Heatrae Sadia Electromax 6kW standard Design, Installation And Servicing Instructions
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Heatrae Sadia Electromax 6kW standard Design, Installation And Servicing Instructions

Electromax combined electric flow boiler and direct unvented hot water cylinder
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Electromax Combined Electric Flow Boiler
and Direct Unvented Hot Water Cylinder
Installation and Servicing Instructions

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Summary of Contents for Heatrae Sadia Electromax 6kW standard

  • Page 1 Electromax Combined Electric Flow Boiler and Direct Unvented Hot Water Cylinder Installation and Servicing Instructions...

  • Page 2: Table Of Contents

    Contents SECTION PAGE SECTION PAGE 1.0 Introduction 7.0 Commissioning 1.1 Important Notes 7.1 Filling the Electromax 1.2 Basic Operation of the Cylinder Electromax 7.2 Filling the Sealed System 1.3 Storage, Unpacking and Primary Circuit Handling 7.3 Check the Operation of the 1.4 Contents Check List Safety Valves 2.0 Technical Data...

  • Page 3: Introduction

    1.0 Introduction 1.1 Important Notes is done by means of an Off-Peak electrical supply. The Electromax must be installed in accordance with the manufacturer’s instructions and all The use of an Off-Peak tariff that provides at relevant regulations in force at the time of least three off peak electricity periods, such installation.

  • Page 4: Storage, Unpacking And Handling

    Electromax control panel, however a “pump aid lifting. Stooping should be avoided and exercise” facility will energise the circulating protective clothing worn when necessary. pump for a brief period every day to prevent pump seizure through long periods without The packaging is recyclable and should be use.

  • Page 5: Technical Data

    2.0 Technical Data Specification / feature Electric boiler & primary circuit Electrical input (max) 9kW @ 240Vac 50Hz or 6kW @ 240Vac 50Hz 8.3kW @ 230Vac 50Hz or 5.5kW @ 230Vac 50Hz Electrical supply voltage 220 - 240 Vac Electrical supply frequency 50Hz Electrical supply rating 37.5 Amps @ 240Vac...
  • Page 6 Cylinder performance Off peak heater 3kW Boost heater 3kW time to heat (mins) Capacity Heatloss Quantity heated (litres) kWh/24hr 15°C to 60°C 50°C temperature though 45° in 60 mins temperature rise differential 57 litres 1.95 Minimum clearance Lifting Points over Top Panel for In Upper Rear access Panel...
  • Page 7 Primary System Expansion Vessel Primary System Air Valve Expansion Vessel Primary Circulating Primary System Pump Expansion Vessel Connection Automatic Air Vent Electric Control Circuitry (Mounted Behind Fascia) Top Panel Fascia Panel User Interface Panel Electrical Connection Panel Mounted Fuses 3 amp Terminal Blocks Primary System Pressure Boiler Electronic Control...
  • Page 8 Setting up the UPM3 pump the key lock by pressing the button for 10 seconds. When you switch on the pump it will run to (d) During a period of 10 seconds, press the pre-set position or the last setting. The shortly on the ‘...
  • Page 9 Control Mode explanation Constant curve Proportional pressure The circulator runs on a constant curve, which means that it runs at a constant speed or The head pressure is reduced at falling power. heat demand and increased at rising heat demand. The duty point of the circulator moves up or The duty point of the circulator will move down the selected curve, depending on the...
  • Page 10 Diagram 4 Automatic Bypass Valve Characteristics 1200 1500 1800 2100 2400 2700 3000 V (l/h) Diagram 4 Automatic Bypass Valve Characteristics Installation & Servicing Instructions...

  • Page 11: General Requirements

    3.0 General Requirements 3.1 Location of the Electromax available pressure and flowrate the better the system performance will be. The Electromax must not be sited outside or in any location where it could be exposed to The Electromax unvented cylinder has an the weather.

  • Page 12: Pipework, Fittings And Outlet/Terminal Fittings

    Failure to flush and add inhibitor to the system water may be drawn should be taken directly will invalidate the appliance warranty. from the main supply before the cold water combination valve to avoid the possibility of 3.3 Pipework, Fittings and Outlet / Terminal warm expanded water being drawn from cold Fittings taps.

