INSTALLATION MANUAL

INSTALLATION MANUAL
PLEASE LEAVE THIS MANUAL WITH THE OSO UNIT AFTER INSTALLATION
EPCI 360
INSTALLATION MANUAL
The EPCI is an indirect unvented cylinder designed and approved for use with a heat pump. The
cylinder is made of a double cylinder construction with a primary buffer vessel in the lower section
and an indirect domestic hot water cylinder in the upper section. The buffer vessel provides a store
of heat for the space heating system. The heating coil has been specifically designed for a heat
pump, information is included in this manual to link the cylinder with the heat pump.
This cylinder is manufactured and approved in accordance with EN 12897:2006.
This manual gives detailed advice for installation and should be read carefully prior to fitting any
unvented unit. Where components are supplied only for indirect units, this is clearly shown.
This OSO cylinder must be installed by a competent person and be installed in compliance with the
OSO Installation and Maintenance Instructions, all current legislation, codes of practice and regulations governing the installation of unvented hot water cylinders in force at the date of installation.
Components supplied with the unit for site fitting
(See also page 2 for component list)
* Multibloc valve, includes pressure reducing valve, line strainer, balanced cold water take off,
(for shower or bidet only) check and expansion valve.
* Tundish
* 1/2’’F x 15 x 15 tee piece
Health and Safety
Manual Handling Operations Regulations 1992 defines
* 2 flexible hoses - 220 mm & 1000 mm
manual handling as: “any transporting or supporting of a
load (including the lifting, putting down, pushing, pulling,
* 1’’ x 22mm Elbow / Drain Cock
carrying or moving thereof) by hand or bodily force”. The
Regulations set no specific requirements such as weight
* 2 sensor pockets
limits. However common sense still has to be used
based on an ergonomic approach for each individual.
* Motorised valve
DIMENSIONS AND WEIGHTS TABLE 1
* Expansion vessel.
PRODUCT REF.
HEIGHT
DIAMETER
WEIGHT EMPTY
MAX WEIGHT FULL
Components factory fitted
* Immersion heater
* Thermostats / thermal cut-out
* Temperature and pressure relief valve.
142038-00
Installation details
360
1950
580
86
427
The OSO unvented unit is designed for use with supply pressure up to 10 bar. For pressures
over 10 bar an additional pressure reducing valve must be fitted in the supply pipe to the unit.
-1-
General Layout Fig: 1
EXTERNAL VIEW
KEY
1
2
3
4
5
6
7
7A
7B
8
9
10
11
12
CUTAWAY VIEW
Part No.
PLAN VIEW
KEY
Return 3/4” BSPF
Flow 3/4” BSPF
Pressure Reducing Valve
355013
Expansion valve
510505
Temperature and Pressure
Relief Valve
550853
Tundish
219002
Immersion Heater
71259
Thermostat Immersion Heater
80020
Cylinder Thermostat
80020
Cold Feed Tube
(Not supplied see Table 2)
Hot Water Outlet 3/4” BSPF
Flexible Hose
202108
Flexible Hose for Expansion Vessel
91911
Secondary Return Connection
Blanking Plug / Sensor Pocket 1/2”
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Part No.
Elbow / Drain Cock
Cable Entry
Electrical Box
Tee Piece
Discharge Pipe (Not supplied)
Motorized Valve M (Not Factory Fitted)
Expansion vessel
Sensor Pocket 1/2”
Buffer vessel flow from heat pump 1”
Buffer vessel flow to heating circuit 1”
Buffer vessel return from heating circuit 1”
Buffer vessel return to heat pump 1”
Pressure Gauge Connection 1/2”
Thermostat Pocket 1/2”
250445
250006
92000
AX 19
TABLE 2
Size Lenght of tube (ø22) mm Exp. vessel pre charge
355
1020
2,5 bar
-2-
COLD WATER SUPPLY
1. To obtain the best performance from your OSO unvented system it is advisable to feed the unit
with an uninterrupted supply.
2. Before connecting to the multibloc, flush the cold supply pipework of all flux and debris.
3. Locate the water heater in a suitable position to facilitate the installation of the cold water supply,
discharge fittings and pipework. Also take into account access to the immersion heaters and the
commissioning valve.
4. Fit the combined male elbow drain cock to cold supply point (13), so that the compression fitting
is vertical.
