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RVR Energy Technology MICROMAT EC 45, Instruction For Usage, Installation & Commissioning, Page: 23 / 56

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RVR Energy Technology MICROMAT EC 45 Instruction For Usage, Installation & Commissioning Download Page 23

23

16.0 hydraulic system 

design

E n e r g y   T e c h n o l o g y

Ltd.

system type 1

Typical Single MICROMAT EC boiler installation serving heating only where the boiler's own in-built circulating
pumps are used to circulate the water around the system (used only where system index resistance <1
metre). Flow temperature may be fixed/constant or weather variable.

Condensate

Expansion

Vessel

CWM

IV

DOC

LSV

Safety Valve

Strainer

Flow to system

Return from system

IV

Micromat

EC Boiler

OS

C

AV's

DOC

DOC

IV

OS = Outside air temperature sensor, used where

direct-on-boiler weather compensated flow
temperatures are required.

C = Room temperature controls e.g. RE2132

modulating room unit from RVR Ltd., or,
separate time clock & room thermostat.

Summary of Contents for MICROMAT EC 45

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Page 3: ...lic system Design circuit diagrams 31 16 1 Water Treatment System Cleaning 16 2 Care With The Use of Soldering Flux 17 0 Electrical Connections 32 41 17 0 Electrical Connections contd 41 18 0 Commissioning The MICROMAT EC Boiler 42 18 1 Pre Commissioning Checks 43 18 2 Dip Switch Settings 44 18 3 First Firing 45 18 3 First Firing contd 45 47 18 4 Setting Weather Compensation 48 18 5 Setting Domest...

Page 4: ...en a service is due although the boiler will continue to operate normally An RVR approved service technician should carry out the annual service Switching ON the MICROMAT EC 1 Ensure the pressure gauge indicates a pressure within the system of not less than 0 5 bar and not more than 3 bar 2 Ensure the gas supply is turned on 3 Switch on the on off switch on the appliance control panel After switch...

Page 5: ...lf power The display shows Flue Emissi If the Engineers button is not pressed again within 10 minutes the MICROMAT EC will switch back to automatic operation after this period Pressing the button again when Flue Emissi is displayed brings 10min Low onto the display In this condition the power output of the boiler can be adjusted using the green potentiometer between 11kW and 57kW EC62H and 14kW an...

Page 6: ...stored domestic hot water temperature or room temperature or a combination of the aforementioned fully condensing stainless steel heat exchanger The MICROMAT EC boiler is designed with extended heat exchange surface area and is fabricated from corrosion resistant long life stainless steel The unique Spiranox heat exchanger will return operating efficiencies from 88 gross 96 nett at 60 C return tem...

Page 7: ...aintenance 11 Range rate adjustment which allows the power to be set to accurately match the maximum needs of the system with the facility to set a different firing rate for heating Output to hot water self adjusts to the heat transfer capability of the calorifier 12 Facility to connect optional matched control components which allow the boiler to control a heating circuit pump HWS primary pump or...

Page 8: ... BSP M 3 4 BSP M 7 Cable Entries Multiple Grommets 8 Gas 3 4 BSP 3 4 BSP 3 4 BSP MODEL MICROMAT EC 45 62 76 Nominal Heat Input Nett max kW 43 57 72 Nominal Heat Output 80 60 C kW 41 3 55 8 70 6 Nominal Heat Output 50 30 C kW 45 2 60 4 76 0 Input Rate Nat Gas max m3 h 4 5 6 01 7 6 Minimum Maximum Gas Pressure mbar 15 60 15 60 15 60 Flue Gas Volume hot m3 h 64 81 104 Pressure at Flue Outlet pa 100 1...

Page 9: ...boiler should only be lifted by contact with the rear grey chassis assembly To remove the casing from the boiler slacken the screw in the underside of the casing unlatch left and right hand catches on underside of case pull casing slightly to the front and lift upwards to disengage casing hooks from rear chassis and then remove casing to the front The MICROMAT EC Boiler is not suitable for install...

Page 10: ...al parts of the appliance important When viewed from the side the axis of the boiler must be vertical The appliance must not be inclined out from the top if necessary block or shim behind the bottom rear of the boiler to achieve a vertical installation The gas connection is located at the base of the appliance rear r h side see fig 2 The pipe size used to supply the appliance must not be smaller t...

