IMPORTANT NOTE TO THE INSTALLER
Read these instructions before commencing installation.
Unvented cylinders are a controlled service as defined in the
latest edition of the building regulations and should only be
fitted by a competent person.
The relevant regulations are : England and Wales – Building Regulation G3 ,
Scotland – Technical Standard P3 , N Ireland – Building Re gulation P5
After installation the Benchmark log book must be
completed and left, with these instructions, with
the householder for future reference.
INSTALLATION INSTRUCTIONS FOR ALBION
ULTRASTEEL UNVENTED CYLINDERS. DIRECT,
INDIRECT, AND SOLAR MODELS.
Issue 1 June 2008
INTRODUCTION
The Ultrasteel Unvented cylinder is made from Duplex Stainless Steel for excellent corrosion
resistance. Ultrasteel has a strong rust-proofed steel case and is highly insulated with
environmentally friendly foam.
It is available in 6 capacities from 120 – 300 litres and in Direct, and Indirect versions.
Solar models are also available in 4 capacities from 180 - 300 litres, in Direct or Indirect
versions.
Ultrasteel is supplied complete with all the necessary safety and control devices needed
to connect to the cold water mains. All are pre-adjusted. High quality controls have
been selected to combine high flowrate performance with minimum pressure drop to
make Ultrasteel perform well in all areas, even those with poor water pressure. Ultrasteel is
WRAS approved to show compliance with Building Regulations G3+L
STORAGE PRIOR TO INSTALLATION
Ultrasteel should be stored in its original packaging in an upright position in an area free from excessive damp.
UNPACKING THE UNIT
ULTRASTEEL COMES COMPLETE WITH ALL
THE FITTINGS YOU NEED TO COMPLETE
THE INSTALLATION:
Expa nsion Ves sel
120 & 150 ltr units - 12 ltr ves sel
180, 210 & 250 ltr units - 19 ltr ves sel
300 ltr u nit - 24 ltr ves sel
Expa nsion Ves sel Hos e Wall Mounting Ki t for
Dual Th ermos tat High Flow Rate
Expa nsion Ves sel
Inlet Co ntrol Se t
15/22mm Tundish
Temperatu re and Pre ssure
Relief Va lve
Two Port Valve
Direc t Models (Electric )
• Inlet control set.
• Temp & Pressure relief valve.
• 15mm / 22mm Tundish.
• Expansion vessel.
• Wall mounting bracket.
• Expansion vessel hose.
• 2 x 3 kW Immersion heaters.
• Installation & Maintenance Instructions.
• Benchmark Logbook.
Direc t Solar Models (Elect ric )
• Inlet control set.
• Temp & Pressure relief valve.
• 15mm / 22m Tundish.
• Expansion vessel.
• Wall mounting bracket.
• Expansion vessel hose.
• 2 x Immersion heaters.
• 1 x Two port valve.
• 1 x Single High limit stat.
• Installation & Maintenance Instructions.
• Benchmark Logbook.
• 2 x Sensor pocket retaining bungs.
Indir ect Models
(Ga s, Oil or Electric bo ilers)
• Inlet control set.
• Temp & Pressure relief valve.
• 15mm / 22mm Tundish.
• Expansion vessel.
• Wall mounting bracket.
• Expansion vessel hose.
• 1 x 3kW Immersion Heater ( 2 x 3kW
250 & 300 litre units).
• Two port zone valve.
• Dual Thermostat.
• Installation & Maintenance Instructions.
• Benchmark Logbook.
Indir ect Solar Models
(Alternative Energy Source)
• Inlet Control set.
• Temp & Pressure relief valve.
• 15mm / 22mm Tundish.
• Expansion vessel.
• Wall mounting bracket.
• Expansion vessel hose.
• Immersion Heater.
• 2 x Two port valves.
• 1 x Dual Thermostat.
• 1 x Single Control stat.
• 1 x Single High limit stat.
• Installation & Maintenance Instructions.
• Benchmark Logbook.
• 2 x Sensor pocket retaining bungs.
Incol oy long li fe 240V x
3kW Imm ersio n Heater
Instal lation &
Mainte nance
Instru ctions
Bench mark
Logboo k
2
WATER SUPPLY
IMMERSION
HEATER
COLD
MAIN
ISOLATING
VALVE
PRESSURE
REDUCING
VALVE
EXPANSION
VESSEL
WITH WALL
BRACKET
FLEXIBLE
HOSE
NON
RETURN
VALVE
EXPANSION
RELIEF
VALVE
TUNDISH
TEMPERATURE
& PRESSURE
RELIEF VALVE
BALANCED
COLD
CONNECTION
COLD
INLET VIA
DRAIN
NON
RETURN
VALVE
BRONZE
PUMP
SECONDARY RETURN CIRCUIT
( 210, 250 & 300 L SIZES )
INDIRECT UNITS ONLY
DUAL
STAT
2 PORT
VALVE
BOILER
FLOW
BOILER
RETURN
HOT OUTLET
Ultrasteel operates at 3 bar (controlled by the inlet control set) and is capable of delivering over 50 litres per minute. The high
quality inlet control set has been designed to make the most of the flow rates available however the performance of any Unvented
system is only as good as the mains water supply. The maximum possible water demand should be assessed taking into
consideration that both hot and cold services are supplied simultaneously from the mains.
