Installation Manual

Pack Contents

• Unvented water heater incorporating immersion heater(s) & thermal controls

• Factory fitted temperature/pressure relief valve (set at 90°C / 1 Mpa (10bar))

• Cold water combination valve assembly

• Expansion vessel & mounting bracket

• Tundish

• 2 Port motorised valve (indirect models only)

• Compression nuts & olives

• Immersion heater spanner

• Installation & servicing instructions

• Guarantee card

IMPORTANT

Please read & understand all these instructions before commencing installation.

Please leave this manual with the customer for future reference.

1

Contents

Introduction ............................................................. 2

General Requirements ........................................... 3

Installation General................................................. 5

Installation Discharge ............................................. 7

Installation Direct ................................................... 11

Installation Indirect................................................. 12

Commissioning ...................................................... 14

Maintenance .......................................................... 15

User Instructions.................................................... 16

Fault Finding & Servicing....................................... 17

Spares ................................................................... 18

Heat Loss .............................................................. 19

Environmental Information..................................... 19

Commissioning Check List .................................... 20

Service Record ...................................................... 21

Guarantee.............................................................. 24

Technical Support .................................................. 24

Introduction

The cylinder is a purpose designed unvented water heater. The unit has a stainless steel inner vessel, which ensures an excellent standard of corrosion resistance. The outer casing is a combination of resilient thermoplastic mouldings and plastic coated corrosion proofed steel sheet. All products are insulated with CFC free polyurethane foam to give good heat loss performance. (see Table 06, page 19)

The unit is supplied complete with all the necessary safety and control devices needed to allow connection to the cold water mains. All these components are preset and not adjustable.

This appliance complies with the requirements of the

CE marking directive and is Kiwa approved to show compliance with Building Regulations (Section G3).

The following instructions are offered as a guide to installation which must be carried out by a competent plumbing and electrical installer in accordance with

Building Regulation G3, The Building Standards

(Scotland) Regulations 1990, or The Building

Regulations (Northern Ireland).

NOTE: Prior to installation the unit should be stored in an upright position in an area free from excessive damp or humidity.

THE BENCHMARK SCHEME

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations and relevant electrical qualifications. The Benchmark Checklist can be used to demonstrate compliance with Building

Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.

centralheating.co.uk for more information.

ORTAN

2

General Requirements

IMPORTANT:

This appliance can be used by children aged from 8 years and above and persons with reduced physical sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

Children must be supervised to ensure they do not play with the appliance.

Table 01: Unit weight s

Type

Model

Reference

Indirect 120 Ind

150 Ind

170 Ind

Direct

210 Ind

250 Ind

300 Ind

120 Dir

150 Dir

170 Dir

210 Dir

250 Dir

300 Dir

Nominal

Capacity

(litres)

Weight of unit full

(Kg)

120

150

170

210

250

300

120

150

170

210

250

300

147

184

203

251

300

360

145

178

199

246

295

355

Weight of unit

(Kg)

WARNING: Do not switch on if there is a possibility that the water in the heater is frozen.

Siting The Unit

The cylinder must be vertically floor mounted. Although location is not critical, the following points should be considered: and capable of permanently supporting the weight when full of water. (see Table 01, above)

Water Supply

Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously.

• The cylinder should be sited to ensure minimum dead leg distances, particularly to the point of most frequent use.

• Avoid siting where extreme cold temperatures will be experienced. All exposed pipe work should be insulated.

• The discharge pipework from the safety valves must have minimum fall of 1:200 from the unit and terminate in a safe and visible position.

• Access to associated controls and immersion heaters must be available for the servicing and maintenance of the system. Where these controls are installed against a wall a minimum distance of

250mm must be left (see Fig. 01, below).

• Ensure that the floor area for the cylinder is level

Fig. 01: Siting the Unit

WALL

It is recommended that the maximum water demand is assessed and the water supply checked to ensure this demand can be satisfactorily met.

Note: A high mains water pressure will not always guarantee high flow rates.

Wherever possible the mains supply pipe should be

22mm. We suggest the minimum supply requirements should be 0.15MPa (1.5 bar) pressure and 20 litres per minute flowrate. However, at these values outlet flow rates may be poor if several outlets are used simultaneously. The higher the available pressure and flow rate the better the system performance.

The cylinder has an operating pressure of 0.35MPa (3.5 bar) which is controlled by the cold water combination valve assembly. The cold water combination valve assembly can be connected to a maximum mains pressure of 1.6MPa (16 bar).

41

50

60

25

27

31

33

28

29

36

45

55

Min 250mm

Min 250mm

Outlet/Terminal Fittings (Taps, Etc.)

The cylinder can be used with most types of terminal fittings. It is advantageous in many mixer showers to have balanced hot and cold water supplies. In these instances a balanced cold water connection should be placed between the expansion vessel connection and the cold water combination valve assembly (see

Fig. 05, page 10). Outlets situated higher than the cylinder will give outlet pressures lower than that at the heater, a 10m height difference will result in a 1 bar pressure reduction at the outlet. All fittings, pipework and connections must have a rated pressure of at least

6 bar at 80°C.

3

Limitations

The cylinder should not be used in association with any of the following:

• Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic control, unless additional and appropriate safety measures are installed.

• Ascending spray type bidets or any other class 1 back syphonage risk requiring that a type A air gap be employed.

• Steam heating plants unless additional and appropriate safety devices are installed.

• Situations where maintenance is likely to be neglected or safety devices tampered with.

• Water supplies that have either inadequate pressure or where the supply may be intermittent.

• Situations where it is not possible to safely pipe away any discharge from the safety valves.

• In areas where the water consistently contains a high proportion of solids, e.g. suspended matter that could block the strainer, unless adequate filtration can be ensured.

