EHC FUSION Series User manual

2
GB-016C_f.783,2
INTRODUCTION
Please read and follow the installation and operating instructions
carefully, to ensure the long life and reliable operation of this
appliance.
The Electric Heating Company may make minor changes
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 are a user
or external control fault.
The warranty will not cover water leaks into the boiler. All
plumbing joints must be checked.
The warranty card should be completed and sent back to The
Electric Heating Company as soon as possible for registration.
A magnetic filter must be fitted to the system in the horizontal
position and cleaned every 12 months.
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
use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Page Contents
INTRODUCTION 2
PREPARATION 3
INSTALLATION 4
ELECTRICAL CONNECTIONS AND CONTROLS 8
EXTERNAL CONTROL WIRING 9
INTERNAL BOILER WIRING 10
EXTERNAL BOILER WIRING 13
BOILER DIMENSIONS 13
USER INSTRUCTIONS 14
FAULT FINDING 18
TECHNICAL SPECIFICATIONS 19

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GB-016C_f.783,2
PREPARATION
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 required when fitting or servicing this
appliance.
PREPARATION
1. Load Check
A load check should be taken into consideration when installing
high output boilers.
2. Boiler location
The boiler must be fitted on a wall that will provide an adequate
fixing, and should be fitted in a location that the boiler and pipe
work are not subject to frost and damp conditions.
3. Central heating
Detailed recommendations are given in BS 5449, BS 6700 and
CP 342, Part 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 2871. Part 1 is recommended.
LOCATION
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.
MOUNTING THE BOILER
Mount the boiler onto a flat wall surface that will be capable
of taking the boilers full weight. Use the mounting template
provided with the boiler, mark and drill the fixing holes taking
into consideration you leave the minimum clearances required
around the fusion boilers.
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 (150 mm for Slimline model).
THE BOILER MUST BE INSTALLED IN THE UPRIGHT POSITION,
FAILURE TO DO SO WILL INVALIDATE THE WARRANTY.
Fusion boiler
48 Fusion boiler

4
GB-016C_f.783,2
INSTALLATION
The boiler must be installed by a professional plumber or heating
engineer and must be connected to the power supply by a qualified
electrician.
The Electric Heating Company Ltd will not be held responsible
for faulty installations which are performed by unqualified
tradespersons.
1. Pipe Connections
All Fusion Electric Boilers have a 22 mm compression connection
at the boiler’s flow and return pipes however the 48kw version
has 28mm compression connections. Please note that the boilers
are supplied with blank washers fitted for transit purposes. These
must be removed and replaced with the washers supplied. The 2
spare pcb fuses supplied must be left inside the boiler.
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
2. Case Removal
Remove outer screws from boiler case and push upwards and
outwards taking care to remove internal earth connections.
(Slimline model: remove screws on the right hand side and swing
the boiler case open).
Earth connections must be re-connected before the case is reinstated.
3. Isolation valves
Consideration should be made for the provision of lockshield
isolation valves on the flow and return pipe-work. Such valves
must be full bore and not ball valves.
We recommend isolation valves on each side of the magnetic
filter.
The insertion of ball valves will reduce the recommended flow
through the boiler and promote premature boiler shut down
caused by poor flow rate.
4. Auto air vents
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.
5. Boiler Sizing
Calculate the space heating requirements in accordance with BS
5449. If the boiler is to heat the domestic hot water, an allowance
of 3kw (10,239 Btu’s ) should be made.
6. Insulation
Where practical and if at all possible, we recommend that all
pipe-work be insulated, in particular the primary pipe-work
within the boiler cupboard. This is to reduce heat loss and reduce
high cupboard temperatures from exposed pipe-work. (BS 6700).
7. System Design
As the boilers are of a low water content an open circuit must be
achieved incorporating 2 metres of continuous 22 mm pipe-work
after boiler connections and before any zone valves.
We recommend the use of an automatic bypass within this circuit
and set to the relevant settings to allow the minimum flow rates to
pass through the boiler (8 l per min) when all radiator thermostats
close.
Allowance should be made for a minimum size radiator of 600mm
x 600mm single convector or equal to 2500 Btu to be installed
within the heating circuit and locked open. This will be located
in the room that has the room stat installed.
To comply with building regulations, Part L and Part J (in Scotland)
room and cylinder stats must be fitted.
8. Water connections
Provisions must be made for the replacement of water lost from
the heating system (sealed systems). Reference should be made to
BS 6798, for the methods 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. Any connection made must be disconnected after use.
9. 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 - Flushing & System Protection.
10. System pressures
All boilers are tested to 4.0 bar. The normal working pressure of
the boilers should be set to 1.5 bar. All sealed systems should
comply with the relevant building regulations and standards and
to BS 4814, (Specification for Expansion Vessels).
Please Note
In order to protect the Flow Sensor located within the boiler, it
is imperative that you install a mechanical-magnetic filter on the
return inlet to the boiler. This will enable you to clean the filter
at regular intervals and will also ensure that the boiler does not
become contaminated by system residue.

