Operating instructions
Contents
1. 220 240 V max 8 bar 200mm head 0 5 5 L min 1 13L min standard or 8 30L min Page 7 6 Technical specifications Cont Dimensions 1620 x 574 x 750 mm Hecommended Clearance O O LO 20mm gt EHC Fusion E10 Solar Combi Installation and technical manual Page 8 T Installation siting Choosing a location The Fusion E10 solar Combi must be installed indoors in a dry and frost free environment It must be vertically mounted on a flat level surface capable of supporting the full weight of the unit When full the unit weighs a total of 290kg Consideration must be given to maintenance clearance must be left around the boiler to allow the front and top panels to be removed and to allow access to the external pipework and controls Care must be taken when lifting this unit A two man lift is recommended Hand holds are provided in the case at the top rear and bottom front of the unit Removing the panels For installation the front door and top panel cab be removed 1 Door B is secured by two spring clips at point C There are two locating studs for door at point D To remove apply light force at edge around point C Once released angle back approx 15 degrees Then lift vertically to remove studs at point D from their location Be careful to store the door where it cannot be damaged Lid A has no securing areas and can be lifted directly off the unit All EARTH connec2. Solar Filling Points For full Solar Install detail please refer to seperate Flowcon A installation manuall 13 Installation Solar Connections Flow from Return to solar solar Panel Panel 6 Bar Pressure relief p Return to solar Panel Flow from solar Panel TOP VIEW WITH DOOR SIDE VIEW WITH DOOR TO FRONT TO FRONT Note it there is not sufficient space this valve can removed and blanked The Pressure relief valve can then be installed in an alternative position For example When installed in an attic space the valve outlet can be taken to a sump collection point such as a feed and expansion tank Additionally any glycol found in the expansion tank can be re used in the solar circuit EHC Fusion E10 Solar Combi nstallation and technical manual Page 17 12 Installation Electrical All electrical connections must be made by a qualified person All wiring must be carried out in accordance with current IEE regulations BS7671 17th edition THIS APPLIANCE including all pipework MUST BE EARTHED A load check should be carried out to ensure that there is sufficient current and voltage for the intended boiler installation Consideration should be taken into account with regard to the remainder of the properties load requirements All boilers must be protected with a double pole RCD with a trip sensitivity of 30mA capable of breaking the full load current to BS EN 61008 1994 Additionally
3. Central Heating pipework 15 12 Installation Electrical 17 13 Commissioning General 21 14 Commissioning Programmer Setting 23 15 Commissioning Fusion Boiler 27 16 Servicing 29 17 Trouble shooting 30 18 Benchmark Service Record 31 19 Guarantee 32 Warranty registration Please ensure that the warranty card is completed and returned to the EHC by post or you can register the Combination Unit online at www electric heatingcompany co uk EHC Fusion E10 Solar Combi Installation and technical manual Page 2 Introduction Thank you for specifying the Fusion E10 Solar Combi Boiler from The Electric Heating Company The Fusion E10 Solar Combi is an integrated electric flow boiler and solar panel heated Duplex SSTL unvented domestic heating cylinder with back up immersion heater This appiance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by the person responsible for their safety Children should be supervised to ensure they do not play with the appliance The Electric Heating Company reserves the right to make minor changes to the specification or design when necessary Safety Please read and understand these instructions before installing the Fusion E10 Combi Following installation and commissi
4. OFF 5 px M s Az CFI 117 11 T p 2 DONE ae da pay fa ALL BAT STO 07 qure un pm du 4 o F 27 b oem a SET i NEXT X 7 RESET Vel Q7 Cu Qu n 5 f Setting the date and time ALL DAT H Press the SET button and the clock icon on the screen will flash Press the buttons to adjust the time Hold down the button to change the time quicker Press SET button till the Y 00 icon year appears and the letter D flashes Press the button to set the year Press NEXT and N 00 appears month Press button to set month Press Next d 00 appears day Press button to set day NOTE The unit will automatically return to run mode if a period of 5 minutes passes without any buttons being pressed Changing programme times The built in programmes for Central heating and Hot water can be easily changed to better suit your needs To change the Central Heating programme press SET P until the radiator icon flashes in the screen and 1 ON appears This indicates the time shown on the display is the first ON time Change this to the required ON time by pressing the buttons mm Press NEXT button the display will now show 1 OFF Change as before Use NEXT and buttons in this way to programme the second time period If the unit is set for 3 ON OFF periods the number 3 will appear This is set
5. Electrical Wiring Diagram Standard 12 N e Immersion Jajiog uolsn i yun Jeuinsuo 1 1 1 H 4 R4 R4 amp n i Es E r H r r i Nae D H 1 F 6 i dl 8 4 T Sepe epe I 102100199 OL SNOLLO3NNOO 3344 LION 9314 1104 H na 150 WOON 110A E NW F F Pe Zs 290 919 90 Z 0 v 6 0 6 0 0 L 0 0 g m C C C co G D el dis se at 0 s 2 8 m s C C C m mc og N dwy c 777 mmm 0 0 0 0 0 coe 0 0 SNOLLO3NNOO 4444 LION 2 2 us 0 0 0 0 0 ynauig 0 0 0 0 0 0 0 0 L nu 2 Bui Page 19 EHC Fusion E10 Solar Combi nstallation and technical manual Diagram 2 Zone with Installation Electrical Wirin 3 Channel Programmer 12 4b Immersion Heater yun Jeunsuo5 R4 1 Relay 1 Or J9 rog 4015 o e 1 D D D CD CD GD GD GD GD GD CD GD GD CD CD OD GD CD GD OD G0 G0 c c c s z ml woe 6 0 6 6
6. Page 21 13 Commissioning General Cont Check Safety Valves Operation 1 Check Temperature and Pressure Relief Valve 2 Check pressure relief valve on reducing set 3 Check that all pressure relief valves flow through tundish outlet Preliminary Electrical Checks 1 Check all electrical connections are tight Loose connections can cause over heating of terminals and the possibility of a fire 2 Check all earth bonding links are connected are tight and un damaged 3 The electrical system should be checked for Earth Continuity Short Circuits Polarity and Resistance to Earth 4 the backup immersion heater should be set to 65 deg this can be achieved by removing the cover and adjusting the thermostat dial as required Start up 1 Switch on all power supplies to the fusion boiler At this stage the boiler will automatically run the system pump Ensure that all air has been removed from pump 2 Switch on power supply to external control circuit 3 Select desired times for heating and hot water on the twin channel programmer as per instructions on page 23 It is beneficial to set the program around the Economy 10 tariff where possible 4 Switch twin channel programmer to cont on both heating and hot water 5 Further bleed system if required 6 Atthis stage set the automatic bypass to 8l m with all thermostatic radiators valves closed After this been achieved open all thermostatic radiators valves 7 Setsystem temperature on the
