Electricaire_installation_instructions_issue_10

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    Contact Details    Please note that some of the contact details on  this PDF document may not be current.    Please use the following details if you need to  contact us:    Telephone: 0844 879 3588  Email: [email protected]      The customer support section of our website also features a wide  range of information which may be of use to you and is available  24 hours a day. It includes:    • Operating and installation instructions  • Easy ‘How to use’ guides for storage heaters  • Service and repairs  • Where to buy our products  • Literature downloads  • Heating requirement calculator         Visit ‐ www.dimplex.co.uk/support  A division of GDC Group Ltd Millbrook House Grange Drive Hedge End Southampton SO30 2DF www.dimplex.co.uk Registered No: 1313016 England VAT GB 287 1315 50004 EEE Producer Registration Number – WEE/GE0057TS Paper from sustainable sources -1- ELECTRICAIRE WARM AIR HEATING SYSTEM Models: R7 - 7kW / 46kWh, R8 - 8kW / 57kWh, R10 - 10kW / 69kWh, R12 - 12kW / 80kWh, R15 - 15kW / 103kWh INSTALLATION INSTRUCTIONS IMPORTANT PLEASE READ THIS LEAFLET CAREFULLY AND RETAIN FOR FURTHER USE. NOTE ALSO THE INFORMATION GIVEN ON THE HEATER -2- Installer Note: Please ensure that the USER INSTRUCTIONS are handed to the User when you have completed the installation if applicable, or left with the heater if the building is unoccupied when the installation is carried out. -3- IMPORTANT IN EVERY CASE THE UNIT MUST BE FITTED ON TOP OF A PLENUM CHAMBER FOR CORRECT OPERATION • The installation must only be carried out by a qualified electrician. • More than one person is required to lift or move this appliance. • A means for disconnection must be incorporated in the fixed wiring in accordance with the wiring rules. • The heater must not be installed immediately below a socket outlet. • The heater is not suitable for connection to a 30A ring circuit. • Do not position the heater beside windows where curtains can contact the heater casing. • WARNING - THE SURFACES ON THIS HEATER CAN BE HOT. • This heater is CE marked and meets current European Safety Directives. However, any heater type becomes hot in normal operation. Care must be taken to ensure that prolonged skin contact with the heater does not occur. WHERE YOUNG CHILDREN, INFIRM PERSONS, OR THE AGED ARE LIKELY TO BE LEFT UNSUPERVISED IN THE VICINITY OF THE HEATER WE RECOMMEND THAT A GUARD IS FITTED. Contact your installer or the manufacturer for further advice. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. • This appliance is extremely heavy. The floor must be checked to ensure that it is capable of bearing the weight of the unit, up to 750KG (¾ TONNE). DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO MOVE OR REPOSITION THIS HEATER WITHOUT SEEKING EXPERT ADVICE. • To maintain stability, it is essential that the heater is placed on a level surface and care should be taken to avoid irregular surfaces, such as may result from carpets or tiled surrounds partially protruding under the heater. • The heater must be installed where it is impossible for switches and other controls to be touched by a person using a bath or shower. • IMPORTANT - Due to the newness of materials the heater will produce a slight smell for the first few days of operation. ROOMS MUST BE WELL VENTILATED AND YOUNG CHILDREN, CAGED BIRDS, OR PERSONS WITH RESPIRATORY COMPLAINTS MUST NOT REMAIN IN CLOSE PROXIMITY TO THE HEATER DURING THE FIRST 48 HOURS OF THE COMMISSIONING PERIOD. • IF, DURING ANY REASSEMBLY OF THE HEATER, A PART OF THE THERMAL INSULATION SHOWS DAMAGE OR DETERIORATION WHICH MAY IMPAIR SAFETY, IT SHOULD ONLY BE REPLACED WITH AN IDENTICAL DIMPLEX PART. • The heater must stand at least 50mm clear of any walls and 150mm below ceilings. -4- INSTALLATION INSTRUCTIONS INTRODUCTION • The Electricaire is an electric ‘warm air’ heating system suitable for domestic and commercial applications. • The unit operates on low cost off peak electricity tariffs. • Electrical energy is stored as heat