INSTALLATION & TECHNICAL MANUAL
Contents
1. o e o 10Way 1 2 3 4 6 7 8 9 10 Junction J 9 J J 9 Box MAINS ISOLATOR 380W e 50 Hz Ne o BL BR GROR BLIBRIGRORI S UPPIY E e HW Zone Valve CH Zone Valve R P CALL FOR HEAT BOILER CONNECTIONS NOTE Call for heat RP connections are Volt free Contacts Figure 7 GB 11 CONNECTION OF EXTERNAL APPLIANCES Figure 8 shows the Control Board Controller to which a number of external appliances can be connected The board can be set for different working modes of operation In addition the board provides signal indicators for start up and diagnostic monitoring of the correct boiler operation Key to Figure 8 MSK7 1 Controller 1 2 3 4 5 I6 7 KP Room Thermostat contacts entries PEAK OFF 230 24OV to support voltage to the control board Pump Circulating Pump entry LED Room Thermostat on signal PEAK OFF LED voltage on at PEAK OFF PUMP LED Pump on signal Jumpers Pump mode Peak enable external voltage control J3 unused J4 unused Front Panel connection f e bai cial Figure 8 GB 12 1 CONNECTION OF EXTERNAL APPLIANCES Room Thermostat A voltage free Room Thermostat should be connected to the boiler through the RP 1 connections When the connections are close2. MAINS CONNECTION Figure 4 hows the electrical mains connection to UK do mestic network Figure 5 shows the boiler connections of the single phase system LNE Neutral Earth amp Phase conductors 6 Temperature Limiter 15 Additional conductor Slim Jim Boiler e i e Oe Se I QO QO OO GB 10 EXTERNAL CONTROL WIRING Heating Only Wiring PROGRAMMER ROOM THERMOSTAT N L 1 2 3 4 1 2 3 4 5 6 e T o o o o o 10Way l 2 3 4 5 6 7 8 9 10 Junction o J J o Box MAINS ISOLATOR R P 240V CALL FOR HEAT BOILER 50 Hz IN eo CONNECTIONS Supply Note Mains connection to 3 Amp fused spur Figure 6 Heating amp Hot Water Wiring S Plan PROGRAMMER N Cylinder Thermostat 1 2 3 ROOM THERMOSTAT 4 2 3 4 O L 1 2 3 4 e se se o lt
3. e pump valves e magnetic filter e automatic by pass if required e EHC sealed system kit e Automatic air vent e Twin Channel Heat Pack if required 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 EN 12828 2003 Heating systems in buildings Design for water based heating systems BS EN 12831 2003 Heating systems in buildings Method for calculation of the design heat load BS EN 14336 2004 Heating systems in buildings Installation and commissioning of water based heating systems BS 7671 2008 Requirements for electrical installations IEE Wiring Regulations Seventeenth edition BS EN 13831 2007 Closed expansion vessels with built in diaphragm for installation in water 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 kW 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 pipe work are not subject to frost and damp conditions 3 Central he
4. mains supply External controls will require an independent fused spur supplied from the consumer unit however this fused spur should be supplied by the same power source as the boiler itself Boiler Protection The recommended protection for hard wired boilers are as follows Model No Boiler size Protection EHCSJIM4KW 4kW BOILER 20 AMP Protection EHCSJIM7KW 7kW BOILER 40 AMP Protection EHCSJIM10KW 10kW BOILER 50 AMP Protection EHCSJIM12KW 12kW BOILER 63 AMP Protection EHCSJIM14 4KW 14 4kW BOILER 80 AMP Protection External Controls We recommend the use of the EHC single channel heat pack for heat ing only installations For Heating and Hot water installations we recommend the use of the EHC twin channel Heat Pack The EHC Slim Jim Heat Pack will incorporate all the relevant parts to comply with current building regulations e g Circulation pump Motorized valves to control the heating and hot water circuits and Room and cylinder thermostats to control the room and water tem peratures This will also provide boiler interlock The use of TRV s alone will not provide boiler interlock We recommend the use of TRV s however they must not be used in the room that has the room thermostat fitted Note This control method is recommended by TACMA The As sociation of Control Manufactures in order to comply with the cur rent Building Regulations GB ELECTRICAL CONNECTIONS AND CONTROLS ELECTRICAL DOMESTIC
