Zircon Installation Manual
Contents
1. 1 Indirect cylinders tested in conformance with BS EN 12897 2006 2 Heat up time from cold through 45 C with a primary flow rate 15ltrs min at 80 C 2 C 3 Direct heating times assume use of lower element only from cold through 45 C 6 Tundish INSTALLATION DISCHARGE DISCHARGE PIPEWORK 3 54 The tundish should be vertical located in the It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed to where it is visible but will not cause danger to persons in or about the building The tundish and discharge pipes should be fitted in accordance with the requirements and guidance notes of Building Regulation G3 The G3 Requirements and Guidance section 3 50 3 63 are reproduced in the following sections of this manual For discharge pipe arrangements not covered by G3 Guidance advice should be sought from your local Building Control Officer Any discharge pipe connected to the pressure relief devices Expansion Valve and Temperature Pressure Relief Valve must be installed in a continuously downward direction and in a frost free environment Water may drip from the discharge pipe of the pressure relief device This pipe must be left open to the atmosphere The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked G3 REQUIREMENT there shall be precautions to ensure that the hot water discharged from safet2. 28mm O D 0 55 I m 10 litres 18m NOTE Secondary circulation is NOT recommended for direct electric units OUTLET The hot water outlet is a 22mm compression fitting located at the top of the cylinder Hot water distribution pipework should be 22mm pipe with short runs of 15mm pipe to terminal fittings such as sinks and basins Pipe sizes may vary due to system design BALANCED COLD WATER CONNECTION NOT SUPPLIED PRESSURE REDUCING VALVE CARTRIDGE amp STRAINER EXPANSION VALVE OUTLET CHECK INLET VALVE DIRECTION OF FLOW oungr l EXPANSION VALVE PRESSURE REDUCING VALVE Fig 2 Cold water combination valve assembly COLD SUPPLY SWEPT TEE SECONDARY RETURN CHECK VALVE SECONDARY COLD INLET CIRCULATION CONNECTION PUMP Fig 3 Secondary circulation connection 595 o OUTLET B VALVE PRIMARY FLOW COLD INLET PRIMARY d LO N Fig 4 General dimensions Type Model Dimensions mm Primary Flow Coil Rating Heat up Time Hot Water Reference Itrs min 80 C KW Capacity Itrs A volume of water drawn off gt 40 C 930 615 15 125 2 4 30 354 indirect 306 direct Indirect qq Direct 120a 930 15 Table 2 Dimensions and performance Notes
3. 2 of BS 6700 2006 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages 3 59 Where a single common discharge pipe serves more than one system it should be at least one pipe size larger than the largest individual discharge pipe D2 to be connected 7 3 60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated that the soil discharge stack is capable of safely withstanding temperatures of the water discharged in which case it should a contain a mechanical seal not incorporating a water trap which allows water into the branch pipe without allowing foul air from the drain to be ventilated through the tundish b bea separate branch pipe with no sanitary appliances connected to it c if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either polybutalene PB to Class S of BS 7291 2 2006 or cross linked polyethylene PE X to Class S of BS 7291 3 2006 and d be continuously marked with a warning that no sanitary appliances should be connected to the pipe Note 1 Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043 1 2 Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to
4. 3 2m Therefore the permitted length equates to 5 8m 5 8m is less than the actual length of 7m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28mm pipe D2 from a G1 2 temperature relief valves equates to 18m Subtract the resistance of 4 No 28mm elbows at 1 0m each 4 0m Therefore the maximum permitted length equates to 14m As the actual length is 7m a 28mm D2 copper pipe will be satisfactory WARNINGS Under no circumstances should the factory fitted temperature pressure relief valve be removed other than by a competent person To do so will invalidate any guarantee or claim The cold water combination valve assembly must be fitted on the mains water supply to the cylinder No control or safety valves should be tampered with or used for any other purpose The discharge pipe should not be blocked or used for any other purpose The tundish should not be located adjacent to any electrical components VALVE OUTLET MINIMUM SIZE OF MINIMUM SIZE OF MAXIMUM RESISTANCE RESISTANCE CREATED BY SIZE DISCHARGE PIPE D1 DISCHARGE PIPE D2 ALLOWED EXPRESSED EACH ELBOW OR BEND FROM TUNDISH AS A LENGTH OF STRAIGHT PIPE I E NO ELBOWS OR BENDS UP TO 9M UP TO 18M UP TO 27M UP TO 9M UP TO 18M UP TO 27M UP TO 9M UP TO 18M UP TO 27M Table 3 Sizing of copper discharge pipe D2 for common temperature relief valve outlet sizes NOTE The above table is based on cop
5. Specialists Products Division Please contact your local branch UK Spares Ltd Tower Lane Warmley Bristol BS30 8XT Tel 0117 961 6670 www uk spares com Advanced Water Company Ltd Unit 5D Enterprise Way Vale Park Evesham Worcestershire WR11 1GS Tel 01386 760 066 Policy Statement The policy of ELSON is one of continuous product development and as such we reserve the right to change specifications without notice 90002344 36006102 issue 02
6. e g in dwellings occupied by people with impaired vision or mobility consideration should be given to the installation of a suitable safety device to warn when discharge takes place e g electronically operated Discharge pipe D2 3 56 The discharge pipe D2 from the tundish should a have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework see Fig 5 and b be installed with a continuous fall thereafter of at least 1 in 200 3 57 The discharge pipe D2 should be made of a metal or b other material that has been demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly and permanently marked to identify the product and performance standard e g as specified in the relevant part of BS 7291 3 58 The discharge pipe D2 should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i e for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device between 18 and 27m at least 3 sizes larger and so on bends must be taken into account in calculating the flow resistance See Fig 1 Table 3 and the worked example Note An alternative approach for sizing discharge pipes would be to follow Annex D section D
