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Hlflo Installation Guide (natural gas)

1. PILOT OR START GAS VALVE Position as shown on the drawing above then wire as shown GV2 MV MAIN GAS VALVE S 2 TO FIT AIR SWITCH remove the two links from the APS APS AIR PRESSURE SWITCH terminals and connect the pressure switch as shown the drawing E C O ENERGY CUT OFF above FLUE DAMPER FI amp F2 FUSES 3 TO FIT A FLUE DAMPER move the flue damper jumper link to the 24 VacON OFF Switch On position as shown on the drawing above then wire as shown FLUE SYSTEMS Fig 4a Terminal Detailed recommendations for flue installation are given in BS 6644 BS5440 Pt 1 and British Gas publication IM 11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters The flue connection is designed for BS 835 type heavy duty flue but light quality flue pipe mild steel or stainless steel sheet may be used using the appropriate adapter Flue pipes etc shall be fitted socket up to keep any condensate within flue and appliance Flues up to 200mm 8in diameter should be fitted with a suitable British Gas Certified terminal Fig 4a The terminal position is most important and must be at least 1000mm 40in above roof surfaces or at least 600mm 24in above any parapet and clear of any adjacent obstruction as well as being clear of any openable windows ventilators or features which could allow re entry of flue products into the building Pressure areas should also be
2. Step 3a Press Temperature Up button to change temperature format to C Changes to C FC Flashes d Status Operational SELECK SEN otep 3b Press Temperature Down button to change temperature format to F Changes to F Flashes Step 4 Press Set button to confirm F or C format F C will stop flashing nor poo Symbol Stops Flashing idle Status Operational APPENDICES Troubleshooting Step 5 Pressing Select button will return display to setpoint in format selected F or C immediately Setpoint shown in F Error Codes and Error History Display If there is an operating problem with the water heater an error code number will appear on the water heater display with Service Needed to the right of the Status indicator error code label is located under the water heater display The following section in this Service Manual explains the error codes with corrective actions to repair the water heater Example of Error Code in the Display Honeywell idle Service Needed SELECT Lockout RESET Error Code History In Service Mode pressing the Select button after the Software Version item 8 in the previously described sequence of service modes will show an error code history if there have been any previous operating problems with the water heater If the display shows there is not a current err
3. Where the water heater s is are installed in boiler house or purpose built compartment a manually operated valve for the boiler house must be fitted in accordance with the Gas Safety Installation and Use Regulations 1998 The valve must be easily identified and readily accessible After installation the system should be pressure tested for soundness and purged in accordance with BS 6891 or IM 2 and IM 5 as appropriate ELECTRICAL HI FLO MODELS STANDARD RANGE MODELS SUPPLY External wiring to the water heater s must be installed in accordance with current I E E AUTO IGNITION Regulations for the wiring of buildings and to any Local Regulations that may apply UNITS The Auto Ignition Heater is designed to operate from a 220 240V 1Phase supply The fuse rating is 5 amps The method of connection to the mains electricity supply should facilitate complete electrical isolation of the appliance preferably by use of an unswitched shuttered socket outlet in conjunction with fused three pin plug both complying with the requirements of BS 1363 Alternatively a fused double pole switch or fused spur box serving only the heater may be used The point of connection to the mains electricity supply should be readily accessible and adjacent to the appliance Fig 3a and 3b Connect the electrical supply to the main control panel terminal block via the cable glands in the base of the control panel Mains input cable should be 0 75mm
4. c Oxidation build up on flame rod Clean flame rod 22 or replace pilot as necessary Pilot j Step 2 Inspect pilot orifice E gt Ignition ft Wire a Remove 7 16 ferrule nut from bottom of pilot 7116 mm ferrule Nut Flame Sense b Remove pilot tube and orifice from pilot aa Wire c Inspect pilot tube for blockage Clean or replace as necessary Aluminum d Inspect pilot orifice for blockage Clean or replace Pilot Tubing as necessary APPENDICES SERVICE PROCEDURE D24 IV Control Board Replacement A DANGER 120 volt exposure To avoid personal injury unplug while performing this procedure Control board replacement Step 1 Disconnect Power Step 2 Unplug wire connections from board Depress plastic tabs fire connections Step 3 To remove board tilt control panel to the right and slide control hook tabs from slots in contro panel F gt 25 To remove lower sensor Remove clip pull sensor out Slots in control panel Unhook tabs from control panel slots Remove clip Pull out sensor IMPORTANT When replacing lower sensor make sure sensor is fully inserted into the well and securely held by the clip on the well groove see photo 25 APPENDICES SERVICE PROCEDURE D24 V Flue Baffle Removal Inspection WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary pr
5. Checking resistance of upper sensor Lower thermister access located inside control box 2 Draw quart of water off Drain Valve Using a thermometer determine water temperature 3 Use table below to verify correct resistance per water temperature measured Are readings N Replace correct thermister Checking resistance of Y lower sensor center and Check harness nee ale continuity harness Continuity okay CAUTION Y Be Careful When Making Resistance Measurem ents Not to Damage or Deform Connectors or Connector Pins Replace E Sensor Resistance at Various Temperatures Example If water temperature is 26 7 C then the resistance through the sensor would be 8449 see shaded area NOTE Sensor resistance increases as the temperature falls In Degrees C C 0 1 2 3 4 5 26109 25400 24712 24045 10 19906 19383 18876 18383 15 5 15314 14925 14548 14180 5 6 7 8 9 22771 22163 21573 21000 20445 17440 16990 16553 16128 15715 13477 13140 12812 12494 12185 21 1 11884 11592 11308 11032 10502 10248 1000 9760 9526 26 7 9299 9078 8862 8653 8250 8057 7869 7685 7507 32 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961 37 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 44 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 49 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112 55 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538 60 2488 2439 2391 2344 2298 2253 2209 2166 2124
6. Manifold Pressure Port with hose barb inserted for measuring pressure Check burner tubes for scale or debris build up Clean burner as necessary see Main Burner and Pilot Removal and Inspection Check tank flues for blockage or debris build up causing restriction see Flue Baffle Removal Inspection APPENDICES SERVICE PROCEDURE D24 IV Main Burner amp Pilot Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Main Burner Removal Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Main Burner Inspection Step 1 Step2 Step 3 Gas Valve Wire Leads Burner Rack Mounting Screw Gas Valve Control Knob Disconnect un plug water heater from electrical supply Gas Supply Line Turn OFF gas supply to water heater Rotate gas valve control knob to the OFF position see photo 17 Disconnect Gas supply line from the gas valve see photo 17 Pilot Flame Sense Disconnect wire leads from gas valve Wire White see photo 17 Disconnect white flame sense wire amp orange ignition wire from Control Board photo 18 Pilot spark wire Orange Remove the two burner rack mounting screws see photo 17 Slide complete burner rack out from heater see p
7. gal h 39 40 61 62 87 es gal h 31 32 49 50 7 Heat Input Gross kW 42 1125 119 149 126 Btu h 40 944 42 650 65 000 65 000 88 712 Heat Input Net kW 41 11 4 17 17 124 Btu h 37 532 38 900 58 004 58 004 81 888 P1 a qu rs ame Burner Gas Pressure mbar 10 10 10 10 10 ins wg 4 4 4 4 4 bee T ME ME MER ME eme Ins Wg 14 14 14 14 14 de am EE MN f amp h 394 4122 62 86 62 86 85 71 Gas Connection Rc in BSP Int 1 2 1 2 41 2 1 2 1 2 GE DON A om Flue Gas Volume m h 17 18 26 31 37 Gas Injector Orifice Diameter mm 295 305 386 386 422 in 0 116 0 120 0 152 0 152 0 166 Flue Size Secondary mm 100 100 100 125 125 in 4 4 4 5 5 Cold Water Feed Connection R in 5 1 1 1 1 11 4 Hot Water Flow Connection R in 5 1 1 1 1 11 4 Return Connection Rp in BSP Int 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Ext 3 4 3 4 3 4 3 4 3 4 Max Working Pressure bar 10 3 10 3 103 10 3 10 3 Ibf in 150 1 150 150 150 150 Max Test Pressure bar 206 206 206 206 206 Ibf in 300 300 300 300 300 Weight Empty REE EO EE EE EEEE boobed Sable 57 LE EE 65 Ao 18 Ib 94 126 144 1244 400 pretend C X M NU LE Ib 334 446 544 1874 1240 Shipping Weight kg 44 59 68 120 194 Ib 98 131 150 264 428 Shipping Dimensions Depth mm 546 587 1587 692 914 in 211 2 231 8 231 8 271 4 36 Shipping Dimensions Width mm 486 537 537
8. Temperature Stratification Stacking When small amounts of hot water are drawn repeatedly the thermostat responds to each feed of cold water and activates the main burners Each time this occurs more heat may be put back in the tank than was drawn off As this continues water in the upper level of the tank gets hotter than the thermostat setting This hotter water does not mix completely with the cold inlet water but rises in a chimney effect to the top of the tank Many repetitions of this over a short time period result in accumulation of excessively hot water in the upper part of the tank even when the thermostat control is within limits This is known as stacking To counter this condition an upper thermostat phial is fitted not on Model 32 143 which senses abnormally hot water and shuts down the main burner until the water cools Most modern commercial pipe installations include a circulating pump which keeps hot water moving continuously throughout the heater This stabilises temperatures in the water heater tank and throughout the pipe system INTRODUCTION PRE SERVICE OPERATIONS BURNER ASSEMBLY STANDARD RANGE BURNER ASSEMBLY HI FLO RANGE Servicing must be carried out by a properly qualified person Whilst giving these instructions for the care of the Heater it is recommended that checks are carried out by the installer or local gas authority at least annually Ensure good ventilation by keeping the heater free of ext
9. Type of Roof Internal Route External Internal External On Ridge Not on Ridge Route Route Route Pitch 1m 3 3 ft 1m 3 3 ft exceeding above roof above roof 450 intersection intersection Pitched 600 mm 24 450 5 terminal should intersection the terminal be 600 mm should be 24 in above With 600 mm 600 mm the level of parapet 2 ft 24 in the top of the Ne above roof above the structure Flat intersection level of the adjacent 250 mm f Without 10 in above roof intersection For all installations please refer to the table below for calculating requirements Detailed AIR SUPPLY recommendations for the air supply are given in BS 5440 Part 2 BS 6644 Clause 19 AND and IGE UP 10 Pt 1 The following notes are provided for general guidance only VENTILATION j 2 Ventilation shall prevent the heater environment from exceeding 32 C 90 F The purpose provided space in which the heater s are installed must have permanent air vents communicating directly with the outside air at high and low level Where communication with the outside air is possible only by means of high level air vents ducting down to floor level for the lower vents must be used For an exposed building air vents must be fitted on at least two sides preferably on all four sides Air vents should have negligible resistance and must not be sited in any p
10. pilot energised thermopile to open the main burner valve 5 The gas valve has a slow burning feature Burners will light several seconds after setting the thermostat 6 Burners will continue to heat water until the preset temperature is reached As the thermostat opens the thermopile current is interrupted and the main gas valve will close Auto Ignition Units Operating Sequence Hi Flo and Standard Range HI FLO AND 1 When the control thermostat senses too cool water a signal is sent to the control sequence unit STANDARD 2 The flue damper unit is de energised and thus allowed to open Hi Flo only RANGE 3 When the flue damper is fully open gas is allowed to pass to the pilot and simultaneous ignition begins Hi Flo only AUTO IGNITION 4 When the pilot flame is established the main gas solenoid is allowed to slowly open and the main burners or burner is lit 5 When the control thermostat is satisfied both pilot and main gas solenoids are closed 6 The damper motor is energised and the damper closes Hi Flo only ECO Energy Cut Off The heater is equipped with an ECO Energy Cut Off device fitted to the control thermostat It is a temperature sensitive switch which opens at high temperature shutting off gas to the burners including the pilot in an overheat condition If the pilot goes out and is associated with high water temperature the ECO is probably operational and the cause of overheating should be investigated
11. result in scalding hot water delivered to the taps It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted Setpoint Flashes idle Status Operational SELECN SEN Step 4 To lower the temperature setpoint press the Temperature Down button until the desired temperature is shown on the water heater display Setpoint Flashes idle Status Operational SELEC APPENDICES Troubleshooting Step 5 When the desired setpoint is reached on the water heater display press the Set button to confirm the new setpoint Setpoint stops flashing in the water heater display Setpoint Stops Flashing d 1 F setpoint IZLI Status Operational SELECN SEIN To Display and Change Temperature Format F C To Change Temperature Format in Display from F to C or C to F Step 1 While in Service Mode press Select button until F C is shown in the upper right portion of the water heater display idle Status Operational Step 2 Press Set button to change temperature format F C symbol will flash in the water heater display F C Flashes idle Status Operational N APPENDICES Troubleshooting
12. specified manifold pressure If the manifold pressure is not within 0 3 w c of the specified pressure then remove the regulator cap from the N Replace Gas Valve gas valve and turn plastic screw clockwise to increase pressure and counterclockwise to decrease pressure Be sure inlet gas pressure is at least 1 w c above the manifold pressure Replace regulator screw and pressure tap cap when finished Is manifold pressure O K Check venting conditions clogged vent down drafts or negative building pressure Is vent system okay LY there sufficient combustion air being supplied to the water heater Are there combustion air openings or supply pipes N to the room Open access door to the utility room to see if problem is V corrected Y Check for unstable pilot flame or oxidation of the flame rod pilot causing weak pilot signal Make sure N Correct improper venting condition Refer to Installation Instructions Line gas pressure port Gas Valve pressure regulator cap adjustment screw accessible by removing cap screw Provide proper combustion air to water heater Refer to Installation Instructions pilot shield is in place and does not WERE touchipilot fame sensor Connect hose barb to manifold ht J pressure port shown above then F connect monometer to measure gas manifold pressure ko See Pilot Inspection section