5
GB-016C_f.783,2
11. System types
The 6, 9, 12, 14.4, 36 & 48kW 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 also recommend the use of thermostatic radiator valves on all
radiators except in the room that has the wall thermostat fitted. If
a bypass radiator has been used in the system, it should be fitted
with lock shield valves and left in the fully open position.
If a bypass radiator has not been used then a system bypass of 2
metres of 22 mm copper pipe incorporating an automatic bypass
valve must be used and can be set to 8l/min from the front control
panel.
Systems should be designed to current building regulations.
12. Expansion vessels
All boilers up to 36kW have an internal 6L expansion vessel,
where the system volume is greater than 50L an additional
external expansion vessel of suitable size will be required. The
48kW fusion does not come with an integral expansion vessel
therefore it is the installers responsibility to correctly size and
install an expansion vessel within the system.
Water Loss
If water loss occurs due to natural evaporation, leakage or any
other breakdown in water seals, the boiler will not operate.
The boilers flow sensor needs a minimum of 5 litres per minute
to operate. If this cannot be achieved the boiler will shut down.
We recommend a minimum flow setting of 8l/min.
Investigation
Should BOIL OVER/ BOIL DRY /WATER LOSS occur, investigation
as to why the system has failed MUST take place. Power should
only be reinstated after the fault has been rectified.
The main overheat stat on the boiler can be re-set, this is
positioned at the top of the boiler market WT3. To re-set, push
the brass pin with a small screwdriver. The pin will click into
place when re-set.
ENSURE THAT THE MAINS POWER SUPPLY TO THE BOILER IS
SWITCHED OFF PRIOR TO RE-SETTING.
13. Commissioning
IMPORTANT:
TURN ON THE ELECTRICAL POWER SUPPLY TO THE BOILER.
MAKE SURE THAT THE PROGRAMMER IS NOT CALLING FOR
HEAT AT THIS STAGE!
FILL ING THE HOT WATER CIRCUT. (If Applicable)
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
Note: Make sure that the filling loop is closed at this stage!
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
FILLING THE PRIMARY HEATING CIRCUT.
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.
System protection:
Failure to protect the system will invalidate the manufacturer’s
warranty.
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 Helpline on 0870 870 0362 for

6
GB-016C_f.783,2
LED
1 2 3 4 5
LED
14. Start-up / commissioning
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 referring to the pressure
gauge at the bottom left of the boiler
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.
Note: holding the pump arrow button for more than 10 seconds
will enter the pump into key lock mode. This prevents the user
from altering the pump settings. To remove the key lock and
allow the pump settings to be changed, hold the pump arrow
button again for more than 10 seconds.
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.
In the case of a seized pump impeller due to a long layover out
of the heating season and simultaneous non-compliance with the
recommendation to cycle the pump every couple of days, please
restore proper movement of the impeller. To do this, please use
PH2 screwdriver, press and turn the screw anti-clockwise, located
in the middle of the front panel of the pump (Figure 3) until the
pump impeller is spinning freely.
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 ● ● ●
9-1-14 6 ● ● ● ●
14 - 36 7 ● ● ●
Alarm status
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.
Display Indication Pump
operation
Counter
action
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 voltage too low Only warning pump runs Control the supply voltage
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
Table 15.2
Table 15.1