• In areas where the water supply contains chloride levels that exceed 250mg/l.

Checklist

• Unvented cylinder

• Cold control pack

- Tundish

- Combination valve

- Expansion vessel

- Tool - Element spanner

- Compression nuts & olives

- 2 Port motorised valve

• Literature pack

- Installation manual

- Guarantee card

Operational Summary

Maximum mains pressure

Operating pressure/PRV

Maximum design pressure

1.6MPa (16 bar)

0.35MPa (3.5 bar)

0.6MPa (6 bar)

Expansion vessel charge pressure 0.35MPa (3.5 bar)

0.6MPa (6 bar)

90-95°C/1.0MPa (10 bar)

Expansion relief valve setting

T&P relief valve setting

Maximum primary circuit pressure 0.3MPa (3 bar)

(Indirect only)

Pressure drop (Primary coil)

Storage capacity

Weight when full

0.02MPa (0.2 bar) see Table 1 - page 3 see Table 1 - page 3

Indirect models in conformance with BS EN 12897:2006

Note: Although the primary coil pressure rating is 1.0Mpa (10 bar) the 2 port zone valve supplied with the cylinder is only rated 0.86MPa (8.6 bar). If the cylinder is to be plumbed into a system delivering 1.0MPa (10 bar) a suitable 2 port zone valve will have to be sourced.

4

Installation General

Pipe Fittings

All pipe fittings are made via 22mm compression fittings directly to the unit. The fittings are threaded 3/4”BSP male parallel, should threaded pipe connections be required.

Cold Feed

A 22mm cold water supply is recommended, however, if a 15mm (1/2”) supply exists, which provides sufficient flow, this may be used (although more flow noise may be experienced).

A stopcock or servicing valve should be incorporated into the cold water supply to enable the cylinder and its associated controls to be isolated and serviced.

Cold Water Combination Valve Assembly

The cold water combination valve can be connected anywhere on the cold water cylinder supply prior to the expansion vessel (see Fig. 05, page 10). The cold water combination valve is installed as a complete one-piece unit. The valve incorporates the pressure reducer, strainer, expansion valve and check valve.

Ensure that the valve is installed with the direction of flow arrows pointing in the correct direction. No other valves should be placed between the cold water combination valve and the cylinder.

Drain Tap

A suitable drain tap should be installed in the cold water supply to the cylinder between the expansion valve (see

Fig. 05, page 10) and the heater at as low a level as possible. It is recommended that the outlet point of the drain pipework be at least 1 metre below the level of the heater (this can be achieved by attaching a hose to the drain tap outlet spigot).

Figure 02: Cold Water Combination Valve Assembly

Expansion valve

Cold mains connection

(22mm)

Expansion valve outlet (15mm)

Outlet connection

(22mm)

Expansion Vessel

The expansion vessel accommodates expansion that results from heating the water inside the unit. The expansion vessel is pre-charged at 0.35MPa (3.5 bar).

The expansion vessel must be connected between the expansion valve and the cylinder (see Fig. 05, page 10).

The location of the expansion vessel should allow access to recharge the pressure as and when necessary, this can be done using a normal car foot pump. It is recommended that the expansion vessel is adequately supported. An expansion vessel wall mounting bracket is supplied for this purpose and should be fitted.

Secondary Circulation

If secondary circulation is required it is recommended that it be connected to the cylinder as shown (see Fig.

06, page 10) v ia a swept tee joint into the cold feed to the unit. A swept tee joint is available as an accessory

(order code no. 5133565).

The secondary return pipe should be in 15mm pipe and incorporate a check valve to prevent backflow. A suitable WRAS approved bronze circulation pump will be required. On large systems, due to the increase in system water content, it may be necessary to fit an additional expansion vessel to the secondary circuit.

This should be done if the capacity of the secondary circuit exceeds 10 litres.

Pipe capacity (copper):

15mm O.D. = 0.13 l/m (10 litres = 77m)

22mm O.D. = 0.38 l/m (10 litres = 26m)

28mm O.D. = 0.55 l/m (10 litres = 18m)

NOTE: In direct electric installations where a secondary circulation is required particular attention should be paid by the installer to maintain the returning water temperature (guidelines state that a minimum of 55°C return temperature is advisable). Factors such as, but not limited to, secondary circulation flow rates, minimising heat loss of all secondary circuit pipework and timed operation during periods of high demand are critical to the correct operation and longevity of the heating element(s) and thermostats.

Secondary circulation is not recommended for direct electric units using off-peak tariffs where the secondary circulation is not controlled in conjunction with the heat source as performance can be affected.

Outlet

The hot water outlet is a 22mm compression fitting located at the top of the cylinder. Hot water distribution pipework should be 22mm pipe with short runs of

15mm pipe to terminal fittings such as sinks and basins.

Pipe sizes may vary due to system design.

Pressure reducing valve cartridge

(3.5bar)

5

Fig. 03: General Dimensions

Ø

550

45°

25°

30°

45°

Hot Outlet

T&P Valve

Primary Flow

Primary Return

Cold Inlet

Table 02: Dimensions and Performance

Type Model

Reference

Dimensions (mm)

A B

Primary Flow

(ltrs/min @80°C

±2°C)

Indirect 120 Ind

150 Ind

170 Ind

210 Ind

250 Ind

300 Ind

931

1114

1241

1499

1752

2065

616

800

927

1184

1379

1694

15

15

15

15

15

15

Coil Rating

(kW)

Heat-up Time

(mins)

12.5

12.5

15

15

18

18

29

37

35

43

43

49

Hot Water

Capacity

(ltrs)

(volume of water drawn off >40°C)

108

135

157

199

240

273

Direct 120 Dir

150 Dir

170 Dir

210 Dir

250 Dir

300 Dir

931

1114

1241

1499

1752

2065

616

800

927

1184

1437

1751

121

152

173

215

260

315

Notes:

1. Indirect cylinders tested in conformance with BS EN 12897:2006

2. Heat up time from cold through 45°C, with a primary flow rate 15ltrs/min at 80°C +/- 2°C.

3. Direct heating times assume use of lower element only, from cold, through 45°C.

6

108

135

157

199

240

273

Installation Discharge

Discharge Pipework

It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed to where it is visible, but will not cause danger to persons in or about the building. The tundish and discharge pipes should be fitted in accordance with the requirements and guidance notes of Building Regulation G3. The G3

Requirements and Guidance section 3.50 - 3.63 are reproduced in the following sections of this manual.

