 92.0 x 3.15 m3/h = 289.8 m3/h

Difference between inlet and extract air (maximum value): = 92.0 x (1.35 + 0.18) m3/h = 140.76 m3/h

Difference between inlet and extract air (minimum value): = 92.0 x (1.35 - 0.18) m3/h = 107.64 m3/h

Extract air (maximum value): = 289.8 m3/h - 107.64 m3/h = 182.16 m3/h

Extract air (minimum value): = 289.8 m3/h - 140.76 m3/h = 149.04 m3/h

10.0 WATER CONNECTIONS

10.1 FLOW/RETURN CONNECTIONS

There are two tee-pieces supplied with the boiler, these are for enlarging the flow/return connections to the boiler and for installing a pressure relief valve (not supplied) and a drain valve (not supplied). It is recommended that isolation valves are fitted to the boiler flow and return connections to allow the appliance to be isolated from the system when required.

The boiler has no internal relief valve; therefore a suitably sized pressure relief valve must be fitted to the boiler flow connection.

10.2 OPEN VENTED SYSTEM ARRANGEMENT

The Lochinvar CP-M+ can be used in an open vented arrangement provided that a vent pipe in accordance with CP 342 or BS6644 as appropriate is fitted. The minimum static head requirement for an open vented system is 1.0 bar.

The appliance is fitted with a water pressure sensor and requires a nominal system pressure of 1.0 bar. The burner control will block the boiler from operating if the system pressure drops below a pressure of 0.8 bar; once the system pressure rises above

1.0 bar, the block will be lifted. The maximum system pressure with the standard pressure sensor is 4.0 bar however, a pressure switch may be used if the static head exceeds this. For further details on the connection of a water pressure switch, please refer to Section 11.0: ELECTRICAL SUPPLY

Page 34

10.3 SEALED SYSTEM ARRANGEMENT

Stored

Temp.

C

0.005

0.006

0.008

0.010

0.012

0.015

0.017

Stored

Temp.

C

0.020

0.023

0.026

0.030

0.031

0.033

0.037

If a sealed system arrangement is required, a suitable pressurisation unit is available from Lochinvar Limited on request. Sealed systems should incorporate a safety valve with a lift pressure no greater than the maximum pressure rating of any component in the heating system. The maximum working pressure of the boiler is 6.0 bar. A suitably sized expansion vessel should also be fitted to the system in accordance with BS4814.

10.3.1 EXPANSION VESSEL SIZING

The following information is based on a static head of 3.5 bar. If a different cold fill pressure is to be used, please consult

BS4814.

V V = S V * e

0.45

Where: V V = Vessel Volume S V = System Volume e = Coefficient of Expansion (See Table 10.1)

TABLE 10.1 COEFFICIENT OF EXPANSION OF WATER AT 3.5 BAR COLD FILL PRESSURE

10.4 CIRCULATING PUMPS

The CP-M+ boiler has a built in circulating pump. This pump has a speed regulator which has been adjusted to the maximum setting. To prevent operational issues, this setting must not be altered.

When there is a call for heat, the pump is energised, once the call for heat expires, the pump overruns for a period of 3 minutes. The pump is also activated for one minute every 24 hours after the boiler power supply is connected in order to prevent the pump seizing.

Page 35

FIGURE 10.1 HYDRAULIC GRAPH – CP-M+60

Hydraulic graph 80kW

ΔT=20K

ΔT=25K

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

Water flow (m³/h)

Head (meter WC)

Resistance Boiler

Head Pump

Head for Installation

Resistance Boiler

Head Pump

Head for Installation

Hydraulic graph 60kW

ΔT=20K

ΔT=25K

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

0,0

0,5

1,0

1,5

2,0

2,5

3,0

Water flow (m³/h)

Head (meter WC)

FIGURE 10.2 HYDRAULIC GRAPH – CP-M+80

Page 36

FIGURE 10.3 HYDRAULIC GRAPH – CP-M+100

Hydraulic graph 120kW

ΔT=20K

ΔT=25K

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

Water flow (m³/h)

Head (meter WC)

Resistance Boiler

Head Pump

Head for Installation

Hydraulic graph 100kW

ΔT=20K

ΔT=25K

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

Water flow (m³/h)

Head (meter WC)

Resistance Boiler

Head Pump

Head for Installation

FIGURE 10.4 HYDRAULIC GRAPH – CP-M+120

Page 37

ΔT=20K

ΔT=25K

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5

Head (meter WC)

Water flow (m³/h)

Hydraulic graph 150 kW

resistance boiler head pump s2 head for installation s2 head pump s3 head for installation s3

ΔT=20K

ΔT=25K

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

5.0 5.5 6.0 6.5 7.0 7.5

Head (meter WC)

Water flow (m³/h)

Hydraulic graph 180 kW

Resistance Boiler Head pump s2 Head for installation s2 Head pump s3 Head for installation s3

FIGURE 10.5 HYDRAULIC GRAPH – CP-M+150

FIGURE 10.6 HYDRAULIC GRAPH – CP-M+180

Page 38

10.5 DIRT SEPARATOR/STRAINER

Due to the high-efficiency, low water content design of the heat exchanger, it is necessary to install a method of removing dirt from the system. A dirt separator or strainer should be installed in the system return line and checked on a weekly basis to ensure an adequate flow is maintained whilst ensuring that the heat exchanger does not get blocked.

Where a strainer is used, it is recommended that isolation valves are installed either side of the strainer and a bleed point is installed to aid in the routine maintenance.

Blockage of the heat exchanger due to the ingress of debris from the system is not a manufacturing defect and is not covered by the warranty.

10.6 AIR SEPARATOR

When a CP-M+ boiler is installed on a heating system containing iron, oxygen in the water can react to form the mineral magnetite. Due to the highly magnetic nature of magnetite, the mineral can create flow restrictions in the heat exchanger, which may result in premature failure.

When installing a CP-M+ boiler the system must be fully flushed to remove all existing traces of magnetite and an air separator should be fitted to prevent any further development.

The air separator should be installed in the hottest part of the heating system, i.e. on the flow out of the low velocity header, and in accordance with the item manufacturer’s instructions.

10.7 ROOF-TOP INSTALLATION

If the CP-M+ boiler is to be positioned at the highest point of the installation, the system flow and return pipes must rise a minimum of 0.5m above the top of the boiler, before re-directing to the desired locations within the building to ensure a minimum water level is maintained within the boiler. A low-water level protection device should also be installed within the system.

10.8 INSTALLATION SCHEMATIC DRAWINGS

The following schematic drawings are for guidance purposes only.

Alternate installation schematic drawings are available; please visit www.lochinvar.ltd.uk.

Page 39

1. LOCKSHIELD VALVE

2. DRAIN VALVE

3. AIR SEPARATOR

4. DIRT SEPARATOR

5. AUTOMATIC AIR VENT

6. EXPANSION VESSEL

7. TEMPORARY FILL CONNECTION (REMOVE AFTER FILLING)

8. DOUBLE CHECK VALVE

9. LOW VELOCITY HEADER

10. NON RETURN VALVE

11. PRESSURE RELIEF VALVE

12. ISOLATION VALVE

13. MANUAL AIR VENT

14. STRAINER

FIGURE 10.7 SINGLE BOILER INSTALLATION ON A SEALED SYSTEM

Page 40

1. LOCKSHIELD VALVE

2. DRAIN VALVE

3. AIR SEPARATOR

4. DIRT SEPARATOR

5. AUTOMATIC AIR VENT

6. EXPANSION VESSEL

7. TEMPORARY FILL CONNECTION (REMOVE AFTER FILLING)

8. DOUBLE CHECK VALVE

9. LOW VELOCITY HEADER

10. NON RETURN VALVE

11. PRESSURE RELIEF VALVE

12. ISOLATION VALVE

13. MANUAL AIR VENT

14. STRAINER

15. CASCADE FLOW SENSOR

FIGURE 10.8 MULTIPLE BOILER INSTALLATION ON A SEALED SYSTEM

Page 41

11.0 ELECTRICAL SUPPLY

Model

Normal Supply

Voltage

External Fuse

Rating

Power Consumption

CP-M+60

230V AC

50 Hz

1 PH

6.0 Amps

355

CP-M+80

355

CP-M+100

355

CP-M+120

370

CP-M+150

600

CP-M+180

600

CONNECTION

NOTES

1 - 2

Outside

Temperature

Sensor

When an outside temperature sensor is connected, the boiler setpoint will be compensated in relation to the outside temperature. The addition of this sensor will reduce the flow temperature of the boiler in warmer temperatures, increasing energy efficiency.

A change in control parameters will be required when this sensor is connected and the control system should be configured to function as required. For further information, please refer to Section 12.10: OUTSIDE TEMPERATURE COMPENSATION.

3 – 4

Cascade Flow

Temperature

Sensor

When a multiple boiler cascade is used, the master boiler requires a flow sensor to be fitted to the common pipework in order to control the firing rate whilst acting as a “lag” boiler.

The sensor should be located on the system flow adjacent to the low velocity header.

No change in control parameters will be required when this sensor is connected.

5-6

Calorifier

Sensor or

Thermostat

Where a DHW calorifier is used, a hot water sensor or an on/off thermostat can be connected. When a sensor is connected, the water temperature will be shown on the display; when a thermostat is used the flow temperature to the indirect storage vessel will be shown.

7-8

General

Blocking

Where an interlock with a safety system such as a flue fan or mechanical ventilation system is required, the safety circuit should be wired to terminals 7 and 8. Where more than one safety system is used, each system should be wired in series.

When the link on 7 and 8 is broken, all heat demands, including frost protection are blocked.

9-10

Empty

N/A

11-12

External Water

Pressure

Switch

A water pressure sensor is mounted in the boiler with a maximum pressure of 4.0 bar. As an option, the sensor can be replaced by a water pressure switch, which can be wired to the terminals. When terminals 1112 are not bridged, the boiler will lock-out.

A change in control parameters is required to activate this function.

1 2

6 9 10

11 12 17

18 19 20

21 222324

OUTSIDE

TEMPERATURE

SENSOR

CASCADE FLOW

TEMPERATURE

SENSOR

CALORIFIER

SENSOR OR

THERMOSTAT

CASCADE

CONNECTION

230 V ~ 1 Ph 50Hz

SUPPLY

A B L N

GENERAL

BLOCKING

EMPTY

EXTERNAL WATER

PRESSURE SWITCH

8 131415 16

0 - 10V DC

+ -

ROOM THERMOSTAT

OR OPEN-THERM

BUS CONTROLLER

LOCK-OUT

(N.O.)

BURNER BURNING

(N.O.)

HEAT DEMAND

(N.O.)

25 26

L N

CENTRAL HEATING

SYSTEM PUMP

(P3)

CALORIFIER

DIVERTER VALVE

OR CALORIFIER

PUMP (P2)

29 30 31 32 33 34

Wiring external to the equipment must be installed in accordance with the I.E.E. Regulations and any local regulations that apply.

TABLE 11.1 ELECTRICAL SUPPLY REQUIREMENTS

WARNING: THIS APPLIANCE MUST BE EARTHED

A suitably competent person MUST check wiring. Normal supply required is 230 volts AC, single phase, 50 Hz. An isolator with a contact separation of at least 3mm in all poles should be sited close to the equipment and must only serve that equipment. The double pole switch must be readily accessible under all conditions.

11.1 CONNECTOR STRIP

FIGURE 11.1 CONNECTOR STRIP

Page 42

13-14

Room

Thermostat or

Open-Therm

Bus Controller

When no time or temperature control is required, these terminals should be linked. In this situation, the boiler flow temperature is set via the control interface; if an outside temperature sensor is connected, the boiler is controlled through the heating curve.

When an On/Off room thermostat (with or without timer) or a BMS enable contact is connected, the boiler will operate when the controller contact is closed. The flow temperature is controlled set via the control interface (with or without outside temperature compensation). To prevent interference in the control circuit, cabling to any control switch should be kept away from sources of electromagnetic interference or suitable screened cable should be used.

When configured (see Section 13.1 SETTING THE PARAMETERS WITH THE DISPLAY MENU for further

information), terminals ‘7’ and ‘8’ can be used to switch the unit between normal and setback operation mode.

When an “Open-Therm” room thermostat is connected, it should be connected to terminals ‘7’ and ‘8’ using

screened cable. The boiler is ready for use with a multifunctional room controller (such as the Lochinvar RC Controller). For further information, please see the controller specific manual.

No change in control parameters will be required when this connection is used.

15-16

0 – 10V DC

The boiler setpoint can or firing rate can be adjusted by an external control, through a 0V to 10V analogue signal. For Further information on 0-10 VDC control, please refer to Section 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU.

The “+” has to be connected to terminal ‘15’, while the “-“ has to be connected to the terminal ‘16’.

17-18

Cascade

Connection

The Lochinvar CP-M+ has a built in cascade management system. When two or more boilers are connected

in a cascade, each boiler of the cascade has to be connected to the next boiler using terminals ‘17’ and ‘18’.

This connection is polarity sensitive (all terminal 17s to be linked and all terminal 18s to be linked) and should be made using screened cable.

One boiler has to be appointed as a Master, while the other boiler(s) are the Slaves. All external controls such as calorifier sensor, outside temperature sensor, system pumps etc. are to be connected to the Master boiler.

For a cascade to work correctly, it is essential that a flow temperature sensor is used.

Each connected boiler needs to be programmed with a different address through the control interface, see Section 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU for further details.

