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 Electric Flow Boiler InsTallaTIon & TEchnIcal Manual2 GB-063C_f.706,7 Please read and follow the installation operating instructions carefully, to ensure the long life and reliable operation of this appliance. The Electric Heating Company may make minor changes when necessary to the appliance that will not be shown in this document, 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 work- manship in the manufacture of the boilers. 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 authorised by the Electric Heating Company Ltd. The warranty will not cover any water leaks into the boiler that may cause damage to the electrical or elec- tronic control system. All plumbing connections must be checked and auto air vents positioned to the side of the boiler and not directly above the unit. A Magnetic Filter must be installed to the boilers return pipe work before the circulation pump. It is recom- mended that the filter is cleaned; failure to clean the Magnetic Filter may result in boiler/system failure. War- ranty calls will not be covered where the above requirements have not been met. The “Slim Jim” boiler is a low temperature boiler intended for use in unvented or vented central heating systems with forced circulation. (Protected according to legally binding directives). This appliance 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 the use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not operate or interfere with the appliance. Page Contents INTRODUCTION 2 PREPARATION 4 LOCATION 4 GENERAL 5 BOILER INTERNAL LAYOUT 7 INSTALLATION 8 SYSTEM PROTECTION - COMMISSIONING 11 ELECTRICAL CONNECTIONS 12 ELECTRICAL CONNECTIONS 14 ELECTRICAL DIAGRAM 15 EXTERNAL CONTROL WIRING 17 BOILER CONTROL PANEL 18 TECHNICAL SPECIFICATION 19 INTRODUCTION3 GB-063C_f.706,7 Boiler Features. • Option of Volt Free OR 240 volt Control Signalling • Water Level Sensor • High Current Safety device • Low Maintenance • Boiler Power Output Selector • Easy to use Controller The central heating system, in which the Slim Jim boiler is being installed into, must be fitted with the following: Vented Systems: • Circulation Pump • Pump Valves • F&E Tank • Magnetic Filter • Automatic Bypass if Req Sealed Systems: • Circulation Pump • Pump Valves • Magnetic Filter • Automatic Bypass if Req • Sealed System Kit • Automatic Air Vent 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 Heating systems in buildings. Design for water-based heating systems. BS EN 12831 Heating systems in buildings. Method for calculation of the design heat load. BS EN 14336 Heating systems in buildings. Installation and commissioning of water based heating systems. BS7671 Requirements for electrical installations. IEE Wiring Regulations. Seventeenth edition. BS EN 13831 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 re- quired when fitting or servicing this appliance. 4 GB-063C_f.706,7 1. Load Check A load check must be taken into consideration when installing high power boilers. This can be carried out by a qualified electrician. There may be a requirement to upgrade the main incoming fuse supplying the property; this will depend on the boiler output being installed and existing electrical load requirements of the property. 2. Boiler location The boiler must be installed onto a wall that will provide an adequate fixing. Precautions must be taken if the boiler is to be installed in areas subject to damp or frost conditions. 3. Central heating (design & installation) Detailed recommendations are given in BS EN 12828, BS 6700: +A1 and CP 342-2. Pipes forming part of the useful heating surface should be insulated to prevent any potential heat loss or frost damage. (BS 6700). 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 and copper tube to BS EN 1057 is recommended. PREPERATION LOCATION The boiler can be installed in almost any location within a domestic or commercial property; however con- sideration should be made for future maintenance. Never leave the boiler switched off if there is a danger of having temperatures below 0°C in the room where it is located, (An additional frost stat must be used if there is a likelihood of the temperature falling below 0°C). We recommend that a minimum clearance of 400 mm should be allocated for the removal of the front cover to allow adequate access to the boilers plumbing and the internal electrical connections. A 50mm allowance should be made at either side of the boiler to allow free flow air into the boiler. ! The boiler must be installed in the upright position; failure to do so will invalidate the Warranty!5 GB-063C_f.706,7 GENERAL 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 certified Electrician. The Electric Heating Company Ltd will not be held responsible for any faulty installations which are performed by unqualified tradespersons. 2. Pipe Connections Slim Jim Electric Boilers have 22mm compression connections at the boiler’s flow and return pipes. Please note that the boilers are supplied with blanking plugs for transit purposes. These must be removed before connections to external pipes can be made. The Flow Outlet (Top Red Connection) and Return Inlet (Bottom Blue Connection) are clearly marked within the boiler case. Under no circumstances should these connections be reversed. Hot Soldered Joints should not be made as a direct connection to the boiler, Compression joints should used. 3. Case Removal In order to take off the front cover, undo the fixing screws at the top and bottom of the unit and pull the cover toward you, Care should be taken not to damage the front controller. 