Megaflo HE PRE-PLUMBED UNVENTED MAINS PRESSURE WATER HEATER 120, 150, 170, 210, 250 AND 300 LITRE INSTALLATION AND SERVICING INSTRUCTIONS 1 36 00 5933 Issue 436 00 5865 Iss 36 00 5823 Issue 2
Contents SECTION 1 INTRODUCTION............................................................................. 3 2 GENERAL REQUIREMENTS.......................................................... 4 3 INSTALLATION - GENERAL........................................................... 6 4 INSTALLATION - DIRECT HEATING.............................................. 14 5 INSTALLATION - PRIMARY CIRCUIT............................................ 16 6 COMMISSIONING......................................
Megaflo HE 1 Introduction The Premier Plus SystemFit is a factory pre-plumbed and wired version of the Premier Plus unvented water heater. The Premier Plus SystemFit is manufactured in the UK from top quality materials and meets all the latest relevant safety and constructional standards. The high grade Duplex stainless steel cylinder offers exceptional strength and corrosion resistance which is backed by a 25 year on site parts and labour guarantee.
2 General Requirements IMPORTANT : PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING THE PREMIER PLUS SYSTEMFIT WATER HEATER. INCORRECT INSTALLATION MAY INVALIDATE GUARANTEE. THE PREMIER PLUS MUST BE INSTALLED BY A COMPETENT INSTALLER IN ACCORDANCE WITH BUILDING REGULATION G3 (ENGLAND AND WALES), TECHNICAL STANDARD P3 (SCOTLAND) OR BUILDING REGULATION P5 (NORTHERN IRELAND). 2.
Megaflo HE If you choose to install the PremierPlus SystemFit in the highest point in the property (e.g. loft space), it is advisable to install an additional Automatic Air vent (AAV) (not suppliedavailable as spare, part number 95 605 050) above the pump to enable air to be removed from the system. The addition of the AAV is not required if siting the cylinder in a lower position. 2.
3 Installation - General 3.1 PIPE FITTINGS The connection points to the heating system are in 22mm o/dia copper pipe on 120 and 150 litre units. On units 170 litres and above the primary flow connection is 28mm, the flow connections to central heating (CH) zones 28mm and the domestic hot water (DHW) return connection 22mm o/dia copper pipe. The use of appropriately sized COMPRESSION FITTINGS is recommended when connecting to the Premier Plus SystemFit pipes.
MEGAFLO MegafloHHE 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 Diagram 1 - Cold Water Combination Valve COLD MAINS CONNECTION (22mm) OUTLET CONNECTION (22mm) PRESSURE REDUCING VALVE HOUSING PRESSURE REDUCING VALVE CARTRIDGE (3.
Incoming Cold Water Main MCWS to Kitchen (unbalanced cold mains supply) Cold Water Combination Valve incorporating Pressure Reducing Valve, Strainer and Check Valve NB Expansion Valve tapping must be blanked off SC SC DOC Expansion Core Unit (combined Expansion Relief Valve/Check Valve) Expansion Vessel DOC Tundish Balanced cold water draw off DOC HWS supply Discharge pipe to atmosphere (See Section 3.
Megaflo HE 3.5 DRAIN TAPS Drain taps are fitted to both the primary system pipework and to the cold water inlet to facilitate draining the unit or indirect heating circuit for maintenance purposes. It is recommended that the outlet point of the drain pipe work be at least 1 metre below the level of the heater (this can be achieved by attaching a hose pipe to the drain tap outlet spigot). 3.
Diagram 4 - Secondary circulation connecCOLD SUPPLY COLD INLET CONNECTION CHECK VALVE SECONDARY RETURN SECONDARY CIRCULATION PUMP TEE PIECE (SUPPLIED CAPPED OFF, REMOVE CAP BEFORE CONNECTION) 10
Megaflo HE 3.9 DISCHARGE PIPEWORK It is a requirement of Building Regulations 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 Regulations. Building Regulation G3 Requirements and Guidance section 3.9 are reproduced in the following sections. Information Sheet No.
