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The COMET Range of Boilers the ultimate solution for central heating InsTallaTIOn & TEChnICal Manual If you require any further assistance: Telephone: 01698 820533 Fax: 01698 825697 E-mail: info@electric-heatingcompany.co.uk or visit our website www.electric-heatingcompany.co.uk 2 GB-031C_f.971 InTRODuCTIOn Please read and follow the installation and operating instructions carefully, to ensure the long life and reliable operation of this appliance. The Electric Heating Company may make minor changes if necessary in the appliance that will not be shown in the operating instructions, so long as the main features of the boiler remain the same. All boilers come with a 24 month warranty that covers all defects originating from faulty materials and workmanship in the manufacture of the boilers. The warranty covers the replacement of any faulty parts and labour costs. The warranty will not cover any damage to the boiler from poor or incorrect installation work. The warranty will not cover any call out charges that have not been organised by the Electric Heating Company Ltd. The warranty will not cover water leaks into the boiler. All plumbing joints must be checked. The warranty card must be completed and sent back to The Electric Heating Company as soon as possible for registration. An internal Magnetic Filter is fitted to the Boiler and it must be cleaned at least annually. (Note: Failure to clean the Magnetic Filter may result in boiler shutdown). Warranty calls will not be covered for this repair. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. Page Contents INTRODUCTION 2 PREPARATION 3 INSTALLATION 4 INSTALLATION ELECTRIC BOILER INTERNAL LAYOUT 5 COMMISSIONING 6 INSTALLATION 7 ELECTRICAL CONNECTIONS AND CONTROLS 10 EXTERNAL CONTROL WIRING 12 CONTROL PANNEL CONNECTIONS 14 POWER BOARD - CONNECTION 415V 3N~ 39kW 15 POWER BOARD - CONNECTION 415V 3N~ 14,4 -23 kW 16 POWER BOARD - CONNECTION 240V 4-14.4kW 17 EXTERNAL BOILER WIRING 18 BOILER DIMENSIONS 18 USER INSTRUCTIONS 19 FAULT FINDING 21 TECHNICAL SPECIFICATIONS 22 3 GB-031C_f.971 PREPaRaTIOn Instructions and Building Regulations This appliance must be fitted in accordance with the following instructions. The Local Building Regulations The Building Regulations The Building Standards, (Scotland-consolidated) Regulations. Local water bylaws. British Standards- code of practice Bs En 12828 Heating systems in buildings. Design for water-based heating systems. Bs En 12831 Heating systems in buildings. Method for calculation of the design heat load Bs En 14336 Heating systems in buildings. Installation and commissioning of water based heating systems Bs7671 Requirements for electrical installations. IEE Wiring Regulations. Seventeenth edition. Bs En 13831 Closed expansion vessels with built-in diaphragm for installation in water C.O.s.h.h. Materials used in the manufacture of this appliance are non- hazardous and no special precautions are required when fitting or servicing this appliance. PREPaRaTIOn 1. load Check A load check should be taken into consideration when installing high output boilers. 2. Boiler location The boiler must be fitted on a wall that will provide an adequate fixing, and should be fitted in a location that the boiler and pipe-work are not subject to frost and damp conditions. 3. Central heating (design & installation) Detailed recommendations are given in BS EN 12828, BS 6700 and CP 342-2 Pipes forming part of the useful heating surface should be insulated to prevent any potential heat loss or frost damage (BS 6700). Drain valves should be fitted at the lowest point of the system pipe work in an accessible position. Drain valves should be in accordance with BS 2879 and copper tube to BS EN 1057. is recommended. lOCaTIOn The boiler can be installed in almost any location within a domestic or commercial property, however consideration should be given to future maintenance. Never leave the boiler switched off if there is danger of having temperatures below 0°C in the room where it is located. We recommend that a minimum clearance of 450 mm should be allocated for the removal of the front cover and adequate access to the boiler plumbing and the internal electrical connections. A 50 mm allowance should be made at either side of the boiler to allow free flow air into the boiler case and allow access to screws on the boiler case. ThE BOIlER MusT BE InsTallED In ThE uPRIGhT POsITIOn, FaIluRE TO DO sO WIll InValIDaTE ThE WaRRanTY 4 GB-031C_f.971 InsTallaTIOn 1. General The boiler must be installed by a professional plumber or heating engineer and must be connected to the public low voltage network by a competent person. For systems that require a three phase electrical supply we strongly recommend this is installed by a 17th Edition certified Electrician. The Electric heating Company ltd will not be held responsible for faulty installations which are performed by unqualified tradespersons. 