ACV E-Tech 09, E-Tech 15, E-Tech 22, E-Tech 28, E-Tech 36 INSTALLATION OPERATING AND SERVICING INSTRUCTIONS

Installation, operating and

servicing instructions

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

E-Tech 09 - 15 Single phase / Tri phase

E-Tech 22 - 28 - 36 Tri phase

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EN • 1

INDEX

WARNINGS 3

Who should read these instructions 3 Symbols 3

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Recommendations 3 Applicable standards 3 Importants notes 3 Manual handling instructions 3 Removing the boiler from the packaging 3

INTRODUCTION 4

Description of the specifications 4 Lining 4 Heating body 4 Heating elements 4

Equipment 4 Connection 4 Dual stage thermostat 4 Certification 4 Legend 4

INSTRUCTIONS 6

User data 6 Setting up 6 Optional internal timeclock 6 Pressure in the heating system 6

HONEYWELL SUNDIAL WIRING DIAGRAMS 24

Honeywell Sundial Wiring Centre ‘S’ Plan 24 Honeywell Sundial Wiring Centre ‘Y’ Plan 25

COMMISSIONING AND MAINTENANCE 26

Commissioning - Water 26 Commissioning - Electrical 26 Starting the boiler 26 Maintenance 26

REMOVAL THE HEATING ELEMENTS 27

TECHNICAL CHARACTERISTICS 7

Electrical data of model 09 8 Electrical data of model 15 9 Electrical data of model 22 10 Electrical data of model 28 11 Electrical data of model 36 12

MOUNTING 13

Dimensions 13 Wall mounting 13 Installation room 13

INSTALLATION 14

Disassembling 14 Heating connection 15 Heating connection + DWL 15 Heating connection + DWL : “Y” plan 16 Heating connection + DWL : “S” plan 16 Electric connection / Models : 09 - 15 17

Electric connection / Models : 22 - 28 - 36 18 Sizing of supply wires 18 Wiring diagrams / Models : 09 - 15 - 22 19

Wiring diagrams / Models : 28 - 36 20 Power wiring / Models : 09 - 15 21 Power wiring / Model : 22 22 Power wiring / Models : 28 - 36 23

SPARE PARTS See at the end of this manual

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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.

Essential instruction for the safety of persons and the environment.

Danger of electrocution.

Danger of burns

RECOMMENDATIONS

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

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 accessoiries

can vary following the market.

Warning : Do not switch ON if there is a possibility

that the water in heater is frozen.

MANUAL HANDLING INSTRUCTIONS

The weight of this boiler is 36Kg, which could

RISK OF INJURY LIFT WITH CARE

HEAVY

APPLIANCE

GET HELP

present a risk of injury.

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

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

• 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.

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

• There are no user parts inside the control panel.

APPLICABLE STANDARDS

The Boilers have been manufactured to comply with the following standards BS EN60335-2-35: 2002, BS EN55014-1: 2001 and BS EN55014-2:1997.

The installation must be in accordance with the current

standards.

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

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.

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.

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INTRODUCTION

DESCRIPTION OF THE SPECIFICATIONS:

This wall hung electric boiler is available in 5 models:

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

• Models 09 and 15 are supplied with 400 Volt triphase + N, convertible to 230 V 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).

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

2 3 3

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.

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EN • 4

INTRODUCTION

Top cover

Brass pocket

Minimum thermostat

(only with direct DHW kit)

Hand side panel

Cable gland

Control panel

Automatic air vent

Heating elements

Heating body

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Rear panel

Water pressure switch

Direct ESC kit connection

(in option)

Pressure safety valve

Expansion vessel

Valve of expansion vessel

Expansion vessel connection

Circulating pump

Expansion vessel connection

Heating return

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Heating out

Manual reset high limit pressure gauge

EN • 5

INSTRUCTIONS

USER DATA

All user controls are situated on the front panel of the boiler, there

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

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.

• 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.

• 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.

1 2 3 4 6 7 85

LEGEND

1. ON/OFF switch

2. Power levels switch

3. Summer/Winter switch

4. Optional internal clock or controler

5. Combined temperature and pressure gauge

6. Boiler shutdown indicator light

7. Manual reset high limit thermostat

8. Control thermostat : 1 = 40°C 2 = 50°C 3 = 60°C 4 = 70°C 5 = 80°C

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TECHNICAL CHARACTERISTICS

Model 09 15 22 28 36

Power

Nominal supply voltage

Ohmic resitance of element

Heating element type

Number of elements

Water capacity (Litres)

