Installation; Pipe Connections; Water Connections; Isolation Valves - EHC Fusion Installation & Technical Manual

The boiler must be installed by a professional plumber or heat-
ing engineer and must be connected to the power supply by a
qualified electrician.
The Electric Heating Company Ltd will not be held responsi-
ble 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. 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 exter-
nal 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. (Slim-
line model: remove screws on the right hand side and swing the
boiler case open).
Earth connections must be re-connected before the case is re-
instated.

3. Isolation valves

Consideration should be made for the provision of lockshield iso-
lation valves on the flow and return pipe-work. Such valves must
be full way 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 addi-
tional 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.
GB-016C_f.493

INSTALLATION

6. Insulation
Where practical and if at all possible, we recommend that all
pipe-work be insulated, in particular the primary pipe-work with-
in 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 Scot-
land) room and cylinder stats must be fitted.
Note: We do not recommend the use of 8 mm micro-bore pipe.

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 ensure that no debris is trapped in
the flow sensor as this may result in boiler failure. Where existing
radiators and pipe-work are utilised a power flush must be carried
out to remove debris.
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.
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