Procon Instructions for Installing, Servicing and Using Procon 15, 25, 45 and 75 Boilers RVR.
Procon Table of Contents 1.0 2.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 11.1 11.2 11.3 11.4 11.7 12.0 13.0 14.0 15.0 15.1 15.2 15.3 15.4 15.5 15.5 15.6 16.0 16.1 16.2 16.3 17.0 17.1 17.2 17.3 17.4 17.5 17.6 17.7 18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9 18.10 19.0 19.1 19.2 20.0 20.1 20.3 20.4 20.5 20.6 20.7 20.8 21.0 21.1 22.0 22.2 23.0 24.0 24.1 24.2 General Notes . . . . . . . . . . . . . . . . . . . . . . . . Product Description . . . . . . . . . . . . . . . . . . . .
Procon 1.0 General Notes These instructions are intended to assist the installer, commissioning and maintenance technicians and the user with the application and use of the Procon 15, 25, 45 & 75 gas fired condensing boilers. Please read this manual fully before commencing the installation of the appliance. The Procon boilers must be installed by competent persons as defined by local, national and European regulations.
Procon 2.0 Product Description The Procon 15, 25, 45 & 75 wall mounted gas fired condensing boilers are state of the art appliances, which include a comprehensive range of features. The appliance must only be used on a sealed and pressurized system. System design must take into account that the boiler operates on a 20°C Δt.
Procon 2.0 Product Description (cont’d) Comprehensive microprocessor control The Procon 15, 25, 45 & 75 boiler control panel includes a user friendly microprocessor control centre which manages the entire function of the appliance and encompasses: 1) Management of the essential safety functions of burner ignition and flame monitoring. 2) Water high temperature and flue gas high temperature safety cut out. 3) Modulation of the burner output in conjunction with operating temperature control.
Procon 3.
Procon 3.
Procon 4.0 Delivery Consignment / Unpacking The Boiler The boiler is delivered as a consignment of a palleted carton containing the boiler and associated fittings, plus any other optional ancillary flue or control components in separate cartons. The boiler carton contains: • Assembled boiler. • Wall mounting bracket and associated fixings. • Fittings bag including, condensate waste outlet, outside air sensor (QAC34). To unpack the boiler, the palleted carton should be laid on the floor.
Procon 7.0 Wall Mounting The Procon 15, 25, 45 & 75 boiler is mounted to the wall via a wall-mounting bracket, which interlocks to a rail mounted on the rear of the boiler. The wall-mounting bracket should be securely fixed to the wall using suitable fixings for the wall construction and boiler weight. The wall-mounting bracket positioning detail is shown in fig 7.1 for Model 15, 25 & 45; and fig 7.2 for model 75 only.
Procon 9.0 Water Connection The Procon 15, 25, 45 & 75 boilers MUST only be installed on a sealed, pressurized heating system. The maximum working pressure of the boiler is 3 bar. A safety valve set at 3.0 bar MUST be installed into the heating flow pipe adjacent to the appliance and before any isolation valves. It is recommended that the final working pressure (hot) of the system should not exceed 2.5 bar. The system that the boiler is installed onto will require an expansion vessel.
Procon 11.0 Flue The flue outlet and combustion air inlet connections to the appliance are located on the top of the appliance; see fig 11.1. These connections are arranged concentrically with a Female 80 mm ∅ flue gas connection centrally within a Male 125 mm ∅ air connection. There are two options for flueing the Procon boiler: 1) Room Sealed, using either concentric 80/125 mm ∅ flue components, or separate 80 mm ∅ flue components; where the air for combustion is taken from outside of the building.
Procon 11.3 Room Sealed Flue The Procon 15, 25, 45 & 75 boilers have an excess pressure combustion system, which coupled with very low flue gas temperatures, allows the appliance to be flued over considerable distances. The Procon 15, 25, 45 & 75 boilers are fitted with a concentric flue outlet on the top of the boiler and uses a female 80 mm ∅ PPS polypropylene flue gas pipe within a male 125 mm ∅ painted metal combustion air pipe, see fig 11.1.
Procon 11.4 Installation of a Horizontal Wall Terminal (cont’d) Side Outlet Assembly Method The following procedure applies to horizontal, side flue terminal position. 1) With the boiler mounted in position, see section 7.0, draw a horizontal line along the wall 210 mm above the top of the boiler. This line should rise at approximately 3° from the horizontal toward the terminal position to allow any condensate to drain through the boiler. See fig 11.4d.