7. able to temporarily adjust the heating programme for example Override Advance or Boost These are explained in the manufacturer s instructions The heating will not work if the room thermostat has switched the heating off And if you have a hot water cylinder the water heating will not work if the cylinder thermostat detects that the hot water has reached the correct temperature The unit is designed to eliminate the possibility of accidental changes to your programme Buttons normally visible only affect your set programme temporarily All buttons which can permanently change your programme are located behind the flip down fascia Selecting operating mode The heating and hot water mode select buttons are used to set the operating mode for Central heating and Hot water respectively Each has 4 modes as described ON Central heating and or hot water on continuously ie on all the time AUTO Central heating and or Hot water will be switched ON or OFF as programmed ALLDAY Central heating and or Hot water will be switched ON only once each day ie on at the first ON time and off at the last OFF time OFF Central heating and or Hot water will be continuously OFF EHC Fusion E10 Solar Combi nstallation and technical manual Page 23 14 Commisioning Programmer Cont ME ce HEEL CUR salen 207 XLS M TU WE TH FR SA al Hep JE Ar MEN z DA R 123 it EZ QM TT Ohl gt
8. control stat TS28 Single high limit stat EHC Fusion E10 Solar Combi nstallation and technical manual Page 29 17 Trouble Shooting Water escaping from unit Cold water from taps Water discharges from expansion relief valve Water discharging from temperature relief valve Milky Cloudy water No hot water flow Possible transit movement Possible programmer settings Dual thermostat set to low Dual thermostat over heat Low boiler pressure If continual check pressure reducing valve If continual expansion PRV may be damaged If intermittent oystem has overheated Oxygenated water Water main off Strainer blocked EHC Fusion E10 Solar Combi nstallation and technical manual Check and tighten all internal compression connections Check programmer is set for desired time settings Set dual thermostat to 60 deg Check dual stat over heat cut out Pressurise to 1 5 bar Set pressure reducing valve to 3 bar Check PRV and replace if required Check expansion vessel pressure when cold re pressurise if required Check if balanced supply is required when using mixer taps showers etc possible back feed Check if backup immersion heater is in use and over heat device has failed Check TP valve and replace if required Water from any high pressure system will release oxygen bubbles when flowing The Check incoming water main Isolate water main and clean as required Page 3
9. in exactly the same way as the previous first and second time period EHC Fusion E10 Solar Combi nstallation and technical manual Page 24 14 Commisioning Programmer Cont If the unit installed is a 7 day programmer the initial programme displayed will be for Monday You can go to any day of the week by pressing the DAY button repeatedly The ON OFF times can be changed for each day as above in the changing programme times If you press the COPY button the current programme will be copied onto the next day If the unit installed is a 5 day 2 day programmer the initial programme displayed will be for Monday to Friday Pressing the DAY button will take you to the programme for Saturday and Sunday The ON OFF times can be changed for each day group as above in the changing programme times If you press COPY the current programme will be copied onto the next day group If the unit is installed as a 24 hour programmer the built in programme will be the same for each day The COPY function is not required if installed as a 24 hour programmer To return to RUN mode press the SET button until the display indicates RUN on the display To change the Hot Water programme press SET button until the tap symbol appears and proceed exactly as for Central Heating above NOTE t is not possible to copy Sunday to Monday For convenience to allow for programmes to go past midnight
10. kWh delivered total heat energy if option OHQM is enabled Adjustable parameters The controller has many parameters that can be set to suit the installation and user preference To give some security from end user tampering most changeable parameters are hidden to access hold down the right button for more than 2 seconds Each parameter has a code and value e g SMX 60 0 C meaning maximum store temperature is 60 C Under the terminal cover is a summary of each outlined below For detail please check the full controller manual The 3 buttons have the following functions left down right up and centre enter buttons Scroll down the list to the code required then press enter to allow change Note the set flag will flash to show change is possible Change the value with up down press enter again and move on to the next parameter required There are 9 main operating modes changed in parameter Arr Arr 1 standard solar system with one collector one store one pump Arr 2 as Arr1 but with heat exchange to second store Arr 3 as Arr1 with boiler thermostat Arr 4 one collector with twin coil cylinder and charging in layers Arr 5 one collector with two stores and valve control Arr 6 one collector with two stores and pump control Arr 7 two collectors East West with one store and pump control Arr 8 one collector with one store and pump control for solid fuel boiler Arr 9 one collector feed
11. normal working pressure of the Fusion E10 boiler should be set to 1 5 bar All sealed systems should comply with current building regulations and standrads factory However all compression joints must be checked again at installation due to All Fusion E10 Solar Combi units are water and pressure tested before leaving the N the possibilty of transit movement 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 1 Fill the system with cold mains water to the recommended pressure 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 AddFernox S5 via a Fernox injector or radiator at the recommended dose One bottle must be used as a minimum per dwelling If you are not sure of the dose rate then contact Fernox 3 Fill the system back up and circulate the Fernox S5 before the boiler is fired up Then commission the system in the normal way The cleansing agent must be in the system for a minimum of hour with the system at normal operating temperature A longer period of time would be more beneficial to the cleansing process especially if excess flux was used 4 Drain and flush the system thoroughly to remove the cleaning chemical and debris present This is a crucial part of the cleansing process and mu
