E-Tech 09, 15, 36, 22, 28 Installation, Operating And Maintenance Instructions

09/09/2004 - 66402800

excellence in hot water

Installation, operating and
maintenance instructions

E-Tech 09 - 15
Single phase

E-Tech 22 - 28 - 36
Tri phase

- 1 -

WARNINGS 2

Who should read these instructions 2
Symbols 2
Recommendations 2
Applicable standards 2
Importants notes 2
Manual handling instructions 2
Removing the boiler from the packaging 2

INTRODUCTION 3

Description of the specifications 3
Lining 3
Heating body 3
Heating elements 3
Equipment 3
Connection 3
Dual stage thermostat 3
Certification 3
Legend 3

INSTRUCTIONS 5

User data 5
Setting up 5
Optional internal timeclock 5
Pressure in the heating system 5

TECHNICAL CHARACTERISTICS 6

Electrical data of model 09 7
Electrical data of model 15 8
Power variation (kW) relative to voltage 8
Electrical data of model 22 - 28 - 36 9

MOUNTING 10

Dimensions 10
Wall mounting 10
Installation room 10

INSTALLATION 11

Disassembling 11
Heating connection 12
Heating connection + DHW : “Y” plan 12
Heating connection + DHW : “S” plan 12
Electric connection / Models : 09 - 15 13
Electric connection / Models : 22 - 28 - 36 14
Sizing of supply wires 14
Wiring diagrams / Models : 09 - 15 - 22 15
Wiring diagrams / Model : 28 16
Wiring diagrams / Model: 36 17
Power wiring / Models : 09 - 15 18
Power wiring / Model : 22 19
Power wiring / Model : 28 20
Power wiring / Model : 36 21

HONEYWELL SUNDIAL WIRING DIAGRAMS 22

Honeywell Sundial Wiring Centre ‘S’ plan 22
Honeywell Sundial Wiring Centre ‘Y’ plan 23

COMMISSIONING AND MAINTENANCE 24

Commissioning - Water 24
Commissioning - Electrical 24
Starting the boiler 24
Maintenance 24

REMOVAL THE HEATING ELEMENTS 25

SPARE PARTS 26

INDEX

- 2 -

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

RECOMMENDATIONS

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

• 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.

APPLICABLE STANDARDS

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.

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 accessories
can vary following the market

MANUAL HANDLING INSTRUCTIONS

WARNINGS

Danger of burns

Essential instruction for
the safety of persons
and the environment.

Danger of electrocution

Essential instruction for
the correct operation
of the installation.

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.

The weight of this boiler is 36Kg, which could
present a risk of injury.

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

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.

RISK OF INJURY
LIFT WITH CARE

HEAVY

APPLIANCE

GET HELP

- 3 -

DESCRIPTION OF THE SPECIFICATIONS

This wall hung electric boiler is available in 5 models :

• models 09 and 15 are supplied with 230 Volt 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).

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.

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

INTRODUCTION

4321

5 6

3

- 4 -

INTRODUCTION

Top cover

Rear panel

Water pressure switch

Expansion vessel connection

Supplementary heating return

(not used)

Heating return

Automatic air vent

Expansion vessel

Valve of expansion vessel

Heating out

Manual reset high limit pressure gauge

Expansion vessel connection

Circulating pump

Heating elements

Heating body

Pressure safety valve

Cable glands

Hand side panel

Control panel

Brass pocket

- 5 -

USER DATA

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

• 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.

• 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.