Examples of acceptable discharge arrangements are: i. ideally below a fixed grating and above the water seal in a` trapped gully. ii. 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 where children may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility. iii. discharges at high level; e.g.
Megaflo HE Table 1 - Sizing of copper discharge pipe (D2) for common T&P relief valve sizes VALVE OUTLET SIZE MINIMUM SIZE OF DISCHARGE PIPE D1 MINIMUM SIZE OF DISCHARGE PIPE D2 FROM TUNDISH MAXIMUM RESISTANCE ALLOWED, EXPRESSED AS A LENTGH OF STRAIGHT PIPE (I.E. NO ELBOWS OR BENDS RESISTANCE CREATED BY EACH ELBOW OR BEND G 1/2 15MM G 3/4 22MM G1 28MM 22mm 28mm 35mm 28mm 35mm 42mm 35mm 42mm 54mm 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 0.8M 1.
4 Installation - Direct Heating 4.1 IMMERSION HEATER(S) The Premier Plus SystemFit is supplied with a factory fitted immersion heater which can be used as an alternative heat source should the boiler supply need to be isolated from the unit. The immersion heater is located within the indirect controls housing. The immersion heater is rated 3kW at 240V (2.7kW at 230V).
Megaflo HE 4.4 SAFETY DO NOT BYPASS THE THERMAL CUT-OUT(S) IN ANY CIRCUMSTANCES DISCONNECT FROM THE MAINS SUPPLY BEFORE REMOVING ANY COVERS NEVER ATTEMPT TO REPLACE AN IMMERSION HEATER OTHER THAN WITH THE RECOMMENDED SANTON PREMIER PLUS SPARE PART Diagram 6 Schematic wiring diagram - Direct immersion heaters THERMOSTAT EARTH TERMINAL FUSED (13A) DOUBLE POLE ISOLATING SWITCH 1.
5 Installation - Primary Circuit 5.1 BOILER SELECTION The Premier Plus SystemFit models are suitable for use with most gas or oil fired or electric boilers compatible with unvented systems i.e. fitted with a temperature control thermostat and thermal cut-out. If in doubt consult the boiler manufacturer. Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic control unless additional and appropriate safety measures are installed should NOT be used.
Megaflo HE nals are provided and identified in the Wiring Centre to enable any wiring to be connected to the same central position. The mains supply must be via a double pole isolating switch with a contact separation of at least 3mm in both poles. The supply must be fused 3Amp. A supply cable of 1.0 to 1.5mm2 cross sectional area should be used. 5.
Diagram 8 - Indirect controls housing INDIRECT THERMAL CUT-OUT RESET BUTTON INDIRECT THERMAL CUT-OUT THERMOSTAT ADJUSTMENT INDIRECT THERMOSTAT CABLE CLAMPS TERMINAL BLOCK NOTE: THE HOUSING COVER AND ELEMENT ASSEMBLY HAVE BEEN REMOVED FROM THIS VIEW FOR CLARITY 18
5 6 BROWN BLUE GREY ORANGE WHITE GREEN/YELLOW DOMESTIC HOT WATER HEATING LIVE NEUTRAL EARTH L N N O GY 3 HEATING ZONE 1VALVE (SUPPLIED FITTED) Br Bl G N 2 W 2 4 N 6 7 2 O 8 3 N Br Bl G O GY (DHW) ZONE VALVE (SUPPLIED FITTED) GY W BOILER L N L N PUMP (SUPPLIED FITTED) N N 9 10 11 12 13 14 15 16 HEATING ZONE 2 VALVE (NOT SUPPLIED) Br Bl G 5 1 INDIRECT THERMAL CONTROLS (SUPPLIED FITTED) Megaflo HE NOTES 1.
6 Commissioning 6.1 FILLING AND FLUSHING THE PREMIER PLUS SYSTEMFIT It is possible for compression fittings to become loose in transit due to transport vibration. Ensure that all fittings and immersion heaters are correctly fitted and tightened. An immersion heater key spanner is provided to aid in tightening the immersion heater(s). i) Open a hot tap furthest from the Premier Plus SystemFit . ii) Open the isolating valve to the Premier Plus SystemFit installation.
