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ETHOS 70, 90, 110 & 130Wall mounted gas fired condensing boilers

I N S P I R E D E F F I C I E N C Y

TECHNICAL DOCUMENTATIONIssue 05/08

Project2:Layout 1 5/1/09 10:44 Page 2

TABLE OF CONTENTS

Technical Data

Dimensions

1. Safety guidelines

Conditions

General guidelines

Service

General restrictions

2. Description

General

Application features

Main components

Boiler control

Safety aspects

3. Delivery & transport

Delivery

Transport

4. Installation

Regulations

Installation area

General

Installation

Ventilation

Connections

Gas connection

Electrical connections

Wiring diagram

Internal controls breakdown

Controls & options

Water connections

Flue connections

Flue gas outlet and air inlet pipe

Flue

Flue parameters

Condense connection

Hydraulic system

Flow and resistance

Pump characteristics

2 Technical Documentation

1

2

3

4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Shut-off valves

Valves

Water flow protection device

Water pressure

System expansion vessel

Water pressure protection device

Water temperature

Water quality

Water hardness

5. Operating Instructions

Operation

Controls

Boiler module

Boiler operation

Adjusting the room temperature setpoint

Heating curve

Boiler temperature setting

Display information

Manual operation

Programming

User levels

List of displays

Error codes

Maintenance codes

Special operation codes

Switching on the appliance

Switching off the appliance

Warnings

6. Commissioning

General

Commissioning

7. Maintenance

Safety

General

Removal of parts

8. Boiler parts

9. Conversion formulae and factors

18

19

20

21

22

23

24

25

26

28

30

31

32

35

36

40

42



TECHNICAL DATA

* With this resistance valuetheheat output will remain within the specifications indicated on the dataplate;if the resistance is higher, the heat output will drop,


DIMENSIONS


Type

B1 mm

B2 mm

D mm

D1 mm

G

L mm

L1 mm

W

70

120

260

80

80

R 3/4”

475

90

R 1 1/4”

90

140

260

100

100

R 3/4”

475

90

R 1 1/4”

110

140

260

100

100

R 3/4”

660

90

R 1 1/4”

130

140

260

100

100

R 3/4”

660

90

R 1 1/4”

(We reserve the right to make changes without prior notification)The data may deviate slightly due to fabrication tolerances.



SAFETY GUIDELINES

Conditions

Mikrofill Systems Ltd. shall not be liable for any damages caused by non-compliance with this manualinstructions. Only original ETHOS parts must be used for service purposes.

General Guidelines

It is a statutory requirement that all gas appliances are installed in accordance with the manufactures instructions and all current regulations in force, all instructions should be fully read before installing or using the appliance.All installations should be carried out by competent persons as described in the Gas Safety (Installation & Use)Regulations. i.e. CORGI registered and holding current certification.

The Manufacturers instructions MUST NOT be taken in any way as overriding statutory obligations.This boiler has been tested and certified to comply with all necessary European directives, latest building regulations and efficiency requirements, is CE marked and complies with;

90/396/EEC Gas Appliance Directive93/68/EEC Low Voltage Directive (was 73/23)92/31/EEC Electromagnetic Compatibility Directive

The boiler should be installed in compliance withThe building regulations (Scotland-consolidated)The Health and safety at work actGas safety (installation & use) regulationsBuilding Regulations (Northern Ireland)Building RegulationsWater fittings regulations or water bylaws in ScotlandLocal water company bylaws

The boiler should not be modified in any way. Any modifications will invalidate the gas approval and invalidate the warranty.

ATTENTION: High Voltage

Before opening the boiler casing for maintenance or servicing the 230VAC main supply to the boiler must be disconnected!!


SAFETY GUIDELINES


Service

Should you require any assistance during installation or in the unlikely event of a product failure please do not hesitate to contact our technical service department on 08452 606020

General restrictions

Mikrofill products should always be used, installed and maintained in accordance with the statutory requirements,specifications and standards applicable to these installations. Mikrofill cannot be held responsible for any losses ordamage whether direct or consequential that have arisen as a result of incorrect or poor installation.

Warning!Particular attention must be given to the safety guidelines in section 1 as non compliance willrender the warranty void and may constitute an illegal installation.

DESCRIPTION

General

The Mikrofill Ethos wall mounted boilers are environmentally friendly gas fired heating boilers with a modulation range between approximately 15% and 100% of their maximum output. The appliances have low NOx and CO emission, which satisfy the most stringent environmental requirements.

The Ethos range has received CE Approval for all relevant European countries and has been registered under the Product Identification Number

The boilers may be used on both open (type B23) as well as room sealed (type C13, C33,C43, C53, C63 or C83) systems.

The boiler is delivered fully wired, fully assembled, tested and preset complete with emissions report.

Working principle and design

Air is drawn in as required, via a variable speed fan. The gas valve measures the negative pressure(draught) in the venturi and modulates the gas valve in response. The gas/air is then thoroughly mixed in the correctratio in the fan housing and fired directly into the burner.

The boiler management system compares the actual water flow temperature to the required watertemperature. The management system computes the load required and adjusts the fan speed.This is a continual process during operation.

The heat transfer takes place in a stainless steel double heat exchanger block. The burner fires into the primary heatexchanger whilst the second heat exchanger ( condenser) is connected downstream in such a manner that the con-dense water cannot enter the primary heat exchanger, both heat exchangers consist of several smooth pipes in theform of a coil and are connected using stainless steel water distribution manifolds.



DESCRIPTION

The design of the boiler incorporates the following:-

Full operation and fault diagnostics via LCD.

Control / high limit sensors

Integral boiler shunt pump

Integral safety relief

Integral weather compensation ( optional external sensor required )

Integral advanced seven day timebase

Two stage frost protection.

