TERMO ELECTRIC BOILER INSTALLATION MANUAL OSO TERMO RS -M

TERMO ELECTRIC BOILER INSTALLATION MANUAL OSO TERMO RS -M

Contents 1. Introduction... 1 1.1. Applicable documents... 1 1.2. Retention of documents... 1 1.3. Features & benefits... 1 1.4. Operation of domestic hot water (where applicable)... 1 1.4.1. Suitability... 1 1.4.2. Operation on S-plan system... 1 2. Termo M range... 2 2.1 Key to Termo boilers... 2 2.2 Technical data... 3 2.3 Power supply characteristics 240V... 3 3.0. Installation... 4 3.1. Content included in delivery... 4 3.2 Standards & Regulations... 4 3.3. Physical Installation site... 4 3.3.1 Select position for boiler... 5 3.3.2 Fitting the boiler hanging bracket... 5 3.3.3 General recommendations when handling... 5 3.3.4. Removing/fixing the front and top case... 5 3.4. Plumbing & Heating installation & commissioning... 6 3.4.1 Installation... 6 3.4.2 Ancilliary components... 6 3.5. Connection to the electrical mains supply... 7 3.6. Connecting external controls... 8 3.6.1 Connect room thermostat/programmer... 8 3.6.2. Connecting external pump on TERMO RS boilers... 8 4. Commissioning... 8 4.1. Control panel key... 8 4.2 Protection from freezing... 9 5. Fault finding guide...10 6. Maintenance...15 6.1. Periodic checking...15 7. After Sales service information...15 8. Cascade power limiter...15 9. OSO Hotwater UK Ltd...15 10. Appendices...15 10.1 Termo RS-M with space heating and water heating...16 10.1.1. Hydraulic diagram Termo RS-M...16 10.1.2. Electric diagram Termo RS-M...16 10.1.3. S-plan wiring layout...17 10.2 Termo RS space heating only...17 10.2.1 Hydraulic diagram Termo RS-M...17 10.2.2. Electric diagram Termo RS-M...18 10.2.3. S-Plan wiring layout Termo RS-M...18

Terminology used in this manual The central heating boiler water circuit is called primary The domestic hot water is called secondary (dhw) 1. Introduction Thank you for purchasing the Oso Termo range electric central heating boiler. To ensure a correct and safe installation and economical use, please read these instructions thoroughly before installation. 1.1. Applicable documents The following additional documents are provided with the appliance: For the owner of the system: Instructions for use Warranty card 1.2. Retention of documents For the qualified technician: Instructions for installation Electrical drawing for the appliance Please pass on this installation manual to the owner of the system. The owner should retain the manuals so that they are available when required. 1.3. Features & benefits TERMO products are modulating and economical central heating boilers that may be used as independent or additional source of heat. The boiler provides wet system central heating by passing the primary water over the immersion heaters. Heating elements are located on under-side of boiler ensuring elements are constantly immersed in heating medium (water with appropriate inhibitor). Power is modulated automatically to control 1, 2 or 3 immersion elements with built in step regulator or manually with switches on the control board. The boiler operates on principle of rapid heating smaller water quantities, energy use is 100% efficient. Power outputs available are 7.2, 10.8, 14.4 kw. The boiler has an automatic pump overrun for both central and water heating that prevents a build up of heat in the boiler. The boiler reservoir is insulated with 19 mm self-extinguishing Armaflex insulating material, which is sufficient to direct the heat only to the heating system. Temperature operation can range from 20 o C to 90 o C. 1.4. Operation of domestic hot water (where applicable) 1.4.1. Suitability Termo RS-M boilers are able to heat a central heating system containing space heating and a separate indirect water storage cylinder using an S-plan system. Termo RS-M boilers can also be used in a space heating only situation where water heating can be achieved by a separate stand-alone direct water storage cylinder. OSO believe that this is a simpler system that is more suitable in most domestic circumstances and will allow use of economy electricity tariffs, thus saving on water heating fuel costs. 1.4.2. Operation on S-Plan system. There is no DHW priority built into the boiler. A standard S-plan system will allow heating and hot water circuits to be heated on demand. If a DHW priority is required, certain central heating programmers will offer this. Recommended temperature inside boiler while heating domestic hot water is 75 o C 80 o C. Observe Honeywell ST6400 manuals for more detailed description of domestic hot water parameters. Page 1

