Installation manual

Installation manual
MEGAFLO Eco SystemFit
Unvented Indirect
Hot Water Cylinders
MEGAFLO Eco SystemFit Product Guide
Contents
1. Introduction................................................................................................. 3
1.1 General..................................................................................................... 3
1.2 Symbols used............................................................................................. 3
1.3 Abbreviations............................................................................................ 3
1.4 Liabilities.................................................................................................... 3
2. Safety............................................................................................................ 4
2.1 General safety warnings............................................................................ 4
2.2 Recommendations..................................................................................... 4
2.3 Specific safety instructions......................................................................... 4
3. Technical specifications............................................................................... 5
3.1 Technical data............................................................................................ 5
3.2 Dimensions................................................................................................ 6
3.3 circulating pump set-up.............................................................................7
3.4 Electrical diagram(s)................................................................................... 9
4. Description of the product........................................................................ 11
4.1 General description.................................................................................. 11
4.2 Operation principle.................................................................................. 11
4.3 Main components.................................................................................... 11
4.4 Standard delivery..................................................................................... 11
5. Before installation..................................................................................... 11
5.1 Installation regulations............................................................................. 11
5.2 Installation requirements.......................................................................... 11
5.3 Choice of location................................................................................... 12
6. Installation................................................................................................. 13
6.1 General................................................................................................... 13
6.2 Water connections................................................................................... 14
6.3 Electrical connections............................................................................... 22
6.4 Filling the installation............................................................................... 22
7. Commissioning........................................................................................... 23
7.1 General................................................................................................... 23
7.2 Checklist before commissioning............................................................... 23
7.3 Commissioning procedure....................................................................... 23
8. Operation................................................................................................... 24
8.1 General................................................................................................... 24
9. Maintenance.............................................................................................. 25
9.1 General................................................................................................... 25
9.2 Standard inspection & maintenance operations........................................ 25
10. Troubleshooting....................................................................................... 26
10.1 Fault finding.......................................................................................... 26
11. Decommissioning..................................................................................... 27
11.1 Decommissioning procedure.................................................................. 27
12.1 Spare parts list....................................................................................... 27
Benchmark checklist...................................................................................... 32
Commissioning & service records..................................................................33
Guarantee....................................................................................................... 35
THE BENCHMARK SCHEME
2
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.
1. Introduction
1.1 General
In the interest of UK customers, we are continuously
endeavouring to make improvements in product quality.
All the specifications stated in this document are therefore
subject to change without notice.
The following instructions are offered as a guide to the
user and installer.
Our liability as the manufacturer may not be invoked in
the following cases:
The installation must be carried out by a competent
plumbing and electrical installer in accordance with
Building Regulation G3 (England and Wales), Technical
Standard P3 (Scotland) or Building Regulation P5
(Northern Ireland) and the Water Fitting Regulations
(England and Wales) or Water Byelaws (Scotland).
`` Failure to abide by the instructions on using the
appliance.
`` Faulty or insufficient maintenance of the appliance.
`` Failure to abide by the instructions on installing the
product.
1.2 Symbols used
In these instructions, various risk levels are employed to
draw the user’s attention to particular information. In
doing so we wish to safeguard the user, avoid hazards
and guarantee the correct operation of the appliance.
DANGER
Risk of a dangerous situation causing serious
physical injury.
WARNING
Risk of dangerous situation causing slight
physical injury.
Installer's liability
The installer is responsible for the installation and the
commissioning of the appliance. The installer must
respect the following instructions:
`` Read and follow the instructions given in the manuals
provided with the appliance.
`` Carry out installation in compliance with the
prevailing legislation and standards.
`` Perform the initial start up and carry out any checks
necessary.
`` Complete the commissioning checklist.
`` Explain the installation to the user.
`` If maintenance is necessary, warn the user of the
obligation to check the appliance and maintain it in
good working order.
`` Give all the instruction manuals to the user.
Users liability
CAUTION
Risk of material damage.

Signals important information.
1.3 Abbreviations
`` T&P - Temperature & Pressure relief valve
`` PRV - Pressure Reducing Valve
`` Prv - Pressure relief valve
1.4 Liabilities
Manufacturers liability
Our products are manufactured in compliance with
the requirements of the various applicable European
Directives.
This appliance complies with the requirements of the CE
marking directive.
To guarantee optimum operation of the appliance, the
user must respect the following instructions:
`` Read and follow the instructions given in the manuals
provided with the appliance.
`` Call on qualified professionals to carry out installation
and initial start up.
`` Get your fitter to explain your installation to you.
`` Have your required checks and services done.
`` Keep the instruction manuals in good condition and
close to the appliance.
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.
3
2. Safety
2.1 General safety warnings
DANGER
This cylinder is unvented and as such becomes
pressurised when in operation. The combination
of pressurisation and hot water could lead to
serious physical injury if the safety instructions in
this manual are not adhered to.
2.3 Specific safety instructions
WARNING
`` If water discharges from the temperature/
pressure relief valve on the cylinder shut
down the boiler/immersion heaters. 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.
`` DO NOT bypass the thermal cut-out(s) in
any circumstances.
WARNING
`` Only competent persons having received
adequate training are permitted to work
on the appliance and the installation.
`` Do not tamper with any of the safety
valves or controls supplied with the
cylinder.
`` Before any work, switch off the mains
supply to the appliance and the water
mains.
`` Do not switch on if there is a possibility
that the water in the cylinder is frozen.
CAUTION
Do not operate immersion heaters until the
cylinder has been filled with water.
2.2 Recommendations
WARNING
When handling the unit, take appropriate
precautions for the weight of the unit. Weights
can be found in section 3, table 1 & 2, page 5
& 6.
CAUTION
Annual maintenance is recommended by a
competent person.
The HWA Charter Statement requires that all members adhere to the following:
`` To supply fit for purpose products clearly and honestly described.
`` To supply products that meet, or exceed appropriate standards and building and water regulations.
`` To provide pre and post sales technical support.
`` To provide clear and concise warranty details to customers.