INSTRUCTIONS

1 2 3 54 6 7

LEGEND

1. ON/OFF switch

2. Power levels switch

3. Optional internal
clock or controler

4. Combined temperature
and pressure gauge

5. Boiler shutdown
indicator light

6. Manual reset high
limit thermostat

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

- 6 -

TECHNICAL CHARACTERISTICS

4545454545Weight empty (kg)

332332332332332Depth (mm)

442442442442442Width (mm)

763763763763763Height (mm)

3/4”3/4”3/4”3/4”3/4”Heating connection

12585452010

Hydraulic presure drop
(mbar)

8585858585

Max. working temperature
(°C)

0.80.80.80.80.8

Min. working pressure
(bars)

33333

Max. working pressure
(bars)

1010101010

Expansion vessel capacity
(Litres)

1313131313

Water capacity
(Litres)

66533Number of elements

3 x 2 kW2 x 2.4 kW2 x 2.4 kW2 x 2.4 kW2 x 1.4 kWHeating element type

26.45 Ohm22 Ohm22 Ohm22 Ohm37.8 Ohm

Ohmic esistance
of element

3 x 400 V + N3 x 400 V + N3 x 400 V + N1 x 230 V1 x 230 VNominal supply voltage

30 to

36 kW

21.6 to

28.8 kW

14.4 to

21.6 kW

7.2 to

14.4 kW

4.2 to

8.4 kW

Power

3628221509Model

- 7 -

TECHNICAL CHARACTERISTICS

Electrical data of model 09

ST AGE 1 ST AGE 2 TOTAL POWER TERMINALS

Single phase 8.4 kW (*)

Terminals 1 and 2 shunted Terminal 3 L1 (A)24 1236
Terminals 3, 4, 5 and 6 shunted Ter minal 1 N (A)24 1236
Relay K3 activated Power (kW) 5.6 2.8 8.4

Single phase 7 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A)24630
Terminals 3, 4 and 5 shunted Terminal 1 N (A)24630
Relay K3 activated Power (kW) 5.6 1.4 7

Single phase 5.6 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A)12 1224
Terminals 3, 4, 5 and 6 shunted Ter minal 1 N (A)12 1224
Relay K3 disactivated (**) Power (kW) 2.8 2.8 5.6

Single phase 4.2 kW

Terminals 1 and 2 shunted Terminal 3 L1 (A)12631.2
Terminals 3, 4 and 5 shunted Terminal 1 N (A)12631.2
Relay K3 disactivated (**) Power (kW) 2.8 1.4 4.2

1N23L456

1N23L456

1N23L456

1N23L456

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 17 and 18 in order to desactivate the relay.

Electrical data of model 15

ST AGE 1 ST AGE 2 TOTAL POWER TERMINALS

- 8 -

TECHNICAL CHARACTERISTICS

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 Ter minal 1 N (A) 41.6 20.8 62.4
Relay K3 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 K3 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, 5 and 6 shunted Ter minal 1 N (A) 20.8 20.8 41.6
Relay K3 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 K3 disactivated (**) Power (kW) 4.8 2.4 7.2

1N23L456

1N23L456

1N23L456

1N23L456

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 17 and 18 in order to desactivate the relay.

220 V 230 V 240 V 3 x 380 V 3 x 400 V 3 x 415 V

E-Tech W 09

7.7 8.4 9.1

E-Tech W 15

13.2 14.4 15.7

E-Tech W 22

19.5 21.6 23.3

E-Tech W 28

26.0 28.8 31.0

E-Tech W 36

32.5 36.0 38.8

Power variation (kW) relative to voltage

Electrical data of model 28

ST AGE 1 ST AGE 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 K4 activated Ter minal 5 L3 (A) 20.8 20.8 41.6

Terminal 1 N (A) 000
Power (kW) 14.4 14.4 28.8

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 disactivated (**) Ter minal 5 L3 (A) 20.8 10.4 31.2

Terminal 1 N (A) 000
Power (kW) 14.4 7.2 21.6

1N2L13L24 5L36

1N2L13L24 5L36

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 19 and 20 in order to desactivate the relay.

- 9 -

TECHNICAL CHARACTERISTICS

Electrical data of model 22

ST AGE 1 ST AGE 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 K43 activated Terminal 5 L3 (A) 20.8 10.4 31.2

Terminal 1 N (A) 000
Power (kW) 14.4 7.2 21.6

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 K3 disactivated (**) Ter minal 5 L3 (A) 10.4 10.4 20.8

Terminal 1 N (A) 000
Power (kW) 7.2 7.2 14.4

1N2L13L24 5L36

1N2L13L24 5L36

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 17 and 18 in order to desactivate the relay.