2. Termo RS-M 2.1 Key to Termo RS-M 1. Primary flow 7. Control panel 13. Drain valve (not supplied) 2. Primary return 8. Cable entry point 14. Isolation valves (not supplied) 3. External boiler jacket 9. Contactors and RCD switch 15. Manual venting valve (not supplied) 4. Boiler 10. Charge and discharge valve 5. Armaflex Insulation 11. Pocket with temperature probe 6. Immersion heaters 12. Safety valve (supplied loose) Page 2

RS - M 2.2 Technical Data For Termo Rs - M Boilers Power kw Capacity Lit. Dimensions mm Weight kg Maximum oprerating pressure Connection Power supply MPa (bar) 7.2 A 330 B 750 10.8 6 C 230 D 100 21.4 0,25 (2,5) 3/4 240V N ~ 50/60 Hz 14.4 E 57 F 126 2.3 Power supply characteristics 240V POWER nominal current MCB Rated short-circuit breaking capacity I cn (EN 60898) Rated short-circuit breaking capacity I cn (IEC 947-2) Cable size* RCD switch type 7.2 kw 30 A B32-1 3 x 6 mm 2 40-2/0.03 A 10.8 kw 45 A B50-1 10 ka 15 ka 3 x 10 mm 2 63-2/0,03A 14.4 kw 60 A B63-1 3 x 16 mm 2 80-2/0,03A min. conductor's cross-section in mm 2 is based on maximum length of 20 m. Cable sizes must be selected according to latest version of IEE wiring regulations. Page 3

3.0. Installation 3.1. Content included in delivery TERMO boilers are delivered pre-assembled. Check that all parts have been delivered intact. For exact list of parts see figure and table below. If parts are damaged or missing, please consult Oso Hotwater UK Ltd. Contents included with delivery Item Description 1 TERMO boiler 2 Instructions Electrical drawing, Warranty card 3 Hanging bracket 4 Safety valve (not fitted to boiler in case of TERMO RS) Table of contents included with delivery 3.2 Standards & Regulations The Oso Termo range of boilers are BEAB approved and CE marked. Health and Safety at Work Act 1974 - When working with Termo boilers, ensure that protective clothing and equipment is used appropriate to parts that may considered hazardous to health and safety Control of Substances Hazardous to Health (COSHH 1988) - Glues, paints and sealants are used in the manufacture of this product and present no known hazards when used in the manner for which they are intended. The guarantee is only valid if the following the following conditions are observed: The boiler must be installed by a registered engineer to comply with current building regulations, IEE electrical wiring regulations (BS 7671), local authority regulations, water supply regulations and health and safety at work regulations. Other Relevant British/European standards should be adhered to, including BS 5449 - Specification for forced circulation hot water central heating for domestic premises, BS 7593, treatment of water in domestic hot water central heating systems 3.3. Physical Installation site IMPORTANT - MOVING THE BOILER EXCEEDS THE RECOMMENDED WEIGHT FOR A ONE MAN LIFT. The boiler must be handled and transported carefully and stored in a safe, dry place. TERMO RS-M is designed for wall installation in an upright position. Wall brackets are provided on the back of the boiler. The boiler should be fixed in position on a suitable load-bearing wall prior to pipe connection. The boiler should be fitted in a dry place not subject to extremes of temperature. Cylinder cupboards and kitchens are acceptable but bath or showers rooms are not. Page 4