7
GB-016C_f.783,2

8
GB-016C_f.783,2
ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH
CURRENT IEE REGULATIONS. BS 7671
ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED
ELECTRICIAN.
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 at the meter position with a 30mA
double 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 prone to lightening strikes or 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.
THIS APPLIANCE MUST BE EARTHED.
All pipe work must be earthed in accordance with the current IEE
Regulations – BS 7671
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 until all power supplies to the boiler
have been disconnected.
ELECTRICAL CONNECTIONS
The boiler connections are clearly marked inside the boiler L N
E (24hr LIVE).
The 24hr live is the permanent Feed connection to the boiler from
the mains supply. External controls will require an independent
fused spur supplied from the consumer unit, however this fused
spur should be supplied by the same power source & protected
by the same RCD as the boiler itself, 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.
Boiler Protection
The recommended protection boilers are as follows:
Model No. Boiler size Protection
FUSION 48Kw 48kW BOILER 80 AMP Protection Per Phase
FUSION 36Kw 36kW BOILER 63 AMP Protection Per Phase
FUSION 14.4kW 14.4kW BOILER 80 AMP Protection
FUSION 12kW 12kW BOILER 63 AMP Protection
FUSION 9kW 9kW BOILER 50 AMP Protection
FUSION 6kW 6kW BOILER 32 AMP Protection
External controls
We recommend the use of the EHC SINGLE CHANNEL PROGRAMMER
and ROOM THERMOSTAT for heating only installations.
For Heating and Hot water installations, we recommend the
use of our “Twin Heat Pack” which includes the EHC ROOM
THERMOSTAT & AN EHC 2 CHANNEL PROGRAMMER. The
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.
Note: this control method is to comply with current building
regulations provided by BEAMA (British Electrotechnical and Allied
Manufacturers Association).
Programmer/Stat connections
The boiler PCB has a voltage free connection for the controls
(RP). Under no circumstances should 240V be connected to the
controller block as this will damage the boiler’s PCB and Void
the Manufacturers warranty.
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.
The boiler has an inbuilt flow sensor. If the boiler has been
switched on with a low or no water content, the system flow
meter will sense this and prevent the boiler from sending power
to the main elements.
If an off-peak electric meter has been installed by an Electricity
Company to supply uninterrupted 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.
ELECTRICAL CONNECTIONS AND CONTROLS
CONTROL PANEL WIRING CONNECTIONS
To main
control
board
Flow sensor
Outlet ow
sensor
connection
Inlet return
sensor
connection
Volt free
control
connection
To main control board
Flow sensor
Outlet ow sensor
connection
Inlet return sensor
connection
Volt free control
connection
UNDER NO CIRCUMSTANCES
SHOULD A VOLTAGE BE
TAKEN TO THE NA OR RP
CONNECTION AS THIS WILL
DAMAGE THE CONTROL
PCB AND INVALIDATE THE
WARRANTY
Q
Tout
Tin
NA

9
GB-016C_f.783,2
EXTERNAL CONTROL WIRING
Heating Only Wiring (Non Standard Volt Free Switching)
Heating & Hot Water Wiring: S Plan (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
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

10
GB-016C_f.783,2
INTERNAL BOILER WIRING
6, 9, 12, 14.4kw 240v~

11
GB-016C_f.783,2
E1 - heating box M1 - Circulating pump F1 - WT-3 safety cut-off A1 - Front panel BV - flow sensor A2 - Power board
T1 - inlet temperature sensor K - Capillary WT-3
T2 - inlet temperature sensor A3 - ZIO-21 board
superordi-
nated
signal
room
thermostat
DHW
thermostat
DS 1820
temperature
sensor
PUMP
INTERNAL BOILER WIRING
36kW 415V~3N

12
GB-016C_f.783,2
N
PE PE
X1
N
U
L1
V
L2
W
L3
G3
L2
G2
L1
G1
L3
N
G3
L2
G2
L1
G1
L3
N
1 2 1 2 1 2
G1 G2 G3
1 2 1 2 1 2
G4 G5 G6
U V W
123
U V W
1 2 3
ZG1 ZG2
F1
ZM1
ZM2
F2
XP1 XP2
ZIO
1
2
NA
POMPA
N L
M1
1
2
RP
N U N
W
U
ZM
X.NA I2C
MSK
MZAN QTout2Tin
Q,T1
T2b
2 5
3
2 2
ZM
ZM
4
4
Kp
8
X1 - electrical connection unit F1, F2 - thermal cut out WT-3 XP1, XP2 - terminal block
ZM1, ZM2 - heating unit ZG1, ZG2 - heating box M1 - circulation pump
ZIO - board MSK - control panel T2a - temperature sensor on outlet(left) Q,T1 - flow sensor, temperature sensor on inlet Kp - front cover
1 2 3 4 5 6
123 456
1 3 1 4 5
6
6
6
7 9 8
9 8 7
10
11
12
13
14
15
16
17
19
21
18
20
22
23
25
27
24
26
28
29
30
31
40.1
36.1
38.1
29 30 31
40.4
36.4
38.4
32
33
34
34 33 32
35 32
36.3
33
38.3
34
40.3
40.2 31 38.2 30 36.2 29 35
36
38
40
35
Tout1
T2a
2
2
T2b - temperature sensor on outlet(right)
INTERNAL BOILER WIRING
48kW 415V~3N