4.2 to

8.4 kW

1 x 230 V

3 x 400 V + N

37,8 Ohm 22 Ohm 22 Ohm 22 Ohm 17,6 Ohm

2 x 1.4 kW 2 x 2.4 kW 2 x 2.4 kW 2 x 2.4 kW 2 x 3 kW

33566

13 13 13 13 13

7.2 to

14.4 kW

1 x 230 V

3 x 400 V + N

14.4 to

21.6 kW

3 x 400 V + N 3 x 400 V + N 3 x 400 V + N

21.6 to

28.8 kW

30 to

36 kW

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Expansion vessel capacity (Litres)

Max. working pressure (bars)

Min. working pressure (bars)

Max. working temperature (°C)

Hydraulic pressure drop (mbar)

Heating connection

Height (mm)

Width (mm)

10 10 10 10 10

33333

0.8 0.8 0.8 0.8 0.8

85 85 85 85 85

10 20 45 85 125

3/4” 3/4” 3/4” 3/4” 3/4”

763 763 763 763 763

442 442 442 442 442

Depth (mm)

Weight empty (kg)

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332 332 332 332 332

45 45 45 45 45

EN • 7

TECHNICAL CHARACTERISTICS

Electrical data of model 09

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 8.4 kW (*)

Terminals 1 and 2 shunted Terminal 3 L1 (A) 6 6 12 Terminals 5 and 6 shunted Terminal 4 L2 (A) 12 0 12 Relay K4 activated Terminal 5 L3 (A) 6 6 12 Terminal 1 N (A) 6 6 0 Power (kW) 5.6 2.8 8.4

Tri phase 7 kW (***) Terminals 1 and 2 shunted Terminal 3 L1 (A) 6 6 12 Relay K4 activated Terminal 4 L2 (A) 12 0 12 Terminal 5 L3 (A) 6 0 6 Terminal 1 N (A) 6 6 6 Power (kW) 5.6 1.4 7

Tri phase 5.6 kW (***) Terminals 1 and 2 shunted Terminal 3 L1 (A) 0 6 6 Terminals 5 and 6 shunted Terminal 4 L2 (A) 6 0 6 Relay K4 disactivated (**) Terminal 5 L3 (A) 6 6 12 Terminal 1 N (A) 6 6 6 Power (kW) 2.8 2.8 5.6

1N23L14L25L36

Tri phase 4.2 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 0 6 6 Relay K4 disactivated (**) Terminal 4 L2 (A) 6 0 6 Terminal 5 L3 (A) 6 0 6 Terminal 1 N (A) 6 6 0 Power (kW) 2.8 1.4 4.2

Single phase 8.4 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 24 12 36 Terminals 3, 4, 5 and 6 shunted Terminal 1 N (A) 24 12 36 Relay K4 activated Power (kW) 5.6 2.8 8.4

Single phase 7 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 24 6 30 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 24 6 30 Relay K4 activated Power (kW) 5.6 1.4 7

Single phase 5.6 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 12 12 24 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 12 12 24 Relay K4 disactivated (**) Power (kW) 2.8 2.8 5.6

1N23L14L25L36

1N23L456

Single phase 4.2 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 12 6 31.2 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 12 6 31.2 Relay K4 disactivated (**) Power (kW) 2.8 1.4 4.2

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 21 and 22 in order to deactivate the relay / (***) Current not balanced.

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1N23L456

TECHNICAL CHARACTERISTICS

Electrical data of model 15

STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 14.4 kW (*)

Terminals 1 and 2 shunted Terminal 3 L1 (A) 10.4 10.4 20.8 Terminals 5 and 6 shunted Terminal 4 L2 (A) 20.8 0 20.8 Relay K4 activated Terminal 5 L3 (A) 10.4 10.4 20.8 Terminal 1 N (A) 10.4 10.4 0 Power (kW) 9.6 4.8 14.4

Tri phase 12 kW (***) Terminals 1 and 2 shunted Terminal 3 L1 (A) 10.4 10.4 20.8 Relay K4 activated Terminal 4 L2 (A) 20.8 0 20.8 Terminal 5 L3 (A) 10.4 0 10.4 Terminal 1 N (A) 10.4 10.4 10.4 Power (kW) 9.6 2.4 12

Tri phase 9.6 kW (***) Terminals 1 and 2 shunted Terminal 3 L1 (A) 0 10.4 10.4 Terminals 5 and 6 shunted Terminal 4 L2 (A) 10.4 0 10.4 Relay K4 disactivated (**) Terminal 5 L3 (A) 10.4 10.4 20.8 Terminal 1 N (A) 10.4 10.4 10.4 Power (kW) 4.8 4.8 9.6