Electrical data of model 36

ST AGE 1 ST AGE 2 TOTAL POWER TERMINALS

Tri phase 36 kW (*)

Terminals 3 and 4 shunted Terminal 2 L1 (A)26 2652
Terminals 5 and 6 shunted Terminal 3 L2 (A)26 2652
Relay K4 activated Ter minal 5 L3 (A)26 2652

Terminal 1 N (A) 000
Power (kW)18 1836

Tri phase 30 kW

Terminals 3 and 4 shunted Terminal 2 L1 (A)26 1743
Terminals 5 and 6 shunted Terminal 3 L2 (A)26 1743
Relay K4 disactivated (**) Ter minal 5 L3 (A)26 1743

Terminal 1 N (A) 000
Power (kW)18 1230

1N2L13L24 5L36

1N2L13L24 5L36

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 19 and 20 in order to desactivate the relay.

- 10 -

MOUNTING

Min.

25 mm

Min.
400 mm

Min.
200 mm

763 mm

763 mm

442 mm

332 mm

178 mm
379 mm

90 mm

101,6 m

m

101,6 mm

48,4 mm

53,2 m

m

53,2 m

m

48,4 m

m

• The boiler must be fixed to a non flammable wall.

• Observing the clearances shown below, drill 2 off
14mm x 100mm holes.

• Fit the 2 bolts supplied and hang the wall bracket.

• Fit washers and nuts

• Hang the boiler

FROST PROTECTION

The boiler is NOT fitted with frost protection. If the
boiler is being installed in a position where freezing
could take place, then a suitable external frost
thermostat should be fitted.

CONNECTING TO THE SYSTEM

The boiler is designed to operate on a sealed system
(ie. no open vent or feed and expansion cistern). Hot
water expansion within the system is taken up by the
internal 10 litre expansion vessel.This is suitable for
systems up to 160 litres capacity. If the system
capacity is more than this then an additional expansion
vessel may be required.This can be fitted external to
the boiler at a convenient place on the pipework.
Please note that the circulation pump is fitted to the
flow connection.

INSTALLATION ROOM

The appliance must be positioned in such a way as to be easily accessible
at all times. In addition, the following minimum distances around the
appliance must be complied with

WALL MOUNTING

DIMENSIONS

- 11 -

INSTALLATION

Panel removal and access to hydraulic connections

1. undo screws

2. tilt panel towards you and lift clear remove the top cover

3. loosen screws of the control panel

4. turn up the control panel

5. block the control panel with the screw

DISASSEMBLING

A

B

C

1

2

2

3

4

5

- 12 -

INSTALLATION

39

38

3

7

36

35

34

3

3

32

31

29

28

2

7

26

25

24

2

3

22

21

19

1

8

1

7

16

15

14

1

3

12

11

9

8

7

6

5

4

3

2

1

39

38

3

7

36

35

34

3

3

32

31

29

28

2

7

26

25

24

2

3

22

21

19

1

8

1

7

16

15

14

1

3

12

11

9

8

7

6

5

4

3

2

1

39

38

3

7

36

35

34

3

3

32

31

29

28

2

7

26

25

24

2

3

22

21

19

1

8

1

7

16

15

14

1

3

12

11

9

8

7

6

5

4

3

2

1

39

38

3

7

36

35

34

3

3

32

31

29

28

2

7

26

25

24

2

3

22

21

19

1

8

1

7

16

15

14

1

3

12

11

9

8

7

6

5

4

3

2

1

15

15

13 14

13 14

11 12

11 12

HEATING CONNECTION

HEATING CONNECTION + DHW : “S” PLAN

HEATING CONNECTION + DHW : “Y” PLAN

Limiting the maximum adjustable temperature

Factory setting

30 - 85°C

Floor heating

30 - 50°C

Limiting the minimum

adjustable temperature

60 - 85°C

Limiting the minimum

adjustable temperature

60 - 85°C

NOTE:

• controller not supplied in standard

NOTE:

• controller not supplied in standard

NOTE:

• controller not supplied in standard

M M

- 13 -

INSTALLATION

• This appliance must be permanently connected to fixed wiring and must be earthed.