7. for 363 days a year and offers Dedicated Trade Advice Line our helpful and qualified specialists are always on hand to help you with even the most complex technical query Installer Priority Call Outs our 280 strong team of specifically trained expert heating engineers covers the UK no one is better qualified to look after Elson s products for the duration of the guarantee Fully Stocked Vans a nationwide fleet of vans fully stocked with spare parts meaning we can repair our appliances on the first visit 95 of call outs Exclusive Service Plans heateam also offer Elson s customers a range of exclusive annual service plans Opening Times Monday Friday 8am 6pm weekends and Bank Holidays 8 30am 2pm excluding Christmas Day and New Year s Day Simply call 0844 3358819 or visit our website at www heateam co uk Fifers Lane Norwch Norfolk NR6 6XB T 0844 335 8819 F 0844 871 1528 E elson service heateam co uk W elsonhotwater co uk PART OF BDR THERMEA Spares For all technical support replacement parts amp service issues please contact Electric Water Heating Co 2 Horsecroft Place Pinnacles Harlow Essex CM19 5BT Tel 0845 0553811 E mail sales ewh co uk SPD Special Product Division Units 9 amp 10 Hexagon Business Centre Springfield Road Hayes Middlesex UB4 OTY Tel 020 8606 3567 Parts Center Tel 0845 270 9800 www partscenter co uk Newey amp Eyre
8. of a cylinder leak a replacement product will be issued provided that the replacement is carried out by one of our heateam engineers for which reasonable labour charges will apply The guarantee is valid provided that l thas been correctly installed as per the instructions contained in the instruction manual and all relevant Codes of Practice and Regulations in force at the time of installation The Benchmark Checklist has been completed upon commissioning and the Benchmark Service Record is completed for each service It has not been modified in any way other than by ELSON It has not been frost damaged It has only been used for the storage of potable water It has not been tampered with or been subjected to misuse or neglect The fault is not scale related Within 60 days of installation the user completes and returns the certificate supplied along with the proof of purchase to register the product It has been installed in the United Kingdom The fault is not caused by high chloride levels in the water supply or incorrect disinfection methods Evidence of purchase and date of supply may be required The guarantee is transferable This guarantee does not affect your statutory rights Servicing heateam heateam is Elson s very own service division With us on your side you can be sure that your customers are in the very best of hands Totally committed to quality and safety heateam is open 7 days a week
9. off points Discharge pipework from valve outlets to tundish INSTALLATION INDIRECT SAFETY DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS Never attempt to replace the immersion heater s other than with the recommended authorised immersion heater s DO NOT BYPASS THE THERMAL CUT OUT S IN ANY CIRCUMSTANCES Ensure the two male spade terminations on the underside of the combined thermostat and thermal cut out are pushed firmly onto the corresponding terminations on the element plate assembly In case of difficulty contact service support contact details available at the back of this booklet ELECTRICAL SUPPLY All electrical wiring should be carried out by a competent electrician and be in accordance with the latest l E E Wiring Regulations Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact separation of at least 3mm in both poles The immersion heater s should be wired in accordance with Fig 8 The immersion heaters MUST be earthed The supply cable should be 1 5mm 3 core HOFR sheathed and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip DO NOT operate the immersion heaters until the cylinder has been filled with water Ensure the thermostat and thermal cut out sensing bulbs are pushed fully into the pockets on the element plate assembly PLUMBING CONNEC
10. the level of the heater this can be achieved by attaching a hose to the drain tap outlet spigot EXPANSION VESSEL The expansion vessel accommodates expansion that results from heating the water inside the unit The expansion vessel is pre charged at 0 35MPa 3 5 bar The expansion vessel must be connected between the expansion valve and the cylinder see Fig 6 Page 10 The location of the expansion vessel should allow access to recharge the pressure as and when necessary this can be done using a normal car foot pump It is recommended that the expansion vessel is adequately supported An expansion vessel wall mounting bracket is supplied for this purpose and should be fitted SECONDARY CIRCULATION If secondary circulation is required it is recommended that it be connected to the cylinder as shown see Fig 3 page 5 via a swept tee joint into the cold feed to the unit A swept tee joint is available as an accessory order code no 5133565 The secondary return pipe should be in 15mm pipe and incorporate a check valve to prevent backflow A suitable WRAS approved bronze circulation pump will be required On large systems due to the increase in system water content it may be necessary to fit an additional expansion vessel to the secondary circuit This should be done if the capacity of the secondary circuit exceeds 10 litres Pipe capacity copper 15mm O D 0 13 I m 10 litres 77m 22mm O D 0 38 I m 10 litres 26m
