EHC ECOSAVE 21K Instruction Manual Download Page 1

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GAS FIRED WALL MOUNTED CONDENSING
COMBINATION BOILER

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOTWATER

THE APPLIANCE IS FOR USE
WITH NATURAL GAS OR L.P.G

EHC ECOSAVE 21K

EHC ECOSAVE 25K

EHC ECOSAVE 32K

EHC ECOSAVE 37K

INSTRUCTION MANUAL

INSTALLATION, COMMISSIONING
& SERVICING

Summary of Contents for ECOSAVE 21K

Page 1: ...N BOILER FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOTWATER THE APPLIANCE IS FOR USE WITH NATURAL GAS OR L P G EHC ECOSAVE 21K EHC ECOSAVE 25K EHC ECOSAVE 32K EHC ECOSAVE 37K INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING ...

Page 2: ... Building Control LABC who will arrange an inspection or contact a government approved inspector LABC will record the data of compliance Gas Safe will record the data of compliance to the property You must ensure that the by Gas Safe is written onto the Benchmark Checklist Scheme Members only Contact Gas Safe or visit www gassaferegister co uk If you notify via Gas Scheme Gas Safe will then notify...

Page 3: ...the Water Pipes and Condensate Pipe 26 12 1 Water Pipes and Condensate Pipe ConnectionProcedures 12 2 GeneralPipeworkConnections 12 3 Water Pipe Size andWater Pressure 12 4 Pressure Relief Valve 12 5 Frost Protection Contents 13 Connecting the Flue 28 13 1 For a concentric flue system 13 2 For a separate flue system 14 Electrical Connections and Settings 29 14 1 Accessing the Controller Assembly 1...

Page 4: ...plier is responsible for properly purging the tank Ignition ploblems may occur if the tank is not bled properly In such cases frst contact the person responsible for filling the tank Safety Definitions 1 1 All safety messages will refer to potential hazards Precisely follow the instructions to avoid the risk of injury This is the safety alert symbol It is used to alert you of potential personal in...

Page 5: ...nal diaphragm BS 5440 Part 1 Flues BS 5440 Part 2 Ventilation BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 5482 2 1977 Domestic butane and propane gas burning installations BS 6281 1 1992 Devices without moving parts for the prevention of contamination of water BS 6282 2 1992 Devices with moving parts for the prevention of contami...

Page 6: ...21K A 19 3 kW 23 1 kW EHC Ecosave 25K A 23 1 kW 23 1 kW EHC Ecosave 32K A 29 5 kW 34 2 kW EHC Ecosave 37K A 34 2 kW 34 2 kW The appliance always gives priority to DHW supply The appliance is designed to be used with a circulation pump a divert valve assembly a flow sensor a DHW plate heat exchanger a safety valve and a CH expansion vessel A separate DHW expansion vessel is not required Internal fr...

Page 7: ...tion pump 11 Flow 12 burner 13 Return 14 Pressure Relief 15 Gas Inlet 16 DHW outlet 17 Mains Water In 18 Cable Entry 19 DHW Flow 20 Condensate Syphon 21 Air Pressure Sensor 22 Gas 23 Gas Air Mix 24 Latent Heat 25 Primary Heat 26 Mixing Flow 27 Exhaust 28 Electronic Ignition 29 Burner Mixing 30 Ignition Control Panel 2 3 ow temperature the pressure in the heating system the operating mode and addit...

Page 8: ...g k Weight 35 38 0 5 Heating Water Connection mm 22 Connecting Diameter Domestic Hot and cold Water Connection mm 15 Technical Data 3 Unit Ecosave 21K A Ecosave 25K A Ecosave 32K A Ecosave 37K A Heat Input Max Min kW 19 6 4 9 23 5 4 9 30 0 7 0 34 9 7 0 Domestic Hot Water Input Max Min kW 23 5 4 9 34 9 7 0 Heating Output Max Min Flow Return 50 30 C kW 19 3 4 8 23 1 4 8 29 5 6 8 34 2 6 8 Domestic Ho...

