INSTALLATION GUIDE, OPERATION AND SERVICE MANUAL

INSTALLATION

GUIDE,

OPERATION

AND SERVICE

MANUAL

NATURAL GAS,

PROPANE & BUTANE

FIRED STORAGE

WATER HEATERS

MODELS

CSC39

CSC59

CSC78

CSC93

CSCL39

CSCL59

CSCL78

CSCL93

Auto Ignition

T H I S M A N U A L M U S T B E K E P T W I T H T H E A P P L I A N C E

February 2008

Part No. E191

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0 8 4 4 8 0 0 3 4 6 0

© Copyright Andrews Water Heaters 2007

Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters.

Andrews Storage Water Heaters have been designed and manufactured to comply with current International standards of safety. In the interests of the health and safety of personnel and the continued safe, reliable operation of the equipment, safe working practices must be employed at all times. The attention of U.K. users is drawn to their responsibilities under the Health and Safety Regulations 1993.

All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel, and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel.

The Andrews Water Heaters policy is one of continuous product improvement, and therefore the information in this manual, whilst completely up to date at the time of publication, may be subject to revision without prior notice.

Further information and assistance can be obtained from:

Andrews Water Heaters

Wood Lane, Erdington, Birmingham B24 9QP

Tel: 0845 070 1055 Fax: 0845 070 1059

Sales: 0845 070 1056

Technical: 0845 070 1057

Service: 0845 070 1058

Email: [email protected]

www.andrewswaterheaters.co.uk

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL

ARE FOR USE WITH NATURAL GAS OR LPG (PROPANE OR BUTANE) GAS ONLY

CONTENTS

SECTION 1

SECTION 2

SECTION 3

SECTION 4

SECTION 5

SECTION 6

SECTION 7

SECTION 8

GENERAL AND SAFETY INFORMATION

General Information

British Standards and Codes of Practice

Health and Safety Regulations 1993

Effectiveness in Combating Legionellae

TECHNICAL DATA

INSTALLATION

Introduction

Location

Gas Supply - Natural Gas

Gas Supply - LPG (Propane or Butane) Gas

Electrical Supply

Flue Systems

Air Supply and Ventilation

Water Quality and Treatment

Water Connections

COMMISSIONING

Filling the Heater with Water

Draining Water from the Heater

Lighting the Burner

Shutting Off the Burner

Checking Main Burner Pressure

Checking Pilot and Burner Flames

User's Safety Guide

OPERATION

Operating Sequence

ECO (Energy Cut-Off)

Temperature Stratification (Stacking)

SERVICING

Introduction

Pre-Service Operations

Annually

Six Monthly

Burner Assembly

Gas Control Valve

Magnesium Anodes

Combined Temperature and Pressure Relief Valve

Cleaning the Storage Vessel

Restart

FAULT FINDING

PARTS LISTS AND ILLUSTRATIONS

PAGE

25

25

26

24

24

24

25

10

11

17

19

20

7

8

6

6

3

3

2

2

4

29

29

29

30

28

28

28

28

30

30

31

32

27

27

27

SECTION 1

GENERAL AND SAFETY INFORMATION

GENERAL

INFORMATION

The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG

(PROPANE OR BUTANE) GAS only and is manufactured to give an efficient, reliable and long service life.

To ensure the continued, trouble-free operation of your heater at maximum efficiency, it is essential that correct installation, commissioning, operation and service procedures are carried out strictly in accordance with the instructions given in this manual. By law, installation and commissioning of the heater must be carried out by properly qualified personnel.

The heater(s) must be installed in accordance with the following requirements;

The current GAS SAFETY (INSTALLATION AND USE) REGULATIONS

The current BUILDING REGULATIONS

The WATER SUPPLY (WATER FITTINGS) REGULATIONS 1999

Additionally, installation should be performed in accordance with all relevant requirements of the Gas Supplier, Local Authority and recommendations of the British

Standards and Codes of Practice detailed below.

BRITISH

STANDARDS

AND CODES OF

PRACTICE

BS 6700: 1997

BS 5440:2000

BS 6644

BS 5546:1990

BS 6891

BS 7206:1990

I/M2

I/M11

I/M16

IGE/UP/10 Pt.1

Edition 2

Specification for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. This standard supersedes the following British Standards and Codes of Practice: CP99, CP310, CP324, 202, CP342 Part 2,

Centralised Hot Water Supply.

Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW.

Installation of gas fired hot water boilers of rated inputs between

60kW and 2MW.

Installation of gas hot water supplies for domestic purposes.

Installation of low pressure gas pipework of up to 28mm in domestic premises.

Specification for unvented hot water storage units and packages.

Purging procedures for industrial and commercial gas installations.

Flues for commercial and industrial gas fired boilers and air heaters.

Notes on installation of gas pipework (excluding 25mm and below).

Installation of Gas Appliances in Industrial and Commercial Premises

NOTE: Consideration should be given to amendments or updates to the above standards.

2

GENERAL AND SAFETY INFORMATION

SECTION 1

It is the duty of manufacturers and suppliers of products for use at work to ensure, so far as is practicable, that such products are safe and without risk to health when properly used and to make available to users, adequate information about their safe and proper operation.

Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual. Although the heaters have been manufactured with paramount consideration to safety, the basic safety precautions highlighted in this manual must be observed by the user.

It is imperative that all users of the heater must be provided with all the information and instruction necessary to ensure correct and safe operation.

HEALTH AND

SAFETY

REGULATIONS

1993

Water systems in buildings have been associated with outbreaks of Legionnaires' Disease, particularly in health care facilities where occupants are significantly more susceptible to infection.

In recognition of the risks in hospitals, a Code of Practice for the Control of Legionellae in Health Care premises has been issued by the Department of Health (1991). Codes of

Practice applicable to other premises have been published by other organisations, principally the Health and Safety Executive (HS)(G70) and the Chartered Institute of

Building Services Engineers (CIBSE, TM13).

All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria. These factors include stagnation, lukewarm conditions (20ºC to 45ºC) and the accumulation of debris, scale and corrosion in the base of tanks and calorifiers.

Andrews Water Heaters has commissioned an independent evaluation of their products to investigate their resistance to build-up of legionellae bacteria.

Experiments were conducted to determine whether, following a substantial challenge by legionellae pneumophilia, after overnight and stagnation conditions, the system was rendered free from viable recoverable legionellae. It was found that at 61ºC, following a challenge of approximately 107 organisms per litre, within one hour, more than 99.999% of organisms had been killed. After a subsequent stagnation period, sampling did not reveal any residual contamination. The design of the base of the water heater precludes legionellae colonisation, even after build-up of debris. The burner positioning ensures that the water at the bottom of the heater reaches the same, or higher temperature as in the rest of the heater.

Based on data obtained through experiment, the Andrews Water Heater can be described as legionellae resistant as it is considered unlikely that, at the temperature tested, the organism would colonise the water heater and present a possible health risk.

EFFECTIVENESS

IN COMBATING

LEGIONELLAE

3

SECTION 2

TECHNICAL DATA

DIMENSIONS

AND

CLEARANCES

ANDREWS MODEL NO.