• The wiring must be carried out by a competent person and be in accordance with the current IEE Wiring Regulations.

• Isolation device must be provided with a minimum contact clearance of 3mm.

• The MCB must be readily accessible and adjacent to the appliance.

7 8

7 8

5 6

5 6

3 4

3 4

1 2

1 2

NL1

53 4

L1

1 2

N

6

Power supply
230 V mono +

Safety contactor

53 4

L1

1 2

N

6

NL1

Power supply

230 V mono

ELECTRIC CONNECTION / MODELS : 09 - 15

- 14 -

INSTALLATION

• This appliance must be permanently connected to fixed wiring and must be earthed.

• The wiring must be carried out by a competent person and be in accordance with the current IEE Wiring Regulations.

• Isolation device must be provided with a minimum contact clearance of 3mm.

• The MCB must be readily accessible and adjacent to the appliance.

7 8

7 8

5 6

5 6

3 4

3 4

1 2

1 2

L3 L2 NL1

5

L3

3 4

L2

1 2

N L1

6

Power supply

3 x 400 V + Neutral +

Safety contactor

L3 L2 NL1

5

L3

3 4

L2

1 2

N L1

6

Power supply

3 x 400 V + Neutral

ELECTRIC CONNECTION / MODELS : 22 - 28 - 36

SIZING OF SUPPLY WIRES

the supply wires are sized depending of the type and current of the MCB, this last is firstly sized depending of the nominal current of the boiler.
The admissible current of the supply wires depends of the ambient temperature, the section and the length of the wires, the wires insulation,
the wires canalisation, the mounting type and the environment.
The following values are given for information for an ambient temperature of 30°C and a maximal length of 5 meters. In all the cases, the
installation must be in accordance with the current IEE Wiring Regulations.

16
25
32
40
63
80

1.5

2.5
4
6

10
16

Nominal current of the MCB

(A)

Nominal section

(mm2)

- 15 -

INSTALLATION

WIRING DIAGRAMS / MODELS : 09 - 15 - 22

L1 1 2

br

br br bk

N 3 4

b

b

or

bbb

bk

bb

7

t

p

bb

8

b

9

b

5

6

b

bk or

g

b

r

3 amp

MCB

C

2

1

r

C

1

2

or

10 11 12 13

y

y

t

or

or or r r

gg

gpk pk

b

bw

b

w

g

b

14 15

16

M

2.1. 2.2.

2.1. 2.2.

17 18

t

w

r

ABC

DE

HJ

JL

I

K1

K3

K2

F

G

b Blue

bk Black

br Brown

g Grey

or Orange

pk Pink

r Red

vViolet

w White

yYellow

A ON/OFF switch

B Manual reset high limit thermostat

CWater pressure switch

D Alarm indicator

E Switch indicator

F Optional room thermostat

G Cirluating pump

H Boiler thermostat 60 - 85°C

I Boiler thermostat 53 - 78°C

J Power level switch

K1 Power relay 1 - level 1

K2 Power relay 1 - level 2

K3 Power relay 2 - level 1

LTimer

1-2: Life (230V ~ 50Hz)

3-4: Neutral

5-6: Time clock

(optional)

7-8: Master Relay

(optional)

10-11: Stop Bridge

12-13: Room thermostat

(optional)

14-15: Boiler pump

17-18: Relay K3 disactivated

- 16 -

INSTALLATION

WIRING DIAGRAMS / MODEL : 28

L1 1 2

br

br br bk

N 3 4

b

b

or

bbb

bk

bb

7

t

p

bb

8

b

9

b

5

6

b

bk or

g

b

r

3 amp

MCB

C

2

1

r

C

1

2

or

10 11 12 13

y

y

t

or

or or r r

gg

gpk pk pk

b

bw

b

w

g

b

14 15

16

M

2.1. 2.2.

2.1. 2.2.