Page 9: ... Data EHC Hydraulic Data 3 2 The following graph shows the development of the Available Head Pump to the System 0 100 200 300 400 500 600 0 200 400 600 800 1000 1200 1400 1600 1800 Heating Flow Rate l h Head mbar ...

Page 10: ...Front view 110 4 10 376 3 37 366 255 Overhead view 55 49 2 39 1 122 5 75 60 60 4 25 5 6 1 366 3 440 67 5 Bottom view All dimensions in mm A Heating outlet 22mm A B C E B Heating inlet 22mm C Gas inlet 22mm D DHW outlet 15mm E Main water inlet 15mm ...

Page 11: ...H Flow CH Return Note Low water pressure error cancelling function If the water pressure falls below 0 4 bar the low water pressure error occurs on the control panel Note Weather Compensation If an outdoor temperature probe is connected the weather compensation function can be used With this function the target primary temperature is automatically set according to the outdoor temperature K factor ...

Page 12: ...s Valve Heat Exchanger outlet Inlet DHW Water Inlet Gas Water Sensor Flow DHW Heat Exchanger Ignition Electrode Flame Sensing Electrode Metal Fibre Burner Expansion Vessel Three way Valve Mixing Flow Guide DHW Pre heating mode If the CH mode is not used and the service setting for the DHW pre heating mode is set to ON the DHW pre heating mode can be used The primary water circulates through the DH...

Page 13: ...Air Flow Checking During the start up sequence the no air check function supply Installation Requirements 6 Location 6 1 DANGER The appliance must be fitted to a suitable wall to prevent fire and explosion At the installation site the flue that passes through the outside wall or roof must be routed properly in order to satisfactorily remove flue products Also an adequate air supply must be provide...

Page 14: ...4 0 2 mm temperature rated to 90 C The appliance must be earthed All pipes to the appliance must be cross bonded Wiring must comply with IEE Wiring Regulations and any local regulations which may apply to a fixed wired stationary appliance External wiring must be correctly earthed polarized and must comply with related regulations rules Note The way the electricity supply is connected must facilit...

Page 15: ...riodical replacement of the limestone chipping or neutralizing agent is required The rate of depletion of the limestone varies depending on the usage of the appliance Occasionally check the depletion of the neutralizer and replace the limestone if any depletion is observed CAUTION Requirements for the condensate piping are as follows So that condensate can be properly drained the t diameter of the...

Page 16: ...fitting Extarnal air break Air gap 3 From the appliance to a soakaway hole surrounded by limestone chipping 2 5ºminimumdrop 100 mm Φ min sealed plastic tube Limestone chippings 500mmmin Ground level Drainage holes 22 mm plastic condensate drainage pipe max extarnal length 3 metres Holes in the soakaway must face away from the building Holedepth 400mmmin by300mmΦ 25 mm 4 From the appliance to the g...

Page 17: ...ot be t within 60 cm of any openings Formula of Length Equivalency This is the formula for sizing the pipes for the intake of the combustible air and the discharge of the combustion products The Length equivalency L eq in these instructions are for the lengths of the pipes which share the same cross sectional dimensions Resistance of the component under standard condition Resistance of a 1 metre l...

Page 18: ...e appliance to be connected to the flue system However the total flue length cannot exceed the prescribed maximum flue length If concentric bends are required please bear in mind that each of them has resistance that corresponds to its specific linear length There are 2 separate connections horizontal and vertical for the concentric flue system and separate flue system Study the following connecti...

Page 19: ...xtended vertical flue system Φ 60 100 mm A B Minimum 350 mm Total flue length A B 2 x 45 elbow 21 2 x 1 19 0 m Diameter of Pipe mm Max Flue Length m Reduced Flue Length m Φ 60 100 21 a b 45 1 0 b 90 1 3 Φ 80 125 70 45 1 0 90 2 2 Grey coloured numbers are used in the calculation of this sample ...

