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Hot Spring Installation, User and Service Manual Quantum
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1. f SC 9 E 100 MAX WHEN REQUIRED SECONDARY CIRCULATION TO BE RETURNED TO HERE VIA NON RETURN VALVE AND SWEPT TEE FOR 250L AND 300L CYLINDERS FIT EXPANSION VESSEL HERE MAINS COLD WATER SUPPLY STOP COCK NOT SUPPLIED PRESSURE REDUCING VALVE SET 3 BAR CHECK VALVE EXPANSION RELIEF VALVE SET 6 BAR DISCHARGE PIPE 22mm DIA SEE SECTION 7 DRAIN COCK NOT SUPPLIED Oo O O1 IIN IMMERSION HEATER 230v 3 Kw 50 Hz O e COLD WATER INLET CONNECTION 22mm DIA PRIMARY FLOW CONNECTION 22mm DIA CONTROL THERMOSTAT SENSOR POCKET ine PRIMARY RETURN CONNECTION 22mm DIA ee TUNDISH 15 TO 22mm A TEMPERATURE AND PRESSURE RELIEF VALVE SET 7 BAR 90C C1 HOT WATER OUTLET 22mm DIA Fig 5 Quantum 7 0 Discharge arrangement Tundishes must be installed in a position so that they are clearly visible by the user In addition the discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge be of metal and a Be at least one pipe size larger than the normal outlet size of the safety device unless its total equipment hydraulic resistance exceeds that
2. 2 PORT ZONE VALVE la 3 PORT DIVERTER VALVE SUPPLIED NOT SUPPLIED R PUMP LJ L D BOILER BLUE G YELLOW BROWN 230v 50hZ THREE PORT pepe DIVERT VALVE 2 1 2 1 C CON 7 MS LIMIT CYLINDER STAT Les BLUE BROWN S S S GS e e e o 9 JUNCTIONBOX L d 4 9 D 8 9 10 TWO PORT S S SS SS S Igor SUPPLIED NOTE ORANGE AND GREY WIRES NOT REQUIRED ELECTRICALLY ISOLATE NEL ioe PUMP BOILER Fig 2 Quantum Installation User and Service Manual Y plan wiring layout and systems schematic HOT SPRINGS WATER CYLINDER t d k RADIATOR H D 2 PORT ZONE VALVE 3 PORT MID POSITION VALVE SUPPLIED NOT SUPPLIED R PUMP J L 8 BOILER BLUE BLUE G YELLOW BROW WHITE GREY TWO PORT ORANGE ZONE VALVE e SUPPLIED H ae MID POSITION i L
3. 6 3 6 4 Secondary circuit installation Connections Secondary circuit connections MUST be made to the cylinder in accordance with Fig 1 and Fig 5 A drain cock not supplied should be fitted in the position shown in Fig 5 to facilitate draining ofthe cylinder Cold water supply Where possible for best results the cylinder should be fed by an uninterrupted 22mm supply pipe into the pressure reducing valve PRV with a supply pressure of between 3 and 12 bar maximum In the UK supply pressures this high are not always available However the system will still work satisfactorily with pressures below this The cylinder should not be used on any system with a supply pressure below 1 5 bar and a flow rate of less than 20 litres per minute Temperature and pressure relief valve The temperature and pressure relief valve T PV is supplied factory fitted to the cylinder This connection MUST NOT serve any other purpose nor have any other valve or obstruction fitted between it and the cylinder The valve is pre calibrated to lift at 7 bar or 90 degrees centigrade Any attempt to adjust it will invalidate the warranty Expansion vessel A 20 litre expansion vessel with a pre charge pressure of 3 bar is fitted at the factory to all cylinders with storage volumes up to and including 200 litres For cylinders of 250 and 300 litres capacity a separate 24 litre expansion vessel is supplied which MUST be connected into the cold water su
4. heater from the mains supply investigate and identify the cause of the operation of this cut out rectify the fault before manually resetting the cut out via the reset button on the cut out Finally switch the mains electricity supply back on Installation User and Service Manual CONTROL STAT WARNING THIS APPLIANCE MUST BE EARTHED Quantum EARTH GREEN YELLOW LIVE BROWN NEUTRAL BLUE Fig 7 9 0 9 1 9 2 9 3 9 4 Filling and commissioning Check that the expansion vessel charge pressure is 3 bar Check that all connections are made tight including the immersion heater Open the main stopcock and fill the secondary system first Open successive taps hot and cold starting with the tap furthest from the cylinder Leave each tap open for afew moments to allow all air and possibly debris from the system to exit Manually lift by rotating the knob both the expansion relief EV and the temperature and pressure relief valve TPV for a short period to remove trapped air from behind the valve seating and to prove the correct function of the discharge arrangement Check all joints for leaks rectify as necessary 14 9 5 9 6 9 7 Check that the control and high limit settings for the indirect system and the immersion heater are as required Fillthe primary side note it will be necessary to manually open the 2 port valve whilst filling the system this is achieved by m
