RVR Energy Technology CAHA Midi 340, CAHA Midi 425, CAHA Midi 510, CAHA Midi 600 Installation, Use And Maintenance Instructions

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CAHA Midi

Floor standing multi-sectional gas boilers

Installation, Usage and Maintenance Instructions

20180713

Models 340, 425, 510 and 600

Thank you for selecting a CAHA Midi Boiler. This product is the result of extensive research and experience in heating

system design.

This manual is an integral part of the product and should be retained. Please read it carefully, as it provides important information regarding the installation and maintenance of the product.

The product should only be installed and maintained by a person qualied in the design and installation of heat-

ing systems. Failure to properly install or maintain the CAHA Midi may lead to injury, death or property damage.

WARNING

Carefully read the instructions contained in the manual as they provide important information regarding safe installation and maintenance. The installation and maintenance must be performed in accordance with current standards and according to the manufacturer’s instructions.

In the case of failure or malfunction of the appliance, do not attempt to repair it yourself. Please contact RVR Energy Technology Ltd by email at info@rvr.ie.

Repairs must be only be carried out by a qualied technicians. Failure to comply with these requirements can compromise the safety of the device.

INSTRUCTIONS FOR THE USER

If you have questions concerning the use of your boiler or heating system, please ask your installer. It is in your own inter-

est and that of the installer that you are aware of how to operate your boiler and heating system safely and efciently.

The appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge. Children, even if being supervised, must not play with the appliance.

In the case of failure or malfunction of the appliance, do not attempt to repair it yourself. Please contact your installer. Repairs must only be carried out by qualied technicians. Failure to comply with these requirements can compromise the safety of the appliance.

OPERATION

Water, coming from the radiators or from the DHW unit is heated in the aluminium heat exchanger. The CH or DHW pump guarantees circulation of water. The air needed for combustion is sucked in by a rpm controlled fan. At low boiler tempera-

tures the flue gases can be cooled down sufciently for condensation of the water. This water is drained to the sewer via a

built in syphon. This drainage must never be blocked. A burner controller with built in micro processor provides the electrical control of the boiler.

TOPPING UP

The built in manometer indicates if the waterpressure is sufcient. As soon as the water pressure drops below 1 bar topping up is necessary. If topping up becomes a regular occurrance, your installation should be checked by an installer.

Disconnect from the main. Connect the lling hose to the cold water tap and to the ll and drain valve of the boiler. Before tightning the coupling in the installation slowly ll the hose with water allowing present air to escape. Now open the ll and drain valve and slowly ll the installation until a pressure between 1.5 and 2.0 bar is reached. When nished connect again

to the main.

BLEEDING

To remove any air present in the heating system and boiler, bleeding is necessary. Disconnect from the main. Open all the

radiator valves. Bleed the air from all the radiators starting with the ones at the lowest point in the system. After bleeding,

check the water pressure and top-up if required (if water pressure has dropped below 1 bar). Connect to the main again.

CAHA Midi

Installation, Usage and Maintenance Instructions

STARTING THE BOILER

Please ask your installer how to start the boiler. Depending on how your heating system is controlled, this could be via an external timeclock, thermostat, switch or otherwise. Once the boiler volt-free enable contacts are closed, the boiler will commence its starting sequence.

BOILER FLOW TEMPERATURE

The burner controller can adjust the flow temperature between 20 ° and 85 °C. The temperature setting can be changed

using the control panel. The installation manual provides the instructions for setting the flow temperature.

DHW (HOT WATER) TEMPERATURE

From the factory, the DHW temperature is set to a value of 60 °C. This set value can be changed to any value between 35 and 65 °C using the buttons on the control panel. If the DHW device has a thermostat the DHW temperature can be adjust-

ed by setting this thermostat.

SWITCHING OFF THE BOILER

During summer time the room thermostat can be set to a lower value to turn off the boiler. During winter or

during a longer period of absence this temperature never should be set to a lower value than 15 °C. Don’t switch off the power. During a period of frost all the radiators should be partly or totally opened to avoid danger

of freezing.

The integrated pump control will activate the pump every 24 hours for a short period even if no demand is present. This prevents the pump jamming.

Only when work on the boiler is being carried out may the main electricity supply and gas supply be turned off (your installer can show where these are located).

ERRORS

If an error occurs rst check the following:

▪ Is the room thermostat properly set? ▪ Is the boiler connected to the main? Power supply present? ▪ Is the gas valve opened? ▪ Are the radiator valves open? ▪ Is the water pressure in the installation higher than 1 bar? ▪ Is the installation bled thoroughly?

An error is indicated by a code on the display. It is very important for the sake of a correct diagnosis to mention this code when calling your installer. Reset the burner controller by pressing the ok button on the control panel. If the error occurs frequently contact your installer.

MAINTENANCE

A yearly inspection of the boiler must be done by your installer. The lifespan and the reliability of the installation are im-

proved by doing so.The casing of the boiler may be cleaned with a soft cloth (no abrasives). Never use solvents like thinner!

CAUTION

The air supply (for air needed for combustion) and the flue parts are essential parts for safe and efcient operation of the boiler. Changes on these systems by non qualied persons are not allowed e.g. the settings of the

gas valve. The gas/air ratio is set to a lambda value of approximately 1.26. This corresponds with a CO2 level of 9,3 % (full load). For further information see installation manual.

CAHA Midi

Installation, Usage and Maintenance Instructions

CONTENTS

1. Description - Boiler ................................................................................................................................... 6

2. Technical Data .......................................................................................................................................... 7

2.1 Component Matrix ........................................................................................................................................ 8

3. Dimensions ............................................................................................................................................... 8

4. Operation .................................................................................................................................................. 9

4.1 General ............................................................................................................................................................ 9

4.2 Central Heating (CH) .................................................................................................................................... 9

4.2.1 On-off room thermostat .................................................................................................................... 9

4.2.2 Optional 0-10V ..................................................................................................................................... 9

4.2.2.1 0-10V DC % power control .................................................................................................. 9

4.2.2.2 0-10V DC Setpoint ............................................................................................................. 10

4.2.3 Outside Temperature Control OTC (optional) ............................................................................ 10

4.2.4 Optional digital communication ................................................................................................... 10

4.2.5 Slow start ........................................................................................................................................... 11

4.2.6 Protection against insufcient flow through boiler ................................................................... 11

4.3 Domestic Hot Water (DHW) ...................................................................................................................... 12

4.3.1 External storage tank with thermostat (electric 3-way valve) ................................................. 12

4.3.2 External storage tank with NTC sensor ....................................................................................... 12

4.3.3 DHW priority/General behaviour with external storage tank ................................................... 12

5. Boiler Control .......................................................................................................................................... 13

5.1 Control Panel ................................................................................................................................................ 13

5.2 Push buttons on control panel ................................................................................................................. 13

5.3 User menu .................................................................................................................................................... 14

5.3.1 Parameter/value setting.................................................................................................................. 14

5.3.2 Parameters accessible by user ...................................................................................................... 14

5.4 Installer (technician) menu ....................................................................................................................... 17

5.4.1 Parameters accessible by installer (technician) ........................................................................ 17

5.5 Manual Chimney sweep mode ................................................................................................................. 23

5.6 Disabling CH request .................................................................................................................................. 23

5.7 Service code ................................................................................................................................................. 23

5.8 Tacho fan speed .......................................................................................................................................... 23

5.9 Errors ............................................................................................................................................................. 23

5.10 ECO working mode ..................................................................................................................................... 23

5.11 Holiday mode ............................................................................................................................................... 23

5.12 Schedules for CH and DHW ...................................................................................................................... 23

5.13 Cascade and Modbus ................................................................................................................................ 23

5.14 Parameter settings ..................................................................................................................................... 23

CAHA Midi

Installation, Usage and Maintenance Instructions

CONTENTS

6. INSTALLATION ........................................................................................................................................ 26

6.1 Installing the boiler ..................................................................................................................................... 26

6.2 Frost protection ........................................................................................................................................... 26

6.3 Water connection ........................................................................................................................................ 27

6.3.1 Pump ................................................................................................................................................... 27

6.3.2 Minimum flow ................................................................................................................................... 27

6.3.3 Water-treatment ................................................................................................................................ 28

6.3.4 Water connection general ............................................................................................................... 28

6.4 Gas connection ............................................................................................................................................ 29

6.5 Air-supply and flue-gas connection ......................................................................................................... 29

6.5.1 B23 ....................................................................................................................................................... 29

6.5.2 C33 ....................................................................................................................................................... 29

6.5.3 C63 ...................................................................................................................................................... 30

6.5.4 Pressure drop calculations ............................................................................................................. 31

6.5.5 Installing flue -exhaust and air inlet .............................................................................................. 34

6.5.5.1 General ................................................................................................................................. 34

6.5.5.2 Brackets, mounting ............................................................................................................ 35

6.5.5.3 Sealing and JOINING ......................................................................................................... 35

6.6 Electrical connection .................................................................................................................................. 36

6.6.1 Wiring diagram .................................................................................................................................. 37

6.6.2 NTC resistance table (12K) ............................................................................................................. 39

6.7 Pneumatic connections ............................................................................................................................. 39

6.8 PC-connection ............................................................................................................................................ 40

7. COMMISSIONING .................................................................................................................................... 41

7.1 Gas category ................................................................................................................................................ 42

7.2 Adjustment % CO2 and check input ......................................................................................................... 43

8. ERRORS .................................................................................................................................................. 44

8.1 General .......................................................................................................................................................... 44

8.2 DHW errors ................................................................................................................................................... 45

8.3 CH-errors ....................................................................................................................................................... 45

8.4 Errors (hard and soft lockouts) ................................................................................................................ 45

9. ANNUAL SERVICE .................................................................................................................................... 47

9.1 Service-maintenance table........................................................................................................................ 48

CAHA Midi

Installation, Usage and Maintenance Instructions

1. DESCRIPTION - BOILER

1 MANOMETER 2 DISPLAY LCD 3 POWER SWITCH 4 FUSE 5 BURNER HOOD 6 SIGHT GLASS 7 FLOW NTC 8 IGNITION ELECTRODE 10 INSPECTION COVER 11 AIR SUPPLY 12 GAS PIPE 13 AIR INTAKE RETARDER 14 OVERHEAT LIMITER SWITCH 15 GAS VALVE 16 FAN 17 FLOW 18 FLUE GAS NTC 19 RETURN 20 FLUE GAS OUT 21 SYPHON 22 SUMP INSPECTION COVER 23 RETURN NTC 24 FILL AND DRAIN VALVE 25 WATER PRESSURE SWITCH 26 AUTO AIR VENT 27 VENTURI 28 BOILER CONTROLLER (MAXSYS) 29 TERMINAL STRIP 30 AIR PRESSURE SWITCH 31 SYPHON PRESSURE SWITCH

CAHA Midi

Installation, Usage and Maintenance Instructions

2. TECHNICAL DATA

Technical data CAHA Midi series

Model 340 425 510 600

Central Heating

Nominal input max load (Hi) 340 425 510 595 kW Nominal input min load (Hi) 68 85 102 119 kW Nominal ouput max load 80-60 °C 331 413.1 495.7 578.3 kW Nominal output min load 80-60°C 66 82.5 99 115.6 kW Efciency max load 80-60 °C (Hi) 97.2 97.2 97.2 97.2 % Efciency min load 80-60 °C (Hi) 97 97 97 97 % Efciency max load 50-30 °C (Hi) 103.1 103.1 103.1 103.1 % Efciency 30 % load 30 °C (return) (Hi) 108.1 108.1 108.1 108.1 % Standing loss 5.57 7.83 8.72 10.15 kW

