Potterton EC Plus 120 Installation Manual Download

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Publication Number: M/EUROCOND/0303 R

All descriptions and illustrations contained in this leaflet have been carefully prepared but we reserve the right to make changes and
improvements in our products which may affect the accuracy of the information contained in this leaflet.

Registered Office: Pentagon House, Sir Frank Whittle Road, Derby DE21 4XA - Registered in England No. 3879156

For further details on Potterton Commercial boiler products contact the following:

COMMERCIAL SALES &:

Potterton Commercial Product Division

TECHNICAL ENQUIRIES

Brooks House, Coventry Road, WARWICK, CV34 4LL
Tel: (08706) 050607

Fax: (08706) 001516

Sales Direct Line:

Tel: 08706 001991

Technical Direct Line:

Tel: 08706 002322

e-mail:

[email protected]

Web Site:

www.pottertoncommercial.co.uk

COMMERCIAL SERVICE

Our service organisation covers the whole U.K. to look after your needs

OFFICES

for all Potterton Commercial Products. We are also able to offer our
services for other manufacturers products. Service Hotline 08702 412759

Our service office offer a wide range of specialised services including:

●

Boiler Site Assembly

●

Burner Commissioning for all Fuels

●

Boiler Maintenance & Maintenance Contracts

●

Breakdown & Repair Services

●

Boiler Dismantling & Re-Jointing

●

Burner & Boiler Replacement

●

Oil/Gas Conversions

●

System Conditioning

●

Water Treatment & Descaling

●

Packaged Units

SPARES

Potterton Commercial spares are available nationwide through the
Potterton Interpart network. Alternatively please contact:

interpart, Brooks House,
Coventry Road, WARWICK, Warwickshire CV 34 4LL
Tel: 08706 000454

Fax: 08706 000545

Summary of Contents for EC Plus 120

Page 1: ...ordance with Potterton commercial quality assurance plan registered to meet the requirements of BSN ISO 9002 A condition of the supply of the appliance for compliance with this is the return of the appliance commisioning report The work must be carried out by a qualified Electrician Gas connection as well as commissioning servicing and maintenance must be carried out by an approved Gas Installer C...

Page 2: ...s on adjustment table for heating engineers 39 to 43 General control strategies 44 and 45 Heating circuit module and room control 46 and 47 Technical data 48 Diagnostic flow chart 49 Fault massages 50 Overview on figures and tables Fig page 1 Dimensions and Connections 0 2 Control panel 0 3 Gas valves 0 4 Electrodes 0 5 Boiler views 0 6 Programm sequence 0 7 Wiring diagram 0 8 Heating curves 0 9 S...

Page 3: ...y utilisation condensing boilers should be operated at a low return temperature However the Eurocondense Plus will also work at designed temperatures of 70 50 C in the condensing mode as the return temperature is under the dew point dew point is 53 C at 8 5 CO2 Condensing boiler Series Eurocondense Plus are designed as hot water heating systems They correspond to EN 676 EN 677 and Category I2H or ...

Page 4: ...0 1989 Part 2 Specifications for Installation of Ventilation for Gas Appliances BS 6644 1991 Installation of Gas Fired Hot Water Boilers for Inputs Between 60 kW and 2 MW BS 7074 1989 Part 2 Application Selection Installation of Expansion Vessels Ancillary Equipment for Sealed Water Systems BS 6880 1988 Codes of Practice for Low Temperature Hot Water Systems EN 677 1997 Gas fired Central Heating B...

Page 5: ... 1065 795 382 328 290 821 466 647 190 EC Plus 160 1150 52 714 535 182 91 809 182 1390 1165 893 472 354 395 140 404 757 210 EC Plus 200 1150 52 714 535 182 91 919 127 1390 1165 893 472 354 340 140 404 867 210 EC Plus 250 1250 52 714 535 182 97 1029 122 1390 1165 893 472 354 335 305 404 977 170 Clearances Special consideration must be given to the exhaust gas flue when selecting the position of the ...

