EHC Fusion Comet Series User manual
2
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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
if 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 in 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.
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.
The warranty card must be completed and sent back to The
Electric Heating Company as soon as possible for registration.
An internal Magnetic Filter is fitted to the Boiler and it must be
cleaned at least annually. (Note: Failure to clean the Magnetic
Filter may result in boiler shutdown). Warranty calls will not be
covered for this repair.
INTRODUCTION 2
PREPARATION 3
INSTALLATION 4
INSTALLATION ELECTRIC BOILER INTERNAL LAYOUT 5
COMMISSIONING 6
INSTALLATION 7
ELECTRICAL CONNECTIONS AND CONTROLS 10
EXTERNAL CONTROL WIRING 12
CONTROL PANNEL CONNECTIONS 14
POWER BOARD - CONNECTION 415V 3N~ 39kW 15
POWER BOARD - CONNECTION 415V 3N~ 14,4 -23 kW 16
POWER BOARD - CONNECTION 240V 4-14.4kW 17
EXTERNAL BOILER WIRING 18
BOILER DIMENSIONS 18
USER INSTRUCTIONS 19
FAULT FINDING 21
TECHNICAL SPECIFICATIONS 22
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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
Heating systems in buildings. Design for water-based heating
systems.
Heating systems in buildings. Method for calculation of the design
heat load
Heating systems in buildings. Installation and commissioning of
water based heating systems
Requirements for electrical installations. IEE Wiring Regulations.
Seventeenth edition.
Closed expansion vessels with built-in diaphragm for installation
in water
Materials used in the manufacture of this appliance are non-
hazardous and no special precautions are required when fitting
or servicing this appliance.
A load check should be taken into consideration when installing
high output boilers.
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.
Detailed recommendations are given in BS EN 12828, BS 6700
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.
The boiler can be installed in almost any location within a domestic
or commercial property, however consideration should be given to
future maintenance. Never leave the boiler switched off if there is
danger of having temperatures below 0°C in the room where it is
located.
We recommend that a minimum clearance of 450 mm should be
allocated for the removal of the front cover and 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.
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All Fusion Electric Boilers have a 22mm compression connection
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 connections be
reversed. Hot connections are not recommended at the boiler for
future maintenance and boiler disconnection. Lockshield valves
are recommended.
Remove outer screws at the bottom of the boiler and pull the front
cover outwards taking care to remove internal earth connections.
Earth connections must be re-connected before the boiler case is
re-installed.
We recommend that lockshield isolation valves are fitted on the
flow and return pipework. Such valves must be „full bore” and not
„standard ball valves”. The installation of „standard ball valves” in
the flow and return pipework will reduce the recommended flow
rate through the boiler and promote premature boiler shutdown.
An auto air vent is integral within the boiler however an additional
auto air vent must be fitted at the cylinder coil if the boiler is being
used for central heating and domestic hot water.
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.
Where practical, and if at all possible, we recommend that all
pipe-work be 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).
The boiler has an integral automatic bypass valve fitted which
should be set to the relevant settings to allow the minimum
flow rates to pass through the boiler (8 l/min) when all radiator
thermostats and zone valves are closed.
Allowance should be made for a radiator to be installed within
the heating circuit and locked open. This will be located in the
room that has the room thermostat installed.
To comply with building regulations, Part L and Part J (in Scot-
land), room and cylinder stats must be fitted.
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.
The system 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 - Flushing & System Protection.
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 Expansion
Vessels.
In order to protect the Flow Sensor located within the boiler, it is
imperative that the 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.
The Fusion Comet range of boilers can be used in various system
designs. Please refer to The Electric Heating Company for more
details on our Fusion Boiler for under floor heating. We are able
to supply a 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 thermostat fitted.
This radiator should be fitted with lock shield valves and left in
the fully open position.
The boiler has an integral automatic bypass valve fitted which
should be set to the relevant settings to allow the minimum
flow rates to pass through the boiler (8 l/min) when all radiator
thermostats and „zone valves are closed”.
Systems should be designed to meet the current building
regulations in force at the current time.
1. Hang the boiler in a vertical position on the fixing points and
screws provided, with the flow and return connections to the
bottom of the boiler, maintaining the clearances as per Figure
12 of this manual.