5. scale corrosion and microbiological growths It is cru cial however that for the protector to work correctly the system must be properly cleansed and flushed 6 The label included within the Fernox Protector carton should be completed and attached adjacent to the boiler 7 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 15 Start up Commissioning 1 Turn mains power on at main Isolating Switch 2 Make sure that all external controls are off not calling for heat at this stage 3 Switch the boiler on by pressing the Power button on the Front Control Panel see figure 9 4 Check to see that the correct installation water pressure is approx 1 0 1 5 bar and correct as necessary Sealed Systems 5 Vent the heating circuit and the externally fitted Pump according to the manufactures installation instructions 6 Make sure the system water pressure is maintained at the correct pressure while venting the system Continue venting until a continuous stream of water is evident at all radiators and the pump b Top up system and re tighten all vent screw points 8 Turn on external controls to call for heat 9 Set the temperature of the boiler to your desired tempera ture normally 65 C GB INSTALLATION Filing Lorp Auto Bypass
6. the boiler is on switch 4 in position 1 the indicator flashes at 1 second intervals 2 Inner temperature sensor failure the indicator flashes at much more frequent intervals than described in 1 above It will also indicate a failure when the boiler is off switch 4 in position 0 Fig 10 Dependence between medium temperature and the outdoor temperature at 20 C room temperature ee cold building standard building OE warm building E ae ee coe S D Q S A S temperature of water in c h s i ONS 30 sae y ie et 2p outdor temp ra N Figure 10 PREVENTIVE MAINTAINANCE We recommend the following routine maintenance in order to assure faultless operation Do not drain the water from central heating system after the heating season Remove any effluent from the central heating system and boiler connection points Do not cut off the power supply to the boiler between the heating seasons Ensure switch 4 is always left in position 0 as this will operate the pump every 24 hours for 90 seconds to protect the installation WL ee bee We recommend that customers ensure a full system inspection is carried out before every heating season by a suitably qualified and competent central heating engineer GB 14 FAULT FINDING Symptom Reason Procedure The 2 indicator does not illumi No mains power supply Check out the elect
7. 172 Weight kg 11 Water connection mm 22 Safety class IP22 Electrical supply V AC 230V 1ph 50Hz Load current A 16 7 29 2 41 7 52 2 60 0 oe diameter of main 6 10 16 Heat output Btu h BTU h 13648 23884 34120 40944 49133 Temperature setting factory set E 80 C Min temperature setting C 30 Overheat protection aC 100 Protection A 20 40 50 63 80 GB 15 the Plectric iea tng company Electric Heating Company Ltd Unit 40 Block 5 Third Road Blantyre Industrial Estate Blantyre Glasgow G72 OUP Tel 01698 820533 Fax 01698 825697 www electric heatingcompany co uk
8. Electric Flow Boiler INSTALLATION amp TECHNICAL MANUAL 8 a the electric hea ting company 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 CONTENTS INTRODUCTION 2 INSTALLATION 4 ELECTRIC BOILER INTERNAL LAYOUT 5 TYPICAL HEATING SYSTEM SCHEMATIC 8 ELECTRICAL CONNECTIONS amp CONTROLS 9 TYPICAL ELECTRICAL SYSTEM SCHEMATIC 11 CONNECTION OF EXTERNAL APPLIANCES 12 FRONT CONTROL PANEL OPERATION 13 FAULT FINDING 15 TECHNICAL SPECIFICATION 15 D This appliance is not intended for use by persons including children with reduced physical sensory or mental cap abilities 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 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 when 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 i
9. Flow Return Expansion Vessel Expansion Vessel Auto Bypass HW Cylinder Return Figure 2 Figure 3 GB ELECTRICAL CONNECTIONS AND CONTROLS ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE BS7671 WIRING REGULATIONS ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALI FIED TRADESPERSON A load check should be carried out to ensure that there is a sufficient current and voltage for the intended boiler installation Considera tion should be taken into account with regard to the remainder of the properties load requirements All boilers must be protected at the meter position with a double pole fused switch with a minimum of 3mm contact separation If the boiler is not fitted local to the meter position then an isolation switch must be fitted local to the boiler THIS APPLIANCE MUST BE EARTHED All pipe work must be earthed in accordance with the IEE BS7671 Wiring Regulations After completion of all electrical works an electrical safety check should be carried out i e short circuit earth continuity resistance to earth and polarity check and all relevant Test Certificates completed Never open the front cover of the boiler until all power supplies to the boiler have been disconnected ELECTRICAL CONNECTIONS The boiler connections are clearly marked inside the boiler L N E 24hr LIVE The 24hr live is the permanent live connection to the boiler from the
