Xylem EHR IM User Manual

4.6 (7)

Installation and Operating Instructions for Electric heater-circulator unit EPR

 

Instruction manual Laing Electric heater circulator unit

A

Terminal strip for Mains

S

J

L

 

I

 

V

 

 

 

 

 

 

 

 

connection

 

 

 

 

 

 

 

 

 

E

Ground terminal

 

 

 

 

 

 

 

 

 

F

Fuse for pump

 

 

 

 

 

 

 

 

 

H

Main switch

 

 

 

 

 

 

 

 

 

I

Jumper wires for remote

 

 

 

 

 

 

 

 

 

 

control input and pump

 

 

 

 

 

 

 

 

 

 

module input

 

 

 

 

 

 

 

 

 

J

Jumper 1 to 8

 

 

 

 

 

 

 

 

 

K

Constant temperature

 

 

 

 

 

 

 

 

 

 

control

 

 

 

 

 

 

 

 

 

L

LEDs

 

 

L1

L2 L3

N

N

N

 

M

Mounting screws for prin-

 

 

 

 

 

 

 

 

 

 

 

 

 

ted circuit board (behind

 

 

 

 

 

 

 

 

 

 

terminal bracket)

 

 

 

 

 

 

 

 

 

N

Cable entry for Mains

 

 

 

 

 

 

 

 

 

 

connection

 

 

 

 

 

 

 

 

 

R

Cable entry for control

H

 

M

A

M

T

 

E

U F

 

and circulator

 

 

 

 

 

 

 

 

 

 

 

 

S

Safety temperature limiter

 

 

 

 

 

 

 

 

 

U

Fuse for control

 

 

 

 

 

 

 

 

 

V

Terminals

 

 

Jumperposition

 

 

 

Z

Reset knob for safety

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

temperature limiter

 

 

 

 

 

 

 

 

 

Terminal usage

1,2 Remote control for heating elements 2 and 3

3,4 Input from pump module

5,6 Remote control input

7,8 Remote control input

10,11 Potential free output for remote trouble indicator

13,14 Power supply for daughter board EPRBW

15,16 Power supply for circulator

17,18 used only for FP 5000 ER models

closed

open

 

K

 

R

 

H

 

R

 

N

 

R

 

Z

See next to last page for jumper positions and error indicators.

 

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Instruction manual Laing Electric heater circulator unit

 

Contents

 

Applications................................................................................................................

5

Design of the EPR model...........................................................................................

5

Technical Data............................................................................................................

6

Dimensional Drawing.................................................................................................

7

Performance Curve....................................................................................................

7

Models Available........................................................................................................

8

Mounting....................................................................................................................

9

Connection to the feed and return line.......................................................................

9

Electrical Connection...............................................................................................

10

Power Supply...........................................................................................................

10

400V N3 Electrical Diagram.....................................................................................

10

230V N1 Electrical Diagram......................................................................................

11

230V N3 Electrical Diagram......................................................................................

11

The integrated control..............................................................................................

12

Schematics of the integrated control........................................................................

12

Design of the Main Printed Circuit Board.................................................................

13

Main switch..............................................................................................................

14

Fuses.......................................................................................................................

14

Constant temperature control...................................................................................

14

Overheating Protection............................................................................................

14

Program selection for the switching sequence of the heating elements..................

15

Pump shut-off ..........................................................................................................

17

Deactivating heating elements.................................................................................

17

Remote control of the second and third heating element.........................................

17

Control input.............................................................................................................

18

Room temperature guided control............................................................................

18

Outside temperature guided control.........................................................................

20

Safety temperature limiter........................................................................................

20

Electronic means to prevent dry running..................................................................

21

Circulator operation control......................................................................................

21

Malfunction detector.................................................................................................

22

Attachment of the sensor for the remote control......................................................

23

Indirect domestic hot water heating with the Electric heater-circulator EPR............

24

Hydraulic connection of the EPR for domestic hot water heating............................

25

Electrical connection of the EPR for domestic hot water heating.............................

26

Control method 1......................................................................................................

26

Control method 2......................................................................................................

27

Operation of heating elements with a load shedding device....................................

28

Filling of the system.................................................................................................

30

Pressure and leak tests............................................................................................

30

Starting operation.....................................................................................................

