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.