New Stainless imp_alt 2/15/05 12:15 PM Page 1 R LWSS STAINLESS STEEL UNVENTED WATER STORAGE HEATER INSTALLATION COMMISSIONING MAINTENANCE THIS UNIT IS SUPPLIED BY APPLIED ENERGY PRODUCTS LTD TEL: 08709 000430
New Stainless imp_alt 2/15/05 12:15 PM Page 2 APPLIED ENERGY PRODUCTS LTD STAINLESS STEEL UNVENTED HOT WATER STORAGE UNITS Please read the following carefully before installation of the product. You should be competent to install the unvented system as defined by the regulations. Special attention must be paid to maintenance and service. Please keep the unit packaged until you are ready to commence installation.
New Stainless imp_alt 2/15/05 12:15 PM Page 3 Please also take into account any fitting that could restrict flow such as water meters, softeners etc. Connection to the unit – Use 22mm compression for all connections. Use gunmetal, DZR or brass fittings, noting local water conditions.
New Stainless imp_alt 2/15/05 12:15 PM Page 4 GUIDANCE NOTES TUNDISH DISCHARGE The unit is supplied with two mechanical safety devices. An expansion relief valve, supplied loose, and a temperature/pressure relief valve fitted to the unit, both discharging into a tundish (supplied loose). Discharge pipes must be left open to atmosphere, not blocking the tundish. The responsibility for supplying and fitting the discharge pipe from the tundish is that of the certified installer.
New Stainless imp_alt 2/15/05 12:15 PM Page 5 GUIDANCE NOTES d.3 Discharges at high level; e.g. in to 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 3m from any plastic guttering systems that would collect such discharges (tundish visible). d.
New Stainless imp_alt 2/15/05 12:15 PM Page 6 GUIDANCE NOTES - TYPICAL DISCHARGE PIPE ARRANGEMENT SAFETY DEVICE (e.g. TEMPERATURE RELIEF VALVE) METAL DISCHARGE PIPE (D1) FROM TEMPERATURE RELIEF TO TUNDISH 500mm MAXIMUM TUNDISH 300mm MINIMUM DISCHARGE BELOW FIXED GRATING (3.9d GIVES ALTERNATIVE POINTS OF DISCHARGE) METAL DISCHARGE PIPE (D2) FROM TUNDISH, WITH CONTINUOUS FALL FIXED GRATING (SEE 3.
New Stainless imp_alt 2/15/05 12:15 PM Page 7 WORKED EXAMPLE: The example below is for 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 1 • Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m. • Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m • Therefore the maximum permitted length equates to 5.8m. • 5.
New Stainless imp_alt 2/15/05 12:15 PM Page 8 ELECTRICAL CONNECTIONS Immersion heaters are rated 3kw at 240v (2.76kw at 230v), incolloy elements, with a thermal energy cutout, and must be connected via double pole switches with a 3mm contact gap separation. Appropriate wiring for the electrical load must be used. The twin immersion heaters supplied with direct units can be switched to utilise low tariff electricity supply. Do not switch on until the unit is full of water.
New Stainless imp_alt 2/15/05 12:15 PM Page 9 WIRING INSTALLATION The wiring diagram for Danfoss systems is given as guidance. For modified Danfoss Randall Y, S and W plan systems when used in conjunction with unvented water storage systems. Programmers recommended are: FP715 (7,5 and 2 day programming and the CP15 5, 2 and 24 hour programming.
New Stainless imp_alt 2/15/05 12:15 PM Page 10 WIRING INSTALLATION The wiring diagram for Danfoss systems is given as guidance. For modified Danfoss Randall Y, S and W plan systems when used in conjunction with unvented water storage systems. Programmers recommended are: FP715 (7,5 and 2 day programming and the CP15 5, 2 and 24 hour programming.
New Stainless imp_alt 2/15/05 12:15 PM Page 11 WIRING INSTALLATION The wiring diagram for Danfoss systems is given as guidance. For modified Danfoss Randall Y, S and W plan systems when used in conjunction with unvented water storage systems. Programmers recommended are: FP715 (7,5 and 2 day programming and the CP15 5, 2 and 24 hour programming.