30

Replacement of the circulation pump.......................................................................

31

Replacement of the safety temperature limiter STBR..............................................

31

Replacement of the main circuit board EPRH..........................................................

32

Important Notices.....................................................................................................

32

Important Notice: How to avoid overheating............................................................

32

Important Notice: In the event of safety temperature limiter failure..........................

33

Important Notice: For proper connection to a floor heating system.........................

33

Factory settings........................................................................................................

33

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Instruction manual Laing Electric heater circulator unit

Applications

Electric heater circulator units Model EPR can be applied in all cases where electric heating has to be installed in a small space to heat an apartment or a single or multiple family house.

This applies to direct electrical heating as well as for electrical heating with a heat storage.

A further application exists in connection with room additions where the electric heating can supplement the existing hydronic heating.

The Electric heater-circulator is also very well suited to heat domestic hot water. The application for heating of domestic hot water is described in “Indirect domestic hot water heating - Application”.

Design of the EPR model

The Electric heater circulator model EPR consists of a circulator pump, an electric heater with three heating elements and an electronic microprocessor control.

The spherical motor circulator operates almost noiselessly and stays quiet over its lifetime.

The arrangement of the pump below the heating elements guarantees good heat conductivity from the heating elements since the swirl created by the impeller extends over the length of the heating elements. This avoids overheating of the heating element

surfaces. The water for the heating loop is drawn in by the circulator, conveyed along the heating elements and discharged through the discharge port at the upper part of the housing. The inlet

has an additional 3/8” port, to which an expansion tank can be connected. An automatic air vent and a pressure relief valve communicate with the outlet port.

Mounting eyelets are included in the castings of the unit.

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Instruction manual Laing Electric heater circulator unit

The Electric heater circulator units EPR 6 to EPR 15 differ only in the performance of the electrical heating elements and the distance between the ports. EPR 6 has a heating performance of 6000 W, EPR 9 has 9000 W, EPR 12 has 12000 W and EPR 15 has 15000W.

The control unit, which controls a variety of control and safety functions, is arranged on top of the Electric heater circulator.

Technical Data

 

 

 

 

Model

EPR

EPR

EPR

EPR

 

6

9

12

15

Pmax.

 

87 PSI

 

Tmax.

 

194°F

 

 

Connection on water side

 

Union 1” male

 

Weight

21.8 lb

22.5 lb

23.8 lb

24.5 lb

Pump

 

 

 

 

Max. Head

 

4.6 PSI

 

Max. Flow

 

14.9 GPM

 

Motor

 

 

 

 

Design

Shaftless spherical motor

Watts Input

 

99 W

 

 

Motor performance

 

35W

 

 

Volts AC

 

230 V

 

 

Amperes

 

0.43 A

 

Electric Heater

 

 

 

 

Electrical performance

6 kW

9 kW

12 kW

15 kW

Number of heating elements

3

3

3

3

Heat capacity per element

2 kW

3 kW

4 kW

5 kW

Voltage

400 V, 3P

400 V, 3P

400 V, 3P

4 0 0 V,

3P

 

 

 

 

Amperes

8.7 A

13.0 A

17.4 A

21.6 A

Connection

Y

Y

Y

Y

Safety Temperature Limiter

 

 

 

 

Maximum temperature

 

203°F+/- 5 K

 

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Instruction manual Laing Electric heater circulator unit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Dimension Drawing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Dimension

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

A

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EPR

6

11.8’’

 

23.66’’

EPR

9

11.8’’

 

23.66’’

 

 

 

 

EPR 12

14.37’’

 

26.2’’

 

 

EPR 15

14.37’’

 

26.2’’

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pump curve

Pump head (ft)

12

10

8

6

4

2

0

0

2

4

6

8

10

12

14

Flow rate (GPM)

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Instruction manual Laing Electric heater circulator unit

Mounting

For safety reasons, the Electric heater circulator must be mounted on a fireproof base. In addition, the unit must be installed with the circulator motor pointing downwards!

The unit must be attached to a flat wall with the help of the mounting eyelets arranged at the top of the unit and at the pump housing. To avoid noise transfer to the wall, both sides of the mounting eyelets have to be covered with rubber insulators. The rubber insulators are supplied with the Electric heater circulator unit and have to be mounted in such a way that no metal contact exists between the castings and the fastening screw. In addition, no part of the Electric heater circulator unit - for example the outer shell or the pump - should be in contact with the wall.