Pressure readout

Compatible with most external BMS options including BUS systems


DESCRIPTION

Main components

1. Flue outlet connection2. Air inlet connection3. Gas connection4. Flow connection5. Automatic air vent6. Return connection7. Flue gas temperature sensor8. Combustion fan9. Automatic burner controller


10. Condense Trap11. Condense outlet12. Boiler pump13. Safety valve14. Heat exchanger and burner package15. Air intake duct16. Air intake drain trap17. Ignition transformer18. Gas valve and venturi



DESCRIPTION

Boiler control

If there is a heat demand, if all necessary conditions have been fulfiled and all safety devices are satisfied the boiler will start. This heat requirement will arise if:

- The flow temperature of the boiler is less than the required flow temperature- The manual option has been selected using the selector switch.- The frost protection has been triggered independently of the operating conditions.

The boiler control unit adjusts the boiler output by changing the fan speed such that the desired temperature is attained and maintained.The actual flow temperature is controlled within 4°C of the target temperature.

Safety aspects

The following safety devices are installed on the boiler :

- Temperature monitoring system- High limit temperature monitoring system- Limit temperature monitoring system- Frost protection system- Using an external sensor, if the external temperature falls below 0°C- Based on the flow temperature, if this is below 5°C and/or the domestic hot water temperatureis below 10°C

- Flame monitoring by means of ionisation measurement- Fan speed monitoring- Flue gas temperature monitoring- Flow monitoring using a combination of flow water temperature and flue gas sensor readings

If one of these safety systems is activated, the boiler will go to an interlocking or lockout condition andwill be switched off. Lockout conditions can only be reset by pressing the reset button, after rectifyingthe fault.


DELIVERY & TRANSPORT


Delivery

The boiler is delivered fully assembled, tested, and packed.

- Check the boiler for damage after receipt.- Check whether the items delivered are correct and in accordance with the items ordered.

Transport

The packing should only be removed after transportation.

Moving

Each boiler is packed in its own carton which has hand holes at both sides for lifting purposes. Refer to the technical data for dimensions and weights in order to work safely within the Health and Safety guidelines when handling these products.

Access requirements

The dimensions of the boiler are such that all Ethos wall mounted boilers can be transported through a standard doorway (600mm).



INSTALLATION

Regulations

The appliance should be installed by a competent installer in accordance with the applicable national and local

standard rules and regulations. Please refer to safety guidelines Section 1.1.

Installation area

General

- Due to the low noise level, there is no need for additional sound insulation of the room- Due to its compact design, very little installation space is required see clearance dimensions below- The location options for the boiler are increased because it is suitable for both open flued and room sealed operation.

Mounting

Solid Walls (brick or block)

Fix the mounting bracket with the bolts provided using a spirit level and ensuring that there is sufficient clearancearound the boiler to allow for access and flue installation.

Non Load Bearing Walls ( Studding or lightweight partitions )

We recommend the use of a purpose designed mounting frame which are available from MikrofillSystems Ltd., alternatively we can supply drawings for site construction of the same.

Installation

The following guidelines should be complied with;- The device should be installed in a frost free room due to the risk of freezing of the condensate drain. The built-in protection system is activated when the temperature of the central heating water falls below 5°C

- Ensure that there is sufficient room around the device for maintenance and the replacement ofcomponents if necessary

The recommended minimum clearance is as follows:- 750 mm to the front (free space for movement);- 400 mm above;- 250 mm below;- 100 mm sides;


INSTALLATION


VentilationThe ventilation of the installation room should conform to current gas regulations.

ConnectionsGas connection

The gas connection should be installed by a competent installer in accordance with applicable national standards.

The gas connection is located on the bottom of the appliance.

A suitable isolation valve should be installed for each boiler and should be in an accessible position. Care should betaken when sizing the pipework to ensure the supply is sufficient for maximum load operation of the boiler.

The pressure on the inlet side of the appliance should be reduced to 20 mbar for natural gas and no more than 50 mbar for propane. Under full load conditions the measured gas pressure at the gas valve should be no less than17 mbar for natural gas(G20) and 30 mbar for propane(G31).

Electrical connection

The electrical connections should be installed by a competent installer in accordance with applicable national standards.

The appliance is fully wired in accordance with the electrical diagrams delivered with the appliance.

The electrical terminal connections are located at the base of the boiler and are protected by a metal enclosure. Access to the terminals is gained by removing the boiler front door and unscrewing the lid from the enclosure. Suitable cable entry points are supplied in the form of cable glands.

The appliance is suitable for a 230 V 50Hz power supply with live/neutral/earth. The appliance is polarity sensitive.

The installer should use a local 2 pole main isolating switch with a contact opening of at least 3mm in the 240 voltsupply circuit to the boiler, a permanent earth must also be installed. In order to prevent problems due to electromagnetic radiation screened cable should be used for all control wiring between the boiler and external management systems. The screening should be earthed on both sides in accordance with current EMC directives.

Wiring diagram

Mainspower supply

BoilerEnable

Volt free

OutsideSensor

(optional)

DHWSensor

DHWOutput*

FaultRelay

Safety interlock

*240

volt output to supply or motorised valve.Terminal 9

240 volt output in no DHW load condition.Fault relay

240 volt output in fault condition.Boiler enable

link if no external control are used.



INSTALLATION

Internal controls breakdown


INSTALLATION


Controls and options

The boilers feature an automatic fully modulating control system and as such can be used as “stand alone” appliances.

The standard controls include;

- Full seven day time control- Optimum start facility- Weather compensation ( optional sensor required)- Domestic hot water priority control ( optional sensor required )- 2 stage frost protection- Shunt pump over run timer- High and low pressure cut out- Condense trap blockage cut out

Further external controls are available including cascade and zone control. The boiler is also compatible with most current “BMS” systems for further information please see our “ Controls Manual”.