2. Connect the boiler to a heating system that is equipped with
isolation valves (see Figures 4 & 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 to the „mains” electrical system as per
Figures 6, 8, 9 & 11
5. Connect the room thermostat / Programmer using the two
control conductors marked RP as in Figure 7 & 10.
6. For all other electrical connections refer to the ELECTICAL
CONNECTIONS & CONTROL section of this manual.
5
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[1] - StainlessSteelHeatExchanger
[2] - FlowSensor
[3] - PressureSensor
[4] - SafetyValve
[5] - CirculatingPump
[6] - SafetyTemperaturelimiter
[7] - Returnconnection
[8] - Flowconnection
[9] - PowerBoard
[10] - ControlModule
[11] - AutomaticVent
[12] - Expansionvessel
[13] - By-passValve
[14] - MagneticFilter
PF - Internal„mains”phaseconnectionsfromthePNconnectionblock
PN - Incoming‘mains’cableconnectionblock
WP - Electriccableaccess
M - Boilerfixingpoints
RP - ExternalControls(VoltFree)
Electrical ‘mains’ input
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TURN ON THE ELECTRICAL POWER SUPPLY TO THE BOILER. MAKE SURE THAT THE PROGRAMMER IS NOT CALLING FOR HEAT
AT THIS STAGE!
1. Check the pressure in the potable vessel is set to 3 Bar.
2. Check that all plumbing connections are tight.
3. Open the furthest away tap outlet.
5. Turn on the mains water supply to the unit.
6. It will take a few minutes to fill the cylinder, once the water comes through the tap outlet let it run.
7. Open the other hot water outlets and purge all air out of the system.
8. Once fully purged close all the outlets and further check for leaks.
THE PRIMARY CIRCUT MUST BE FLUSHED IN ACCORDANCE TO BS 7593
1. Connect the primary filling loop and tighten.
2. Make sure that all primary connections are tight before filling.
3. Open the filling loop and allow the system to start filling.
4. Press the right arrow key on the boiler control panel until the A (bar) led is illuminated.
5. fill the system to 2 bar, then start to purge the radiators until all the air is out the system.
6. This will have to be repeated several times to fully purge the system re-filling as you go.
Failuretoprotectthesystemwillinvalidatethemanufacturer’swarranty.
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 F3 cleaner to the system at the furthest point from the boiler, this is to allow the substance to fully dilute throughout the
system. If you are unsure of the correct dose rate, contact Fernox on 03301007750 for advice.
3. Re-fill the system and circulate the F3 cleaner prior to the boiler being fired up. Commission the system in the normal way. The
cleansing agent must be in the system for a minimum 1 hour with the system running at normal operating temperature. A longer
period of time would be more beneficial to the cleansing process especially if excess flux was used or is an old system. F3 cleaner
can be left in the system for up to a maximum of one week running on a normal heating cycle. (We recommend that existing systems
are power flushed as per BS 7593 and PAS33 regulations)
4. Drain and flush the system thoroughly to remove the cleaning agent and any debris or contaminants. 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. After the system has been thoroughly flushed and TDS readings are within 10% you can now add Fernox F1. This will protect against
the formation of scale, corrosion and microbiological growths. It is crucial however, that for the protector to work correctly, the
system must be properly cleansed and flushed.
6. Now attach the label included within the Fernox F1 packaging completed and attached adjacent to the boiler.
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. Fernox Technical Service Help line on 0870 870 0362 for further assistance.
7
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LED 1
2
3
4
5
LED
Rated
power
[kW]
Pump lifting
height [m]
LED 1
red
LED 2
yellow
LED 3
yellow
LED 4
yellow
LED 5
yellow
4● ●
6-9 5 ● ● ●
9-12 6 ● ● ● ●
14 - 39 7 ● ● ●
If the pump has detected one or more alarms, the bicolored LED
1 switches from green to red. When an alarm is active, the LEDs
indicate the alarm type as defined in the table below. If multiple
alarms are active at the same time, the LEDs only show the error
with the highest priority. The priority is defined by the sequence of
the table. When there is no active alarm anymore, the user interface
switches back to operation mode.
One red LED + one
yellow LED (LED 5)
Rotor is
blocked.