Fluegas

Temperature flue-gas max load 80-60 °C 65-70 65-70 65-70 65-70 °C Temperature flue-gas min load 80-60 °C 60-65 60-65 60-65 60-65 °C

Mass-flow flue-gasses at max load G25 556 695 835 974 m3/h Mass-flow flue-gasses at min load G25 111 139 167 195 m3/h

Maximum flue-resistance 250 250 300 300 Pa Emission CO (Gaskeur SV) 116 110 100 90 ppm

Emission NOx (Gaskeur SV) 20 20 20 20 ppm Types B23.C33.C63 yes yes yes yes

Gas

Gasflow max load G25 41.8 52.3 62.8 73.2 m3/h Gasflow min load G25 8.4 10.5 12.6 14.6 m3/h

Gasflow max load G20 36 45 54 63 m3/h Gasflow min load G20 7.2 9 10.8 12.6 m3/h CO2 content max load G25/G20 9.3 9.3 9.3 9.3 % CO2 content min load G25/G20 9.1 9.1 9.1 9.1 %

Water

Maximum flow temperature 85 85 85 85 °C Content heat-exchanger (without manifolds) 36.2 43.7 51.1 58.5 ltr Minimum/maximum operating pressure 0.8/6 0.8/6 0.8/6 0.8/6 bar Hydraulic resistance (DT 20 nominal flow at full load 80-60 200 210 220 230 mbar Maximum DT max load/min load 25/35 25/35 25/35 25/35 °C Maximum waterflow 28.5 35.6 42.7 49.8 m3/h

Weight

Mass heat-exchanger* 150 180 215 245 kg Total mass of boiler 330 365 429 464 kg

Casing

Width 700 700 700 700 mm Depth without exhaust connection 1222 1222 1553 1553 mm Height (including wheels) 1540 1540 1540 1540 mm Height (without wheels) 1431 1431 1431 1431 mm

Electrical

Protection 00B 00B 00B 00B IP Electrical voltage/frequency 230/50 230/50 230/50 230/50 V/Hz Standby power consumption* 21 21 36 36 W Min load power consumption* 78 78 105 105 W Max load power consumption* 587 587 874 874 W Maximum allowable power consumption 2300 2300 2300 2300 W Fuse 10 10 10 10 A

* as coming from factory without extra devices connected

CAHA Midi

Installation, Usage and Maintenance Instructions

2.1 COMPONENT MATRIX

Overview of main components used in the CAHA Midi:

Part 340 425 510 600

Boiler control Honeywell Maxsys S4966V2052 S4966V2052 S4966V2052 S4966V2052

Display (user interface) DSP 49G2193 DSP 49G2193 DSP 49G2193 DSP 49G2193 Fan MVL 230 VAC G3G200-GN20-30 G3G200-GN20-30 G3G250-GN17-01 G3G250-GN17-01 Gas-valve Dungs 230 VAC MBC-700-SE-S02 MBC-700-SE-S02 MBC-700-SE-S02 MBC-700-SE-S02 Venturi Honeywell VMU500A VMU500A VMU680 VMU680 Texi Burner round 130 mm Worgas 433 529 623 718 Silencer air-inlet yes

Silencer flue-gas round 250 mm L=300mm yes double yes single yes single yes single NTC 12 k L=50 3 3 3 3 NTC 12 k OTC optional optional optional optional

Water low pressure device 1,6/0,8 bar yes yes yes yes Pressure difference switch 40 Pa in and 25 Pa out yes yes yes yes Syphon pressure difference switch 12,4 mbar out yes yes yes yes

3. DIMENSIONS

CAHA Midi

Installation, Usage and Maintenance Instructions

4. OPERATION

In the case of failure or malfunction of the appliance, do not attempt to repair it yourself. Please contact your installer.

Repairs must only be carried out by qualied technicians. Failure to comply with these requirements can compromise

the safety of the appliance.

4.1 GENERAL

The CAHA Midi is a floor standing boiler, equipped with a cast aluminium heat-exchanger. During heat demand the controller activates the pump. The controller checks the air pressure switch (zero check) and increases the fan speed to perform

an airflow-check. Once the air pressure switch closes, the fan speed increases to ignition speed and a 5 second pre-purge

is performed. The water pressure sensor, gas pressure switch and siphon pressure switch are checked. When all pressure switches are closed and the water pressure is ok, the ignition is started.

The air needed for combustion is taken in from the outside (if room sealed) or the boiler house (type B flue installation) by

the fan. The air is transported through a gas/air mixing device creating a negative pressure. This negative pressure is an indication of the amount of air being transported. The negative pressure is supplied to the gas valve by an internal tube. The gas valve automatically adjusts the amount of gas that will be injected into the venturi and that will be mixed with the air-flow. This mixture is supplied to the burner.

Ignition and flame-control of the mixture is done by two separate electrodes mounted on the burnerhood.

Temperature control and safeguarding is done using two NTC sensors. The boiler monitors the sensors continuously in

order to control operation and ensure safe operation.

4.2 CENTRAL HEATING (CH)

4.2.1 ON-OFF ROOM THERMOSTAT

As standard the boiler is programmed for using an on-off room thermostat. The room thermostat has to be connected to the pin nrs. 1 + 2 on the terminal strip. Open Therm will be recognized if connected on 1 + 2. The desired flow temperature

is adjustable, but as standard is set to 85 °C.

At CH heat request from the room thermostat (and no DHW heat request present) the CH-pump is activated after 10 sec-

onds. The controller will adjust the burner-input in such a way that a flow-temperature of 85 °C towards the CH-circuit is

achieved.

Warning : do not supply any voltage to these terminals as you may damage the controller

4.2.2 OPTIONAL 0-10V

The boiler may be controlled using a 0-10 V DC signal. Connect the negative (0V DC) to No. 3, and the positive (0-10V DC) to No.4 on terminal strip C2.

A loop of wire must be placed between the pin nrs. 1 and 2 of terminal strip C2. In the technician menu , enable 0-10V in the advanced CH settings menu by setting , CH request to either 0-10V DC % or 0-10V DC SP.

4.2.2.1 0-10V DC % POWER CONTROL

A value between 2 and 10V DC generates a CH power demand proportional to this value between 0 and 100% (0% = minimum load, 100% = nominal load). The heat demand is removed when the control signal falls below 1 volt.

The setpoint of maximum flow temperature is set to 90°C. In the user/technician menu , under diagnostics, boiler information the actual voltage input and target power are displayed.

CAHA Midi

Installation, Usage and Maintenance Instructions

4.2.2.2 0-10V DC SETPOINT

A value between 2 and 10V DC generates a CH setpoint demand proportional to this value between CH minimum flow temperature and maximum CH flow temperature. The heat demand is removed when the control signal falls below 1 volt. The minimum and maximum CH flow temperature can be set in the technician menu, advanced CH settings, CH temperatures.

In the user/technician menu , under diagnostics, boiler information the actual voltage input and boiler setpoint are displayed.

Caution : Ensure that the 0-10V DC signal is free from electrical interference!

4.2.3 OUTSIDE TEMPERATURE CONTROL OTC (OPTIONAL)

The boiler may use an outdoor sensor to provide weather compensation (OTC).

To activate weather compensation connect an oudoor sensor to numbers 5 and 6 on the terminal strip C2. Pin numbers 1

and 2 have to be bridged by a wire. Alternatively those pin numbers ( 1 and 2) can be used for connecting room thermostat on/off. In the technician menu, under advanced CH settings, CH request, OTC only must be selected. The outdoor sensor is then automatically detected by the controller. The parameters corresponding with A-E in the gure below can be set in the technician menu (advanced CH settings).

A OTC offset: minimum CH setpoint value B OTC setpoint maximum: maximum CH setpoint value C OTC weather cold: external temperature value at which the

maximum CH value will be used.

D OTC weather warm: external temperature value at which the

minimum CH value will be used

E OTC warm weather shutdown: external temperature value at which the CH demand will end

In the user menu an eco setpoint reduction (night reduction) can be set. Day, week and weekend options are also available (on, eco, off)

The outdoor sensor is available as an optional accessory.

The sensor should be installed on the north-side of the building at a height of approximately 2 meters.

Note : The resistance of the outdoor NTC should be 12 kOhm at 25 °C.

Also see table of resistance for NTC’s at 6.6.2

4.2.4 OPTIONAL DIGITAL COMMUNICATION

The boiler supports digital communication with room thermostats using Open-Therm communication protocols (automatically recognised if connected to pins 1 + 2 on terminal strip C2, also see 4.2.1.) .

CAHA Midi

Installation, Usage and Maintenance Instructions

4.2.5 SLOW START

The boiler uses the “slow start” procedure to prevent the boiler from supplying excessive power in low load situations. After “zero check” APS and closure APS with pre purge ignition starts. Following, a stabilization period, the boiler modulates down to low capacity and maintains this capacity for 1 minute. Subsequently the boiler power increases at a target rate

of 4 °C/min until maximum capacity or set temperature has been reached. Once heat demand has nished the burner will

turn off following a set post purge period.

The graph below illustrates this.

4.2.6 PROTECTION AGAINST INSUFFICIENT FLOW THROUGH BOILER

When the requirements of 6.3.2 are fullled the boiler will protect itself against insufcient flow. This is done by checking the difference in temperature between flow and return (so called ΔT).

In a low flow scenario the ΔT will rise rapidly. The ΔT safe-guarding principle is as follows:

▪ AtΔT > 22 the boiler starts modulating ▪ AtΔT between 22 and 27 the boiler continues modulating ▪ AtΔT > 27 boiler the fan speed will reduce until T < 25

CAHA Midi

Installation, Usage and Maintenance Instructions

4.3 DOMESTIC HOT WATER (DHW)

4.3.1 EXTERNAL STORAGE TANK WITH THERMOSTAT (ELECTRIC 3-WAY VALVE)

As standard the DHW conguration is factory pre-set for an external storage tank + tank thermostat. For hydraulic connection of an external storage tank to the boiler via an electric 3 way valve one should either use :

- the default conguration 2 pumps: 230 VAC DHW pump (terminal strip C1: 12,13,14) and CH pump (terminal strip C1: 15,16,17)

- an electric 3-way valve with a maximum travel time of 255 sec. (terminal strip C1: 13,14,15,16). At the end of the travel

time in either direction DHW or CH the 230 VAC on the 3-way valve will be switched off.

The 2 wires of the tank thermostat must be connected to numbers 7 and 8 on terminal strip C2. In the case of using an electric 3-way valve adjust the setting in the technician menu, system settings, boiler parameters,

number of pumps to: pump and 3-way valve.

The 3-way valve travel time can be changed in the technician menu, system setting, boiler parameters, 3-way valve travel time.

4.3.2 EXTERNAL STORAGE TANK WITH NTC SENSOR

In case the storage tank is equipped with an NTC sensor, adjust the setting in technician menu, advanced DHW settings,

DHW request to sensor.

Note: The resistance of the NTC sensor must have a value of 12 kOhm at 25 °C.

The 2 wires of the tank NTC sensor must be connected to numbers 7 and 8 on terminal strip C2.

The set point temperature of the storage tank is adjustable (default set at 60°C,the flow temperature is DHW setpoint + 20K). Warning : if a CH heat demand exists immediately after nishing the heat request for DHW, it is possible for high temperatures to flow into the CH system regardless of CH set point (hot shot).