Megaflo HE Switch on the electrical supply to the Premier Plus SystemFit indirect controls and the boiler. Programme the Premier Plus SystemFit controller as detailed in the Fitting and User Instruction leaflet supplied with the controller. Set the controller for Hot Water operation only (the +1HR ON Hot Water over-ride button can be used if the time is during a Hot Water OFF period). Check that the Heating 2-Port motorised valve is closed and that the Hot Water 2-Port motorised valve opens.
If the user temperatures or On and Off times have been adjusted for commissioning purposes the controller should be reset to the desired settings. The operation of the controller should be demonstrated to the user and the Controller Installation and User Instructions left with them for future reference. 6.5 AUTOMATIC SYSTEM BY-PASS An automatic differential bypass valve is fitted to the Premier Plus SystemFit. This has been factory set to an optimum position for most domestic heating systems.
User Instructions 7.1 WARNINGS Megaflo HE 7 IF WATER ISSUES FROM THE TEMPERATURE/PRESSURE RELIEF VALVE ON THE PREMIER PLUS UNIT SWITCH OFF ELECTRICAL SUPPLY TO THE IMMERSION HEATER(S) OR SHUT DOWN THE BOILER. DO NOT TURN OFF THE WATER SUPPLY. CONTACT A COMPETENT INSTALLER FOR UNVENTED WATER HEATERS TO CHECK THE SYSTEM. DO NOT TAMPER WITH ANY OF THE SAFETY VALVES FITTED TO THE PREMIER PLUS SYSTEM, IF A FAULT IS SUSPECTED CONTACT A COMPETENT INSTALLER. 7.
7.3 FLOW PERFORMANCE When initially opening hot outlets a small surge in flow may be noticed as pressures stabilise. This is quite normal with unvented systems and does not indicate a fault. In some areas a cloudiness may be noticed in the hot water. This is due to aeration of the water, is quite normal and will quickly clear. 7.4 OPERATIONAL FAULTS Operational faults and their possible causes are detailed in Section 9.3. It is recommended that faults should be checked by a competent installer.
Maintenance 8.1 MAINTENANCE REQUIREMENTS Megaflo HE 8 To ensure the continued optimum performance of the Premier Plus SystemFit it should be regularly maintained. This is of particular importance in hard water areas or where the water supply contains particulate matter. Maintenance should be carried out by a competent person and any replacement parts used should be authorised Santon Premier Plus spare parts.
8.4 DRAINING THE PREMIER PLUS UNIT Switch off the electrical supply to the immersion heater(s) and/or shut down the boiler. Turn off the mains water supply to the Premier Plus unit. Attach a hosepipe to the drain cock having sufficient length to take water to a suitable discharge point below the level of the unit, at least one metre below the unit is recommended. Open hot water tap nearest to the Premier Plus to relieve the system pressure. Open drain cock.
Megaflo HE 9 Fault Finding & Servicing 9.1 IMPORTANT i) Servicing should only be carried by authorised Santon Service Engineers or Agents or by competent installers in the installation and maintenance of unvented water heating systems. ii) Any spare parts used MUST be authorised Santon parts. iii) Disconnect the electrical supply before removing any electrical equipment covers. iv) NEVER bypass any thermal controls or operate system without the necessary safety valves.
Diagram 10 - Exploded view of the Cold Water Combination Valve Valve Body Spare Part No. 95 605 030 Check Valve Housing Spare Part No. 95 605 028 Pressure Reducing Valve Housing Spare Part No. 95 605 027 Pressure Reducing Valve Cartridge Spare Part No. 95 605 029 Housing Securing Screws (4 off) Strainer Mesh Cold Water Combination Valve Complete Spare Part No. 95 605 022 9.
