Thermo Sphere TSEFB-P4.5 User manual

Live well...
Live well...
Instructions
Electric Flow Boiler with Pump

2+44 (0) 800 019 5899
Contents
General information
General information 2
Specications 3
Conguration 3
Safety 4
How the boiler works 4
Installing the boiler 5
Wiring diagrams 6
Commissioning 7
Troubleshooting 7
Warranty information 10
Maintenance 11
These instructions contain information
about the design and operation
principles of ThermoSphere Electric
Flow Boilers, and dene the advised
operation.
The required plumbing, electrical and
control connections are also detailed.
The design of the heating and/or hot
water system including the provision
of appropriate safety devices and
functional components is the sole
responsibility of the installer.
Please read this guide in full before
attempting to install and commission
an Electric Flow Boiler.
Proper installation, commissioning and
maintenance of the boiler will ensure
its safe and reliable operation.
This appliance must not be used
by children, vulnerable people or
persons with a lack of experience and
knowledge of plumbing and electrics.
Who can install the boiler?
This appliance must only be installed
and maintained by professionals
with the required knowledge and
experience.
The boiler must be isolated from
the electrical supply before the
cover is removed for installation or
maintenance. Failure to do so can
result in serious injury or death.
This appliance must be safely earthed
at all times and have a suitably rated,
dedicated supply circuit.
Provision must be made to allow safe
electrical isolation of the appliance.
What systems can it be used with?
Electric Flow Boilers are intended
to heat the water (heat carrier) in
pressurised, closed loop heating
systems with pumped circulation.
The appliance can also be used to
provide domestic hot water when
used in conjunction with a pressurised
indirect hot water storage cylinder.
Pressure
The rated pressure of the system
must be no lower than 0.5 BAR and
no greater than 2 BAR. 1.5 BAR is
recommended.
Electrical supply connections
Electric Flow Boilers up to and
including 12kW can be connected to
either a single-phase (240V) or three-
phase (400V) electrical supplies.
The jumper clip must be removed
from the live supply terminals to allow
separate connection of the three live
phases.
It is the responsibility of the electrical
installer to ensure that the cable
and components used on the supply
circuit are suitably rated to allow safe
and reliable operation.
If you are in doubt about the required
cable or circuit breaker specications
please consult your copy of the wiring
regulations or contact the IEC.
The electrical installation must be
compliant with all relevant local
standards.
The plumbing installation must be
compliant with all relevant local water
and plumbing regulations.
The Electric Flow Boiler is IP22 rated
and must be installed in compliant
locations only.
Cables and other supporting materials
for the installation are not supplied.

3[email protected]
Specications
Dimensions
Code Output
(Kw)
Output per
element
No. of
elements Voltage Current (A)
Working
pressure (BAR)
Max working
temp (°C)
Weight
(Kg)
TSEFB-P4.5 4.5 1.5 3 230/400 21 2.0 65 14
TSEFB-P6 6.0 2.0 3 230/400 27 2.0 65 14
TSEFB-P9 9.0 3.0 3 230/400 40 2.0 65 14
TSEFB-P12 12.0 4.0 3 230/400 53 2.0 65 14
TSEFB-P15 15.0 5.0 3 400 22 2.0 65 14
TSEFB-P18 18.0 6.0 2 400 26 2.0 65 22
TSEFB-P24 24.0 9 + 15 2 400 35 2.0 65 22
H
W D
TSEFB-P4.5 TSEFB-P6 TSEFB-P9 TSEFB-P12 TSEFB-P15 TSEFB-P18 TSEFB-P24
W (mm) 215 215 215 215 215 350 350
H (mm) 730 730 730 730 730 730 730
D (mm) 122 122 122 122 122 122 122

