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Lotus E300 Manual

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Summary of Contents for Lotus E300

  • Page 1 E300...

  • Page 2: Table Of Contents

    1. Contents Contents.......................... Introduction........................2.1. Important Notes......................5 Basic Operation of the Lotus E300 heat unit..............8 3.1. Storage, Unpacking and Handling of the Lotus E300 heat unit.........9 3.2. Contents Check List....................9 Technical Data Sheet....................10 4.1. Mechanical Installation...................11 4.2. Hydraulic Installation....................12 4.3.
  • Page 3 10.1. Check Operation of the Lotus E300 heat unit............28 Commissioning......................11.1. Filling the Lotus E300 heat unit................29 11.2. Filling the Sealed System Primary Circuit............30 11.3. Check the Operation of the Safety Valves............31 11.4. Set the Programmable PCB Thermostat.............31 11.5. Demonstration to User..................31 WILO KSL/7-50/SC Para Pump.................33...
  • Page 4 Removing the Primary System Pressure Relief Valve.........47 15.4. Removing the Primary System Expansion Vessel..........47 15.5. Removing the Lotus E300 heat unit Main Control PCB........47 15.6. Removing the 2 amp Panel mounted fuses............48 15.7. Removing the Lotus E300 heat unit Status Display PCB........48 15.8.

  • Page 5: Introduction

    The Lotus E300 heat unit is the Turkey’s first cold plasma powered heat source. It has the same features as a traditional combination boiler without the need for a direct gas / oil fuel source.
  • Page 6 Following installation of the primary system the system should be flushed in accordance with recent regulations and an inhibitor added. The Lotus E300 heat unit does not contain any substances harmful to health; it does not contain any asbestos. Small quantities of adhesives and sealants used in the manufacture of the product are cured and present no known hazards.
  • Page 7 Special Instructions and Building Regulations This appliance must be fitted in accordance with the following instructions.  The Local Building Regulations  The Building Regulations Part L1A, L1B & G3  The Building Standards, (Scotland-consolidated) Regulations.  Local water bylaws. British Standards- code of practice ...

  • Page 8: Basic Operation Of The Lotus E300 Heat Unit

    Electricity is then passed through the electrodes within the body of the heating unit by means of mains electrical supply, through the main Lotus E Series electric combi boiler PCB, within this balanced water to be burned on plasma.

  • Page 9: Storage, Unpacking And Handling Of The Lotus E300 Heat Unit

    Note the weight of the product (42Kg) and the handling instructions applied to the packaging. If using a handling device, e.g. a sack barrow, to manually move the Lotus E300 heat unit, trucking must be done from the rear to avoid damage to the outer panels.

  • Page 10: Technical Data Sheet

    4. Technical Data Sheet Heat Unit & Primary Circuit Electrical input (max) 6 – 8 kW @ 230 - 240Vac 50Hz Electrical supply voltage 230 Vac/400 Vac Electrical supply frequency 50/60Hz Peak current intensity 32 A(monophase) , 25amp (triphase) Absorbed electrical power 6 –...

  • Page 11: Mechanical Installation

    Domestic Hot Outlet Blow-Off (safety valve connection) Plastic tube connection Thermostat Electrical connection (Y/N) Yes, Volt free switch on external stat Wifi Connection Max Distance from boiler if wired 25 meters Minimum Permitted Cable Diameter twin core cable of 0.5 mm Max Distance from boiler if unwired (wifi) Complete unit...
  • Page 12 Installation is carried out with 2 screws or hooks to hang the boiler with 2 inlets and the distance between the holes in the body of the boiler is 282 mm.
  • Page 13 Fig 1: Mechanical Dimensions Thoroughly cleanse the heating system before connecting the appliance! By doing this, residue such as flux, solder and detritus is removed from the pipes. Failure to flush and cleanse the system will invalidate the warranty. The first meter of pipework and fittings from the unit to the system pipework must be in plastic The appliance is fitted with an expansion vessel.
  • Page 14 Fig 2. Pipe connections Pipe Connections Fig 2. Pipe connections Below Fig 3. is a simple flow diagram of the heating and hot water system identifying key areas of the Lotus E300 heat unit.
  • Page 15 It is mandatory to connect the boiler to the individual grounding line. If this is not done, the device will not be commissioned by Lotus authorized service, the device will be out of warranty and Lotus shall not be liable for any possible damages / problems.
  • Page 16 Fig 4. Electrical Connection Diagram...

