Lochinvar CP-M Series Installation, Commissioning & Maintenance Instructions Download Page 1

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The CP-

M+™ range

High Efficiency Gas Fired Condensing Boilers

Installation, Commissioning & Maintenance
Instructions

Models:

CP-M+60

CP-M+80

CP-M+100

CP-M+120

CP-M+150

CP-M+180

INS0034 Issue No 5 | November 2013

Summary of Contents for CP-M Series

Page 1: ...he CP M range High Efficiency Gas Fired Condensing Boilers Installation Commissioning Maintenance Instructions Models CP M 60 CP M 80 CP M 100 CP M 120 CP M 150 CP M 180 INS0034 Issue No 5 November 20...

Page 2: ...L INSTALLATION 28 8 7 1 TYPE B23 CONVENTIONAL FLUE 28 8 7 2 TYPE C13 HORIZONTAL BALANCED FLUE 29 8 7 3 TYPE C33 VERTICAL BALANCED FLUE 29 8 7 4 TYPE C43 30 8 7 5 TYPE C53 TWIN PIPE FLUE 30 8 8 COMMON...

Page 3: ...AND TESTING 72 14 1 ELECTRICAL INSTALLATION 72 14 2 GAS INSTALLATION 72 14 3 WATER CONNECTIONS 72 14 4 COMMISSIONING THE EQUIPMENT 72 14 4 1 GENERAL CHECKS PRIOR TO LIGHTING 72 14 4 2 EQUIPMENT CHECK...

Page 4: ...pressurised system care must be taken to ensure all extra safety requirements are satisfied should a high or low pressure condition occur in the system The equipment is designed for direct connection...

Page 5: ...5 2 0 PRINCIPAL PARTS FIGURE 2 1 REMOVABLE COMPONENTS CP M 60...

Page 6: ...6 FIGURE 2 2 REMOVABLE COMPONENTS CP M 60 CONTINUED...

Page 7: ...taining screws 40 Automatic air vent 13 Gas air mixing pipe 41 Condensate drain hose air supply duct 14 Combustion fan gas air mixing pipe gasket 42 Wall bracket 15 Combustion fan 43 Flue gas outlet p...

Page 8: ...8 FIGURE 2 3 REMOVABLE COMPONENTS CP M 80 CP M 100...

Page 9: ...9 FIGURE 2 4 REMOVABLE COMPONENTS CP M 80 CP M 100 CONTINUED...

Page 10: ...gas temperature sensor 12 Gas air mixing pipe retaining screws 38 Heat exchanger outlet flue spigot gasket 13 Gas air mixing pipe 39 Automatic air vent 14 Combustion fan gas air mixing pipe gasket 40...

Page 11: ...11 FIGURE 2 5 REMOVABLE COMPONENTS CP M 120...

Page 12: ...12 FIGURE 2 6 REMOVABLE COMPONENTS CP M 120 CONTINUED...

Page 13: ...air mixing pipe retaining screws 39 Flue gas temperature sensor 13 Gas air mixing pipe 40 Heat exchanger outlet flue spigot gasket 14 Combustion fan gas air mixing pipe gasket 41 Automatic air vent 1...

Page 14: ...14 FIGURE 2 7 REMOVABLE COMPONENTS CP M 150 CP M 180...

Page 15: ...15 FIGURE 2 8 REMOVABLE COMPONENTS CP M 150 CP M 180 CONTINUED...

Page 16: ...re sensor 13 Gas air mixing pipe 39 Heat exchanger outlet flue spigot gasket 14 Combustion fan gas air mixing pipe gasket 40 Automatic air vent 15 Combustion fan 41 Condensate drain hose air supply du...

Page 17: ...1 45 1 55 6 67 3 Gas inlet connection size BSP 1 GAS DATA G31 Nominal gas inlet pressure mbar 37 0 Maximum gas inlet pressure mbar 45 0 Minimum gas inlet pressure mbar 25 0 Gas flow rate m3 hr 2 27 3...

