Varmebaronen EP 900 G2 Use And Installation

400v 30-stage electric boilers
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MANUAL
Use and Installation
400V 30-stage Electric Boilers
EP 900 G2, EP 1080 G2, EP 1200 G2
and EP 1400 G2
EP900-1400_G2_400V_v1.2._241010.fm

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Summary of Contents for Varmebaronen EP 900 G2

  • Page 1 MANUAL Use and Installation 400V 30-stage Electric Boilers EP 900 G2, EP 1080 G2, EP 1200 G2 and EP 1400 G2 EP900-1400_G2_400V_v1.2._241010.fm...
  • Page 2: Table Of Contents

    Contents 1. About the Manual ......... 4 2.
  • Page 3 10.8. Power Circuit, EP 900 G2 400V ....... . 35...
  • Page 4: About The Manual

    1. About the Manual This manual contains information and instructions for installation, operation, and maintenance. For more information about the control system, see Manual EP G2, Control System and Menus. The instructions must be handed over to the user, who must read through them carefully and under- stand the content.
  • Page 5: Safety

    2.3. Safety • These instructions contain information regarding the installation, operation, and maintenance of the electric boiler. The instructions and documentation for connected equipment must be read and understood before starting installation, operation and maintenance. • The installation, operation, and maintenance of the boiler must be carried out in accordance with these instructions and applicable standards and norms for heating systems, and be performed by a qualified person with knowledge about boilers and associated equipment.
  • Page 6 • When handling the boiler, be aware of its centre of gravity: Boiler model The boiler’s centre of gravity Slope when the boiler Slope when boiler tips over (degrees) tips over (percent) EP 450 – 700 G2 Approx. 75 cm from bottom >...
  • Page 7: Installation Information

    Boiler Electrical installer Plumbing installer Serial number: Name: Name: Installation date: Telephone number: Telephone number: Boiler type Model EP 900 G2 EP 1080 G2 EP 1200 G2 EP 1400 G2 Art. 5850 5852 5854 5856 Settings Installed power Number of stages...
  • Page 8: Overview

    4. Overview 5: “STOP” button. 6: Display 47: Pressure gauge 48: Design label 5. Functions The EP 900 – 1400 G2 series consists of boilers with power of 900–1400 kW. The boilers adjust the temperature, with thirty power stages that can be limited down to one power stage.
  • Page 9: External Power Limiting

    5.7. External Power Limiting Connection for external blocking, analogue control signal 0 - 10V or 4 - 20mA for control of power. 5.8. External Boiler Set Value Connection for external setpoint in the form of a 0–10 V or 4–20 mA signal. 5.9.
  • Page 10: Installation

    6. Installation 6.1. Installation Overview 1. Prepare accessories and installation materials that are not included in the boiler delivery. 2. Install the boiler. 3. Install the pipe system. 4. Fill with water. 5. Instal the electricity. 6. Test the boiler in accordance with the Installation engineer’s checklist. 7.
  • Page 11: Flow Requirements

    Table 1: Recommended Diluted Water Values Subject Recommended value Risk in the event of deviating value Alkalinity At least 60 mg/l Corrosion. Carbonic acid Max. 25 mg/l Corrosion. content Corrosion. If the sulphate content is higher Sulphate content Max. 100 mg/l than the chloride content, copper corrosion may occur.
  • Page 12: Pipe Installation

    • The boiler is placed standing indoors. The installation site shall be dimensioned for the weight of the water-filled boiler. • Place the boiler on a firm surface, preferably a concrete foundation. • If the product is to stand on a soft surface, base plates must be placed under the boiler’s adjusta- ble foot bolts.
  • Page 13: System Principles - Legend

    6.5.1. System Principles - Legend Stop valve Check valve Safety valve Shunt valve Flow direction Circulation pump Automatic venting High pressure guard Low pressure guard Open expansion tank Closed expansion tank 6.5.2. System Principle - Open System When assembling an open system, keep the following in mind: •...
  • Page 14: Filling And Draining

    • Dimension the safety valve discharge line so that the blow-off capacity is not impeded. • Steam or liquid flowing out of the safety valve when it opens must be led away safely in accordance with the requirements of SS EN 12828. Normally, this means on the outside of the building or in a flash tank.
  • Page 15: Electrical Installation

