STRATA GAS FIRED HIGH EFFICIENCY/ C O N S D E N S I N G U LT R A L O W N O x B O I L E R SINGLE UNIT OUTPUT 120kW INSTRUCTIONS FOR INSTALLATION, SERVICING & OPERATION
STRATA2 Index page section 3 . . . . . . . . .1.0 1.1 1.2 General Product Description Certification Details 3-5 . . . . . .2.0 Product Description 6 . . . . . . . . .3.0 3.1 Technical Details Technical Data 7 . . . . . . . . .3.2 Critical Dimensions 8 . . . . . . . . .3.3 3.4 4.0 System Guidance Flue Options Appliance Installation Requirements Statutory Requirements 4.1 8-9 . . . . . .4.2 Boiler Position 9-15 . . . .4.3 Flue Options & Terminal Position 15 . . . . . . .4.
STRATA2 1.0 general 1.1 general notes These instructions are intended to assist the installer, commissioning engineer, maintenance engineer and user with the installation, maintenance and usage of the Strata 2-120 gas fired condensing boiler. Please read this manual fully before commencing the installation of the appliance. MHS Boilers Ltd shall not be responsible for any damage resulting from failure to carefully observe the instructions given.
STRATA2 2.0 product description (contd) Extended Flue Lengths and Difficult Flue Routes The excess fan pressure from the combustion system is in the order of 100Pa which allows the appliance to be exhausted using small diameter flue components over long distances or awkward routes, which allows a considerable degree of flexibility in boiler siting.
STRATA2 2.0 product description (contd) ● The ‘master’ RVA47 (CLI) controller provides: • Overall modulating output in accordance with the demands of the system. • Inbuilt weather compensation giving direct-on-boiler VT control if required. • Remote stored domestic hot water temperature control • Domestic hot water primary pump or diverter valve control. (2 Amps max) • Heating system pump control. (2 Amps max) • Inbuilt heating system time control with 35 on and 35 off programmable set points within 7 days.
STRATA2 3.0 technical details 3.1 technical data Table 1 Model Strata 2 Single 120 No. of Boilers 1 2 3 4 5 No. of Burners/ Ht Exchangers 2 4 6 8 10 1 master 1 master 1 master + 1 Slave 1 master + 2 Slave 1 master + 3 Slave No. of Cascade RVA Controllers Master & Slaves Multiple Boilers 480 600 10:1 20:1 30:1 40:1 50:1 107.8 11.1 367 37 215.6 11.1 735 37 323.4 11.1 1,103 37 431.2 11.1 1,471 37 539 11.1 1,839 37 Btu/h x 1000 119.7 12.2 408 41 239.4 12.2 816 41 359.1 12.
STRATA2 3.2 critical dimensions appliance dimensions side rear 275 1570 1370 G G B 222 162 A E F 35 36 E F 66 220 279 410 A 690 B 40 50 50 E F G Condense-Outlet (R3/4") Syphon clean point Gas (R1") plan 600 Note: Re flow and return connections. Each boiler is equipped with 2Nr flow and 2Nr return connections. The installer may use either both top or both rear or one of each.
STRATA2 3.3 system guidance In summary, the Strata is designed for use with a sealed pressurised hydronic circuit operating upon a design temperature difference of 20ºC. The integral primary pumps have approximately 1m head available to overcome a primary loop incorporating a low velocity mixing header. Full details regarding suitable system designs are given in section 4.3. 3.4 flue options The Strata 2-120 may be used with either an open or room sealed flue and air system.
STRATA2 4.2 boiler position (contd) Where installation will be in an unusual location, special procedures may be necessary. BS6798 gives detailed guidance on this aspect. The unit cannot be used in the vicinity of chlorine, halogen or sulphur as may be the case in environments such as swimming pools, coolant filling stations etc. In such cases the appliances MUST be room sealed to take air for combustion from outside of the building. 4.