Page 6: ... 16 Guidance Notes on the Installation of Gas Pipework Boosters and Compressors in Customers Premises published by British Gas Plc The gas booster should be electrically interlocked to the burner The boiler is adjusted by the factory to a maximum nominal heat load and for use with natural gas G20 or with LPG G31 See boiler data badge for details The supply pressure of natural gas must be between t...

Page 7: ...oilers Third Edition of the 1956 Clean Air Act Memorandum In addition to the above requirements of the Building Regulations should be strictly observed Care should be exercised with tall flue systems to ensure that excess buoyancy is not created If this is unavoidable draught stabilisers should be considered plus a time delay device to prevent the boiler short cycling otherwise frequent nuisance l...

Page 8: ...onditions Where gas boosters are required attention is drawn to the Gas Act 1986 Schedule 5 Part II paragraph 8 4 Guidance is given in IM 16 Guidance Notes on the Installation of Gas Pipework Boosters and Compressors in Customers Premises published by British Gas Plc The gas booster should be electrically interlocked to the burner The boiler is adjusted by the factory to a maximum nominal heat loa...

Page 9: ...ler fixed in the strain relief clamps The electrical permitted load for each pump output is IN max 1 A Fuses in the control unit F1 T 6 3 H 250 mains The wiring diagram must be followed Optional extras must be fitted and connected according to the instructions provided and the wiring diagram Connect to the mains Check earth continuity and resistance to earth The outside temperature sensor is locat...

Page 10: ... illuminates when the burner is in operation Note If an outdoor temperature sensor is not connected the Eurocondense Plus is heated up to a boiler temperature of approx 55 C l If the burner does not start up the red fault indicator LED 8 and display 13 flash with the error code see Table 13 The Eurocondense Plus can be reset with the Reset button 7 and the burner is then ready for a new start atte...

Page 11: ...e Check the adjustment of the CO2 values at full load and minimum load Activate the controller stop mode on the boiler module 1 See Fig 2 for designation of controls Hold the Chimney sweep button 12 down for more than 6 sec until the display Fault 8 flashes in red at intervals 2 x short and pause The current relative burner load then appears on the display 0 min 100 max whereby the number 100 is o...

Page 12: ...eck the full load if the gas valve has been readjusted check the minimum load again It is not possible to activate and adjust the Controller stop mode on the RRG However the display can be called up at the RRG Info level To complete the CO2 adjustment deactivate the Controller stop mode by pressing the Chimney sweep button 12 1 sec and then releasing P 3 sec 1 sec P kurz antippen press momentarily...

Page 13: ...ure Natural gas G20 15 0 mbar 6 0 8 0 5 5 7 5 9 5 11 0 9 0 10 5 13 0 14 5 Propan mbar 8 5 10 5 8 0 9 5 14 0 19 0 12 0 17 0 16 0 17 0 Values in parenthesis Wobbe index WoN in kWh m3 At pressure at end of boiler 0 mbar 1013 hPa 15 C the CO2 content should be between 8 0 and 8 5 for natural gas between 9 5 and 10 0 for LPG EC PLUS 90 120 between 9 0 and 9 5 for LPG EC PLUS 160 200 250 Table 3 Guide v...

Page 14: ...e this function set param 618 to 4 or 5 see table 7 for details For a proper use of this input disconnect all external controls from the boiler e g room control RRG and set the heating curves to 1 parameters 532 and 533 see tab 7 Note If any other relay module e g CIST CIR CITF is installed the CISP must be taken out It is essential to clean the boiler heat exchanger and burner once a year by an a...

Page 15: ...minal heat load and exhaust gas values To ensure proper function of the ignition and ionization ensure that installation length and spacings are observed as shown in Fig 4 The ionization current should have the following values for burner operation at min output 5 µA DC switching threshold at 0 7 µA DC at max output 10 µA DC The current ionization current can be checked as follows directly in µA o...

