Lochinvar Mini Copper-Fin MCB136CE Installation, Commissioning And Maintenance Instructions Download Page 9

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4.0

GENERAL REQUIREMENTS

The Lochinvar Mini Copper-Fin has been designed to operate trouble free for many years. These instructions

should be followed closely to obtain the maximum usage and efficiency of the equipment. PLEASE read the

instructions fully before installing or using the appliance.

4.1

RELATED DOCUMENTS

It is law that all gas appliances are installed by competent persons, in accordance with The Gas Safety

(Installation and Use) Regulations 1998. Failure to install appliances correctly could lead to prosecution. It is in

your own interest, and that of safety, to ensure that this law is complied with.

The installation of the equipment MUST be in accordance with the relevant requirements of the Gas Safety

Regulations, Building Regulations, I.E.E. Regulations and the bylaws of the local water undertaking. The

installation should also be in accordance with any relevant requirements of the local gas distributor and local

authority.

In addition the installation should follow the relevant guidance offered in the following documents. It is not

practical to list all relevant information but emphasis is placed on the following documents, as failure to comply

with the guidance given will almost certainly result in an unsatisfactory installation:

BS EN 1858: 2003

Chimneys. Components. Concrete flue blocks

BS 5440-1: 2008

Installation and maintenance of flues and ventilation for gas appliances of rated input

not exceeding 70kW net (1st, 2nd and 3rd family gases)

Part 1: Specification for installation and maintenance of flues

BS 5440-2: 2009

Installation and maintenance of flues and ventilation for gas appliances of rated input

not exceeding 70kW net (1st, 2nd and 3rd family gases)

Part 2: Specification for installation and maintenance of ventilation for gas

appliances

BS 6644: 2005

Specification for Installation of gas fired hot water boilers of rated inputs between

70kW

+ A1: 2008

(net) and 1.8MW (net) (2

and 3

family gasses)

BS 6700: 1997

Design, installation, testing and maintenance of services supplying water for

domestic use within buildings and their curtilages

BS 6880: 1988

Code of practice for low temperature hot water systems of output greater than 45kW

Parts 1, 2 and 3

BS 7074: 1989

Application, selection and installation of expansion vessels and ancillary equipment

Parts 1and 2

for sealed systems

BS 7671: 2008

Requirements for electrical installations, I.E.E. wiring regulations seventeenth edition

CP 342:

Code of practice for centralised hot water supply-buildings other than dwellings

Part 2 1974

IGE/UP/1:

Installation pipework on industrial and commercial premises

Edition 2

IGE/UP/2:

Gas installation pipework, boosters and compressors on industrial and commercial

Edition 2

premises

Summary of Contents for Mini Copper-Fin MCB136CE

Page 1: ... and Boilers Installation Commissioning and Maintenance Instructions Models MCW91CE MCW136CE MCW181CE MCW226CE MCW271CE MCW316CE MCW361CE MCW401CE MCW501CE MCB91CE MCB136CE MCB181CE MCB226CE MCB271CE MCB316CE MCB361CE MCB401CE MCB501CE INS0023 Issue No 6 August 2011 ...

Page 2: ...VES 16 10 1 6 EXPANSION VESSEL SIZING 17 10 1 7 DE STRATIFICATION 17 10 1 8 CIRCULATING PUMPS 17 10 1 9 PIPEWORK SIZE 18 10 2 HEATING BOILERS 19 10 2 1 GENERAL 19 10 2 2 OPEN VENTED SYSTEM ARRANGEMENT 19 10 2 3 SEALED SYSTEM ARRANGEMENT 19 10 2 4 DRAIN VALVES 19 10 2 5 EXPANSION VESSEL SIZING 20 10 2 6 PRIMARY CIRCULATING PUMPS 20 10 3 POOL HEATING 21 10 4 FLOW SWITCH 21 11 0 ELECTRICAL SUPPLY 21 ...

