STRATA WALL MOUNTED, GAS FIRED, U LT R A H I G H E F F I C I E N C Y C O N D E N S I N G B O I L E R I N S T R U C T I O N S F O R I N S TA L L AT I O N , S E R V I C I N G & O P E R AT I O N F O R M O D E L S 4 5 , 6 0 & 7 5 L 102
STRATA1 Index page section 3 . . . . . . . . . . .1.0 . . . . . . . . . . . .2.0 General Notes Product Description 4 . . . . . . . . . . .2.0 Product Description (contd) 5 . . . . . . . . . . .3.0 Technical Data & Dimensions 6 . . . . . . . . . . .4.0 . . . . . . . . . . . .5.0 . . . . . . . . . . . .6.0 Delivery Consignment/Unpacking The Boiler Boiler Location Installation Clearances 7 . . . . . . . . . . .7.0 . . . . . . . . . . . .8.0 Wall Mounting Gas Connection 8 . . . . . . . . . . .9.
STRATA1 1.0 general notes These instructions are intended to assist the installer, commissioning engineer, maintenance engineer and user with the installation, maintenance and usage of Strata 1, 45, 60 and 75 models gas fired condensing boilers. Please read this manual fully before commencing the installation of the appliance. The Strata 1 must only be installed by persons deemed to be competent i.e. Corgi Registered.
STRATA1 2.0 product description (contd) energy saving In addition to the extremely efficient burner and heat exchanger system employed in the Strata 1, each appliance includes a modulating speed boiler primary pump. This feature allows the boiler to self-maintain a 20°C ∆t across the heat exchanger, optimising the heat exchanger efficiency and reducing also the electrical consumption of the pump motors.
STRATA1 3.0 technical data & dimensions Model plan - models 45/60/75 38 435 231 55 108 4 2 45 60 kW 43 57 72 Nominal Heat Output 80/60°C kW 41.3 54.7 69.1 75.6 Nominal Heat Output 50/30°C 458 229 1 Strata 1 Nominal Heat Input Nett (max) kW 45.2 59.9 Input Rate Nat Gas (max) m3/h 4.7 5.9 7.6 Input Rate LPG G31 (max) m3/h 1.76 2.33 2.
STRATA1 4.0 delivery consignment /unpacking the boiler The boiler is delivered as a consignment of a carton containing the boiler and associated fittings, plus any other optional ancillary flue or control components in separate cartons. The boiler carton contains:• Assembled boiler • Wall mounting bracket • Fittings carton including 2Nr 11/4” x 11/4” x 1/2” BSP Tees, 2Nr 11/4” x 1/2” BSP reducing sockets, 1Nr 3/4” BSP Inlet x 1” BSP outlet safety valve set 3.
STRATA1 7.0 wall mounting The Strata 1 boiler mounts to the wall via a wall mounting bracket which interlocks to a rail mounted upon the rear of the boiler. The wall mounting bracket should be firmly a fixed to the wall using suitable fixings with a countersunk head. The wall mounting bracket positioning detail is shown in fig 1.
STRATA1 9.0 system flow & return connections Note The Strata 1 boiler must only be installed on sealed and pressurised systems. The maximum working pressure of the boiler = 3 bar. A safety valve set 3.0 bar is supplied with the boiler and must be installed onto the flow pipe adjacent to the boiler. It is recommended that the final working pressure (hot) of the system does not exceed 2.3 bar.
STRATA1 10.0 condense waste connection (contd) If any part of the condense waste pipe is to be run external to the building or is at risk of freezing, then the pipe must be suitably insulated to protect from freezing. If a suitable drain for accepting the condense waste is not available nearby to, and below the boiler, (e.g.
STRATA1 12.0 conventional flue installation The Strata 1 boiler has an excess pressure combustion system, which coupled with the very low flue gas temperatures produced allows the appliance to exhausted over considerable distances using 80mm Polypropylene PPS flue pipe and fittings. Suitable flue pipe and fittings are available from MHS Boilers Ltd and are listed below.
STRATA1 13.0 room sealed flue installations The Strata 1 boiler has an excess pressure combustion system, which coupled with the very low flue gas temperatures produced allows the appliance to be exhausted and supplied with room sealed combustion air using a concentric flue arrangement of 80 mm PPS polypropylene flue pipe within a 125 mm outer painted metal air tube over considerable distances. A range of concentric flue components are available from MHS Boilers Ltd and are listed below.
