E-Tech 15 Installation, Operating And Maintenance Instructions

Installation, operating and maintenance instructions

E-Tech 09 - 15

Single phase

E-Tech 22 - 28 - 36

Tri phase

excellence in hot water

09/09/2004 - 66402800

WARNINGS

Who should read these instructions

Symbols

Recommendations

Applicable standards

Importants notes

Manual handling instructions

Removing the boiler from the packaging

INTRODUCTION

Description of the specifications

Lining

Heating body

Heating elements

Equipment

Connection

Dual stage thermostat

Certification

Legend

INSTRUCTIONS

User data

Setting up

Optional internal timeclock

Pressure in the heating system

TECHNICAL CHARACTERISTICS

Electrical data of model 09

Electrical data of model 15

Power variation (kW) relative to voltage

Electrical data of model 22 - 28 - 36

MOUNTING

Dimensions

Wall mounting

Installation room

INSTALLATION

Disassembling

Heating connection

Heating connection + DHW : “Y” plan

Heating connection + DHW : “S” plan

Electric connection / Models : 09 - 15

Electric connection / Models : 22 - 28 - 36

Sizing of supply wires

Wiring diagrams / Models : 09 - 15 - 22

Wiring diagrams / Model : 28

Wiring diagrams / Model: 36

Power wiring / Models : 09 - 15

Power wiring / Model : 22



HONEYWELL SUNDIAL WIRING DIAGRAMS

Honeywell Sundial Wiring Centre ‘S’ plan

Honeywell Sundial Wiring Centre ‘Y’ plan

COMMISSIONING AND MAINTENANCE

Commissioning - Water

Commissioning - Electrical

Starting the boiler

Maintenance

REMOVAL THE HEATING ELEMENTS

SPARE PARTS

INDEX

- 1 -

3

3

3

3

3

3

3

3

3

3

2

2

2

2

2

2

2

2

5

5

5

5

5

6

7

8

8

9

10

10

10

10

22

22

23

24

24

24

24

24

11

11

12

12

12

13

14

14

15

16

17

18

19

20

21

25

26

WARNINGS

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

Essential instruction for the correct operation of the installation.

IMPORTANTS NOTES

These instructions are an integral part of the equipment to which they relate and must be handed to the user.

The product must be installed and serviced by qualified engineers in accordance with the regulations in force.

The manufacturer declines all liability for any damage caused as a result of incorrect installation or in the event of the use of appliances or accessories that are not specified by the manufacturer.

The manufacturer reserves the right to change the technical characteristics and specification of its products without notice.

the availability of certain versions and their accessories can vary following the market

Essential instruction for the safety of persons and the environment.

MANUAL HANDLING INSTRUCTIONS

Danger of electrocution

Danger of burns

RISK OF INJURY

LIFT WITH CARE

HEAVY

APPLIANCE

The weight of this boiler is 36Kg, which could present a risk of injury.

Care should be taken when loading and unloading the boiler to and from vehicles.

GET HELP

RECOMMENDATIONS

We recommend that the boiler be handled by two people until it is securely fixed to a wall.

• These instructions are an integral part of the equipment to which they refer and the user must be provided with a copy.

• The product must be installed and serviced by qualified engineers, in compliance with current standards.

• The manufacturer cannot accept liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by the manufacturer.

• Any failure to follow instructions relating to tests and test procedures may result in personal injury or risks of pollution.

The safest route from the vehicle to the point of installation should be carefully assessed before unloading the boiler.

Mechanical lifting aids should be utilised whenever possible.

It is important to switch the boiler off before carrying out any work.

APPLICABLE STANDARDS

The Boilers have been manufactured to comply with the following standards BS EN60335-2-35: 1998,

BS EN55014-2:1997 and BS EN50081-1-1: 1992.

- 2 -

REMOVING THE BOILER FROM THE PACKAGING

• Before lifting the boiler from the packaging, ensure that the installation area is clear and that there are no obstacles making installation difficult or unsafe.

• Lay the boiler on its back (as shown on the box side), open the box and remove the cardboard packaging.

• Remove the polythene cover and the polystyrene corner protection pieces.

• With help from another person, lift the boiler from the packaging holding the lipped front edges of the side panels.