  • Page 17: Location Of The Lotus E300 Heat Unit

     Or places where there is a possibility of excessive heat or freezing and condensation.  The Lotus E300 heat unit must not be sited outside or in any location where it could be exposed to the weather.  It must be installed in a dry and ideally a frost-free environment.

  • Page 18: Pipework & Fittings

    5.5. Sealed Primary Systems The Supply to the Lotus E300 heat unit must be installed in a sealed primary system. All necessary primary system controls are supplied fitted to the Lotus E300 heat unit. The sealed system expansion vessel fitted has a capacity of 7 litres. If in doubt the total primary system volume must be calculated to determine if additional expansion volume is required.

  • Page 19: Positioning The Lotus E300 Heat Unit

    6.1. Positioning the Lotus E300 heat unit Decide where the Lotus E300 heat unit is to be installed. Reference must be made to the dimensions of the unit and the minimum access space requirements. For maintenance the boiler should be installed with a minimum distance of: 100mm between the sides of the heat unit and the wall, 600mm between the top of the heat unit and the ceiling, 500mm from the front.
  • Page 20 The unit is fitted with a 1 meter extendable room temperature sensor and built in time clock for operation. An additional connection on the Control PCB is provided for a fixed wire room temperature sensor (not provided). Select operating time interval by means of the arrow keys and confirm by pressing the enter key (center of arrow keys) the corresponding square will turn black and saved...

  • Page 21: Installation - Plumbing

    6.5. Outlet Pipework The pipework from the Lotus E300 heat unit to the hot outlet fittings should be in 22mm pipe with short runs of 15mm pipe to showers and basins. Small bore pipe can be used to suit some taps but runs should be kept as short as possible. Pipe sizes may vary due to system design.
  • Page 22 Tundish - Fitted to Lotus E300 heat unit 3.54 The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible to, and lower than, the valve, with no more than 600mm of pipe between the valve outlet and the tundish (diagram 11 &...
  • Page 23 identify the product and performance standard (e.g. as specified in the relevant part of BS 7291). 3.58 The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e.
  • Page 24 To do so will invalidate any guarantee or claim.  The cold-water combination valve assembly must be fitted on the Lotus E300 heat unit water supply to the Lotus E300 heat unit. ...
  • Page 25 OF STRAIGHT 0.8M PIPE 15mm 22mm 1.0M G 1/2 UP TO 9M 28mm 1.4M UP TO 18M 35mm 1.0M UP TO 27M 28mm 22mm 1.4M UP TO 9M G 3/4 35mm 1.7M UP TO 18M 42mm UP TO 27M 1.4M 35mm 1.7M 28mm...
  • Page 26 22mm o/dia. pipe. Isolating valves fitted to Lotus E300 heat on primary flow and return connecti ons to enable 6.8. Prim Lotus (Cent E300 heat Heati unit to Pipe isolated work from the primary circuit mainten ance servicin Connect ions to...
  • Page 28 Use water soluble flux for making soldered joints and ensure any flux residue is removed following installation. A filling loop is provided within the Lotus E300 heat unit to fill the primary circuit directly from the cold-water supply.

  • Page 29: Installation - Electrical

    All pipe work must be cross bonded 6.10. Boiler Connection The Lotus E300 heat Unit has a rated maximum output of 7.2kW at 240V ~. The supply cable must therefore be separate and dedicated to the heat unit. The supply cable should...
  • Page 30 1.6.11.c) The room thermostat must be located away from the sun, radiators, electrical devices and/or other heat generators and approx. 1.5 m in height from the floor on an interior wall. (see Diagram 2, below) 1.6.11.d) External controls can be connected to terminals marked “CN_ROOM”, no voltage is to be applied to these terminals.

  • Page 31: Preliminary Electrical Checks

    10. 10.1. Check Operation of the Lotus E300 heat unit Starting up of the boiler is only carried out by Lotus authorised service personnel. Starting up of the boiler should only be carried out by authorized professional companies or service personnel who have a valid agreement with the manufacturer.

  • Page 32: Filling The Lotus E300 Heat Unit

    11. Commissioning Commissioning of the heat unit must only be carried out by a Lotus® approved installer. 11.1. Filling the Lotus E300 heat unit Cold Water Supply (Via an anti-Calc Filter) Open all domestic hot water taps supplied by the boiler, turn on the mains water supply to the boiler and open the mains water isolating valve below the heat unit.

  • Page 33: Filling The Sealed System Primary Circuit

    2.d) Open the filling loop isolating valves and allow primary system to fill until the pressure gauge on the fascia of the Lotus E300 heat unit reads approx. 2.0 bar. 2.e) Purge air from all radiators and air vent points in the primary system.

