1 1 IMPORTANT: PLEASE READ AND UNDERSTAND ALL THESE

1 1 IMPORTANT: PLEASE READ AND UNDERSTAND ALL THESE
UNVENTED MAINS PRESSURE SOLAR WATER HEATERS
210, 250 AND 300 LITRE CAPACITY INDIRECT MODELS
INSTALLATION AND SERVICING INSTRUCTIONS
PACK CONTENTS
The MAIN SOLAR unvented solar cylinder water heater incorporating immersion heater and thermal controls
Factory fitted temperature/pressure relief valve l Cold water combination valve assembly l Expansion vessel
and mounting bracket l Tundish l Motorised valve l Compression nuts and olives l Immersion heater spanner l
Installation instructions
IMPORTANT: PLEASE READ AND UNDERSTAND ALL THESE INSTRUCTIONS
BEFORE COMMENCING INSTALLATION. PLEASE LEAVE THIS MANUAL WITH
THE CUSTOMER FOR FUTURE REFERENCE.
THE BENCHMARK SCHEME
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers
are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in
accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of
the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with
Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark
Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote
the Scheme. Visit www.centralheating.co.uk for more information.
IMPORTANT NOTE TO USER: PLEASE REFER TO THE USER INSTRUCTIONS SECTION ON PAGES 22 AND 23 FOR
IMPORTANT INFORMATION WITH RESPECT TO THE BENCHMARK SCHEME
INTRODUCTION
The MAIN SOLAR cylinder is a purpose designed
unvented solar water heater. The unit has a stainless
steel inner vessel, which ensures an excellent standard
of corrosion resistance. The outer casing is a combination
of resilient thermoplastic mouldings and corrosion
proofed steel sheet. All products are insulated with
CFC/HCFC free polyurethane foam to meet the latest
European heat loss requirements (see Table 6 Page 19).
The unit is supplied complete with all the necessary
safety and control devices needed to allow connection
to the cold water mains. All these components are
preset and not adjustable.
This appliance complies with the requirements of the
CE marking directive and is Kiwa approved to show
compliance with Building Regulations (Section G3).
The following instructions are offered as a guide to
installation which must be carried out by a competent
plumbing and electrical installer in accordance with
Building Regulation G3, The Building Standards
(Scotland) Regulations 1990, or The Building
Regulations (Northern Ireland).
NOTE: Prior to installation the unit should be stored in
an upright position in an area free from excessive damp
or humidity.
1
1
Contents
PAGE
INTRODUCTION.................................................................1
GENERAL REQUIREMENTS.............................................3
INSTALLATION-GENERAL...............................................4
INSTALLATION - SOLAR PRIMARY...............................9
INSTALLATION - AUXILLARY HEATING COIL...........10
COMMISSIONING.............................................................12
MAINTENANCE..................................................................13
USER INSTRUCTIONS.......................................................14
FAULT FINDING AND SERVICING.................................15
HEAT LOSS ..........................................................................19
ENVIRONMENTAL INFORMATION...............................19
COMMISSIONING CHECK LIST......................................20
SERVICE RECORD..............................................................21
GUARANTEE.......................................................................24
TECHNICAL SUPPORT AND SPARES...........................24
2
IMPORTANT: THIS APPLIANCE IS NOT INTENDED
FOR THE USE BY PERSONS (INCLUDING CHILDREN)
WITH REDUCED PHYSICAL, SENSORY OR MENTAL
CAPABILITIES, OR LACK OF KNOWLEDGE AND EXPERIENCE, UNLESS THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING THE USE OF
THE APPLIANCE BY A PERSON RESPONSIBLE FOR
THEIR SAFETY. CHILDREN MUST BE SUPERVISED.
WATER SUPPLY
Bear in mind that the mains water supply to the
property will be supplying both the hot and cold water
requirements simultaneously. It is recommended that
the maximum water demand is assessed and the
water supply checked to ensure this demand can be
satisfactorily met.
Note: A high mains water pressure will not always
guarantee high flow rates.
GENERAL REQUIREMENTS
SITING THE UNIT
The MAIN SOLAR must be installed vertically. Although
location is not critical, the following points should be
considered:
t The MAIN SOLAR should be sited to ensure minimum dead leg distances, particularly to the point
of most frequent use.
t Avoid siting where extreme cold temperatures will
be experienced. All exposed pipework should be
insulated.
t The discharge pipework from the safety valves
must have minimum fall of 1:200 from the unit
and terminate in a safe and visible position.
t Access to associated controls and immersion
heaters must be available to provide for the
servicing and maintenance of the system. Where
these controls are installed against a wall a minimum
distance of 250mm must be left (see Fig. 1).
t Ensure that the floor area for the MAIN SOLAR
cylinder is level and capable of permanently
supporting the weight when full of water. (See
Table 1).
WALL
Min 250mm
Min 250mm
Fig. 1: Siting the Unit
Nominal
capacity
Model
reference (litres)
INDIRECT
210I
210
250I
250
300I
300
Type
Table 1: Unit weights
Weight of
unit full
(kg)
264
308
367
Wherever possible the mains supply pipe should be
22mm. We suggest the minimum supply requirements
should be 1.5 bar pressure and 20 litres per minute flow
rate. However, at these values outlet flow rates may
be poor if several outlets are used simultaneously. The
higher the available pressure and flow rate the better
the system performance.
The MAIN SOLAR cylinder has an operating pressure of
3.5 bar which is controlled by the cold water combination
valve assembly. The cold water combination valve
assembly can be connected to a maximum mains
pressure of 16 bar.
OUTLET/TERMINAL FITTINGS (TAPS, ETC.)
The MAIN SOLAR cylinder can be used with most types
of terminal fittings. It is advantageous in many mixer
showers to have balanced hot and cold water supplies.
In these instances a balanced pressure cold water
connection should be placed between the 2 pieces
of the cold water combination valve assembly (see
Fig. 2). Outlets situated higher than the MAIN SOLAR
cylinder will give outlet pressures lower than that at
the heater, a 10m height difference will result in a 1 bar
pressure reduction at the outlet. All fittings, pipework
and connections must have a rated pressure of at least
6 bar at 80°C.