3.3.1 Select position for boiler The boiler should preferably be installed on the lowest point in relation to the installation. This ensures that elements are always immersed in water and there is no danger of burning out. When positioning the boiler, ensure there is adequate space surrounding to allow for pipe connection, ventilation, servicing and replacement of components including the immersion heaters. Refer to diagrams below for guidance. Access is required to the control panel connections at underside of the boiler and the power supply connection, located at left bottom side of boiler. Ensure the boiler is in a location where it will not be affected by water drips or splashing. Ensure that ventilation to the boiler is not impeded by towels, linen etc placed very close to the boiler. Do not place towels or linen on top of the boiler. The figure below shows minimum recommended clearances Recommended minimal distances 3.3.2 Fitting the boiler hanging bracket Fix the hanging bracket (see page 9 No. 3) to the wall using suitable plastic plugs and M8 or M10 screws (not supplied). Decide the position of the bottom of the boiler, giving due consideration to the recommended minimum clearance and then drill holes to accept the boiler mounting plate. Screw points should to be drilled 624mm above the bottom of the boiler casing. Note: If the boiler is to be fitted in a timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler. 3.3.3 General recommendations when handling Clear the route before attempting the lift. Ensure safe lifting techniques are used keep back straight bend using legs. Keep load as close to body as possible. Do not twist reposition feet instead. If 2 persons performing lift, ensure coordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip. Always use assistance if required. Positioning of Appliance for Final Installation Lift up boiler (3) above hanging bracket (2) Gently lean it to the wall (1) Slide it down to hanging bracket (2). Wall mounting 3.3.4. Removing/fixing the front and top case 1. Grasp the front case by its sides 2. Pull it towards the front and remove it by lifting it off the unit 3. Push top cover towards back 4. Lift it off the unit. Page 5

3.4. Plumbing & Heating installation & commissioning 3.4.1 Installation Fit the supplied safety valve to the heating return point on the installation see point 12 page 2 diagram. Ensure that no valve is placed between the safety valve and the boiler. To avoid draining the entire primary system during boiler maintenance it is recommended that isolation valves are fitted to the flow and return pipes immediately below the boiler. Connect the primary flow and return pipes for the central heating system to the labeled connections on the boiler. Connections can be made using wither the top or bottom connections as shown on page 2. Connect the mains water supply via a filling loop to the charge and discharge valve on the boiler incorporating a stop valve and double check valve which must be left disconnected after commissioning. Drain taps must be located in accessible positions which permit the draining of the whole system including the primary and the secondary (dhw) system. Any water loss from the system should be replaced from the filling loop connection. When draining the boiler allow air in using the boiler venting valve. Do not drain the boiler by opening the pressure relief valve. All capillary joints in all DHW pipework must be made with lead free solder. RS-M is a self contained system boiler that manages heating flow to the radiators and/or under floor and also supplies heat to an indirect domestic hot water cylinder via an S-plan system. External motorized valves and an automatic bypass are required for the S-plan system. Termo boilers can also be used on an open vented central heating system. Wherever possible all pipe work should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated under-floor spaces. 3.4.2 Ancilliary components. On RS M boilers a boiler pressure gauge, circulation pump and expansion vessel must be fitted. The expansion vessel should be sized to the total system volume. The water capacity of the boiler itself is 6 litres. Diagram of recommned pump on RS-E for radiator heating Diagram of recommned pump on RS-E for underfloor heating To comply with Part L of building regulations, a room thermostat must be fitted with the boiler. The room thermostat should not be sited over radiator or other heat emitter and should not be in direct sunlight. Thermostatic radiators valves may also be used, but should not be fitted in the same room as the room thermostat. After the central heating circuit has been laid open all service valves, flush pipes through and check for leaks before commissioning and introduce the correct inhibitor for a central heating circuit in accordance with BS7593. Commission the boiler slowly to allow air to escape through the automatic air vent. Remove air from pump using front screw on pumps. Pressurize the system to 1.5 bar. Where the boiler is being retro-fitted to an existing installation, it is equally important to flush the system and commission using inhibitor to BS7593., TERMO boilers are fitted with an automatic and manual air vent. The boilers are also equipped with an airindicator which detects the presence of air in the boiler. If air is detected and It exceeds the permitted level, airindicator switches off immersion heaters and circulation pump remains active, so that air is allowed to escape easily. Once the air is dispelled the immersion heaters will be active. Page 6