19-20

Lock-Out

Signal

Terminals ‘19’, and ‘20’ are normally open volt free terminals that can be used to give status signals to a BMS panel in the event of a ‘Lock-Out ’condition.

No change in control parameters will be required when these connections are used.

21-22

Burner Burning

Signal

Terminals ‘21’, and ‘22’ are normally open volt free terminals that can be used to give status signals to a BMS panel when the burner is operational.

The contacts can also be configured to close when a specific firing rate is reached to enable a non-cascaded boiler.

A change in control parameters is required to activate this function.

23-24

Burner

Demand

Signal

Terminals ‘23’ and ‘24’ are normally open volt free terminals that can be used to give status signals to a BMS panel when a demand for heat is present.

A change in control parameters is required to activate this function.

25-26-

Central

Heating

System Pump

If required, a central heating system pump can be connected to terminals ’25 – 27’.

When a calorifier is connected to the boiler (or to the Master, when a cascade system is installed), the system pump is switched off when there is a DHW demand.

If the pump has an electrical loading in excess of 250 watts, a relay should be used to energise the pump.

28-29-

30-31

Calorifier

Diverter Valve

or Calorifier

Pump

Where a diverter valve is used to separate the CH circuit from the DHW circuit, this can be controlled by the

boiler using terminals ’28 – 31’. Where the DHW circuit is operated by an additional pump, this can be enabled using terminals ’29 – 31’

See Section 13.1: SETTING THE PARAMETERS WITH THE DISPLAY MENU for details on configuring this output.

If the pump has an electrical loading in excess of 250 watts, a relay should be used to energise the pump.

32-33-34

230 V ~ 1 Ph 50 Hz Supply

The 230 VAC 1PH 50Hz power supply should be connected to terminals ’24 – 26’. Terminal ‘32’ should be Live Terminal ‘33’ should be Earth Terminal ‘34’ should be Neutral.

TABLE 11.2 CONNECTION TERMINAL DETAILS

Page 43

11.2 ARC WELDING PRECAUTIONS

The appliance must be isolated from the mains electricity supply in the event of electric arc welding being carried out on any connecting pipework.

11.3 ANCILLARY EQUIPMENT

11.3.1 OUTSIDE TEMPERATURE SENSOR

When an outside temperature sensor is fitted to compensate the flow temperature of the boiler, it should be located in an area where it is not influenced by other heat sources i.e. out of direct sunlight (ideally on a north facing wall) and away from flue terminals and heat extract fans.

11.3.2 SAFETY CIRCUIT

Where additional safety devices are used such as emergency stop controls, system pressurisation units and fire control systems, the safety circuits should be linked in series and connected to terminals ‘7’ & ‘8’ on the connection strip. This will ensure that the appliance does not fire in an unsafe situation but maintains all of its protection features such as combustion post-purge and pump over-run.

11.4 CASCADE CONTROL

11.4.1 CASCADE WIRING

If the heaters are to be operated in a cascade, shielded 2-wire twisted pair communication cable should be used.

The shielding should be connected to a suitable earth point and then all “17” terminals should be linked together and all “18” terminals should be linked together.

11.4.2 CASCADE SENSOR

A strap-on pipe sensor is required for the cascade control to function correctly. This should be located as close to the low velocity header as practicably possible on the system flow pipework.

11.5 TIME, TEMPERATURE AND ZONE CONTROL

Lochinvar can supply time, temperature and zone control options for a variety of heating system installations. For further details, please refer to the Systems and Controls Guide, available from www.lochinvar.ltd.uk.

Page 44

ref.1

only when unit is

cascaded

to slave boiler

master

boiler

Remote temperature

setpoint or burner input

signal form BMS

water pressure

switch

Calorifier themostat

Calorifier

sensor 10K

External

flow sensor 10K

Outdoor

sensor 12K

connection

examples

POWER SUPPLY

Heat demand

N.O.

Flame on

N.O.

Lock-out

N.O.

CN4

CN not used

1098

1 2 4

3 5 6

71 2 4

3 5 6

653

421

K10

FAN

internal

connections

internal

connections

connection

examples

fuse 2

fuse 1

F2 F1

ref.1

N.C.

boiler casing

CN10

[close]

boiler pump

(pump1)

gas valve(s)

Heat demand NO

ionisation and/or ignition

CN8

ignition

transformer incl.

ionisation input.

CN7

display

CN6

Heat demand NO

OpenTherm/

power stealing

thermostat

fan control

fan PWM

fan Hall

+24Vdc

siphon pressure switch (PSW)

clixon/maximum (S6/S7)

water thermostat 24vdc

return sensor ntc (S2) 10K

flow sensor ntc (S1) 10K

CN5CN1CN3

CN12

1413121110

76543

CN10

CN11

2 3 4 5 6 7816

1 2 3 4 5 6

7 8

9 10 11 12

567

1011121314

MAINS L'

MAINS N'

Lock-Out NO

Flame on NO

Lock-Out NO

Flame on NO

Pump 3, N'

Pump 3, L'

Gas Valve, N'

Gas Valve, L'

Pump 1, L'

Pump 1, N'

Pump 2 / 3-way, L' (NO)

Pump 2 / 3-way, N'

[open] 3-way, L' (NC)

out

Gnd

91718

18179

10 11 12 13 14 15 1687

L N Mains 230 VAC

L N CH System

Pump P3

BURNER BURNING

+ 0 - 10

VDC

On/Off Stat or OpenTherm Heating Circuit

343332272625212019161514136

321

GENERAL BLOCKING

22 23 24

HEAT

DEMAND

LOCK-OUT

N.O. N.O.N.O.

EXTERNAL

FLOW

SENSOR

CALORIFIER

SENSOR

THERMOSTAT

8 9 10 11 12

EXTERNAL

WPS

OUTDOOR

SENSOR

17 18

A B

CASCADE

CONNECTION

28 29 30 31

CN15

EMPTY

L1 N L2 Divertor Valve Calorifier

by Calorifier Pump P2

wire bridge

External safety device:

- External flow switch

- Smoke detection

- Gas detection

- Ventilation fan

- Flue gas fan

- End switch motor actuated flue gas valve

- Gas leakage tester

- etc

WIRING COLORS K0=white K6=blue K1=yellow K7=red K2=brown K8=black K3=green K9=purple K4=grey K10=yellow/green K5=orange

K10

Therm.stat 230v

pump

connector

flue sensor ntc (S5) 10K

water pressure sensor

(water pressure switch will

be mounted above 4 Bar)

+5V

out

Gnd

N.C.

rear wall thermal

fuse

(water pressure switch

connection) Not used

Model 60 has no thermal fuse

and no thermal switch.

Both connections are bridged.

N.C.

burner door thermal

switch

11.6 CP-M+ WIRING DIAGRAM

FIGURE 11.2 WIRING DIAGRAM

Page 45

COMM.

PORT

SERVICE

DISPLAY

2 rows / each 20 characters

ON/OFF RESET ENTER

COMM.

PORT

Buttons to toggle through measured temperatures.

These are also used for navigating through the menus and

used for changing values.

Buttons can be pushed to open menu. [ hold for 1 second ]

Connector for connecting computer cable.

ON/OFF

RESET ENTER

Press and hold for 6 seconds to switch boiler on/off. Is also used as RESET button and ENTER button when programming.

SERVICE

Button to activate service function. [ hold for 3 seconds ]

Schornsteinfeger function (only for Germany).

Light: will light up when controller sees good flame signal. Lights when burner is burning.

CONTROL PANEL

12.0 CONTROL INTERFACE

12.1 CONTROL PANEL / DISPLAY UNIT

FIGURE 12.1 CONTROL INTERFACE

Page 46

H E A T I N G : S t a n d - b y > > > : 1 1 8 ° C ( 1 2 5 ° C )

BASE SCREEN : (what shows during operation)

press:

"MONITOR" screens

One can toggle through the measured values and status of

the heater. Pressing "ON/OFF, RESET, ENTER" briefly will cause the display to go back to the base menu.

When no button has been pressed for 3 minues the display

will automatically go to the BASE DISPLAY. (This time period can be set by a parameter)

press: MENU

"SETPOINT" menu

In this menu one can change temperature settings without the need for a password.

- Heating setpoint Flow set point when controlling on/off on set flow temp.

- Heating reduced

The amount of degrees diff. relative to "Heating setpoint" during night reduction.

- Parallel shift +/- relative to outdoor curve

(also in outdoor menu possible)

- Hot water setpoint Calorifier or Water heater (depends on heater type)

- Hot water reduced

The amount of degrees diff. relative to "Hot water setpoint" during night reduction.

By pressing ( ) one can toggle though the available menu's.

"PARAMETERS" menu

In this menu one can change parameters. The possible access depends on the password that is used.

Enter password:

Password

"LEVEL 2"

entered

"PROGRAM" menu

In this menu one can set the CH, DHW and Anti legionair program.

"TIME/DATE/DAY" menu

In this menu one can set the time and the date.

CONFIRMATION CHANGE !

When changes are being made in the menu's within this dashed rectangle, the user presses ENTER to confirm the changes. To prevent customers making changes by accident the following happens when changes are made:

Step 1 : The user presses "ENTER" to confirm the change made. Step 2 : The display asks the user to be sure to make these

changes. The user can cancel and confirm by using the left and right arrows.

CANCEL = CONFIRM =

"OUTDOOR" menu

In this menu one can set all Outdoor relevant parameters.

"USER LOCK" menu

In this menu one can lock the menu for users 0=UNLOCKED

1=LOCKED

When un-locked the user can enter the "MENU" by pressing the menu button and all sub menu's will show. When locked the user has to push the : MENU and simulatenously press for 6 seconds to get acces to all sub menu's. This is to prevent accidental changes! NOTE: The parameters sub menu can always be accessed.

press:

Display shows

for 3 seconds

- Heater type

- Time, date and day

example:

Z-FG 550 13:51 US(or EU) 06 / 01 / 2010 Wed

After this message the display shows for 3 seconds

- Software version and

- Cascade designation

example:

Firmware : Mk 00197

Adress : 0

press:

Display shows

2x20 digit message for 3 seconds

Message can be set in parameters.

example:

Company name City, Country

These three messages will also show when:

- Heater is connected to the power

- When heater is turned ON

- When heater is turned OFF sequence: The messages will show from TOP to BOTTOM each for three seconds.

"OPERATING HISTORY" menu

Shows burning hours DHW, Heating, etc.

"FAULT HISTORY" menu

Reading last 15 faults (only reading!).

"MAINTENANCE" menu

By pressing ( ) one can set the following options.

- Maintenance reset

- Maintenance Mode

- All

- Date

- Ignition cycles

- Burning hours

- Mainten Off

Password

"LEVEL 1"

entered

3 second message confirming acces:

"LEVEL 1"

3 second message confirming acces:

"LEVEL 2"

12.2 CONTROL PANEL MENU STRUCTURE

FIGURE 12.2 CONTROL MENU STRUCTURE

Page 47

Display during HEATING DEMAND

Heat demand type: Actual status:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Cascade Temperature Setpoint Measured temperature at control sensor

Communication

Indicator

Can be turned off by altering P5 BJ

When there is no heat demand it alway s shows heating.

Display during HOT WATER DEMAND

Heat demand type: Actual status:

H O T W A T R : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Cascade Temperature Setpoint Measured temperature at control sensor

Communication Thermostat = Coil Flow Temp.

Indicator

Sensor = Water Setpoint Temp.

Can be turned off by altering P5 BJ

Actual status text descriptions

Actual status:

B o i l e r o f f

The boiler is turned off at the control interface.

N o d e m a n d

No heat demand signal is received from the room thermostat or calorifier sensor/thermostat.

S t a n d - b y

Room thermostat or calorifier sensor/thermostat heat demand present but setpoint is reached.

P r e - p u r g e

The fan is purging the combustion chamber before starting an ignition cycle.

P r e - i g n i t i o n

Ignition process has started but the gas valve hasn't been opened.

I g n i t i o n

The burner is attempting to ignite.

P o s t - p u r g e

The fan is purging the combustion chamber after burner switches off.

B u r n i n g 1 0 0 %

The burner is firing at the indicated rate.

Cascade Communication Indicator

NO CASCADE COMMUNICATION

> > > Screen 1

Display is fixed showing Screen 1

CORRECT CASCADE COMMUNICATIO N

> > Screen 1

> Screen 2

Display alternates between Screen 1 & Screen 2 at 1 second intervals

When heat is needed for the calorifier the text "HEATING" changes into "H OTWATR".

12.3 DISPLAY DURING OPERATION

During normal operation the text in the display shows the status of the boiler. In the following figures the possble displays during normal operation are explained.

FIGURE 12.3 OPERATION SCREEN

Page 48

Pressing [◄] or [►] when the display shows the "operating screen" toggles through the screens below .

Pressing [ON /OFF, RESE T, ENTER] or [MEN U] at any time returns the display to the base menu.

SCREEN: 1

T 1 F l o w 1 2 3 , 9oC Temperature measured by the internal flow sensor.

T 2 R e t u r n 1 2 3 , 9oC Temperature measured by the internal return sensor.

O p e n Shown when the controller does not detect this sensor.

S h o r t e d Shown w hen the sensor wires or the sensor itself is shorted.

SCREEN: 2

T 3 E x t e r n a l 1 2 3 , 9oC Temperature measured by the external sensor.