5. Fit both 1/2’’ male solar sensor pockets to the Solar Sensor bosses (19).
6. Fit the female outlet of the tee piece to the temperature and pressure relief valve (5) with the
horizontal connection facing right at approx. 45°.
7. Fit the tundish (6) to the tee piece using a short length of 15mm copper tube.
8. Fit the length of copper tube 22mm specified in Table 2 to the cold feed elbow (see 4 above) to
include a T piece (20) for expansion vessel flexible hose.
9. Fit the pressure reducing valve (3) to the top of the copper tube (see 8 above), so that the black
knob is facing right.
10.Connect the flexible hose to the 1/2’’ outlet of the expansion valve (4) and the horizontal outlet
of the tee piece (see 6 above). Discard compression nut & ring.
11.If a balanced mains pressure cold water supply is required to a shower or bidet (over rim type
only), remove the blanking cap from the pressure reducing valve (3) and connect to the shower
or bidet cold supply. Using the balanced cold connection to feed bath taps can reduce the
flow available to the unvented cylinder. (Major shower manufacturers advise fitting a mini
expansion vessel in the pipework to accommodate thermal expansion and prevent
tightening of shower controls)
12.Connect the cold supply to the Multibloc (3).
13.Fit the expansion vessel to the wall close to the water heater using the enclosed mounting bracket.
Connect the expansion vessel hose to the T piece in the cold feed pipe to the cylinder. The expansion
vessel is supplied with the OSO unit, fit as shown on page 2.
Hot water supply
14.Connect the hot water supply pipe to the outlet (9). Ensure connection is water tight.
Secondary return (optional)
15.Connect secondary return if required to fitting according to diagram on page 16.
Discharge pipe
16. Connect the discharge pipe from the tundish (6). This must have a continuous fall and be fitted
in accordance with The Building Regulations (see page 16). The tundish should be installed away
from electrical devices.
Primary flow & return & motorised valve - heat pump
17.The heat pump primary flow and return connections should be made to the unit. The motorised valve
can be connected to wither the primary or return connections. The primary flow and return
connections are ¾” female. The valve has 22mm copper connections. The direction of the primary
flow in the coil is top to bottom.
18. Connect the primary flow and return from the heat pump into the heating circuit using the
connections 21 – 24 in the buffer vessel section of the EP unit. This will provide a store of heating fluid
to supply to the heating circuit that will improve the efficieny of the heat pump.
-3-
COMMISSIONING
Filling up
1. Open a hot tap.
2. Open the cold water supply valve
3. when water flows from hot tap, close the tap
4. Allow the system to stabilize for 5 minutes
5. Open each hot water tap in turn to expel air from the system pipe work.
7. Check for leaks.
8. Manually operate Temperature and Pressure Relief Valve (5) to ensure free water flow through
discharge pipe. (Turn knob to left.)
Draining/flushing
1. Turn off mains supply.
2. Connect hose pipe to drain cock at base of cylinder.
3. Open hot tap. Open drain valve and open temperature & pressure relief valve.
4. Allow to drain. Follow commissioning instructions (above) to refill.
SAFETY AND MAINTENANCE
Safety Cut-out
1. The safety cut-out operates if:
a. Wiring is incorrect.
b. The immersion heater thermostat or cylinder thermostat fails.
c. Thermostat is set too high.
2. Remember before resetting the safety cut-out or altering the thermostat setting, isolate electrical
supply to the unit prior to removal of the electrical box lid.
3. Reduce thermostat setting and press the reset button. After adjustments are completed, ensure
the lid to the electrical box is replaced correctly and the retaining screw is fitted.
4. If still out of operation, contact installer.
RECOMMISSIONING INSTRUCTIONS
Cold or tepid water discharge from tundish - The tundish should be installed away from electrical devices.
1. Close cold water supply valve
2. Open a hot tap.
3. Repressurise the expansion vessel air charge to its set level.
4. Close hot tap
5. Open the cold water supply valve
Hot water discharge from tundish
This indicates a malfunction of a thermal cut-out, operating thermostat or the combined temperature
and pressure relief valve. Turn off the electrical supply to the immersion heater and also isolate an
indirect unit from the boiler. Contact the installer or competent engineer.