Page 18: ...120 AI Air Inlet 80 100 100 125 125 150 150 FG Flue Gas 80 100 100 80 80 100 100 F Flow R 1 male C Condensate Flexible hose 25 21 x 750 mm R Return R 1 male G Gas R male Dimension A 112 112 112 155 1...

Page 19: ...ncentric CP M 150 CP M 180 CP M 150 CP M 180 AI Air Inlet 130 130 150 150 FG Flue Gas 130 130 100 100 F Flow R 1 male C Condensate Flexible hose 25 21 x 750 mm R Return R 1 male G Gas R 1 male FIGURE...

Page 20: ...essels using an internal diaphragm for sealed hot water heating systems BS 5440 1 2008 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 1s...

Page 21: ...TION Precautions must be taken to remove air and dirt from the heating system The system should be fully flushed with an air separator and dirt separator fitted to fully protect against contamination...

Page 22: ...C If such a situation is unavoidable appropriate insulation should be provided When mounting the boiler on a wall investigations should be made as to whether the wall is strong enough to support the f...

Page 23: ...s between pH 6 5 and 10 0 If it is determined that these levels cannot be achieved an in line condensate neutralisation kit is available as an ancillary option from Lochinvar Limited This unit is capa...

Page 24: ...ressure booster is fitted 7 5 PLANT ROOM CONTROL VALVE A manual valve for plant room isolation must be fitted in the gas supply line It must be clearly identified and readily accessible for operation...

Page 25: ...a suitable alternative CP M 60 CP M 120 boilers are supplied for connection to a concentric flue system If twin pipe or conventional flue is used a conversion kit will be required Contact Lochinvar L...

Page 26: ...ystem is determined by the resistance of the components within the flue The resistance must not exceed 200 Pa CP M 60 80 125 CP M 80 80 125 CP M 100 100 150 CP M 120 100 150 CP M 150 100 150 CP M 180...

Page 27: ...xhaust cap 100 5 6 9 8 15 2 22 1 X X Vertical exhaust cap 130 2 0 3 5 5 3 7 8 12 0 17 3 TABLE 8 6 EXHAUST COMPONENT RESISTANCES Pa When a conventional flue is to be used the maximum length of the flue...

Page 28: ...m wind effects and disperse the products of combustion to open external air The flue must terminate in a freely exposed position and be so situated as to prevent the products of combustion entering an...

Page 29: ...king progressively away from the boiler supporting the pipes as necessary FIGURE 8 3 HORIZONTAL TERMINAL INSTALLATION 8 7 3 TYPE C33 VERTICAL BALANCED FLUE When the heater is installed as a Type C33 a...

Page 30: ...g sec 23 2 30 6 38 8 46 2 57 0 69 0 Flue Gas Mass Rate G31 25 g sec 5 8 7 7 9 7 11 6 14 3 17 3 TABLE 8 11 FLUE GAS MASS RATES 8 7 5 TYPE C53 TWIN PIPE FLUE When installing the heater as a Type C53 ap...

Page 31: ...ommon flue is used precautions should be taken to ensure that all condensation formed in the flue system is not drained through one boiler It is recommended that a condensate drain point is installed...

Page 32: ...alculated by subtracting the difference volume from Table 9 4 from the actual supplied volume of inlet air If therefore a larger than required inlet volume is provided the extract flow rate will need...

Page 33: ...ONS There are two tee pieces supplied with the boiler these are for enlarging the flow return connections to the boiler and for installing a pressure relief valve not supplied and a drain valve not su...

Page 34: ...For further details on the connection of a water pressure switch please refer to Section 11 0 ELECTRICAL SUPPLY 10 3 1 EXPANSION VESSEL SIZING The following information is based on a static head of 3...

Page 35: ...2 0 3 0 4 0 5 0 6 0 7 0 8 0 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 Water flow m h Head meter WC Resistance Boiler Head Pump Head for Installation Resistance Boiler Head Pump Head for Installation Hydraulic...

Page 36: ...4 0 5 0 6 0 7 0 8 0 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 Water flow m h Head meter WC Resistance Boiler Head Pump Head for Installation Hydraulic graph 100kW T 20K T 25K 0 0 1 0 2 0 3 0 4 0 5 0...