10. ating design amp installation Detailed recommendations are given in BS EN 12828 2003 BS 6700 2006 A1 2009 and CP 342 2 1974 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 1980 and copper tube to BS EN 1057 1996 is recommended LOCATION The boiler can be installed in almost any location within a do mestic or commercial property however consideration should be given to future maintenance Never leave the boiler switched off if there is a danger of having temperatures below C in the room where it is located We recommend that a minimum clearance of 400 mm should be allocated for the removal of the front cover 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 THE BOILER MUST BE INSTALLED IN THE UPRIGHT POSI TION FAILURE TO DO SO WILL INVALIDATE THE WARRAN TY GB INSTALLATION 1 General The boiler must be installed by a professional plumber or heating engineer and must be connected to the public low voltage network by a competent person We recommend this is installed by a 17th Edition certifi
11. d a call for heat has been requested to the boiler Once Room Thermostat temperature setting has 3 Choosing pump mode There are jumpers on the control board to control the operating mode of the pump 7 Bridging the jumper described as Pump mode will operate the pump constantly despite the status of the room thermostat If it is been reached the call for heat will cease and the boiler will switch the heating off The 4 led indicator on the Controller Board illuminates when the Room Thermostat RP connections are closed not bridged the pump will operate in an automatic cycle i e when the room temperature reaches the set limit of the Room Thermostat the pump will be turned off 4 PEAK OFF voltage entries optional You can control the boiler i e enable disable its operation by means of external voltage signal by bridging PEAK enab connection 7 In this situation the boiler will operate only when 230V AC is con nected to PEAK OFF 2 When this mode is enabled the led diode indicator 5 on the control board is illuminated 2 Pump The circulation pump shouldbe connected to connection block 3 The pump is connected to the mains input voltage via a fuse 1A delayed 230V that is situated on the control board When the pump is operating the led indicator 6 is also illuminated Note Connections of a Room Thermostat or other control device to the RP connection point withi
12. d BS EN 14336 If the boiler is to heat the domestic hot water an additional allowance of 3kW 10 239 Btu s should be made to the space heating calculation 7 Insulation Where practical and if at all possible we recommend that all pipe work be insulated in particular the primary pipe work with in a boiler cupboard This is to reduce heat loss and re duce high cupboard temperatures from exposed pipe work BS 6700 2006 A1 2009 Allowance should be made for a radiator to be installed with in the heating circuit and locked open This will be located in the room that has the room thermostat installed 8 System Design As the boilers are of low water content an open circuit must be achieved incorporating 2 metre s of continuous 22mm 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 I 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 ther mostat installed To comply with building regulations Part L and Part J in Scotland room and cylinder thermostats must be fitted Note We do not recommend the use of 8mm micro bore pipe 9 Water Conn
13. ections 10 11 Provisions must be made for the replacement of water lost from the heating system sealed systems Reference should be made to BS EN 14336 for the method of filling and make up of water There must be no direct connection between the boilers cen tral heating system and the main water supply When mains water is required to fill the system directly all local water bylaws must be observed and any connection made must be disconnected after use Flushing When installing a new Boiler to existing radiators amp pipe work these items should be flushed before a new boiler is installed New boiler installations also require to be flushed before boil er start up This is to ensure that no