4+44 (0) 800 019 5899
Safety
How the boiler works
ThermoSphere Electric Flow Boilers
are equipped with several safety
devices which are designed to help
prevent issues arising in relation to
temperature and pressure.
Thermal cut-out
The thermal cut-out switch isolates
the heating elements if a temperature
over 75°C is detected.
Pressure switch
The pressure switch is designed to
prevent the heating elements from
switching on unless there is adequate
ow of water (pumped version only).
Fused control circuit supply
The control circuit is protected by an
internal 3 Amp fuse.
Electrical grounding
The boiler wiring features Earth
grounding which must be connected
to the mains Earth at all times.
Electric Flow Boilers use resistive
electric heating elements to heat
water up to a maximum of 65°C
for the purposes of heating central
heating radiators, underoor heating
circuits and domestic hot water
cylinder coils.
The heating element cluster is housed
in an insulated steel cylinder and
there are ow and return plumbing
connections at the top and bottom of
the boiler.
Cold water is pumped through the
lower pipe connection marked blue,
and hot water leaves the boiler
through the pipe connection at the
top of the cylinder, marked red.
The boiler also has a pump set and
temperature/pressure release valve
located under the heating cylinder.
The operating temperature is set on
the dial at the front of the boiler. Use
the temperature gauge to set the
temperature accurately.
When there is a call for heat from the
control circuit (if connected) or the
temperature of the water is below
the set point on the boiler thermostat
(no controls connected) the boiler will
begin to heat the water as it passes
through the heat exchange cylinder.
The boiler will continue to heat the
water to the set point temperature
until the call for heat from the
controls stops, or the set point
temperature is satised.
When the temperature is satised,
the pump will continue to run for a
set period to ensure the hot water is
circulated throughout the system and
prevent thermal runaway.
IMPORTANT!
Do not connect or attempt to carry
out maintenance or repairs while
the boiler is connected to the mains
power supply circuit. The boiler must
be safely isolated from the supply
before you remove the casing.
Before energising the boiler for
the rst time, it is advised that all
electrical connections, including
factory connections are checked.
The integrity of the internal earth
connections and the connection
with the earth terminal must also be
checked before energising the boiler.
You must not turn the boiler on
before the plumbing circuit lled with
water and pressurised to the required
level.
A temporary lling loop must be used
to ll the heating/hot water circuit to
the required pressure. According to
UK water regulations the mains water
and heating circuit must never be
permanently connected.
A magnetic lter is recommended on
plumbing circuits to catch any ferrous
deposits and prevent them from
entering the boiler.
The water in the heating and hot
water coil circuits should be treated
with a suitable corrosion inhibitor to
prevent scaling and corrosion.
If the mains water supply is over 3
BAR a reducing valve must be tted
ahead of the boiler.
A suitably sized expansion vessel must
be included in the plumbing circuit to
allow for expansion of heated water.
If installing a pressurised hot water
cylinder, a suitable temperature
and pressure release valve must be
installed at the cylinder.
Isolation valves must never be installed
between the boiler and the expansion
tank, air valve and temperature/
pressure release valve.
This product should only be installed by a qualied and
competent professional.
It is the installer’s sole responsibility to ensure that the boiler and heating/hot water system
is installed in a safe way, in compliance with all relevant local standards and regulations. This
applies to both the electrical and plumbing aspects of the installation.