4.3.3 DHW PRIORITY/GENERAL BEHAVIOUR WITH EXTERNAL STORAGE TANK

Disabling hot water operation : press Summer-Winter button R2-C4( not active in main screen). See later in manual for

further explanation.

Enabling hot water operation : press Summer-Winter button R2-C4 (active in main screen). See later in manual for further

explanation.

In the default boiler conguration, (2 pumps-DHW and CH pump), a DHW request has priority over CH request

In the technician menu, advanced DHW settings, DHW priority, the DHW priority over CH can either be disabled or a maximum DHW priority time can be set.

In the case where the DHW priority is disabled and both demands are active at the same, both pumps (CH and DHW) will

be activated. During this time the flow temperature is set to either 80 °C (tank thermostat) or DHW setpoint + 20K (NTC

sensor).

CAHA Midi

Notice : In some countries, at outputs ≥ 40 kW double separation between exchanging media is required. Please

check your local regulations.

Installation, Usage and Maintenance Instructions

5. BOILER CONTROL

5.1 CONTROL PANEL

The control panel has 12 buttons and a display as shown in the gure below.

5.2 PUSH BUTTONS ON CONTROL PANEL

CAHA Midi

Installation, Usage and Maintenance Instructions

5.3 USER MENU

By pressing the “menu-button” the display will show the text as given in the gure below.

By pressing the button marked “3”in the gure shown,

the user menu is accessed.

Pressing the button rmarked “5” returns back to the

main screen.

By pressing the button marked “4”, the installer menu is

accessed.

In the user menu the following options will be shown :

1. HEATING

2. DOMESTIC HOT WATER

3. HOLIDAY

4. MAINTENANCE

By pressing up and down (R1-C2 and R3-C2) one of the six options as shown above will highlight the desired parameter. By pressing the OK button (R2-C2) the chosen option will be selected.

Once an option has been slected it is possible to change the parameters corresponding with the chosen option.

5. SETTINGS

6. CHIMNEY-SWEEPER

7. DIAGNOSTICS

5.3.1 PARAMETER/VALUE SETTING

Pressing the up and down (R1-C2 and R3-C2) buttons will highlight the desired parameter. Pressing the OK button (R2-C2) will allow the chosen parameter to be modied. This is shown below.

The actual value can be changed by pressing the R1-C1 and R2-C1 buttons.

The changed value can be conrmed by pressing the OK (R2-C2) button.

Pressing the back (R3-C1) button leaves the actual displayed parameter.

If there are more parameters shown in the parameter value area (4) the desired parameter can be selected by pressing the up and down ((R1-C2 and R3-C2) buttons.

5.3.2 PARAMETERS ACCESSIBLE BY USER

An overview of the parameters accessible by the user is given on the next pages

CAHA Midi

Installation, Usage and Maintenance Instructions

1 CH setpoint Adjust setpoint of CH circuit

Set the external temperature at which Heat demand is removed . If set OFF,

heat demand will never be removed.by controller (Only by removing RT or

bridge between terminal strip C2:1,2)

ECO mode is activated

Based on selection is possible to enable/disable on board scheduler

Enable Enable on board scheduler

Disable Disable on board scheduler

2 Outside tempera-

ture for CH off

1 Enable/disable on

board scheduler

Used to program on board scheduler (On, Off , Eco)

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

2 Scheduler set Select to set scheduler

DHW temperature, in case of DHW with thermostat this is the base boiler flow

temperature)

when ECO mode is activated

Based on selection possible to enable/disable DHW on board scheduler

5 Friday

6 Saturday

7 Sunday

8 Monday – Friday

9 Monday – Sunday

10 Saturday - Sunday

Enable Enable on board scheduler

1 Enable/disable on

board scheduler

Used to program on board scheduler (On, Off, Eco)

Disable Disable on board scheduler

1 Monday

2 Scheduler set Select to set scheduler

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

8 Monday – Friday

9 Monday – Sunday

10 Saturday - Sunday

1 CH temperature /OTC set Set the CH temperature and OTC curves parameters

USER MENU SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

1 Heating Heating user settings

CAHA Midi

2 ECO setpoint reduction Set the temperature that will be subtracted from the actual setpoint when

3 Scheduler set Invoke scheduler menu

Installation, Usage and Maintenance Instructions

1 DHW set point Set the DHW temperature (in case of a DHW with sensor this is the actual

2 Domestic hot water Domestic hot water user settings

2 ECO set point reduction Set the temperature that that will be subtracted from the actual setpoint

3 Scheduler set Invoke scheduler menu

entered info

is shown on lower part of main screen asking for

service

time format 24/12 Hours is opened. When selected ap-

propriate format screens jump to time entering screen

original factory default settings. See 1)

% of power

Timeout 15 minutes. While test in progress navigating

through other menus is allowed.

Will display the information shown in SUBMENU 2

10 DHW storage temperature

When the line has a * at the end of the line means that

hitting OK when the line is highlighted will open a graph

that shows the latest 120 variable values stored every

12 minutes (24 hour history)

11 Boiler fan speed

12 CH ignitions

13 CH runtime

14 DHW ignitions

15 DHW runtime

16 System pressure

17 Heat Exchanger Temp.

18 0-10V input

19 Target power"

1 CH holiday set point Set CH temperature used when Holiday mode active

USER MENU SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

3 Holiday Holiday temperatures settings

CAHA Midi

2 DHW holiday set point Set DHW temperature used during holiday mode

1 Service information Used to display service company phone number or

2 Service due date Show next service due date . When date expire a MSG

4 Maintenance Set maintenance related info

5 Settings Boiler option settings

English Select for English

Italian Select for Italian

German Select for German

Russian Select for Russian

Fahrenheit Select for Fahrenheit

1 Select Language Allow selection of a different language

Celsius Select for Celsius

2 Select units Allow selection of different unit

3 Set date Allow RTC date setting

4 Set time Allow RTC time set. When selected a screen asking for

24 hours Select for 24 hours clock

12 hours Select for 12 hours clock

5 Restore factory data Pressing OK all the user settings will be restored to the

Installation, Usage and Maintenance Instructions

6 Chimney sweeper Manual mode. Hitting OK will force boiler to operate at

"1 CH request

2 DHW demand

1 Boiler information Boiler information

7 Diagnostics Will display boiler usage information and errors

3 Firing rate

4 Flame ionization

current

5 Boiler set point

6 Boiler supply tempera-

ture

7 Return temperature

8 Flue temperature

9 Outdoor temperature

5.4 INSTALLER (TECHNICIAN) MENU

If the button marked “4” (see page 14) is pressed the screen as given in the gure below will appear.

Please contact RVR Energy Technology Ltd to receive the technician access code.

Once the menu is accessed by entering the code the following options will be shown

1. ADVANCED CH SETTINGS

2. ADVANCED DHW SETTINGS

3. SYSTEM SETTINGS

4. DIAGNOSTICS

Pressing the up and down (R1-C2 and R3-C2) buttons will highlight the desired parameter group. Pressing the OK button

(R2-C2) selects the chosen parameter group.

Pressing the up and down (R1-C2 and R3-C2) buttons will highlight the desired parameter subgroup. Pressing the OK button (R2-C2) selects the chosen parameter subgroup.

Once a parameter subgroup option has been chosen it is possible to change the parameters corresponding with the selected subgroup

Follow the instructions as per 5.3.1 to set or change a parameter.

5. USER SETTINGS

6. CASCADE

7. RESTORE FACTORY SETTINGS

5.4.1 PARAMETERS ACCESSIBLE BY INSTALLER (TECHNICIAN)

An overview of the parameters accessible by the installer (technician) is given on the following pages.

Certain paramaters are marked with a caution or warning symbol. Setting inappropriate values in these parameters may lead to instability or overheating, or in extreme cases damage to the boiler, connected equipment, or persons. RVR does not accept responsibility for any damage caused by inappropriate settings.

Take care when altering the value of parameters marked with the caution symbol

Parameters carrying the warning symbol have explicit directions associated with them. Failure to observe these directions will immediately invalidate the product's warranty.

CAHA Midi

Installation, Usage and Maintenance Instructions

screens that contain details on boiler status when error occurred

exceed). DO NOT EXCEED 90°C

1 Maximum power Set % of boiler maximum power in CH mode

2 Minimum power Set % of boiler minimum power in CH mode

1 Absolute max temp Set CH absolute max temperature (CH temperature boiler settings will never

2 CH maximum set point Determine higher boundary of CH setpoint

be switched off)

3 CH minimum set point Determine lower boundary of CH setpoint

4 CH set point hysteresis Set CH setpoint hysteresis (temperature above setpoint at which boiler will

1 Outside temp for max CH Dene external temperature at which OTC will set maximum CH setpoint

2 Outside temp for min CH Dene external temperature at which OTC will set the minimum CH setpoint

3 Outside temp for CH off Set the external temperature at which Heat demand is removed . If set OFF

heat demand will never be removed.by controller (Only by removing RT or

bridge between terminal strip C2:1,2)

determined by the OTC parameter selection

4 OTC set point table Show in a table the link between external temperature and actual setpoint

5 OTC curve Show in a curve the link between external temperature and actual setpoint

Set the ant cycling timer (minimum time between boiler goes off till next

ignition)

1 post pump time Set the CH pump overrun time.

Only OTC Select OTC: outdoor Temperature controller 3)

Room Tstat Select RT/OT: Room Thermostat or OpenTherm

0-10V Signal [%] Select 0-10Vdc input for Power mode 3)

0-10V Signal[SP] Select 0-10Vdc input for setpoint mode 3)

1 Maximum power Set % of boiler maximum power in DHW mode

2 Minimum power Set % of boiler minimum power in DHW mode

Set Flow temperature during DHW mode when DHW done via a thermostat

(Switch)

Set DHW temperature setpoint when DHW done with temperature sensor

1 Storage temperature set

point

2 Boiler temperature set

point

Lockout history Show a list of recent errors. Hitting OK on the highlighted error will open

TECHNICIAN MENU SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

CAHA Midi

1 CH power set Set power of boiler in CH mode

1 Advanced CH settings Heating installer advanced settings

2 CH temperatures Set (selecting OK) and show CH temperatures

3 OTC parameters Set the OTC parameters

4 CH pump settings Set pump usage related parameters

5 CH anti cycling

timer

6 CH request type Allow selection of different CH requests:

Installation, Usage and Maintenance Instructions

1 DHW power Set power of boiler in DHW mode

2 Advanced DHW settings Domestic hot water advanced settings

2 DHW temperatures Set (selecting OK) and show DHW temperatures

Enabled Enable

Disabled Disable

DHW post pump time Set the DHW pump overrun time added to the prexed time of 3 minute.

1 DHW priority status Enable /disable DHW priority over CH

present for the same amount of time).

Off Select for no timeout (While DHW priority status is enabled)

1..60 minutes Set timeout in minutes. (While DHW priority status is enabled)

2 DHW priority timeout Dene after how much time DHW priority is ended. (CH can be served if

Switch DHW start when DHW thermostat closes

Sensor DHW start based on required vs actual DHW temperature

1 Ignition power Set power % used when igniting burner. DO NOT EXCEED 30%

System with pump and 3-way valve

Pump and

2 Delay siphon check Delay time to validate a syphon error DO NOT ALTER

3 Number of boiler pump Dene Pump and 3-way valve or 2 pumps

3WayValve

Two pumps System with 2 pumps

4 Pump speed max Maximum % of PWM pump speed

Enabled Enable Antilegionella protection

Disabled Disable Antilegionella protection

5 Pump speed min Minimum % of PWM pump speed

6 Antilegionella Based on selection possible to enable/disable Antilegionella protection

7 Modbus parameters Set Modbus parameters

Address Set address default: 1

Baudrate Set baudrate default: 38400 bps

Frame Set frame 8N!