T 4 C a l o r i f i 1 2 3 , 9oC Temperature measured by the calorifier sensor.

O p e n Shown when the controller does not detect this sensor.

S h o r t e d Shown w hen the sensor wires or the sensor itself is shorted.

SCREEN: 3

T 5 O u t d o o r 1 2 3 , 9oC Temperature measured by the outdoor sensor.

T 6 F l u e 1 2 3 , 9oC Temperature measured by the flue gas sensor.

O p e n Shown when the controller does not detect this sensor.

S h o r t e d Shown w hen the sensor wires or the sensor itself is shorted.

SCREEN: 4

d T F l o w R e t u r n 1 2 3 , 9oC Temperature difference between internal flow & internal return sensor.

d T F l u e R e t u r n 1 2 3 , 9oC Temperature difference between flue gas & internal return sensor.

SCREEN: 5

d T E x t R e t u r n 1 2 3 , 9oC Temperature difference between external & internal return (ΔT LLH).

S i g n a l P o w e r External supplied 0-10 Volt dc signal.

S e t p o i "Power" = power output control or "Setpoi" = temperature setpoint control.

SCREEN: 6

F a n s p e e d 9 9 9 9 r p m Actual fan speed in rpm.

F a n s p e e d 1 0 0 % Actual fan speed % of maximum allowable fan speed.

SCREEN: 7

F l a m e s i g n a l 1 0 0 μ A Flame signal given in μA.

W a t e r P r e s s u r 1 , 0 b a r Shows water pressure w hen sensor is connected.

SCREEN: 8

P u m p 1 H e a t e r O f f Pump 1 (Internal pump) On or Off.

P u m p 1 S i g n a l 1 0 0 % M odulating signal Pump 1 in (%).

SCREEN: 9

P u m p 2 C a l o r i O f f P ump 2 (Calorifier pump) O n or Off.

3 - w a y V a l v e H e a t i n g Signal to the 3-way v alve: "HEATING" or "HOTWATER".

SCREEN: 1 0

P u m p 3 S y s t e m O f f Pump 3 (Sy stem pump) On or Off.

h h : m m D D / M M / Y Y Y Y D a y Time & Date: hh=hour; mm=minutes; DD=date; MM=month; YYYY=y ear; Day

12.4 MONITOR SCREENS

During normal operation and stand-by, the “◄” and “►” buttons can be used to show some boiler information, including measured temperatures, settings and data. The following figure explains which values can be shown in the display. When no button is activated for 2 minutes the display will return to its status display.

FIGURE 12.4 MONITOR SCREENS

Page 49

SCREEN: 1 1

C a s c D e s i g n 0 Shows the cascade address of the boiler 0 = M ASTER, 1 ..... 11 = SLAVE S

C a s I n f 0 1 2 3 4 5 6 7 8 9 A B Displays number, priority and state of cascade boilers. (See below)

SCREEN: 1 2

C a s c P o w e r 9 9 9 % 9 9 9 % % heat demand of total (cascade) power available (% ).

D u a l B u r n e r : N o One heat exchanger equipped with two burners: "Yes" or "N o".

SCREEN: 1 3

M a x T h e r m O p e n Status of the maximum thermostat: "Open" or "Closed" .

G e n B l o c k C l o s e d Status of the general blocking contact: "Open" or "Closed".

SCREEN: 1 4

S i p h o n p r e s s C l o s e d Status of the condensate drain pressure switch: "Open" or "C losed".

N R V C o n t a c t O p e n Status of the non return valve contact: "Open" or "Closed".

Scre en 11 "CASCINF" Description

The CasInf screen sh ows the numb er of bo ilers connected with the Cascade. The Master/Lead boiler is designated as 0. Slave/L ag boilers will be desig nated 1, 2, 3,

4, 5, 6, 7, 8, 9, A, B. When a “-“ is used instead of a number, than that boiler is eithe r not connected, or in a locko ut mode and not available for the Cascade. When an “x“ is use d inste ad of a number, than that boiler is conn ected, but in locko ut mode.

When a “d” is used inste ad of a number, than that boiler is handling a DHW demand.

When the numb er is flashing, then that boiler is p roviding heat to the cascade. When the leading boiler is cha nged according to the set priority change time, then that

boiler’s ad dress will be shown first in the row of numbers.

Exa mple 1: "3 4 5 - -- - - - 0 1 2"

There are six bo ilers presen t and number 3 boiler has priority.

Exa mple 2: "3 4 x - -- - - - d 1 2 "

There are six bo ilers presen t and number 3 boiler has priority. Boiler 0 is h eating up an indirect DHW tank. Boiler 5 is present, but in a lockout.

FIGURE 12.5 MONITOR SCREENS (ctd.)

Page 50

Model

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

Max. set point* - (RPM)

6500

5700

Max. actual** - (RPM)

6500

6230

6095

5700

Margin on actual - (RPM)

+/- 50

+/- 175

+/- 50

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [SERVICE] and hold for 3 seconds.

The burner will start and show the display below.

Operating screen:

H E A T I N G : S e r v i c e 2 6 %

> > > 9 0 . 0oC ( 6 0 . 0oC )

"HEATING": The appliance is operating as a heating boiler.

"Service": It is operating in the service mode.

"26% ": The burner is firing at 26% .

"90,0oC": Max. allowable water temp. during service.

"60,0oC": Actual measured water temp. (when P5BJ active).

Press [ME NU ] to return to the service menu.

Use [◄] & [►] buttons to brow se through the monitor screens.

Press [ME NU ] to go to the operation menu or the service mode.

The unit will return to the standard operation display.

Press [SERVICE] to exit. The unit will go to the operating screen. Or

Press [ON /OFF] for 3 seconds to exit. The unit will be switched off.

Press [ME NU ] to access the main menu.

By using the [▲] & [▼] buttons the burner firing rate % can be changed.

Press [SERVICE] to exit the service mode.

12.5 SERVICE FUNCTION

The following figure describes how to use the service function.

* The maximum rpm that the controller is to use as a set point. ** The maximum rpm that the fan is actual able to run.

The maximum actual rpm can be lower than the maximum rpm set point. This is because the fan is not able to reach the maximum rpm set point, due to the unit’s resistance. The tolerance varies according to the design of each specific unit. The relation between the maximum rpm set point and the maximum actual rpm is given in this table. This table applies also to the service and “Schornsteinfeger” function of the boiler.

FIGURE 12.6 SERVICE MODE

TABLE 12.1 MAXIMUM COMBUSTION FAN SPEED

Page 51

ENGELSE UITVO ERING

"SCHORNST EINFEGER" function

When the "Schornsteinfeger" button is pressed for 3 seconds:

The boiler will fire at minimum firing rate (% )

In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : M i n i m u m

When the button is pressed momentarily again:

The boiler will fire at 50% firing rate

In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : 5 0 %

When the button is pressed momentarily again:

The boiler will fire at maximum firing rate (% )

In this state the display shows:

F l u e s e r v i c e m o d e

P o w e r : M a x i m u m

When the button is pressed momentarily again:

The boiler will return to the normal operation mode.

The "Schornsteinfeger" function is switched off.

NOTES:

The purpose of this function is to have an easy interface for the "Schorsteinfegers" in

Germany, to be able to do their required testing on the boiler. This is a simplified function

similar to the normal service function of the boiler.

When the heater is burning during Schorsteinfeger function (when top display line shows

"Flue service mode") and no button is pressed for 12 minutes the boiler will return

automatically to the normal operation mode.

All normal maximum temperature safeties remain active and the boiler/water heater pump

and the sy stem pump are running.

The "Schorsteinfeger function" can be activated by altering parameter (P5 BK)

12.6 SCHORNSTEINFEGER FUNCTION

The following figure describes how to use the Schornsteinfeger function.

NOTE: This function is only required in Germany and can be activated by parameter (P5 BK). By default, this function is disabled.

FIGURE 12.7 SCHORNSTEINFEGER FUNCTION

Page 52

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU ]

Main menu screen:

M a i n M e n u

C l o c k

The display shows "CLOCK" press [EN TER]

Setting Time and Date:

S e t t i m e / d a t e 0 8 : 3 3

3 0 / 0 3 / 2 0 1 0 T u e

The day is now flashing/selected and can be changed.

Use [▲] & [▼] to change the value.

Use [◄] & [►] to select another value.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [EN TER] for the confirmation screen after all changes are done.

Press [◄] to cancel the changes made (display goes back to operating screen).

Press [►] to confirm the changes made. The time and day will start flashing for

a few seconds. After this, the display returns to its operating screen.

12.7 SETTING THE TIME & DATE

The following figure describes how to program the time and date of the unit.

FIGURE 12.8 SETTING THE DATE AND TIME

Page 53

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "Setpoints" using [◄] & [►]

M a i n M e n u

S e t p o i n t s

Press [EN TER]

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

H e a t i n g s e t p o i n t

8 0

C H N i g h t s h i f t

- 1 0

H e a t i n g P a r s h i f t

D H W s e t p o i n t

6 0

D H W R e d u c e

1 0

The reduction of the DHW setpoint relative to normal setpoint. This reduction is

used outside the programmed DHW periods (Parameter P4 AA = 1/2).

Press [►] to confirm the changes. The value set in the screen when pressing

enter w ill be shown for a few seconds. After this the display returns to the normal

operating screen.

By pressing [◄] & [►] the following screens can be selected.

Press [ME NU] to exit. The unit will reset and return to the operating screen.

Press [EN TER] for confirmation screen when all the changes are made.

This is the w ater temperature setpoint that is active during the programmed DHW

periods (Parameter P4 AA = 1/2).

By pressing [▲] & [▼] the flashing values in the selected screen can be

changed.

Setting the parallel shift of the heating curve in relation to the outdoor temperature

control (Parameter P6 BB).

The flow temperature setpoint that will be activ e during normal CH operation

periods.

The reduction relative to the normal setpoint. This reduction is used outside the

programmed CH periods. NOT E: This parameter should be a negative

value or night time temperature will be increased relative to day time

temperature.

12.8 SETPOINTS

The following figure describes how to program the heating and hot water set points.

FIGURE 12.9 SETTING SETPOINTS

Page 54

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "Timer" using [◄] & [►]

M a i n M e n u

T i m e r

Press [EN TER]

P r o g r a m C H

M o n 1 0 6 : 0 0 - 2 3 : 0 0

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Three programmed time periods can be set each day. During these time periods the unit will use the normal C H and DHW

setpoints. Outside the programmed period(s) the unit will use the reduced temperature setpoints. If no time program is

required, blanks should be left e.g. "Mon 3 --:-- ---:--".

Press [►] to browse through the values that can be set on the bottom line. The

flashing v alue can be changed.

Press [►] to confirm the changes. The last alternation will be flashing for a few

seconds and return to base menu.

> > > Continued on next page < < <

Press [▲] & [▼] to change the selected (flashing) value.

Press [EN TER] for confirmation screen when all settings are done.

Press [ME NU] to exit. The boiler will reset and go to the operating screen.

Press [◄] for next SCREE N

12.9 SETTING THE TIMER PROGRAMS

Three different programs can be set with the boiler, these are:

 Central Heating (CH) program  Domestic Hot Water (DHW) program  Anti legionnaire’s disease (pasteurisation) program

NOTE: The anti legionnaire’s disease (pasteurisation) program can only be used when the boiler is set as an

“indirect” boiler configuration or a “direct” hot water boiler configuration. If DHW is deactivated, the day and time program of the anti legionnaire’s disease function will be hidden. The default setting for this function is “OFF”.

FIGURE 12.10 SETTING THE TIMER PROGRAMS

Page 55

C o p y f r o m : C H M o n

C o p y t o : C H T u e

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Setting DHW program times:

P r o g r a m D H W

M o n 1 0 6 : 0 0 - 2 3 : 0 0

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Copy programmed day for CH:

Press [►] to switch betw een "Copy from" and "Copy to". The flashing day is

selected and can be changed.

> > > From previous page < < <

> > > Continued on next page < < <

Press [►] to browse through the values that can be set on the bottom line. The

flashing v alue can be changed.

Press [►] to confirm the changes. The last alternation will be flashing for a few

seconds and return to base menu.

Press [◄] for next SCREE N

Press [▲] & [▼] to change the selected (flashing) value.

Press [EN TER] for confirmation screen when all settings are done.

Press [►] to confirm the changes. The two days will blink for a moment.

Press [ME NU] to exit. The boiler will reset and go to the operating screen.

Press [◄] for next SCREE N

Press [▲] & [▼] to change the selected (flashing) value.

Press [EN TER] for confirmation screen when all settings are done.

Press [ME NU] to exit. The boiler will reset and go to the operating screen.

FIGURE 12.11 SETTING THE TIMER PROGRAMS (ctd.)

Page 56

Copy programmed day for DHW:

C o p y f r o m : D H W M o n

C o p y t o : D H W T u e

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Setting legionella program (day and time):

P r o g r a m L e g i o n e l l a

M o n 0 9 : 5 1

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

Press [►] to confirm the changes. The two days will blink for a moment.

Press [►] to confirm the changes. The last alternation will be flashing for a few

seconds and return to base menu.

Press [►] to browse through the values that can be set on the bottom line. The

flashing v alue can be changed.

> > > From previous page < < <

Press [►] to switch betw een "Copy from" and "Copy to". The flashing day is

selected and can be changed.

Press [ME NU] to exit. The boiler will reset and go to the operating screen.