Storage Capacity

Recovery thro' 44ºC/80ºF

Recovery thro' 56ºC/100ºF

Heat Input Gross

Heat Input Net

Gas Flow Rate

Gas Flow Rates LPG

Gas Family

Feed /Flow Connections

Return Connections

Gas Connection

Flue Gas Temperature

Flue Gas Volume

Max. Working Pressure

Min. Working Pressure

Burner Pressure

Natural Gas

Burner Pressure

Propane & Butane

Injector Diameter

(Natural Gas)

Injector Diameter (LPG)

Weight Empty

Weight Full

Shipping Weight

Shipping Dimensions Height

Shipping Dimensions Width

Shipping Dimensions Depth

Mains Voltage

Frequency

Fuse

4 kg

Lb kg

Lb mm

In mm

In mm

In

V

Hz

A

Rp (BSP)

Rp (BSP)

Rp (BSP)

ºC m 3 /hr bar lbf/in 2 bar lbf/in 2 mbar ins wg.

mbar ins wg.

mm in mm

In kg

Lb l gal l/h gal/h l/h gal/h kW

Btu/h kW

Btu/h m 3 /hr ft 3 /hr m 3 /hr ft 3 /hr

CSC39

CSCL39

CSC59

CSCL59

CSC78

CSCL78

CSC93

CSCL93

636

1402

354

780

2110

83

770

30

1210

47

110

10

150

0.15

2.2

11.25

4.5

25

10

2.4

0.094

1.65

0.064

340

750

636

1402

354

780

2110

83

770

30

109

10

150

0.15

2.2

11.25

4.5

25

10

2.9

0.114

1.95

0.076

340

750

1210

47

220/240 - IP 20

50

5

1210

47

140

10

150

0.15

2.2

11.25

4.5

25

10

2.9

0.114

1.90

0.074

345

760

641

1412

358

790

2110

83

770

30

276

61

749

165

600

132

276

61

1149

253

922

203

276

61

1517

334

1213

267

350

77

1808

398

1445

318

44 66 88 106

150,128 225,192 300,256 361,672

40 60 80 96

136,480 204,720 272,960 327,552

4.09

144.6

1.78

63

6.15

217.2

2.54

90

8.20

289.8

3.39

120

9.88

349.2

4.09

144.6

1

2

H

NATURAL and I

3

LPG

1

1

⁄

2

1

1

⁄

2

1

1

⁄

2

3

⁄

4

3

⁄

4

137

3

⁄

4

3

⁄

4

160

3

⁄

4

3

⁄

4

171

0.15

2.2

11.25

4.5

25

10

3.1

0.122

2.1

0.082

381

840

1

1

⁄

2

3

⁄

4

3

⁄

4

171

164

10

150

727

1603

399

880

2110

83

770

30

1210

47

TECHNICAL DATA

SECTION 2

Horizontal or

Vertical Flue

Adaptor

1168mm

Minimum

Service clearance with standard

Anodes.

615mm

Minimum

Service clearance with Correx

Anodes.

CSC39 and CSC59 Alternative Flue Systems

H

ANDREWS MODEL NO.

A. Height of Heater

B. Diameter

C. Gas Connection

D. Cold Inlet

E. Optional Front Outlet

F. Height to Centre of Flue

G. Height to Flue Spigot

H. Min. Flue Horizontal

Max. Flue Horizontal

I.

Min. Flue Vertical

Max. Flue Vertical

J. Electrical Connection

K. Flue Diameter

L. Flue Adaptor

Cold Water

Inlet 1⏲“

B.S.P.

Drain or Return

3/4” B.S.P.

500mm Recommended for panel access and switching. Absolute min 300mm.

Ideal Service clearance Dimensions

1125

725.0 Min.

500mm Recommended for panel access and switching.

Absolute min 300mm.

475.0

N.B. Access of 500mm must be provided one side for 6 months fan lubrication

300mm

Minimum

Horizontal

Flue can be rotated

360º

UNVENTED SYSTEM

Tee & T/P Valve supplied

Can be used for

Hot Water outlet or can be capped

Alternative

Hot Water outlet

VENTED SYSTEM

Vent from here if used for Top

Hot Water outlet

‘X’

If side connection is used for Hot Water outlet Air vent must be fitted at ‘X’ mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm

In mm mm

In

CSC78 and CSC93 Alternative Flue Systems

H

K

CSC39 CSC59 CSC78 CSC93

840

33

7000

276

1310

51

7000

276

1250

49

1623

64

720

28

355

14

530

21

1307

51

2060

81

1780

70

840

33

7000

276

1310

51

7000

276

1250

49

1623

64

720

28

355

14

530

21

1307

51

2060

81

1780

70

100/150 100/150 130/200 130/200

970

38

7000

276

1610

63

7000

276

1250

49

1623

64

720

28

355

14

530

21

1535

60

1980

78

1780

70

970

38

7000

276

1610

63

7000

276

1480

58

1851

73

720

28

355

14

530

21

1535

60

2217

87

2020

80

95

4

95

4

Not supplied with these models

DIMENSIONS

AND

CLEARANCES

5

I

I

SECTION 3

INSTALLATION

INTRODUCTION

THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A

PROPERLY QUALIFIED PERSON

Installations must be carried out in accordance with Gas safety (Installation and Use)

Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations

1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire

Authorities and the current British Standards and Codes of Practice listed in Section 1.

LOCATION

The location selected for installation of the heater must allow the provision of a satisfactory flue, adequate air supply, drain facilities and must be well illuminated.

A purpose built boiler room or compartment is strongly recommended.

A manual valve for isolation of the boiler room should be installed in the gas supply; it should be clearly identified and readily accessible for use at all times.

If a purpose built boiler room is not available, measures should be taken to protect the heater from damage and prevent any extraneous matter from being stored on or around the heater. See BS 6644 Clauses 4, 5 and 6 for details.

The heater must not be installed in any location which contains a bed, bath or shower.

There must be easy access to the boiler room and heater at all times.

The water heater must be located in an area where leakage from the tank, water connections or the combination temperature and safety valve will not result in damage to the area adjacent to the water heater. When such locations cannot be avoided, a suitable drain tray must be installed under the water heater. The drain tray must be no deeper than 38mm (1.5in) and have a minimum length and width of 100mm (4in) wider than the heater. The drain tray must be piped to an adequate drain using 20mm (0.75in) diameter pipe, angled for proper drainage.

Access must be provided to the front of the water heater and adequate clearance for it's servicing and operation.

The floor on which the heater is installed must be flat, level and of sufficient strength to withstand the weight of the heater when filled with water, and should satisfy the requirements of the Local Authority & Building Regulations.

Any Combustible material adjacent to the heater must be so placed and shielded as to ensure that it's temperature does not exceed 66ºC (150ºF).

The minimum clearance to combustibles for the heater Is:

50mm (2in) from the front of the burner access box.

Zero clearance from the air intake boot and vent tubes.

300mm (12in) from the direct vent terminal.

A minimum of 726mm (30 inches) from the burner access panel shall be provided for inspection and servicing.

All service clearances to the water heater must be maintained as specified in the

CSC Range Installation and Design Guide.

6

INSTALLATION

SECTION 3

The installation of the gas supply must conform, depending on it's size, to the requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

A gas meter will be connected to the service pipe by British Gas plc or it's authorised contractor.

The meter and service pipe should be checked by British Gas or it's authorised contractor to ensure that they are adequate to deal with the gas supply to the water heater(s) in addition to any existing or additional requirements.

CAUTION!

DO NOT APPLY HEAT IN CLOSE PROXIMITY TO THE GAS CONTROL THERMOSTAT

AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL.

GAS SUPPLY

NATURAL GAS

Fit the gas cock immediately upstream of the gas control valve using a suitable jointing compound and connect to the gas supply. An inlet nipple and m/f elbow is factory fitted to the gas control valve to avoid possible damage.