8 3 Way valve travel time Select for setting travel time 3WV in seconds

English Select for English

1 Select language Allow selection of a different language

Italian Select for Italian

German Select for German

Russian Select for Russian

3 DHW pump settings Dene pump usage in DHW mode

4 DHW priority Dene DHW priority over CH

TECHNICIAN MENU SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

CAHA Midi

5 DHW request type Dene DHW request switch or sensor

1 Boiler parameters Boiler related parameters

3 System setting Boiler and system parameters

Installation, Usage and Maintenance Instructions

2 User interface set-

tings

Fahrenheit Select for Fahrenheit

Celsius Select for English

done as per technician password enter)

Will display the information shown in SUBMENU 2 When the line has a * at the end of the line means that

10 DHW storage temperature

hitting OK when the line is highlighted will open a graph

that shows the latest 120 variable values stored every 12

minutes (24 hour history)

11 Boiler fan speed

12 CH ignitions

13 CH runtime

14 DHW ignitions

15 DHW runtime

16 System pressure

17 Heat Exchanger Temp.

18 0-10V input

lighted error will open new screen that contains details of

the boiler status when the error occurred.

19 Target power"

1 CH set point Adjust setpoint of CH circuit

Set the external temperature at which Heat demand is

2 Outside

removed .

temperature

for CH off

al setpoint when ECO mode is activated

Based on selection is possible to enable/disable on board

scheduler

1 Enable/dis-

able on board

Enable Enable on board scheduler

scheduler

Disable Disable on board scheduler

2 Select unites Allow selection of different unit

SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

TECHNICIAN

CAHA Midi

3 Set date Set system date

4 Set time Set system time

1 Service information Used to insert service company phone number (selection

3 Service settings Service information

2 service due date Next service due date (input done as per date entering)

"1 CH request

2 DHW demand

1 Boiler information Boiler information

4 Diagnostics Boiler information and lockout history

3 Firing rate

4 Flame ionization current

5 Boiler set point

6 Boiler supply temperature

7 Return temperature

8 Flue temperature

9 Outdoor temperature

2 Lockout history Shows the list of recent errors. Hitting OK on the high-

3 Manuel test See chimney sweeper.

Installation, Usage and Maintenance Instructions

1 CH temperature/ OTC set Set the CH temperature and OTC curves parameters

1 Heating Heating user settings

5 User settings Access the user settings from the advanced menu.

2 ECO set point reduction Set the temperature that will be subtracted from the actu-

3 Scheduler set Invoke scheduler menu

Select to set scheduler

Used to program on board scheduler

"1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

Domestic hot water user settings

6 Saturday

7 Sunday

8 Monday – Friday

9 Monday – Sunday

10 Saturday - Sunday"

is the actual DHW temperature, in case of DHW with thermo-

stat this is the base boiler flow temperature)

Invoke scheduler menu

Based on selection is possible to enable/disable on board

scheduler

Enable on board scheduler

Disable on board scheduler

Enable

Disable

Used to program on board scheduler

"1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

8 Monday – Friday

9 Monday – Sunday

10 Saturday - Sunday"

2 Scheduler set

SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

TECHNICIAN

1 Enable/disable on

board scheduler

1 DHW set point Set the DHW temperature (in case of a DHW with sensor this

2 Domestic hot

water

2 ECO set point reduction

3 Scheduler set Invoke scheduler menu

2 Scheduler set Select to set scheduler

1 CH holiday set point Set CH temperature used when Holiday active

2 DHW holiday set point Set DHW temperature used during holiday mode

3 Holiday Holiday temperatures settings

CAHA Midi

Installation, Usage and Maintenance Instructions

Access to cascade information and settings

Delay between switching on and of different boilers

Number of boilers assigned to DHW

Base time for PI loop calculation

Heterogeneous mode with 2 power groups DHW+ CH /CH only

Disable Heterogeneous mode

Enable Heterogeneous mode

Disabled

Enabled

Cascade pump full speed

Cascade pump min speed

Role of boiler in cascade mode= MASTER, SLAVE, TERMINAL

SLAVE. If not in cascade mode : STANDALONE

graph that shows the latest 120 variable values stored every 12 minutes

(over the past 24 hours). Samples will not be averaged over the 12

minutes period.

Number of burners that are switched on

SEE NOTE BELOW

Pressing OK will start the auto detection of the cascade congu-

ration. Can only be started from the master boiler.

Pressing OK all the advanced settings will be restored to the orig-

inal factory defaults

Do not perform a factory reset prior to consulting with RVR Energy Technology Ltd. Depending on the

rmware version present on the controller, additional steps may be required to restore normal operation.

1 Cascade set

TECHNICIAN MENU SUBMENU 1 SUBMENU 2 SUBMENU 3 SUBMENU 4 NOTES

7 Cascade

CAHA Midi

1 cascade switch delay

2 cascade min power Minimum power of boilers in cascade

3 Burner power Max power of SINGLE boiler in cascade

4 Boiler for DHW

5 PI loop period

6 Burner water flow delay Water propagation time delay. DO NOT ALTER

7 Different boiler size

8 Cascade pump speed max

Installation, Usage and Maintenance Instructions

9 Cascade pump min

speed

2 System temperature * Cascade temperature value. Hitting OK when highlighted will open

2 Cascade info 1 Cascade role

3 Numbers of burners on

4 Modulation level Actual percentage of cascade modulation level

3 Cascade auto detect

7 Restore factory settings

5.5 MANUAL CHIMNEY SWEEP MODE

For routine maintenance and/or service purposes a CH request can be generated to force the burner to a specic load from

minimum to nominal (0-100%). This is only possible if no error condition is present. The chimney sweep function can be

started from the user menu and will be active for 15 minutes.While active it is possible to navigate through other menus to

check the boiler status and functionality.

5.6 DISABLING CH REQUEST

The CH function can be disabled. See 5.3.2 parameters accessible by user at 1 HEATING nr 3 scheduler set.

5.7 SERVICE CODE

To access the service-level of the controller it is necessary to enter the service-code. How this done is explained in 5.4

installer (technician) menu.

5.8 TACHO FAN SPEED

For service purposes it is possible to read the fan speed. See 5.4.1 parameters accessible by installer (technician) at 4 DIAGNOSTICS nr 1 boiler information.

5.9 ERRORS

For service purposes it is possible to see a list of recent errors. See 5.3.2 parameters accessible by user at 6 DIAGNOSTICS

nr error history.

5.10 ECO WORKING MODE

When the ECO button (R3-C4) is pressed a programmable value (see user menu 1.HEATING under 2 ECO set point reduction) is automatically subtracted from the flow temperature setpoint weather compensated (OTC) set point, or 0-10V setpoint. . The same principal is applicable for DHW (see user menu 2.DOMESTIC HOT WATER under 2 ECO set point reduction)

5.11 HOLIDAY MODE

When the Holiday button (R3-C3) is pressed a start and end date of a holiday period may be entered.The desired flow temperature and the DHW temperature for this period can be set (see user menu 3. HOLIDAY under 1 and 2)

5.12 SCHEDULES FOR CH AND DHW

For CH and DHW separate schedules can be set. Both schedules are set to enabled and always on by default. Schedules may be set (ON, ECO, OFF) for each day, for a group of weekdays, for weekend days or for an entire week. The status of the schedule is shown on the main screen (ON, ECO, OFF). The schedule can be set in the user menu, heating or domestic hot

water or in the technician menu, user settings, heating or domestic hot water.

Eco mode can also be forced by pushing the ECO button on the control panel (R3-C4).

5.13 CASCADE AND MODBUS

Cascade and Modbus options are shown in two separate attachments “Modbus” and “Cascade”.

5.14 PARAMETER SETTINGS

The parameter settings are listed on the following pages.

CAHA Midi

Installation, Usage and Maintenance Instructions

Higher than 90 not allowed

Recommended Min Max After factory reset

User Menu

1 Ch setpoint 85 20 90/Technician 75

2 Outside temperature for CH off OFF 7 30 OFF

2 Scheduler set ON ON | OFF ECO ON

Recommended Min Max After factory

Technician Menu

2 Minimum power 0 0 100 0

2 CH maximum setpoint 85 20 Abs. max CH 75

3 CH minimum setpoint 20 20 70 40

4 CH setpoint hysteresis 5 2 10 3

2 Outside temp for min CH 18 15 25 18

3 Outside temp for CH off OFF 7 30 OFF

5 OTC curve OTC curve

4 OTC setpoint table OTC table

1 Maximum power 100 0 100 100

2 Minimum power 0 0 100 0

1 Storage temperature setpoint 80 35 85 80

2 Boiler temperature setpoint 60 35 65 60

3 DHW setpoint hysteresis 6 2 10 3

1 DHW priority Status Enabled Enabled Disabled Enabled

2 DHW priority TimeOut Off 1 60 Off

1 CH temperature/OTC set

CAHA Midi

2 ECO setpoint reduction 50 0 50 50

1 HEATING

Scheduler set 1 Enable/disable on board scheduler Enabled Disabled Enabled Enabled

1 DHW setpoint (Switch) 80 35 85 80

1 DHW setpoint (NTC sensor) 60 10 65 60

2 ECO setpoint reduction 20 0 50 20

2 DOMESTIC HOT WATER

Scheduler set 1 Enable/disable on board scheduler Enabled Disabled Enabled Enabled