STRATA1 13.
STRATA1 13.
STRATA1 13.0 room sealed flue installations (contd) Installation of Standard Wall Terminal In order to determine the length of concentric tube required to correctly terminate a rear outlet arrangement, the following procedure should be followed. 1. Measure wall thickness W in mm - see fig 10. 2. Mark off and cut flue tubes following guidance shown in fig 11 below. Flue tubes should be cut to length TL in mm. Both inner and outer tubes should be cut flush with each other, square and any burrs removed.
STRATA1 13.0 room sealed flue installations (contd) Method of assembly of horizontal concentric flue system using standard wall terminal. 1. Lubricate male ends of concentric bend with silicone grease and locate bend into flue and air tube connection sockets on the top of the boiler and gently push fully 6 1 3 home. 2. Slip flue tube and terminal assembly through prepared hole in the outside wall. 4 3. Locate wall bezel plate loosely onto air tube. 2 4.
STRATA1 Installation of Vertical Discharge Wall Terminal With Side Outlet ø80 PPS 90º Bend Side Outlet ø80 Bird Mesh ø80 PPS Tube Exhaust Outlet Installed vertically Upwards on Some Wall Aspect Required Length Cutting Line measure from this point TL (mm) TL = W+L1+260mm 170 Wall Bezel Plates W Fig 14. Fig 15.
STRATA1 Method of assembly of extendable vertical discharge wall terminal assembly. See fig. 18 1. Lubricate male ends of concentric bend with silicone grease and locate bend into flue and air tube connection sockets on the top of the boiler and gently push fully home. 2. Slip flue tube and terminal assembly through prepared hole in the outside wall. 3. Locate internal wall bezel plate loosely onto air tube. 4.
STRATA1 14.0 examples of calculating flue pressure loss example 1 thermal up-draught when flue gas temp 80°C and outside temp -5°C A Strata 1-60 boiler is installed with a concentric flue system which takes an all horizontal route to a wall terminal. Length of flue = 3m including one 90° bend. A = Insulated or within the building B = Un-insulated and exterior to the building Resistance = 3 x 1m length 80/125 concentric tube @ 8.5 Pa = 25.5 1 x 90° 80/125 concentric bend @ 8.5 Pa = 8.
STRATA1 14.0 calculating flue resistance The excess pressure available for overcoming the frictional resistance of a flue system is 100 Pa. The adjacent table of flue component resistances will assist the designer in calculating total flue system frictional loss. If the total installed flue system resistance exceeds 100 Pa., then the result will be a reduction in boiler output. Reference to the “Effect of Flue System Resistance On Boiler Output”, graphs will assist.
STRATA1 15.0 flue terminal positions (contd) Minimum dimensions of flue terminal positions see fig 19 Dimension Terminal Position Balanced flue room sealed Non room sealed A Directly below an opening, air brick, windows etc. Not Recommended. 300 mm 300 mm Below gutters, soil pipes or drain pipes 75 mm 75 mm C Below eaves 200 mm 200 mm D Below balconies or car port roof. Not Recommended. 200 mm 200 mm but installation not recommended. but installation not recommended.
STRATA1 16.0 ventilation requirements single appliances The room or space in which the Strata 1 boiler is installed may require to be ventilated in accordance with BS5440: Part 2: 2000 or BS 6644: 1991 as appropriate to the boiler input. The following tables must be read to ascertain the amount of ventilation required. Table 1 Room Installation - Non Room Sealed Flue.
STRATA1 16.0 ventilation requirements single appliances (contd) Table 6 Compartment Installation - Room sealed flue Natural Ventilation direct to outside air.
STRATA1 17.0 hydraulic system design ● The Strata 1 boiler can be operated to serve a heating load in a number of ways: 1. Constant flow temperature, with the option to set either high temperature (85°C), medium temperature (75°C) or low temperature (55°C). 2. Direct-on-boiler weather compensated flow temperatures, with adjustable maximum flow temperature. 3. Underfloor heating coils via a VT mixing valve with a maximum flow temperature of 55°C plus a second circuit (eg.
STRATA1 17.0 hydraulic system design System Type 1 24 OS= Outside air temperature sensor, used where direct-on-boiler weather compensated flow temperatures are required C= Room temperature & time controls e.g. RE2132 modulating room unit from MHS Boilers, or, separate time clock & room thermostat PS= Low water pressure cut off switch.