Procon 12.0 Calculating the Flue Pressure Loss The excess pressure available from the boiler fan for overcoming the frictional resistance of the flue system is 400 Pa. The adjacent table lists the resistances of the flue components, which will assist the designer in calculating the resistance of the total flue system. As with all vertical flue systems, thermal up-draught is generated in the vertical sections of a flue, the graph below (fig 12.
Procon 13.0 Flue Terminal Positions The flue terminal of the Procon 15, 25, 45 & 75 boilers’ will plume water vapour, heavily and care must be taken when selecting the terminal position to ensure that a “nuisance situation” is not created. Where the flue terminal discharges within 2 metres of ground or any upper part of the building where people have general access, i.e. balcony level, etc., a terminal guard MUST be fitted to prevent the terminal from being touched. Fig 13.
Procon 14.0 Ventilation Requirements The room or space in which the Procon 15, 25, 45 & 75 boiler is installed may need to be ventilated in accordance with BS 5440: Part 2:2000, or BS 6644: 2005, as appropriate. The table below details the ventilation required for individual Procon 15, 25, 45 & 75 boiler installations ONLY. Conventional Flue Installation Room Installation. Natural Ventilation direct to outside. Room Installation.
Procon 15.1 Low Water Pressure Protection. A low water pressure switch has been incorporated into the boiler and therefore an external unit is not required. The activation setting of the switch is 0.5 bar, with a 0.3 bar differential; therefore the system pressure must be in excess of 0.8 bar for the switch to activate and allow the appliance to function. 15.2 Water Treatment and System Cleaning The entire primary system MUST be thoroughly cleaned and flushed to remove debris, flux residues, etc.
Procon 15.5 Filling the System The Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by the local authority and complies with building regulations. In general Water Regulation Advisory Scheme (WRAS) recommendations will be acceptable in Ireland.
Procon 16.0 Electrical Connections. In accordance with BS 5440: 2000, BS 6644: 2005, WRAS Regulations, and Local Authority Water Regulations, as applicable, the installer shall install a suitably sized, and approved, Expansion Vessel to ensure that the water capacity of the system has ample expansion capacity. The location of the expansion vessel shall only be isolatable from the system via a Lockable Type Service Valve which shall be locked in the OPEN position, to prevent accidental isolation.
Procon 16.1 Internal Wiring Diagrams Fig 16.1a – Internal Wiring Diagram for Models 15, 25 & 45 Fig 16.
Procon 16.2 Low Voltage Cables All low voltage cables should be of a suitable screened type for 24-volt data transfer. The Outside Air Sensor (QAC34), and optional QAA73 unit and Hot Water Sensor (QAZ36), all require Low Voltage Cables. The adjacent table gives guidance on the size of cable required for the length of cable required.
Procon 17.3 AGU2.511 Clip-In Module BMS Interface (Part No – 96.38000-7005) With the use of an AGU2.511 Clip-In Module, the boiler controller can communicate with a BMS System. This Clip-In Module has three 240V (50Hz) progra mm able outputs that can be configured to respond to the operational status of the boiler, for remote monitoring, such as, Healthy, Run and Lock-Out. This Clip-In Module can also accept a 0-10V dc or 020mAmp input signal for Set-point Temperature, or Percentage Output control.
Procon 17.6 RVA46 Zone Controller (Black) The RVA46 Zone Controller (Black) is a match controller for the RVA47 (Grey), and is located in the Left-Hand position of the RVA47 Housing. The RVA46 can provide the drive signals for the Zone Circulation pump and Mixing Valve (Supplied by Others). If a mixing value is required to acco mm odate lower operating temperatures from that of the other Zones, then a QAD21 flow sensor will be required, available as an optional extra.
Procon 18.1 System Type 1. Typical single Procon 15, 25, 45 & 75 boiler installation serving heating only. Please note: • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pump may not be required. The hydraulic resistance of the Index Circuit MUST NOT exceed the amount of the Residual Head pressure available, please refer to the Technical Data detailed in Section 3.
Procon 18.1 System Type 1 (cont’d) Notes *1 Only fit one type of Room Temperature Control. Fig 18.1c – Wiring Diagram for Model 75 Potential Parameter Changes Applicable to System Type 1.
Procon 18.2 System Type 2. Typical single Procon 15, 25 & 45 boiler installation serving heating and domestic hot water (priority) via a 3 Port Valve. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external systempump may not be required. The hydraulic resistance of the Index Circuit MUST NOT exceed the amountof the Residual Head pressure available, please refer to the Technical Data detailed in Section 3.