For discharge pipe arrangements not covered by G3 guidance advice should be sought from your local

Building Control Officer. Any discharge pipe connected to the pressure relief devices (expansion valve and temperature/pressure relief valve) must be installed in a continuously downward direction and in a frost free environment.

Water may drip from the discharge pipe of the pressure relief device. This pipe must be left open to the atmosphere. The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked.

G3 REQUIREMENT

“...there shall be precautions...to ensure that the hot water discharged from safety devices is safely conveyed to where it is visible but will not cause danger to persons in or about the building.”

The following extract is taken from the latest G3

Regulations

Discharge pipes from safety devices

Discharge pipe D1

3.50 Each of the temperature relief valves or combined temperature and pressure relief valves specified in 3.13 or 3.17 should discharge either directly or by way of a manifold via a short length of metal pipe (D1) to a tundish.

3.51 The diameter of discharge pipe (D1) should be not less than the nominal outlet size of the temperature relief valve.

3.52 Where a manifold is used it should be sized to accept and discharge the total discharge form the discharge pipes connected to it.

3.53 Where valves other than the temperature and pressure relief valve from a single unvented hot water system discharge by way of the same manifold that is used by the safety devices, the manifold should be factory fitted as part of the hot water storage system unit or package.

Tundish

3.54 The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible to, and lower than, the valve, with no more than 600mm of pipe between the valve outlet and the tundish (see Fig 04 page 9).

Note: To comply with the Water Supply (Water Fittings)

Regulations, the tundish should incorporate a suitable air gap.

3.55 Any discharge should be visible at the tundish. In addition, where discharges from safety devices may not be apparent, e.g. in dwellings occupied by people with impaired vision or mobility, consideration should be given to the installation of a suitable safety device to warn when discharge takes place, e.g. electronically operated.

Discharge pipe D2

3.56 The discharge pipe (D2) from the tundish should:

(a) have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework (see Fig. 04 page 9); and

(b) be installed with a continuous fall thereafter of at least 1 in 200.

3.57 The discharge pipe (D2) should be made of:

(a) metal; or

(b) other material that has been demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly and permanently marked to identify the product and performance standard (e.g. as specified in the relevant part of BS

7291).

3.58 The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e. for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device; between 18 and 27m at least 3 sizes larger, and so on; bends must be taken into account in calculating the flow resistance. (See, Table 03 page 9), and the worked example.

Note: An alternative approach for sizing discharge pipes would be to follow Annex D, section D.2 of

BS 6700:2006 Specification for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

3.59 Where a single common discharge pipe serves more than one system, it should be at least one pipe size larger than the largest individual discharge pipe

(D2) to be connected.

7

8

3.60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated that the soil discharge stack is capable of safely withstanding temperatures of the water discharged, in which case, it should:

Worked Example of Discharge Pipe Sizing

Fig. 04: shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of

7m from the tundish to the point of discharge.

(a) contain a mechanical seal, not incorporating a water trap, which allows water into the branch pipe without allowing foul air from the drain to be ventilated through the tundish;

(b) be a separate branch pipe with no sanitary appliances connected to it;

(c) if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either polybutalene (PB) to Class S of BS 7291-2:2006 or cross linked polyethylene (PE-X) to Class S of BS

7291-3:2006; and

(d) be continuously marked with a warning that no sanitary appliances should be connected to the pipe.

From Table 03:

Maximum resistance allowed for a straight length of

22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m.

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

Therefore the permitted length equates to: 5.8m

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

Maximum resistance allowed for a straight length of

28mm pipe (D2) from a G1/2 temperature relief valves equates to 18m.

Note:

1. Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043-1.

2. Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to the discharge stack.

Subtract the resistance of 4 No. 28mm elbows at 1.0m each = 4.0m

Therefore the maximum permitted length equates to:

14m

Termination of discharge pipe

3.61 The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge.

3.62 Examples of acceptable discharge arrangements are:

(a) to a trapped gully with the end of the pipe below a fixed grating and above the water seal;

(b) downward discharges at low level; i.e. up to

100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility; and

(c) discharges at high level: e.g. into a metal hopper and metal downpipe with the end of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges.

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

Warnings:

• Under no circumstances should the factory fitted temperature/pressure relief valve be removed other than by a competent person. To do so will invalidate any guarantee or claim.

• The cold water combination valve assembly must be fitted on the mains water supply to the cylinder.

• No control or safety valves should be tampered with or used for any other purpose.

• The discharge pipe should not be blocked or used for any other purpose.

• The tundish should not be located adjacent to any electrical components.

3.63 The discharge would consist of high temperature water and steam. Asphalt, roofing felt and nonmetallic rainwater goods may be damaged by such discharges.

Table 03: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes

NOTE: The table below is based on copper tube. Plastic pipes may be of different bore and resistance. Sizes and maximum lengths of plastic should be calculated using data prepared for the type of pipe being used.

