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- 32 Pages
E-Tech 15 Installation, Operating And Maintenance Instructions
E-Tech 15 is a single-phase electric boiler with adjustable power from 7.2 to 14.4 kW, ideal for heating homes or providing hot water. It features a steel lining, mild steel heat exchanger, and stainless steel Incoloy 800 immersion heaters for durability. The boiler includes a 10-liter expansion vessel, pressure and temperature gauge, safety valve, circulating pump, and control and high limit thermostats for safe operation. It can be connected to heating and hot water systems with a maximum working pressure of 3 bar and temperature of 85°C.
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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
Power wiring / Model : 28
Power wiring / Model : 36
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 15: Adjustable power from 7.2 to 14.4 kW
- Model 22: Adjustable power from 14.4 to 21.6 kW
- Model 28: Adjustable power from 21.6 to 28.8 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
TECHNICAL CHARACTERISTICS
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 -
TECHNICAL CHARACTERISTICS
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 1 and 2 shunted
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
Terminals 1 and 2 shunted
Terminals 3, 4, 5 and 6 shunted
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
Single phase 4.2 kW
Terminals 1 and 2 shunted
Terminals 3, 4 and 5 shunted
Relay K3 disactivated (**)
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 -
TECHNICAL CHARACTERISTICS
Electrical data of model 15
STAGE 1 STAGE 2 TOTAL
Single phase 14.4 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)
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
Terminals 1 and 2 shunted
Terminals 3, 4 and 5 shunted
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
Single phase 9.6 kW
Terminals 1 and 2 shunted
Terminals 3, 4, 5 and 6 shunted
Relay K3 disactivated (**)
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
Single phase 7.2 kW
Terminals 1 and 2 shunted
Terminals 3, 4 and 5 shunted
Relay K3 disactivated (**)
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
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.
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 -
TECHNICAL CHARACTERISTICS
Tri phase 21.6 kW (*)
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
Relay K43 activated
Electrical data of model 22
STAGE 1 STAGE 2 TOTAL
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
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
Relay K3 disactivated (**)
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
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.
Electrical data of model 28
STAGE 1 STAGE 2 TOTAL POWER TERMINALS
Tri phase 28.8 kW (*)
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
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
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
Relay K4 disactivated (**)
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
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 19 and 20 in order to desactivate the relay.
Electrical data of model 36
STAGE 1 STAGE 2 TOTAL POWER TERMINALS
Tri phase 36 kW (*)
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
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
Terminals 3 and 4 shunted
Terminals 5 and 6 shunted
Relay K4 disactivated (**)
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
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 19 and 20 in order to desactivate the relay.
- 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:
• controller not supplied in standard
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:
• controller not supplied in standard
- 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 DIAGRAMS
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 -
HONEYWELL SUNDIAL WIRING DIAGRAMS
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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