  • Page 13: Sealed Primary Systems

    3.5 Sealed Primary Systems likely to collect. The Electromax boiler must be installed in a An automatic bypass valve is fitted to the sealed primary system. All necessary primary Electromax to allow thermostatic radiator system controls are supplied fitted to the valves to be fitted to the system.

  • Page 14: Installation - General

    4.0 Installation - General 4.1 Positioning the Electromax recesses either side of the panel. Once removed, the two M5 screws securing the Decide where the Electromax is to be installed. lower edge of the upper front panel must be Reference must be made to the dimensions removed.

  • Page 15: Cable Entry Positions

    4.3 Cable Entry Positions 4.4 Programmable Room Thermostat The electrical supply cables can be routed to The Electromax is supplied with a Danfoss enter the unit from the left or right hand side TP5000 Programmable Room Thermostat. This (see diagram 8, page 15). There are four cable is in the accessory kit supplied with your unit.

  • Page 16: Installation - Plumbing

    5.0 Installation - Plumbing 5.1 Pipe fittings Expansion valve Pressure reducing Pipe connections to the Electromax must be (6bar) valve cartridge made using 22mm compression type fittings. (3.5bar) Solder connections directly to the unit must Cold mains Expansion valve not be made as the heat may damage the connection outlet (15mm) (22mm)

  • Page 17: Balanced Cold Water Supplies

    5.4 Balanced Cold Water Supplies pressure relief devices (expansion valve and temperature/pressure relief valve) must be It is advantageous in many mixer showers installed in a continuously downward direction or taps to have balanced pressure hot and and in a frost free environment. cold water supplies, in these instances the balanced cold water supply is available on the Water may drip from the discharge pipe of...
  • Page 18 single unvented hot water system discharge by the product and performance standard (e.g. way of the same manifold that is used by the as specified in the relevant part of BS 7291). safety devices, the manifold should be factory fitted as part of the hot water storage system 3.58 The discharge pipe (D2) should be unit or package.
  • Page 19 polyethylene (PE-X) to Class S of BS 7291- Worked example of discharge pipe sizing 3:2006; and (d) be continuously marked with a warning Diagram 11, page 20: shows a G1/2 that no sanitary appliances should be temperature relief valve with a discharge pipe connected to the pipe.
  • Page 20 MINIMUM MINIMUM SIZE MAXIMUM RESISTANCE RESISTANCE VALVE SIZE OF OF DISCHARGE ALLOWED, EXPRESSED CREATED BY OUTLET SIZE DISCHARGE PIPR D2 FROM AS A LENGTH OF EACH ELBOW OR PIPE D1 TUNDISH STRAIGHT PIPE BEND 22mm UP TO 9M 0.8M G 1/2 15mm 28mm UP TO 18M...

  • Page 21: Primary (Central Heating) Pipework

    5.8 Primary (Central Heating) Pipework there is no requirement to allow a hot water loading factor in designing the primary system. Connections to the Electromax primary flow and return must be in 22mm o/dia. pipe. Use water soluble flux for making soldered Isolating valves are fitted to the Electromax joints and ensure any flux residue is removed unit on the primary flow and return connections...

  • Page 22: Installation - Electrical

    Off-Peak electrical supply. The “Economy 10” tariff, which is available from most major electricity suppliers, is recommended. Other Off-Peak tariffs may be suitable, consult the Heatrae Sadia Specification Team or your electricity supplier Installation & Servicing Instructions...
  • Page 23 24 Hour supply connection (NB NOT Boiler connection) A suitable electrical connection must be taken from the 24 Hour supply to the Electromax terminal block. The supply cable should be 1.5mm cross sectional area 3 core HOFR sheathed cable and must be routed into the Electromax via one of the 20mm cable glands previously fitted (see section 3.3, page 12).

  • Page 24: Boiler Connection

    6.3 Boiler Connection Programmable Room Thermostat Connection The Electromax boiler has a rated maximum output of 9kW or 6kW at 240V ~ . The supply Refer to the instruction leaflet supplied with cable must therefore be separate and the programmable room thermostat and dedicated to the boiler.