STRATA1 17.0 hydraulic system design System Type 2 IV IV 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 MHS Boilers, or, separate time clock & room thermostat S= HWS sensor from MHS Boilers.
STRATA1 17.0 hydraulic system design System Type 3 Strainer IV IV Max Velocity 0.5m/s Low Velocity Mixing Header 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 MHS Boilers, or, separate time clock & room thermostat. PRO1=Pump regulation module from MHS Boilers.
STRATA1 17.0 hydraulic system design System Type 4 DOC Typical Single Strata 1 boiler installation serving heating & domestic hot water. Hot water is priority and is served via a divertor valve and the boiler's in built circulating pump where index loss through HWS primaries is less than boiler pump residual head*. Heating circuit index loss exceeds boiler pump residual head* and is served via a low velocity mixing header and a separate pump.
STRATA1 17.0 hydraulic system design System Type 5 DOC Typical Single Strata 1 boiler installation serving heating & domestic hot water with hot water priority. Hotwater & heating circuits both have index resistance exceeding boiler pump residual head* & are served by independent pumps from a low velocity mixing header. Heating flow temperature may be fixed/constant or weather variable. W/T= Alternative to "S" where "W" is a time switch in series with a cylinder thermostat "T". Allows for timed HWS.
STRATA1 17.0 hydraulic system design System Type 6 IV Expansion Vessel LSV CWM Filling Point Strainer IV PS IV IV NRV NRV IV NRV IV FS= Flow temperature sensor RS= Return temperature sensor Condense Waste Room temperature controls e.g. RE2132 modulating room unit from MHS Boilers, or, separate time clock & room thermostat. DOC C= Strata 1 Boiler Outside air temperature sensor, used where direct-on-boiler weather compensated flow temperatures are required.
STRATA1 17.0 hydraulic system design System Type 7 DOC Under Floor Coils Zone ∆t 10ºc RC 2 IV IV IV V Max 0.
STRATA1 17.0 hydraulic system design System Type 8 Typical Single Strata 1 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. Strainer IV Filling Point CWM IV DOC Expansion Vessel PS LSV DOC Condense Waste DOC IV SV AAV P= WC= RS= CS= PS= Indirect Cylinder/Calorifier Reg Valve Low Velocity Mixing Header Max Velocity 0.
STRATA1 Typical Schematic Arrangement Where System Has Multiple Pumps That Will Operate At The Same Time. Flow Header Circuit Pumps That Can/Will Run At The Same Time Boiler/s Low Velocity Mixing Header Max Velocity 0.5m/s 17.1 water treatment system cleaning The entire system must be thoroughly cleansed and flushed to remove debris, flux residues etc before opening the boiler isolation valves & flooding the boiler.
STRATA1 17.4 care with the use of soldering flux The Strata 1 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 before use, and that any flux manufacturers recommendations are strictly followed with regards to use in conjunction with stainless steel. 18.
STRATA1 34 FUSE 2 (X) 230 VAC FUSE 24V 10 1 5 1 1 8 1 X9 1 3 6 5 HSP TOP 6 3 5 5 F 2 1 F RS232 1 PRO1/MRO3 2 ALARM CONTACT L L 6 L 7 L 1 N N 5 N 2 N 4 PE PE 3 PE PE PE K20 X51 L N N PE PE 1 = Lower Burner/Heat Exchanger.
4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel 1 2 X16 6 5 1 2 1 Not Used PMW +24V Boiler Dip Switch Settings GND Air * Outside Sensor 4 3 2 5 1 RE2132 Modulating Room Unit ** Room Thermostat And Time switch Supply 230 V X3 10 O S Low Pressure Switch break on Pressure Fall Install only one method of external time and room temperature control. If room and stat time switch are required, then do not install RE2132 room unit and vice versa.
STRATA1 36 1 3 4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel 2 Not Used 1 Boiler Dip Switch Settings Outside sensor installed. Room stat & time switch installed. 3 6 L1 PE N L2 L1 PE N No outside sensor. Room stat & time switch installed. Outside sensor installed. RE2132 modulating room unit installed. No outside sensor. RE2132 modulating room unit installed. Clo se SPDT Relay ** Weiland plug Nr2-notshown.