12. than by each annual service the manufacturer The guarantee period starts from the date of It has not been misused tampered with or purchase and no registration is required subjected to neglect The extended guarantee is not transferable and rests It has only been used for the storage of potable with the original householder water The system is fed from a public water supply The following Guarantee periods apply from date of purchase Stainless Steel Cylinder 25 years Fusion Slimline electric Boiler 2 years DHW Expansion Vessel 5 Years All other valves fittings and electrical parts 2 Years Please note that invoices for servicing may be requested to prove that the unit has been serviced annually All the components fitted to or supplied with the E10 Combi carry a 2 year guarantee EXCLUSIONS THE GUARANTEE DOES NOT COVER the effects of scale build up any labour charges associated with replacing the unit or its parts nor any consequential losses caused by the failure or malfunction of the unit Periodic loss of charge pressure from expansion vessels is normal and is not covered under the guarantee This guarantee does not affect your statutory rights For advice support or further information on The Electric Heating Company s full range of electric heating products or one of our free Product guide and installation DVDs call now on 01698 820 533 Bigrtric heatim Ra company The Electric Hea
13. z 2 i uu H lu D N H Lu 1 gt a aot A f f 4 e LOE 100 99 Jojenjoy c euoz LOL XIL a 1 6 n M 0 0 a H a pce gfe 8 A Lai 0 SNOILO3NNOO 3444 110A Ex 0 8 0 4 401En19V LP euoz i 9 0 ts 5 I k n i 7 iu 4 QIJUDD 6 4 66226 DUUM Page 20 EHC Fusion E10 Solar Combi nstallation and technical manual 13 Commissioning Genaral IMPORTANT DO NOT SWITCH ON THE ELECTRICAL SUPPLIES TO THE FUSION E10 COMBI UNIT UNTIL THE CYLINDER AND PRIMARY CIRCUIT HAVE BEEN CORRECTLY FILLED WITH WATER Filling the cylinder Check that all pipe connections to the Fusion E10 Combi are tight Open a hot tap furthest from the Fusion E10 Combi Check the Primary System Filling Loop isolating valves are closed Open the cold water supply isolating valve and allow the Fusion E10 Combi cylinder to fill When water flows from the tap allow to run for a few minutes to thoroughly flush through any residue dirt or swarf then close tap Open any other hot and any cold services supplied by the balanced cold outlet to r
14. 0 17 Trouble Shooting Cont Possible programmer Check programmer is set for desired No heating to radiators settings time settings Pressurise to 1 5 bar Low boiler pressure System must have a minimum of 5 Lom to operate press right arrow key on boiler until L min is eliminated No heating and hot Poor flow rate this will show you system flow rate water Possible chocked Close isolation valves and clean Poor flow rate magnetic filter filter If filter is clean Replace boiler flow sensor Press right arrow key until blue circle is illuminated at top of control panel if Flashing boiler control Inlet outlet sensor fault an E is shown replace inlet sensor panel follow same procedure for red circle outlet sensor Check overheat cut outWT3 Power to boiler but front If brass pin is out turn of main power boiler control panel Possible boiler overheat to boiler and reset a firm push is blank require to reset WT3 you will feel it click into position 1 Reset WT3 2 Turn power on to unit 3 Switch programmer off 4 check for power to main heat Boiler continually cutting Possible power board fault exchanger 6 brown cables on LHS out on WT3 of terminal strip within boiler 5 if power is found on any connection REPLACE power board EHC Fusion E10 Solar Combi nstallation and technical manual Page 31 18 Benchmark Service Record Installation Commissioning and Service Record CUSTOMER DETAILS CYLI
15. 14 11 Installation Central Heating pipework Flow and return connections are located at the bottom of the left hand side of the unit We recommend compression joints at this point to prevent damage to the units internal seals The return connection will need to temporarily incorporate a filling loop as shown in the diagram below Reference should be made to BS 6798 for methods of filling and make up of water There must be no direct permanent connection between the central heating system and the mains water supply all filling loop connections must be removed local water bylaws must be observed System Design As the Fusion E10 boiler is of low water content an open circuit must be achieved at all times Allowances should made for a system bypass radiator or valve This radiator should be installed in the same room as the room thermostat Flow rates can be obtained from the control panel on the fusion boiler by pressing the right hand arrow key until the L min LED illuminates System Flushing When the Fusion E10 solar Combi is being installed into an existing central heating system we highly recommend that the system is power flushed to prevent contamination from existing debris and magnatite The Fusion E10 boiler has an inbuilt magnetic filter to protect internal components and pump EHC Fusion E10 Solar Combi nstallation and technical manual Page 15 1 Installation Central Heating pipework Cont System Pressures The
16. Bends must be taken into account in calculating the flow resistance Refer to diagram 1 Table 1 and the worked example An alternative approach for sizing discharge pipes would be to follow BS6700 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages B Have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework EHC Fusion E10 Solar Combi nstallation and technical manual Page 12 9 Installation discharge arrangement cont C Be installed with a continuous fall D It is preferable for the discharge to be visible at both the tundish and the final point of discharge but where this is not possible or practically difficult there should be clear visibility at one or other of these locations Examples of acceptable discharge arrangements are 1 Ideally below the fixed grating and above the water seal in a trapped gulley 2 Downward discharges at a low level i e up to 100mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that where children play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility 3 Discharges at a high level e g in to metal hopper and metal down pipe with the end of the discharge pipe clearly visible tundish visible or not or onto