• Do not lift or carry the boiler using the top automatic air vent and bottom pump.

INTRODUCTION

DESCRIPTION OF THE SPECIFICATIONS

This wall hung electric boiler is available in 5 models :

• models 09 and 15 are supplied with 230 Volt single phase

• models 22, 28 and 36 are only supplied with 400 V triphase + N

The maximum power can be adjusted for all models by acting on the terminals bridges.

- Model 09: Adjustable power from 4.2 to 8.4 kW




- Model 36: Adjustable power from 30 to 36 kW

LINING

The boiler is protected by a steel lining that first of all undergoes a degreasing and phosphation process before being lacquered and burnt at 220°C.

HEATING BODY

The boiler heat exchanger is constructed from mild steel with welded joints. It is hydraulic tested under a pressure of 4.5 bar

(maximum working pressure = 3 bar).

HEATING ELEMENTS

Immersion heaters, constructed from stainless steel Incoloy 800 and mounted in the top of the boiler, provide the power source for the Boiler.

EQUIPMENT

The boiler is equipped with all the necessary components to allow direct connection to a heating system without the need for a feed and expansion cistern.

These components include; primary 10 litre expansion vessel

(suitable for a system water content of up to 160 litres), pressure and temperature gauge, safety valve, circulating pump, low water pressure switch, control and high limit thermostats, on/off and power level switches.

CONNECTION

The boiler is suitable for connection to most heating and hot water systems, with a maximum working pressure of 3bar and a maximum temperature of 85°C. It can also be used in multiple boiler installations allowing greater outputs to be achieved.

The boiler, and connection glands for both the main power supply and optional external controls are provided, suitable for single or three phase electrical supply depending upon boiler output required.

An internal 3 amp MCB is linked to the incoming electrical supply to provide the internal control circuit, from which optional controls can be connected e.g. internal or external timeclock, room thermostat or Honeywell Sundial controls.

DUAL STAGE THERMOSTAT

The temperature of the boiler is controlled by a dual stage thermostat which is set by the user to give the desired boiler temperature.

When the boiler has heated up to within 7°C of the set temperature, the thermostat switches off one power stage and therefore reduces the heat input. Thanks to this simple but effective form of modulation, the boiler has longer working cycles and requires less stops and starts, thus resulting in a more even temperature across the boiler.

It also means less wear and tear on components and, importantly it uses less power once it has reached working temperature.

- 3 -

CERTIFICATION

The boilers have been manufactured to comply with the following standards BS EN60335-2-35: 1998, BS EN55014-2:1997 and

BS EN50081-1-1: 1992.

LEGEND

1. Base for relay of DWL priority

2. Control circuit

3. Relay

4. Timer

5. Control terminals

6. Power terminals

1 2

5

3 4 3

6

Top cover

Brass pocket

Hand side panel

Cable glands

Control panel

Rear panel

Water pressure switch

Supplementary heating return

(not used)

Expansion vessel connection

Heating return

INTRODUCTION

- 4 -

Automatic air vent

Heating elements

Heating body

Pressure safety valve

Expansion vessel

Valve of expansion vessel

Expansion vessel connection

Circulating pump

Heating out

Manual reset high limit pressure gauge

INSTRUCTIONS

USER DATA

All user controls are situated on the front panel of the boiler, there are no user controls inside the boiler casing.

The following instructions assume that the boiler has been commissioned, and that the system is filled with water and has been fully vented.

SETTING UP

• Before switching on any electrical supplies to the boiler ensure that the combined temperature and pressure gauge reads at least 1 bar and the control thermostat is set to the desired temperature.

• If an internal time clock is fitted ensure that this is switched on

(see “Optional Internal Time Clock”) and if any other auxiliary controls are fitted e.g. programmer, room thermostats, cylinder thermostats etc, consult appropriate manufacturers' instructions to switch these on.

• Switch on any local means of isolation to boiler.

• Switch the boiler on using the ON/OFF switch (the neon light on the switch should now glow).

• Turn on both power level switches - after a short period of time the boiler temperature should start to rise, indicated by the combined temperature and pressure gauge. If the boiler fails to operate, the overheat safety thermostat should be checked.