1 CH holiday setpoint 20 20 90/Technician 20

1 CH power set 1 Maximum power 100 0 100 100

2 DHW holiday setpoint (Thermostated) 80 35 85 80

3 HOLIDAY

2 DHW holiday setpoint (NTC sensor) 60 10 65 60

1 Service information Service tel. set by Technician

4 MAINTENANCE

2 Service due date Date set by Technician

1 Select language English English|Italian German | Russian

2 Select units Celsius Fahrenheit Celsius

3 Set date set date

4 Set time 24 hours 24 hours 12 hours

5 SETTINGS

5 Restore factory settings Reset to factory/check settings

1 Boiler information Real time boiler status

2 Lockout history Overview lockout history Status boiler at time of lock/block

6 CHIMNEY SWEEPER OFF 0 100

7 DIAGNOSTICS

2 CH temperatures 1 Absolute max. temperature 90 20 90 80

Installation, Usage and Maintenance Instructions

3 OTC parameters 1 Outside temp for max CH -10 -34 10 -10

1 ADVANCED CH SETTINGS

DHW temperatures

4 CH pump settings 1 Post pump time 10 1 30 5

5 CH anticycling timer 3 0 15

6 CH request type RT+SP/OT onlyOTC|RT 01-Vdc % | SP RT+SP/OT

1 DHW power

3 DHW pump settings 1 DHW post time 1 OFF 180 30

4 DHW priority

5 DHW request type Switch Switch Sensor Switch

2 ADVANCED DHW SETTINGS

Higher than 30 not allowed

Check syphon is not emptied by new value

Reccommended Min Max After factory reset

2 Delay siphon check 3 0 20

3 Number of boiler pumps 2 pump Pump 3-w-valve 2 pump 2 pump

4 PWM pump speed Max 100 1 100 100

5 PWM pump speed min 40 1 100 30

6 Antilegionella Enabled Disabled Enabled Disabled

7 Modbus parameters Adress Baudrate Frame

8 3 Way valve travel time 180 1 255 10

2 Select units Celsius Fahrenheit Celsius

3 Set date Set date

4 Set time 24 Hours 24 hours 12 hours

2 Service due date Set service date

2 Outside temperature for CH off off 7 25 off

2 Scheduler set Set time scheduler (Time/On/ECO/OFF)

2 Cascade min power 20 0 100

3 Burner power (default value x 0 2550

4 Boiler for DHW 0 1 6 0

5 PI loop period 5 0 15 5

6 Burner water flow delay 30 0 255 30

7 Different boiler size Disabled Disabled Enabled Disabled

8 Cascade pump speed mx. 100 15 100 100

9 Cascade pump speed min 40 15 100 30

2 System temperature Actual temperature Cascade system sensor

3 Number of boilers on Actual number of burners /boilers on in cascade

4 Modulation level Actual cascade modulation level

3 SYSTEM SETTINGS 1 Boiler parameters 1 Ignition power 0 100

CAHA Midi

2 User interface settings 1 Select language English English | Italian German | Russian

3 Service settings 1 Service information Set telelphone number

Installation, Usage and Maintenance Instructions

2 Lockout history Overview lockout history Status boiler at time of lock/block

3 Manual test See chimney sweeper

4 DIAGNOSTICS 1 Boiler information Real time boiler status

5 USER SETTINGS 1 CH temperature/OTC set 1 CH set point 85 20 90/abs max CH 75

2 ECO setpoint reduction 50 0 50

3 Scheduler set 1 Enable/disable on board scheduler Enabled Disabled Enabled

1 DHW setpoint (NTC sensor) 60 35 65

1 DHW setpoint (Thermostated) 80 35 85

2 ECO setpoint reduction 20 0 50

3 Scheduler set 1 Enable/disable on board scheduler Enabled Disabled Enabled

1 CH holiday setpoint 20 20 90/Abs max CH

1 DHW holiday setpoint (Thermostated) 80 35 85

2 DHW holiday setpoint (Sensor) 60 10 65

6 CASCADE 1 Cascade set 1 Cascade switch delay 30 0 255

2 Cascade info 1 Cascade Role : see Cascade auto Standalone Standalone Master | Slave

3 Cascade auto detect : press OK to start detecting role boiler in cascade chain Standalone Standalone Master | Slave

7 RESTORE FACTORY SETTINGS Reset to factory/check settings

6. INSTALLATION

6.1 INSTALLING THE BOILER

The installation must be done in accordance with all local and national codes, regulations and standards, and in accordance with the directives of all relevant authorities.

1. The boiler must only be installed in an area where it is allowed to install it. Make sure that this area is protected against

the danger of freezing.

2. The area should have sufcient ventilation and cooling to prevent overheating.

3. When delivered the boiler is on a pallet. Install the boiler on a flat non-combustible floor and level it by using its posi-

tioning bolts.

4. A minimum free space of 50 cm should be left on each side of the boiler for service access.

5. Remove the sealing/protection caps from the connection tubes. Warning : take care as residual water from testing may

drip

6. Fill the condensate trap with clean water. This can be done by flushing some water into the cast aluminium exhaust

connection from the rear. This water will then drain into the syphon and ll it.

6.2 FROST PROTECTION

The boiler is protected against frost.

If the boiler detects an NTC flow temperature below 8 ºC, the CH-pump will be activated. If temperatures continues to fall the boiler will start at a flow temperature of 6 ºC and it will run on minimum load until the flow NTC senses a temperature of 15 °C. The CH-pump will stay running for another 10 minutes. This only protects the

boiler and does not protect the installation, pipework or radiators against freezing.

During longer periods of absence in the winter, the installation itself should be protected by activating the heating periodically and by partly opening the radiator valves. Where a room thermostat is controlling the demand, do not set the room

thermostat to a value below 15 °C.

To protect frost sensitive radiators against frost it is possible to connect a frost thermostat in parallel with a Volt free room thermostat.

It is also possible to set the CH pump to activate automatically under OTC settings when an outdoor sensor is present (this

must be set by the installer). In this case,the CH pump will be activated if the outdoor temperature drops below 8 ºC.

CAHA Midi

Installation, Usage and Maintenance Instructions

6.3 WATER CONNECTION

6.3.1 PUMP

The boiler does not have a built in CH-pump. Therefore a CH-pump must be mounted separately . Select a pump that matches the hydraulic resistance of the boiler and the installation. The graph below shows the resistance characteristics for the different boiler models

For electrical connections see chapter 6.7.

6.3.2 MINIMUM FLOW

The minimum flows shown below must be guaranteed.

Type Flow [m3/h] @ ΔT25 Full Load Flow [m3/h] @ ΔT30 Start = 15% Flow [m3/h] @ ΔT30 Part Load

340

425

510

600

CAHA Midi

11.7 3.1 1.9

14.6 3.9 2.4

17.5 4.7 2.9

20.5 5.5 3.4

Installation, Usage and Maintenance Instructions

6.3.3 WATER-TREATMENT

Before lling up the installation (old and new), the installation should be rinsed thoroughly with clean water from

the tap.There are some rinsing/cleaning products listed below and it is recommended that these are used.

▪ The pH must be kept between 7 and 8,5 at all times ▪ The maximum allowed content of chlorides is 150 mg/ltr. ▪ The water hardness of the heating system must be according to the German VDI guideline 2035. See following table:

<0,11 ºdH = demineralised ºdH =German VDI hardness

50-300kW total boiler capacity <11,2 ºdH <8,4 ºdH <0,11 ºdH 300-600kW total boiler capacity <8,4 ºdH <0,11 ºdH <0,11 ºdH >600kW total boiler capacity <0,11 ºdH <0,11 ºdH <0,11 ºdH

▪ Example: for a CAHA Midi 340kW boiler and a total hardness of 8,40 ºdH (German VDI hardness) the total volume of

lled, relled and topped up water must not exceed 20 ltrs/kW. If this hardness value is exceeded the total amount of lling, relling and topping up water is (8,4 / actual hardness in ºdH) x ltrs/kW. In the case of water hardness of 15ºdH the maximum volume/kW is: (8,4/15) x 20 = 11,2 ltr/kW. If higher values are present, the water should be softened.

▪ The water may only be partly softened to a value of 20% of its original value. Example : if the initial hardness is 15°D,

then it may only be softened to 3,0 ºD Note that water softening by means of ion exchange principle is not allowed. If the installation is lled with demineralised or distilled water additives must be added to stabilise the pH value in order to prevent corrosion. Before lling with demineralised water the complete installation must be rinsed.

▪ The conductivity of the non treated installation water must not exceed the value of 300 μs/cm in combination with a

max O2 content of 0,1 mg/ltr. If the O2 content is lower than 0,02 mg/ltr a higher conductivity limit of 600 μs/cm is

allowed. if the conductivity is higher than the values mentioned above, empty the system, flush and ll with clean tap

water, prefeably by adding the recommended cleaning products. ▪ The water pressure must be higher than 0,8 bar ▪ The water quality must be checked on a regular basis (at least annually) ▪ There are many products available on the market which pretend to clean and protect heating systems. Unfortunately

there are only a few that have really proven this in practice.Therefore RVR Energy Technology only allows the following

quality products for water treatment ;

Installation < 20 ltr/kW

Installation between 20 and 50 ltr/kW

Installation > 50 ltr/kW

Producer : Fernox www.fernox.com

- Cleaner F3 : removes corrosion, lime and sludge

- Protector F1 : protects against corrosion, lime and sludge

- Alphi-11 : anti-freeze and protection against corrosion and lime

Producer : Sentinel www.sentinelprotects.com

- X100 : Inhibitor scale and corrosion protection

- X200 : Noise reducer long life system treatment to eliminate noise

- X300 : System cleaner for new hydronic heating systems

- X400 : System restorer non acid cleaning of older systems

- X500 : Inhibites antifreeze against scale and corrosion in all types of indirect heating systems at low temperatures

Note that these products must be used strictly in accordance with the water treatment manufacturers instructions.

Furthermore we strongly recommend the following ;

▪ Use the above mentioned water treatment protection products to ll and protect the installation ▪ Use a log book to record water lling, relling, topping up, water quality measurements and water treatment ▪ Only use diffusion tight material, especially for under floor heating ▪ Always mount air vents at the highest points in the installation. ▪ Install isolation/check valves near the boiler and on strategic locations (anticipating any future expansions of the sys-

tem) to avoid lls, rells and topping up as much as possible.

▪ Install a water meter to check the amount of lled, relled and topped up water. ▪ Install a lter (magnetic and dirt) in the return. ▪ Install an isolation heat-exchanger to separate the boiler from the installation to protect dirt or lime in the secondary

system from affecting the boiler. ▪ Avoid leaks and if there is a leak, repair as soon as possible.

CAHA Midi

Installation, Usage and Maintenance Instructions

6.3.4 WATER CONNECTION GENERAL

1. Water connections for flow and return are size DN100

2. The installation must have a pressure relief valve (with a capacity higher than the boiler output) and an expansion ves-

sel. The capacity of this vessel should be sufcient for the installation.

3. To avoid blocking and non volatile lock-out of the boiler control it is recommended to install a by-pass in the installation to guarantee the minimum flow through the boiler. The by-pass valve should be mounted as far away from the boiler as possible to have the biggest possible content of the bypass-circuit (also a big radiator without valves could be used).

4. Drain the condensate via a tundish and an U-trap to the sewer.

5. At the highest point of the installation a de-airing device should be mounted.

6.4 GAS CONNECTION

6. The gas connection must be done in accordance with all local and national codes, regulations and standards, and in accordance with the directives of all relevant authorities.

7. The gaspipe of the boiler has a R 1,5” connection.

8. In order to avoid blockage of the gas valve, ensure that there is no dirt in the gas pipework prior to commissioning.

9. The maximum allowable inlet pressure for the gas valve is 50 mbar.

10. Check the heat input of the boiler. The load as given on the type plate should be checked.

6.5 AIR-SUPPLY AND FLUE-GAS CONNECTION

Air connection : All types have air connection ø 150 mm Flue gas connection : ø 250 mm for all types Allowed Appliance types: Possibilities for air / flue system ; B23 C33 C63 Note : C63 is not possible for Belgium.

6.5.1 B23

As standard the boiler is delivered as type B23 where the supply air is taken from the room where the boiler has been

installed in.

If the inlet air contains dust or dirt one should install a lter or a leaf catcher in the air supply.

A vertical terminal is recommended

Roof terminals and extensions and/or condensate trap/collector must be approved by RVR Energy Technology. See page

33.

For pressure drop calculation of appliance type B23 use the table for pressure drop per component and the table for total

pressure drop calculation. See page 44.

For total available pressure drop see table on page 42.

6.5.2 C33

A vertical terminal is recommended.

Roof terminals and extensions and/or condensate trap/collector must be approved by RVR Energy Technology. See page

44.

For pressure drop calculation of appliance type C33 use the table for pressure drop per component and the table for total pressure drop calculation. See page 42. For total available pressure drop see table on page 42.

Terminals should be installed in the same pressure area (within a plane of 1m2)

CAHA Midi

Installation, Usage and Maintenance Instructions

6.5.3 C63

C63 appliances may only be equipped with Gastec QA materials and terminals or according NEN 14989-2

Note: When using a C63 type flue conguration it is essential to ensure that C63 is allowed in the country

were the boiler is installed.

