Broughton WB22 User manual

WB22
22Kw PORTABLE ELECTRIC BOILER.
PRODUCT MANUAL
P 1 OF 11

WARNINGS
These instructions should be read by:
The specifying engineer.
The installation engineer.
The user.
The service engineer.
Any failure to follow these instructions may result in risk of •
personal injury or pollution.
The appliance must be installed and serviced by qualified •
engineers, in compliance with local regulations.
Do not switch on if there is a risk that the boiler is frozen. •
Do not attempt to alter factory set digital controller •
parameters.
The appliance must be switched off and disconnected from •
it's power supply before any work is carried out.
There are no user controls inside the appliance casing. •
Do not by-pass or over-ride safety devices. •
A copy of these instructions must be provided to the user. •
Do not run the boiler with the hot water inlet and outlet •
valves closed. This could result in failure of the circulation
pump.
The correct operation of the pressure safety valve must be •
verified before each installation.
Risk of scalding. Always allow the boiler to cool before •
carrying out any work.
Do not exceed the maximum system capacity. •
Always add a rust inhibitor to the system during each installation. •
Failure to add an inhibitor could damage the low pressure water
switch.
Specifications:
The WB22 is a 22Kw 3-phase portable electric boiler.
It is connected to the power supply with a 3P+N+E 32A plug.
The heat exchanger is of a welded mild steel construction and has been
hydraulically tested to 5 bar.
The boiler can be connected to a heating system without the need
for a feed and expansion system.
Maximum system capacity 160 Litres.
The appliance comes complete with: 10 Litre expansion vessel,
circulation pump, pressure gauge, digital thermostat / controller,
safety valve, low water pressure switch, safety limit thermostat and
control switches.
The boiler is suitable for connection to most heating systems with a
maximum working pressure of 3 bar and a maximum working temperature
of 85 C.
P 2 OF 11

Digital controller.
Warning lamp.
Pressure
gauge
Safety pressure valve
Heat exchanger
Control
circuit mcb.
Expansion
vessel
Dust cap
Automatic air vent
Low water pressure
switch.
Heating
elements
Digital thermostat / controller:
The boiler temperature is controlled by a digital controller which is set by
the user to give the desired boiler temperature. This is the set point.
During normal operation the contoller display shows the actual boiler temperarture
not the set temperature.
This controller incorporates a warning alarm in cases of high or low operating
temperatures. Please note ! The alarm acts as a visual warning only and does not
inhibit the operation of the boiler.
P 3 OF 11

Circulation
pump
Heating out
Manual reset safety
limit thermostat
Heating
return
P 4 OF 11

Valve 1.
Hot water
out.
3/4 BSP
Valve 2.
Water return.
3/4 BSP
Valve 3.
System fill
point.
3/4 BSP
Installing the boiler:
Before connecting to the power supply:
The system should be cleansed prior to connection of the boiler and the •
system water should be treated to prevent corrosion.
Connect water pipes to the radiator system or air handler. •
Open valves 1 & 2 on the boiler. •
Loosen the protective dust cap on the automatic air vent. Do not re-tighten. •
Connect a filling hose to valve 3. •
Open all valves at radiators or air handling unit. •
Fill the system to a pressure of between 1 -1.5 bar. Shut off valve 3. •
Bleed any air from the radiators or air handling unit. Top system back up to a •
pressure of between 1 - 1.5 bar. Shut off valve 3. Do not pressurise above 2 bar.
Inspect the entire system for leaks. •
Connect the appliance to the power supply. Press the 'power on' switch. •
The digital controller will illuminate and the circulation pump will operate.
Check the pump operation by feeling the outlet pipe for small vibration.
Set the digital controller set point to the desired temperature. •
The boiler has two power level switches. I=11Kw and I + II=22Kw. Select the •
required setting.
P 5 OF 11

Power on
switch
Power level
switches.
Digital
controller
Warning
lamp
Pressure
gauge
How to change the set point:
How to see the set point:
The set point is the maximum temperature the boiler will operate up to. •
To see the set point push and immediately release the SET key: the display will •
show the set point value.
Push and immediately release the SET key or wait for 5 seconds to display the •
boiler temperature.
Push the SET key for more than 2 seconds to change the set point value. •
The value of the set point will be displayed and the "
C" LED starts blinking. •
To change the set point value push the up or down arrows within 10 seconds. •
The maximum set point is 70 C It is normal for the boiler to cycle a few degrees
above this point.
To memorise the new set point value push the SET key again or wait 10 seconds. •
Set key
Up/down
arrows
P 6 OF 11

Safety devices:
The boiler is fitted with three safety devices. These must not be by-passed or disabled
at any time:
Safety pressure valve: Should the system pressure rise above 3bar the safety •
pressure valve on the bottom of the boiler will open and drain the water.
In this instance please contact your installer.
Low water pressure switch: to prevent the boiler operating with insufficient •
water a low water pressure switch is fitted. Should the water pressure fall below
approximately 0.8 bar this switch will activate the warning lamp and shut the
system down.
Manual reset safety limit thermostat: Should the temperature of the boiler rise •
above 85 C the safety limit thermostat will activate the warning lamp and shut
the system down. In this instance please contact your installer.
Frost prevention:
Do not operate the boiler if there is a risk that it is frozen:
If the boiler is not in regular daily use during cold periods it is recommended that it is •
set to power level I and the set point is lowered to 5 C, this will offer basic frost
protection. Alternatively the system can be fitted with a frost sensing thermostat
to prevent freezing.
Should the temperature of the heat exchanger fall to 1 C a warning will be displayed •
on the digital controller. 'LA'. This is a visual warning only, it does not shut down
the boiler and does not indicate if any radiators or air handler units are frozen.
If the boiler is not used for prolonged periods it is recommended that the system is •
drained.
Maintenance:
For safety reasons it is recommended that regular servicing be carried out by a •
qualified engineer. These should include inspections of the steel heat exchanger
in accordance with local regulations.
During each installation operation of the safety pressure valve and low water •
pressure switch should be verified.
A visual inspection of all cables and terminations should be performed before •
each installation.
P 7 OF 11



Heating element removal:
1
2
When refitting the element ensure rubber sealing washer is present.
Digital contoller alarm codes:
LA....... Low temperature warning. •
HA....... High temperature warning. •
P1........ Temperature probe fail. •
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ELECTRICS PANEL
WB22-16 EXPLODED VIEW
P 9 OF 11

WB22-16 SPARE PARTS
P 10 OF 11
FAULT FINDING

Pump performance curve:
UPS3 Circulation pump error codes.
Rotor shaft seized.
Depress the grub screw at the centre of the pump
and rotate anti-clockwise. Repeat procedure and rotate clockwise.
When the shaft will rotate clockwise the fault has been rectified.
Low supply voltage.
Check power supply to pump and rectify.
Pump failure.
Replace pump.
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