13. 2083 65 5 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720 T1 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427 76 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191 82 1170 1150 1129 1110 1090 1071 1053 1035 1017 999 88 9 82 965 949 933 917 901 886 871 857 842 93 828 814 801 788 775 762 749 737 725 713 APPENDICES Ay DANGER 120 volt exposure To avoid personal injury use caution while performing this procedure SERVICE PROCEDURE D24 II Pilot Operation Testing A CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins Condition Pilot will not light or stay lit Heater Display Reset control by pressing the lower right button under reset on the display for 3 seconds Does control board start ignition sequence and start sparking sparking noise at pilot or at board 0 Is there spark at the pilot v terminal pins 8 amp 2 on Control plug of Control Board Carefully insert meter probe in wire plug to check pin terminals Make sure control is in the trial for ignition sequence see Sequence of Operation Is there 22 27 volts AC input across wire leads MV PV amp PV yellow amp red wires at Gas Valve see photo 12 E Y Check wire harness for damage or loose connections Repair or replace as needed Turn on power to the water h
14. AFTER CLOSING GAS VALVE FLAME DETECTED BEFORE IGNITION FLAME DETECTED AFTER A HEATING CYCLE COMPLETES UPPER SENSOR READINGS FAULTY LOWER SENSOR READINGS FAULTY FLAME ROD SHORTED TO GROUND AC LINE FREQUENCY ERROR SIGNAL TOO NOISY OR FREQUENCY INCORRECT LINE VOLTAGE TOO LOW OR HIGH DC OUTPUT VOLTAGE UNSTABLE MAXIMUM NUMBER OF RETRIES DETECTED MAXIMUM NUMBER OF IGNITION RECYCLES DETECTED ELECTRONICS FAILURE HIGH WATER TEMPERATURE OVER 200 F IF ANY OF THE ABOVE CODES APPEAR ON THE CONTROL DISPAY CONTACT YOUR PLUMBER OR QUALIFIED SERVICE AGENT FOR SERVICE OF THIS WATER HEATER 238 47617 00A APPENDICES WARNING The following procedure is for service and installation personnel only Resetting lockout conditions without correcting the malfunction can result in a hazardous condition If an error code is displayed except for 4 low flame sense current the water heater will be in a lockout condition with the water heater display showing the error code number and Service Needed in the status section of the display window Error codes 62 maximum number of retries detected and 63 maximum number if ignition recycles detected are Soft Lockouts in which the control can be reset in the User Mode by pressing the lower right button under Lockout Reset shown in the lower right portion of the display The control will also go through 3 attempts to relight the burners every hour in the soft lockout
15. Burner Assy comprising items 1 B2 B6 and B8 B9 B2 C503 C503 Burner Bar 7 9 B3 C545 C550 Burner Manifold 1 B4 C546 E550 Injector 3 45 3 18mm 7 C551 Injector 3 60mm PP 9 E549 Injector 3 26mm A 1 9 5 C507 C507 Pilot Assy c w injector and electrode 1 B6 C547 C547 Pilot Supply Pipe 1 B7 252 252 Pilot Injector 1 B8 C552 C552 Thermopile 1 B9 C511 C511 Multifunctional Valve 1 B10 C539 C539 Control Thermostat with remote 1 phial and ECO B12 C560 C560 Lead Assy 1 Thermostat to Gas Valve 1 B13 C136 C136 Pressure Test Nipple 1 B14 C514 C514 Piezo Igniter 1 B16 C498 C498 Gas Cock 3 4 BSP FxF 1 B17 E418 E418 Pilot Shield 1 C1 C481 C482 Flue Damper Assy 8 10 1 C2 Control Box Assy complete 1 C8 Gas Control Valve 1 C9 C969 C969 Damper Harness 1 C10 Pilot Assembly 1 Permanent Pilot Auto Ignition PARTS LIST AND ILLUSTRATIONS Unvented Systems Kit Standard Range Unvented Systems Kit Hi Flo Range PARTS LIST AND ILLUSTRATIONS Unvented Systems Kit Complete D1 Pressure Reducing Valve Strainer D2 Check Valve Expansion Valve D3 Expansion Vessel D4 Temperature Pressure Relief Valve D5 Tundish Adaptor Wall Mounting Kit for Expansion Vessel D7 Hose Assembly D8 Wall Bracket Assembly Unvented Systems Kit Complete C1 Pressure Reducing Valve Strainer C2 Check Valve Expansion Vessel C4 Temperature Pressure Relief Valve C5 Tundish C6 Expansio
16. Regulations 1991 Approved Document G3 All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with Part G of Schedule 1 of the Building Regulations 1991 Typical water service layout for Standard Range single heater unvented system is shown in Fig 9 Typical water service layout for Standard Range multiple heater unvented system is shown in Fig 10 meldte SECTIONS gt WATER CONNECTIONS Terminal See Table page 9 Split Flue Clamp Hot Water Service OF zm T Cold Water Take off Secondary Return Coid Water Inlet via Tee H M Fig 9 To drain Terminal Hot Water Service A A Split Flue Clamp D3 Cold Water Take off Ji D4 D1 CK Op x I LS Coid Fig 10 V drain drain WE Inlet sections CONNECTIONS VENTED SYSTEMS Hi Flo RANGE The water heater must be fed from a cold water feed cistern or static water tank A safety valve must be fitted as specified in BS 6644 Clause 9 The safety valve must be fitted either directly to an upper tank tapping or not further than 1 metre along the outlet flow pipe of size not less than the safety valve There must be no valve separating the heater from the safety valv
17. and storage vessel Therefore if heaters are to be installed in locations where halogens are likely to be present they should be isolated from such compounds and ventilated from and to outside uncontaminated atmosphere Some of the vulnerable areas are a Hairdressing salons and adjoining rooms and basements b Establishments where dry cleaning solutions are used or stored c Degreasing plants using hydrocarbon solvents d Premises where refrigerant gases are used or stored sections QUALITY AND TREATMENT Where extreme conditions of water hardness exist scale can form in any water heating equipment especially when the heater is working under conditions of constant heavy demand and at high temperatures Each water heater is fitted with one or more magnesium anode s which protect the tank from corrosion caused by electrolytic action Magnesium anodes are sacrificial in that they corrode as they protect When the anode has eroded to less than 50 of it s original diameter it may not offer protection The anodes should be inspected annually and replaced as necessary Frequency of anode replacement will vary dependent on water quality Andrews Water Heaters offer Correx UP powered anodes as an alternative to the standard magnesium anodes These anodes do not need maintenance or replacement The potentiostat which regulates the current to the Correx anode features an indicator light which shows green
18. at least 5 minutes to allow unburnt gas to disperse Ventilate the area if possible COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only 7 days or more turn control knob to PILOT partially depress knob then turn clockwise to OFF Turn off gas service cock For shorter periods leave heater under thermostat control Checking Main Burner Pressure 1 Turn gas control knob to OFF 2 Release bleed screw and connect pressure gauge tube 3 Light burner as described above 4 Remove valve cap from port B and adjust pressure using exposed screw in accordance with data plate Turn screw clockwise to increase pressure and counterclockwise to decrease If possible check gas rate see Technical Data with meter and watch Refit valve cap to port B 5 Turn gas control to PILOT Remove pressure gauge tube and tighten bleed screw A 6 Turn gas control knob to ON and light burner as described above Fig 22 STANDARD Lighting the burner RANGE AUTO IGNITION MODELS Thermostat Control On Off Switch Gas Control valve Fig 23 Ensure gas supply is on Set thermostat control knob to the required water temperature See below Ensure time switch if fitted is in the ON position Move electrical ON OFF switch to ON and the burner will light Check pilot and main gas connections at gas control valve using leak detection fluid whilst burner is alight Turn OFF seal any leakages then re test UR
19. or purchaser that for continued efficient and safe operation of the heater it is important that magnesium anodes are inspected annually and that adequate servicing is carried out at regular intervals by the installer or by the local gas authority USERS For your safety read before lighting appliance SAFETY WARNING GUIDE 1 Always follow manufacturers instructions when lighting the appliance Failure to do 5 may result in damage to property personal injury or loss of life 2 Before lighting check all round the appliance area for gas Be sure to check at low level because some gas i e LPG is heavier than air and will settle on the floor 3 Do not make any attempt to re light the appliance if the main burner has extinguished Wait at least 5 minutes to allow for any unburnt gas to disperse Ventilate the area if possible FOR YOUR SAFETY IF YOU SMELL GAS 1 Turn off gas supply and open windows 2 Do not operate electrical switches 3 Extinguish any naked flames 4 Contact gas supplier if the smell of gas persists FOR YOUR SAFETY Do not store or use petrol aerosol or other flammable vapours or liquids in the vicinity of this or any other atmospheric gas appliance WARNING Hotter water increases the risk of scalding Before changing the temperature refer to instruction manual or data label Hot water can produce third degree burns in 6 seconds at 140 F 60 C 30 seconds at 130 F 54 C When properly instal
20. the Temperature Down button to change to the next error code index and press Select to view the error code number if any for that index number Continue on to index 1 the oldest error code index The water heater display will store up to 10 error codes with the oldest code starting in code index 1 with the most recent code in code index 10 Step 7 10 seconds after the last button press the Water Heater Display will revert back to the current error code display To exit Service Mode either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds setpoint idle Statu Operational 5 O Exiting Service Mode APPENDICES Troubleshooting ERROR CODE DEFINITIONS If the water heater has an operating problem there will be a number in the water heater display with Service Needed shown below the error code number Note the error code and the definition in the chart below This label appears on the control box under the water heater display The following sections will provide instructions for servicing each error code ERROR CODE 4 55 56 6 23 24 31 32 57 58 59 61 62 63 64 65 HONEYWELL INTEGRATED CONTROL ERROR CODE DISPLAY FOR 24 VOLT DAMPER MODELS DEFINITION LOW FLAME SENSE CURRENT DAMPER END SWITCH FAILED TO CLOSE STUCK OPEN DAMPER END SWITCH FAILED TO OPEN STUCK CLOSED FLAME SENSED OUT OF NORMAL SEQUENCE BEFORE OPENING GAS VALVE OR
21. using leak detection fluid whilst burner is alight Turn off seal any leakages then re test RR _ Shutting The Burner For long periods only 7 days or more move electrical ON OFF switch to OFF then turn gas control knob to OFF Turn off gas service cock For shorter periods leave heater under thermostat control Checking Main Burner Pressure Turn gas control knob to OFF Release bleed screw A and connect pressure gauge tube Light burner as described previously Remove valve cap from port B and adjust pressure using exposed screw in accordance with data plate Turn screw clockwise to increase pressure and counterclockwise to decrease If possible check gas rate see Technical Data with meter and watch Refit valve cap to port B 5 Turn gas control to PILOT Remove pressure gauge tube and tighten bleed screw A 6 Turn gas control knob to ON and light burner as described above COMMISSIONING SECTION 4 Check correct shape and size of Pilot Flame HI FLO No adjustment is provided for the pilot The restrictor C on the gas control see Fig 22 RANGE should be turned fully conterclockwise to the fully open position PERMANENT PILOT MODELS Piezo Electrode and Lead Assembly Plan View Thermopile Setting Gap 3mm Pilot Burner Front View FE Pilot Burner Main Burner Fig 26 When viewed from the front of the heater the pilot flame should appear as shown in the
22. 103 E021 C533 C235 N A N A C486 C488 E391 C694 C300 C301 C247 C534 E050 1 C503 C505 E017 E552 C507 C508 252 552 511 512 513 136 514 498 418 C480 C970 Permanent Pilot Auto Ignition 65 173 C500 C333 C334 C381 C103 C475 536 C235 C479 E056 C486 C488 C489 C694 C300 C301 C247 C534 E050 5 C503 C505 C538 7 E991 C507 C508 252 552 511 C539 C399 C136 C514 C498 E418 C480 C969 81 264 C501 C333 C432 C381 C103 C476 C540 235 479 55 486 488 489 694 C300 C301 C247 C534 E050 C541 C503 C505 C542 E553 C507 C508 C252 C552 C511 C539 559 136 514 498 E418 C480 969 Description Draught Divider Service Magnesium Anode Flue Connector 150mm BS 835 Flue Connector 200mm BS 835 Drain Cock BS 2879 3 4 Socket Coupler 3 4 Data Badge Flue Baffle Andrews Label Hot Outlet Connection 1 1 2 BSP Hydrojet Cold Inlet Connection top 1 1 2 BSP Top Cover Insulation Pad Flue Box Top Cover Cleanout Pad Seal Cleanout Pad Cleanout Pad Cover Drain Tapping Connector 3 4 BSP Nipple 1 1 2 BSP Hydrojet Cold Inlet Connection side 1 1 2 BSP Burner Assy comprising items B2 B6 and B8 B9 Burner Bar Burner Manifold Injector 2 69mm 2 40mm Injector 2 87mm 2 58mm A I Injector 3 66mm PP 3 25mm Pil
23. 2339 3b X X X X i __ 2440 b X X X X X dic X X X X X 2442 23 X X X X X i __ 24933 7b X X X X X 244 0 5 X X X 2445 0 5 j XP L m fo 5 e J JG 200 y da X X X X X mm 8a X X X X X 248 1a X X X ___ 2449 S XP X i 2 550 9a X5 1 9a 0 XS 2152 9a _ X5 2553 9a _ 252 J il Publication Date OCT2013 Baxi Commercial Wood Lane Erdington Birmingham B24 9QP N INVESTORS NJ v 4 IN PEOPLE ISO 9001 Quality Management RS 33961 Sales Technical ZS 0845 070 1056 0845 070 1057 tt Email andrews baxicommercialdivision com ANDREWS www andrewswaterheaters co uk WATER HEATERS
24. 333 C694 C300 C301 C247 E003 C407 997 974 C684 C136 C683 382 E016 112 252 688 514 670 669 C689 C664 C698 Description Adaptor Ring Draught Diverter Hot Outlet Nipple Cold Inlet Dip Tube Plug Return Connection Drain Cock Socket Coupler 3 4 Cover Combustion Chamber Cover Burner Access Data Badge Flue Baffle Service Magnesium Anode Service Magnesium Anode Cleanout Pad Seal Cleanout Pad Cleanout Pad Cover Nipple 3 4 NPT x 3 4 BSP Nipple 3 4 NPT x 3 4 BSP Burner Assy comprising items B2 B3 5 7 B12 Pilot Supply Pipe Burner Supply Pipe Multifunctional Control Thermocouple Pressure Test Nipple Injector Gas Cock Control Knob Knob Pilot Burner Jet Type N18 Pilot Burner c w Jet Pipe Electrode and Lead Piezo Igniter Top Cover Outer Jacket Base Assy c w Radiation Pan Special Screw Combustion Chamber Leg Qty I I lI lI lA PARTS LIST AND ILLUSTRATIONS Hi Flo Model 32 143 r TTE t F s TAERE Hi Flo Models 65 173 and 81 264 PARTS LIST AND ILLUSTRATIONS HI FLO MODELS Model Ref Part Numbers 1 2 4 5 7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A19 A20 B1 B2 B3 B4 B4 B4 B5 B6 B7 B8 B9 B10 B10 B12 B13 B14 B16 B17 C1 C2 C8 Co C10 RE A I 32 143 E023 C333 C334 C381 C
25. 4 Commissioning REPLACING COMPONENTS Hi Flo RANGE THERMOPILE PILOT BURNER PILOT RESTRICTOR Om A VW N Disconnect thermopile and pilot supply pipe from gas control valve Remove two screws and withdraw burner assembly Remove two screws and withdraw pilot assembly Unscrew gland nut securing thermopile to it s bracket and withdraw Unscrew pilot feed pipe nut and withdraw pipe The pilot injector will be left in the pilot burner and may be withdrawn by inverting the burner and allowing it to fall out Re assemble pilot assembly and connect pilot pipe only to gas control valve with the pilot assembly outside the heater Turn on gas service cock Turn gas control to PILOT and press knob whilst testing pilot connection at gland nut for soundness with leak detection fluid Seal any leakages and re test Turn gas control valve and service cock to OFF Re assembly is reverse of steps 2 to 5 9 Light the heater in accordance with lighting instructions All gas joints must be checked for soundness using leak detection fluid Turn off and seal any leakages DO NOT EXAMINE WITH A NAKED FLAME 10 Re light the heater and set thermostat to user s requirements NOTE Models 62 341 54 418 and 54 440 are fitted with an anchor bracket between the burner manifold and the heater body Remove two screws to release the anchor bracket KR W N gt CON WD VU Turn off the gas control and the service cock Disco
26. 651 762 in 19 1 8 21 1 8 21 1 8 25 5 8 30 uen P ME E T E in 47 49 59 60 72 TECHNICAL DATA SECTION 2 gt ANDREWS MODEL NO Storage Capacity 145 32 295 65 368 81 32 143 65 173 81 264 62 341 54 418 54 440 relser A e ST ee eset SNE a Gn E A E Pera AS a tere aR CRE sorti B iw Dr SES Ce ee ee eee m rca 45 73 249 076 317 316 395 792 282 245 1245 Hi Flo NE UN 2 RANGE 1549 1900 1998 341 418 440 1239 1520 1598 273 334 352 9538 1169 1223 210 257 270 102 128 139 8 024 436 736 474 268 93 116 126 430 000 Burner Gas Pressure Pernament Pilot eer eer cee eee ee ee eee e