4
3. Technical specifications
125 indirect
145 indirect
170 indirect
210 indirect
250 indirect
300 indirect
3.1 Technical data:
Max direct kW rating @240v
3
3
3
3
3
3
Coil surface area m2
0.58
0.72
0.79
0.79
0.79
0.79
Coil rating (kW)
15l/min
18.3
18.7
24.3
24.3
23.9
24.5
Indirect heat time
(mins)
15l/min
23
24
22
28
34
39
Recovery
(mins)
15l/min
15
17
16
19
23
27
Heat loss (kWh in 24h) / Day
1.05
1.18
1.20
1.42
1.61
1.69
Weight full (kg)
Weight empty (kg)
183
203
234
254
297
352
43
48
52
55
61
69
Max supply pressure
1.6 MPa (16 bar)
Max design pressure
1.5 MPa (15 bar)
Max operating pressure (PRV)
0.3 MPa (3 bar)
Expansion relief valve setting
0.8 MPa (8 bar)
T&P valve setting
90° / 1 MPa (10 bar)
Table 1: Technical data - Indirect
Notes:
1. Indirect cylinders tested in accordance with BS EN 12897:2006.
2. Heat up time from cold through 45°C, based on a flow temperature of 80°C +/- 2°C & normal volume.
3. Although the primary coil pressure rating is 1.0MPa (10bar) the 2 port zone valve and coil compression nuts
supplied with the cylinder is only rated 0.86MPa (0.86 bar). If the cylinder is to be plumbed into a system
delivering 1.0MPa (10 bar) a suitable 2 port zone valve and the coil compression nuts supplied will have to
be sourced.
Model(s)
125i
145i
170i
210i
250i
300i
B
B
B
B
C
C
Storage volumes V in Litres
137.0
155.0
178.0
195.0
233.0
283.0
Standing loss in W
50.0
55.0
59.0
65.0
70.0
79.0
Energy efficiency class
Table 2: Technical parameters in accordance with European Commission regulations 814/2013 and 812/2013
5
3.2 Dimensions and connections
300
A
B
430
300
390
C
Table 3: General dimensions table - Indirect
210I
1095
1486
1011
250I
1323
1738
1238
300I
1574
2053
1526
355
316
393
650
720
Item 125I 145l 170I
A
794 895 1020
B 1102 1229 1384
C
709 810 934
Figure 1: General dimensions - Indirect
Danfoss TP9000 Programmable Thermostat
with timed Domestic
Hot Water (DHW) control:
Programmer dimensions: 135mm (W) x 88mm (H) x 32mm
(D)
Room temperature sensor dimensions: 60mm (W) x 45mm
(H) x 21mm (D)
Power supply: 220V/240V ac, 50Hz
Switch action 2 x SPDT, Type 1B. Switch rating 220/240V
ac, 50/60Hz, 3(1)A
Power reserve: minimum 24 hours
Memory back up retained for life of product
Enclosure rating: IP30
Control temperature range: selectable 5 to 30oC
Holiday mode with room temperature setback
Timing accuracy: +/- 1 minute/month
Maximum ambient temperature: 45oC
Danfoss TP5000 programmable thermostat:
Programmer dimensions: 110mm (W) x 88mm (H) x 32mm
(D)
Power supply: 2xAA / MN1500 / LR6 alkaline batteries
Swithch type: SPDT
Memory retention: 1 minute during battery change
Temperature range: off, 5-30°C
Maximum ambient temperature: 45°C
6
Honeywell 2 Port Motorised Valves:
Model No.: V4043H
Voltage rating: 230V ac, 50HZ
Power consumption: 6W
Primary water temperature range: 5 to 88oC
Maximum ambient temperature: 52oC
Automatic Differential By-pass Valve:
Model No.: RWC DIFF 200 005
Setting range: 0 to 0.05 MPa (0 to 0.5 bar) differential pressure
Maximum primary water temperature: 110oC
Maximum operating pressure 1.0MPa (10 bar)
3.3 Circulating pump set-up
Primary Circulating Pump:
Model No.: Grundfos UPM3 Auto L 25-70 130
Working pressure: 1 MPa (10 bar) max.
Voltage rating: 230V ac, 50Hz
Starting capacitor: 2uF
Enclosure rating: IP42
Setting up the UPM3 pump
When you switch on the pump it will run to the
pre-set position or the last setting. The diagram
opposite shows the current operation status.
To change the pump stting, follow below:
(a) Press the ‘ ’ to switch to switch to the settings
view. The LEDs show the current setting for2
seconds.
(b) Release ‘ ’ for more than 2 seconds. The user
interface shows the current performance in
“operation status”.
(c) Press ‘ ’ for more than 2 seconds and the circulator switches to “setting selection”. The
LEDs flash and show the current setting mode.
Please note that if the key lock is disabled, the
circulator will not switch to “setting selection”.
MODE
PRE-SET
MODE
MODE
U PM 3 x x- 5 0
In this case, unlock the key lock by pressing the
button for 10 seconds.
(d) During a period of 10 seconds, press shortly
on the ‘ ’ and the pump switches to the next
setting.
(e) To select between the settings, instantly press
the button until you find the setting you want.
If you pass the setting, you will need to continue until the setting appears again. It is not
possible to go back.
(f) Release ‘ ’ for more than 10 seconds and the
user interfaces switches back to the performance view and the last setting is stored.
(g) Press ‘ ’ and the display switches to the setting view and the LEDs show the current setting for 2 seconds.
(h) Release ‘ ’ for more than 2 seconds and the
user interface switches back to the performance view.
U PM 3 x x-70
1
1
2
2
3
3
U PM 3 x x- 5 0
U PM 3 x x-70
1
1
2
2
3
3
U PM 3 x x- 5 0
U PM 3 x x-70
1
1
2
2
3
3
MAX
MAX
7
Control Mode explanation
Propotion pressure
The head pressure is reduced at falling heat
demand and increased at rising heat demand.
The duty point of the circulator will move up or
down on the selected proportional pressure
curve depending on the heat demand in the
system.
Constant pressure
The head pressure is kept constant, irrespective
of the heat demand.
The duty point of the circulator will move out
or in on the selected constant pressure curve,
depending on the heat demand in the system.
• PP1: lowest proportional
pressure curve
• PP2:
Intermediate
proportional
pressure
curve
• PP3: Highest proportional
pressure curve
• PP1:
lowest
pressure curve
• PP2: Intermediate constant
pressure curve
• PP3: Highest
pressure curve
Constant curve
The circulator runs on a constant curve, which
means that it runs at a constant speed or
power.
The duty point of the circulator moves up or
down the selected curve, depending on the
heat demand in the system.
8
constant
Constant
Curve
CC1
CC2
CC3
CC4
(max.)