STRATA2 4.3 flue options & terminal position (contd) Table 3 PPS Component Resistance Pa For Single Boiler PPS Component Resistance Pa For Single Boiler 1m Length DN100 Flue Gas tube 7.0 DN150 Air Tube Termination with Rain Cap 1m Length DN100 Tube Carrying Air 4.0 1m Length DN125 Flue Gas tube 2.5 90° Bend DN100 Carrying Flue Gas 7.0 1m Length DN125 Tube Carrying Air 1.5 90° Bend DN100 Carrying Air 4.0 90° Bend DN125 Carrying Flue Gas 2.5 45° Bend DN100 Carrying Flue Gas 4.
STRATA2 examples of calculating flue pressure loss example 2 A single Strata 2-120 boiler is to be installed with a room sealed flue using separate air and flue gas tubes effect of flue system resistance on boiler output of DN100. The flue gas tube takes a part horizontal, part vertical internal route to a roof termination. The air tube takes a similar route. Flue gas route vertical section = 3m, horizontal section = 2m. System includes 2 x 90º bends.
STRATA2 4.3 flue options & terminal position (contd) multiple flue system calculation For flue component resistance for multiple boiler installations refer to graph below. Volume flue gas per boiler = 170m3/h Volume combustion air per boiler = 1303/h Assume resistance of 45° bend = 0.5 tube Assume resistance of 90° bend or tee = 1.
STRATA2 4.3 flue options & terminal position (contd) flue system layouts flueing possibilities single boiler room sealed concentric flue with horizontal discharge Fig 4.
STRATA2 4.3 flue options & terminal position (contd) Additional Notes for Room Sealed Appliances: The Clean Air Act Memorandum prevents the use of balanced flue appliances discharging at low level where the total heat input to the plant room exceeds 150kW. Where the Clean Air Act does not prevent installation, the following rules must be applied.
STRATA2 4.
STRATA2 4.5 hydraulic system design Important Note: Strata 2 boilers must only be installed on sealed and pressurised systems. A sealed system must only be filled by a competent person. Instructions for filling the system are supplied in section 6.0. A low pressure cut off switch must be installed into the system. All systems must be thoroughly cleansed prior to the connection of the boiler.
STRATA2 4.5 hydraulic system design (contd) recommended system design typical multiple Strata 2 boiler installation Outside Air Temperature Sensor Room Unit RE3231 To HWS Sensor AAV Strata 2 - 360 (3 x 120 Boiler) Flow to Load Circuits eg. Heating Circuit & HWS Calorifier Temperature Sensor (Boiler) SV DOC DOC Condensate Waste SV DOC Low Velocity Mixing Header SV Max Velocity 0.
STRATA2 5.0 installation intructions 5.1 unpacking the boiler The boiler is delivered in a palletted carton containing the boiler and associated fittings, plus any other optional ancillary flue or control components in separate cartons. The boiler carton contains: ● Fully assembled boiler. The Strata 2-120 is also delivered with the following items: ● User manual and operating instructions. ● Installation and Servicing instructions for the Engineer.
STRATA2 5.5 Water Connections The central heating flow and return connections are 11/4" BSP male. Two sets of flow and return connections are provided and located on the rear top of the appliance and the rear of the appliance. The installer may use both top or both rear connections or one of each for connection of the flow and return pipes. A suitable safety valve must be installed onto the boiler flow pipe between the boiler and any isolation valve.
STRATA2 5.7.2 connecting of system safety interlocks These switches are connected to the ‘dark green’ 3 pole plug. The central pole provides the common output (230V AC). The left hand terminal enables the lower module and the right hand terminal enables the upper module. 5.7.3 connecting remote run indication lamps Connection points have been provided for the connection of run indication lamps (20W max). See “Electrical Connection Details” fig 5.7a, for terminal positions.
STRATA2 5.7.3 connection diagrams suggested wiring arrangement for high/low pressure switches and Strata 2 boilers Strata 2/120 Boiler Low Pressure Switch High Pressure Switch Break on Pressure Fall Break on Pressure Rise Supply Remote Safety Interlocks 240 Volts out from centre tapping return to either side for complete boiler operation interlock required for each boiler Contactor N Fig 5.