17 18

t

w

r

ABC

DE

HJ

JL

I

K1

K3

bw

19 20

w

pk

K4

K2

F

G

b Blue

bk Black

br Brown

g Grey

or Orange

pk Pink

r Red

vViolet

w White

yYellow

A ON/OFF switch

B Manual reset high limit thermostat

CWater pressure switch

D Alarm indicator

E Switch indicator

F Optional room thermostat

G Cirluating pump

H Boiler thermostat 60 - 85°C

I Boiler thermostat 53 - 78°C

J Power level switch

K1 Power relay 1 - level 1

K2 Power relay 1 - level 2

K3 Power relay 2 - level 1

K4 Power relay 2 - level 2

LTimer

1-2: Life (230V ~ 50Hz)

3-4: Neutral

5-6: Time clock

(optional)

7-8: Master Relay

(optional)

10-11: Stop Bridge

12-13: Room thermostat

(optional)

14-15: Boiler pump

17-18: Relay K3 disactivated

19-20: Relay K4 disactivated

- 17 -

INSTALLATION

WIRING DIAGRAMS / MODEL : 36

L1 1 2

br

br br bk

N 3 4

b

b

or

bbb

bk

bb

7

t

p

bb

8

b

9

b

5

6

b

bk or

g

b

r

3 amp

MCB

C

2

1

r

C

1

2

or

10 11 12 13

y

y

t

or

or or r r

gg

gpk pk pk

b

bw

b

w

g

b

14 15

16

M

2.1. 2.2.

2.1. 2.2.

17 18

t

w

r

ABC

DE

HJ

JL

I

K1

K3

bw

19 20

w

pk

K4

bw

21 22

w

r

K5

bw

23 24

w

pk

K6

K2

F

G

b Blue

bk Black

br Brown

g Grey

or Orange

pk Pink

r Red

vViolet

w White

yYellow

A ON/OFF switch

B Manual reset high limit thermostat

CWater pressure switch

D Alarm indicator

E Switch indicator

F Optional room thermostat

G Cirluating pump

H Boiler thermostat 60 - 85°C

I Boiler thermostat 53 - 78°C

J Power level switch

K1 Power relay 1 - level 1

K2 Power relay 1 - level 2

K3 Power relay 2 - level 1

K4 Power relay 2 - level 2

K5 Power relay 3 - level 1

K6 Power relay 3 - level 2

LTimer

1-2: Life (230V ~ 50Hz)

3-4: Neutral

5-6: Time clock

(optional)

7-8: Master Relay

(optional)

10-11: Stop Bridge

12-13: Room thermostat

(optional)