2. Pipe Connections All Fusion Electric Boilers have a 22mm compression connection at the boiler’s flow and return pipes. Please note that the boilers are supplied with blank washers fitted for transit purposes. These must be removed before connections to pipe-work can be made. The flow (red) and return (blue) are clearly marked on the external case and under no circumstances should these connections be reversed. Hot connections are not recommended at the boiler for future maintenance and boiler disconnection. Lockshield valves are recommended. 3. Case Removal Remove outer screws at the bottom of the boiler and pull the front cover outwards taking care to remove internal earth connections. Earth connections must be re-connected before the boiler case is re-installed. 4. Isolation Valves We recommend that lockshield isolation valves are fitted on the flow and return pipework. Such valves must be „full bore” and not „standard ball valves”. The installation of „standard ball valves” in the flow and return pipework will reduce the recommended flow rate through the boiler and promote premature boiler shutdown. 5. auto air vents An auto air vent is integral within the boiler however an additional auto air vent must be fitted at the cylinder coil if the boiler is being used for central heating and domestic hot water. 6. Boiler sizing Calculate the „space heating” requirements in accordance with BS EN 12831 and BS EN 14336. If the boiler is to heat the domestic hot water, an additional allowance of 3kW (10,239 Btu’s) should be made to the ‘space heating’ calculation. 7. Insulation Where practical, and if at all possible, we recommend that all pipe-work be insulated, in particular the primary pipe-work within a boiler cupboard. This is to reduce heat loss and reduce high cupboard temperatures from exposed pipe-work. (BS 6700). 8. system Design The boiler has an integral automatic bypass valve fitted which should be set to the relevant settings to allow the minimum flow rates to pass through the boiler (8 l/min) when all radiator thermostats and zone valves are closed. Allowance should be made for a radiator to be installed within the heating circuit and locked open. This will be located in the room that has the room thermostat installed. To comply with building regulations, Part L and Part J (in Scot- land), room and cylinder stats must be fitted. 9. Water Connections Provisions must be made for the replacement of water lost from the heating system (sealed systems). Reference should be made to BS EN 14336 for the method of filling and make up of water. There must be no direct connection between the boilers central heating system and the main water supply. When mains water is required to fill the system directly, all local water bylaws must be observed, and any connection made must be disconnected after use. 10. Flushing The system must be flushed to within 10% of mains water PPM to ensure that no debris is trapped in the system as this may result in boiler failure. Where existing radiators and pipe-work are utilized a power flush must be carried out to remove debris. For further guidance please see section - Flushing & System Protection. 11. system pressures All boilers are tested to 4.0 bar. The normal working pressure of the boiler should be set to approx 1.0 / 1.5 bar. All sealed systems should comply with the relevant building regulations and standards, including BS EN 13831 – Specification for Expansion Vessels. Please note: In order to protect the Flow Sensor located within the boiler, it is imperative that the pre-installed magnetic filter is removed and cleaned at least annually. Failure to carry out this action will increase contamination of the boiler by system residue. 