TABLE 3
Size Max. design
litres
pressure
355
8 bar
Operating pressure
CW feed & coil
cw in 2 bar, coil 2.5 bar
Pressure drop
primary heater (coil)
0,1 bar
-4-
Temp. / pressure
Safety valve
relief valve
Pressure / conn.
90-95°C / 10 bar 8 bar / 15mm - 1/2”
Exp. vessel
capacity
19 l.
INSTALLATION AND SERVICING INSTRUCTIONS
Positioning the unit
The water heater should be fitted level on a hard surface with sufficient load strenght to take the
full weight of the cylinder (see table 1 page 1). Adjustable feet are fitted to ensure the unit can be
adjusted to a level position. There is no limitations regarding the fitting distance from walls etc., but
it is strongly recommended to ensure easy access to all pipe fittings etc. There should be at least 80
cm of free space in front of the water heater to ensure easy access for servicing and maintenance.
Protection from frost
If the water heater is in danger of being exposed to frost while not operating under electric power,
the unit must be drained to avoid damage. Make sure the electric power is turned off before draining,
otherwise the heating elements can be damaged and the warranty is void. Draining instructions, see
“Commissioning” on page 4.
Cold water inlet control (Multibloc) See Page 2 Items 3 - 4
This combination consists of a pressure reducing valve with integral strainer, check valve and
expansion valve with stainless steel seat. The pressure settings are set and locked in the factory and
are shown on the top of each valve. For optimum performance the following installation instructions
should be complied with.
Installation
1. Cold water supply to be 22mm nominal size.
2. Flush supply pipework before connection to remove all flux and debris prior to fitting the inlet
controls. Failure to do this may result in irreparable damage to the controls and will invalidate
the warranty.
3. The “MULTIBLOC” can be fitted in any orientation to suit the installation as long as it is fitted in
the correct flow direction. Check the flow arrows on the side of the body.
4. The expansion valve should be either horizontal or pointing downwards. If fitted upwards, debris
may be deposited on the seat and cause fouling of the seat when the valve operates. Check
direction of flow arrows.
5. The black plastic plugs in the body are pressure gauge connections to enable pressure
monitoring to be carried out, should the system develop a fault. It is recommended that these
be accessible (the pressure reducing valve has two - only one need be accessible).
6. Expansion relief drain pipework must be connected to a safe visible discharge point via a
tundish and the pipework must have a continuous fall.
7. The pressure reducing valve has two outlets, the second one is for a balanced cold water
supply, to a shower or a bidet (over rim type only, ascending spray type requires type AA,
AB or AD air gap). (Major shower manufacturers advise fitting a mini expansion vessel in
the balanced cold supply to accommodate thermal expansion and prevent tightening of
shower controls).
Using the balanced cold connection to feed bath taps can reduce the flow available to the
unvented cylinder. If not required the balanced cold supply is blanked off.
The Benchmark Log Book enclosed with the cylinder should be completed after commissioning
of the system and handed to the customer for future use.
TABLE 4
Product DHW actual Primary Buffer Weight Weight Heat-up (mins) Rating (kW)
Heat loss
Primary
Hot Water
code capacity (l.) actual capacity (l.) empty full
coil
coil
kWh/24h
flow rate
Capacity (l.)
EPCI 360
258
94 86
427
23
27,6
2,1 / 0,8 (upper/lower) 15 l/min. - 80°C
208
Note: Temperature rise is from 15 to 60°C. Coil heating performance based on a primary flow rate of 15 l/min. at 80°C.
-5-
MAINTENANCE
It is recommended that annually a competent person
(a) Inspects and cleans the line strainer.
(b) Checks the operation of the expansion relief valve and temperature & pressure relief valve.
(c) Recommissions the cylinder in accordance with the instructions on page 4.
Corrosion resistance
Duplex stainless steel is naturally corrosion resistance to mains water supply. No specific maintenance is required to maintain this resistance. Please see guarantee terms for permissable water
content. Please note: OSO cylinders are not guaranteed for use with a private water supply.
The immersion heater can be removed to provide visual inspection access to the cylinder.
Pressure reducing valve
1. Isolate the cold water supply
2. Unscrew the pressure reducing cartridge
3. Clean the filter mesh and the cartridge
under running water.
4. Replace cartridge ensuring that strainer is
correctly located and reassemble the unit.
Pressure Reducing Valve cartridge and
strainer Part No. REDC355013 2.1 Bar.