Page 11: ...sion kit On the inlet side of the left hand gas combi valve only replace the NG jet with the 3 5mm LPG Prejet Re tighten the flange joint Do not forget the O rings Check for Leakage On the MICROMAT EC 45 H 62 H 76 H when converting to LPG the front bore on both gas air mixing chambers must be closed using the black ø10mm plugs supplied in the conversion kit In addition with the MICROMAT EC 76H bot...

Page 12: ... of the appliance to install drain cocks The appliance is supplied with 2Nr 11 4 x 11 4 x 1 2 BSP Tees see fig 4 item B which may be used to connect the supplied safety valve into the flow pipe adjacent to the appliance and either a system filling point expansion vessel or a drain cock The flow and return pipework should include isolation valves and a method of disconnection local to the boiler Th...

Page 13: ... on the top of the appliance see fig 6 These connections are arranged concentrically with the 70mm flue gas connection centrally within the 125mm air inlet connection There are two options for flueing the MICROMAT EC boiler i Conventionally using flue gas tube only and air for combustion from the room or compartment in which the appliance is installed If using a conventional flue arrangement then ...

Page 14: ...ide of the MICROMAT EC The following components and options are available from RVR Limited 70 125 concentric wall terminal set complete with flue products sampling tee 500mm straight concentric flue wall sealing plates and outside terminal These are finished in RAL 7035 the 125mm galvanised pipe and light grey natural colour of 70mm PPS pipe RVR Order Code SBA050 The system may be extended using t...

Page 15: ...sed with either of the above kits Pitched Roof Flashing 20 45 RVR Order Code SBA062 or Flat Roof Flashing RVR Order Code SBA063 The system may be extended using the following accessories 125mm Ø Extension Pipe Black PPS 1020mm long RVR Order Code SBA064 125mm Ø Extension Pipe Black PPS 2000mm long RVR Order Code SBA065 70mm Ø Extension Pipe Grey PPS 1000mm long RVR Order Code SBA059 70mm Ø Extensi...

Page 16: ...r Code SBA059 The system may be extended using the following accessories 70mm Ø Extension Pipe PPS 250 mm long RVR Order Code SBA057 70mm Ø Extension Pipe PPS 500mm long RVR Order Code SBA058 70mm Ø Extension Pipe PPS 2000mm long RVR Order Code SBA066 70mm Ø 90 bend PPS RVR Order Code SBA060 Birdscreen for 70mm Pipe RVR Order Code ACB002 MICROMAT EC 70mm Ø 90 Bend Grey PPS Order Code SBA060 70mm Ø...

Page 17: ...al With Rain Cap 21 9 32 2 46 8 1m length 70 125 Concentric Tube 10 7 16 6 23 4 93 C 70 125 Concentric Bend 10 7 16 6 23 4 45 C 70 125 Concentric Bend 5 4 8 3 11 7 1m length DN 70 PPS Tube Carrying Fluegas 9 7 14 6 21 4 1m length DN 70 PPS Tube Carrying Combustion Air 5 8 9 7 13 6 90 DN 70 PPS Bend Carrying Fluegas 9 7 14 6 21 4 90 DN 70 PPS Bend Carrying Combustion Air 5 8 9 7 13 6 45 DN 70 PPS B...

Page 18: ...al route to a vertical open termination with bird mesh Length of horizontal section 4m length of vertical uninsulated section 11m with 4 x 90 bends and 2 x 45 bends Resistance 15 x 1m lengths DN 70 PPS tube 21 4 Pa 321 4 x 90o DN 70 PPS bends 21 4 Pa 85 6 2 x 45o DN 70 bends 10 7 Pa 21 4 1 x DN 80 open termination 15 6 Pa 15 6 Total Resistance 443 6 Pa Take into account that 11m of vertical uninsu...

Page 19: ...m a surface facing the 2000mm 2000mm terminal I From a terminal facing the 2000mm 2000mm terminal J From an opening in the car 1200mm 1200mm port e g door window into But installation But installation dwelling not recommended not recommended K Vertically from a terminal on 1500mm 1500mm the same wall L Horizontally from a terminal 300mm 300mm on the same wall M From the wall on which the N A 50mm ...

Page 20: ...ted direct to outside air MICROMAT EC 62 76 Ventilation from adjacent room not permitted see Table 1 for ventilation area direct to outside air Table 3 Room Installation Room Sealed Flue There are not specific requirements for a room to be ventilated where the appliance is room sealed However consideration should be given to providing ventilation for general cooling BS6644 specifies room temperatu...