27. 6B Description Control Box and Wiring Assy 26 Lower T Stat Sensor 25 Control Box and Wiring Assy 26 Control Box and Wiring Assy 26 Upper T Stat Sensor 28 Lower T Stat Sensor 25 Control Box and Wiring Assy 26 Upper T Stat Sensor 28 Lower T Stat Sensor 25 Control Board T Stat Board S9360B1010C 3b Control Board T Stat Board S9360B1015C 3b Control Display 1B Transformer 230V 24V 13c Sensor Well 23 Main Power On Off Switch 7b Damper 6 Effikal PCF Series 5 Damper 8 Effikal PFC Series 5 Damper 10 Effikal PCF Series 5 Gas Valve VR8601CB1012 4a Pilot Assembly PSE 46N 8a Pilot Tubing Supply Pipe Alum 24 10a Pilot Tubing Supply Pipe Alum 30 10a Main burner Injector 2 40 mm 9a Main burner Injector 2 58 mm 9a Main burner Injector 3 25 mm 9a Main burner Injector 3 18 mm 9a Main burner Injector 3 25 mm 19B 20B 14B Interpart Movex Number po 43d EG 26 KT __ 2 30 25 X J j __ 2531 26 X __ 22 26 _ X L 099 J 28 _ x 4d 4 234 25 _ X X 2335 26 _ X X i 21336 28 _ J X X i 237 25 j _ X X i 2338 3b X
28. ANDED 105 OU L EQUIVALENT WIRING DIAGRAM For enable option time control break terminal No 1 on secondary side of transformer APPENDICES Troubleshooting A CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals Water Heater Fault Water heater does not operate Display Error Code Water heater display does not operate blank display Check main power supply to water heater fuse circuit breaker plug receptacle line cord or wiring to water heater Check to make sure switch on top of control panel is in the ON position Checking line voltage to board Checking primary voltage to Pins to black and white wires g Primary g transformer from board Pins to black and white wires Voltage at primary pins 1 amp 3 white and black wires should be 110 120 If not check Line In pins 1 amp 4 Check line cord with ohmeter Replace line cord if defective Verify Primary and Secondary voltage at the control board If there is not 24 volts at Secondary pins on the control board check transformer Replace transformer or wire harness Checking secondary voltage from Checking transformer voltage front transformer Pins to blue and yellow terminals are 24 volts rear terminals wires are 120 volts i 2 Water Neate With the control cover tilted down Does damper begin to open Increase thermostat setting if tank is Check
29. Flue Clip 1 This flue run 2 amp 3 are recommended flue runs Fig 4b must not be used A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all natural draught flue installations If this dimension cannot be achieved please contact Andrews Water Heaters Please note this is not required where a common flue header is used on multiple installations Fig 5 Common flues may be used on multiple installations only if all the heaters are of the same burner system and fuel type and should be sized to ensure complete evacuation of the flue products from the installation Where one flue is to be used more regularly or for longer periods than the others in the group it should be connected at the point nearest to the main flue See BS 6644 Clause 20 for further information and recommendations on this as well as general flue requirements Each unit has an atmospheric burner system amp uses natural gas Heater with highest usage fitted nearest to main flue if applicable Fig 5 Fit a flue clip or flange joint close to the diverter so that it is secure but can be disconnected for servicing The weight of the flue must be borne by securing clips etc and not by the heater Minimum Heights from Roof to Base of Flue Terminal Not within 1 5m 5ft of a Within 1 5m 5ft of a vertical surface of a vertical surface of a structure on the roof structure on the roof
30. ION SECTION 3 gt IMPORTANT AIR SUPPLY 1 The effective area requirements specified in the table are related to the maximum AND net input of the heater s and are equivalent to those specified in BS 6644 and IGE UP 10 Pt 1 VENTILATION 2 The free area of the grilles should not be less than the size of the recommended ventilation opening 3 The supply of air to a space housing the heater s by mechanical means should be a Mechanical inlet with natural extraction b Mechanical inlet with mechanical extraction NOTE Natural inlet with mechanical extraction must not be used Where a mechanical inlet and mechanical extraction system is used the design extraction rate must not exceed one third of the design inlet rate All mechanical ventilation systems must be fitted with automatic gas shut off safety systems which cut off the supply of gas to the heater s in the event of failure of either the inlet or extract fans The requirements for air supply by mechanical ventilation are given in BS 6644 Clause 19 3 and IGE UP 10 Pt 1 The permanent air vents shall be sited away from any extract fans Where an extract fan is fitted check for spillage at the draught diverter as detailed in BS 5440 Part 1 Appendix B It may be necessary to increase the ventilation area to compensate for the extract fan 4 The vapours emitted by halogen based compounds can if drawn into the combustion air cause corrosion of the gas burner thermocouple
31. Pressure Relief Valve Cold Water Inlet of Water Heater C2 Check Valve C6 Expansion Valve Water C1 Pressure Reducing inlet Valve Strainer Balance Cold Water Take off if required C5 Tundish NB Tees elbows stop valve and pipework not supplied Fig 15 C4 must be fitted into the temperature relief port in the water heater tank When assembling items C1 and C2 ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn from the 22mm compression port on item C1 a The water pressure at this point will be similar to that available at the hot water outlet of the water heater If port a is not used it should be sealed with the blanking plug supplied secus WATER CONNECTIONS Fig 16 If higher flow rates are required for the cold water services a suitable tee fitting should be fitted to the pipework upstream of item C1 The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain see Building Regulations 1991 Approved Document G3 All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with Part G of Schedule 1 of the Building Regulations 1991 Typical water
32. Thames House 89 St Leonards Road Windsor Berkshire SL4 3BZ Contact Patrick McCart Tel 0175 383 3880 Fax 0175 383 3990 ECO SYSTEMS Po Box 330 Walton on Thames Surrey KT12 5YU Contact James Christie Tel 01932 221679 INSTALLATION SECTION 3 gt WATER CONNECTIONS Hydrojet System The upper jet ports direct the flow outward to begin the dynamic mixing action The lower jet ports direct the flow inward to increase the turbulence All models now incorporate the new Mini Hydrojet system on cold inlet side connections This system ensures water is directed onto tank Mini which minimises sediment build Hydrojet Inlet Nipple up from day one of installation Side Cold Inlet Connection The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet dip tube The tube is designed to increase turbulence and reduce sediment build up reduce thermal stacking and increase delivery CONNECTIONS VENTED SYSTEMS STANDARD RANGE The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644 The Water Supply Water Fittings Regulations 1999 must be observed when installing the system The cold water feed cistern must have an actual capacity greater than the hourly recovery rate of the heater or heaters to which it is fi
33. This manual must be kept with the appliance October 2013 No E132 Gas Fired Storage Water Heaters Installation guide operation and service manual HI FLO RANGE Models 32 143 65 173 81 264 62 341 54 418 54 440 Permanent Pilot Auto Ignition with Flue Damper E F Series SIANDARD RANGE Models 24 39 32 40 40 61 63 62 and 84 87 Permanent Pilot Auto Ignition Working towards cleaner future ANDREWS WATER HEATERS uud ANDREWS WATER HEATERS Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters Andrews Storage Water Heaters have been designed and manufactured to comply with current International standards of safety In the interests of the health and safety of personnel and the continued safe reliable operation of the equipment safe working practices must be employed at all times The attention of U K users is drawn to their responsibilities under the Health and Safety Regulations 1993 All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whil
34. WN Shutting OFF burner To shut OFF the burner move switch to OFF then turn OFF the gas service cock The water heater should only be turned OFF for long periods eg holidays or in an emergency Otherwise the heater should be left to operate under normal thermostat control NB When using a time control ensure the heater is not turned OFF before the final water draw off occurs This will ensure the water in the tank is left in a hot condition THERMOSTAT SETTING APPROX WATER TEMP 104 F 40 C 1319 55 C 158 F 70 C COMMISSIONING SECTION 4 Checking main burner pressure Turn gas supply OFF Release bleed screw A and connect pressure gauge tube See Fig 24 Light burner as described previously D st Remove cap from port and adjust pressure using exposed screw in accordance with data plate See Fig 24 5 Shut OFF burner as described previously Remove pressure gauge tube and tighten bleed screw A 6 Re light burner as described previously Fig 24 Hi Flo RANGE Lighting the Burner AUTO IGNITION 29 DAMN Bus ON AY E Gas control 072 dt nob Pink MV Black PV MV ig 25 Purple PV Ensure gas supply is ON Turn gas control knob to ON position Using control thermostat select required water temperature Move electrical ON OFF switch to ON After delay of about 10 seconds the burner will light 5 Check pilot and main gas connections at gas control valve
35. a screw driver to pry underneath jacket head see photo 33 Step 9 Remove insulation from top of water heater to expose collector cover remove if necessary see next page for approx anode locations Step 10 Remove screws from side or top of collector cover Note it may be necessary to chisel away some foam to access screws see photo 34 Step 11 Locate and remove anode rods from top of water heater 1 1 16 hex socket Note anodes located outside of the collector see photo 35 may require foam to be chiseled away to access anode rods see next page for approx anode locations Step 12 Visually inspect anode rod Anode rod may show signs of depletion this is normal If the anode shows signs of depletion approximately 5 8 see photo 36 replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 13 Upon completion of inspection or subsequent replacement reinstall anode rods into water heater A Step 14 Check for leaks Step 15 Reinstall collector cover amp insulation over collector cover Step 16 Reinstall jacket head flue damper and draft diverter Reconnect venting Step 17 Reconnect plumbing connection to top of water heater if required Step 18 Restore water supply and power to water heater Step 19 Verify proper operation APPENDICES See description and part number table overleaf 20A APPENDICES 17B 18B 1
36. as failed and water is overtemperature ECO may operated In which case determine cause of overheating a Check gas is available b Check thermopile and ECO connections Replace if necessary c Check if inlet gas pressure is too high or too low Pressure to multifunctional control should be 17 mbar 7in WG to 25 mbar 10in Wg d Pilot jet blocked Clean or replace pilot jet e Faulty magnet coil Replace multifunctional control f ECO safety thermostat operating at too low a temperature Replace faulty control 400 from thermopile indicates a good thermopile a Thermostat setting too low b Gas control knob not set to ON c Check thermostat for failure to close d Check gas control valve a Check pilot connection for loose joints b Check correct ventilation is available c Check flue is clear and is correctly designed and flue terminal is correctly positioned d Check for presence of halogen compounds ALL MODELS FAULT HEATER SOOTING YELLOW FLAME POOR COMBUSTION WATER TEMPERATURE TOO HIGH WATER TEMPERATURE TOO LOW NOT ENOUGH HOT WATER WATER DRIPPING FROM BASE OF HEATER RUMBLING NOISE ACTION a Check gas burner pressure and injector size If possible check heat input with meter and watch b Clean burners and injectors c Flue obstruction Clean flue ways d Check flue design and termination position e Check for correct ventilation a Re
37. ater Heater Not Operating Display shows error code 31 Upper Sensor Readings Faulty or error code 32 Lower Sensor Readings Faulty m Unplug or disconnect electrical power to the water heater P Check continuity of wire harness to affected sensor Measurement of ohmeter should be close to O ohms Replace wire harness if high resistance is measured over 0 5 ohms Check wires for intermittent connections shorts frayed insulation Replace if necessary see photo 8 Checking continuity of upper sensor wire harness If wire harness checks out O K check resistance of sensor Refer to section on Sensor Resistance Testing If sensor resistance is not near the values shown in the table then replace upper or lower sensor as indicated by error code number Y Turn power on to water heater Run water heater through heating cycle and verify proper operation Sensor temperature can be viewed when burner shuts off see section on viewing the display in Service Mode Ce i Removing lower sensor from well Held in place by a clip fastened to well shoulder Condition Water Heater Not Operating Display shows error code 65 High Water Temperature over 200 deg F AWARNING Do not reset the display from the hard lockout state without correcting the cause of the overheating condition Turn power OFF Draw water to cool tank below 120 deg F If sens
38. avoided to prevent blowdown See recommendations in BS 6644 BS 5440 Part 1 also provides useful additional advice Terminal 1000mm 40 Minimum Flue materials including jointing materials and fittings shall be asbestos free robust durable corrosion resistant and non combustible and shall comply with BS 5854 and BS 715 or BS 4076 as appropriate as well as being of a type accepted by the Local Gas Authority When passing up through or adjacent to combustible materials measures shall be taken to prevent the temperature of the combustible material from exceeding 60 C 1509F The flue shall not be closer than 50mm 2in to any combustible material except when passing through when it must be enclosed by a non combustible sleeve and separated from the sleeve by not less than 25mm 1in air space Flues shall be of a size not less than specified in Section 2 Technical Data i e nominal flue size and fitted so that there is no risk to persons in the building or from accidental damage Fig 4b If using an existing brick chimney it should be swept and lined and checked for soundness before connecting the flue and should take the shortest possible route and rise continuously to the terminal avoiding the use of 90 bends where a change of direction is required Horizontal and very shallow runs of flue should be avoided since they impede the flow of gases and increase local cooling INSTALLATION SECTION 3 FLUE SYSTEMS Split
39. aying the temperature setpoint Pressing temperature up and down buttons changes the temperature setpoint Temperature format may be displayed in degrees F or degrees C e Single control board with plug in wiring controls temperature ignition and flue damper operation Reduced number of parts for servicing and wiring Plug in wiring reduces chance of miswiring Water heater display will show diagnostic codes in the event the water heater needs servicing Aids in diagnosing and servicing the water heater Water heater display can show up to 10 previous error codes in the service mode to further aid in servicing the water heater APPENDICES i Specifications Power Supply Dedicated 120 60 Hz 15 Current Draw Less than 5 Amps Gas Supply Connection 1 NPT connection to gas valve for 370 000 Btu hr and over for natural gas 34 NPT for rest Schedule 40 black iron pipe recommended Approved Gas Type Natural or Propane Gas supply must match the gas type listed on the water heater rating label Minimum Clearance for Servicing 24 Front Clearance 20 Top 6 Sides Maximum Water Supply Pressure 150 PSI Thermostat Sensor s Redundant thermister with 11 900 or 0 596 ohms resistance at 70 deg Sensor inside well for lower sensor Some models use an additional upper sensor w o well with same resistance values Control Board Honeywell Integrat