5[email protected]
Installing the boiler
Fixing to the wall
The boiler must be located in a area
that is away from possible tampering,
but allows safe and easy access for
maintenance and servicing.
At least 500mm clearance is
recommend on all sides of the boiler.
The wall that the boiler is xed
to must be strong enough to
permanently hold the weight of the
boiler. Fixings must be suitable the
wall type.
1. Remove the front cover by
unscrewing the xings at the top
and bottom of the boiler housing.
2. Place the cover aside somewhere
it cannot be damaged.
3. Offer the boiler up to the wall in
the position it is to be installed.
4. Check the boiler is level and
that all plumbing and electrical
connections can be made easily.
5. Mark the position of the xing
holes at the top and bottom of
the boiler.
6. Place the boiler one side,
somewhere it cannot be
damaged.
7. Drill holes into the wall, sized to
t your desired xings, and t
suitable wall anchors into the
holes.
8. Wall xings should go to a depth
of at least 35mm and be strong
enough to hold the full weight of
the boiler.
9. Offer the boiler up to the wall and
align with the mounting holes.
10. Secure the top xings in place
rst, followed by the bottom
xings. The sue of washers is
recommended. Do not over
tighten the xings as this can
distort the casing.
Plumbing connections
1. The plumbing connections on the
boiler are 3/4”. You may need
adaptor ttings depending on the
pipes you are using.
2. Connect the cold water feed to
the pipe connection at the bottom
of the boiler, ahead of the pump.
3. Connect the hot water ow to
the pipe connection at the top of
the boiler.
4. The water in the plumbing circuit
must be treated with a suitable
level of inhibitor and a magnetic
lter is recommended ahead of
the boiler.
5. Isolation valves are recommended
close to the cold feed and after
the safety devices (expansion
valve, automatic air valve) on
the hot side. This is to allow
easy isolation of the boiler for
maintenance.
Electrical wiring connections
1. The boiler‘s electrical supply
should be on a dedicated circuit,
protected by a suitably rated
circuit breaker at the distribution
board.
1. The suitably sized electrical supply
cable should enter the boiler
through the gland at the top of
the boiler.
2. The earth core should be
insulated with earth sheath and
connected to the earth terminal.
3. The neutral core should be
connected to the neutral terminal.
4. If connecting to a single-phase
supply, the live core should be
connected to the central live
terminal. Leave the jumper clip
(covered with a white cap) in
place for single-phase installation.
5. If connecting to a three-phase
supply, rst remove the jumper
clip between the three live
terminals. To do this, remove the
white plastic cover and use a at
screwdriver to lever the clip out.
6. Connect each one of the three
live phases to one of the live
terminals.
7. Ensure all terminals are fastened
securely with no possibility for
cable movement. Also ensure that
no copper is visible.
8. The pressure relief valve,
located near the pump, must be
connected to a length of high
temperature hose, through a
tundish, and plumbed to a waste
pipe or outside according to your
local plumbing regulations.
Control connections
1. The boiler can be connected to
external thermostatic controls
or as part of an S Plan or Y plan
control system.
2. If the boiler is not connected to
external controls, leave the red
jumper wire across the control
terminals to provide a constant
call for heat.
3. If the boiler is going to be
connected to external controls,
remove the red jumper wire
before doing so.
4. The call for heat wire from the
control circuit must be connected
to the right-hand control terminal.
5. The boiler provides a 3Amp
supply for the control circuit. This
removes the need for installing a
separate 3Amp fused spur for the
controls.
6. The live supply to the control
circuit can be connected to the
left Live control terminal.
7. The control circuit supply neutral
and earth can be connected to
the neutral and earth control
terminals.
8. Further control circuit connections
should be made in the wiring
centre, in accordance with the
control manufacturer‘s instruction
guide.
9. Once all connections are made,
checked and veried, the front
cover of the boiler must be xed
back in place using the screws.
10. It is advised that the electrical
installer ts relevant safety labels
to the front of the boiler to warn
of live electrics inside the boiler
enclosure.

6+44 (0) 800 019 5899
Wiring diagrams
Single-phase (230V) without
external controls
If no external controls are to be
connected the red jumper wire must
be left in place to provide a constant
call for heat. In this case the boiler
and pump will always be on unless
the set temperature on the boiler
thermostat dial is satised.
The live phase jumper must be left
in to provide a live connection to all
three live supply terminals.
Single-phase (230V) with external
controls
When external controls are connected,
the red jumper wire must be removed.
The control circuit can be supplied by
the 3A control supply within the boiler.
The terminal labelled C is the call for
heat terminal and should be connected
to the call for heat/switched live at the
wiring centre.
Three-phase (400V) connection
For three-phase connections the live
phase jumper must be removed to
allow each phase to be connected to
an individual live supply terminal.
The example shows three phase
with external controls, however the
electrical supply connections are the
same if there are no external controls.
ABCNN C L
3 AMP FUSE
Live supply Neutral Earth
ABCNN C L
3 AMP FUSE
Live out
Call for heat
Neutral Earth Live supply Neutral Earth
N C L ABCN
3 AMP FUSE
Live out Call for heat Neutral Earth
Live 2 supply Neutral Earth Live 3 supply Live 1 supply
!Remove red control jumper wire when connecting controls
!Remove live phase jumper clip for three-phase connection
Remove red control jumper wire when connecting controls
!Leave live phase jumper clip in for single-phase connection
Leave red control jumper wire in when not using extra controls

