Varmebaronen EK 13 Instruction Manual

21/12/2011
Installation and maintenance
Electric cartridge EK 13

2Värmebaronen EK 13
Operation
EK 13
Power 13 kW, which is divided into three stages, 6 + 4 + 3 kW.
Power can be limited to 10, 9, 7, 6, 4 or 3 kW.
EK 13 has a main switch, overheating protection, a thermostat,
operating indication, time delay and a fuse-protected outlet for a
circulation pump.
The electric cartridge has connection for external control/tariff
control.
Stainless electric elements
The electric elements are of stainless, acidproof steel, SS 2353.
Low-energy
A low volume of water and a well-insulated tank mean extremely
low heat loss.
Operation
The electric cartridge maintains a constant flow temperature in the
range 30-85 °C.
Simple connection
In terms of pipes, the electric cartridge may be connected to the
boiler via an expansion pipe or a docking outlet and drain cock.
Installation
Brackets for wall mounting are enclosed.
Accessories
Load guard VBB 12 TX. The load guard senses the load on the main
fuses and, if necessary, temporarily disconnects power from the
electric cartridge.
Contents
General...................................................................................2
Operation ...............................................................................2
Notes......................................................................................3
Technical data .......................................................................4
General
Water quality
Pipe installation.....................................................................5
General
Flow
Pressure drop diagram
Freestanding heating unit
Open system
Closed system
Supplement to boiler
System principles
Electrical installation ............................................................6
General
Terminal block, supply
Connection of circulation pump
External blocking
Connection delay after power cut
Limitation of power
Load guard
Electrical installation - wiring diagram ...............................7
Control panel ........................................................................ 8
Operation and maintenance .................................................8
General
Operation
Overheating protection
Venting
Action in the event of electrical operation
Safety valve
Draining
Action in the event of a risk of freezing
Frost protection
Connection delay
Troubleshooting.....................................................................9
Components......................................................................... 10
Safety and handling
Read these instructions carefully before installation,
adjustment or service is carried out. Follow the
instructions.
• Keep these instructions close to the cartridge.
• If the cartridge is correctly installed and adjusted and serviced
regularly, it will operate very reliably.
• Switch off the operating switch before any service/repair.
• Only authorised persons may intervene in the boiler.
• Never carry out maintenance work/service on pressure-bear-
ing parts when they are pressurised.
• The boiler must not be modified, changed or converted in
any way.
• The electric cartridge may not be used by children or people
with physical or mental impairments. Nor by children/people
who lack knowledge about the electric cartridge.
Children may not play with the electric cartridge and connect
accessories.
• Contact your installer for service.
• The type and production number of the cartridge must always be
specified when contacting Värmebaronen. See the rating plate.
• Värmebaronen AB reserves the right to change the specifica-
tion, in accordance with its policy of continuous improvement
and development, without prior notice.

3
Värmebaronen EK 13
Tel.:
Notes
Production number:
Installation date:
Installer:
Other:
To be completed when the cartridge is installed

4Värmebaronen EK 13
552
340
585
310
Technical data
Alternative bracket location
General
The ambient temperature must not exceed 30 °C.
Cables and pipes must be laid so that it is possible to remove
the front plate and open the roof plate for service. For installa-
tion and accessibility for service, there must be at least 60 cm
space above and in front of the cartridge.
The electric cartridge is not designed for oxygenated water.
No work must take place on the electric cartridge's facing
plates.
Water quality
Tap water is usually classified from the point of view of hygiene.
Good water classified on this basis is not automatically suitable
for a heating system. To avoid problems a technical water analysis
should take place. Any nonconformities with standard values
should be corrected.
If the volume of the heating system is low, it can be filled with
water that was not classified as good system water. When the
water is heated, some oxygen and carbonic acid are emitted to the
expansion tank or vent valves. The remainder will react with the
metals in the system. This corrosion is often insignificant as the
same volume of water circulates and it soon becomes oxygen-free.
The system must be leakproof so that the water does not need
to be replaced with new oxygen-rich water and the water is not
oxygenated during installation.
Water quality, in respect of suitable tap water:
The alkalinity should exceed 60 mg/l to avoid corrosion.
Contents of carbonic acid over 25 mg/l increase the risk of
corrosion.
Sulphate contents over 100 mg/l may accelerate corrosion.
If the sulphate content is higher than the alkalinity, there is
a risk of copper corrosion.
Hard water causes boiler scale and is not suitable in a heating
system.
Very soft water may cause corrosion damage.
Chloride contents over 100 mg/l make the water aggressive,
in particular with lime deposits.
Low pH values may cause corrosion damage. The pH value
should be 7.5-8.5.
The incidence of carbonic acid in combination with low pH
and hardness values makes the water aggressive.
1. Terminal block.
8. Overheating protection.
9. Contactor.
18. Printed circuit board.
28. Flow line R25 ext.
29. Return line R 25 ext.
30. Cover over mounting plate.
31. Mounting plate.
32. Cable opening.
33. Wall bracket.
8
28
29
30
1
9
18
8
31
32
33
Weight: 13 kg Design temperature: 110 °C Current: 18.8 A
Volume: 3.6 litre Operating temperature: 30-85 °C Fuse: 3 x 20 A
Design pressure: 3 bar Power: 13 kW Enclosure protection class: IP 21
Test pressure: 4.3 bar Voltage: 400V 3N~, 50 Hz Manufactured to PED 97/23/EC article 3.3

