H I G H O U T P U T, F U L LY M O D U L A T I N G , F U L LY C O N D E N S I N G , G A S F I R E D B O I L E R S WITH SINGLE UNIT OUTPUTS UP TO 331kW INSTRUCTIONS FOR INSTALLATION, SERVICING & OPERATION L 258
Index page section page section 3 . . . . . . . . .1.0 1.1 1.2 General General Notes Certification Details 17 . . . . . . .5.7.9 LPG Operation 5.7.10 Connecting the DHW Primary Pump 3-4 . . . . . .2.0 Product Description 18 . . . . . . .5.7.11 Circuit Diagram 5 . . . . . . . . .3.0 3.1 Technical Details Technical Data 19 . . . . . . .5.8 Add On Modules 5.8.1 Pump Module PRø1 6 . . . . . . . . .3.2 3.3 3.4 Critical Dimensions System Guidance Flue Options 20 . . . . . . .5.8.
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 use of the Midimat HT gas fired condensing boiler. Please read this manual fully before commencing the installation of the appliance. RVR Ltd. Ltd shall not be responsible for any damage resulting from failure to carefully observe the instructions given. The Midimat HT must only be installed by persons deemed to be competent i.e.
2.0 product description (contd) Low Noise The Special burner system employed in the Midimat HT boiler is extremely quiet in operation and in many cases it emits less noise than a gas fired atmospheric boiler of equivalent output. Room sealed option If required the boiler may be completely room sealed, taking combustion air directly from outside the building. Note: Ventilation to boiler space will be required for cooling purposes.
3.0 technical details 3.1 technical data Table 1 Model Midimat HT 220 330 Nominal Heat Input (Nett) kW 42 – 210 63 – 316 Nominal Heat Output @ 80/60°C kW 40.7 – 203.7 61.1 – 306.5 Nominal Heat Output @ 50/30°C kW 44.1 – 220.5 66.2 – 331.8 Input Rate Nat Gas G20 (max) m3/h 18.87 28.31 Input Rate LPG G31 (max) kg/h 15.54 23.31 Minimum/Maximum Gas Pressure mbar 18/50 18/50 Max Flue Gas Volume hot (Nat Gas) m3/h 254.59 381.96 m3/h 210.18 315.
3.2 critical dimensions H C 360 A E K L1 P L2 O N R B J D 35 : 50 G M F I S Fig 3.
3.5 thermal performance – heat output limits The Strata 3 – 220 can be limited to a maximum thermal loading between 42kW and 210kW. The Strata 3 – 330 can be limited to a maximum thermal loading between 63kW and 316kW. 4.0 appliance installation requirements 4.1 statutory requirements Gas Safety (Installation and Use) Regulations (Current Issue). It is the law that all gas appliances are installed by a registered person, in accordance with the above regulations.
4.3 flue systems 4.3 flue systems Midmat HT boilers are fully condensing, fully modulating appliances and it is recommended that each boiler is flued independently, however, it is possible to connect multiple boiler flues together providing no part of the common flue pipe is horizontal. A suitable flue must be connected to the boiler and routed to discharge above the roof of the building.
4.5 hydraulic system design The Midmat HT boilers are designed to operate on a flow to return temperature drop of 20K (∆t 20°C). Systems must be sealed and pressurised and operate within the range 0.5 bar to 5.3 bar. The system design should incorporate a pressure gauge, visible from the filling point to indicate the system water pressure. Table 3 - Boiler hydraulic resistance Model 220 330 Design Flow Rate at 80/60 Flow/Return Temperatures 2.38 l/s 3.
4.5 hydraulic system design (contd) recommended system design typical multiple Midimat HT boiler installation SV AAV Flow Header IV AAV IV IV Vertical Low Velocity Mixing Header Vmax 0.5m/s IV IV AAV Return Header IV Strainer BLR Pump NRV Strata 3 Boiler SV IV IV Pumps IV IV IV Heating Load IV HWS Load DOC DOC Fill Point* DOC DOC * Fill Point. In accordance with BS6644, automatic pressurisation unit must be installed Expansion Vessel IV LSV IV IV BLR Pump NRV Strata 3 Boiler Fig 4.
4.7 gas supply The Midmat HT boiler is designed and delivered ready for Natural Gas group G20. For operation with LPG. The LPG conversion kit must be ordered and installed and the multifunctional gas valve adjusted as necessary. (See section 5.4). The Gas Supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas. An existing service pipe MUST NOT be used without prior consultation with the gas supplier.