14-15: Boiler pump

17-18: Relay K3 disactivated

19-20: Relay K4 disactivated

21-22: Relay K5 disactivated

23-24: Relay K6 disactivated

- 18 -

INSTALLATION

POWER WIRING / MODELS : 09-15

K1 K2 K3

3 x b

3 x b

2 x or

2 x bk

r

r

r

bk

b

b

b

b

b

b

bk

or

or

r

r

bk

b

b

b

b

b

b

bk

or

or

r

8.4 kW

Type 9

MONO

PHASE

7 kW 5.6 kW 4.2 kW

1

N

23

L

456 1

N

23

L

456 1

N

23

L

4561

N

23

L

456

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

17 18

14.4 kW

Type 15

MONO

PHASE

12 kW 9.6 kW 7.2 kW

1

N

23

L

456 1

N

23

L

456 1

N

23

L

4561

N

23

L

456

- 19 -

INSTALLATION

POWER WIRING / MODEL : 22

21.6 kW

Type 22

TRI

PHASE

14.4 kW

1

N

2

L1

3

L2

45

L3

6 1

N

2

L1

3

L2

45

L3

6

17 18

17 18

17 18

17 18

3 x b

3 x or

2 x bk

1 x bk

2 x r

1 x r

K1

or

r

bk

b

or

r

bk

b

K2

Or

r

Bk

b

or

r

bk

b

K3

or

r

bk

b

or

r

bk

b

- 20 -

INSTALLATION

POWER WIRING / MODEL : 28

28.8 kW

Type 28

TRI

PHASE

21.6 kW

1

N

2

L1

3

L2

45

L3

6 1

N

2

L1

3

L2

45

L3

6

19 20

19 20

19 20

19 20

4 x b

4 x or

3 x bk

1 x bk

3 x r

1 x r

K1

or

r

bk

b

or

r

bk

b

K2

Or

r

Bk

b

or

r

bk

b

K4

or

r

bk

b

or

r

bk

b

K3

or

r

bk

b

or

r

bk

b

- 21 -

INSTALLATION

POWER WIRING / MODEL : 36

6 x b

6 x or

5 x bk

1 x bk

5 x r

1 x r

K1

or

r

bk

b

or

r

bk

b

K2

Or

r

Bk

b

or

r

bk

b

K3

or

r

bk

b

or

r

bk

b

K4

or

r

bk

b

or

r

bk

b

K5

or

r

bk

b

or

r

bk

b

K6

or

r

bk

b

or

r

bk

b

36 kW

Type 36

TRI

PHASE

30 kW

1

N

2

L1

3

L2

45

L3

6 1

N

2

L1

3

L2

45

L3

6

19 20

19 20

19 20

19 20

- 22 -

HONEYWELL SUNDIAL WIRING DIAGRAMS

Note: Illustrated model = 36 kW Tri Phase

Note: All bold numbers indicate a DIN rail terminal connection

CYLINDER
STAT

HTGHW

NL

143256

T6306B
ROOM STAT

2

1

3

V4043H
HTG ZONE VALVE

MOTOR

789 10

V4043H
DHW ZONE VALVE

MOTOR

Honeywell
Sundial Wiring Centre
`S ` Plan

Note: Earth wires not shown for clarity

During installation the earth wires from each
component connect to terminal 3 in the wiring centre

E

bk- black
br- brown
r-red
w-white
y- yellow
o - orange
b - blue
v - violet
p - pink
gr - grey

CABLE COLOUR CODES

gr

gr

gr

gr

b

b

b

b

b

brbr

br

br

o

o

o

o

C

L1 1 2

br

br br bk

N 3 4

b

b

or

bbb

bk

bb

7

t

p

bb

8b9

b

5

6

b

bk or

g

b

r

3 amp

MCB

C

2

1

r

C

1

2

or

10 11 12 13

y

y

t

or

or or r r

gg

gpk pk pk

b

bw

b

w

g

b

14 15

16

M

2.1. 2.2.

2.1. 2.2.

17 18

t

w

r

ABC

DE

HJ

JL

I

bw

19 20

w

pk

bw

21 22

w

r

bw

23 24

w

pk

F

G

- 23 -

HONEYWELL SUNDIAL WIRING DIAGRAMS

Note: Illustrated model = 36 kW Tri Phase

Note: All bold numbers indicate a DIN rail terminal connection

CYLINDER
STAT

HTG

HW ON

NL

143256

T6306B
ROOM STAT

2

1

3

78910

Honeywell
Sundial Wiring Centre
`Y ` Plan

Note: Earth wires not shown for clarity

During installation the earth wires from each
component connect to terminal 3 in the wiring centre

E

bk- black
br- brown
r-red
w-white
y- yellow
o - orange
b - blue
v - violet
p - pink
gr - grey

CABLE COLOUR CODES

gr

b

b

b

o

1

2

C

HW OFF

V4073A
MID POSITION
ZONE VALVE

w

w

L1 1 2

br

br br bk

N 3 4

b

b

or

bbb

bk

bb

7

t

p

bb

8b9

b

5

6

b

bk or

g

b

r

3 amp

MCB

C

2

1

r

C

1

2

or

10 11 12 13

y

y

t

or

or or r r

gg

gpk pk pk

b

bw

b

w

g

b

14 15

16

M

2.1. 2.2.

2.1. 2.2.