40. condition Error Code Shown in Water Heater Display Press for 2 seconds All other error codes will put the water heater into a Hard Lockout condition in which the water heater will not operate and cannot be reset in the User Mode To reset a hard lockout first enter the Service Mode described earlier by pressing both the Temperature Up and Select Buttons at the same time for 3 seconds Then press the lower right button under Lockout Reset in the water heater display and hold for 3 seconds Resetting Error Codes in Hard Lockout Condition Error Code Shown in Water Heater Display Nm Status Service Needed SELECT SEN O Step 1 Press for 3 seconds otep 2 Press for 3 seconds to to enter service mode reset control in service mode APPENDICES SERVICE PROCEDURE D24 I Thermostat Circuit Testing A CAUTION A DANGER Be Careful When Making Voltage 120 volt exposure To avoid personal injury Measurements or Jumping Terminals use caution while performing this procedure Not to Damage or Deform Connectors or Connector Pins This procedure assumes the flue damper is in working order Be sure damper opens under its own power when the thermostat circuit is by passed Damper must be open or removed during this test Do not force damper open using your hands or tools Measuring upper sensor resistance through wire harness disconnected at control board Condition W
41. control board or pilot if wire is damaged 1 0 micro amp or less Clean pilot flame rod or replace pilot J APPENDICES SERVICE PROCEDURE D24 IIT Main Burner Operation Testing A CAUTION A DANGER Be Careful When Making Voltage 120 volt exposure To avoid personal injury Measurements or Jumping Terminals use caution while performing this procedure Not to Damage or Deform Connectors or Connector Pins Checking MV amp MV PV control plug pins to gas valve for 24 volts output during heating cycle pilot must be lit with no sparking Is Pilot lit N See Pilot Wil Not Light Y Does control board continue to spark with See Pilot Lights No Flame M Condition Main burner will not light Display shows Heating under temperature setpoint Tank is cold d N neen IMO MACK Of Be sure control display is showing Heating Control plug on control board to contact litand control is nol snarkin N pins for measuring voltage N pror m n 18 sparing gt Recheck voltage across control board Replace control board Is there 22 27 volts AC across pin terminals 5 amp 8 Refer to wiring diagram also see photo 14 pin terminals 5 amp 8 MV PV Is voltage present Brown wire disconnected Ground lug of from MV terminal of gas gas valve valve Check incomi
42. e The size of the discharge pipe must be not less than the nominal size of the safety valve outlet It should be self draining and any water discharged must be visible and create no hazard to persons in or about the building A low pressure open vented system can be used or where the natural circulating pressure is insufficient pumped circulation can be employed The heater must be fitted with an open vent pipe which is not valved and which rises continuously to the open vent It should be sized with reference to Technical Data BS 6644 Clauses 9 and 10 and CP 342 Local Regulations and Bye Laws must be observed when installing the system Water draw off dead legs should comply with CP 342 Part 2 Table 1 and BS 6700 Fig 11 Models 65 173 81 264 Optional top inlet outlet water connections Select the cold hot location required i e top inlet outlet or front inlet outlet and using a suitable jointing compound blank off the two ports not required All Models Front inlet outlet water connections Models 32 143 Optional rear inlet outlet water connections Assemble onto the 3 4 BSP thread the 3 4 BSP coupler socket 1 and drain cock using a suitable jointing compound Select the Cold Hot location required and using a suitable jointing compound blank off the two ports not required Models 32 143 62 341 54 418 54 440 A 3 4 BSP thread connection is available at the top of the heater this is suitable for a Automatic Air Vent if r
43. e ee ee ee ee GAAR ee ee ee ee ee ee ee ee ee ee ee ee ee 9 8 VERS SERT E RES ee ee ee ea ee SSE HER SEE HESS RS Ue 2 RUN ee eR EUR RUP SURGE ee ee er ee ee ee ee eee Burner Gas Pressure Auto Ignition vere be ke ee 7 44 VERN verre pr rn fre ren TM seein acted esee Uribe DU eot dese ub eade eS tng ak Eb ac due dad ca aad EE ye Abd cr but s aer ER dant Tartaro Rue tib ir tee gai ROC LR EORR Bhi WERE EE SR EE EEE URL RET EE PORA RR Ge CE ne ME DR EE BEE BING BUG EAE DE BALE RE HAC LOR kt 6 POR CR Bie Rc Gas Injector Orifice Diameter Permanent Pilot Gas Injector Orifice Diameter Auto E ET SE Gs TATT ESS KE EN EEE TEGE SKE ROE SE KE NS Wee Nair A ow E aO Si Bri Ses A Sa SS Rhee BAe Re EE See Sp Se eee ee Ws ere Ei AP aes EE Aq Up qu EE ALTEAST EE SSE dee AE Ba tacos ace ped A SME Se EPER TU Tc bar Ic bar PE DIS nr uU UID f the water heater is t
44. eater and verify proper operation f Error codes 62 or 63 shown on Water f ls there 22 27 volts AC output across see photo 13 E Check across MV PV amp PV Wire leads to gas valve Replace control board N Check for Loose or damaged ignition wire Grounded pilot electrode Damaged pilot mI Replace control board Loosen pilot tubing connection at the gas valve and soap test Y Is there pilot gas flow out of the Y gas valve See pilot illustration for pilot inspection Wires must Check for clogged or kinked pilot tube clogged pilot orifice Clean or replace as needed see Pilot Burner Inspection be connected to gas valve during V this test J N Tighten pilot tube connection at the gas valve Check incoming gas pressure to water heater if okay replace gas valve Checking for 24 volts output to pilot valve yellow and red wire pin terminals on control board control plug APPENDICES SERVICE PROCEDURE D24 II Condition Error code 57 Flame Rod Shorted to Ground Disconnect power Shut off gas supply to water heater Slide out Check to see if pilot shield is touching pilot flame sensor or flame sensor Pilot Inspection gt burner assembly see section on J9 touching pilot hood Bend shield to removing pilot and main burner pre
45. ecaution to prevent personal injury Step 1 Disconnect unplug water heater from electrical supply Step 2 Disconnect venting from draft diverter and remove draft diverter from top of water heater Step 3 Disconnect flue damper from wire harness and remove flue damper from top of water heater see photo 27 Step 4 If required turn OFF water supply amp disconnect top plumbing connection from top of water heater Step 5 Remove screws holding jacket head to top of water heater and remove jacket head from top of water heater Note it may be necessary to use screw driver to pry underneath jacket head see photo 28 Step 6 Remove insulation from top of water heater to expose collector cover B udi Step 7 Remove screws from side or top of collector cover Note it may be necessary to chisel away some foam to access screws see photo 29 Step 8 Remove collector cover from water heater by using pipe wrench as illustrated in photo 30 Step 9 Remove flue baffles from water heater Note it may be necessary to use pliers to loosen and remove baffles from flue tubes See photo 31 Step 10 Visually inspect flue baffles Flue baffles may show signs of oxidation this is normal If the oxidation has deteriorated any portion of the flue baffle replacement is recommended If any restrictors are missing replacement is recommended Step 11 Upon completion of inspection or subsequent replacement rei
46. ed Control Board for Temperature Control Flue Damper and Ignition Control Functions Operates on 24 volts AC current from transformer Some models use single sensor boards others use two sensors Control Display Honeywell LCD Control Display with Temperature Setpoint Format and Error Code Display in User Mode Diagnostic Functions in Service Mode Communicates with Control Board Transformer 120 VAC Primary 24 VAC Secondary 40 VA Pilot Intermittent Pilot with Spark Electrode and Flame Sensor monitored by Control Board Flue Damper 24 VAC 60 Hz 80 Ma APPENDICES Thermostat calls for heat C to the flue damper between trials Control Board simultaneously sends 1 24 volts from control pin terminal 8 to MV PV terminal of gas valve common terminal 2 24 volts from control pin terminal 2 to PV terminal of gas valve to establish gas flow at pilot 3 Low current high voltage from spark terminal to generate spark at the pilot and ignite pilot gas flow 4 Pilot flame proving signal measured in micro amps from the sense terminal to prove pilot flame 4 Once pilot flame is proven sparking will stop Once sparking stops 24 volts is sent from control pin terminal 5 on control board to MV terminal on gas valve to establish main burner gas flow Main burners ignite from the pilot flame The control board constantly monitors pilot flame thro
47. en screw A 7 Refit brass cap to pressure adjustment port MW RAVN gt SECTION 4 Fig 20 HI FLO RANGE PERMANENT PILOT MODELS Fig 21 Lighting the Burner Open the main gas supply cock after all connections to the gas control are completed and test all connections using a manometer Purge air from pipework and ensure there are no loose connections to burner or pilot pipe NOTE The gas control will be damaged if inlet pressure exceeds 35mbar 14in Ensure gas supply is on Turn gas control knob to PILOT position Depress knob and activate piezo igniter Keep knob pressed in for a further 40 seconds after pilot lights then release knob and check that pilot remains lit If not turn off then wait 3 minutes before repeating from step 2 Observe via the view port 5 Turn control knob to ON and turn control thermostat dial to required water temperature The burner will now light 6 Check pilot and gas connections for soundness with leak detection fluid whilst burner is alight Turn off seal any leakages then re test AUN Gas Control Knob Position Indicator Cal Thermostat Gas Control Valve Thermopile WARNING if pilot goes out do not attempt to relight gas until at least 3 minutes have elapsed If gas supply has been interrupted and immediately reconnected unburnt gas will pass into the combustion chamber due to operation of the thermopile Do not attempt to re light for
48. equired Not supplied NOTE When using a secondary return circuit see Fig 11 for the locations of the return tappings It is recommended that all water connections be made to the heater s using union fittings for ease of servicing Pipe support intervals should comply with CP 342 Part 2 Table 4 After Installation of the water system open the main water supply valve flush the system and fill the heater Open the hot taps to allow air to escape from the system When the system is free of air close the taps and check for leaks at the gas control thermostats drain cock and pipe connections on the heater Typical water service layout for Hi Flo Range single heater vented system is shown in Fig 12 Typical water service layouts for Hi Flo Range multiple heater vented systems are shown in Figs 13 and 14 INSTALLATION SECTION 3 gt WATER All connection sizes are CONNECTIONS shown on page 5 Optional Top Cold Inlet Hot Outlet on models 65 173 81 264 Automatic Air Vent 32 143 62 341 54 418 54 440 Front ANDREWS T amp P Valve Tapping Cold Inlet Hot Outlet All Models Drain amp Optional Rear Cold Inlet Hot Outlet Tappings 32 143 only Secondary Return Tapping Fig 11 1 0m 40 Open Vent Open Vent Cold water Feed Overflow m 4 Hot Water Service Front Entry Eee Models Supply Valve Top Entry Models 65 173 81 264 Safety Vaive see note T amp P Valve Ta P Val
49. er attention is drawn to the following guidelines CAUTION DUE TO THE CORROSIVE NATURE OF DESCALING FLUID IT IS ESSENTIAL THAT SUITABLE PROTECTIVE CLOTHING IS USED AND ADEQUATE VENTILATION AVAILABLE 1 Turn gas control to OFF and isolate gas supply 2 Close water inlet valve and drain heater tank 3 Remove magnesium anode s It is recommended that new anode s is are fitted 4 Add suitable hydrochloric acid based descale fluid The requirement is normally 5 litres for Standard Models and 10 litres for Hi Flo Models or more dependant on amount of limescale present After a minimum of one hour restore gas supply and turn on main gas burner for 2 minutes maximum Isolate gas supply and drain descale fluid through drain port Open cold water feed valve and fill heater tank Drain and flush out heater for 20 minutes minimum Replace anode s Restore gas supply and re light heater ON OV IMPORTANT Remove Correx anode s if fitted and plug off the connections using 3 4 BSP plugs Hi Flo models only Re fit the Correx anode s when the descaling operation is complete Magnesium sacrificial anode s is are fitted to the top of the storage vessel The anode s will prevent corrosion of the storage vessel Anode condition should be checked annually and replaced if excessive wear is present We recommend that the anode s are replaced annually 1 Withdraw each anode using a 1 46in AF sock
50. er delivered to the taps It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted To change the Maximum Setpoint Limit Max Setpoint for the temperature setpoint Step 1 In service mode press the Select button until Max Setpoint is displayed APPENDICES Troubleshooting Step 2 Press Set button to enter setting mode Max Setpoint will flash to indicate setting mode Max Setpoint Flashes Iq T Setet idle Status Operational SELECT SEN Step 3 Press the UP or DOWN buttons to change the maximum setpoint value This will limit the maximum setpoint the user can select Note The maximum setpoint is approximately 180 F Max Setpoint continues to flash while making adjustments Setpo nt I otep 4 Press Set button to confirm new Max Setpoint value and stop setting mode Max Setpoint stops flashing ITF setpoint idle Status Operational SET APPENDICES Troubleshooting Step 5 30 Seconds after the last button press the Water Heater Display will go back to User Mode It will read Max Setpoint without showing a temperature value if the temperature setpoint is at the maximum set
51. er Short Cycles Era Error code 56 on display Check for debris limiting damper rotation If no debris replace damper Does water heater begin to operate Check for debris limiting damper rotation If no debris replace damper Damper vane show in open position If damper is closed disconnect from harness and REMOVE damper from water heater Harness shown disconnected from damper with BLACK and YELLOW wires jumped Error Code Shown m 1 1 Status Service Needed SELECT Lockout RESET Example of error code shown on control display in Water Heater Display APPENDICES Troubleshooting Using Control Display for Servicing the Water Heater ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY FOR SERVICE PERSONNEL ONLY The display has a service mode for changing the maximum setpoint and accessing information in aiding servicing of the water heater This procedure is for service and installation personnel only To enter the Service Mode follow the steps illustrated below Step 1 Press Select and Temperature Up buttons together and hold for seconds until Max Setpoint is shown in the display Max Setpoint next to Temperature Setpoint value idle Statu Operational 5 Step 2 Pressing Select button will change display to next mode TT Wm BE idle Status Operational SELECN SETA The following is the seq