7[email protected]
!All installation, commissioning and maintenance should
only be done by a competent, qualied professional.
Commissioning the boiler
Troubleshooting the boiler
1. Turn off all 3 heating element
switches on the front of the
boiler.
2. Set the boiler thermostat dial to
zero.
3. Verify that there is heat carrier
(water treated with inhibitor) in
the system.
4. Check that all isolation valves on
the plumbing system are open.
5. Check that the pressure reading
on the front of the boiler is at 1.5
BAR. The boiler requires at least
0.5 BAR to operate.
6. Check the whole plumbing
system for leaks and repair as
required.
7. Check the electrical circuit is
connected safely and that all
necessary safety devices are in
place.
8. Switch the electrical supply circuit
on.
9. Set the boiler thermostat dial to
the desired temperature (Max
65°C).
10. Set any external controls (room
or cylinder thermostats) to the
desired temperature.
11. Switch the rst element switch
on and check the operation of the
pump. If everything is operating
correctly, switch the 2nd and
3rd element switches on in
succession.
12. Check that the water reaches the
required temperature and the
heating elements switch off. The
pump should stay on for a period
of time to circulate the heat, after
the call for heat has ceased.
13. Verify the heating system is
working as designed and rectify
any issues if they become
apparent.
Issue Possible cause Things to try
Boiler won‘t turn on Power fault When the boiler has an active power supply the power light
will be illuminated. The power light is on the control panel on
the front of your boiler and if it is illuminated then your boiler
has an active power supply.
Check isolation switches and distribution board. If there is no
power the light will be off and you need to check that any
isolation switches are on and also that the MCB, RCBO or
RCD is switched on at the distribution board. If all of these
are on and you expect power at the boiler, the next thing to
do is check the wiring inside the boiler.
Isolate the electrical supply again and remove the boiler cover.
Check the wiring connections in the supply terminals at the
top of the boiler. There should be a live (brown), neutral
(blue) and earth connected. The boilers require quite large
power supplies so the cables will be quite thick. Check the
connections in the boiler and make sure they match the
relevant wiring diagram.
If the wiring is correct, the next thing to do is check for
voltage. To do this you will need to switch the power
supply on again. This check should only really be done by a
professional electrician because the boiler could be live at
this point. Using a multimeter, check for a voltage across the
L & N supply terminals. You should get a reading of around
230~240V if connected to UK single phase mains. If you do
detect a voltage but the light is off, then the power light has
failed. Contact us for a replacement.
If there is no voltage at this point you will need to check the
electrical supply circuit for faults and restore power to your
boiler.

8+44 (0) 800 019 5899
Issue Possible cause Things to try
Boiler is not heating Temperature settings It sounds obvious, but you should check that the thermostatic
dial is turned up to request a temperature that is higher
than the measured temperature on the gauge. The boiler
will only heat up if the water inside it is cooler than the set
temperature on the thermostatic dial.
When you turn the thermostatic dial up and pass the
measured temperature you should hear a click and then hear
the relays and the pump switch on. You will then see the
temperature and pressure begin to rise.
Check the temperature readings on the gauge because the
dials are not always positioned correctly, and the numbers are
not always reliable. You can also use a separate thermometer
to verify the temperature if there is any doubt.
Over temp protection switch Each boiler is equipped with a high temperature cut off
switch (or over temperature switch) which, depending on
your model, will be set to turn the boiler off if temperatures
over 75°C are detected. This is a safety feature designed to
prevent overheating.
The high temperature cut-off switches must be manually reset
before the boiler will start working again. To reset the switch,
you need to isolate the electrical supply and remove the boiler
casing. You will see the cut-off switch located on the water
cylinder inside the boiler and you can identify it by the small
red button. Press the small red button to reset the switch.
Replace the boiler cover and turn the power supply back
on. The boiler should now operate as normal. If this switch
activates and turns the boiler off a lot, you will need to turn
the operating temperature down to a stable level.
Control wiring or setting The boiler requires a 230V call for heat signal into the control
terminal in order to re up the boiler. This usually comes
from a switched live connection from the wiring centre.
Check that any external controls are wired correctly and that
the temperature on the dial is set higher than the current
measured temperature. Use a multimeter to check for 230V
at the call for heat terminal inside the boiler, when a call for
heat is expected.
Pressure warning light
(Pumped version only)
Low system pressure Your boiler will not operate unless there is sufcient water
pressure of at least 0.5 Bar. This protects the boiler from
heating up when there is no water inside it.
Low pressure is indicated by the pressure warning light on the
control panel on the front of the boiler. You will also be able
to read the pressure gauge to verify the low pressure.
You need to check the whole plumbing circuit for leaks to
ensure you are not losing water anywhere.
Once you‘ve xed any leaks you can re-pressurise the system.
Use the temporary lling loop to top up the system to 1.5 Bar.
When you have topped up the system the pressure warning
light should turn off and the system should then run normally.