debris is trapped in the system as this may result in boiler failure System pressures All boilers are tested to 4 0 bar The normal working pressure of the boiler should be set to approx 1 0 1 5 bar All sealed systems should comply with the relevant building regulations and standards including BS EN 13831 Specification for Ex pansion Vessels Please Note It is imperative that a pre installed magnetic filter is removed and cleaned at least annually Failure to carry out this action will increase contamination of the boiler by system residue GB INSTALLATION ELECTRIC BOILER INTERNAL LAYOUT 1 Water outlet flow 7 Cold water inlet temperature sensor 2 Water outlet temperature sensor 8 Control b
14. ed Electrical Engineer The Electric Heating Company Ltd will not be held responsi ble for faulty installations which are performed by un quali fied tradespersons 2 Pipe Connections All Slim Jim Electric Boilers have a 22mm compression con nection 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 before connections to pipe work can be made The flow red and return blue are clearly marked on the external case and under no circumstances should these con nections be reversed Hot connections are not recommended at the boiler for future maintenance and boiler disconnection Lock shield valves are recommended 3 Case Removal In order to take off the front cover undo the fixing screws at the top and bottom of the unit and disconnect the wires from the Front Control Panel 4 Isolation Valves We recommend that lock shield isolation valves are fitted on the flow and return pipe work Such valves must be full way and not ball valves The installation of ball valves in the flow and return pipe work will reduce the recommended flow rate through the boiler and promote premature boiler shutdown 5 Auto air vents An auto air vent must be fitted to the external pipe work when installed in an unvented system 6 Boiler Sizing Calculate the space heating requirements in accordance with BS EN 12831 an
15. mp CONTROL section of this manual 14 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 Procedure 1 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 2 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 3 Re fill the system and circulate the Heavy Duty Restorer prior to the boiler being fired up then commission the system in the normal way 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 espe cially if excess flux was used 4 Drain and flush the system thoroughly to remove the cleaning agent and any debris or contaminant This is a critical part of the cleaning process and must be carried out correctly Use a rinse test meter TDS such as the Fernox CTM The reading must be within 10 of the mains ppm value 5 Then add the Fernox Protector Copal MB1 or Super concentrate This will protect against the formation of
16. n the boiler must be voltage free connections otherwise damage to the boiler will take place FRONT CONTROL PANEL OPERATION Figure 9 Front Control Panel key II Temperature dial from 30 to 60 degrees 2 Green LED indicator boiler on off signal constant light when the boiler is on flashes when the boiler is off but the pump is still working i e the pump will work for 90 seconds after the boiler shuts down 3 Red LED indicator heating signal Constant light when any of the heating elements are on Flashes even if the switch is in position 0 if any of the inlet or outlet temperature sensors has a failure 4 Power on off switch oy Ss KOSPEL Figure 9 The Front Control Panel consists of a temperature dial 1 switch 4 and 2 signaling led indicators green 2 and red 3 In order to start the boiler place the switch in position 1 The On mode will be confirmed by a constant light from the green 2 indicator The dial 1 should be set according to external temperature approximately based on the graph in Fig 10 The heating itself is signaled by the constant light from the red 3 indicator To switch off the boiler set the switch 4 in position 0 The green indicator will flash 2 for 90 seconds after which the pump will stop running The boiler is now in the fully off mode GB 13 Failure signals 1 Flow failure when