Page 16: ...emperatur begrenzer Vorlauffühler hintenliegend am Wärmetauscher Fig 5 Boiler views Eurocondense Plus Control LMU Mixing chamber Gas valve Fan Flow temperature sensor on the back side of the heat exchanger Sight glass Ignition electrode 1 Ignition electrode 2 Ignition transformer 1 Ignition transformer 2 Ionisation electrode Temperature stat Siphon Return temperature sensor Pressure switch Drain c...

Page 17: ...Z 7494f01D 1000 NoG_Null BV Zündung LP 4 NoG_Max N_VL N_TL N_Vor N_ZL N_TL_Delta N_ZL_Delta N_ZL_Delta N_Vor_Delta N_VL_Delta abhängig von Parametrierung abhängig von Parametrierung abhängig von Parametrierung abhängig von Parametrierung abhängig von Parametrierung abhängig von Parametrierung LP 3 LP 2 Z Z Z Z Z Z Z Z Z Z Z Z Z Z PH_ THL2 Fig 6 BMU control centre program sequence Type LMU64 002 A1...

Page 18: ...terval time mode THL2 0 2 51 0 Fault position 2nd fan startup time tn 0 51 0 Continuation Subsequent ventilation Code A 4 Operating state Function description 0 Standby no heat requirement Burner on standby 1 Start disable 2 Fan startup Self test for burner start and fan startup 3 Pre purging time Pre purging fan deceleration time to starting load speed 4 Waiting time 5 Ignition phase Ignition and...

Page 19: ...oom control RRG 1 B6 Flow sensor QAD 21 B9 Outdoor temperature sensor QAC 34 M1 Primary loop pump M3 Tank charging pump M6 Secondary loop pump constant temperature heating circuit N Control unit LMU N3 Heating module HKM N6 Temperature relay module CITF for B6 and M6 optional extra 1 alternatively RRG or HKM and EMS Example 1b 1 constant temperature heating circuit with room control RRG or with he...

Page 20: ...ing Hydr System 50 circuit VTC with room control RRG and or with heating module HKM and timer EMS including DHW tank temperature control with primary loop header and secondary loop pump M5 Alternatively VTC with zone controller ZR EC 1 2 M2 M B5 Y1 HK 2 B1 Gemischtes Heizsystem M3 T M1 B9 HK 1 PHK MHK NETZ 230V AC B3 N N3 N4 N7 M5 Hydraulische Weiche oder Wärmetauscher Sonderzubehör bauseits M2 M ...

Page 21: ...ump circuit with heat exchanger e g air heater with zone control ZR EC 1 2 Legende B1 Flow sensor QAD36 B3 Tank sensor QAZ 36 B5 Room control RRG B9 Outdoor temperature sensor QAC 34 M1 Pumpe 1st constant temp heating circuit M2 Pumpe 2nd constant temp heating circuit M3 Tank charging pump N Control Unit LMU N3 Heating module HKM N4 Mixer module CIM optional extra Example 3 2 constant temperature ...

Page 22: ...230V AC N N4 Anwendungsbeispiel 5b 1 variable temperature heating circuit VTC with CIM and room control RRG Hydr System 50 including DHW tank temperature control with primary loop header and secondary loop pump M5 Alternatively VTC with zone controller ZR EC 1 2 Hydraulische Weiche oder Wärmetauscher Sonderzubehör bauseits M2 M B5 Y1 HK 2 MHK B1 M3 T B9 B3 M5 NETZ 230V AC N N4 Legende B1 Flow sens...

Page 23: ...h ZR EC 1 2 up to 15 circuits possible Alternatively Both VTCs with zone controller ZR EC 2 Legende B1 Flow sensor QAD36 B3 Tank sensor QAZ 36 B5 Room control RRG B9 Outdoor temperature sensor QAC 34 M1 Pump constant temp heating circuit M2 Pump variable temp heating circuit M3 Tank charging pump N Control unit LMU N3 Heating module HKM N4 Mixer module CIM 1 N7 Zone control ZR EC 1 2 Y1 3 way valv...