The Electric heater circulator should be mounted at least 2.4’’ above the floor to allow replacement of the circulator motor if necessary.

Connection to the feed and return line

The unit is connected to the heating loop by 1” male threaded fittings. The feed line is at the top of the unit, the return line at the bottom. The expansion tank should be connected to the 3/8” port next to the return line. If the expansion tank cannot be connected there, it should be connected somewhere else in the return line, but not in the feed line. There are two ˝” ports at the top of the unit. The automatic air vent for the heating circuit is connected to the ˝” port closest to the wall, the pressure relief valve to the port in front.

When the Electric heater circulator unit is used solely for floor heating, the chapter “Important Notice: Proper connection to a floor heating system” has to be observed.

Air vent

Safety relief valve

 

Heating

 

loop feed

 

side

 

Mounting

 

eyelet

Mounting

Connection

eyelet

 

for expansi-

 

on tank

 

Heating

 

loop return

 

side

 

Mounting

 

eyelet

Connection EPR series

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Instruction manual Laing Electric heater circulator unit

Electrical Connection

Notice: The electrical connection has to be performed by a licensed electrician!

The pump must not be operated without water.

To make the electrical connections, the control box at the top of the heater has to be opened by removing the 4 screws. A cable with a sufficient cross section for the performance of the Electric heater circulator unit has to be inserted through the strain relief and connected to the input terminal (see Electrical Diagram below)

The circulator is already wired to the control box.

Power Supply

The Electric heater-circulator is designed for three different kinds of power supply. In all cases the following information has to be taken into account: The electronic switches integrated into the Electric heater circulator unit do not separate the heating elements from the power supply. Therefore, a master switch that interrupts all phases has to be installed in an accessible place, taking into account all applicable safety codes.

As a protection for the semiconductor relays each phase has to have a fast acting fuse.

400V N3 Electrical Diagram

230V N1 Electrical Diagram

T

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Instruction manual Laing Electric heater circulator unit

In this case, the Electric heater circulator unit has to be connected with 7 leads to protect each of the semiconductor relays separately. After this has been done, the leads are combined into one phase.

L2

230V N3 Electrical Diagram T

In this case, it is important to ensure the proper phase sequence of the connectors 1 to 3 and 4 to 6.

The integrated control

T

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Instruction manual Laing Electric heater circulator unit

The integrated microprocessor control in the housing on top of the Electric heater circulator unit performs a variety of control functions for a large number of applications.

The heating elements are noiselessly switched by electronic relays.

Schematics of the integrated control

The block diagram shows the control in schematic presentation

PI

G

IS

W

 

 

 

 

TI

 

Y

 

MP

X

Q

 

 

RA

O

 

 

 

 

 

 

 

B C D P TS

 

 

BTemperature sensor for feed temperature

CTemperature sensor for the safety temperature limiter

DTemperature sensor for the semiconductor relays

G Pump operation control logic

IS Input for external control and remote control

MP Microprocessor

OControl for the semiconductor relays

PPotentiometer for constant temperature setting

PI

Pump performance control

Q

Safety temperature limiter

RA

Analog inputs for temperature sensors and temperature pre-selection

T

Potentiometer for safety temperature setting

TI

Safety temperature limiter control logic

WHeating elements

XSemiconductor relays

YJumper settings for operation mode

Temperature sensor B monitors the temperature of the feed line water and

10

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Xylem EHR IM User Manual

Instruction manual Laing Electric heater circulator unit

passes the information on to the microprocessor. The microprocessor then activates the solid state relays which in turn activate the heating elements according to the jumper selected program. An independent sensor C also monitors the temperature of the feed line water and switches the pump off when the temperature exceeds a pre-set temperature.

A further sensor D monitors the temperature of the solid state relays and turns off the heating elements in case of overheating.

A special control logic verifies the rotation of the circulator and prevents the heating elements from being turned on if the circulator is not running. The safety temperature limiter turns the heating elements off permanently - independent of the electronic control - when the temperature exceeds 194°F.

Design of the Main Printed Circuit Board

(See also page 2)

Fastening points

Processor

Connector for

solid state relays, power supply and sensors.

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11

 

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