9[email protected]
Issue Possible cause Things to try
Boiler is tripping
RCBO or MCB
Overloaded circuit The rst thing to check is the total load on the circuit that the
boiler is connected to. The boiler must be fed by a dedicated
supply circuit with suitably sized cable and circuit breaker.
Check the total load of your boiler, you can nd this in the
technical data table in the instructions or on our website and
check the load of the circuit that the boiler is fed by. The
MCB or RCBO that feeds the boiler should be rated higher
than the maximum current of your boiler. For example, if your
boiler needs 21 Amps you should use a 25Amp MCB.
The boiler should be fed by a dedicated circuit but if this
is not the case, you should turn off and disconnect every
other appliance that is connected to the circuit. Try the boiler
again and if the MCB holds you know the problem lies with
overloading or another appliance and not the boiler. Consult
an electrician to rectify the issue.
Boiler is tripping RCD Leak to earth A leak to earth could be caused by damaged heating
elements or damage to one of the cables supplying the boiler.
To verify the cause of the leak to earth isolate the electrical
supply and remove the boiler cover.
Disconnect the supply cables from the terminals inside the
boiler and make safe. Try to re-energise the supply circuit.
If the RCD still trips, with the boiler disconnected, then the
boiler is OK and external wiring should be investigated and
rectied by a competent electrician.
If the RCD now holds then the fault is within the boiler
and is likely to be caused by a failed element. To verify this
(while the supply cables are still disconnected) switch off the
boiler MCBs on the control panel and perform an insulation
resistance test between the element terminals and the main
earth terminal.
A fault to earth will be identied by a low reading. This is
generally a reading below 499 Mega Ohms depending on the
tester being used. Contact us on 0800 019 5899 for advice
on repair and replacement.
Boiler looks to be
functioning normally
there is no heat
output
Heating element issue An electrician will be able to use a current clamp to measure
the current being drawn by the boiler when it is on and
calling for heat. This can be done by placing the clamp over
the live supply cable (or cables in a three-phase installation)
and recording the reading the meter gives. Check the meter
reading against the expected current values in the data table
in the instruction manual.
A lower current reading than expected could indicate that
one or more of the heating elements within the boiler may
have expired. Contact us on 0800 019 5899 for advice on
repair and replacement.
Pump is not running Wiring or failed pump You will notice 2 LEDS on the pump timer relay. The red LED
switches on when the relay is on/ashing and sending power
to the pump. If the pump is not running while the red LED
is on/ashing you need to use a volt meter to verify 230V at
terminal 18 on the timer relay. If there is 230V present but the
pump is not working, then the pump is likely to have failed
and must be replaced. If there is no voltage, there is likely to
be a fault with the control wiring which must be investigated.
Pump is on constantly
but I have external
controls connected
Control jumper still in place If you have connected external controls the boiler and
pump will only re up when there is a call for heat from the
controls. If the boiler and pump are running constantly the
jumper wire across the control terminals must be removed.