5
Värmebaronen EK 13
Flow
The electric cartridge requires a constant adequate flow to work. If
the heating system's valves are able to throttle circulation, an over-
flow valve must be installed.
The circulation pump must press the
water through the cartridge with the
flow direction shown in the figure.
Recommended flow: 0.3 litre/second, ∆t = 10 °C.
Flow too low: • High difference between desired temperature
and achieved temperature.
• Irregular control with increased wear on the
electromechanical components, with reduced
service life as a result.
• Increased risk of the overheating protection
being triggered.
Flow too high: • Vibrations in the immersion heaters with noise
and reduced service life as a result.
• Unnecessary wear on the system's components.
Pressure drop diagram
Freestanding heating unit
EK 13 must be connected to:
Open system: The expansion tank is connected in an unbroken,
uninterruptible connection to the cartridge. The
distance between the top of the highest radiator
and the tank may not be less than 2.5 metres to
avoid oxygenation of the heating system.
Closed system: The cartridge is connected to a closed expansion
tank and in an unbroken, uninterruptible
connection to a type-approved safety valve
with maximum 3 bar opening pressure and an
automatic vent valve.
Pipe installation
Installation must take place according to existing regulations
and standards.
The cartridge must be located indoors in a suitable location.
The cartridge must be installed horizontal with the pipe
connections vertical so that air that is released can escape.
The cartridge must be connected to an open or closed expan-
sion system.
A system with a closed expansion tank must undergo an
installation inspection prior to first operation. The inspection
must be carried out by a person who is qualified for the task.
The electric cartridge or expansion tank may not be replaced
without another inspection.
System principles
The system must be installed according to existing rules and
standards.
Radiator system
A
G
C F
B
D
E
H
D
Underfloor heating system
E
A
C
B
D
D
G
I
F
With boiler
A
D
C
B
H
C
J
A. EK 13 F. Drain valve
B. Expansion tank, open G. Bypass/overflow valve
C. Circulation pump H. Radiator system
D. Stop valves I. Underfloor heating system
E. Filling valve J. Boiler

6Värmebaronen EK 13
Electrical installation
The installation must be carried out according to existing
regulations and standards under the supervision of a qualified
electrician.
The electric cartridge and heating system must be filled with
water and vented before the electric cartridge is connected to
the power supply.
All connections must be with high voltage-insulated cable.
Terminal block, supply
The electric cartridge is connected with 5 x 4 mm2cable with
3 x 20 A fuses.
The terminal block is in the automatic control cabinet.
1
2
Connection of circulation pump
Fused power outlet, 10 A, to supply the circulation pump, max.
load 1 A.
3
1
External blocking.
If the electric cartridge is to have tariff or external control, a 2-pole
relay must be connected as shown in the diagram below, 230 V.
The relay must be closed in operating mode and open in idle mode.
25
4
1
To external control unit
Connection delay after power cut
The electric cartridge has connection-delayed power stages after
a power cut according to the standard. This means that, after a
power cut that has lasted for more than three minutes, only power
stage one is connected, 6 kW. The remaining power is connected
approximately two hours after the power has returned.
For testing and inspection, the delay may be switched off
temporarily by short-circuiting the pins marked with arrows until
the LED goes out.
24
26
Limitation of power
The power of the electric cartridge may be limited by removing
jumpers as shown in the diagram below.
4 25
Load guard
A load guard VBB 12 TX is available as an accessory. It senses the
total load on the main fuses and reduces the power in the electric
cartridge in the event of overload. When the load on the main fuses
falls, the load guard reconnects the power disconnected in stages.
Further information is available in the instructions for the VBB 12TX.