LIMITATIONS
The MAIN SOLAR cylinder should not be used in association with any of the following:
t 4PMJEGVFMCPJMFSTPSBOZPUIFSCPJMFSJOXIJDIUIF
energy input is not under effective thermostatic
control unless additional and appropriate safety
measures are installed.
t "TDFOEJOHTQSBZUZQFCJEFUTPSBOZPUIFSDMBTT
1 back syphonage risk requiring that a type A
air gap be employed.
t 4UFBN IFBUJOH QMBOUT VOMFTT BEEJUJPOBM BOE
appropriate safety devices are installed.
t 4JUVBUJPOT XIFSF NBJOUFOBODF JT MJLFMZ UP CF
neglected or safety devices tampered with.
t 8BUFS TVQQMJFT UIBU IBWF FJUIFS JOBEFRVBUF
pressure or where the supply may be
intermittent.
t 4JUVBUJPOTXIFSFJUJTOPUQPTTJCMFUPTBGFMZQJQF
away any discharge from the safety valves.
t *OBSFBTXIFSFUIFXBUFSDPOTJTUFOUMZDPOUBJOT
a high proportion of solids, e.g. suspended
matter that could block the strainer, unless
adequate filtration can be ensured.
3
3
OPERATIONAL SUMMARY
Maximum mains pressure
16 bar
Operating pressure
3.5 bar
Expansion vessel charge pressure 3.5 bar
Expansion relief valve setting
6 bar
T&P relief valve setting
90°C/10 bar
Maximum primary circuit pressure
(auxillary coil, indirect only)
3 bar
Maximum primary circuit pressure 6 bar (Solar coil)
Storage capacity
See Table 1
Weight when full
See Table 1
IMPORTANT NOTE:
MAIN SOLAR MUST BE INCORPORATED INTO A FULLY
PUMPED SOLAR PRIMARY CIRCUIT. CONTROL OF
THE SOLAR PRIMARY IS ACHIEVED BY THE USE OF
EXTERNAL CONTROLS NOT SUPPLIED WITH THE UNIT.
CONTROL MUST BE VIA A PURPOSE DESIGNED SOLAR
HYDRAULIC STATION AND SOLAR DIFFERENTIAL
TEMPERATURE CONTROLLER.
INSTALLATION - GENERAL
(FIGS 4 & 6)
PIPE FITTINGS
All pipe fittings are made via 22mm compression
fittings directly to the unit. The fittings are threaded
3/4”BSP male parallel should threaded pipe
connections be required.
COLD FEED
A 22mm cold water supply is recommended, however
if a 15mm (1/2”) supply exists which provides sufficient
flow this may be used (although more flow noise may
be experienced).
A stopcock or servicing valve should be incorporated
into the cold water supply to enable the MAIN SOLAR
cylinder and its associated controls to be isolated and
serviced.
COLD WATER COMBINATION VALVE ASSEMBLY (FIG 2)
The 2-piece cold water combination valve assembly
can be located anywhere on the cold water mains
supply prior to the expansion vessel (see Fig. 6 Page
8 ) but the two pieces do not have to be installed
together. The pressure reducing valve incorporates the
pressure reducer and strainer and the expansion valve
incorporates the expansion and check valves. Ensure
that the valves are installed in the correct order and
orientation. No other valves should be placed between
the expansion valve and the MAIN SOLAR unit. A
connection can be made between the expansion and
pressure reducing valves to provide a balanced cold
water connection. The expansion valve connection
must not be used for any other purpose.
4
Fig. 2: Cold water combination valve assembly
DRAIN TAP
A suitable draining tap should be installed in the
cold water supply to the MAIN SOLAR cylinder unit
between the expansion valve (see Fig. 6 Page 8
) and the heater at as low a level as possible. It is
recommended that the outlet point of the drain
pipework be at least 1 metre below the level of the
heater (this can be achieved by attaching a hose to the
drain tap outlet spigot).
EXPANSION VESSEL
The expansion vessel accommodates expansion
that results from heating the water inside the unit.
The expansion vessel is pre-charged at 3.5 bar. The
expansion vessel must be connected between the
expansion valve (see Fig. 2) and the MAIN SOLAR
cylinder (see Fig. 6 Page 8). The location of the
expansion vessel should allow access to recharge the
pressure as and when necessary, this can be done
using a normal car foot pump. It is recommended
that the expansion vessel is adequately supported. An
expansion vessel wall mounting bracket is supplied for
this purpose and should be fitted.
NOTE: DO NOT USE THE POTABLE WATER
EXPANSION VESSEL SUPPLIED WITH THE MAIN
SOLAR CYLINDER FOR ANY OTHER PURPOSE. IT
IS NOT SUITABLE FOR USE ON A SOLAR PRIMARY
CIRCUIT.
SECONDARY CIRCULATION
If secondary circulation is required it is recommended
that it be connected to the MAIN SOLAR cylinder as
shown in Fig. 3. The secondary return pipe should be
in 15mm pipe and incorporate a check valve to prevent
backflow. A suitable WRAS approved bronze circulation
pump will be required. On large systems, due to the increase in system water content, it may be necessary to fit
an additional expansion vessel to the secondary circuit.
This should be done if the capacity of the secondary
circuit exceeds 10 litres.
Pipe capacity (copper)
15mm O.D = 0.13 l/m (10 litres = 77m)
22mm O.D = 0.38 l/m (10 litres = 26m)
28mm O.D = 0.55 l/m (10 litres = 18m)
OUTLET
The hot water outlet is a 22mm compression
fitting located at the top of the cylinder. Hot water
distribution pipework should be 22mm pipe with
short runs of 15mm pipe to terminal fittings such as
sinks and basins. Pipe sizes may vary due to system
design.
