Made with FlowPaper - Flipbook Maker
The Fusion 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 Fusion MERCURY COMBI 2 GB 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 product registration ,alternatively the boiler can also be registered online when you visit the link below. https://www.electric-heatingcompany.co.uk/support/ warranty- registration/ This appliance can be used by children aged from 3 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Page Contents INTRODUCTION 2 PREPARATION 3 INSTALLATION 4 BOILER DIMENTIONS & PLUMBING SCHEMATIC 5 COMMISSIONING 6 ELECTRICAL CONNECTIONS AND CONTROLS 7 BOILER INTERNAL LAYOUT 8 CONTROL PANEL WIRING 9 EXTERNAL WIRING 9 BOILER WIRING 12/15 kW 10 INTERNAL BOILER WIRING 19/26 kW 11 USER INSTRUCTIONS 12 ADVANCED SETTINGS 14 FAULT FINDING 15 TECHNICAL SPECIFICATIONS 16 Mercury Combi 3 GB 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 INSTALLATION 1. General Mercury boilers must be installed by a professional plumber or heating engineer. All Electrical works must be carried out by a fully qualified electrician in accordance with the current revision of BS7671 wiring Regulations. The Electric heating Company Ltd will not be held responsible for faulty installations which are performed by unqualified tradespeople. 2. Pipe Connections Mercury boilers Plumbing connections are of the compression type. (22mm for Flow & Return & 15mm for Hot & Cold). 3. Case Removal Remove outer screw at the bottom of the boiler and pull the front cover outwards and upwards taking care to remove internal earth connection. Earth connections must be re-connected before the boiler case is re-installed. 4. Isolation Valves We recommend that lever isolation valves are fitted on the flow and return pipework. Such valves must be „full bore” and not „ball valves”. The installation of “ball valves” will reduce the recommended flow through the boiler that could promote premature boiler shut-down. 5. Mains Water inlet We recommend that a lockshield stopcock is fitted on the mains inlet of the boiler to allow you set the recommended flow rate. (Flow rates can be found in the technical table within this manual) When the boiler is fitted in hard water areas, a water softener must be used. Note: Salt softeners must not be used to fill the heating system. 6. 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. 7. 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. 8. Insulation Where practical, and if at all possible, we recommend that all pipe-work be insulated, in particular the pipe-work within a boiler cupboard. This is to reduce heat loss and reduce high cupboard temperatures from exposed pipe-work. (BS 6700). 9. System Design 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 Scotland), room and cylinder stats must be fitted. 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 .For further guidance please see - Commissioning section on page 6. 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. 12. System types The Fusion Mercury Combi Boilers can be used in various heating designs including underfloor systems. When the boiler is used with an underfloor manifold, the manifold must be of the type that has a thermostatic mixing valve fitted to protect the floor surface. For standard radiator systems 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. Systems should be designed to meet the current building regulations in force at the current time. 13. Hanging the Boiler Hang the boiler in a vertical position using the mounting bracket and fixing screws provided. Make sure the boiler has the minimum recommended clearances as mentioned within this manual. Connect the boiler to a heating system that is equipped with full bore isolation valves and external magnetic filter. 5 GB BOILER DIMENTIONS & PLUMBING SCHEMATIC 260mm 406mm inlet CH outlet CH inlet DHW outlet DHW min 150mm min. 60mm min. 60mm 120mm 50mm 5mm Width 451mm Height 690mm Depth 258mm MM F - Magnetic Filter ZK - Full Bore Isolation Valves Z - Drain Valve G - Radiator ZT/ZP - TRVs RP - Programmer / Thermostat Locksheild MS - Stop Cock (To regulate Flow) Note: We don’t recommend the using single phase boilers to fill baths due to the lower flowrates produced by them. Plumbing Schematic External Weather Sensor 6 GB COMMISSIONING IMPORTANT: Make sure that all plumbing connections are tight before filling the boiler and heating system. Bleeding DHW pipework. 1. Open the DHW tap outlets one at a time. 2. Slowly open the mains Stopcock feeding the DHW circuit of the boiler, until the air has been removed from the hot water pipework, close each tap after water starts to flow. 3. Adjust the DHW flow rate. 4. Open one of the tap outlets and adjust the flow rate by slowly closing the (MS) regulator valve to the recommended flow rate for your boiler size. Refer to the technical table shown on page 17. 5. After the boiler has been electrically wired and tested, you can now turn on the electrical power supply to the boiler. 