Models: 95 022 001 C-400 95 022 002 C-600 95 022 003 C-900 95 022 004 C-1100 95 022 005 C-1200 GC No.EB-205-06 GC No.EB-205-02 GC No.EB-205-03 GC No.EB-205-01 GC No.EB-205-04 95 022 101 U-401 95 022 102 U-601 95 022 103 U-901 95 022 104 U-1101 95 022 105 U-1201 GC No.EB-205-08 GC No.EB-205-09 GC No.EB-205-10 GC No.EB-205-11 GC No.
THANK YOU FOR PURCHASING THIS HEATRAE SADIA AMPTEC FLOW BOILER. IT HAS BEEN DEVELOPED TO PROVIDE YOU WITH MANY YEARS OF TROUBLE-FREE SERVICE WHEN INSTALLED IN THE PROPER MANNER. PLEASE READ AND UNDERSTAND THESE INSTRUCTION PRIOR TO INSTALLING YOUR HEATRAE SADIA AMPTEC FLOW BOILER. THIS AMPTEC ELECTRIC BOILER MUST BE INSTALLED (SECTIONS 1.0 - 7.0), COMMISSIONED (SECTION 8.0) AND MAINTAINED (SECTION 10.0) BY A COMPETENT PERSON ONLY.
1.0 DESCRIPTION The AMPTEC electric flow boiler is designed to heat re-circulated water used in wet central heating systems. The water is heated when it is passed over electric immersion elements, which are contained in a chamber. The temperature of the water is monitored and controlled by a modulation technique switching on the immersion elements. The switching of the elements is carried out by solid-state technology contained in the control section of the boiler.
.0 INSTALLATION - GENERAL Care must be taken when handling and connecting the boiler not to damage or stress it in any way. Prior to installation the boiler must be stored in a dry, safe place. The boiler must be mounted in an upright position. The boiler must be fixed to a wall before connecting pipework. When choosing the position for the boiler, ensure sufficient clearances to house the unit and for servicing. 50mm minimum clearance each side of the boiler is required.
.0 installation PLUMBING The installation must be carried out in accordance with the relevant requirements of: The appropriate Building Regulations, either The Building Regulations, The Building Regulations (Scotland) or Building Regulations (Northern Ireland) The Water Fittings Regulations or Water Byelaws in Scotland.
NOTE: TO COMPLY WITH BUILDING REGULATIONS, PART L (PART J IN SCOTLAND), WHEN THE AMPTEC IS USED FOR CENTRAL HEATING PURPOSES, A ROOM THERMOSTAT MUST BE FITTED TO CONTROL THE BOILER (SEE PAGE 15). Do not fit thermostatic radiator valves to the room with the control thermostat, other rooms may be fitted with thermostatic radiator valves. DO NOT OPERATE UNDER THERMOSTATIC RADIATOR VALVES ONLY. Use standard pumps, controls, room thermostat, valves, etc.
EXPANSION / SAFETY RELIEF SYSTEM AUTOMATIC AIR VENT 150mm MINIMUM OPEN VENTED SYSTEMS MUST HAVE A MINIMUM HEAD OF 1.
AUTOMATIC AIR VENT 22mm PIPE FLOW 12 LITRE/ MIN 28mm PIPE FLOW 24 LITRE/ MIN EXPANSION / SAFETY RELIEF SYSTEM 35mm PIPE FLOW 36 LITRE/ MIN PUMP AMPTEC BOILER AMPTEC BOILER AMPTEC BOILER RELAY SYSTEM 95970136 SERVICE VALVE 35mm PIPE FLOW RETURN 36 LITRE/ MIN 28mm PIPE FLOW 24 LITRE/ MIN 22mm PIPE FLOW 12 LITRE/ MIN DRAIN VALVE FIGURE FOUR: THREE BOILER PLUMBING SCHEMATIC A typical plumbing schematic connecting 3 x 1200 boilers together.
6.0 installation - electrical requirements all wiring must be carried out in accordance with CURRENT iee WIRING regulations. The AMPTEC boiler must be installed by a qualified competent tradesman in accordance with supplied instructions and drawings to ensure correct operation. Check the main incoming supply to the property to ensure there is sufficient current and voltage for the size of the boiler or boilers to be installed.
Connections for 2 or more boilers. 1 CONN5: Main power-supply cables. Connect each boiler to its supply live, neutral, and earth, as described above. The supplies to each boiler can be on different phases if using a 3-phase supply. 2 CONN1 pins 2 & 3: Control signal. Join all the boiler ‘R’ terminals on the control terminal block together, and then connect them to the switched live control signal to the programmer control circuit.