inside the insulated casing. Warm air is delivered by the integral fan from a distribution chamber mounted directly below the unit or through attached duct work. • The fan may be controlled by a central thermostat and/or time clock to suit the installation. • The Electricaire unit can be connected to single phase or 3 Fig. 1 phase supplies. Important - The Electricaire must be installed in one of two modes ‘Standard’ or ‘Boost’ option. ‘Standard’ - As supplied. In this mode a restricted supply will provide the main heating load and the 24 hour supply will power the fan. ‘Boost’ - This option can be selected at the time of installation. This mode allows stored energy to be topped up outside restricted hours, for example, where the fan has been working continuously and the core has been depleted. In this situation the conductors from the 24 hour supply are connected to the mains terminal block. The conductors from the restricted supply, supply an auxiliary circuit inside the Electricaire unit. Refer to the circuit diagrams adjacent, Fig 1, 2 & 3. Fig. 2 REQUIREMENTS The heater will arrive separately from its storage bricks, the following bricks will be required. R 7 / 8 / 10 R12 R15 - 40 bricks 48 bricks 64 bricks Boost ELECTRICAL SUPPLY Two supplies are required for the operation of this heater, an off peak or restricted supply and an on peak or unrestricted supply. Both supplies must be connected through isolator switches. Only use heat resisting cables (min rating T85). WARNING – This appliance must be earthed A time clock / thermostat control circuit may also be required. Fig. 3 -4- -5- PREPARATION Important! The unit must be fitted on top of a distribution chamber known as a plenum chamber for correct operation. It is recommended a Dimplex plenum chamber be used. Plenum chamber: Dimplex part no. PLEN/12 Any floor covering eg. carpet, should be removed from the area where the unit is to be positioned. The unit can be installed free standing or in a suitable cupboard. For minimum clearances refer to Fig 4. The floor must be flat and level and capable of bearing the weight Fig. 4 of up to 750kg. VENTILATION AND DUCTING Important Ventilation is required when installed in a cupboard. Two return air grilles minimum size 400mm x 250mm, should be fitted in the cupboard door. Fig. 5 Vent 1 - 50mm below the top of the cupboard door. Vent 2 - 25mm above the level of the plenum. Ducting will be required if a heater is placed in a cupboard or if connecting to adjacent rooms. Important Holes to suit the air ducts should be cut in the distribution/plenum chamber no closer that 30mm to the sides top or bottom of the plenum. See Fig 5. Ensure that all joints are sealed by suitable 50mm duct tape with a heat resistance of up to 100°C. INSPECTION BEFORE INSTALLATION Before installation check the unit and the storage brick for any sign of damage caused in transit Remove the filter panel by pulling the top end away first and lifting it away from the locating hooks. See Fig 6. Remove screws retaining the mesh guard. Set aside. Check all wiring connections are secure and that the fan rotates freely. Fig. 6 -6- INSTALLATION Important More than one person is required to lift these units. Lift the heater unit on to the top of the plenum chamber, and using the guides, work it gently backwards to the stop ensuring it is secure and stable at all times. Fig. 7 Fig. 7 CONNECTION OF MAINS CABLE Confirm whether the ‘Standard’ configuration or the optional ‘Boost’ configuration is required. Fig. 8 Carefully examine the relevant wiring diagrams. Refer to Fig’s 1, 2 & 3. Cable entry, accessing the mains terminals is at the bottom right hand corner when viewed from the front. Fig. 8. Bushing Several blanking plugs are provided for any cable entry bushings that are not used. The main heating load can be provided from either a single phase or 3 phase supply. Clamping Bar Earth Terminal Block The linking bar assembly supplied has to be fitted across L1, L2 and L3 for single phase operation only. See Fig. 9. Note! If 3 phase is chosen the switching circuit must