ELECTRIC BOILER INSTALLATION AND OPERATION MANUAL

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1 ELECTRIC BOILER PW INSTALLATION AND OPERATION MANUAL JASPI UK Telephone: JÄSPI KNOWS HOW TO CREATE WARMTH AND COMFORT

2 1. Contents 1. Contents 2. EC Compliance 3. Operating Principle 3.1. Function Diagram 4. Technical Data 4.1. Equipment 4.2. Mounting to the Wall 5. Piping Installation 6. Electric Wiring 6.1. To Be Considered During Installation 6.2. External Connections to the Boiler Terminal Strip 6.3. Electric Boiler Power Table 6.4. PCB Low Current Terminals Standard Supply 6.5. PCB Low Current Terminals Optional Supply 7. Electrical Diagram 8. Boiler Operation and Maintenance 9. Heat Control with Outdoor Temperature Control 9.1. Front Panel 9.2. Screen Modes 9.3. Settings 9.4. Temperature Decrease 9.5. Maintenance Menu 10. Troubleshooting Insufficient Heat Empty Automatic Control Screen If the Cause of the Trouble Is Not Found Resistance Values of Boiler Sensors for PCB Current Transformer Check 11. Installation Form 12. Warranty 13. Recycling Keep these instructions for the end user! Please make sure that the form on section 11 is completed after installation! Warranty is valid only when installation form is completed! READ THE INSTRUCTIONS THROUGH CAREFULLY AND ENSURE THAT YOU AND YOUR INSTALLER ARE FAMILIAR WITH THE UNIT BEFORE INITIAL START-UP. KEEP THE INSTRUCTIONS FOR FUTURE REFERENCE FOR YOURSELF AND OTHER POSSIBLE USERS. RECYCLE PACKING MATERIALS PROPERLY. All packing material parts are recyclable.

3 2. EC Compliance EC COMPLIANCE ASSURANCE KAUKORA OY Tuotekatu 11, P.O.Box Raisio, Finland The assurance covers electric boiler Jäspi PW. During manufacture proper manufacturing procedures have been used pursuant to the following directives and standards: 89/336/EEC 92/31/EEC 73/23/EEC 93/68/EEC Raisio Kari Björklund Quality Controller 3. Operating Principle Jäspi PW is a small-sized outdoor temperature controlled electric boiler designed for heating systems in small houses and flats. A small water volume of only 3,5 liters and fine automatic adjustment ensure effective energy savings. The water tank is made of very durable stainless steel alloy. PW's circulating pump, expansion tank, safety relief and filling valves are located behind the front plate. PW s automatic heat control based on outdoor / heating water temperatures maintains suitable user-defined temperature in the heating system. The boiler also functions without outdoor temperature control with a so-called set temperature control. PW is equipped with an automatic power control system which has a current transformer enabling effective use of the main fuse (25-63 A) considering other electric load of the house. Functioning heating system requires that the total heating power of the house is taken into consideration and planning and installation are made carefully. Where underfloor heating systems are used, the water temperature should not exceed the permitted value, that is why PW is fitted with a limiting thermostat to turn heating off when the set value is achieved (factory setting at 55 ºC). When the temperature drops below this value heating is resumed. Where radiators are used, the thermostat set value should be raised e.g. to 75 ºC. Thermostat boil dry protection (105 ºC) is provided as extra protection which is reseted by pressing the limiter button.

4 3.1. Function Diagram

5 4. Technical Data Dimensions (mm) (AxBxC) 660x470x250 Weight 35 kg Volume 3,5 l Design pressure 2.5 bar Max. power 12.2 kw Voltage 240 V, 1~ Frequency 50/60 Hz Backup power 4 kw Expansion tank volume 12 l Circulation pump 180 mm, 25/40 R3/4 Safety relief valve DN 15, 1.5 bar Automatic deaeration Shutoff drain R1/2 Max. temperature 100 C Min. temperature 0 C Supply: - Outdoor temperature sensor - 1 current transformer Optional supply: - Remote controller - Room condenser (only recommended for houses with radiator heating system). If room condenser is installed programme change must be done. - BY-PASS valve

