EHC Fusion E10 Combi Series Installation And Technical Manual

EHC Fusion E10 Combi Series

Combination Boiler Range

Installation and

technical manual

THESE INSTRUCTIONS SHOULD BE READ CAREFULLY AND

RETAINED FOR FUTURE REFERENCE.

The Fusion E10 must be installed by a competent person with accordance
with this installation manual and all relevant regualtions in force at time of
installation

The Fusion E10 combination unit’s Unvented Cylinder is a controlled service
as defined in the latest edition of the building regulations.
The relevant regulations are:

England and Wales – Building Regulation G3
Scotland – Technical Standard P3
N Ireland – Building Regulation P5

After installation the Benchmark log table on page X must be completed
and left with the householder for future reference.

The Electric Heating C

ompany Ltd

Unit 40, Block 5, Third Road, Blantyre Industrial Estate, Blantyre, Glasgow, G72 0UP

Tel. [phone]
Fax. [phone]

[e-mail]

www.electric-heatingcompany.co.uk

EHC Fusion E10 Combi – Installation and technical manual Page 2

Contents Page

Warranty registration

Please ensure that the warranty card is completed

and returned to the EHC by post, or you can register the Combination Unit

online at www.electric-heatingcompany.co.uk

.

1. Introduction

3.

2. Safety 3.

3. Storage, handling & unpacking 4.

4. Contents Check List 5.

5. Key Components 6.

6. Technical Specifications 7.

7. Installation – Siting 9.

8. Installation - Plumbing 10.

9. Installation - Discharge arrangement 12.

10. Installation - External pipework schematic

14.

11. Installation – Central Heating pipework 15.

12. Installation – Electrical 17.

13. Commissioning – General 21.

14. Commissioning – Programmer Setting 23.

15. Commissioning – Fusion Boiler 27.

16. Servicing 29.

17. Trouble shooting 30.

18. Benchmark Service Record 31.

19. Guarantee 32.

EHC Fusion E10 Combi – Installation and technical manual Page 3

1. Introduction

Thank you for specifying the Fusion E10 Combi Boiler from The Electric Heating Company.
The Fusion Combi is an integrated electric flow boiler and indirect heated Duplex

TM

SSTL

unvented domestic heating cylinder with back up immersion heater.

This appiance 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 the person responsible
for their safety.

Children should be supervised to ensure they do not play with the appliance.

The Electric Heating Company reserves the right to make minor changes to the
specification or design when necessary.

2. Safety

Please read and understand these instructions before installing the Fusion E10 Combi.
Following installation and commissioning the operation of the Fusion E10 Combi, the central
heating system and associated controls should be explained to the customer and these
instructions left with them for future reference.

The Fusion E10 Combi must be installed in accordance with the manufacturer’s instructions
and all relevant regulations in force at the time of installation. The Fusion E10 Combi’s
Domestic Hot Water Cylinder is of the UNVENTED type. Its installation is subject to Building
Regulation G3 (England and Wales), Technical Standard P3 (Scotland) or Building
Regulation P5 (Northern Ireland). Installation must be carried out by a competent person.

The Fusion E10 Combi electric central heating boiler must be installed into a sealed
(pressurised) primary system. Following installation of the primary system the system
should be flushed in accordance with BS 7593 and an inhibitor added.

The E10 Combi hot water cylinder is indirectly heated by the Fusion electric boiler located
within the cabinet. Additionally the hot water cylinder has an immersion heater for backup.

Please note a load check should be taken into consideration when installing high
output electrical appliances.

The use of an Off-Peak tariff that provides at least three off peak electricity periods, such as
Economy 10 from Scottish and Southern Energy, is recommended. Where possible the
central heating and hot water “on” periods should be programmed to coincide with the off
peak electricity periods available. For more information on the best use of the Economy 10
tariff please contact the Electric Heating Company direct

C.O.S.H.H.

Materials used in the manufacture of the Fusion E10 Combi are non-hazardous and no
special precautions are required when fitting or servicing the appliance.

EHC Fusion E10 Combi – Installation and technical manual Page 4

3. Storage, handling & unpacking

The Fusion E10 Combi is protected in corrugated packaging with reinforced corner posts.
The assembly is wrapped in heavy duty polythene. The Fusion E10 Combi unvented fitting
kit is supplied within the boiler. The assembly must be stored upright, under cover in dry
conditions. Units must not be stacked. The packaging must be removed prior to installation.

Note the weight of the product and the handling instructions applied to the packaging.

If using a handling device, eg. a sack barrow, to manually move the Fusion E10 Combi,
trucking must be done from the rear to avoid damage to the outer panels.

The Fusion E10 Combi should be lifted and handled by two persons. Handholds are
provided in the top rear panel and underneath at the front of the Fusion E10 Combi
assembly to aid lifting. Stooping should be avoided and protective clothing worn when
necessary.

Care must be taken when removing the packaging to avoid any damage to the surface
of the unit.

The packaging is recyclable and should be disposed of in accordance with environmental
guidelines.

EHC Fusion E10 Combi – Installation and technical manual Page 5

4. Contents check list

The following components are supplied in the bag at the front of the Fusion E10 Combi
cabinet. Please check that all parts are present and available before commencing
installation.