use the phase coloured red or brown. Important! All mains supplies must be installed with independent isolators. WARNING - This appliance must be earthed Fig. 9 -7- STANDARD CONFIGURATION RESTRICTED SUPPLY Main element supply - single phase Connect the live lead (coloured red or brown) of the mains supply cable to the live connector marked ‘L2’ on the large mains terminal block. Connect the neutral lead (coloured blue or black) to neutral terminal marked ‘N’. Connect all earth leads (bare conductor or coloured green or green and yellow) to the earth terminal marked with the symbol . All bare conductors must be sleeved with earth sleeving. Ensure the linking bar assembly is fitted to L1, L2 & L3. Ensure all screws are tightened securely. Main element supply - three phase Important! Ensure the linking bar assembly is not fitted across L1, L2 & L3 on the mains terminal block. UNRESTRICTED SUPPLY cont’d Room thermostat and/or time clock A room thermostat and/or time clock can be fitted to the fan circuit as required. See Fig. 1 and Fig. 2 on page 4 on this manual. Alternatively remove the loop of wire in the 4 way connector block and remake the connection with a circuit running to the room thermostat and/or time clock. See Fig. 11. Important! Ensure that all cables are held neatly in the cable clamp, and tighten the clamp firmly on all incoming cables. Ensure no surplus wire is left inside the heater and that the air mixing flap is not obstructed. Connect each phase of the incoming mains supply to the respective live terminals, i.e. phase wire coloured red or brown to L1 phase wire coloured yellow or black to L2 and phase wire coloured blue or grey to L3 Connect the neutral lead of the incoming mains supply (coloured black or blue) to neutral terminal marked ‘N’. Connect all earth leads (bare conductor or coloured green or green and yellow) to the earth terminal marked with the symbol . All bare conductors must be sleeved with earth sleeving. Fig. 10 UNRESTRICTED SUPPLY 8 Way Connector Block For standard configuration leave as supplied with ‘S’s aligned. See Fig. 10 - 11. Fan supply Locate the 4 way connector block in the centre of the lower wiring panel, (see Fig 10 and 11). Connect the live lead (coloured red or brown) of the fan supply to the terminal marked L(u). Connect the neutral terminal (coloured blue or black) to the terminal marked N(u). Connect all earth leads (bare conductor or coloured green or green and yellow) to the earth terminal marked with the symbol . All bare conductors must be sleeved with earth sleeving. Fig. 11 RESTRICTED SUPPLY 8 WAY BLOCK 4 WAY BLOCK UNRESTRICTED D SUPPLY -8- OPTIONAL BOOST CONFIGURATION UNRESTRICTED SUPPLY In the ‘Boost’ configuration the conductors for the main heating load do not operate as restricted supplies but are permanently live. The conductors from the restricted supply are wired to the 4 way terminal block inside the Electricaire unit. Refer to the circuit diagram in Fig 3 on page 4 of this manual. Room thermostat and/or timeclock Remove the loop of wire in the 4 way connector block and remake the connection with a circuit running to the room thermostat and/ or timeclock. Refer to Fig. 3 on page 4 of this manual. Main Element Supply - single phase or 3 phase Connect the conductors for the main element supply for either single phase or 3 phase as required. Refer to ‘Standard Configuration’ on Page 7 of this manual. 8 Way Connector Block For the ‘Boost’ option the 8 way snap together connector block has to be configured with ‘W’s’ in line. Release the single screw, indicated, on the right hand strip and pull apart, Fig. 13. Lower the right hand strip down one position to align ‘W’s and reconnect. See Fig. 14. Refit the screw to secure block in position. Refer to Fig. 15. Fan supply In this configuration the fan supply will be provided automatically from an internal circuit within the unit. RESTRICTED SUPPLY The restricted supply from the Supply Authority time clock is connected to the 4 way block at connector L(u) and N(u). Refer to diagram Fig. 3 on page 4 of this manual. Connect