Page 21: ...cm2 High Level Low Level MICROMAT EC 45 454 454 MICROMAT 62 76 Ventilation from adjacent room not permitted see table 6 for ventilation area direct to outside air Multiple Appliances Installed in the Same Room or Space Where multiple MICROMAT EC boilers are installed in the same room or space then The aggregate of the appliance inputs must be taken to determine from the following Data the amount o...

Page 22: ... EC includes in built primary pumps with a residual head pressure as listed below Appliances may be installed as single units or in multiples Single units may or may not require additional system pumps which will be dictated by the system configuration and by the index resistance Multiple units and single units which require additional pumps should always be installed with a low loss mixing header...

Page 23: ...where system index resistance 1 metre Flow temperature may be fixed constant or weather variable Condensate Expansion Vessel CWM IV DOC LSV SafetyValve Strainer Flow to system Return from system IV Micromat EC Boiler OS C AV s DOC DOC IV OS Outside air temperature sensor used where direct on boiler weather compensated flow temperatures are required C Room temperature controls e g RE2132 modulating...

Page 24: ...Water Hot Water Calorifier T W S OS C AV s IV Expansion Vessel SafetyValve IV Strainer DOC Divertor Valve LSV CWM Condensate IV Flow to system Return from system DOC DOC DOC W T Alternative to S where W is a time switch in series with a cylinder thermostat T Allows for timed HWS Divertor valve will require SPDT relay if not spring return Divertor valve must be so installed as to spring return to h...

Page 25: ...s are required C Room temperature controls e g RE2132 modulating room unit from RVR Ltd or separated time clock room thermostat Low velocity mixing header Max velocity 0 5m s LSV IV DOC DOC Expansion Vessel IV Strainer DOC Safety Valve AV PRO 1 C OS Micromat EC boiler AV s Condensate CWM IV Flow to system circuits Return from system circuits PR01 Pump regulation module from RVR Ltd Allows heating ...

Page 26: ...tandstill exercising Must be used where RE2132 modulating room unit is installed Max pump motor load 2A Divertor valve will require SPDT relay if not spring return Divertor valve must be so installed as to spring return to heating OS Outside air temperature sensor used where direct on boiler weather compensated flow temperatures are required C Room temperature controls e g RE2132 modulating room u...

Page 27: ...g pump to be driven from boiler providing for auto operation frost protector running summer standstill exercising Must be used where RE2132 modulating room unit is installed Max pump motor load 2A OS Outside air temperature sensor used where direct on boiler weather compensated flow temperatures are required C Room temperature controls e g RE2132 modulating room unit from RVR Ltd or separated time...

Page 28: ...Modulating Kaskade Manager Up to 9Nr boilers may be controlled using 2Nr linked KKm2 s AV s Micromat EC Boiler KKM 2 OS Heating pump 2A Max HWS Primary Pump 2A Max FS Calorifier S Low Velocity Mixing header Max Velocity 0 5m s LSV IV IV DOC DOC Return from system curcuits CWM RS IV IV IV NRV SV SV DOC IV IV IV NRV NRV SV DOC DOC Condensate C Flow to System Circuits OS Outside air temperature senso...

Page 29: ...er stand still protection running Provides drive for underfloor coil zone VT mixing valve with max flow temperature limitation set at 55 C Includes ratio setter for compensation of under floor coils Max pump motor loads 2A RC1 RE2132 modulating room unit from RVR Ltd provides Time Temperature control for radiator heating zone RC2 As RC1 but for underfloor coil zone VS Underfloor zone VT flow senso...

Page 30: ...mer WC Wiring Centre Junction Box RS Room Thermostat CS Cylinder Thermostat system type 8 Typical Single MICROMAT EC boiler installation serving heating and domestic hotwater via a system pump and 2Nr 2Port motorised valves with conventional controls i e programmer room stat cylinder stat NOTE system temperature will be fixed constant and direct on boiler weather compensation is not possible Typic...

Page 31: ...ion is 1 2 of system capacity Failure to observe these requirements will render the guarantee on the product void Cleansing flushing and water treatment must be carried out in accordance with the requirements of BS 7593 1992 The MICROMAT EC boiler has heat exchangers fabricated from 316L stainless steel It is most important that the compatibility of any flux is checked with the flux supplier befor...