A
29
Fig. 3: Secondary circulation connection
B
594
C
D
Ø550
433
370
412
81
20
30°
45°
°
25°
Fig. 4: General dimensions
NOMINAL
CAPACITY
(litres)
TY P E
INDIRECT
DIMENSIONS (mm)
A
B
C
D
SOLAR
SURFACE
AREA (m2)
AUXILLARY
VOLUME
SURFACE
(litres)
AREA (m2)
AUXILLARY COIL
HEAT UP RECOVERY
RATING
(kW)
(mins)
(mins)
210
1473
1009
1111
1184
1.1
120
0.68
15.2
33
17
250
1731
1160
1258
1391
1.1
145
0.79
15.2
40
21
300
2038
1438
1573
1715
1.1
175
0.79
17.4
42
22
NOTES:
1. Recovery time based on heating 70% of auxillary volume through 45°C
2. Direct heating times assume use of lower element only and auxillary cylinder volume being heated.
Table 2: Dimensions and performance
5
5
DISCHARGE PIPEWORK
It is a requirement of Building Regulation G3 that
any discharge from an unvented system is conveyed
to where it is visible, but will not cause danger to
persons in or about the building. The tundish and
discharge pipes should be fitted in accordance with the
requirements and guidance notes of Building Regulation
G3. The G3 Requirements and Guidance section 3.50 3.63 are reproduced in the following sections of this
manual. For discharge pipe arrangements not covered
by G3 Guidance advice should be sought from your
local Building Control Officer. Any discharge pipe
connected to the pressure relief devices (Expansion
Valve and Temperature/Pressure Relief Valve) must be
installed in a continuously downward direction and in a
frost free environment.
Water may drip from the discharge pipe of the pressure
relief device. This pipe must be left open to the
atmosphere. The pressure relief device is to be operated
regularly to remove lime deposits and to verify that it is
not blocked.
Tundish
3.54 The tundish should be vertical, located in the same
space as the unvented hot water storage system and be
fitted as close as possible to, and lower than, the valve,
with no more than 600mm of pipe between the valve
outlet and the tundish (see Figure 5).
Note: To comply with the Water Supply (Water Fittings)
Regulations, the tundish should incorporate a suitable air
gap.
3.55 Any discharge should be visible at the tundish. In
addition, where discharges from safety devices may not
be apparent, e.g. in dwellings occupied by people with
impaired vision or mobility, consideration should be given
to the installation of a suitable safety device to warn when
discharge takes place, e.g. electronically operated.
Discharge pipe D2
3.56 The discharge pipe (D2) from the tundish should:
G3 REQUIREMENT
“...there shall be precautions...to ensure that the hot water
discharged from safety devices is safely conveyed to where
it is visible but will not cause danger to persons in or about
the building.”
Notes:
1. Discharge pipe-work D2 can now be a plastic
pipe but only pipes that have been tested to a
minimum 110°C must be used.
2. Discharge pipe D2 can now be plumbed into
the soil stack but only soil stacks that can handle
temperatures of 99°C or greater should be used.
The following extract is taken from the latest G3
Regulations
Discharge pipe D1
3.50 Safety devices such as temperature relief valves or
combined temperature and pressure and pressure relief
valves (see paragraphs 3.13 or 3.18) should discharge
either directly or by way of a manifold via a short length of
metal pipe (D1) to a tundish.
3.51 The diameter of discharge pipe (D1) should be not
less than the nominal outlet size of the temperature relief
valve.
3.52 Where a manifold is used it should be sized to accept
and discharge the total discharge form the discharge
pipes connected to it.
3.53 Where valves other than the temperature and
pressure relief valve from a single unvented hot water
system discharge by way of the same manifold that is used
by the safety devices, the manifold should be factory fitted
as part of the hot water storage system unit or package.
6
(a) have a vertical section of pipe at least 300mm long
below the tundish before any elbows or bends in the
pipework (see Diagram 1); and
(b) be installed with a continuous fall thereafter of at
least 1 in 200.
3.57 The discharge pipe (D2) should be made of:
(a) metal; or
(b) other material that has been demonstrated to be
capable of safely withstanding temperatures of the water
discharged and is clearly and permanently marked to
identify the product and performance standard (e.g. as
specified in the relevant part of BS 7291).
3.58 The discharge pipe (D2) should be at least one pipe
size larger than the nominal outlet size of the safety device
unless its total equivalent hydraulic resistance exceeds
that of a straight pipe 9m long, i.e. for discharge pipes
between 9m and 18m the equivalent resistance length
should be at least two sizes larger than the nominal outlet
size of the safety device; between 18 and 27m at least 3
sizes larger, and so on; bends must be taken into account
in calculating the flow resistance. See Figure 5, Table 3
and the worked example.
Note: An alternative approach for sizing discharge pipes
would be to follow Annex D, section D.2 of BS 6700:2006
Specification for design, installation, testing and
maintenance of services supplying water for domestic use
within buildings and their curtilages.
3.59 Where a single common discharge pipe serves more
than one system, it should be at least one pipe size larger
than the largest individual discharge pipe (D2) to be
connected.
3.60 The discharge pipe should not be connected to a soil
discharge stack unless it can be demonstrated that that
the soil discharge stack is capable of safely withstanding
temperatures of the water discharged, in
which case, it should:
(a) contain a mechanical seal, not incorporating a water
trap, which allows water into the branch pipe without
allowing foul air from the drain to be ventilated through
the tundish;
(b) be a separate branch pipe with no sanitary
appliances connected to it;
(c) if plastic pipes are used as branch pipes carrying
discharge from a safety device they should be either
polybutalene (PB) to Class S of BS 7291-2:2006 or cross
linked polyethylene (PE-X) to Class S of BS 7291-3:2006;
and
( d) be continuously marked with a warning that no
sanitary appliances should be connected to the pipe.
Note:
1. Plastic pipes should be joined and assembled with
fittings appropriate to the circumstances in which they are
used as set out in BS EN ISO 1043-1.
2. Where pipes cannot be connected to the stack it may
be possible to route a dedicated pipe alongside or in close
proximity to the discharge stack.
Termination of discharge pipe
3.61 The discharge pipe (D2) from the tundish should
terminate in a safe place where there is no risk to persons
in the vicinity of the discharge.
The example below is for a G1/2 temperature relief
valve with a discharge pipe (D2) having 4 No. elbows
and length 7m from the tundish to the point of
discharge
From Table 3:
Maximum resistance allowed for a straight length
of 22mm copper discharge pipe (D2) from a G1/2
temperature relief valve is 9.0m.
Subtract the resistance for 4 No. 22mm elbows at 0.8m
each = 3.2m
Therefore the permitted length equates to: 5.8m
5.8m is less than the actual length of 7m therefore
calculate the next largest size.