11. tightening the immersion heater s Check expansion vessel pre charge pressure The vessel is supplied precharged to 0 35MPa 3 5 bar to match the control pressure of the pressure reducing valve The precharge pressure is checked using a car tyre gauge by unscrewing the plastic cap opposite the water connection Check all connections for tightness including the immersion heater s An immersion heater key spanner is supplied for this purpose Ensure the drain cock is CLOSED Open a hot tap furthest from the cylinder Open the mains stop cock to fill the unit When water flows from the tap allow to run for a few minutes to thoroughly flush through any residue dirt or swarf then close the tap Open successive hot taps to purge the system of air SYSTEM CHECKS Check all water connections for leaks and rectify as necessary Turn off mains water supply Remove the pressure reducing valve head work to access the strainer mesh clean and re fit Manually open for a few seconds each relief valve in turn checking that water is discharged and runs freely through the tundish and out at the discharge point Ensure that the valve s reseat satisfactorily DIRECT UNITS Switch on electrical supply to the immersion heater s and allow the cylinder to heat up to normal working temperature 60 C recommended approximately graduation 4 on the thermostat If necessary the temperature can be adjusted by in
12. 19 COMMISSIONING CHECK L_LIST 22 SERVICE RECORD R tente hse teneas 23 GUARANTEE traits idet oe e teet reote 24 TECHNICAL SUPPORT tuae ttt ith ti GEN ER 24 kiwa kiwa pproved roduct approved product BEAB Approved The cylinder is a purpose designed unvented water heater The unit has a stainless steel inner vessel which ensures an excellent standard of corrosion resistance The outer casing is a combination of resilient thermoplastic mouldings and plastic coated corrosion proofed steel sheet All products are insulated with CFC free polyurethane foam to give good heat loss performance see Table 6 page 19 The unit is supplied complete with all the necessary safety and control devices needed to allow connection to the cold water mains All these components are preset and not adjustable This appliance complies with the requirements of the CE marking directive and is Kiwa approved to show compliance with Building Regulations Section G3 The following instructions are offered as a guide to installation which must be carried out by a competent plumbing and electrical installer in accordance with Building Regulation G3 The Building Standards Scotland Regulations 1990 or The Building Regulations Northern Ireland NOTE Prior to installation the unit should be stored in an upright position in an area free from excessive damp or humidity bencfmar THE MARK OF OUALITY FOR
13. E APPLIANCE SITING THE UNIT The cylinder must be vertically floor mounted Although location is not critical the following points should be considered The cylinder should be sited to ensure minimum dead leg distances particularly to the point of most frequent use Avoid siting where extreme cold temperatures will be experienced All exposed pipe work should be insulated The discharge pipework from the safety valves must have minimum fall of 1 200 from the unit and terminate in a safe and visible position Access to associated controls and immersion heaters must be available to provide for the servicing and maintenance of the system Where these controls are installed against a wall a minimum distance of 250mm must be left see Fig 1 Ensure that the floor area for the cylinder is level and capable of permanently supporting the weight when full of water see Table 1 WALL Min 250mm Min 250mm Fig 1 Siting the Unit N Nominal Weight of Capacity unit full litres Kg indirect Direct Table 1 Unit weights Model Reference WATER SUPPLY Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously It is recommended that the maximum water demand is assessed and the water supply checked to ensure this demand can be satisfactorily met Note A high mains water pressure will not always guarantee h
14. RS TO CHECK THE SYSTEM DO NOT TAMPER WITH ANY OF THE SAFETY VALVES FITTED TO THE SYSTEM IF A FAULT IS SUSPECTED CONTACT A COMPETENT INSTALLER BENCHMARK The cylinder is covered by the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety efficiency and performance Benchmark is managed and promoted by the Heating and Hotwater Industry Council For more information visit www centralheating co uk Please ensure that the installer has fully completed the Benchmark Checklist Page 22 amp 23 of this manual and that you have signed it to say that you have received a full and clear explanation of its operation The installer is legally required to complete a commissioning checklist as a means of complying with the appropriate Building Regulations England amp Wales All installations must be notified to Local Area Building Control either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer who should on receipt write the Notification Number on the Benchmark Checklist This product should be serviced regularly to optimise its safety efficiency and performance The service engineer should complete the relevant Service Record on the Benchmark Checklist after each service The Benchmark Checklist may be require
15. RY SETTINGS indirect heating only Is the primary circuit a sealed or open vented system Sealed Open What is the maximum primary flow temperature C ALL SYSTEMS What is the incoming static cold water pressure at the inlet to the system bar Has a strainer been cleaned of installation debris if fitted Yes No Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted What is the hot water thermostat set temperature C What is the maximum hot water flow rate at set thermostat temperature measured at high flow outlet l min Time and temperature controls have been fitted in compliance with Part L of the Building Regulations Yes Type of control system if applicable Y Plan S Plan L Other m Is the cylinder solar or other renewable compatible Yes No What is the hot water temperature at the nearest outlet C All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes UNVENTED SYSTEMS ONLY Where is the pressure reducing valve situated if fitted What is the pressure reducing valve setting M bar Has a combined temperature and pre
16. THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS THE BENCHMARK SCHEME Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information IMPORTANT NOTE TO USER PLEASE REFER TO THE USER INSTRUCTIONS SECTION ON PAGE 16 FOR IMPORTANT INFORMATION WITH RESPECT TO THE BENCHMARK SCHEME GENERAL REQUIREMENTS IMPORTANT THIS APPLIANCE IS NOT INTENDED FOR THE USE BY PERSONS INCLUDING CHILDREN WITH REDUCED PHYSICAL SENSORY OR MENTAL CAPABILITIES OR LACK OF KNOWLEDGE AND EXPERIENCE UNLESS THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING THE USE OF THE APPLIANCE BY A PERSON RESPONSIBLE FOR THEIR SAFETY CHILDREN MUST BE SUPERVISED TO ENSURE THEY DO NOT PLAY WITH TH
17. TIONS Indirect cylinders require the following pipework connections Cold water supply to and from inlet controls Outlet to hot water draw off points Discharge pipework from valve outlets to tundish Connection to the primary circuit All connections are 22mm compression However 3 A BSP parallel threaded fittings can be fitted to the primary coil connections if required BOILER SELECTION The boiler should have a control thermostat and non self resetting thermal cut out and be compatible with unvented storage water heaters Where use of a boiler without a thermal cut out is unavoidable a low head open vented primary circuit should be used The feed and expansion cistern head above the cylinder should not exceed 2 5m 12 PRIMARY CIRCUIT CONTROL The 2 port motorised valve supplied with the cylinder MUST be fitted on the primary flow to the cylinder heat exchanger and wired in series with the indirect control thermostat and thermal cut out fitted to the unit Primary circulation to the cylinder heat exchanger must be pumped gravity circulation WILL NOT WORK SPACE AND HEATING SYSTEMS CONTROLS The controls provided with the cylinder will ensure the safe operation of the unit within the central heating system Other controls will be necessary to control the space heating requirements and times that the system is required to function see Fig 8 below The cylinder is compatible with most heating controls examp
18. UPPLIED WITH THE CYLINDER AS THIS WILL INVALIDATE ANY GUARANTEE Mains supply off Check and open stop cock Strainer blocked Turn off water supply Remove strainer and No hot water flow clean Cold water combination valve incorrectly Check and refit as required fitted Direct immersion heater not switched on Check and switch on Direct immersion heater thermal cut out Check reset by pushing button on thermostat has operated Indirect programmer set to central heat Check set to domestic hot water programme ing only Water from hot tap i is cold Indirect boiler not working Check boiler operation If fault is suspected consult boiler manufacturer s instructions Indirect thermal cut out has operated Check reset by pushing button on thermostat Check operation of indirect thermostat Indirect motorised valve not connected Check wiring and or plumbing connections to correctly motorised valve INTERMITTENTLY See Maintenance section for re charging of Expansion vessel charge pressure has expansion vessel procedure reduced below 3 5bar or set to high Water discharges CONTINUALLY Check pressure from cold water combination from expansion cold water combination valve pressure valve If greater than 3 5bar replace pressure valve reducer not working correctly reducing valve Expansion valve seat damaged Remove expansion valve cartridge check condition of seat If necessary fit new expansion valve Thermal control failure Swi
19. Zircon Installation Manual Unvented Direct amp Indirect Water Heaters eison Installation amp Servicing Instructions Pack Contents Zircon unvented water heater incorporating immersion heater s amp thermal controls Factory fitted temperature pressure relief valve set at 90 C 1 Mpa 10bar Cold water combination valve assembly Expansion vessel amp mounting bracket Tundish 2 Port motorised valve indirect models only Compression nuts amp olives Immersion heater spanner Installation amp servicing instructions Guarantee card IMPORTANT Please read amp understand all these instructions before commencing installation Please leave this manual with the customer for future reference CONTENTS INTRODUCTION INTRODUCTION L aq na etenim eerta asas 2 GENERAL REQUIREMENT S u ee ee ee ee ee ee 3 INSTALLATION GENERAL ee ee ee see ee ee ee ee ee ee ee 5 INSTALLATION DISCHARGE 7 INSTALLATION DIRECT ee esse see ee ee ee ee ee se ee ee ee 11 INSTALLATION INDIRECT ees ee ese ee ee ee ee ee ee ee 12 COMMISSIONING arte ten ESE ESE Ee ee eke ge eta 14 MAINTENANCE es SERS uu aa 15 USER INS TRUC TIONS crescini gee RSA Wee Ne ER Sk Ru 16 FAULT FINDING amp SERVICING 17 AAR EE EE EE qa 18 HEAT LOSS sees eb SE Ee EA tette ten 19 ENVIRONMENTAL INFORMATION
20. co uk SERVICE 1 Date Engineer Name Company Name SERVICE 2 Date Engineer Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 3 Date Engineer Name SERVICE 4 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 5 Date Engineer Name SERVICE 6 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 7 Date Engineer Name SERVICE 8 Date Engineer Name Company Name Telephone Number Company Name Telephone Number Comments Comments Signature SERVICE 9 Date Engineer Name Signature SERVICE 10 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature Sales amp Support Guarantee On site service support including parts and labour for 12 months from date of installation After the initial 12 months a guarantee will apply for a further 24 years for the stainless steel inner vessel only During this 24 year period in the event
