Part 3.0 Storage Tanks - Solar Edwards Adelaide

Part 3.0 Storage Tanks - Solar Edwards Adelaide
Part 3.0
Storage Tanks
Title
Section
SV Series
3.1
GXC Series
3.2
LEX Series
3.3
EX Series
3.4
EHX Series
3.5
SHX Series
3.6
HEV Series
3.7
TC Series
3.8
05/07
SV Storage Tank
3.1
This information expands on the relevant SV Configuration detail from Section 2.1 of this manual.
Installation Details
Location of Tank Connections
Positioning
•
•
•
•
An SV Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 50mm clearance at the top and sides.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water services & any other system components.
Cold Water Supply
•
•
The tank is classified by AS3500.1 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
Section 4.0 of Australian Standard AS3500.1 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
If the incoming water pressure exceeds 550kPa then a 450kPa pressure-limiting valve must be fitted.
Cold Water Valving
optional
•
Size the incoming cold water pipe in accordance with the guidelines provided in AS3500.1. If you
require the full flow capacity of the tank then we recommend the pipe be sized the same as the tank
connection which is 50mm.
SV Storage Tank
3.1
Hot Water Supply
•
•
•
•
•
As the storage tank is a direct type, it requires a both a pressure and a temperature relief valve to be
fitted in the circuit for the heat source. These valves are provided as part of the heat-source
provided with this system.
A pressure relief valve of 1000 KPa rating is to be fitted. The SV has its own dedicated type
connection on the outlet of the storage tank. This valve is used for eliminating air on filling (by being
held open) and also to test the temperature of the water once the system is operational.
A water hammer arrestor must be installed where the unit is subject to pulsing ie. Fast acting
solenoids on washing machines etc.
All hot water pipe-work should be insulated.
Make sure the pump is installed with its shaft in the horizontal position.
Hot Water Circulation Pump
If the building has a secondary or ring-main return it must be connected back into the cold water supply
after the cold water check valve. The ring-main circulation pump should have isolating valves either side
of it for servicing and a check valve fitted downstream of it but before entering back into the cold water
supply.
SV Storage Tank
3.1
Connecting A Heat Source & Control Box
•
•
Depending on the application, the SV tank can be connected to a variety of different heat sources
and control boxes. Refer to the relevant configuration diagram in Section 2.1 of the manual and this
will then refer you to the appropriate Section 4.0 and Section 5.0 for specific installation details.
50 mm flow and return pipes connecting the tank and the heat-source together are to be installed as
shown in the relevant configuration diagram of Section 2.1. The flow line to the heat-source is
connected via a tee piece in the cold water supply (prior to the cold water expansion control valve)
and the return line from the heat-source is connected to the 50mm tank connection shown.
Manifolding Tanks Together
Note: Pipe work must be balanced.
Equal length in / equal length out.
Electrical Connection
Power is provided to the Control Box (see Section 4.0). The temperature sensor is attached to the
storage tank by inserting it into the sensor pocket located in the tank.
SV Storage Tank
3.1
Filling the Tank with Water
•
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed and
tightened. Remember to open any valves in the water circuit that are connected to the heat-source.
Jam open the pressure/temperature relief valve in the heat source circuit and storage tank to allow
air to escape from the system.
Open the hot water outlet furthest away from the heater.
Open the cold water supply to the tank. Commence filling the tank.
Allow the entire tank and circuit to fill until water is running continuously from the relief valve drain &
the hot water outlet.
Close the cold water supply valve, hot tap and the relief valve. Check for any leaks in the circuit.
Commissioning
The SV tank will normally have a remote heat-source attached. The heat-source has its own
commissioning instructions contained in Section 5.0 of this manual.
Completion Checklist
All pipe-work & fittings are water tight & sound by
pressure testing.
Operating thermostat is set at clients desired
temperature. This will usually be approx. 60°C.
Check all valves operate correctly including expansion
control (if fitted) & T&PR valves (pull levers to check
discharge).
Plastic protective coating around the tank is removed
and any marks tidied up.
A copy of the User Guide has been handed to the client
for their future referral & owners instructions explained.
SV Storage Tank
3.1
Maintenance
Full maintenance on the SV Series tank should only be carried out by a qualified trades-person. As the
owner however, you can do a few simple things to help maintain the tank at its peak.
Every 6 months check:
•
•
There are no water leaks in any joins or fittings and electrical cables are secure and undamaged.
The cold water expansion control valve (if fitted - located in the cold water supply near the tank) is
operating correctly by pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person.
Visual Inspection
•
•
•
Inspect the shell for any leaks or weeps.
Check that all connections are tight and not corroded.
Replace any deteriorating insulation on the pipe-work.
Performance Check
•
Check that the water temperature from the tank is within
7ºC of the thermostat setting on the control box.
Final
•
•
•
Detail the tank.
Tidy up the plant room.
Complete paperwork.
Spare Parts
Description
Cold Water Expansion
Control Valve
Washer
Pressure Relief Valve
(not suitable for energy
relief)
Pressure Limiting Valve
(if needed)
Type / Model
Stock Code
RMC H50 - 700kPa (not supplied in kit)
2020319
50mm x 3mm Fibre Washer
RMC HT575 1000kPa
4040077
220604
RMC PSL50 – 500 kPa
or
SYR Adjustable Red Valve.
2020350
2020349
SV Storage Tank
3.1
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer (if fitted) is
blocked
Blockage in pipe-work
Water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, refit and turn
water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels. If too high contact Edwards for advice.
Refer to AS3500.1 for sizing guidelines.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
• A hot water relief valve will drip if the temperature begins to exceed 99°C or the
pressure increases above 850 kPa. Is this the case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
The thermostat settings have
been changed or are
malfunctioning.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Check the thermostat settings on the control box,
readjust or replace if faulty (see Section 4.0 for
instructions on how to do this).
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Remedy
Flush out the pipe-work and any supply tanks.
SV Storage Tank
3.1
Not Enough Hot Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe/fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Faulty cold water expansion
control valve is dumping all
the water.
Remedy
Adjust thermostat setting to a higher set point (see
Section 4.0 for instructions on how to do this).
See Section 5.0 for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Isolate the cold water & replace the valve.
Not Enough Water Flow
Possible Cause
Block in the pipe-work
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger, which will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for
assistance.
Isolate the water supply, remove the strainer, clean &
re-fit.
Pipe-work is too small.
Blocked strainer in the cold
water supply.
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped
properly.
Taps are ‘fast
opening/closing’ types.
Appliance (such as a
dishwasher) uses ‘fast
opening’ solenoid valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in Australian
Standard AS3500.4
Replace taps with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester valve into the pipe-work.
Warranty
Item
Storage Cylinder
Associated parts- valves
Labour, Travel & Freight
Coverage
5 years (Pro-rata) 3yrs full, 4th year
75%, 5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
GXC Storage Tank
3.2
This information expands on the GXC Configuration detail from Section 2.2 of this manual.
Installation Details
Note: Refer to the GXC Technical
Data Sheet for unit dimensions and
further information on connection
sizes and mounting data.
Positioning
•
•
•
•
•
A GXC Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top for access to the
expansion tank (if located on top of tank) and 50 mm around sides. Allow sufficient space between
adjacent tanks for service and maintenance.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water, electric and fuel supplies.
Sufficient access must be provided to all valves and auxiliary plant.
GXC Storage Tank
3.2
Cold Water Supply
•
•
•
The tank is classified in AS/NZS3500.1.2 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
AS/NZS3500.1.2 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
Isolation valves shall be either Ball or Globe valves.
Shell pressure must not exceed coil pressure by more than 150kPa.
Cold Water Valving
•
•
Incoming cold water pipe-work shall be sized in accordance with the guidelines provided in
AS/NZS3500.1.2. If you require the full flow capacity of the tank then we recommend the pipe be sized
the same as the tank connection.
All valves fitted in the system shall be at least line size to minimise any restriction in pipe-work.
Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on top of the tank.
Option 1
Option 2
GXC TANK
GXC TANK
Hot/Warm Water Supply
•
•
•
For use as a warm water heater under NSW Health Approvals, refer to the Edwards Hot Water - Warm
Water Systems Manual. This Manual should be supplied when ordered as a warm water heater. If it has
not been supplied, ask your nearest Edwards distributor to arrange a copy.
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot and warm water pipe-work should be insulated to AS4426.
GXC Storage Tank
3.2
Expansion Tank
IMPORTANT: Always fill the heat exchanger coil with mains or full pressure water BEFORE you start
filling the main tank. Otherwise you could damage the heat exchange coil by partially crushing it.
Failure to follow this instruction will void the warranty.
•
•
•
•
The expansion tank (25 litre supplied as standard) must be fitted to the GXC storage tank. This tank acts
as a reservoir to allow expansion and contraction of the treated water in the GXC tank.
It must be installed at the highest point of the treated water circuit.
If necessary due to site restrictions, you can locate the expansion tank away from the GXC tank. Ensure
that it is no higher than 40 m from the top of the GXC tank to the bottom of the expansion tank and that
there is a continually falling gradient between the tanks and that the flow of water is unrestricted by any
valve.
If the GXC tank is being used as a solar pre-heater, the expansion tank must be mounted above the solar
panels at the highest point of the treated water circuit. Direct solar contribution is not permitted on warm
water systems.
Expansion Tank Layout
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the LEX tank and via an air-break into a tundish
or drain connected to the buildings drainage system.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion tank cold water supply line, unless the expansion supply is
connected after the strainer/filter in the heater main supply. An isolating valve must also be fitted so that it
can be isolated during servicing – this valve must remain open when the system is operational.
GXC Storage Tank
3.2
Hot Water Circulation Pump
•
•
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water supply
after the cold water check valve. The ring-main circulation pump should have isolating valves either side
of it for servicing and a check valve fitted downstream of it but before entering back into the cold water
supply.