Gas Cock

Nipple

M/F Elbow

Gas Valve

BSP Thread

U.P.T. Thread

Where the water heater(s) is(are) installed in a boiler house or purpose built compartment, a manually operated valve for the boiler house must be fitted in accordance with the Gas Safety (Installation and Use) Regulations 1998. The valve must be easily identified and readily accessible.

After installation, the system should be pressure tested for soundness and purged in accordance with BS 6891 or IM/2 and IM/5 as appropriate.

Fig 1.

7

SECTION 3

INSTALLATION

GAS SUPPLY

PROPANE OR

BUTANE

Contact Calor Gas who will provide the appropriate type and size of LPG supply vessel and ensure it's safe location and installation.

The installation of the gas supply must conform to LPGA Code of Practice, 22 LPG Piping

Systems: Design and installation plus the requirements of British Standards and Codes of

Practice listed in Section of this manual.

PROPANE:

BUTANE:

37mbar (14.86 in wg)

28mbar (11.26 in wg)

When using propane or butane cylinders, connect a minimum number of cylinders as listed below, together with a manifold before connecting to the union.

Use a minimum pipe size of

3

⁄

4 in bore.

Two Cylinders CSCL39 and CSCL59

Three Cylinders CSCL78

Four Cylinders CSCL93

WARNING!

PROPANE AND BUTANE CYLINDERS MUST BE USED AND STORED IN

ACCORDANCE WITH 'THE HIGHLY FLAMMABLE LIQUIDS AND LIQUIFIED

PETROLEUM GASES REGULATIONS 1972', AND SHOULD COMPLY WITH LPGA

CODE OF PRACTICE 7, 'STORAGE OF FULL AND EMPTY LPG CYLINDERS AND

CARTRIDGES.

8

INSTALLATION

Regulator Set to give 37 mbar

(14.86” Wg)

Propane

Regulator normally fitted at tank

To bulk Supply

Installation of

Propane supply

1” Heavy Steel Sleeved

Pipe Through Wall

Gas emergency control at entry point to building

Steel Liner sealed to pipe at inside end

3/4” Spring loaded gas cock

Pigtail

Assembly

Automatic change over device

Nipple

1” Heavy Steel Sleeved

Pipe Through Wall

Gas emergency control at entry point to building

Steel Liner sealed to pipe at inside end

Cylinder regulator Set to give

37 mbar (14.86”) Propane

3/4” Spring loaded gas cock

Propane cylinder must be outside building

SECTION 3

BULK STORAGE

VESSEL

INSTALLATION

CYLINDER

INSTALLATION

Fig 2.

9

SECTION 3

INSTALLATION

ELECTRICAL

SUPPLY

External wiring to the water heater(s) must be installed in accordance with current I.E.E.

Regulations for the wiring of buildings and to any Local Regulations that may apply.

The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply.

The fuse rating is 5 amps.

The method of connection to the mains electricity supply should facilitate complete

Electrical isolation of the appliance, preferably by use of a fused double pole switch or fused spur box serving only the heater. The disconnection of the supply shall have a contact separation of 3mm in all poles.

The point of connection to the mains electricity supply should be readily accessible and adjacent to the appliance.

Fig 3.

Wiring diagram for natural gas appliance and LPG appliance.

Connect the electrical supply the main control panel terminal block via the cable glands in the base of the control panel. Mains input cable should be 0.75mm

2 , 3 core, and should be connected to the mains supply as detailed above.

It is recommended that screen cable is used where the volt-free contacts are to be connected from an external supply. This will eliminate the risk of possible interference from nearby high voltage cables.

Mains Voltage: 220/240Volts - IP 20

Frequency:

Fuse:

Fan Motor:

50Hz

5 Amps

1.4 Amps

10

INSTALLATION

SECTION 3

Your Andrews Water Heater is a Direct Fan Flued Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are charged to the outside atmosphere. The flue system is a single coaxial (pipe within pipe) design where the flue products are discharged through the inside flue tube and the combustion air supply surrounds the flue surrounded by the outside pipe. The flue system incorporates both combustion air supply and the flue exhaust. The flue system component which is outside the building and takes in the combustion air supply and discharges the flue products (whilst keeping them separate) is referred to as the 'direct flue terminal'.

WARNING!

The direct flue system must be properly installed. Failure to do so could result in property damage or personal injury. DO NOT install any damaged components. Contact Andrews

Water Heaters for replacement parts. The flow of combustion air must not be restricted.

Keep direct flue terminal openings clear of any objects likely to cause flow restriction.

Direct Flue Terminal

Shall terminate at least 1.5m (5ft) above any forced air inlet located on the same wall.

This provision does not apply to the combustion air intake of a direct flue appliance or the circulating air inlet and flue gas discharge of listed outdoor appliances.

Shall be installed with at least a 300mm (12in) flue termination clearance from any air opening into a building.

The bottom of the direct flue terminal shall be located at least 300mm (12in) above ground.

Consideration should be given to the location of the flue terminal. The flue terminal should be located where the discharge of flue products does not cause a nuisance.

Consideration should also be given with regard to noise that may be emitted by this flue system. In all cases the flue termination must meet the requirements of BS6644.

A suitable terminal guard must be fitted if less than 2 mtrs above ground level.

FLUE

SYSTEMS

The Andrews Direct Fan Flued Gas Water Heater is supplied with one direct flue kit.

The flue system supplied with this water heater is a coaxial design with the flue discharge tube on the inside and combustion air supply on the outside. Optional direct flue components are available that can extend the horizontal length and/or vertical height of the direct flue to the maximum distances listed in the table below. This water heater must be installed using the supplied or optional listed components without modification.

Refer to the table on Page 36 for the various vertical and horizontal direct flue system components.

NOTE! The supplied horizontal flue terminal may be used through outside walls up to

600mm (24in) thick.

Maximum Flue Distances (Horizontal or Vertical)

Number of 90º Elbows Maximum length of straight pipe

(excluding vent terminal) to exterior wall

2

3

0

1

7m (22ft 9in)

6m (19ft 6in)

5m (16ft 3in)

4m (13ft 0in)

NOTE! Each 45º elbow reduces the maximum flue distance by 500mm (19.5in).

IMPORTANT! Do not exceed the flue distances or the number of elbows listed above. This may cause heater malfunction or an unsafe condition.

HORIZONTAL

AND VERTICAL

DIRECT FLUE

LENGTHS

11

SECTION 3

INSTALLATION

HORIZONTAL

AND VERTICAL

DIRECT FLUE

LENGTHS

Installation Procedure

Determine location of flue exit.

1. The supplied kit includes a horizontal (through the wall) flue terminal, an elbow, flue connector clamps and 2m (6.5ft) of coaxial flue pipe. The 150mm (6in) diameter flue system is also supplied with a 200mm (8in) to 150mm (6in) reducer for the waterheater flue connection. The coaxial flue pipe includes both the flue exhaust

(inside pipe) and combustion air (outside pipe). The coaxial flue pipe may be cut on the unflared end (end without gasket) as required for the installation.

2. Determine if additional flue components are required for the installation. Refer to the flue component table below for available optional flue components.

3. Ensure that the flue terminal location complies with requirements described earlier and the Local Gas Authority.

4. Measure the vertical and horizontal distance from the water heater flue connection to determine the number of vent flue needed.

1

1

1

1

Flue Component Table for 150mm (concentric) (6in) Diameter Flue Size

(58.7 kWh 199,999 Btu/h Input Models).