3.5 Connection to the electrical mains supply Before working with the appliance, turn off the power supply (MCB) and secure against restart. This device must be earthed. Check that the electrical supply to the building has sufficient current and voltage to supply the boiler and other appliances to be used. Miniture circuit breakers (MCB) must be fitted in the wiring prior to the boiler. For MCB ratings see table on page 3. Connect the boiler to the mains using a double pole linked switch with 3mm contact gap in both poles. Measure exact voltage between L and N lines prior to connecting boiler, if it 10% higher than nominal voltage on appliance, appliance itself can be damaged. Central heating control equipment please note that all heating control equipment (programmer, timer, thermostats etc MUST be supplied with power from the boiler connections plate see section 3.6. DO T supply controls with power directly from the mains supply. To connect power supply cable power connection protection cover must be removed by unwinding two nuts M6 and pulling protection cover out. Power cable must be connected directly to RCD, earth must be connected to separate terminal. After connecting power cable and control units, protective cover must be replaced and secured. For 240V power supply RCD switch in boiler from 7.2 up to 14,4 kw is 2-pole Power supply connection RCCB (RCD) connection close-up Power cables must be connected from bottom side of boiler with the use of provided plastic inducer for electric cable. Ensure that the wires are securely fixed. The appliance must be connected to mains electricity and tested according to current IEE regulations. An NICEIC inspection and completion certificate must be issued. The appliance must be connected to mains electricity and tested according to current IEE regulations. An NICEIC inspection and completion certificate must be issued. All exposed pipework must be earthed according to current IEE regulations Page 7

3.6. Connecting external controls External controls (Programmer, thermostats, pump, zone valves) must be supplied with power from the green boiler connections plate. See diagram (right) via removable connector as shown below Terminals OUTDOOR TEMP. DOMESTIC WATER, 3 HW ON & HW PUMP are not used. L, N & PE Power supply to control unit - (3 port green) 4 CH ON switched live from external unit for heating & DHW (2 port grey/black) L, N & PE to Central heating pump (3 port grey/black) Connection plate 3.6.1 Connect programmer/room thermostat Supply power to central heating programmer/room stat assembly from L, N, PE on connections plate. Use a junction box if necessary. From this point follow thermostat manufacturer s instructions to connect programmer/stat assembly & S-Plan system. The boiler is supplied with a fixed link between L and 4. If an external control device (room thermostat and/or programmer) is used, remove this link. Switched live from room thermostat and water heater thermostat must be connected to 4 CH ON. 3.6.2. Connecting external pump on TERMO RS boilers TERMO RS boilers do not have inbuilt central heating pump and pump for domestic water cylinder. Empty terminals on connection plate are provided to fit external pumps. Terminal CH PUMP is provided for central heating pump for heating and DHW. Connect pump L, N, PE wires to the appropriate connection ports. Termo RS-M is fitted with an automatic pump overrun.. Factory settings is 3 min 4. Commissioning 4.1. Control panel key 1 Indicator of temperature /pressure in boiler 2 Working thermostat 3 Switch for the 2 nd and 3 rd operation stage 4 Cutout thermostat with manual deactivation (operates at 100 o C) 5 Air Indicator/Low voltage indicator 6 - Switch for ON/OFF and 1 st heating stage 7 Fuse (2.5A) protecting pump and switches 8 Indication of heater operation Page 8