4m
5m
6m
7m
constant
3.4 Electrical diagram(s)
PROGRAMMER - HEATING ZONE 1
& DOMESTIC HOT WATER
(SUPPLIED)
L
N
HTG
ON
DHW
ON
4
3
PROGRAMMABLE
ROOM THERMOSTAT
FOR ZONE 2
(SUPPLIED)
5
2
1
6
INDIRECT
THERMAL CONTROLS
(SUPPLIED FITTED)
1
2
(DHW)
ZONE VALVE
(SUPPLIED FITTED)
3
Br
Bl
G
O
GY
N
N
ROOM SENSOR
(SUPPLIED)
N.B. A DOUBLE POLE ISOLATING
SWITCH MUST BE INSTALLED IN
THE MAINS SUPPLY
1
WIRING CENTRE
(SUPPLIED FITTED)
FUSED (3 AMP)
MAINS SUPPLY
L
N
KEY
Br BROWN
Bl
BLUE
G
GREY
O
ORANGE
W
WHITE
GY GREEN/YELLOW
DHW DOMESTIC HOT WATER
HTG HEATING
L
LIVE
N
NEUTRAL
EARTH
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16
N
N
Br
Bl
G
O
GY
HEATING ZONE 1VALVE
(SUPPLIED FITTED)
W
Br
Bl
N
N
N
G
O
GY
HEATING ZONE 2 VALVE
(SUPPLIED FITTED)
W
L
N
PUMP
(SUPPLIED FITTED)
L
N
BOILER
NOTES
1. ALL EARTH CONNECTIONS MUST BE LINKED BACK TO THE EARTH TERMINALS IN THE WIRING CENTRE
2. ALL NEUTRAL CONNECTIONS MUST BE LINKED BACK TO THE NEUTRAL TERMINALS IN THE WIRING CENTRE
3. ASSUMES BASIC BOILER
4. THE 22MM MOTORISED VALVES DO NOT HAVE A WHITE WIRE
5. THE ABOVE DIAGRAM IS FOR GUIDANCE ONLY, THE MANUFACTURER ACCEPTS NO LIABILITY FOR ANY LOSS OR DAMAGE ARISING FROM
ANY ERRORS OR OMISSIONS THAT MAY BE INADVERTENTLY CONTAINED WITHIN THIS DIAGRAM. THE VARIOUS EQUIPMENT
MANUFACTURERS SHOULD BE CONSULTED TO CONFIRM THE CORRECT OPERATION OF THEIR PRODUCTS WITHIN THE SYSTEM
Figure 2: Schematic wiring diagram - basic 2 x 2 port valve system
9
Access to Control Unit:
Control Housing Details
Disconnect from mains supply before removing any
covers.
Removing the Control Cover.
`` Unscrew the large screw using a flat ended screw
driver.
`` Lift from bottom of cover at point indicated until
cover comes away freely.
Replacing the Control Cover:
`` Tilt and align the top 2 lugs in the holes indicated.
`` Firmly press the cover until it "snaps" back in place.
`` Tighten the large screw.
Element connections
1
2
3
Indirect control
wiring
Figure 4: Indirect wiring schematic
WARNING
`` Do not over tighten
LUGS
N
LIFT OFF
L
1.5mm² 3 Core
HOFR sheathed
cable
Figure 5: Direct wiring schematic
LIFT FROM THIS POINT
REPLACE
Figure 3: Cover Access
10
L
N
1.5mm² 3 core
HOFR sheathed
cable
4. Description of the product
4.1 General description
This product 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 pre-coated steel. All products are
insulated with CFC free polyurethane foam to give good
heat loss protection.
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
should not be tampered with.
4.2 Operation principle
The unvented cylinder is used to heat and store hot water
for use in domestic.
Depending on the model the water can be heated directly
using Immersion heater(s) or indirectly through a coil in
the unit using an indirect heat source.
4.3 Main connections
See Figures 6 : Main connections on page 13
4.4 Standard delivery
The delivery includes:
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
``
Cylinder
Factory fitted
Immersion heater(s) and thermal controls
Temperature and Pressure Relief Valve (set at 90ºC /
1 Mpa (10bar))
Indirect thermostat and thermal cut-out
8 bar pressure relief valve (incorporating a check
valve)
Tundish
T&P relief valve insulation set
Drain valve
Wiring center
3 x 2 Port motorised valve
Primary circulation pump
Lock shield flow balancing valve
Differential bypass valve
Filling Loop, straight
Primary circuit pressure gauge
Drain valve (with quarter turn lever)
Literature pack
Instructions (inc benchmark commissioning checklist
& service record)
Fixing template
3 bar pressure reducing valve (incorporating strainer)
Automatic air vent
Stop cock
Lifting handle
CD/DHW programmer and room temperature sensor
Primary circuit expansion vessel (including wall
mounting bracket)
5. Before installation
5.1 Installation regulations
WARNING
Installation of the appliance must be carried
out by a qualified engineer in accordance
with prevailing and national regulations as
listed below.
`` Building Regulations G3
`` The Building Standards (Scotland)
`` The Building Regulations (Northern
Ireland)
`` I.E.E Electrical Regs
`` UK Water Regulations
5.2 Installation requirements
Water supply
In an unvented system the pressure and flowrate is directly
related to the incoming water supply. For this reason it
is recommended that the maximum water demand is
assessed and the water supply checked to ensure this
demand can be satisfactorily met.
`` We suggest the minimum supply requirements
should be 0.15MPa (1.5 bar) pressure and 20 litres
per minute flow rate. However, at these values outlet
flow rates may be poor if several outlets are used
simultaneously.
`` A 22mm cold water supply is recommended,
however, if a smaller supply exists, which provides
sufficient flow, this may be used (although more
flow noise may be experienced).
`` The higher the available pressure and flow rate the
better the system performance.
`` See table 1 on page 5 for cylinder operating pressures.
This is controlled by the cold water combination
valve assembly.
`` The water supply must be of wholesome water
quality (Fluid Category 1 as defined by the Water
Supply Regulations 1999).
Outlet/terminal fittings (taps, etc.)
`` The cylinder can be used with most types of terminal
fittings.
`` 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 8 bar (dependant on
cylinder being fitted) at 80°C.
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.
11
`` 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.
`` Gravity circulation primaries.
5.3 Choice of location
The cylinder must be vertically floor mounted. Although
location is not critical, the following points should be
considered:
`` 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.
`` Ensure that the floor area for the cylinder is level and
capable of permanently supporting the weight when
full of water (see table 1, page 5 for weights).
`` Prior to installation the unit should be stored and
transported in an area free from excessive damp or
humidity. The Unit should be stored in a frost free
environment.
12
6. Installation
6.1 General
After reading the previous sections in this booklet and
choosing a good location for the unit please install,
paying attention to the following hydraulic, electrical and
commissioning sections.
Boiler selection
with unvented storage water heaters.
`` Can be a sealed system or open vented type maximum primary pressure 3 bar.
`` The primary flow from the boiler must be pumped.
Gravity circulation will not work due to the
special design of the primary heat exchanger. It is
recomended that an air bleed point or automatic air
vent is incorporated in the primary return pipework
close to the unvented system.
`` The boiler cannot be vented through the cylinder.
`` The boiler should have a control thermostat and non
self-resetting thermal cut-out and be compatible
TO HOT OUTLET
3 BAR PRESSURE
REDUCING VALVE
BALANCED COLD WATER
CONNECTION (IF REQUIRED)
STOP COCK (IF USED
IN THIS POSITION)
SECONDARY RETURN
TAPPING (IF REQUIRED)
MAINS WATER
SUPPLY
PRIMARY
FLOW
8 BAR PRESSURE RELIEF VALVE
T&P VALVE
TUNDISH
HEATING ZONE 1
HEATING ZONE 2
DRAIN COCK
PRIMARY
RETURN
DISCHARGE PIPE
ELEMENT/CONTROLS
HOUSING
Figure 6: Typical installation schematic (not to scale)
13
6.2 Water connections
WARNING
`` 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.