52. estic use within buildings and their curtilages This standard supersedes the following British Standards and Codes of Practice CP99 CP310 CP324 202 CP342 Part 2 Centralised Hot Water Supply BS 5440 Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW Part 1 2000 Specification for installation of flues Part 2 2000 Specification for installation of ventilation for gas appliances BS 5546 1990 Installation of gas hot water supplies for domestic purposes BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic premises BS 7206 1990 Specification for unvented hot water storage units and packages I M2 Purging procedures for non domestic gas installations 5 Soundness testing procedures for industrial and commercial gas installations I M11 Flues for commercial and industrial gas fired boilers and air heaters I M16 Notes on installation of gas pipework excluding 25mm and below IGE UP 10 Pt 1 Edition 2 Installation of Gas Appliances in Industrial and Commercial Premises Hi Flo RANGE As STANDARD RANGE plus BS 6644 Installation of gas fired hot water boilers of rated inputs between 60kW and 2MW NOTE Consideration should be given to amendments or updates to the above standards GENERAL AND SAFETY INFORMATION It is the duty of manufacturers and suppliers of products for use at work to ensure so far as is practicable that such products are safe and wi
53. et spanner A new anode measures 21mm diameter 2 An anode should be replaced if at any point along it s length the diameter is reduced to half or less of original Particular attention should be paid to the ends 3 If the anode is encrusted with limescale it should be either wire brushed to reveal bright metal or replaced Where Correx anodes are fitted no maintenance is necessary Check the condition and operation of the safety valve as described below During Servicing Examine the safety valve for deposits or let by Clean or replace as necessary When Re Commissioning Operate the safety valve ensuring no let by when the valve is reset and reseated NOTE For adjustable valves reduce the rating until the valve operates and gives full flow Reset the valve and check for let by For lever operation valves operate lever and check for let by when reseated Re light and carry out commissioning checks as detailed in Section 4 Commissioning Set the thermostat control to the required user setting REPLACING COMPONENTS Hi Flo RANGE NOTE Models 62 341 54 418 and 54 440 are fitted with an anchor bracket between GAS CONTROL the burner manifold and the heater body Remove two screws to release the anchor 4 VALVE bracket 1 Turn gas control knob and gas service cock to OFF 2 Disconnect pilot feed pipe thermocouple and thermostat leads from gas valve 3 Disconnect union joint from gas service cock 4 Unscrew two wing nu
54. f 3 core and should be connected to the mains supply as detailed above It is recommended that screen cable is used where the volt free contacts are to be connected from an external supply This will eliminate the risk of possible interference from nearby high voltage cables Data sheets available for Hi Flo and Standard Range Automatic Ignition Control System Contact Andrews Water Heaters INSTALLATION Standard Range EARTH BINDING POST Maclaren Gas Block Gas Io Main Burner 4 BSP Volt Free Output For Ovar Heat Free Output J For Lack Out interlock Contact 2 Tima santch EPSSX Automalic Gas Bumer Control Unit jquiassy JEUINg 101 Brown Cable Er NOTE The intertock contact terminals 344 Control Thermostat Limil Thermostat 586 must be linked no device is Tirne switch Motor If Fitted Fig3b RED YELLOW LED LED LIVE Electrical Mains NEUTRAL Input Mains On Overheat Flame failure Flue Fan Fan N 230 Vac 20 mm Cartridge Fuse Timeswitch 24Vac 20 mm Cartridge Fuse Volt free contacts Timer Link Green Yellow Main Printed Circuit Board Air Switch 24 Vac 2 5 n Ex 2 ECO 1 Stat Always remove links when fitting an air pressure switch Flue Damper Flue Damper i N 24Vac i 5 NJ FITTING OPTIONS KEY 1 TO FIT A TIMESWITCH move the timer jumper link to the On
55. gs provided Attach the legs to the draught diverter with the nuts and bolts provided Fit the draught diverter 1 as shown in Fig 1 to the water heater using the screws provided For Standard Range fit the draught diverter to the top of the water heater using the location holes Top Connections Top Connections 81 264 Only 65 173 Elbows must be used NB Elbows Not Provided In some cases it may be necessary to drill the fixing holes in the top cover to fit the draught diverter to the water heater By using the draught diverter as a template position carefully over the flueway and mark the hole positions to be drilled 4mm Fit the adaptor socket 2 and caulk into the draught diverter as shown in Fig 1 The location selected for installation of the heater must allow the provision of a satisfactory flue adequate air supply drain facilities and must be well illuminated A purpose built boiler room or compartment is strongly recommended A manual valve for isolation of the boiler room should be installed in the gas supply it should be clearly identified and readily accessible for use at all times If a purpose built boiler room is not available measures should be taken to protect the heater from damage and prevent any extraneous matter from being stored on or around the heater See BS 6644 Clauses 4 5 and 6 for details INSTALLATION SECTION 3 gt The heater must not be installed in any location which contains a bed bath or s
56. h compressed air 5 Remove two screws securing main burner supply tube to bottom of burner to gain access to main jet Remove main jet and clean with acetone Blow through main burner with compressed air CLEAN ORIFICES WITH WOOD SPLINTER DO NOT USE SHARP METALLIC OBJECTS 6 Re assemble in reverse order of steps 2 5 but note i Be sure to engage rear section of main burner supply pipe in it s location bracket on base pan of heater li DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION SCREW IN FINGER TIGHT THEN TIGHTEN A FURTHER 1 4 TURN USING A SPANNER Replace and secure inner cover with two screws on Models 63 62 and 84 87 7 Turn gas control knob to PILOT and depress Using leak detection fluid check joints at both ends of the pilot supply tube Seal if necessary DO NOT EXAMINE WITH A NAKED FLAME 8 Allow 3 minutes for unburnt gas to disperse Light the pilot and check flame is correct see Fig 19 p26 Slide inner door to left on Models 63 62 and 84 87 lower the inspection port and turn gas control knob to ON The main burner will light 9 Check main burner connection tube at control valve with leak detection fluid and seal if necessary Replace outer cover The burner assembly should be checked and cleaned annually NOTE Models 62 341 54 418 and 54 440 are fitted with an anchor bracket between the burner manifold and heater body Take out 2 screws to remove 1 Turn gas control valve knob to OFF and disconnect u
57. h the pilot burner alight hold gas control knob in for 20 seconds When gas control knob is released the pilot should remain lit If not repeat this operation 4 Close and refit covers 5 Set temperature indication dial to required temperature as follows Setting 0 1 2 3 Approx Water Temperature 1049F 40 C 125 F 52 C 143 F 62 C 159 F 71 C 6 Turn the gas control knob to ON and the burner should light If not wait for at least 3 minutes and repeat from step 1 Correct size and shape of Note European Symbols the pilot flame OFF 0 84 87 only PILOT w correct size ON shape of the pilot flame COMMISSIONING Shutting Off The Burner For long periods only 7 days or more turn gas control knob to PILOT depress slightly and turn clockwise to OFF Turn off the gas service cock For shorter periods leave the heater under thermostat control NOTE If the pilot goes out for any reason turn off heater and wait for 3 minutes before relighting Checking Main Burner Pressure Turn burner OFF as above Remove brass cap from pressure adjustment port Release bleed screw A one turn and connect pressure gauge tube Light burner according to the preceding instructions Adjust burner pressure at screw B in accordance with data plate Turn screw clockwise to increase pressure and counterclockwise to decrease Turn burner OFF as described above Remove pressure gauge tube and tight
58. hoto 19 To install burner reverse above procedure Check for gas leaks and verify proper operation Burner tubes should be free of any flue scale or other debris Clean burner tubes using a stiff brush and or shop vac Burner ports should have uniform openings Replacement is recommended for burners where port area is deteriorated or other unintended openings are present Insure pilot shield is in place See photo 20 Inspect pilot position to insure smooth burner ignition from pilot flame Pilot should be mounted using the two mounting screws through the burner support bracket resulting in a level pilot position APPENDICES SERVICE PROCEDURE D24 IV Main Burner amp Pilot Removal and Inspection Pilot Shield Pilot Burner Removal Step 1 With burner rack removed from heater disconnect pilot tube connection from gas valve Step 2 Remove the two pilot burner mounting screws securing the pilot and pilot shield in place Step 3 Remove pilot shield and pilot from burner rack Step 4 To install pilot burner and pilot shield reverse above procedure Be sure to reconnect green ground wire Pilot amp Pilot Shield Mounting Screws Pilot Burner Inspection Step 1 Inspect pilot for the following a Broken or cracked ceramic insulators If found pilot must be replaced Flame Rod b Damaged electrode or flame sense wire If found pilot must be replaced Ceramic Insulators
59. hower LOCATION There must be easy access to the boiler room and heater at all times A clearance of 800mm 318 for Hi Flo and 300mm for Standard Range should be left at the front of the heater for removal of the burner Clearances at the sides and rear of the heater should be at least 305mm 12 in Service clearances for removal of the anodes and flue baffles should be provided as detailed below STANDARD RANGE 0099000000000009000000000009000000000000090000009000090000000900000000900000900000900000090000000000900000000000009000000900000000000000000000000000000090000090000000000090000000000000900000000009009 Models 24 39 32 40 40 61 762mm 30 in Model 63 62 1143mm 45 in Model 84 87 1270mm 50 in HI FLO RANGE 0990000090090000000000000900000009000000009090000009000000000000000900000009000000000009090009000009000000000900000000000000000000009000000900900000000000000900000909000000000900000900000900090000009000000000909 Model 32 143 597mm 23 in Model 81 264 1300mm 52 in Models 65 173 62 341 54 418 54 440 1143mm 45 in The floor on which the heater is installed must be non combustible flat level and of sufficient strength to withstand the weight of the heater filled with water see Section 2 Technical Data and should satisfy the requirements of the Local Authority and Building Regulations NOTE If the heater is in an exposed position and out of use during a period of heavy frost it is recommended that the
60. illustration above Checking for Spillage at the Draught Diverter If an extract fan is fitted carry out a spillage check as set out in BS 5440 Part 1 Appendix B If spillage does occur increase the ventilation area until the products clear well If an openable window is in the boiler house or room containing the heater s turn on the extract fan and heater s Open the window fully and using a stiff card gradually reduce the opening until the appliance s just spills Then increase the opening until the products clear well Measure the opening for the additional area required When satisfactory commissioning and testing has been achieved hand this manual to the User or Purchaser and explain the method of economic and efficient operation INSTRUCTING THE USER Explain that 1 Other than for long shutdown periods the heater must be left operating normally ALL STANDARD 2 It is important that the control thermostat is set at the lowest temperature consistent AND Hi Flo with the user s needs MODELS Ensure that the user or purchaser is fully conversant with the lighting shutdown and general operating procedures including the emergency procedure see p 34 Advise that any air vents must be kept clear and items must not be placed or stored in the vicinity of the heater Advise of precautions necessary to prevent damage to the heater and systems in the event of the system remaining inoperative during frost conditions Advise the user
61. ition control MAIN BURNER terminal No 3 Replace control if faulty DOES NOT b Faulty Solenoid Coil Replace if faulty AUTO FAULT ACTION IGNITION CONTINUOUS a Check gas service cock is open UNITS IGNITION NO b Check gas control knob is ON HI FLO PILOT FLAME c Check ECO for failure MODELS PILOT LIGHTS BUT a Main gas valve not energised opal light is on Check for MAIN BURNER loose contacts DOES NOT b Check for 24V AC at intermittent pilot ignition control terminal No 3 Replace control if faulty c Check for 24V AC at main gas valve terminals Replace valve if faulty FLUE DAMPER a Faulty damper unit replace REMAINS OPEN b Power is being interrupted to the unit WHEN BURNER IS OFF NO a Electrical ON OFF switch is not ON IGNITION AT PILOT b Thermostat set too low c Power to unit interrupted d Flue damper not open faulty unit replace Checking Correx Anodes 1 If red light is flashing on power pack immerse wires in water including the earth anode wires white wires HIflo x 2 OR Standard Range x 1 and black earth wire power pack earth low voltage side 2 If light stays red replace power pack E010 2 x Anode on Hlfllo C995 single Anode on Standard Range heaters 3 If light goes green investigate anode rods poor connection bad earth or too much p t f e around threads acting as insulator anode part number E048 For checking individual Correx anodes leave
62. iverter and HI FLO RANGE adaptor ring Remove top insulation and keep safe Remove flue collector cover Remove flue and brush flue tube using 75mm diameter brush with minimum length of 1 4m 7 Remove deposits from tank top and burner compartment Replace baffles 8 Re assemble collector cover insulation top cover flue system and burner assembly 9 Carry out relevant commissioning procedures as detailed in Section 4 NOTE For models 65 173 and 81 264 where top inlet outlet connections are used both hot and cold connections must be disconnected before removing the top cover CLEANING THE STORAGE VESSEL ALL MODELS MAGNESIUM ANODE S ALL MODELS SAFETY VALVE HI FLO RANGE RESTART ALL MODELS The storage vessel should be checked and cleaned annually Scale formation in the base of the vessel may occur particularly in hard water areas and is normally associated with high usage and high water temperatures It is characterised by a rumbling noise when the main burner is lit Scale formation in the base of the vessel will affect the efficiency of the water heater and reduce the life of the storage vessel It should be noted that the failure of the storage vessel due to scale formation on the base will not be covered by the terms of the warranty Any scale formation which cannot be removed by normal means of cleaning should be removed by chemical descaling See below DESCALING When descaling the heat
63. ked Remove any debris from the valve inlet filter using a soft brush or by blowing with low pressure air GAS CONTROL After servicing check VALVE 1 Soundness of any gas joints broken or disturbed and seal any leaks 2 Burner pressure gas rate at maximum thermostat setting HI FLO RANGE 3 Operation of heater is correct Reset controls to user s requirements The flue ways should be checked and cleaned annually 1 Remove burner as described in Burner Assembly Standard Range FLUE WAYS 2 Remove split flue clip from flue and lift off draught diverter STANDARD 3 Inspect and clean secondary flue installation as necessary RANGE 4 Lift out baffle from inside central flue way not Model 84 87 5 Clean flue way with a brush and remove deposits from underside of storage vessel and from flue baffle Re assemble in reverse order Be sure to engage rear section of main burner supply pipe in it s location bracket on base pan of heater DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION SCREW IN FINGER TIGHT THEN TIGHTEN A FURTHER 1 4 TURN USING A SPANNER 7 Re light heater and carry out relevant commissioning procedures as detailed in Section 4 OY The flue ways should be checked and cleaned annually 1 Remove burner as described in Burner Assembly Hi Flo Range FLUE WAYS 2 Remove the split clamp and raise the flue system to clear the draught diverter socket 3 Remove securing screws and remove top cover complete with draught d