6 4.1. Equipment 1. Automatic heating system deaerator 2. Safety relief valve 3. Expansion tank 4. Immersion heating element 5. Foam isolation 6. Water level switch 7. Circulation pump 8. Pressure gauge 9. Wall bracket 10. Sensor probe 11. Safety valve pipe R Drain and filling valve R Return / Inlet R Outlet R Electric leads 16. Main switch, pump switch, heating mode switch 17. Control board 18. Backup heating thermostat 19. Overtemperature thermostat

7 4.2. Mounting to the Wall 1. Pull out two screws on top of the boiler (back side) and detach the bracket. 2. Mount the bracket to a reinforced wall with four screws. 3. Hang the boiler on the bracket hooks. 4. Attach the two screws pulled out on phase 1 on top of the boiler. 5. Put a drain valve to the connection point.

8 5. Piping Installation Complete installation form (section 11) after installation. Install piping in accordance with current regulations and ensure that pipes cannot break. - The unit should be installed vertically in a designated dry warm room. - Check whether the expansion tank has sufficient volume for your site. - Ensure that the pre-pressure of the expansion tank is at least 0.5 bar. - To fill and empty the system easily, fit the connections of the electric boiler and heating system with shutoff valves. - Make sure to provide boiler drainage e.g. through the safety relief valves. The drain lines should be laid from the safety relief valves to the floor drain (drain pit). 6. Electric Wiring Only an authorized and qualified wiring company can install electric wiring. Unit s internal connections have been factory installed and tested. These connections cannot be modified. The unit should be connected to the power mains on site in accordance with current regulations and the connection diagram (see section 7). A power cable and fuses are determined according to the power rating of the unit. The maximum power of PW boiler (see picture 1, maximum power control) can be - Leave at least 0.8 m free space in front of the unit according to safety regulations. - When filling the heating system leave the safety valve open until some water comes out of the discharge pipe. Close the safety valve and continue filling the system until no air comes out and the pressure gauge is at 1 bar. - Heating system must be deaerated a couple of times so that there is no extra air in the system. - Heating system circulation between pump and boiler cannot be closed. When required, heating circle must be equipped with a valve (BY-PASS valve), which ensures the circulation between pump and boiler. selected from a number of options, and the boiler is suitable only for 1~ wiring. To achieve maximum efficiency of the main fuses, the electronic system is fitted with automatic current limitation. Current transformers must be installed at the central board of the house for measuring total current on site. Power lines should be laid through leads in the base plate to the connection point behind the front plate To Be Considered During Installation The current transformers connected to the mains must be closed when not connected to the unit. Check load balance applied to the main fuses of the house while giving consideration to: - ventilation (incoming air heating) - garage / warehouse electric heaters - car socket groups - refrigerating system groups - dish / clothes washing machine groups etc.

9 6.2. External Connections to the Boiler Terminal Strip Power wire 240 V, 50/60 Hz. Fuses and power wire determined for the unit according to the selected power rating. See table below for maximum power options Electric Boiler Power Table Step Power (kw) Current (A) * *= factory setting Picture 1. maximum power control 6.4. PCB Low Current Terminals Standard Supply Installed to look to the north-west on the shadowed external wall of the house at a distance from the vent valves. - Ensure that melt water and icing will not cause damage to the sensor. - If the outdoor sensor is installed near the wall inlet, make sure that the inlet is insulated properly. Connection of current transformer, wiring separately from power cables e.g. 2 x 1,5 N. Connected at the central board of the house for measuring total current on site. 2-3 Connection to external heating system e.g. heat pump. 240 VAC max. 5A PCB Low Current Terminals Optional Supply Optional external potential free control e.g. for clockwork or temperature drop switch in case you leave the house. Normally open. - Remote controller = optional supply. If outdoor sensor is connected remote controller can be used for fine adjusting of outdoor temperature curve.