Page 24: ...de B3 Tank sensor QAZ 36 B6 Flow sensor QAD 36 B9 Outdoor temperature sensor QAC 34 K2 Extension module HTS 2 M1 Primary loop pump M3 Tank charging pump M6 Pump CTC 1 M7 Pump CTC 2 M8 Pump CTC 3 N Control unit LMU N3 Heating module HKM with EMS timmer N5 1 Room thermostat heating circuit 1 N5 2 Room thermostat heating circuit 2 N5 3 Room thermostat heating circuit 3 N6 Temperature relay module CIT...

Page 25: ... alternatively CIM or ZR EC 2 with CIB Legend ZR EC B1 Flow sensor QAD 21 B5 Room control QAA 70 K1 Bus module CIB M2 Pump variable temp heating circuit N7 Zone control ZR EC ZR MSR or EC M 1 Y1 3 way valve optional extra Example 9b 1 VTC with CIM and room control RRG and or heating module HKM and time EMS Hydr System 66 including DHW tank temperature control with primary loop 1 additional mixer c...

Page 26: ...low sensor QAD 21 B70 Return sensor QAD 21 K1 Bus module CIB Example 11 Boiler cascade with 2 EUROCONDENSE PLUS and BCA 2 1 CTC and 1 VTC Hydr System 80 up to 15 circuits possible including DHW tank temperature control via BCA 2 M Boiler pump exit M1 of individual boiler M1 Pump CTC of the BCA or primary loop pump 1 M2 Pump VTC M3 Tank charging pump N Control unit LMU N7 EC M EC ZR 1 2 EC MSR for ...

Page 27: ...iler pump exit M1 of individual boiler M1 Pump CTC to BCA 2 M2 Pump VTC to BCA 2 M3 Tank charging pump to BCA 2 N Control unit LMU N2 EUROCONTROL KK N7 EC M EC ZR 1 2 EC MSR for mixer circuits N8 EC BCA 2 Y1 3 way valve 1 M1 or M5 before or behind the tank see param 99 of BCA 2 for details Mains 230V AC to other circuits with EC M SGB 2 ZR EC 1 2 EC MSR or EC M Note In applications without primary...

Page 28: ... controlled by RRG 10 CTC controlled by HKM EMS VTC controlled by RRG 615 KonfigAusgang 2 0 6b c primary loop pump only 558 0 KonfigRg4 0 OFF 1 ON 6b c primary loop pump only Example 7 1 552 HydrSys 2 2 555 2 KonfigRg1 1 ON 0 OFF Set room thermostat function 618 KonfigEingangR 0 6 Set input to flow sensor 619 KonfigAusgang1R 2 8 Set output to secondary loop pump Connect pump M1 to exit M1 Connect ...

Page 29: ...5 90 915 20 1224 40 5330 95 786 25 1000 45 4372 100 677 30 823 50 3605 L N H1 Fault indicator red H2 Burner operating indicator green H3 Operation state indicator H4 Temperature display H5 P display K3 Fault connector volt free K5 0 10V relay module Status displays Legend B2 1 Boiler flow sensor QAK 36 670 B2 2 Boiler return sensor QAL 36 B3 Tank sensor 1 QAZ 36 B4 Tank sensor 2 QAZ 36 B5 Room con...

Page 30: ...hout HKM 10 30 20 75 C 20 55 C l j P 2 Setting for hot water temperature without HKM 10 65 C 45 C l j P 3 Function not used l j P 5 Steepness of heating curve 1 40 25 Value l j P 6 Parallel offset for heating curve 31 K 31 K Value l j Note Other parameters displayed are not used 1 Display j Flashing l Illuminated m Not illuminated Parameters in the group A can be selected by momentarily pressing t...

Page 31: ...g the Display mode button 10 Approx 2 sec after selecting the parameter the current value is displayed It is only possible to change parameters P0 through P6 For this purpose wait until the value for the parameter flashes on the display 13 Basic procedure To increase value Press Display mode button 10 a number of times 3 sec To decrease value Press Chimney sweep button 12 a number of times 3 sec S...