Tri phase 7.2 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 0 10.4 10.4 Relay K4 disactivated (**) Terminal 4 L2 (A) 10.4 0 10.4 Terminal 5 L3 (A) 10.4 0 10.4 Terminal 1 N (A) 10.4 10.4 0 Power (kW) 4.8 2.4 7.2

1N23L14L25L36

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Single phase 14.4 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 41.6 20.8 62.4 Terminals 3, 4, 5 and 6 shunted Terminal 1 N (A) 41.6 20.8 62.4 Relay K4 activated Power (kW) 9.6 4.8 14.4

Single phase 12 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 41.6 10.4 52 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 41.6 10.4 52 Relay K4 activated Power (kW) 9.6 2.4 12

Single phase 9.6 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 20.8 20.8 41.6 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 20.8 20.8 41.6 Relay K4 disactivated (**) Power (kW) 4.8 4.8 9.6

Single phase 7.2 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A) 20.8 10.4 31.2 Terminals 3, 4 and 5 shunted Terminal 1 N (A) 20.8 10.4 31.2 Relay K4 disactivated (**) Power (kW) 4.8 2.4 7.2

1N23L456

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TECHNICAL CHARACTERISTICS

Electrical data of model 22

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 21.6 kW (*)

Terminals 3 and 4 shunted Terminal 2 L1 (A) 20.8 10.4 31.2 Terminals 5 and 6 shunted Terminal 3 L2 (A) 20.8 10.4 31.2 Relay K4 activated Terminal 5 L3 (A) 20.8 10.4 31.2 Terminal 1 N (A) 0 0 0 Power (kW) 14.4 7.2 21.6

Tri phase 19.2 kW (***) Terminals 3 and 4 shunted Terminal 2 L1 (A) 20.8 10.4 31.2 Relay K4 activated Terminal 3 L2 (A) 20.8 10.4 31.2 Terminal 5 L3 (A) 10.4 10.4 20.8 Terminal 1 N (A) 10.4 0 10.4 Power (kW) 12 7.2 19.2

Tri phase 16.8 kW (***) Relay K4 activated Terminal 2 L1 (A) 20.8 10.4 31.2 Terminal 3 L2 (A) 10.4 10.4 20.8 Terminal 5 L3 (A) 10.4 10.4 20.8 Terminal 1 N (A) 10.4 0 10.4 Power (kW) 9.6 7.2 16.8

1N2L13L24 5L36

Tri phase 14.4 kW

Terminals 3 and 4 shunted Terminal 2 L1 (A) 10.4 10.4 20.8 Terminals 5 and 6 shunted Terminal 3 L2 (A) 10.4 10.4 20.8 Relay K4 disactivated (**) Terminal 5 L3 (A) 10.4 10.4 20.8 Terminal 1 N (A) 0 0 0 Power (kW) 7.2 7.2 14.4

1N2L13L24 5L36

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TECHNICAL CHARACTERISTICS

Electrical data of model 28

STAGE 1 STAGE 2 TOTAL POWER TERMINALS

Tri phase 28.8 kW (*)

Terminals 3 and 4 shunted Terminal 2 L1 (A) 20.8 20.8 41.6 Terminals 5 and 6 shunted Terminal 3 L2 (A) 20.8 20.8 41.6 Relay K5 activated Terminal 5 L3 (A) 20.8 20.8 41.6 Terminal 1 N (A) 0 0 0 Power (kW) 14.4 14.4 28.8

Tri phase 26.4 kW (***) Terminals 3 and 4 shunted Terminal 2 L1 (A) 20.8 20.8 41.6 Relay K5 activated Terminal 3 L2 (A) 20.8 20.8 41.6 Terminal 5 L3 (A) 20.8 10.4 31.2 Terminal 1 N (A) 0 10.4 10.4 Power (kW) 14.4 12 26.4

Tri phase 24 kW (***) Relay K5 activated Terminal 2 L1 (A) 20.8 20.8 41.6 Terminal 3 L2 (A) 20.8 10.4 31.2 Terminal 5 L3 (A) 20.8 10.4 31.2 Terminal 1 N (A) 0 10.4 10.4 Power (kW) 14.4 9.6 24

Tri phase 21.6 kW

Terminals 3 and 4 shunted Terminal 2 L1 (A) 20.8 10.4 31.2 Terminals 5 and 6 shunted Terminal 3 L2 (A) 20.8 10.4 31.2 Relay K5 disactivated (**) Terminal 5 L3 (A) 20.8 10.4 31.2 Terminal 1 N (A) 0 0 0 Power (kW) 14.4 7.2 21.6

1N2L13L24 5L36

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

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 23 and 24 in order to deactivate the relay / (***) Current not balanced.

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