64. lation of the appliance preferably by use of an unswitched shuttered socket outlet in conjunction with a fused three pin plug both complying with requirements of BS1363 A Alternatively a fused double pole switch o rfused spur box serving only the heater may be used The point of connection to the mains should be readily accessible and adjacent to the appliance A To install the kit 1 Drain down water heater 2 Remove cold inlet hydrojet nipple and replace with 1 nipple supplied in fittings pack 3 Fit correx anodes into front hot and cold water connections using tees and bushes If top water connections of heater are to be used dependent on model type cap off front connections with blanking caps see Figs 1 and 2 on page 21 Note leave existing magnesium anodes in position 4 Fix potentiostat to heater casing using retaining bracket See Fig 1 5 Connect output leads onto anode connections Cut leads to required length and use two spade connectors provided See Fig 1 6 Fit earth strap to 1 4BSP sq tee optional hot outlet connection Connect earth return at this point Cut lead to required length and use spade terminal provided see Fig 1 7 Connect potentiostat mains input cable to a permanent 240V electrical supply via an unswitched spur outlet fuse rating 3 Amps B Test the installation 1 Refill the water heater and check for leaks 2 Switch on electrical supply to correx powered anode 3 The green cont
65. led and adjusted the heater will require minimal attention STANDARD Should it become necessary to completely drain the heater close the cold water inlet valve RANGE and open a hot water tap to allow air to enter the system Fit a suitable hose to the drain cock and open Whenever the heater is filled with cold water condensation will form on the storage vessel surfaces when the burner is lit This is normal and will disappear when the heater warms up The gas control fitted to the heater has a built in limit thermostat ECO In the event of high water temperature the gas supply will be shut off automatically The high temperature condition must be identified and rectified before the heater is relit The gas control is fitted with a recycling type ECO This means that once the water has cooled sufficiently the ECO circuit will close and allow the heater to be relit A replacement gas control valve must be an identical model with the same code number Permanent Pilot Models Operating Sequence HI FLO 1 With the pilot lit the solenoid coil holds the inlet gas port on the gas valve open 2 The knob on the gas valve is set to the ON position RANGE 3 The control thermostat is set to the desired water temperature 49 C to 82 C 120 F to 180 F To set the thermostat remove the outer cover and turn the adjustment dial to the required temperature 4 The thermostat should now be in a closed position allowing the current generated by the
66. mmended that a maximum test pressure of 8 62bar 125lbf in is employed Fig 8 The heater can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit part number B171 available from Andrews Water Heaters See Parts List Page 51 The Wall Mounting Kit is available as an optional extra Balanced Cold Water if required 23 Expansion Vessel D4 Temperature Pressure Relief Valve Cold Water inlet of Water Heater D2 Check Valve Expansion Valve D1 Pressure Heducing Valve Strainer D5 Tundish Fig 8 Cold Water Feed D4 must be fitted into the temperature relief port in the water heater tank D6 Adaptor For use with D4 on heater models 40 61 63 62 amp 84 87 When assembling items D1 and D2 ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn from the 22mm compression port on item 01 a The water pressure at this point will be similar to that available at the hot water outlet of the water heater If port a is not used it should be sealed with the blanking plug supplied If higher flow rates are required for the cold water services a suitable tee fitting should be fitted to the pipework upstream of item D1 The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain see Building
67. n Valve Wall Mounting Kit Optional C7 Hose Assembly C8 Wall Bracket Assembly Qty I Unvented Systems Kit Standard Range Unvented Systems Kit Hi Flo Range PARTS LIST AND ILLUSTRATIONS 24 Volt Auto System Kit B217 24 Volt Auto System Kit B258 PARTS LIST AND ILLUSTRATIONS Part No 217 C521 C641 0122 115 116 117 E120 G059 E126 2092 2093 127 128 E135 Part No B258 E839 C521 C531 C644 C989 2090 E669 240 Volt Auto System Kit Complete nat gas On Off Switch Mains Indicator Light EP6 Control Module Transformer Limit Thermostat Control Thermostat Control Thermostat Knob 230 volt Gas Valve 24 volt Solenoid Coil Gas Valve automatic ignition complete with 240 volt Solenoid Coils 240 volt Solenoid Coil s Pilot Assembly nat gas Ignition Flame Probe HT Lead 24 240 Volt Auto System Kit Pilot assembly On Off Switch Label Andrews Label Warning Label On Off Label Wiring Gas Control Valve Control circuit board Qty ea cA a 2 _ Qty I cA 24 Volt Auto System Kit Standard Range 24 Volt Auto System Kit Hi Flo Range APPENDICES HI FLO AUTO IGNITION SERIES ADDENDUM FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM e Attractive digital water heater display on control panel for setting and displ
68. ng gas pressure to gas valve and manifold Disconnect brown wire lead from B pressure to burners See next MV terminal of gas valve page for procedure for Is there 22 27 volts AC across m gt checking manifold pressure If brown wire lead amp ground inlet gas pressure is O K see photo 15 J replace gas valve See photo on next page for gas valve N inlet pressure tap Check wire harness for damage or loose connections Repair or replace as needed Checking main valve MV voltage to gas valve APPENDICES Av DANGER 120 volt exposure To avoid personal injury use caution while performing this procedure SERVICE PROCEDURE 024 Main Burner Operation Testing A CAUTION Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins Condition Main burner short cycles Control Display may show error code 63 57 or 4 and be in Soft Lockout state Check gas inlet pressure to the water heater gas valve Line pressure should be Nat Min 5 5 W C Max 14 0 W C LP Min 11 0 W C Max 14 0 w c N Is gas pressure within proper V specification see photo below Determine cause of incorrect gas pressure and correct Contact your gas supplier Check manifold pressure See photo on lower right section of page for manifold pressure tap location Refer to water heater rating label for
69. nion joint from gas service cock 2 Disconnect thermostat connections black red and white wires from gas control valve 3 Remove two screws and slide out burner assembly 4 Disconnect pilot tube and thermopile connections from gas valve Remove two screws and withdraw pilot thermopile assembly 5 Unscrew two wing nuts and remove draught shield Remove four screws and disconnect manifold from burner tray 6 Clean burners by brushing internally and externally and by blowing through with compressed air Do not remove individual burners from the burner tray 7 Remove the burner and pilot injectors and clean with acetone CLEAN ORIFICES WITH 8 Re assemble in reverse order but note i The flueways and combustion chamber must be cleaned first ii Use an approved jointing compound when re fitting burner injectors 9 Light heater in accordance with lighting instructions All gas joints must be checked using leak detection fluid Turn off and seal any leakages DO NOT EXAMINE WITH A NAKED FLAME 10 Re light the heater and set the thermostat to the user s requirements The gas control valve should be checked and serviced by a qualified person fully GAS CONTROL conversant with this item VALVE STANDARD RANGE To remove gas control first drain appliance disconnect gas pipe union and turn control anti clockwise taking care not to damage threads knobs or the valve itself Fig 27 The gas control valve should be cleaned and chec
70. nly when the burners are in operation Step 1 Make sure the status displays Heating or draw enough hot water to start the burners Step 2 Enter the Service Mode described previously Step 3 Press the Select button until a number value is displayed with Flame Current to the right of the number The value displayed is in microamps Flame Current ILL Heating Status Operational SELECT SET To Display and Change Temperature Setpoint Step 1 In Service Mode press the Select button until Setpoint is shown in the water heater display Honeywell of setpoint idle Status Operational O APPENDICES Troubleshooting Step 2 Press the Set button to enter the setting mode Setpoint will flash in the water heater display Setpoint Flashes F setpoint Il idle Status Operational SELECIN SEN Step 3 To raise the temperature setpoint press the Temperature Up button until the desired temperature is shown on the water heater display NOTICE The maximum temperature that can be set in the Water Heater Display is limited to the Max Setpoint described previously To change the Max Setpoint refer to the procedure To Change the Maximum Setpoint Limit described previously under Accessing the Service Mode the Water Heater Display WARNING Setting the water temperature to the maximum set point can
71. nnect union joint on service cock Disconnect thermostat connections black red and white wires from gas control valve Remove two screws and slide out burner assembly Disconnect pilot tube and thermopile connections from gas valve Remove two screws and withdraw pilot thermopile assembly Remove two screws to remove burner manifold and draught shields Remove two screws and remove burner fixing bracket Draw burner forwards to clear it s rear location slot Replace with new burner Re assembly is the reverse of steps 2 to 5 Light the heater in accordance with the lighting instructions All gas joints must be checked for soundness using leak detection fluid Turn off and seal any leakages DO NOT EXAMINE WITH A NAKED FLAME 10 Re light the heater and set thermostat to user s requirements FAULT WATER DOES NOT GET HOT PILOT FLAME FAILURE PILOT WILL NOT STAY ON BURNER WILL NOT LIGHT PILOT ESTABLISHED THERMOPILE THERMOCOUPLE BURNS OUT FREQUENTLY PERMANENT PILOT MODELS STANDARD AND HI FLO RANGES ACTION a Check gas service cock is open b Check water valves are open c Check pilot is alight d Check thermostat setting reset to higher temperature e Check gas pressures at burner and at gas inlet to appliance f Standard Range Check cold dip inlet tube for damage a Try to light burner b Pilot will not light Wait 3 minutes then try again NOTE If pilot flame h
72. nstall flue baffles into heater Step 12 Reinstall collector cover and insulation over collector cover Step 13 Reinstall jacket head flue damper and draft diverter Reconnect venting Step 14 Reconnect plumbing connection to top of water heater amp turn on water supply if required Step 15 Check for leaks and verify proper operation APPENDICES SERVICE PROCEDURE D24 VI Anode Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Disconnect unplug water heater from electrical supply Step 2 Turn OFF water supply to water heater Step 3 Open a near by hot water faucet to relieve tank pressure Step 4 Connect hose to drain valve of water heater and route to an open drain Open drain valve and drain a minimum of 5 gallons of water from the water heater Close drain valve and disconnect drain hose from water heater Step 5 Disconnect venting from draft diverter and remove draft diverter from top of water heater Step 6 Disconnect flue damper from wire harness and remove flue damper from top of water heater see photo 32 Step 7 If required turn off water supply and disconnect top plumbing connection from top of water heater Step 8 Remove screws holding jacket head to top of water heater and remove jacket head from top of water heater Note it may be necessary to use
73. o be used on an unvented system the combined temperature pressure relief valve must be fitted directly into the tank The secondary return is then connected to the drain port via a suitable tee Shipping Dimensions Height 6 8 6 8 272 273 10 4 35 35 14 14 9 48 11 94 33624 42198 3 4 3 4 195 185 149 186 3 45 1350 0 136 0 138 3 18 N A 0 125 N A 200 250 8 10 11 2 112 11 2 112 3 4 13 4 3 4 13 4 10 3 10 3 150 1150 20 6 20 6 300 300 257 269 566 1594 538 5504 1186 1134 282 293 623 1645 914 1914 36 36 762 1762 30 30 1960 1960 77 77 INTRODUCTION ASSEMBLING THE DRAUGHT DIVERTER Fig 1 Draught Diverter Assembly LOCATION THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON Installations must be carried out in accordance with Gas safety Installation and Use Regulations 1998 Building Regulations The Water Supply Water Fittings Regulations 1999 and any requirements of the local Gas Authority Local Authority Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1 The fittings pack supplied with the heater contains the items listed below 1 Installation and Service Manual 1 Coupler Socket in BSP 1 Gas Cock 1 Drain Cock 1 Flue Adaptor Socket Where required 2 Cap End 1 in BSP Hi Flo only 2 1 in x 3in Nipples 32 143 Model only The draught diverter must be assembled with the le
74. one white wire connected and put the remaining white wire and black wire into water If the power pack goes green then this proves that Anode is OK 4 If necessary to replace a power pack it is supplied with a 2 pin shaver plug which needs to be connected to an un switched permanent power supply fused 3amps DO NOT cut off any wire ONLY the plug PARTS LIST AND ILLUSTRATIONS 63 62 only STANDARD Models 24 29 32 40 40 61 63 62 63 62 only STANDARD Model 84 87 PARTS LIST AND ILLUSTRATIONS STANDARD MODELS Model 2933 Ref Part Numbers A1 A2 A3 A4 5 7 A8 A9 A10 A11 A12 A12 A13 A14 A15 A16 A16 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 C1 C2 C3 4 C5 32 40 C654 C655 C285 C292 C641 C381 C103 C449 C450 C702 C671 C333 N A N A N A C247 E146 C406 C994 C965 C684 C136 C680 C382 E016 C112 E507 C686 C514 C465 C417 C689 C662 N A 40 61 C654 C655 C285 C293 C641 C381 C103 C449 C451 C703 C672 C333 N A N A N A C247 E147 C406 C994 C965 C684 C136 E149 C362 E016 C112 E507 C686 C514 C465 C417 C689 C662 N A 63 62 C657 C656 C285 C293 C641 C381 C103 C660 C329 C704 C673 C333 C694 C300 C301 C247 E148 C407 C996 C966 C684 C136 E149 C362 E016 C112 E507 C687 C514 C466 C668 C689 C663 C698 84 87 C657 C658 C690 C691 C641 C381 C103 C660 C229 C705 C
75. or clip is damaged Check lower sensor Is the sensor fully inserted into the well N replace clip Replace lower See next page Sensor is held in place with a clip fastened to the well see photo 9 sensor if damaged Check lower sensor wire making sure it is not damaged or has breaks in the wire insulation Check upper harness wires to upper sensor if used some models Y Check Sensor Resistance nw J see Sensor Resistance Testing section amp photo 7 APPENDICES SERVICE PROCEDURE 024 1 Thermostat Circuit Testing A WARNING Do not operate water heater without verifying that the overheating condition has been corrected Condition Water Heater Not Operating Display shows error code 65 High Water Temperature over 200 deg F Continued N Once cause of overheating condition has been diagnosed and corrected the control may be reset Reconnect and switch on power to water heater Enter service mode on the water heater display see illustration Press button under Lockout Reset and hold for 3 seconds Set thermostat to the desired setting Water heater should start Monitor temperatures for one complete heating cycle making sure the maximum tank temperature remains well below 200 deg F a This water heater is equipped with a manual reset type gas shutoff device designed to shut off the gas to the burners if exce