4. Isolation Valves We recommend that lock-shield isolation valves are fitted on the Flow and Return pipe-work. Such valves must be full bore and not “ball valves”. The installation of “ball valves” in the flow and return pipe-work will reduce the recommended flow rates through the boiler. ! Care must be made when installing the isolation valves that the PRV and expansion positions are not impaired. 5. Auto air vents An auto air vent must be fitted to the external pipe work when installed in an unvented system. ! Do not install AAV’s directly above the SlimJim boilers. AAV’s should be installed to either the top left or right hand side of the boilers. (This is to prevent any water entering the boiler in the event of an AAV leaking). 6. Boiler Sizing Calculate the “Space Heating” requirements in accordance with BS EN 12831 and 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 to determine the correct boiler output. 7. Insulation Where practical, and if possible, we recommend that all pipe-work is insulated, in particular the primary pipe-work within a boiler cupboard. This is to reduce heat loss and reduce high cupboard temperatures from exposed pipe-work. (BS 6700 +A1). 8. System Design As the SlimJim boilers are of low water content an open circuit must be achieved incorporating approx 2 metres of continuous 22mm pipe work after the boiler connections and before any zone valves. (S Plan) We also recommend that a magnetic filter is used and installed into the return pipe work of the system before the pump as per the schematic on page 10. Provision should be made to allow the filter to be cleaned without draining the full heating system.6 GB-063C_f.706,7 ! We recommend the use of an automatic bypass within this circuit. If a bypass radiator is used an allowance should be made for a minimum radiator size 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 where the thermostat is installed). To comply with building regulations, Part L and Part J (in Scotland), room and cylinder thermostats must be fitted. 9. Water Connections 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 central 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. 10. Flushing The system must be flushed to within 10% of mains water PPM to ensure that no debris is trapped in the system as this may result in boiler failure. Where existing radiators and pipe-work are utilized a power flush must be carried out to remove debris. For further guidance please see section 14 - Flushing & System Protection. 11. System Pressures All boilers are pressure tested in the factory. 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 Expansion Vessels. ! It is imperative that a pre-installed magnetic filter is removed and cleaned annually. Failure to carry out this action will increase contamination of the boiler by the system residue.7 GB-063C_f.706,7 Figure 1 1 - Flow Outlet Connection 2 - Run Dry Sensor 3 - Outlet Temperature Sensor 4 - Heat Exchanger 5 - Power Board 6 - Contactor 7 - WT3 Safety Thermal Cut-Out 8 - Inlet Temperature Sensor 9 - Control board 10 - Return Inlet Connection 11 - Pump & Control Cable Entry Points 12 - Main Power Entry Point 13 - Front Control Panel 1 2 3 6 5 7 8 9 10 11 12 13 4 ! The boiler is fitted with a safety temperature cut-out that protects the boiler from failure. The safety temperature cut-out (Item 7) cuts the power to the boiler if the temperature reaches approx 100°C. if this occurs the boiler will shut off the main power to the unit. A service engineer will be required to re-set the boiler. However further investigation will be required to identify the cause of the fault. BOILER INTERNAL LAYOUT 8 GB-063C_f.706,7 12. System types The “Slim Jim” boiler range can be used in various system designs including under floor systems. There are two heating schematics on page 10 Figure 1 & 2 that illustrate an Indirect System (S Plan) & Direct System (Heating Only). We recommend the use of Thermostatic Radiator valves on all radiators excluding the bypass radiator; this radiator should be fitted with lockshield valves and left in the fully open position. In addition we recommend that an automatic bypass is used in zoned systems and set to the relevant flow rates required for the system design. (The bypass radiator should be a minimum size 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 same area as the room thermostat). ! The system design should meet all current building regulations in force at the time of installation. 13. Hanging the Boiler 1 Take care when removing the boiler from its packaging. Do not open with sharp objects as this may damage the unit. 2 Hang the boiler in a vertical position using the template and screws provided within the boiler packaging. Take care to leave all the recommended clearances as shown in the schematic drawing below. 3 A Clearance of approx 400mm at the front of the unit is recommended to allow access for any future maintenance that maybe required. INSTALLATION M4x8 M4x8 130 200 203 130 min.50 min.50 Front Cover Fixing ScrewsBoiler Dimensions & Fixing Positions9 GB-063C_f.706,7 Figure 2 aav Expansion Vessel Pump Magnetic Filter Gauge PRV Flow Return Filling Loop Auto Bypass aav HW Cylinder Zone valve Zone valve Pressure aav Expansion Vessel Pump Magnetic Filter Gauge PRV Flow Return Filling Loop Auto Bypass Pressure Figure 1 ! The boilers may also be configured to run multi zone heating systems or under floor heating circuits if required.Next >