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MHG Heating ProCon MCS 320, Installation And Operating Manual

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MHG Heating ProCon MCS 320 Installation And Operating Manual Download Page 4

© MHG Heating Ltd 

 

4 

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR 

Telephone 08456 448802 Fax 08456 448803 Email 

[email protected]

 Web www.mhgheating.co.uk 

020315 Draft 

ProCon MCS Configuration. (210-535) 

 

1 

Stainless Steel Double Heat Exchanger

 

2 

Manometer

 

3 

Pressure Switch Maximum

 

4 

Pump Differential Pressure Switch

 

5 

Return Pipework

 

6 

6bar Pressure Relief Valve.

 

7 

Pressure Switch Minimum

 

8 

High Head Pump

 

9 

Thermometer

 

10 

Flow Pipework

 

11 

Limit Thermostat

 

12 

Gas Pipework

 

13 

Condensate Discharge Pipework

 

14 

Low NOx Premix Burner

 

15 

Weather Proof Casing.

 

 

 

ProCon MCS Hidro Configuration. (580-2150) 

 

 

 

 

 

  

 

1 

Stainless Steel Double Heat Exchanger

 

2 

Pump Differential Pressure Switch

 

3 

High Head Pump

 

4 

6bar Pressure Relief Valve.

 

5 

Common Flow Pipework DN150 PN6

 

6 

Common Return Pipework  DN150 PN6

 

7 

Common Gas Pipework  DN65 PN16

 

8 

Common Condensate Discharge Pipework DN50

 

9 

Limit Thermostat

 

10 

Thermometer

 

11 

Manometer

 

12 

Pressure Switch Maximum

 

13 

Pressure Switch Minimum

 

14 

Low NOx Premix Burner

 

15 

Weather Proof Casing.

 

Summary of Contents for ProCon MCS 320

Page 1: ...etro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Installation and Operating Manual for the ProC...

Page 2: ...ring Guide Single Unit Option 3 Heating HWS 27 Hydraulic and Wiring Guide Single Unit Option 4 Heating Multi Zone HWS 28 Three Boiler Cascade Hidro Units Option 1 Heating Only 29 Three Boiler Cascade...

Page 3: ...ProCon MCS 850 Hidro ProCon MCS 940 Hidro ProCon MCS 1000 Hidro ProCon MCS 1250 Hidro ProCon MCS 1320 Hidro ProCon MCS 1380 Hidro ProCon MCS 1450 Hidro ProCon MCS 1600 Hidro ProCon MCS 1800 Hidro Pro...

Page 4: ...mum 8 High Head Pump 9 Thermometer 10 Flow Pipework 11 Limit Thermostat 12 Gas Pipework 13 Condensate Discharge Pipework 14 Low NOx Premix Burner 15 Weather Proof Casing ProCon MCS Hidro Configuration...

Page 5: ...S 5449 1990 Specification for forced circulation hot water central heating systems for domestic premises BS 6644 2011 Specification for gas fired hot water boilers of rated inputs between 70kW net and...

Page 6: ...ect of delivery and if no replacement parts of outside origin have been fitted Parts subject to wear such as ignition electrodes seals etc are strictly excluded from the guarantee In addition to the a...

Page 7: ...System Return MCS 260 G 2 1 2 Male 4 System Return MCS 320 G 2 1 2 Male 5 Gas Inlet 210 260 G 1 1 2 Male 6 Gas Inlet320 G 1 1 2 Male 7 3 Way Water Outlet Valve G 1 1 2 Male 8 Condensate Discharge 25 9...

Page 8: ...02 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft ProCon MCS Hidro Units ProCon MCS 320 Hidro 210 260 for use in Hidro Cascade units only ProCon MCS 400 and 535 Hid...

Page 9: ...som Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft ProCon MCS Hidro Layouts A 400kW an...

Page 10: ...5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Installation and Service Clearances ProCon MC 210 260 320 400 535 ProCon MCS Hidro All mo...

Page 11: ...itioning of the unit All packaging materials should be disposed of in an environmentally way Case Removal The MCS front case is removable and secured in place by four screw tight swizzle lugs The MCS...