17. EHC Solar E10 Combi Series Solar Combination Boiler Range Installation and Technical Manual THESE INSTRUCTIONS SHOULD BE READ CAREFULLY AND RETAINED FOR FUTURE REFERENCE This Manual is provided to assisit the installation and mainteneance of the following EHCSCOMB9 180 EHCSCOMB12 180 EHCSCOMB14 180 The E10 Solar Combi must be installed by a competent person with accordance with this installation manual and all relevant regualtions in force at time of installation The Fusion E10 combination unit s Unvented Cylinder is a controlled service as defined in the latest edition of the building regulations The relevant regulations are England and Wales Building Regulation G3 Scotland Technical Standard P3 N Ireland Building Regulation P5 After installation the Benchmark log table on page 31 must be completed and left with the householder for future reference The Electric Heating Company Ltd Unit 40 Block 5 Third Road Blantyre Industrial Estate Blantyre Glasgow G72 OUP Tel 01698 820533 info electric heatingcompany co uk Fax 01698 825697 www electric heatingcompany co uk Contents Page f Introduction 3 2 Safety 3 3 Storage handling amp unpacking 4 4 Contents Check List 5 5 Key Components 6 6 Technical Specifications 7 7 Installation Siting 9 8 Installation Plumbing 10 9 Installation Discharge arrangement 12 10 Installation External pipework schematic 14 11 Installation
18. Fusion E10 boiler to 65 C as per instructions 8 Set Thermostat to Max temperature 9 Allow system to circulate 10 After the system has circulated and reached desired temperature The system can then be set to the individual users preference EHC Fusion E10 Solar Combi nstallation and technical manual Page 22 14 Commisioning Programmer 2 Channel Note if you have a 2 Zone system with 3 channel Programmer Please refer to the enclosed 3 Channel Programmer user guide Select 307 XLS SN a is i SNe salei 207 IIE MO TU WE TH FR SA 3U Tier Lim Jd M RUN DATE 423 HR IM n N OFF fo GOB QFIF Taz pay COPY Zak ALL DAY ENT i 6 AUTO K EN P eer C next X7 RESET The programmer allows you to set ON OFF time periods Some models switch the domestic hot water on and off at the same time while others allow the domestic hot water and heating to come on and go off at different times Set the On and Off time periods to suit your own lifestyle On some programmers you must also set whether you want the heating and hot water to run continuously run under the chosen On and Off heating periods or be permanently off The time on the programmer must be correct Some types have to be adjusted in spring and autumn at the changes between Greenwich Mean Time and British Summer Time You may be
19. NDER DETAILS SERVICE RECORD DETAILS Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the manufacturer s instructions and in compliance with all relevant codes of practice It is recommended that your hot water system is serviced regularly and that your com priate Service Interval Record below service engineer SERVICE 2 DATE ENGINEER COMPANY SIGNATURE SERVICE 1 DATE SIGNATURE EHC Fusion E10 Solar Combi SERVICE 3 DATE EHGINEER COMPANY TEL NO COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER COMPANY TEL NO COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER COMPANY SIGNATURE SERVICE 9 DATE ENGINEER COMPANY TEL NO COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER COMPANY COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER COMPANY COMMENTS SIGNATURE SERVICE 8 DATE SIGNATURE SERVICE 10 DATE ENGINEER COMPANY COMMENTS SIGNATURE Installation and technical manual Page 32 19 Guarantee The Fusion E10 Combination Unit is guaranteed against faulty materials or manufacture provided that thas been correctly installed as per this t has not been subjected to frost damage document and all the relevant standards regulations and codes of practice in force at the The unit has been serviced annually time The benchmark log book has been filled in after It has not been modified in any way other
20. a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges tundish available 4 Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected If unvented hot water storage systems are installed where discharges from safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device to warn when discharge takes place Worked example The example below is for G1 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length of 7m from the tundish to the point of discharge From Table 1 Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a G1 2 temperature relief valve is 9 0m Subtract the resistance for 4 No 22mm elbows at 0 8m each 3 2m Therefore the maximum permitted length equates to 5 8m 5 8m is less than the actual length of 7m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28mm pipe D2 from a G1 2 temperature relief valve equates to 14m As the actual le
21. a double pole switch with a minimum of 3mm contact separation must be installed local to the boiler Boiler control wiring the boilers internal controls are prewired within the unit using a plug it system for easy replacment of components The control power supply cable exits the boiler on the left hand side this cable must be connected and protected via a 3 amp fused spur and wired so that when the main power to the boiler is removed the control circuit is isolated When other high current devices are installed within the same property eg electric showers we recommend that our flow sensor should be installed interrupting the volt free control signal to the boiler when the shower is in use Cable entry positions The electrical supply cables can be routed from the top left hand panel of the unit see Diagram below There are 3 cable entry holes 2 at the top of the left hand side panel and 1 on bottom right Cable grommets are supplied and fitted to the boiler s cable entry points All cables should be secured to meet current regulations Cable ties are provided within the fusion boiler to secure incoming power cables CABLE ENTRY POINT CONTROLS WIRING Immersion heater mains supply The Fusion E10 Solar combi is fitted with a 3 Kw immersion heater It is recommended that this is connected as per wiring diagrams on pages 19 amp 20 EHC Fusion E10 Solar Combi nstallation and technical manual Page 18 Installation
