EHC Fusion Installation & Technical Manual
The FUSION Range of Boilers
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
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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 are a user
or external control fault.
The warranty will not cover water leaks into the boiler. All
plumbing joints must be checked.
The warranty card should be completed and sent back to The
Electric Heating Company as soon as possible for registration.
A magnetic filter must be fitted to the system in the horizontal
position.
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
ELECTRICAL CONNECTIONS AND CONTROLS 7
EXTERNAL CONTROL WIRING 8
INTERNAL BOILER WIRING 9
EXTERNAL BOILER WIRING 10
BOILER DIMENSIONS 10
USER INSTRUCTIONS 11
FAULT FINDING 13
TECHNICAL SPECIFICATIONS 14
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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 5449, 1990, forced circulating hot water systems.
BS 7671, IEE wiring regulations.
BS 4814, 1990, Specification for expansion vessels (sealed systems only)
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 pipework are not subject to frost and damp conditions.
3. Central heating
Detailed recommendations are given in BS 5449, BS 6700 and
CP 342, Part 2.
Pipes forming part of the useful heating surface should be insulated to prevent any potential heat loss or frost damage.
(BS 6700:1997).
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 2871. Part 1 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.
MOUNTING THE BOILER
Mount the boiler onto a flat wall surface that will be capable of
taking the boilers full weight. Use the mounting template provided with the boiler, mark and drill the fixing holes taking into consideration you leave the minimum clearances required around
the fusion boilers.
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 (150 mm for Slimline model).
THE BOILER MUST BE INSTALLED IN THE UPRIGHT POSITION,
FAILURE TO DO SO WILL INVALIDATE THE WARRANTY.
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INSTALLATION
The boiler must be installed by a professional plumber or heating engineer and must be connected to the power supply by a
qualified electrician.
The Electric Heating Company Ltd will not be held responsible for faulty installations which are performed by unqualified
tradespersons.
1. Pipe Connections
All Fusion Electric Boilers have a 22 mm 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 and replaced with the washers supplied. The 2
spare pcb fuses supplied must be left inside the boiler.
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
2. Case Removal
Remove outer screws from boiler case and push upwards and
outwards taking care to remove internal earth connections. (Slimline model: remove screws on the right hand side and swing the
boiler case open).
Earth connections must be re-connected before the case is reinstated.
3. Isolation valves
Consideration should be made for the provision of lockshield isolation valves on the flow and return pipe-work. Such valves must
be full way and not ball valves.
We recommend isolation valves on each side of the magnetic
filter.
The insertion of ball valves will reduce the recommended flow
through the boiler and promote premature boiler shut down
caused by poor flow rate.
4. 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.
5. Boiler Sizing
Calculate the space heating requirements in accordance with BS
5449. If the boiler is to heat the domestic hot water, an allowance
of 3kw (10,239 Btu’s ) should be made.
6. Insulation
Where practical and if at all possible, we recommend that all
pipe-work be insulated, in particular the primary pipe-work within the boiler cupboard. This is to reduce heat loss and reduce high
cupboard temperatures from exposed pipe-work. (BS 6700).
7. System Design
As the boilers are of a low water content an open circuit must be
achieved incorporating 2 metres of continuous 22 mm pipe-work
after boiler connections and before any zone valves.
We recommend the use of an automatic bypass within this circuit
and set to the relevant settings to allow the minimum flow rates to
pass through the boiler (8 l per min) when all radiator thermostats
close.
Allowance should be made for a minimum size radiator of 600mm
x 600mm single convector or equal to 2500 Btu to be installed
within the heating circuit and locked open. This will be located
in the room that has the room stat installed.
To comply with building regulations, Part L and Part J (in Scotland) room and cylinder stats must be fitted.
Note: We do not recommend the use of 8 mm micro-bore pipe.
8. Water connections
Provisions must be made for the replacement of water lost from
the heating system (sealed systems). Reference should be made to
BS 6798, for the methods 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. Any connection made must be disconnected after use.
9. Flushing
The system must be flushed to ensure that no debris is trapped in
the flow sensor as this may result in boiler failure. Where existing
radiators and pipe-work are utilised a power flush must be carried
out to remove debris.
10. System pressures
All boilers are tested to 4.0 bar. The normal working pressure of
the boilers should be set to 1.5 bar. All sealed systems should
comply with the relevant building regulations and standards and
to BS 4814, (Specification for Expansion Vessels).