Water connections

The boiler is designed for sealed systems only and should not be used for open vented systems.

It is recommended that manually operated valves should be installed between the water connections and the installation.

It is recommended that the flow and return pipes are securely fixed with brackets. This prevents damage and makes maintenance easier.



INSTALLATION

Flue connection

During installation, a choice can be made between a ‘room sealed’ or ‘openflued’ system. The standard two pipe (eccentric) connections can be easily converted using the Mikrofill adaptor.

The flue gas discharge outlet and air intake system should be installed by a competent installer according to applicable national and local standard and specifications. When using multiple boilers on a single application care should be taken to ensure compliance with the Clean Air Act.

• Type B23: Open type appliance without draught stabiliser, air supply from the room, flue gas dischargeoutlet above the roof.

• Type C13: Room sealed appliance, connected to a concentric air supply / flue discharge through the wall.• Type C33: Room sealed appliance, connected to a concentric air supply / flue discharge through the roof.• Type C43: Room sealed appliances in cascade, connected to a common concentric air supply / flue discharge

at the appliance.• Type C53: Room sealed appliance, connected to a separate air supply and flue discharge pipe, opening into

different pressure areas.• Type C63: Room sealed appliance, sold without related connecting and/or discharge fittings• Type C83: Room sealed appliances in cascade, connected to separate air supplies but common flue discharge

through the roof.

Flue gas outlet and air inlet pipe

The air inlet and flue gas outlet pipes may be single wall, smooth or flexible, and be made of:• plastic• aluminium• stainless steelAlways consider the large resistance when using flexible material.Always consider condensate formation due to the suction of cold air.

The connection for the air supply is on the top of the boiler.

The air supply pipe should be airtight. This is to prevent the suction of ‘false air’. Horizontal components in the airsupply should be installed sloping in the direction of the supply opening.

Type

Ethos 70

Ethos 90

Ethos 110

Ethos 130

80

100

100

100

Diameter of air inlet D1 (mm)

80

100

100

100

Diameter of Flue gas outlet D (mm)

Table 3. Diameter of air inlet and flue gas outlet.


Type

Ethos 70

Ethos 90

Ethos 110

Ethos 130

70

70

70

70

ºC

Maximum flue gastemperature at full load

Quantity of flue gasat full load

Maximum permissible flue resistance

113

149

168

209

m3/h

0.031

0.041

0.046

0.058

kg/s

140

140

140

200

ºC

INSTALLATION


The flue gas outlet is located on the top of the appliance and is designed for direct connection to acorrosion resistant fluepipe.

The flue gas discharge pipe to be used should be airtight and watertight at the joints and connections,or should be seamless. Horizontal components in the fluepipe should be installed slopingin the direction of the appliance (minimum 25 mm per meter).

Care should be taken when making joints to ensure that the seals are not damaged and the jointsshould be sited to enable access wherever possible.

A direct connection to a brick chimney is not permissible unless a suitable liner is installed.The following table gives the flue gas data for all the types

FlueFlue length

Since the boiler is equipped with a “premix burner ”with a fan, an over pressure is created in the boiler. This over pressure is sufficient to overcome the resistance of the burner, the heat exchanger, and the chimney.

The back pressure outside the boiler depends on:- The resistance of the flue pipe- The degree of cooling of the combustion gases- The resistance of the discharge outlet

The degree of cooling of the combustion gases depends on the following:- The insulation value of the flue- The ambient temperature- The flue system and outlet

There is a maximum over pressure of around 1.4 mbar (140 pa) for the types 70,90,110 and2.0 mbar (200 pa) for the type 130 in the boiler for the flue gas discharge system.

Calculation of diameter and length

For the calculation and control of the inner diameter of a discharge system with mechanical discharge,please refer to the applicable national and local standards and regulations.

Table 5. Flue gas data / Load 100% / Flow temperature 80ºc / Return temperature 0ºc



INSTALLATION

Ethos resistance table

By using either concentric or the 2 pipe system different flue lengths can be achievedIn case a concentric system is used, its length should not exceed 12 metres.

Table 3. Flue discharge resistance

Example of calculation,

boiler type: Ethos 70

Concentric pipe 80/125 mm vertical 3m + horizontal 1m = total 4m concentric straight pipe1x Concentric 90° bend;2x Concentric 45° bend;Vertical terminal 80/125.

Concentric pipe 80/125: 3m 3 x 9.3Concentric 90° bends: 1 pieces 1 x 14.7Concentric 45° bends: 2 pieces 2 x 12.1Vertical terminal 80/125*Total resistance

Total resistance is 138.6 Pa, so the boiler output is not changed by the resistance ( lower than 140 Pa) and total concentric length is lessthan maximum allowed 12 metres. *Vertical terminal includes 1 metre length.

Resistance

27.9 Pa14.7 Pa24.2 Pa65 Pa

138.6 Pa


Type

Ethos 70

Ethos 90

Ethos 110

Ethos 130

◊t 20 K Pump data

Nominal

flow rate

Q

Boiler

resistance

nom. flow

R

Pump type

Grundfos

Pump

seed

Pump head

at nom.

flow

Q

Available

head at

nom. flow

Q

Maximum*

Power

consumption

m3/h KPa KPa KPa W

2.79

3.64

4.29

5.14

20

21

19

26

UPS 25-80

UPS 25-80

UPS 25-80

UPS 25-80

2

2

2

3

48

37

29

42

28

16

10

16

190

190

190

190

Table 9. Water flow quantity and pump data for the Ethos *Maximum power consumed is given in pump position 3

INSTALLATION


Condense Connections

The boiler includes an anti syphon condense trap enabling the condense pipework to be taken directly to drain. The condense water is slightly acidic (PH3-4) and should be run in a standard drain pipe material, e.g. polyvinyl chloride (PVC), unplasticized polyvinyl chloride (PVC-U), acrylonitrile-butadiene-styrene (ABS), polypropylene (PP) or cross- linked polyvinyl chloride (PVC-C). The condensate pipe should, ideally, run and terminate internally to a soil stack or a waste pipe. Alternatively, the condensate can be discharged into the rainwater system or a purpose-made soakaway. All connecting drainage pipework should have a fall of at least 2,5° to the horizontal, or approximately 25mm per metre of pipe run. If the drainage pipe has an external run it should be kept to a minimum length with a minimum diameter of 22mm and insulate in order to minimize the effects of freezing. It should be noted that connection of a condensate pipe to a drain may be subject to building controls.