The pump should also be installed using either union or flange fittings to help facilitate maintenance or
removal.
Make sure the pump is installed with its shaft in the horizontal position.
Pressure tappings either side of the pump, to aid flow-rate checks, must also be provided.
Connecting A Heat Source & Control Box
•
•
•
•
The GXC tank is usually connected to a heat source and control box. Refer to the relevant configuration
diagrams in Section 2.2 of this manual and this will then refer you to the appropriate parts of Section 4.0
and Section 5.0 for specific installation details.
Warm water systems installed under the NSW Health Approvals must also be installed in conjunction with
the Edwards Hot Water – Warm Water Systems manual.
Burner flow and return connections are shown below.
Isolating ball valves are recommended to be fitted to all connections for easier servicing.
GXC Storage Tank
3.2
Burner connections
Manifolding Tanks Together
GXC Storage Tank
3.2
Electrical Connection
Power is provided to the Control Box (see Section 4.0 of this Manual). The temperature sensor is attached to
the storage tank by inserting it into the sensor pocket in the tank.
Filling the Tank with Water
Important: Always fill the heat exchanger coil with mains or full pressure water BEFORE you start
filling the main tank. Otherwise you could damage the heat exchange coil by partially crushing it.
Failure to follow this instruction will void the warranty.
•
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed, tightened
and checked for leaks. Remember to open any valves in the treated water circuit that are connected to
the heat-source.
Connect a temporary cold water supply to the service valve located on one of the burner connections.
Open the service valve and commence filling up the treated water storage tank until it is approximately
half full. Shut off service valve.
Add the water treatment to the unit through the expansion tank connection.
Recommence filling the system by opening the service valve again until the water level rises just enough
to start entering the expansion tank. Shut off the service valve and disconnect the cold water supply to it.
Set the float valve inside the expansion tank (by gently bending the arm) so that it will shut-off after filling
the tank to a maximum of 20 mm above the bottom of the expansion tank.
GXC TANK
•
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until the
float valve automatically shuts off – check for air locks!
GXC Storage Tank
3.2
Commissioning
The GXC tank will normally have a remote heat-source attached. The heat-source has its own
commissioning instructions contained in Section 5.0 of this Manual.
NSW Health approved warm water applications will also need to be commissioned in accordance with the
Edwards Hot Water – Warm Water Manual. Use a photocopy of this page as a working sheet.
Completion Checklist
Model Number: __________________________
Serial Number: __________________________
The model and serial numbers can be found on the identification sticker fixed on the front of the unit.
All pipe-work & fittings are water tight & sound by pressure testing (this also
confirms that the heat exchanger coil is OK).
Flush or clean system as per AS/NZS3500.1.2
Operating temperature is set at clients desired temperature, when checked at the
outlet fixture. Refer Warm Water Manual for warm water systems.
The expansion tank is connected correctly and there is a continuous gradient.
The isolating valve to the expansion tank is open & the float valve is set at
approx. 20 mm above the bottom of the expansion tank.
Water treatment is at the correct dosage.
Take a small sample of water from the service valve and place it in a
container. 250 to 500 ml is plenty.
Use a pH tester (such as litmus paper) and check that the pH of the water is
between 8.5 – 9.0
This should be done once the heat source has been installed as the treated water
must be circulating for 30 minutes to evenly distribute the water treatment.
Plastic protective coating around the tank is removed and any marks tidied up.
A copy of the User Guide and any other applicable documents has been handed
to the client for their future referral & owners instructions explained.
GXC Storage Tank
3.2
Maintenance
Full maintenance on the GXC Series tank should only be carried out by a qualified trades-person. As the
building owner/manager however, you can do a few simple things to help maintain the tank at its peak. Refer
also to the Edwards Hot Water – Warm Water Manual if system is being used to generate warm water.
Every 6 months check:
•
•
•
•
There are no water leaks in any joints or fittings and electrical cables are secure and undamaged.
The water treatment has a pH of 8.5 to 9.0 – see completion checklist above for instructions on how to do
this.
There is water in the expansion tank – it should be dark in colour.
The cold water expansion control valve (located in the cold water supply near the tank) is operating
correctly by slowly pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person. Use a photocopy of this page as a working sheet.
Model Number: __________________________
Serial Number: __________________________
The model and serial numbers can be found on the identification sticker located on the front of the unit.
The following can only be performed by or under the direct supervision on site of a qualified trades-person.
Visual Inspection
- Inspect shell for any leaks or weeps
- Check that all connections are tight and not corroded
- Replace any deteriorating insulation on pipe-work
Valves and Fittings - Service backflow prevention device as per AS2845.3
Expansion Tank
- Inspect for any water treatment stains
- Adjust float level to shut-off water at 20mm from bottom.
- Check that float valve shuts completely, and service as necessary
Water Treatment
- Drain approximately 250 ml of treated water from service drain valve on
main tank.
- Check pH level of sample, using litmus paper. pH must be within 8.5-9.0
- If pH level is outside this range, re-dose with water treatment using a
plumbers pump connected to the service valve. Retest pH level
Performance Test
- Check that the temperature at the outlet fixture is within the clients
specifications.
- If the unit is being used in a harsh water environment, the heat exchange
coil may need to be flushed out regularly. Contact Edwards.
- Check for any complaints from end users.
Final
- Detail Tank
- Tidy up plant room
- Complete paperwork and hand a copy of the maintenance report to client
GXC Storage Tank
3.2
Spare Parts
Description
Cold Water Expansion
Control Valve
Washer
Water Treatment
Expansion Tank
Service Valve
Float Valve
Type / Model
Stock Code
RMC H50 – 1200kPa
2020316
50mm x 3mm Fibre washer
Gendex – 500mL per unit, mix to 0.1% ie
1 litre per 1000 litres
Replace with 25L polypropelene tank
15mm BSP Brass ball valve
Philmac Valve 3005 &
Plastic Float 4993
4040077
8080049
3030032
2020075
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Supply water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the incoming water quality against the
recommended levels stated in the warranty handbook.
If too high contact Edwards for advice.
Refer to AS/NZS3500.1.2 for sizing guidelines or
contact Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
GXC Storage Tank
3.2
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe or
fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Cold water expansion control
valve dumps all the water.
Recirculation rate for system
is inadequate
Excessive heat losses
Remedy
Adjust thermostat setting to a higher set point (see
Section 4.0 for instructions on how to do this).
See Section 5.0 of this Manual for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
Check flow-rate for circulation pump
Check for uninsulated pipes, damaged insulation on
pipes or inadequate insulation on pipes.
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped properly.
Draw-off taps/solenoids are ‘fast
opening/closing’ type.
Appliance (such as a dishwasher)
uses ‘fast opening’ solenoid
valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in AS/NZS
3500.4.2
Replace taps/solenoids with slow opening type.
Check with the appliance manufacturer to see if
slower opening solenoids are available.
Fit a water hammer arrester into the supply pipework. Consult supplier for type and size.
GXC Storage Tank
3.2
Heated Water too Hot or Too Cold
Possible Cause
Thermostat set too high or
too low
Control box on overtemperature lock-out
Heat source not functioning
correctly.
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Excessive heat losses
Remedy
Adjust thermostat setting to correct limit.
Rectify cause of over-temperature lock-out and recommission as required
See Section 5.0 of this Manual for instructions.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Check for uninsulated pipes, damaged insulation on
pipes or inadequate insulation on pipes.
Not Enough Water Flow
Possible Cause
Blockage in the pipe-work
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Additional load being placed
on heat exchange coil
Water level in the tank is low
Blocked strainer in the cold
water supply.
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger which will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for advice.
Check that the flow rate for this model (see brochure)
meets the requirements of the project. Additional load
has been added to system.
Remove source of additional load. Increase input from
heat source (if possible). Replace heater with larger
unit. Contact your nearest Edwards Distributor for
advice.
Check the level of water inside the expansion tank is
approx. 20 mm above the bottom of the expansion tank.
Make sure that the isolating valve to the float valve is
not turned off.
Isolate the water supply, remove the strainer, clean &
re-fit.
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is
leaking.
Remedy
Drain some water from the expansion tank and slowly
bend the arm of the valve until the float is approx. 50
mm from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 450 litre tank requires a 25
litre expansion tank.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
GXC Storage Tank
3.2
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Heat exchange coil or pipework is leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
3 years full cover
4th year 75% cover
5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration form
provided with the system has been completed and returned to Edwards.
LEX Storage Tank
3.3
This information expands on the LEX Configuration details from Section 2.3 of this Manual.
Installation Details
Location of Tank Connections
Note: Refer to the LEX Technical
Data Sheet for unit dimensions and
further information on connection
sizes and mounting data.
Positioning
•
•
•
•
•
A LEX Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top for access to the
expansion tank (if located on top of tank) and 50 mm around sides. Allow sufficient space between
adjacent tanks for service and maintenance.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water, electric and fuel supplies.
Sufficient access must be provided to all valves and auxiliary plant.
Cold Water Supply
•
•
•
The tank is classified in AS/NZS3500.1.2 as a low hazard device. This means that it requires only a
non-testable back-flow prevention device be fitted in the incoming water supply prior to the system.
AS/NZS3500.1.2 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
Isolation valves shall be either Ball or Globe valves.
Shell pressure must not exceed coil pressure by more than 150kPa.
LEX Storage Tank
3.3
Cold Water Valving
•
•
Incoming cold water pipe-work shall be sized in accordance with the guidelines provided in
AS/NZS3500.1.2. If you require the full flow capacity of the tank then we recommend the pipe be
sized the same as the tank connection.
All valves fitted in the system shall be at least line size to minimise any restriction in pipe-work.
Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on top of the tank.
Option 1
Option 2
Hot/Warm Water Supply
•
•
•
For use as a warm water heater under NSW Health Approvals, refer to the Edwards Hot Water Warm Water Systems Manual. This Manual should be supplied when ordered as a warm water
heater. If it has not been supplied, ask your nearest Edwards distributor to arrange a copy.