4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel 5 6 1 2 L1 PE N 4 A1 A2 R1 R2 R3 3 L1 PE N L2 L1 PE N 1 X3 10 2 5 PRO1 Heating Pump 2A Max Boiler Dip Switch Settings +24V GND * Sensor Outside sensor installed. Room stat & time switch installed. PWM Outside Air O S No outside sensor. Room stat & time switch installed. RE2132 Modulating Room Unit QAW 44 Optional Remote Sensor Install only if direct-on-boiler weather compensated flow temperature is required.
STRATA1 38 1 3 4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel. PRO1 has factory made on plugs and leads for these connections 6 X3 1 2 6 5 1 2 L PE N HWS sensor PRO1 Low Pressure Switch break on Pressure Fall 1 2 ** Install only if direct-on-boiler weather compensated flow temperature are required. Install only one method of external time and room temperature control. If room and stat time switch are required, then do not install RE2132 room unit and vice versa.
4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel. PRO1 has factory made on plugs and leads for these connections 6 1 2 L1 PE N 5 L1 PE N 4 A1 A2 R1 R2 R3 3 L1 PE N L2 1 X3 6 5 1 2 1 2 C2 RE2132 Modulating Room Unit ** ** Install only if direct-on-boiler weather compensated flow temperature are required. Boiler Dip Switch Settings Weiland plug Nr2-notshown. Used only on LPG installations where an additional remote gas safety shut off valve is req'd.
STRATA1 40 1 4 = Weiland Plugs/Sockets on boilers X1,X2,X4 = Terminal Rails on KKM2 Kaskade Manager 2 4 6 1 3 10 5 7 12 9 X1 14 11 16 13 15 18 20 17 22 19 24 X2 21 26 23 28 25 30 27 32 29 34 31 33 38 35 37 X4 +24V GND R2 R3 Boiler No3 1 1 1 R 1/1 L1 PE N R 1/2 L1 PE N R2 R3 Boiler No2 * R 1/3 Supply 230 V Supply 230 V * External Controls For Heating Circuit * - If Required * Cylinder Stat/HWS Time Switch RE2132 Modulating Room Unit 21 R2 R3 19 Boiler No
4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel.
STRATA1 42 1 3 4 5 6 = Weiland Plugs/Sockets X3,X16 = Controls Sockets on Control panel 6 X3 1 2 L1 PE N 5 A1 A2 R1 R2 R3 L1 PE N L2 L1 PE N 4 X16 10 6 5 1 2 1 NOT USED Supply 230 V HW M\V Low Pressure Switch break on Pressure Fall M Boiler Dip Switch Settings CH M\V M L 3 4 5 6 7 N N E E Junction Box HW M/V & CH M/V = typical spring return type motorised valves with end switches R/Stat Cyl Stat L L N PE System Pump Max 2A 2 L N HW HW OFF ON CH CH OFF ON Typi
STRATA1 18.1 0-3/0-10 volt control The Strata 1 can be operated via 0-3 volt or 0-10 volt control. The connection details are shown in fig 22. For further details on 0-3 or 0-10 volt control please contact the Technical Department. To Boiler Socket Nr: 4 Weiland Plug Nr: 4 0-10 volt Adapter A1 A2 R1 0v R2 R3 V+ 0-3 volt control direct to boiler plug Nr: 4 without adaptor. 0-10 volt control via 0-10 volt adapter (optional extra).
STRATA1 19.1 Pre-commissioning checks a) Ensure system has been thoroughly cleansed and flushed, any strainers have been cleaned and that the appropriate water treatment has been added to the system to prevent corrosion, scale formation etc. b) Ensure the system and boiler has been properly and fully flooded and vented of air and the cold fill pressure at the boiler is at a minimum 0.5 bar.
STRATA1 19.
STRATA1 19.3 First Firing (contd) c) Turn the green potentiometer (HWS) fully clockwise(60ºC). Control Panel Display d) e) Attach U tube manometer to inlet pressure test point on right hand gas valve (See figure 21) nominal pressure should be 20mb for NG or 37mb for LPG. Press the “Engineers” test button twice - the screen should/must display “10 min Low”. The boiler should now ignite and following stabilisation of the flame, will turn down to and hold at minimum output.