Safety Valve Connection

The discharge pipe from the safety valve shall be self draining and shall terminate in a visible position where the discharge cannot result in hazard to any person or to the plant. The size of the discharge pipe shall be no less thanthe nominal size of the valve outlet.

Hydraulic system

Flow and resistance

The minimum required water circulation over the boiler should be maintained at all times (equivalent to Δt 25 K at full load). The minimum required water circulation should not be adversely affected by the use of valves, non-return valves, systems in which several boilers are connected to a common distribution pipe, etc. The maximum water flow is achieved at Δt 15 K.

When using another Δ t you can use the following formula for calculating the flow rate and resistance of the boiler.After this you have to check the available head of the pump.

The boiler has a pump control circuit. When the boiler is enabled, the pump is switched on. If the boiler is disabled,the pump will continue to run for a few minutes more. This run on time can be adjusted. The standard time is 2 minutes.



INSTALLATION



Shut-off valves

It is recommended that manual valves should be installed between the flow and return connectionsto the installation.

Valves (boilers in cascade arrangement)

To prevent water flow through non firing boilers, and hence unnecessary heat loss, a spring loadednon return valve may be installed on the return pipework external to the boiler.

Water flow protection device

The boiler is equipped with water flow protection devices.The fl ow sensor and the flue gas sensor ensure that the protection device is triggered if thewater flow is too low.

UPS 25-80 180 1 x 230 V, 50 Hz


INSTALLATION


Water pressure

At a maximum flow temperature of 90°C and with the minimum water flow that occurs at at of 20K, the minimum operating pressure should be at least 1.5 bar. The operating pressure should be measured when thepump is switched off. If a lower operating pressure is required, it is necessary to adjust the maximum flow temperature.

System expansion vesselThe size of the expansion vessel is determined by the water volume of the system. We recommend that the systemexpansion vessel is installed on the return pipework in a suitable neutral pressure position.

Water pressure protection deviceA 3 bar pressure relief valve is integral within the boiler casing . Should it be necessary to protect thesystem at a lower pressure, an external safety valve will need to be fitted to the system.

Water temperatureThe maximum permissible water flow temperature is 90°C. If the limit thermostat is triggered at 97°C, the boilerwill switch off and will automatically restart when the water temperature falls below the limit temperature that hasbeen set. The high limit thermostat is set to 100°C, if activated the boiler will switch off and will not automaticallyrestart when the water temperature falls.

Water qualityThe composition and quality of the system water directly effects the performance of any hydronic (water filled)heating system. The life of the boiler and associated equipment will depend on the correct use of water treatmentsand (when required) deaerators, water filters and or air and dirt seperators. This is particularly important when connecting the boiler into an existing older system.

Care should be taken to ensure that pipework is sound and leaks are eliminated thus reducing the need for fresh‘top up’ water to a minimum.



INSTALLATION

Water Hardness

Water hardness levels are caused by dissolved minerals in the water and vary geographically. The harder the waterthe more likely that problems with precipitation (limescale deposits) will occur, causing permanent damage to theboiler and associated equipment, this is a system fault and is not covered by warranty.

The water hardness is generally expressed in terms of “ppm” ( parts per million) and is sub-divided as follows;

The system should contain soft to medium hard water, with a water hardness that does not exceed 250 ppm at a flow temperature of 80°C and t 20 °C. Before supplying water, the hardness and chloride value of the systemwater should always be determined.

The chloride value should never exceed 200 mg/l.

If the chloride value does exceed this value, the cause should be determined. Compare the chloride value of thesupply water and the central heating system water. If this content is much higher, and if no materials containing chloride have been added, this indicates evaporation. If the chloride content is very high, the water is rendered moreaggressive (Can be caused by, amongst other things, improperly regenerated water softener). The system should be flushed clean and filled with low chloride water.

In order to counter unnecessary wear and tear and blockages due to impurities present in the system, we recommend the use of a filter system with a mesh size of 100 microns. Always place this in the return line of thesecondary part of the system. In order to guarantee a properly working system and long life, one should removesuspended and corrosive particles by installing a suitable filter system.

A periodic inspection, including the analysis of the system water and the cleaning of the filters, should be performed.

Operating instructions

Operation

The fan, wh ich is modulated by the temperature controller, supplies the combustion air. Due to the resultant underpressure in the venturi, the zero pressure controller in the gas valve mixes in the required quantity of gas. Gas and airare completely mixed in the venturi. The gas-air mixture is then fi red directly in the burner. The fan also removesthe combustion gases. The boiler has no lower limit to the return water temperature. If this temperature is low,condensate will be formed, which is removed via the discharge system.

Controls

Depending on the heat requirement of the system, the boiler output will automatically modulate between 14% and 100% ( 7:1 Turn down ratio). Below 14% load, the boiler operates on/off, based on temperature.