Access to the thermostat reset button is obtained by unscrewing

(anti-clockwise) the domed button cover on the front panel

(a screwdriver is not required).The reset button can then be seen - press the button, a click should be heard and the button is reset. If no click was heard the device is not at fault and further investigation is required by a suitably qualified engineer.

• The internal clock or external programmer can now be set to allow on/off periods as desired. The ON/OFF switch and 2 power level switches should be left in the ON position during normal use.

the power level switches will automatically switch on and off during normal boiler operation, depending on boiler temperature.

• If the boiler is not in regular daily use during cold periods, it is recommended that it be fitted with a frost sensing thermostat to override the timeclock and prevent the system from freezing.

• As with most boilers and heating appliances the casing and pipework can get hot during normal running so the boiler must not be covered and the surrounding area must be kept clear.

OPTIONAL INTERNAL TIMECLOCK

• This operates on a 24-hour sequence. Around- the outside of the clock there are a number of white tabs - these allow 15 minute switching times.To set a boiler cycle simply push outwards the number of tabs required for your heating period.

Remember : tab OUT = BOILER ON tab IN = BOILER OFF

The time of day is marked by an arrow on the inner part of the clock

- set the outer time to coincide with this arrow.

On the centre part of the clock there is a switch.

This has three positions :

• Switch down - timeclock off

• Switch middle - timeclock timed (normal position)

• Switch up - timeclock on constant.

PRESSURE IN THE HEATING SYSTEM

The CH pressure must be a minimum of 1 bar and must be checked by the end user on a regular basis. If the pressure drops under 0.5

bar, the integrated water pressure switch blocks the appliance until the pressure in the system returns to a level above 0.8 bar.

The installer fits the system with a separate fill valve underneath the appliance. Make sure that the appliance is powered off when filling the system. To do this, turn the on/off switch.

For more information, please ask your installer when the system is delivered.

A safety valve is provided underneath the appliance. If the system pressure exceeds 3 bars, this valve opens and drains the water from the system. In this case, please contact your installer.

1 2 3

LEGEND

1. ON/OFF switch

2. Power levels switch

3. Optional internal clock or controler

4. Combined temperature and pressure gauge

5. Boiler shutdown indicator light

6. Manual reset high limit thermostat

7. Control thermostat :

1 = 40°C

2 = 50°C

3 = 60°C

4 = 70°C

5 = 80°C

4

- 5 -

5 6 7


Model

Power

09

4.2 to

8.4 kW

1 x 230 V

15

7.2 to

14.4 kW

22

14.4 to

21.6 kW

28

21.6 to

28.8 kW

36

30 to

36 kW

1 x 230 V 3 x 400 V + N 3 x 400 V + N 3 x 400 V + N

Nominal supply voltage

Ohmic esistance of element

Heating element type

Number of elements

Water capacity

(Litres)

Expansion vessel capacity

(Litres)

Max. working pressure

(bars)

Min. working pressure

(bars)

Max. working temperature

(°C)

Hydraulic presure drop

(mbar)

Heating connection

Height (mm)

Width (mm)

Depth (mm)

Weight empty (kg)

37.8 Ohm

13

10

13

10

13

10

22 Ohm

2 x 1.4 kW 2 x 2.4 kW 2 x 2.4 kW 2 x 2.4 kW

3

3

0.8

85

10

3/4”

763

442

332

45

22 Ohm

3

3

0.8

85

20

3/4”

763

442

332

45

22 Ohm

5

3

0.8

85

45

3/4”

763

442

332

45

6

13

10

3

0.8

85

85

3/4”

763

442

332

45

26.45 Ohm

3 x 2 kW

6

13

10

3

0.8

85

125

3/4”

763

442

332

45

- 6 -


Electrical data of model 09

STAGE 1 STAGE 2 TOTAL

Single phase 8.4 kW (*)

Terminals 1 and 2 shunted

Terminals 3, 4, 5 and 6 shunted

Relay K3 activated

Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

24

24

5.6

12

12

2.8

36

36

8.4

POWER TERMINALS

1

N

2 3

L

4 5 6

Single phase 7 kW


Terminals 3, 4 and 5 shunted

Relay K3 activated

Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

24

24

5.6

6

6

1.4

30

30

7

1

N

2 3

L

4 5 6

Single phase 5.6 kW



Relay K3 disactivated (**)

Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

12

12

2.8

12

12

2.8

24

24

5.6

1

N

2 3

L

4 5 6





Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

12

12

2.8

6

6

1.4

31.2

31.2

4.2

1

N

2 3

L

4 5 6

This values are based on standard supply voltage in Europe, that is 1 x 230V for single phase and 3 x 400V + N for tri phase.

