Heatrae Sadia ElectroMax Installation & Servicing Instructions Manual
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Heatrae Sadia ElectroMax Installation & Servicing Instructions Manual

Combined electric flow boiler and direct unvented water heater
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See also: Instructions for Using
ELECTROMAX
Combined Electric Flow Boiler
and Direct Unvented Water Heater
Please read and understand these instructions before starting work
INSTALLATION &
SERVICING INSTRUCTIONS
commissioning
Installation & Servicing Instructions
1

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Summary of Contents for Heatrae Sadia ElectroMax

  • Page 1 ELECTROMAX INSTALLATION & Combined Electric Flow Boiler and Direct Unvented Water Heater SERVICING INSTRUCTIONS Please read and understand these instructions before starting work commissioning Installation & Servicing Instructions...

  • Page 2: Table Of Contents

    1.4 Contents Check List Safety Valves 2.0 Technical Data 7.4 Set the Programmable Room 3.0 General Requirements Thermostat 3.1 Location of the Electromax 7.5 Preliminary Electrical Checks 24 3.2 Water Supply 7.6 Check Operation of the 3.3 Pipework, Fittings and Outlet/ Electric Boiler Terminal Fittings 7.7 Setting the Automatic By-pass...

  • Page 3: Introduction

    1.0 Introduction 1.1 Important Notes The Electromax Domestic Hot Water cylinder is directly heated by means of The Electromax must be installed in electric immersion heaters. The electric accordance with the manufacturer’s central heating boiler although housed instructions and all relevant regulations in the same casing operates completely in force at the time of installation.

  • Page 4: Storage, Unpacking And Handling

    Programmable Room Thermostat which is supplied loose 1.4 Contents check list with the Electromax for remote siting in a suitable, convenient position. Within the Electromax packaging the following The necessary cold water mains supply components are supplied.

  • Page 5: Technical Data

    2.0 Technical Data S peci f i cat i on / f eat ure El ect ri c B oi l er & P ri m ary C i rcui t 8. 3kW at230 V E l ect r i calsuppl y f r equency 50 H z I nt er nalf use r at i ng ( P um p suppl y) 2 A m ps...
  • Page 6 Diagram 1 Dimensions Minimum clearance Lifting Points over Top Panel for In Upper Rear access Panel LEFT HAND FRONT SIDE Tundish Viewing Window Side Panel Lifting Points (Mirrored in Right Hand Side Panel) Min. clearance either side Lifting Points In Base Installation &...
  • Page 7 Diagram 2 Key Components Primary System Primary System Expansion Vessel Expansion Vessel Air Valve Primary Circulating Primary System Pump Expansion Vessel Connection Electric Control Circuitry Automatic Air Vent (Mounted Behind Fascia) Top Panel Fascia Panel User Interface Panel Electrical Connection Panel Mounted Fuses 3 amp Terminal Blocks Primary System Pressure...
  • Page 8 Diagram 3 Pump Characteristics SPEED SPEED INPUT FULL LOAD LOCKED ROTOR SETTING R.P.M. POWER (W) CURRENT (A) CURRENT (A) 2300 0.23 0.30 2100 0.20 0.25 1700 0.16 0.20 H (m) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Q (m /h) Diagram 4 Automatic Bypass Valve Characteristics 1200 1500...

  • Page 9: General Requirements

    3.1 Location of the Electromax Wherever possible the mains water supply pipe should be in 22mm OD (copper) or The Electromax must not be sited outside or 25mm OD (Blue MDPE). The minimum mains in any location where it could be exposed to water supply requirements should be 1.0 bar...

  • Page 10: Pipework, Fittings And Outlet/Terminal Fittings

    Electromax immediately after the Cold Water Combination Valve (see diagram 5). Electromax Housing Unvented Cylinder Unvented System...

  • Page 11: Sealed Primary Systems

    Electromax additional air vents must warranty. return pipes and at any point where air is 3.5 Sealed Primary Systems likely to collect. The Electromax boiler must be installed in a sealed primary system. All necessary primary Electromax to allow thermostatic radiator Automatic Circulating...

  • Page 12: Installation - General

    4.1 Positioning the Electromax The lower front panel (Panel A on Diagram 7) is secured by spring clips and is removed Decide where the Electromax is to be installed. Reference must be made to the either side of the panel. Once removed, the...