21. d in the event of any warranty work and as supporting documentation relating to home improvements in the optional documents section of the Home Improvements Pack FLOW PERFORMANCE 16 When initially opening hot outlets a small surge in flow may be noticed as pressures stabilise This is quite normal with unvented systems In some areas cloudiness may be noticed in the hot water This is due to aeration of the water is quite normal and will quickly clear TEMPERATURE CONTROLS DIRECT UNITS IMMERSION HEATER S A combined adjustable thermostat and thermal cut out is provided for each immersion heater The thermostat is factory set to give a water storage temperature of approx 55 C to 60 C Access to the thermostat can be made by opening the immersion heater cover DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE COVER S Temperature adjustment is made by inserting a flat bladed screwdriver in the slot on the adjustment disc on top of the thermostat and rotating The adjustment range 1 to 5 represents a temperature range of 12 C to 68 C 60 C will be approximately position 4 If in any doubt contact a competent electrician DO NOT bypass the thermal cut out s in any circumstances TEMPERATURE CONTROLS INDIRECT UNITS The cylinder units are fitted with an indirect thermostat and thermal cut out These controls must be wired in series with the 2 port motorised zone valve supplied to interrupt the flow of primary wate
22. djustment range 1 to 5 represents a temperature range of 12 C to 68 C Check the operation of thermostat s and that no water has issued from the expansion relief valve or temperature pressure relief valve during the heating cycle INDIRECT UNITS Open the cover s to the immersion heater housing s and disconnect wiring from immersion heater s thermostat s Remove thermostat by carefully pulling outwards Remove thermostat capillary sensors from the pockets on the immersion heater Unscrew immersion heater backnut s and remove immersion heater from the unit A key spanner is supplied with the cylinder unit for easy removal tightening of the immersion heater s Over time the immersion heater gasket may become stuck to the mating surface To break the seal insert a round bladed screwdriver into one of the pockets on the immersion heater and gently lever up and down Carefully remove any scale from the surface of the element s DO NOT use a sharp implement as damage to the element surface could be caused Ensure sealing surfaces are clean and seals are undamaged if in doubt fit a new gasket part number 95 611 822 Replace immersion heater s ensuring the lower right angled element hangs vertically downwards towards the base of the unit It may be helpful to support the immersion heater using a round bladed screwdriver inserted into one of the thermostat pockets whilst the backnut is tightened Replace thermostat capillaries i
23. eaded 3 4 BSP male parallel should threaded pipe connections be required COLD FEED A 22mm cold water supply is recommended however ifa 15mm 1 2 supply exists which provides sufficient flow this may be used although more flow noise may be experienced A stopcock or servicing valve should be incorporated into the cold water supply to enable the cylinder and its associated controls to be isolated and serviced COLD WATER COMBINATION VALVE ASSEMBLY The 2 piece cold water combination valve assembly see Fig 2 can be located anywhere on the cold water mains supply prior to the expansion vessel see Fig 6 Page 10 but the two pieces do not have to be installed together The pressure reducing valve incorporates the pressure reducer and strainer and the expansion valve incorporates the expansion and check valves Ensure that the valves are installed in the correct order and orientation No other valves should be placed between the expansion valve and the cylinder A connection can be made between the expansion and pressure reducing valves to provide a balanced cold water connection The expansion valve connection must not be used for any other purpose DRAIN TAP A suitable draining tap should be installed in the cold water supply to the cylinder between the expansion valve see Fig 6 Page 10 and the heater at as low a level as possible It is recommended that the outlet point of the drain pipework be at least 1 metre below
24. he cylinder internally SAFETY VALVE OPERATION Manually operate the temperature pressure relief valve for a few seconds Check water is discharged and that it flows freely through the tundish and discharge pipework Check valve reseats correctly when released NOTE Water discharged may be very hot Repeat the above procedure for the Expansion Relief Valve STRAINER Turn off the cold water supply boiler and immersion heaters The lowest hot water tap should then be opened to de pressurise the system Remove the pressure reducing cartridge to access the strainer mesh Wash any particulate matter from the strainer under clean water Re assemble ensuring the seal is correctly fitted DO NOT use any other type of sealant DESCALING IMMERSION HEATER S Before removing the immersion heater s the unit must be drained Ensure the water electrical supply and boiler are OFF before draining Attach a hosepipe to the drain cock having sufficient length to take water to a suitable discharge point below the level of the unit Open a hot tap close to the unit and open drain cock to drain unit DIRECT UNITS Switch on electrical supply to the immersion heater s and allow to heat up to normal working temperature 60 C recommended approximately graduation 4 on the thermostat If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob on top of the immersion heater thermostat and rotating The a
25. igh flow rates Wherever possible the mains supply pipe should be 22mm We suggest the minimum supply requirements should be 0 15MPa 1 5 bar pressure and 20 litres per minute flowrate However at these values outlet flow rates may be poor if several outlets are used simultaneously The higher the available pressure and flow rate the better the system performance The cylinder has an operating pressure of 0 35MPa 3 5 bar which is controlled by the cold water combination valve assembly The cold water combination valve assembly can be connected to a maximum mains pressure of 1 6MPa 16 bar OUTLET TERMINAL FITTINGS TAPS ETC The cylinder can be used with most types of terminal fittings It is advantageous in many mixer showers to have balanced hot and cold water supplies In these instances a balanced pressure cold water connection should be placed between the 2 pieces of the cold water combination valve assembly see Fig 2 Outlets situated higher than the cylinder will give outlet pressures lower than that at the heater a 10m height difference will result in a 0 1MPa 1 bar pressure reduction at the outlet All fittings pipework and connections must have a rated pressure of at least 0 6MPa 6 bar at 80 C 3 LIMITATIONS The cylinder should not be used in association with any of the following Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic control unless addi