Page 37: ...ead meter WC Water flow m h Hydraulic graph 150 kW resistance boiler head pump s2 head for installation s2 head pump s3 head for installation s3 T 20K T 25K 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 5 0 5 5...

Page 38: ...of magnetite the mineral can create flow restrictions in the heat exchanger which may result in premature failure When installing a CP M boiler the system must be fully flushed to remove all existing...

Page 39: ...VE 2 DRAIN VALVE 3 AIR SEPARATOR 4 DIRT SEPARATOR 5 AUTOMATIC AIR VENT 6 EXPANSION VESSEL 7 TEMPORARY FILL CONNECTION REMOVE AFTER FILLING 8 DOUBLE CHECK VALVE 9 LOW VELOCITY HEADER 10 NON RETURN VALV...

Page 40: ...VALVE 3 AIR SEPARATOR 4 DIRT SEPARATOR 5 AUTOMATIC AIR VENT 6 EXPANSION VESSEL 7 TEMPORARY FILL CONNECTION REMOVE AFTER FILLING 8 DOUBLE CHECK VALVE 9 LOW VELOCITY HEADER 10 NON RETURN VALVE 11 PRESS...

Page 41: ...te whilst acting as a lag boiler The sensor should be located on the system flow adjacent to the low velocity header No change in control parameters will be required when this sensor is connected 5 6...

Page 42: ...s calorifier sensor outside temperature sensor system pumps etc are to be connected to the Master boiler For a cascade to work correctly it is essential that a flow temperature sensor is used Each con...

Page 43: ...nection strip This will ensure that the appliance does not fire in an unsafe situation but maintains all of its protection features such as combustion post purge and pump over run 11 4 CASCADE CONTROL...

Page 44: ...7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 MAINS L MAINS N Lock Out NO Flame on NO Lock Out NO Flame on NO Pump 3 N Pump 3 L Gas Valve N Gas Valve L Pump 1 L Pump 1 N Pump 2 3 way L NO Pump 2 3 w...

Page 45: ...s and used for changing values MENU Buttons can be pushed to open menu hold for 1 second Connector for connecting computer cable ON OFF RESET ENTER Press and hold for 6 seconds to switch boiler on off...

Page 46: ...prevent customers making changes by accident the following happens when changes are made Step 1 The user presses ENTER to confirm the change made Step 2 The display asks the user to be sure to make t...

Page 47: ...g P5 BJ Actual status text descriptions Actual status B o i l e r o f f The boiler is turned off at the control interface N o d e m a n d No heat demand signal is received from the room thermostat or...

Page 48: ...by the outdoor sensor T 6 F l u e 1 2 3 9 o C Temperature measured by the flue gas sensor O p e n Shown when the controller does not detect this sensor S h o r t e d Shown when the sensor wires or th...

Page 49: ...osed Screen 11 CASCINF Description The CasInf screen shows thenumberof boilers connectedwith the Cascade The Master Leadboileris designated as 0 Slave Lagboilers will be designated1 2 3 4 5 6 7 8 9 A...

Page 50: ...le applies also to the service and Schornsteinfeger function of the boiler Operating screen H E A T I N G S T A N D B Y 1 2 3 4 o C 1 2 3 4 o C Press SERVICE and hold for 3 seconds The burner will sta...

Page 51: ...boiler will fire at maximum firing rate In this state the display shows F l u e s e r v i c e m o d e P o w e r M a x i m u m When the button is pressed momentarily again The boiler will return to the...

Page 52: ...e and Date S e t t i m e d a t e 0 8 3 3 3 0 0 3 2 0 1 0 T u e The day is now flashing selected and can be changed Use to change the value Use to select another value Confirmation screen A r e y o u s...

Page 53: ...value set in the screen when pressing enter will be shown for a few seconds After this the display returns to the normal operating screen By pressing the following screens can be selected Press MENU...