It is recommended to use a full aluminium flue system. A PP (Temperature class T120) or stainless steel flue system can also be used (See TPW table below). In this case the condensate must be drained before it flows back into the aluminium parts of the boiler. Otherwise aggressive condensate from the non-aluminium flue system can corrode the aluminium parts

of the boiler. A condensate trap/collector must be mounted just before entering the silencer(s) of the boiler (also see 6.5.5.1

general).

T-P-W Class

Temperature range T120 Pressure range P1 Condensate resistance (W=wet / D=Dry) W

The minimal combustion products temperature, mass flow rate and CO2 are given in the table below.

Model Part Load Vol. Flue m3/h Vol. Air m3/h CO2 % T Fluegas ºC rho kg/m

340 68 88 76 9.1 30 1.12

425 85 110 95 9.1 30 1.12 510 102 132 115 9.1 30 1.12 600 119 154 134 9.1 30 1.12

The maximum allowed recirculation rate under wind conditions is 10 %

Maximum allowable combustion air temperature 45 °C

The tables below give an indication of maximum lengths (in mtrs) for parallel air supply and flue outlet pipes. The equiva-

lent of pipe length in mtrs of bends 90 ° and 45 ° is given

Model Max. allowed pressure drop* Parallel Air/Fluegas

Ø150/ø200

Parallel Air/Fluegas

Ø150/ø250

Parallel Air/Fluegas

Ø180/ø250

340 250 Pa 36m 48 m 89 m 425 250 Pa 20 m 29 m 54 m 510 250 Pa 15 m 24 m 43 m

600 250 Pa 8 m 16 m 30 m

(*) : Without roof terminal, bend(s) and condensate trap

Equivalent of pipe length in meters

Bend Pipe Diameter

Parallel Air/Fluegas

Ø150/ø200

Parallel Air/Fluegas

Ø150/ø200

Parallel Air/Fluegas

Ø180/ø250

Bend 90° 4.4 4.1 4.3 Bend 45° 2.2 1.9 2.1

CAHA Midi

Warning : Do not install the terminals for supply of combustion air and for the exhaust of combustion products on opposite walls of the building

Terminals should be installed in the same pressure area (within a plane of 1m2).

Installation, Usage and Maintenance Instructions

6.5.4 PRESSURE DROP CALCULATIONS

The rst 90 ° bend must be mounted directly to the boiler and followed by the chimney silencer (this bend is not part of the

calculation (as it is already taken into account)).

Flue-outlet and air-supply calculations:

Total pressure drop available for flue-outlet and air-supply is given in the table below.

Air connection : All types have air connection ø 150 mm Flue gas connection : ø 250 mm for all types

Type Total available Pressure drop in [Pa] for B23, C33, C63

340 250 425 250 510 300

600 300

For pressure drop calculation of appliance types B23,C33 use the next two tables on the following pages.

PRESSURE DROP TABLE PER COMPONENT

Boiler type

1 2 3 4 5 6 7 8

340 425 510 600

Pressure drop [Pa] Flue gas

[Pa]

Air [Pa]

Flue gas [Pa]

Air [Pa]

Flue gas [Pa]

Air [Pa]

Flue gas [Pa]

Air [Pa]

Pipe length 1m Ø 250mm 0.6 0.9 1.3 1.8

Pipe length 1m Ø 150mm 4.2 6.5 9.4 12.7

Bend 90° Ø 250mm 3.4 5.2 7.5 10.3

Bend 90° Ø 150mm 16.2 25.3 36.5 49.7

Bend 45° Ø 250mm 5.3 8.3 12.0 16.3

Bend 45° Ø 150mm 6.9 10.7 15.4 21.0

Terminal C33 Ø250mm, Ø150mm 20.8 32.5 46.8 63.7

Terminal B23 Ø200mm 6.2 9.8 14.0 19.1

1 2 3 4 5 6 7 8 9

Number

Flue gas

Ø250mm

Number

Air

Ø150mm

delta pressure component Fluegas

delta pressure component Air

Total pressure drop Fluegas out [Pa] (2*4)

Total pressure drop Air in

[Pa] (3*5)

Total Pressure Terminal In [Pa]

Total pressure drop Fluegas + air in [Pa] (6 + 7 + 8)

1 Meter Pipe

Bend 90°

Bend 45°

Terminal:

CAHA Midi

Total delta pressure [Pa]

Installation, Usage and Maintenance Instructions

How to use the table:

- Column 1 : used material

- Column 2: total number of used material of column 1 for flue gas out

- Column 3: total number of used material of column 1 for air in

- Column 4: pressure drop from pressure drop table /component for flue gas components

- Column 5: pressure drop from pressure drop table /component for air components

Select the correct column for the selected boiler type

(340: 1,2 , 425: 3,4 , 510: 5,6 600: 7,8)

- Column 6: total pressure drop flue gas: multiply column 2 *4

- Column 7: total pressure drop air: multiply column 3 *5

- Column 8: total pressure drop terminal

- Column 9: total pressure drop flue gas and air: column 6 + 7 + 8

- Finally add all together column 9

Total pressure drop must be lower than 250 Pa (CAHA Midi 340 and CAHA Midi 425) or 300 Pa (CAHA Midi 510 and CAHA Midi 600).

If the combined inlet/outlet system exceeds the maximum allowed pressure, this will result in a decrease of

more than 5 % of heat capacity. This is not allowed.

Components must be approved by RVR Energy Technology. A list of allowed articles with corresponding OEM nrs is given below.

COMPONENTS RVR ART. NO ALUMINUM Ø 250 mm

90° Bend Aluminium 250mm SIA532 45° Bend Aluminium 250mm SIA533 1m Extension Aluminium 250mm SIA530 500mm Extension Aluminium 250mm SIA531 Roof Terminal Aluminium 250mm B23 SIA535 Roof Terminal Aluminium 250/250mm to

250mm/350mm C33

PP Ø 150 mm

ELBOW PP 160 90° SIA1032 ELBOW PP 160 45° SIA1033 EXTENSION PP 160x2000 SIA1031 EXTENSION PP 160x1000 SIA1030 EXTENSION PP 160x500 SIA1034 Leaf catcher DN 160x180 SIA1037 150 to 160mm Adaptor SIA1080

GENERAL

Wall Bracket 250 SIA537 Wall Bracket 160 SIA1035 Seal EPDM 250 mm SIA538

Seal EPDM 160 mm SIA1036

Weather slate flat ALU 368 0° SIA1090 Weather slate steep LEAD 210 25°-45° Per Application

SIA536

APPLIANCE TYPE B23

FLUEGAS OUTLET:

ROOF TERMINAL ALU 250

SUPPLY AIR INLET:

LEAF CATCHER ALU DN 150 X180

B23

APPLIANCE TYPE C33

FLUEGAS OUTLET:

ROOF TERMINAL ALU 250

SUPPLY AIR INLET:

LEAF CATCHER ALU DN 150 X180

CAHA Midi

Installation, Usage and Maintenance Instructions

6.5.5 INSTALLING FLUE -EXHAUST AND AIR INLET

6.5.5.1 GENERAL

• Do not use materials from different manufacturers for either exhaust or air inlet

• Only the manufacturers of flue way and air inlet components as mentioned in this manual may be used

• Both systems (exhaust and air) should be mounted free of tension

CONDENSATE, ICE-FREE TERMINAL, TUNDISH AND U-TRAP

The boilers can produce flue gasses with very low temperatures, which can lead to condensation in the flue pipes and flue

terminal. Therefore one should always mount an ice free terminal. Drain the condensate via a tundish and a U-trap to the

sewer.

AIR INLET

If PP material is used for the air inlet a minimum distance of 35 mm between exhaust and air inlet should be respected.

The minimum insert length of the sleeve, leaf catcher or pipe must be 40 mm.

FLUE EXHAUST

A horizontal flue gas (exhaust) pipe must be installed with a fall of 3° (50 mm per mtr) downwards towards the boiler to

allow condensate to flow back in the sump or condensate collector.

The minimum insert length into the sleeve and the minimum length of the pipe end for aluminium and stainless steel must be 40 mm.

If PP is used pay attention to the expansion (elongation) of the PP due to rise in flue gas temperature.

Insert the PP pipe into the sleeve and redraw over a length of 10 mm ( 10 mm for maximum pipe length of 2 mtr). After mounting the minimum insert length into the sleeve and the pipe end must be 40 mm.

CONDENSATE TRAP/COLLECTOR

The condensate trap/collector must be either connected by a tube to a syphon that provides the same height of water column as the one supplied with the boiler or by a T-piece to the syphon as supplied with the boiler

Note: The chimney pieces (silencers) that are delivered with the boiler need to be mounted correctly as shown in the g- ures beneath

For 6,7 and 8 section boilers one silencer must be mounted with its sticker as shown in the rst gure below. For the 5

section boiler two silencers must be mounted with its sticker as shown overleaf.

CAHA Midi

Installation, Usage and Maintenance Instructions

Silencer of 6,7 and 8 section boiler

(425-600 kW)

6.5.5.2 BRACKETS, MOUNTING

Two silencers mounted on a

5 section boiler

(340 kW)

AIR INLET

• The rst bracket should be mounted 0.5 mtr away from the boiler

• Horizontal and non vertical pipes should be bracketed equally divided with a maximum distance of 1 mtr between the brackets

• Vertical pipes should be bracketed equally divided with a maximum distance of 2 mtrs between the brackets

• In case of a chimney shaft, rst identify the air inlet. The end of the air inlet pipe should be at least 0.5 mtr above the shaft. The last component before entering the shaft should be xed. If a bend is the last component also x the component before the bend.

FLUE GAS (EXHAUST)

• A bracket must be mounted to every component except in the case that the length of the pipe before and after the

bend < 0.25 mtr. In this case mount the rst bracket at a length of max 0.5 mtr away from the boiler

• Horizontal and non vertical pipes that have a distance between the xing brackets > 1 mtr should be equipped with a non clamping (to allow minor movement) bracket in between

• Vertical pipes should be bracketed equally divided with a maximum distance of 2 mtrs between the brackets

• In case of a chimney shaft, rst identify the flue outlet. Check if the used shaft pipes are damaged or blocked.The ends

of the exhaust pipe should be at least 0.5 mtr above the shaft. The last component before entering the shaft should be xed. If a bend is the last component also x the component before the bend.

6.5.5.3 SEALING AND JOINING

• Prevent incorrect or damaged seals by shortening pipes squarely and by deburring after shortening.

• Joins or connections in the exhaust flue may not be screwed.

• In the air inlet only aluminium or stainless steel joins or connections may be screwed. It is not allowed to screw PP joins or connections.

• Do not use glue or foam like silicon or PUR.

• To assure soundness all components must be sealed.

• For smooth joining only use a soap solution (1% in water). Do not use oil, grease or (acid free) Vaseline

Important notice

If instructions as written above are not followed and or the materials for air inlet and flue gas exhaust as quoted above are not used RVR Energy Technology can not be held responsible for eventual consequences

CAHA Midi

Installation, Usage and Maintenance Instructions

6.6 ELECTRICAL CONNECTION

1. The electrical installation should be in accordance with national and local codes and regulations.

2. As standard the boiler is congured for 230 VAC / 50 Hz

3. The terminal strip is accessible by opening the front cover (unscrew with hexagonal wrench) behind which the control is mounted.