T&P Relief Valve Insulation
A set of insulating components is supplied with the
water heater and should be installed to gain maximum
heat and energy saving benefits. See Figure 7 below, for
installation instructions.
IMPORTANT INFORMATION:
HOW TO INSULATE YOUR T&P RELIEF VALVE
TO SAVE HEAT AND ENERGY A SET OF INSULATING PARTS FOR
THE T&P RELIEF VALVE HAVE BEEN SUPPLIED WITH THIS WATER
HEATER. INSTALL THE HEATER FIRST THEN FIT THE INSULATING
PARTS BY FOLLOWING THE DIAGRAMS BELOW.
B
A
T&P RELIEF
VALVE
DISCHARGE
Refer to the installation schematic (fig 11, page 16) for
details on the pipework layout. Specific details for the
discharge pipework layout is also provided in figure 13
on page 20.
`` The connection points to the heating system are in
22mm O/D copper pipe for 125, 145, 170, and 210
litre units.
`` The connection points to the heating sytem are in
28mm O/D copper pipe for 250 and 300 litre units.
`` All pipe fittings are made via 22mm compression
fittings directly to the unit (nuts and olives supplied).
`` Solder fittings can be used, but extreme care must be
taken to ensure the plastic coating of the unit casing
is not damaged by heat.
`` Push fit type fittings can be used for connection to
the copper pipes.
`` The cold water inlet control kit supplied with the
unvented unit incorporates a full flow isolating valve
which will enable the unvented water haeter to be
isolated from the mains supply for maintenance or
servicing..
`` A suitable draining tap should be installed in the cold
water supply to the cylinder between the expansion
valve 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).
`` If the 2nd heating zone is not used, it is recommended
that for the installer to cap off the valve, using a
correctly sized pipe and and pipe end cap.
14
PIPEWORK
LEFT HAND
INSULATING PIECE
RIGHT HAND
INSULATING PIECE
TUNDISH
D
C
PLASTIC COVER
Figure 7: T&P insulation
DISCHARGE PIPE
CLIP INTO
PLACE !
Cold water control pack
CAUTION
`` 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 any warranty.
`` The expansion relief valve should be installed with
the discharge pipework in either the horizontal
position or facing downwards.
`` No other valves should be placed between the cold
water combination valve and the cylinder.
`` Where discharge pipework is difficult to attain, the
local building control officer from the local council
should be sought for advice as this falls under G3
guidelines and is not down to the manufacturer for
unvented systems
Primary circuit control
`` The 3 bar pressure reducing valve can be connected
anywhere on the cold water cylinder supply. There
is no requirementto site it close to the unit, it can
be located at a point whee the mains supply enters
the premises if this is more convenient but you must
install a non-return valve just after the rducing valve
for ease of maintenance.
`` The control pack incorporates the strainer, check
valve, core unit and expansion relief valve.
`` The pressure setting is set to 3 bar.
`` The valve can be fitted in any orientation to suit
the installation as long as the valve is installed with
the direction of flow arrows pointing in the correct
direction.
`` Primary circulation to the cylinder heat exchanger
must be pumped; gravity circulation WILL NOT
WORK.
`` It is recommended that an air bleed or automatic air
vent is incorporated in the primary return pipe work
close to the unit.
`` Boiler flow temperature should be set to 82°
(maximum flow temperature to primary heat
exchanger 89°C).
Pressure Reducing Valve
Cartridge (3 bar)
Take note of flow
direction
Mains in
Outlet to MEGAFLO Eco
22mm compression connection
Figure 8: 3 bar pressure reducing valve
15
Stopcock is grouped with the 3 Bar
pressure Reducing valve. Make sure
the flow is correct to the markings
on the valve.
3 Bar Pressure
Reducing Valve
Stopcock
Figure 9: Stopcock and an 8 bar pressure relief valve
From 3 Bar Pressure Reducing Valve
22mm Compression
connection
8 Bar Expansion
Relief Cartridge
8 Bar Pressure Relief
Tee with Check Valve
To Tundish
To Megaflo eco SystemFit
inlet Connection
Figure 10: valve set can be grouped two ways
16
Figure 11: Schematic installation diagram using 3bar pressure
reducing valve in conjunction with 8bar pressue relief valve.
17
KEY
MCWS =
HWS =
SC =
DOC =
Mains cold water supply
Hot water service
Stop Cock / Isolating Valve
Drain Off Cock
Isolating/Regulating
Valves, as required
Balanced HWS and
MCWS to bathrooms,
showers, cloakrooms,
etc
DOC
Tundish
Temperature/Pressure
Relief Valve
Balanced cold water
draw-off
Discharge pipe to atmosphere
(see page 18 “Discharge Pipework”)
DOC DOC
Megaflo eco
SystemFit
HWS supply
SC
DOC
SC
Incoming Cold
Water Main
MCWS to Kitchen
(unbalanced cold
mains supply)
3 Bar Pressure Reducing
Valve incorporating
Pressure Reducing Valve,
Strainer,and Check Valve.
(Stop cock can be fitted
here)
8 Bar Pressure Relief
Valve (combined
Expansion Relief
Valve/Check Valve)
Secondary circulation
If secondary circulation is required it is recommended
that it be connected to the cylinder as shown (see fig.
12, below).
`` 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.

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.
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: Plastic pipe capacities may be reduced due to
thicker wall sections.
TO HOT OUTLET
MAINS WATER
SUPPLY
CHECK VALVE
SECONDARY RETURN
WRAS APPROVED
PUMP
Figure 12: Secondary circulation schematic
18
Discharge
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
3.50Each 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.
3.51The diameter of discharge pipe (D1) should be not
less than the nominal outlet size of the temperature relief
valve.
3.52Where a manifold is used it should be sized to accept
and discharge the total discharge from the discharge
pipes connected to it.
3.53Where 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
3.54The 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 13).
Note: To comply with the Water Supply (Water Fittings)
Regulations, the tundish should incorporate a suitable air
gap.
3.55Any 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
3.56The 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. 13); and
(b) be installed with a continuous fall thereafter of at
least 1 in 200.
3.57The 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).
3.58The 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 Fig 13,
Table 3 and the worked example.
Note: An alternative approach for sizing discharge
pipes would be to follow Annex D, section D.2 of BS
6700:2006 Specification for design, installation, testing
and maintenance of services supplying water for domestic
use within buildings and their curtilages.