MAINS SUPPLY N BOILER SUPPLY MCB L CONSUMER UNIT AIR MCB GAP MCB MCB DOUBLE POLE RCD OR DOUBLE POLE ISOLATION 3A FUSED SPUR OR MCB L LOCAL TO BOILER DOUBLE POLE ISOLATION SWITCH OR DOUBLE POLE RCD TO CONTROLS PROGRAMMER / ETC N DEMAND SIGNAL FROM CONTROLS/ PROGRAMMER ETC (SEE TYPICAL WIRING DIAGRAMS) PUMP N R E N HEAT RESISTANT CABLE L N CONN1 E T L CONN5 AMPTEC BOILER EARTH BONDING TO BE PERFORMED IN ACCORDANCE WITH BS7671 FIGURE EIGHT: BOILER SUPPLY USING EXISTING CONSUMER UNI 11
MAINS SUPPLY CABLE PUMP SUPPLY CABLE 0.5mm2 - 1mm2 BOILER CONTROL CABLE 0.5mm 2 - 1mm2 LIVE EARTH NEUTRAL LIVE NEUTRAL EARTH RUN NEUTRAL CASE EARTH NO CONNECTION CONTROL PUMP NC N R E N L NC N R E N L CONTROL PUMP CONN 1 REMOVE TOP COVER ONLY TO GAIN ACCESS TO THE CONNECTIONS ON THE PRINTED CIRCUIT BOARD INSIDE THE BOILER HOUSING FS 1 2A 240V (5 X 20mm) FIGURE NINE: BOILER WIRING DIAGRAM 12 N L SUPPORT BACK OF PCB WHEN TIGHTENING SCREWS SUPPLY CONN 5 ENSURE SCREWS ARE TIGHT.
CYLINDER STAT C 1 2 ROOM STAT 2 1 3 2 PORT VALVES BLUE GRN/YLW BROWN GREY ORANGE FROM 3A FUSED SPUR OR MCB BLUE GRN/YLW BROWN GREY ORANGE E N L 1 TO BOILER 2 3 4 5 6 7 8 9 10 N RUN L N CH ON HW ON CH OFF HW OFF TIME CONTROLLER FIGURE TEN: TYPICAL S PLAN WIRING DIAGRAM 13
MID POSITION VALVE CYLINDER ROOM STAT STAT 2 1 3 C 1 2 FROM 3A FUSED SPUR OR MCB E N L 1 TO BOILER BLUE G/YELLOW BROWN GREY ORANGE 2 3 4 5 6 7 8 9 10 9 10 N RUN L N CH ON HW ON CH OFF HW OFF TIME CONTROLLER FIGURE ELEVEN: TYPICAL Y PLAN WIRING DIAGRAM PROGRAMMABLE ROOM THERMOSTAT A B C FROM 3A FUSED SPUR OR MCB E N L 1 TO BOILER 2 3 4 5 N RUN FIGURE TWELVE: TYPICAL HEATING ONLY WIRING DIAGRAM 14 6 7 8
7.0 INSTALLATION - REVISED BUILDING REGULATIONS Heating Controls To Comply With The Revised Building Regulations (Part L For England. Part J for Scotland). New Dwelling 1. 2. 3. 4. 5. 6. 7. 8. 9. The installation must be a fully pumped system. Independent temperature and time controls for both heating and domestic hot water. Controls to interlock with the boiler. TRV’s alone do not comply. An automatic bypass must be used if a bypass is required. Gate-valves do not comply.
8.0 COMMISSIONING The boiler controls are fully automatic, making the operation very simple. Only after the system has been flushed through and then filled with water, inhibitor and set to the correct pressure (sealed systems), can the electrical supply be switched on. Check 1. When filling the system check for leaks. The warranty will be invalidated if water leaks into the boiler. Ensure the joints above the boiler are sound. Check 2.
5. The pump is operated from the boiler control. It should be connected to the pump terminals on the boiler control board. The pump will run whenever the call indicator is illuminated (green) either flashing or steady, and it will also continue to run if the boiler is hot, even after the demand has ceased. It will turn off the pump when the boiler temperature falls below approximately 750C. It will also turn the pump back on if the water temperature rises above 750C again.
MAIN POWER ON IS TEMP SWITCH OPEN I.E. FAULTY OR BOILER OVER TEMP YES CALL LED RED ALARM LED FLASHING NO CONTINUE CHECK FOR ALL AS LONG AS BOILER IS POWERED RUN TO ON PUMP ON AND PRE-HEAT ON THEN WAIT FOR 1 - 1.5 MINUTES DO BOTH THERMISTOR BEADS READ SAME VALUE I.E.
9.0 Operation and indicators The Supply indicator (green) will remain illuminated all the time the supply is present to the boiler. The Call indicator will illuminate (green) on demand from the programmer and thermostats or (red) for an alarm overheat condition. It will flash (green) for 2 to 3 minutes during which it carries out self-tests before allowing the boiler to produce heat. At the end of this period it will remain on steady (green), until the heating demand is satisfied.