  • Page 25: Commissioning

    7.0 Commissioning through any residue, dirt or swarf, then IMPORTANT : DO NOT SWITCH ON close tap. ELECTRICAL SUPPLIES (e) Open successive hot taps and any cold ELECTROMAX UNTIL THE CYLINDER AND outlet supplied by a balanced take off to PRIMARY CIRCUIT HAVE BEEN CORRECTLY purge any air from the system.

  • Page 26: Filling The Sealed System Primary Circuit

    7.2 Filling The Sealed System Primary Circuit Primary flow pipe (a) The primary system must be flushed Primary in accordance with BS 7593 and the pressure relief manufacturer’s instructions supplied with valve the flushing agent selected. Temperature / (b) Connect the primary filling loop and pressure relief tighten connections (see diagram 15, valve...

  • Page 27: Set The Programmable Room Thermostat

    7.4 Set The Programmable Room by isolating the electrical supply to the Thermostat immersion heaters and then removing the immersion heater covers and rotating (a) Fit batteries supplied the thermostat adjustment knob (see programmable room thermostat. The diagram 18, page 27) using a flat bladed battery compartment is located behind screwdriver.

  • Page 28: Setting The Automatic By-Pass Valve

    Hot Water Boiler Status Primary System “BOOST” On Display Pressure Gauge Indictator Hot Water Hot Water Central / Underfloor Heating Primary Flow “ON” Switch “BOOST” Temperature “ON” Switch Switch Adjustment Diagram 19 Fascia Panel Features - Radiator Model Graphics Shown (g) Check the primary FLOW pipework 7.7 Setting the Automatic By-pass Valve from the Electromax begins to rise in...

  • Page 29: Check Operation Of The Immersion Heaters

    7.8 Check Operation of the Immersion 7.9 Demonstration to User Heaters Following commissioning any panels or covers (a) The Off-Peak immersion heater removed must be replaced and fully secured controlled by the Off-Peak electrical in place. The system, its function and control supply and will only switch on during Off- should be fully explained to the user.

  • Page 30: Maintenance

    Heatrae Sadia Electromax spare parts. It is recommended that maintenance is carried (a) Disconnect the electrical supplies to the out annually and should include the checks Electromax.

  • Page 31: Operation Of Cylinder Safety Valves

    heater and gently lever up and down. combination valve. (g) Carefully remove any scale from the surface of the immersion heater elements. DO NOT use a sharp implement as damage to the element surface could be caused. Ensure sealing surfaces are clean and seals are undamaged.

  • Page 32: Operation Of Primary System Safety Valve

    8.5 Operation of Primary System Safety Valve (a) Close the primary flow and return isolating valves (see diagram 15, page 25). (b) Slowly open the primary system pressure relief valve (see diagram 16, page 26) by twisting its cap for a few seconds. (c) Check water is discharged and that it flows freely through the tundish and discharge pipework.

  • Page 33: Fault Finding And Servicing

    9.0 Fault Finding and Servicing 9.1 Fault Finding IS 240V BOILER ELECTRICAL SUPPLY AT 24 CHECK ELECTRICAL The fault finding diagrams can be used to SUPPLY FAULT HOUR & 45 AMP SUPPLIES FINDING TERMINALS diagnose problems with the Electromax unit. These checks should be carried out by a competent installer or an authorized Heatrae Sadia service engineer or agent.
  • Page 34 IS THERE 240V AT THE DEMAND INDICATOR ROOM THERMOSTAT CHECK 3 AMP PANEL FAULTS CONNECTIONS MOUNT FUSE CHECK PROG. ROOM IS CALLING FOR HEAT IS THERE 240V BETWEEN CHECK WIRING R AND N ON CONTROL NEUTRAL MUST BE CONNECTED TO N ON CONTROL CONNECTOR REPLACE THE...
  • Page 35 OPERATED GO TO T&P RELIEF VALVE FAULT FINDING REPLACE THERMOSTAT SWITCH OFF WATER HEATER. CONTACT HEATRAE SADIA Diagram 27 Water Heater Fault Finding Off Peak Diagram 26 Water Heater Fault Finding Master (Lower) Immersion Heater Faults Installation & Servicing Instructions...
  • Page 36 IS 240V CHECK 24 HOUR BOOST (UPPER) SUPPLY AT CHECK INTERNAL IMM. HEATER NOT ELECTRICAL SUPPLY 24 HOUR WIRING IS ON OPERATING TERMINALS IS 240V IS 240V SUPPLY AT SUPPLY AT PRESS BOOST BOOST (UPPER) BOOST (UPPER) SWITCH THERMOSTAT THERMOSTAT TERMINALS TERMINALS NOTE:...