3.59Where a single common discharge pipe serves more
than one system, it should be at least one pipe size larger
than the largest individual discharge pipe (D2) to be
connected.
3.60The 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:
(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;
19
(c) if plastic pipes are used as branch pipes carrying
discharge from a safety device they should be either
polybutylene (PB) to Class S of BS 7291-2:2006 or cross
linked polyethylene (PE-X) to Class S of BS 7291-3:2006;
and
(d) be continuously marked with a warning that no
sanitary appliances should be connected to the pipe.
Note:
1. Plastic pipes should be joined and assembled with
fittings appropriate to the circumstances in which they
are used as set out in BS EN ISO 1043-1.
2. Where pipes cannot be connected to the stack it
may be possible to route a dedicated pipe alongside or in
close proximity to the discharge stack.
Termination of discharge pipe
3.61The 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.
3.62Examples 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.
3.63The discharge would consist of high temperature
water and steam. Asphalt, roofing felt and non-metallic
rainwater goods may be damaged by such discharges.
20
Worked example of discharge pipe sizing
Fig. 13: 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.
From Table 3:
Maximum resistance allowed for a straight length of
22mm copper discharge pipe (D2) from a G1/2
temperature relief valve is 9.0m.
Subtract the resistance for 4 No. 22mm elbows at 0.8m
each = 3.2m
Therefore the permitted length equates to: 5.8m
5.8m is less than the actual length of 7m therefore
calculate the next largest size.
Maximum resistance allowed for a straight length of
28mm pipe (D2) from a G1/2 temperature relief valves
equates to 18m.
Subtract the resistance of 4 No. 28mm elbows at 1.0m
each = 4.0m
Therefore the maximum permitted length equates to:
14m
As the actual length is 7m, a 28mm (D2) copper pipe will
be satisfactory.
Valve Outlet
Size
Minimum Size Of
Discharge Pipe D1
Minimum Size Of
Discharge Pipe D2 From
Tundish
Maximum Resistance
Allowed, Expressed As A
Length Of Straight Pipe (I.E.
No Elbows Or Bends)
Resistance Created
By Each Elbow Or
Bend
G1/2
15mm
22mm
28mm
35mm
up to 9m
up to 18m
up to 27m
0.8m
1.0m
1.4m
G3/4
22mm
28mm
35mm
42mm
up to 9m
up to 18m
up to 27m
1.0m
1.4m
1.7m
G1
28mm
35mm
42mm
54mm
up to 9m
up to 18m
up to 27m
1.4m
1.7m
2.3m
Table 4: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes
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
Figure 13: Typical discharge pipe arrangement (extract from Building Regulation G3 Guidance Section 3.50)
21
6.3 Electrical connections
In case of difficulty contact service support; contact
details are available on page 32 of this booklet.
WARNING
`` Disconnect from the mains electrical
supply before removing any covers.
`` Never attempt to replace the immersion
heater(s) other than with genuine
manufacturers
components.
Using
other manufacturers components may
invalidate the warranty on the cylinder.
`` DO NOT bypass the thermal cut-out(s) in
any circumstances. 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.
`` DO NOT operate the immersion heaters
until the cylinder has been filled with
water.
`` The immersion heater(s) should be wired in
accordance with fig 4 and 5, page 10.
Space and heating systems controls
`` The controls provided with the cylinder will ensure
the safe operation of the unit within the central
heating system.
`` Connections to the various system components is
made via the wiring centre fitted to the front of the
cylinder and the terminal identification labels within
the wiring centre to aid in connecting the various
external system components such as the mains
supply, programmer and boiler.
`` Provision is made for the connection of a second
CH zone (connection pipe supplied blanked off).
Additional controls will be necessary to control the
operation of the second CH zone, usually a second
22mm CH zone valve and a programmable room
thermostat. Connection terminals are provided and
identified in the wiring centre to enable any wiring to
be connected to the same central position.
Programmer and room temperature sensor
`` The programmer and room temperature sensor are
supplied loose such that they can be installed at a
convenient location within the property.
`` These items are supplied with their own installation
and user instruction leaflet which should be referred
to for details of mounting, wiring and programming.
`` Temperature setting of the room temperature is also
done at the programmer, there is no adjustment at
the room temperature sensor.
22
CAUTION
The room sensor is wired directly to the
programmer, not to the wiring centre.
Basic programmer features:`` 24 hour or 5/2 day operation.
`` Room temperature setting at programmer.
`` Set temperature over-ride facility.
`` 1 hour hot water boost facility.
`` Battery back up retains programmed information in
the event of a power interruption.
`` Low temperature set back option for periods when
the property is unoccupied, eg. holiday periods.
`` Independent time control of central heating and
domestic hot water (Building Regulation Part L1
compliant).
6.4 Filling the installation
`` Ensure the drain cock is CLOSED.
`` Open a hot tap furthest from the cylinder.
`` Open the isolating valve on the 3 bar pressure
reducing valve by turning the blue habdle on the stop
cock (if fitted in this position) so that it lies parallel to
the direction of flow. Open the mains stop cock to fill
the unit. When water discharges from the tap, alow
`` to run for a few minutes to throughly flush through
any residue, dirt or swarf, then close the tap.
`` Open successive hot taps to purge the system of air.
`` 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.
7. Commissioning
7.1 General
After filling the installation with water in the previous
section please follow the following steps to complete the
installation of the unit.
WARNING
DO NOT operate the immersion heaters or
primary circuit until the cylinder has been
filled with water.
7.2 Checklist before commissioning
`` 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 the water supply back 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.
7.3 Commissioning procedure
Direct Heating
Indirect units
`` Fill the indirect (primary) circuit following the boiler
manufacturer’s commissioning instructions.
`` Ensure the filling loop hose is connected at both ends
and is tight.
`` Open the isolaing valves at either end of the filling
loop and allow to fill from the mains inlet supply.
`` To ensure the cylinder primary heat exchanger is
filled, both of 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.
`` Air can be vented from the primary heating coil by
unscrewing the small dust cap on the auto air vent
by half a turn.
`` The primary system should be pressurised to the
minimum pressure required by the boiler (usually 1
bar), the pressure guage fitted should be used to
ensure the correct system pressure is set.
`` When full and pressurised, the filling loop isolating
valves should be closed and the levers on the
motorised valves returned to the Auto position.
`` Switch on the boiler, ensure the programmer is
set to Hot Water and allow the cylinder to heat
up to a normal working temperature (60 - 65oC
recommended).
`` Switch on electrical supply to the immersion
heater(s) and allow the cylinder to heat up to normal
working temperature (60 - 65°C recommended).
`` If necessary the temperature can be adjusted by
inserting a flat bladed screwdriver in the adjustment
spindle on front of the immersion heater thermostat
and rotating. The adjustment represents a
temperature range of 12°C to 68°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.