(*) Factory configuration / (**) Remove the shunt 17 and 18 in order to desactivate the relay.

- 7 -




Single phase 14.4 kW (*)



Relay K3 activated

Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

41.6

41.6

9.6

20.8

20.8

4.8

62.4

62.4

14.4

POWER TERMINALS

1

N

2 3

L

4 5 6

Single phase 12 kW



Relay K3 activated

Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

41.6

41.6

9.6

10.4

10.4

2.4

52

52

12

1

N

2 3

L

4 5 6





Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

20.8

20.8

4.8

20.8

20.8

4.8

41.6

41.6

9.6

1

N

2 3

L

4 5 6





Terminal 3 L1 (A)

Terminal 1 N (A)

Power (kW)

20.8

20.8

4.8

10.4

10.4

2.4

31.2

31.2

7.2

1

N

2 3

L

4 5 6



E-Tech W 09

E-Tech W 15

E-Tech W 22

E-Tech W 28

E-Tech W 36

220 V

7.7

13.2

Power variation (kW) relative to voltage

230 V

8.4

14.4

240 V

9.1

15.7

3 x 380 V 3 x 400 V 3 x 415 V

19.5

26.0

32.5

21.6

28.8

36.0

23.3

31.0

38.8

- 8 -


Tri phase 21.6 kW (*)



Relay K43 activated



Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

20.8

20.8

20.8

0

14.4

10.4

10.4

10.4

0

7.2

31.2

31.2

31.2

0

21.6

POWER TERMINALS

1

N

2

L1

3

L2

4 5

L3

6

Tri phase 14.4 kW




Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

10.4

10.4

10.4

0

7.2

10.4

10.4

10.4

0

7.2

20.8

20.8

20.8

0

14.4

1

N

2

L1

3

L2

4 5

L3

6




STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 28.8 kW (*)



Relay K4 activated

Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

20.8

20.8

20.8

0

14.4

20.8

20.8

20.8

0

14.4

41.6

41.6

41.6

0

28.8

1

N

2

L1

3

L2

4 5

L3

6

Tri phase 21.6 kW




Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

20.8

20.8

20.8

0

14.4

10.4

10.4

10.4

0

7.2

31.2

31.2

31.2

0

21.6

1

N

2

L1

3

L2

4 5

L3

6




STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 36 kW (*)



Relay K4 activated

Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

26

26

26

0

18

26

26

26

0

18

52

52

52

0

36

1

N

2

L1

3

L2

4 5

L3

6

Tri phase 30 kW




Terminal 2 L1 (A)

Terminal 3 L2 (A)

Terminal 5 L3 (A)

Terminal 1 N (A)

Power (kW)

26

26

26

0

18

17

17

17

0

12

43

43

43

0

30

1

N

2

L1

3

L2

4 5

L3

6



- 9 -

DIMENSIONS

MOUNTING

442 mm

332 mm

178 mm

379 mm

90 mm

WALL MOUNTING

53,2 mm

48,4 mm

101,6 mm

101,6 mm

48,4 mm

53,2 mm

• The boiler must be fixed to a non flammable wall.

• Observing the clearances shown below, drill 2 off

14mm x 100mm holes.

• Fit the 2 bolts supplied and hang the wall bracket.

• Fit washers and nuts

• Hang the boiler

FROST PROTECTION

The boiler is NOT fitted with frost protection. If the boiler is being installed in a position where freezing could take place, then a suitable external frost thermostat should be fitted.

CONNECTING TO THE SYSTEM

The boiler is designed to operate on a sealed system

(ie. no open vent or feed and expansion cistern). Hot water expansion within the system is taken up by the internal 10 litre expansion vessel.This is suitable for systems up to 160 litres capacity. If the system capacity is more than this then an additional expansion vessel may be required.This can be fitted external to the boiler at a convenient place on the pipework.