Very soft < 50 ppm

Soft 50-160 ppm

Moderately Hard 160-250 ppm

Hard & very Hard < 250 ppm


OPERATING INSTRUCTIONS


DHW selection button

Heating selection button

Show information

Settings accept

Chimney sweep functionSTB test

Manual mode

Adjust room comfort setpointNavigation and settings

Service plug (BSB)

Quit setting

Heating to Comfort setpoint

Heating to Reduced setpoint

Heating to frost protection setpoint

Process running - please wait

Change battery

Burner operating

Info level activated

Programming activated

Heating temporarilyswitched offECO function active

Holiday function active

Reference to heating circuit

Maintenance / special operation

Error messages

Boiler Module




Boiler operation

Selecting heating module

This setting is used to switch between the different operating modes. The selection made is indicated by a bar which appears below the respective symbol.

Automatic mode

Automatic mode controls the room temperature according to the time program.

Characteristics of automatic mode:

Heating mode according to the time programTemperature setpoints according to heating program “Comfort setpoint“ or “Reduced setpoint“Protective functions activeAutomatic summer / winter changeover (ECO functions)

Continuous operation or

Continuous operation or Continuous operation maintains the room temperature at the selected operating level.

Heating to Comfort setpointHeating to Reduced setpoint

Characteristics of continuous operation:Heating mode with no time programProtective functions activeAutomatic summer / winter changeover (ECO functions)




Protection

When using protection, the heating system is off. But it remains protected against frost(frost protection temperature) provided there is no power failure.Characteristics of Protection:

Heating offTemperature according to frost protectionProtective functions activeAutomatic summer / winter changeover (ECO functions) and automatic 24-hour heating limit active

Selecting DHW heating mode

The button is used to switch DHW heating mode on and off. The selection made isindicated by a bar which appears below the respective symbol.

DHW heating

OnThe DHW is heated according to the selected switching program.

OffNo DHW heating, the protective function is active.Triggering is effected by keeping the DHW operating mode button on the operator or room unit depressed for at least 3 seconds.It can also be started when:

The operating mode is “Off“Operating mode changeover acts via H1 or centrally (LPB)All heating circuits use the holiday function

Adjusting the room temperature setpoint

Turn the setting knob to increase or decrease the Comfort setpointFor the Reduced setpoint

Press OKSelect operating page “Heating circuit“ andAdjust the “Reduced setpoint“

If no external sensors are connected, the boiler flow temperature will be determined by using the heatingcurve with an external temperature of 0°C. Please see following graph for equivalent temperatures.

After each re-adjustment, wait at least 2 hours, allowing the room temperature toadapt.




Heating curve

The rate of change, with respect to weather compensation, is adjusted by the heating curve setpoint,selection of a higher setpoint will result in a higher rate of temperature gain. Reducing the setpointwill result in a lower rate of temperature gain.

Increase adjustment: Raises the flow temperature, especially when outside temperatures are low.Decrease adjustment: Lowers the flow temperature, especially when outside temperatures are low.

Displacement of heating curve

Parallel displacement of the heating curve is used to change the flow temperature evenly across the entire outsidetemperature range or, in other words, if the room temperature is always too high or too low, a readjustment mustbe made with the help of parallel displacement.Adaptation of the heating curve

Adaptation of the heating curve is used by the controller to automatically adapt the heating curve to the prevailingconditions. In that case, a readjustment of the heating curve slope and parallel displacement is not required. It can only be switched on or off.

Boiler Temperature setting

ComfortSetpoint

BoilerTemperature

ComfortSetpoint

BoilerTemperature

Above table based on a heat slope of 2.0 at 0°c outside air temperature




Displaying information

Various data can be displayed by pressing the info button.

Possible displays

Depending on the type of unit, configuration and operating state, some of the info lineslisted below may not appear.Display:

Possible error messagesPossible service messagesPossible special mode messages

Other displays:

Room temperatureState of DHWState of boilerBoiler temperatureOutside temperatureDate and time of dayDHW temp 1State of heating circuit 1

Exception

In exceptional cases, the basic display shows one of the following symbols:

Maintenance or special operation

If this symbol appears, a maintenancealarm is delivered or the plant haschanged to special mode. Press theinfo button and read furtherinformation.

Error messages

If this symbol appears, an error inthe plant has occurred. Press theinfo button and read furtherinformation




Manual operation

When manual operation is active, the relays are no longer energized and deenergized according to the control state,but are set to a predefined manual operation state depending on their function.

The burner relay energized in manual control can be deenergized by the electronic temperature controller (TR).

Setpoint adjustment in Manual control

After manual control has been activated, a change to the basic display must be made.

There, the maintenance / special mode symbol appears.

Press the info button to switch to info display “Manual mode“, where the setpoint can be adjusted.

Chimney sweep function

The chimney sweep function is activated by a short press (maximum 3 seconds) on the chimney sweep button. This function produces the operating state required to make emission measurements (flue gas, maximum load only).




Setting principle

Settings that cannot be made directly with the operating elements are made in the form of programming. For this purpose, the individual settings are structured in the form of operating pages and operating lines, thus forming practical groups of settings. The following example shows how to set the time of day and the date.

Example: “Setting the time of day“

Press ESC to go one step back at a time, readjusted values are not be adopted.If no setting is made for 8 minutes, the display returns automatically to the basic display.Operating lines may be hidden, depending on the type of controller, the configuration made and the user level.

Basic display.

If the basic display is not shown,press the ESC button to return to it.

Press OK.

The bottom section of the display

shows a number of operating pages.

Turn the setting knob untiloperating page Time of day anddate appears.

Press OK to confirm.

In the bottom section of the display, the

first operating line of operating page

Time of day and date appears.

Turn the setting knob until operating lineHours / minutes appears.

To confirm, press OK.




The display shows the hoursflashing .Turn the setting knob until the

hours of the time of day are

correct.


The display shows the minutesflashing.Turn the setting knob until the

minutes of the time of day are

correct.