Page 32: ...32 17 0 electrical connections E n e r g y T e c h n o l o g y Ltd plan of internal electrical connections ...

Page 33: ...tat time switch installed Outside sensor installed RE2132 modulating room unit installed No outside sensor RE2132 modulating room unit installed 1 2 3 4 5 6 7 8 ON OFF Boiler Dip Switch Settings 1 2 3 4 5 6 7 8 ON OFF 1 2 3 4 5 6 7 8 ON OFF 1 2 3 4 5 6 7 8 ON OFF Not Used X3 X16 10 5 6 1 2 1 1 2 L1 PE N 5 6 Install only if direct on boiler weather compensated flow temperature are required Install ...

Page 34: ... Open C lo s e 3 6 L1 PE N L2 L1 PE N Room Thermostat And Time Switch C1 Outside sensor installed Room stat time switch installed No outside sensor Room stat time switch installed Outside sensor installed RE2132 modulating room unit installed No outside sensor RE2132 modulating room unit installed Install only if direct on boiler weather compensated flow temperature are required Install only one m...

Page 35: ...e is required 2 Supply 230V Room Thermostat And Time Switch L1 PE N L1 PE N L2 1 3 1 3 4 5 6 X16 X3 Weiland Plugs Sockets Control sockets on control panel A1 A2 R1 R2 R3 1 2 L1 PE N 4 5 6 1 2 Not Used X3 X16 10 5 6 1 2 1 PRO 1 L1 PE N Outside sensor installed Room stat time switch installed No outside sensor Room stat time switch installed Outside sensor installed RE2132 modulating room unit insta...

Page 36: ...imary Cylinder Thermostat Time Switch C2 HWS Primary Divertor Valve Spring Return Type NOTE All Connections into PRO 1 are made via labelled factory fitted Cables Outside sensor installed Room stat time switch installed No outside sensor Room stat time switch installed Outside sensor installed RE2132 modulating room unit installed No outside sensor RE2132 modulating room unit installed Install onl...

Page 37: ...ating Pump 2A Max 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ON OFF 1 2 3 4 5 6 7 8 ON OFF Outside sensor installed Room stat time switch installed No outside sensor Room stat time switch installed Outside sensor installed RE2132 modulating room unit installed No outside sensor RE2132 modulating room unit installed Install only if direct on boiler weather compensated flow temperature are required Install onl...

Page 38: ...kets X1 X2 X4 Terminal Rails on KKM2 Kaskade Manager 1 3 5 7 9 10 6 4 2 HWS Primary Pump 230V 2A Max Supply 230V L N PE L N PE Heating Circuit Pump 230V 2A Max If Required L N PE 15 17 19 20 16 18 22 21 X2 Alternative External Control Options Cylinder Stat HWS Time Switch External Controls for Heating Circuit RE2132 Modulating Room unit QAW44 optional Remote Sensor Supply 230V Supply 230V Supply 2...

Page 39: ...Zone VT Pump 2A Max Underfloor Zone VT Mixing Valve Underfloor Zone VT Flow Sensor L1 N L2 Boiler Dip Switch Settings RE2132 Modulating Room unit for underfloor zone 1 2 3 4 5 6 7 8 ON OFF GND PMW 24V 4 3 2 5 1 Cylinder Thermostat Time Switch Weiland Plug No 2 not shown Used only on LPG installations where an additional gas safety shut off valve is required Install only one method of HWS temperatu...

Page 40: ...A2 R1 R2 R3 1 2 L1 PE N L1 N PE Supply 230V M CH M V HW M V M Not Used Junction Box 1 2 3 4 5 6 7 8 ON OFF Boiler Dip Switch Settings L N P E System Pump 2A Max L N HW OFF HW ON CH OFF CH ON E Typical Programmer Cyl Stat R Stat L L 3 4 5 6 7 N N E E HW M V CH M V Typical spring return type motorised valves with end switches Weiland Plug No 2 not shown Used only on LPG installations where an additi...

Page 41: ...t free contacts indicate common alarm upon closing The actual fault description will be displayed upon the LCD screen of the boiler Connection to the volt free contacts is made via an alarm plug and lead assembly available from RVR Ltd The alarm plug and lead Connects to socket x9 located in the lower area of the boiler control panel The MICROMAT EC boiler should be expertly commissioned by a comp...