EHC Fusion E10 Combi – Installation and technical manual Page 6

5. Key components

1

2

1 Enclosure
2 Removable door retaining clips
3 Twin channel programmer
4 Fusion Slimline Boiler
5 Rear compartment – expansion vessels
6 Rear compartment – cylinder
7 Automatic bypass
8 Cylinder stat
9 Wiring centre
10 Domestic hot water temp/pressure relief outlet
11 Programmer cable
12 Domestic hot water outlet
13 Central heating pressure relief outlet
14 Magnetic filter
15 Zone valves
16 Immersion Heater
17 Cold main
18 Central heating return
19 Central heating flow

1 Control Panel
2 Over-heat cutout
3 Automatic air vent
4 Heating elements
5 Copper heat exchanger
6 Printed circuit board
7 Voltage free control connections
8 Circulation pump
9 Flow and Return sensors
10 Flow switch
11 Pressure gauge
12 Heating flow
13 Heating return
14 Pressure relief valve
15 Enclosure

EHC Fusion E10 Combi – Installation and technical manual Page 7

6. Technical specifications________________________

General

Boiler range

9 kW 12 kW 14.4 kW

Cylinder

Heating output 30,717 Btu 40,956 Btu 49,147 Btu

Electricity Supply 230/240V single phase 50Hz

Load/Current 39.1 Amps 52.2 Amps 62.6 Amps

Protection required 45.0 Amps 63.0 Amps 80.0 Amps

CH Max temp setting

Factory setting

85°C 55/60°C

CH Min temp setting 40°C 25°C

CH Overheat protection 100°C

Pump included Yes

Recommended pump

setting

Maximum

CH Flow and Return pipes 22mm

Domestic & Primary

connections

22mm

Min Water Pressure 1.0 Bar 3.0 Bar

Max Water Pressure 3.0 Bar 7.0 Bar

Expansion Vessels 8 litre 12 litre

Back up immersion heater 3.0 kW

Performance

150 litre

9 kW 12 kW 14.4 kW

Time to re-heat from 15C to

56C

63 mins 47 mins 38 mins

180 litre

9 kW 12 kW 14.4 kW

Time to re-heat from 15C to

56C

79 mins 59 mins 48 mins

EHC Fusion E10 Combi – Installation and technical manual Page 8

6. Technical specifications/ Cont..._________________

Dimensions

150 litre 180 litre

Dry weight 96 kg 104 kg

Full weight 250 kg 290 kg

Dimensions 1470 x 574 x 750 mm 1620 x 574 x 750 mm

200mm 50mm

20mm

500mm

Recommended Clearance

EHC Fusion E10 Combi – Installation and technical manual Page 9

7. Installation: siting

Choosing a location

The Fusion E10 Combi must be installed indoors in a dry and frost free environment. It must
be vertically mounted on a flat, level surface capable of supporting the full weight of the unit.

When full the unit weighs a total of 250kg - 290kg.

Consideration must be given to maintenance – clearance must be left around the
boiler to allow the front and top panels to be removed and to allow access to the
external pipework and controls.

Care must be taken when lifting this unit. A two man lift is recommended. Hand holds
are provided in the case at the top rear and bottom front of the unit.

Removing the panels

For installation, the front door and top panel cab be removed.

1. Door B is secured by two spring clips at point C. There are two locating studs for door at
point D.

To remove apply light force at edge around point C. Once released angle back

approx 15 degrees. Then lift vertically to remove studs at point D from their location.

Be careful to store the door where it cannot be damaged.

2. Lid A has no securing areas and can be lifted directly off the unit.

All EARTH connections must be reconnected to removable side panels

A

B

C

D

EHC Fusion E10 Combi – Installation and technical manual Page 10

8 Installation: Plumbing

Water supply requirements

The Fusion E10 Combi operates at 3 bar (controlled by the inlet control set) and is capable
of delivering over 50 litres per minute. The high quality inlet control set has been designed to
make the most of the flow rates available, however the performance of any unvented system
is only as good as the mains water supply to the unit. The maximum possible water demand
should be assessed by taking into consideration that both hot and cold services are supplied
simultaneously from the mains. The water supply should be checked to ensure it can meet
these requirements. If necessary consult the local water company regarding the likely
pressure and flow rate availability.

If measuring the water pressure, please note that a high static (no flow) mains pressure is no
guarantee of a high flow rate. In a domestic installation 1.5 bar and 25 l/m should be
regarded as the minimum. The maximum recommended mains pressure for the inlet control
set is 16 bar. Consideration should be given to upgrading existing ½” (15mm) cold mains
pipework to a larger size if the recommended minimum pressure/flowrate is not being
achieved.

Cold mains pipework Example

1. Run the cold main pipework to where the Fusion E10 Combi unit is to be installed. Take
care not to run the cold mains pipework near the hot water or heating pipe work so that heat
pick up is minimized.

2. Identify the cold water supply pipe and fit an isolating valve (not supplied). A 22mm
BS1010 stopcock can typically be used, however a 22mm quarter turn full bore valve is
preferable as it does not restrict the flow as much. Do not use “screwdriver slot” or similar
valves.

3. Make the connection to the cold feed of the Fusion E10 Combi and incorporate a drain
valve. Position the inlet control immediately above the Temperature & Pressure Relief Valve
(TPRV) mounted on the side of the unit (see diagrams below). This ensures that the unit
does not have to be drained down in order to service the inlet control set. Ensure that the
arrow points in the direction of the water flow.