    6.6. Electrical Installation 6.6.1. Electrical Safety Electrical installation must be carried out in accordance with the app- licable regulations, by an authorised electrical installer or by someone who is covered by the company’s self-inspection programme. Cables must be dimensioned and routed in accordance with applicable electrical installation rules.
  • Page 16: Operating Voltage

    For more information, see Component Location, Ch. 10.5. 500 hrs after installation, re-tighten incoming power cable connections using torque tools 6.6.3. Operating Voltage The boiler control circuit is supplied by an external power supply of 230V ~, fused with 6A. An all-pole switch with a mini- mum break distance of 3 mm must be installed before the boi- ler.
  • Page 17: Safety Equipment - Pressure Guards

    6.6.6. Safety Equipment - Pressure Guards If the boiler was supplied without pressure guards, the installation must be supplemented with these. Connect external safety equipment as shown in the image below. For more information, see Control Circuit, Ch. 10.7. 6.6.7. Load Limiter Short circuit the current transformer when switching on/off, otherwise the circuit board can be damaged! Metering is done with primary/secondary current transformers.
  • Page 18: Shared Safety Equipment

    6.6.9. Shared Safety Equipment The alarm signal must use the same phase as boiler control! If the boiler can share the safety equipment with other boilers in the installation: Connect the alarm signal, 230 V~, from existing safety equipment to terminal 1 in terminal block X01.
  • Page 19: Outdoor Sensor (Optional)

    To control the external temperature setpoint through current or voltage: Plug the signal cables into input P20 or P21. For more information, see Control Circuit, Ch. 10.7. For configuration of control signal, see the sections Regula- tion, Setpoint Source and Installation/Analogue Input P20 and P21 in Manual EP G2, Control System and Menus.
  • Page 20: After Installation

    7. After Installation 7.1. Checklist Before Start-up Has the electrical installation been adapted to the local power supply? Are the boiler and heating system filled with water and vented? Is the pressure correct? Are all pipe connections leakproof? Is the vent valve open so that the air can escape? Are all necessary valves open? Are the power cable connections tightened to the specified torque? Is the flow direction for the circulation pump correct?
  • Page 21: Operation And Maintenance

    • Explain alarms, warnings and limitations. • Show how to acknowledge an alarm or warning. • Show how to reset the overheating protection devices. • Show how to reset the pressure guards. 8. Operation and Maintenance 8.1. Safety Valve To maintain the safety function, the heating system’s safety valves must be operated regularly. 8.2.
  • Page 22: Alarm, Load Switches And Safety Guards

    8.5. Alarm, Load Switches and Safety Guards Always check the cause of a guard being triggered. If the guards are triggered repeatedly, the cause must be remedied. The following applies to guards: • The display shows which guard(s) has/have been triggered. •...
  • Page 23: Adjust Pressure Guards (Optional)

    8.5.4. Adjust Pressure Guards (Optional) Set the pressure guard so that the trigger pressure is between the boi- ler’s normal operating pressure and the safety valves’ opening pressure. Set the low pressure guard so that the trigger pressure is slightly below the system pressure when the system is not heated up.
  • Page 24: Troubleshooting

    9. Troubleshooting 9.1. Irregular Operation If the electric boiler steps up a number of stages and immediately steps down again, the reason may be that the boiler has too low flow. Troubleshoot the boiler by following these steps: 1. Check that circulation pumps are working. 2.
  • Page 25: Technical Data

    10. Technical Data 10.1. Limitation Levels Table 4: Limitation Levels Stage EP 900 G2 EP 1080 G2 EP 1200 G2 EP 1400 G2 43.3 57.7 46.6 67.4 86.6 103.9 115.5 93.2 134.7 129.9 155.9 173.2 139.8 202.1 173.2 207.8 230.9 186.4...
  • Page 26 Table 5: Electrical Specifications Power 1080 1200 1400 Switch B1 326.2 Switch B2 372.8 Switch B3 349.5 Switch B4 349.5 Current 1299 1559 1732 2021 Switch B1 Switch B2 Switch B3 Switch B4 Fuse protection 8 groups of 8 groups of 315 8 groups of 315 8 groups of 315 power, max...
  • Page 27: Hvac Specifications