5. water areas it may be necessary from time to time to remove and de scale the immersion heater element Replace the gasket eachtime it is removed Remove the cartridge from the pressure reducing valve PRV Check the strainer and if necessary remove any debris from in front of it Replace the cartridge l5 Installation User and Service Manual 10 8 10 9 10 10 10 11 10 12 Check the charge pressure in the expansion vessel and top up as necessary The charge pressure should be 3 0 bar Whilst the hose pipe is connected the drain cock open and with the immersion heater removed the cylinder may be flushed out to remove any debris sand or lime scale particles that may have collected in the bottom by using a further hose pipe connected to the cold water main Close the drain cock disconnect the hose refit the immersion heater and close all hot water taps before reopening the stopcock Allow the cylinder time to fill whilst checking for any leaks Release any air from the system by opening each hot water tap individually starting with the one furthest from the cylinder Manually lift the expansion relief and temperature and pressure relief valve one at a time every 12 months more frequently in hard water areas to prevent debris from building up behind the valve seat Whilst carrying out this operation check that the discharge to waste is unobstructed Check that each valve seals correctly when released As the v
6. 0 550 Overall including immersion heater in mm 605 605 605 605 605 605 605 Overall height in mm 977 1202 1827 1477 1677 1977 2287 Weight when full in kg 120 159 188 212 246 299 353 Primary flow return connections in mm 22 22 22 22 22 22 22 Cold feed hot draw off connections in mm 22 22 22 22 22 22 28 Maximum water supply pressure in bar 12 12 12 12 12 12 12 System operating pressure pre set in bar 3 3 3 3 3 3 3 Expansion vessel charge pressure in bar 3 3 3 3 3 3 3 Expansion relief valve set pressure in bar 6 6 6 6 6 6 6 Temperature and pressure relief valve set Lift pressure in bar T 7 7 Y 7 7 7 Lifttemperature in degrees centigrade 90 90 90 90 90 90 90 Maximum primary working pressure in bar 3 3 3 3 3 3 3 Performance Hot water generation time in minutes from 26 36 37 36 33 35 40 15 to 65 degrees C for Indirect cylinder Hot water generation time in minutes from 52 72 86 98 108 144 202 15 to 65 degrees C for Direct cylinder Regeneration time in minutes for 70 of 18 25 26 25 24 25 29 Contents for Indirect cylinder Regeneration time in minutes for 70 of 27 37 45 51 63 75 136 Contents for Direct cylinder Quantum 3 0 Check list 4 0 4 1 4 2 4 3 Model Number Hot Spring 90 125 Installation User and Service Manual 150 170 200 250 300 Cylinder expansion vessel assembly 90 Itr Cylinder expansion vessel assembly 125 Itr Cylinder expansion vessel assembly 150 Itr Cylinder expansion vessel assem
7. NE LI ZONE VALVE OTE ORANGE AND GREY WIRES Es OT REQUIRED ELECTRICALLY ISOLATE 2 1 2 1 9 o CONTROL up LIMIT CYLINDER STAT S GH S S S S S S S JUNCTION BOX Be s sl e B el s s sl 0 BOILER Fig 3 Quantum Installation User and Service Manual S S plan wiring layout and systems schematic HOT SPRINGS WATER CYLINDER Ee RADIATOR qm no0 2 PORT ZONE VALV SUPPLIED R PUMP jJ See U 7 BOILER a z s le I O m Ol m 230v 2 H g H 8 50hZ ZONE VALVE ZONE VALVE HTG DHW LN E EH T 2 1 2 1 Q o CO m Nerea C C OYLINDER STAT 94 8 S S S amp 8 172 3 4 5 6 7 8 9 10 S AN NEL HW HTG PaT PUMP o L ee TIME 5 4 CONTROLLER ES N Fig 4 Quantum 6 0 6 1 6 2
8. Quantum Installation User and Service Manual T1 Hot Spring Domestic Hot Water Cylinder Storage Capacities 90 125 150 170 200 250 and 300 Litres Quant um Installation User and Service Manual Important This Manual should be left with the householder after installation Index Section oa P WN ch 1 0 2 0 Page No Section Page No Introduction 2 7 Discharge arrangement 11 Technical specifications 2 8 Electrical installation 13 Check List 3 9 Filling and commissioning 14 General requirements 3 10 Servicing and maintenance 15 Primary circuit installation 5 11 Fault Finding 16 Secondary circuit installation 9 12 User Instructions 16 Introduction The Quantum Hot Spring is a high quality use When the unit is supplied for unvented stainless steel domestic hot water oylinder applications it comes complete with all the suitable for use on unvented or open vented necessary safety equipment to comply with hot water systems The indirect heat exchange legislation governing the installation of such surfaces are designed to provide a rapid heat systems The immersion heater and temperature up The unit incorporates a 3kW electric and pressure relief valve when required are immersion heater as a backup or for summer factory fitted Technical specifications Model Number Hot Spring 90 125 150 170 200 250 300 Storage capacity in litres 90 125 150 170 200 250 300 Overall diameter in mm 550 550 550 550 550 55