The settings are saved and thedisplays stops flashing.Now, you can make further settings

or you press the operating mode

button to return to the basic

display.

Now, you see the basic display again.


User levels

The user levels only allow authorized user groups to change settings. To reach the requireduser level, proceed as follows:

Basic display.

If the basic display is not shown,press the ESC button to return to it.

Press OK.

You are on the user level Enduser.

Press the info button for 3

seconds.

You are now given a choice of user levels.

Turn the setting knob until the required

user level is reached.

Press OK.

You are now on the requireduser level.






Setting structure “Enduser”

The example given here shows that certain user levels do not allow certain settings to bemade. The example shows them highlighted. On the unit, they are hidden.

Setting structure ”Heating engineer“




List of displays

Error code

Maintenance code

Special operation code

Error Code Description of maintenance



102028405081105109110113117118121126127128129131133146178217218320

Outside temperature sensor errorBoiler temperature 1 sensor errorFlue gas temperature sensor errorReturn temperature 1 sensor errorDHW temperature 1 sensor errorShort-circuit LPBMaintenance messageBoiler temperature supervisionLockout by SLTSafety shutdown flue gasUpper pressure limit (crossed)Critical lower pressure limit (crossed)Flow temperature 1 (HC1) supervisionDHW charging supervisionLegionella temperature not reachedLoss of flame in operationWrong air supplyBurner faultSafety time exceededConfiguration error common messageTemperature limiter heating circuit 1Sensor error common messagePressure supervision common messageDHW charging temperature sensor error

1235

18

102122

Burner hours run exceededBurner starts exceededMaintenance interval exceededWater pressure heating circuit too low(dropped below lower pressure limit 1)Water pressure 2 heating circuit too low(dropped bel ow lower pressure limit 2)

Replace battery of outside sensorMaximum flue gas temperature exceededWater pressure 3 too low(dropped below lower pressure limit 3)

301302303309310314

Manual operationSLT testChimney sweep functionSimulation outside temperatureAlternative energy operationEconomy mode




Switching-on the appliance

1 Open the gas valve.2 Switch on the boiler using the on/off switch on the control panel.3 Set the type of operation to “automatic operation ” using the “heating selection” button.

Switching-off the appliance

The appliance can be switched off in three ways:

A The boiler remains available for hot water operation. Using the “heating selection” button,set thetype of operation to .

B The boiler is out of operation and only comes into operation due to the automatic frost protectionsystem. Using the “heating selection” button, set the type of operation to .

C Switch off the boiler completely.1 Switch off the boiler using the on/off switch.2 Close the gas valve.

Warnings

The appliance should be installed by a competent installer.These operating instructions should be closely followed.If the cause of the fault cannot be determined, contact the Service department. Never carry out repairs on your own.

General

The commissioning should only be carried out by qualified personnel. The guarantee may be void if this is not adhered to.

COMMISSIONING


COMMISSIONING


Before operating the appliance, the following should be done:

- Switch off the electrical power supply of the appliance- Remove the front door casing- Check the leak-tightness of the gas connection- Check whether the electrical connection including earthing have been correctly made.Also check whether the phase (L) has been connected properly. The boiler is phase sensitive.

- Twist open the cap of the automatic air vent.- Fill the appliance and the system with water.- Fill the condensate bottle trap with water. The beaker on the bottom can be easily unscrewedand filled.

- Check the flue gas discharge connection and, if present, the air supply connection.- Open the gas valve and vent the gas pipe.- Switch on the electrical power supply of the appliance.- Check the built in pump.- Check the boiler at maximum load.Start the boiler. Allow the boiler to run at full load and stabilise (around 3 minutes). At full load, the following settings should be checked and corrected if necessary:

Reference value for maximum loadReference value for CO2

9.0% + 0.2 for natural gas G20, G25Ethos 70,90 & 110 10.3% + 0.2 for propane G31Ethos 130 10.0% + 0.2 for propane G31

Reference value for CO< 50 ppm for natural gas G20, G25< 70 ppm for propane G31

Measure the gas pressure before the gas valve. At maximum load, this must be at least 17 mbar for natural gas and30 mbar for propane. If there are several boilers, this pressure should be measured with all the boilers operating atmaximum load.

Check the water-side temperature difference (Δt) between the fl ow and return connections of the boiler. The Δt should be between 15 and 25 K at full load.

- Check the boiler at minimum load.Set the boiler back to minimum load. At minimum load, the following settings should bechecked and corrected if necessary:

Reference value for minimum loadReference value for CO2

8.4% + 0.2 for natural gas G20, G25Ethos 70,90 & 110 9.5% + 0.2 for propane G31Ethos 130 9.2% + 0.2 for propane G31

Reference value for CO< 10 ppm for natural gas G20, G25< 10 ppm for propane G31



COMMISSIONING

Maximum load adjustment

Press and hold the ‘heating selection’ button until ‘controller stop function on’ appears on the display, the boiler will then start to operate. The display will the show;

To adjust to maximum rate press the ‘OK’ button, the display will then flash, turn the dial clockwise to 100% and press the ‘OK’ once more. The boiler will modulate to maximum load

Minimum load adjustment

Press and hold the ‘heating selection’ button until ‘controller stop function on’ appears on the display, the boiler will then start to operate. The display will the show;

The boiler will modulate to minimum load. If the boiler is already operating at maximum load i.e. display showing100%, Press the ‘OK’ button and turn the dial anti clockwise to 0%, press the ‘OK’ button once more and the boilerwill modulate to minimum load

To return to normal operation press and hold the ‘heating selection’ button until ‘controller stop function off ’ appears in the display.