Page 3: ...R SYSTEM 29 14 4 WATER HEATER SERVICING 29 14 4 1 REMOVING SCALE AND SEDIMENT FROM THE STORAGE VESSEL 29 14 4 2 SACRIFICIAL MAGNESIUM ANODES 29 14 5 CLEANING THE HEAT EXCHANGER 30 14 6 REFILLING THE SYSTEM 31 14 7 OTHER CHECKS 32 14 7 1 RELIEF VALVES 32 14 7 2 FLUE SYSTEM 32 14 8 TTB DEVICE 32 14 9 FAULT FINDING 32 15 0 USER INSTRUCTIONS 33 ...

Page 4: ...her than that for which it has been designed and adjusted This equipment must be installed by a competent person registered with a H S E approved body All installations must conform to the relevant Gas Safety and Building Regulations Health Safety requirements must also be taken into account when installing any equipment Failure to comply with the above may lead to prosecution If the equipment is ...

Page 5: ...5 2 0 PRINCIPAL PARTS FIGURE 2 1 EXPLODED DIAGRAM FIGURE 2 2 EXPLODED DIAGRAM CONTROL PANEL ASSEMBLY ...

Page 6: ...d 16 On off switch 4 Main burner injector 17 Heat exchanger 5 Gas inlet flange 18 V baffle 6 Manifold flange 19 Temperature gauge 7 Gas valve 20 Pressure temperature relief valve 8 Gas valve 21 Bulbwell pocket 9 Sequence control 22 Right side fibre board 10 Relay 23 Left side fibre board 11 Time delay relay 24 Front fibre board 12 High limit thermostat 25 Rear fibre board 13 Overheat thermostat TA...

Page 7: ... water heaters C 90 90 90 90 90 90 90 90 90 Maximum water temperature boilers C 105 105 105 105 105 105 105 105 105 GAS DATA G20 Gas inlet connection BSP 1 Gas Flow Rate m3 hr 2 51 3 77 5 03 6 27 7 53 8 79 10 05 11 16 13 91 Burner Pressure mbar 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 Minimum Gas Inlet Pressure mbar 17 5 17 5 17 5 17 5 17 5 17 5 17 5 17 5 17 5 Maximum Gas Inlet Pressure mbar 25 25 25 2...

Page 8: ...6 546 546 546 559 559 D Centreline of flue 197 248 298 337 375 413 451 565 667 E Flue diameter 126 152 178 178 203 203 228 254 254 F Height of gas inlet 171 171 171 171 171 171 171 171 321 G Centreline of gas inlet 475 475 475 475 475 475 475 475 493 H Service clearance above 355 355 355 737 737 737 737 737 737 TABLE 3 1 DIMENSIONS GAS CONNECTION TO CENTRE OF GAS INLET INLET OUTLET RECOMMENDED CLE...

Page 9: ...ation BS EN 1858 2003 Chimneys Components Concrete flue blocks BS 5440 1 2008 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Part 1 Specification for installation and maintenance of flues BS 5440 2 2009 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70...

Page 10: ...propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride waxes and process chemicals are corrosive Products of this sort should not be stored near the water heater or outside by the air intake if applicable The fitting of this equipment in a situation where aerosols or other chemicals may be entrained into the combustion air w...

Page 11: ... information on LPG pipework installation guidance 7 4 BOOSTED SUPPLIES Where it is necessary to employ a gas pressure booster the controls must include a low pressure cut off switch at the booster inlet The local gas distributor must be consulted before a gas pressure booster is fitted For details of how to connect a low pressure cut off switch please refer to Section 11 ELECTRICAL SUPPLY 7 5 PLA...

Page 12: ...al efficiency of the equipment the flue gas temperature is approximately 130 C 160 C Condensation in the flue is thus more likely to occur than with lower efficiency equipment It is strongly recommended that twin wall or insulated flue pipe is used on all installations Care should be taken to ensure that the flue is installed such that any condensation is continuously drained All flues should have...

Page 13: ...ght flue system is a Flue dilution system which is suitable for connection to the Mini Copper Fin s but must be properly designed by a specialist flue company 8 6 BALANCED COMPARTMENTS The equipment is suitable for siting within a balanced compartment This compartment must be designed by a specialist company 9 0 AIR SUPPLY The following information is based on single appliance installations only I...