12. system types The Fusion Comet range of boilers can be used in various system designs. Please refer to The Electric Heating Company for more details on our Fusion Boiler for under floor heating. We are able to supply a heat pack that contains the relevant control valves, cylinder and room thermostats required to configure an „S” plan heating system. The heat pack has all the necessary components that you need to connect the systems controls and plumbing configurations for „S” Plan design. We recommend the use of thermostatic radiator valves on all radiators except in the room that has the wall thermostat fitted. This radiator should be fitted with lock shield valves and left in the fully open position. The boiler has an integral automatic bypass valve fitted which should be set to the relevant settings to allow the minimum flow rates to pass through the boiler (8 l/min) when all radiator thermostats and „zone valves are closed”. Systems should be designed to meet the current building regulations in force at the current time. 13. hanging the Boiler 1. Hang the boiler in a vertical position on the fixing points and screws provided, with the flow and return connections to the bottom of the boiler, maintaining the clearances as per Figure 12 of this manual. 2. Connect the boiler to a heating system that is equipped with isolation valves (see Figures 4 & 5). 3. Fill the heating system with treated water, which will substantially extend the life of the heating coils. See item 14 „System Protection” below. 4. Connect the boiler to the „mains” electrical system as per Figures 6, 8, 9 & 11 5. Connect the room thermostat / Programmer using the two control conductors marked RP as in Figure 7 & 10. 6. For all other electrical connections refer to the ELECTICAL CONNECTIONS & CONTROL section of this manual. 5 GB-031C_f.971 InsTallaTIOn ElECTRIC BOIlER InTERnal laYOuT Figure 1 [1] - Stainless Steel Heat Exchanger [2] - Flow Sensor [3] - Pressure Sensor [4] - Safety Valve [5] - Circulating Pump [6] - Safety Temperature limiter [7] - Return connection [8] - Flow connection [9] - Power Board [10] - Control Module [11] - Automatic Vent [12] - Expansion vessel [13] - By-pass Valve [14] - Magnetic Filter PF - Internal „mains” phase connections from the PN connection block PN - Incoming ‘mains’ cable connection block WP - Electric cable access M - Boiler fixing points RP - External Controls (Volt Free) Electrical ‘mains’ input 6 GB-031C_f.971 COMMIssIOnInG IMPORTanT: TURN ON THE ELECTRICAL POWER SUPPLY TO THE BOILER. MAKE SURE THAT THE PROGRAMMER IS NOT CALLING FOR HEAT AT THIS STAGE! FIll InG ThE hOT WaTER CIRCuT. (If applicable) 1. Check the pressure in the potable vessel is set to 3 Bar. 2. Check that all plumbing connections are tight. 3. Open the furthest away tap outlet. note: Make sure that the filling loop is closed at this stage! 5. Turn on the mains water supply to the unit. 6. It will take a few minutes to fill the cylinder, once the water comes through the tap outlet let it run. 7. Open the other hot water outlets and purge all air out of the system. 8. Once fully purged close all the outlets and further check for leaks. FIllInG ThE PRIMaRY hEaTInG CIRCuT. THE PRIMARY CIRCUT MUST BE FLUSHED IN ACCORDANCE TO BS 7593 1. Connect the primary filling loop and tighten. 2. Make sure that all primary connections are tight before filling. 3. Open the filling loop and allow the system to start filling. 4. Press the right arrow key on the boiler control panel until the A (bar) led is illuminated. 5. fill the system to 2 bar, then start to purge the radiators until all the air is out the system. 6. This will have to be repeated several times to fully purge the system re-filling as you go. system protection: Failure to protect the system will invalidate the manufacturer’s warranty. 1. Fill the system with cold mains water to the recommended pressure 1.5 bar and check for leaks, then drain the system thoroughly making sure all drain cocks are fully open and that the system is completely drained. 2. Add Fernox F3 cleaner to the system at the furthest point from the boiler, this is to allow the substance to fully dilute throughout the system. If you are unsure of the correct dose rate, contact Fernox on 03301007750 for advice. 3. Re-fill the system and circulate the F3 cleaner prior to the boiler being fired up. Commission the system in the normal way. The cleansing agent must be in the system for a minimum 1 hour with the system running at normal operating temperature. A longer period of time would be more beneficial to the cleansing process especially if excess flux was used or is an old system. F3 cleaner can be left in the system for up to a maximum of one week running on a normal heating cycle. (We recommend that existing systems are power flushed as per BS 7593 and PAS33 regulations) 4. Drain and flush the system thoroughly to remove the cleaning agent and any debris or contaminants. This is a critical part of the cleaning process and must be carried out correctly. Use a rinse test meter (TDS), such as the Fernox CTM. The reading must be within 10% of the mains ppm value. 