COMMISSIONING


Setting the CO2 value for the Ethos Range

Any adjustments should only be carried out by competent persons

After adjustment of the gas valve the adjusters must be resealed

There is a setting screw on the gas valve with which the CO2 value can be set at maximum load. Set the boiler atmaximum load and check the CO2 value. If necessary, adjust with the fl at setting screw: clockwise gives less CO2,anti-clockwise gives more CO2.

There is a torcx setting screw on the gas valve with which the CO2 value can be set at minimum load. Set the boilerat minimum load and check the CO2 value. If necessary, readjust with the torcx setting screw: clockwise gives lessCO2, anti-clockwise gives more CO2 . After the CO2 values have been set, they should be checked once again andcorrected if necessary.

When setting the CO2 levels on the boiler thereadings can be taken from the flue gas temperature sensor tapping. Disconnect the electrical connection from the sensor. Unscrew thesensor and remake the electrical connection.

Upon completion of tests replace the flue gas temperature sensor in reverse order

Flue gas temperature sensor tapping

Ethos 70 - 110 Gas Valve Ethos 130 Gas Valve

Maximum Load Adjustment Screw

Minimum Load AdjustmentScrew Under Cap

Maximum Load Adjustment Screw

Minimum Load AdjustmentScrew Under Cap



COMMISSIONING

- Conversion from natural gas to propane.- For the Ethos range a throttle ring will be required for propane.- This should be installed between the gas valve and venturi. After

the conversion, the CO 2 values should be set at full load and minimum load.

- For the Ethos 130 it’s only necessary to change the gas volume on the gas valve by using the setting screws.

- Remove the measuring equipment and re-fit the case- The boiler is now ready for operation

Safety

Maintenance should only be carried out by competent persons. Always isolate the gas supply at the gas service valveand isolate and disconnect the electrical supply prior to removal of any components. Ensure that all external controlsare isolated. After completion of maintenance or component replacement the following should be checked:

- Test for gas soundness- Check the water system is correctly filled and free of air. Air in the boiler could cause damage to the heatexchanger. For this reason the automatic air vent in the boiler must be left open.

- With the system hot check the boiler for signs of water leakage.- Check the gas rate and measure the CO2 content to ensure it is within the specified range.Adjust if necessary(see commissioning section page 32).

- Carry out functional tests.- If in the unlikely event there is a component failure please refer to pages 36,37,38 & 39 for instructions onremoval of major components.

Servicing schedule

To ensure the safe and efficient operation of the appliance it is recommended that is checked at regular intervals andmaintained as necessary. The frequency of maintenance will depend upon the installation condition and usage butshould be carried out at least annually. Mikrofill systems limited does not accept liability resulting from the use ofunauthorised components or the repair and maintenance of appliances not out in the companies recommendationsand specifications.

- Light the boiler and carry out function checks, noting any operational faults.- Run the system up to operating temperature then check the gas consumption rate. Refer to the commissioningsection (page 32) on how to operate the boiler at maximum rate.

- Connect a suitable flue gas analyser to the flue gas test point ( see commissioning section page 32) and check the CO2 values are within those specified in the commissioning section, if values are correct and CO/CO2 ratio is within legal limits, then no further action is required. If the values are incorrect remove and clean the burner as described in the removal of components section.

- Inspect the heat exchanger, if there are signs of debris, vacuum heat exchanger and flush with water.- Remove the condensate trap cap and flush through with water.- Check that the flue terminal is unobstructed and that the flue system is sealed correctly.- After completing maintenance carry out safety checks as above.

MAINTENANCE

Type Diameter of throttle ring

Ethos 70 6.0mm

Ethos 90 6.0mm

Ethos 110 6.8mm


MAINTENANCE


Removal of gas valve and venturi (Ethos 70,90 & 110 models)

- Isolate gas and electrical supplies to the boiler- Remove 4 No. screws from flange on rear of gas valve (see diagram below (1))- Remove electrical connection on gas valve- Remove 2 No. screws from venturi/fan ( see diagram below (2))- Remove gas valve/venturi assembly from boiler- To separate gas valve and venturi remove 3 No. screws on gas valve/venturi assembly (see diagram below (3))

- Replace in reverse order ensuring all seals/ gaskets are in good condition (renew if necessary).



MAINTENANCE

Removal of gas valve and venturi (Ethos 130)

- Isolate gas and electrical supplies to the boiler- Remove 4 No. screws from flange on rear of gas valve (see diagram below (1))- Remove electrical connection on gas valve- Remove 6 No. screws from venturi/fan (see diagram below (2))- Remove gas valve/venturi from boiler- To separate gas valve and venturi remove 4 No. screws on gas valve/venturi (see diagram below (3))- Replace in reverse order ensuring all seals/ gaskets are in good condition(renew if necessary)

.


MAINTENANCE


Removal of fan and burner assembly

- Isolate the gas and electrical supplies to the boiler- Remove plugs from ignition electrode and ionisation probe- Remove gas valve and venturi as described on pages ? & ?- Remove the two electrical connections from the fan- Remove 6 no. nuts from burner (1)- Extract the burner/fan assembly- To separate the fan from the burner remove 4 No. screws from fan (2)- Replace in reverse order ensuring all seals/gaskets are in good condition (renew if necessary)

.



MAINTENANCE

Removal of pump/pump head

- Isolate gas and electrical supplies- Isolate and drain water from boiler- Disconnect electrical supplies from pump- For complete pump removal unscrew pump unions (1) and extract pump- For removal of pump head, remove 4 no. screws (2) from pump and separate pump head from base- Replace in reverse order ensure all seals/gaskets are in good condition (renew if necessary)

.