Page 14: ...t volume is provided the extract flow rate will need to be increased accordingly If the ventilation discharge from the plant room is through the means of simple openings relying on thermal effects the minimum free areas of the openings and any associated grilles should be as specified for natural ventilation see separate Free Area Requirements Combustion specification sheet The ventilation opening...

Page 15: ...6 54 m3 h Extract air minimum value 266 28 m3 h 213 98 m3 h 52 30 m3 h Worked Example Mechanical inlet mechanical discharge alternate combustion air flow rate Lochinvar MC361CE Heat input net 95 1 kW Minimum combustion air flow rate 95 1 x 2 8 m3 h 266 28 m3 h Actual combustion air flow rate 95 1 x 3 15 m3 h 299 57 m3 h Difference between inlet and extract air maximum value 95 1 x 2 07 0 18 m3 h 2...

Page 16: ...rage vessel 4 Tapping sizes for connection to the water system are detailed in Table 3 1 5 Ideally individual valves should be fitted to each unit to enable isolation from the system The arrangement must comply with the requirements of BS6644 6 Every system should be provided with a water gauge complete with isolating valve so that the pressure of the system may be displayed for commissioning and ...

Page 17: ...nvar Limited for details 10 1 8 CIRCULATING PUMPS In order to ensure the correct flow rates through the water heater the unit requires a bronze glanded pump sized to overcome the resistance of the heat exchanger and a primary pipework loop The primary loop should be no longer than 14 metres plus the following fittings 6 x 90 Elbows 2 x Unions 2 x Full bore lever ball valves 2 x Tee fittings cold f...

Page 18: ...witch the burner on and allow the temperature to stabilise Record the difference between the inlet and outlet temperature The difference will be the temperature rise 5 Compare the temperature rise with the required figure shown in Table 10 2 A If the temperature rise is too high water velocity is too low Check the following 1 No restrictions in the outlet of the heater 2 All valves are open betwee...

Page 19: ...ystem including the unit 4 Tapping sizes for connection to the heating system are detailed in Table 3 1 5 Ideally individual valves should be fitted to each unit to enable isolation from the system The arrangement must comply with the requirements of BS6644 6 Every system should be provided with a water gauge complete with isolating valve so that the pressure of the system may be displayed for com...

Page 20: ...in accordance with that stated in Table 10 4 The pump should be sited to facilitate servicing It is important that the existing pump size is checked when the boiler is being used for a refurbishment project to ensure that the minimum flow rate can be achieved Model Differential K Flow l s Total System Pressure Loss Metre H20 MCB91CE 20 0 12 0 06 MCB136CE 20 0 20 0 06 MCB181CE 20 0 24 0 06 MCB226CE...

Page 21: ...t is detrimental to the heater to be fired without adequate water flow as localised over heating will occur In order to overcome this problem the units are supplied complete with a flow switch to ensure that the heater will not fire unless the pump is operational It should be noted that the flow switch is not an accurate flow measuring device and only proves that the pump is operational 11 0 ELECT...

Page 22: ...remote stop start circuit across terminals R and W Any safety interlocks should be wired in series with the integral flow switch across terminals X and B Power is supplied from the equipment for these functions and will be the same as the equipment s power supply Volt free terminals for a fault alarm condition are marked VFA Additionally the equipment puts a 230 volt signal on to the brown wire in...

Page 23: ... BK W OR BK W OR R BR R W G OR R R BR BL Y GR Y GR Y GR BR BR BL BL BR BR BL BL BL R R OR OR BR BL I O NO C 8 7 2 6 3 5 4 1 2 3 4 5 6 7 8 10 9 11 12 1 TERMINAL STRIP 2 ROCKER SWITCH TTB DEVICE 6 FLAME FAILURE RESET 7 8 IGNITION SEQUENCE CONTROLLER 12 FAULT RELAY TIME DELAY 11 RUN RELAY 9 PILOT ASSY GAS VALVE 10 OVERHEAT LIMIT RESET 3 OPERATING THERMOSTAT 5 4 LIMIT THERMOSTAT ...