17 18

t

w

r

ABC

DE

HJ

JL

I

bw

19 20

w

pk

bw

21 22

w

r

bw

23 24

w

pk

F

G

- 24 -

COMMISSIONING - WATER

1. The system must be thoroughly cleansed prior to connection
of the boiler. The system water should be treated to prevent
general corrosion and deposition of scale or sludge in the
boiler, please refer to BS7593. If installing the boiler onto an
existing system, ACV recommend that an approved system
cleaner is used.

2. Fill and pressurise the boiler and system to 1.5 bar, making
sure to vent the boiler via the automatic air vent on top of the
boiler. Note that the black dust cap on the air vent should be
left loose to allow the auto vent to function.

3. Check for leaks.
For specialist advice on water treatment products, contact:

Fernox, Britannia Works
Clavering, Essex CB11 4QZ
Tel [phone]

COMMISSIONING - ELECTRICAL

The Electrical installation supplying this boiler must conform to the
current IEE Regulations.

1. Remove the front panel and check all electrical connections for
tightness.

2. Ensure all internal relays, contactors etc are secure on the DIN
rails.

3. Set all panel control switches to off.

4. Check the power stage delay timer settings - Adjuster (A) is
factory set to the 1 to 10 minute position which is the optimum
setting for the boiler and should be verified during commissioning.

- Adjuster (B) is used to set the DELAY ON time of the following
stage contactors, the available settings are in 1 minute
increments if A is set to 1 to 10 minutes.
This function is particularly useful in areas where gradual
switching of electrical load is required and the resulting
maximum demand kept to a minimum.The timers add to the
flexibility of the installation but must be optimised by a qualified
engineer.The normal setting is 1.

5. Set internal MCB to off position.

6. Set the control thermostat to desired temperature.

ST ARTING THE BOILER

1. Switch on the internal or external timeclock (if fitted)

2. Switch on internal MCB

3. Switch on local isolator to boiler

4. Turn the boiler on using the ON/OFF switch

5. Switch on the power levels switch stage 1, the first stage
contactors will energise

6. Switch on the power levels switch stage 2, after a short delay
the second stage contactors will energise. Note: the power
stage delay timer settings should be verified as shown in item
4 under "Commissioning - Electrical"

7. The boiler temperature will now rise as indicated by the combined
temperature and pressure gauge

8. The temperature will continue to rise until the control thermostat
temperature setting is reached then the boiler will switch off.

Once these procedures have been followed the system can be left
to operate normally by the following method.

1. Ensure that boiler thermostat is set to the desired temperature

2. Turn the boiler on using the ON/OFF switch

3. Turn on power level switch 1

4. Turn on power level switch 2

5. Set timeclock (if fitted) and/or external controls to desired boiler
operating on/off times.

After one week of operation all electrical
connections should be re-checked for tightness and
the boiler water system checked for leaks and air
and rectified if necessary.

MAINTENANCE

For safety reasons it is recommended that the boiler is serviced
annually and that servicing is carried out by a qualified service
engineer.

Before carrying out any work on the system ensure that
the boiler is cool and all electrical supplies are isolated.

1. After removing front cover undo the four screws retaining the
front control panel and gently let the panel suspend on the
wiring to the rear of the panel. Undertake a visual inspection of
the boiler looking out for signs of water leakage from joints,
expansion vessel, and the area around the elements on top of
the boiler.

2. Undertake a visual inspection of all cabling in the boiler casing
checking for signs of overheating or burning.

3. Check all push-on electrical connectors for tightness and good
connection to the relative components.

4. Using a correct fitting screwdriver check all electrical terminals
on DIN rails and on all components for tightness.

5. Check the settings on the internal timers in accordance with
the "Commissioning - Electrical" section.

6. Replace the control panel and the boiler front cover and refit
screws.

7. Reinstate the electrical supply and follow the procedures set
out in the commissioning section.

COMMISSIONING AND MAINTENANCE

A

B

- 25 -

REMOVAL THE HEATING ELEMENTS

2

1

3

N° Casing 09 15 22 28 36

A01 Side panel 21471421 21471421 21471421 21471421 21471421
A02 Front panel 21473421 21473421 21473421 21473421 21473421
A03 Top cover 21475421 21475421 21475421 21475421 21475421
A04 Rear panel 21474421 21474421 21474421 21474421 21474421
A05 Control panel ABS 497B1025 497B1025 497B1025 497B1025 497B1025
A06 Wall mounting 21480069 21480069 21480069 21480069 21480069
A07 Body heating 30537482 30537482 30537482 30537482 30537482
A08 Control panel 21477421 21477421 21477421 21477421 21477421