Press [◄] for next SCREE N

Press [▲] & [▼] to change the selected (flashing) value.

Press [EN TER] for confirmation screen when all settings are done.

Press [ME NU] to exit. The boiler will reset and go to the operating screen.

Press [◄] for next SCREE N

Press [▲] & [▼] to change the selected (flashing) value.

Press [EN TER] for confirmation screen when all settings are done.

FIGURE 12.12 SETTING THE TIMER PROGRAMS (ctd.)

Page 57

OUTSIDE TEMPERATURE

FLOW TEMPERATURE

-40

-30

-20 0 -10

30 0 90

P5 AE

outside temp high

P5 AC

outside temp low

P5 AF

- Flow temp at

outside temp high

P5 AD

- Flow temp at outside temp low

P6 BC

- Parallel shift

HEATING CURVE - main settings

12.10 OUTSIDE TEMPERATURE COMPENSATION

12.10.1 MAIN PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE

FIGURE 12.13 COMPENSATED HEATING CURVE – MAIN SETTINGS

When using this function the flow temperature is calculated based on the measured outdoor temperature. The relation between the outdoor temperature and the flow temperature can be programmed with the following parameters. This setting creates the so called “heating curve”.

P5 AA Outside present Config (1=on 0=off) *

To enable outside temperature compensation, this parameter must be set to a value of 1 and an outside temperature sensor must be connected to the boiler. When a cascade of CP-M+ boilers is used, these changes should be made to the master boiler only.

P5 AC Heat curve minimum outside temperature °C

This sets the minimum outside temperature at which the maximum flow temperature that is set.

P5 AD Heat curve flow temperature at minimum °C

This sets the desired maximum flow temperature at the set minimum outside temperature.

P5 AE Heat curve maximum outside temperature °C

This sets the maximum outside temperature at which the minimum flow temperature that is set.

P5 AF Heat curve flow temperature at maximum °C

This sets the desired minimum flow temperature at the set maximum outside temperature.

P6 BC Heat curve Parallel Shift °C

This parameter defines actual parallel shift that is set by the user. The bandwidth of the shift allowed is limited by the control software.

Page 58

FLOW TEMPERATURE

OUTSIDE TEMPERATURE

P5 AG

- min flow temp

P5 AH

- Warm weather shutdown

P2 HA

- Outdoor sensor hysteresis

HEATING CURVE - additional settings

P6 BB

- Heatcurve night shift

P6 BA

- max flow temp

-10 0 -20

-30

-40

12.10.1 ADDITIONAL PARAMETERS FOR SETTING THE COMPENSATED HEATING CURVE

FIGURE 12.14 COMPENSATED HEATING CURVE – ADDITIONAL SETTINGS

P5 AG Heat curve minimum flow temperature °C

The set point will never be lower than the flow temperature set in parameter P5AG. The minimum temperature is limited, even when the calculated set temperature should be lower because of the heating curve.

P5 AH Summer Outside temperature Central heating °C

When the outside temperature is higher than set in P5AH any central heating demand will be blocked.

P2 HA Outdoor sensor hysteresis °C

If the outdoor temperature reaches the temperature set in P5 AH (warm weather shutdown) all heating demands will be ignored. If the measured outdoor temperature drops P5 AH minus P2 HA heating demands will resume.

P6 BA CH User Setting °C

The setpoint will never be higher than the flow temperature set in parameter P6BA. The maximum temperature is limited, even when the calculated set temperature should be higher because of the heating curve.

P6 BB Heat curve night shift °C

The heating curve is set by the above parameters. In addition to these settings, the end user has the ability to influence the flow temperature by doing a parallel shift setting. Parameter P6BB sets the margins within which the user can increase and decrease the calculated flow temperature relative to the calculated flow temperature by the heating curve that is set.

Page 59

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "Outdoor" using [◄] & [►]

M a i n M e n u

O u t d o o r

Press [EN TER]

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes made (unit will reset).

0 1 O u t s i d P r e s P5 AA

0 2 H C m i n O u T m p

P5 AC

- 1 5

0 3 H C m i n F l T m p P5 AD

8 5

0 4 H C m a x O u T m p P5 AE

2 0

0 5 H C m a x F l T m p P5 AF

2 0

0 6 H C m i n F l L i m

P5 AG

2 0

0 7 S u m S h D w n O u

P5 AH

3 0

0 8 H C m a x F l L i m P6 BA

8 5

0 9 H C n g h t s h f t P 6 BB

- 1 0

0 A H C p a r a s h f t

P6 BC

0 B O u t S 1 2 k 1 0 k P5 AR

Press [►] to confirm the changes made. The time and day w ill start flashing for

a few seconds. After this, the display returns to its operating screen.

Press [◄] & [►] to browse through the screens that are shown below.

Press [▲] [▼] to change the flashing value in the selected screen.

Press [ME NU] to exit. The unit will reset and go to the operating screen.

Press [EN TER] for confirmation screen after all changes are made.

12.10.2 SETTING OUTSIDE TEMPERATURE COMPENSATION

The following figure describes how to program the outside temperature compensation curve.

FIGURE 12.15 SETTING OUTDOOR TEMPERATURE COMPENSATION

Page 60

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "Operate" using [◄] & [►]

M a i n M e n u

O p e r a t e

Press [◄] & [►] to browse through the 5 screens.

SCREEN: 1

O p e r a t i n g h i s t o r y

P o w e r O n h r s 1 3 1 4 0 0

SCREEN: 2

h r s C h T o t 1 0 0 0 0 0 0

h r s D h w T o t 1 0 0 0 0 0 0

SCREEN: 3

h r s C h < 5 0 % 1 0 0 0 0 0 0

h r s C h = > 5 0 % 1 0 0 0 0 0 0

SCREEN: 4

h r s D h w < 5 0 % : 1 0 0 0 0 0 0

h r s D h w = > 5 0 % : 1 0 0 0 0 0 0

SCREEN: 5

T i a 1 0 0 0 0 0 F i a 1 0 0 0 0 0

S s l 1 0 0 0 0 0 S s t 1 0 0 0 0 6

Bottom line: Ssl = Soft Starts last

Sst = Soft Starts Total

Bottom line: Burner-on hours for DHW w hile the burner was firing at equal to or

more than 50% .

Top line: Burner-on hours for central heating while the burner was firing at less

than 50% .

Bottom line: Burner-on hours for central heating while the burner was firing at

equal to or more than 50% .

Top line: Shows the operating history menu is activated.

Press [ME NU] or [ENTER] to exit. The unit will return to the operating screen.

Press [EN TE R]

Top line: Total burner-on hours for central heating demand.

Bottom line: Total burner-on hours for DHW demand.

Top line: T ia = Total Ignition Attempts

Fia = Failed Ignition Attempts

Top line: Burner-on hours for DHW while the burner was firing at less than 50%.

Bottom line: Total number of hours that the boiler has been powered on for.

12.11 CHECKING THE OPERATING HISTORY

The following figure describes how to check the operating history of the boiler.

FIGURE 12.16 CHECKING THE OPERATING HISTORY

Page 61

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "Faulthist" using [◄] & [►]

M a i n M e n u

F a u l t h i s t

F a u l t h i s t N o . 0 1

2 1 / 0 4 / 2 0 1 0 W e d 2 2 : 2 3 A

▲ flashing to ▼

S i p h o n S w i t c h

S v 9 9 9 / C U M 9 9 9 / R 9 9 9 9 , 5

Press [◄] & [►] to browse through the last 10 faults.

CUM: The total number of this type of fault that has occurred. As this v alue

cannot be erased after service, this shows the fault history of the burner control

since the start of operation.

R: The elapsed time in hours between the fault occurring and it being reset.

Press [EN TE R]

The fault menu shows the last 10 faults. For each fault the display flashes

betw een the two screens shown above.

The top line of the second screen shows the fault type. The bottom line shows

the following:

Press [ME NU] or [ENTER] to exit. The unit will return to the operating screen.

The top line of the first screen shows the fault number. The bottom line of the first

screen shows the date, day and time that the fault occurred.

SV: The number of this type of fault that has occurred since the service history

was last erased (after service was done).

12.12 CHECKING THE FAULT HISTORY

The following figure describes how to check the fault history of the boiler.

FIGURE 12.17 CHECKING THE FAULT HISTORY

Page 62

MAINTENANCE SETTINGS

The unit can be programmed in such a way that an automatic maintenance message is displayed.

There are three options that can be selected. A maintenance message appears after:

* A programmed date is reached.

* An amount of burning hours is reached.

* An amount of ignition cycles is reached.

A single option can be activated or all three options.

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU ]

Select "M aintenan" using [◄] & [ ►] and press [EN TE R]

M a i n M e n u

M a i n t e n a n

M a i n t e n R e s e t

Press [▲] to reset the:

Counter for the total amount of burning hours.

Counter for the total amount of ignition cycles.

(The text w ill flash once briefly after resetting).

Operating screen:

M a i n t e n M o d e

flashing second line.

Press [▲] or [▼] to change the selected

flashing option.

Screen: Selecting of all maintenance options.

M a i n t e n M o d e

A l l

Press [►] to set:

The option that is flashing can be changed using by [▲] & [▼]

* Date for the Maintenance message.

* Total amount of burning hours for the Maintenance message.

* Total amount of ignition cycles for the Maintenance message.

After selecting one of these values the boiler returns to the

maintenance operating screen.

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the

Press [EN TER] to confirm the changes.

changes. After the boiler returns to operating screen.

Press [EN TER]

What is flashing at the second line (before a selection is made) is the active

maintenance option.

> > > Continued on next page < < <

12.13 SETTING THE MAINTENANCE SPECIFICATIONS

The following figures describe how to check and program the maintenance settings. The standard factory setting for this function is “OFF”.

FIGURE 12.18 SETTING MAINTENANCE ALERTS

Page 63

Screen: Selecting message at certain date.

M a i n t e n M o d e

D a t e

Press [►] to set:

The date for the maintenance message.

Press [◄] to:

Return to maintenance mode selection.

Press [►] to browse through the values that can be set

at the bottom line.

The flashing v alue can be changed with [▲] & [▼]

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the

Screen: Message after total amount of ignition cycles.

M a i n t e n M o d e

I g n i t i o n c y c l e s

Press [►] to set:

The total amount of ignition cycles for the M aintenance message.

Press [◄] to:

Return to maintenance mode selection.

The flashing v alue can be changed with [▲] & [▼]

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the

> > > Continued on next page < < <

Press [EN TER] to confirm the changes.

changes. After the boiler returns to operating screen.

Press [EN TER] to confirm the changes.

changes. After the boiler returns to operating screen.

> > > From previous page < < <

FIGURE 12.19 SETTING MAINTENANCE ALERTS (ctd.)

Page 64

Screen: M essage after total amount of burning hours.

M a i n t e n M o d e

B u r n i n g h o u r s

Press [►] to set:

The total amount of burning hours for the Maintenance message.

Press [◄] to:

Return to maintenance mode selection.

The flashing value can be changed with [▲] & [▼]

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the

Screen: N o maintenance message will be displayed.

M a i n t e n M o d e

M a i n t e n O f f

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

Press [◄] to cancel the changes or [►] to confirm the

Note: T he [MENU] button will return the display to the operating screen.

changes. After the boiler returns to operating screen.

Press [EN TER] to confirm the changes.

changes. After the boiler returns to operating screen.

Press [EN TER] to confirm the changes.

> > > From previous page < < <

FIGURE 12.20 SETTING MAINTENANCE ALERTS (ctd.)

NOTE: This maintenance reminder function is disabled by default; it is a programmable function to be used as a

notification that maintenance is required. Because the parameters are freely programmable, the function cannot be used as a reason to not carry out the required routine maintenance or as an argument in warranty cases.

The boiler must be maintained in accordance with Section 16.0: MAINTENANCE irrespective the settings/working of this function.

Page 65

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU ]

Select "U serlock" using [◄] & [►]

M a i n M e n u

U s e r l o c k

Press [EN TER]

S e t U s e r l o c k = 0

The "0" is now flashing/selected and can be changed.

Use [▲] & [▼] to change the value.

0 = User lock function OFF

1 = User lock function ON

Confirmation screen:

A r e y o u s u r e

< C a n c e l ; > C o n f i r m

NOTE: Pressing the [ME NU ] button during the User lock display, w ill reset the

boiler and the boiler will return to the operating screen. Changes will be neglected

in this case.

Press [◄] to cancel the changes (the unit will reset and the display returns to

the operating screen).

Press [EN TER] for the confirmation screen after the selection has been made.

Press [►] to confirm the changes. The changed value will be flashing for a few

seconds. After this, the display returns to the operating screen.

12.14 SETTING THE USER LOCK

When the user lock function is activated, it prevents accidental changes being made to the operating characteristics of the boiler. It should be noted that whilst access to the basic settings is disabled, the parameter menus can still be accessed using the required passwords.

Once the boiler is locked, the [MENU] button and [▲] button should be pressed simultaneously and held for 5

seconds.

The following figure describes how to activate the user lock of the display. The standard factory setting for this function is “OFF”.

FIGURE 12.21 ACTIVATING THE USER LOCK

Page 66

RELATES

PASSWORD: PASSWORD:

XEPK7

SOFTW.