4. A means of disconnection must be incorporated in the xed wiring in accordance with the wiring rules. Use the lower cable guide indicated with a 230 VAC sticker on the backpanel of the boiler. As it is a stationary appliance without means for disconnection from the supply a contact separation in all poles that provide full disconnection under voltage category III must be provided. The minimum cross section of the supply wire is 3 x 1.0 mm2 and must be connected to

the numbers, 1 (=PE), 2 (=L) and 3 (=N) of strip C1. The supply wire should be secured by a pull relief.

5. It is not permissible to alter the internal wiring as tted by the manufacturer.

6. The enable connected to numbers 1 and 2 of the strip C2 must be Volt free (also see warning under 4.2.1). To set, select from the technician menu, advanced settings, CH request to Room Tstat. The 0-10 V DC (Power or Setpoint mode)

should be connected to the numbers 3 (=negative-) and 4 (=plus+) and a short wire loop should be placed between the

numbers 1 and 2 of strip C2. To set, from the technician menu, advanced CH settings, CH request select either 0-10V % (power mode) or 0-10 V SP (setpoint mode). Digital communication (open Therm OT+ version 3.0) should be connected to the numbers 1 and 2 of the strip C2. Select from the technician menu, advanced CH settings, CH request for

Room Tstat. For digital communication with EBV like RS30 or Theta an additional communication module is required. For the internal OTC (outdoor temperature controller) a 12 kohm at 25º C (see NTC table at 6.2.2) should be connected to the numbers 5 and 6 of strip C2 and a short wire loop should be placed between the numbers 1 and 2 of strip C2.

Finally from the technician menu, advanced CH settings, CH request, select only OTC.

7. If a storage tank is connected to the boiler, the tank thermostat (or the tank NTC) should be connected to the numbers

7 and 8 on the strip C2. Note that a tank NTC should be12 kohm at 25 ºC (see NTC table at 6.6.2.)

8. The CH system pump should be connected to the numbers 9 (=PE), 10 (=L), 11 (=N) on strip C1 if in use in combination with a 3-way valve. (also see chapter 4.3). A PWM pump should be connected to 18 (=PE), 19 (=L) and 20 (=N) on strip

C1.The PWM signal should be connected to 14 (PWM signal) and 13 (PWM ground) om strip C2. From the technician menu, system settings, boiler parameters the max and min pump speed can be set.

9. The DHW pump (or 230 VAC 3-way valve) should be connected to 12 (=PE), 13 (=L), and 14 (=N) on strip C1. If a CH

pump is used it should be connected to 15 (=PE), 16 (=L) and 17 (=N) on strip C1.

10. If the system pump, CH pump, PWM pump, DHW pump, alarm connection or the 3-way valve consumes more than 0,8 A, it needs to be switched by an auxiliary relay.

11. The alarm output on the numbers 24 and 25 on strip C1 is a potential free relay output (230 VAC), max 0,8 A). The cas- cade/system pump output on the numbers 29 and 30 on strip C1 is a potential free relay output (230 VAC, 0,8A).

12. The B-B (Burner Block) on the numbers 31 and 32 on strip C1 provides an external (remote) burner block (error 77). The external contact must be a potential free contact (rated at 230 VAC).

13. The SPS_B (Burner Block) on the numbers 11 and 12 on strip C2 also provides an external (remote) burner block (error 77). In this case the external contact must be a potential free contact (rated at 24 VDC).

14. The B-L (Burner Lock) on the numbers 9 and 10 on strip C2 provides an external burner lock (error 3). The external contact must be a potential free contact (rated at 24 VDC).

15. The main-fuse (10,0 A) is near the on/off switch on the right side of the control panel.

16. If the supply wire needs to be replaced, act as described under

17. Connect current carrying conductors in such a way that they

become taut before earthing conductor. See gure to the right.

General remarks :

Use the tube on the left side to guide the low voltage connections

from C2 and C3

Use the 4 tubes on the right side to guide the 230 V connections

from C1 Also see wiring diagram on next pages

CAHA Midi

Installation, Usage and Maintenance Instructions

6.6.1 WIRING DIAGRAM

9 8 7 3 2 1 6 12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 5 4 3 2 61718

D-X03

G R T G T R G A B

Service

Fr-MP

Fr-CP

Fr-FP

green-yellow

230V

PELN

2 N 3

blue

brown

green-yellow

7 PE 8

A-P

L10

L13 NPE

DHW-P

or 3WV

CH-P

PWM-P

18 N19

PE21

L22

N23

Pf24 PfPE

C-P

25 L26 N27 Pf28

B-B

3131

white

32 32

green-yellow

Ignition

brown

black

24 -25-29 30

black

123

63 54

X05 D-

Trafo

HEX

black

white

blue

brown

213

X05

white

X00

yellow

5 10

F01

X04

F00

X07

black

white

black

123

D-X05

blue

black

blue

black

blue

white

3 8 4

5 10

X00

X01

X02

X03

X06

X01

D-X01

blue

black

125

X12 X15 X14 X11

X13

12 11

4 3

X02

white

blue

grey

grey grey

grey

X11

X14

X15

X13

5 4

14 13

6 5

X15

white

black

blue

red brown

white white

blue

9 4 8 3 6 7 2 1

grey

black

1 5

grey

grey grey

grey

6 2 3 4 5 1

red

- +

grey blue

blue

grey

red

grey

purple

white

black

white

orange

grey

11 4 14 7 10 3 13 6 12 5 8 2 1

D-X04

2 3 6 1 4 5 7 8

D-X07

D-X06

WPS

red

grey

green

grey

yellow

white

green

white

3 6 5

3 4 2

4 2 5

NTC 5

brown

red

black

brown

red

black

brown

red

black

GPS

NTC2

NTC1

SPS

MT 2 MT 1

blue

brown

green-yellow

Fan

green-yellow

black

N V1 V2 PE PE N

PWM

Tach

Fan

APS

D-X01

12 6 1 2 3 7 8 9

white

blue

pwm

NTC6

-ground

Cascade

pwm

-ground

SPS-B

B-L

white white

NTC3

NTC4

- +

OTC 0-10Vdc

OT-RT

DHW

brown red

black

5 2 3

CAHA Midi

Installation, Usage and Maintenance Instructions

Legend

BC Burner control

D Display C1 Connector 230V C2 Connector low voltage

CH-P Central heating pump

DHW-P Domestic hot water pump

PWM-P Modulating pump

A-P Appliance pump max 0,8A

HE Heat exchanger

NTC1 Flow temperature sensor NTC2 Return temperature sensor NTC3 Domestic hot water sensor or switch NTC4 Outside temperature sensor NTC5 Flue gas temperature sensor NTC6 Cascade sensor

WPS Waterpressure sensor

APS Air pressure switch SPS Siphon pressure switch

GPS Gas pressure switch

GV Gas valve

S Switch on/off

3WV 3 way valve

OT- RT Open therm or room thermostat on

OTC Outdoor temperature control 12K

F Fuse

SPS-B Siphon pressure switch block

B-L Burner lock

A Alarm

C-P Cascade pump potential free contact

B-B Burner block

PE Earth cable or connector

Fr Frame

MP Mounting plate

CP Cover plate FP Front plate

6.6.2 NTC RESISTANCE TABLE (12K)

Temperature [°C] Resistance [kΩ] Temperature [°C] Resistance [kΩ] Temperature [°C] Resistance [kΩ]

-30 30 9.80 85 1.47

-20 98.20 35 8.05 90 1.26

-15 75.90 40 6.65 95 1.10

-10 58.80 45 5.52 100 0.95

-5 45.90 50 4.61 105 0 36.10 55 3.86 110

CAHA Midi

Installation, Usage and Maintenance Instructions

6.7 PNEUMATIC CONNECTIONS

Sump

A pneumatic diagram for the CAHA Midi 340 (5 sections) and the CAHA Midi 510 (7 sections) is given in the gure below.

SPS

Syphon Pressure Switch

P1 P2 P1 P2

APS

Air Pressure Switch

Restric�on 90 mm

Air inlet

Gas valve

Venturi

A pneumatic diagram for the CAHA Midi 425 (6 sections) and the CAHA Midi 600 (8 sections) is given in the gure below.

SPS

Syphon Pressure Switch

APS

Air Pressure Switch

P1 P2 P1 P2

Gas valve

Air inlet

Venturi

The siphon pressure switch, connected to the sump (P1), prevents overflow of the syphon in the case of excess back pressure in the flue.

The air pressure switch, (P1 and P2), connected to the venturi, checks the amount of air (by means of a Δp measurement)

before startup.

6.8 PC-CONNECTION

For information regarding connection of a PC to the boiler please contact your supplier.

Installation, Usage and Maintenance Instructions

CAHA Midi

7. COMMISSIONING

1. Fill and bleed the system. Fill the boiler until a pressure between 1.5 and 2 bar isachieved. The maximum working pressure is 6 bar. The boiler (not the installation!) is automatically bled by a built in automatic air vent.

2. Check all gas and water connections thoroughly for leaks.

3. Bleed the gas pipe.

4. As standard the boiler is set for G20 or G25. Check that the installation provides the correct type of gas to the boiler.

5. Check the inlet pressure : 20 mbar or 25 mbar

6. Turn on the boiler by setting the main switch on the control panel of the boiler to position 1 (on).

7. Generate (create) a heat demand.

8. Just before ignition the control checks if the contacts of the gas pressure,syphonpressure and water pressure switches are closed.If not, the boiler will block and the display will show E76.

9. If gas, water syphon pressure switches are closed the burner will be ignited.

10. Perform a thorough check on flue-gas joints for leakage.

11. Check the heat input and the gas pressure at maximum load.

12. Heat up the installation. Stop the heat request.

13. Bleed the installation again, topping up the water system pressure if required.

14. Explain the operation of the boiler to the user.

15. Explain to the user the signicance of error codes and the need to report themwhen requesting service engineer support.

16. After installation the datasheet as shown in chapter 9.1 should be lled in.This should be repeated at every service-interval.

17. Safely store the installation and the user manual preferably in close proximity to the boiler.

CAHA Midi

Installation, Usage and Maintenance Instructions

7.1 GAS CATEGORY

The types of gas and supply pressures vary by country. In the table below the gas category and supply pressure are listed by country.

Countries Countries Category Pressure Countries Countries Category Pressure

AT Austria I2H 20 IT Italy I2H 20

BE Belgium I2E(R) 20/25 LT Lithuania I2H 20 BG Bulgaria I2H 20 LU Luxembourg I2E 20

HR Croatia I2H 20 LV Latvia I2H 20 CY Cyprus I2H 20 NL Netherlands, the I2L , I2EK 25 CZ Czech Republic I2H 18 PL Poland I2E 20 DE Germany I2E 20 PT Portugal I2H 20 DK Denmark I2H 20 RO Romania I2E, I2H 20

EE Estonia I2H 20 SE Sweden I2H 20

ES Spain I2H 20 SL Slovenia I2H 20

FI Finland I2H 20 SK Slovakia I2H 20 FR France I2Esi , I2Er 20 / 25 NO Norway I2H 20 GB United Kingdom I2H 20 CH Switzerland I2H 20 GR Greece I2H 20 LI Liechtenstein I2H 20 HU Hungary I2H 25 IS Iceland

IE Ireland I2H 20 MT Malta

This boiler can be adjusted for category K(I2K) and is in this case suitable for the use of G and G+ distribution gasses according to the specications as shown in NTA 8837:2012 Annex D with Wobbe-index 43,46-45,3 MJ/m3 (dry, 0 °C, Hs) or 41,23 – 42,98 (dry, 15 °C, Hs)

This boiler can also be converted and re-adjusted for category E (I2E)

This means that the boiler is : either is suitable for G+ gas and H-gas or provable suitable is for G+ gas and provable can be made suitable for H-gas as meant by “Besluit van 10 Mei 2016” until changes in this document are made

CAHA Midi

Installation, Usage and Maintenance Instructions

7.2 ADJUSTMENT % CO2 AND CHECK INPUT

The boiler is equipped with an automatic gas/air regulator. This means that the amount of gas is regulated depending on the amount of air. The % CO2 needs to be adjusted according to the table below ;

Type of boiler Gas type Inlet pressure %CO2

340 G20 / G25 20 / 25 mbar 9.3 +0.2-0.05 9.1 +0.15-0.2 425 G20 / G25 20 / 25 mbar 9.3 +0.2-0.05 9.1 +0.15-0.2 510 G20 / G25 20 / 25 mbar 9.3 +0.2-0.05 9.1 +0.15-0.2 600 G20 / G25 20 / 25 mbar 9.3 +0.2-0.05 9.1 +0.15-0.2

The boiler has a gas valve that is connected to a venturi. See gure below.