Page 42: ...ace vent screws d Ensure Gas supply has been purged and there is the availability of working inlet pressure of nominal 20 mbar Nat gas or 37 mbar LPG e Check that the flue installation has been properly made f Check that a condensate pipe in plastic copper tube is not acceptable has been connected to the boiler and that the syphon cleaning point cap is in place g Where the appliance is taking air ...

Page 43: ...43 18 2 dipswitch settings E n e r g y T e c h n o l o g y Ltd ...

Page 44: ...not occur after 4 attempts the appliance will go to ignition failure lockout Remove the cover cap screws from Qmin adjustment on gas valves See figure 21 3 turn adjustment screw half turn clockwise Press reset button appliance will post purge and vent again Press Engineers test button twice to reset appliance to 10 min Low and ignition sequence will start again If ignition fails again after 4 atte...

Page 45: ...Press Engineer s test button once to exit 10 minute test mode m Turn off electricity and gas supplies and remove manometer from inlet pressure test point and refit test point screw n Turn on gas and electricity supplies a If direct on boiler weather compensated flow temperatures are required then ensure the supplied outside air temperature sensor has been installed and Dip switch No2 has been set ...

Page 46: ...46 18 4 setting weather compensation E n e r g y T e c h n o l o g y Ltd ...

Page 47: ...47 18 4 setting weather compensation E n e r g y T e c h n o l o g y Ltd ...

Page 48: ...tom right hand of control panel and has a number of functions a Setting maximum output to heating The output to heating may be limited if required and may be set between 20 and 100 by performing the following i Press red reset button once Press service button once Screen display will show Mxhea The figures to the left of the symbol are the current settings for maximum heating output as a percentag...

Page 49: ...lt of 365 days of an electrical supply being applied to the boiler a message to the user is shown on the screen displaying service reminding the user that the appliance should now be serviced Following a service visit by the specialist engineer the service message may be cancelled by pressing and holding the service button for approximately 10 seconds There is no adjustment necessary or possible a...

Page 50: ...leaning rinsing point at the base of the unit f If you have a notebook computer connect it and check the service page for any errors messages starts and successful restarts Special communication lead and service software required g Run the unit at maximum capacity and measure the input and the C02 h Run the unit at minimum capacity and measure the input and the CO2 i Listen to the sound of the in ...

Page 51: ...umps are more than 5 years old it is recommended that the pumps should be replaced by way of preventive action Note the pumps are fully modulating and do have characteristic a yet yet noise which is normal at low speeds at j NEVER CLEAN THE BURNER ITSELF If the interior of the heat exchanger is contaminated and or there is a deposit on the surfaces of the coiled stainless steel pipes the latter mu...

Page 52: ...ion Limit F R The flow and or return temperature is too high currently Fan 1 high The lower burner fan is running too fast currently Fan 1 low The lower burner fan is running too slow currently Fault room u There is a fault with the modulating unit RE2132 or Cascade manager KKM2 or a fault in the wiring to these controls in these circumstances the boiler runs continuously in heating mode to protec...

Page 53: ...wer burner fan speed is too high 9 11 29 31 33 Fan 1 Low Lower burner fan speed during 9 10 11 14 18 29 31 33 pre purge is too low Fan 1 oper Lower burner fan is detected as 3 4 11 29 31 operating when should be idle Ignit 1 fault Ignition to lower burner has not 12 13 15 16 17 19 22 been successful after 4 attempts 23 27 29 30 31 35 Flame 1 out Flame at lower burner has been lost 13 15 17 19 20 2...

Page 54: ...gas valve interrupted 16 26 28 29 31 33 Soft fault Error in software in the control 29 Reset button There is a fault with the reset button 29 31 34 Eeprom There is a fault in the EEPROM in 29 the control CAUSE No REASON ACTION 1 Dip switches not set correctly Check and correct settings 2 Unsound electrical connections to flue limit stat Check and correct 3 Sensor not correctly connected or sensor ...

Page 55: ...lue or air supply tubes or flue blocked Check flue for suitability or clear obstruction 23 Leakage of flue gas from flue gas tube into air tube vitiating the combustion air Strip out flue system and remake joints 24 Zone pumps not running Check and rectify 25 Heat exchangers fouled internally with silt or scale Clean descale heat exchangers and system and re dose system with water treatment 26 Hea...

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