Expansion relief cartridge
1. Isolate the cold water supply.
2. Unscrew blue expansion relief headwork
from valve body.
3. Clean valve seat face and seating - do not
scratch or damage either seat face or
seating.
4. Refit in reverse order. Do not overtighten
Expansion valve cartridge and seat Part
No. 214009 8.0 Bar. Complete Expansion
Valve Part No. 510 505 8.0 Bar.
SPARE PARTS
Expansion valve
(Cartridge and seat)
Part No. 214009
8.0 Bar
Pressure reducing valve
Cartridge and strainer
Part No. REDC 355013 - 2,1 bar
Part no. 320001 adjustable
1.5 - 5 bar
Expansion valve
Part No. 510 505
8.0 Bar
Tundish
Install theTundish in a vertical position within a maximum of 600mm from the temperature and
Pressure Relief Valve drain connection. Ensure the expansion relief pipework discharges through the
tundish. Tundish pipework must be 22mm with a minimum vertical length of 300mm below tundish.
Maximum permitted length of 22mm pipework is 9m. Each bend or elbow is equivalent to 0.8m of
pipework.
All pipework must have continuous fall and discharge in a safe, visible position. If any doubt, refer to
Building Regulation G3.
-6-
ELECTRICAL INSTALLATION
Immersion heaters
The EPCI is provided with twin immersion heaters. The upper immersion heater is designed as
an auxiliary heater to supplement the heat pump energy and will ensure the top section of the
water heater is fully heated.
All EPCI units are supplied with an immersion heater at low level. This immersion heater is to
allow full heating of the entire cylinder should it be required for cleansing purposes. The lower
immersion heater should not be in regular use as this will severely compromise the heat pump
efficiency of the cylinder.
Wiring instructions for the immersion heater is located on the reverse side of the lower lid. Follow
the wiring instructions connecting the live, neutral and earth as indicated. The electrical connection
to the immersion heater must conform to current IEE wiring regulations. The unit must be
permanently connected to the electrical supply through a double-pole linked switch with a
minimum break capacity of 13 amps. All internal wiring is factory mounted. Each immersion
heater has a working thermostat adjustable between 40°C - 70°C. A safety cut-out is also
incorporated within the thermostat and will operate at 85°C ± 3°C. Should this happen, press the
reset button.
Important: Before resetting the safety cut-out or altering the thermostat setting, isolate
electrical supply to the unit prior to removal of the lid. Ensure the lid to the electrical box
is replaced correctly and the retaining screw is fitted.
Heating coil
Heat sources to unvented hot water cylinders must be controlled by a thermal cut-out as well
as a thermostat. The OSO EPCI is supplied both with bosses for solar sensor pockets and the
pockets themselves.
The top half of the thermostats fitted to the cylinder is a thermal cut-out. The heat pump controller (not supplied) and heat pump sensor point should be wired through the OSO thermal cut-out.
See fig. 4 pages 8 & 10.
Please note that the direction of flow in the heat pump coil is reversed compared to the boiler
coil. If the cylinder is not being used for heat pump use, connect the boiler to the lower coil with
the primary flow in a bottom to top direction.
OSO Hotwater (UK) Limited can not be responsible if alternative wiring plans are used.
Important: Before resetting the safety cut-out or altering the thermostat setting isolate
electrical supply to the unit before removal of the lid.
-7-
Wiring Layout for heat pumps controlled by S-plan system
If the heat pump is designed for control by a traditional S-plan wiring system, incorporating cylinder and room thermostats and motorised valves, follow the wiring plan below.
Heat pump
The wiring plan shown is based on the use of a 10-way Junction Box (Honeywell Part no. 42002116-001)
Junction Box terminal 10 is switched live and, if needed, terminal 9 is pump live.
-8-
Wiring Layout for heat pumps controlled by S-plan system
T = Optional positions for temperature
sensor pocket (lenght max. 150 mm).
EPCI 360
Upper
element
T
T
Heat Pump
with built-in
Pump
3-way valve
Condensator
Pump
Central heating
Lower
element
T
Pressure gauge
T
Safety valve
(not supplied)
Electrical spare parts:
Direct units
Indirect units
Thermostat
80020 Right thermostat
80030
Left thermostat
80020
00071259
00071259
Immersion heater
71259 Immersion heater
71259
-9-
Wiring Layout for heat pumps controlled by integral thermal sensors
If the heat pump is designed for control using temperature sensors placed in the rooms
and on the water heater, follow the wiring plan below.