Page 24: ...BR W BR BL BR BR BL BL BL R R OR OR I O NO C R2 W2 R BK Y GR BL Y GR BL BK R BK R BK R BK BK BL BK 11 BL 4 6 3 1 2 5 1 8 7 2 6 3 5 4 12 5 4 3 2 1 7 6 8 9 10 LIMIT THERMOSTAT 4 5 OPERATING THERMOSTAT 3 OVERHEAT LIMIT RESET 10 GAS VALVES PILOT ASSY 9 RUN RELAY 11 FAULT RELAY TIME DELAY 12 IGNITION SEQUENCE CONTROLLER 8 7 FLAME FAILURE RESET 6 TTB DEVICE ROCKER SWITCH 2 TERMINAL STRIP 1 10 BR ...

Page 25: ...oom 3 The system is fully charged with water ready to receive heat All necessary valves are open and the secondary pump if fitted is circulating water 4 The gas supply pipework is clear of any loose matter tested for soundness and purged 5 Any condensate drain fitted to the flue system is installed correctly and the condensate trap is filled with water NOTE If a condensate trap is not filled befor...

Page 26: ...ly 10 minutes switch off the equipment 2 Open the pressure test point on the inlet side of the gas valve attach a manometer and check the standing gas inlet pressure 3 Relight the appliance and check the operating gas inlet pressure NOTE The equipment has been designed to conform to the requirements of the Gas Appliance Safety Regulations 1992 For Natural Gas the gas pressure governor control syst...

Page 27: ...ve the desired water temperature 3 Adjust the limit thermostat to 10 C above the operating thermostat setting 4 Re fit the control cover 12 7 INSTALLATION NOISE If care has been taken to follow the manufacturer s instructions there should be no discernible noise from the equipment The allied pump motor may have a level of sound that could lead to consideration for acoustic insulation but care must...

Page 28: ...ocedure on LPG is similar to that when the heater is firing on Natural Gas Please refer to Section 12 0 COMMISSIONING AND TESTING 14 0 MAINTENANCE 14 1 GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS AND FLAMMABLE VAPOURS AND LIQUIDS A competent person should check and ensure that the flue system ventilation to the plant room safety valve drain pressure gauge etc are in a ser...

Page 29: ... 14 3 DRAINING THE WATER SYSTEM The appliance must be drained if it is to be shut down and exposed to freezing temperatures Maintenance and service procedures may also require draining the appliance 1 Turn off the electrical disconnect switch 2 Connect a hose to the drain valve 3 Locate hose s discharge in an area where hot water will not cause any damage or injury 4 Close the cold water inlet val...

Page 30: ...es securing the ionisation and spark cables coloured white and orange respectively taking care not to damage the insulation of any secured wires Disconnect the ionisation and spark cables from ignition module pins 13 and 16 and pull cables through to the pilot assembly taking care not to strip any insulation on bare metal parts 8 Remove the self tapping screws from the insulation panel with slight...

Page 31: ...f tapping screws To reassemble the heater sections 1 13 of the above procedure should be carried out in reverse To access the ignition module terminal strip and fault relay PCB the self tapping screws must be undone on the large Left hand cover at the header end To access the thermostat dials and reset buttons the thumb screw under the smaller right hand cover at header end should be aligned with ...

Page 32: ...efore allowing the equipment to operate again This device shall not be put out of operation due to the seriousness of untimely interference If required this device should only be replaced with a genuine Lochinvar part 14 9 FAULT FINDING MINI COPPER FIN SERIES FAULT FINDING GUIDE Situation Corrective Action No Power Check circuit breaker Fuses Equipment will not start ignition sequence Check that t...

Page 33: ...ing and operating instructions A practical demonstration should be given describing each functional step Incorrect use may result in injury and will also invalidate the warranty The installers guide should be handed over and kept in a safe place for easy reference It is strongly recommended that the users read and understand the separate User Instructions ...

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