WARNING
`` If the unit is to be left unused following
installation and commissioning e.g.
unocupied properties, the water heater
should be drained or regularly flushed
through with fresh mains water once a
week.
`` When placing the unit into service, the
procedure for filling the unit and the
system checks above should be observed.
THERMAL CUT-OUT RESET BUTTON
SPINDLE POSITIONS
= MINIMUM TEMP
= MAXIMUM TEMP
= APPROX 60 °C
ROTATE SPINDLE CLOCKWISE
FOR TEMPERATURE INCREASE
AND COUNTER CLOCKWISE
FOR TEMPERATURE DECREASE
Figure 14: Indirect controls
TEMPERATURE ADJUSTING
SPINDLE
23
8. Operation
8.1 General
WARNING
`` If
water
discharges
from
the
temperature/pressure relief valve on the
cylinder shut down the heat source. 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.
`` DO NOT bypass the thermal cut-out(s) in
any circumstances.
Temperature controls – direct units immersion
heater(s)
`` All immersion heaters are fitted with a thermostat
which is fitted in the centre of the heater plate and a
cut-out which is fitted to the side of the thermostat.
`` 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 rotating the
adjustment knob on the top of the thermostat. The
adjustment represents a temperature range of 12°C
to 68°C.
`` Maximum working temperature is 68°C/154°F. In
very hard water areas limit to 60/65°C (140/150°F).
DO NOT bypass the thermal cut-out(s) in any
circumstances.
Temperature controls - indirect units
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 (page 30) 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).
All installations must be notified to Local Area Building
Control either directly or through a Competent Persons
Scheme. A Building Regulations Compliance Certificate
will then be issued to the customer who should, on
receipt, write the Notification Number on the Benchmark
Checklist.
This product should be serviced regularly to optimise its
safety, efficiency and performance. The service engineer
should complete the relevant Service Record on the
Benchmark Checklist after each service.
The Benchmark Checklist may be required in the event of
any warranty work.
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.
24
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 valves supplied
to interrupt the flow of primary water around the heat
exchanger coil when the control temperature has been
reached.
DO NOT bypass the thermal cut-out(s) in any
circumstances.
Operational faults and their possible causes are detailed
in the Fault Finding section (p.25) of this book. It is
recommended that faults should be checked by a
competent installer.
The air volume within the product will periodically require
recharging to ensure expanded water is accommodated
within the system. 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.
To recharge the air volume:`` Turn off the heat source to the cylinder via
programmers / immersion isolation switch(es).
`` Turn off the water supply to the cylinder by turning
off the isolating valve on the 3 bar pressure reducing
valve if fitted at this point or at the 8 bar pressure
relief valve if fitted there. Turn the handle so that
it lies at 90° to the direction of flow. See figure 17
page 27.
`` Open the lowest hot tap.
`` Hold open the temperature / pressure felief valve
until water ceases to run from the tap and gurgling
noise at the valve stops.
`` Close the temperature / pressure relief valve.
`` Turn on the isolating valve at the cold water
combination valve by turning the handle so it lies
parallel to the direction of flow, when water flows
from the hot tap, close tap.
`` The air volume will be automatically recharged as
the unit refills. If after following the above actions
water still dischargesfrom the expansion relief valve,
further advice should be sought from a competent
installer or the Megaflo service department.
9. Maintenance
9.1 General
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. Maintenance of this appliance
should only be carried out by a suitably qualified person.
Failure to do so could invalidate the warranty.
Similarly cleaning of the strainer element and replacement
of the air in the product 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 30 of this document.
9.2 Standard inspection & maintenance
operations
Descaling immersion heater(s)
`` Turn off the mains water supply, isolate the electrical
supply and turn off boiler
`` 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. If water fails to drain vent the unit
manually by opening the temperature and pressure
relief valve.
`` Open the cover(s) to the immersion heater housing(s)
and disconnect wiring from immersion heater(s)
thermostat(s).
`` Unscrew the immersion heater backnut(s) and
withdraw the immersion heater from the cylinder. A key
spanner is supplied with the product for easy removal
and tightening of the immersion heater(s). Over time
the immersion heater gasket may become stuck to the
mating surface. To break the seal insert a round shafted
screwdriver into one of the pockets on the immersion
heater and gently lever up and down. Take care when
lifting the immersion heater out of the cylinder and
work within safe working practices.
`` Carefully remove any scale from the surface of the
element(s).
CAUTION
DO NOT use a sharp implement as damage
to the element surface could be caused.
Inspection
The immersion heater boss can be used as an access for
inspecting the cylinder internally.
Safety valve operation
CAUTION
Water discharged may be very hot!
`` 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.
`` Repeat the above procedure for the expansion relief
valve.
Strainer
`` Turn off the isolating valve prior to the Pressure
Reducing Valve or the main stop cock to the system.
`` Open the lowest hot tap in the system to relieve the
system pressure.
`` Using a spanner unscrew the pressure reducing
cartridge and remove the moulded housing. The
strainer will be removed with the cartridge.
`` Wash any particulate matter from the strainer under
clean running water.
`` Replace the strainer and screw the Pressure Reducing
Valve cartridge into the moulded housing.
`` Close hot tap, turn on isolating valve or main stop
cock to the system. Check for leaks.
`` Ensure sealing surfaces are clean and seals are
undamaged, if in doubt fit a new gasket. (spare part
number 95611822)
`` Replace immersion heater(s), making sure not to trap
the gasket.
`` Rewire, check, close and secure immersion heater
housing cover(s).
Re-commissioning
`` Check all electrical and plumbing connections are
secure. Close the drain cock.
`` With a hot tap open, turn on the cold water supply
and allow unit to refill.
`` DO NOT switch on the immersion heater(s) or boiler
until the unit is full.
`` When water flows from the hot tap allow to flow
for a short while to purge air and flush through any
disturbed particles.
`` Close hot tap and then open successive hot taps in
system to purge any air.
`` When completely full and purged check system for
leaks.
`` The heating source (immersion heater(s) or boiler)
can then be switched on.
25
10. Troubleshooting
WARNING
Do not tamper with any of the safety valves
or controls supplied with the cylinder as this
will invalidate any guarantee.
10.1 Fault finding
`` 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.
The fault finding chart (table 5, 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.
Important
`` After servicing, complete the relevant Service Interval
Record section of the Benchmark Checklist located
on pages 30 and 31 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.
Fault
No hot water flow
Water from hot tap
is cold
Water discharges
from expansion
valve
Water discharges
from T&P relief valve
A full range of spare parts are available for the
cylinder range (table 6, page 26). 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.
Possible Cause
Remedy
Mains water supply off
Check and open stop cock
Strainer blocked
Turn off water supply. Remove strainer and clean
Cold water combination valve incorrectly
fitted
Check and refit as required
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
Indirect programmer set to central
heating only
Check, set to domestic hot water programme
Indirect boiler not working
Check boiler operation. If fault is suspected
consult boiler manufacturer’s instructions
Indirect thermal cut-out has operated
Check, reset by pushing button on thermostat.