PARAM Display Modify Display Modify

P5BE Step modulation (1=on 0=off) - S t e p m o d u l yes no yes yes

P5AO Blocking offset flowtemperatur control

H E s O f f 1 3 yes yes yes yes

P5AP Proportional range temperature control

H E s P r b 1 3 yes no yes yes

P5AL Hysterese CH Flow temperatur control

H E s c D i f 1 3 yes yes yes yes

P2IC Intergration time temperature control sec H E s I n t 1 3 yes no yes yes

P2MI Blocking offset System CH temperatur control

H E c O f f 3 yes yes yes yes

P2MJ Proportional range System CH temperature control

H E c P r b 3 yes no yes yes

P2MK Intergration time CH temperature control sec H E c I n t 3 yes no yes yes

P5AB Timer Contact (1=on) - T i m e r C o n t yes yes yes yes

P4AB DHW Pump Config 0=Pump 1=TWV - D H i p m p / t w v yes yes yes yes

P5CB Flow temperature Dhw tank low

D H i f l o w L O yes yes yes yes

P5CK Flow temperature Dhw tank hi

D H i f l o w H I yes yes yes yes

P5CL Low Flowtemperature time Dhw min D H i L O t i m e yes yes yes yes

P5CD Legionella temperature

L e g i o t e m p yes no yes yes

P5CI Legionella hyst Dhw tank temperatur

L e g i o h y s t yes no yes yes

P5CJ Legionella hold time (0=off) min L e g i o h o l d yes no yes yes

P2KI CH interrupt by Legionella (0=yes)(1=no) - L e g i o i n t r yes no yes yes

P2LC Regulation temperatur ofset DHWd

D H d s c O f f 2 yes yes yes yes

P2LE Proportional range DHWd modulation

D H d s c P r b 2 3 yes no yes yes

P2LD Regulation temperatur hysteres DHWd

D H d s c D i f 2 yes yes yes yes

P2LF Intergration time DHWd modulation sec D H d s c I n t 2 3 yes no yes yes

P2ML Sys temp blocking ofset DHW tank

D H d s c O f f 3 yes yes yes yes

P2MM Sys temp blocking hysteres DHW tank

D H d s c D i f 3 yes yes yes yes

P5CA Hysterese Dhw tank temperatur

D H i s c D i f 4 yes yes yes yes

P2KH Gradient heatdemand detect Dhw tank temperatur

D H i d e t g r a d yes yes yes yes

P2MA Max number extra boilers - M a x C a s c U n t yes no yes yes

P5DA Busdadres boiler - B u s a d r e s s yes no yes yes

P5DC Dhw on entire cascade(0) only master(1) - D H i c a s / m a s yes no yes yes

P5DE Extra Boiler output enable(1) - E x t r a u n i t yes yes yes yes

P5DF Cascade detection (0=standalone 1=Leader) - C a s S i / M a yes no yes yes

P5BL Power off total cascade (1) - P w r O f f T o C a yes no yes yes

P5DB Number of boilers with common flue 0=None - C o m F l u N u m yes no yes yes

P5BB Analog input Config (0=off 1=temp 2=power) - A n I n p C o n yes yes yes yes

P5AI Minimum Temperature 0-10V input

0 - 1 0 M i n T m p yes yes yes yes

P5BI Altitude (* 100 ft) ft/100 A l t * 1 0 0 f t yes yes yes yes

P2LK Max cooling time. min M a x C o o l T i m yes yes yes yes

P5BJ Temperature display 1=on - T e m p O n D i s p yes yes yes yes

P4AA DHW 0=off 1=Indirect 2=Direct - D H W 1 = i 2 = d yes no yes yes

LEVEL 2

LEVEL 1

UNITS

DESCRIPTION

DESCR. (display)

HEATING

DHW

CASCADE

GENERAL

4153

1342

13.0 PARAMETERS

13.1 SETTING THE PARAMETERS WITH THE DISPLAY MENU

The operating parameters of the boiler are embedded in the burner control system electronics. Some of the values and settings that are used to control the boiler operation can be changed by modifying these parameters in order to configure the appliance to meet the specific requirements of the installation. Modification should be carried out by a trained service technician with the help of a computer, the correct software and an interface cable. Certain parameters can be programmed on the unit itself, without the use of a computer.

The following table gives a list of these parameters that can be programmed through the user interface display. All parameters that are shown in the display can be changed.

TABLE 13.1 PARAMETERS

The parameter table above shows all of the parameters that can be set on the unit without the use of a laptop/computer.

In the following section, a description of each parameter is given and the procedure for modifying it (if applicable) is given.

NOTE: Some parameters can be set, but are not used when the control is configured to operate as a heating

boiler. Parameters P2CL, P2LD, P2ML, P2MM, P5BI may affect boiler operation and must therefore not be changed.

Page 67

Operating screen:

H E A T I N G : S T A N D - B Y

> > > : 1 2 3 . 4oC ( 1 2 3 . 4oC )

Press [ME NU]

Select "P arameter" using [◄] & [ ►]

M a i n M e n u

P a r a m e t e r

Press [EN TER]

Parameter menu:

I n s t a l l e r c o d e

0 0 0 0

Enter the 4-digit code with the [◄] & [►] and the

[▲] & [▼] buttons and select [EN TE R]

The code will blink a few seconds and when entered

correctly, the following parameters will be displayed.

Menu A: H eating

A 1 S t e p m o d u l

Menu A: H eating

A 2 H E s o f f 1 3

4 o C

Menu A: H eating

A 3 H E s P r b 1 3

2 5 o C

Menu A: H eating

A 4 H E s c D i f 1 3

1 0 o C

Menu A: H eating

A 5 H E s l n t 1 3

6 0 S e c

Menu A: H eating

A 6 H E c O f f 3

4 o C

> > > Continued on next page < < <

This parameter sets the CH integration time. This is the time period over which

an average temperature is recorded in order to determine the firing rate.

This parameter sets the Cascade CH offset value. This is the v alue above the

setpoint temperature that each boiler in the cascade boiler can reach before

shutting down.

NOTE: The two codes are user defined and give access to the parameters

which can be v iewed and modified (as detailed in T able 13.1)

This parameter activates the step modulation feature. Step modulation holds

the firing of the appliance at defined rates for pre-defied time periods. A

value of 0 disables this function, a value of 1 enables it.

This parameter sets the CH offset value. This is the value above the setpoint

temperature that the boiler can reach before shutting down.

This parameter sets the CH proportional band. This is the temperature range

below the setpoint temperature in which the boiler will modulate.

This parameter sets the CH differential. This is the temperature below the offset

temperature which the boiler must reach before the firing sequence will restart.

FIGURE 13.1 SETTING PARAMETERS

Page 68

Menu A: H eating

A 7 H E c P r b 3

2 5 o C

Menu A: H eating

A 8 H E c l n t 3

8 0 S e c

Menu A: H eating

A 9 T i m e r C o n t

Menu B: H ot w ater

B 1 D H i p m p / t w v

Menu B: H ot w ater

B 2 D H i f l o w L O

2 5 o C

Menu B: H ot w ater

B 3 D H i f l o w H I

8 5 o C

Menu B: H ot w ater

B 4 D H i L O t i m e

1 M i n

Menu B: H ot w ater

B 5 L e g i o t e m p

8 5 o C

Menu B: H ot w ater

B 6 L e g i o h y s t

2 o C

> > > From previous page < < <

> > > Continued on next page < < <

This parameter sets the Cascade CH proportional band. This is the temperature

range below the setpoint temperature in which each boiler in the cascade boiler

will modulate (as measured by the cascade sensor).

This parameter sets the cascade CH integration time. This is the time period over

which an average temperature is recorded in order to determine the firing rate (as

measured by the cascade sensor).

This parameter activates the external time control feature. When enabled, a

closed contact across terminals 13 & 14 runs the boiler at daytime temperatures,

an open contact runs the boiler at night-time temperatures. A v alue of 0 disables

this function, a value of 1 enables it.

This parameter sets how DH W production is controlled. A v alue of 0 is used

when a separate pump supplies the DHW v essel. A v alue of 1 is used when

the DHW supply is controlled by a 3-way v alve.

This parameter sets the time period during which the DHW flow temperature will

be at the 'low level'. A fter this time period expires, the setpoint will automatically

switch to the 'high level.

This parameter sets the indirect DHW flow temperature from the boiler during a

DHW pasteurisation demand.

This parameter sets the differential during the pasteurisation function. This is the

temperature below the offset temperature which the boiler must reach before the

firing sequence will restart.

This parameter sets the 'low level' indirect DHW flow temperature from the boiler

during a DHW demand.

This parameter sets the 'high level' indirect DHW flow temperature from the boiler

during a DHW demand.

FIGURE 13.2 SETTING PARAMETERS (ctd.)

Page 69

Menu B: H ot w ater

B 7 L e g i o h o l d

2 M i n

Menu B: H ot w ater

B 8 L e g i o i n t r

Menu B: H ot w ater

B 9 D H d s c O f f 2

4 o C

Menu B: H ot w ater

B A D H d s c P r b 2 3

2 0 o C

Menu B: H ot w ater

B B D H d s c D i f 2

1 0 o C

Menu B: H ot w ater

B C D H d s c l n t 2 3

2 0 0 S e c

Menu B: H ot w ater

B D D H d s c O f f 3

4 o C

Menu B: H ot w ater

B E D H d s c D i f 3

8 o C

Menu B: H ot w ater

B F D H i s c D i f 4

5 o C

Menu B: H ot w ater

B G D H i d e t g r a d

3 o C

This function is not used on the C P-M+ boiler and should not be altered.

This parameter sets the differential used when the DHW vessel is controlled by a

temperature sensor. This is the temperature below the setpoint temperature which

the vessel must reach before the firing sequence will restart.

This parameter is used w hen the DHW vessel is controlled by a temperature

sensor. If the boiler detects an accelerated hot water demand (e.g. a drop within

1 second) the firing sequence will start even if the differential temperature has not

been reached.

This parameter sets the time period that the pasteurisation function runs for.

This parameter determines whether a pasteurisation demand takes priority over a

CH demand over the boiler. A value of 0 gives pasteurisation priority, a v alue of

1 gives heating priority.

> > > From previous page < < <

This function is not used on the C P-M+ boiler and should not be altered.

> > > Continued on next page < < <

This function is not used on the C P-M+ boiler and should not be altered.

FIGURE 13.3 SETTING PARAMETERS (ctd.)

Page 70

Menu C: C ascade

C 1 M a x C a s c U n t

1 1

Menu C: C ascade

C 2 B u s a d r e s s

Menu C: C ascade

C 3 D H i c a s / m a s

Menu C: C ascade

C 4 E x t r a u n i t

Menu C: C ascade

C 5 C a s S i / M a

Menu C: C ascade

C 6 P w r O f f T o C a

Menu C: C ascade

C 7 C o m F l u N u m

Menu D: General

D 1 0 - 1 0 V c o n t r

> > > From previous page < < <

> > > Continued on next page < < <

This parameter sets the cascade address of each appliance. The master boiler

should be set as 0 and each slave shall be independently addressed from 1 to

This parameter sets w hether the slave boilers continue to operate if the master

boiler is switched off. A value of 0 sets the slave boilers to operate w ithout the

master, a value of 1 sets the slave boilers to shut down when the master is not

present.

This parameter determines whether an additional boiler is connected to terminals

21 & 22 of the master boiler. Once a pre-determined output of the cascade is

reached, a contact in the burner control will close and an additional non-cascaded

boiler can be enabled.

This parameter sets w hether the boiler operates as a standalone boiler/slave

boiler or as a master boiler. Each cascade should only have one master boiler.

A v alue of 0 sets the boiler to act as a slave, a value of 1 sets the boiler to act

as a master.

This parameter sets how many of the cascaded appliances operate on a

common flue system.

This parameter sets the function of the 0-10 VDC input on terminals 15 & 16. A

value of 0 disables the function, a value of 1 relates the input voltage to setpoint

temperature and a value of 2 relates the input voltage to power output.

This parameter sets the maximum number of slave boilers within a cascade. The

maximum number is 11 therefore this parameter should not be changed.

This parameter determines whether all boilers in the cascade are used to meet a

DHW demand or whether it is the master only. A value of 0 will fire all boilers, a

value of 1 will fire the master only.

FIGURE 13.4 SETTING PARAMETERS (ctd.)

Page 71

Menu D: General

D 2 0 - 1 0 M i n T m p

2 0 o C

Menu D: General

D 3 A l t * 1 0 0 f

Menu D: General

D 4 M a x C o o l T i m

2 M i n

Menu D: General

D 5 T e m p O n D i s p

Menu D: General

D 6 D H W 1 = i 2 = d

> > > From previous page < < <

This parameter sets how a DHW demand is handled. A v alue of 0 sets the boiler

as heating only (no DHW), a value of 1 sets the boiler as heating and indirect

DHW, a v alue of 2 sets the boiler as direct DH W. A setting of 2 should not be

used on the CP-M+ boiler.

This parameter sets whether the measured temperatures are displayed on the

operating screen.

When Parameter D1 set to '1' (temperature control) this parameter sets the

temperature required with a signal of 1 Volt

This function is not used on the CP -M+ boiler and should not be adjusted.

This parameter sets the fan over-run time and is used to cool the heat exchanger

after a firing sequence. A value of 0 disables this function.

FIGURE 13.5 SETTING PARAMETERS (ctd.)