Procon 18.2 System Type 2 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. Fig 18.2c – Wiring Diagram for Model 75 (Not Recommended, please consider System Type 3) Potential Parameter Changes Applicable to System Type 2.
Procon 18.3 System Type 3 Typical single Procon 15, 25, 45 & 75 boiler installation serving a heating and domestic hot water (priority) with individual charging pumps, using a low velocity mixing header. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pumpis not required.
Procon 18.3 System Type 3 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. Fig 18.3c – Wiring Diagram for Model 75 Essential Parameter Changes Applicable to System Type 4. Line ID H587 -b6 Description HWS Charging Pump (Standing Operation) {16, 31} {0 = OFF, 1 = ON} Default Setting New Setting for This System 0 1 Default Setting New Setting for This System 1 As Required 0 As Required Potential Parameter Changes Applicable to System Type 3.
Procon 18.4 System Type 4. Typical single Procon 15, 25, 45 & 75 boiler installation serving two heating zones and domestic hot water (priority) with individual charging pumps, using a low velocity mixing header. AGU2.500 Clip-In Module required. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pumpis not required.
Procon 18.4 System Type 4 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. *3 Heating Zone 1 *4 Heating Zone 2, via AGU2.500 Clip-In Module. Fig 18.4c – Wiring Diagram for Model 75 Essential Parameter Changes Applicable to System Type 4.
Procon 18.5 System Type 5 Typical single Procon 15, 25, 45 & 75 boiler installation utilizing an AGU2.500 Clip-In Module serving two heating zones, one with a mixing valve, and domestic hot water (priority) with individual charging pumps, using a low velocity mixing header. AGU2.500 Clip-In Module and QAD36 flow sensor required. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pump is not required.
Procon 18.5 System Type 5 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. *3 Heating Zone 1 *4 Heating Zone 2, via AGU2.500 Clip-In Module. Fig 18.5c – Wiring Diagram for Model 75 Essential Parameter Changes Applicable to System Type 5.
Procon 18.6 System Type 6. Typical single Procon 15, 25, 45 & 75 boiler installation utilizing an RVA63 Controller serving two heating zones each with a mixing valve, and domestic hot water (priority) with individual charging pumps, using a low velocity mixing header. RVA63 Controller & Housing, 2 No QAD21/26 flow sensors, and an OCI420 Communication Clip-In Module required. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pumpis not required.
Procon 18.6 System Type 6 (cont’d) Fig 18.6c – Wiring Diagram for Model 75 Essential Boiler Parameter Changes Applicable to System Type 6. Line ID H516 Description Summer/Winter Changer Over Default Setting 18 New Setting for This System 30 Default Setting 18 2 0 0 3 New Setting for This System 30 0 1 1 2 Default Setting New Setting for This System 0 1 Fig 18.6d – Wiring Diagram for RVA63 Essential RVA63 Parameter Changes Applicable to System Type 6.
Procon 18.7 System Type 7. Typical single Procon 15, 25, 45 & 75 boiler installation utilizing an AGU2.500 Clip-In Module and an RVA63 Controller serving four heating zones, three of which having mixing valves, and domestic hot water (priority) with individual charging pumps, using a low velocity mixing header. RVA63 Controller & Housing, 2 No QAD21/26 flow sensors, an AGU2.500 Clip-In Module, a QAD36 flow sensor, and an OCI420 Communication Clip-In Module required.
Procon 18.7 System Type 7 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. *3 Heating Zone 1 *4 Heating Zone 2, via AGU2.500 Clip-In Module. Fig 18.7c – Wiring Diagram for Model 75 Essential Boiler Parameter Changes Applicable to System Type 8.
Procon 18.8 System Type 8 Typical multiple Procon 15, 25, 45 & 75 boiler installation utilizing an RVA47 Cascade Manager serving a heating and domestic hot water with individual charging pumps, using a low velocity mixing header. RVA47 Controller & Housing (complete with 2 No QAD21/26 sensors), and OCI420 Communication Clip-In Modules (1 per boiler) required. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pump is not required.
Procon 18.8 System Type 8 (cont’d) Notes *1 Only fit one type of Room Temperature Control. *2 Parameter Change may be required. Fig 18.8d – Wiring Diagram for RVA47 Essential RVA47 Parameter Changes Applicable to System Type 8. Line ID P16 Description Summer / Winter Cut-Off Default Setting 18 New Setting for This System 20 Default Setting New Setting for This System 0 1 Potential RVA47 Parameter Changes Applicable to System Type 8.