9. alves are pre calibrated they require no further maintenance Finally switch on the mains electricity supply to the immersion heater and the boiler As the system heats up check again for any leaks and rectify as necessary Quantum 11 0 Fault finding Installation User and Service Manual Notice Disconnect electrical supply before removing any electrical equipment cover Fault Possible cause Remedy No hot water 1 Mains supply off 2 Strainer blocked 99 Pressure reducing valve PRV incorrectly fitted Water from hot taps is cold 1 Programmer set to heating Intermittent water discharge Continuous water discharge 1 Pressure reducing valve PRV only or not switched on Central heating boiler ho malfunction 99 tripped High limit thermostat has 4 Motorised valve malfunction charge pressure working ho seating correctly 99 12 0 Users instructions 12 1 12 2 Your Quantum Hot Spring unvented hot water oylinder has been deigned to give many years of trouble free service and is made from hygienic high grade stainless steel It includes a 3 kW electric immersion heater for times when your central heating is switched off during the summer for instance The flow temperature of the hot water can be set to your requirements on the immersion heater up to 60 deg C and the indirect side thermostat up to 65 deg C These temperatures should not be set any higher oth
10. bly 170 Itr Cylinder expansion vessel assembly 200 Itr Cylinder assembly 250 Itr Cylinder assembly 300 Itr Expansion vessel 24 ltr part No D145 2149 31 Pressure reducing valve part No D145 2149 32 22mm Check valve part No D145 2149 39 28mm Check valve part No D145 2149 40 Expansion relief valve part No D145 2149 33 T P valve pre fitted part No D145 2149 34 15 22 Tundish part No D145 2149 35 22mm motorised valve part No D145 2149 36 Control limit thermostat part No D145 2149 37 Immersion heater pre fitted part No D145 2149 38 Direct cylinder quantity in brackets General requirements The Quantum Hot Spring domestic hot water cylinder MUST be installed by a competent person in accordance with section G3 of the current Building Regulations Important It is important that the installer reads and understands these instructions unpacks and familiarises themselves with the equipment before commencing the installation Failure to observe these installation instructions could invalidate the warranty Water supply The warranty requires that the water to be heated be of drinking water quality and that if water treatment equipment is installed it must function correctly The unit where possible should be fed via a 22 mm diameter supply pipe It requires a supply pressure of 1 5 bar with a flow rate of at least 20 litres per minute as a minimum for it to function Even with these rates flow from the outlets will b
11. discharge pipe discharge pipe allowed expressed created by each in inches D1 in mm D2 from tundish in mm as a length of straight pipe elbow or bend in m i e no elbows or bends 22 up to 9 0 8 L 15 28 up to 18 1 0 35 up to 27 1 4 28 up to 9 Sa 22 35 up to 18 42 up to 27 1 7 35 up to 9 1 4 1 28 42 up to 18 1 7 54 up to 27 2 3 Worked example The example below is for a diameter temperature relief valve with a discharge pipe D2 having 4 No elbows and a length of 7 m from the tundish to the point of discharge From Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a v diameter temperature relief valve is 9 0 m Subtract the resistance for 4 No 22mm elbows at0 8m each 3 2m Therefore the maximum 2 permitted length equates to 5 8m 5 8 m is less than the actual length of 7 m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28mm pipe D2 from a 2 diameter temperature relief valve equates to 18m Subtract the resistance for 4 No 28mm elbows at 1 0 each 4m Therefore the maximum permitted length equates to14 m As the actual length is 7 m a 28mm diameter copper pipe will be satisfactory Quantum 8 0 8 1 Immersion heater installation and wiring instructions Electrical installation WARNING THIS EQUIPMENT MUST BE EARTHED All electrical wiring must be carried out by a compete