SUPPLIED KIT COMPONENTS

Quantity Flue Length Part Description Part Number

600mm (24in)

90º Elbow

Horizontal Flue Terminal

Large Stepped Adaptor Connection Clamp

200mm (8in) to 150mm (6in) flue reducer

E205

E236

E237

E238

12

INSTALLATION

SECTION 3

Quantity

1

1

1

1

1

1

1

1

1

Optional Components for 150mm (concentric) (6in) Diameter Flue Size

Flue Length

1 mtr

1 mtr

0.5 mtr

Part Description

Flue Pipe with clamp

Cutable Flue Pipe with clamp


90º Elbow

45º Elbow

1360mm (54in) Vertical Flue Terminal

Flat roof flashing for vertical flue terminal with adjustable cap

Roof flashing for pitched roofs

150mm (6in) dia vent size

Wall Clamp 150mm (6in) dia.

Part Number

E202

E203

E204

E205

E206

E239

E207

E208

E209

FLUE

SYSTEMS

Flue Component Table for 200mm (concentric) (8in) Diameter Flue Size

(88 kWh/300,00 Btu/h and 105.6kW/360,000 Btu/h Input Models.

SUPPLIED KIT COMPONENTS

Quantity

1

1

1

Flue Length

600mm (24in)


90º Elbow


Large Stepped Adopter

Connection Clamp

Part Number

E215

E240

E237

Quantity

1

1

1

1

1

1

1

1

Optional Components for 200mm (concentric) (8in) Diameter Flue Size

Flue Length

1 mtr

1 mtr

0.5 mtr



Cutable Flue Pipe with clamp


90º Elbow

45º Elbow

Flat roof flashing for vertical flue terminal with adjustable cap

Roof flashing for pitched roofs

150mm (6in) dia flue size

Wall Clamp 200mm (8in) dia.

Part Number

E212

E213

E214

E215

E216

E217

E218

E219

13

SECTION 3

INSTALLATION

FLUE

SYSTEMS

INSTALLING THE FLUE TERMINAL

NOTE! The horizontal flue terminal supplied may be used through outside walls up to

600mm (24in) thick.

1. Horizontal flue Terminal (Through the Wall) supplied

a) Cut an opening of at least 165mm (6.5in) diameter through the outside for the

58.7kWh input models or 216mm (8.5in) for the 88kWh and 105.6kWh input models.

b) Slide the flue terminal through the wall opening to the rib closest to the intake air openings of the terminal even with the outside wall.

Hole through Wall flue Terminal

Outer Wall

Mount Plate

Wall Anchor

(4 Places)

Fig 4.

Screw

(Supplied)

(4 Places)

Intake Air Openings

(Must Face Ground) c) Slide the outside wall plate over the flue terminal and fasten to the wall with four screws. Depending on the wall construction, wall anchors may be required to reinforce the screws.

d) Install inside wall plate on the inside wall and secure with four screws. Depending on wall construction, wall anchors may be required to reinforce the screws.

Hole through Wall

Inner Wall

Mount Plate

Flue Terminal

Wall Anchor

(4 Places)

Fig 5.

Screw

(Supplied)

(4 Places)

14

INSTALLATION

SECTION 3

2. Vertical Flue Terminal (Through the Roof - Optional)

a) Determine the exact location where the roof flue terminal will exit the roof, ensuring the flue system clears all obstructions. For pitched roofs, the flue cap must be the distance above the roof line as specified, (300mm to base of Flue Clamp, minimum).

The top of the roof terminal may extend up to 760mm (2.5ft) above the roof line as required.

b) Run the coaxial flue system to the proper distance below the roof sheathing required for the correct distance of the roof terminal above the roof surface. See the following sections on installing the rest of the flue system.

c) Cut a minimum 165mm (6.5in) diameter hole for the smaller flue size or a 216mm

(8.5in) minimum diameter hole for the larger flue size centred in the desired location for the roof terminal. See Fig. 6.

d) Centre the roof flashing over the hole using either the flat roof flashing or universal flashing for pitched roofs.

e) Slip the storm collar supplied with the roof flashing kit over the outside of the flue terminal and align with the flue pipe end below roof opening. Insert the terminal into the flue pipe.

f) Fasten the roof flashing with nails. Seal the flue terminal and flashing to the roof.

g) Install the gasketed clamp around the joint between the flue terminal and flue pipe.

FLUE

SYSTEMS

Flat Roof

Flue Terminal

Storm Collar

Roof Flashing

(Nail & Seal

To Roof)

Flue Terminal Pipe

Flue Terminal Pipe

Flue Pipe

(From Water Heater)

Hole Through Roof

Fig 6.

INSTALLING FLUE PIPING SECTIONS

a) The coaxial flue pipe sections are designed to fit tightly together and seal with the integral flue pipe seal and supplied pipe clamps. No silicone caulk or special tools are required.

b) All flue sections and fittings come complete with silicone flue pipe gaskets and outside gasketed pipe clamps for making air tight connections between the flue pipe connections.

d) Raise the flue pipe to the flue terminal connection with the gasketed end of the flue pipe towards the flue terminal. Insert the flue pipe into the flue terminal connection and grasp the end of the flue pipe while twisting and pushing the pipe until inserted all the way into the flue terminal.

e) Connect the outside pipes together using the gasketed clamps provided. The flue pipes have ribs located near each end. When the flue piping is connected, the gasketed clamps shall cover the ribs and joints of the connecting flue tubes. Support each pipe section with hangers attached to the supporting joists in the wall or ceiling.

f) Continue connecting pipe sections together with clamps and supporting with hangers.

15

SECTION 3

INSTALLATION

FLUE

SYSTEMS

Gasket End

Straight End

(Ungasketed)

16

Fig 7.

Ribs Locked Beneath

Gasketed Clamp g) The last pipe section may be cut to fit the distance required to reach the water heater flue connections. First, install the supplied condensate trap with crimped end into the gasketed end of the elbow (horizontal flue installations) and clamp the condensate tee and elbow together. Then install the crimped end of the elbow into the flue connection of the water heater. On vertical installations, install the the crimped end of the condensate trap directly onto the water heater flue connection. The 58.7kWh

models require the installation of a flue reducer (supplied) into the water heater flue assembly before attaching the elbow or condensate trap (vertical flue).

IMPORTANT! In order for the condensate trap to collect and dispose of the condensate from the flue pipe, the flue system must have a downward slope of 21mm per metre (0.25in/ft) towards the condensate trap. The condensate trap must be installed as close as possible to the flue adaptor to prevent condensate from accumulating and draining into the flue adaptor or blower.

h) Carefully measure the length of straight flue pipe needed, allowing for about 50mm

(2in) insertion into the elbow. Mark the ungasketed end of the pipe to be cut and carefully make a straight cut on the outside pipe to the desired length. Make sure the inside tube is not cut. Then cut the inside flue pipe about 50mm (2in) more than the outside pipe so that the flue pipe protrudes slightly beyond the outside pipe. Connect the flue pipe and clamp at each end.

i) Use the large clamp supplied in the flue kit with the stepped gasket to seal the elbow or condensate trap to the blower flue connector. The larger step of the gasket seals the flue pipe to the cast flue adaptor.

j) Condensate disposal: Connect either a 32mm (1.25in) slip joint drain connection or a

25mm (1in) PVC compression coupling from the condensate trap nipple to 25mm

(1in) PVC piping to a drain or condensate disposal pump. Install a drain trap after the condensate fitting to seal the flue system.

Note: On all flue installations, for distances over 1.5 metres, we recommend that a condensate trap is fitted.

Condensate Trap Nipple

Fig. 8.

Drain Trap

1”(25mm) Compression

Coupling or 1

1

⁄

4

” (32mm)

Slip joint Connection

1”(25mm) PVC Piping

To Suitable Drain or

Condensate Disposable Pump

INSTALLATION

SECTION 3

The following notes are intended to give guidance:

Where the heater is to be installed in a room, NO VENTS ARE REQUIRED.