26. les of electrical circuits are shown in Figs 9 and 10 Page 13 However other systems may be suitable refer to the controls manufacturers instructions supplied with the controls selected for alternative system wiring schemes Element Connections Indirect control 1 5mm 3 Core wiring L 1 HOFR sheathed cable Fig 8 Electrical connections indirect schematic CYLINDER TERMINAL BLOCK ZONE VALVE DHW SUPPLIED BOILER PROGRAMMER NOTES CONTROL TERMINAL NUMBERING MAY DIFFER FROM THOSE SHOWN REFER TO INSTRUCTIONS WITH CONTROLS SELECTED A DOUBLE POLE ISOLATING SWITCH MUST BE INSTALLED IN THE MAINS SUPPLY ALL EARTH CONNECTIONS MUST BE CONNECTED BACK TO THE MAINS EARTH SUPPLY Fig 9 Schematic wiring diagram Basic 2 x 2 port valve system CYLINDER TERMINAL BLOCK ZONE VALVE DHW SUPPLIED ROOM STAT BOILER NOTES CONTROL TERMINAL NUMBERING MAY DIFFER FROM THOSE SHOWN REFER TO INSTRUCTIONS WITH CONTROLS SELECTED A DOUBLE POLE ISOLATING SWITCH MUST BE INSTALLED IN THE MAINS SUPPLY ALL EARTH CONNECTIONS MUST BE CONNECTED BACK TO THE MAINS EARTH SUPPLY Fig 10 Schematic wiring diagram 3 port mid position valve system N B Must be used in conjunction with 2 port zone valve supplied 13 COMMISSIONING FILLING THE UNIT WITH WATER Ensure that all fittings and immersion heaters are correctly fitted and tightened An immersion heater key is provided to aid
27. mmersion heater s DO NOT BYPASS THE THERMAL CUT OUT S INANY CIRCUMSTANCES Ensure the two male spade terminations on the underside of the combined thermostat and thermal cut out are pushed firmly onto the corresponding terminations on the element plate assembly In case of difficulty contact service support contact details available at the back of this booklet ELECTRICAL SUPPLY All electrical wiring should be carried out by a competent electrician and be in accordance with the latest LE E Wiring Regulations 1 5mm 3 Core HOFR sheathed Each circuit must be protected by a suitable fuse cable and double pole isolating switch with a contact separation of at least 3mm in both poles The immersion heater s should be wired in Fig T Electrical connections direct schematic accordance with Fig 7 The immersion heaters MUST be earthed The supply cable should be 1 5mm2 3 core HOFR sheathed and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip DO NOT operate the immersion heaters until the cylinder has been filled with water Ensure the thermostat and thermal cut out sensing bulbs are pushed fully into the pockets on the element plate assembly PLUMBING CONNECTIONS Direct cylinders require the following pipework connections Cold water supply to and from inlet controls Outlet to hot water draw
28. modate the expansion SPARE PARTS FAU LT FINDING amp SERVICING A full range of spare parts are available for the cylinder range Table 5 Page 18 Refer to the IMPORTANT technical data label on the unit to identify the model After servicing complete the relevant Service installed and ensure the correct part is ordered You Interval Record section of the Benchmark will need to quote the serial number which is printed Checklist located on page 22 and 23 of this on the data label document Servicing should only be carried out by FAULT FINDING competent persons in the installation and The fault finding chart Table 4 Page 17 will enable maintenance of unvented water heating operational faults to be identified and their possible Systems causes rectified Any work carried out on the cylinder Any spare parts used MUST be authorised unvented water heater and its associated controls parts MUST be carried out by a competent installer for Disconnect the electrical supply before removing unvented water heating systems In case of doubt any electrical equipment covers contact service support see contact details on back NEVER bypass any thermal controls or operate page system without the necessary safety valves Water contained in the cylinder may be very WARNING hot especially following a thermal control failure Caution must be taken when drawing water from DO NOT TAMPER WITH ANY OF THE SAFETY VALVES the unit OR CONTROLS S
29. ng Heat Loss materials At the end of their useful life they should be Capacity I i Litres d disposed of at a Local Authority Recycling Centre in per gay per year order to realise the full environmental benefits KWh 24h GAIA Insulation is by means of an approved CFC HCFC free polyurethane foam with an ozone depletion factor of zero Table 6 Standing heat losses based on an ambient air temperature of 20 C and a stored water temperature of 65 C NOTES 20 NOTES 21 MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name 1 Al Telephone Number Address Oylinder Make and Model Cylinder Serial Number _ ll II TL ll lI ttt tte tte ete ee te lll l T L l Commissioned by print name Registered Operative ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable ALL SYSTEMS PRIMA
30. nto pocket Replace the immersion heater thermostat by carefully plugging the two male spade terminations on the underside of the thermostat head into the corresponding terminations on the element Rewire check close and secure immersion heater housing cover s EXPANSION VESSEL CHARGE PRESSURE Remove the dust cap on top of the vessel Check the charge pressure using a tyre pressure gauge The pressure with system de pressurised should be 0 35MPa 3 5 bar If it is lower than the required setting it should be re charged using a tyre pump Schrader valve type DO NOT OVER CHARGE Re check the pressure and when correct replace the dust cap RE COMMISSIONING Check all electrical and plumbing connections are secure Close the drain cock With a hot tap open turn on the cold water supply and allow unit to refill DO NOT switch on the immersion heater s or boiler until the unit is full When water flows from the hot tap allow to flow for a short while to purge air and flush through any disturbed particles Close hot tap and then open successive hot taps in system to purge any air When completely full and purged check system for leaks The heating source immersion heater s or boiler can then be switched on 15 USER INSTRUCTIONS WARNINGS IF WATER DISCHARGES FROM THE TEMPERATURE PRESSURE RELIEF VALVE ON CYLINDER SHUT DOWN THE BOILER DO NOT TURN OFF ANY WATER SUPPLY CONTACT A COMPETENT INSTALLER FOR UNVENTED WATER HEATE