Page 20: ...ter of Pipe mm Max Flue Length m Reduced Flue Length m Φ 80 80 110 a b 45 1 4 a 90 2 2 Grey coloured numbers are used in the calculation of this sample Separate Vertical Flue D C A B Total flue length A B C D 2 x 45 elbow 110 2 x 1 4 107 2 m Diameter of Pipe mm Max Flue Length m Reduced Flue Length m Φ 80 80 110 a 45 1 4 90 2 2 a Grey coloured numbers are used in the calculation of this sample Min...

Page 21: ...ction 10 Making the Gas Connection section 11 Electrical connections and Settings section 14 Final Check and Commissioning section 15 Instructing the End User section 16 Fitting the flues t JUUJOH UIF DPODFOUSJD øVF TFDUJPO t JUUJOH UIF TFQBSBUF øVF TFDUJPO Connecting the Flue TFDUJPO G UIF øVFT BSF OPU öUUFE CFGPSF UIF JOTUBMMBUJPO PG UIF BQQMJBODF BT DPOWFSTJPO G OFDFTTBSZ QQFOEJY ...

Page 22: ...ng Bracket including washers and nuts User instructions t Installation Instructions t Tapping Screws Anchors 4 sets Flue Adapter Condensate Drain Hose Transporting the Appliance 9 1 CAUTION The appliance may be damaged if it is not properly transported Transport the appliance using the right transportation t equipment such as a hand truck with a fastening belt or special equipment for maneuvering ...

Page 23: ... vertically level Make a hole for the flues minimum diameter 116 mm 2 Drive the supplied anchor bolts for the bracket into the 3 marked points minimum diameter 13 mm Fit the wall mounting bracket with the tapping screws and 4 anchors Take great care when applying the boiler to the wall 5 mounting bracket CAUTION This appliance must always be lifted and carried by two people Hook 167 165 130 Boiler...

Page 24: ... installation and connection of the gas supply to the boiler must be in accordance with BS 6891 When connecting a gas meter to the pipe t the gas meter must be connected to the pipe by a gas supplier or contractor only an existing meter should be checked to ensure that it is capable of measuring the required gas supply rate When fitting the gas pipe t do not use pipes that are smaller than the boi...

Page 25: ... checked for leaks and purged as described in the standards Gas leaks may cause an explosion that induces serious harm or property damage When purging open all doors and windows and extinguish cigarettes pipes or any other naked lights Gas inlet adapter Bottom view Valve kit for external connections 3 Each boiler is supplied with an EHC Valve Kit for each external connection Please refer to the in...

Page 26: ...ot use excessive force to connect the pipes This t might damage external parts and cause leaks Water Pipes and Condensate Pipe 12 1 Connection Procedures Connect the water pipe to the water inlet adapter and 1 DHW outlet adapter located at the bottom of the appliance which is clearly indicated on the boiler Connect the water pipe to the heating supply adapter and 2 to the heating return adapter th...

Page 27: ... modes and this function works even if the The Energy Saving 2 staged Frost Protection system protects both inside the unit automatically operates to circulate water when the All exposed pipework should be insulated to meet current standards isolate gas supply valve isolate the electrical supply If the appliance is installed in an extremely cold location take necessary measures such as covering th...

Page 28: ...m kit includes an adapter as shown in the figure which helps connect the appliance to the flue system Assemble the components and seals as shown in the figure Flue Outlet t Install the flue adapter to the appliance 1 Connect the flue bend to the adapter and seal 2 Air Intake t Remove the blanking plate 1 Connect the flue adapter to the appliance The adapter 2 comes with this appliance Connect the ...

Page 29: ...d pull up the hooks 2 on the top 2 and 2 on the bottom of the appliance Lift off the front panel from the wall mounted unit 3 Remove the 3 screws on the underside of the controller assembly 4 and 1 screw to the right of the controller assembly Then pull Controller assembly Clamp the controller assembly downward 5 Remove the screw on the front of the controller cover and then the controller cover r...