17. n 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 In addition the Warranty will not cover any call out charges that have not been organised by the Electric Heating Company Ltd The warranty will not cover water leaks into the boiler All plumbing joints must be checked A Magnetic Filter must be fitted to the Boiler in the return pipe work and before the circulation pump The Magnetic Filter must be cleaned at least annually Failure to clean the Magnetic Filter may result in boiler system failure Warranty calls will not be covered where the above requirements have not been met Note Some models of boilers may be supplied with a Magnetic Filter The Slim Jim boiler is a low temperature boiler intended for unvented or vented central heating systems with forced circulation protected according to legally binding directives The boiler features e automatic control e low maintenance requirements e internal temperature control e a high current safety temperature cut out The central heating installation in which the Slim Jim boiler is being installed into must be fitted with the following GB Vented Systems e circulation pump e pump valves e F amp E tank e magnetic filter e automatic by pass if required Unvented Systems e circulation pump
18. oard 3 Heating exchanger 6 stage 9 Water inlet return 4 Contactor 10 Pump and room thermostat cable entries 5 Power board 11 Electric mains entry 6 WT3 safety temperature limiter 12 Front control panel Figure 1 10 Note The boiler is fitted with a Safety Temperature cut out that protects the boiler from failure The Safety Temperature cut out item 6 above cuts the power to the boiler once the temperature reaches 100 C Once this occurs the boiler will not operate and a service engi neer would need to be called to re set the boiler However further investigation is required to identify the cause of the fault GB 6 INSTALLATION 12 System types The Slim Jim range of boilers can be used in various system designs Please refer to The Electric Heating Company for more details on under floor heating requirements We are able to supply a Slim Jim 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 recommend the use of thermostatic radiator valves on all radiators except in the room that has the wall room thermostat fitted This radiator should be fitted with lock shield valves and left in the full
19. ric mains parameters and fuses nate The inner safety temperature limiter has locked out Call competent service engineer The 3 indicator flashes Inner temperature sensor failure Call competent service engineer Pump off Call competent service engineer check out the fuse on the control board The 3 indicator flashes at 1 sec ond intervals switch 4 in posi tion 1 No flow Check out efficiency of the central heating installation the pump amp clean the Magnetic Filter Pump s failure Call competent service engineer replace the pump The boiler does not heat although the 3 indicator is illuminated Control board fuse failure Call competent service engineer change the fuse Note Where the above checks fail to cure the fault call a competent service engineer or alternatively contact the Electric Heating Com pany at Tel 01698 82053 TECHNICAL SPECIFICATION EHC Part Number EHCSJIM4KW EHCSJIM7KW EHCSJIM4KW EHCSJIM4KW EHCSJIM14 4KW Boiler range kW 4k W 7kW 10kW 12kW 14 4kW Pipe entry boilers flow top Pipe entry boilers return bottom Central heating flow amp return pipes mm 22 Max pressure MPa 0 3 Min pressure MPa 0 05 Out flow water temperature C 30 80 Max water temperature SG 100 a height x width 912 x 203 x
20. y open position In addition we recommend that an automatic bypass is fitted within this circuit and set to the relevant settings to allow the minimum flow rates to pass through the boiler 8 l 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 thermostat installed System should be designed to meet the current building regula tions in force at the current time 13 Hanging the Boiler 1 Hang the boiler in a vertical position on the fixing points and screws provided with the flow and return connections as identified in Figure 1 maintaining the clearances as identified in the Location section of this manual page 3 2 Connect the boiler to a heating system that is equipped with isolation valves see Figures 4 amp 5 3 Fill the heating system with treated water which will substantially extend the life of the heating coils See item 14 System Protection below 4 Connect the boiler system to the UK domestic mains electrical system as per the Electrical Installation section using conductors sizes as recommended in THE TECHNI CAL SPECIFICATION at the end of this manual 5 Connect the Room Thermostat amp Programmer and all other required electrical connections as per the ELEC TRICAL CONNECTIONS a
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