Installation instructions

DHW cylinders TSW-120/CSW-120 for gas-fired condensing boilers and conventional gas-fired boilers

Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.de

07/07 GB 1

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Index

Index .................................................................................................................. Page

General information ................................................................................................. 2

Safety notice / DHW cylinders / Standards and regulations .................................... 3

Specification ............................................................................................................. 4

Dimensions .............................................................................................................. 5

Layout ....................................................................................................................... 6

Positioning / Installation dimensions ...................................................................... 7

Installation ................................................................................................................ 8

Installation of the tundish ................................................................................... 9-11

Installation of the domestic water connection ....................................................... 12

Final assembly ....................................................................................................... 14

Circulation / Commissioning ........................................................................... 15-16

Maintenance ..................................................................................................... 17-18

General information

Delivery

Handle and store

2

This manual is an integral and essential part of the product. Please read carefully the instructions and notices about the appliance contained in this manual, as they provide important information regarding the safe installation, use and maintenance of the cylinder. Failure to do so may invalidate the guarantee.

The CSW-120 range is supplied as following;

1) The cylinder with factory fitted temperature & pressure relief valve.

2) Box containing

- reducing valve

- expansion valve with check valve

- tundishes

- pipes

- connection supplies

3) Box containing expansion vessel

Don’t stack the packages. Don’t transport lying.

Keep the packages in dry conditions.

Installation instructions DHW cylinders TSW-120/CSW-120

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Safety notice

DHW cylinders

Safety notice / DHW cylinders / Standards and regulations

• Installation must be carried out by a suitably qualified installer and in accordance with current regulations and codes of practice.

• Only the safety valves supplied with the cylinder should be used.

• The cylinder must not be used without the safety valves and expansion vessels.

• The cylinder must not be used with a boiler without thermostatic control.

• The cylinder and ancillary controls must be adequately maintained.

• The installation must have a sufficient and constant supply of mains fed cold water.

• No valve should be fitted between the expansion relief valve and the storage cylinder.

• Only Wolf approved replacement parts should be used.

• The discharge pipe must be terminated where it is visible and will not cause danger to people in the vicinity of the discharge.

Note: The discharge could consist of scalding water and steam.

DHW cylinders, type TSW-120 / CSW-120, made from steel with top flange and pipework connections for gas-fired boilers.

Corrosion protection through dual enamel coating on internal cylinder walls and indirect coils, acc. to DIN 4753 pt. 3.

Additional corrosion protection through magnesium anode. Suitable for all water conditions and any type of pipework.

Standards and regulations

Domestic hot water cylinder

TSW-120

Domestic hot water cylinder

CSW-120

Observe the following instructions during the installation of the

DHW cylinders:

- BS 6920

- BS 7206

- DIN 1988 - Technical regulations for DHW installations

- DIN 4708 - Centralised DHW systems

- VDE requirements

- Requirements by public water suppliers

Installation instructions DHW cylinders TSW-120/CSW-120

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3

Specification

Warning to the user

Warning to the installer

Note to the installer

4

Specification

The safety system of the DHW cylinder TSW-120/CSW-120 is attuned to use only in combination with Wolf boiler TGG-18, TGG-

24 and TGB-20.

Type of DHW cylinder TSW/CSW -120

Cylinder capacity litres 115

Const. DHW cyl. rating (80/60 - 10/45°C) kW-ltrs./h 29-710

Standby consumption at 60°C

Performance factor N

L60

Max. supply temperature

Heating up time with 25kW

Re heat time with 25kW kWh/24h

°C min min

1.5

1.0

60

22

15

Max. operating pressure - DHW

Max. operating pressure - heating water

Max. permissible DHW cylinder temperature

Max. permissible heating water temperature

P+T-valve opening temperature

P+T-valve opening pressure

Max. water supply pressure

Expansion valve setting

Expansion vessel charge pressure bar bar

3.5

12

°C 95

°C 110

°C bar

95

7 bar 16.0

bar 6.0

bar 4.0

Weight (empty)

Weight of the full cylinder

Connections Cold water

Hot water

DHW flow

DHW return

DHW circulation

Sensor well

R

R

R

Ø mm kg 75 kg 190

R

R

¾ ”

¾ ”

¾ ”

¾ ”

¾ ”

14 a) Do not remove adjust any component part of this unvented water heater: Contact the installer b) If this unvented water heater develops a fault, such as a flow of hot water from the discharge pipe, switch the heater off and contact the installer.

a) This installation is subject to building regulation approval, notify the Local Authority of intention to install.

b) Use only manufacturer´s recommended replacement parts.

c ) Installed by: Name:

Adress:

Tel.No.:

Completion date

Leave the manual with the householder after installation.