the live lead (coloured red or brown) of the fan supply to the terminal marked L(u). Connect the neutral terminal (coloured blue or black) to the terminal marked N(u). Connect all earth leads (bare conductor or coloured green or green and yellow) to the earth terminal marked with the symbol . All bare conductors must be sleeved with earth sleeving. Important! Ensure that all cables are held neatly in the cable clamp, and tighten the clamp firmly on all incoming cables. Ensure no surplus wire is left inside the heater and that the air mixing flap is not obstructed. Fig. 13 Fig. 14 Fig. 15 Screw ew Fig. 12 Screw UNRESTRICTED SUPPLY 8 WAY BLOCK 4 WAY BLOCK RESTRICTED D SUPPLY -9- PREPARATION FOR CORE ASSEMBLY Remove the two screws securing the bottom of the outer front Fusible Link panel. Lift up front and set safely to one side. Remove the ceramic tube taped to the vertical right hand wiring Inner Front loom (see Fig. 16), keep safely until required later and remove surplus tape. Remove the 3 fusible links located across the inner front panel. Release the charge control capillary which is coiled and clipped to the inner front, carefully and gently bend it down to ensure it is not damaged when the inner front panel is removed. Remove all the screws securing the inner front panel and carefully Ceramic Tube lift it out and set to one side. Remove the lower plastic spacer, the element packs and insulation sealing strips and set carefully to one side. (Fig. 17). Ensure the base insulation has not moved during transit and that the air passages are not obstructed at either side. Refer to Figs. Fig. 16 17 and 18. Open and inspect each element in case of breakages before proceeding to build the core. Charge Control Capillary Fig. 17 Spacers Sealing Strips Box containing Elements Ensure base insulation has not moved during transit. Do not cover air inlet and outlet holes. Fig. 18 - 10 - CORE ASSEMBLY Important! Take care not to damage the insulation inside the unit especially the moulded side insulation pieces, during installation. Build the bricks of the core tightly together ensuring the inlet and outlet passages in the base are not covered. Each layer uses 4 bricks. The first layer, layer ‘a’, is constructed from 4 brick running front to back with the grooves uppermost. See Fig. 19. Carefully unpack the element. Ensure the legs of the element are not twisted and that the element tails are to the outside. See Fig. 20. Position each leg of the element in a groove in the brick as shown in Fig. 21. Build the second layer and each subsequent layer taking care to align each layer of bricks as detailed by the letters in Fig. 22, while referring the orientation as Fig. 19. Fig. 19 Fit elements only in those positions indicated by the numbers in Fig. 22. Fig. 20 Fig. 21 - 11 - CORE ASSEMBLY cont’d SPECIAL INSTRUCTIONS TO CONVERT R10 TO R7/R8 Fig. 23 In some installations it may be necessary to downrate the R10(10kW) to an 8kW or even 7kW rating. Follow these instructions carefully, referring to Fig. 22, to ensure the Electricaire units operate safely and reliably MODEL R7 - Only four elements must be used for this specification. Install 4 elements in positions 3, 4, 5 and 6 only MODEL R8 - Only five elements must be used for this specification. Install 5 elements in positions 2, 3, 4, 5 and 6 only. MODEL R10 - All six elements must be used for this specification. Self adhesive labels are supplied. Please ensure correct label is fitted if the unit is derated as above, Fig.23. Fig. 22 - 12 - CONNECTING THE ELEMENTS Important! The element tails are insulated with ceramic beads. These must cover all the wire leaving no gaps. No part of the element wire or the tail should be exposed or close Fig. 24 to the brick. Route each element tail to the side over the insulation and through the bushing in the terminal panel. See Fig. 24. Secure the end of the element tail in the adjacent terminal block, a maximum of 2 tails per block. See Fig. 25. Note! The element tails must be very securely tightened in the terminal block, check and retighten. Important! Before