76. or code The Water Heater Display will provide up to 10 previous error codes The oldest error code will be stored in code index 1 and the most recent in code index 10 APPENDICES Troubleshooting To view previous error codes Step 1 In Service Mode press the Select button until the next display after the Software Version If there are no current error codes the display will show No Current Error Code F idle Status Operational SELECTY SEN O Step 2 Press the Temperature Down button to select the error code index starting with the most recent error code 10 Error Code Index Status Operational SELECN SE IN otep 3 Press the Select button to view the error code for code 10 If there is a number displayed note what the number is The label next to the water heater display will identify the code number If no number is displayed with only in the water heater display then there has not been an error code for error code index 10 No Error Code Shown for Code Index 10 APPENDICES Troubleshooting Step 4 Press the Temperature Down button to change to the previous code index code 9 Error Code Index Status Operational SELECN SEN Step 5 Press the Select button for code index 9 to view if there are any code numbers Stored Error Code For Code Index 9 Step 6 Continue pressing
77. osition where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour Grilles or louvers should be so designed that high velocity air streams do not occur within the space housing the heater s The grilles should have a total minimum free area for the water heater s in addition to any other requirements as follows Where the heater is to be installed in a room the following permanent ventilation is required per kW in excess of 7kW net for installations up to 54kW net For installations exceeding 60kW the following permanent ventilation is required Low Level inlet 540cm plus 5cm per kilowatt in excess of 54kW total net input High Level outlet 270cm plus 2 5cm per kilowatt in excess of 54kW total net input Where the heater is to be installed in a compartment permanent air vents are required in the compartment at high and low level These air vents must either communicate with a room or internal space or be direct to outside air The minimum effective areas of the permanent air vents required in the compartment are as follows Position of Air Vents Air from room or internal space Air direct from outside High Level 10 per kW net per kW net Low Level 20cm per kW net 10cm per kW net Note Both air vents must communicate with the same room or internal space or must both be on the same wall to outside air INSTALLAT
78. ot Assy c w injector and electrode Pilot Supply Pipe Pilot Injector Thermopile Multifunctional Valve Control Thermostat Overheat ECO Control Thermostat with remote phial and ECO Lead Assy Thermostat to Gas Valve Pressure Test Nipple Piezo Igniter Gas Cock 3 4 BSP FxF Pilot Shield Flue Damper Assy 6 Control Box Assy complete Gas Control Valve Damper Harness Pilot Assembly Qty i SG OO M 59 6 LA ux LX OY 0n IX ol l2 lA lx IA PARTS LIST AND ILLUSTRATIONS B9 Auto CB Hi Flo Models 62 341 and 54 418 440 PARTS LIST AND ILLUSTRATIONS HI FLO MODELS Model 62 341 54 418 440 A1 C501 C548 Draught Diverter 1 A2 C333 C333 Service Magnesium Anode 2 432 Flue Connector 200mm BS 835 1 335 Connector 250mm BS 835 1 A4 C381 C381 Drain Cock BS 2879 3 4 1 5 103 103 Socket Coupler 3 4 1 474 473 492 Data Badge 1 7 C543 Flue 11 543 16 C235 C235 Andrews Label 1 A11 C487 C554 Top Cover 1 A12 C488 C488 Insulation Pad 1 A13 C490 E392 Flue Box Top Cover 1 A14 C694 C694 Cleanout Pad Seal 1 A15 C300 C300 Cleanout Pad 1 A16 C301 C301 Cleanout Pad Cover 1 17 247 C247 Drain Tapping Connector 3 4 BSP 1 A19 C534 C534 Nipple 1 1 2 BSP 4 A20 E050 E050 Hydrojet Cold Inlet Connection 1 side 1 1 2 BSP B1 C544 C549
79. plug Flue damper begins to rotate open Once the flue damper is fully open the damper end switch closes and 24 volts is allowed to continue through damper to damper pin terminal 5 Trial for ignition three 90 second ignition trials with 65 second pauses CONNECTION DIAGRAM UPPER LOWER MAUS GAS AN LT BR MV 7 8 69 24V lt 7 x 1 Y MVPV de 4 5 BK 1 2 3 LN 12 ri 123 PILOT SENSOR 2 E COM WHERE USED SOME MODELS SENSOR 1 Ww w IT rR THZS SENSE 3o BK 9 24V 2 CONTROL DISPLAY eb LONE 1 1 F me AN da H 2 2 41 R SECONDARY D 1821 8K END SWITCH BL 6 3 24V 1 4 Y OPEN CLOSE WwW OUTPUT LOAD 2 LINE IN DAMPER PLUG CONNECTION H LINE 3 lt ON OFF SWITCH TRANSFORMER PRIMARY 120 VOLTS AC WIRING DIAGRAM BLACK GROUND WHITE 115VOLTS SWITCH 115 VAC 115 VOLTS e Te T T e W B 7 9 T Muse 5 24 V WE TSTAT 50 je lt a DISPLAY sense L HIGH VOLTAGE e PILOT SPARK GAS VALVE R _ 225 RY MV f R M Ww DAMPER MOTOR B5 Y NOTE IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH 18 GA STRANDED 105 C WIRE OR ITS EQUIVALENT SI UN DES CONDUCTEURS D ORIGINE FOURNI AVEC L APPAREIL ETRE REMPLACE UTILISER UN CONDUCTEUR 18 GA STR
80. raneous materials and clear of dust and lint Keep pipework flue and tops of heaters clear of any combustible materials A water softener or lime inhibitor should be employed in hard water areas The heater should be inspected every few months via the hand hole cleanout and lime or silt deposits removed Failure to do so will shorten heater life and may invalidate the warranty NOTE The cleanout hole gasket must be renewed whenever the cover is removed C694 See parts lists pages 46 49 Before servicing carry out the following operations 1 Turn off the gas service cock 2 Turn off the cold water supply to the heater 3 Turn on the hot water draw off taps served by the water heater or for multiple installations turn off the hot water outlet connection valve and secondary return valve 4 Drain down using the drain valve on the heater The burner assembly should be checked and cleaned annually 1 Depress gas control knob and turn to OFF Remove outer burner cover and slide inner door to the right On models 63 62 and 84 87 remove two screws to release the inner cover 2 Disconnect pilot tube thermocouple and main burner supply tube from bottom of control valve Withdraw burner assembly from heater 3 Remove screw securing pilot assembly to main burner 4 Remove gland nut securing pilot tube to pilot assembly Withdraw pilot tube and remove pilot restrictor Clean pilot restrictor with acetone and blow through pilot burner wit
81. rol lamp on the potentiostat indicates that the installation is functioning correctly 4 The red control lamp on the potentiostat indicates a fault Switch off electrical supply before any repair work is carried out The installation is now complete INSTALLATION sections gt 1 Earth return connection using earth strap Output lead anode connections Fit correx anodes via 11 2 tee and red bush fittings into front hot and cold connections Potentiostat 240V Output lead anode connections Permanent supply Remove hydrojet nipple and replace with 1 nipple supplied in fittings pack FIG 2 HI FLO RANGE WATER HEATERS NAT GAS AND LPG Powered anode fittings pack Part No B184 ANODE OSEE 2 Correx powered anodes E048 1 Potentiostat 10 65 173 2 1 BSP Sq tees C856 81 264 2 11 2 x 3 4 BSP Red Bushes C857 62 341 1 17 Nipple C534 54 418 1 Earth Strap E049 54 440 1 Envelope spade and ring terminals fixing clamps clips WATER UNVENTED SYSTEMS STANDARD RANGE CONNECTIONS Unvented Systems should be fitted by an Approved Installer When used in an unvented system the Andrews Water Heater will supply hot water at a pressure of 3 5bar 50 8lbf in provided that this pressure is available at the mains feed During conditions of no flow system pressure may rise to a maximum of 6bar 87lbf in whilst the burner is operating When testing the system it is reco
82. rosion in the base of tanks and calorifiers Andrews Water Heaters has commissioned an independent evaluation of their products to investigate their resistance to build up of legionellae bacteria Experiments were conducted to determine whether following a substantial challenge by legionellae pneumophilia after overnight and stagnation conditions the system was rendered free from viable recoverable legionellae It was found that at 61 C following a challenge of approximately 107 organisms per litre within one hour more than 99 999 of organisms had been killed After a subsequent stagnation period sampling did not reveal any residual contamination The design of the base of the water heater precludes legionellae colonisation even after build up of debris The burner positioning ensures that the water at the bottom of the heater reaches the same or higher temperature as in the rest of the heater Based on data obtained through experiment the Andrews Water Heater can be described as legionellae resistant as it is considered unlikely that at the temperature tested the organism would colonise the water heater and present a possible health risk HEALTH AND SAFETY REGULATIONS 1993 EFFECTIVENESS IN COMBATING LEGIONELLAE 2 STANDARD QYPE eue 32 40 140 61 63 62 84 87 RANGE Storage Capacity 109 145 1182 286 382 gal 24 40 63 84 Recovery thro 449C 809F Wh 178 1182 1278 1281 1397
83. service layout for Hi Flo Range single heater unvented system is shown in Fig 16 Typical water service layouts for Hi Flo Range multiple heater unvented systems are shown in Figs 17 and 18 1 0m 140 Terminal away from any obstructions or any openings or features that may allow products re entry into the building Top Entry Models Split Flue Clip 65 173 81 264 Hot Water Service Front Entry All Models Split Flue Clip Cold Water Cold Water Hot Water Take Off Service Return Tee To Drain Y Return via Tee INSTALLATION SECTION 3 gt WATER CONNECTIONS 4 0m 40 Hot Water A A Cold Water Service pipe Take Off drain Fig 17 AA Common Return Cold Water Inlet Cold Water Inlet Common Return Fig 18 SECTION 4 COMMISSIONING STANDARD RANGE PERMANENT PILOT MODELS Fig 19 CAUTION DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER WITH WATER RUNNING FROM ALL HOT TAPS Open the main gas supply cock after all connections to the gas control are completed and test all connections using proprietary leak detection fluid Lighting the Burner 1 Remove outer cover and slide inner cover to right On 63 62 and 84 87 Models raise the inspection port cover Wait for 3 minutes for any unburnt gas to vent 2 Turn the gas control knob to pilot 3 Fully depress the gas control knob and the piezo igniter Wit
84. set thermostat to lower temperature b Thermostat faulty Check and replace if necessary c Main gas valve not closing Clean or replace a Reset thermostat to higher temperature b Check gas pressures at burner and at gas inlet to heater c Thermostat faulty Check and replace if necessary a Check gas pressures at burner and at gas inlet to heater b Check amount of water being used against recovery rate given on data plate If usage too high more heating capacity needed a Check if this stops when water in heater is hot If yes then condensation is the problem caused by incorrectly designed flue or by tank cooling excessively i e more hot water being used than recovery rate of heater If so more heating capacity needed b If water continues to drip when heater is hot problem is leaking joint or storage vessel a Scale formation in heater consult water treatment specialist Heater must be descaled and suitable water treatment provided to avoid re occurrence AUTO FAULT ACTION IGNITION NO a Check gas service cock is open UNITS IGNITION AT PILOT b Electrical ON OFF switch is not ON STANDARD c Power to unit interrupted d Thermostat set too low RANGE e Check ECO for failure Reset f Check for 24V AC at intermittent pilot ignition control terminal No 1 Replace control if faulty g Faulty Solenoid Coil Replace if faulty PILOT LIGHTS BUT a Check for 24V AC at intermittent pilot ign
85. ssive water temperature occurs To reset the control first press the temperature up and select buttons on the water heater display for 3 seconds to enter service mode Then press the lower right button under RESET in the display for 3 seconds Error code 65 indicates high limit lockout condition Ne z fe EN y CN Ke O de Step 1 Press for 3 seconds Step 2 Press for 3 to enter service mode seconds to reset control APPENDICES Conditions Upper or Lower Sensor Reading SERVICE PROCEDURE D24 Faulty High Water Temperature or suspect Thermostat Circuit Testing thermostat is not accurate Sensor Resistance Testing Upper Sensor 1 Determine resistance value of upper sensor Test across grey wires Upper thermister location applicable models 2 Draw quart of water off T amp P valve Using a thermometer determine water temperature 3 Use table below to verify correct resistance per water temperature measured Lower Sensor 1 Determine resistance value of lower sensor Test across center wire common to each outside wire Resistance of both thermisters in the lower sensor should be close to each other If the resistance values for both thermisters are not close to each other replace the lower sensor The dual thermisters are used to provide high limit protection in case the thermostat circuit fails to shut off the water heater
86. st completely up to date at the time of publication may be subject to revision without prior notice Further information and assistance can be obtained from Andrews Water Heaters Wood Lane Erdington Birmingham B24 9 Technical Helpline Tel 0845 070 1057 Fax 0845 070 1059 THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL ARE FOR USE WITH NATURAL GAS ONLY SECTION 1 GENERAL AND SAFETY INFORMATION General Information 4 British Standards 4 Health and Safety Regulations 1993 5 Legionellae in Water Heaters 5 SECTION 2 TECHNICAL DATA Standard Range 6 Hi Flo Range Z SECTION 3 INSTALLATION Introduction 8 Draught Diverter 8 Location 8 Gas Supply 9 Electrical Supply 10 Flue Systems 12 Air Supply and Ventilation 14 Water Quality and Treatment 16 Water Connections Hydrojet System 17 Vented Systems Standard Range 18 Correx Powered Anodes 20 Unvented Systems Standard Range 22 Vented Systems Hi Flo Range 24 Unvented Systems Hi Flo Range 27 SECTION 4 COMMISSIONING Standard Range 30 Hi Flo Range 32 SECTION 5 OPERATION Standard Range 39 Hi Flo Range 39 SECTION 6 SERVICING Introduction 40 Burner Assembly Standard Range 40 Burner Assembly Hi Flo Range 40 Gas Control Valve Standard Range 41 Gas Control Valve Hi Flo Range 41 Flue Ways 41 Cleaning the Storage Vessel 42 Magnesium Anode s 42 Safety Valve 42 SECTION 7 REPLACING COMPONENTS Hi Flo RANGE Gas Control Valve 44 Burner 44 SECTION 8 FAULT FINDING Permanen
87. t Pilot Models Standard and Hi Flo Range 45 All Models 46 Auto Ignition Models Hi Flo Range 47 SECTION 9 PARTS LISTS AND ILLUSTRATIONS Standard Range 49 Hi Flo Range 50 Unvented Systems Kit 54 24V Auto System Kit 56 APPENDICES HI FLO AUTO IGNITION SERIES ADDENDUM 58 GENERAL INFORMATION BRITISH STANDARDS AND CODES OF PRACTICE GENERAL AND SAFETY INFORMATION The Andrews Water Heater has been designed for use with NATURAL GAS only and is manufactured to give an efficient reliable and long service life To ensure the continued trouble free operation of your heater at maximum efficiency it is essential that correct installation commissioning operation and service procedures are carried out strictly in accordance with the instructions given in this manual By law installation and commissioning of the heater must be carried out by properly qualified personnel The heater s must be installed in accordance with the following requirements The current GAS SAFETY INSTALLATION AND USE REGULATIONS The current BUILDING REGULATIONS The Water Supply WATER FITTINGS REGULATIONS 1999 Additionally installation should be performed in accordance with all relevant requirements of the Gas Supplier Local Authority and recommendations of the British Standards and Codes of Practice detailed below STANDARD RANGE BS 6700 1997 Specification for design installation testing and maintenance of services supplying water for dom
88. t for Standard Range multiple heater vented system is shown in Fig 7 T amp P Valve Tapping Hot Water Cold Water outlet Fn Inlet All connection sizes are ANDREWS shown on page 4 ANDREWS T amp P Valve Tapping 84 87 only Drain amp Secondary Return Tapping INSTALLATION SECTION 3 Terminal Open Vent Stop Valve en Cold Water Feed 4 Hot Water Service Pipe Split Flue Clamp Cold Water niet Valve Draught Diverter Union Adaptor Gas Valve Gas Control Thermostat Gas Supply Pipe Secondary Return Check Valve Fig 6A Open Vent Cold Water Feed Hot Water Cold Water Supply Service Pipe from Cistern ANDREWS malta aden Fig 7 sections RUD CORREX POWERED ANODES FITTING AND OPERATING INSTRUCTIONS THE INTRODUCTION OF THIS KIT HAS THREE MAIN ADVANTAGES TO BE CONSIDERED a LOW MAINTENANCE COSTS Correx is non sacrificial therefore no anode maintenance is needed b LOW RUNNING COSTS LESS THAN 35kWH PER YEAR c BETTER PROTECTION PARTICULARLY IN AREAS OF LOW ELECTRICAL CONDUCTIVITY Wiring external to the water heater must be installed in accordance with the I E E Regulations for the wiring of buildings and to any loca Iregulations that may apply This kit is designed to run off 220 240V 1ph 50Hz permanent supply and the fuse rating is 3Amp The method of connection to the mains electricity supply should facilitate complete electrical iso