22. ains on after dusk until T store has fallen to lt S MX to cool system Tube collector function Used to overcome non ideal sensor position If option collector temp rises by 2 C pump circulates for 30 sec to force system fluid past collector sensor OHQM Heat Quantity measurement Uses S4 to measure the collector return option arr 1 3 4 5 only temperature and determine the heat supplied in kWh If enabled the maximum system flow rate in litres min FMAX antifreeze type MEDT and concentration MED also need to be entered nMN Sets the minimum pump speed Note valves etc n1MN should be set at 100 n2MN HND2 between OFF ON and AUTO LANG Language choice J PRIO Store priority for 2 stores 1 Connection diagrams and descriptions for common systems Each arrangement is pre programmed with typical settings to suit that system and normally the factory settings will give close to optimum operation Sometimes it is desirable to alter SMX setting above 60 C allows more energy storage in good solar conditions assuming other scald and limescale control measures are in place Drainback systems may benefit from an increased DTO and increased CMX e Most pumps can be used with pump speed control valves must have 100 nMN e wo store systems may have different SMX and DTO DTF requirements EHC Fusion E10 Solar Combi nstallation and technical manual Page 35 Arr 1 standard one collector o
23. al guidelines EHC Fusion E10 Solar Combi nstallation and technical manual Page 4 4 Contents check list The following components are supplied in the bag at the front of the Fusion E10 Solar Combi cabinet Please check that all parts are present and available before commencing installation Note if your unit is a non standard type there may be additional components these should be checked against your order HC Pinion tb Serien rara oan Cau Installation and technical manual Installation Manual 15 22mm Tundish High flow rate inlet TLX 4101 Filling loop control set Room Thermostat EHC Fusion E10 Solar Combi Installation and technical manual Page 5 Key components lu OONOOBRWND Programmer Rear compartment expansion vessels Enclosure Fusion Slim line Boiler Rear Compartment 180L Cylinder Flovv and Return to Solar Panel Solar Pressure Relief Outlet Solar filling connections Solar Controller Solar Pump Set Removable door retaining clips Domestic Hot water Temp Pressure Relief Outlet Domestic Hot water Outlet Central Heating Pressure Relief Outlet Magnetic filter Immersion Heater Cold Main Central Heating Return Central Heating Flow Solar Sensor Control Panel Over heat cutout Automatic air vent Heating elements Copper heat exchanger Printed circuit board Voltage free control connections Circulation pump Flow and Return sensors Flow s
24. e of electric boilers require no ignition or lighting sequence to be executed by the end user All the end user is required to do is ensure that the system is filled with water and the room stat or programmer is calling for heat Boiler operation a Switch on unit power supply Press Q to switch the boiler on Switch the boiler off using the same switch by holding it for 2 seconds b Switch on programmer or room stat to call for heat c When the system reaches the required boiler set point temperature the boiler will modulate and will automatically stage down d Modulation this is when the boiler controls the heating load and the power that is required to maintain the relevant temperature setting e During the periods when the boiler is switched off the pump will operate every day for 15 minutes This protects the boiler and the central heating system from being blocked and silted up Temperature Setting We recommend boiler temperature to be set to 65 C Raise and lower the temperature in your installation with the use of the switches and e Refer to the diagram below to learn how to adjust the right temperature to make the boiler work comfortably and economically Should the temperature on the front panel be set to too low a value the boiler will not reach the required room temperature Working parameters control You can check all the working parametres of the boiler by pressing First pressing of switch inle
25. emove any air from the system Check all connections including immersion heater for leaks and rectify as required The strainer housed within the Cold Water Combination Valve should be cleaned to remove any debris that may have been flushed through the main supply pipe Filling the sealed system primary circuit 1 The primary system must be flushed in accordance with BS 7593 and the manufacturer s instructions supplied Failure to to do this will invalidate warranty Connect the Filling Loop and tighten connections Check all radiator valves are in the open position Open the Filling Loop isolating valves and allow primary system to fill until the pressure gauge on the fascia of the Fusion E10 Solar Combi reads approx 2 0 bar Purge air from all radiators and air vent points in the primary system including the pump in the fusion boiler Check the primary system pressure This should be between 1 0 and 1 5 bar If lower open Filling Loop isolating valves until gauge reads approx 2 0 bar Repeat air purging operation This sequence may need to be repeated several times to ensure all air is purged from the system Check primary system for leaks and rectify as necessary When the pressure gauge remains steady at between 1 0 and 1 5 bar ensure both Filling Loop isolating valves are closed and remove Filling Loop flexible hose from the Primary system connection point EHC Fusion E10 Solar Combi nstallation and technical manual
26. ensor is faulty Press to show Flow Return and Set Temperature Press to check flow rate Press to check power consumption DHWC Indicator EHC Fusion E10 Solar Combi nstallation and technical manual Page 28 16 Servicing Servicing should only be carried out by competent installers and any spare parts used must be purchased from The Electric Heating Company NEVER bypass any safety devices or operate the unit without them being fully operational Draining Isolate from the electrical supply to prevent the immersion heaters burning out Isolate the unit from the cold mains Attach a hose to the draining tap ensuring it reaches to a level below the unit This will ensure an efficient syphon is set up and the maximum amount of water is drained from the unit Open the hot tap closest to the unit and open the draining tap WARNING WATER DRAINED OFF MAY BE VERY HOT Annual maintenance The Fusion E 10 Solar requires an annual service on the cylinder in order to ensure safe working and optimum performance It is essential that the following checks are performed by a competent installer on an annual basis The internal fusion electric boiler does not require any servicing but it is good practace to check electrical connections are all good to prevent any damage to the electrical terminals due to a loose connection The magnetic filter within the unit should also be cleaned at this stage Twist the cap of the expansion relief val