proceeding, check the wiring for electrical continuity and insulation resistance. Fig. 25 - 13 - REASSEMBLY OF THE UNIT Fit the insulation sealing strips on each side, against the brick Fig.26 Fig. 27 while covering the element tails. Fig. 26. Replace the inner front insulation panel. Fig. 27. Replace the insulated inner front panel. Set the bottom edge Sealing Strip in position first, making sure not to trap the long capillary of the charge control and secure tightly all the screws. Reconnect the fusible links in the 3 way block on each side and ensure they rest in the support bracket and are correctly connected red to red etc. The charge control phial must be fitted through the hole in the inner front and into the brick core, as follows; • Inner Front Insulation Use a screwdriver to create a hole in the insulation and then insert the ceramic tube fully to the circlip stop. Fig. 28. • Fit the charge control phial into the ceramic tube; The capillary of the charge control must be inserted until the end of the phial touches the bottom of the tube. About 150mm of the capillary follows the phial into this tube in the process. Fig. 29. • Secure the remainder of the capillary to the inner front with the clips provided. Fig. 30. • Replace the outer front and secure with 2 screws. • Replace the lower mesh guard and secure. • Replace the filter panel. Fig. 28 Ceramic Phial Holder Fig. 29 Clip Capillary Tube Fig. 30 - 14 - COMMISSIONING THE UNIT All units must be checked for satisfactory operation once assembled. Fig. 31. The following must be checked; • Check the operation of the fan; (i) Normal Speed (ii) High Speed If room thermostat or timeclocks are installed these will need to be adjusted to check fan operation. If the unit has been installed in Boost mode this can be confirmed by firstly switching on the fan to deliver air when the Boost switch is on, the operation of a contactor should be heard. After several minutes the air should be slightly warm. IMPORTANT - Re-check all electrical connections for tightness, especially incoming mains terminal blocks. If the installed unit is to supply heat through a ducted system check the air delivery to all outlets is adequate. Refer to the next page if adjustment of the fan speed is required. Fig. 31 - 15 - ADJUSTMENT OF FAN SPEED If the air delivery from the unit needs to be adjusted it is best done when the unit is warm by following the instructions below; Fan speeds and outlet temperatures are factory preset but can Adjust as follows; • Switch off the mains supplies. • Remove the filter panel and mesh grille behind. • Loosen the first moveable band from the left on the fan be adjusted, see Fig. 32. • Switch on the fan at high speed and run for fifteen minutes. • Check the airflow delivered. speed resistor. Move to the left to increase fan speed to the right to decrease fan speed, typically ± 10mm. • Tighten up the band and reassemble the unit. • Switch on the mains supplies and check if the airflow is satisfactory. • Next switch the fan to the normal speed. • In this case it is the second moveable band that needs to be adjusted on the resistor. • Adjust to speed up or slow down as required. Move to the left to increase fan speed to the right to decrease fan speed, ± 10mm. 2nd moveable band 1st moveable band HIGH SPEED NORMAL SPEED ± 10mm ± 10mm + -+ - Fig. 32 - 16 - RECYCLING For electrical products sold within the European Community. At the end of the electrical products useful life it should not be disposed of with household waste. Please recycle where facilities exist. Check with your Local Authority or retailer for recycling advice in your country. ELECTRICAIRE Tel: Fax: Web-site 0845 600 5111 01489 773 050 www.dimplex.co.uk Dimplex UK Limited, Millbrook House, Grange Drive, Hedge End, Southampton, SO30 2DF. 71186 © GDC Group Ltd. All rights reserved. Material contained in this publication may not be reproduced in whole or in part, without prior permission in writing. A division of the GDC Group Ltd, Millbrook House, Grange Drive, Hedge End, Southampton SO30 2DF Issue 10 : 08.10