Page 32: ... winter switchover temperature 20 C 517 dTbreMinP Max control difference for termination when 30 K minimum pause time is exceeded 519 TiAussenNorm Standard outdoor temperature 20 C not activated 520 dTrAbsenk X Reduction of room temperature setting when 10 K timer is connected HKM EMS 521 dTkTrNenn Flow return temperature spread at standard outdoor temperature 20 K not activated 523 SdHzEin Switch...

Page 33: ...MU 0 607 TbwBereit Reduced setting for hot water 40 C 614 KonfigEingang Programmable input F2 0 0 Standard 1 Modem function 2 Modem function neg logic 3 Door veil 615 KonfigAusgang Programmable output M5 2 0 Standard 1 Signal output 2 Alarm output 3 Operating signal 4 External transformer transformer T2 5 M5 Q2Y2 6 DHW circulation pump 7 Door veil 8 Primary loop pump 9 RegC1 10 Basic function K2 1...

Page 34: ...7 StrDia_akt Current value of internal SW diagnostic code b0 Display 4 718 BetrStd Burner operating time Display h 719 BetrStdHz Heating mode operating time Display h 720 BetrStdBw Hot water mode operating time Display h 721 BetrStdZone Zone operating time Display h 722 InbetrSetz Startup counter Display h 723 Pmittel Average boiler output Display kW 724 MmiStatus Current summer winter setting for...

Page 35: ...rm effect which switches off the heating during the summer when the outdoor temperature is higher than the S W switchover temperature set here for a longer period of time and switches it back on only when the outdoor temperature is below the value set here for a longer period of time By pressing button on heating circuit module HKM Fig 2 With automatic S W switchover via outdoor temperature When o...

Page 36: ... can be set are shown in Table 7 The factory settings for the heating curve as follows Pump heating circuit 25 and Mixer heating circuit 25 Fig 8 The heating curves can be adjusted as following depending on the system equipment with room control module RRG On heating engineer level for RRG program No 70 or 80 The values from the RRG write over parameters 532 and 533 with heating circuit module HKM...

Page 37: ...ump is switched off for a maximum of 15 hours At outdoor temperatures below 5 C the pump is not switched off Note Low constant for lightweight buildings which cool down quickly High constant for heavy well insulated buildings Table 9 Switch off times Mixed outdoor Pump switch off times in hours h for program No 551 Kon temperature Kon 0 Kon 4 Kon 8 Kon 12 Kon 15 20 C 0 0 0 0 0 10 C 0 0 5 1h 1 5h 2...

Page 38: ...tung nach Wärme anforderung Start bzw Zündleistung Leistung ZReglVerz Kessel Min leistung Fig 9 Function sequence following burner startup for heating operation Startup or ignition output Output ZRegVerz Minimum boiler output Output according to heat requirement ...

Page 39: ...educed by the value set in param No 520 dTrAbsenk by 10 K factory setting The pump runs in standard mode and in reduced mode except for rapid reduction Note When param No 520 code 0 the heating mode is switched off completely when the timer contact is open Various options for adjustment codes Example e g Program No 555 555 KonfigRg1 Bit setting for hot water priority Bit setting for terminal assig...

Page 40: ...ing In program No 561 it is only permissible to change bits 0 1 and 2 when then pump function is modified according to the application schematics or the PWM pump is replaced by a stage pump See also Service note on Page 48 561 3 On and 561 4 Off Medium system volume factory setting 561 3 Off and 561 4 Off Small system volume 561 3 Off and 561 4 On Large system volume A medium system volume corresp...

Page 41: ...e g ZR EC 1 2 or EC MSR are also inhibited Note The modem function is active when the contact is closed Code 2 Modem function negative logic See Code 1 for Function Note The modem function is active when the contact is open Code 3 Door veil air heater In this setting the boiler temperature setting is set to the max setting TkSmax as well as a heat requirement for heating circuit 1 This function is...