Installation instructions DHW cylinders TSW-120/CSW-120

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Dimensions

810

595

Fig.: TSW-120

542

Filling and draining for TSW-120 below the decorative panel

810

DHW circulation

Cold water

DHW return

Domestic hot water

DHW cylinder flow

Sensor well

542

Fig.: CSW-120

542

Installation instructions DHW cylinders TSW-120/CSW-120

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5

Layout

DHW circulation pump

Please note:

DHW cylinder sensor connection (blue plug)

Gas-fired boiler control unit i

Domestic hot water

DHW circulation

Cold water supply according to British

Standards

Expansion vessel

Expansion valve with discharge outlet to tundish

Check valve

Pressure reducing valve

Stop valve

Drain

Cold water to

DHW cylinder

The layout is provided to provide a general overview, not a piping prescription.

6 Installation instructions DHW cylinders TSW-120/CSW-120

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Positioning

Installation of wall hung appliance an hot water storage tank

Positioning / Installation dimensions

Install the DHW cylinder only in a frost protected location, otherwise drain, if there is a risk of frost.

Consider the total weight of a full DHW cylinder when selecting the installation location.

Adjustable feet allow you to compensate for uneven floors.

The DHW cylinder ...SW-120 may be installed in a top or bottom cupboard or free-standing.

CSW centered!

mounting bracket

TSW without covering panel

480

344

400 mounting bracket

TSW with covering panel

480

344

400 notch for water pipes mounting bracket notch for water pipes notch for water pipes

Install appliance as described in Installation Instructions.

Please note when using the pipe cover:

The installation dimensions apply to TSW-120 as well as CSW-120.

If you intend installing the DHW cylinder with a pipe cover, check the fit (dimension 300 mm) with the pipe cover prior to commencing the pipe installation. The adjustable cylinder feet can compensate a max. of ±10 mm.

Please note the fixing hole position on the installation template when using a fixing bracket (accessory).

Installation instructions DHW cylinders TSW-120/CSW-120

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7

Connection of

DHW cylinder flow

DHW cylinder return

Installation

Remove the dummy plug from the heating return of the gas-fired boiler. Remove the elbow from the heating flow of the gas-fired boiler and insert the three-way changeover valve with a union nut and flat gaskets. Trim the DHW cylinder flow and return pipes to size. Secure the installation with compression fittings on the DHW cylinder ...SW

as well as with flat gaskets and union nut on the gas-fired boiler.

Note

Connection of

Three-way changeover valve

DHW cylinder temperature sensor

8

Bend

Three-way changeover valve

Dummy plug

HRL HVL

HVL

Please note:

When installing the pipe bezel, the dimension between the bottom edge of the casing and the top edge of the cylinder must not be a min. of 240 mm and a max. of 420 mm, but instead must be 300 mm.

Lower edge casing

Flow pipe

SVL HVL HRL

GAS

HRL

Return pipe

SRL

Siphon

WW Z KW

Upper edge

DHW cylinder

HVL : Central heating flow

HRL : Central heating return

SVL : DHW flow

SRL : DHW return

WW : DHW connection

KW : Cold water inlet

Z : DHW circulation

Pipework on finished walls

Because of heat expansion, water may during heating be discharged from the safety valve. Never shut off the blow-off line. Safeguard the drainage to the drain funnel via a drain pipe.

The selection of pipework material (i.e. connection fittings on site) has to be in accordance with the rules of engineering and possible electro-chemical reactions have to be taken into account (mixed component installation).

If copper connections are used, utilise compression fittings made from brass or bronze to prevent contact corrosion at the DHW cylinder connections. Cylinder relief valve connections should not be used for any other purpose.