6. Make sure the programmer is not calling for heat at this stage. Note: When the boiler is fitted in hard water areas, a water softener must be used. Salt softeners must not be used to fill the heating system. Filling the Heating Circuit: 1. Turn on the electrical power supply to the boiler. 2. Make sure the programmer is not calling for heat at this stage. 3. Connect the filling loop and tighten. 4. Make sure that all connections are tight before filling. 5. Open the filling loop and allow the system to start filling. 6. Press the right arrow key on the boiler control panel until the A (bar) led is illuminated. 7. fill the system to 1,5 bar, then start to purge the radiators until all the air is out the system. 8. This will have to be repeated several times to fully purge the system re-filling as you go. System protection: Note: THE HEATING CIRCUT MUST BE FLUSHED IN ACCORDANCE TO BS 7593 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 Electrical „mains” connection Boiler Protection The recommended protection for hard wired boilers are as follows: Model No Boiler size Protection (per phase) MER26KW 3ph 25,8 kW BOILER 3x40 AMP Protection M ER19KW 3ph 19,5 kW BOILER 3x32 AMP Protection MER15KW 14.4 kW BOILER 80 AMP Protection MER12KW 12 kW BOILER 63 AMP Protection External Controls We recommend the use of the EHC SINGLE CHANNEL PROGRAMMER and EHC ROOM THERMOSTAT Note: This control method is recommended by BEAMA (The association of Control Manufactures) in order to comply with the current Building Regulations. CURRENT IEE BS7671 WIRING REGULATIONS. ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED ELECTRICIAN. Load check must be taken into consideration when installing high power boilers. This will be carried out by a qualified electrician. There may be an additional requirement to upgrade the incoming main fuse supplying the property if other high power devices are used within the property. E.g Electric Showers. If an electric shower is present we recommend that a Shower Sensor is installed within the system. This will cause an interrupt to the boilers control signal when the shower is in use. It will disable the boiler protecting the electrical system from overload. All boilers Must be protected with a 30mA double pole RCD with a minimum of 3mm contact separation accompanied by a suitably rated MCB. If the boiler is not fitted local to the meter position then an additional isolation switch must be fitted local to the boiler for each supply. If the property is supplied by a rural power supply or prone to lightening strikes & power cuts it is recommended to install a suitable surge protection device to the boiler supply. This will reduce the risk of damage to the boiler electronics during these events. THIS APPLIANCE MUST BE EARTHED. All pipe-work must be earthed in accordance with the IEE BS7671 Wiring Regulations. After completion of all electrical works, an electrical safety check should be carried out i.e. short circuit, earth continuity, resistance to earth and polarity check, and all relevant Test Certificates completed and issued to the customer. Never open the front cover of the boiler until all power supplies to the boiler have been disconnected. ELECTRICAL CONNECTIONS The boiler connections are clearly marked inside the boiler L N E (24hr LIVE). The 24hr live is the permanent Feed connection to the boiler from the mains supply. External controls will require an independent fused spur supplied from the same consumer unit & protected by the same RCD as the boiler itself. Where a single phase boiler is installed within a 2 Phase or 3 Phase installation the control circuit should also be supplied by the same phase as the boiler. The control circuit should be protected by a 6Amp. MCB. The Boiler & control circuit RCD should be independent of all other domestic circuits. The boiler supply cable should be calculated by the means of a cable calculation in accordance with BS7671 by a suitably qualified electrician. ELECTRICAL CONNECTIONS AND CONTROLS 8 GB INSTALLATION BOILER INTERNAL LAYOUT 3 2 4 6 10 12 20 1917161514 13 11 9 7 1 5 18 8 1 - Wall Bracket 2 - Main Electrical Connection 3 - WT3 Thermal cut-out 4 - PSK Controller 5 - Return Temp Sensor 6 - Thermal WTC3 7 - Power Board 8 - Water Heater PCB 9 - Smart Pump 10 - DHW Heat Exchanger 11 - Heat exchanger 12 - DHW flow Sensor 13 - Flow Temp Sensor 14 - PRV 15 - Flow Outlet 16 - Return Inlet 17 - Pressure Sensor 18 - Expansion pipe 19 - DHW outlet 20 - Mains Water Inlet 9 GB CONTROL PANEL WIRING (Volt Free) SAFETY NOTE: „RP”, and „NA” are signal conductors only. DO NOT CONNECT ANY VOLTAGE to these as this will damage the boiler and invalidate the boilers warranty! Shower Sensor connection (Optional) External Volt Free Call Signal (Programmer / Thermostat FF TT eext.xt. External Weather Sensor Note: If the weather sensor is not used it will have to be disabled in the advance settings. Pump Connections (factory made) EXTERNAL WIRINGNext >