89. thout risk to health when properly used and to make available to users adequate information about their safe and proper Operation Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual Although the heaters have been manufactured with paramount consideration to safety certain basic precautions specified in this manual must be taken by the user It is imperative that all users of the heater must be provided with all the information and instruction necessary to ensure correct and safe operation Water systems in buildings have been associated with outbreaks of Legionnaires Disease particularly in health care facilities where occupants are significantly more susceptible to infection In recognition of the risks in hospitals a Code of Practice for the Control of Legionellae in Health Care premises has been issued by the Department of Health 1991 Codes of Practice applicable to other premises have been published by other organisations principally the Health and Safety Executive HS G70 and the Chartered Institute of Building Services Engineers CIBSE 13 All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria These factors include stagnation lukewarm conditions 20 C to 45 C and the accumulation of debris scale and cor
90. ting The Water Heater Display can be set back to the User Mode immediately by pressing both the Temperature Up and Select buttons together for 3 seconds idle Status Operational O Exiting Service Mode Display of Water Temperature Step 1 In Service Mode Press the Select button until Water Temp is displayed in the upper right section of the water heater display For water heaters using two temperature sensors in the tank this will be the average reading between the two sensors For water heaters using a single sensor this is the reading for the sensor E oF Water T I idle Status Operational Step 2 For water heaters using two temperature sensors pressing the Select button again displays the Upper Sensor temperature reading Upper Sensor will be displayed in the lower right side of the status window of the water heater display idle Status Operational Upper Sensor APPENDICES Troubleshooting Step 3 For water heaters using two temperature sensors pressing the Select button again displays the Lower Sensor temperature reading Lower Sensor will be displayed in the lower left side of the status window of the water heater display HET F HL idle Status Operational SELECN SEN To Display Flame Sense Current of the Pilot Flame Sensor The pilot flame sense current is available o
91. to indicate correct function and red to indicate malfunction An additional Correx BEMS version is available which provides a remote warning signal These anodes are available as an optional extra on all Andrews heaters In hard water areas scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used the more problematic the scale build up can be Water treatment is normally recommended when the hardness reaches 100 150 7 10 degrees Clark and above This problem can be minimised by reducing the water temperature in the heater and by fitting suitable water pre treatment equipment When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted The following companies have supplied water treatment equipment in the UK for a number of years to various establishments including those where Andrews water heaters have been installed WATER TECHNOLOGY LTD Powke Lane Ind Estate Blackheath Birmingham B65 OAH Contact Gareth Morris Tel 0121 561 3144 Fax 0121 561 4184 LIFF INDUSTRIES LTD Bay Hall Miln Road Huddersfield West Yorkshire Contact Ingrid Ashman Tel 0148 451 2357 Fax 0148 451 3597 WARD Saffron Walden Unit 3 Concord Farm School Road Rayne Essex CM77 65 Contact Michael Ward Tel 01376 559670 Fax 01376 340004 THE ENERGY SHOP
92. ts and remove draught shield Remove four screw located at each end of the burner manifold and withdraw gas control burner manifold as a unit UT Unscrew the control valve from the burner manifold noting position of the parts OY Remove gas service cock union from the control valve 7 Re assembly is reverse of above The joints between the gas cock union and the control valve to burner manifold must be made using an approved jointing compound suitable for natural gas The gas valve must be fitted so that it is square relative to the centre line of the injectors 8 Re commission the heater as detailed in Section 4 Commissioning NOTE These instructions apply to all models but Model 32 143 is not fitted with a limit USER sensor phial ADJUSTABLE 1 Turn off the gas control and the service cock CONTROL 2 Drain the heater THERMOSTAT 3 Remove front cover from control thermostat WITH LIMIT 4 Disconnect black red and white leads and withdraw SENSOR PHIAL 5 Remove phial guard by removing two screws AND OVERHEAT 6 Remove the clips locating the thermostat capillary ECO 7 Unscrew gland nut securing limit phial and pull out the phial 8 Rotate control thermostat limit phial unit anti clockwise using a smooth jawed spanner and withdraw 9 Re assembly is reverse of above The joint between control thermostat and tank must be made using an approved jointing compound 10 Re commission the heater as detailed in Section
93. tted the minimum actual capacity allowed for a feed cistern being 227 litres 50 gallons The actual cistern capacity is the capacity to the normal water line of the cistern All cisterns should be manufactured to the relevant British Standard The distance from the normal water line to the top of the cistern should comply with that specified by the Water Authorities The cold water inlet and hot water outlet connection nipples are identified on top of the heater Remove nipples and re make prior to installation Connect the cold water feed and hot water outlet to these nipples with union adaptors for ease of servicing CAUTION DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS MAKE THE CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER A DRAIN COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE BOSS AS SHOWN ON THE DRAWING After installation of the water system open the main water supply valve flush the system and fill the heater Open the hot taps to allow air to escape from the system When the water is free of air close the taps and check for leaks at the gas control thermostat drain cock and the pipe connections at the top of the heater All water connections for Standard Range are shown in Fig 6 Typical water service layout for Standard Range single heater vented system is shown in Fig 6A Typical water service layou
94. uence of modes available in Service Mode by pressing the Select button Error Code Number Display Reset This is only shown if there is an operating error in the User Mode Error Code Shown in Water Heater Display d LI Status Service Needed SELECT Lockout RESET APPENDICES Troubleshooting 1 Max Setpoint Display Change Max Setpoint value in Water Heater Display me Seien 11 idle Status Operational 2a Water Temperature Average Displays average if there are two sensors sensor temperature displayed if single sensor is used Honeywell oF Water Temp idle Status Operational IL idle Status Operational Upper Sensor SELECN SEN idle Status Operational Lower Sensor APPENDICES Troubleshooting Flame Current of Pilot Flame Sensor Displays only in the Heating Cycle 4 Setpoint Display Change oF setpoint idle Status Operational O 5 F C Display Change 6 T F Differential E idle Status Operational APPENDICES Troubleshooting 7 Software Version Display only 8 Error Code History Displays if there are present error codes or up to 10 previous error codes Water Heater Display will show a if there are no error codes WARNING Setting the water temperature to the maximum set point can result in scalding hot wat
95. ugh the flame sensor rod If pilot flame is lost pilot and main burners are shut down After a 65 second inter purge period the control will attempt to re light the pilot beginning at sequence 3 above Main burner fires until the thermostat is satisfied The control board interrupts 24 volts through the damper and the gas valve circuit Pilot and main burners are turned off Flue damper rotates to the closed position LOCKOUT CONDITION Control board will go into Soft Lockout if the pilot cannot be lit after 3 ignition trials The water heater display indicates a lockout condition by showing an error code number 62 or 63 with Service Needed in the display window Refer to error codes in the diagnostic section of this Service Manual In a Soft Lockout condition the control will wait for 60 minutes and then make 3 more attempts to light the pilot and establish the main burners Soft lockout reset is accomplished by depressing the lower right button under Reset for 3 seconds If the water heater should reach 200 degrees then the high limit control will shut off the burners and the water heater will go into a Hard Lockout Error code 65 will be shown in the water heater display The control can only be reset in the service mode which is detailed in the next section of this Service Manual Sequence of Operation The control board sends 24 volts from damper terminal 2 on the control
96. und wires okay Meter Probe Correct improper venting condition Refer to Installation Instructions Check venting conditions or negative pressure Is vent system okay Checking pilot flame sensor wire and flame rod for continuity LII and not bent or damaged refer to section on main burner and p Y Make sure pilot shield is in place Is heater condensing causing pilot Y pilot assembly Determine interruption cause for condensing and correct N Possible under sized water 4 heater or high demand periods ee N NOTE N The microamp output of the pilot may be Check continuity of sense lead SEN checked by entering Service Mode on the to flame rod If no continuity water heater display and pressing Select clean pilot flame rod or replace CO CO until the flame current is shown The control pilot Check pilot flame UE 5 must be in the heating mode with the pilot lit appearance if weak check for to display a reading See section on clogged pilot orifice bent pilot accessing service mode on the water heater tubing or low inlet gas Pilot flame sensor microamp output display pressure shown in display using service mode k 17 C see above illustration J Pilot must be lit to get reading Micro amp readings 0 000 Micro Amp Replace
97. ve Tapping Tapping e Hot Water amp Service Secondary Return amp Sam fe lt i Tapping Return Cold Water inlet Tappin 2 gt lt SNE e co up alve T E E i Fig 12 Gas inlet Gas Service Cock sections CONNECTIONS E 1 0m 40 Hot Water Service Pipe Fig 13 E Ct p IT pm zm Drain and Secondary Common Drain and Secondary Return Tapping Return Return Tapping Hot AU HT Service Pipe Fig 14 Drain and Secondary Common Drain and Secondary Return Tapping Return Return Tapping INSTALLATION SECTION 3 UNVENTED SYSTEMS Hi Flo RANGE WATER Unvented Systems should be fitted by an Approved Installer CONNECTIONS When used in an unvented system the Andrews Water Heater will supply hot water at a pressure of 3 5bar 50 8Ibf in provided that this pressure is available at the mains feed During conditions of no flow system pressure may rise to a maximum of 6bar 87lbf in whilst the burner is operating When testing the system it is recommended that a maximum test pressure of 8 62bar 125lbf in is employed Fig 15 The heater can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit part number B172 available from Andrews Water Heaters See Parts List Page 51 The Wall Mounting Assembly is available as an optional extra OPTIONAL PARTS C4 Temperature
98. vent interference or replace pilot assembly shield 2 Ne 2 Make sure pilot shield clears flame sense rod fane Sense Rod i Spark Electrode 7 M Check pilot flame sense wire for broken insulation Replace pilot if defective lt P Reinstall pilot and burner assembly Reconnect gas line union turn on gas ES Check for Gas Leaks Reconnect power and verify proper ignitions APPENDICES SERVICE PROCEDURE D24 II Pilot Operation Testing A CAUTION A DANGER Be Careful When Making Voltage 120 volt exposure To avoid personal injury Measurements or Jumping Terminals use caution while performing this procedure Not to Damage or Deform Connectors or Connector Pins Condition Pilot lights no or low flame signal Control Display shows 4 or 62 for Error Codes Service Needed Control continues to spark until system Lock Out Main burner will not light Meter Probe lead from pilot to Control Board see illustration to the right Is flame sense lead okay for loose or damaged ground wire s Repair wire lead or replace pilot Multi meter set Flame rod to check continuity a Check for loose or damaged flame sense Repair ground wire s or replace as needed from gas valve to control board Check continuity of wires with ohmeter Are gro
99. whole system is drained down to prevent damage due to the formation of ice inside the storage vessel THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST GAS SUPPLY ONLY BE USED WITH NATURAL GAS The installation of the gas supply must conform depending on it s size to the requirements of British Standards and Codes of Practice listed in Section 1 of this manual A gas meter will be connected to the service pipe by British Gas plc or it s authorised contractor The meter and service pipe should be checked by British Gas or it s authorised contractor to ensure that they are adequate to deal with the gas supply to the water heater s in addition to any existing or additional requirements Gas Supply Cock Standard Models Fit the gas supply cock immediately upstream of the gas control thermostat using a suitable jointing compound and connect to the gas supply Do not apply heat in close proximity to the gas thermostat as damage to the control will result A pressure test point nipple is fitted to the gas control thermostat at the gas inlet to test the incoming gas pressure GAS SUPPLY Gas Supply Cock Hi Flo Models Fig 2 Fit the gas cock immediately upstream of the gas control valve using a suitable jointing compound and connect to the gas supply An inlet nipple complete with pressure test point nipple is factory fitted to the gas control valve to avoid possible damage Gas Valve Gas Cock BSP Thread U PT Thread Fig 2
100. wire connections of One tee ane rae cure INE board to display See black wire pin connections to display illustration Voltage should be 24 volts AC display status reads Heating measured at the back of the Control Display See next page 40 a lt 99 If no voltage at Display check wire 1 harnesses and voltage at E com screw terminals see photo 5 Replace display if voltage is present at display pin terminals Replace control board if no voltage is present at E com terminals 1 amp 3 white black wires and 1 amp 2 white red wires to display APPENDICES Troubleshooting CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals From previous page Does damper blade move to the full open position Is there pilot flame Y Does Main Burner operate Y Does burner continue until thermostat set point is reached See setting display in Service Mode and displaying temperature sensors Does the flue damper rotate to the fully closed position Y System okay Error code 55 on display Remove damper from heater and jump black amp yellow wires of heater harness Refer to photo on this page Error code 62 on display See Pilot Will Not Light Error code 62 on display See Pilot Lights No Flame Signal Error code 63 on display See Main Burn

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