11.0 Replacing the Main Power PCB Note. Before any maintenance is carried out on the system, ensure that the electrical supply has been disconnected first. Care must be taken as the water may be scalding hot and at high pressure. Maintenance on the boiler can only be carried out by a qualified and competent tradesman in accordance with supplied instructions. Removal of the Main Power PCB 1 Switch OFF electrical supplies to the boiler.
12.0 FAULT FINDING 1 Should the alarm indicator illuminate ‘flashing’ (red) instantly on power up, then the connections ‘Conn 4’have become loose or disconnected in transit or if the ALARM indicator is ‘flashing’ (red) and the CALL indicator is (red), then ‘Conn 3’ or the thermostatic switch wires have become loose. 2 Should the alarm indicator illuminate ‘flashing’ (red) during the call checking period then there is a problem due to lack of water or air in the system.
THE BOILER IS NOT OPERATING IS THE SUPPLY LED ILLUMINATED PLEASE CHECK THE FOLLOWING BEFORE GOING THROUGH THE FAULT FINDING CHART: CHECK INSTALLATION IS CORRECT ALL ISOLATING VALVES ARE OPEN THE PUMP IS RUNNING GO TO SUPPLY LED OFF FAULT FINDING SECTION YES GO TO ALARM FAULT FINDING SECTION NO GOTO CALL LED FA ULT FINDING SECTION YES IS THE ALARM LED ILLUMINATED THE SYSTEM IS FULL OF WATER (PRESSURISED) AND PURGED OF AIR THE PROGRAMMER AND CONTROLS ARE ON NO NO IS THE CALL LED FLASHING THE EL
SUPPLY LED OFF IS THE MAIN SUPPLY AVAILABLE NO CHECK 240V IS SUPPLIED TO THE MAIN POWER TERMINAL CONN5 YES IS THERE 230V ON TVR 1 MAIN PCB NO CHECK FOR SHORT CIRCUITS ON WIRING TO THE PUMP. IF OK REPLACE FS1 FUSE. T 2A 240V 20 x 5mm YES IS THERE 8V DC ON C1 MAIN PCB NO REPLACE THE MAIN POWER PCB YES REPLACE THE CONTROL PCB FIGURE EIGHTEEN: SUPPLY LED OFF ALARM TRIPS INSTANTLY ON POWER UP.
ALARM TRIPS DURING SELF CHECKING BUT NOT INSTANTLY THERE IS NO WATER IN THE SYSTEM. SWITCH OFF IMMEDIATELY. CHECK AND FILL BEFORE RESTARTING. FIGURE TWENTY: ALARM TWO ALARM TRIPS AFTER A FEW MINUTES OF OPERATION IS THE PUMP RUNNING YES CHECK FOR A RESTRICTION IN THE FLOW. CHECK THE BYPASS, CHECK THE SERVICE AND RADIATOR VALVES. CHECK FOR AIR IN THE SYSTEM. NO IS THE PUMP NEON ILLUMINATED YES NO FIGURE TWENTY ONE: ALARM THREE CHECK AND OPEN SERVICE VALVES. CHECK AND REPLACE THE PUMP.
CALL LED NOT FLASHING IS THE 230V DEMAND AVAILABLE NO CHECK AND SET THE PROGRAMMER AND THERMOSTATS ON YES IS THERE 230V BETWEEN R AND N CONTROL NO CHECK THE WIRING TO THE BOILER YES IS NEUTRAL CONNECTED TO N CONTROL NO NEUTRAL MUST BE CONNECTED TO N ON THE CONTROL CONNECTOR YES CHANGE THE CONTROL PCB FIGURE TWENTY THREE: CALL LED NOT FLASHING CALL LED NOT STEADY AFTER 3 MINUTES DOES THE MAIN RCD TRIP YES NO CHANGE CONTROL PCB CHECK THE INSULATION ON THE ELEMENTS FIGURE TWENTY FOUR: CALL
14.0 PUMP - RELAY CONTROL FOR AMPTEC BOILERS 2 or 3 boilers on single phase 240V or three phase 415V supply Isolation relays must be used as shown in figure twenty three below for 2 or more boilers to operate the pump. Boilers can be connected on a single phase 240V supply or on separate phases of a 415V supply. Relay specification: Coil Contacts Isolation Capacitor 240V 50 Hz 240V 10Amps N/O (Normally Open) Coil to Contact - 415V minimum working. 4.
15.0 SHOWER – RELAY CONTROL FOR AMPTEC® BOILERS. Limitations on electrical supply Where there is an electric shower and an electric flow boiler installed, the electrical supply may be overloaded if both units are operating at the same time. To prevent this condition a simple switch over relay box must be added. Connections: - The coil of the relay is connected across the switched supply to the electric shower.
16.0 GUARANTEE. This product is guaranteed against faulty materials and manufacture for a period of 2 years from the date of purchase provided that: 1. The unit has been installed in accordance with the Installation and User Instructions and all relevant Codes of Practice and Regulations in force at the time of Installation, and that all necessary controls and safety valves have been fitted correctly. 2.