  • Page 13: 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. (see Diagram 8). There are four cable entry This is supplied in the accessory kit supplied holes in each upper side panel;...

  • Page 14: Installation - Plumbing

    Electromax a point remote from the unit if this is more to accommodate any water expansion that convenient.

  • Page 15: Balanced Hot Water Supplies

    In these systems it is essential that the tundish is Secondary circulation is not recommended for the Electromax as it is intended for of discharge will not be visible. Consult Off-Peak electrical operation. During other periods the electricity supply is interrupted the manufacturer’s recommendations with...
  • Page 16 Water may drip from the discharge pipe of b. have a vertical section of pipe at least the pressure-relief device and that this pipe 300mm long below the tundish before any must be left open to the atmosphere. elbows or bends in the pipework. The pressure-relief device is to be operated c.
  • Page 17 Worked example of discharge pipe Subtract the resistance allowed for 4 No. sizing 22mm elbows at 0.8m each = 3.2m The example below is for a G1/2 temperature Therefore the permitted length equates to: relief valve with a discharge pipe (D2) having 5.8m 4 No.

  • Page 18: Primary (Central Heating) Pipework

    A filling loop is provided within the Electromax casing to fill the primary circuit directly from the cold water supply. to enable the Electromax boiler to be isolated When the system is full and correctly from the primary circuit for maintenance and servicing.

  • Page 19: Installation - Electrical

    The main incoming electrical supply to the running costs from your Electromax unit it should be connected to an Off-Peak electrical and voltage for the Electromax and any other supply. The “Economy 10” tariff, which is electrical requirements for the property.
  • Page 20 24 Hour supply connection (NB NOT Boiler connection) A suitable electrical connection must be taken from the Off Peak supply to the Electromax A suitable electrical connection must be taken terminal block. The supply cable should from the 24 Hour supply to the Electromax be 1.5mm...

  • Page 21: Boiler Connection (45 Amp)

    IEE Wiring Regulations for correct cable sectional area suitable for a 240V supply, sizing). It must be routed into the Electromax bell wire MUST NOT be used. The cable must be routed into the Electromax via one (see section 3.3, page 10). The Live (Brown) conductor should be connected to the (see section 3.3, page 10).

  • Page 22: Cylinder

    Loop isolating valves are closed (see Diagram 15). d. Open the cold water supply isolating valve and allow the Electromax cylinder to fill. When water issues from the tap, allow to run for a few any residue, dirt or swarf, then close tap.
  • Page 23 Repeat the above steps for the Valves Primary System Pressure Relief Valve on the Electromax (see Diagram 16). a. Slowly manually open, for a few After this operation check that the seconds, the Temperature and Pressure...

  • Page 24: Thermostat

    c. The electrical system should be Thermostat checked for Earth Continuity, Short Circuits, Polarity and Resistance to a. Fit the batteries supplied to the Earth. Programmable Room Thermostat. d. The immersion heaters are factory set The battery compartment is located to give a hot water storage temperature behind the hinged cover under a snap of approx.

  • Page 25: Valve

    Check the primary FLOW pipework valve. from the Electromax begins to rise in c. With the boiler on (“DEMAND” and temperature. “HEAT” indicators illuminated) and h. When the boiler is operating at its the pump running, slowly turn the maximum power output (“HEAT”...

  • Page 26: Demonstration To User

    (indicated by a “tap” symbol, e. User Instructions – see Diagram 19, page 25). The switch Hand over the Electromax Installation should be illuminated when on. Instructions, the Danfoss TP 5000 d. Press the DHW Boost switch (indicated Installation and User Instructions and by a “tap”...

  • Page 27: Maintenance

    To e n s u r e t h e c o n t i n u e d o p t i m u m be 3.5 bar. If lower than the required performance of the Electromax it should be setting it should be re-charged using regularly maintained.

  • Page 28: Operation Of Cylinder Safety Valves

    e. Disconnect the wiring from the immersion heater thermostats. Remove the thermostats by carefully pulling outwards from the immersion particles. heaters. n. Close hot tap and then open successive f. Unscrew immersion heater backnuts hot taps to purge any air. using the key spanner supplied with 8.4 Operation of cylinder safety valves the unit.