27. ework near the hot water or heating pipe work so that heat pick up is minimized 2 Identify the cold water supply pipe and fit an isolating valve not supplied A 22mm BS1010 stopcock can typically be used however a 22mm quarter turn full bore valve is preferable as it does not restrict the flow as much Do not use screwdriver slot or similar valves 3 Make the connection to the cold feed of the Fusion E10 solar Combi and incorporate a drain valve Position the inlet control immediately above the Temperature amp Pressure Relief Valve TPRV mounted on the side of the unit see diagrams below This ensures that the unit does not have to be drained down in order to service the inlet control set Ensure that the arrow points in the direction of the water flow r pis EHC Fusion E10 Solar Combi nstallation and technical manual Page 10 8 Installation Plumbing Cont Balanced cold connection If the system includes showers bidets or monobloc taps then a balanced cold supply is necessary Do not use monobloc mixer tap or showers if the balanced cold connection is not used Outlets of this type can back pressurise the unit and result in discharge A 22mm balanced cold mains outlet can be found on the control set supplied see diagram below Use the balanced cold mains outlet from the inlet control set as shown in the illustration to feed all mixer taps showers instead of connecting them to the cold main I
28. f the control set supplied with your Fusion E10 solar Combi unit is of the two part type it can be split into its two main assemblies Site the pressure reducing valve immediately after the incoming cold mains stopcock typically under the kitchen sink All outlets in the house will be set to 3 bar and thus automatically balancing the system The expansion relief valve section must still be mounted just above the TPRV on the cylinder see diagram below Cold Mains Inlet Balanced Cold Mains Outlet Hot Water pipework Ensure the first part of the hot water pipework is run in 22mm pipe This can reduce to 15mm 10mm depending on the type of tap etc Your aim should be to reduce the volume of the hot draw off pipework to a practical minimum so that the time taken for the hot water is as quick as possible EHC Fusion E10 Solar Combi nstallation and technical manual Page 11 9 Installation discharge arrangement metal discharge pipe D1 from temperatura relief valve to tundish safety device temperature relief valve 300mm minimum metal discharge pipe D2 from tundish with continuous fall See 3 9d i iv Table 1 and worked example below Discharge below fixed grating 3 9d gives alternative points of discharge fixed grating trapped gulley The above diagram is of a typical discharge pipe arrangement extract from Building Regulation G3 Note The discharge w
29. ill consist of scalding water and steam Asphalt roofing felt and non metallic rainwater goods may be damaged by such discharges Note It is not acceptable to discharge straight into a soil pipe Position the inlet control group so that the discharge from both the two safety valves can be joined together via a 15mm end feed Tee Connect the Tundish and route the discharge pipe The discharge pipework must be routed in accordance with Part G3 of schedule 1 of the Building Regulations The information that follows is not exhaustive and if you are in doubt you should seek advice The two safety valves will only discharge water under fault conditions When operating normally water will not be discharged The tundish should be vertical located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e g the temperature relief valve The discharge pipe D2 from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge be of metal and A Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i e discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the the nominal outlet size of the safety device between 18 and 27m at least 3 sizes larger and so on
30. ing heating circuit buffer tank to preheat boiler Description of parameters and factory set values setting setting Arr Arrangement changes between the standard solar system with 1 one pump Arr 1 to one of the other 8 pre orogrammed systems DTO switch on temperature Two store systems will have DTO for each channel 6 C DT1O differential DT2O EHC Fusion E10 Solar Combi nstallation and technical manual Page 34 DTF switch off temperature Two store systems will have DTF for each channel 4 C DT1F differential DT2F S MX Maximum store temperature Offers adjustment for scald protection and for 60 C limiting scale build up in hard water areas If other anti scald measures are used e g TMVs and water hardness is low this can be increased to 85 C to enable more solar energy capture Note this uses sensor 2 generally at the store base ug exerum erum oo shutdown temperature off the system pump to protect the system WEE ral mn option stagnation Note this temporarily overrides SMX us temperature OCN Minimum collector function Prevents system operation until the minimum collector temperature CMN factory set to 10 C has been exceeded OCF OTC Antifreeze function option Will run circulating pump if collector temperature falls to less than CFR factory set to 4 C Not recommended for use in UK OREC Recooling function option Overides SMX to runs pump to prevent system staganation Pump rem
31. le For more information on the best use of the Economy 10 tariff please contact the Electric Heating Company direct C O S H H Materials used in the manufacture of the Fusion E10 Combi are non hazardous and no special precautions are required when fitting or servicing the appliance EHC Fusion E10 Solar Combi nstallation and technical manual Page 3 3 Storage handling amp unpacking The Fusion E10 Solar Combi is protected in corrugated packaging with reinforced corner posts The assembly is wrapped in heavy duty polythene The Fusion E10 Solar Combi unvented fitting kit is supplied within the boiler The assembly must be stored upright under cover in dry conditions Units must not be stacked The packaging must be removed prior to installation Note the weight of the product and the handling instructions applied to the packaging If using a handling device eg a sack barrow to manually move the Fusion E10 solar Combi trucking must be done from the rear to avoid damage to the outer panels The Fusion E10 Combi should be lifted and handled by two persons Handholds are provided in the top rear panel and underneath at the front of the Fusion E10 solar Combi assembly to aid lifting Stooping should be avoided and protective clothing worn when necessary Care must be taken when removing the packaging to avoid any damage to the surface of the unit The packaging is recyclable and should be disposed of in accordance with environment
32. ne store solar system The controller monitors the collector temperature S1 and displays it as COL If COL exceeds the store base sensor TST by more than the switch on temperature difference DTO relay 1 is energised and the pump starts The pump remains on until the collector temperature falls to less than TST plus the switch off temperature difference DTF Once the store base temperature TST exceeds the maximum store temperature SMX the system switches off Note S3 can set up as a thermostat to control relay 2 if Arr3 is used instead all other functions are the same 7 F OD InR2IN RIN L 12 13 14 15 46 17 1 19 20 E R1 aN E S3 Store top sensor SA Sensor for heat quantity smr lt 277 ie Solar pump The solar pump station has been setup before leaving our factory to allow the immersion heater interrupt to be activated when the solar system reaches 55 60 deg C When this temperature is reached the immersion heater will be disabled to allow full benefit from solar gain EHC Fusion E10 Solar Combi nstallation and technical manual Page 36