Maximum resistance allowed for a straight length of
28mm pipe (D2) from a G1/2 temperature relief valves
equates to 18m.
Subtract the resistance of 4 No. 28mm elbows at 1.0m
each = 4.0m
Therefore the maximum permitted length equates to:
14m
As the actual length is 7m, a 28mm (D2) copper pipe
will be satisfactory.
3.62 Examples of acceptable discharge arrangements
WARNINGS
are:
t 6OEFSOPDJSDVNTUBODFTTIPVMEUIFGBDUPSZ
(b) to a trapped gully with the end of the pipe below a
fitted temperature/pressure relief valve be
fixed grating and above the water seal;
removed other than by a competent person. To
(c) downward discharges at low level; i.e. up to 100mm
do so will invalidate any guarantee or claim.
above external surfaces such as car parks, hard standings,
t 5IF DPME XBUFS DPNCJOBUJPO WBMWF BTTFNCMZ
grassed areas etc. are acceptable providing that a wire
must be fitted to the mains water supply to the
cage or similar guard is positioned to prevent contact,
MAIN SOLAR cylinder.
whilst maintaining visibility; and
t /PDPOUSPMPSTBGFUZWBMWFTTIPVMECFUBNQFSFE
(d) discharges at high level: e.g. into a metal hopper
with or used for any other purpose.
and metal downpipe with the end of the discharge pipe
t
5IFEJTDIBSHFQJQFTIPVMEOPUCFCMPDLFEPS
clearly visible or onto a roof capable of withstanding high
used for any other purpose.
temperature discharges of water and 3m from any plastic
t
5IFUVOEJTITIPVMEOPUCFMPDBUFEBEKBDFOUUP
guttering system that would collect such discharges.
any electrical components.
3.63 The discharge would consist of high temperature
water and steam. Asphalt, roofing felt and non-metallic
rainwater goods may be damaged by such discharges.
VALVE OUTLET
SIZE
MINIMUM SIZE OF
DISCHARGE PIPE D1
MINIMUM SIZE OF
DISCHARGE PIPE D2
FROM TUNDISH
MAXIMUM RESISTANCE
ALLOWED, EXPRESSED
AS A LENGTH OF
STRAIGHT PIPE (I.E. NO
ELBOWS OR BENDS
RESISTANCE CREATED BY
EACH ELBOW OR BEND
G 1/2
15MM
G 3/4
22MM
G1
28MM
22mm
28mm
35mm
28mm
35mm
42mm
35mm
42mm
54mm
UP TO 9M
UP TO 18M
UP TO 27M
UP TO 9M
UP TO 18M
UP TO 27M
UP TO 9M
UP TO 18M
UP TO 27M
0.8M
1.0M
1.4M
1.0M
1.4M
1.7M
1.4M
1.7M
2.3M
Table 3: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes
7
7
Safety device
(e.g. Temperature
relief valve)
Metal discharge pipe (D1) from
Temperature relief valve to tundish
600mm maximum
Tundish
Discharge below
fixed grating
(Building Regulation
G3 section 3.61 gives
alternative points
of discharge)
300mm
minimum
Discharge pipe (D2) from tundish,
with continuous fall. See Building
Regulation G3 section 3.55,
Table 4 and worked example
Fixed grating
Trapped
gully
Fig.5: Typical discharge pipe arrangement (extract from Building Regulation G3 Guidance section)
BALANCED
COLD WATER
SECONDARY RETURN TAPPING T&P RELIEF EXPANSION CONNECTION
VESSEL (IF REQUIRED)
VALVE
(IF REQUIRED)
COLD WATER
COMBINATION
VALVE
(2-PIECE)
MAINS
WATER
SUPPLY
TO HOT
OUTLETS
BOOST ELEMENT/
AUX. CONTROL
HOUSING
AUX. PRIMARY
RETURN
ISOLATING
VALVE (NOT
SUPPLIED)
AUX. PRIMARY
FLOW
SOLAR PRIMARY
RETURN
TUNDISH
SOLAR PRIMARY
FLOW
DRAIN COCK
SOLAR INLET
(NOT SUPPLIED)
CONTROLS
HOUSING
Fig. 6: Typical installation - schematic
8
DISCHARGE
PIPE
INSTALLATION - SOLAR PRIMARY
CONNECTION TO SOLAR PRIMARY CIRCUIT
The lower (solar) coil of the MAIN SOLAR cylinder
must be connected to a fully pumped solar primary
circuit. The connections are suitable for 22mm copper
pipe direct to the compression fittings provided. The
connections are also threaded 3/4” BSP male parallel
should BSP be required.
The solar primary circuit should have its own dedicated
circulating pump and safety controls which must be
installed as per the manufacturer’s instructions.
CONTROL OF SOLAR PRIMARY CIRCUIT
Temperature control of the MAIN SOLAR cylinder
must be carried out using a suitable proprietory Solar
Controller/Programmer. The cylinder temperature
sensing probe (supplied with the solar controller)
should be fully inserted into the pocket provided on
the MAIN SOLAR cylinder and its cable secured using
the cable clamps on the controls housing ( see Fig. 7 ).
Connection to the solar controller should be in
accordance with the manufacturers instructions.
The solar controller should be programmed to give a
cylinder temperature of approximately 60° (maximum
70°C ).
Fig. 7: Solar Control Connections
The solar controller and solar primary circulation
pump must be wired via the over-temperature cutout mounted in the lower solar controls housing.
This will ensure that the heat input to the solar coil is
interrupted in the event of the cylinder over-heating.
There must also be suitable check (non-return) valves
installed in the solar primary flow and return to
prevent the possibility of any thermo-syphoning if the
solar circulation is stopped.
AUXILLARY HEATING CONTROL
Fig.8 Electrical Connections (Schematic)
9
9
SAFETY
DISCONNECT FROM THE MAINS SUPPLY BEFORE REMOVING ANY COVERS. Never attempt
to replace the immersion heater other than with
the recommended MAIN immersion heater.
