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21

IGE/UP/10:

Installation of flued gas appliances in industrial and commercial premises

Edition 3

Gas Safety (Installation and Use) Regulations 1998 (England, Scotland & Wales)

CIBSE: Guide parts A, B and C

CIBSE Commissioning Code B:

Boilers

CIBSE Commissioning Code W:

Water Distribution Systems

BISRIA AG1/2001.1:

Pre-commission cleaning of pipework systems

H.S.E. guidance

Automatically controlled steam and hot water boilers

note PM5:

Third edition of the 1956 Clean Air Act Memorandum on Chimney Heights

Manufacturer's notes must not be taken in any way as overriding statutory obligations.

5.0

WATER QUALITY

5.1

WATER CHEMISTRY

In hard water areas, scale formation can occur in hot water systems. The situation can intensify where higher temperatures or
demands exist.

The pH value of the water must be between 7.5 and 9.5.

Water hardness must be between 50 ppm CaCO

3

and 150 ppm CaCO

3

The Aluminium content of the TDS (Total Dissolved Solids) should not exceed 8.5 ppm.

If the above requirements cannot be satisfied, a water treatment specialist must be consulted. Details of companies that provide

such a service can be obtained from Lochinvar Limited.

5.2

AIR/DIRT SEPARATION

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 of the heat exchanger. If there is any doubt of the water
staying free of any kind of debris/contamination in the period after installing, a plate heat exchanger should be installed to

separate the boiler circuit from the heating circuit.

5.3

WATER PRESSURE

The CP-M+ boiler has an in-built water pressure sensor, with this sensor the minimum water pressure in the boiler is 0.8 bar and
the maximum pressure is 4.0 bar (sensor values). The recommended water pressure is between 1.5 and 2.0 bar. The pressure

sensor will stop the boiler from firing when the water pressure drops below 0.8 bar, and start the boiler firing again when the water
pressure reaches above the 1.0 bar.

If pressures higher than 4.0 bar are required within the heating system, it is recommended that the system is separated from the
boiler by means of a plate heat exchanger. This will allow the boiler pressure to be under 4.0 bar and the boiler control remains as

described above. If this is not possible, a water pressure switch must be fitted to the boiler instead of the water pressure sensor -
the maximum allowed value in the boiler now is 6.0 bar and the boiler control needs to be adjusted.

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Содержание CP-M Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 92: ..._________________________________________________________________ __________________________________________________________________________________ ___________________________________________________...

Страница 93: ..._________________________________________________________________ __________________________________________________________________________________ ___________________________________________________...

Страница 94: ...94...

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