5.1 unpacking the boiler (contd) The unit must be inspected immediately after delivery. Any damage to the consignment must be reported within 3 days. Firstly move the packaged appliance to the desired location. To unpack the boiler, carefully remove the outer crate and cut away the outer packaging. By holding the steel base only, lift the boiler and remove the palette. 5.
5.6 condensate waste connections The condensate waste connection is located at the lower rear of the appliance. During the operation of the boiler , because of the low exhaust gas temperatures in both the heating boiler itselfand in the exhaust gas system, a slightl y acidic condensation water ( pH value between 3.5 and 5) is deposited. The condensate waste connection is a 40mm plastic tube located at the rear of the appliance. Only plastic components must be used for the condensation discharge.
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5.7.2 fuses (contd) Fuses 1 and 2 protect the power supply phase and neutral. Fuse 3 protects the entire 24V AC circuit. The 24V AC power supply is rectified in the boiler control panel and controls the fan and supplies the room unit(s) with voltage. The supply voltage of the sensors is not accessibly fused in the boiler control panel. This applies also for the protection of the ignition transformer. In the case of a fault in these areas, the boiler control panel must be replaced. 5.7.
Other types of cascade controllers with a continuous 0 to 3V, or 0 to 10V signal can also be connected. An optional adapter is required, for 0 to 10V. See Fig 5.7e (Below) 0 - 10v adaptor To Boiler Socket Nr: 4 Welland Plug Nr: 4 0-10 volt Adaptor A1 A2 R1 R2 0v R3 V+ 0-3 volt control direct to boiler plug Nr: 4 without adaptor. 0-10 volt control via 0-10 volt adaptor (optional extra) Welland Connection Plug Nr: 4 Fig 5.7e 5.7.
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5.8 Add on Modules 5.8.1 Pump module PR 01 The PR 01 pump control serves to control an additional heating circuit pump (pump 2). Technical Information ● Supply Voltage – 230V 50Hz (mains from Strata 3 appliance) ● Maximum contact load – 2A ● Maximum contact rating – 120W 140 PR01 Control Module 60 115 Fig 5.7j Mounting ● Remove the 4 screws on the front of the pump control. ● Remove the cover. ● Mount the unit in the space provided inside the boiler casing.
5.8.1 Pump module PR 01 (contd) X3 PR 01 L NETZ N X2 PUMPE 2 N L System heating pump Pump 2 Power Supply Control Panel Wiring X3 X16 Weiland Plug 3 L1 PE N L2 6 5 4 3 2 1 Cable sets are supplied, labeled, and approximately 140cm in length 20 Fig 5.
5.8.2 mixer module MR 03 The mixer module MR 03 is used if a standard heating circuit (eg for normal temperatures for radiators) and a mixed heating circuit (eg for under floor heating 55/45°C) with different flow temperatures are connected to the Strata 3. The mixer module MR 03 is intended for mounting inside the boiler casing, and contains a potentiometer for setting the heating compensation slope for the underfloor circuit.
5.8.2 installation and elect connection – MR 03 The MR 03 must be connected in accordance with the schematic diagram – fig 5.8e.
5.8.2 installation and elect connection – MR 03 There are 3 options for room temperature:● Both circuits, weather variable, without room control influence. ● Room control influence with one room controller for the entire building – must be electrically connected direct to the boiler. Weiland Plug 4.
S1 S4 S5 S6 S7 AF Flow Temperature Sensor Return Temperature Sensor Domestic Hot Water Temperature Sensor Outside Temperature Sensor (KKM2) MR03 Mixed Flow Sensor Outside Temperature Sensor (Boiler) 6.0 commissioning & testing The Midimat should be commissioned by a competent engineer. Before commissioning the appliance, the whole gas installation including the meter MUST be purged and tested for gas soundness in accordance with IGE/UP/1.
6.2 appliance operation The start of operation of theMidimat heating boiler should commence only after the following points have been checked: Flue system ● Check that the flue system is correctly assembled. ● Ensure that the connections for the condensate drain are water tight and the condensate can be freely drained. Electrical connections ● ON/OFF switch set to OFF. ● Check the polarity of the power supply. Water Check that the setting of the safety valve is correct. Max boiler operating pressure 6 bar.