VALVE

OUTLET

SIZE

G 1/2

G 3/4

G1

MINIMUM

SIZE OF

DISCHARGE

PIPE D1

15mm

22mm

28mm

MINIMUM SIZE OF

DISCHARGE PIPR

D2 FROM TUNDISH

22mm

28mm

35mm

28mm

35mm

42mm

35mm

42mm

54mm

MAXIMUM RESISTANCE

ALLOWED,

EXPRESSED AS A

LENGTH OF STRAIGHT

PIPE

(I.E. NO ELBOWS

OR BENDS)

UP TO 9M

UP TO 18M

UP TO 27M

UP TO 9M

UP TO 18M

UP TO 27M

UP TO 9M

UP TO 18M

UP TO 27M

RESISTANCE

CREATED BY

EACH ELBOW

OR BEND

0.8M

1.0M

1.4M

1.0M

1.4M

1.7M

1.4M

1.7M

2.3M

Figure 04: Typical Discharge Pipe Arrangment (Extract From Building Regulation G3 Guidance Section 5.50)

Safety device

(e.g. Temperature relief valve)

Metal discharge pipe (D1) from

Temperature relief valve to tundish

Tundish

600mm maximum

300mm minimum

Discharge below fixed grating

(Building Regulation

G3 section 3.61 gives alternative points of discharge)

Fixed grating

Discharge pipe (D2) from tundish, with continuous fall. See Building

Regulation G3 section 3.56,

Table 1 and worked example

Trapped gully

9

Figure 05: Typical Installation - Schematic

To hot outlets T&P relief valve

Expansion vessel

Balanced cold water connection

(if required)

Cold water combination valve

Isolating valve

(not supplied)

Blank housing

(250 & 300 Indirect models only)

Mains water supply

Element/ controls housing

Primary return

Primary flow

Secondary return

(if required) use swept tee

Inlet

Drain cock

(not supplied)

Tundish

Discharge pipe

Figure 06: Secondary Circulation Connection

Cold Supply

Check Valve

Swept Tee

Secondary

Circulation

Pump

Secondary

Return

Cold Inlet

Connection

10

Installation - Direct

Safety

DISCONNECT FROM THE MAINS ELECTRICAL

SUPPLY BEFORE REMOVING ANY COVERS.

Never attempt to replace the immersion heater(s) other than with the recommended immersion heater(s).

DO NOT BYPASS THE THERMAL CUT-OUT(S) IN

ANY CIRCUMSTANCES. Ensure the terminal shroud is fitted. Ensure the two male spade terminations are pushed firmly into the corresponding terminations on the element assembly.

In case of difficulty contact service support; contact details available at the back of this booklet.

Electrical Supply

All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E Wiring Regulations.

Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact separation of at least 3mm in both poles.

The immersion heater(s) should be wired in accordance with Fig 07, opposite. The immersion heaters MUST be earthed. The supply cable should be 1.5mm

2

3 core

HOFR sheathed and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip.

DO NOT operate the immersion heaters until the cylinder has been filled with water.

Ensure the thermostat and thermal cut-out sensing bulbs are pushed fully into the pockets on the element plate assembly.

Plumbing Connections

Direct cylinders require the following pipework connections.

• Cold water supply to and from inlet controls.

• Outlet to hot water draw off points.

• Discharge pipework from valve outlets to tundish.

Figure 07: Electrical Connections (Direct Schematic)

1.5mm2 3 Core

HOFR sheathed cable

N L

11

Installation - Indirect

Safety

DISCONNECT FROM THE MAINS ELECTRICAL

SUPPLY BEFORE REMOVING ANY COVERS.

Never attempt to replace the immersion heater other than with the recommended authorised immersion heater.

Boiler Selection

The boiler should have a control thermostat and non self-resetting thermal cut-out and be compatible with unvented storage water heaters. Where use of a boiler without a thermal cut-out is unavoidable a “low head” open vented primary circuit should be used. The feed and expansion cistern head above the cylinder should not exceed 2.5m.

DO NOT BYPASS THE THERMAL CUT-OUT(S)

IN ANY CIRCUMSTANCES. Ensure the two male spade terminations on the underside of the combined thermostat and thermal cut-out are pushed firmly onto the corresponding terminations on the element plate assembly.

Primary Circuit Control

The 2 port motorised valve supplied with the cylinder

MUST be fitted on the primary flow to the cylinder heat exchanger (coil) and wired in series with the indirect control thermostat and thermal cut-out fitted to the unit. Primary circulation to the cylinder heat exchanger

(coil) must be pumped; gravity circulation WILL NOT

WORK.

In case of difficulty contact service support; contact details available at the back of this booklet.

Electrical Supply

All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E Wiring Regulations.

Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact separation of at least 3mm in both poles.

The immersion heater should be wired in accordance with Fig 08, opposite. The immersion heater MUST be earthed. The supply cable should be 1.5mm

2

3 core

HOFR sheathed and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip.

Space and Heating Systems Controls

The controls provided with the cylinder will ensure the safe operation of the unit within the central heating system. Other controls (eg. room thermostat and timer) will be necessary to control the space heating requirements and times that the system is required to function, (see Fig. 08 below). The cylinder is compatible with most heating controls, examples of electrical circuits are shown in Figs. 09 and 10 (Page

13). However, other systems may be suitable, refer to the controls manufacturers’ instructions, supplied with the controls selected, for alternative system wiring schemes.

Figure 08: Electrical Connections (indirect schematic)

DO NOT operate the immersion heaters until the cylinder has been filled with water.

Ensure the thermostat and thermal cut-out sensing bulbs are pushed fully into the pockets on the element plate assembly.