Where the heater is to be installed in a compartment, permanent air vents are required in the compartment at high and low level. These air vents must either communicate with a room or internal space or be direct to outside air.

The minimum effective areas of the permanent air vents required in the compartment are as follows:

Air Vents Areas

Position of Air Vents Air from Room or Internal Space Air Direct from Outside

High Level 10cm

2 per kW net 5cm

2 per kW net

10cm 2 per kW net 5cm 2 per kW net Low Level

In a Room or

Internal Space

No Requirement for Ventilation

AIR SUPPLY

AND

VENTILATION

Note: - Both air vents must communicate with the same room or internal space or must both be on the same wall to outside air.

Air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour.

Consideration must be given to the position of the high level ventilation opening. A high level vent must not be sited within 300mm (1ft) measured vertically, of the flue terminal.

Grilles and louvres should be so designed that high velocity air streams do not occur within the space housing the heater(s).

17

SECTION 3

INSTALLATION

AIR SUPPLY

AND

VENTILATION

IMPORTANT:

1. The effective area requirements specified in the table are related to the maximum heat input of of the heater(s), and are equivalent to those specified in BS6644 and

IGE/UP/10 Pt.1

2. The free area of the grilles should not be less than the size of the recommended ventilation opening.

3. The supply of air to a space housing the heater(s) by mechanical means should be:-

(a) Mechanical inlet with natural extraction.

(b) Mechanical inlet with mechanical extraction.

NB!! Natural inlet with mechanical extraction must not be used.

Where a mechanical inlet and mechanical extraction system is used, the design extraction rate must not exceed one third of the design inlet rate.

All mechanical ventilation systems must be fitted with automatic gas shut off safety systems which cut off the supply of gas to the heater(s) in the event of failure of either the inlet or extract fans.

The requirements for air supply by mechanical ventilation are given in BS6644

Clause 19.3 and IGE/UP/10 Pt.1.

The permanent air vents shall be sited away from the extract fans. It may be necessary to increase the ventilation area to compensate for the extractor fan.

18

INSTALLATION

SECTION 3

Where extreme conditions of water hardness exist, scale can form in any water heating equipment, especially when the heater is working under conditions of constant heavy demand and at high temperatures.

Each water heater is fitted with one or more magnesium anode(s) which protects the tank from corrosion caused by electrolytic action. Magnesium anodes are sacrificial in that they corrode as they protect. When the anode has eroded to less than 50% of it's original diameter, it may not offer protection. The anodes should be inspected annually and replaced as necessary. Frequency of anode replacement will vary, dependent on water quality.

Andrews Water Heaters offer Correx TM UP powered anodes as an alternative to the standard magnesium anodes. These anodes do not need maintenance or replacement.

The potentiostat which regulates the current to the Correx TM anode features an indicator light which shows green to indicate the correct function and red to indicate the malfunction. These anodes are available as an optional extra on all Andrews heaters.

In hard water areas, scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used, the more problematic the scale build-up can be. Water treatment is normally recommended when the hardness reaches 100 - 150ppm (7 - 10 degrees Clark) and above. This problem can be minimised by reducing the water temperature in the heater and by fitting suitable water pretreatment equipment.

When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted.

WATER

QUALITY AND

TREATMENT

Hydrojet System

Fig. 9.

Tank

Heater Casing

All models now incorporate the new Mini Hydrojet system on cold inlet side connections.

This system ensures water is directed onto the tank base which minimises sediment build up from day one of installation.

The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet nipple. The system is designed to increase turbulence and reduce sediment build-up, reduce thermal stacking and increase delivery.

Hydrojet Inlet Nipple

(Front Cold Inlet

Connection)

19

SECTION 3

INSTALLATION

WATER

CONNECTIONS

VENTED SYSTEMS

The water heater must be fed from a cold water feed cistern or static water tank.

A safety valve must be fitted as specified in BS 6644 Clause 9.

The safety valve must be fitted either directly to an upper tank tapping or not further than 1 metre along the outlet flow pipe of size not less than the safety valve.

There must be no valve separating the heater from the safety valve.

The size of the discharge pipe must be not less than the nominal size of the safety valve outlet. It should be self-draining and any water discharged must be visible and create no hazard to persons in or about the building.

A low pressure open vented system can be used or where the natural circulating pressure is insufficient, pumped circulation can be employed.

The heater must be fitted with an open vent pipe which is not valved and which rises continuously to the open vent. It should be sized with reference to Technical Data,

BS 6644 Clauses 9 and 10 and CP 342. Local Regulations and Bye-Laws must be observed when installing the system.

Front Cold inlet / Top Hot outlet water connections / Optional Front Hot outlet water connection

Select the hot outlet location required, and using a suitable jointing compound blank off the outlet not required. We recommend that the top hot outlet water connection is used.

Assemble onto the

3

⁄

4

BSP thread, the suitable jointing compound.

3

⁄

4

BSP coupler socket and drain cock using a

Assemble onto the 1

1

⁄

2

“ hot water outlet (front) the 1

1

⁄

2

“ cap end using a suitable jointing compound.

Water draw-off dead legs should comply with CP 342 Part 2, Table 1 and BS 6700.

NOTE:

When using a secondary return circuit, see Fig 10 for the location of the return tappings.

It is recommended that all water connections be made to the heater(s) using union fittings for ease of servicing. Pipe support intervals should comply with CP 342,

Part 2 Table 4.

After Installation of the water system, open the main water supply valve, flush the system and fill the heater. Open the hot taps to allow air to escape from the system. When the system is free of air, close the taps and check for leaks at the thermostats, drain cock and pipe connections on the heater.

Typical water service layout for a vented system is shown in Fig 10.

20

INSTALLATION

Optional

Hot Water Service

Overflow

Open Vent

Cold Water

Cistern

Stop Valve

Cold Water Feed

SECTION 3

WATER

CONNECTIONS

VENTED SYSTEMS

Hot Water Service

Secondary Return

Check Valve

Cold Water

Inlet Valve

Fig 10.

Typical Installation

Vented System

21

SECTION 3

INSTALLATION

WATER

CONNECTIONS

UNVENTED

SYSTEMS

Unvented Systems should be fitted by an Approved Installer

When used in an unvented system, the Andrews water Heater will supply hot water at a pressure of 3.5bar (51lbf/in 2 ), provided that this pressure is available at the mains feed.

During conditions of no-flow, system pressure may rise to a maximum of 6bar (87lbf/in 2 ) whilst the burner is operating. When testing the system, it is recommended that a maximum test pressure of 8.6bar (125 lbf/in 2 )is employed.

The heater can be used on unvented hot water storage systems, with the addition of an

Unvented Systems Kit, part number B228 available from Andrews Water Heaters.

See Parts List Page 37. The Wall mounting assembly is available as an optional extra.

C5

Temperature/

Pressure

Relief Valve

C4

OPTIONAL PARTS

22

Fig 11.

C9

Wall bracket Assembly

C6

1 1 ⁄

2

” Sq Tee

C8

Hose Assembly

Cold Water

Inlet of

Water Heater

C2 Check Valve/

C3 Expansion Valve

(a)

C1 Pressure Reducing

Valve / Strainer

Balance Cold Water

Take-off

(if required)

Cold Water Inlet

NB. Tees, elbows, stop valves and pipework not supplied.

C7 Tundish

Item C5 must be fitted into C6 and fitted on the hot water outlet nipple (See fig.12).