Page 54: ...T i m e r Press ENTER P r o g r a m C H M o n 1 0 6 0 0 2 3 0 0 Confirmation screen A r e y o u s u r e C a n c e l C o n f i r m Press to cancel the changes made unit will reset Three programmed time...

Page 55: ...m previous page Continued on next page Press to browse through the values that can be set on the bottom line The flashing value can be changed Press to confirm the changes The last alternation will be...

Page 56: ...confirm the changes The last alternation will be flashing for a few seconds and return to base menu Press to browse through the values that can be set on the bottom line The flashing value can be cha...

Page 57: ...e temperature C This sets the minimum outside temperature at which the maximum flow temperature that is set P5 AD Heat curve flow temperature at minimum C This sets the desired maximum flow temperatur...

Page 58: ...ps P5 AH minus P2 HA heating demands will resume P6 BA CH User Setting C The setpoint will never be higher than the flow temperature set in parameter P6BA The maximum temperature is limited even when...

Page 59: ...3 H C m i n F l T m p P5 AD 8 5 o C 0 4 H C m a x O u T m p P5 AE 2 0 o C 0 5 H C m a x F l T m p P5 AF 2 0 o C 0 6 H C m i n F l L i m P5 AG 2 0 o C 0 7 S u m S h D w n O u P5 AH 3 0 o C 0 8 H C m a...

Page 60: ...0 0 0 0 S s l 1 0 0 0 0 0 S s t 1 0 0 0 0 6 Bottom line Ssl Soft Starts last Sst Soft Starts Total Bottom line Burner on hours for DHW while the burner was firing at equal to or more than 50 Top line...

Page 61: ...cannot be erased after service this shows the fault history of the burner control since the start of operation R The elapsed time in hours between the fault occurring and it being reset Press ENTER Th...

Page 62: ...et the Counter for the total amount of burning hours Counter for the total amount of ignition cycles The text will flash once briefly after resetting Operating screen M a i n t e n M o d e flashing se...

Page 63: ...s or to confirm the Screen Message after total amount of ignition cycles M a i n t e n M o d e I g n i t i o n c y c l e s Press to set The total amount of ignition cycles for the Maintenance message...

Page 64: ...d e B u r n i n g h o u r s Press to set The total amount of burning hours for the Maintenance message Press to Return to maintenance mode selection The flashing value can be changed with Confirmation...

Page 65: ...G S T A N D B Y 1 2 3 4 o C 1 2 3 4 o C Press MENU Select Userlock using M a i n M e n u U s e r l o c k Press ENTER S e t U s e r l o c k 0 0 The 0 is now flashing selected and can be changed Use to...

Page 66: ...Pump Config 0 Pump 1 TWV D H i p m p t w v yes yes yes yes 2 P5CB Flow temperature Dhw tank low o C D H i f l o w L O yes yes yes yes 3 P5CK Flow temperature Dhw tank hi o C D H i f l o w H I yes yes...

Page 67: ...orded in order to determine the firing rate This parameter sets the Cascade CH offset value This is the value above the setpoint temperature that each boiler in the cascade boiler can reach before shu...

Page 68: ...l time control feature When enabled a closed contact across terminals 13 14 runs the boiler at daytime temperatures an open contact runs the boiler at night time temperatures A value of 0 disables thi...

Page 69: ...he temperature below the setpoint temperature which the vessel must reach before the firing sequence will restart This parameter is used when the DHW vessel is controlled by a temperature sensor If th...

Page 70: ...2 of the master boiler Once a pre determined output of the cascade is reached a contact in the burner control will close and an additional non cascaded boiler can be enabled This parameter sets whethe...

Page 71: ...of 1 sets the boiler as heating and indirect DHW a value of 2 sets the boiler as direct DHW A setting of 2 should not be used on the CP M boiler This parameter sets whether the measured temperatures...

Page 72: ...and begin by making the following checks 1 Flueway passages are clear 2 Adequate ventilation exists in the plant room if necessary 3 The system is fully charged with water ready to receive heat All n...

Page 73: ...gas inlet appliance isolating valve reset the unit by depressing the button on the control panel and place the boiler back in to service mode 7 The combustion fan will repeat the pre purge procedure...