Please Note
In order to protect the Flow Sensor located within the boiler, it
is imperative that you install a mechanical-magnetic filter on the
return inlet to the boiler. This will enable you to clean the filter
at regular intervals and will also ensure that the boiler does not
become contaminated by system residue.
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11. System types
The 6,9,12 & 14.4 kW 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 also recommend the use of thermostatic radiator valves on all
radiators except in the room that has the wall thermostat fitted. If
a bypass radiator has been used in the system, it should be fitted
with lock shield valves and left in the fully open position.
If a bypass radiator has not been used then a system bypass of 2
metres of 22 mm copper pipe incorporating an automatic bypass
valve must be used and can be set to 8l/min from the front control
panel.
Systems should be designed to current building regulations.
12. System protection
Failure to protect the system will invalidate the manufacturer’s
warranty.
After the system has been installed the cleansing and inhibiting
procedure must be carried out as follows: -
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.
Add Fernox Heavy Duty restorer through the header tank or via
filling loop at the recommended dose. One bottle must be used
as a minimum per dwelling. If you are unsure of the correct dose
rate, contact Fernox.
Re-fill the system and circulate the heavy-duty restorer prior
to the boiler entering modulation mode, then commission the
system as normal.
The cleansing agent must be in the system for a minimum 1
hour with the system at normal operating temperature. A longer
period of time would be more beneficial to the cleansing process
especially if excess flux was used.
Drain and flush the system thoroughly, then add the Fernox
Protector (Copal MB1 or Superconcentrate). 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.
The label included within the Fernox Protector carton should be
completed and attached adjacent to the boiler.
Note: motorised valves must be manually opened when flushing
the system.
Note: If the system is to be drained for any reason, the Fernox
Protector must be re-introduced to the system.
Any further information you may require regarding the protection
and cleansing products, please contact: -
Fernox Technical Helpline on 0870 870 0362.
Fernox Method Statement for New Domestic Systems
Cleansing and inhibiting a new central heating installation using
Fernox Heavy Duty Restorer and a Fernox Protector (Copal,
MBI and Superconcentrate).
Procedure:
1. Fill the system with cold mains water to the recommended
pressure 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 Heavy Duty Restorer through the header tank or
via a Fernox injector at the recommended dose. One bottle
must be used as a minimum per dwelling. If you are not sure
of the dose rate, then contact Fernox.
3. Fill the system back up and circulate the Heavy Duty Restorer
before the boiler is fired up. Then commission the system in
the normal way. The cleansing agent must be in the system
for a minimum of I hour with the system at normal operating
temperature. A longer period of time would be more beneficial
to the cleansing process especially if excess flux was used.
4. Drain and flush the system thoroughly to remove the cleaning
chemical and debris present. This is a crucial part of the cleansing process and must be done correctly. Use a rinse test meter
(TDS), such as the Fernox CTM. The reading must be within
10% of the mains ppm value.
5. Once the system has been cleansed thoroughly, then add a
Fernox Protector (Copal, MB1 or Superconcentrate), to the
system. The product must be added as per the manufacturer’s
instructions. This will protect against the formation of scale, corrosion and microbiological growths. lt is crucial, however, that
for a protector to work correctly, the system must be properly
cleansed and flushed.
6. The sticker included within the Fernox Protector carton should
be correctly filled in and attached adjacent to the boiler.
7. Please note: 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.
8. Fernox Technical Services can be contacted on 0870 8700362
for further assistance.
NB: Motorised valves should be manually opened during the
flushing process and any anti-gravity valves should be by-passed
or removed temporarily.
If it is necessary to cap off the open vent during the mains flush
to prevent overflow ensure the cap is removed prior to starting
the appliance.
Advice as contained within BS 7593:1992 and PAS33:1999
should be followed in conjunction with this method statement.
Failure to protect systems will void manufacturers warranty.
Water Loss
If water loss occurs due to natural evaporation, leakage or any
other breakdown in water seals, the boiler will not operate.
The boilers flow sensor needs a minimum of 4 litres per minute to
operate. If this cannot be achieved the boiler will shut down.
We recommend setting to 8l/min.
Investigation
Should BOIL OVER/ BOIL DRY /WATER LOSS occur, investigation
as to why the system has failed MUST take place. Power should
only be reinstated after the fault has been rectified.
The main overheat stat on the boiler can be re-set, this is
positioned at the top of the boiler market WT3. To re-set, push
the brass pin with a small screwdriver. The pin will click into
place when re-set.
ENSURE THAT THE MAINS POWER SUPPLY TO THE BOILER IS
SWITCHED OFF PRIOR TO RE-SETTING.
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