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot and warm water pipe-work should be insulated to AS4426.
LEX Storage Tank
3.3
Expansion Tank
•
•
•
•
An expansion tank (not supplied as standard) must be fitted to the LEX storage tank. This tank acts
as a reservoir to allow expansion and contraction of the treated water in the LEX tank. The size of
the expansion tank will vary depending on the type of system being installed, its heat source and if it
is being used with solar pre-heat.
It must be installed at the highest point of the treated water circuit.
If necessary due to site restrictions, you can locate the expansion tank away from the LEX tank.
Ensure that it is no higher than 40 m from the top of the LEX tank to the bottom of the expansion
tank and that there is a continually falling gradient between the tanks and that the flow of water is
unrestricted by any valve.
If the LEX tank is being used as solar pre-heater, the expansion tank must be mounted above the
solar panels at the highest point of the treated water circuit. Direct solar contribution is not permitted
on warm water systems.
Note: If you wish to install a single expansion tank for both the LEX and its heat source, refer to Section
2.3.
Expansion Tank Layout
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the LEX tank and via an air-break into a
tundish or drain connected to the buildings drainage system.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion cold water line, unless the expansion supply is connected
after the strainer/filter in the heater main supply. An isolating valve must also be fitted so that it can be
isolated during servicing – this valve must remain open when the system is operational.
LEX Storage Tank
3.3
Hot Water Circulation Pump
•
•
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water
supply after the cold water check valve. The ring-main circulation pump should have isolating valves
either side of it for servicing and a check valve fitted downstream of it but before entering back into
the cold water supply.
The pump should also be installed using either union or flange fittings to help facilitate maintenance
or removal.
Make sure the pump is installed with its shaft in the horizontal position.
Pressure tappings either side of the pump, to aid flow-rate checks, must also be provided.
Connecting A Gas/Oil Heat Source & Control Box
•
•
•
•
•
The LEX tank is usually connected to a heat source and control box. Refer to the relevant
configuration diagrams in Section 2.3 of this manual and this will then refer you to the appropriate
parts of Section 4.0 and Section 5.0 for specific installation details.
Warm water systems installed under the NSW Health Approvals must also be installed in conjunction
with the Edwards Hot Water – Warm Water Systems manual.
The flow line to the heat source from the tank is from the lower connection on the right hand side of
the tank. The return line from the heat source is connected to the tank connection on the lower lefthand side of the tank. These are clearly marked on the tanks.
A process flow line (eg. central heating) is connected at the top of the tank and the process return
line is connected to the bottom. These connections will need to be blanked off if not needed.
Isolating ball valves are recommended to be fitted to all connections for easier servicing.
LEX Storage Tank
3.3
Connecting A Solar Heat Source
The LEX can be connected to a number of solar panels to reduce fuel costs. The LEX tank must be
connected into the cold water supply prior to the separate gas/oil boost tank. This is known as a solar
pre-heater. LEX systems configured as solar pre-heaters in this manner are not permitted to be used as
warm water systems.
•
•
The same connections used for the gas/oil heat source are also used for the connection of solar ie.
the solar flow line is connected to the heat source flow line. The solar return line is connected to the
heat source return line.
For details on the installation of the solar panels themselves, refer to Section 5.3 of this manual.
Solar Heat Source
LEX Storage Tank
3.3
Manifolding Tanks Together
Electrical Connection
Power is provided to the Control Box (see Section 4.0 of this Manual). The temperature sensor is
attached to the storage tank by inserting it into the socket located in the tank.
Filling the Heater Tank with Water
Important: Always fill the heat exchanger coil with mains or full pressure water BEFORE you start
filling the main tank. Otherwise you could damage the heat exchange coil by partially crushing it.
Failure to follow this instruction will void the warranty.
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed,
tightened and checked for leaks. Remember to open any valves in the treated water circuit that are
connected to the heat-source.
LEX Storage Tank
3.3
•
Connect a temporary cold water supply to the service valve located near the ‘Process Flow’
connection.
•
Open the service valve and commence filling up the treated water storage tank until it is
approximately half full. Shut off service valve.
Using the same method pour the contents of the water treatment container into the unit via the
service valve.
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
Set the float valve inside the expansion tank (by gently bending the arm) so that it will shut-off after
filling the tank to a maximum of 20 mm above the bottom of the expansion tank.
•
•
•
•
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks!
LEX Storage Tank
3.3
Commissioning
The LEX tank will normally have a remote heat-source attached. The heat-source has its own
commissioning instructions contained in Section 5.0 of this manual.
NSW Health approved warm water applications will also need to be commissioned in accordance with
the Edwards Hot Water – Warm Water Manual.
Use a photocopy of this page as a working sheet.
Completion Checklist
Model Number: __________________________
Serial Number: __________________________
The model and serial numbers can be found on the identification sticker fixed on the front of the unit.
All pipe-work & fittings are water tight & sound by pressure testing (this also
confirms that the heat exchanger coil is OK).
Flush or clean system as per AS/NZS3500.1.2
Operating temperature is set at clients desired temperature, when checked at
the outlet fixture. Refer Warm Water Manual for warm water systems.
The expansion tank is connected correctly and there is a continuous gradient.
The isolating valve to the expansion tank is open & the float valve is set at
approx. 20 mm above the bottom of the expansion tank.
Water treatment is at the correct dosage.
Take a small sample of water from the service valve and place it in a
container. 250 to 500 ml is plenty.
Use a pH tester (such as litmus paper) and check that the pH of the water
is between 8.5 – 9.0
This should be done once the heat source has been installed as the treated
water must be circulating for 30 minutes to evenly distribute the water
treatment.
Plastic protective coating around the tank is removed and any marks tidied up.
A copy of the User Guide and any other applicable documents has been
handed to the client for their future referral & owners instructions explained.
LEX Storage Tank
3.3
Maintenance
Full maintenance on the LEX Series tank should only be carried out by a qualified trades-person. As the
building owner/manager however, you can check a few simple things to help maintain the tank at its
peak. Refer also to the Edwards Hot Water – Warm Water Manual if system is being used to generate
warm water.
Every 6 months check:
•
•
•
•
There are no water leaks in any joints or fittings and electrical cables are secure and undamaged.
The water treatment has a pH of 8.5 to 9.0 – see completion checklist above for instructions on how
to do this.
There is water in the expansion tank – it should be dark in colour.
The cold water expansion control valve (located in the cold water supply near the tank) is operating
correctly by slowly pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person. Use a photocopy of this page as a working
sheet.
Model Number: __________________________
Serial Number: __________________________
The model and serial numbers can be found on the identification sticker located on the front of the unit.
The following can only be performed by or under the direct supervision on site of a qualified tradesperson.
Visual Inspection
- Inspect shell for any leaks or weeps
- Check that all connections are tight and not corroded
- Replace any deteriorating insulation on pipe-work
Valves and Fittings - Service backflow prevention device as per AS2845.3
Expansion Tank
- Inspect for any water treatment stains
- Adjust float level to shut-off water at 20mm from bottom.
- Check that float valve shuts completely, and service as required
Water Treatment
- Drain approximately 250 ml of treated water from service drain valve on main
tank.
- Check pH level of sample, using litmus paper. pH must be within 8.5-9.0
- If pH level is outside this range, re-dose with water treatment using a
plumbers pump connected to the service valve. Retest pH level
Performance Test
- Check that the temperature at the outlet fixture is within the clients
specifications.
- If the unit is being used in a harsh water environment, the heat exchange coil
may need to be flushed out regularly. Contact Edwards.
- Check for any complaints from end users.
Final
- Detail Tank
- Tidy up plant room
- Complete paperwork and hand a copy of the maintenance report to client
LEX Storage Tank
3.3
Spare Parts
Description
Type / Model
Cold Water Expansion
Control Valve
Water Treatment
Expansion Tank
Service Valve
Temperature Gauge
Float Valve
Stock Code
RMC H50 – 1200kPa
2020316
Gendex – use 1 ml for every litre of
storage capacity eg. 1 litre per 1000
litres.
Replace with same capacity as
original
15mm BSP Brass ball valve
Caleffi 688000
Philmac Valve 3005 &
Plastic Float 4993
8080049
2020075
2020427
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Supply water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels stated in the warranty handbook. If too high
contact Edwards for advice.
Refer to AS/NZS3500.1.2 for sizing guidelines or
contact Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
LEX Storage Tank
3.3
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated because
the water will expand up to 5% of the stored water per day. Is this the case?
If the answer is no;
Possible Cause
The incoming water pressure is too
high for the valve setting.
Dirt has built up under the seal in the
valve stopping it from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low or faulty.
Heat source not functioning correctly.
Leaking hot water pipe or fitting.
No check valve fitted in the secondary
return line (if connected to a ringmain)
Hot & cold water pipes have been
interconnected.
Hot & cold connections reversed on
tank.
Cold water expansion control valve
dumps all the water.
Recirculation rate for system is
inadequate
Excessive heat losses
Remedy
Adjust thermostat setting to a higher set point (see
Section 4.0 for instructions on how to do this).
See Section 5.0 of this Manual for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
Check flow-rate for circulation pump
Check for uninsulated pipes, damaged insulation on
pipes or inadequate insulation on pipes.
LEX Storage Tank
3.3
Heated Water too Hot or Too Cold
Possible Cause
Thermostat set too high or
too low
Control box on overtemperature lock-out
Heat source not functioning
correctly.
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Excessive heat losses
Remedy
Adjust thermostat setting to correct limit.
Rectify cause of over-temperature lock-out and re-commission
as required
See Section 5.0 of this Manual for instructions.
Trace pipe-work, remove the interconnecting pipe & reweld.
Cold inlet should be the right hand side of the tank (looking from
the front).