Please note that the circulation pump is fitted to the flow connection.

INSTALLATION ROOM

The appliance must be positioned in such a way as to be easily accessible at all times. In addition, the following minimum distances around the appliance must be complied with

Min.

25 mm

Min.

400 mm

Min.

200 mm

- 10 -

DISASSEMBLING

A

2

1

INSTALLATION

Panel removal and access to hydraulic connections

1. undo screws

2. tilt panel towards you and lift clear remove the top cover

3. loosen screws of the control panel

4. turn up the control panel

5. block the control panel with the screw

2

B

3

C

5

4

- 11 -

INSTALLATION

HEATING CONNECTION

Limiting the maximum adjustable temperature

Factory setting

30 - 85°C

Floor heating

30 - 50°C

31

32

3

3

34

35

36

37

38

39

1

2

3

4

5

6

7

8

9

7

28

2

26

25

24

22

23

21

19

18

17

16

15

14

3

1

12

28

31

32

3

3

34

35

36

37

38

39

1

2

3

4

5

6

7

8

9

7

2

25

26

24

23

22

21

19

18

16

17

15

14

3

1

12

NOTE:

• controller not supplied in standard

HEATING CONNECTION + DHW : “Y” PLAN

Limiting the minimum adjustable temperature

60 - 85°C

31

32

3

3

34

35

36

37

38

39

1

2

3

4

5

6

7

8

9

7

28

2

26

25

24

22

23

21

19

18

17

16

15

14

3

1

12

NOTE:


HEATING CONNECTION + DHW : “S” PLAN

Limiting the minimum adjustable temperature

60 - 85°C

31

32

3

3

34

35

36

37

38

39

1

2

3

4

5

6

7

8

9

7

28

2

26

25

24

22

23

21

19

18

17

16

15

14

3

1

12

M M

NOTE:


- 12 -

INSTALLATION

ELECTRIC CONNECTION / MODELS : 09 - 15

• This appliance must be permanently connected to fixed wiring and must be earthed.

• The wiring must be carried out by a competent person and be in accordance with the current IEE Wiring Regulations.

• Isolation device must be provided with a minimum contact clearance of 3mm.

• The MCB must be readily accessible and adjacent to the appliance.

L1 N

Power supply

230 V mono

N L1

1 2 3 4 5 6

Power supply

230 V mono +

Safety contactor

L1 N

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

N L1

1 2 3 4 5 6

- 13 -

INSTALLATION

ELECTRIC CONNECTION / MODELS : 22 - 28 - 36

• This appliance must be permanently connected to fixed wiring and must be earthed.

• The wiring must be carried out by a competent person and be in accordance with the current IEE Wiring Regulations.

• Isolation device must be provided with a minimum contact clearance of 3mm.

• The MCB must be readily accessible and adjacent to the appliance.

L3 L2 L1 N

Power supply

3 x 400 V + Neutral

N L1 L2 L3

1 2 3 4 5 6

L3 L2 L1 N

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

Power supply

3 x 400 V + Neutral +

Safety contactor

N L1 L2 L3

1 2 3 4 5 6

SIZING OF SUPPLY WIRES

the supply wires are sized depending of the type and current of the MCB, this last is firstly sized depending of the nominal current of the boiler.

The admissible current of the supply wires depends of the ambient temperature, the section and the length of the wires, the wires insulation, the wires canalisation, the mounting type and the environment.

The following values are given for information for an ambient temperature of 30°C and a maximal length of 5 meters. In all the cases, the installation must be in accordance with the current IEE Wiring Regulations.