Page 42: ...ive if Parameter 558 0 is ON Code 10 Basic function M5 K2 Exit M5 according to hydraulic system for header pump M5 Code 11 Function not available for EUROCONDENSE EC Code 12 Analogue threshold M5 activated via limits set by the entry of the relay modules CIST or CISP If the hydraulic schematic requires a header pump connect its plug to X1 M5 Programming header pump function 1 Set program No 615 to...

Page 43: ...x value ist calculatet into a power signal of 0 100 If the analogue signal is higher than the minimal value the boiler operates at min output At the max value the boiler operates at max output If the analogue signal is below the minimum threshold the output setpoint is not active Other settings of param 618 are not possible with the CISP If other clip in modules are connected see the specific inst...

Page 44: ...temperature is simultaneously more than 1 5 C below the room temperature setting even when room temperature setting is increased on room control module Quick heat up is terminated when the room temperature is less than 0 25 C below the room temperature setting When the heating circuit is switched over from Standard mode to Reduced mode or Frost protection mode the rapid reduction feature is active...

Page 45: ... 12 3 sec fault indicator 8 flashes once The burner is switched on and heats up the EUROCONDENSE EC at the maximum boiler output until the temperature monitor trips at 82 C Note SF appears on display 13 and the fault indicator 8 flashes Press the chimney sweep button 12 min 1 sec to deactivate the chimney sweep function In the event of component failure an error message is output see Table 13 lead...

Page 46: ...button Function Automatic operation Heating function according to heating program Holiday function effective Continuous operation Heating circuit continuous according to room temperature setting or reduced setting holiday function not active Stand by Heating circuit switched off Holiday function not effective frost protection functions active Auto HKM Fig 10 Heating circuit module HKM Installation...

Page 47: ...ymbol Heating operates at set temperature Moon symbol Heating operates at reduced temperature The Presence button is effective until the timer program switches the next time The presence button has no effect on the hot water heating You can readjust the set temperature with the temperature knob One increment corresponds to approx 1 C Before changing the temperature setting on the temperature knob ...

Page 48: ...30 C C 46 46 48 50 53 Flue Gas Volume NG 15 C 1013 mbar Pressure ml hr 127 169 225 282 352 Nominal Gas Inlet Pressure NG 20 mbar Gas Inlet Pressure LPG Min 25 mbar max 45 mbar CO2 for Natural Gas 8 0 8 5 CO2 for LPG 9 5 10 0 9 0 9 5 High Level Natural Ventilation to BS 6644 cmk 360 435 531 635 761 Low Level Natural Ventilation to BS 6644 cmk 720 870 1062 1269 1522 Hydraulic resistance at 11K Dt kP...

Page 49: ... D 20 21 Switch off diagnostic phase Fan continues to run 134 flashing in display Retries 3 times then lockout A B NO 0 Stand by A A NO Appliance runs 11 DHW 10 CH Flame detection 22 Transition phase NO 133 flashing in display Retries 3 times then lockout A A NO Restart A A YES A A 160 or 135 flashing in display Manual reset necessary A NO 132 flashing in display Automatic reset when pressure rise...

Page 50: ...or F5 open 133 No flame detected no flame message after Reset if fault occurs a number of time notify heating engineer expiration of safety time insufficient gas see Page 20 check polarity of line power connection ignition electrodes and ionization current 1 2 134 Flame failure during operation Automatic restart attempt by PARAMOUNT 135 Incorrect air supply Fan speed above or below speed threshold...

Page 51: ...51 ...

Page 52: ...Line Tel 08706 002322 e mail commercia potterton co uk Web Site www pottertoncommercial co uk COMMERCIAL SERVICE Our service organisation covers the whole U K to look after your needs OFFICES for all Potterton Commercial Products We are also able to offer our services for other manufacturers products Service Hotline 08702 412759 Our service office offer a wide range of specialised services includi...

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