ADJUSTMENT FOR MAX. LOAD

• Wait until the boiler is stable and measure % CO

• If required, correct CO2 with the throttle ; turning towards + gives a higher CO2 percentage (a ½ turn (180°) causes a change of approximately 0,85 % CO2)

•

ADJUSTMENT FOR MIN. LOAD

• Wait until the boiler is stable

• If required, correct the CO2 with the off-set ; turning towards + gives a higher CO2 percentage. Note : this offset adjustment is very sensitive : half a turn (180°) causes a change of approximately 1 % CO2.

on max load

%CO2

on min load

Throttle

Off-set

CHECK ON HEAT INPUT

In the table below the relationship between nominal input and fan speed and gasflow is given. The nominal fan speed can

be ± 5% due to adjustments in production

Model 340 425 515 600

Nominal input

Fan speed nominal

Gasflow G20

340 425 515 595

4600 4600 4600 4600

36 45 54 63

If the gas flow is too low it may be due to an obstruction (dirt) in the air/flue system. Check and if necessary clean. The gas flow must then be re-checked.

[kW Hi]

[rpm]

[m3/h]

CAHA Midi

Installation, Usage and Maintenance Instructions

8. ERRORS

8.1 GENERAL

If there is no data visible on the display, the fuse (10,0 A Slow blow) in the control panel ,near the main switch, should be checked (as well as the position of the on/off switch) and should if required be replaced (after the cause for break down

has been determined and rectied).

WARNING! THIS FUSE IS PART OF THE 230 V CIRCUIT. DISCONNECT THE BOILER FROM THE MAINS ELECTRICITY SUPPLY BEFORE REPLACING THE FUSE!

If there is still no data visible on the display, one has to check if there is 230 VAC present on the connections “L”

and “N” of connector X1 in the MAXSYS. Also see electrical wiring diagram.

If there is 230 VAC present (terminal connector C1: 12,13) , then the 230 V fuses F1 and F2 inside the Maxsys should be

renewed. Disconnect the boiler from the main 230V supply and remove the connectors from the Maxsys.

Notice : for this it is not necessary to unscrew the Maxsys from the mounting plate

Release the six security clips with a long thin screw driver. Then remove the protective cover of the Maxsys. Replace the

230 V fuse(s) F1: T3.15 AL 250V and/or F2 T3.15 AL 250V inside the Maxsys.

A blown fuse in the Maxsys controller could be caused by a short-circuited pump. It is recommended to also check the CHpump and also the DHW pump in this case.

If the 230 V fuses are OK and the display is still blank, then the cable of the display to the Maxsys (X15) should be checked.

If this is also ok, the Maxsys should be replaced.

Six security clips

F1: T3.15A 250 V

F2: T3.15A 250 V

If you are not sure that there is any heat demand, you can force the boiler to start as described in 5.5.

On heat demand, the boiler control will perform a zero-check of the air pressure switch before starting the fan. Following this, the fan will start and wait for air pressure switch to close. As soon as APS has closed, starting procedure will continue.

APS closes at P > 40 Pa.

If there is a problem with APS, the display will show blower speed error.

The boiler control checks the status of the built-in pressure switches for water, gas and syphon just before ignition ; Water

pressure should be > 1,4 bar (E47); Gas pressure should be > 14 mbar (E76); Syphon pressure should be < 12,4 mbar (E77)

CAHA Midi

Installation, Usage and Maintenance Instructions

8.2 DHW ERRORS

Boiler does not respond to DHW heat request

- Check the storage tank-NTC or thermostat and its wiring (also see electrical wiring diagram).

- Check if DHW is enabled using the control panel

Insufcient DHW flow

- Dirty lters in taps.

- Insufcient water pressure.

DHW temperature too low

- Tapping flow too high

- Temperature set point too low

- 3 way valve not fully in DHW position

- Faulty DHW pump

- DHW operation set to off

- Storage tank-NTC or thermostat and or wiring defect.

- Input too low due to too much resistance in air/flue system.

Boiler operates only for DHW

- Storage tank-NTC or thermostat defect and or its wiring.

- 3-way valve stuck (remains in direction towards storage tank)

8.3 CH-ERRORS

CH circuit stays cold

- Incorrect connection to the mains electricity supply

- Main switch on control panel is switched off (boiler off).

- Room thermostat defect, incorrect wiring, temperature set too low

- Outdoor sensor and/or its wiring defect.

- CH operation off

- 3-way valve defect (remains in direction towards storage tank)

8.4 ERRORS (HARD AND SOFT LOCKOUTS)

Errors are indicated by a text and an E-code on the bottom line on the display.

The error message can be displayed by pressing the ”information” button

Following an error with a hard lockout, the boiler will not re again until a manual reset is performed (eg max temp limit).

These errors can be found under column “hard lockout code” in the following table.

Following an error with a soft lockout, the boiler will automatically resume normal operation after the cause of block is solved (eg gas pressure too low). They can be found under column “soft lockout code” in table beneath.

The cause of error (hard or soft lockout) can be found with the help of the error-list in the following table.

After the cause of error has been determined and the error has been resolved, the boiler can be put back into operation again.

CAHA Midi

Installation, Usage and Maintenance Instructions

Hard Lockouts

Hard Lockout Code Description

E1 Failed ignition E2 False flame E3 High boiler temperature E4 Air flow/damper

E5 Blower speed

E6 Air flow/damper E8 Flame circuit error

E9 Gas valve circuit error E15 Sensor drift E16 Supply sensor stuck E17 Return sensor stuck E18 Sensor failure E21 Internal control fault E30 Supply sensor shorted E31 Supply sensor open E43 Return sensor shorted E44 Return sensor open E80 Return > Flow E87 External limit open

Soft Lockouts

Soft Lockout Code Description

E7 High flue temperature E12 Internal control fault E13 Reset limit reached E25 Internal control fault E32 DHW sensor shorted E33 DHW sensor open E34 Low voltage E37 Low water E45 Flue sensor shorted E46 Flue sensor open E47 Water pressure error E76 Low gas pressure E77 Siphon error E81 Sensor drift E87 Overtemp lockout E89 Incorrect setting

E90 Firmware mismatch E91 System sensor shorted E92 System sensor open E93 Outdoor sensor shorted E94 Internal display fault E95 Supply sensor error E96 Outdoor sensor open E97 Cascade mismatch E98 Cascade bus error E99 Controller bus error

CAHA Midi

Installation, Usage and Maintenance Instructions

9. ANNUAL SERVICE

Maintenance should only be done by a qualied installer or technician. The following maintenance routine

should be done annually (see also 9.1)

Put the boiler into operation on max. load (see section 5.5). Determine the heat input of the boiler. Check % CO2 . Compare

the heat input with that measured at installation. If the heat input is now considerably lower then there is probably an obstruction in the air inlet or the flue-outlet or in the boiler itself.

Switch off the boiler. First check the air-inlet and the exhaust flue-outlet. Disconnect from the mains electricity supply. Remove the front cover, top cover and side cover. Remove the syphon and clean it. Remove the inspection cover* of the sump on the front side beneath the controls. The inner part of the sump and the bottom part of the heat-exchanger should be inspected and, if necessary, be cleaned. If the bottom part of the heat-exchanger is clogged, the inspection covers on the left-hand side of the heat-exchanger

should be removed*. Using a special tool (see gure below) makes it possible to clean the heat-exchanger lids partially . In

case of dirt in the sump it is also advisible to inspect the upper part of the heat-exchanger as well. Remove the fan* togeth-

er with the burner hood*, the gas valve* and the gas pipe*. Now the burner* is visible and can be taken out and inspected.

If necessary clean the cold side with a vacuum cleaner (or carefully with compressed air) and a nylon brush (never use a steel brush). Inspect the combustion chamber. In case of a dirty heat-exchanger it can be cleaned with water. Check the

burner seal* and replace if necessary.

Rell the condensate trap with clean water and reconnect it. Check the electrode, especially the distance between the two pins (4,5± 0,5 mm).

Replace electrode if necessary. Put everything back in its place. Check the CO2-content and correct if necessary. Check the gas-parts for leakages. Check the flue-gas parts for flue-gas leakages and condensate leakages.

CAHA Midi

Installation, Usage and Maintenance Instructions

*Note: be careful during inspection not to damage seals. Any seals damaged by ageing or other causes should be replaced.

9.1 SERVICE-MAINTENANCE TABLE

When commissioning the boiler, it is recommended to measure load, CO2, CO, T flow, T return, P air pressure switch and

Psyphon pressure switch and write the values down in the table below.

Measure these values when the boiler is in equilibrium at maximum load (also see chapter 5.5).

During annual maintenance we advise to measure and write down these values also and compare them to the previous values and analyse any changes.

Date Gasflow

[m3/h] or load

[kW]

CO2 [%] CO

[ppm]

Tflow [°C] Treturn [°C] P air pressure

switch [mbar]

P syphon

pressure

switch

[mbar]

At the factory the maximum load of the boiler was measured within 5% tolerance from the nominal load.

In the eld the load can decrease due to increased resistance in the boiler, the air inlet or the exhaust outlet or due to mal-

functioning of the fan or other causes.

At maximum load the installation should be designed for nominal T of 15 K to 20 K.

When the T is higher than 25 K, the boiler cannot continue at maximum load anymore and will start to modulate because water flow through the boiler is insufcient.

T flow and T return can be read in “info mode” on the display (see 5.4 diagnostics)

Valves, malfunctioning pumps, dirt, corrosion products from the installation, dirty lters etc. can have negative impact on

water flow through the boiler.

Before ignition the boiler control checks P aps during prepurge. During burner operation this check will be carried out. If

the value decreases over successive years, this could indicate a problem, e.g. malfunctioning of the fan, dirty air inlet, dirty burner, dirty heat exchanger or dirty exhaust system.

Syphon pressure (P sps) should be lower than the maximum allowable flue resistance. If P sps is too high (> 12,4 mbar),

the boiler will be stopped.

In this case the exhaust system may be blocked.

CAHA Midi

Installation, Usage and Maintenance Instructions

CAHA Midi

Installation, Usage and Maintenance Instructions

RVR Energy Technology Limited

Kenmare Co. Kerry

V93 F386 Ireland

Sales direct line: +353 (0)64 6689522 Email: sales@rvr.ie

RVR Energy Technology CAHA Midi 340, CAHA Midi 425, CAHA Midi 510, CAHA Midi 600 Installation, Use And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

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