12. e 1 i 1 i A 2 4 4 4 5 o ech e oL at X A ech disappointing if several outlets are used simultaneously Generally speaking the higher the supply pressure the better the system will function The oylinder control equipment is factory set to limit the system operating pressure to 3 bar The maximum supply pressure into the pressure reducing valve is 12bar Taps and fittings All taps and fittings incorporated in the unvented system should have a rated operating pressure of 7 bar or above Location The unit is designed to be floor standing vertically mounted indoors in a frost free environment When choosing a suitable location for the cylinder consideration should be given to the routing of the discharge pipe to a convenient point see section 7 and also the availability of an adequate power supply for connecting the immersion heater s Quantum The cylinder may stand on any flat and level surface without any special foundation preparations provided that it is sufficiently robust to support the full weight of the cylinder See Technical specifications forweights The position of the cylinder should be such that easy access is provided for servicing the controls and replacing the immersion heater shouldthe need arise Generally pipe runs should be made as short as possible and lagged to prevent heat loss Pipework connections Fig 1 4 6 4 7 Ins
13. erwise nuisance tripping of the high limit thermostat will occur If you are in any doubt these adjustments should be best leftto a qualified electrician Expansion vessel has lost its Expansion relief valve not lemperature and pressure relief valve not seating correctly 12 3 12 4 12 5 1 Open stopcock 2 Turn water supply off remove strainer and clean see 10 6 Re fit correctly 99 Set programmer to call for hot water Check boiler operation if faulty consult your boiler manufacturers instructions Check and re set ho 99 A Check wiring and or plumbing connections to motorised valve Turn off stopcock open a hot water tap check vessel charge pressure and recharge to 3 bar Check pressure from PRV if greater than 3 bar replace cartridge Manually lift the valve once or twice to clear any debris from the seat otherwise replace valve Same remedy as above ho 99 When a hot tap is turned on there may be a short surge of water this is quite normal with unvented systems and does not mean there is a fault When you first fill a basin the water may sometimes appear milky This is due to very tiny air bubbles in the water which will clear very quickly WARNING If water issues from the temperature and pressure relief valve TPV or from the expansion relief valve EV seek expert advice immediately Quantum Heating Ltd Helmn Way Whitewalls Ind
14. harges tundish visible Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than six systems so that any installation discharging can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected If unvented hot water stored systems are installed where discharges from safety devices may not be apparent i e in dwellings occupied by blind or disabled people consideration should be given to the installation of an electrically operated device to warn when discharge takes place Warning Notice The discharge will consist of scalding water and steam Asphalt roofing felt and non metallic rainwater goods may be damaged by such discharges Quantum Typical discharge pipe arrangement r SAFETY DEVICE E G TEMPERATURE RELIEF VALVE L 500mm MAX 300mm MAX METAL DISCHARGE PIPE FROM TUNDISH WITH CONTINUOUS FALL SEE TABLE AND WORKED EXAMPLE BELOW Installation User and Service Manual Le METAL DISCHARGE PIPE FROM TEMPERATURE RELIEF VALVE TO TUNDISH DISCHARGED BELOW FIXED GRATING pm FIXED GRATING TRAPPED GULLEY Fig 6 Sizing of copper discharge pipe D2 for common temperature relief value outlet sizes Valve outlet Min size of Min size of Max resistance Resistance size diameter