Trying to start
again every 1,5
seconds
Wait or
deblock the
shaft.
One red LED + one
yellow LED (LED 4)
Supply volt-
age too low
Only warning
pump runs
Control the
supply volt-
age
One red LED + one
yellow LED (LED 3)
Electrical
error
Pump is stopped
because of low
supply voltage or
serious failure
Control the
supply voltage
/Exchange the
pump
IF SUPPLIED WITH THE GRUNDFOS UPM3 PUMP
1. Ensure the system is filled with water and correctly vented.
2. Check if the appropriate system installation pressure is reached
(see the “TECHNICAL DATA” section) by pressing the down
arrow button whilst the control panel is off, the pressure value
will be displayed. When the installation pressure is too low The
“A’’indicator flickers (see “Operating’’ section). This doesn’t
concern open vented system installations.
3. Set the external controls to call for heat.
4. Switch the boiler on by pressing the power button.
5. Check the pump is set to the correct mode (see table 15.1).
To do this, press the pump arrow button for no more than 2
seconds. The LED’s should signal an operating mode at the
place pointed by arrow.
6. If the LEDs are signalling a different operating mode than
recommended in table 15.1, set the appropriate mode according
to the following instructions: press the pump arrow button for
longer than 2 seconds, but less than 10 seconds (LED’s will start
to flash),the pump then switches to the programming mode.
LEDs glows to indicate the current settings. To change the
settings of the pump in accordance with table 15.1, you can set
the right combination of glowing LEDs by pressing the pump
arrow button. Once the LED combination is set correct, by not
pressing the button for 10 seconds the pump will remember
this setting and will exit from the programming mode back to
performance view.
7. Ensure adequate flow through the boiler is reached (the ‘H’
indicator is on with a constant light). The pump should self vent
after a short period of running. If necessary assist the venting
process in the following way; Warning the screw head in the
centre of the pump is not intended to be used to assist venting
of the pump, Damage to the pump internals may occur!
• close the isolation valve on the outlet,
• leave boiler running for 15 sec.
• open the isolation valve.
8. Set the external controls to the required program and the boiler
to the required system temperature, see the “Operating” section.
Table 15.1
Table 15.2
8
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Temporary
Filling Loop
Mains Water
Supply
9
GB-031C_f
Temporary
Filling Loop
Mains Water Supply
10
GB-031C_f
„”
RCD as the boiler itself. Where a single phase boiler is installed within
a 2 Phase or 3 Phase installation the control circuit should also be
supplied by the same phase as the boiler. The control circuit should
be protected by a 6Amp
MCB. The Boiler & control circuit RCD should be independent of all
other domestic circuits. The boiler supply cable should be calculated
by the means of a cable calculation in accordance with BS7671 by
a suitably qualified electrician.
The recommended protection for hard wired boilers are as
follows:
Model No Boiler size Protection (per phase)
38.7kW BOILER 3x63 AMP Protection
22.6kW BOILER 3x32 AMP Protection
14.4kW BOILER 3x32 AMP Protection
12kW BOILER 3x20 AMP Protection
14.4kW BOILER 80 AMP Protection
12kW BOILER 63 AMP Protection
9kW BOILER 50 AMP Protection
6kW BOILER 32 AMP Protection
We recommend the use of the EHC SINGLE CHANNEL
PROGRAMMER and EHC ROOM THERMOSTAT for heating only
installations.
For Heating and Hot water installations, we recommend the
use of the TWIN HEAT PACK which includes the EHC ROOM
THERMOSTAT & AN EHC 2 CHANNEL PROGRAMMER.
The TWIN HEAT PACK will incorporate all the relevant parts to
comply with current building regulations i.e. Motorized valves to
control the heating and hot water circuits and Room and cylinder
thermostats to control the room and water temperatures. 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.
Load check must be taken into consideration when installing high
power boilers. This will be carried out by a qualified electrician.
There may be an additional requirement to upgrade the incoming
main fuse supplying the property if other high power devices are
used within the property. E.g Electric Showers. If an electric shower
is present we recommend that a Shower Sensor is installed within the
system. This will cause an interrupt to the boilers control signal when
the shower is in use. It will disable the boiler protecting the electrical
system from overload.