6.3 initial lighting/commissioning (contd) Turn on the appliance ON/OFF switch TheMidimat begins with a two minute de-aeration program. After this 2 minute program the appliance will start. If the Strata 3 does not start up and the message IGNITION FAILED is flashing on the status indicator on the display panel, press the red re-set button to allow up to four further automatic ignition attempts. If ignition is still not established: ● Ensure the gas supply is correctly purged of air.
6.4 potentiometer adjustments 6.4.1 limiting the output for heating operation The nominal heat output for the boiler can be limited if required to any value between 42kW and 210kW for the Midimat 220 and between 63kW and 316kW for the Strata 3 330. The maximum output continues to be available for domestic hot water production. To adjust the limit: ● Press the red ‘reset’ button. On the lower line in the display, the flow temperature T1 of the sensor S1 is displayed. ● Press the ‘service button’.
6.4.2 setting weather compensation (contd) default compensation slope Dip Switch Settings When compensation req'd outside sensor must be installed and dip switch No.2 set to "ON". 90 Max Flow Temperature Slope A - Dip 6 ON & Dip 7 OFF 80 Slope B - Dip 6 OFF & Dip 7 ON A Slope C - Dip 6 OFF & Dip 7 OFF Boiler Flow Temperature ºC 70 B 60 C 50 40 30 20 10 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 -1 Outside Air Temperature ºC Fig 6.
6.4.2 setting weather compensation (contd) range of parallel displacement of slope B * 1 +10 -10 K 90 RED -20 * -20 70 RED +20 +20 * 2 60 50 40 +10 -10 lt fau de Boiler Flow Temperature ºC 80 K +20 -20 30 20 * BLUE +20 BLUE 10 -20 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 -1 Outside Air Temperature ºC Fig 6.
6.4.3 adjusting the fixed point of the mixer circuit If the MR 03 mixer control is connected to the Strata 3, the fixed point of the heating curve of the mixer can be adjusted. ● Press the red ‘reset’ button. On the lower line in the display, the supply flow temperature T1 of the sensor S1 is displayed. ● Press the ‘service button’ ● Press the red ‘reset’ button 3 times. On the display (MI MIN) is displayed.
6.6 screen display The screen display indicates information about the operating condition of the Strata 3 in plain text. The displays are distinguished as operation messages (non flashing) and fault messages (flashing). 6.6.1 operation messages (non flashing) In the case of the following status signals, the Midimat is in normal operating mode.
6.6.3 Engineers button This button is reserved for the Service Engineer. Note: Pressing this button once instructs the Strata 3 to operate at half load. The status indicator shows (EMISSIONS). If the 'Engineers' button is not pressed again within 10 minutes, the Strata 3 switches back into automatic operation. After further pressing during the (EMISSIONS) display, (10 MIN LOW) appears on the status indicator.
7.1 adapting the control to the heating system (contd) One Screw One Screw Casing Cross Member Fig 7.1b The following specifications must be adjusted: ● Whether the boiler is to be controlled with direct weather compensation. ● Whether an underfloor mixer circuit is connected. ● Whether a room unit, cascade control or a volt free switch are connected. ● Whether the primary heating circuit is a high, medium or low temperature operation.
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8.0 maintenance and inspection 8.1 maintenance procedure After 365 operating days (8760 hours) the message ‘service’ appears in the display. The following work must then be carried out: 1. Refer to the user with regard to any known problems, or any other comments about the appliance. 2. We recommend that the fault data from the boiler control panel be read via a lap top computer and RS-232 interface. The service software is available from MHS Boilers Ltd.
9.0 fault diagnosis 9.1 fault list Possible faults are entered in the following tables. The right column contains the corresponding line numbers of the error correction list – see section 9.2. The error correction list contains possible causes as well as information about the elimination of the fault. Fault Indication on the Display Type of fault (no text) Strata 3 is turned on, ON/OFF switch does not light up, no indication in the display. Error correction list line number – Section 9.
9.2 error correction list The error correction list contains possible causes as well as information about the elimination of the fault.
10.0 guarantees The boiler body and exhaust system both carry a five year guarantee against defect in material or manufacturing process. The burners and all electrical components and other component parts carry a one year guarantee. This guarantee only applies if correct commissioning and regular maintenance has been carried out.
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QW/1101/4511