Remove the dummy plug at the control unit and connect with the socket of the three-way changeover valve.

Remove the blue dummy plug from the control unit and connect with the socket of the DHW cylinder temperature sensor. Insert the sensor into the sensor well until it bottoms out.

Installation instructions DHW cylinders TSW-120/CSW-120

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Discharge pipework

Installation of the tundish

1. The tundish must be vertical and fitted within 500mm of the temperature & pressure relief valve and must be located with the cylinder. The tundish must also be in a position visible to the occupants, and positioned away from any electrical devices.

The discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vincinity of the discharge and to be of metal.

2. Discharge pipes from the temperature & pressure relief and expansion relief valve may be joined together.

3. The pipe diameter must be at least one pipe size larger than the nominal outlet size of the safety device unless it’s total equivalent hydraulic resistance exceeds that of a straight pipe

9m long. i.e. Discharge pipes between 9m and 18m and

27 m at least 3 larger, and so on.

Bends must be taken into account in calculating the flow resistance. Typical discharge pipe arrangement on page 10.

4. The discharge pipe must have a vertical section of pipe at least

300mm in length, below the tundish before any elbows or bends in the pipework.

5. The discharge pipe must be installed with a continous fall.

6. The discharge must be visible at both the tundish and the final point of discharge, but where this is not possible or practically difficult; there should be clear visibility at one or other of these locations. Examples of acceptance are: i) Ideally below a fixed grating and above the seal in a trapped gully.

w a t e r ii) Downward discharges at a low level; i.e. up t

100mm above external surfaces such as o c a r parks, hard standings, grassed areas etc.

T h e s e 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.

iii) Discharges at high level; l.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 3 m from any plastic guttering systems that collect would such a discharge (tundish visible).

iv) 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 can be traced reasonably easily. The single common discharge pipe should be at least one pipe size large than the largest individual discharge pipe to be connected. If unvented hot water storage systems re-installed where discharges from safety devices may not be apparent l.e. in dwellings occupied by the blind, infirm or disable people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.

Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

Installation instructions DHW cylinders TSW-120/CSW-120

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9

Typical discharge pipe arrangement safety device

(eg.

temperature relief valve)

500 mm maximum

300 mm minimum

Installation of the tundish

metal discharge pipe (D1) from temperature relief valve to tundish tundish discharge below fixed grating or as para 1 (b) fixed louvred grating metal discharge pipe (D2) from tundish, with continous fall, see table an worked example trapped gully

Sizing of copper discharge pipe ‘D2’ for common temperature relief valve outlet sizes

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 (ie.

no elbows or bends)

Resistance created by each elbow or bend

G½ 22 mm

28 mm

35 mm

42 mm up to 9 m up to 18 m up to 27 m

1.0 m

1.4 m

1.7 m

* See Worked examples and scheme above

Worked example

The example below is for a G½ temperature relief valve with a discharge pipe (D2) having 4

No. elbows and length of 7 m from the tundish to the point of discharge.

From Table

Maximum resistance allowed for a straight length of 22 mm copper discharge pipe (D2) from a G½ temperature relief valve equates to: 9 m

Subtract the resistance for 4 No. 22 mm elbows at 0.8 m each = 3.2 m

Therefore the maximum permitted length equates to: 5.8 m.

5.8 m is less than the actual length of 7 m therefore calculate the next largest size.

Maximum resistance allowed for a straight length of 28 mm pipe (D2) from a G½ temperature relief valve equates to: 18m

Subtract the resistance for 4 No. 28 mm elbows at 1 m each = 4 m

Therefore the maximum permitted length equates to: 14 m

As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory.

10 Installation instructions DHW cylinders TSW-120/CSW-120

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Installation of the tundish

The discharge pipe from the tundish should terminate in a safe place where is no risk to person in the vicinity of the discharge.

Position the tundish where it can be readily seen.

Position the tundish away from any electrical devices.

Installation of the pipes domestic water connecting set

Between storage tank and safety valve no other valves or sieves must be installed.

passed expansion vessel always use copper inserts tundish

DO NOT USE THIS TUNDISH

WITH THE P+T-VALVE hold a distance of 25mm between the tundish and the pipe end.