DO NOT BYPASS THE THERMAL CUT-OUT(S)
IN ANY CIRCUMSTANCES. Ensure the two male
spade terminations on the underside of the combined thermostat and thermal cut-out are pushed
firmly into the corresponding terminations on the
element plate assembly.
In case of difficulty contact service support; contact details available at the back of this booklet.
INSTALLATION - AUXILLARY
HEATING COIL
PLUMBING CONNECTIONS
MAIN SOLAR cylinders require the following
pipework connections.
tCold water supply to and from inlet controls.
tOutlet to hot water draw off points.
tDischarge pipework from valve outlets to
tundish
tConnection to the auxillary primary circuit.
Primary connections are 22mm compression. However,
3/4”BSP parallel threaded fittings can be fitted to the
primary coil connections if required.
ELECTRICAL SUPPLY (FIG. 8 Page 9)
All units are fitted with a 3kW immersion heater and a
combined thermostat and thermal cut-out to control
the primary heating source. The MAIN SOLAR cylinder MUST be earthed.
All wiring to the unit must be installed in accordance
with the latest IEE Wiring Regulations and the supply
circuits must be protected by a suitable fuse and
double pole isolating switch with a contact separation
of at least 3mm in both poles. All connections are
made to the terminal block located under the terminal
cover mounted on the side of the unit. The supply
cable(s) must be routed through the cable grip(s) in
the terminal housing.
DISCONNECT FROM MAINS SUPPLY BEFORE
REMOVING ANY COVERS. Never attempt to
replace the immersion heater other than with the
recommended MAIN SOLAR immersion heater.
DO NOT BYPASS THE THERMAL CUT-OUTS IN
ANY CIRCUMSTANCES. Ensure the two male spade
terminations on the underside of the combined
thermostat and thermal cut-out are pushed firmly into
the corresponding terminations on the element plate
assembly. In case of difficulty contact service support;
contact details available at the back of this booklet.
10
BOILER SELECTION
The boiler should have a control thermostat and non
self-resetting thermal cut-out and be compatible with
unvented storage water heaters.
Where use of a boiler without a thermal cut-out is
unavoidable a “low head” open vented primary circuit
should be used. The feed and expansion cistern head
above the MAIN SOLAR cylinder should not exceed
2.5m.
AUXILLARY PRIMARY CIRCUIT CONTROL
The 2-port motorised valve supplied with the MAIN
SOLAR cylinder MUST be fitted to the primary auxillary
circuit flow to the MAIN SOLAR cylinder heat exchanger
and wired in series with the indirect thermostat and
thermal cut-out fitted to the unit. Primary circulation
to the MAIN SOLAR cylinder heat exchangers must be
pumped; gravity circulation WILL NOT WORK.
SPACE AND HEATING SYSTEMS CONTROLS
The controls provided with the MAIN SOLAR cylinder
will ensure the safe operation of the unit within
the central heating system. Other controls will be
necessary to control the space heating requirements
and times that the system is required to function.
The MAIN SOLAR cylinder is compatible with most
heating controls, examples of electrical circuits are
shown in Figs. 9 and 10. However, other systems
may be suitable, refer to the controls manufacturers’
instructions, supplied with the controls selected, for
alternative system wiring schemes.
CYLINDER
TERMINAL BLOCK
2
1
3
3
ZONE VALVE (HTG)
G
Br
1
Bl
O
3
1
GY
2
ZONE VALVE(DHW)
(SUPPLIED)
ROOM STAT
3
2
G
2
1
Br
Bl
GY
O
2
3
(SUPPLY)
L N
1
2
L
N
1
2
3
4
5
6
7
8
9 10
1
2
3
4
5
6
7
8
9 10
2
3
HTG
ON
L
DHW
ON
JUNCTION BOX
3
L
3
N
BOILER
PROGRAMMER
N
2
PUMP
NOTES:
CONTROL TERMINAL NUMBERING MAY DIFFER FROM THOSE SHOWN.
REFER TO INSTRUCTIONS WITH CONTROLS SELECTED.
A DOUBLE POLE ISOLATING SWITCH MUST BE INSTALLED IN THE MAINS SUPPLY.
ALL EARTH CONNECTIONS MUST BE CONNECTED BACK TO THE MAINS EARTH SUPPLY.
CONTROL CIRCUIT FOR AUXILLARY HEATING BOILER ONLY.
SEPARATE CONTROLS WILL BE REQUIRED FOR THE SOLAR PRIMARY CIRCUIT.
Fig. 9: Schematic wiring diagram - Basic 2 x 2 port valve system
CYLINDER
TERMINAL BLOCK
2
1
3
3
ZONE VALVE(DHW)
(SUPPLIED)
ZONE VALVE (HTG)
G
W
Bl
O
2
GY
G
3
1
Br
Bl
2
O
GY
3
(SUPPLY)
L N
1
2
L
N
1
2
3
4
5
6
7
8
9 10
1
2
3
4
5
6
7
8
9 10
JUNCTION BOX
3
L
HTG
ON
DHW
ON
PROGRAMMER
2
DHW
OFF
1
3
2
ROOM STAT
2
L
3
N
3
2
N
PUMP
BOILER
NOTES:
CONTROL TERMINAL NUMBERING MAY DIFFER FROM THOSE SHOWN.
REFER TO INSTRUCTIONS WITH CONTROLS SELECTED.
A DOUBLE POLE ISOLATING SWITCH MUST BE INSTALLED IN THE MAINS SUPPLY.
ALL EARTH CONNECTIONS MUST BE CONNECTED BACK TO THE MAINS EARTH SUPPLY.
CONTROL CIRCUIT FOR AUXILLARY HEATING BOILER ONLY.
SEPARATE CONTROLS WILL BE REQUIRED FOR THE SOLAR PRIMARY CIRCUIT.
Fig.10: Schematic wiring diagram - 3 port mid position valve system. N.B. Must be used in conjunction with 2
port zone valve supplied
11
11
COMMISSIONING
At the time of commissioning, please ensure all relevant
sections of the Benchmark Checklist, ( Page 20 and 21 )
of this document, are completed.
FILLING THE UNIT WITH WATER
t Check expansion vessel pre-charge pressure.