Check for uninsulated pipes, damaged insulation on pipes or
inadequate insulation on pipes.
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped properly.
Draw-off taps/solenoids are ‘fast
opening/closing’ type.
Appliance (such as a dishwasher)
uses ‘fast opening’ solenoid
valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in AS/NZS 3500.4.2
Replace taps/solenoids with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester into the supply pipe-work.
Consult supplier for type and size.
Not Enough Water Flow
Possible Cause
Blockage in the pipe-work
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Additional load being placed
on heat exchange coil
Water level in the tank is low
Blocked strainer in the cold
water supply.
Remedy
Flush the pipe-work with water. If the water quality is poor there
could be a build up of calcium or silt in the pipes or heat
exchanger which will require flushing with a suitable cleaning
agent – contact Edwards.
Contact your nearest Edwards Distributor for advice.
Check that the flow rate for this model (see brochure) meets the
requirements of the project. Additional load has been added to
system.
Remove source of additional load. Increase input from heat
source (if possible). Replace heater with larger unit. Contact
your nearest Edwards Distributor for advice.
Check the level of water inside the expansion tank is approx. 20
mm above the bottom of the expansion tank. Make sure that the
isolating valve to the float valve is not turned off.
Isolate the water supply, remove the strainer, clean & re-fit.
LEX Storage Tank
3.3
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Remedy
Drain some water from the expansion tank and slowly
bend the arm of the valve until the float is approx. 50
mm from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 450 litre tank requires a 25
litre expansion tank.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is leaking.
Water treatment Is Low
Possible Cause
Regular maintenance is not being
carried out
Heat exchange coil or pipe-work is
leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
3 years full cover
4th year 75% cover
5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
EX Storage Tank
3.4
This information expands on the EX Configuration details from Section 2.4 of manual.
Installation Details
Location of Tank Connections
Positioning
•
•
•
•
An EX Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top for access to the
expansion tank (if located on top of tank) and 50 mm around sides.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water services & any other system components.
Cold Water Supply
•
•
The tank is classified by AS3500.1 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
Section 4.0 of Australian Standard AS3500.1 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
EX Storage Tank
3.4
Cold Water Valving
•
Size the incoming cold water pipe in accordance with the guidelines provided in AS3500.1. If you
require the full flow capacity of the tank then we recommend the pipe be sized the same as the tank
connection. This is 32 mm for the EX450 and 50 mm for the EX850 & EX 1250.
Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on top of the tank.
Option 1
Option 2
Hot Water Supply
•
•
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot water pipe-work should be insulated.
Expansion Tank
Important: Always fill the heat exchanger coil with mains or full pressure water BEFORE you start
filling the main tank. Otherwise you could damage the heat exchange coil by partially crushing it.
Failure to follow this instruction will void the warranty.
•
•
An expansion tank is already fitted to the top of the EX storage tank. This tank acts as a reservoir to
allow expansion and contraction of the treated water in the EX tank. This is a vented circuit.
The expansion tank can be removed for easier access into a plant-room. If necessary due to site
restrictions, you can locate the expansion tank away from the EX tank. However, you must ensure
that it is no higher than 100 mm from the top of the EX tank to the bottom of the expansion tank and
that there is a continually falling gradient between the tanks so that the flow of water is unrestricted.
EX Storage Tank
3.4
Expansion Tank Layout
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the EX tank and into a tundish or drain.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion cold water line (unless connected after the filter in the main
supply line). An isolating valve must also be fitted so that it can be isolated during servicing – this valve
must remain open when the system is operational.
EX Storage Tank
3.4
Hot Water Circulation Pump
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water
supply after the cold water check valve. The ring-main circulation pump should have isolating valves
either side of it for servicing and a check valve fitted downstream of it but before entering back into
the cold water supply.
Make sure the pump is installed with its shaft in the horizontal position.
Electrical Connection
Systems that have 1 element (up to 4.8kW) require a 240 Volt, 20 amp single phase power supply wired
into the terminal block inside the tank’s control box. For those systems fitted with more than 1 element
you require a 415 Volt, 3 phase power supply with an amperage to suit the number of elements (refer
table below and details in Section 5.5). Each phase must be balanced.
For further information eg. wiring diagrams, refer to Section 5.5 of this manual.
EX Storage Tank
3.4
Electric Element Amperage Requirements
No. of 4.8kW
Elements
1
2
6
9
12
15
18
21
24
Rating
Kilowatts
4.8
14.4
28.8
43.2
57.6
72
86.4
100.8
115.2
Power Supply
Volts
240
415
415
415
415
415
415
415
415
Phase
1
3
3
3
3
3
3
3
3
Amperage per
Phase Amps
20
25
50
75
100
125
150
175
200
Manifolding Tanks Together
Note: Pipe work length must be
balanced. Equal in / equal out
EX Storage Tank
3.4
Filling the Tank with Water
•
•
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed and
tightened.
Connect a temporary cold water supply to the service valve located on the tank.
Open the service valve and commence filling up the storage tank until water has reached approx.
two thirds of the tank. Shut off service valve.
Using the same method pour the contents of the water treatment container into the unit via the
service valve.
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
Set the float valve inside the expansion tank (by bending the arm) so that it will shut off after filling
the tank to a maximum of 20 mm above the bottom of the expansion tank.
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks!
EX Storage Tank
3.4
Commissioning
The heat-source has its own commissioning instructions contained in Section 5.0 of this manual.
Completion Checklist
All pipe-work & fittings are water tight & sound by
pressure testing (this also confirms that the heat
exchanger is OK).
Operating thermostat is set at clients desired
temperature. This will usually be approx. 60°C for hot
water.
The expansion tank is connected correctly ie. There is a
continuous gradient.
The isolating valve to the expansion tank is open & the
float valve is set at approx. 20 mm above the bottom of
the expansion tank.
Water treatment is at the correct dosage.
• Take a small sample of water from the service valve
and place it in a container. 250 to 500 ml is plenty.
• Use a pH tester (such as litmus paper) and check
that the pH of the water is between 8.5 – 9.0
This should be done once the heat source has been
installed because the water must be circulating for 30
minutes to evenly distribute the water treatment.
The cold water expansion control valve is operating
correctly (check the valve by pulling on the lever).
Plastic protective coating around the tank is removed
and any marks tidied up.
A copy of the User Guide has been handed to the client
for their future referral & owners instructions explained.
EX Storage Tank
3.4
Maintenance
Full maintenance on the EX Series tank should only be carried out by a qualified trades-person. As the
owner however, you can do a few simple things to help maintain the tank at its peak.
Every 6 months check;
•
•
•
•
There are no water leaks in any joins or fittings and electrical cables are secure and undamaged.
The water treatment is within 8.5 to 9.0 – refer completion checklist for method.
There is water in the expansion tank – it should be dark in colour.
The cold water expansion control valve (located in the cold water supply near the tank) is operating
correctly by pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person.
Visual Inspection
•
•
•
Inspect the shell for any leaks or weeps.
Check that all connections are tight and not corroded.
Replace any deteriorating insulation on the pipe-work.
Expansion Tank
•
•
Inspect for any water treatment stains.
Adjust the level of the float valve so that it shuts off at
approx. 20mm of water level.
Check that the float valve shuts off completely.
•
Water Treatment
•
•
•
Performance Check
Final
•
Drain approx. 250 ml of treated water from the service
valve on the main tank.
Check the pH of the water (using litmus paper) to see if it is
within 8.5 – 9.0.
If the level is below this range, re-dose with water treatment
using a plumbers’ pump connected to the service valve.
Retest the pH level.
•
Check that the water temperature from the tank is within
7°C of the thermostat setting for hot water.
If the unit is connected to harsh water you may need to get
the heat exchanger flushed out regularly – contact
Edwards.
•
•
•
Detail the tank.
Tidy up the plant room.
Complete paperwork.
EX Storage Tank
3.4
Spare Parts
Description
Cold Water Expansion
Control Valve
Water Treatment
Expansion Tank
Service Valve
Element
Thermostat
Float Valve
Type / Model
Stock Code
RMC H50 - 1200kPa
2020316
Gendex – use 1 ml for every litre of storage
capacity eg. 450 ml for 450 litres.
EX450 & EX 850 = 25 litre capacity
EX1250 = 45 litre capacity
15mm BSP Brass ball valve
4.8kW 25mm BSP Screw In
Robertshaw
Philmac Valve 3005 & Float 4993
8080049
5012025
5012045
2020075
6060115
6060301
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels. If too high contact Edwards for advice.
Refer to AS3500.1 for sizing guidelines or contact
Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
EX Storage Tank
3.4
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe or
fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Faulty cold water expansion
control valve is dumping all
the water.
Remedy
Isolate the power supply to the heater. Adjust
thermostat settings to a higher set point by opening the
control box cover and adjusting each set point
individually.
See Section 5.5 for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped
properly.
Taps are ‘fast
opening/closing’ type.
Appliance (such as a
dishwasher) uses ‘fast
opening’ solenoid valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in Australian
Standard AS3500.4
Replace taps with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester valve into the pipe-work.
EX Storage Tank
3.4
Not Enough Water Flow
Possible Cause
Block in the pipe-work
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger which will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for
assistance.
Check that the flow rate for this model (se brochure)
meets the requirements of the project.
Check the level of water inside the expansion tank is
approx. 20 mm high. Make sure that the isolating valve
to the float valve is not turned off.
Isolate the water supply, remove the strainer, clean &
re-fit.
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Water level in the tank is low
Blocked strainer in the cold
water supply.
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Remedy
Drain some water from the expansion tank and bend
the arm of the valve until the float is approx. 50 mm
from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 450 litre tank requires a 25
litre expansion tank.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is
leaking.
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Heat exchange coil or pipework is leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
5 years full cover (pro-rata)
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
EHX Storage Tank
3.5
This information expands on the EHX Configuration details from Section 2.5 of this manual.