13
GB-016C_f.783,2
Return inlet Flow Outlet
EXTERNAL BOILER WIRING
BOILER DIMENSIONS
Return Inlet Flow Outlet
Fusion boiler 48 Fusion boiler

14
GB-016C_f.783,2
USER INSTRUCTIONS
Unlike other system boilers such as Gas, Oil and Propane, the
FUSION 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 stat or programmer is calling for heat.
I. Boiler operation
1.1 Switch on unit power supply. Press to switch the boiler on.
Switch the boiler off using the same switch by holding it for
2 seconds.
1.2 Switch on programmer or room stat to call for heat.
1.3 When the system reaches the required boiler set point
temperature the boiler will modulate and will automatically
stage down.
1.4 Modulation - this is when the boiler controls the heating
load and the power that is required to maintain the relevant
temperature setting.
1.5 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.
2. 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. Refer to the diagram opposite to learn how to adjust
the right temperature to make the boiler work comfortably and
economically.
ATTENTION: Should the temperature on the front panel be set
on too low 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 inlet temperature displayed
(indicators „D” and „E” on).
Next pressing of switch - outlet temperature displayed
(indicators „F” and „E” 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.
NOTE: The indicators not only describe the state of the boiler
but also inform about failures.
3. Front Control Panel
Indicator B When GREEN light is on the pump is operating.
When this light flashes the flow rate is in
sufficient (less than 5 l per min) Refer to technical
specifications.
Indicator C When light is off room thermostat temperature
has been achieved. (RP is open) When the green
light flashes the NA connection is open. When
RED light is on, the boiler is operating When
GREEN light is on boiler temperature has been
achieved.
Indicator F Set Temperature.
Indicator D Return Temperature.
When this indicator flashes the return temperature
sensor is faulty.
Indicator E Flow Temperature
When this indicator flashes the flow temperature
sensor is faulty.
Indicator G Press to show Flow, Return and Set Temperature.
Indicator H Press to check flow rate.
Indicator I Press to check power consumption.
Indicator A DHWC Indicator.
Indicator K
DHWC temperature indicator (when electronic
DHWC temperature sensor is used).

15
GB-016C_f.783,2
Slimline boiler
1 - heat exchanger
2 - flow sensor
3 - pressure guage
4 - safety valve
5 - circulating pump
6 - safety temperature limiter
7 - return inlet
8 - flow outlet
9 - ZIO board
10 - power board
11 - automatic vent
12 - PSK control board
PF - 3 phase electric mains connection (phases)
PN - electrical connections
L - live
PE - permanent earth
N - neutral
M - boiler fixing positions
RP - control stat connections

16
GB-016C_f.783,2
Fusion boiler
1 - heat exchanger
2 - flow sensor
3 - pressure guage
4 - safety valve
5 - circulating pump
6 - safety temperature limiter
7 - return inlet
8 - flow outlet
9 - ZIO board
10 - power board
11 - automatic vent
12 - PSK control board
13 - expansion vessel connection
14 - expansion vessel
PF - 3 phase electric mains connection (phases)
PN - electrical connections
L - live
PE - permanent earth
N - neutral
M - boiler fixing positions
RP - control stat connections

17
GB-016C_f.783,2
48 Fusion boiler
[1] - water inlet (return)
[2] - water outlet (flow)
[3] - heat exchanger
[4] - power board
[5] - ZIO board
[6] - safety temperature limiter
[7] - automatic vent valve
[8] - vortex flow sensor
[9] - safety valve
[10] - outlet temperature sensor
[11] - inlet temperature sensor
[12] - circulating pump
[13] - pressure guage
[14] - PSK control board
[15] - electrical connector
PF - phase conductors connection point
WP - electric cable-bush
M - boiler fixing positions