  • Page 34: Set The Programmable Pcb Thermostat

    The system, its function and control should be fully explained to the user. This must include: 4.a) DHW supply – Explain how the complete Lotus E300 heat unit is only heated. 4.b) Central Heating – Explain how the central heating system works. Explain the operation of the programmable PCB thermostat and the settings that have been programmed.

  • Page 35: Wilo Ksl/7-50/Sc Para Pump

    12. WILO KSL/7-50/SC Para Pump 12.1. Starting the pump 1.a) Before startup Do not start the pump until the system has been filled with liquid and vented. Make sure that the required minimum inlet pressure is available at the pump inlet. (0.5 Bar) When using the pump for the first time, the system must be vented.

  • Page 36: Alarm Or Warning

    12.3. Alarm or warning If the pump has detected one or more alarms or warnings, the LED lights up/flashes in case of a fault. When the fault has been resolved the operating panel switches back to operating status. 12.4. Control modes Recommended for two-pipe heating systems with Variable differential pressure radiators to reduce the flow noise at thermostatic valves.
  • Page 37 External control The required setpoint/actual value comparison for via iPWM signal & iPWM 1 control is performed by an external controller. mode A PWM signal (pulse-width modulation) is fed as a correcting variable to the pump. The PWM signal generator gives the pump a periodic sequence of impulses (the duty cycle) in accordance with DIN IEC 60469-1.

  • Page 38: Changing From Recommended To Alternative Pump Setting

    ptimum operation within minutes or hours. 12.5. Changing from If the recommended pump setting does not recommended to give the desired distribution of heat in the alternative pump rooms of the house, change the pump setting to the shown alternative. setting 12.6.

  • Page 39: Setting The Product

     Variable differential pressure We recommend Variable differential pressure mode in variable flow systems with relatively large pressure losses in the distribution pipes such as: two-pipe heating systems with thermostatic valves and long distribution pipes. two-pipe heating systems with thermostatic valves and high-pressure losses in system parts with total flow.

  • Page 40: Lock/Unlock The Button

    13. Maintenance and Servicing 13.1. Maintenance Requirements To ensure the continued optimum performance of the Lotus E300 heat unit it should be regularly maintained. Maintenance should be carried out by a competent person and any replacement parts used should be authorised Lotus E300 heat unit spare parts. It is recommended that maintenance is carried out annually and should include the checks detailed in the sections below.

  • Page 41: Annual Full Maintenance Procedures

    2.j) Interior cleaning. 2.k) Read error codes, correcting the error (record the error and send it to the Lotus technical support if necessary). 2.l) Software update if necessary (Card replacement is done in service and not software download).

  • Page 42: Electrical Checks

    13.5. Electrical Checks 5.a) Inspect all electrical terminations for signs of over-heating. 5.b) Check all earth bonding 5.c) Check all terminations are tight. 5.d) Check cable glands are tightened and grip cables securely. 5.e) Replace all panels before re-starting system.

  • Page 43: Fault Finding And Servicing

    14.1. Fault Finding Any suspected faults should be brought to the attention of your Lotus® authorised person for investigation and rectification if necessary. Investigation of faults is NOT permitted by the user. If the heat unit emits a buzzing noise and experiences reduced performance, it is likely that the heat unit is short of water and requires topping up.

  • Page 44: Summary Safety Features

    14.4. Summary Safety Features Function Effect Description Mechanical To take any expansion within This vessel contains air, 7 Litre feed and expansion the heating system body of as well as water from the tank with a 2 bar pressure the water (7Ltr@2Bar) central heating system.

  • Page 45: Protection Features

    feeds the electrodes and To sense DHW temperature, cuts power to the unit. if sensor goes out of range DHW Temperature Sensor The boiler will lock out or open circuit, the boiler (S4) and display an error code goes into lockout advising sensor error To sense room temperature (Fault Code 1141)
  • Page 46 pendently circul of the ation control pump unit. This fault is shown in boiler display as for 5 critical minut fault 5.c) Protection “No.X” Function 3: 5.b) Protection This fault Protection Function may only against Switching overheating heating system repaired protection heat If the...

  • Page 47: Pump Fault Finding

    disc controlle r is equippe d with a boil function that deactiva inst tes the alla boiler if tion voltage is less than 150 V or higher than 250 V. When low, voltage erro is in the 150-250 V range, the heat unit returns...
  • Page 48 electricia...