15. nt person and in accordance with the current LEE Wiring Regulations A suitable Earthing point is provided on the oylinder pedestal directly below the immersion heater see Fig 1 The control equipment supplied will ensure that the oylinder functions safely From an economic and convenience point of view it is intended that these controls operate in conjunction with other control packages for example Honeywell S W or Y plan systems which incorporate a programmable time clock etc The immersion heater A 3kW 230v 50Hz immersion heater is pre fitted to the cylinder at the factory It should be wired in accordance with the instructions given in Fig 7 The cable MUST be routed through the strain relief bush We recommend that the control thermostat is set at 60 C the high limit trip is factory set at 85 C The immersion heater conforms with EEC Directive 76 889 for radio interference and complies with BS 800 1977 8 Ensure the mains voltage corresponds to the voltage rating of the immersion heater as shown on the rating label on the terminal cover b Install the immersion heater into the domestic hot water cylinder using the gasket provided Use a shaped spanner Stillsons should not be used The use of sealing compound is not recommended c Wire the immersion heater in accordance with the wiring diagram in Fig 7 It should be wired through a double pole isolator switch or controller having contact separation of at leas
16. of a straight pipe 9 m long i e discharge pipes between 9 m and 18 m equivalent resistance length should be at least two sizes larger then the normal outlet size of the safety device between 18 m and 27 mat least three sizes larger and so on Bends must be taken into account in calculating the flow resistance Refer to the diagram tables and worked example detailedin Fig6 Have a vertical section of pipe at least 300 mm long below the tundish before any elbows or bends in the pipework Beinstalled with a continuous fall Have discharges visible at both tundish and the final point of discharge but where this is not possible or practically difficult examples of acceptable discharge arrangements are Ideally below a fixed grating and above the water seal in a trapped gully Downward discharge at low level i e up to 100 mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that where children play or otherwise come into contact with discharges awire cage or similar guard is positioned to prevent contact whilst maintaining visibility 11 Installation User and Service Manual Discharge at high level e g into a metal hopper and metal down pipe with the end of the discharge pipe clearly visible tundish visible or not or onto a roof capable of withstanding high temperature discharges of water and 3 m from any plastic guttering system that would collect such disc
17. oving the lever on the valve head sideways Check for leaks and rectify as necessary Vent all heat emitters of air and following the manufacturers lighting instructions ignite the boiler Check that while the cylinder is heating up no water issues from either the expansion relief or the temperature and pressure relief valve and when the cylinder reaches temperature that the 2 port valve closes Quantum 10 0 Servicing and maintenance 10 1 10 2 10 3 10 4 10 5 10 6 10 7 Servicing and maintenance must only be carried out by a competent unvented hot water installer or by Quantum Heating Limited authorised personnel Before any work whatsoever is carried out on the installation it MUST first be isolated from the mains electricity supply WARNING both the primary and secondary systems will contain very hot water that will scald therefore care should be taken when opening any joints seals or valves Only use spare parts authorised by Quantum Heating Limited The use of unscheduled spare parts will invalidate the warranty Drain the cylinder When draining the cylinder always switch off the boiler and the immersion heater first Turn off the water supply at the stopcock see Fig 5 Connect a hose pipe to the drain cock see Fig 5 and route it to a convenient gulley Open the drain cock and all hot taps that are served by the cylinder The cylinder may take several minutes to empty completely In hard
18. pply side between the check valve and the cylinder The expansion vessel MUST be positioned with the entry point atthe bottom IMPORTANT Regular checks must be carried out to ensure that the expansion vessel is correctly pressurised to 3 bar at alltimes 6 5 6 6 6 7 6 8 6 9 Installation User and Service Manual Pressure reducing valve Taking due account of the directional arrow fit the pressure reducing valve PRV in accordancewith Fig5 Thiscan be connected to a supply pressure of between 1 5 and 12 bar maximum Expansion relief valve Fit the expansion relief valve ERV in accordance with Fig 5 This valve has been pre set to lift at 6 bar No other valve should be fitted between the expansion relief valve and the cylinder Check valve Taking due account of the directional arrow fit the check valve CV in accordance with Fig 5 Secondary circulation If the installation requires a secondary circulation circuit a 15mm return leg which incorporates a check valve should be connected via the cold feed using a 22 x22x15swepttee IMPORTANT If a secondary circulation circuit is installed then a larger expansion vessel may be required to handle the increase in volume Tundish The tundish must not be positioned above or in close proximity of any electrical current carrying devices or wiring Quantum Installation User and Service Manual Secondary circuit arrangement