BOILER PARTS


No. Part No. Description No. Part No. Description

1 301000 Ethos 70 heat exchanger 16 301022 Ethos 70 air/gas inlet tube

302000 Ethos 90 heat exchanger 302022 Ethos 90 air/gas inlet tube

303000 Ethos 110 heat exchanger 303022 Ethos 110 air/gas inlet tube

304000 Ethos 130 heat exchanger 304022 Ethos 130 air/gas inlet tube2 301002 Grundfos 25-80 Pump 17 301023 Burner Gasket

3 301001 Ethos 70-110 combustion fan 18 301024 Ethos 70-110 fan gasket304001 Ethos 130 combustion fan 304024 Ethos 130 fan gasket

4 301003 Ethos 70-110 gas valve 19 301025 Burner door mounting nuts

304002 Ethos 130 gas valve 20 301019 3/4” pressure relief valve5 301004 Ethos 70 venturi 21 301026 Ethos 70 gas inlet pipe

301004 Ethos 90 venturi 302026 Ethos 90 gas inlet pipe

301004 Ethos 110 venturi 303026 Ethos 110 gas inlet pipe301004 Ethos 130 venturi 304026 Ethos 130 gas inlet pipe

6 301011 Ignition electrode 22 301027 Ethos 70 - 110 sealed air inlet box

7 301012 Ionisation probe 304027 Ethos 130 sealed air inlet box

8 301010 Ignition electrode cap 23 301008 Sealed air inlet trap9 301010 Ionisation probe cap 24 301028 Ethos 70 - 110 air inlet tube

10 301017 Flow temperature sensor 304028 Ethos 130 air inlet tube11 301018 Return temperature sensor 25 301009 Condense siphon

12 301016 Flue gas temperature sensor 26 301029 70 - 110 venturi gasket

13 301020 Automatic air vent 27 301030 Burner door insulation

14 301015 Pressure sensor

15 301021 Ethos 70 Burner

302021 Ethos 90 Burner





BOILER PARTS

No. Part No. Description No. Part No. Description

1 301031 Ethos 70 top casing 7 301037 Ethos 70 - 90 bottom casing302031 Ethos 90 top casing 303037 Ethos 110 - 130 bottom casing

303031 Ethos 110 - 130 top casing 8 301038 Front door casing

2 301032 Ethos 70 - 90 right hand casing 9 301039 Electrical isolation switch303032 Ethos 110 - 130 right hand casing 10 301040 Control fascia

3 301033 Back panel c/w fillets 11 301041 Controls reset switch4 301034 Main control pcb 12 301042 Control panel casing

5 301035 Ignition transformer

6 301036 Ethos 70 - 90 left hand casing7 303036 Ethos 110 - 130 left hand casing


CONVERSION FORMULAE & FACTORS


Formulae

CO2 =20.9 - measured 02

20.9x 11.7 O2 = 20.9 -

measured C02 x 20.9

11.7

11.7% CO2 is the maximum CO2 percentage that is generated by stoichiometric burning of G20 natural gas (H-gas).

Excess air N:

N =20.9

20.9 - measured O2x 0.914 N = 1+

11.7

CO2 measuredor 1 x 0.914( (

Conversion factors

For NOx (N=1):1 ppm = 2.05 mg/m3 =1.759 mg/kWh = 0.498 mg/MJ

For CO (N=1):1 ppm = 1.24 mg/m3 =1.064 mg/kWh = 0.298 mg/MJ

Example:

Measured values for an environmentally friendly unit:NOx = 15 ppmCO2 = 10%

What is the value for NOx according to the most usual standard in mg/kWh for N=1?

O2 = 20.9 -10 x 20.9

11.7= 3% N =

20.9

20.9 - 3= 1.17

NOx (for N = 1) =15.0 × 1.17 = 17.6 ppm17.6 × 1.759 = 30.9 mg/kWh

Table 13 Conversion factors

W Kcal/h Btu/h

1 0.86 3.41

1.163 1 3.97

0.293 0.252 1



CONVERSION FORMULAE & FACTORS

1 kcal = 4.187 kJ1 kWh = 3.6 Mj

Efficiency at the flue gas side.The difference between gross and nett calorifi c values is the heat of evaporation of the combustion produced water. At 298.15 K (25°C), this is 2442.5 kJ/kg (583.38 kcal/kg).

For non-condensing boilers;

nb = 90 -0.339

CO2x ΔT( (

+ 0.008 no = 100 -0.377

CO2x ΔT( (

x 0.009

For condensing boilers;As a result of condensation, the efficiency at the lower value increases.

nb = 90 -0.339

CO2x ΔT + A( (

+ 0.008 ( (

7.5 + 0.006 ΔT

no/ nb = 1.11

Δt = Difference in temperature between the flue gases and the environmental temperature (K)nb = Fuel efficiency at the gross calorifi c valueno = Fuel efficiency at the nett calorifi c valueCO2 = The volume of CO2 in the flue gas (%)O2 = The volume of O2 in the flue gas (%)A = The quantity of condensed water in the appliance per m3 gas in kg (kg/ m3 gas).

meg/1

ºdH

ºf

ºe

MgCaCO3/1

0.37

0.2

0.285

0.02

1

1

0.56

0.8

0.056

2.8

1.78

1

1.43

0.1

5

1.25

0.7

1

1.54

50

17.8

10

14.3

1

meg/L ºdH ºf ºe MgCaCO3/1

Table 14 Derivation of degree

1 degree English hardness (°e) = 65 mg CaCO3/imp. gallon1 Grain/US Gallon = 0.958 odH1 milligram equivalent per l (mval/l) = 2.8 odH1 ppm (parts per million) CaCO3 = 1 mg CaCO3/1


MIKROFILL SYSTEMS LTDWEST COURTMERSE ROADNORTH MOONS MOATREDDITCH WORCESTERSHIRE B98 9HL

T: +44 (0)8452 60 60 20

F: +44 (0)8452 60 60 21

E: [email protected]

W: www.mikrofill.com MFS/PM10080087


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