7
Värmebaronen EK 13
Electrical installation
27
1
2
34
5
6
7
8
9
10
11
12 13 14
15 16
17
18
21
22
23
24
25 26
41 31 21
42 32 22 30-90 °C
31 21 11
32 22 12
N
102 °C
N
6 kW 4 kW 3 kW
41 31 21 11
42 32 22 12 30-90 °C
L1L2L3 1122F N N
230V~
6 kW
20
19
1. Terminal block.
2. Power cable connection.
3. Power supply, circulation pump, 230 V~.
4. Blocking, power stage one.
5. All-pole switch.
6. Operation indicator.
7. Miniature circuit breaker for control and circulation pump.
8. Overheating protection.
9. Contactor, blocking, power stage one.
10. Thermostat, power stage one.
11. Indicator, power stage one.
12. Electric elements, power group one, 6 kW.
13. Electric elements, power group two, 4 kW.
14. Electric elements, power group three, 3 kW.
15. Indicator, power stage two.
16. Indicator, power stage three.
17. Thermostat, power stages two and three.
18. Printed circuit board.
19. Relay group, power stage two.
20. Relay group, power stage three.
21. Selection of connection delay:
Jumpered: power stages two and three delayed for two hours
(standard).
Unjumpered: power stage three delayed for two hours.
22. Neutral for the electronics. The incoming control phase for the
circuit board comes via relay group no. 19, connection no. 4.
23. Selection of connection delay, one or two hours.
24. The two-hour lock may be disabled by short-circuiting the pins
until LED no. 26 goes out.
25. Connection of load guard or other external blocking:
closure 1 - 2, relay group no. 19 picked up.
closure 2 - 3, relay group no. 20 picked up.
26. LED, flashes when the two-hour lock is operating, normally off.
27. Connection pin for power groups on immersion heater.

8Värmebaronen EK 13
Operation and maintenance
After installation, check with the installer that the system is in
perfect condition.
Ask the installer to demonstrate the control and functions so
that you know how the system should work and be maintained.
Check that:
- No tools have been left in the cartridge's connection space.
- The electric cartridge and the heating system have been filled
with water and vented.
Air may remain for a while, for which reason a few more checks
should be made.
- Pipe connections are leakproof.
- Safety valves work. Water must enter the blow-off pipe when
the valve is operated.
- Start the electric cartridge by switching the main switch to
position 1.
Set the thermostats to the required temperature.
As the cartridge has been without power, the connection delay will
limit the power connection for the first two hours.
- The circulation pump works and has the right speed.
- Heat is distributed to the radiator system.
- The temperature matches the temperature selected. It may take
a while before the temperature in the system has been stabilised.
Control panel
5
8
6
10
17
11
16
7
15
5. Main switch.
6. Operation indicator.
7. Miniature circuit breaker.
8. Reset overheating protection.
10. Thermostat for power stage one.
11. Indicator for power stage one.
15. Indicator for power stage two.
16. Indicator for power stage three.
17. Thermostat, power stages two and three.
Operation
The electric power is controlled by two thermostats. The thermo-
stats have a difference of approximately 5 °C between breaking
and closing. This means that if the thermostat is set to 65 °C, it
breaks when the temperature reaches this level. The thermostat
closes again when the temperature has fallen to approximately 60
°C.
The thermostat for power stages two and three works in two
stages. Stage two is connected at 5 °C lower than stage three.
Otherwise it works in the same way as the thermostat for power
stage one.
Overheating protection
The electric cartridge has overheating protection that is triggered
when the temperature exceeds approximately 95 °C.
The overheating protection is reset on the side of the electric
cartridge. It may only be reset when the temperature has fallen
below 80 °C. You need to press quite hard to reset the protection.
Venting
Check regularly that there is water in the system. After venting,
the pressure must be checked and water may need to be added.
Action in the event of electrical operation
When EK 13 is installed as a supplement to a boiler and the electric
cartridge takes over the heating, any unnecessary air throughput
and thus cooling of the boiler should be avoided.
Safety valve
To maintain safety protection, any safety valve should be operated
regularly, approximately four times a year.
Draining
If the heating system needs to be drained of water, the electric
cartridge must first be switched off so that the immersion heater
is not damaged.
Action in the event of a risk of freezing
When it is extremely cold, no part of the heating system must be
switched off as there is a risk of bursting. If you suspect that any
part of the system is frozen, contact an installation engineer.
If the system is to be switched off for an extended period of time,
the system should be drained or filled with water mixed with glycol.
Frost protection
If the system water is mixed with glycol, it is important for the
glycol to contain a suitable quantity of corrosion-protection agent.
When glycol breaks down, carbonic acid is produced, which
increases the risk of corrosion.
Connection delay
According to the standard, a maximum of 6 kW may be con-
nected directly. The remainder must be delayed for two hours.
This means that, after a power cut that has lasted for longer than
three minutes, only two of the electric cartridge's power stages are
connected directly. The remainder are connected (if required) two
hours after the power has returned.