Installation Details
Location of Tank Connections
Positioning
•
•
•
•
An EHX Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top for access to the
expansion tank (if located on top of tank) and 50 mm around sides.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water services & any other system components.
Cold Water Supply
•
•
The tank is classified by AS3500.1 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
Section 4.0 of Australian Standard AS3500.1 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
EHX Storage Tank
3.5
Cold Water Valving
•
Size the incoming cold water pipe in accordance with the guidelines provided in AS3500.1. If you
require the full flow capacity of the tank then we recommend the pipe be sized the same as the tank
connection. This is 50 mm for the EHX1500, EHX2000, EHX3500 and 80mm for the EHX5000.
Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on the front of the tank.
Option 1
Option 2
Hot Water Supply
•
•
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot water pipe-work should be insulated.
Expansion Tank
Important: Always fill the heat exchanger coil with mains or full pressure water BEFORE you start
filling the main tank. Otherwise you could damage the heat exchange coil by partially crushing it.
Failure to follow this instruction will void the warranty.
•
•
•
An expansion tank (not supplied as standard) must be fitted to the EHX storage tank. This tank acts
as a reservoir to allow expansion and contraction of the treated water in the EHX tank.
It must be installed at the highest point of the treated water circuit.
If necessary due to site restrictions, you can locate the expansion tank away from the EHX tank.
Ensure that it is no higher than 40 m from the top of the EHX tank to the bottom of the expansion
tank and that there is a continually falling gradient between the tanks so that the flow of water is
unrestricted.
EHX Storage Tank
3.5
Expansion Tank Layout
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the EHX tank and into a tundish or drain.
Cold Water Supply to Expansion Tank
You must connect the float valve inside the Expansion tank to the cold water supply using a 15mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the Expansion cold water line (unless connected after the filter in the main
supply line). An isolating valve must also be fitted so that it can be isolated during servicing – this valve
must remain open when the system is operational.
Hot Water Circulation Pump
EHX Storage Tank
3.5
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water
supply after the cold water check valve. The ring-main circulation pump should have isolating valves
either side of it for servicing and a check valve fitted downstream of it but before entering back into
the cold water supply.
Make sure the pump is installed with its shaft in the horizontal position.
Electrical Connection
For further information eg. wiring diagrams, refer to Section 5.5 of this manual.
Systems that have 1 element (up to 4.8kW) require a 240Volt, 20amp single-phase power supply wired
into the terminal block inside the tank’s control box.
For those systems fitted with more than 1 element you require a 415 Volt, 3 phase power supply with an
amperage to suit the number of elements (see table below and refer to Section 5.5). Each phase must
be balanced.
Electric Element Amperage Requirements
No. of 4.8kW
Elements
1
2
6
9
12
15
18
21
24
27
Rating
Kilowatts
4.8
14.4
28.8
43.2
57.6
72
86.4
100.8
115.2
129.6
Power Supply
Volts
240
415
415
415
415
415
415
415
415
415
Phase
1
3
3
3
3
3
3
3
3
3
Amperage per
Phase Amps
20
25
50
75
100
125
150
175
200
225
EHX Storage Tank
3.5
Manifolding Tanks Together
Note: Pipe work must be balanced.
Equal in / equal out
Filling the Tank with Water
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed and
tightened. Remember to open any valves in the treated water circuit that are connected to the heatsource.
Connect a temporary cold water supply to the service valve located on the tank.
Open the service valve and commence filling up the storage tank until water has reached approx.
two thirds of the tank level. Shut off service valve.
Pour the contents of the water treatment container into the Expansion tank so that it makes its own
way down into the main tank (or through service valve).
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the Expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
EHX Storage Tank
3.5
•
Set the float valve inside the Expansion tank (by bending the arm) so that it will shut off after filling
the tank to approx. 50 mm above the bottom of the Expansion tank.
•
Open the cold water supply valve to the float valve in the Expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks!
EHX Storage Tank
3.5
Commissioning
The heat-source has its own commissioning instructions contained in Section 5.0 of this manual.
Completion Checklist
All pipe-work & fittings are water tight & sound by
pressure testing (this also confirms that the heat
exchanger is OK).
Operating thermostat is set at clients desired
temperature. This will usually be approx. 60°C for hot
water.
The Expansion tank is connected correctly ie. There is
a continuous gradient.
The isolating valve to the Expansion tank is open & the
float valve is set at approx. 50 mm above the bottom of
the Expansion tank.
Water treatment is at the correct dosage.
• Take a small sample of water from the service valve
and place it in a container. 250 to 500 ml is plenty.
• Use a pH tester (such as litmus paper) and check
that the pH of the water is between 8.5 – 9.0
This should be done once the heat source has been
installed because the water must be circulating for 30
minutes to evenly distribute the water treatment.
The cold water Expansion control valve is operating
correctly (check the valve by pulling on the lever).
Plastic protective coating around the tank is removed
and any marks tidied up.
A copy of the User Guide has been handed to the client
for their future referral & owners instructions.
EHX Storage Tank
3.5
Maintenance
Full maintenance on the EHX Series tank should only be carried out by a qualified trades-person. As
the owner however, you can do a few simple things to help maintain the tank at its peak.
Every 6 months check:
•
•
•
•
There are no water leaks in any joins or fittings and electrical cables are secure and undamaged.
The water treatment is within 8.5 to 9.0 – see completion checklist for method.
There is water in the Expansion tank – it should be dark in colour.
The cold water Expansion control valve (located in the cold water supply near the tank) is operating
correctly by pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person.
Visual Inspection
•
•
•
Inspect the shell for any leaks or weeps.
Check that all connections are tight and not corroded.
Replace any deteriorating insulation on the pipe-work.
Expansion Tank
•
•
Inspect for any water treatment stains.
Adjust the level of the float valve so that it shuts off at
approx. 50mm of water level in the expansion tank.
Check that the float valve shuts off completely.
•
Water Treatment
•
•
•
Performance
Check
Final
•
Drain approx. 250 ml of treated water from the service valve
on the main tank.
Check the pH of the water (using litmus paper) to see if it is
within 8.5 – 9.0.
If the level is below this range, re-dose with water treatment
using a plumbers’ pump connected to the service valve.
Retest the pH level.
•
Check that the water temperature from the tank is within 7°C
of the thermostat setting for hot water.
If the unit is connected to harsh water you may need to get
the heat exchanger flushed out regularly – contact Edwards.
•
•
•
Detail the tank.
Tidy up the plant room.
Complete paperwork.
EHX Storage Tank
3.5
Spare Parts
Description
Cold Water
Expansion Control
Valve
Washer
Water Treatment
Expansion Tank
(if supplied)
Service Valve
Element
Thermostat
Float Valve
Type / Model
Stock Code
RMC H50 - 1200kPa
2020316
50mm x 3mm Fibre Washer
Gendex – use 1ml for every litre of storage
capacity eg. 1000ml for 1000 litres.
EHX1000 & EHX 2000 = 120 litre capacity
EHX3500 & EHX5000 = 305 litre capacity
4040077
8080061
15mm BSP Brass ball valve
4.8kW 25mm BSP Screw In
Robertshaw WIM2A/5018
Philmac Valve 3005 &
Float 4993
5013120
5013300
2020075
6060115
6060301
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels. If too high contact Edwards for advice.
Refer to AS3500.1 for sizing guidelines or contact
Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the Expansion tank, drain
water level in the main tank until it is level with the
bottom of the Expansion tank. If the Expansion tank
fills up again then the coil is leaking – contact Edwards.
EHX Storage Tank
3.5
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water Expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water Expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe or
fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Faulty cold water Expansion
control valve is dumping all
the water.
Remedy
Isolate the power supply to the heater. Adjust
thermostat settings to a higher set point by opening the
control box cover and adjusting each set point
individually.
See Section 5.5 for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe & reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
EHX Storage Tank
3.5
Not Enough Water Flow
Possible Cause
Block in the pipe-work
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Water level in the tank is low
Blocked strainer in the cold
water supply.
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger. This will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for
assistance.
Check that the flow rate for this model (se brochure)
meets the requirements of the project.
Check the level of water inside the Expansion tank is
approx. 50 mm high. Make sure that the isolating valve
to the float valve is not turned off.
Isolate the water supply, remove the strainer, clean &
re-fit.
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped
properly.
Taps are ‘fast
opening/closing’ type.
Appliance (such as a
dishwasher) uses ‘fast
opening’ solenoid valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in Australian
Standard AS3500.4
Replace taps with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester valve into the pipe-work.
EHX Storage Tank
3.5
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Remedy
Drain some water from the Expansion tank and bend
the arm of the valve until the float is approx. 50 mm
from the bottom of the tank.
Realign the Expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the Expansion tank should be 6% of the
main tank capacity eg. A 5000 litre tank requires a 305
litre Expansion tank.
Isolate the water supply to the Expansion tank, drain
water level in the main tank until it is level with the
bottom of the Expansion tank. If the Expansion tank
fills up again then the coil is leaking – contact Edwards.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is
leaking.
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Heat exchange coil or pipework is leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the Expansion tank, drain
water level in the main tank until it is level with the
bottom of the Expansion tank. If the Expansion tank
fills up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
3 years full cover
4th year 75% cover
5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
SHX Storage Tank
3.6
This information expands on the SHX Configuration details from Section 2.6 of this manual.
Installation Details
Location of Tank Connections
Positioning
•
•
•
•
A SHX Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 50 mm all around sides.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water services & any other system components.
Cold Water Supply
•
•
The tank is classified by AS3500.1 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
Section 4.0 of Australian Standard AS3500.1 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
SHX Storage Tank
3.6
Cold Water Valving
•
Size the incoming cold water pipe in accordance with the guidelines provided in AS3500.1. If you
require the full flow capacity of the tank then we recommend the pipe be sized the same as the tank
connection.