Nominal section

(mm 2

1.5

2.5

4

6

10

16

)

Nominal current of the MCB

(A)

16

25

32

40

63

80

- 14 -

INSTALLATION

- 15 -

INSTALLATION

- 16 -

INSTALLATION

- 17 -

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

INSTALLATION

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18 r b b or r b or b or b b bk or b b bk b bk b r b r bk b

- 18 -

r r

2 x bk

2 x or

3 x b

3 x b

INSTALLATION

17 18

17 18

17 18

17 18 b r bk or bk or b r b r bk or b r

Bk

Or b r bk or b r bk or

- 19 -

1 x r

2 x r

1 x bk

2 x bk

3 x or

3 x b

INSTALLATION

19 20

19 20

19 20

19 20 b r bk or bk or b r b r bk or b r bk or b r bk or b r

Bk

Or b r bk or b r bk or

- 20 -

1 x r

3 x r

1 x bk

3 x bk

4 x or

4 x b

INSTALLATION

bk or b r bk or b r b r bk or b r bk or b r bk or b r bk or b r bk or b r bk or b r bk or b r

Bk

Or bk or b r bk or b r

- 21 -

1 x bk

5 x bk

1 x r

5 x r

6 x or

6 x b

19 20

19 20

19 20

19 20


Honeywell

Sundial Wiring Centre

`S ` Plan

b br

MOTOR gr o

V4043H

HTG ZONE VALVE

T6306B

ROOM STAT

2 1 3

CYLINDER

STAT

C b br

MOTOR gr

V4043H

DHW ZONE VALVE o

Note: Earth wires not shown for clarity

During installation the earth wires from each

component connect to terminal 3 in the wiring centre o o

HW HTG

N L

1 2 3 4 5 6 7 8 9 10

E

CABLE COLOUR CODES

bk- black br- brown r-red w-white y- yellow o - orange b - blue v - violet p - pink gr - grey

Note: All bold numbers indicate a DIN rail terminal connection

L1 or

1 br

2 br

3 amp

MCB

br

A

bk bk

C

B

t

2

r g

1

bk

5

C

C

p

2

1

or or

10 y

11 y

12 or

F

t or

13

7 r

E

b

D

g

N b

3 b

4 b b

6 b b b b b

8 b b

9 b g

2.1.

H

2.2.

or

J

r g g

2.1.

I

t pk

2.2.

L

w r

17 r

21 w w

14

G

18

22

M 15 b

16 r b w b w b

J

pk pk

19 pk

23 w w

20

24 pk b w b w b

Note: Illustrated model = 36 kW Tri Phase

- 22 -


w b

V4073A

MID POSITION

ZONE VALVE

Honeywell

Sundial Wiring Centre

`Y ` Plan

T6306B

ROOM STAT

2 1

3

CYLINDER

STAT

1

C 2

Note: Earth wires not shown for clarity

During installation the earth wires from each

component connect to terminal 3 in the wiring centre

N L

1 2 3 4 5 6 7 8 9 10

E

CABLE COLOUR CODES

bk- black br- brown r-red w-white y- yellow o - orange b - blue v - violet p - pink gr - grey

Note: All bold numbers indicate a DIN rail terminal connection

L1 or

1 br

2 br

3 amp

MCB

br

A

bk bk bk

C

B

2

r g t

1

5

C

C

p

2

1

or or

10 y

11 y

12 or

F

or t

13

7 r

E D

b g

N b

3 b

4 b b

6 b b b b b

8 b b

9 b g

2.1.

H

2.2.

or

J

r g g

2.1.

I

t pk

2.2.

L

w r

17 r

21 w w

14

G

18

22

M

15 b

16 r w b b w b

J

pk pk

19 pk

23 w w pk b

20

24 w b w b

Note: Illustrated model = 36 kW Tri Phase

- 23 -

COMMISSIONING AND MAINTENANCE

COMMISSIONING - WATER

1. The system must be thoroughly cleansed prior to connection of the boiler. The system water should be treated to prevent general corrosion and deposition of scale or sludge in the boiler, please refer to BS7593. If installing the boiler onto an existing system, ACV recommend that an approved system cleaner is used.

2. Fill and pressurise the boiler and system to 1.5 bar, making sure to vent the boiler via the automatic air vent on top of the boiler. Note that the black dust cap on the air vent should be left loose to allow the auto vent to function.

3. Check for leaks.

For specialist advice on water treatment products, contact:

Fernox, Britannia Works

Clavering, Essex CB11 4QZ

Tel 01799 550811

COMMISSIONING - ELECTRICAL

The Electrical installation supplying this boiler must conform to the current IEE Regulations.

1. Remove the front panel and check all electrical connections for tightness.

2. Ensure all internal relays, contactors etc are secure on the DIN rails.

3. Set all panel control switches to off.

4. Check the power stage delay timer settings - Adjuster (A) is factory set to the 1 to 10 minute position which is the optimum setting for the boiler and should be verified during commissioning.

- Adjuster (B) is used to set the DELAY ON time of the following stage contactors, the available settings are in 1 minute increments if A is set to 1 to 10 minutes.

This function is particularly useful in areas where gradual switching of electrical load is required and the resulting maximum demand kept to a minimum.The timers add to the flexibility of the installation but must be optimised by a qualified engineer.The normal setting is 1.

5. Set internal MCB to off position.

6. Set the control thermostat to desired temperature.

A

STARTING THE BOILER

1. Switch on the internal or external timeclock (if fitted)

2. Switch on internal MCB

3. Switch on local isolator to boiler

4. Turn the boiler on using the ON/OFF switch

5. Switch on the power levels switch stage 1, the first stage contactors will energise

6. Switch on the power levels switch stage 2, after a short delay the second stage contactors will energise. Note: the power stage delay timer settings should be verified as shown in item

4 under "Commissioning - Electrical"

7. The boiler temperature will now rise as indicated by the combined temperature and pressure gauge

8. The temperature will continue to rise until the control thermostat temperature setting is reached then the boiler will switch off.

Once these procedures have been followed the system can be left to operate normally by the following method.

1. Ensure that boiler thermostat is set to the desired temperature

2. Turn the boiler on using the ON/OFF switch

3. Turn on power level switch 1

4. Turn on power level switch 2

5. Set timeclock (if fitted) and/or external controls to desired boiler operating on/off times.

After one week of operation all electrical connections should be re-checked for tightness and the boiler water system checked for leaks and air and rectified if necessary.

MAINTENANCE

For safety reasons it is recommended that the boiler is serviced annually and that servicing is carried out by a qualified service engineer.

Before carrying out any work on the system ensure that the boiler is cool and all electrical supplies are isolated.

1. After removing front cover undo the four screws retaining the front control panel and gently let the panel suspend on the wiring to the rear of the panel. Undertake a visual inspection of the boiler looking out for signs of water leakage from joints, expansion vessel, and the area around the elements on top of the boiler.

2. Undertake a visual inspection of all cabling in the boiler casing checking for signs of overheating or burning.

3. Check all push-on electrical connectors for tightness and good connection to the relative components.

4. Using a correct fitting screwdriver check all electrical terminals on DIN rails and on all components for tightness.

5. Check the settings on the internal timers in accordance with the "Commissioning - Electrical" section.

6. Replace the control panel and the boiler front cover and refit screws.

7. Reinstate the electrical supply and follow the procedures set out in the commissioning section.

B

- 24 -

REMOVAL THE HEATING ELEMENTS

1

3

2

- 25 -

N° Casing

A01 Side panel

A02 Front panel

A03 Top cover

A04 Rear panel

A05 Control panel ABS

A06 Wall mounting

A07 Body heating

A08 Control panel

A09 Electric support

A01

SPARE PARTS

09

21471421

21473421

21475421

21474421

497B1025

21480069

30537482

21477421

21479421

15

21471421

21473421

21475421

21474421

497B1025

21480069

30537482

21477421

21479421

22

21471421

21473421

21475421

21474421

497B1025

21480069

30537482

21477421

21479421

28

21471421

21473421

21475421

21474421

497B1025

21480069

30537482

21477421

21479421

36

21471421

21473421

21475421

21474421

497B1025

21480069

30537482

21477421

21479421

A03

A06

A07

A04

A02

A05

- 26 -

A08

A09

A01

SPARE PARTS

N° Accessories

B01 Base for relay

B02 Control circuit “Siemens”

B03 Relay Siemens 3TG

B04 Timer “Crouset”

B05 Blocking

B06 Terminal WKN 16/U blue

B07 Terminal 16 mm 2 WKN 16/U

B08 Terminal end APN 16 mm 2

B09 Terminal WKN10 sl/u

B10 Shunt IVBWKN 16-2

B11 Control terminal block

B12 Green switch

B13 Yellow switch

B14 Combined T° and pressure gauge Ø 40mm

B15 Red alarm indicator Ø 10mm / 240V

B16 Control thermostat 2 Stages

B17 Button thermostat

B18 Manual reset high limit thermostat 103°C

B19 Cable gland (PG29)

B20 Brass pocket

B21 Heating element 2 x 1.4 kW

B22 Heating element 2 x 2.4 kW

B23 Heating element 3 x 2 kW

B24 Water pressure switch

B25 Circulating pump

B26 Pressure safety valve 3 bars Ø 1/2”

B27 Automatic air vent

B28 Flexible tube

B29 Expansion vessel 10 Litres

B30 Complete control panel

15

54428195

54766015

54452082

54428192

54452092

54767014

54428179

54428091

54428155

54428278

54767015

54766016

54766017

54763012

54766001

54764017

54764021

54764009

54428113

63438003

-

54428182

-

557D3011

557A4009

55426017

55445007

557A7006

24614142

09

54428195

54766015

54452082

54428192

54452092

54767014

54428179

54428091

54428155

54428278

54767015

54766016

54766017

54763012

54766001

54764017

54764021

54764009

54428113

63438003

54428183

-

-

557D3011

557A4009

55426017

55445007

557A7006

24614142

28

54428195

54766015

54452082

54428192

54452092

54767014

54428179

54428091

54428155

54428278

54767015

54766016

54766017

54763012

54766001

54764017

54764021

54764009

54428113

63438003

-

54428182

-

557D3011

557A4009

55426017

55445007

557A7006

24614144

22

54428195

54766015

54452082

54428192

54452092

54767014

54428179

54428091

54428155

54428278

54767015

54766016

54766017

54763012

54766001

54764017

54764021

54764009

54428113

63438003

-

54428182

-

557D3011

557A4009

55426017

55445007

557A7006

24614143

36

54428195

54766015

54452082

54428192

54452092

54767014

54428179

54428091

54428155

54428278

54767015

54766016

54766017

54763012

54766001

54764017

54764021

54764009

54428113

63438003

-

-

54428204

557D3011

557A4009

55426017

55445007

557A7006

24614145

- 27 -

SPARE PARTS

B16

B21

B26

B01

B06

B11

B30

B17

B22

B27

B02

B07

B12

B28

-

B18

B23

B03

B08

B13

-

- 28 -

B04

B09

B14

B19

B24

-

-

B29

B05

B10

B15

B20

B25

-

-

- 29 -

excellence in hot water

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E-Tech 15 Installation, Operating And Maintenance Instructions

Assistant Bot

Installation, operating and maintenance instructions

excellence in hot water

WARNINGS

INTRODUCTION

INSTRUCTIONS

TECHNICAL CHARACTERISTICS

MOUNTING

INSTALLATION

HONEYWELL SUNDIAL WIRING DIAGRAMS

COMMISSIONING AND MAINTENANCE

REMOVAL THE HEATING ELEMENTS

SPARE PARTS

3

2

5

6

10

22

24

11

25

26

WHO SHOULD READ THESE INSTRUCTIONS

SYMBOLS

IMPORTANTS NOTES

MANUAL HANDLING INSTRUCTIONS

RECOMMENDATIONS

APPLICABLE STANDARDS

REMOVING THE BOILER FROM THE PACKAGING

DESCRIPTION OF THE SPECIFICATIONS

LINING

HEATING BODY

HEATING ELEMENTS

EQUIPMENT

CONNECTION

DUAL STAGE THERMOSTAT

CERTIFICATION

LEGEND

1 2

5

3 4 3

6

USER DATA

SETTING UP

OPTIONAL INTERNAL TIMECLOCK

PRESSURE IN THE HEATING SYSTEM

1 2 3

LEGEND

4

5 6 7

Power

Nominal supply voltage

Ohmic esistance of element

Heating element type

Number of elements

Water capacity

(Litres)

Expansion vessel capacity

(Litres)

Max. working pressure

(bars)

Min. working pressure

(bars)

Max. working temperature

(°C)

Hydraulic presure drop

(mbar)

Heating connection

Height (mm)

Width (mm)

Depth (mm)

Weight empty (kg)

DIMENSIONS

WALL MOUNTING

FROST PROTECTION

CONNECTING TO THE SYSTEM

INSTALLATION ROOM

DISASSEMBLING