33. ngth is 7m a 28mm D2 copper pipe will be satisfactory Table 1 Sizing of copper discharge pipe D2 for a temperature relief valve with a G1 2 outlet size as supplied Size of Maximum length of straight Deduct the figure below from the discharge pipe no bends or elbows maximum length for each bend or pipework elbow in the discharge pipe EHC Fusion E10 Solar Combi nstallation and technical manual Page 13 Hot Water IC k schemat ipewor External pi Installation 10 1S AMO 16 pai 01 A PA ueq MO 4 DuneoH e41u82 osn Jaye poejoeuuoosip pue doo Suli e jo esn eu unjeH Sune H jeug yom edid p xil eq 104 snw siu uon uuo2 SUIN AD JO HO ure1q EHC Fusion E10 Solar Combi nstallation and technical manual TN See ee jenno JeijeH eunssaJg DuneoH e41u925 Jaye 10H 9iseuog Fusion Electric Boiler UIN jenno l y H 9 usipun Jaye 10H les Buionpeyu 10 2 0S oJnssaJg pee bd R M8IA epis yaaa un uoneuliquio uoisn sn Page
34. oning the operation of the Fusion E10 Combi the central heating system and associated controls should be explained to the customer and these instructions left with them for future reference The Fusion E10 Solar Combi must be installed in accordance with the manufacturer s instructions and all relevant regulations in force at the time of installation The Fusion E10 Solar Combi s Domestic Hot Water Cylinder is of the UNVENTED type Its installation is subject to Building Regulation G3 England and Wales Technical Standard P3 Scotland or Building Regulation P5 Northern Ireland Installation must be carried out by a competent person The Fusion E10 Solar Combi electric central heating boiler must be installed into a sealed pressurised primary system Following installation of the primary system the system should be flushed in accordance with BS 7593 and an inhibitor added The E10 solar Combi hot water cylinder is indirectly heated by Solar panels 9not supplied Additionally the hot water cylinder has an immersion heater for backup Please note a load check should be taken into consideration when installing high output electrical appliances The use of an Off Peak tariff that provides at least three off peak electricity periods such as Economy 10 from Scottish and Southern Energy is recommended Where possible the central heating and hot water on periods should be programmed to coincide with the off peak electricity periods availab
35. st be done correctly Use a rinse test meter TDS such as the Fernox CTM The reading must be within 1096 of the mains ppm value 5 Once the system has been cleansed thoroughly then add a Fernox Protector Copal MB1 or Superconcentrate to the system The product must be added as per the manufacturer s instructions This will protect against the formation of scale corrosion and microbiological growths It is crucial however that for a protector to work correctly the system must be properly cleansed and flushed 6 The sticker included within the Fernox Protector carton should be correctly filled in and attached adjacent to the boiler 7 Please note 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 8 Fernox Technical Services can be contacted on 0870 8700362 for further assistance NB Motorised valves should be manually opened during the flushing process and any anti gravity valves should be by passed or removed temporarily If it is necessary to cap off the open vent during the mains flush to prevent overflow ensure the cap is removed prior to starting the appliance Advice as contained within BS 7593 1992 and PAS33 1999 should be followed in conjunction with this method statement EHC Fusion E10 Solar Combi nstallation and technical manual Page 16 12 Installation Solar Fillin
36. t temperature displayed indicators D and F on Next pressing of switch outlet temperature displayed indicators E and F on Next pressing of switch medium water rate of flow displayed indicator H on Next pressing of switch power with which the boiler currently heats indicator I on Next pressing of switch returns to the standard state where you can change the temperature setting in the central heating system The indicators not only describe the state of the boiler but also inform about failures EHC Fusion E10 Solar Combi nstallation and technical manual Page 27 15 Commissioning Fusion boiler instructions Cont Front Control Panel Indicator B Indicator C Indicator F Indicator D Indicator E Indicator G Indicator H Indicator Indicator A When GREEN light is on the pump is operating When this light flashes the flow rate is insufficient less than 5 Itr per min Refer to technical specifications When light is off room thermostat temperature has been achieved RP is open When the green light flashes the NA connection is open na should always have link installed When RED light is on the boiler is operating When GREEN light is on boiler temperature has been achieved Set Temperature Return Temperature When this indicator flashes the return temperature sensor is faulty Flow Temperature When this indicator flashes the flow temperature s
37. the maximum of three hours extra heating If the Central Heating mode is OFF then it will switch on for the extra hours selected If the Central heating mode is AUTO or ALL DAY then during an OFF period it will switch on for the extra hours selected If during an ON period then it will temporarily extend that programme by the number of hours selected EHC Fusion E10 Solar Combi nstallation and technical manual Page 25 14 Commisioning Programmer Cont The display indicates how many hours have been requested in the bottom left hand corner Hot Water can be temporarily switched on in the same way using the HR button on the right of the display Power interruption In the event of a mains supply failure the back up battery ensures the programmer continues to keep time and retain your stored programme The screen will go blank but will return when power is restored Resetting the programmer Press the reset button with a non metallic pointed tool to restore the built in programme plus the time and date The display will then show the current state of the configuration switches British Summer Time The programmer will automatically change from Greenwich mean time to BST and vice versa EHC Fusion E10 Solar Combi nstallation and technical manual Page 26 15 Commissioning Fusion boiler instructions Introduction Unlike other system boilers such as Gas Oil and Propane the FUSION rang