All boilers Must be protected with a 30mA dou- ble pole RCD with
a minimum of 3mm contact separation accompanied by a suitably
rated MCB. If the boiler is not fitted local to the meter position then
an additional isolation switch must be fitted local to the boiler for
each supply.
If the property is supplied by a rural power supply or prone to
lightening strikes & power cuts it is recommended to install a suitable
surge protection device to the boiler supply. This will reduce the risk
of damage to the boiler electronics during these events.
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
and issued to the customer.
Never open the front cover of the boiler until all power supplies to the
boiler have been disconnected.
The boiler connections are clearly marked inside the boiler L N E
(24hr LIVE).
The 24hr live is the permanent Feed connection to the boiler from
the mains supply. External controls will require an independent fused
spur supplied from the same consumer unit & protected by the same
11
GB-031C_f
After the cleansing and protection of the system has been carried out,
set the external controls to the customers selected times.
If an off-peak electric meter has been installed by an Electricity
Company to supply OFF-peak rate electricity at selected times, the
appropriate settings should be entered into to the system programmer
to take advantage of the OFF-peak rate electricity.
The boiler has an inbuilt pressure sensor. If the boiler has been
switched on with a low or no water content, the system will sense
this and prevent the boiler from sending power to the main elements.
The stat / programmer connections are clearly marked within the
boiler.
Only after all connections have been made and checked should the
system be filled with water and set to the proper pressure 1.5 bar
(Sealed systems).
Check the system for leaks. If water leaks into the boiler this may
damage the boiler electrics and the manufacturers warranty will be
invalid.
Under no circumstances should the boiler be switched on when the
system is dry.
„”
„”
12
GB-031C_f
PROGRAMMER ROOM
THERMOSTAT 1
11 12 13 14 16
15
N L
N L
1
HTG 1 Call
3
EC10001 - 1 Channel
COM Call
Volt free
Control
Connections
3A Switched
Fuse Isolator
6Amp
240V
50Hz
Supply N
NOTE!
RP...are Volt free Contacts
(Non Standard Volt Free Switching)
13
GB-031C_f
(Non Standard Volt Free Switching)
PROGRAMMER ROOM
THERMOSTAT 2
ROOM
THERMOSTAT 1
DUAL CYLINDER
THERMOSTAT
11 12 13 14 16
15
N L
N L
3 4
357
HTG 1 CallHTG 1 Call
HW Call HTG 2 Call
EC10002 - 2 Channel
EC10003 - 3 Channel COM Call
Volt free
Control
Connections
3A Switched
Fuse Isolator
6Amp
240V
50Hz
Supply N
NOTE!
RP...are Volt free Contacts
COM Call
COM Call
COM
16 Way
Junction Box
BL
HC10008 HC10008 HC10008
HW Zone Valve HTG Zone Valve 1 HTG Zone Valve 2
BR GR OR BL BR GR OR BL BR GR OR
Product: EC10010
Description: 16 Way junction box
--------------------
Optional 2nd
heating zone
230V~10A 50Hz ClassII -15T55 BS6220 FIXED
WIRING MAX 1.5mm
14
GB-031C_f
„”„”
15
GB-031C_f
L1 N
L2 L3
Grz 1
Grz 2
Grz 3
Grz 4
Grz 5
Grz 6
L1
L2
L1 L2
L3
L3
G1 G1
G2
G2 G3
G3 G4 G5
G5 G6 G4 G6
P
R
F
N L PUMP
L N
red
blue
Ground
Power supply 230/400V~
16
GB-031C_f
Power supply 230/400V~
UN
Ground
H.e 1
H.e 2
H.e 3
red
blue
L3 G3 L2 G2 L1 G1 N
VW
P
R
F
N L PUMP
L N
17
GB-031C_f
Power supply 230/400V~
UN
Ground
H.e 1
H.e 2
H.e 3
red
blue
L3 G3 L2 G2 L1 G1 N
VW
P
R
F
N L PUMP
L N
18
GB-031C_f
Return Inlet Flow Outlet
710
19
GB-031C_f
R
F
P
ControlPanelKey
A - Waterpressureindicator(bar)
B - Waterflowrateindicator(l/min)
C - kWindicator
D - Watertemperatureindicator(°C)
E - Digitaldisplay
F - SummerMode
G - CallforHeat
H - Pumpoperationindicator
I - Returntemperatureindicator
J - Flowtemperatureindicator
K - Boilerheatingindicator
Heat Indicator.