Page 72

14.0 COMMISSIONING AND TESTING

14.1 ELECTRICAL INSTALLATION

Notes on the requirements for electrical installation are provided in Section 11: ELECTRICAL SUPPLY. A schematic drawing of the control circuit is shown in Figure 11.2

14.2 GAS INSTALLATION

For design see Section 7: GAS SUPPLY. See Figure 3.1 or Figure 3.2 for details on the position of the gas connection.

14.3 WATER CONNECTIONS

For design see Section 10: WATER CONNECTIONS

The system should be thoroughly flushed in accordance with CIBSE Commissioning Codes B & W and BSRIA AG1/2001.1: Pre-commission cleaning of pipework systems.

Check the system for leaks and repair as necessary. If the system is configured in a sealed arrangement, check the expansion vessel cushion pressure and pressurisation unit settings.

14.4 COMMISSIONING THE EQUIPMENT

14.4.1 GENERAL CHECKS PRIOR TO LIGHTING

A person deemed competent MUST be responsible for the commissioning of this equipment. Before attempting to commission any equipment, ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks:

1. Flueway passages are clear.

2. Adequate ventilation exists in the plant room (if necessary)

3. The system is fully charged with water, ready to receive heat. All necessary valves are open and all

allied pumps are circulating water.

4. The gas supply pipework is clear of any loose matter, tested for soundness and purged.

5. The condensate drain is installed correctly and the condensate trap is filled with water. (see Section 6.6:

FILLING THE CONDENSATE TRAP)

NOTE: If the condensate trap is not filled with water before use, products of combustion may escape

and may cause severe personal injury or death.

14.4.2 EQUIPMENT CHECKS PRIOR TO LIGHTING

This unit has been designed for a nominal gas inlet pressure of 20 mbar when used on natural gas. Information relating to propane firing can be found in Section 15: LPG FUEL

1. Gas supply is connected but turned to the “off” position. Any unions or fittings are correctly tightened,

test points are closed and the ignition electrode lead is connected correctly. Ensure the ceramic sheath around the ignition electrode is not cracked or broken.

2. Ensure electricity supply is connected.

3. Check that the heat exchanger is fully bled by opening the bleed automatic air vent screw cap.

Page 73

boiler type

load

G20 1

CO2 (%)

O2 (%)

CP-M+60-120 2 max. load

9.0 (± 0.3)

4.8 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

CP-M+ 150 2

max. load

9.0 (± 0.3)

4.8 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

CP-M+ 180 2

max. load

9.0 (± 0.3)

4.8 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

Cf. EN437

All values are measured without boiler door.

Display message D e a i r a t i o n

9 9 9 , 5 h r s

Reason

The deaeration process has not completed due to insufficient system pressure.

CP-M+60

CP-M+80 & 100

CP-M+120

CP-M+150 & 180

14.4.3 PROCEDURE FOR INITIAL LIGHTING

IF THE UNIT IS TO OPERATE ON LPG REFER TO SECTION 15.2 BEFORE PROCEEDING

1. Ensure that the gas-inlet appliance isolating valve, provided by the installer, is in the “off” position.

2. Turn on the local electrical isolator, to bring the equipment on.

3. The boiler will go through a de-aeration sequence of starting and stopping the integral pump three times.

NOTE: If the system pressure is not above 1.0 bar during the deaeration process, the boiler will stop responding

and display the following screen:

System pressure will need to be increased to above 1.0 bar before any further works can be carried out.

4. Press and hold the service button for three seconds to place the boiler into service mode.

5. The combustion fan should ramp up to full speed to purge the combustion chamber and then drop back

to half rate in order to light. The spark generator should create a spark, visible through the burner sight glass. As the gas inlet appliance isolating valve is closed, the controls should go to a flame failure condition after four ignition attempts.

6. If the above occurs correctly, open the gas inlet appliance isolating valve, reset the unit by depressing

the button on the control panel and place the boiler back in to service mode.

7. The combustion fan will repeat the pre-purge procedure and attempt to light. Once a flame is

established, the display will change to indicate that the boiler is in service mode and the firing rate.

8. Press the [◄] button once to display the flow and return temperatures. If the difference between these

values is below 13°C or above 25°C shut the boiler down and check that there is sufficient water flow through the boiler.

9. If sufficient flow exists, press the on/off/reset button for 5 seconds to shut the boiler down. Once this has

been done, check that the main flame has extinguished.

14.4.4 GAS PRESSURE ADJUSTMENT AND COMBUSTION CHECKS

FIGURE 14.1 GAS VALVES

TABLE 14.1 COMBUSTION GAS READINGS

Page 74

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

Display message H E A T I N G : S e r v i c e 1 0 0 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 100% (maximum).

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

The most effective way of setting the heat source is through the use of a CO2 measuring device such as a flue gas analyser. The procedure is as follows:

1. Put the boiler into ‘Service Mode’. This is done by depressing the service button for three seconds. The

display should show:

2. Press the [▲] button until the display shows:

3. Adjust screw 2 to give the CO

output as detailed in Table 14.1. Turning the screw clockwise will reduce

the CO2 level, turning anti-clockwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

4. Press the [▼] button until the display shows:

5. Adjust screw 1 to give the CO

output as detailed in Table 14.1. Turning the screw clockwise will

increase the CO2 level, turning anti-clockwise will reduce the CO2 level. On the CP-M+120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

6. Using the [▲] and [▼] buttons, re-check the combustion reading at high and low fire. Trim the gas

valve settings as necessary.

7. Once the setting has been completed, depress the service button for 3 seconds to return the boiler to its

normal operating mode.

8. Record the combustion data and leave with the appliance for future reference.

NOTE: The dust cap, once reinstalled, should be marked with an anti-tamper indicator.

Combustion figures for Propane firing can be found in Section 15: LPG FUEL.

14.5 TEMPERATURE ADJUSTMENT PROCEDURE

Setpoint temperatures are altered via the user control system; refer to Section 12.8 SETPOINTS for further information.

14.6 INSTALLATION NOISE

If care has been taken to follow the manufacturer’s instructions there should be no discernible noise from the equipment. The allied pump motor may have a level of sound that could lead to consideration for acoustic insulation, but care must be taken not to impede ventilation or airflow to the pump motor.

Page 75

Boiler Type

Number of Turns Open

(Counterclockwise)

Propane G31

CP-M+60

0.5

CP-M+80

0.75

CP-M+100

1.5

CP-M+120

CP-M+150

CP-M+180

*2.25

* Both gas valves must be opened this number of turns

Boiler Type

“p-out” Pressure at Gas Valve

Propane G31

CP-M+120

-4 to -2 Pa

CP-M+150

-7 to -5 Pa

CP-M+180

-7 to -5 Pa

boiler type

load

G31 1

CO2 (%)

CP-M+60-120 2 max. load

10.3 (± 0.3)

min. load

9.3 (± 0.3)

CP-M+ 150 2

max. load

10.4 (± 0.3)

min. load

9.3 (± 0.3)

CP-M+ 180 2

max. load

10.5 (± 0.3)

min. load

9.3 (± 0.3)

Cf. EN437

All values are measured without boiler door.

15.0 LPG FUEL

NOTE! IT IS STRONGLY RECOMMENDED THAT, ON LPG INSTALLATIONS, GAS DETECTION EQUIPMENT IS FITTED. THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE APPLIANCE AND AT LOW LEVEL. IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE APPLIANCE IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL. THIS APPLIANCE MUST NOT BE LOCATED BELOW GROUND E.G. IN A CELLAR

15.1 RELATED DOCUMENTS

In addition to those documents listed in Section 4.1: RELATED DOCUMENTS within the main body of the

installer’s guide the gas installation should also comply with the guidance offered in the following documents.

BS 5482-1: 2005 Code of practice for domestic butane and propane gas burning installations. Part 1: Installations at permanent dwellings, residential park homes and commercial

premises, with installation pipework sizes not exceeding dn25 for steel and dn28 for corrugated stainless steel or copper.

The operation of the CP-M+ range on LPG-Propane (3rd Family) 3P is similar to that on Natural Gas (2nd Family) 2H and the design and installation details described in the main body of the installer’s guide should be followed.

15.2 CONVERSION AND COMMISSIONING PROCEDURE

This process must be carried out in the order stated when the boiler is switched on for the first time. Failure to follow the following procedure may lead to non-warrantable damage to the boiler.

TABLE 15.1 PRE-ADJUSTMENT OF GAS VALVES

TABLE 15.2 PRESSURE ADJUSTMENT OF LEFT GAS VALVE

TABLE 15.3 COMBUSTION GAS READINGS

Due to the design of the boiler, the conversion to LPG-Propane requires adjustment of the gas valve(s) only (see Figure 15.1). The sequence is as follows:

1. Turn screw 2 (Figure 15.1) clockwise until fully closed. On models with two gas valves, this should be

done to both valves.

2. Turn screw 2 counter clockwise in accordance with Table 15.1. On models with two gas valves, this

should be done to both valves.

Page 76

Display message H E A T I N G : S e r v i c e 1 0 0 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 100% (maximum).

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

CP-M+60

CP-M+80 & 100

CP-M+120

CP-M+150 & 180

3. On models CP-M+120, CP-M+150 & CP-M+180, remove the screw from the outlet pressure test point of

the left hand gas valve (identified as screw 4 in Figure 15.1) and attach a manometer.

4. Put the boiler into ‘Service Mode’. This is done by depressing the service button for three seconds.

5. If the burner does not light after three attempts, turn screw 2 through ¼ turn counter clockwise. On the

CP-M+ 120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

6. Once the flame has established, press the [▲] button until the display shows:

7. Adjust screw 2 to give the CO

output as detailed in Table 15.3. Turning the screw clockwise will reduce

the CO2 level, turning anti-clockwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

8. Press the [▼] button until the display shows:

9. On models CP-M+120, CP-M+150 & CP-M+180 adjust Screw 1 of the left hand gas valve to give the

required pressure as detailed in Table 15.2.

10. Adjust screw 1 (right hand gas valve only on CP-M+120, CP-M+150 & CP-M+180) to give a CO

as detailed in Table 15.3. Turning the screw clockwise will increase the CO2 level, turning anticlockwise will reduce the CO2 level.

11. Using the [▲] and [▼] buttons, re-check the combustion reading at high and low fire. Trim the gas

valve settings as necessary.

12. Once the setting has been completed, depress the service button for 3 seconds to return the boiler to its

normal operating mode.

13. Remove the manometer (if used) and replace all dust caps and test point sealing screws, testing for

leaks as appropriate.

14. Record the combustion data and leave with the appliance for future reference.

NOTE: The dust cap, once reinstalled, should be marked with an anti-tamper indicator.

output

FIGURE 15.1 GAS VALVES

Page 77

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

Display message H E A T I N G : S e r v i c e 1 0 0 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 100% (maximum).

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

16.0 MAINTENANCE

16.1 GENERAL

KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS AND FLAMMABLE VAPOURS AND LIQUIDS.

A competent person should check and ensure that the flue, its support and terminal, the ventilation to the boiler house, safety valve, drain, pressure gauge etc. are in a serviceable and working condition and still comply with the relevant standards and codes of practice, as detailed in Section 4: GENERAL REQUIREMENTS.

Servicing is recommended at intervals no greater than 12 months to aid trouble free operation. Even if a maintenance schedule is determined to be less than annually, it is important that all controls and safety features are checked for correct operation on an annual basis.

Measuring flue gas CO2 and flue gas temperatures will give an indication of the state of the flue and burner. Results of the flue gas analysis should be compared with previously measured values to identify any changes in operational characteristics.

16.2 BURNER INSPECTION

The heat exchanger has a sight glass for inspection of the flame picture.

NOTE: If the appliance has been in recent operation, this area may be hot. Appropriate precautions

should be taken to prevent personal injury.

To check the flame picture at high and low fire, the following procedure should be used:

1. Put the boiler into ‘Service Mode’. This is done by depressing the service button for three seconds. The

display should show:

2. Press the [▲] button until the display shows:

3. Check the flame condition.

4. Press the [▼] button until the display shows:

5. Check the flame condition.

6. Depress the service button for 3 seconds to return the boiler to its normal operating mode.

Page 78

16.3 BURNER REMOVAL

If it has been determined that the flame picture is unacceptable, the burner can be removed and cleaned using the following procedure:

1. Isolate the electrical and gas supplies to the heater.

2. Allow the boiler to cool down.

3. Disconnect the wiring connections to the ignition electrode.

4. Disconnect the power and control connection leads and earthing wire from the combustion fan.

5. Apply a suitable release oil to the 6 studs around the edge of burner door.

6. Remove the 6 retaining nuts around the edge of the burner door.

NOTE: Once loosened, the nuts should be removed by hand. If any of the nuts seize, the nut should

gently be re-tightened and additional release oil used.

7. Withdraw the heat exchanger front plate and burner assembly from the heat exchanger complete with

the combustion fan.

8. With the burner assembly away from the boiler, the burner can be gently cleaned with the brush

attachment of a vacuum cleaner.

The reassembly procedure is the reverse of the above taking care to ensure that the for the heat exchanger front plate sealing gasket, the combustion fan connection gasket, the burner door insulation and the combustion chamber rear wall insulation are in good condition or are replaced as necessary.

When refitting the burner door, the door should be carefully located on the studs and pushed firmly in to place whilst all of the retaining nuts are tightened by hand. Once all nuts are hand tight, they should be tightened in the order stated in Figure 16.1 to a torque of 8 Nm

NOTE: PARTICULAR ATTENTION SHOULD BE PAID TO THE COMBUSTION CHAMBER REAR WALL

INSULATION. IF ANY DETERIORATION IN THE INSULATING MATERIAL IS NOTED, THE INSULATION PANEL MUST BE REPLACED.