38. the programme day is from 3 00am to 2 50 am the next day If your programme gets scrambled or if you want to start again press the reset button using a non metallic tool to re load the default programmes then press any button to clear the DIP switch configuration code The unit should revert to time setting mode ready for programming Using Advance This function is only available when programme is in AUTO or ALL DAY operating modes To advance central heating Press the Central Heating ADV button on the left by the display This will turn the Central Heating ON if it s in an OFF period and OFF if it s in an ON period It will stay in this state until either ADV is pressed again or until a programmed ON OFF period commences The word ADV will appear in the top left hand corner of the screen WE i I M m RUN To advance Hot water press Hot Water ADV button This will turn the Hot water ON if it s in an OFF period and OFF if it s in an ON period It will stay in this state until either ADV is pressed again or until a programmed ON OFF commences The word ADV will appear in the top right hand corner of the screen Using HR buttons To temporarily switch the central heating on for a short while press the left hand HR button One press of the button will give one extra hour of heating Two presses of the button will give two extra hours of heating Three presses of the button will give
39. ting Company Ltd Unit 40 Block 5 Third Road Blantyre Industrial Estate Blantyre Glasgow G72 OUP Tel 01698 820533 info electric heatingcompany co uk Fax 01698 825697 www electric heatingcompany co uk EHC Fusion E10 Solar Combi nstallation and technical manual Page 33 Concise Instructions for RESOL DeltaSol BS Pro controller Overview 2 collector 1 store or 1 collector 2 store system controller e 4temperature sensor inputs e 2 semiconductor relay outputs with pump speed control option e heat quantity measurement option via flow gauge e illuminated graphic display simple 3 button menu system 9 pre programmed systems with optimum values User display The graphic display changes to suit the system Two collector systems will nave CULI ana UUL2 two store systems TST1 TST2 etc Using the left and right buttons changes the display to show the following COL collector temperature display Changes to for two collector systems TST store lower temperature sensor changes to TSTL or TST1 TST2 depending on Arr o3 third temperature sensor usually shows temp in boiler heated zone of cylinder changes to TST2 in two store systems o4 fourth temperature sensor used as collector return sensor for heat quantity measurement Changes to THF in some systems hP hours run counter for pump Changes to hP1 hP2 in some systems n pump speed for relay Changes to n1 n2 in two pump systems
40. tions must be reconnected to removable side panels EHC Fusion E10 Solar Combi nstallation and technical manual Page 9 8 Installation Plumbing Water supply requirements The Fusion E10 solar Combi operates at 3 bar controlled by the inlet control set and is capable of delivering over 50 litres per minute The high quality inlet control set has been designed to make the most of the flow rates available however the performance of any unvented system is only as good as the mains water supply to the unit The maximum possible water demand should be assessed by taking into consideration that both hot and cold services are supplied simultaneously from the mains The water supply should be checked to ensure it can meet these requirements If necessary consult the local water company regarding the likely pressure and flow rate availability If measuring the water pressure please note that a high static no flow mains pressure is no guarantee of a high flow rate In a domestic installation 1 5 bar and 25 l m should be regarded as the minimum The maximum recommended mains pressure for the inlet control set is 16 bar Consideration should be given to upgrading existing 7 15mm cold mains pipework to a larger size if the recommended minimum pressure flowrate is not being achieved Cold mains pipework Example 1 Run the cold main pipework to where the Fusion E10 solar Combi unit is to be installed Take care not to run the cold mains pip
41. ve on the inlet control set and allow water to flow for 5 seconds Release and make sure it resets correctly Repeat with the pressure temperature relief valve In both cases check that the discharge pipework is carrying the water away adequately If not check for blockages etc and clear WARNING THE WATER DISCHARGED MAY BE VERY HOT Check that any immersion heaters fitted are working correctly and that they are controlling the water at a temperature between 55 C and 65 C Check the pressure in the expansion vessel is charged to 3 0 bar Turn off the water supply to the unit and open a hot tap first The air valve on expansion vessel is a Schrader car tyre type Air or COs may be used to charge the expansion vessel Unscrew the head on the inlet control set and clean the mesh filter within The benchmark log book supplied with this unit should be updated at each service YOUR GUARANTEE MAY BE VOID WITHOUT PROOF OF ANNUAL SERVICING Spare parts We carry the full range of spares listed below in stock If you order before noon we will dispatch the same day for delivery the next to most locations Tel 01698 820533 TS201 Inlet control set pressure reducing valve strainer and expansion relief valve TS202 Temperature amp pressure relief valve TS3 Tundish TS4 Expansion relief valve cartridge only TS105 2 port valve TS207 Dual thermostat TS9 Immersion heater same on all models TS212 12 litre Expansion Vessel TS27 Single
42. witch Pressure gauge Heating flow Heating return Pressure relief valve Enclosure EHC Fusion E10 Solar Combi Installation and technical manual Page 6 6 Technical specifications General Heating output Electricity Supply Load Current Protection required CH Max temp setting Factory setting CH Min temp setting CH Overheat protection Pump included Recommended pump setting CH Flow and Return pipes Domestic amp Primary connections Min VVater Pressure Max VVater Pressure Expansion Vessels mmersion heater Solar Pump Station Flat sealings ring seal Solar Non return Valve Insulation max temp Connections Cirulation Pump Opperating pressure o gt A 0 0 _ gt gt HC Fusion E10 Solar Combi gt Tl 3 5 E z 2 o 0 o o lt r c 5 lt lt o 12 kW 14 4 kW 30 717 Btu 40 956 Btu 49 147 Btu Cylinder 230 240V single phase 50Hz 39 1 Amps 52 2 Amps 62 6 Amps 45 0 Amps 63 0 Amps 80 0 Amps 85 C 40 C 100 C Yes Maximum 22mm 22mm 1 0 Bar 3 0 Bar 3 0 Bar 7 0 Bar 8 litre 12 litre 3 0 kW Brass Klingerit max 200 Deg C VITON EPDM max 180 Deg C PPS max 180 Deg C EPP max 120 Deg C Continuous and up to 180 Deg C intermittent 0 120 Deg C continuous and up to 180 Deg C IL ILCIEITIETILLCIIL 3 4 IT Wilo Star ST20 6
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