The vessel is supplied pre-charged to 3.5 bar
to match the control pressure of the pressure
reducing valve. The pre-charge pressure is
checked using a car tyre gauge by unscrewing
the plastic cap opposite the water connection.
t Check all connections for tightness including
the immersion heater. An immersion heater key
spanner is supplied for this purpose.
t Ensure the drain cock is CLOSED.
t Open a hot tap furthest from the MAIN SOLAR
cylinder.
t Open the mains stop cock to fill the unit. When
water flows from the tap, allow to run for a
few minutes to thoroughly flush through any
residue, dirt or swarf, then close the tap.
t Open successive hot taps to purge the system
of air.
SECONDARY HEATING COIL
Fill the indirect secondary circuit following the boiler
manufacturer’s commissioning instructions. To ensure
the MAIN SOLAR cylinder auxillary heat exchanger is
filled, the 2 port motorised valve (supplied) should be
manually opened by moving the lever on the motor
housing to the FLUSHING ONLY setting. When the
circuit is full return the lever to the MANUAL position.
Switch on the boiler, ensure the programmer is set
to Domestic Hot Water and allow the MAIN SOLAR
cylinder to heat up to a normal working temperature
(60oC recommended, approximately graduation 4
on the thermostat). If necessary the temperature can
be adjusted by inserting a flat bladed screwdriver
in the adjustment knob (located on the front of the
thermostat mounting bracket - see Fig.11) and
rotating. The minimum thermostat setting is 10oC.
The adjustment range 1 to 5 represents a temperature
range of 30 to 70oC. Check the operation of the
indirect thermostat and 2-port motorised valve and
that no water has issued from the expansion relief
valve or temperature/pressure relief valve during the
heating cycle.
SYSTEM CHECKS
t Check all water connections for leaks and rectify
as necessary.
t Turn off mains water supply.
t Remove the pressure reducing valve headwork
to access the strainer mesh; clean and re-fit.
t Manually open, for a few seconds, each relief
valve in turn, checking that water is discharged
and runs freely through the tundish and out at
the discharge point.
t Ensure that the valve(s) reseat satisfactorily.
SOLAR PRIMARY CIRCUIT
Fill the solar primary circuit following the instructions
provided with the solar hydraulic controls. The
cylinder temperature control probe supplied with
the solar controller must be fully inserted into the
pocket in the lower controls housing and the cable
securely clamped. Heating by the solar primary
circuit is controlled by the solar controller; refer to the
manufacturer’s installation instructions for details of
how to set up and connect the solar primary circuit.
The solar controller should be programmed to give a
maximum storage temperature in the MAIN SOLAR
cylinder of 70oC, (60oC is recommended to minimise
scaling).
12
Fig. 11: Indirect thermostat and thermal cut-out
MAINTENANCE
MAINTENANCE REQUIREMENTS
Unvented hot water systems have a continuing
maintenance requirement in order to ensure safe
working and optimum performance. It is essential
that the relief valve(s) are periodically inspected and
manually opened to ensure no blockage has occurred
in the valves or discharge pipework. Similarly cleaning
of the strainer element and replacement of the air
in the expansion vessel will help to prevent possible
operational faults.
The maintenance checks described below should be
performed by a competent installer on a regular basis,
e.g. annually to coincide with boiler maintenance.
After any maintenance, please complete the relevant
Service Interval Record section of the Benchmark
Checklist ( Page 21 ) of this document.
SAFETY VALVE OPERATION
Manually operate the temperature/pressure relief
valve for a few seconds. Check water is discharged and
that it flows freely through the tundish and discharge
pipework. Check valve reseats correctly when released.
NOTE: Water discharged may be very hot!
Repeat the above procedure for the expansion valve.
STRAINER
Turn off the cold water supply, boiler and immersion
heaters. The lowest hot water tap should then be
opened to de-pressurise the system. Remove the
pressure reducing valve cartridge to access the strainer
mesh. Wash any particulate matter from the strainer
under clean water. Re-assemble ensuring the seal is
correctly fitted, DO NOT use any other type of sealant.
DESCALING IMMERSION HEATER
Before removing the immersion heater the unit must
be drained. Ensure the water, electrical supply, boiler
and solar primary circuit are OFF before draining.
Attach a hosepipe to the drain cock having sufficient
length to take water to a suitable discharge point
below the level of the unit. Open a hot tap close to the
unit and open drain cock to drain unit.
Open the cover to the immersion heater housing and
disconnect wiring from immersion heater. Remove
the thermostat by carefully pulling outwards from
the immersion heater. Remove thermostat capillary
sensors from the pockets on the immersion heater.
Unscrew immersion heater backnut and remove
immersion heater from the unit. A key spanner is
supplied with the MAIN SOLAR cylinder for easy
removal/tightening of the immersion heater. Over
time the immersion heater gasket may become stuck
to the mating surface. To break the seal insert a round
bladed screwdriver into one of the pockets on the
immersion heater and gently lever up and down.
Carefully remove any scale from the surface of the
element(s). DO NOT use a sharp implement as damage
to the element surface could be caused. Ensure sealing
surfaces are clean and seals are undamaged, if in
doubt fit a new gasket. ( part number 95 611 822 ).
Replace immersion heater ensuring the right angled
element hangs vertically downwards towards the
base of the unit. It may be helpful to support the
immersion heater using a round bladed screwdriver
inserted into one of the thermostat pockets whilst the
backnut is tightened. Replace thermostat capillaries
into pocket. Replace the immersion heater thermostat
by carefully plugging the two male spade terminations
on the underside of the thermostat head into the
corresponding terminations on the element. Rewire,
check, close and secure immersion heater housing
cover.
EXPANSION VESSEL CHARGE PRESSURE
Remove the dust cap on top of the vessel. Check the
charge pressure using a tyre pressure gauge. The
pressure (with system de-pressurised) should be
3.5bar. If it is lower than the required setting it should
be re-charged using a tyre pump (Schrader valve
type). DO NOT OVER CHARGE. Re-check the pressure
and when correct replace the dust cap.
RE-COMMISSIONING
Check all electrical and plumbing connections are
secure. Close the drain cock. With a hot tap open, turn
on the cold water supply and allow unit to refill. DO
NOT switch on the immersion heater or boiler until the
unit is full. When water flows from the hot tap allow to
flow for a short while to purge air and flush through
any disturbed particles. Close hot tap and then open
successive hot taps in system to purge any air.