Procon 18.9 System Type 9 Typical multiple Procon 15, 25, 45 & 75 boiler installation utilizing an RVA47 Cascade Manager and a RVA63 Controller, two heating zones, one of which having mixing valves, and domestic hot water with individual charging pumps, using a low velocity mixing header. RVA63 Controller & Housing, an RVA47 Controller & Housing, 3 No QAD21/26 flow sensors, and OCI420 Communication Clip-In Modules (1 per boiler) required.
Procon 18.9 System Type 9 (cont’d) Fig 18.9d – Wiring Diagram for RVA47 Essential RVA47 Parameter Changes Applicable to System Type 9. Line ID P16 Description Summer / Winter Cut-Off Default Setting 18 New Setting for This System 30 Default Setting 18 2 0 0 3 New Setting for This System 30 0 1 1 2 Default Setting New Setting for This System 0 1 Fig 18.9e – Wiring Diagram for RVA63 Essential RVA63 Parameter Changes Applicable to System Type 6.
Procon 18.10 System Type 10 Typical single Procon 15, 25, 45 & 75 boiler installation serving domestic hot water and heating systems using a low velocity mixing header, single primary pump and two number 2 Port Valves with conventional controllers. Typical ‘S’ Plan system. Please note; • The Procon15, 25 & 45 models include an internal pump and therefore an external boiler pumpis not required.
Procon 18.10 System Type 10 (cont’d) Fig 18.10c – Wiring Diagram for Model 75 Essential Parameter Changes Applicable to System Type 10. Line ID H554-b3 Description Weather Compensation / Constant Temperature {0 = Constant Temp.
Procon 19.0 Commissioning The Procon MUST be commissioned by a competent engineer who will need, in addition to standard hand tools, a U-Tube or Digital manometer and a combustion analyser. Before attempting to set the Procon to work, the following check list must be worked through. See Section 19.1 19.
Procon 20.0 Control Panel The control panel for the Procon boilers includes a double pole ON/OFF switch and comprehensive information display screen and adjustment buttons. On the Left Hand side of the boiler front is a system water pressure gauge, The Boilers’ LMU64 controller has various levels of control options and adjustments are made via the units display screen. Standard Features Include. • General Operation Information. • Boiler Status - Flow temperature, etc.
Procon 20.2 Controller Display The Boiler controller has various levels of access, this section relates to understanding the controller fascia, display symbols and buttons. Actual Boiler Temp LMU Version, or Manual Reset ERROR Code Mode Selected Symbol Mode Selection Button.
Procon 20.3 Level One Parameters Review and Alternation A limited number of (Customer) parameter levels are available via the control panel, these parameters are as listed in table below, and can be accessed by using the ▲ & ▼ Program Buttons.
Procon 20.4 LMU64 Controller, Fault Indication If the boiler fails to operate correctly the unit will ‘Lockout’ and require manual intervention to reset the controller. On the LCD display will appear in the bottom ‘Left-Hand’ corner, and a LARGE ERROR code will be displayed. If more than one error has occurred, these can be displayed by pressing the ‘INFO’ button. These error messages can be referenced against the table below. To reset the boiler, simply press the ‘RESET’ button.
Procon 20.4 LMU64 Controller, Fault Indication (cont’d) If the optional QAA73 Room Unit, RVA47 Cascade Controller, or Sequence Description RVA63 Zone Controller has been connected to the boiler, and a fault Number occurs, the or ER will appear on the display of the respective Unit 3 Fan operating at pre-purge rate as well as the boiler.
Procon 20.
Procon 20.8 Boiler Operating Sequence Numeric Indication By pressing the ‘INFO’ button three times, the Boiler Sequence Description Operating Sequence can be witnessed, indicated by Large Number numeric notation on the display. Having reviewed the Operating Sequence, press the ‘MODE’ button once to return to the standard screen. The controller will also automatically return to the standard screen after approximately 10 seconds. The adjacent table details the numeric notation of the ignition sequence. 21.
Procon 21.0 First Firing / Burner Commissioning (Cont’d) n) To adjust the LOW FIRE rate, use the ‘-‘ or ▼ buttons to set the Low Fire controller to 0% burner output. After the burner has stabilized, Adjustment adjustments can be made to ‘Low Fire’ adjuster on the gas valve (clockwise to increase, anti-clockwise to decrease the CO2). After each adjustment, let the burner stabilize for a minute, then check levels again. See Fig 21.0b. Continue until the CO2 levels are as listed in the table above.