When assembling items C1 and C2, ensure that the flow arrows marked on the components are pointing in the direction of flow, i.e. towards the water heater.

The cold water for services may be drawn from the 22mm compression port on item C1(a).

The water pressure at this point will be similar to that available at the hot water outlet of the water heater. If port (a) is not used, it should be sealed with the blanking plug supplied.

INSTALLATION

SECTION 3

If higher flow rates are required for the cold water services, a suitable tee fitting should be fitted to the pipework, upstream of item C1.

The pipework fitted to the tundish outlet should be one size larger than the outlet pipe of the safety device and should be terminated at a suitable drain.

(See Building Regulations 1992 Approved Document G3).

All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre " Materials and Fittings Directory".

Installation of unvented hot storage water systems must comply with Part G3 of the

Building Regulations 1992.

Typical water service layout for unvented system is shown in Fig 12.

WATER

CONNECTIONS

Hot Water Service

Optional Hot Water

Service

Secondary Return

Check Valve

To Drain

Balanced

Cold Water

Take Off

Cold Water

Inlet Valve

Fig 12.

23

SECTION 4

COMMISSIONING

CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE

VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER RUNNING FROM

ALL HOT TAPS.

Open the main gas supply cock after all connections to the gas control are completed and test all connections, using proprietary leak detection fluid.

Filling the Heater with Water

1. Close the water heater drain valve.

2. Open the cold water supply valve.

3. Open several hot water taps to allow air to escape from system.

4. When a steady stream of water flows from the taps. the heater is filled.

5. Close the taps and check for leaks at the drain valve, temperature/pressure relief valve and the hot and cold water connections.

Draining Water from the Heater

If it becomes necessary to drain the heater, follow the steps below.

1. Depress control panel rocker switch to the OFF position (see Operating).

2. Rotate and partially depress gas control knob clockwise to OFF position.

3. Shut off the gas supply to the heater.

4. Close the cold water supply shut-off valve.

5. Open the drain valve on the water heater.

6. Open a hot water tap to allow air to enter the system.

Refill the water heater as described above.

Lighting the Burner

1. Ensure gas supply is ON.

2. Turn gas control knob to ON position.

3. Using control thermostat, select required water temperature.

4. Move electrical ON/OFF switch to ON. After a delay of about 10 seconds, the burner will light.

5. Check pilot and main gas connections at gas control valve using leak detection fluid whilst burner is alight. Turn off, seal any leakages, then re-test.

24

COMMISSIONING

Shutting Off The Burner

1. For long periods only, (7 days or more) move electrical ON/OFF switch to OFF, then turn gas control knob to OFF. Turn off gas service cock. For shorter periods, leave heater under thermostat control.

SECTION 4

B

Gas control

Knob

MV Brown

PV/MV Yellow

PV Red

A

Checking Main Burner Pressure

1. Turn gas control knob to OFF.

2. Release bleed screw (A) and connect pressure gauge tube to port (A).

3. Light burner as described previously.

4. Remove valve cap from port (B) and adjust pressure using exposed screw in accordance with data plate. Turn screw clockwise to increase pressure and counterclockwise to decrease. If possible, check gas rate (see Technical Data) with meter and watch. Refit valve cap to port (B).

5. Turn gas control to OFF. Remove pressure gauge tube and tighten bleed screw (A).

6. Turn gas control knob to ON and light burner as described above.

Checking Pilot and Burner Flame

1. Visually check that pilot and burner flames are burning properly.

2. The main burner and pilot flame may be viewed through the viewing window on the front of the combustion air box.

3. Adjustment to the air shutter setting is not normally required for the heater.

4. The burner flames should be blue with yellow tips.

5. A blue/orange flame is characteristic of LPG operation.

If the burners resonate (produce an harmonic noise and vibration, usually with LPG gas), close down the burner air shutters until the resonance stops. The resonance during burner operation should only be checked with the front panel held in place, since resonance may be more pronounced with the front panel off. Ensure flame appearance is satisfactory after adjusting the burner air shutters as described above.

IMPORTANT! IN THE EVENT OF AN EMERGENCY, TURN OFF GAS AND

ELECTRIC SUPPLY.

Fig 13.

25

SECTION 4

COMMISSIONING

USER'S SAFETY

GUIDE

For your safety read before lighting the appliance.

WARNING

1. Always follow manufacturer's instructions when lighting the appliance. Failure to do so may result in damage to property, personal injury or loss of life.

2. Before lighting, check all around the appliance area for gas. Be sure to check at low level because some gas (i.e. LPG) is heavier than air and will settle on the floor.

3. Do not make any attempt to re-light the appliance if the main burner has extinguished. Wait at least 5 minutes to allow for any unburnt gas to disperse.

Ventilate the area if possible.

FOR YOUR SAFETY IF YOU SMELL GAS

1. Turn off gas supply and open windows.

2. Do not operate electrical switches.

3. Extinguish any naked flames.

4. Contact gas supplier if the smell of gas persists.

FOR YOUR SAFETY

Do not store or use petrol, aerosol or other flammable vapours or liquids in the vicinity of this or any other atmospheric gas appliance.

WARNING

Hotter water increases the risk of scalding. Before changing the temperature, refer to the instruction manual or data label. Hot water can produce third-degree burns in:-

6 seconds at 140ºF (60ºC)

30 seconds at 130ºF (54ºC)

26

OPERATION

When properly installed and adjusted, the heater will require minimal attention. Should it become necessary to completely drain the heater, follow instructions given in Section 4,

Commissioning.

Whenever the heater is filled with cold water, condensation will form on the storage vessel surfaces when the burner is lit. This is normal and will disappear when the heater warms up.

Operating Sequence

1. When the control thermostat senses too-cool water, a signal is sent to the control sequence unit.

2. When the pilot solenoid opens, gas is allowed to pass to the pilot and simultaneous ignition begins?

3. When the pilot flame is established, the main gas solenoid is allowed to slowly open and the main burners or burner is lit.

4. When the control thermostat is satisfied, both pilot and main gas solenoids are closed.

ECO (Energy Cut-Off)

The heater is equipped with an ECO (Energy Cut-Off) device, fitted to the control thermostat. It is a temperature sensitive switch which opens at high temperature, shutting off gas to the burners, including the pilot in an overheat condition. When the water has cooled sufficiently, the manual reset on the ECO needs to be depressed to allow the heater to be re-lit. If the pilot goes out and is associated with high water temperature, the ECO is probably operational and the cause of overheating should be investigated.

Temperature Stratification (Stacking)

When small amounts of hot water are drawn repeatedly, the thermostat responds to each feed of cold water and activates the main burners. Each time this occurs, more heat may be put back in the tank than was drawn off. As this continues, water in the upper level of the tank gets hotter than the thermostat setting. This hotter water does not mix completely with the cold inlet water, but rises in a 'chimney effect' to the top of the tank.

Many repetitions of this over a short time period results in accumulation of excessively hot water in the upper part of the tank, even when the thermostat control is within limits. This is known as stacking.

To counter this condition, an upper thermostat phial is fitted which senses abnormally hot water and shuts down the main burner until the water cools. Most modern commercial pipe installations include a circulating pump which keeps hot water moving continuously throughout the heater. This stabilises temperatures in the water heater tank and throughout the pipe system.

SECTION 5

27

SECTION 6

SERVICING

INTRODUCTION

Servicing must be carried out by a properly qualified person.

Whilst giving these instructions for the care of the Heater, it is recommended that checks are carried out by the installer or local gas authority, at least annually. Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint.