When completely full and purged check system for
leaks. The heating source (immersion heater, boiler or
solar primary circuit) can then be switched on.
13
13
USER INSTRUCTIONS
WARNINGS
IF WATER ISSUES FROM THE TEMPERATURE/
PRESSURE RELIEF VALVE ON THE MAIN SOLAR
CYLINDER SWITCH OFF ELECTRICAL SUPPLY TO
THE IMMERSION HEATER, SHUT DOWN THE BOILER
AND SHUT DOWN THE SOLAR PRIMARY CIRCUIT.
DO NOT TURN OFF ANY WATER SUPPLY. CONTACT
A COMPETENT INSTALLER FOR UNVENTED WATER
HEATERS TO CHECK THE SYSTEM.
DO NOT TAMPER WITH ANY OF THE SAFETY VALVES
FITTED TO THE MAIN SOLAR SYSTEM. IF A FAULT IS
SUSPECTED CONTACT A COMPETENT INSTALLER.
BENCHMARK
The MAIN SOLAR cylinder is covered by the Benchmark
Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot
water systems in the UK and to encourage regular servicing to optimise safety, efficiency and performance.
Benchmark is managed and promoted by the Heating
and Hotwater Industry Council. For more information
visit www.centralheating.co.uk.
Please ensure that the installer has fully completed the
Benchmark Checklist on Page 20 of this manual and that
you have signed it to say that you have received a full
and clear explanation of its operation.
The installer is legally required to complete a
commissioning checklist as a means of complying with
the appropriate Building Regulations (England and
Wales).
All installations must be notified to Local Area Building
Control either directly or through a Competent Persons
Scheme. A Building Regulations Compliance Certificate
will then be issued to the customer who should, on
receipt, write the Notification Number on the Benchmark
Checklist.
This product should be serviced regularly to optimise its
safety, efficiency and performance. The service engineer
should complete the relevant Service Record on the
Benchmark Checklist after each service.
The Benchmark Checklist may be required in the event of
any warranty work and as supporting documentation.
14
TEMPERATURE CONTROLS - SOLAR
Temperature control of the solar primary coil is by
means of solar differential temperature controller.
This will usually have been set during commissioning
to give a storage temperature of approximately 60oC.
Refer to user instructions supplied with the controller
for details of how to adjust this if required.
TEMPERATURE CONTROLS
The MAIN SOLAR cylinders are fitted with an indirect
thermostat and thermal cut-out. These controls must
be wired in series with the 2-port motorised zone
valve supplied to interrupt the flow of primary water
around the heat exchanger coil when the control
temperature has been reached. The controls are
located within the upper white terminal housing along
with the immersion heater thermostat. The thermostat
temperature adjustment is made by inserting a flat
bladed screwdriver in the adjustment knob and
rotating. The minimum thermostat setting is 10oC.
The adjustment range 1 to 5 represents a temperature
range of 30 to 70oC (60oC will be approximately
position 4). If in any doubt contact a competent
electrician.
On MAIN SOLAR units an immersion heater is also
provided for use should the indirect heat source be
shut down for any purpose. The immersion heater
control temperature is set using the immersion heater
(direct) thermostat.
DO NOT bypass the thermal cut-out(s) in any
circumstances.
FLOW PERFORMANCE
When initially opening hot outlets a small surge in flow
may be noticed as pressures stabilise. This is quite
normal with unvented systems. In some areas
cloudiness may be noticed in the hot water. This is
due to aeration of the water, is quite normal and will
quickly clear.
OPERATIONAL FAULTS
Operational faults and their possible causes are
detailed in the Fault Finding section of this book. It
is recommended that faults should be checked by a
competent installer.
The air volume within the expansion vessel will
periodically require recharging to ensure expanded
water is accommodated within the unit. A discharge of
water INTERMITTENTLY from the expansion valve will
indicate the air volume has reduced to a point where it
can no longer accommodate the expansion.
FAULT FINDING AND SERVICING
IMPORTANT
t After servicing, complete the relevant
Service Interval Record section of the Benchmark
Checklist located on page 20 and 21 of this
document.
t Servicing should only be carried out by
competent persons in the installation and
maintenance of unvented water heating
systems.
t Any spare parts used MUST be authorised MAIN
SOLAR parts.
t Disconnect the electrical supply before removing
any electrical equipment covers.
t NEVER bypass any thermal controls or operate
system without the necessary safety valves.
t Water contained in the MAIN SOLAR cylinder
may be very hot, especially following a thermal
control failure. Caution must be taken when
drawing water from the unit.
15
15
SPARE PARTS
A full range of spare parts are available for the
MAIN SOLAR cylinder range (See Table 4). Refer
to the technical data label on the unit to identify
the model installed and ensure the correct part is
ordered. You will need to quote the serial number
and the guarantee code, which are printed on the
data label.
1
D e s c r ip t io n
Imme r s io n h e a t e r
P a r t No .
95 606 961
2
3
4
5
6
7
Imme r s io n
Imme r s io n
Imme r s io n
T u n d is h
E x p a n s io n
E x p a n s io n
95
95
95
95
95
95
8
C o ld w a t e r c o mb in a t io n v a lv e
c o mp le t e
95 605 047
9
C o ld w a t e r c o mb in a t io n v a lv e b o d y
95 605 048
P r e s s u r e r e d u c in g v a lv e c a r t r id g e
3.5bar
T e mp e r a t u r e /P r e s s u r e R e lie f V a lv e
In d ir e c t t h e r mo s t a t
95 607 029
95 605 810
95 612 697
In d ir e c t t h e r ma l c u t -o u t
95 612 698
M o t o r is e d v a lv e 2 p o r t
T e r min a l cover
95
95
95
95
10
11
12
13
14
15
16
17
18
v a lv e c a r t r id g e - 6 b a r
v a lv e c o mp le t e - 6 b a r
4 W a y t e r min a l b lo c k
Combined thermostat and
thermal cut out
A c c e s s o r y kit (in d ir e c t a n d w it h o u t
e x p a n s io n v e s s e l)
611
607
607
605
605
607
605
614
607
612
822
869
861
838
864
030
049
094
902
026
95 607 968
19
Blanking Plate Assembly
95 605 881
20
Expansion vessel 24 litre
95 607 612
21
Immersion heater (straight)
95 606 962
Table 4: Spares
16
h e a t e r g a s ke t
h e a t e r b a c kn u t
h e a t e r ke y s p a n n e r
11
1
2
3
15
17
16
13
2
16
12
13
19
3
15
Fig 12: Spares Diagram
17
17
FAULT FINDING
The Fault Finding chart ( Table 5 ) will enable
operational faults to be identified and their possible
causes rectified. Any work carried out on the MAIN
SOLAR cylinder water heater and its associated controls
MUST be carried out by a competent installer for
unvented water heating systems. In case of doubt
contact Service Support. (see contact details on back
page).