A09 Electric support 21479421 21479421 21479421 21479421 21479421

- 26 -

SPARE PARTS

A01

A03

A07

A06

A02

A04

A05

A08

A09

A01

- 27 -

SPARE PARTS

N° Accessories 09 15 22 28 36

B01 Base for relay 54428195 54428195 54428195 54428195 54428195
B02 Control circuit “Siemens” 54766015 54766015 54766015 54766015 54766015
B03 Relay Siemens 3TG 54452082 54452082 54452082 54452082 54452082
B04 Timer “Crouset” 54428192 54428192 54428192 54428192 54428192
B05 Blocking 54452092 54452092 54452092 54452092 54452092
B06 Terminal WKN 16/U blue 54767014 54767014 54767014 54767014 54767014
B07 Terminal 16 mm2WKN 16/U 54428179 54428179 54428179 54428179 54428179
B08 Terminal end APN 16 mm

2

54428091 54428091 54428091 54428091 54428091
B09 Terminal WKN10 sl/u 54428155 54428155 54428155 54428155 54428155
B10 Shunt IVBWKN 16-2 54428278 54428278 54428278 54428278 54428278
B11 Control ter minal block 54767015 54767015 54767015 54767015 54767015
B12 Green switch 54766016 54766016 54766016 54766016 54766016
B13 Yellow switch 54766017 54766017 54766017 54766017 54766017
B14 Combined T° and pressure gauge Ø 40mm 54763012 54763012 54763012 54763012 54763012
B15 Red alar m indicator Ø 10mm / 240V 54766001 54766001 54766001 54766001 54766001
B16 Control ther mostat 2 Stages 54764017 54764017 54764017 54764017 54764017
B17 Button ther mostat 54764021 54764021 54764021 54764021 54764021
B18 Manual reset high limit ther mostat 103°C 54764009 54764009 54764009 54764009 54764009
B19 Cable gland (PG29) 54428113 54428113 54428113 54428113 54428113
B20 Brass pocket 63438003 63438003 63438003 63438003 63438003
B21 Heating element 2 x 1.4 kW 54428183 ---­B22 Heating element 2 x 2.4 kW - 54428182 54428182 54428182 ­B23 Heating element 3 x 2 kW ----54428204
B24 Water pressure switch 557D3011 557D3011 557D3011 557D3011 557D3011
B25 Circulating pump 557A4009 557A4009 557A4009 557A4009 557A4009
B26 Pressure safety valve 3 bars Ø 1/2” 55426017 55426017 55426017 55426017 55426017
B27 Automatic air vent 55445007 55445007 55445007 55445007 55445007
B28 Flexible tube
B29 Expansion vessel 10 Litres 557A7006 557A7006 557A7006 557A7006 557A7006
B30 Complete control panel 24614142 24614142 24614143 24614144 24614145

- 28 -

SPARE PARTS

B01 B02 B03 B04 B05

B06 B07 B08 B09 B10

B11 B12 B13 B14

B16 B17 B18 B19

B21 B22 B23 B24

B15

B20

B25

B26 B27 B28 B29

- - -

B30

- - -

- 29 -

INTERNATIONAL

ACV international n.v

KERKPLEIN, 39
B-1601 RUISBROEK - BELGIUM
TEL.: [phone]
FAX:[phone]
E-MAIL: [e-mail]

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ACV BELGIUM nv/sa

KERKPLEIN, 39
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TEL.: [phone]
FAX:[phone]
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excellence in hot water

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ALFEREZ BOUCHARD 4857
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