Switching boiler on Test the RCD switch by pressing T button on it. Reset the RCD switch. Switch on boiler at switch (6). Switch will illuminate. First power stage activates if there is heating demand. If the boiler is heating, heaters in operation light (8) will illuminate. Switches (3) manually enable activation of second and third immersion heaters in boiler. These switches will illuminate if heating demand activate these heaters. Boilers with 3 stages have soft start for second and third stage and switches (3) have only limiting function. If heaters are not working and boiler is in standby only ON/OFF light is on. Normal practice is to have switches 6 & 3 on and to leave the control system to modulate boiler. Switching off the 2 nd or 3 rd stage will manually limit boiler power and may provide insufficient heat for the property. Adjustment of desired temperature of central heating Select desired temperature in boiler using working thermostat (2). Recommended temperature is about 60ºC (12 clock position). Thermostat range is 20ºC to 90ºC. If boiler is switched on with working thermostat in off position (6 o clock) central heating pump will operate. If working thermostat is turned up and there is no heating demand, pump will stop. If working thermostat is turned up and there is heating demand, pump will continue and immersion heaters will heat as shown on light8. Activation of 2 nd & 3 rd immersion heaters is shown by illumination of their lights 3. Air in the boiler/ Low Voltage (5), red light Light will illuminate red if air appears in the boiler. The boiler shuts down automatically. To continue operation, vent the boiler. When venting is completed the boiler restarts automatically. If the voltage drops below 180V per phase, low voltage protection light (5) illuminates, the boiler automatically switches off in order to protect electronics and contactors inside the boiler. The boiler will automatically restart when the network voltage exceeds 180V. Cutout thermostat - turning on Cutout thermostat (safety thermostat) (4) protects the boiler against rapid increase of temperature above 115 C. The fuse turns off the boiler and trips the RCD switch. To restart boiler. Unscrew protection cover (4) from the cutout thermostat and press the red key. Cut-out cannot be reset until the temperature of the boiler cools. TE: If the room thermostat is fitted, boiler will only operate if thermostat is calling for heat. 4.2 Protection from freezing Freezing protection is dependent on the room thermostats. To protect a property from freezing when the occupiers are away, the boiler must be left in the ON position with the central heating programmer and/or room thermostat set to freezing protection. If there is no preset freezing protection state on the programmer/thermostat, lower the set temperature in the property to 5 C. This will reduce energy consumption whilst offering system freezing protection. Page 9

5. Fault finding guide The boiler is not operating or radiators are cold Please check the following before going through fault finding flowchart. Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Is the boiler switched ON? Electrical part of boiler (heater, switch, relay) is faulty Switch boiler ON Switch ON MCB Is the green LED light ON? Are the MCB (on master switch board) and RCD (in boiler and master switch board) switched ON? Switch ON RCD Reset safety thermostat and try again to switch RCD ON RCD can't be switched ON Does DISPLAY show temperature inside boiler? Faulty control panel Is the temperature of water same as desired? Wait for boiler to heat up One or more heaters are faulty Is the room thermostat switched ON? Switch ON room thermostat Check isolation valves Page 10

When switched on, switches on control panel show the voltage, however the boiler does not heat Is the RED lamp ''air in the boiler'' illuminated? Check the water pressure and purged of air Please check the following before going through fault finding flowchart. Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Is the limiting thermostat activated? Safety thermostat can be activated if air is present in installation or operation thermostat is faulty or relay is blocked Is the room thermostat too low? Adjust correct temperature Is the operating thermostat defective? Replace the operating thermostat with new Is the voltage present on immersion heaters Replace the immersion heaters Page 11

Boiler ''roars'' while heating Central heating system was not vented properly Lower the speed on central heating pump (see guide below) Please check the following before going through fault finding chart: Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Check the water pressure and vent the central heating system Defective immersion heaters - change the heaters RCCB switch cannot be switched ON Check the status of safety thermostat, try to reset it Switch on RCCB switch Please check the following before going through Fault finding chart. Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Check existance of resistance between terminals N,3,5,7 or RCCB switch and PE Find component which has contact between earth (PE) and change it. Change the RCCB switch Page 12