Cold & Hot Water Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on the tank.
Option 1
Option 2
Hot Water Supply
•
•
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot water pipe-work should be insulated.
Expansion Tank
Always fill the heat exchanger coil with mains or full pressure water BEFORE you start filling the
main tank. Otherwise you could damage the heat exchange coil by partially crushing it. Failure to
follow this instruction will void the warranty.
•
•
•
An expansion tank (not supplied as standard) must be fitted to the SHX storage tank. This tank acts
as a reservoir to allow expansion and contraction of the treated water in the SHX tank.
It must be installed at the highest point of the treated water circuit – this is usually above the solar
panels.
If necessary due to site restrictions, you can locate the expansion tank away from the SHX tank.
Ensure that it is no higher than 14 m from the top of the SHX tank to the bottom of the expansion
tank and that there is a continually falling gradient between the tanks so that the flow of water is
unrestricted.
SHX Storage Tank
3.6
Expansion Tank Layout
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the SHX tank and into a tundish or drain.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion cold water line (unless connected after the filter in the main
supply line). An isolating valve must also be fitted so that it can be isolated during servicing – this valve
must remain open when the system is operational.
Hot Water Circulation Pump
SHX Storage Tank
3.6
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water
supply after the cold water check valve. The ring-main circulation pump should have isolating valves
either side of it for servicing and a check valve fitted downstream of it but before entering back into
the cold water supply.
Make sure the pump is installed with its shaft in the horizontal position.
Connecting Solar Heat Source
The SHX can be connected to a number of solar panels for the reduction of fuel costs. If installed as a
Pre-heater (see Section 2.6), the SHX tank must be connected into the cold water supply prior to the
separate boost tank. If the SHX is fitted with electric elements it does not require a separate boost tank.
•
For details on the installation of the solar panels themselves, refer to Section 5.3 for details.
Solar Heat Source
•
•
The flow line to the heat source from the tank is from the lower connection on the left-hand side of
the tank (B). The return line from the heat source is connected to the tank connection on the lower
right-hand side of the tank (A).
Isolating valves are recommended to be fitted to both connections for easier servicing.
SHX Storage Tank
3.6
Connecting A Solar Control Box
•
•
The solar control box operates a pump that circulates treated water from the SHX tank to the solar
panels and back again.
Full details of the solar controller are provided in Section 4.4.
Electrical Connection For Elements (If Fitted)
For further information eg. wiring diagrams, refer to Section 5.5 of this manual.
Systems that have 1 element (up to 4.8kW) require a 240Volt, 20amp single-phase power supply wired
into the terminal block inside the tank’s control box.
For those systems fitted with more than 1 element you require a 415 Volt, 3 phase power supply with an
amperage to suit the number of elements (see below and refer to Section 5.5). Each phase must be
balanced.
Electric Element Amperage Requirements
No. of 4.8kW
Elements
1
2
6
9
12
15
18
21
24
Rating
Kilowatts
4.8
14.4
28.8
43.2
57.6
72
86.4
100.8
115.2
Power Supply
Volts
240
415
415
415
415
415
415
415
415
Phase
1
3
3
3
3
3
3
3
3
Amperage per
Phase Amps
20
25
50
75
100
125
150
175
200
A 240V 15amp power supply is provided to the Solar Control Box (see Section 4.4). The temperature
sensor is attached to the storage tank by inserting it into the socket located in the tank.
Filling the Tank with Water
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed and
tightened. Remember to open any valves in the treated water circuit for the solar panels.
Connect a temporary cold water supply to the service valve located on the tank.
Open the service valve and commence filling up the storage tank until water has reached approx.
two thirds of the tank. Shut off service valve.
SHX Storage Tank
3.6
•
•
•
•
Pour the contents of the water treatment container into the tank (or through service valve).
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
Set the float valve inside the expansion tank (by bending the arm) so that it will shut off after filling
the tank to approx. 50 mm above the bottom of the expansion tank.
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks!
SHX Storage Tank
3.6
Commissioning
Commissioning the SHX tank involves a few small steps. The solar panels are detailed in Section 5.3.
Completion Checklist
All pipe-work & fittings are water tight & sound by
pressure testing (this also confirms that the heat
exchanger is OK).
Operating thermostat is set at clients desired
temperature. This will usually be approx. 60°C for hot
water.
The Expansion tank is connected correctly ie. There is
a continuous gradient.
The isolating valve to the Expansion tank is open & the
float valve is set at approx. 50 mm above the bottom of
the Expansion tank.
Water treatment is at the correct dosage.
• Take a small sample of water from the service valve
and place it in a container. 250 to 500 ml is plenty.
• Use a pH tester (such as litmus paper) and check
that the pH of the water is between 8.5 – 9.0
This should be done once the heat source has been
installed because the water must be circulating for 30
minutes to evenly distribute the water treatment.
The cold water Expansion control valve is operating
correctly (check the valve by pulling on the lever).
Plastic protective coating around the tank is removed
and any marks tidied up.
A copy of the User Guide has been handed to the client
for their future referral & owners instructions explained.
SHX Storage Tank
3.6
Maintenance
Full maintenance on the SHX Series tank should only be carried out by a qualified trades-person. As
the owner however, you can do a few simple things to help maintain the tank at its peak.
Every 6 months check:
•
•
•
•
There are no water leaks in any joins or fittings and electrical cables are secure and undamaged.
The water treatment is within 8.5 to 9.0 – see completion checklist above for instructions on how to
do this.
There is water in the expansion tank – it should be dark in colour.
The cold water expansion control valve (located in the cold water supply near the tank) is operating
correctly by pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person.
•
•
Visual Inspection
•
•
•
Expansion Tank
•
•
Water Treatment
•
•
Performance Check
Final
•
Inspect the shell for any leaks or weeps.
Check that all connections are tight and not
corroded.
Replace any deteriorating insulation on the
pipe-work.
Inspect for any water treatment stains.
Adjust the level of the float valve so that it
shuts off at approx. 50mm of water level.
Check that the float valve shuts off
completely.
Drain approx. 250 ml of treated water from the
service valve on the main tank.
Check the pH of the water (using litmus
paper) to see if it is within 8.5 – 9.0.
If the level is below this range, re-dose with
water treatment using a plumbers’ pump
connected to the service valve. Retest the pH
level.
•
Check that the water temperature from the tank is within
7°C of the thermostat setting for hot water.
If the unit is connected to harsh water you may need to
get the heat exchanger flushed out regularly – contact
Edwards.
•
•
•
Detail the tank.
Tidy up the plant room.
Complete paperwork.
SHX Storage Tank
3.6
Spare Parts
Description
Type / Model
Cold Water Expansion
Control Valve
Water Treatment
Expansion Tank
Service Valve
Temperature Gauge
Element
Thermostat
Float Valve
Stock Code
RMC H50 - 1200kPa
2020316
Gendex – use 1 ml for every litre of
storage capacity eg. 450 ml for 450
litres.
Check size with Edwards
15mm BSP Brass ball valve
Caleffi 688000
4.8kW 25mm BSP Screw In
Robertshaw WIM2A
Philmac Valve 3005 &
Float 4993
8080049
8080061
2020075
2020427
6060115
6060301
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels. If too high contact Edwards for advice.
Refer to AS3500.1 for sizing guidelines or contact
Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
SHX Storage Tank
3.6
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe or
fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Cold water expansion control
valve dumps all the water.
Remedy
Adjust thermostat setting to a higher set point (see
Section 4.0 for instructions on how to do this).
See Section 5.0 for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe &
reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
Not Enough Water Flow
Possible Cause
Block in the pipe-work
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Water level in the tank is low
Blocked strainer in the cold
water supply.
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger which will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for
assistance.
Check that the flow rate for this model (se brochure)
meets the requirements of the project.
Check the level of water inside the expansion tank is
approx. 50 mm high. Make sure that the isolating valve
to the float valve is not turned off.
Isolate the water supply, remove the strainer, clean &
re-fit.
SHX Storage Tank
3.6
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped
properly.
Taps are ‘fast
opening/closing’ type.
Appliance (such as a
dishwasher) uses ‘fast
opening’ solenoid valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in Australian
Standard AS3500.4
Replace taps with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester valve into the pipe-work.
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Remedy
Drain some water from the expansion tank and bend
the arm of the valve until the float is approx. 50 mm
from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 5000 litre tank requires a 305
litre expansion tank.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is
leaking.
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Heat exchange coil or pipework is leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
3 years full cover
4th year 75% cover
5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
HEV Storage Tank
3.7
This information expands on the HEV Configuration details from Section 2.7 of this manual.
Installation Details
Location of Tank Connections
Positioning
•
•
•
•
•
A HEV Series tank is designed to be installed inside but can be installed outside providing adequate
weatherproofing is provided.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top for access to the
expansion tank (if located on top of tank) and 50 mm around sides.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water services & any other system components.
It should be in a well ventilated area.
Cold Water Supply
•
•
The tank is classified by AS3500.1 as a low hazard device. This means that it requires only a nontestable back-flow prevention device be fitted in the incoming water supply prior to the system.
Section 4.0 of Australian Standard AS3500.1 provides you with details on these devices.
The valves required for the cold water supply are shown below and must be fitted before the heater.
Cold Water Valving
HEV Storage Tank
3.7
•
Size the incoming cold water pipe in accordance with the guidelines provided in AS3500.1. If you
require the full flow capacity of the tank then we recommend the pipe be sized the same as the tank
connection.
Connection Methods
You have 2 options for connecting pipes to the inlet & outlets on top of the tank.
Option 1
Option 2
Hot Water Supply
•
•
As the storage tank is an open vented (heat exchanger) type, it does not require a pressure and
temperature relief valve to be fitted in the tank
All hot water pipe-work should be insulated.