Installation instructions DHW cylinders TSW-120/CSW-120

3048420_0707 wall plug Ø 10mm threaded rod 8 x

160 wall mounted pipe clip plug domestic cold water reduce compression fitting 22/18 expansion valve with check valve pressure reducing valve

11

View of complete mounted DHW cylinder with tundish and domestic water connection

Installation of the domestic water connetoin

View of complete mounted DHW cylinder with tundish, domestic water connection and connection accessory to the boiler

12 Installation instructions DHW cylinders TSW-120/CSW-120

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Drinking water filter

Pressure reducing valve

Check valve

Expansion valve

Expansion vessel

Drain

DHW connection free-standing DHW cylinder ...SW-120

Secondary return

Installation

We recommend the installation of a drinking water filter into the cold water supply, as foreign bodies introduced into the system can block fittings and may lead to pipe corrosion.

Generally, we would recommend the installation of a pressure reducer. On the DHW side, the DHW cylinder may be operated with a max. pressure of 10 bar. Install a pressure reducer if the supply system delivers a higher pressure. To avoid flow noise inside of buildings, regulate the pipe pressure to approx. 3.5 bar.

Provide a centralised pressure reducer, if mixer taps are used.

Exceeding the permissible operating pressure may cause leakages and destruction of the storage tank.

The check valve is included into the expansion valve.

Install a type-tested safety valve into the cold water supply. The installation of dirt traps or other restrictions into the supply pipe to the safety valve is not permitted.

Note: Do not fit a valve between the expansion valve and the

DHW cylinder.

Install the expansion vessel with the T-piece directly into the line, that a flow through is guaranteed

Install the DHW cylinder so that it can be removed without dismantling. The TSW-120 is provided with a drain below the decorative panel.

When installing the DHW cylinder ...SW below the gas-fired boiler, use the Wolf accessory “DHW cylinder connection set for subsurface installation“ or the “DHW cylinder connection set for surface installation“.

A secondary return may be fitted (consult the lavel on the face of the unit for the correct location). A non-return valve (not supplied) must be fitted to prevent back-flow and a bronze pump will be needed in conjunction with a pipe thermostat to circulate the hot water (both not supplied).

Note: An extra expansion vessel may be required where the additional volume of the secondary return exceeds the capacity of the expansion vessel supplied.

Connection set ...SW-120 for surface installation (accessory)

Installation instructions DHW cylinders TSW-120/CSW-120

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13

Decorative panel

TSW-120

Final assembly

For TSW-120 the following final steps must be completed:

Press the black plastic clips (4 pieces) into the corners of the decorative panel. Clip the decorative panel with the pre-assembled plastic clips into the fixing holes of the DHW cylinder front panel.

Please note: Six black plastic clips are surplus and should be retained as spare parts.

Black plastic clip

White plastic plugs

On CSW-120 use the white plastic plugs supplied to close the four holes in the front panel and the three holes in each of the l.h./r.h.

rear side panels. Please note: Two white plastic plugs are surplus and should be retained as spare parts.

On TSW-120 use the white plastic plugs supplied to close the three holes in each of the l.h./r.h. rear side panels.

Pipe cover

Decorative panel

After the installation, locate the pipe cover (accesory) on the DHW cylinder ...SW-120 and push back.

14

Pipe cover

Installation instructions DHW cylinders TSW-120/CSW-120

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DHW circulation

Circulation / Commissioning

You may connect an optional DHW circuit at the circulation connector.

The DHW circuit should be connected only, if the draw-off points are located a fair distance away and should be installed with a DHW circulation pump with time switch control.

Implement the electrical connection in accordance with the following wiring diagram.

DHW circulation pump

Commissioning

L1 N

230VAC

Netz

L

Z

N L N

230VAC

FV

L1

AK

L PE

Only an approved contractor must install and commission this equipment; this contractor is also responsible for the appropriate equipment level.

Thoroughly flush the pipes and the DHW cylinder after completing the installation. Check for obvious signs of damage to the cylinder and controls and also that the controls fitted correspond with the references quoted in these instructions.

Ensure that the Drain Cock at the base of the appliance is closed before commencing.