New Stainless imp_alt 2/15/05 12:15 PM Page 12 COMMISSIONING INSTRUCTIONS BEFORE FILLING, CHECK EXPANSION VESSEL CHARGE IS AT 3.0 BAR. 1. Open all terminal fittings on the domestic hot water circuit. Open the main supply to the unit. 2. Flush through until all air is expelled. 3. Close hot outlets and open all cold outlets connected to the tee after the pressure control valve. 4. Flush through until all air is expelled. 5. The system is now full of water.
New Stainless imp_alt 2/15/05 12:15 PM Page 13 STAINLESS INDIRECT UNIT WITH COMPONENT I.D. 3 /4 " Female boss for expansion vessel C A D H F E G I B J H COLD MAIN IN THROUGH E, THEN G. D IS TEED OFF BETWEEN G AND THE UNIT. A B C D E F G H I J HOT DRAW-OFF TO TAPS. 3 KW IMMERSION HEATER WITH MANUAL RE-SET TEMPERATURE HIGH LIMIT CUT-OUT. TEMPERATURE AND PRESSURE RELIEF VALVE. EXPANSION RELIEF VALVE. PRESSURE REDUCING VALVE/LINE STRAINER. EXPANSION VESSEL (SUPPLIED LOOSE). NON RETURN VALVE.
New Stainless imp_alt 2/15/05 12:15 PM Page 14 STAINLESS DIRECT UNIT WITH COMPONENT I.D. C A B B COLD MAIN IN THROUGH E, THEN G. D IS TEED OFF BETWEEN G AND THE UNIT. A HOT DRAW-OFF TO TAPS. B 3 KW IMMERSION HEATER WITH MANUAL RE-SET TEMPERATURE HIGH LIMIT CUT-OUT. C TEMPERATURE AND PRESSURE RELIEF VALVE. D EXPANSION RELIEF VALVE. E PRESSURE REDUCING VALVE/LINE STRAINER. F EXPANSION VESSEL (SUPPLIED LOOSE). G NON RETURN VALVE. H GUAGE.
New Stainless imp_alt 2/15/05 12:15 PM Page 15 SIZING GUIDE & SPECIFICATIONS SIZING GUIDE NOM SIZES NOM WEIGHT INDIRECT (FULL) NOM WEIGHT DIRECT (FULL) INDIRECT APPLICATION (LITRES) HEAT-UP TIME/RE-HEAT TIME HEAT-UP TIME/RE-HEAT TIME 150 1120 x 560 230kg 201kg TWIN BATH 30mins / 21mins SINGLE BATH - 3 BED 88mins / 50mins 200 1470 x 560 300kg 266kg 2 BATH & 2 SHOWERS 33mins / 24mins TWIN BATH 108mins / 63mins 250 1770 x 560 360kg 319kg 3 BATH & 2 SHOWERS 36mins / 26mins TWIN BATH
New Stainless imp_alt 2/15/05 12:15 PM Page 16 GUARANTEE Applied Energy Products Ltd guarantees the shell of the unit for 25 years. The component parts, including the expansion vessel, are guaranteed for 2 years from date of purchase. THE FOLLOWING INFORMATION IS IMPORTANT – WITHOUT IT YOUR GUARANTEE MAY BE INVALID 1. Keep proof of purchase 2. Maintain log book on unit 3. Service annually 4.