10 7. Electrical Diagram

11 8. Boiler Operation and Maintenance Prior to start-up, ensure that: - The boiler and the heating system are filled with water and circulation is working - The air vent is open for air escape - Piping connections are sealed. Check also the internal factory made connections in the boiler piping. - The safety relief valve is working i.e. water escapes from the drain pipe during valve testing. When the installation is completed, connect the main switch of the unit, rotate the control switch to position 1=heating, and set desired temperatures at the printed circuit board (see section 9); now the unit is ready for operation. After the above start-up procedure, monitor the system functioning and ensure that the connections are tight, the safety relief valves function properly, and the heating system pressure is high enough. As the heating system can contain air after installation it should be deaerated several times. After deaeration check the pressure and add water if necessary. The protective hood of the air vent should be open. The system pressure should be approx. 1 to 1.5 bar (check pressure gauge at section 4.1.). Expansion tank pre-pressure must be checked every couple of years. PW operation is fully automated, thus ensuring easy service and maintenance. However, every user should be familiar with the boiler service instruments: pressure gauge, regulating and safety devices, switches, and automatic controls. Check the safety relief valves of the heating unit at least twice a year. The safety valve is activated by turning it anti-clockwise, and water flows through the safety valve pipe. If this does not happen, the valve is faulted and must be replaced. Do not discharge over ½ litre of water per check-up. Carefully add some water after check-ups and adjust system pressure at 1 to 1,5 bar. The pressure of the system s water space should remain stable and unchanged unless temperature varies. Variations depend on the expansion tank and its water space. If the amount of water in the system constantly decreases, i.e. you have to add water all the time, find and repair the leak point as soon as possible. Constantly adding fresh water contributes to corrosion in the piping. During summertime when no heating is required, the electric boiler can be switched off with the main switch of the unit. At the beginning of the heating period, ensure that the circulation pump functions properly and the system pressure is correct. Normal pump speed is III. To deaerate the pump, loosen the pump air screw holding the cap over the outlet as it can discharge water. If the pump has been out of use for a long while troubles can occur during start-up; if this is the case, use auxiliary start by turning the pump shaft next to the deaeration screw manually with a screwdriver (see picture 2.). Pump malfunction is avoided by switching pump on for a while once a month. Picture 2. Circulation pump activation. 1. Open plug. 2. Turn pump s axle with e.g. a screwdriver. 3. Close plug

12 9. Heat Control with Outdoor Temperature Control PW control automatically adjusts the temperature of heating system water. Need of heat varies according to outdoor temperature. Heating system water temperature is controlled via the heating curve. The colder outdoor temperature is, the warmer the heating system water is adjusted. Low-pitched curve (22-25) is typically suitable for houses with underfloor heating system, for which over 40 C temperature cannot be used. For example: If the selected curve is 25, heating system water temperature is approx. 25 C, when outdoor temperature is 0 C. The curve can be steeper in houses with radiator heating system. Recommended starting curve is 35. With this curve heating system water temperature is approx. 35 c, when outdoor temperature is 0 C. In less energy-efficient houses even steeper curves can be used. If room temperature decreases when outdoor temperature drops, select steeper curve (bigger number) and vice versa. If room temperature is constantly either too cold or too warm, adjust temperature increase + x C or decrease - x C in fine adjustment board. If PW is introduced at the construction stage of the property and the floors are still drying up, we recommend using low temperatures for heating system. Select lowest curve (22) and set fine adjustment for temperature at -20 C C. Picture 3. Heating curve

13 9.1. Front Panel

14 9.2. Screen Modes PW automatic control unit screens. Normally the screen visible is basic screen state, but when the timer is set or the unit receives power limitation or trouble messages, the screen varies between basic screen state and additional screen state.

15 9.3. Settings Heating control basic settings, heating curve selecting, fine adjusting and temperature limits.

16 9.4. Temperature Decrease This screen state is for selecting if a lower or higher heating setting is being used at a certain time of day.

17 9.5. Maintenance Menu For the installer only! The service menu is for setting main fuse size of the property and max. power of the unit.