Expansion Tank
•
•
An expansion tank must be fitted above the HEV storage tank. This tank acts as a reservoir to allow
expansion and contraction of the treated water in the HEV tank. This is a vented circuit.
The expansion tank can be removed for easier access into a plant-room. If necessary due to site
restrictions, you can locate the expansion tank away from the HEV tank. However, you must ensure
that it is no higher than 8m from the top of the HEV tank to the bottom of the expansion tank and that
there is a continually falling gradient between the tanks so that the flow of water is unrestricted.
Expansion Tank Layout
Note: If you wish to install a single expansion tank for both the HEV series and a storage tank, refer to
Section 2 .7.
HEV Storage Tank
3.7
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the HEV tank and into a tundish or drain.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion cold water line (unless connected after the filter in the main
supply line). An isolating valve must also be fitted so that it can be isolated during servicing – this valve
must remain open when the system is operational.
Hot Water Circulation Pump
•
•
If the building has a secondary or ring-main return it must be connected back into the cold water
supply after the cold water check valve. The ring-main circulation pump should have isolating valves
either side of it for servicing and a check valve fitted downstream of it but before entering back into
the cold water supply.
Make sure the pump is installed with its shaft in the horizontal position.
HEV Storage Tank
3.7
Connecting A HEV Control Box
The HEV tank is connected to a control box to control a forced draft burner. Refer to Section 4.4 for
specific installation details.
Connecting A Forced Draft Burner
A gas or oil burner (type B appliance) is fitted to the HEV tank. This burner can be supplied by various
manufacturers and must be sized to suit the Input (MJ) rating of the HEV tank. Refer to Section 5.4 of
this manual for general details on forced draft burners or specifically to the Manufacturers manual that is
supplied with the burner itself.
Gas Connection (if applicable)
•
The gas connection must be made in accordance with AS5601 and any other local gas authority
regulations and must be connected by a qualified person.
•
Pipe-work should be sized according to the pressure and flow rate (gas consumption) required.
•
Refer to Section 5.4
Oil Connection (if applicable)
•
Unless otherwise specified, fuel oil should be light oil distillate Class D. The supply and return
(where fitted) pipes should be of copper only. Final connection to the burner can be made with the
flexible fuel pipe.
•
Refer to Section 5.4
Plant Room Ventilation
Ventilation requirements vary according to the size of the burner, but it is essential for both gas and oil
burners to have adequate ventilation that meets the AGA codes and EPA regulations. Refer to Section
5.4
Fluing
All gas or oil heaters must be flued in accordance with AS5601. Refer to Section 5.4
HEV Storage Tank
3.7
Process Heating Connections
The HEV tank can be connected to a closed heating circuit via optional process sockets. The flow line
from the heater is connected from the top socket on the right–side of the tank and the return line into the
lower socket on the right-side of the tank. Isolating valves should be fitted to each socket.
Ensure that the circulation pump is fitted in the flow line so that it draws water directly from the tank.
Pumps should be correctly sized to prevent sny overflowing of the expansion tank or oxygen entering
the system.
Electrical Connection
Power is provided to the Control Box (see Section 4.4). The temperature sensors are attached to the
storage tank by inserting it into the socket located in the tank.
Filling the Tank with Water
Always fill the heat exchanger coil with mains or full pressure water BEFORE you start filling the
main tank. Otherwise you could damage the heat exchange coil by partially crushing it. Failure to
follow this instruction will void the warranty.
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed and
tightened. Remember to open any valves in the treated water circuit.
Connect a temporary cold water supply to the service valve located on the tank.
Open the service valve and commence filling up the storage tank until water has reached approx.
two thirds of the HEV tank. Shut off service valve.
Using the same method pour the contents of the water treatment container into the unit via the
service valve. Shut off service valve.
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
HEV Storage Tank
3.7
•
Set the float valve inside the expansion tank (by bending the arm) so that it will shut off after filling
the tank to a maximum of 20 mm above the bottom of the expansion tank.
•
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks!
HEV Storage Tank
3.7
Commissioning
Commissioning the HEV tank involves a few small steps. The burner requires commissioning by a
suitably qualified person. Refer to Section 5.4 for general details on the burner and the specific
manufacturers information.
Completion Checklist (Tank Only)
All pipe-work & fittings are water tight & sound by
pressure testing (this also confirms that the heat
exchanger is OK).
Operating thermostat is set at clients desired
temperature. This will usually be approx. 60°C for hot
water.
The expansion tank is connected correctly ie. There is a
continuous gradient.
The isolating valve to the expansion tank is open & the
float valve is set at approx. 20 mm above the bottom of
the expansion tank.
Water treatment is at the correct dosage.
• Take a small sample of water from the service valve
and place it in a container. 250 to 500 ml is plenty.
• Use a pH tester (such as litmus paper) and check
that the pH of the water is between 8.5 – 9.0
This should be done once the heat source has been
installed because the water must be circulating for 30
minutes to evenly distribute the water treatment.
The cold water expansion control valve is operating
correctly (check the valve by pulling on the lever).
Plastic protective coating around the tank is removed
and any marks tidied up.
A copy of the User Guide has been handed to the client
for their future referral & owners instructions explained.
HEV Storage Tank
3.7
Maintenance
Full maintenance on the HEV Series tank should only be carried out by a qualified trades-person. As
the owner however, you can do a few simple things to help maintain the tank at its peak.
Every 6 months check:
•
•
•
•
There are no water leaks in any joins or fittings and electrical cables are secure and undamaged.
The water treatment is within 8.5 to 9.0 – see completion checklist above for instructions.
There is water in the expansion tank – it should be dark in colour.
The cold water expansion control valve (located in the cold water supply near the tank) is operating
correctly by pulling the lever and allowing water to discharge.
Full Maintenance
This can only be performed by a qualified trades-person.
Visual Inspection
•
•
•
Expansion Tank
•
•
•
Water Treatment
•
•
•
Performance Check
Final
•
Inspect the shell for any leaks or weeps.
Check that all connections are tight and not
corroded.
Replace any deteriorating insulation on the
pipe-work.
Inspect for any water treatment stains.
Adjust the level of the float valve so that it
shuts off at approx. 20mm of water level.
Check that the float valve shuts off
completely.
Drain approx. 250 ml of treated water from
the service valve on the main tank.
Check the pH of the water (using litmus
paper) to see if it is within 8.5 – 9.0.
If the level is below this range, re-dose with
water treatment using a plumbers’ pump
connected to the service valve. Retest the
pH level.
•
Check that the water temperature from the
tank is within 7°C for hot water.
If the unit is connected to harsh water you
may need to get the heat exchanger flushed
out regularly – contact Edwards.
•
•
•
Detail the tank.
Tidy up the plant room.
Complete paperwork.
HEV Storage Tank
3.7
Spare Parts
Description
Type / Model
Cold Water Expansion
Control Valve
Water Treatment
Expansion Tank (if
supplied)
Service Valve
Float Valve
Stock Code
RMC H50 - 1200kPa
2020316
Gendex – use 1ml for every litre of
storage capacity eg. 45ml for 450 litres.
HEV60 & HEV 95 = 25 litre capacity
HEV330 = 120 litre capacity
15mm BSP Brass ball valve
Philmac Valve 3005 &
Float 4993
8080049
5012025
5013120
2020075
2020368
2020369
Problem Solving
Lack Of Water Pressure
Possible Cause
Line strainer is blocked
Blockage in pipe-work
Water is too harsh
Cold or hot water pipes too
small
Check valve in reverse
Remedy
Turn off cold water, remove strainer, flush, re-fit and
turn water back on.
Isolate the likely area. Try and flush by quickly
opening/closing a hot top. If unsuccessful remove pipe,
clean or replace.
Check the water quality against the recommended
levels. If too high contact Edwards for advice.
Refer to AS3500.1 for sizing guidelines or contact
Edwards for recommendations.
Remove the valve and fit with the arrow on its body
pointing in the same direction as the flow of water.
Brown Coloured Water From Taps
Possible Cause
Mud or silt built up in cold
water supply
Heat exchange coil inside
tank is leaking
Remedy
Flush out the pipe-work and any supply tanks.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
HEV Storage Tank
3.7
Relief Valve Drips
A relief valve is designed to drip as part of its normal operation:
• A cold water expansion control valve will normally drip when water is being heated
because the water will expand up to 5% of the stored water per day. Is this the
case?
If the answer is no;
Possible Cause
The incoming water pressure
is too high for the valve
setting.
Dirt has built up under the
seal in the valve stopping it
from fully closing.
Remedy
Turn off the water supply and fit a pressure limiting
valve in the cold water supply to the heater prior to the
cold water expansion control valve.
Turn off the cold water supply, remove the valve, flush
the valve with water, check the closing operation and
re-fit.
Not Enough Hot or Warm Water
Possible Cause
Thermostat setting is too low
or faulty.
Heat source not functioning
correctly.
Leaking hot water pipe or
fitting.
No check valve fitted in the
secondary return line (if
connected to a ring-main)
Hot & cold water pipes have
been interconnected.
Hot & cold connections
reversed on tank.
Faulty cold water expansion
control valve is dumping all
the water.
Remedy
Adjust thermostat setting to a higher set point (see
Section 4.0 for instructions on how to do this).
See Section 5.0 for instructions.
Re-weld or tighten the effected area.
Fit a check valve in the ring-main secondary return line
downstream of the circulation pump but prior to entry
back into the cold water supply.
Trace pipe-work, remove the interconnecting pipe & reweld.
Cold inlet should be the right hand side of the tank
(looking from the front).
Isolate the cold water & replace the valve.
Not Enough Water Flow
Possible Cause
Block in the pipe-work
Pipe-work is too small.
Heat exchange coil is
undersized for the load
Water level in the tank is low
Blocked strainer in the cold
water supply.