Keep pipework, flue and tops of heaters clear of any combustible materials. A water softener or lime inhibitor should be employed in hard water areas. The heater should be inspected every few months via the hand hole cleanout and lime or silt deposits removed.

Failure to do so will shorten heater life and may invalidate the warranty.

NOTE! The cleanout hole gasket must be renewed whenever the cover is removed.

PRE-SERVICE

OPERATIONS

Before servicing, carry out the following operations.

1) Turn off the gas service cock.

2) Turn off the cold water supply to the heater.

3) Turn on the hot water draw-off taps served by the water heater, or, for multiple installations, turn off the hot water outlet connection valve and secondary return valve.

4) Drain down using the drain valve on the heater.

ANNUALLY

Annual checks of the ignition systems, temperature controls and any other controls are necessary to ensure continued safe and efficient operation.

The entire combustion system must be sealed for this water heater to function correctly.

Ensure that the burner access panel is kept tightly sealed. The combustion air supply pipe at the rear of the heater must be tightly clamped to the vent adopter and combustion air box boot. Replace any damaged parts.

The entire venting system and combustion air supply must be inspected at least annually for integrity of all joints and gaskets.

SIX MONTHLY

BLOWER MOTOR BEARINGS

Every six months lubricate the blower motor bearings. Apply four drops of SAE 20 motor oil to the ports of the front and rear motor bearings.

28

SERVICING

SECTION 6

Annually, remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign matter. Inspect the burner ports for obstructions or debris and clean with a wire brush, vacuum, or use a mild detergent to clean as necessary. Inspect the pilot. Carefully clean the electrode and flame sense rod with emery cloth. The spark electrode (rod closest to the pilot hood) gap should be 1/8 in.

NOTE: It is vital for proper and safe operation that the main burner rack is replaced in it's original position.

To remove the burner rack assembly, follow the procedures outlined below.

a) Shut off the gas and electrical supply to the heater.

b) Remove the pilot tube fittings at the gas valve and combustion box.

c) Disconnect wires to gas valve. Open control box and disconnect pilot spark and flame sense wires. Remove the wire raceway cover below the control box.

d) Disconnect the gas pipe union below the gas valve.

e) Remove the three screws securing the gasketed manifold pipe flange on the left side of the combustion box.

f) Remove the burner access panel from the front of the combustion box.

g) Carefully remove and push the pilot wire grommet into the combustion box with the pilot wires.

h) Disconnect the pilot tube fitting on the inside bulkhead fitting of the combustion box.

i) Unthread the gas pipe assembly from the manifold inside the combustion box.

j) Remove the screw securing the burner rack on the top right panel of the combustion box.

k) Slide out the burner rack assembly.

To re-install the burner rack, reverse the above procedures.

BURNER

ASSEMBLY

The gas control valve should be checked and cleaned. Remove any debris from the valve inlet filter using a soft brush or by blowing with low pressure air.

After servicing, Check:-

1. Soundness of any gas joints broken or disturbed and seal any leaks.

2. Burner pressure/gas rate at maximum thermostat setting.

3. Operation of heater is correct. Reset controls to user's requirements.

GAS CONTROL

VALVE

Magnesium sacrificial anode(s) is (are) fitted to the top of the storage vessel. The anode will prevent corrosion of the storage vessel. Anode condition should be checked annually and replaced if excessive wear is present.

1. Withdraw each anode using an

21mm diameter.

11

⁄

16 in AF socket spanner. A new anode measures

2. An anode should be replaced, if, at any point along it's length, the diameter is reduced to half, or less of original. Particular attention should be paid to the ends.

3. If the anode is encrusted with limescale, it should be either wire brushed to reveal bright metal or replaced.

Where Correx TM anodes are fitted, no maintenance is necessary.

MAGNESIUM

ANODES

29

SECTION 6

SERVICING

COMBINED

TEMPERATURE

AND PRESSURE

RELIEF VALVE

Check the condition and operation of this component at least once a year to ensure it is free from limescale deposits.

Lift the lever at the top of the valve several times until the valve seats properly without leakage and operates freely.

Clean or replace as necessary.

CLEANING THE

STORAGE

VESSEL

The storage vessel should be checked and cleaned annually

Scale formation in the base of the vessel may occur, particularly in hard water areas and is normally associated with high usage and high water temperatures. It is characterised by a rumbling noise when the main burner is lit. Scale formation in the base of the vessel will affect the efficency of the water heater and reduce the life of the storage vessel.

It should be noted that the failure of the storage vessel due to scale formation on the base will not be covered by the terms of the warranty.

Any scale formation which cannot be removed by normal means of cleaning should be removed by chemical descaling. See below.

Descaling

When descaling the heater, attention is drawn to the following guidelines.

CAUTION!

DUE TO THE CORROSIVE NATURE OF DESCALING FLUID, IT IS ESSENTIAL THAT

SUITABLE PROTECTIVE CLOTHING IS USED AND ADEQUATE VENTILATION

AVAILABLE.

1. Turn gas control to OFF and isolate gas supply.

2. Close water inlet valve and drain heater tank.

3. Remove magnesium anode(s). It is recommended that new anode(s) is (are) fitted.

4. Add suitable hydrochloric acid based descale fluid. The requirement is normally

10 litres or more dependent on amount of limescale present.

5. After a minimum of one hour, restore gas supply and turn on main gas burner for 2 minutes maximum.

6. Isolate gas supply and drain descale fluid through drain port.

7. Open cold water feed valve and fill heater tank.

8. Drain and flush out heater for 20 minutes minimum.

9. Replace anode(s).

10. Restore gas supply and re-light heater.

IMPORTANT

Remove Correx TM anodes if fitted and plug off the connections using 3/4” BSP plugs.

Re-fit the Correx

TM anodes when the descaling operation is complete.

RESTART

Re-light and carry out commissioning checks as detailed in Section 4, Commissioning.

Set the thermostat control to the required user setting.

30

FAULT FINDING

FAULT

WATER DOES

NOT GET HOT

HEATER SOOTING,

YELLOW FLAME

(POOR

COMBUSTION)

WATER

TEMPERATURE

TOO HIGH

NOT ENOUGH

HOT WATER

WATER DRIPPING

FROM BASE OF

HEATER

RUMBLING NOISE

CONTINUOUS

IGNITION

NO PILOT FLAME

PILOT LIGHTS BUT

MAIN BURNER

DOES NOT

NO IGNITION AT

PILOT

ACTION

(a) Check gas service cock is open.

(b) Check water valves are open.

(c) Check thermostat setting. (reset to higher temperature)

(a) Check gas burner. If possible, check heat input with meter and watch.

(b) Clean burners and injectors.

(c) Flue obstruction. Clean flue ways.

(d) Check flue and termination position.

(e) Check for correct ventilation.

(a) Reset thermostat to lower temperature.

(b) Thermostat faulty. Check and replace if necessary.

(c) Main gas valve not closing. Clean or replace.

(a) Check gas pressures at burner and at gas inlet to heater.

(b) Check amount of water being used against recovery rate given on data plate. If usage too high, more heating capacity needed.

(a) Check if this stops when water in heater is hot. If yes, then condensation is the problem caused by incorrectly designed flue or by tank cooling excessively, i.e. more hot water being used than recovery rate of heater. If so, more heating capacity needed.

(b) If water continues to drip when heater is hot, problem is leaking joint or storage vessel.

(a) Scale formation in heater, consult water treatment specialist. Heater must be descaled and suitable water treatment provided to avoid re-occurrence.

(a) Check gas service cock is open.

(b) Check gas control knob is ON.

(c) Check ECO for failure.