Page 74: ...en completed depress the service button for 3 seconds to return the boiler to its normal operating mode 8 Record the combustion data and leave with the appliance for future reference NOTE The dust cap...

Page 75: ...COMMISSIONING PROCEDURE This process must be carried out in the order stated when the boiler is switched on for the first time Failure to follow the following procedure may lead to non warrantable dam...

Page 76: ...ssure as detailed in Table 15 2 10 Adjust screw 1 right hand gas valve only on CP M 120 CP M 150 CP M 180 to give a CO2 output as detailed in Table 15 3 Turning the screw clockwise will increase the C...

Page 77: ...erational characteristics 16 2 BURNER INSPECTION The heat exchanger has a sight glass for inspection of the flame picture NOTE If the appliance has been in recent operation this area may be hot Approp...

Page 78: ...ger complete with the combustion fan 8 With the burner assembly away from the boiler the burner can be gently cleaned with the brush attachment of a vacuum cleaner The reassembly procedure is the reve...

Page 79: ...and exposed to freezing temperatures Maintenance and service procedures may also require draining the boiler 16 5 1 DRAINING AN INDIVIDUAL BOILER 1 Turn off the boiler electrical disconnect switch 2...

Page 80: ...ect for obstructions or corrosion Replace with a new valve of the recommended size as necessary 16 7 2 FLUE SYSTEM Examine the exhaust and air intake system at least once a year Points of inspection a...

Page 81: ...E boiler type load G20 1 G31 1 CO2 O2 CO2 O2 CP M 60 120 2 max load 9 0 0 3 4 8 0 5 10 3 0 3 5 2 0 5 min load 8 7 0 3 5 3 0 5 9 3 0 3 6 7 0 5 CP M 150 2 max load 9 0 0 3 4 8 0 5 10 4 0 3 5 0 0 5 min l...

Page 82: ...ed in Table 15 2 10 Adjust screw 1 right hand gas valve only on CP M 120 CP M 150 CP M 180 to give a CO2 output as detailed in Table 15 3 Turning the screw clockwise will increase the CO2 level turnin...

Page 83: ...manually resetting the appliance corrective action may need to be taken to prevent further occurrences of the lock out situation When the boiler is in lockout the backlight of the display flashes on a...

Page 84: ...d Cause Corrective Action Cause Corrective Action Replace the return sensor Display message F l u e s e n s o r e r r o r F6 p u m p o n 9 9 9 5 h r s Reason Flue sensor is not detected Cause Correcti...

Page 85: ...ective Action Ensure all isolation valves in the gas supply line are completely open The nominal gas inlet pressure should be 20 mbar Check that the gas supply pipework has been correctly purged start...

Page 86: ...urner Check the condition of the ignition cable and replace if necessary Check the condition of the earth wire connection of the ignition electrode and replace if necessary Check for correct electrica...

Page 87: ...PCB Replace the PC interface cable Replace the display PCB Display message C l i x o n F a u l t F15 p u m p o n 9 9 9 5 h r s Reason Heat exchanger fuse exceeded maximum value Cause The heat exchange...

Page 88: ...e condensate drain system is blocked causing the condensate to build up above the measuring point of the pressure Pressure fluctuations in the building drainage system are affecting the heat exchanger...

Page 89: ...Action Cause There is no water in the unit while firing Corrective Action Cause Heat exchanger failure Corrective Action Display message A n t i c y c l e t i m e 9 9 9 5 h r s Reason Cause System wat...

Page 90: ...cessary Display message H e a t e x c h a n g a t r i s k 9 9 9 5 h r s Reason Cause Low water flow Corrective Action Check the pump for correct operation Check that all valves that may restrict the w...

Page 91: ...a flame was rectified Cause The circuit connected to the general blocking terminals is not closed Corrective Action Display message C a s c a d e B l o c k 9 9 9 5 h r s Reason Connection failure with...

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Lochinvar CP-M Series, Installation, Commissioning & Maintenance Instructions

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