19. stic hot water DHW production See Fig 2 This particular system allows all the boiler s energy to go into satisfying the hot water demand before switching over on to central heating duty If an existing system is a flow share arrangement such as a Honeywell S or Y plan type system see Figs 3 and 4 they will also provide satisfactory results but during central heating demands hot water production will not be as responsive 5 3 5 4 5 5 Installation User and Service Manual Connections The primary flow and return connections should be made in accordance with Fig 1 using 22mm compression fittings not supplied The 2 port valve To prevent gravity circulation when the boiler switches off the 2 port motorised valve supplied with the unvented hot water kit MUST be fitted in the primary flow pipe to the cylinder and wired in accordance with Figs 2 3 or 4 depending on system design to comply with current legislation Hard water areas If the cylinder is to be used in a hard water area we recommend that the primary flow temperature be limited to 75 degrees centigrade This will help reduce the migration of suspended solids in the water and help preventthe build up of lime scale Quantum Installation User and Service Manual W plan wiring layout and systems schematic HOT SPRINGS E
20. t 3 mm using 1 5mm sq flexible cable 85 deg C rubber insulated HOFR sheathed to comply with BS 6141 table 8 and must be fully earthed 8 2 8 3 Installation User and Service Manual WARNING Never fit an immersion heater without a thermal cut out The indirect temperature controller The control and high limit thermostat for use with indirect systems is supplied separately with the unvented hot water safety kit It should be fitted into the sensor pocket in the cylinder see Fig 1 for position The control thermostat has an adjustment range between 30 C and 90 C however it is recommended this it be set to 60 C WARNING The manual re set high limit thermostat MUST NOT under any circumstances be bypassed This is pre set to 80 C and to prevent nuisance tripping the control thermostat should always be at least 15 C below this The 2 port valve To prevent gravity circulation when the boiler switches off the 2 port motorised valve supplied with the unvented hot water kit MUST be fitted in the primary flow pipe to the cylinder and wired in accordance with Figs 2 3 or 4 depending on system design to comply with current legislation d The BEAB approval certification on this immersion heater only applies if rod type thermostats types Sunvic VKL or Cotherm SHD are used The temperature setting of the control thermostat must not exceed 60 deg C e In the event of the manual reset cut out operating isolate the immersion
21. tallation User and Service Manual Storage and handling If the cylinder is not being installed immediately it should remain in its carton with all pipe end protective caps in situ to to prevent damage We recommend that the cylinder be transported to its installation position on a sack truck or similar with the outer carton in place Pipework connections All Pipework connections to the cylinder MUST be made in accordance with Fig 1 CYLINDER SUPPLIED WITH PRESSURE VESSEL ALREADY FITTED KEY LETTER DESCRIPTION A HOT WATER B T amp P VALVE C HEATING WATER RETURN D THERMOSTAT POCKET E IMMERSION HEATER F HEATING WATER FLOW G COLD WATER H EARTHING CONNECTION Quantum 5 0 5 1 5 2 Primary circuit installation The Quantum Hot Spring cylinder is suitable connecting to most fully pumped domestic gas or oil fired central heating boilers working on an open vented or sealed system having a maximum working pressure of 3 bar and a maximum working temperature of 85 degrees centigrade If you are in any doubt concerning the suitability of the boiler consult the boiler manufacturer Solid fuel or wood burning boilers MUST NOT be used on unvented hot water systems Gravity circulation should also beavoided Systems For the best results we recommend that the Quantum Hot Spring cylinder be connected to a Honeywell W plan type system that gives priority to dome
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