(a) Main gas valve not energised. Check for loose contacts.

(b) Check for 24V AC at intermittent pilot ignition.

Replace control if faulty.

(c) Check for 24V AC at main gas valve terminals. Replace valve if faulty.

(a) Electrical ON/OFF switch is not ON.

(b) Thermostat set too low.

(c) Power to unit interrupted.

SECTION 7

31

SECTION 8

PARTS LIST AND ILLUSTRATIONS

A17

A16

A1

A21

A18

A4

A5

A3

A9

A7

A2

A19

A8

B6

A13

A15

B5

A20

B1

C1

A6

A10

A11

A12

A14

B2

C2

B3

B4

B7

32


SECTION 8

B4

B5

B6

B 7

C1

C 2

Model

Ref.

CSC39

CSCL39

C534

E050

E631

C 2 9 9

C300

C 3 0 1

C 2 4 7

C381

E 2 2 1

C 2 8 8

E223

E 6 6 9

C521

E 1 9 3

C103

E346

E593

E 5 8 6

E671

E673

E727

E225

-

E226

-

E 2 2 7

-

-

-

E 2 3 0

G058

C498

E235

E 3 8 6

E348

E 3 4 9

A7

A8

A9

A 1 0

A11

A 1 2

A 1 3

A14

A 1

A 2

A3

A 4

A5

A 6

A15

A16

A17

A 1 8

A19

A20

A21

B1

B2

B 3

CSC59

CSCL59

P a r t N u m b e r s

CSC78

CSCL78

C103

E346

E593

E 5 8 6

E671

E673

E727

E225

-

E226

-

E 2 2 8

-

E 2 2 1

C 2 8 8

E223

E 6 6 9

C521

E 1 9 4

C534

E050

E631

C 2 9 9

C300

C 3 0 1

C 2 4 7

C381

-

-

E 2 3 1

G058

C498

E235

C103

E346

E593

E 5 8 6

E671

E673

E727

-

-

-

E225

E226

-

-

-

E 2 2 8

E 2 3 2

-

G058

C498

E235

E 2 2 1

C 2 8 8

E223

E 6 6 9

C521

E 1 9 5

C534

E050

E631

C 2 9 9

C300

C 3 0 1

C 2 4 7

C381

E 3 8 6

E348

E 3 4 9

E 3 8 6

E348

E 3 4 9

CSC93

CSCL93

E 2 2 1

C 2 8 9

E223

E 6 6 9

C521

E 1 9 6

C534

E050

E632

C 2 9 9

C300

C 3 0 1

C 2 4 7

C381

C103

E346

E593

E 5 8 6

-

-

-

E 2 2 9

-

E 2 3 3

G058

C498

E235

E671

E673

E728

-

E225

E226

-

-

E

E348

E

3

3

8 6

4 9

D e s c r i p t i o n

F a n M o t o r A s s e m b l y

S a c r i f i c i a l A n o d e

Flue Baffle

C o n t r o l C i r c u i t B o a r d

On / OffSwitch

D a t a B a d g e N a t .

G a s

Nipple 1 1 ⁄

2

” BSP

Hydrojet Cold Inlet 1

Pressure Switch

C l e a n o u t P a d S e a l

1 ⁄

2

”

Cleanout Pad

C l e a n o u t P a d C o v e r

D r a i n T a p p i n g C o n n e c t o r

Drain Cock BS2879

3

⁄

4

”

B S P

Socket Coupler

Fan Motor

3 ⁄

4

”

Capacitor

F a n M o u n t i n g F l a n g e

Nipple 1 1 ⁄

2

” x 1

Bulkhead Union

2 ” B S P

Air Vent Pipe

Burner bar

Burner bar

Pilot Assembly

I n j e c t o r 2 .

4 m m N a t .

G a s

I n j e c t o r 2 .

9 m m N a t .

G a s

I n j e c t o r 2 .

9 m m N a t .

G a s

I n j e c t o r 3 .

1 m m N a t .

G a s

I n j e c t o r 1 .

6 5 m m L P G

I n j e c t o r 1 .

9 5 m m L P G

I n j e c t o r 1 .

9 0 m m L P G

I n j e c t o r 2 .

1 m m L P G

Gas Valve

Gas Cock

3

⁄

4

” B S P F x F

Control Thermostat with

R e m o t e P h i a l a n d E C O

C o m b u s t i o n B o x C o v e r

Gas Valve Assembly complete with fittings LPG

P li o t A s s e m b l y L P G

1

1

1

1

Qty

5

5

7

7

5

5

7

1

1

1

7

7

1

5

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

9

1

1

4

33

SECTION 8


5

9

6

11

12

10

8

2

7

3

13

1

14

150mm (6in) Flue Kit

200mm (8in) Flue Kit

34

5

8

10

11

9

7

2

6

3

12

1

13


SECTION 8

Ref.

Part No.

Description Qty

9

10

11

12

13

14

7

8

5

6

3

4

1

2

E205

E202

E236

E209

E237

E238

E203

E204

E239

E210

E207

E208

E105

E206

90˚ Elbow with Clamp

1 mtr Flue with Clamp


Wall Clamp (Not Shown)


200mm (8in) to 150mm (6in) Reducer

1 mtr Cutable Flue with Clamp

0.5 mtr Flue with Clamp

Vertical Flue Terminal

Condensate Trap Tee

Flat Roof Plate

Angled Roof Plate

Horizontal Flue Outlet Terminal Guard


Note: Extra lengths of flue tubing can be supplied to suit each installation requirement.

Also extra 90˚ and 45˚ elbows can be supplied.

150mm (6in)

Flue Kit

Ref.

Part No.

8

9

10

11

12

13

6

7

4

5

1

2

3

E241

E220

E217

E218

E630

E216

E215

E212

E240

E219

E237

E213

E214

Description


1 mtr Flue with Clamp


Wall Clamp (Not Shown)


1 mtr Cutable Flue with Clamp

0.5 mtr Flue with Clamp

Vertical Flue Terminal

Condensate Trap Tee

Flat Roof Plate

Angled Roof Plate

Horizontal Flue Outlet Terminal Guard Extended


Qty

Note: Extra lengths of flue tubing can be supplied to suit each installation requirement.

Also extra 90˚ and 45˚ elbows can be supplied.

200mm (8in)

Flue Kit

35

SECTION 8


CSC39, 59, 78 & 93, CSCL39, 59, 78 & 93 Unvented System Kit

C4

C5

C6

C9

C3

C2

C1

C8

C7

Unvented System kit

CSC39, 59, 78 & 93, CSCL39, 59, 78 & 93 Parts List

Ref.

Part No.

Description

C1

C2

C3

C4

C5

C6

C7

C8

C9

B228

C784

C785

C786

C782

E242

C856

E326

B173

C788

C787

Unvented Systems Kit Complete

Combined Reducing Valve/Strainer

Check Valve

Expansion Valve

Expansion Vessel (25 Litre)

Temperature/Pressure Relief Valve 1

1

⁄

2

”

1

1

⁄

2

” Square Equal Tee

Tundish from Expansion Valve and T/P Valve

Wall Mounting Kit (Optional)

Hose Assembly

Wall Bracket Assembly

Qty

1

1

1

1

1

1

1

1

1

1

36

Notes

37

Notes

38

Andrews Water Heaters

Wood Lane, Erdington, Birmingham B24 9QP

Tel: 0845 070 1055 Fax: 0845 070 1 059

Sales: 0845 070 1056

Technical: 0845 070 1057

Service: 0845 070 1058

Email: [email protected] www.andrewswaterheaters.co.uk

02/08

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