Page 12: ...351 Residual Flue Pressure Pa 100 100 Carbon Dioxide Concentration 9 0 9 0 ProCon MCS 320 400 535 580 Hidro Nominal Heating Capacity kW 30 300 38 380 50 500 25 550 Nominal Thermal Power 80 60 C kW 29...

Page 13: ...550x1150x1552 1550x1150x1552 1550x1150x1552 Flue Gas Mass Flow Kg h 42 1 1062 33 7 1180 1 42 1 1264 3 50 6 1348 6 Residual Flue Pressure Pa 100 100 100 100 Carbon Dioxide Concentration 9 0 9 0 9 0 9 0...

Page 14: ...2 2325x1500x1552 2325x1500x1552 3100x1500x1552 Flue Gas Mass Flow Kg h 50 6 2191 5 64 1 2362 4 84 3 2528 7 33 7 2865 9 Residual Flue Pressure Pa 100 100 100 100 Carbon Dioxide Concentration 9 0 9 0 9...

Page 15: ...entre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Load Loss on Water Input Side Curve DT 20C ProCon MC...

Page 16: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft ProCon MC...

Page 17: ...4 the installer shall install as suitably sized Pressure Safety Relief Valve The location of this valve is important with respect to the applied pressure of the boiler circulation pump it is therefore...

Page 18: ...Modules Controller Data Appliance and Module Power Isolators Green Lockout Indicator Red Providing central control of power to each appliance pair of burners K3 Relay Safety interlock relay K11Relay...

Page 19: ...Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Module GFA Co...

Page 20: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Theta Cas...

Page 21: ...Heating Ltd 21 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 D...

Page 22: ...Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Theta Cascade...

Page 23: ...Heating Ltd 23 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 D...

Page 24: ...le TR2 Module Return Sensor Lower Module EVG1 Gas Valve Upper Module Module TRS Module Limit Thermostat Module EVG2 Gas Valve Lower Module Module TSF1 Module Flue Gas Thermostat Module F0 Main 16 Amp...

Page 25: ...Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Single Unit Option 1 H...

Page 26: ...owns Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Single Units Option 2 H...

Page 27: ...g Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Sin...

Page 28: ...Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Single U...

Page 29: ...Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Hidro Units Option 1 H...

Page 30: ...g Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Hid...

Page 31: ...Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Hydraulic Design Hidro Un...

Page 32: ...a dedicated housing and associated sensors The Theta Cascade Controller can proved direct control of Up to Four ProCon MCS One Direct Heating Zone With Optional Room Unit With or Without Direct on Bo...

Page 33: ...I 3 N X 23 System Heating Pump CMI 37 38 N ProCon MCS GFA Controller CSOL 11 N Solar Pump SE 26 23 X 31 Outside Air Sensor T3 27 23 X 15 1 Common Flow Sensor T4 28 23 X 15 1 HWS Sensor Volt Free Enabl...

Page 34: ...mm Flue Extension TBC 500mm Flue Extension TBC 87 Bend TBC 45 Bend TBC 30 Bend TBC DN200 PPS Flue Components Pa Resistances Exhaust Pipe Terminal TBC Air Pipe Terminal TBC 1955mm Flue Extension TBC 95...

Page 35: ...td Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Single Unit Flue Option...

Page 36: ...w Level 100mm Above Floor Level 25C As a guide reduction of air temperature may be achieved by increasing the inlet and outlet air supply by 0 15 m3 h or 0 2 cm2 kW of net heat input per 0C of tempera...

Page 37: ...Air System Type Operational Time Grille Location Heating or HWS Operation 50 time operation during summer months Heating or HWS Operation 50 75 time operation during summer months Heating or HWS Oper...

Page 38: ...al Free Area Heating or HWS Operation 50 75 time operation during summer months Biomass Solid Fuel Boiler Additional Free Area Heating or HWS Operation 75 time operation during summer months Biomass S...

Page 39: ...lve on the Mains Cold Water pipework Temporary Connecting Hose which must be disconnected after use Control Valve on the heating system For Category 4 systems the approved method of filling must compr...

Page 40: ...drain facility should be provided adjacent to the expansion vessel to aid the routine maintenance overhaul of the vessels Air Pressure setting For information on a comprehensive range of expansion ves...