FA ULT
WARNING
DO NOT TAMPER WITH ANY OF THE SAFETY VALVES
OR CONTROLS SUPPLIED WITH THE MAIN SOLAR
CYLINDER AS THIS WILL INVALIDATE ANY GUARANTEE
POS S IBLE CA US E
1. Mains supply off.
2. Strainer blocked.
REMEDY
1. Check and open stop cock.
2. Turn off water supply. Remove strainer
and clean (see Maintenance section).
3. Cold Water Combination Valve
incorrectly fitted.
1. Immersion heater not
switched on.
3. Check and refit as required.
2. Immersion heater
thermal cut-out has operated.
3. Programmer set to
Central Heating only.
4. Boiler not working.
2. Check. Reset by pushing button.
No hot water flow
Water from hot taps is cold
5. Thermal cut-out has
operated.
6. Motorised valve not
connected correctly.
1. Check and switch on.
3. Check. Set to a Domestic Hot Water
programme.
4. Check boiler operation. If fault is
suspected consult boiler manufacturer's
instructions.
5. Check. Reset by pushing button on cutout. Check operation of indirect
thermostat.
6. Check wiring and/or plumbing
connections to motorised valve (see Fig. 9,
Page 11).
1. INTERMITTENTLY
Expansion Vessel charge pressure 1. See Maintenance section for re-charging
has reduced below 3.5bar.
procedure.
Water discharges from
Expansion Valve
2. CONTINUALLY
a. Cold Water Combination Valve
Pressure Reducer not working
correctly.
Water discharges from T&P
Relief Valve
b. Expansion Valve seat damaged. 2b. Remove Expansion Valve cartridge.
Check condition of seat. If necessary fit
new Expansion Valve cartridge.
1. Thermal control failure NOTE
1. Switch off power to immersion heater
water will be very hot.
and shut down boiler. DO NOT turn off
water supply. When discharge stops check
all thermal controls, replace if faulty.
1. Oxygenated water.
1. Water from a pressurised system releases
oxygen bubbles when flowing. The
milkiness will disappear after a short while.
Milky water
Table 5: Fault Finding Chart
18
2a. Check pressure from Cold Water
Combination Valve. If greater than 3.5bar
replace Pressure Reducer cartridge.
ENVIRONMENTAL INFORMATION
HEAT LOSS
Standing Heat Loss
Nominal
Capacity
(litres)
per day
(kWh/24h)
per year
(kWh/365d)
210
250
300
1.75
1.98
2.33
664
670
850
MAIN SOLAR products are manufactured from many
recyclable materials. At the end of their useful life they
should be disposed of at a Local Authority Recycling
Centre in order to realise the full environmental
benefits.
Insulation is by means of an approved CFC/HCFC free
polyurethane foam with an ozone depletion factor of
zero.
Table 6: Standing heat losses (based on an ambient air
temperature of 20oC and a stored water temperature
of 65oC)
While the following Checklist can be used for any installation covered by its description, only appliances
manufactured by Scheme Members will be covered by the rules and requirements of the Benchmark Scheme.
19
19
20
21
21
NOTES
22
NOTES
23
23
GUARANTEE
On site service support including parts and labour for 12 months from date of installation.
After the initial 12 months, a guarantee will apply for a further 24 years for the stainless steel
inner vessel only. During this 24 year period, in the event of a cylinder leak, a replacement
product will be issued provided that the replacement is carried out by one of our heateam
engineers, for which reasonable labour charges will apply.
The guarantee is valid provided that:
t
t
t
t
t
t
t
t
t
t
*UIBTCFFODPSSFDUMZJOTUBMMFEBTQFSUIFJOTUSVDUJPOTDPOUBJOFEJOUIFJOTUSVDUJPO
manual and all relevant Codes of Practice and Regulations in force at the time of
installation.
5IF #FODINBSL $IFDLMJTU IBT CFFO DPNQMFUFE VQPO DPNNJTTJPOJOH BOE UIF
Benchmark Service Record is completed for each service.
*UIBTOPUCFFONPEJöFEJOBOZXBZPUIFSUIBOCZ."*/
*UIBTOPUCFFOGSPTUEBNBHFE
*UIBTPOMZCFFOVTFEGPSUIFTUPSBHFPGQPUBCMFXBUFS
*UIBTOPUCFFOUBNQFSFEXJUIPSCFFOTVCKFDUFEUPNJTVTFPSOFHMFDU
The fault is not scale related.
8JUIJOEBZTPGJOTUBMMBUJPOUIFVTFSDPNQMFUFTBOESFUVSOTUIFDFSUJöDBUFTVQQMJFE
along with the proof of purchase to register the product.
*UIBTCFFOJOTUBMMFEJOUIF6OJUFE,JOHEPN
5IF GBVMU JT OPU DBVTFE CZ IJHI DIMPSJEF MFWFMT JO UIF XBUFS TVQQMZ PS JODPSSFDU
disinfection methods.
Evidence of purchase and date of supply may be required. The guarantee is transferable.
This guarantee does not affect your statutory rights.
TECHNICAL SUPPORT & SPARES
For all technical support, replacement parts and service issues please
contact:
MAIN
Brooks House,
Coventry Road,
Warwick,
CV34 4LL
Tel: 0844 871 1532
The policy of MAIN SOLAR is one of continuous product development and, as such, we reserve the right to
change specifications without notice.
24
36006095 Issue 05
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