Plumbing Connections

Indirect cylinders require the following pipework connections.

• Cold water supply to and from inlet controls.

• Outlet to hot water draw off points.

• Discharge pipework from valve outlets to tundish.

• Connection to the primary circuit.

All connections are 22mm compression. However,

3/4”BSP parallel threaded fittings can be fitted to the primary coil connections if required.

Element Connections

Indirect control wiring

1 2 3 L N

1.5mm² 3 Core

HOFR sheathed cable

12

Fig. 09: Schematic Wiring Diagram - Basic 2 x 2 port valve system ( ‘S’ plan )

Cylinder terminal block

1 2 3

3

Zone valve (HTG)

G Br Bl 0

GY

1 2 3

Room stat

1 3 2

2

Zone valve (DHW)

(supplied)

G Br Bl 0

1 2

L

(Supply)

N

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

Junction box

1 2 3 2 3

L N

HTG

ON

Programmer

DHW

ON

L N

Boiler

NOTES: Control terminal numbering may differ from those shown.

Refer to instructions with controls selected.

A double pole isolating switch must be installed in the mains supply.

All earth connections must be connected back to the mains earth supply.

2

L

N

3

Pump

Fig. 10: Schematic Wiring Diagram - 3 port mid position valve system. ( ‘Y’ plan ) N.B. Must be used in conjunction with 2 port zone valve supplied

3 Port Zone valve

G W Bl 0

GY

2 3

Cylinder terminal block

1 2 3

3

Zone valve (DHW)

(supplied)

G Br Bl 0

1 2

L

(Supply)

N

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

Junction box

1

L

2 3

N

HTG

ON

DHW

ON

Programmer

DHW

OFF

2

1 3 2

Room stat

2 3

L N

Boiler

NOTES: Control terminal numbering may differ from those shown.

Refer to instructions with controls selected.

A double pole isolating switch must be installed in the mains supply.

All earth connections must be connected back to the mains earth supply.

2

L

N

3

Pump

13

Commissioning

Filling The Unit With Water

Ensure that all fittings and immersion heaters are correctly fitted and tightened. An immersion heater key is provided to aid tightening the immersion heater(s)

• Check expansion vessel pre-charge pressure The vessel is supplied precharged to 0.35MPa (3.5 bar) to match the control pressure of the pressure reducing valve. The precharge pressure is checked using a car tyre gauge by unscrewing the plastic cap opposite the water connection.

• Check all connections for tightness including the immersion heater(s). An immersion heater key spanner is supplied for this purpose.

• Ensure the drain cock is CLOSED.

• Open a hot tap furthest from the cylinder.

• Open the mains stop cock to fill the unit. When water flows from the tap, allow to run for a few minutes to thoroughly flush through any residue, dirt or swarf, then close the tap.

• Open successive hot taps to purge the system of air.

System Checks

• Check all water connections for leaks and rectify as necessary.

• Turn off mains water supply.

• Remove the pressure reducing valve head work to access the strainer mesh, clean and re-fit.

• Turn mains water supply on.

• Manually open, for a few seconds, each relief valve in turn, checking that water is discharged and runs freely through the tundish and out at the discharge point.

• Ensure that the valve(s) reseat satisfactorily.

Direct Units

Switch on electrical supply to the immersion heater(s) and allow the cylinder to heat up to normal working temperature (60°C recommended). If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob on front of the immersion heater thermostat and rotating. The adjustment represents a temperature range of 10°C to 72°C. Check the operation of thermostat(s) and that no water has issued from the expansion relief valve or temperature/pressure relief valve during the heating cycle.

Indirect Units

Fill the indirect (primary) circuit following the boiler manufacturer’s commissioning instructions. To ensure the cylinder primary heat exchanger is filled, the 2 port motorised valve (supplied) should be manually opened by moving the lever on the motor housing to the MANUAL setting. When the primary circuit is full return the lever to the AUTOMATIC position.

Switch on the boiler, ensure the programmer is set to

Domestic Hot Water and allow the cylinder to heat up to a normal working temperature 60 o

C (recommended),.

If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob and rotating. The minimum thermostat setting is

10°C. Adjustment represents a temperature range of

10°C to 72°C. Fig. 11, below.

Check the operation of the indirect thermostat, and 2 port motorised valve, and that no water has emitted from the expansion relief valve or temperature/pressure relief valve during the heating cycle.

Benchmark Log Book

On completion of the installation and commissioning procedures detailed in this manual the Benchmark

Installation, Commissioning and Service Record Log, pages 20 and 21 should be completed and signed off by the competent installer or commissioning engineer in the relevant sections. The various system features, location of system controls, user instructions and what to do in the event of a system failure should be explained to the customer. The customer should then countersign the Benchmark

TM

Commissioning Checklist (page 20) to accept completion. The service record should be filled in when any subsequent service or maintenance operation is carried out on the product.

Fig. 11: Temperature Adjustment Details

THERMAL CUT-OUT RESET BUTTON

TEMPERATURE ADJUSTING

SPINDLE

SPINDLE POSITIONS

= MINIMUM TEMP 10ºC

= MAXIMUM TEMP 72ºC

= APPROX 60 °C

ROTATE SPINDLE CLOCKWISE

FOR TEMPERATURE INCREASE

AND COUNTER CLOCKWISE

FOR TEMPERATURE DECREASE

14

Maintenance

Maintenance Requirements

Unvented hot water systems have a continuing maintenance requirement in order to ensure safe working and optimum performance. It is essential that the relief valve(s) are periodically inspected and manually opened to ensure no blockage has occurred in the valves or discharge pipework.

Similarly cleaning of the strainer element and replacement of the air in the expansion vessel will help to prevent possible operational faults.