STRATA2 5.7.3 connection diagrams suggested hydraulic layout and basic wiring for Strata 2 120 condensing boilers HKP VFO Flow Sensor AF Outside Sensor SLP SF HWS Sensor/ Stat RFO Return Sensor Boiler No.1 Low Loss Header Max Velocity 0.5 m/s Boiler No.
STRATA2 5.7.
STRATA2 5.7.
STRATA2 5.7.5 connecting remote fault alarms The boiler includes a normally open volt free contact for each module, which closes in the event of a lockout failure. See “Electrical Connection Details” section 5.7. 5.8 connecting additional boilers A second boiler unit does not require an additional RVA 47 manager, as the manager in the first unit is capable of controlling up to 4 burners. Connect the power supply to the second unit.
STRATA2 5.8.3 mixing valve controller RVA 46 installation procedure Complete the following steps to install the RVA 46: ● Remove the blank panel beside the manager. ● Unpack the RVA 46 and insert it in the opening of the control panel. ● Place the wiring harness with 7-pin connector in the bottom of the RVA 46 and click the other end into the wiring upstand at the rear of the boiler.
STRATA2 5.9.1 Condensate Receptacle and Pump – Model No. KHP1 The KHP1 condensate pump is designed to collect and pump away condensate water produced by condensing boilers and is particularly suitable for use with the Strata 2. The KHP1 may be installed directly inside the base area of the Strata 2 making a concealed installation. The receptacle includes a permanently wet sump area where pH adjustment granules may be dosed to neutralise the pH of the condensate water.
STRATA2 6.2 appliance operation A B C D 1 2 0 E H I I 3 4 F G A Double pole on/off switch (main) F Lower burner status panel B Lower burner on/off switch G Upper burner status panel C Upper burner on/off switch H RVA 47 cascade control manager D Fuse holder I E Altitude gauge Knockout for additional optional controls Fig 6.2a 6.2.1 left switch panel Refer to Figure 6.
STRATA2 6.2.3 DIP switches The unit has a number of DIP switches that must always be set. These switches have different functions. To access the DIP switches, the cover plate over the circuit boards must be removed. 1. Remove the two fixing screws on the lower edge of the top cover panel. 2. Slide the panel towards the front of the boiler and lift away. 3. The DIP switches are easily accessible at the left side of each control circuit board.
STRATA2 6.3 firing the appliance At the time of starting the appliance, the working gas pressure must be measured: ● The inlet working gas pressure must be measured at the inlet test nipple of the gas control valve. (see fig 6.4a). ● Nominal pressure should be 20 mbar for the Natural gas and 37 mbar for LPG (Propane). 6.3.1 initial start up Ensuring that the installation has been fully tested and having found everything in order, power can be applied to the unit by switching the main switch (fig 6.
STRATA2 6.4.1 setting minimum load gas valve To set the minimum load refer to figure 6.4a and follow the instructions below: ● Press the ‘Chimney Sweep’ button once, the letter ‘L’ will appear in the display and the unit will commence operation at minimum capacity, for up to 10 minutes. 3 Q max ● Check the combustion figures with those stated above. 2 Q min ● If the CO2 content is below the stated figure, increase the gas throughput by turning the adjusting screw (2) clockwise.
STRATA2 6.6 setting domestic hot water The RVA 47 cascade manager can be set to control the temperature of the DHW either by means of a dedicated sensor or thermostat. 6.7 switching off the appliance It is recommended to leave the appliance running throughout the year in order to prevent the unit from freezing, or moving parts from becoming blocked by corrosion. In order to avoid this, set the RVA 47 controller to the ‘standby’ position.
STRATA2 7.1 end user parameter settings (contd) Table 10 (Prog#) Description of Prog # Range Inputs Preset Actual Values 18 Actual room temperature 19 Actual outside temperature (Pressing the + and – buttons simultaneously until the display stops flashing will reset the averaged value) -50.