• „on” – calling for heat,
• „off” – the required temperature has been reached – no call for heat is required,
• Flashing – NA entry is open – (external boiler interrupt active).
P Pump Indicator.
• „on” – pump is active, proper flow rate of water has been reached,
• Flashing – lack of flow or insufficient flow rate of water – heating elements are off.
Temperature Indicator.
• Red light – Boiler is in heating mode.
• Green light – Boiler temperature has been reached in radiators.
Indicator flashing – water pressure is not sufficient (below 0.5 bar).
When boiler is in Summer Mode (i.e. switched off) indicator will blink.
Indicator flashing – relative temperature sensor failure.
Indicator flashing – relative temperature sensor failure.
Messages on electronic display – data record error.
– parameter out of range or a temperature sensor failure.
20
GB-031C_f
Unlike other system boilers such as Gas, Oil and Propane the
FUSION „Comet” range 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 thermostat or programmer is calling for heat.
2.1 Switch the boiler on by pressing the button. (Note: When
switching the boiler off use the same button by pressing
and holding it in for 3 seconds.).
2.2 The recommended Water Pressure is approx 1.0/1.5 bar and this
can be checked by pressing the button until indicator A is
illuminated. The water pressure can be adjusted by connecting
the external filling loop and pressurizing to the desired pressure.
Note: the filling loop must be disconnected after the system
has been re-pressurised.
2.3 First set the required Boiler Temperature (we recommend
a setting of 65
0C) by pressing the button until only indicators
D and K are illuminated. Press the button or the button
until the desired temperature setting is achieved.
2.4 Ensure the room thermostat is switched on and is calling for
heat. If the boiler is not yet at the desired heat setting then
indicators D, G, H, I, J & K will be illuminated. Indicator K
illuminated in red. Once the room has reached the required
setting the K indicator should change from red to green. Refer
to the Control Panel diagram above to learn how to adjust to
the right temperature to make the boiler work comfortably and
economically.
2.5 EHC recommends adjusting the pump settings and system Flow
Rate to best suit the system design during the installation of the
boiler. To check this setting press the button a number of
times until only indicator B is illuminated and then read the
figure on the digital display. The minimum permissible system
flow rate for the by-pass circuit should be set to 8L/min, If the
system flow rate figure is well below the 8 L/min call a Service
Engineer for assistance. The boiler will enter fault mode if the
flow rate drops below 5L/min and therefore blocking any further
heating until the flow rate is improved.
2.6 To check the amount of kW energy being used by the boiler
at any point in time press the button a number of times
until only indicator C is illuminated. The Kw figure will now
be shown.
2.7 When indicator H is illuminated the pump is running.
We recommend the boiler temperature be set to 65°C. Raise or
lower the temperature in your installation with the buttons on
the right hand side of the control panel as per 2.3 in the previous
section.
„”
The customer has the option to switch the boiler onto „stand-
by” mode during summer months and this can be carried out by
pressing the „button and holding this in for 3 seconds”.
All indicators will go off except the F indicator which will
intermittently illuminate.
In the „stand-by” mode all the boiler functions are switched off
except the circulation pump. This is activated for 15 minutes
each day which protects the boiler and the whole central heating
system from being blocked and silted up. In this „stand by” mode
the circulation pump will run each day at the same time. (e.g. If
you switch the boiler to „stand by” at 6pm then the circulation
pump will run every day at 6pm for 15 minutes) To return to
a „Winter” mode setting press and hold the button for 3
seconds again.
In the Winter mode setting the digital display will be active and
will show the temperature of the water at various points within
the boiler. Those indicators which are illuminated will show
the current status of the boiler. If the boiler is being called for
heat by the thermostat then the G, H, I, J & K indicators will be
illuminated. In the winter mode both the two port valves are
active and they will direct heat as required.
Width 418 mm
Height 710 mm
Depth 251.5 mm
This manual suits for next models
6
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