  • Page 37: Replacement Parts

    Sadia service engineers or agents. the Electromax unit. Refer to the following diagrams to aid in identifying the parts you require and the relevant Heatrae Sadia order code. Only use genuine Heatrae Sadia parts, the use of un-approved spare parts may render...
  • Page 38 Spares list Element Assembly Replacement Parts Description Part Number Immersion heater (upper) 95606963 Immersion heater (lower) 95606964 Immersion heater gasket 70 351 65 Immersion heater backnut 95607869 Bottom Element Thermostat 95612023 Assembly difference. Immersion heater cover 95614020 Key spanner (not shown) 95607861 Diagram 33 - Element Assemblies Immersion heater - lower wire...

  • Page 39: Servicing

    9.3 Servicing 9.3.2 Draining the Electromax Water Heater Cylinder WARNING: DISCONNECT FROM ELECTRICAL SUPPLIES BEFORE BEGINNING (a) Turn off the mains water supply to the ANY WORK ON THE UNIT. THE WATER unit. CONTAINED IN EITHER THE WATER HEATER (b) Open a hot tap supplied by the Electromax CYLINDER OR THE PRIMARY HEATING to relieve the system pressure.
  • Page 40 (f) Replacement is a reversal of the above Automatic air vent procedure. Ensure the pump sealing Pump washers are correctly located before tightening union nuts. Ensure the correct electrical connections are made (Brown wire to “L” terminal, Blue wire to “N” terminal, Green/Yellow wire to “EARTH CONNECTION“...
  • Page 41 9.3.6 Removing the Automatic Bypass Valve (see diagram 37) Automatic Bypass (a) Drain primary circuit. Valve (b) Unscrew the compression connections at inlet and outlet of the valve. (c) Remove the automatic bypass valve. Primary Off Peak (d) Replacement is a reversal of the above Flow Immer- procedure.
  • Page 42 9.3.8 Removing Primary System Primary expansion vessel Expansion Vessel (see diagram 39) Support nest (a) Drain primary circuit. (b) Unscrew union nut at connection between the expansion vessel and the flexible hose coupling. (c) Lift expansion vessel from moulded support nest. Note: the expansion vessel may contain some water, take care not to spill this into the product by lifting from the connection end of the vessel.
  • Page 43 9.3.10 Removing the Electric Boiler Main Control PCB Terminal Blocks (a) Remove cover from over the electric boiler control pcb (see diagram 43, page 44). (b) Disconnect cables from the terminal blocks. (c) Unplug ribbon cable connector CONN 2. (d) Unplug the thermistor connector from CONN 5 CONN 4.
  • Page 44 9.3.12 Removing the Front Fascia Panel (see diagram 43) Front facia panel (a) Drain primary circuit. (b) Unscrew the securing screws from the top of the front fascia moulding (note: these screws can only be accessed with the top panel removed). (c) Push the front fascia moulding up slightly and then pull forward to remove.

  • Page 45: Guarantee

    • Any valves and controls fitted are of and a Global Warming Potential (GWP) of 3.1. Heatrae Sadia recommended type and specification. • The unit has not been modified or tampered with in any way and has been regularly maintained as detailed in these instructions.
  • Page 46 Product name Electromax Supplier’s model identifier standard underfloor Standard underfloor Storage volume V in litres 180.0 180.0 180.0 180.0 Mixed water at 40 °C V40 in litres The declared load profile The water heating energy efficiency class of the model The water heating energy efficiency in % 36.2 36.2...
  • Page 47 Notes: Installation & Servicing Instructions...

  • Page 48: Spares Stockists

    Parts Center OUR NATIONWIDE NETWORK OF CUSTOMER SUPPORT ENGINEERS Tel: 0344 292 7057 Heatrae Sadia has its very own dedicated nationwide network of highly trained www.partscenter.co.uk customer support engineers so you can have peace of mind that we’re always here to help.

This manual is also suitable for:

Electromax 6kw underfloorElectromax 9kw standardElectromax 9kw underfloor

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