Remedy
Flush the pipe-work with water. If the water quality is
poor there could be a build up of calcium or silt in the
pipes or heat exchanger. This will require flushing with
a suitable cleaning agent – contact Edwards.
Contact your nearest Edwards Distributor for
assistance.
Check that the flow rate for this model (se brochure)
meets the requirements of the project.
Check the level of water inside the expansion tank is
approx. 50 mm high. Make sure that the isolating valve
to the float valve is not turned off.
Isolate the water supply, remove the strainer, clean &
re-fit.
HEV Storage Tank
3.7
Water Hammer in Pipes
Possible Cause
Pipe-work is not clipped
properly.
Taps are ‘fast
opening/closing’ type.
Appliance (such as a
dishwasher) uses ‘fast
opening’ solenoid valves.
Water pressure is too high.
Remedy
Clip pipes at the intervals specified in Australian
Standard AS3500.4
Replace taps with slow opening type.
Check with the appliance manufacturer to see if slower
opening solenoids are available.
Fit a water hammer arrester valve into the pipe-work.
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Remedy
Drain some water from the expansion tank and bend
the arm of the valve until the float is approx. 20 mm
from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 1000 litre tank requires a 60
litre expansion tank.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil is
leaking.
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Heat exchange coil or pipework is leaking.
Remedy
Make sure a full service is done.
Isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Warranty
Item
Heat Exchange Storage Tank
Associated parts - valves
Labour, Travel & Freight
Coverage
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
TC Storage Tank
3.8
This information expands on the TC Configuration details from Section 2.8 of this Manual.
Installation Details
Location of Tank Connections
Note: Refer to the TC Technical
Data Sheet for unit dimensions and
further information on connection
sizes and mounting data.
TC Storage Tank
3.8
Positioning
•
•
•
•
•
A TC Series tank can be installed inside or outside.
Make sure it is accessible for maintenance - allow 250 mm clearance at the top if possible and 50
mm around sides. Allow sufficient space between adjacent tanks for service and maintenance.
The tank must sit on a solid, well-drained and level base.
Locate as near as possible to water, electric and fuel supplies, the boost water heater and the solar
panels.
Sufficient access must be provided to all valves and auxiliary plant.
Expansion Tank
•
•
•
An expansion tank (not supplied as standard) must be fitted to the TC storage tank. This tank acts as
a reservoir to allow expansion and contraction of the treated water in the TC tank. The size of the
expansion tank will vary depending on the type of system being installed, its heat source and if it is
being used with solar pre-heat.
The expansion tank must be mounted above the solar panels at the highest point of the treated
water circuit.
If necessary due to site restrictions, you can locate the expansion tank away from the TC tank.
Ensure that it is no higher than 40 m from the top of the TC tank to the bottom of the expansion tank
and that there is a continually falling gradient between the tanks and that the flow of water is
unrestricted by any valve.
Note: If you wish to install a single expansion tank for both the TC and its heat source, refer to Section
2.8.
Expansion Tank Layout
TC Storage Tank
3.8
Expansion Pipe
Never install an isolating valve in this pipe – always keep it unobstructed.
Overflow Pipe
It is recommended that you direct water away from the top of the TC tank and via an air-break into a
tundish or drain connected to the buildings drainage system.
Cold Water Supply To Expansion Tank
You must connect the float valve inside the expansion tank to the cold water supply using a 15 mm pipe.
This allows the system to automatically replace evaporated water with a small amount of fresh water. A
strainer/filter must be fitted to the expansion cold water line, unless the expansion supply is connected
after the strainer/filter in the heater main supply. An isolating valve must also be fitted so that it can be
isolated during servicing – this valve must remain open when the system is operational.
Connecting A Heat Source & Control Box
•
•
•
•
The TC tank is usually connected to a heat source and control box. Refer to the relevant
configuration diagram in Section 2.8 of this manual and this will then refer you to the appropriate
parts of Section 4.0 and Section 5.0 for specific installation details.
Warm water systems installed under the NSW Health Approvals must also be installed in conjunction
with the Edwards Hot Water – Warm Water Systems manual.
The flow line to the heat source from the TC tank is from the upper connection on top of the tank (the
smaller socket is the expansion line). The return line from the heat source is connected to the lower
tank connection near the bottom of the tank (between the solar flow/return). These are clearly
marked on the tanks.
Isolating ball valves are recommended to be fitted to all connections for easier servicing.
Connecting a Solar Heat Source
•
•
The TC can be connected to a number of solar panels to reduce fuel costs. The connections shown
in the diagrams for the heat source connection are used for the connection of solar ie. the solar flow
line is connected to the heat source flow line. The solar return line is connected to the heat source
return line.
For details on the installation of the solar panels themselves, refer to Section 5.3 of this manual.
Electrical Connection
Power is provided to the Control Box (see Section 4.0 of this Manual). The temperature sensor is
attached to the storage tank by inserting it into the socket located in the tank.
TC Storage Tank
3.8
Filling the Heater Tank with Water
•
•
•
•
•
•
•
Check that all your pipe-work, valves, fittings & associated equipment have been completed,
tightened and checked for leaks. Remember to open any valves in the treated water circuit that are
connected to the heat-source.
Connect a temporary cold water supply to the service valve located near the lower connections.
Open the service valve and commence filling up the treated water storage tank until it is
approximately half full. Shut off service valve.
Using the same method pour the contents of the water treatment container into the unit via the
service valve.
Recommence filling the system by opening the service valve again until the water level rises just
enough to start entering the expansion tank. Shut off the service valve and disconnect the cold
water supply to it.
Set the float valve inside the expansion tank (by gently bending the arm) so that it will shut-off after
filling the tank to a maximum of 20 mm above the bottom of the expansion tank.
Open the cold water supply valve to the float valve in the expansion tank and let the system fill until
the float valve automatically shuts off – check for air locks in both the heater and solar circuits!
TC Storage Tank
3.8
Commissioning
The TC tank will normally have a remote heat-source attached. The heat-source has its own
commissioning instructions contained in Section 5.0 of this manual.
Completion Checklist
Model Number: __________________________
Serial Number: __________________________
All pipe-work & fittings are water tight & sound by pressure testing
The expansion tank is connected correctly and there is a continuous gradient.
The isolating valve to the expansion tank is open & the float valve is set at
approx. 20 mm above the bottom of the expansion tank.
Water treatment is at the correct dosage.
Take a small sample of water from the service valve and place it in a
container. 250 to 500 ml is plenty.
Use a pH tester (such as litmus paper) and check that the pH of the water is
between 8.5 – 9.0
This should be done once the heat source has been installed as the treated
water must be circulating for 30 minutes to evenly distribute the water treatment.
Plastic protective coating around the tank is removed and any marks tidied up.
A copy of the User Guide and any other applicable documents has been handed
to the client for their future referral & owners instructions explained.
TC Storage Tank
3.8
Maintenance
Full maintenance on the TC Series tank should only be carried out by a qualified trades-person. As the
building owner/manager however, you can arrange for a few simple things to be done to help maintain
the tank at its peak.
Every 6 months check:
•
•
•
There are no water leaks in any joints or fittings and electrical cables are secure and undamaged.
The water treatment has a pH of 8.5 to 9.0 – see completion checklist above for instructions on how
to do this.
There is water in the expansion tank – it should be dark in colour.
Full Maintenance
The following can only be performed by or under the direct supervision on site of a qualified tradesperson. The model and serial numbers can be found on the identification sticker located on the front of
the unit.
Model Number: __________________________
Serial Number: __________________________
Visual Inspection
- Inspect shell for any leaks or weeps
- Check that all connections are tight and not corroded
- Replace any deteriorating insulation on pipe-work
Expansion Tank
- Inspect for any water treatment stains
- Adjust float level to shut-off water at 20mm from bottom.
- Check that float valve shuts completely, and service as required
Water Treatment
- Drain approximately 250 ml of treated water from service drain valve on main
tank.
- Check pH level of sample, using litmus paper. pH must be within 8.5-9.0
- If pH level is outside this range, re-dose with water treatment using a
plumbers pump connected to the service valve. Retest pH level
Final
- Detail Tank
- Tidy up plant room
- Complete paperwork and hand a copy of the maintenance report to client
TC Storage Tank
3.8
Spare Parts
Description
Water Treatment
Expansion Tank
Service Valve
Temperature Gauge
Float Valve
Type / Model
Stock Code
Gendex – use 1 ml for every litre of
storage capacity eg. 1 litre per 1000 litres.
Replace with same capacity as original
15mm BSP Brass ball valve
Caleffi 688000
Philmac Valve 3005 &
Plastic Float 4993
8080049
8080061
2020075
2020427
2020368
2020369
Problem Solving
Overflow Pipe Runs Continuously
Possible Cause
Float valve is set too high.
Expansion tank is not level.
Expansion tank is too small
Heat exchange coil in the
Heat Source is leaking.
Remedy
Drain some water from the expansion tank and slowly
bend the arm of the valve until the float is approx. 50
mm from the bottom of the tank.
Realign the expansion tank so that it is level. You can
use blocks of wood or readjust brackets if fitted.
The size of the expansion tank should be 6% of the
main tank capacity eg. A 450 litre tank requires a 25
litre expansion tank.
Go to the Heat Source connected to the TC tank and
isolate the water supply to the expansion tank, drain
water level in the main tank until it is level with the
bottom of the expansion tank. If the expansion tank fills
up again then the coil is leaking – contact Edwards.
Water treatment Is Low
Possible Cause
Regular maintenance is not
being carried out
Remedy
Make sure a full service is done.
TC Storage Tank
3.8
Warranty
Item
Storage Tank
Associated parts- valves
Labour, Travel & Freight
Coverage
3 years full cover
4th year 75% cover
5th year 50% cover
1 year
1 year
Also refer to General Warranty terms & Conditions (Section 1.3). Ensure that the warranty registration
form provided with the system has been completed and returned to Edwards.
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