Procon 22.1 Routine Service Inspection Before commencing any service/maintenance work, the following tasks must be undertaken. a) Ask the end user about any problems with the operation of the boiler unit and note their comments. b) Check the water pressure of the installation. h) Utilizing the instructions in Section 20.5, review the LMU Operating Error Codes, and note the recorded codes onto the Service Report. c) Remove the boiler casing and visually inspect all pipe and water joints for signs of leakage.
Procon 22.2 Routine Cleaning & Maintenance (Cont’d) i) Following the cleaning of the Heat Exchanger, the condensate syphon must be flushed to ensure that all mineral deposits/debris that has been washed from the heat exchanger surface is correctly removed. Open the syphon cleaning point cap at the base of the boiler, with a suitable receptacle directly below to collect the syphon contents. Safely dispose of the contents of the syphon.
Procon Display or QAA73 H505 H506 H507 H508 H509 H510 H511 H512 H513 H514 H515 H516 H517 H518 H519 H520 H521 H522 H523 H524 H525 H526 H527 H528 H529 H528 H529 H530 H531 H532 H533 H534 H535 H536 H537 H538 H539 H540 Function / Description Range Boiler setpoint at design outside temperature 20… 90 °C Minimum flow setpoint temperature (20 20… 90 °C °C≤TvSmin≤TvSmax) Maximum flow setpoint temperature 20… 90 °C (TvSmin≤TvSmax≤90 °C) Minimum DHW setpoint temperature (10 10… 80 °C °C≤TbwSmin≤TbwSmax) Maximum DHW
Procon Display or QAA73 Function / Description H541 Maximum degree of modulation in heating mode (LmodTL ≤ PhzMax ≤ LmodVL) H542 Minimum boiler output in kW (lower calorific value) H543 Maximum boiler output in kW (lower calorific value) H544 H545 H546 H547 H548 H549 H550 H551 H552 H553 Range 0… 100 % 0… 9999 kW 0… 9999 kW 0… 255 min Overrun time of pumps, max.
Procon Display or QAA73 Function / Description Range H560 Setting flags 0… 255 H561 Setting flags 0… 255 H562 Minimum boiler water pressure H563 Maximum boiler water pressure H564 Max head of modulating pump (supplier specification) H565 H566 Min head of modulating pump (supplier specification) Proportional coefficient of DHW controller H567 Derivative action time of DHW controller H568 H569 Integral action time of DHW controller Proportional coefficient of heating circuit controller H5
Procon Display or QAA73 H592 H593 H594 H595 H596 H597 H598 Function / Description Triggering threshold for boiler shutdown at high flue gas temperatures Triggering threshold for output reduction at high flue gas temperatures (limitation) Water pressure above which boiler and pump will be shut down Switching differential of water pressure Running time of actuator in heating circuit 2 (TimeOpening / TimeClosing) P-band of heating circuit 2 controller Output during controller delay time (LmodTL ≤ LmodRgVerz ≤
Procon Display or QAA73 H624 H625 H626 H627 Function / Description Output-related start on controller release in instantaneous DHW heating mode (LmodTL ≤ LmodRgStartDLH ≤ LmodVL) Set limit for the number of operating hours (interval) since last service visit Set limit for the number of startups (interval) since last service visit Set limit for the number of months (interval) since last service visit H628 Set limit of fan speed for service visit H629 Enduser can acknowledge a pending maintenance alarm v
Procon Display or QAA73 Function / Description H711 H712 H713 H714 H715 H716 H717 4th Historical Fault – Operating Error Code 5th Historical Fault – Number of Occurrences. 5th Historical Fault – Operating Phase. 5th Historical Fault – Operating Error Code Current Historical Fault – Number of Occurrences Current Historical Fault – Operating Phase.
Procon 24.0 Exploded Views & Short Parts List The following diagrams show the internal components for the Procon 15, 25, 45 & 75 Boilers, with a short parts list of the internal components. Before ordering any replacement parts, we would recommend that you consult with RVR boilers Spares Department to confirm that the parts numbers listed are still current. 24.1 Procon 15, 25 & 45 Fig 24.
Procon 24.1 Procon 15, 25 & 45 (cont’d) Fig 24.
Procon 24.1 Procon 15, 25 & 45 (cont’d) Fig 24.
Procon 24.2 Procon 75 Fig 24.
Procon 24.2 Procon 75 (cont’d) Fig 24.
Procon 24.2 Procon 75 (cont’d) Fig 24.
Procon 67
RVR Limited, Kenmare, Co. Kerry, Ireland Telephone: +353 64 41344 • Fax: +353 64 89520 www.RVR.ie 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 which are available on www.rvr.ie RVR.