  • Page 49: Fault Signals

    Pump is not running Electrical fuse defective Check fuses although the power No voltage supply at pump Rectify the power interruption supply is switched on Cavitatio Increas n due to e the insufficie system pressur suction e within pressure permiss ible range Therma...

  • Page 50: Manual Restart

    Remed outside of conditio ns, and specificati request ckin ons (e.g. custom high Flashe modul service green Short temper circui ture). speed lower Check than during mains normal voltag operati water quanti ty/pre ssure ambie er/o conditi volt Manual restart volt The pump attempts an automatic •...
  • Page 51 Activate manual restart via the operating button: • press and hold for 5 seconds, then release. The restart function is initiated, and lasts max. 10 minutes. The LEDs flash in succession clockwise. To cancel, press and hold the operating button for 5 seconds. NOTICE After the restart, the LED display shows the previously set values of the pump.

  • Page 52: Replacement Parts

    Attach a hose to the hose connector and secure in place with a hose clip. Place the discharge point of the hose at a point below the level of the Lotus E300 heat unit where the water drained will safely drain away.

  • Page 53: Removing The Primary Circulating Pump

    1.e) Water carrying parts attached to the Lotus E300 heat unit primary circuit can now be removed. However, take care when removing parts as some residual water may still be contained and this may be very hot. 15.2. Removing the Primary circulating pump 2.a)

  • Page 54: Removing The 2 Amp Panel Mounted Fuses

    To fit the new main fuse, place new fuse into housing and follow these instructions in reverse followed by the commissioning instructions 15.7. Removing the Lotus E300 heat unit Status Display PCB 7.a) Switch off the power supply before starting any work on the product. Make sure that the power supply cannot be accidentally switched on.

  • Page 55: Removing The De-Stratification Pump

    15.9. Removing the Plasma Heating Unit Heat exchanger 9.a) Turn off the electrical supply. 9.b) Remove the keypad. 9.c) Release the water from the heating system. 9.d) Remove the sensors from the heat exchanger. 9.e) Drain the water from the heat exchanger or cap off. 9.f) Making a note of their position for reference, disconnect the electrical connections to the anode &...

  • Page 56: User Manual

    16. User Manual 16.1. Winter/ Summer Mode Short self-test is performed at the moment of initial power-up. At the time of the first power- up, everything is closed, except “Protection function 1 and 2” (section 12.5: Protection features) WINTER MODE: Operate the reactor if the conditions are appropriate (see Operation lower and upper threshold table).
  • Page 57 Table 2. Operation lower and upper threshold...

  • Page 58: General Controls

    16.2. General Controls When the ON / OFF button is pressed [ON]:  The LED of the corresponding button lights up.  All functions and buttons are available. Press the ON / OFF button again [OFF]:  The LED of the corresponding button goes out. ...
  • Page 59 If one of the WINTER and SUMMER MODE buttons is pressed, the other button is deactivated. If WINTER and SUMMER MODE buttons are pressed together for 1 sec.;  The LED of both buttons flash 3 times.  Reset The processor is reset. ...

  • Page 60: Menus

    16.3. Menus When the ENTER button (Navigation/Centre) is pressed, the MENU screen is displayed. Pressing it again or after 30 seconds of inactivity displays the main display screen. Switching between menus are done with the navigation keys. The preferences are shown in contrasts. Main Menu Selection Mode...
  • Page 61 Date Clear Error Codes Clear error codes on the system Select Boiler Mode E100/ E200/E300 E300 is always selected >90 Boiler Temperature Reaction time in degrees to be undertaken. i.e. a 5C Set Limit drop before producing heat again Exit Service Menu Select if want to cancel the settings.

  • Page 62: Warranty

    The water supply does not have a Chloride content greater than 250ppm. m) Units are not installed with uncontrollable heat sources (E.g. Wood Burning Stoves). n) The warranty card must be completed and sent back to Lotus as soon as possible for registration.
  • Page 63 h) The primary water circuit has been flushed and treated with a suitable inhibitor and is used only for domestic heating purposes. Within 60 days of installation the user completes and returns the guarantee Registration card supplied with the unit in order to register the product. Periodic loss of charge pressure from the expansion vessels is normal (indicated by an intermittent discharge of water from the expansion or primary pressure relief valves) and is not covered under the product guarantee.
  • Page 64 Ferhatpaşa mah . 4. sok. No :28 A3 Ataşehi r /i s tanbul 34888 nfo@utet.com.tr...

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