31. per tube Plastic pipes may be of different bore and resistance Sizes and maximum lengths of plastic should be calculated using data prepared for the type of pipe being used Safety device e g Temperature relief valve Metal discharge pipe D1 from Temperature relief valve to tundish h 600mm maximum d Tundish Discharge below fixed grating Building Regulation G3 section 3 61 gives alternative points of discharge 300mm minimum Discharge pipe D2 from tundish with continuous fall See Building Regulation G3 section 3 56 Table 1 and worked example Fixed grating Trapped gully Fig 5 Typical discharge pipe arrangement extract from Building Regulation G3 Guidance section 3 50 TO HOT OUTLETS lt ELEMENT CONTROLS HOUSING PRIMARY RETURN PRIMARY FLOW BALANCED COLD WATER COLD WATER COMBINATION MAINS T amp P RELIEF EXPANSION CONNECTION VALVE WATER VALVE VESSEL IF REQUIRED 2 PIECE SUPPLY AT IN 4 OT T ISOLATING I VALVE NOT BI j SUPPLIED LI H W Ve TUNDISH Kup P KA INLET DRAIN COCK SECONDARY RETURN DISCHARGE NOT SUPPLIED TAPPING IF REQUIRED PIPE NOT SUPPLIED Fig 6 Typical installation schematic 10 HIHI CM AANUHARHI INSTALLATION DIRECT SAFETY DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS Never attempt to replace the immersion heater s other than with the recommended i
32. r around the heat exchanger coil when the control temperature has been reached The controls are located within the lower terminal housing along with the immersion heater thermostat The thermostat is factory set to give a water storage temperature of approx 55 C to 60 C Access to the thermostat can be made by opening the terminal housing cover DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE COVER Temperature adjustment is made by inserting a flat bladed screwdriver in the adjustment knob and rotating The minimum thermostat setting is 12 C The adjustment range 1 to 5 represents a temperature range of 12 C to 68 C 60 C will be approximately position 4 If in any doubt contact a competent electrician An immersion heater is also provided for use should the indirect heat source be shut down for any purpose The immersion heater control temperature is set using the immersion heater thermostat DO NOT bypass the thermal cut out s in any circumstances OPERATIONAL FAULTS Operational faults and their possible causes are detailed in the Fault Finding section of this book It is recommended that faults should be checked by a competent installer The air volume within the expansion vessel will periodically require recharging to ensure expanded water is accommodated within the unit A discharge of water INTERMITTENTLY from the expansion valve will indicate the air volume has reduced to a point where it can no longer accom
33. res detailed in this manual the Benchmark Installation Commissioning and Service Record Log pages 22 and 23 should be completed and signed off by the competent installer or commissioning engineer in the relevant sections The various system features location of system controls user instructions and what to do in the event of a system failure should be explained to the customer The customer should then countersign the Benchmark commissioning checklist page 22 to accept completion The Service Record should be filled in when any subsequent service or maintenance operation is carried out on the product MAINTENANCE MAINTENANCE REQUIREMENTS Unvented hot water systems have a continuing maintenance requirement in order to ensure safe working and optimum performance It is essential that the relief valve s are periodically inspected and manually opened to ensure no blockage has occurred in the valves or discharge pipework Similarly cleaning of the strainer element and replacement of the air in the expansion vessel will help to prevent possible operational faults The maintenance checks described below should be performed by a competent person on a regular basis e g annually to coincide with boiler maintenance After any maintenance please complete the relevant Service Interval Record section of the Benchmark Checklist on Page 22 of this document INSPECTION The immersion heater boss can be used as an access for inspecting t
34. serting a flat bladed screwdriver in the adjustment knob on top of the immersion heater thermostat and rotating The adjustment range 1 to 5 represents a temperature range of 12 C to 68 C Check the operation of thermostat s and that no water has issued from the expansion relief valve or temperature pressure relief valve during the heating cycle 14 INDIRECT UNITS Fill the indirect primary circuit following the boiler manufacturer s commissioning instructions To ensure the cylinder primary heat exchanger is filled the 2 port motorised valve supplied should be manually opened by moving the lever on the motor housing to the MANUAL setting When the primary circuit is full return the lever to the AUTOMATIC position Switch on the boiler ensure the programmer is set to Domestic Hot Water and allow the cylinder to heat up to a normal working temperature 60 C recommended approximately graduation 4 on the thermostat If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob and rotating The minimum thermostat setting is 12 C The adjustment range 1 to 5 represents a temperature range of 12 C to 68 C Check the operation of the indirect thermostat and 2 port motorised valve and that no water has issued from the expansion relief valve or temperature pressure relief valve during the heating cycle BENCHMARK LOG BOOK On completion of the installation and commissioning procedu