Check operation of indirect thermostat
Indirect motorised valve not connected
correctly
Check wiring and/or plumbing connections to
motorised valve
Intermittently
Air volume in product has reduced
See Maintenance section (p.24) for re-charging of
expansion vessel procedure
Continually
Cold water combination valve pressure
reducer not working correctly.
Expansion valve seat damaged
Check pressure from cold water combination
valve. If greater than 3bar replace pressure
reducing valve cartridge.
Remove expansion valve cartridge, check
condition of seat. If necessary fit new expansion
valve
Thermal control failure
CAUTION: Water will be very hot!
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
Oxygenated water
Water from a pressurised system releases oxygen
bubbles when flowing. The milkiness will
disappear after a short while
Milky water
Table 5: Fault finding chart
26
Spare Parts
11. Decommissioning
11.1 Decommissioning procedure
``
``
``
``
``
``
Isolate electrical supplies and make safe
Isolate the water supply
Drain the cylinder
Drain the primary circuit (indirect only)
Remove cylinder
Cap pipework
Environmental information
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.
12. Spare parts
12.1 Spare parts list
A full range of spare parts are available for the cylinder range. Refer to the Technical Data label on the unit to identify the
model installed and ensure the correct part is ordered.
DESCRIPTION
SPARES NUMBER
Cold water inlet control kit - complete
95605894
3 bar pressure reducing valve - complete
95605886
8 bar pressure relief valve - complete
95605893
Stopcock
95605885
Immersion heater backnut
95607940
Immersion heater gasket
95611822
Immersion heater key
95607861
Immersion heater blanking plug
95605881
Titanium immersion heater - upper
95606989
Direct combined thermostat / thermal cut-out
95612717
Direct combined thermostat / thermal cut-out (spade terminals)
95612721
Tundish
95605838
Insulation set (T&P relief valve)
95607922
Mounting plate (indirect)
95607931
Indirect control cover
95614118
6 way terminal block
95607933
2 port motorised valve (22mm connections)
95605819
Incoloy immersion heater - lower
95606984
Indirect combined thermostat and cut-out
95612716
Indirect combined thermostat and cut-out (spade terminals)
95612722
Temperature and pressure relief valve
95605810
Set of compression nuts and olives
95607838
Drain valve 1/4 turn
95605051
Wiring centre
95612702
TP9000 Programmer
95607903
TP1 room temperature sensor
95607904
Automatic differential bypass valve (straight)
95607692
2 port motorised valve (28mm connections)
95605884
Pressure gauge
95607065
Automatic air vent
95605050
12 Litre primary expansion vessel
95607066
Expansion vessel hose
95607067
Circulating pump
7032841
Expansion relief valve (3 bar primary circuit)
95607095
Filling loop and connection
95607096
Danfoss programmable room stat
95607044
Table 6: Spares
27
Figure 15: Exploded view of 3bar pressure reducing valve
Pressure Reducing
Valve Cartridge (3 Bar)
Strainer Mesh
3 Bar Pressure Reducing Valve - Complete
95:605:886
Expansion Relief Cartridge
8 Bar Pressure Relief Valve, Complete
95:605:893
Figure 16: Exploded view of 8bar pressure relief valve
Stopcock can be used either with
3 bar inlet control valve or 8 bar
pressure relief valve
95605885
Figure 17: Exploded view of stopcock
28
Indirect Control Assembly
For 210 litre and above a further
indirect control assembly accessory
is available 95:970:554
Mounting plate (indirect)
95:607:931
Terminal cover (indirect)
95:614:118
Indirect combined
thermostat and
thermal cut-out
95:612:716
Direct combined
thermostat and
thermal cut-out
95:612:717
Backnut
95:607:940
Gasket
95:611:822
Incoloy immersion
heater lower
95:606:984 6 Way terminal block
95:607:933
Figure 18: Indirect exploded view
29
T&P valve
95:605:810
8 bar pressure relief valve
95:605:893
Circulating pump
70 328 42
2 port motorised valve
(22mm connections)
96:605:819
Filling loop and
connections
95:607:096
Pressure gauge
95:607:065
Automatic differential
bypass valve
95:607:692
Drain valve (1/4 turn)
95:605:051
Wiring centre
95:612:702
Figure 19: Indirect exploded view
30
Tundish
95:605:838
NOTES.
31
Benchmark checklist
32
Commissioning &
service records
33
Warranty
Lifetime Warranty*
The MEGAFLO Lifetime Warranty provides unrivalled levels of customer support and peace of mind in the unlikely event that
a problem arises from a manufacturing defect. It is supported by a large nationwide team of company-employed field-based
engineers and our own call centre, which is open 363 days a year.
This Lifetime Warranty applies in relation to the following MEGAFLO products:
•MEGAFLO cylinders
•MEGAFLO calorifiers
The MEGAFLO Domestic Lifetime* Warranty
The MEGAFLO Domestic Lifetime* Warranty covers MEGAFLO cylinders installed in domestic properties† against corrosion for
the lifetime* of the owner.
The cold water combination valve (and expansion vessel, where supplied) is covered by a five year warranty from the date of
purchase of the MEGAFLO product that includes both parts and labour. All other components, including any other valves,
fittings and controls are covered by a two year warranty from the date of purchase of the MEGAFLO product that includes both
parts and labour.
In the case of the Megaflo Systemready, Megaflo Systemfit and Megaflo SolaReady units the supplied pumps and motorized
valves ( where fitted ) are also covered by this two year warranty.
Incalloy immersion heaters ( where fitted ) are covered by a two year warranty.
Titanium Immersion heaters ( where fitted ) are covered by a five year warranty.
The MEGAFLO Commercial Lifetime* Warranty
The MEGAFLO Commercial Lifetime Warranty covers MEGAFLO cylinders and calorifiers installed in non-domestic properties^
against corrosion for a period of 30 years from the date of purchase.
All other components, including valves, expansion vessels, immersion heaters, fittings and controls are covered by a two year
warranty from the date of purchase of the MEGAFLO product that includes both parts and labour.
Accessories
Shower heat recovery units are covered against manufacturing defects for a period of two years. Flat plate solar collectors are
covered against manufacturing defects for a period of 10 years from the date of purchase of the MEGAFLO product. Evacuated
tube solar collectors are covered against manufacturing defects for a period of five years from the date of purchase of the
MEGAFLO product. All other solar accessories are covered against manufacturing defects for a period of two years from the
date of purchase of the MEGAFLO product.
Outside of the UK
These warranties are valid for installations within the United Kingdom.