5. After the system has been thoroughly flushed and TDS readings are within 10% you can now add Fernox F1. This will protect against the formation of scale, corrosion and microbiological growths. It is crucial however, that for the protector to work correctly, the system must be properly cleansed and flushed. 6. Now attach the label included within the Fernox F1 packaging completed and attached adjacent to the boiler. We recommend inhibitor levels are checked on an annual basis (usually during the service) or sooner if the system content is lost. This should be carried out using a Fernox inhibitor Test Kit. Fernox Technical Service Help line on 0870 870 0362 for further assistance. 7 GB-031C_f.971 InsTallaTIOn Figure 2 Figure 3 LED 1 2 3 4 5 LED Rated power [kW] Pump lifting height [m] LED 1 red LED 2 yellow LED 3 yellow LED 4 yellow LED 5 yellow 4 ●● 6-95●●● 9-126 ●●●● 14 - 397●●● alarm status If the pump has detected one or more alarms, the bicolored LED 1 switches from green to red. When an alarm is active, the LEDs indicate the alarm type as defined in the table below. If multiple alarms are active at the same time, the LEDs only show the error with the highest priority. The priority is defined by the sequence of the table. When there is no active alarm anymore, the user interface switches back to operation mode. DisplayIndication Pump operation Counter action One red LED + one yellow LED (LED 5) Rotor is blocked. Trying to start again every 1,5 seconds Wait or deblock the shaft. One red LED + one yellow LED (LED 4) Supply volt- age too low Only warning pump runs Control the supply volt- age One red LED + one yellow LED (LED 3) Electrical error Pump is stopped because of low supply voltage or serious failure Control the supply voltage /Exchange the pump IF SUPPLIED WITH THE GRUNDFOS UPM3 PUMP 15. start-up / Commissioning 1. Ensure the system is filled with water and correctly vented. 2. Check if the appropriate system installation pressure is reached (see the “TECHNICAL DATA” section) by pressing the down arrow button whilst the control panel is off, the pressure value will be displayed. When the installation pressure is too low The “A’’indicator flickers (see “Operating’’ section). This doesn’t concern open vented system installations. 3. Set the external controls to call for heat. 4. Switch the boiler on by pressing the power button. 5. Check the pump is set to the correct mode (see table 15.1). To do this, press the pump arrow button for no more than 2 seconds. The LED’s should signal an operating mode at the place pointed by arrow. 6. If the LEDs are signalling a different operating mode than recommended in table 15.1, set the appropriate mode according to the following instructions: press the pump arrow button for longer than 2 seconds, but less than 10 seconds (LED’s will start to flash),the pump then switches to the programming mode. LEDs glows to indicate the current settings. To change the settings of the pump in accordance with table 15.1, you can set the right combination of glowing LEDs by pressing the pump arrow button. Once the LED combination is set correct, by not pressing the button for 10 seconds the pump will remember this setting and will exit from the programming mode back to performance view. note: holding the pump arrow button for more than 10 seconds will enter the pump into key lock mode. This prevents the user from altering the pump settings. To remove the key lock and allow the pump settings to be changed, hold the pump arrow button again for more than 10 seconds. 7. Ensure adequate flow through the boiler is reached (the ‘H’ indicator is on with a constant light). The pump should self vent after a short period of running. If necessary assist the venting process in the following way; Warning the screw head in the centre of the pump is not intended to be used to assist venting of the pump, Damage to the pump internals may occur! • close the isolation valve on the outlet, • leave boiler running for 15 sec. • open the isolation valve. 8. Set the external controls to the required program and the boiler to the required system temperature, see the “Operating” section. In the case of a seized pump impeller due to a long layover out of the heating season and simultaneous non-compliance with the recommendation to cycle the pump every couple of days, please restore proper movement of the impeller. To do this, please use Ph2 screwdriver, press and turn the screw anti-clockwise, located in the middle of the front panel of the pump (Figure 3) until the pump impeller is spinning freely. Table 15.1 Table 15.2 8 GB-031C_f.971 Temporary Filling Loop Mains Water Supply InsTallaTIOn Figure 4 9 GB-031C_f.971 Figure 5 Temporary Filling Loop Mains Water SupplyNext >