    10.3. HVAC Specifications Table 6: HVAC Specifications: EP 900 G2 EP 1080 G2 EP 1200 G2 EP 1400 G2 Volume Litres Design pressure Design pressure Test pressure 0.86 Test pressure Design temperature °C Operating temperature (20-95) °C Ambient temperature ≤10-30 °C...
  • Page 28: Components

    10.4. Components Table 7: Components Art. no. Description EP 900 G2 EP 1080 G2 EP 1200 G2 EP 1400 G2 110035 Immersion heater, 15 kW 110037 Immersion heater, 18 kW 110038 Immersion heater, 20 kW 110039 Immersion heater, 23.3 kW...
  • Page 29 Table 9: Included in Safety Equipment Art. no. Description Quantity 440197 Pressostat DSL, 0-6 bar 245077 Automatic air bleed valve Safety valve...
  • Page 30: Component Location

    10.5. Component Location 1: Terminal block, X01, control circuit F1 Fuse for Power Group 1 8: Overheating Protection, 1, maximum temperature F2: Fuse for Power Group 2 limiter, STB 9: Overheating Protection 2, maximum temperature F3, F4: Fuses for Power Group 3 limiter, STB 10: Switched power supply, 230Vac /24Vdc F5 - F8: Fuses for Power Group 4...
  • Page 31: Dimensions, Ep G2 900-1400V

    10.6. Dimensions, EP G2 900-1400V 33: Screwed cable joint 41: Automatic air bleed valve 34: Safety pipes 42: Safety valves 35: Flow line 43: High pressure guard 1 36: Return line 44: High pressure guard 2 37: Draining 45: Low pressure guard 38: Adjustable foot bolts 46: Terminal block, X02, for pressure guards 39: Cable flanges...
  • Page 33: Control Circuit, Ep 900 - 1400 G2

    10.7. Control Circuit, EP 900 - 1400 G2 Pressure guards are included in factory-fitted safety equipment (optional). Any intervention in the boiler’s electrical equipment that requires tools must be carried out under the supervision of a qualified electrician! The control voltage is not affected by the load switches! External voltage may be present.
  • Page 34 1: Terminal block, X01, control circuit 23: Connection for the load guard’s current transformers. 2: Output, main alarm. 24: Connection, level sensor, P17 3: Connector, clamps 3, 4, 5 and 6. Removed when con- 25: Analogue output, P18 and P19 necting pressure guards or safety equipment.
  • Page 35: Power Circuit, Ep 900 G2 400V

    10.8. Power Circuit, EP 900 G2 400V The control voltage is not affected by the load switches! External voltage may be present. To cut the power supply to the boiler, all load switches must be set to 0 position. Lock the switches!
  • Page 36: Power Cicuit Ep 1080 G2 400 V

    10.9. Power Cicuit EP 1080 G2 400 V The control voltage is not affected by the load switches! External voltage may be present. To cut the power supply to the boiler, all load switches must be set to 0 position. Lock the switches! A: Temperature sensor Power Group Power (kW)
  • Page 37: Power Circuit, Ep 1200 G2 400V

    10.10. Power Circuit, EP 1200 G2 400V The control voltage is not affected by the load switches! External voltage may be present. To cut the power supply to the boiler, all load switches must be set to 0 position. Lock the switches! A: Temperature sensor Power Group Power (kW)
  • Page 38: Power Cicuit Ep 1400 G2 400 V

    10.11. Power Cicuit EP 1400 G2 400 V The control voltage is not affected by the load switches! External voltage may be present. To cut the power supply to the boiler, all load switches must be set to 0 position. Lock the switches! A: Temperature sensor Power Group Power (kW)
  • Page 40 Värmebaronen AB Arkelstorpsvägen 88 SE-291 94 Kristianstad Tel. + 46 44 22 63 20 www.varmebaronen.se www.varmebaronen.com info@varmebaronen.se...

This manual is also suitable for:

Ep 1080 g2Ep 1200 g2Ep 1400 g2

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