The maintenance checks described below should be performed by a competent person on a regular basis, e.g. annually to coincide with boiler maintenance.

After any maintenance, please complete the relevant

Service Interval Record section of the Benchmark

Checklist on page 20 of this document.

Inspection

The immersion heater boss can be used as an access for inspecting the cylinder internally.

Safety Valve Operation

Manually operate the temperature/pressure relief valve for a few seconds. Check water is discharged and that it flows freely through the tundish and discharge pipework. Check valve reseats correctly when released.

NOTE: Water discharged may be very hot!

Repeat the above procedure for the expansion relief valve.

Strainer

Turn off the cold water supply, boiler and immersion heaters. The lowest hot water tap should then be opened to de-pressurise the system. Remove the pressure reducing cartridge to access the strainer mesh. Wash any particulate matter from the strainer under clean water. Re-assemble ensuring the seal is correctly fitted. DO NOT use any other type of sealant.

Descaling Immersion Heater

Before removing the immersion heater the unit must be drained.

Before draining ensure the water, electrical

supply and boiler are OFF. Attach a hosepipe to the drain cock having sufficient length to take water to a suitable discharge point below the level of the unit.

Open a hot tap close to the unit and open drain cock to drain unit.

Remove the cover to the immersion heater housing and disconnect wiring from immersion heater.

Carefully remove the thermostat capillaries. Note. the order of the capillaries within the pocket. Remove the terminal shroud.

If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob on front of the immersion heater thermostat and rotating. The adjustment represents a temperature range of 10°C to 72°C. Check the operation of thermostat(s) and that no water has issued from the expansion relief valve or temperature/pressure relief valve during the heating cycle.

Indirect Units

Switch OFF electrical supply to the immersion heater before removing the cover. Open the cover to the immersion heater housing and disconnect wiring from immersion heater. Carefully remove the thermostat capillaries. Remove the terminal shroud. Unscrew immersion heater backnut and remove immersion heater from the unit. A key spanner is supplied with the cylinder unit for easy removal/tightening of the immersion heater. Over time the immersion heater gasket may become stuck to the mating surface. To break the seal insert a round bladed screwdriver into one of the pockets on the immersion heater and gently lever up and down.

Carefully remove any scale from the surface of the element. DO NOT use a sharp implement as damage to the element surface could be caused. Ensure sealing surfaces are clean and seals are undamaged, if in doubt fit a new gasket (part number 95 611 822).

Replace immersion heater ensuring the (right angled) element hangs vertically downwards towards the base of the unit. It may be helpful to support the immersion heater using a round bladed screwdriver inserted into one of the thermostat pockets whilst the backnut is tightened. Replace the terminal shroud. Replace thermostat capillaries into pockets. Connect wiring to element. Check, and close and secure immersion heater housing cover.

Expansion Vessel Charge Pressure

While system is de-pressurised check expansion vessel charge pressure. Remove the dust cap on top of the vessel. Check the charge pressure using a tyre pressur e gauge. The pressure (with system depressurised) should be 0.35MPa (3.5 bar). If it is lower than the required setting it should be re-charged using a tyre pump (Schrader valve type). DO NOT OVER-

CHARGE. Re-check the pressure and when correct replace the dust cap.

Re-Commissioning

Check all electrical and plumbing connections are secure. Close the drain cock.

DO NOT switch on the immersion heater(s) or boiler while the unit

is empty. With a hot tap open, turn on the cold water supply and allow unit to refill. When water flows from the hot tap allow to flow for a short while to purge air and flush through any disturbed particles. Close hot tap and then open successive hot taps in system to purge any air. When completely full and purged check system for leaks. Replace and secure immersion heater housing cover. The heating source (immersion heater or boiler) can then be switched on.

15

Warnings

User Instructions

I F W AT E R D I S C H A R G E S F R O M T H E

TEMPERATURE/PRESSURE RELIEF VALVE ON

CYLINDER SHUT DOWN THE BOILER. DO NOT

TURN OFF ANY WATER SUPPLY. CONTACT

A COMPETENT INSTALLER FOR UNVENTED

WATER HEATERS TO CHECK THE SYSTEM.

DO NOT TAMPER WITH ANY OF THE SAFETY

VALVES FITTED TO THE SYSTEM. IF A FAULT IS

SUSPECTED CONTACT A COMPETENT INSTALLER.

Temperature Controls – Direct Units Immersion

Heater(S)

A combined adjustable thermostat and thermal cut-out is provided for each immersion heater. The thermostat is factory set to give a water storage temperature of approx. 55°C to 60°C. Access to the thermostat can be made by opening the immersion heater cover -

DISCONNECT THE ELECTRICAL SUPPLY BEFORE

OPENING THE COVER(S). Temperature adjustment is made by inserting a flat bladed screwdriver in the slot on the adjustment disc on top of the thermostat and rotating. The adjustment represents a temperature range of 10°C to 72°C (60°C recommended) (Fig.

11, page 14). If in any doubt contact a competent electrician.

Benchmark

The cylinder is covered by the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety, efficiency and performance.

Benchmark is managed and promoted by the Heating and Hotwater Industry Council. For more information visit www.centralheating.co.uk.

Please ensure that the installer has fully completed the

Benchmark Checklist (pages 20 & 21) of this manual and that you have signed it to say that you have received a full and clear explanation of its operation. The installer is legally required to complete a commissioning checklist as a means of complying with the appropriate

Building Regulations (England & Wales).

DO NOT bypass the thermal cut-out(s) in any circumstances.