  • Page 29: Electrical Checks

    d. Check the charge pressure of the Vessel using a tyre pressure gauge. The pressure (with system de-pressurised) should be 1.0 to 1.2 bar. If lower than the required setting it should be re- charged using a tyre pump (Schrader valve type).
  • Page 30 These checks should be carried out TERM I N ALS by a competent installer or an authorized Heatrae Sadia service engineer or agent. A range of replacement parts (see Section 9.2) D O ES TH E C H O N SW I TC H...
  • Page 31 Diagram 25 Electric Boiler Fault Finding Diagram 28 Electric Boiler Fault Finding Alarm 2 Demand Faults 1 TH ER E I S N O W ATER I S TH ERE I N TH E SYSTEM . 240V AT TH E ALARM TR I PS DU R I N G SW I TC H O FF D EM AN D I N DI C ATO R...
  • Page 32 Diagram 30 Water Heater Fault Finding Diagram 31 Water Heater Fault Finding Master Off Peak (Lower) Immersion Heater Faults I S 240V I S D H W C H EC K O FF PEAK O FF PEAK ( LO W ER ) SW I TC H O N SU PPLY AT C H EC K ELEC TR I C AL...
  • Page 33 Diagram 32 Water Heater Fault Finding Boost (upper) Immersion Heater Faults I S 240V C H EC K 24 H O U R BO O ST ( U PPER ) SU PPLY AT C H EC K I N TERN AL I M M .H EATER NO T ELECTR I C AL SU PPLY 24 H O U R...
  • Page 34 Diagram 34 Water Heater Fault Finding Expansion Valve Faults C H EC K D H W D I SCH AR G E EXPAN SI O N R ELI EF EXPAN SI O N I N TER M I TTEN T VALVE D I SC H AR G ES VESSEL C HAR G E PR ESSU R E I S 3.

  • Page 35: Replacement Parts

    A range of replacement parts is available for authorized Heatrae Sadia service engineers the Electromax unit. Refer to the following or agents. diagrams to aid in identifying the parts you require and the relevant Heatrae Sadia order code.
  • Page 36 Diagram 37 - Pump Assembly Pump Assembly Replacement Parts i r c 1. Auto air vent and extension 95605031 Diagram 38 - Element Assemblies Element Assembly Replacement Parts i r c 1. Immersion heater (upper) 95606963 2. Immersion heater (lower) 95606964 3.

  • Page 37: Servicing

    Filling Loop draining are indicated. (see Diagram 20, page 27). Place the discharge point of the hose at a point below the level of the Electromax Circuit where the water drained will safely a. To avoid draining the complete primary drain away.
  • Page 38 Diagram 40 Pump Removal pump (see Diagram 40) Pump Extension Auto Air a. Drain primary circuit. Vent b. Unscrew top of Pump electrical housing Pump O Ring and remove by pulling upwards. c. Unscrew Pump cable securing gland. Disconnect Pump connections from O Ring terminals by pressing the spring Pump...
  • Page 39 Diagram 42 Auto By-pass Valve Removal Valve (see Diagram 42) Automatic a. Drain primary circuit. Bypass b. Unscrew the compression connections Valve at inlet and outlet of the Valve. c. Remove the Automatic Bypass Valve. Primary Off Peak Flow d. Replacement is a reversal of the above Immersion Heater procedure.
  • Page 40 Diagram 44 Primary Expansion Vessel Expansion Vessel (see Diagram 44) Removal a. Drain primary circuit. Primary Expansion b. Unscrew union nut at connection Vessel between the Expansion Vessel and Support c. Lift Expansion Vessel from moulded Nest 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...
  • Page 41 D i agr am 46 El ect r i c B oi l erC ont r olPC B Control PCB Ter m i nalBl ocks a. Remove cover from over the Electric Boiler Control pcb (see Diagram 43, page 39). b.
  • Page 42 Diagram 48 Fascia Panel Removal (see Diagram 48) Front Fascia a. Drain primary circuit Panel 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.

  • Page 43: Guarantee

    Global Warming Potential (GWP) of 3.1. Any valves and controls fitted are of Heatrae Sadia recommended type and The unit has not been modified or tampered with in any way, and has been regularly maintained as detailed in these instructions.

  • Page 44: Spares Stockists

    Tel: 0117 961 6670 William Wilson Ltd. Unit 3A, 780 South Street, Whiteinch, Glasgow, G14 0SY Tel: 0141 434 1530 The policy of Heatrae Sadia Heating is one of continuous product development and, as Main No.: 01603 420100 Main Fax: 01603 420218...

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