Page 30: ...ance Remove the black silicone tube B from the cable gland 2 Insert wire C into cap A and the silicone tube B 3 Insert the prepared cable into the cable gland put the cap 4 back on and secure Important Please ensure tha all electrical connections t are tight and secure This unit must be earthed t Note The main supply to the boiler must be t connected through a double pole isolator B C 3 2 4 1 A an...

Page 31: ...e on the PCB use a 3A quick blow fuse Isolate the boiler at the mains 1 Remove the plastic access cover at the rear of the control 2 panel to gain access Locate and replace the fuse in the upper portion of the PCB 3 L N E 1 2 Room Thermostat Room Controller Detail view 3 4 Tank Storage Thermostat 5 6 Outdoor Temperature Sensor 12 EXT 3 WAY CH 13 EXT 3 WAY DHW 14 EXT 3 WAY COM 9 P E 10 Neutral 11 L...

Page 32: ...EXT 3 WAY DHW 14 EXT 3 WAY COM 9 10 11 12 13 14 1 2 3 4 5 6 1 2 Room Thermostat Room Controller 5 6 Outdoor Temperature Sensor DIP Switch Settings 14 5 The dip switches are on the top of the control panel as shown on the diagram Refer to the following table to ensure that the dip switches are properly set to the correct position depending on boiler type Switch No Function ON OFF 1 2 Maximum operat...

Page 33: ... Amp fused spur DANGER Before turning on the power ensure that the appliance is t earthed Electrocution may occur if the appliance is not properly earthed Controller cover Turning the Power ON OFF Press the main ON OFF button on the control panel to turn on the power Hold the button for more than one second to turn the power off main ON OFF button DANGER Before turning on the power replace the con...

Page 34: ... supply pressure should be 20mb system will be full of water at this stage and set to a pressure of 1 5bar and free of air as per the filling and pressurising instructions appliances turned ON and the boiler set to maximum you can set the boiler to maximum output by selecting dip switch No 2 to ON we recommend the minimum working pressure with the boiler running at maximum should read 17mb at test...

Page 35: ...he right to increase the CO2 level and turn it to the left to decrease it Enter actual values in the service report 5 The following mentioned items are done in conjunction 6 with the checking and adjusting of the CO2 level 6 1 Prepare the water column meter or manometer Maintain the appliance at the minimum rated output while checking the gas air ratio with a water column meter or manometer Set th...

Page 36: ...Final Check and Commissioning 36 EHC Installing the Front Cover 15 5 Replace the controller assembly 1 Install the front cover and secure 2 Controller assembly ...

Page 37: ...ve been satisfactorily removed The system can be regarded as being thoroughly flushed when the system water value is within 10 of the mains water value Differences over 10 mean that significant cleaner residues have been left in the system and further flushing is required If not removed cleaner residues will promote corrosion and negate the cleaning process 5 Once the system has been cleaned thoro...

Page 38: ... the appliance Open the full bore drain point at the same time introduce fresh Use a rinse test meter such as the Fernox TDS meter to ensure that 6 Repeat step 6 on all radiators appliance and circulator pipework 7 Re open all radiators and circulate for a further 15 minutes and 8 Once the system has been cleansed thoroughly then add a Fernox Protector F1 to the system The product must be added as...

Page 39: ... Display the domestic hot water temperature by pressing the MODE 2 button Check whether the set temperature and the domestic hot water 3 temperature are the same Check whether the reset operation is normal Press the RESET button 1 Check whether the display is the same as shown on the right 2 Check whether the operation set in the service menu is correct Display the service menu by holding the MODE...

Page 40: ...hen doing a gas conversion Check the gas pressure CO settings Check the gas equipment for soundness Check the operation of the control panel If it works normally when the switch is ON If the water pressure for the heating system is normal If the temperature setting for the heating system is normal If the temperature setting for the domestic hot water is normal If the reset operation is normal If t...

Page 41: ...nce incorrectly t Countermeasures for appliance malfunctions t Location and operation of the gas shutoff valve t Explain the following error codes if the appliance malfunctions The error codes will blink and be displayed on the digital control Panel Error Code Reason Action required E02 Low water level Contact Engineer E03 Ignition failure Reset the appliance E04 Flame simulation E05 Supply water ...