Temperature Controls - Indirect Units

The cylinder units are fitted with an indirect thermostat and thermal cut-out. These controls must be wired in series with the 2 port motorised zone valve supplied to interrupt the flow of primary water around the heat exchanger coil when the control temperature has been reached. The controls are located within the lower terminal housing along with the immersion heater thermostat. The thermostat is factory set to give a water storage temperature of approx. 55°C to 60°C. Access to the thermostat can be made by opening the terminal housing cover - DISCONNECT

THE ELECTRICAL SUPPLY BEFORE OPENING THE

COVER. Temperature adjustment is made by inserting a flat bladed screwdriver in the adjustment knob and rotating. The minimum thermostat setting is 10°C. The adjustment represents a temperature range of 10°C to 72°C (Fig. 11, page 14) . If in any doubt contact a competent electrician.

All installations must be notified to Local Area

Building Control either directly or through a

Competent Persons Scheme. A Building Regulations

Compliance Certificate will then be issued to the customer who should, on receipt, write the

Notification Number on the Benchmark Checklist.

This product should be serviced regularly to optimise its safety, efficiency and performance. The service engineer should complete the relevant Service Record on the Benchmark Checklist after each service.

An immersion heater is also provided for use should the indirect heat source be shut down for any purpose.

The immersion heater control temperature is set using the immersion heater thermostat.

The Benchmark Checklist may be required in the event of any warranty work.

Flow Performance

When initially opening hot outlets a small surge in flow may be noticed as pressures stabilise. This is quite normal with unvented systems. In some areas cloudiness may be noticed in the hot water. This is due to aeration of the water, is quite normal and will quickly clear.

DO NOT bypass the thermal cut-out(s) in any circumstances.

Operational Faults

Operational faults and their possible causes are detailed in the Fault Finding section of this book. It is recommended that faults should be checked by a competent installer.

The air volume within the expansion vessel will periodically require recharging to ensure expanded water is accommodated within the unit. A discharge of water

INTERMITTENTLY from the expansion valve will indicate the air volume has reduced to a point where it can no longer accommodate the expansion.

16

Fault Finding & Servicing

Important

• After servicing, complete the relevant Service

Interval Record section of the Benchmark Checklist located on pages 20 and 21 of this document.

• Servicing should only be carried out by competent persons in the installation and maintenance of unvented water heating systems.

• Any spare parts used MUST be authorised parts.

• Disconnect the electrical supply before removing any electrical equipment covers.

• NEVER bypass any thermal controls or operate system without the necessary safety valves.

• Water contained in the cylinder may be very hot, especially following a thermal control failure. Caution must be taken when drawing water from the unit.

Spare Parts

A full range of spare parts are available for the cylinder range (Table 05, page 18). Refer to the technical data label on the unit to identify the model installed and ensure the correct part is ordered. You will need to quote the serial number, which is printed on the data label.

Fault Finding

The fault finding chart (Table 04, below) will enable operational faults to be identified and their possible causes rectified. Any work carried out on the unvented water heater and its associated controls MUST be carried out by a competent installer for unvented water heating systems. In case of doubt contact service support (see contact details on back page).

Warning

Water discharges from expansion valve

Water discharges from T&P relief valve

DO NOT TAMPER WITH ANY OF THE SAFETY

VALVES OR CONTROLS SUPPLIED WITH THE

CYLINDER AS THIS WILL INVALIDATE ANY

GUARANTEE.

Table 04: Fault Finding Chart

Water from hot tap is cold

Fault

No hot water flow

Milky water

Possible Cause Remedy

Mains supply off

Strainer blocked

Indirect programmer set to central heating only

Indirect boiler not working

Check and open stop cock

Turn off water supply. Remove strainer and clean

Check and refit as required Cold water combination valve incorrectly fitted

Direct immersion heater not switched on Check and switch on

Direct immersion heater thermal cut-out has operated

Check, reset by pushing button on thermostat

Check, set to domestic hot water programme

Indirect thermal cut-out has operated

Check boiler operation. If fault is suspected consult boiler manufacturer’s instructions

Check, reset by pushing button on thermostat

Check operation of indirect thermostat

Indirect motorised valve not connected correctly

INTERMITTENTLY

Expansion vessel charge pressure has reduced below 3.5 bar, or set to high

CONTINUALLY

Cold water combination valve pressure reducer not working correctly.

Expansion valve seat damaged

Thermal control failure

NOTE: water will be very hot

Oxygenated water

Check wiring and/or plumbing connections to motorised valve

See maintenance section for re-charging of expansion vessel procedure

Check pressure from cold water combination valve. If greater than 3.5 bar replace pressure reducing valve

Remove expansion valve cartridge, check condition of seat. If necessary fit new expansion valve

Switch off power to immersion heater(s) and shut down boiler

DO NOT turn off water supply. When discharge stops check all thermal controls, replace if faulty

Water from a pressurised system releases oxygen bubbles when flowing. The milkiness will disappear after a short while

17

Spares

Table 05: Spares

Item

Number

Description

1

2

Immersion heater ( lower )

Immersion heater (upper)

3

4

5

6

7

Immersion heater gasket

Immersion heater backnut

Immersion heater key spanner

Tundish

8

9

10

Cold water combination valve complete

Temperature/pressure relief valve

Expansion vessel - 12 litre

(120 & 150 litre models)

Expansion vessel - 18 litre

(170 & 210 litre models)

11

12

13

14

15

16

17

18

19

20

21

22

Part Number

95 606 984

95 606 986

95 611 822

95 607 869

95 607 861

95 605 838

95 605 897

95 605 810

95 607 863

95 607 864

Expansion vessel - 24 litre

(250 & 300 litre models)

Nut & olive pack (4 of each) 95 607 838

Terminal cover 95 614 305

Accessory kit (direct and without expansion vessel)