STRATA2 7.2 heating engineer parameter setting (contd) Table 11 (Prog#) Description of Prog# Range Preffered Setting 51 Output test 0 Automatic control 1 All outputs off 2 DHW pump/valve on 3 Circulating pump on 0…3 0 52 Input test 0 Return temperature value 1 DHW temperature value 2 Flow temperature value 3 Outside temperature value 4 Room temperature value 5 0-10 V equiv. Temp 0.5 0 53 Plant Type # refer to drawings at rear of manual * 27…36 –– 54 Display of PPS communication details 1..
STRATA2 7.2 heating engineer parameter setting (contd) Table 11 (Prog#) Description of Prog# Range Preffered Setting 100 Displacement of heating curve -4.5..+4.5 0 101 Gain factor for room temperature influence 0 Active 1 Inactive 0..1 1 102 Room temperature pump switching differential Higher = Less stable temperature Lower = More stable temperature – – –/0.5..4 0.
STRATA2 7.2 heating engineer parameter setting (contd) Table 11 (Prog#) Description of Prog# Range Preffered Setting LPB communication setting 140 LPB control device address 0 Standalone single RVA 47 1 Master RVA 47 cascade manager with sensors attached 2…16 Slave RVA 47s operating from master RVA 47 (ie House No.) (Each subsequent RVA 47 should be given consecutive numbers) 0..16 1 141 LPB control segment addres 0 Heat generator (ie Street name) 1….14 Heat consumer 0..
STRATA2 7.3 OEM parameter setting ● To enter the OEM Parameter Program, the door of the RVA 47 must be opened and the UP and DOWN Prog buttons must be depressed for at least 10 seconds until 00000 appears in the window. ● The 00000 display must be changed to 11111 by inputting a password. The password for the RVA 47 is DOWN, DOWN, PLUS, MINUS, UP. ● A # between 2 and 92 will appear in a bracket on the left of the display window. These can be paged through by using the UP and DOWN buttons.
STRATA2 7.3 OEM parameter setting (contd) Table 12 (Prog #) Description of Prog # Range Preferred setting 51 Minimum output % reached prior to cascade switching modules Off 5..100 40 52 Maximum output % reached prior to cascade switching modules On 5..100 80 56 Time spent by module on ignition rate prior to modulation. (delay time between modules) 0..1200 0 60 Minimum temperature difference between flow and return temperature 0..
STRATA2 8.2 maintenance Any maintenance must be carried out as a result of faults noted in the inspection. Remarks and comments made by clients must be considered and the causes of any faults or problems must be found. Note: The pressure of the installation must be not less than 0.5 bar, any leakage within the system will affect the pressure and so must be identified.
STRATA2 9.1.1 operation indicator (contd) 2. Unit prevented from operating. Water temperature too high, measured by the flow sensor. When the water temperature drops by more than 20ºC the unit will start to operate. 3. Unit prevented from operating. Anti-cycling time. When the anti-cycling time (3 minutes has expired, the unit will automatically fire up again). 5. Unit prevented from operating. Combustion fan speed too high. The combustion fan has been switched off, but a speed indication is still detected.
STRATA2 9.1.3 system faults These faults are indicated with a letter, occasionally followed by a number. To avoid confusion in the indication, the letters and numbers are fixed as follows: Table 15 E1 Fault with flow sensor E2 Fault with cable for gas valve or gas valve coil E3 Fault with rectification circuit E4 Burner control circuit board has a fault –– Communication via RS232 connection possible E5 Parameter fault E6 Communication fault 9.
STRATA2 10.0 parts list The Parts List is for service purposes. If no numbers have been listed, the parts concerned are non serviceable parts. Short spaces parts list: Description of Part Part Number Water temperature sensor 252014 Limit thermostat 250083 Fan 252013 Pump 130160 Gas valve 251166 Ignition electrode 251095 Ignition transformer 252033 Control PCB, Fmt 310 252032 Fuse 6.3A 250V 252037 Manometer 0-4 bar 252027 O-ring set O-ring kit 11.
STRATA QW/04/01 A member of the Modular Heating Group Plc 35 Nobel Square, Burnt Mills Industrial Estate, Basildon, Essex SS13 1LT Tel: 01268 591010 Fax: 01268 728202 http://www.modular-heating-group.co.uk This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale.