Page 42: ...l a c i r t c e l E 18 Wiring Diagram 18 1 Electrical 42 EHC ...

Page 43: ...CP20011 ALL APS bracket 3 ECP20003 ALL Bottom bracket 12 ECP20012 ALL Tube 4 ECP20004 ALL Lock out 13 ECP20013 ALL Cover 5 ECP20005 ALL Insulation top 14 ECP20014 ALL Controller Ass y 6 ECP20006 ALL Insulation side 15 ECP20015 ALL Air Intake Packing 7 ECP20007 ALL Controller bracket L 16 ECP20016 ALL Air Intake Plate 8 ECP20008 ALL Controller bottom bracket 17 ECP20017 ALL Case Clip 9 ECP20009 ALL...

Page 44: ...5 32 37kW ECP60035 32 37kW Mixer Chamber Assembly ECP30046 21 25kW ECP30038 21 25kW ECP40046 32 37kW ECP40038 32 37kW ECP30047 21 25kW 39 ECP20039 ALL Gas outlet adapter ECP40047 32 37kW 40 ECP20040 ALL Gas control valve 48 ECP20048 ALL Gas nozzel packing 41 ECP20041 ALL Gas inlet adapter 49 ECP20049 ALL O ring Mixer box sealing ECP30042 21 25kW 50 ECP20050 ALL Air supply pipe packing ECP40042 32 ...

Page 45: ...Water Way Parts 19 3 82 120 45 Parts List EHC ...

Page 46: ... adaptor 111 ECP20111 All 3 way valve 91 ECP20091 All Secondary heat exchanger inlet adaptor 112 ECP20112 All Heating supply adaptor 92 ECP20092 All Primary and secondary heat exchanger connection pipe 113 ECP20113 All Water pressure sensor ECP30093 21 25kW 114 ECP20114 All Check valve ECP40093 32 37kW 115 ECP20115 All Temperature limit sensor 94 ECP20094 All Primary heat exchanger inlet adaptor E...

Page 47: ... the CO level and turn it to the left to decrease it After adjusting it check the maximum output CO level again Adjusting the nozzle pressure value Adjust the nozzle pressure with the gas air ratio adjustment screw C so that the offset value falls between 0 to 0 1 mbar After the adjustment turn off the power 13 Close off the flue test point after you are satisfied that the 14 analyzer reading are ...

Page 48: ... 866 23 1 23 5 2 513 0 955 Min 4 128 4 8 4 9 0 542 0 196 Ecosave 32K A Max 25 370 29 5 30 0 3 214 1 207 Min 5 848 6 8 7 0 0 750 0 281 Ecosave 37K A Max 29 412 34 2 34 9 3 720 1 398 Min 5 848 6 8 7 0 0 750 0 281 CO2 Level Gas Type Mode Ecosave 21K A Ecosave 25K A Ecosave 32K A Ecosave 37K A G20 CH Mode 9 4 9 4 DHW Mode G31 9 1 9 1 CH Mode DHW Mode Max Output Min Max Min 9 4 9 4 10 4 10 4 10 0 10 4 ...

Page 49: ...ing accessories are disposed of properly Packaging Leave the disposal of the transport packaging to the installer that installed the appliance Warranty Standard Terms Warranty Conditions To receive your 2 years parts labour warranty please complete WarrantyRegistraiton Card supplied with the appliance or simply Our Promise If you experience any malfunctions with your new appliance we aim to provid...

Page 50: ...STALLATIONS If required by the manufacturer record the following CO2 OR CO ppm OR CO CO2 Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood b...

Page 51: ...E 7 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Gas Safe Register Number Comments Signature SERVICE 9 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Gas Safe Register Number Comments Signature SERVICE 2 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Gas Safe ...

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Page 55: ...Disclaimer All details within this document are correct at the time of printing however they may be subject to change ...

Page 56: ...EHC Ltd ISO 9001 2008 ...

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