Blanking plate assembly

95 607 612

95 607 969

95 605 881

95 612 717 Direct combined thermostat and thermal cut-out

Indirect combined thermostat and thermal cut-out

95 612 716

Motorised valve 2 port

6 way terminal block

3 way terminal block

Accessory kit (indirect and without expansion vessel)

Terminal shroud

95 605 049

95 607 933

95 607 932

95 607 968

95 606 993

Fig. 12: Indirect Cylinder Spares

18

4

16

20 19 23

11

3 1

26 4

16

Fig. 13: Direct Cylinder Spares

19 24

11

16

3

2

26 4

19

24

4

3

1 26

16

18

Heat Loss

Table 06: Standing heat losses (ba sed on an ambient air temperature of 20°C and a stored water temperature of 65°C)

Nominal

Capacity

(Litres)

Standing Heat Loss

120

150

170

210

250

300 per day

(kWh/24h)

1.25

1.45

1.63

1.91

2.22

2.52

per year

(kWh/365d)

456

529

595

697

810

920

Environmental

Products are manufactured from many recyclable materials. At the end of their useful life they should be disposed of at a Local Authority Recycling Centre in order to realise the full environmental benefits.

Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone depletion factor of zero.

Direct

Supplier’s name or trade mark

Supplier’s model identifier

Storage volume V in litres

Mixed water at 40 °C V40 in litres

The declared load profile

The water heating energy efficiency class of the model

The water heating energy efficiency in %

The annual electricity consumption in kWh

Daily fuel consumption Q fuel in kWh

The thermostat temperature settings of the water heater, as placed on the market by the supplier

Specific precautions that shall be taken when the water heater is assembled, installed or maintained and disposed of at end of life

Indirect

Model(s)

Energy efficiency class

Standing loss in W

Storage volume V in litres

120

120.0

180

M

C

36.0

1424

6.680

120L

B

52.0

120.0

Main

150

150.0

234

L

170

170.0

265

L

210

210.0

332

XL

250

250.0

395

XL

300

300.0

464

XL

C

37.3

C

37.1

C

38.1

D

36.9

D

36.6

2741 2759 4395 4538 4573

12.730

12.840

20.300

20.790

21.350

60°C

See page 5 to 19

150L

C

60.0

150.0

170L

C

68.0

170.0

210L

C

80.0

210.0

250L

D

93.0

250.0

300L

D

105.0

300.0

Table: Technical parameters in accordance with European Commission regulations 814/2013 and 812/2013

19

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer name:

Address:

Cylinder Make and Model

Cylinder Serial Number

Commissioned by (PRINT NAME):

Company name:

Company address:

Telephone number:

Registered Operative ID Number

Telephone number:

Commissioning date:

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system?

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system?

Is the installation in a hard water area (above 200ppm)?

What is the hot water thermostat set temperature?

Sealed

Yes

Yes

Yes

Type of control system (if applicable)

Is the cylinder solar (or other renewable) compatible?

What is the hot water temperature at the nearest outlet?

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed

UNVENTED SYSTEMS ONLY

Y Plan S Plan

Yes

What is the pressure reducing valve setting?

Yes

The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations

Has the expansion vessel or internal air space been checked?

THERMAL STORES ONLY

What store temperature is achievable?

What is the maximum hot water temperature?

ALL INSTALLATIONS

The hot water system complies with the appropriate Building Regulations

The system has been installed and commissioned in accordance with the manufacturer’s instructions

The system controls have been demonstrated to and understood by the customer

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Commissioning Engineer’s Signature

Customer’s Signature

Yes

Yes

Open

°C bar

No

No

No

°C

I/min

Yes

Other

No

°C

Yes bar

No

Yes

No

No

°C

°C

Yes

Yes

Yes

Yes

*

© Heating and Hotwater Industry Council (HHIC)

20

www.centralheating.co.uk

SERVICE RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE 01

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

SERVICE 02

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Signature

SERVICE 03

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Signature

SERVICE 05

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Signature

SERVICE 04

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Signature

SERVICE 06

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Date:

Signature

SERVICE 07

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Signature

SERVICE 09

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Signature

Date:

Signature

SERVICE 08

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Date:

Signature

SERVICE 10

Engineer name:

Company name:

Telephone No:

Email Address:

Comments:

Signature

Date:

21

22

Notes

Notes

23

Guarantee

On site service support including parts and labour for 12 months from date of installation.

After the initial 12 months, a guarantee will apply for a further 24 years for the stainless steel inner vessel only. During this 24 year period, in the event of a cylinder leak, a replacement product will be issued provided that the replacement is carried out by one of our heateam engineers, for which reasonable labour charges will apply.

The guarantee is valid provided that:

• It has been correctly installed as per the instructions contained in the instruction manual and all relevant Codes of Practice and Regulations in force at the time of installation.

• The Benchmark Checklist has been completed upon commissioning and the

Benchmark Service Record is completed for each service.

• It has not been modified in any way other than by MAIN.

• It has not been frost damaged.

• It has only been used for the storage of potable water.

• It has not been tampered with or been subjected to misuse or neglect.

• The fault is not scale related.

• Within 60 days of installation the user completes and returns the certificate supplied along with the proof of purchase to register the product.

• It has been installed in the United Kingdom.

• The fault is not caused by high chloride levels in the water supply or incorrect disinfection methods.

Evidence of purchase and date of supply may be required. The guarantee is transferable. This guarantee does not affect your statutory rights.

Technical Support & Spares

For all technical support and replacement parts issues please contact:

MAIN

Brooks House,

Coventry Road,

Warwick,

CV34 4LL

Tel: 0344 871 1532

The policy of MAIN is one of continuous product development and, as such, we reserve the right to change specifications and guarantee terms and conditions without notice.

36005994_issue_09