18
GB-016C_f.783,2
6
FAULT FINDING
boiler key
1. Control Panel
2. Over Heat Stat
3. Automatic Air Vent
4. Heating Elements
5. Heat Exchanger
6. Printed Circuit Board
7. Voltage Free Control Connections
8. Circulation Pump
1
3
4
5
6
9
7
8
11
13
14
16
15
12
10
2
Symptom Reason Procedure
The indicators on the front panel
are off
No power to the boiler Check electricity mains power supply
Main over heat stat cut-out
Check the power board fuse F2
Check the WT3 temperature safety cut-out investige cause - possibly
fault / return sensors
The „B” indicator is flashing
Flow sensor is blocked
Check flow sensor
The central heating system airlock - vent the central heating system
and the pump
Check for choked pipes
Circulating pump is blocked Move the pump rotor manually
Flow sensor failure Check the flow sensor and replace if neccesary.
The room thermostat indicates
that the boiler is switched on.
„C” indicator does not light
Control panel fuse failure
Find the failure reason then replace the fuse.
Check external controls, room stats, etc. are calling for heat.
Link out control stats connections to eliminate external controls
If boiler operates the fault is with the external controls
The „D” or „E” indicator are
flashing Temperature sensor failure Replace temperature sensor.
17
2
3
4
5
15 13
10
9
14 11 8
9. Flow & Return Sensors
10. Flow Switch
11. Pressure Guage
12. Expansion Vessel
13. Heating Flow
14. Heating Return
15. Pressure Relieve Valve
16. Enclosure
16

19
GB-016C_f.783,2
TECHNICAL SPECIFICATIONS
NB: Voltage free control connections
Boiler range
Fusion
EHCFUS
6kW
Fusion
EHCFUS
9kW
Fusion
EHCFUS
12kW
Fusion
EHCFUS
14,4kW
Fusion
EHCFUS
36kW
Fusion
EHCFUS
48kW
Pipe entry from boilers Bottom
Entry
Bottom
Entry
Bottom
Entry
Bottom
Entry
Bottom
Entry
Bottom
Entry
Central heating flow & return pipes 22 mm 28 mm
Min water pressure 1 bar
Max water pressure 3 bar
Expansion vessel
6 lt. 48kw no expan-
sion vessel tted
maximum system water volume about 60 litres at initial system pressure 1,5 bar
Vessel charge pressure 1,5 bar
Overall dimensions (height x width x depth) 700 x 420 x 285
Dry weight 25kg 29kg
Electrical supply 240V 1ph 50Hz
Load/current 240V; 25,0 A 240V; 37,5 A 240V; 50,0 A 240V; 60,0 A 415V; 50,1 A 415V: 66,7A
Heating output 20,478 Btu 30,717 Btu 40,956 Btu 49,147 Btu 122,837 Btu 163,782 Btu
Max temp setting 85°C
Min temp setting 40°C
Overheat Protection 100°C
Pump included Yes
Recommended Pump settings Set to system kW rating (See page 6)
Protection 32 A 50 A 63 A 80 A 63 A 80A
The maximum allowed network impedance 0,39 Ω 0,32 Ω 0,24 Ω 0,22 Ω 0,09 Ω 0,03 Ω
ERP Rating
D
D
D
D
D
D
Boiler Dimensions
Slimline
Width 380mm
Height 660mm
Depth 175mm
FUSION
Width 420mm
Height 700mm
Depth 285mm
Controls
Central Heating Only:
EHC Single Channel Heat Pack
Central Heating & Domestic Hot Water:
EHC Twin Channel Heat Pack
48 FUSION
Width 503mm
Height 815mm
Depth 197mm

(Waste Electrical & Electronic Equipment)
(Applicable in the European Union and other European countries with separate collection
systems).
This marking shown on the product or its literature, indicates that it should not be disposed of
with other household wastes at the end of its working life.
To prevent possible harm to the environment or human health from uncontrolled waste dis-
posal, please separate this from other types of wastes and recycle it responsibly to promote
the sustainable reuse of material resources. Household users should contact either the retailer
where they purchased this product, or their local government office, for details of where and
how they can take this item for environmentally safe recycling.
Business users should contact their supplier and check the terms and conditions of the pur-
chase contract. This product should not be mixed with other commercial wastes for disposal.
Electric Heating Company Ltd
Unit 40, Block 5
Third Road
Blantyre Industrial Estate
Blantyre
Glasgow
G72 0UP
Tel: [phone] Fax: [phone]
www.electric-heatingcompany.co.uk