FIGURE 16.1 BURNER DOOR RETAINING NUT TIGHTENING ORDER

Page 79

16.4 CLEANING THE HEAT EXCHANGER

To clean the heat exchanger, the following procedure should be carried out:

1. Remove the burners as above.

2. Use a vacuum cleaner to remove any accumulation on the heating surfaces.

3. Inspect the heat exchanger to ensure that the 1 mm flueway is clear between all coils.

4. If any debris is still present, brush the heat exchanger with a non-metallic brush taking care not to

damage the insulation panel on the rear wall of the heat exchanger.

NOTE: A kit of components to aid with cleaning the heat exchanger is available from Lochinvar Limited.

For models CP-M+60 – CP-M+120 use part number KIT30063, for models CP-M+150 & CP-M+180 use part number KIT30064.

NOTE: It is very important to inspect and remove all deposits from the heat exchanger. If all deposits

cannot be removed from the heat exchanger, contact Lochinvar Limited for further guidance.

5. Once the heat exchanger has been brushed it should be rinsed with fresh water to remove all residues.

6. Remove the condensate water trap and clean out any debris.

7. Refit the condensate drain and fully recharge by pouring 1 litre of water through the heat exchanger

coils.

8. Reinstall the burner.

9. Restart the boiler as detailed in Section 14.4.3: PROCEDURE FOR INITIAL LIGHTING.

16.5 DRAINING THE BOILER SYSTEM

The boiler must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the boiler.

16.5.1 DRAINING AN INDIVIDUAL BOILER

1. Turn off the boiler electrical disconnect switch.

2. Turn off the boiler isolation valves.

3. Attach a hose to the boiler drain valve and locate the discharge in an area where hot water will not

cause any damage or injury.

4. Open the boiler drain valve and the automatic air vent plug to allow water to escape.

5. Once the boiler is drained, close the drain valve.

16.5.2 DRAINING THE COMPLETE SYSTEM

1. Turn off the boiler electrical disconnect switch.

2. Connect a hose to the system drain valve.

3. Locate hose’s discharge in an area where hot water will not cause any damage or injury.

4. Close the cold-water inlet valve from the header tank or pressurisation unit to boiler system.

5. Open the drain valve.

6. Working systematically from the highest point in the heating system, open bleed valves to allow the

system to drain.

7. Close all bleed valves

8. If the system is being drained for an extended shutdown, it is suggested the drain valve be left open

during this period.

16.6 REFILLING THE SYSTEM

1. Close the drain valve.

2. Open the cold-water inlet valve from the header tank or pressurisation unit to boiler system.

3. Working systematically towards the highest point in the system, open all bleed valves and allow any

trapped air to escape.

4. Follow the lighting instructions as detailed in Section 14.4.3: PROCEDURE FOR INITIAL

LIGHTING.

5. Check for water leakage and airlocks, remedy as necessary.

Page 80

16.7 OTHER CHECKS

16.7.1 RELIEF VALVES (IF FITTED)

At least once a year, the pressure relief valve should be checked to ensure correct operation. To check the valve, lift the lever or turn the screw cap at the end of the valve several times. The valve should operate freely and seat properly.

If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new valve of the recommended size as necessary.

16.7.2 FLUE SYSTEM

Examine the exhaust and air intake system at least once a year. Points of inspection are as follows:

1. Check for obstructions and/or deterioration of flue piping and terminal. Replace immediately where

needed.

2. Check the terminal for any foreign material and remove as necessary.

3. Check all flue system connections for leakage and reseal as required.

4. Check that ventilation grilles comply with current regulations.

Page 81

Boiler Type

Number of Turns Open

(Counterclockwise)

Nat. Gas G20

Propane G31

CP-M+60 1 0.5

CP-M+80

1.5

0.75

CP-M+100

3.5

1.5

CP-M+120

*2.25

CP-M+150

*2.25

CP-M+180

*4.25

*2.25

* Both gas valves must be opened this number of turns

Boiler Type

“p-out” Pressure at Gas Valve

Nat. Gas G20

Propane G31

CP-M+120

-2 to 0 Pa

-4 to -2 Pa

CP-M+150

-2 to 0 Pa

-7 to -5 Pa

CP-M+180

-2 to 0 Pa

-7 to -5 Pa

boiler type

load

G20 1

G31 1

CO2 (%)

O2 (%)

CO2 (%)

O2 (%)

CP-M+60-120 2 max. load

9.0 (± 0.3)

4.8 (± 0.5)

10.3 (± 0.3)

5.2 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

9.3 (± 0.3)

6.7 (± 0.5)

CP-M+ 150 2

max. load

9.0 (± 0.3)

4.8 (± 0.5)

10.4 (± 0.3)

5.0 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

9.3 (± 0.3)

6.7 (± 0.5)

CP-M+ 180 2

max. load

9.0 (± 0.3)

4.8 (± 0.5)

10.5 (± 0.3)

4.7 (± 0.5)

min. load

8.7 (± 0.3)

5.3 (± 0.5)

9.3 (± 0.3)

6.7 (± 0.5)

Cf. EN437

All values are measured without boiler door.

CP-M+60

CP-M+80 & 100

CP-M+120

CP-M+150 & 180

16.8 SETTING A REPLACEMENT GAS VALVE

When a replacement gas valve is fitted, the following procedure must be carried out in the order stated when the boiler is switched on for the first time. Failure to follow the following procedure may lead to non-warrantable damage to the boiler.

TABLE 16.1 PRE-ADJUSTMENT OF GAS VALVES

TABLE 16.2 PRESSURE ADJUSTMENT OF LEFT GAS VALVE

TABLE 16.3 COMBUSTION GAS READINGS

1. Turn screw 2 (Figure 16.1) clockwise until fully closed. On models with two gas valves, this should be

done to both valves.

2. Turn screw 2 counter clockwise in accordance with Table 16.1. On models with two gas valves, this

should be done to both valves.

3. On models CP-M+120, CP-M+150 & CP-M+180, remove the screw from the outlet pressure test point of

the left hand gas valve (identified as screw 4 in Figure 16.1) and attach a manometer.

FIGURE 16.1 GAS VALVES

Page 82

CP-M+60

CP-M+80 & 100

CP-M+120

CP-M+150 & 180

Display message H E A T I N G : S e r v i c e 1 0 0 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 100% (maximum).

Display message H E A T I N G : S e r v i c e 2 6 %

> > > 1 2 3 . 4oC ( 1 2 3 . 4oC )

Reason Boiler is activated and operates at service mode at 26% (minimum).

4. Put the boiler into ‘Service Mode’. This is done by depressing the service button for three seconds.

5. If the burner does not light after three attempts, turn screw 2 through ¼ turn counter clockwise. On the

CP-M+ 120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

6. Once the flame has established, press the [▲] button until the display shows:

7. Adjust screw 2 to give the CO

output as detailed in Table 15.3. Turning the screw clockwise will reduce

the CO2 level, turning anti-clockwise will increase the CO2 level. On the CP-M+ 120, CP-M+150 and CP-M+180, this adjustment should be made to the right hand gas valve only.

8. Press the [▼] button until the display shows:

9. On models CP-M+120, CP-M+150 & CP-M+180 adjust Screw 1 of the left hand gas valve to give the

required pressure as detailed in Table 15.2.

10. Adjust screw 1 (right hand gas valve only on CP-M+120, CP-M+150 & CP-M+180) to give a CO

as detailed in Table 15.3. Turning the screw clockwise will increase the CO2 level, turning anticlockwise will reduce the CO2 level.

11. Using the [▲] and [▼] buttons, re-check the combustion reading at high and low fire. Trim the gas

valve settings as necessary.

12. Once the setting has been completed, depress the service button for 3 seconds to return the boiler to its

normal operating mode.

13. Remove the manometer (if used) and replace all dust caps and test point sealing screws, testing for

leaks as appropriate.

14. Record the combustion data and leave with the appliance for future reference.

NOTE: The dust cap, once reinstalled, should be marked with an anti-tamper indicator.

output

FIGURE 16.1 GAS VALVES

Page 83

Display message F l o w s e n s o r e r r o r

F0 p u m p o n 9 9 9 , 5 h r s

Reason:

Flow sensor is not detected.

Cause:

Corrective Action:

Cause:

Corrective Action:

Replace flow sensor.

Display message F l o w h i g h T e m p

F1 p u m p o n 9 9 9 , 5 h r s

Reason:

Flow temperature exceeds limitation (lock-out) value.

Cause:

The water flow through the heat exchanger is restricted.

Corrective Action:

Check the operation of the pump.

Check that all v alves that might restrict the w ater flow through the boiler are open.

Check for an external system pump that influences flow through the boiler.

Check if the system resistance exceeds the spare capacity of the boiler pump.

Faulty w iring or connection in the flow sensor circuit.

Check for loose or damaged wiring and or connections in the flow sensor circuit and repair as necessary.

Defective temperature sensor causing a fault signal.

17.0 TROUBLESHOOTING

To avoid electric shocks, disconnect electrical supply before performing troubleshooting. To avoid burns, allow the unit to cool before performing troubleshooting. Be aware that a fault code is an indication that the unit or the system needs attention. When a fault occurs repeatedly remedial work should be undertaken by a suitably qualified person.

The first step is to check if the unit is installed according to the instructions. If not, first make sure the installation complies with the installation manual. Always check the fuses on the control board before replacing any major components. A blown fuse can prevent the controller or other components from operating.

Most faults can also be caused by a bad wiring and/or connections, even if it is not specifically mentioned. With every fault it is wise to check wiring and connections (at both ends) that connect to the safety device/component that generates the fault.

17.1 LOCK-OUT CODES

If the boiler locks out, it signifies that a serious situation has occurred and that the boiler has shut down and will not fire again until manually reset. Before manually resetting the appliance corrective action may need to be taken to prevent further occurrences of the lock-out situation. When the boiler is in lockout the backlight of the display flashes on and off.

When a lock-out occurs, the display will show a description of the fault in the top line of the display; the bottom line of the display will show the status of the pump when the fault occurred and the time that has elapsed since the fault occurred.

Page 84

Display message R e t u r n h i g h T e m p

F1 p u m p o n 9 9 9 , 5 h r s

Reason: Maximum return temperature exceeds limit value.

Cause:

An external heat source (CHP, heat pump etc.) has heated the return temperature above the maximum return temperature.

Corrective Action:

Reduce pre heat temperature of external heat source.

Cause:

The external heating controls suddenly close causing excessive return water temperature.

Corrective Action:

Dampen the reaction time of the external heating control system to prevent sudden boiler temperature rise.

Display message L a c k o f w a t e r

F2 p u m p o n 9 9 9 , 5 h r s

Reason

Cause:

Corrective Action:

Ensure that the system if full of water and all air-locks are removed.

Display message R e t u r n s e n s o r e r r o r

F3 p u m p o n 9 9 9 , 5 h r s

Reason Return sensor is not detected

Cause:

Corrective Action:

Cause:

Corrective Action:

Replace the return sensor.

Display message F l u e s e n s o r e r r o r

F6 p u m p o n 9 9 9 , 5 h r s

Reason Flue sensor is not detected

Cause:

Corrective Action:

Cause:

Corrective Action:

Replace the flue sensor.

When the boiler starts firing, the control expects to measure a difference in temperature between inlet and outlet. If no

temperature rise is detected, the burner control assumes that there is no medium (water) present, to transfer heat from

combustion to the sensor and locks out to prevent damage.

Defectiv e temperature sensor causing a fault signal.

Faulty w iring or connection in the return sensor circuit.

Check for loose or damaged w iring and or connections in the return sensor circuit and repair as necessary.

Defectiv e temperature sensor causing a fault signal.

Faulty w iring or connection in the flue sensor circuit.

Check for loose or damaged w iring and or connections in the flue sensor circuit and repair as necessary.

No temperature rise measured during firing.

Page 85

Display message F l u e t e m p t o o h i g h

F7 p u m p o n 9 9 9 , 5 h r s

Reason Flue gas temperature limitation value exceeded 3 times within a preset time period.

Cause:

Heat exchanger polluted and not able to effectiv ely transfer heat to the system w ater.

Corrective Action:

Check and clean the heat exchanger.

Cause:

Defectiv e (partially shorted) flue gas sensor or sensor connection.

Corrective Action:

Cause:

There is no water in the unit while firing.

Corrective Action:

Cause:

Heat exchanger failure.

Corrective Action:

Display message F a i l e d b u r n e r s t a r t

F8 p u m p o n 9 9 9 , 5 h r s

Reason Boiler not operational after 4 starting attempts.

Cause:

No spark.

Corrective Action:

Check the condition of the ignition electrode and clean/replace if necessary.

Check the distance between the electrode pin, earth pin and burner.

Check the condition of the ignition cable and replace if necessary.

Check the condition of the earth wire/connection of the ignition electrode and replace if necessary.

Check the condition of the electrode cap and replace if necessary.

Check the incoming power supply. The supply voltage must be 230 VAC 50Hz 1Ph.

Check for correct electrical earthing of the boiler.

Failed burner control system. Change the burner control PC B.

Cause:

Ignition spark, but no flame.

Corrective Action:

Ensure all isolation valves in the gas supply line are completely open. The nominal gas inlet pressure should be 20 mbar.