1) Open all outlet taps;

2) Turn on mains water supply and allow the water heater to fill;

3) Close taps in turn after having purged the system of air;

4) Check for leaks around the controls and immersion heaters and again after the unit has heated up.

5) Check that no water is passing to waste through the relief valves;

6) Test the operation of the temperature and pressure relief and expansion valves by lifting/turning the manually operated test lever/cap and observing that water flows through freely and safely to waste.

Installation instructions DHW cylinders TSW-120/CSW-120

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Circulation / Commissioning

Fill the heating system at a low water pressure (approx. 1 bar).

During filling, open the three-way changeover valve several times manually if the system includes a gas-fired boiler. On gas-fired condensing boilers, open the air vent valve in the DHW cylinder flow. Check whether the lid on the quick-action air vent valve is loose. Briefly start up the boiler (circulation pump).

Demonstrate operation to user, including operation of temperature and relief valve and what to do if it operates.

Give this manual to the user to retain for future reference and make the customer aware that periodic checks of the equipment are essential for safety.

Selecting the DHW cylinder temperature

Adjust the DHW cylinder temperature on the Wolf gas-fired boiler between 15 - 70 °C using the cylinder thermostat. For reasons of economy, thermostat setting 7 (approx. 60 °C) is recommended. For regular pasturisation, a DHW cylinder thermostat setting of 70 °C

(position 9) may be selected. This setting is only intended for brief and supervised operation.

In hard water areas we recommend thermostat setting 7 (approx.

60°C) to prolong element life.

The DHW cylinder temperature can be read off at the display if a Wolf gas-fired boiler is connected to digital control accessories DRT, DWT or DWTM, (see operating instructions of the respective control unit).

Selecting the DHW cylinder loading times

When using digital control accessories DRT, DWT or DWTM for Wolf gas-fired boilers, the cylinder loading time for the CSW-120 DHW cylinder may be selected via a two-channel time switch CSW-120.

The loading times can be freely selected via the day/week program.

Programming the cylinder loading times is detailed in the control unit operating instructions.

16 Installation instructions DHW cylinders TSW-120/CSW-120

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Maintenance

Checking the protective anode

The integral magnesium anode can be sacrificed through electrical reaction to protect the DHW cylinder from corrosion. Therefore check and, if necessary, replace the anode every two years.

Remove the connection cable between the anode and the hand hole cover. To check the protective anode, connect an ammeter between earth and the anode. Replace the protective anode if the actual value falls below 0.1 mA.

Protective anode

Earth = hand hole cover

Draining the DHW cylinder

Fully release the DHW cylinder pressure, switch OFF the boiler and the DHW circulation pump, and open a hot water tap in your house.

A hose nozzle is factory-fitted below the fill and drain cock cover.

On TSW-120, the decorative panel must first be removed by slightly lifting and pulling it forward.

Filling/draining aperture

Hose connection

Replacing the protective anode

Remove the six nuts on the hand hole cover. Remove the cover, together with the protective anode. Remove the locking nut and fit a new protective anode.

Installation in reverse order.

Access trap to be fitted with new seal only, torque of nuts 20-25 Nm.

Fill the system and check for leaks.

Hand hole cover

Nuts

Installation instructions DHW cylinders TSW-120/CSW-120

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Unvented Controls

Maintenance

Check controls as per the following:

1) Line strainer - with the water supply turned off remove screen from strainer and clean of any detritus;

2) Expansion vessel - with the water supply turned off and taps open, check expansion vessel pressure and top up as necessary;

3) Temperature and pressure relief valve - with the water supply turned on; check manually by lifting the test lever/turning the test knob (ensure valve closes after testing);

4) Expansion relief valve - check manually by turning the test knob

(ensure valve closes after testing);

5) Discharge pipes - from both temperature and pressure relief and expansion relief valve for obstructions;

6) Tundish and discharge pipe - open either valve gradually to produce a full bore discharge into tundish without any back pressure;

7) Pressure reducing valve - check that the correct outlet pressure is being maintained by recording the pressure at an in-line terminal fitted i.e. tap.

18 Installation instructions DHW cylinders TSW-120/CSW-120

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Notice

Installation instructions DHW cylinders TSW-120/CSW-120

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19

Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.de

20 Installation instructions DHW cylinders TSW-120/CSW-120

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