9
Värmebaronen EK 13
Troubleshooting
Intervention that requires tools must be performed by a qualified electrician.
Fault Possible cause of fault Action
Operating indicators off. Electric cartridge without
power.
Check the main fuses.
Main switch off. Turn the switch to position I. The time delay function will lock the power
stages if it has been without power for more than three minutes.
The electric cartridge is
blocked by external equipment.
Check whether the electric cartridge is blocked by external control or
similar.
Overheating protection
triggered.
If the overheating protection has been triggered, the operation of the
system's circulation pumps and valves must be checked.
Reset by pressing the overheating protection button. This may take place
when the temperature has fallen below 80 °C.
Connection is limited by
a power cut.
It is possible to bypass the time delay function on the printed circuit board.
Load guard limits power
stages.
Check whether the load guard is connected and whether it is limiting the
power stages.
Operating indicator for
stage one off. Stage two
and/or stage three on.
Miniature circuit breaker in
automatic control cabinet
triggered.
Check where the short-circuit is. Take action. Then reset the miniature
circuit breaker.
Operating indicators for
stages two and three off.
Stage one on.
Miniature circuit breaker on
circuit board triggered.
Check where the short-circuit is. Take action. Then reset the miniature
circuit breaker.
Group fuses for electric
cartridge triggered.
Immersion heater faulty. Switch off the main switch. Check the insulation of the immersion heater's
power groups. If any of the electric elements is faulty, replace the immersion
heater and the tank for the immersion heater.
The operation of the
electric cartridge is
irregular. The thermostats
are switching on and off
at regular intervals.
Water flow too low. Check that the circulation pumps are working and that all necessary valves
are open.
The flow through the electric cartridge is checked as follows:
a. Limit the power stages of the electric cartridge so that the power output
is constant, for example to 1 power stage.
b. Let the temperature of the electric cartridge become stabilised and
measure the temperature increase between the flow and return lines of
the electric cartridge.
c. Calculate the water flow using the formula below.
Recommended flow: 0.3 litre/second, ∆t = 10 °C.
q = P
∆t x 1.16
q = water flow in m3/h
P = cartridge's power output in kW.
∆t = temperature difference in °C.
1.16 = water's thermal absorption coefficient.
To obtain the flow in litre/second, multiply q by 1/3.6

10 Värmebaronen EK 13
Components
Item Art. no. Designation Qty.
8 120002 Overheating protection, 102° 1
10, 17 120004 Thermostat, 30-90° 2
120005 Thermostat dial 2
5 130024 Switch 1
32 140010 Sealing nipple 18.6 5
140011 Sealing nipple 22.5 2
140012 Sealing nipple 28.3 2
140031 Locking nut 18.6 5
140032 Locking nut 22.5 2
140033 Locking nut 28.3 2
150057 Cables, complete, EK 13 1
1 160003 12-pole terminal block 1
160006 End plate 1
160009 2-pole bridge 2
160011 4-pole bridge 1
9 170046 Contactor, 230 V 1
7 180021 Miniature circuit breaker, 10 A 1
11, 15, 16 190002 Indicator lamp, 400 V 3
6190008 Indicator lamp, 230 V1
18 211003 Circuit board 1
280012 Insulation 1
280038 Insulating disc 1
280100 Pipe insulation (m) 0.13
295430 Outer cover 1
295431 Rear 1
295433 Roof 1
31 295437 Mounting plate. 1
370022 Cover washer 1
400211 Flat-pin contact 1
81216 Jumper 2
90030 Tank, including immersion heaters 1
33 90032 Bracket 2
92011 Panel 1

Värmebaronen AB
Arkelstorpsvägen 88
SE-291 94 Kristianstad
Tel. [phone]
Fax [phone]
www.varmebaronen.se
www.varmebaronen.com
[email protected]