FAULT No hot water flow Water from hot taps is cold POSSIBLE CAUSE 1. Mains supply off 2. Strainer blocked 3. Cold Water Combination Valve incorrectly fitted 1. DIRECT immersion heater not switched on 2. DIRECT immersion heater thermal cut-out has operated 3. INDIRECT programmer set to Central Heating only 4. INDIRECT boiler not working 5. INDIRECT thermal cutout has operated 6. INDIRECT motorised valve not connected correctly Water discharges from Expansion Relief Valve 1.
10 Dimensions & Specifications Diagram 11a FILLING LOOP CONNECTIONS (HOSE REMOVED FOR CLARITY) Ø550 PRIMARY FLOW OUTLET COLD INLET TEMPERATURE & PRESSURE RELIEF VALVE AIR BLEED VALVE PUMP GATE VALVE (2 OFF) DIM A PRESSURE GAUGE DIM C 1028 DIM B BYPASS VALVE 2 PORT MOTORISED VALVE (2 OFF) 418 414 DRAIN VALVE (PRIMARY CIRCUIT) 250 PRIMARY RETURN 120B PUMP IS HIGHER THAN THE TOP OF THE CYLINDER 30 WIRING CENTRE FLOW TO RAD CIRCUIT EXPANSION VESSEL CONNECTION DRAIN VALVE (CYLINDER)
285 Dashed line denotes minimum space required for installation NOTE: Minimum distance for centre Dashed minimum space line of unit to rearline walldenotes is 284mm. required for installation NOTE: Minimum distance for centre line of unit to rear wall is 284mm.
OUTLINE SPECIFICATIONS Maximum mains water supply pressure (to Cold Water Combination Valve) 16.0 bar Operating pressure (Pressure reducing valve set pressure - non adjustable) 3.5 bar Expansion valve set pressure 6.0 bar Temperature/Pressure relief valve set temp/pressure 90oC/10 bar Immersion heater rating (a.c. supply only) 3.0kW 240V 2.7kW 230V Outer casing: Grey textured plastic coated corrosion proofed steel Water container: Stainless steel (grade 1.4362 to EN10088).
Megaflo HE Danfoss TP9 Programmable thermostat with timed Domestic Hot Water (DHW) control: Programmer dimensions: 136mm (W) x 88mm (H) x 32mm (D) Room temperature sensor dimensions: 60mm (W) x 45mm (H) x 21mm (D) Power supply: 220V/240V ac, 50Hz Switch action 2 x SPDT, Type 1B.
Primary circulating pump: Model No.: Grundfos UPS15-60 Working pressure: 10 bar max. Voltage rating: 230V ac, 50Hz Starting capacitor: 2uF Enclosure rating: IP42 Electrical data SPEED SETTING SPEED R.P.M. lll ll l 1750 1100 750 INPUT POWER (W) 95 65 40 FULL LOAD CURRENT (A) LOCKED ROTOR CURRENT (A) 0.44 0.30 0.17 0.47 0.31 0.18 Pump Curves H (m) 6.0 5.0 4.0 3 3.0 2.0 1.0 0.0 34 2 1 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 (m3/h) 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.
Megaflo HE 11 Guarantee 11.1 WARNING Should the factory fitted Temperature and Pressure Relief Valve be tampered with or removed your guarantee will be invalidated. Neither the Distributor or Manufacturer shall be responsible for any consequential damage howsoever caused. 11.2 GUARANTEE TERMS Santon guarantee the electrical parts, thermal controls and valves for a period of two years from the date of purchase, with the exception of damage due to scaling.
12 Contacts ADDRESS Santon Hurricane Way Norwich Norfolk UK NR6 6EA SWITCHBOARD Tel: 01603 420100 LITERATURE Tel: 01603 420127 AFTER SALES SERVICE Tel: 0844 871 1530 Fax: 0844 871 1528 Email: santonservice@heatteam.co.uk Approved spares stockists Electric Water Heating Co. 2 Horsecroft Place, Pinnacles, Harlow, Essex, CM19 5BT Tel: 0845 0553811 E-mail: sales@ewh.co.
