Albion MAINSFLOW INSTALLATION GUIDE

September 2004

T H E R M A L S T O R E U N I T S

F O R U S E R G U I D E S E E

P A G E S 1 2 T O 1 4

INSTALLATION GUIDE

®

MAINSFLOW

CASED CONTRACTOR

THERMAL STORE UNITS

PLEASE LEAVE IN POCKET

PROVIDED ON THE UNIT

FOR USER GUIDE SEE

PAGES 12 TO14

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THERMAL STORE

SPECIFICATION

P

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W

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IMPORTANT

Please ensure that all installations meet current by-laws

and comply to best industry practice.

Follow component manufacturer's guidelines. This booklet

is published as a guide only, Albion cannot accept

responsibility for errors or ommissions.

MAINSFLOW CASED CONTRACTOR UNIT

INDIRECT DIRECT

A

C

B

D

DOMESTIC

HOT OUT

E

DOMESTIC

JH

A Warning pipe (Installer to fit)
B Ball float (Supplied)
C Primary Coil/ Boiler Tappings
D Blending valve
E Expansion vessel
F Service valve
G 3.0 bar pressure reducing valve
H Drain Point
J Thermostat connection
K Radiator circuit tappings

COLD OUT

F

G

COLD

MAINS

A

C

C

B

D

DOMESTIC

HOT OUT

E

G

F

K

J

K
H

DOMESTIC
COLD OUT

COLD

MAINS

1

INTRODUCTION

The Albion Mainsflow operates on the Thermal Store principle
eliminating the need for cold water storage in the loft and
producing mains pressure hot water to all taps and shower
facilities at high flow rates in accordance with BS6700.

The Mainsflow Thermal Store principle reverses the traditional
operation of the cylinder in the heating system. The store of water
is heated from the boiler, DIRECTLY to the store or INDIRECTLY
via a second coil. The secondary (domestic) water is provided
through a multi-tube heat exchanger, fed from the main.

Mainsflow DIRECT (single coil) must be fitted in open vented mode,
preferably in twin pump configuration (See page 2, diagram 1).

Mainsflow INDIRECT (twin coil) units can be used with sealed
system boilers i.e. a fully sealed heating system, or with more
traditional open vented systems, where flexible siting is required

- the store being static. The Indirect is usually fitted into a Y
plan system. (See page 2, diagram 2).

Mainsflow Indirect can also be used in central boiler schemes
linking several cylinders to a single boiler or buffer store.

Mainsflow Indirect Cased Contractors are corrosion proofed
and guaranteed for five years. The corrosion proofer is supplied
inside the unit as a soluble crystal. It will not degrade and will
dilute in hot water.

For Direct Units or if you re-commission after use, please add
new inhibitor eg. Fernox MBI or MB2 or Sentinel X100. Follow
manufacturers' instructions to maintain guarantees.

2

TYPICAL SCHEMATIC LAYOUTS

The Mainsflow units have been engineered to ensure maximum
efficiency from fully pumped systems.

They are not for use in systems with gravity flow and return pipes.
In addition each system is insulated with Albion's unique 100%

CFC free foam and cased in a smart white appliance finish.

DIRECT MAINSFLOW
TWIN PUMP

INDIRECT MAINSFLOW
'Y' PLAN/SEALED SYSTEM

COLD MAINS

PUMP

1

PUMP 2

SPACE

HEATING

HOT

ROOM

THERMOSTAT

COLD

BOILER

STORE

THERMOSTAT

PROBE TYPE

BLENDING

VALVE

EXPANSION

VESSEL

HOT

COLD

BY-PASS

SPACE HEATING

BOILER

*FEED/EXPANSION - OPEN VENTED ONLY

STATIC
STORE

POTABLE

WATER

COLD MAINS

GAS OR OIL

BOILER,

SEALED OR

*OPEN VENTED

PRIMARY

WATER

DIVERTER

VALVE

STORE

THERMOSTAT

PROBE TYPE

BLENDING

VALVE

EXPANSION

VESSEL

Diagram 1

Diagram 2

3

COLD SUPPLY

Mainsflow units are designed to provide hot water directly from the rising
main. Output performance is directly related to the adequacy of the
incoming mains supply. When choosing Mainsflow, installers and
specifiers must take into account flow rates and pressure. The units are
designed to deliver hot water at given flow rates and it is therefore
important to ensure that the mains supply into the property is adequate, ie
a minimum of 2 bar pressure at 20 litres per minute for single bathroom

applications and appropriately for larger installations.

The supplied pressure reducing valve must be fitted. It is recommended
that some cold outlets are connected direct to the mains (kitchen, utility
and outside taps) prior to the pressure reducing valve. The pressure
reducing valve needs to be as far upstream from the cylinder as possible.
The Mainsflow multi-tube heat exchangers are such that scale deposition
will be minimised. However, in areas where concentration of CaCO

3

is
greater than 200mg/l it is recommended that suitable in line scale
eliminators are fitted. If fitted, a by-pass pipe must be installed so that the
system can build up a natural patina for protection prior to using a
proprietary scale eliminator. Consult the manufacturers' guidelines.

INSTALLATION

Albion Mainsflow units should be sited to enable access and removal of all
plumbing connections and components including the unit and overflow
pipes. The units should be positioned on a flat base capable of supporting

them when full up to 300kg (250 litre model).

Where Mainsflow Direct model is used care must be taken to ensure that the
unit is sited to ensure sufficient head for trouble free operation of the system.
They must be sited with the water level at least 500mm above the top of the
highest radiator or highest point in the primary circuit*. Care must always
be taken to allow a clearance of 200mm between the top of all
combination units and the ceiling to allow access to the ball valve for

servicing and adjustment.

The Mainsflow Indirect can be sited anywhere within the property as the
store is static, taking care to discharge pipes effectively.

* Check boiler minimum head requirements.

4

PIPE SIZING

To enable effective distribution of the available supply it is
important in any mains pressure system that pipe sizing is in
accordance with BS6700. As an indication the following pipe
connections are necessary.
Mains supply to the dwelling 22mm (25mm MDPE).
Mains cold supply to the Mainsflow should be run in 22mm
copper.

The hot water draw-off should be 22mm to the bath tap
branch.
The tee-offs to the basins/sinks should be in 10mm, whilst

the tee-offs to the showers should be 15mm.
Primary flow and return pipework should be a minimum of
22mm and sized to 28mm or 35mm according to the boiler
manufacturers' instructions. By-pass pipework must be strictly
in accordance with boiler manufacturers' requirements.

Cold feed to heat exchanger 22mm.

Expansion tank discharge pipework 22mm copper or
22mm plastic solvent weld.

1.)

2.)

MAINSFLOW SIZING

A GUIDE TO SIZING YOUR MAINSFLOW CASED CONTRACTOR

MODEL

MFT140 CON

Specify DIRECT

or INDIRECT

MFT170 CON

Specify DIRECT

or INDIRECT

MFT200 CON

Specify DIRECT

or INDIRECT

MFT250 CON

Specify DIRECT

or INDIRECT

APPLICATION

(TO BS6700)

Single bath and
en-suite shower

2/3 bed property

Two baths

2/3 bed property

Three bath

4 bed property

Three baths and two

en-suite showers

5 bed property

CYLINDER

SIZE

1280 x 560

1500 x 560

1700 x 560

2200 x 560

BOILER

(x 1000 BTU)

40

60

80

100

SIZING

(kW)

12 kW

18 kW

24 kW

30 kW

WEIGHT
(EMPTY)

35kg

37kg

39kg

41kg

WEIGHT

(FULL)

175kg

217kg

249kg

291kg

5