For installation in the Republic of Ireland please contact Potterton Myson (Ireland) Limited on 00353 (0) 1 4590870
For installations outside of the United Kingdom and the Republic of Ireland, please telephone MEGAFLO Export on +44 1603
420271 for further details of the warranty terms and conditions applicable.
These guarantees are valid provided that:
•The MEGAFLO product has been installed by a competent installer in accordance with the instructions contained in the
installation instructions and in compliance with all relevant laws, guidance, codes of practice and regulations in force at the time
of installation.
•The MEGAFLO product has not been modified or tampered with in any way, other than by a Heatrae Sadia or Baxi Customer
Support approved engineer.
•The MEGAFLO product has not been subject to damage by scale.
•The MEGAFLO product and any part or parts of the MEGAFLO product (whether factory fitted or otherwise) have not been
repaired or replaced other than by a Baxi Customer Support approved engineer and any replacement parts used on
34
the MEGAFLO product are authorised MEGAFLO spare parts.
•The factory fitted temperature and pressure relief valve have not been tampered with or removed.
•The MEGAFLO product has not been subject to misuse or neglect.
•The MEGAFLO product has only been used for the storage of wholesome water. Should another substance be put through
the product, the warranty will be invalid unless it is part of a disinfectant procedure carried out in accordance with BS EN 806.
•The MEGAFLO product has not been subjected to frost or freezing temperatures (except for solar collectors which are
designed for external installation).
•The Benchmark™ commissioning checklist service record, included in the MEGAFLO installation instructions has been
completed.
•Regular maintenance has been carried out by a competent person/, an approved engineer from Heatrae Sadia or any
other part of the Baxi Group Baxi Customer Support approved engineer in accordance with the requirements set out in the
maintenance section of the installation instructions.
•Access is available, at reasonable times and upon reasonable notice, to the MEGAFLO product to allow for any inspection
repair or replacement.
•The product is registered within 60 days of purchase. This can be done by telephone, online or by using the registration form
provided with the product.
•Evidence of purchase (for example a receipt or delivery note) and date of supply is submitted when making a claim.
•The MEGAFLO product has not been affected by any cause beyond our reasonable control including, without limitation: an
act of God, explosion, flood, fire or accident; war or civil disturbance; strike, industrial action or stoppages of work; any form of
government intervention; a third party act or omission including theft or malicious damage; failure by you to give us a correct
delivery address or notify us of any change of address.
.
If any of the following situations occur, the MEGAFLO Lifetime Warranty* will not apply:
•Any wilful or accidental damage caused by your negligence
•Damage caused as a result of scale.
•Installation not in line with the installer and user manuals provided,
•Failure to comply with installation instructions (whether oral or in writing),
•Misuse of the MEGAFLO product or alteration of the MEGAFLO product not in accordance with the requirements set out abo
ve.
•Defects which are not reported to us outside of the warranty period on 03444 8711535 or [email protected]
•Any third party repair or replacement costs unless those costs have been agreed and authorised by Baxi Customer Support or
Heatrae Sadia in writing prior to incurring the costs.
•In relation to the MEGAFLO Commercial Lifetime Warranty only, we will not be liable for any indirect and consequential losses
and any loss of earnings, loss of business, or losses in relation to stress and inconvenience, howsoever caused.
35
Claims
Defects should be reported to us as soon as you are aware of them. Please report defect to us by contacting 03444 8711535
or [email protected] .
Notes
We are only able to carry out warranty repair/replacement to MEGAFLO solar collectors which have safe access and that meet
current Health & Safety working at heights requirements. The customer will cover the cost of any safety equipment including
but limited to scaffolding and lifting equipment that is required to meet this standard and will appoint a contractor to carry this
work out.
Heatrae Sadia accepts no liability for any third party damage.
These warranties do not affect your statutory rights and remedies in relation to the MEGAFLO products.
Annual service
Annual services are available from Baxi Customer Support, the service division of Heatrae Sadia.
Please contact Baxi Customer Support on 0344 871 1535 for details.
*In domestic† properties, lifetime is the period during which the first owner of the MEGAFLO or new build home continues
to own the property. Should the property be sold, the new owner and any subsequent owners will receive a 30 year warranty
from the date the original owner purchased the MEGAFLO or new home with a MEGAFLO installed. In non-domestic properties
lifetime is a period of 30 years from the date of purchase by the original owner and is transferable to any new owner of the
property.
†Domestic is any premises not being, or ever having been, wholly or partly utilised for business purposes.
^Non-domestic premises are any premises other than those defined as Domestic.†
All MEGAFLO warranties are conditional on the installation being carried out in accordance with the installation instructions
supplied with the product. These warranties do not affect your statutory rights. Full terms and conditions of these warranty
packages are available on request or via www.heatraesadia.com/megaflo
Heaatrae Sadia*, Hurricane Way, Norwich, Norfolk, NR6 6EA
MEGAFLO may introduce modifications to their products from time to time. Consequentially the details given in this brochure
are subject to alteration without notice.
Contacts
Specification Advice Hotline
T: 01603 420220
F: 01603 420229
E: [email protected]
www.heatraesadia.com
* Heatrae Sadia is a trading name of Baxi Heating UK Limited, Brooks House, Coventry Road, Warwick, CV34 4LL
July 2015
36
Spares Stockists
Electric Water Heating Co.
2 Horsecroft Place
Pinnacles
Harlow
Essex CM19 5BT
Tel: 0845 0553811
E-Mail: [email protected]
SPD
Special Product Division
Units 9 & 10
Hexagon Business Centre
Springfield Road
Hayes
Middlesex UB4 0TY
Tel: 020 8606 3567
Parts Center
Tel: 0344 292 7057
www.partscenter.co.uk
Newey & Eyre
Unit 3-5 Wassage Way
Hampton Lovett Ind. Estate
Droitwich, Worcestershire
WR9 0NX
Tel: 01905 791500
Fax: 01905 791501
UK Spares Ltd
Unit 1155
Aztec West
Almondsbury
Bristol BS32 4TF
Tel: 01454 620500
Alternatively contact your local supplying merchant
or wholesale branch or use our online stockist finder
at www.interpartspares.co.uk
37
NOTES.
38
NOTES.
39
Customer service
Telephone:
0344 871 1535
Megaflo
E-mail:
[email protected]
Hurricane Way
Norwich
Norfolk
NR6 6EA
Important notice to installations outside of the UK:
References to legislation, legal requirements, regulations,
building regulations benchmark, spares stockists,
guarantees and warranty are ONLY APPLICABLE WITHIN
THE UK.
For local legislation, legal requirements, regulations,
building regulations outside of the UK, contact your
local Authority.
For spares stockists, guarantees and warranty outside
the UK, contact your local supplier or,
Export Sales
T: +44 (0)1603 420271
F: +44 (0)1603 420199
E: [email protected]
© 2015
Unvented Hot Water Cylinder
36
7032985 _issue_02
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement