Varmeteknikk MB 35, MB 45, MB 90, MB 105, MB 120 Installation, Operation & Service Manual

Installation - operating - servicing

MB – boilers

35 – 45 – 60 – 75 – 90
105 - 120 - 140 -150kW

Varmeteknikk AS August 2017 e-mail: [e-mail]

2

T e c h n i c a l d a t a

Model

MB 35

MB 45

MB 60

MB 75

MB 90

Power 35kW 45kW 60kW 75kW 90kW

Nominal supply voltage

Power circuit 3 x 400V 3 x 400V 3 x 400V 3 x 400V 3 x 400V

Control circuit 1 x 230V

50/60Hz

1 x 230V

50/60Hz

1 x 230V

50/60Hz

1 x 230V

50/60Hz

1 x 230V

50/60Hz

Amps 51A 65A 87A 108A 130A

Number of elements 4 4 7 7 7

Temp.controller (steps) 7 7 7 7 7

Temp. range 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C

Water contents (liters) 75 75 75 75 75

Tube connections

Outlet/inlet DN65/16 DN65/16 DN65/16 DN65/16 DN65/16

Expansion/drain 1" 1" 1" 1" 1"

Water circulation Δt=20 °C
(m³/h) 1,5 1,9 2,6 3,2 3,9

Pressure drop(Wc) 2 3 5 7 10

Water speed(m/s) 0,11 0,14 0,19 0,23 0,28

Max. working pressure 6bar 6bar 6bar 6bar 6bar

Min. working pressure 1bar 1bar 1bar 1bar 1bar

Dime

nsions size

(cm)

Height 128 128 128 128 128

Width 38 38 38 38 38

Depth 69 69 69 69 69

Weight empty, (kg) 130 130 135 135 140

Varmeteknikk AS August 2017 e-mail: [e-mail]

3

T e c h n i c a l d a t a

Model

MB 105

MB 120

MB 140

MB 150

Power 105kW 120kW 140kW 150kW

Nominal supply voltage

Power circuit 3 x 400V 3 x 400V 3 x 400V 3 x 400V

Control circuit 1 x 230V

50/60Hz

1 x 230V

50/60Hz

1 x 230V

50/60Hz

1 x 230V

50/60Hz

Amps 152A 173A 202A 217A

Number of elements 7 7 7 8

Temp.controller (steps) 7 7 7 7

Temp. range 30 – 95 °C 30 – 95 °C 30 – 95 °C 30 – 95 °C

Water contents (liters) 75 75 75 75

Tube connections

Outlet/inlet DN65/16 DN65/16 DN65/16 DN65/16

Expansion/drain 1" 1" 1" 1"

Water circulation Δt=20 °C
(m³/h) 4,5 5,2 6,0 6,5

Pressure drop(Wc) 14 18 24 28

Water speed(m/s) 0,33 0,37 0,43 0,47

Max. working pressure 6bar 6bar 6bar 6bar

Min. working pressure 1bar 1bar 1bar 1bar

Dimensions(cm)

Height 128 128 128 128

Width 38 38 38 38

Depth 69 69 69 69

Weight empty, (kg) 145 150 150 155

Varmeteknikk AS August 2017 e-mail: [e-mail]

4

MB 35 - 150kW

590

690

NB! Fri høyde over kjel,
ca. 100cm

1

2

3

4

5

6

7

8

9

10

1. Temp. controller

2. Safety temp .limiter

3. ON/OFF –switch

4. Contactors

5. Fuses/circuit breakers

6. Bus bars for connecting

Supply cables

7. Drain

8. Return

9. Flow

10. Expansion

Varmeteknikk AS August 2017 e-mail: [e-mail]

5

Technical data 2

General information

Installation 6
Pressure safety valve 6
Connection 6
Control voltage 6

Commissioning

Start up 7
Temperature controller 7
Settings 8
Additional functions 9

Remote control

Boiler Start/stop 10
Temperature control 10
Power control 10

Monitoring

Operation signal 11
Failure signal 11
Output signals 0-10V 11
Terminal block 11

Menus 12

Maintenance 13

Troubleshooting 14

Circuit diagrams

Control circuit 15
Power circuit 16

Temp. controller

Terminals 17

Spare parts 18

Content

Varmeteknikk AS August 2017 e-mail: [e-mail]

6

Installation

THE BOILER MUST BE POSITIONED IN SUCH A WAY THAT IT DOES NOT PREVENT
PERFORMANCE OF SERVICE AND MAINTENANCE.

Required free height above the boiler for disassembly of heating elements is 1m. Front and at least
one side should be free in order to perform service and maintenance.

Pressure safety valves

The boiler must be equipped with pressure safety valves. The pressure safety valves should
be placed as close as possible to boiler and it should not be any shutoff between the valves
and the vessel. The opening pressure must not exceed maximum operating pressure of the
boiler. To avoid damage a pipe pointing down towards the floor, should be fixed to the pressure
safety valves.

Connection

NOTE! INSTALLATION MUST ONLY BE EXECUTED BY QUALIFIED PERSONNEL

All applicable regulations must be observed when electrical and plumbing connections.
Sufficient provision must be made for expansion, in accordance with applicable regulations

Supply cables

Connect supply cables to the bus bars by using a ring terminal or suitable cable clamps.
Two earth clamps is located in bottom of the switch gear for earth cables.

Control voltage

220-230V control voltage is required. Connection to be done on F1 & F2 on the terminal block
inside the boiler. See page 11.

E x p a ns io n

F lo w

R e tu rn

D r a in

C o n ne c ti n g
m a in p o we r

C o n ne c ti n g
co n tro l v olt a g e

A95-30A95-30

Li f tin g h o o k

Varmeteknikk AS August 2017 e-mail: [e-mail]

7

Commissioning

Note! BEFORE SWITCHING ON THE BOILER CHECK THE FOLLOWING:

- Check that the water system is completely filled with water. To prevent heating element break
down make sure there is no air pockets in plant.

- Switch on circulating pump and check water flow and direction.

- Hydraulic expansion system has to be controlled. Min. pressure, 1bar.

- Check for correct supply voltage

Note! Before start up, retighten all electrical connections.

This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance by a person responsible for
their safety.

Children should be supervised to ensure that they do not play with the appliance.

Start up

Switch on the boiler by using the ON/Off-switch on the front panel. Display will after a few seconds
show actual water temp., preset temp. in brackets. The line below shows connected power. Boiler
will now step by step increase power to obtain preset temperature.

The temperature is factory set at 80 °C, and step time is set to 40 sec. Unless corrections of preset
temperature or step time are required, no further adjustments are needed.

Note! If boiler is controlled by external signals, missing signal can prevent boiler from
running.

Temperature controller

The boiler is equipped with a 7-steps electronic temperature controller located in front of the boiler.
All settings can be done at the front. The controller has a proportional and integrating control and is
designed to maintain constant boiler temperature. Temperature range is from 5 - 95°C in steps by
1 °C. 3 relays control the power contactors which are connected in a binary order. This gives a high
degree of reliability

If a failure occurs, an alarm diode starts flashing. Type of failure will be shown in display and could
be:

Don’t switch on the boiler if there is a possibility that the

water in boiler

is frozen.

Varmeteknikk AS August 2017 e-mail: [e-mail]

8

Error temp: Temperature sensor is broken
Alarm net: Control voltage < 190V
Alarm power: Power supply missing*

* Alarm power is activated if controller when reaching step 3, doesn’t measure any power. The
reason for this could be that main switch/circuit breaker on the switch board is OFF, security
temp. limiter (STB) released because of high temperature, heating element/fuse is broken, or
contactor is not connected.

Settings

Failure Menu button Enter button

Preset temperature:

Temperature range is from 30 – 95 °C. Preset temperature is factory set to 80 °C. If correction is
needed do the following:

Press + or – button to set desired temperature. Then press enter to save new value.

Step time:

Step time is adjustable between 20-250 sec. (factory setting is 40 sec.) and refer to connection of
power steps. When disconnecting power, step time is 5 sec. with step time below 60 sec., 10 sec
with step time above 60 sec. If correction is required do the following: Press menu button once to
enter step limitation mode. Then press + or – button. To enter step time mode press menu button.
With +/- button choose desired step time. Press E button to save new value.

Step 0( 7)

Step time 40s

►

Step lim 0( 7

)

Step time 40s

Step lim 0( 7)

Step time 40s

►

Step 0( 7)

Step time 50s

To return to temp/power mode, press menu button.

Varmeteknikk AS August 2017 e-mail: [e-mail]

9

Additional functions

The temp. controller has been provided with a large number of other functions in addition to
several possibilities for remote control.

Remote boiler in/out

The temp. controller is equipped with a potential free input for start/stop of the boiler. The
disconnecting signal can be either an “OFF” or an “ON” switch. With a clamp on the PCB the
temp. controller can be adjusted to either type of signal (see page 30). If start signal is missing
display shows:

Step S 0 ( 0)

Step time 40s

See page 11 for connecting start/stop signal.

Power limitation

The maximum output of the boiler can easily be limited. It is only possible to limit the boiler on a whole
step base. Limitation can be done in the menu or on a potentiometer located on the PCB.

Limitation in menu:

Enter Step mode and press – button. Choose number of power steps and then press E button to save
new value.

Step lim 0(30

)

Step time 40s

►

Step lim 0(25)

Step time 40s

For limitation on the PCB, see page 17

Outdoor temperature compensator

The temp. controller is prepared for outdoor temperature compensation. If outdoor sensor is connected,
boiler will calculate and set flow temperature depending on outdoor temperature. Both curve and
parallel are available for fine-tuning flow temperature. When outdoor sensor is connected, display
shows:

TempU 47.0 (50)°C

Power 60kW

Temperature in brackets is calculated flow temperature depending on outdoor temperature. It is
not possible to change calculated temperature when outdoor sensor is connected.

Outdoor t. 24°C

Parallel 0°C

For further information, contact Varmeteknikk.

Varmeteknikk AS August 2017 e-mail: [e-mail]

10

Remote control by external signals

The boiler offers several possibilities for remote control. With a start/stop signal (potential free),
boiler can be connected/disconnected from running. Maximum output or preset temperature
can be controlled by a 0-10V DC signal.

Remote start/stop of boiler

Boiler can be switched On/Off by an external signal. Before connecting signal, remove bridge on
terminal 1 & 2, see next page. If start/stop-signal is connected and boiler gets start signal, display
shows:

Temp 47.0 (75)°C

Step 0 (30)

Temperature control by 0-10V signal

Desired temperature can be controlled by a 0-10V DC signal. 0V = 20°C, 10 V = 120C°. Normal
temp. range is from 20 – 95°C, equivalent to 0 - 8,5V. Connection on terminal 30(-) and 31( +)

on PCB (see page 17). Signal must be activated in service menu, see page 12. "Temp IN" must
be set in ”ON” position. Press + button twice and then E to enter new value.

Temp IN

ON

Press menu button twice to return to "Temp/Power" mode. When signal is activated display
shows:

TempE 47.0(75)°C

Power 60kW

Note! When desired boiler temperature is controlled by a external 0-10V signal, internal set point

must be set as high as boiler should work. Internal thermostat is now working as a maximum
thermostat and limit the temperature. This must be done before signal is activaded.

Power control by 0-10V signal

Boiler output can be controlled by a 0 -10V DC signal. 0V = 0 step, 10V = all steps (15/30). Con­nection on terminal 29(+) and 30(-) on PCB (see page 17). Signal must be activated in service
menu, see page 12. "Power IN" must be set in "ON" position. Press + button twice and then

E to enter new value.

Power IN

ON

Press menu button twice to return to "Temp/Power" mode. When signal is activated display
shows:

StepE 3 ( 7)

Step time 40s

Temp 47.0 (75)°C

Step S 0 ( 0)

If start signal is missing,
display shows:

Varmeteknikk AS August 2017 e-mail: [e-mail]

11

Monitoring

Boiler is prepared for output digital signals to a central monitoring system. The signal contacts
are wired to a terminal block inside the boiler. The outlet signals are:

Operation signal: indicates boiler is ON connection on terminal 3 & 4.

Failure: indicates STB released, sensor broken or control voltage < 190V. Connection

on terminal 5 & 6. Type of error is shown in display.

Output 0-10V DC signals:

External power indication: 0V = 0kW, 10V = Max kW (terminal 36 & 39)
External temp.indication: 0V = 20 °C, 10V = 120°C (terminal 36 & 38)
External preset temperature: 0V = 20 °C, 10V = 120°C (terminal 36 & 37)

Connection diagram, see page 17.

Terminal block inside boiler

2

6

8

7

9

5

4

3

F2

F1 F1

F2

1

Transformer

Control voltage

On/off ext.

230V 50Hz, 10A

Styrespenning

Inn-/utkobling

Failure

6

8
9

7

Trafo

3

5

4

1

2

L2

L1

Operation

Driftsignal

Feilsignal

Varmeteknikk AS August 2017 e-mail: [e-mail]

12

Menus

By pressing menu button, different modes appears

Start up:

EL 7 v0549

El 15: 7-steps controller
v0549: version

Main menu

Temp 60.0(80)°C

Power 120kW

Step

1( 7)+

Step time 40s

Outdoor t.

-

15°C

Parallel 0°C

(appears only if outdoor sensor is
connected)

Settings in main menu:

- Desired temperature

- Number of power steps

- Step time

Service menu

To get access to service menu,
press and hold menu button for
more than 5sec.

Temp 60.0(80)°C

Power 120kW

Curre

nt lim

0,0(5,0)A

Current marg

1,0A

Power

factor

60kW/A

Curve 40°C

Curve min 20°C

(Appears only if outdoor sensor
is connected)

Test contactor 0

K1-4 0000 A1

Step time

Service 0

Power

IN

OFF

Temp IN

OFF

English

Node 0 Net 107

Varmeteknikk AS August 2017 e-mail: [e-mail]

13

Maintenance

NOTE!

BEFORE SERVICE AND MAINTENANCE, BE SURE SUPPLY CABLES ARE DEAD.

Always use an appropriate voltage detector to verify that there is no voltage present.

After boiler has been in operation for some time, retighten electrical connections. To prevent
breakdown, boiler should be checked annually. This check should contain the following points:

- Leakage control

Make a visual inspection of the boiler checking for signs of water leakage. Remove top cover
and check on top of the pressure vessel for leakage from heating elements.

- Power checking

Check if circuit breakers have tripped. Check by resistance measurement if any heating elements
are broken.

- Contactors

Check all individual contactors if they are in normal position. Undertake a visual inspection of
all wiring to the contactors and check for signs of overheating or burning. Any noise from con­tactor indicates wear and requires a thorough check. Be aware that burnt contactors may cause
major damage.

- Electrical connections

Retighten all electrical connections on fuse holders, contactors and heating elements.

- Temp.controller

Check if temp.controller connect or disconnect power steps when adjusting preset temp. up and
down. By entering service menu connection of power groups/contactors can be checked.

- Safety temp.limiter

Check safety temp.limiter. This can be done by switching off circulation pump or close valves.
The boiler will then soon reach release temp. Safety temp. limiter must be manually reset.

Note!

SERVICE AND MAINTENANCE SHOULD ONLY BE CARRIED OUT BY QALIFIED PERSONNEL

Tightening torques for contactors:

Contactor, type Connection screw Tightening torque
AF9, AF12, AF 16 M3,5 1,5Nm
AF26, AF30, AF 38 M4 2,5Nm
AF40, AF52, AF 65 M6 4Nm

Tightening torques for circuit breakers:

type Connection screw Tightening torque

MS132/10 M3,5 1,2Nm

MS132/12 - 16 M4 1,5Nm
MS132/20 - 32 M4 2Nm

XT1 M6 6Nm

Tightening torque for heating element: M4 - 1,2Nm
M12 - 15Nm

Varmeteknikk AS August 2017 e-mail: [e-mail]

14

Troubleshooting

NOTE! TROUBLESHOOTING MUST ONLY BE EXECUTED BY QUALIFIED PERSONNEL

FAILURE DISPLAY TEXT

POSSIBLE CAUSE OF TROUBLE

CONTROL /REPAIR

BOILER
”dead”

Control voltage missing Boiler needs separate

control voltage

Fuse/s for control voltage broken Check fuses and replace if

required

NO POWER

Temp 30.0 (80)°C

StepS 0 ( 0)

External start signal missing Check external signal. (See

terminal 1& 2 on –X1)

Temp 30.0 (80)°C

StepE 0 ( 0)

External signal for power control
missing

Check external signal

TempE 20.0 (20)°C

Power 0kW

External signal for temperature
control missing

Check external signal

Temp 0.0 (80)°C

Error Temp

Defect temp.sensor

Change temp.sensor and
Replace if required

BOILER
STOPS AT
STEP 3

(Alarm diode is
flashing)

Temp 30.0 (80)°C

Alarm Power

Connecting box mounted on left
side without moving transformer

Transformer must be
mounted on same side as
connecting box

Temp 30.0 (80)°C

Alarm Power

Safety temp.limiter has tripped Reset safety temp.limiter

(STB) on front panel

Temp 30.0 (80)°C

Alarm Power

Main switch off or broken fuses Check switch board/fuses

Replace if required

LITTLE HEAT
FROM BOILER

Temp 50.0 (80)°C

Step 4 ( 4)

Maximum power limited
from outside

Check external signals from
a central monitoring system

TempU 30.0 (30)°C

Power 0kW

Check if boiler is limited from
outdoor compensator

Check curves for outdoor
compensation

Defect heating elements,

fuses, contactors

Check heating elements,
fuses, contactors and
replace if required

STB, safety
temp.limiter
released

(Display shows
"Alarm Power")

Temp 30.0 (80)°C

Alarm Power

circulation in boiler Check pump/valves

Burned contactor

Check contactors and
replace if required

LEAKAGE

Loose screws for heating element Tighten screws

Gasket for heating element Replace if required

Defect heating element Replace if required

Varmeteknikk AS August 2017 e-mail: [e-mail]

15

Circuit diagram MB 35 - 150kW

Varmeteknikk AS August 2017 e-mail: [e-mail]

16

Power circuit MB 35-150kW

Appa ratplate

400V

MB 105 kW/120kW/140kW

Appa ratplate

400V

MB 60kW/75kW/90kW

Appa ratplate

400V

MB 35kW/45kW

-E1

-E2

-E3

-E4

-E1

-E2

-E3

-E4

-E5

-E6

-E7

-E1

-E2

-E3

-E4

-E5

-E6

-E7

Appa ratplate

400V

MB 150kW

-E1

-E2

-E3

-E4

-E5

-E6

-E7

-E8

Switc h gear

Switc h gear

Switc h gear

Switc h gear

Varmeteknikk AS August 2017 e-mail: [e-mail]

17

Temp.controller, terminals

Varmeteknikk AS August 2017 e-mail: [e-mail]

19

Spare parts MB 35 – 150kW

Number

Item

Article no.

35kW

45kW

60kW

75kW

90kW

105kW

120kW

140kW

150kW

Heating element 5kW 6613 0001-K 1
Heating element 6kW 6613 0001-P 1
Heating element 7,5kW 6613 0001-AR 2
Heating element 9kW 6613 0001-N 5 1
Heating element 10kW 6672 0242-A 3 3 3 1
Heating element 12kW 6613 0001-G 2 3
Heating element 15kW 6672 0242-D 1 4 7 4
Heating element 20kW 6672 0242-G 3 7 7
Gasket 2152 0022-4 4 4 7 7 7 7 7 7 8
Temp.controller 7-steps 901 310 1 1 1 1 1 1 1 1 1
Sensor temp.controller 200 232 1 1 1 1 1 1 1 1 1
ON/OFF-switch 6672 0235-3 1 1 1 1 1 1 1 1 1
Safety temp.limiter (STB) 6672 0235-1 1 1 1 1 1 1 1 1 1

230V

400V

230V

400V

230V

400V

230V

400V

230V

400V

230V

400V

230V

400V

230V

400V

230V

400V

Contactor AF12 41 175 16 1 1
Contactor AF16 41 175 32 1 1 1 1 1 1
Contactor AF26 41 175 48 3 1 3 1 2 3 1 3 4 1 1 1 1 2
Contactor AF30 41 175 56 1 1 1 3 1
Contactor A50 41 147 56 1 3 2 3 3 3 3 3
Contactor A63 41 148 16 3
Contactor A75 41 148 46 3
Contactor A95 41 149 36 2
Contactor A110 41 150 26 2 2
Fuse control voltage 10A 6672 0235-27 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Circuit breaker MS132/10-16 43 640 80 1 2 1 1 1 1
Circuit breaker MS132/16-20 43 640 81 1
Circuit breaker MS132/20/25 43 640 82 1 1 1 1 1
Circuit breaker MS132/25-32 43 640 83 1 1 1 1 1
Circuit breaker XT1-32 067 411
Circuit breaker XT1-40 067 412 1 1 1 1 1
Circuit breaker XT1-50 067 413 1 1 1 3 1
Circuit breaker XT1-63 067 414 1 1 1 3 1 3 3
Circuit breaker XT1-80 067 415 1 1 1 3 1
Circuit breaker XT1-100 067 416 1 3
Circuit breaker XT1-125 067 417 1 3 3
Circuit breaker XT1-160 067 418 1
Transformer Natek 200 018 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Transformer 100/5A 6672 0235-50 1 1 1 1
Transformer 200/5A 6672 0235-51 1 1 1 1 1 1 1 1
Transformer 300/5A 6672 0235-53 1 1 1
Transformer 400/5A 6672 0235-54 1 1 1

Spare parts valid from 29

.2015

Varmeteknikk AS August 2017 e-mail: [e-mail]

21

Notes