35. ssure relief valve and expansion valve been fitted and discharge tested Yes No The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes Are all energy sources fitted with a cut out device Yes No Has the expansion vessel or internal air space been checked Yes No THERMAL STORES ONLY What store temperature is achievable C What is the maximum hot water temperature C ALL INSTALLATIONS The hot water system complies with the appropriate Building Regulations Yes The system has been installed and commissioned in accordance with the manufacturer s instructions Yes The system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer pen china THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating
36. tch off power to immersion heater s and NOTE water will be very hot shut down boiler DO NOT turn off water supply When discharge stops check all thermal controls replace if faulty Oxygenated water Water from a pressurised system releases Milky water oxygen bubbles when flowing The milkiness will disappear after a short while Water discharges from T amp P relief valve Table 4 Fault Finding Chart 17 SPARES Item Description Part Number Number 6 Immersion heater backnut 95 607 869 7 Immersion heater key 95 607 861 spanner Indirect thermostat amp 95 612 716 thermal cut out Direct thermostat amp thermal 95 612 717 cut out 14 Temperature Pressure 95 605 810 relief valve 95 605 838 16 Expansion valve complete 95 607 030 0 6MPa 6 Bar 17 Cold water combination 95 605 047 valve complete Motorised 2 port valve 95 605 049 19 Accessory Kit Indirect 95 607 968 without expansion vessel 20 Accessory Kit Direct 95 607 969 without expansion vessel 21 Expansion vessel 12 litre 95 607 863 120 amp 150 litre models 22 Expansion vessel 18 litre 95 607 864 170 amp 210 litre models 23 Expansion vessel 24 litre 95 607 612 250 amp 300 litre models Table 5 Spares 18 Fig 11 Indirect Cylinder Spares Diagram Pa Fig 12 Direct Cylinder Spares Diagram HEAT LOSS ENVIRONMENTAL Products are manufactured from many recyclable Nominal Standi
37. the discharge stack Termination of discharge pipe 3 61 The discharge pipe D2 from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge 3 62 Examples of acceptable discharge arrangements are a toa trapped gully with the end of the pipe below a fixed grating and above the water seal b downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility and c discharges at high level e g into a metal hopper and metal downpipe with the end of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges 3 63 The discharge would consist of high temperature water and steam Asphalt roofing felt and non metallic rainwater goods may be damaged by such discharges Worked example of discharge pipe sizing Fig 5 shows a G1 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length of 7m from the tundish to the point of discharge From Table 3 Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a G1 2 temperature relief valve is 9 0m Subtract the resistance for 4 No 22mm elbows at 0 8m each
38. tional and appropriate safety measures are installed Ascending spray type bidets or any other class 1 back syphonage risk requiring that a type A air gap be employed Steam heating plants unless additional and appropriate safety devices are installed Situations where maintenance is likely to be neglected or safety devices tampered with Water supplies that have either inadequate pressure or where the supply may be intermittent e Situations where it is not possible to safely pipe away any discharge from the safety valves lnareas where the water consistently contains a high proportion of solids e g suspended matter that could block the strainer unless adequate filtration can be ensured In areas where the water supply contains chloride levels that exceed 250mg I OPERATIONAL SUMMARY Maximum mains pressure 1 6MPa 16 bar Operating pressure 0 35MPa 3 5 bar Maximum design pressure 0 6MPa 6 bar Expansion vessel charge pressure 0 35MPa 3 5 bar Expansion relief valve setting 0 6MPa 6 bar T amp P relief valve setting 90 95 C 1 0MPa 10 bar Maximum primary circuit pressure 1 0MPa 10 bar indirect only Pressure drop Primary coil 0 02MPa 0 2 bar Storage capacity see Table 1 Weight when full see Table 1 Indirect Models in conformance with BS EN 12897 2006 INSTALLATION GENERAL PIPE FITTINGS All pipe fittings are made via 22mm compression fittings directly to the unit The fittings are thr
39. y devices is safely conveyed to where it is visible but will not cause danger to persons in or about the building The following extract is taken from the latest G3 Regulations Discharge pipes from safety devices Discharge pipe D1 3 50 Each of the temperature relief valves or combined temperature and pressure relief valves specified in 3 13 or 3 17 should discharge either directly or by way of a manifold via a short length of metal pipe D1 to a tundish 3 51 The diameter of discharge pipe D1 should be not less than the nominal outlet size of the temperature relief valve 3 52 Where a manifold is used it should be sized to accept and discharge the total discharge form the discharge pipes connected to it 3 53 Where valves other than the temperature and pressure relief valve from a single unvented hot water system discharge by way of the same manifold that is used by the safety devices the manifold should be factory fitted as part of the hot water storage system unit or package same space as the unvented hot water storage system and be fitted as close as possible to and lower than the valve with no more than 600mm of pipe between the valve outlet and the tundish see Diagram 1 Note To comply with the Water Supply Water Fittings Regulations the tundish should incorporate a suitable air gap 3 55 Any discharge should be visible at the tundish In addition where discharges from safety devices may not be apparent
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