New Stainless imp_alt 2/15/05 12:15 PM Page 17 TROUBLESHOOTING - NO HOT WATER - INDIRECT START NO IS BOILER ON? SWITCH ON YES IS PROGRAMMER SWITCHED TO HOT WATER? NO SET PROGRAMME YES IS MID POSITION VALVE IN CORRECT POSITION NO RE-SET, CHECK WIRING & PLUMBING IS CORRECT YES IS CONTROL TEMPERATURE SET o o AT 55 C-60 C? NO RE-SET YES HAS HIGH LIMIT CUT OUT? YES RE-SET NO IS ALL WIRING TO THE CONTROLS OK? YES REPLACE THERMOSTAT END 16 NO RE-WIRE
New Stainless imp_alt 2/15/05 12:15 PM Page 18 TROUBLESHOOTING - NO HOT WATER - DIRECT START IS POWER ON TO ELEMENTS? NO SWITCH ON YES IS CONTROL TEMPERATURE SET o o AT 55 C-60 C? NO RE-SET YES HAS HIGH LIMIT TRIPPED? NO REPLACE ELEMENT YES CHECK WIRING LINKS CONTINUITY AND RE-SET END 17
New Stainless imp_alt 2/15/05 12:15 PM Page 19 TROUBLESHOOTING - POOR WATER FLOW AT HOT TAPS START IS NO INCOMING MAINS SUPPLY FLOW/PRESSURE ADEQUATE WATER SERVICE CHECK BY SUPPLY COMPANY REQUIRED YES CLEAN OR REPLACE STRAINERS AS APPROPRIATE IS YES IN-LINE STRAINER (IN PRV) DIRTY NO YES SERVICE/ REPLACE PRV AS APPROPRIATE IS PRV FAULTY NO IS SYSTEM FREE FROM RESTRICTIONS/ BLOCKAGES NO CLEAR OBSTRUCTIONS YES END 18
New Stainless imp_alt 2/15/05 12:15 PM Page 20 TROUBLESHOOTING - WATER DISCHARGING INTO TUNDISH START NO IS PRESSURE DOWNSTREAM OF TPRV CORRECT YES IS VALVE SEAL AND SEAT CLEAN & UNDAMAGED? NO CLEAN OR REPLACE AS REQUIRED YES IS EXPANSION VESSEL CHARGE CORRECT? YES NO IS HEATER OPERATING AT LESS oTHAN 60 C? NO RECOMMISSION EXPANSION LEVEL YES YES REPLACE ERV/TPRV IS ERV/TPRV DISCHARGING RESET TEMPERATURE NO RE-CALIBRATE PRV 19 END
New Stainless imp_alt 2/15/05 12:15 PM Page 21 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate Service Interval Record below. SERVICE PROVIDER Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions and in compliance with all the relevant codes of practice.
New Stainless imp_alt 2/15/05 12:15 PM Page 22 COMMISSIONING PROCEDURE INFORMATION BOILER PRIMARY SETTINGS IS THE PRIMARY SEALED OR OPEN VENTED SYSTEM? Sealed IF SEALED THEN WHAT IS THE SYSTEM PRESSURE? Hot Open Cold BAR IF SEALED THEN WHAT IS THE CHARGE PRESSURE OF EXPANSION VESSEL? BAR WHAT IS THE AVAILABLE BOILER FLOW TEMPERATURE? o WHAT IS THE BOILER RETURN TEMPERATURE WHEN CYLINDER/STORE IS SATISFIED? o C C BOILER PRIMARY SETTINGS IS THE VENT PIPE CORRECTLY INSTALLED? YES NO WHAT I
New Stainless imp_alt 2/15/05 12:15 PM Page 23 CUSTOMER DETAILS NAME ADDRESS TEL No. INSTALLER DETAILS NAME DATE ADDRESS TEL NO. REGISTRATION DETAILS (Where applicable for unvented systems etc) REG No. ID SERIAL No. etc. COMMISSIONING ENGINEER DETAILS NAME DATE ADDRESS TEL NO. REGISTRATION DETAILS (Where applicable for unvented systems etc) REG No. ID SERIAL No. etc. APPLIANCE DETAILS MANUFACTURER CAPACITY MODEL LITRES SERIAL NO.
New Stainless imp_alt 2/15/05 12:15 PM Page 24 TM is supported by W AT E R H E AT E R MANUFACTURERS A S S O C I AT I O N Storage Waterheater Installation, Commissioning and Service Record Log Book (To be retained by customer). INSTALLER DETAILS APPLIANCE DETAILS COMMISSIONING RECORDS SERVICE INTERVAL RECORD IMPORTANT FAILURE TO INSTALL & COMMISSION THIS APPLIANCE TO THE MANUFACTURER’S INSTRUCTIONS MAY INVALIDATE THE WARRANTY This note does not affect your statutory rights.