18 10. Troubleshooting - In case of any trouble first ensure that it is not a case of power disruption or breakdown of main / group fuses. - Ensure that there is enough water in the system (check water level). - Ensure that the heating system pressure is at 1 to 1,5 bar. - Check the circulation pump and circulation through the pump and piping. Excess air in Insufficient Heat - Ensure that there is enough water in the system (check the pressure gauge). - Check that the power limitation message is not constantly on the unit screen, the cause is too much load on the main fuses at a time (sauna, washing machine, dryer etc.). - Check from the screen if the water temperature in the system meets the desired one. - If everything functions properly, increase the heating water temperature first by approx. 4 C. Monitor changes for 12 hours before the next possible adjustment. - If a red trouble-indicating lamp on the screen is on, check water level in the boiler Empty Automatic Control Screen Check power fuses on the board and the control circuit breaker in the boiler. If you cannot locate the trouble take the following steps to connect the backup heating of the system: - Ensure that there is enough water in the system and the pump is working. - Adjust the backup heating (see section 4.1. part number 18.) temperature to the desired level with the thermostat e.g. to ºC for heating system may prevent water flow. Check pump manual and section 8. of this boiler manual. - Check if overtemperature control has been activated. If so, deactivate by releasing plug and pressing in acknowledgement button once temperature has decreased (see section 4.1. part number 19.). Overtemperature control turns the main switch to off-position; switch power back on from the main switch. - In case of outdoor/boiler sensor troubles, the Error NOT CONNECTED message will be displayed on the screen. When the outdoor sensor fails, the automatic system will "assume" the outdoor temperature to be 0 ºC. When the boiler sensor fails, heating will be interrupted. Contact the installer / service provider. - Ask the circuit installer to find out which of the electric devices limits the boiler power. Also ask from the circuit installer whether the boiler maximum power was constrained during installation. Have the main fuses total load measured. houses with underfloor heating system and to ºC with radiator heating system (scale 0-80 ºC). - Then move the backup heating switch (see section 4.1. part number 16.) to the backup heating position; the indicator lamp will switch on and the unit will provide heating at partial power (4 kw) bypassing outdoor temperature automatic control. - Contact the installer / service provider If the Cause of the Trouble Is Not Found - Ensure that there is enough water in the system. - Ensure proper rotating of the circulation pump. - Contact your installer or service firm. Always use only original spare parts!

19 10.4. Resistance Values of Boiler Sensors for PCB Disconnect the sensor wire during measurement Boiler sensor type 22K NTC Outdoor sensor type 150R NTC INDICATE THE UNIT NUMBER AND YEAR OF MANUFACTURE UPON ORDER OF SPARE PARTS. Outdoor temperature (ºC) Outdoor sensor resistances (Ω) Boiler water temperature (ºC) Boiler sensor resistances (kω) When the outdoor sensor is removed the regulator will function at set temperature according to set value (10-80 C) Current Transformer Check Current values applied to the main fuses of the house (= current transformer measurement / location point) can be measured in PW by measuring the alternating current (AC) between the common connection point / each current transformer of the printed circuit Through A current transformers When the boiler sensor is removed the regulator will switch power off. board. By comparing the measured values with the table below you can see the currents flowing through the current transformers in correspondence with voltages. The adjustment range is between 25 and 63 A. Measured AC voltage from PCB 10 A 0.5 V 20 A 0.9 V 30 A min. adjustment range 1.4 V 40 A 1.8 V 50 A 2.3 V 60 A 2.7 V 70 A max. adjustment range 3.2 V

20 11. Installation Form The end user should ensure that the following form is completed after the installation of the unit. Unit number / year of manufacture Unit type Installer / company Date Wiring installer / company Date System operation / adjustment training Installer / company Date Installer settings prior to start-up Installed values Factory setting Max./min. temperature PCB settings of heating water Min. ºC Min.18 ºC in the heating system. Max. ºC Max. 40 ºC Max. installed power of the boiler (stage limitation 1-6). See table at section 6 and 6.3. kw Step 6 = 12.2 kw Set value corresponding to the main fuse of the house A. A 63 A Temperature decrease 0-20 ºC. ºC 0 ºC Selected heater water temperature at outdoor temperature of 0 ºC. See instruction. ºC 25 ºC 12. Warranty The warranty is confirmed to be two years for the boiler and one year for the components. The warranty is effective provided that installation is provided (or approved) by an authorized agent in accordance with this manual. 13. Recycling When removed from use, it must be agreed with a qualified installer that the unit is recycled according to agreement and local regulations.

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