The OSO EP is supplied both with bosses for solar sensor pockets and the pockets themselves.
To comply with regulations governing the installation of indirect unvented cylinders, cylinders
must be protected by a thermal cut-out as well as controlled by a thermostat.
The cylinder is supplied with a separate working thermostat which contains a thermal cutout.
The top half of the thermostat is a thermal cut-out. If the cylinder temperature control is to be
governed by thermal sensors, the heat pump temperature control mechanism must be wired via
the thermal cutout on the cylinder. Follow the wiring diagram below.
HEAT PUMP CONTROLLER WIRING
Cylinder
thermostat
1
1
Safety
Cut-out
3
RESET
Heat
Pump
Control
L
2
N
2
E
3
1
L
1
N
2
2
E
3
+
Electrical spare parts:
Immersion Heater
Immersion Heater Thermostat
Coil Thermostats
Reset
button
4
-
71259
80020
80030
A motorised valve must be fitted in the primary flow. Your OSO unit has been supplied with a two port motorised valve,
which will act as a positive energy cut-out should the safety cut-out operate.
-10-
Radiators/UFH
Heat
source
Automatic
bypass
Electrical spare parts:
Direct units
Indirect units
Thermostat
80020 Right thermostat
80030
Left thermostat
80020
00071259
00071259
Immersion heater
71259 Immersion heater
71259
-11-
1. Heat pump not activated.
2. Immersion heater not switched
on.
3. Immersion heater thermal cut out has operated.
4. Programmer set to central
heating or not switched on.
5. Cylinder thermal cut-out has
operated.
6. Motorised valve not operating
correctly.
1. Reduced expansion vessel charge.
-12-
1. Check Heat Pump operation. If fault
suspected consult installer or heat
pump manufacturer.
2. Check and switch on.
3. Check and reset button (see
thermostat diagram page 9 and
safety cut-out on page 4 of
installation manual).
4. Check and set to hot water.
5. As at No. 2.
6. Check wiring and/or plumbing
connections to motorised valve.
(See page 8 of the installation
manual).
1. Repressurize expansion vessel.
Follow recommissioning
instructions on page 4.
2. Switch off power to immersion
heater(s) and boiler supply to
the unit. When discharge has
stopped, check thermal
controls, replace it faulty.
Contact a competent person.
Repressurize expansion vessel. Follow recommissioning
instructions on page 4.
DIRECT HEATING
INDIRECT HEATING
Is the heat pump
working?
Is Thermostat wired
as per layout for “S”
plan installation
-14-
NOTES:
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-15-
ALTERNATIVE DISCHARGE
Downward discharges at low
FIGURE 4
level, i.e. up to 100mm above
external surfaces such as car
parks, hard standings, grassed
areas etc, are acceptable providing that where children may
play or otherwise come into
contact with discharges, a wire
cage or similar guard is positioned to prevent contact, whilst
maintaining visibility.
Discharge at high level, i.e.
into a metal hopper and metal
down pipe with the end of the
discharge pipe clearly visible
(tundish visible or not) or onto
a roof capable of withstanding
high temperature discharges of
water and 3m from any plastics guttering system that would collect such discharges (tundish visible).
Where a single pipe serves a number of discharges, such as in blocks of flats, the number served
should be limited to not more than 6 systems so that any installation discharging can be traced
reasonably easily. The single common discharge pipe should be at least one pipe size larger than
the largest individual discharge pipe to be connected. For further information contact your Building
Control Office or The British Board of Agrément.
SECONDARY RETURN
FIGURE 5
1. Secondary Return Fitting (T piece not supplied)
2. Non Return Valve
3. Circulation Pump
4. Secondary Return Line
5. Balanced cold supply for showers or bidet only
HOTWATER UK Ltd.
All replacement parts must be supplied by OSO HOTWATER (UK) LIMITED.
To obtain the address of a local stockist contact:
OSO HOTWATER (UK) LTD.
E15 Marquis Court - Team Valley Trading Estate - Gateshead - Tyne&Wear, NE11 0RU
Phone: (0191) 482 0800 • Fax: (0191) 491 3655 • www.oso-hotwater.com
E-mail: [email protected][email protected][email protected]
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