Page 41: ...ing the boiler Additional device cleaning may be required during the first heating cycles The system water must have the following characteristics to ensure the long term operation security of all boi...

Page 42: ...ents and settings are undertaken via the Theta Cascade Manager The individual modules are not equipped with display panels The controller can provide the following levels of information and adjustment...

Page 43: ...rned off The ignition of the burner is impeded 21 Manual The combustion fan has broken and the Non Return valve has locked open The ignition of the burner is impeded 24 Automatic M anual Electric fan...

Page 44: ...Module Range Fuel Injector CO2 Max Output Fan Speed Max Output CO2 Min Output Fan Speed Min Output MCS 210 10 100kW Nat Gas G20 None 9 10 5600 8 90 1700 MCS 210 10 100kW Propane G31 None 8 70 5600 8...

Page 45: ...the system water has been cleansed and treated with a suitable inhibitor as detailed in Filling the System and System Water Quality Prior to applying power to the appliance its circulation pump 10 sh...

Page 46: ...commissioning mode is activated by pressing the MODE buttons simultaneously To leave the commissioning mode press the RESET button or the Button simultaneously It is advisable to check the combustion...

Page 47: ...en by inserting the analyser s probe in to plugged hole within the flue collector of the appliance or in the tapping in the flue immediately above the appliance if present The combustion setting requi...

Page 48: ...or signs of water leakage or ingress e Run the unit in Commissioning Mode HIGH FIRE with the use of a flue gas analyzer record the CO2 level f Run the unit in Commissioning Mode LOW FIRE with the use...

Page 49: ...owing the de scale works h If the heat exchanger has not suffered from dis colouration as Item g above then a Standard Service can be undertaken Using a natural bristled brush ONLY remove the worst of...

Page 50: ...g water joints to also change any adjacent joints at the same time p Inspect all gas joints with a suitable leak detection method Any joints found to be leaking MUST be replaced It is also advisable w...

Page 51: ...field Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Weather Compensation Slope System Flow Temperature Outside Air...

Page 52: ...sage will be displayed if the following process is not undertaken Prior to undertaking any work with a PCB please earth yourself by touching a secure earth connection within the boiler 1 Check the bui...

Page 53: ...g 1 bottom housing 2 New GFA PCB 3 Top Housing 7 Clip the new controller on to the DIN rail and reconnect the dedicated plug assemblies Special attention needs to be paid to the JUMPER location and th...

Page 54: ...eld Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Apply power to the new GFA module controller Set the Theta Contro...

Page 55: ...Heating Ltd 55 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 D...

Page 56: ...powering up of the appliance a series of internal checks are undertaken This can take a number of minutes If the unit fails to operate and displays an error code please make a note of the code prior...

Page 57: ...m Description MI Boiler Flow GAS Gas Inlet SC Condensate Outlet RI System Return 1 Combustion Fan 2 Air Gas Mixing Venturi 3 Heat Exchanger 4 Premix Burner 5 Flow Sensor NTC 1 6 Return Sensor NTC 2 7...

Page 58: ...ing Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Operational Diagra...

Page 59: ...ng Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Operational Diagram...

Page 60: ...ing Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Operational Diagra...

Page 61: ...de Air Sensor Flow Sensors T C R k 20 1 383 18 1 408 16 1 434 14 1 459 12 1 485 10 1 511 8 1 537 6 1 563 4 1 590 2 1 671 0 1 644 2 1 671 4 1 699 6 1 727 8 1 755 10 1 783 12 1 812 14 1 840 16 1 869 18...

Page 62: ...HG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded Sp...

Page 63: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded S...

Page 64: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded S...

Page 65: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded S...

Page 66: ...Heating Ltd 66 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 D...

Page 67: ...MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded S...

Page 68: ...om Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded Spares Diagram Control Pane...

Page 69: ...Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draft Exploded Spares Diagram Hidro 260...

Page 70: ...ting Ltd 70 MHG Heating Ltd Unit 4 Epsom Downs Metro Centre Waterfield Tadworth Surrey KT20 5LR Telephone 08456 448802 Fax 08456 448803 Email info mhgheating co uk Web www mhgheating co uk 020315 Draf...

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