Check that the gas supply pipework has been correctly purged (start-up new sy stems).

Check if the gas v alve settings are correct and adjust if necessary.

Check if the air supply to the boiler is free from obstruction.

Cause:

Flame, but not enough ionisation to establish the flame.

Corrective Action:

Check the condition of the ignition electrode and clean/replace if necessary.

Check the distance between the electrode pin, earth pin and burner.

Check the condition of the ignition cable and replace if necessary.

Check the condition of the earth wire/connection of the ignition electrode and replace if necessary.

Check for correct electrical earthing of the boiler.

Check the incoming power supply. The supply voltage must be 230 VAC 50Hz 1Ph.

Check the condition of the electrode cap and replace if necessary.

Check the condition of the ceramic insulator. Replace electrode if any sign of damage is present.

Contact Lochinvar Limited for further guidance.

Check if the gas v alve opens. When there is power supply to the gas valve, but the v alve does not open, the gas valve

must be replaced.

Check for moisture in the sensor connections or replace sensor.

Bleed all air from the unit so the heat from combustion can be transferred to the water and won't leave through the flue

Check the condition of the ceramic insulator. Replace electrode if any sign of damage is present.

Page 86

Display message F l a m e l o s t

F9 p u m p o n 9 9 9 , 5 h r s

Reason Flame signal lost during operation.

Cause:

Incorrect gas supply pressure.

Corrective Action:

Be aware that the nominal gas inlet pressure must be met under all operation conditions.

Check the incoming gas supply pressure is correct. Contact the gas transported if incorrect.

Check if all gas valv es in the supply line are completely open.

Check if the gas supply pipework is correctly sized.

Check if the dirt filter mesh in the gas valve inlet is clean.

Check that any external dirt filter in the gas supply line is not blocked.

Check if an external gas pressure regulator is selected/installed correctly.

Cause:

Incorrect gas valve settings.

Corrective Action:

Check and set gas v alve settings.

Cause:

Faulty gas valve.

Corrective Action:

Replace gas v alve.

Cause:

Faulty electrode/electrode wiring affecting the ionisation signal.

Corrective Action:

Check ionisation signal.

Check the condition of the ignition electrode and clean/replace if necessary.

Check the distance between the electrode pin, earth pin and burner.

Check the condition of the ignition cable and replace if necessary.

Check the condition of the earth wire/connection of the ignition electrode and replace if necessary.

Check for correct electrical earthing of the boiler.

Cause:

Flue gas and/or air supply sy stem fault.

Corrective Action:

Check all seals in the flue gas and air supply sy stem.

Display message F a l s e f l a m e s i g n a l

F10 p u m p o n 9 9 9 , 5 h r s

Reason Flame signal detected, when no heat demand is present.

Cause:

The flame detection circuit detects a flame which is not supposed to be present.

Corrective Action:

Check the condition of the ignition electrode and clean/replace if necessary.

Check the incoming power supply for correct polarity.

Check the incoming power supply for incorrect frequency or voltage peaks.

Check external wiring for v oltage feedback.

Check the internal wiring for bad connections.

Check if the gas v alve is closing correctly.

Replace the burner control PCB.

Check the condition of the ceramic insulator. Replace electrode if any sign of damage is present.

Check if the design of the flue gas and air supply sy stem complies w ith the maximum combined resistance as specified.

Check if the flue gas and air supply sy stem is installed in accordance with the relevant standards.

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Display message F a n s p e e d i n c o r r e c t

F11 p u m p o n 9 9 9 , 5 h r s

Reason Actual fan speed differs from the unit rpm setpoint.

Cause:

An incorrect fan speed is detected.

Corrective Action:

Check the 4 wired fan control wiring and connections at the fan and at the main control board.

Check the 3 wired power supply w iring and connections at both ends.

Replace the fan.

Replace the main control board.

Display message p r o g r a m m i n g e n d

F12 p u m p o n 9 9 9 , 5 h r s

Reason Programming of the parameters completed successfully.

Cause:

Programming of the parameters completed successfully.

Corrective Action:

Display message P a r a m / H a r d w f a u l t

F13 p u m p o n 9 9 9 , 5 h r s

Reason Failure during programming of the parameters.

Cause:

Programming of the parameters NOT successfully completed.

Corrective Action:

Check the PC interface cable and connections and try parameter programming again.

Check if the software version is correct for the burner control PC B.

Replace the PC interface cable.

Replace the display PC B.

Display message C l i x o n F a u l t

F15 p u m p o n 9 9 9 , 5 h r s

Reason: Heat exchanger fuse exceeded maximum value.

Cause:

The heat exchanger thermal fuse has opened permanently.

Corrective Action:

Isolate the electrical power and gas supply to the boiler and contact Lochinvar Limited for further guidance.

Display message W a t e r h i g h l i m i t

F17 p u m p o n 9 9 9 , 5 h r s

Reason: High-temperature limit thermostat has exceeded the limitation value.

Cause:

The water flow is restricted.

Corrective Action:

Check for correct operation of the integral pump.

Check that all v alv es that may restrict the water flow through the boiler are fully open.

Ensure that any strainers installed in the primary circuit are free from debris.

Check for an external system pump that influences the flow through the unit.

Check if the system resistance exceeds the spare capacity of the integral pump.

This message occurs to confirm the end of programming. Pressing RESET will return the unit in normal operating status.

Unit was not in stand-by mode when an attempt to program the parameters w as made (fan must not run during

programming).

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Display message S i p h o n s w i t c h

F19 p u m p o n 9 9 9 , 5 h r s

Reason: S iphon pressure switch detects high pressure in the flue/condensate drain system.

Cause:

Corrective Action:

Check if the flue system is blocked.

Check the flue gas system diameter & length complies with Section 8.4 or Section 8.5.

Cause:

Corrective Action:

Cause:

Corrective Action:

Cause:

Blockage of the signal hose to the pressure switch.

Corrective Action:

Check the signal hose and clean or replace it if necessary.

Cause:

Faulty pressure switch causing an incorrect signal.

Corrective Action:

Replace the pressure switch.

Cause:

Bad wiring/connection in the pressure sw itch circuit.

Corrective Action:

Check for loose wiring/connections in the pressure switch circuit.

The condensate drain system is blocked causing the condensate to build up above the measuring point of the pressure

Pressure fluctuations in the building drainage system are affecting the heat exchanger.

Make sure that there is an air-break betw een the condensate drain hose and the drainage sy stem of the building

Check the condition of the heat exchanger and clean if necessary.

Check that the condensate drain hose between the heat exchanger and the water trap is free from blockages, ensuring the

condensate can flow freely to the trap.

Check if the condensate water trap is free of debris that might block the condensate flow and clean if necessary.

Check the condensate drain hose between the water trap and the condensate drain point in the external installation for

blockages. Condensate must be able to flow freely.

There is too much resistance in the flue system causing excessive pressure in the heat exchanger.

Display message F l o w t e m p h i g h

9 9 9 , 5 h r s

Reason:

Cause:

The w ater flow is restricted

Corrective Action:

Check the operation of the integral pump.

Check that all valves that may restrict the water flow through the unit are fully open.

Check for an external sy stem pump that influences the flow through the boiler.

Check if the system resistance exceeds the spare capacity of the integral pump.

The flow temperature has exceeded the blocking temperature but not the lock-out

17.2 BLOCKING CODES

Blocking codes signify that a situation is present under which the boiler is not safe to operate but once the situation clears, operation can safely continue. When a blocking of the boiler is active, the display is constantly illuminated.

When a blocking occurs, the display will show a description of the condition in the top line of the display; the bottom line of the display will show the time that has elapsed since the blocking occurred.

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Display message R e t u r n t e m p h i g h

9 9 9 , 5 h r s

Reason

Cause:

An external heat source (CHP, heat pump etc.) has heated the return temperature above the blocking temperature.

Corrective Action:

Reduce pre heat temperature of the external heat source.

Cause:

The external heating controls suddenly close causing excessive return water temperature.

Corrective Action:

Dampen the reaction time of the external heating control system to prevent sudden boiler temperature rise.

Display message F l u e t e m p h i g h

9 9 9 , 5 h r s

Reason The flue gas temperature has ex ceeded the blocking temperature.

Cause:

Heat exchanger polluted and not able to effectiv ely transfer heat to the system w ater.

Corrective Action:

Check and clean the heat exchanger.

Cause:

Defectiv e (partially shorted) flue gas sensor or sensor connection.

Corrective Action:

Cause:

There is no water in the unit while firing.

Corrective Action:

Cause:

Heat exchanger failure.

Corrective Action:

Display message A n t i c y c l e t i m e

9 9 9 , 5 h r s

Reason

Cause:

Sy stem water temperature cooling and causing a heat demand within the anti-cycling time period.

Corrective Action:

Dampen external heating system controls to slow down the cooling time of the heating medium (water).

Increase system v olume to act as a buffer between the boiler circuit and heating circuit.

Cause:

Rapid opening and closing of external thermostat

Corrective Action:

Check switching differential of on/off thermostat

The return temperature has exceeded the blocking temperature but not the lock-out

temperature.

Check for moisture in the sensor connections or replace sensor.

Bleed all air from the unit so the heat from combustion can be transferred to the water and won't leave through the flue

Contact Lochinvar Limited for further guidance.

The controller received a new heat demand too soon after the last heat demand finished.

Page 90

Display message W a t e r p r e s s u r e f a u l t

9 9 9 , 5 h r s

Reason Sy stem water pressure is too high or too low.

Cause:

The water pressure in the system is too high.

Corrective Action:

Check if the system pressure is too high after (re)filling.

Check the settings of any automatic pressurisation unit attached to the system.

Cause:

The water pressure in the system is too low.

Corrective Action:

Display message L i n e f a u l t

p u m p o n 9 9 9 , 5 h r s

Reason Incorrect electrical power supply

Cause:

The electrical power supply does not comply with specifications.

Corrective Action:

Check if the power supply is connected correctly to the unit. Refer to Section 11.0 of this document.

Check the v oltage and frequency. The electrical supply should be 230VAC 50Hz 1ph.

Make sure there is no signal fouling or v oltage peaks in the power supply.

Display message O u t d o o r s e n s o r f a i l

9 9 9 , 5 h r s

Reason No outdoor sensor detected.

Cause:

Corrective Action:

Check for loose wiring/connections in the outdoor sensor circuit.

Check the condition of the outdoor sensor and replace if necessary.

Display message H e a t e x c h a n g a t r i s k

9 9 9 , 5 h r s

Reason

Cause:

Low water flow.

Corrective Action:

Check the pump for correct operation.

Check that all v alves that may restrict the water flow through the unit are fully open.

Check for an external system pump that influences the flow through the boiler.

Check if the system resistance exceeds the spare capacity of the integral pump.

Check the heating system for leaks and repair as necessary.

Where fitted to an open v ented system, check to ensure that the header tank giv es a static head of at least 1.0 bar.

The boiler is programmed to give outside temperature compensation but does not detect an outdoor sensor.

Make sure that there is a pressure relief v alv e and expansion vessel installed in the sy stem, according to the applicable

standards.

Ensure that any external system pump cannot cause an under pressure situation in the boiler. Wherever possible, a low-

velocity header should be used to separate the boiler from the system.

Clean the water circuit of the heat exchanger. A partial blockage of the heat exchanger will increase the resistance

causing the water flow to drop.

The temperature difference between flow and return has exceeded the blocking temperature

3 times, causing the unit to run in reduced input mode.

Page 91

Display message G e n B l o c k

9 9 9 , 5 h r s

Reason The general blocking circuit is activated during operation (after a flame was rectified).

Cause:

The circuit connected to the general blocking terminals is not closed.

Corrective Action:

Display message C a s c a d e B l o c k

9 9 9 , 5 h r s

Reason C onnection failure with one of the boilers of the cascade.

Cause:

Corrective Action:

Troubleshoot the fault with the locked-out boiler.

Check all external safety devices that are in the circuit connected to the general blocking terminals, and determine why the

contact is not closed during heat demand.

The unit is programmed in such a way that none of the boilers in a cascade will fire, if one has a lockout. One unit has a

lockout and therefore the whole cascade is blocked.

Display message N e e d s M a i n t e n a n 0 . 0

I g n i t i o n c y c l e s h r s

Reason

Display message N e e d s M a i n t e n a n 0 . 0

D a t e h r s

Reason

Display message N e e d s M a i n t e n a n 0 . 0

B u r n i n g h o u r s h r s

Reason

Display message N e e d s M a i n t e n a n 0 . 0

A l l h r s

Reason

One of the all selected maintenance options has been reached.

Maintenance option of total amount of ignition cycles has been reached.

Maintenance option of the date has been reached.

Maintenance option of total amount of burning hours has been reached.

17.3 IMPORTANT MESSAGES

The following graphs describe the messages at the boiler display. Depending on the selected and activated options for the boiler, it is possible that some messages will show up at the display of the boiler. For example a maintenance message after a certain programmed date has been reached. The boiler will operate independently of these messages.

18.0 USER INSTRUCTIONS

Once the installation and commissioning is complete, the equipment owner or their representative should be made aware of the operation of the appliance and its safety devices. A practical demonstration should be given describing each functional step. Incorrect use may result in injury and will also invalidate the warranty. The installers guide should be handed over and kept in a safe place for easy reference. It is strongly recommended that the users read and understand the separate User Guide.

Page 92

NOTES

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NOTES

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Page 94