10 [phone]
Thermogroup Ltd (T/A ThermoSphere)
will repair or, if necessary, at its
sole discretion, replace a faulty
ThermoSphere Electric Flow Boiler,
which falls within the Warranty
Periods and Territory specied below,
subject to the warranty conditions and
the warranty exclusions.
Warranty Period within the United
Kingdom is 3 years from the date of
purchase by the installer/consumer
as dened by the Competition and
Consumer Act 2010.
Our goods come with guarantees
that cannot be excluded under the
UK Consumer Law. You are entitled
to a replacement or refund for a
major failure that occurs because of a
manufacturing fault or manufacturing
defect. It is the responsibility of the
end user to provide proof of purchase
within the Territory, to initiate a
warranty claim.
WARRANTY CONDITIONS
This warranty is applicable only for
ThermoSphere Electric Flow Boilers
(herein referred to as “The boiler”).
The boiler must be installed in
accordance with the ThermoSphere
Installation Instructions, supplied
with the boiler and/or available as a
digital download, and in accordance
with all relevant statutory and local
regulations of the Territory in which
the boiler is installed.
Where a failed component or boiler is
replaced under warranty, the balance
of the original warranty period will
remain effective. The replaced part or
boiler does not carry a new warranty.
Where a failed component is
replaced or repaired under warranty,
ThermoSphere will incur costs
associated with shipping and repair
at its sole discretion, if the unit is
installed within the UK. If the unit is
outside the UK, the associated costs
are the responsibility of the owner.
Where the heating system is installed
in a position that does not allow safe,
ready access, the cost of accessing
the site safely, including the cost of
additional materials handling and/
or safety equipment, shall be the
owner‘s responsibility.
The warranty applies to the boiler only
and, therefore, does not cover any
electrical, plumbing heating or hot
water parts supplied by others that
are not an integral part of the boiler,
for example but not limited to; valves,
cylinders, pipes, expansion vessels.
The benets of this warranty are in
addition to other rights and remedies
of the consumer under laws in relation
to the goods and services to which
the warranty relates.
PROCEDURE FOR HONOURING
WARRANTY
To initiate a claim for a warranty
against defects, the consumer
must contact: Thermogroup Ltd
T/A ThermoSphere, Bridge House,
Pattenden Lane, Marden, Kent, TN12
9QJ, United Kingdom.
[email protected]. 0800
0195899.
The process will then follow the
ThermoSphere Product Warranty Flow
Chart to assess whether the product
is under warranty.
WARRANTY EXCLUSIONS
Repair and replacement work will
be carried out as set out in the
ThermoSphere warranty. However, the
following exclusions may cause the
ThermoSphere warranty to become
void and may incur a service charge
and/or cost of parts:
Accidental damage to the boiler or
any component, including: Acts of
God; failure due to misuse, abuse,
re or ood damage; incorrect
installation; damage as the result of
transportation, removal or storage;
attempts to repair the boiler other
than by a ThermoSphere Accredited
Service Agent, the ThermoSphere
Service Department or a repairer not
approved by ThermoSphere.
Where it is found there is nothing
wrong with the boiler; where the
complaint is related to circumstances
where there is no power supply due
to faulty electrics; where faults are
related to the electrical supply or
incorrect installation; where the fault
lies on the wider plumbing system,
not the within the boiler and not the
boiler or boiler components; where
there is a failure of electricity supply;
where the supply of electricity does
not comply with relevant standards,
codes or acts, ThermoSphere may
then charge the consumer/installer a
nominal service charge if a site visit is
carried out and inspection reveals no
fault with the heating system.
If the boiler or boiler component
has failed directly or indirectly as a
result of accidental damage, incorrect
installation that does not comply
with the ThermoSphere Installation
Instructions or relevant statutory
requirements, the warranty id void
and any repairs or replacements will
be fully chargeable.
Subject to any rights you have under
UK Consumer Law or other statutory
provisions to the contrary, this
warranty excludes any and all claims
for damage to property, building
fabric, possessions or any other
consequential loss either directly or
indirectly due to damage from the
heating system, workmanship or
other.
Warranty information

11[email protected]
!All maintenance should only be done by a competent,
qualied professional.
Maintaining the boiler
Notes
The boiler and complete heating
and hot water system should be
checked annually for signs of wear
and to ensure the safety devices are
operational.
The water drain that the temperature
and pressure relief valve is connected
to should be checked every 6 months.
All electrical connections should be
checked to make sure they are tight
and there are no loose cables.
Any parts of the heating or hot water
system that are not manufactured
by ThermoSphere must be installed,
checked and maintained in
accordance with the manufacturer‘s
recommendations.
If there are any signs of faults or
wear and tear with the boiler, contact
ThermoSphere for advice on spare
parts and repairs.
If there are any signs of faults or
wear and tear with other components
in the heating or hot water system
please consult the manufacturer for
advice.
Do not attempt repair without
speaking to ThermoSphere.

ThermoSphere Electric Flow
Boiler Instructions
Issue 2 June 2023
ThermoSphere
Bridge House
Pattenden Lane
Marden
Kent
TN12 9QJ
UNITED KINGDOM
www.thermosphere.com
[email protected]
[phone]
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All content © 2023 Thermogroup Ltd. ThermoSphere is a trading name of Thermogroup Ltd