STRATA1 19.3 First Firing (contd) NOTE: Test period expires after 10 minutes - if this expires whilst commissioning is still in progress, press Engineers button twice to reset and carry on with necessary checks and adjustments. To exit “10 min Low” test period - press Engineers button once, this will set controls to auto. h) Turn the green potentiometer (whilst still in “10 min Low” operation) fully anti-clockwise (20ºC). This will set the burners to maximum output.
STRATA1 Default Compensation Slope Dip Switch Settings When compensation req'd outside sensor must be installed and dip switch No.2 set to "ON".
STRATA1 Range of Parallel Displacement of Slope B * 1 +10 -10 K 90 RED -20 80 +20 +20 * 2 60 50 40 +10 -10 lt fau de Boiler Flow Temperature ºC * -20 70 RED K +20 -20 30 20 * BLUE +20 BLUE 10 -20 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 -1 Outside Air Temperature ºC Range of Parallel Displacement of Slope C * 1 +10 -10 K 90 -20 80 +20 RED 70 Boiler Flow Temperature ºC RED * 2 60 * -20 +20 +10 -10 50 K 40 -20 +20 30 20 * 10 BLUE +20 BLUE -20 -20 -15 -
STRATA1 19.5 Setting domestic hot water temperature A) With HWS sensor in/on DHW Calorifier. 1) B) Set desired stored hotwater temperature by using the “green” potentiometer on the boiler control panel. This arrangement will give the potential to charge hot water continuously (24 hour/day) with priority over the heating demand. This arrangement is recommended only with high/quick recovery type calorifiers. With cylinder thermostat in/on DHW Calorifier.
STRATA1 19.6 Service button/setting heating output. (contd) c) d) e) Setting minimum pump speed. If it is required to limit the minimum pump speed of the in built boiler pumps then this may be done by the following: i) Press “red” reset button once. Press service button once. Press “red” reset button three times. Screen display will show “Mn pum”???
STRATA1 21. Servicing instruction GENERAL In general, maintenance/inspections should take place: a) When the display on the unit indicates that inspection is required (status shows “SERVICE”). b) At least every 18 months, before carrying out any maintenance the unit must be inspected. 21.1 Inspection a) Ask the user about any problems with the boiler unit or any other comments. b) Check the water pressure of the installation.
STRATA1 21.2 Maintenance (contd) at b) The pressure of the installation must be between 1 and 2 bar: any possible leaks in the system must be identified; if necessary, have a pipework engineer solve the problem. at c) Possible leaks or weeping must be resolved immediately. at d) In case of water leakage or ingress from the air supply pipe, the cause must be found. at e) The siphon must be rinsed.
STRATA1 22. Screen display/ Diagnosis of faults 22.1 Screen display The control panel of the Strata 1 boiler has an LCD screen, displaying two lines of data. This screen provides information about the operation of the appliance; it shows operation messages (non flashing) and fault messages (flashing display). The first line contains text information about the status of the unit.
STRATA1 22.1 Screen display/Diagnosis of faults (contd) STATUS MESSAGES (FLASHING DISPLAY) INDICATING A FAULT A flashing display indicates a fault and that the boiler has shutdown (lockout). The boiler will not attempt to operate until the “red” reset button is pressed. Any repetitive flashing fault message should be investigated, the cause found and corrective action taken. for each flashing display message there is a possible cause, see list of cause numbers following the “flashing status” list.
STRATA1 22.
STRATA1 22.2 (possible) Causes of fault (contd) 11 - Fan is defective / Replace fan 12 - There is no gas supply available / Investigate, restore gas supply 13 - Low gas pressure / Investigate and rectify 14 - Fuse defective / Check fuses and replace as necessary 15 - Gas valve min output setting is incorrect / Check and adjust min output CO2% 16 - Oxidation on burner mounting screws. Loosen and retighten screws.
STRATA1 23.0 Instructing the user The installer should inform the user about the operation and use of the Strata 1 boiler and in particular point out:- Any safety provisions -The need to carry out regular maintenance when the screen display shows a “SERVICE” message The installer must provide the user with all documentation relating to the Strata 1 boiler and any ancillary items. 23.2 To turn on the appliance 1- Ensure the manometer indicates a pressure within the system of not less than 0.5bar.
STRATA QW/08/00 A member of the Modular Heating Group Plc 35 Nobel Square, Burnt Mills Industrial Estate, Basildon, Essex SS13 1LT Tel: 01268 591010 Fax: 01268 728202 http://www.modular-heating-group.co.uk This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale.