Central heating is working but domestic hot water (DHW) is not working Are the parameters for DHW on control panel or/and external programmer correct? Change parameters Please check the following before going through Fault finding chart. Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Is the relay RHW in ON possition? Is the voltage present on terminals a1(l) and a2(n) of relay RHW? Check external programmer Change the relay RHW Is the votage present on DHW pump therminals? Find and restore break of connection Change the DHW pump Page 13

Domestic hot water is working but central heating is not working Are the parameters for central heating on control panel or/and external programmer correct? Change parameters Please check the following before going through Fault finding chart. Check the installation is correct. All isolating valves are open. The system is full of water (pressurised) and purged of air. Programmer and controls outside of boiler are on. Check the electrical supply is connected correctly and present Is the relay RCH in ON possition? Is the voltage present on terminals a1(l) and a2(n) of relay RCH? Check external programmer / room thermostat Change the relay RCH Is the votage present on CH pump therminals? Find and restore break of connection Change the CH pump Page 14

6. Maintenance 6.1. Periodic checking The safety valve should be checked annually, preferably before the heating season to ensure correct operation and avoid accumulation of lime scale. It is not recommended to annually drain the system to protect the system from freezing as refilling with fresh water will increase the risk of limescale attack We recommend inspection of the boiler once a year by an authorized service engineer. This service is not included in the guarantee. During the inspection all electric and water connections should be tightened, the system should be vented and if necessary filled up, valves and general functionality of the device and safety valves should be checked. When cleaning the product do not use an aggressive liquid as e.g. gasoline, kerosene or solvent. For the external shell and decorative cover, liquid for cleaning plastics or dish washing media may be used. Control panel should be cleaned with dry or moist cloth (not wet). 7. After Sales service information If after using the fault-finding guide above the problem cannot be rectified by the installation engineer on site, a qualified Oso Service Engineer is available during normal office hours to attend a breakdown. A charge will be made if: There is not a fault with the Termo boiler or the breakdown was caused by incorrect installation of the product that does not conform to the installation manual. Components fitted on the system that were not supplied by Oso are preventing the satisfactory operation of the Termo boiler. The terms and conditions of the guarantee have not been satisfied or the warranty period of the Termo boiler has expired. Many boiler manufacturers find that a very large proportion of service calls are not caused by a product fault. Please read the fault finding guide and the other instructions in this manual carefully. Oso will not accept unauthorized invoices from any third party for repair or service work to Termo boilers. 8. Cascade power limiter Where there are other high load electrical appliances e.g. electric ovens, electric showers etc fitted in the property with the boiler there is a possibility of overload on the electrical system. The Oso cascade power limiter is a unique device that continually monitors the electricity consumption of the property and if required will power down the boiler temporarily to prevent overload. 9. OSO Hotwater UK Ltd Oso Hotwater UK Ltd E15, Marquis Court Team Valley Tarding Estate, Gateshead Tyne & Wear NE11 0RU Tel: 0191 482 0800 Fax: 0191 491 3655 www.oso-hotwater.com technical.uk@oso-hotwater.com sales.uk@oso-hotwater.com spareparts.uk@oso-hotwater.com 10. Appendices Appendices with further technical information are displayed on the following pages. These appendices should be used in conjunction with the information supplied elsewhere in the manual and show additional schematic and electrical diagrams to assist in the installation of Termo boilers into different central heating systems. Advice is given for a variety of standard systems commonly used in the UK, however the list is not exhaustive and OSO Hotwater UK Ltd cannot guarantee that the advice will be correct for any particular system. All diagrams are shown for informational purposes only. Diagrams are not comprehensive and do not show every system detail. Page 15

10.1 Termo RS-M with space heating and water heating 10.1.1. Hydraulic diagram Termo RS-M 10.1.2. Electric diagram Termo RS-M Page 16

10.1.3. S-plan wiring layout 10.2 Termo RS space heating only 10.2.1 Hydraulic diagram Termo RS-M Page 17

10.2.2. Electric diagram Termo RS-M 10.2.3. S-Plan wiring layout Termo RS-M Page 18