The water supply should be checked to ensure it can meet these requirements. If necessary consult the local water company
regarding the likely pressure and flow rate availability.
If measuring the water pressure note that a high static (no flow) mains pressure is no guarantee of good flow availability. In a
domestic installation 1.5 bar and 25 l/m should be regarded as the minimum. The maximum mains pressure the inlet control set
can cope with is 16 bar.
Consideration should be given to upgrading existing ½” (15mm) cold mains pipework to a larger size if the recommended
minimum pressure/flowrate is not being achieved.
SITING THE UNIT
Ultrasteel can supply outlets above it or at some distance from it. Site the unit to minimise “dead leg” distances especially to the
point of most frequent use.
Outlets above the Ultrasteel will reduce the outlet pressure available by 0.1 bar for every 1m of height difference The unit should
be protected from frost. Particular care is needed if siting in a garage or outbuilding. All exposed pipework should be insulated
Ultrasteel must be installed VERTICALLY on a flat base capable of supporting the weight of the cylinder when full (see technical
specification section for weights). The minimum recommended cupboard size is 650mm square.
Access for maintenance of the valves should be considered. The immersion heaters are 375mm long and care should be taken
that they can be withdrawn for servicing if required. The discharge pipework from the safety valves should fall continuously and
terminate safely.
SCHEMATIC DIAGRAM
Notes :
The Pressure reducing valve, Non return valve and
Expansion relief valve are combined together in the
inlet control set. On 120 – 180 litre sizes there is no
dedicated secondary return boss and the secondary
return circuit should be tee’d into the cold feed pipe
just above the drain elbow
3
GENERAL INSTALLATION
COLD MAINS PIPEWORK
Run the cold main through the building to the place where the Ultrasteel is to be
installed. Take care not to run the cold pipe near hot water or heating pipe work
so that the heat pick up is minimized. Identify the cold water supply pipe and fit an
isolating valve (not supplied) A 22mm BS1010 stopcock can typically be used but a
22mm quarter turn full bore valve would be better as it does not restrict the flow as
much. Do not use “screwdriver slot” or similar valves. Make the connection to the
cold feed of the cylinder and incorporate a drain valve. Position the inlet control just
ABOVE the Temperature & Pressure Relief Valve (TPRV) mounted on the side of the
cylinder. This ensures that the cylinder does not have to be drained down in order
to service the inlet control set. Ensure that the arrow points in the direction of the
water flow.
Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided. Use the hose to connect to the
inlet control group.
BALANCED COLD CONNECTION
If there are to be showers, bidets or monobloc taps in the installation then a
balanced cold supply is necessary. There is a 22mm balanced connection on the
inlet control set. An alternative method where a two part inlet control set is supplied
is to split the inlet control set into its two main assemblies. Site the pressure
reducing valve immediately after the incoming cold mains stopcock (typically under
the kitchen sink.) All outlets in the house will be at 3 bar and thus automatically
balanced. The expansion relief valve section must still be mounted just above the
TPRV on the cylinder. A ¾”F-22mm compression adaptor will be needed (not supplied).
Cold Main s In
Turn to test
(At Rear)
Expans ion Vessel
Connect ion
(Remove 3 /4” Plug)
(expans ion vessel not to sca le)
HOT WATER PIPEWORK
Run the first part of the hot water distribution pipework in 22mm. This can be
reduced to 15mm and 10mm as appropriate for the type of tap etc. Your aim should
be to reduce the volume of the hot draw off pipework to a practical minimum so that
the time taken for the hot water is as quick as possible. Do not use monobloc mixer
tap or showers if the balanced cold connection is not provided. Outlets of this type
can back pressurize the unit and result in discharge. Select a suitable position for
Pressure G auge Port
Balance d Cold
Connect ion
the expansion vessel. Mount it to the wall using the bracket provided and connect to
the inlet control set with the flexible hose provided. Ensure that the top of the vessel is accessible for servicing.
Outlet to Cyc linder
Expans ion
Relief to
Tundish
PRIMARY COIL CONNECTIONS
Connect the primary connections ( Indirect only ) using the compression connections provided. The primary circuit must be
positively pumped. Gravity circulation is not suitable. Either primary connection may be used as the primary flow. Reheat times
are identical either way. The primary circuit can be open vented or sealed with up to a maximum pressure of 3.5 bar. If you seal
the primary circuit an additional expansion vessel and safety valve is required. The boiler may be Gas, Electric, or Oil but must
be under effective thermostatic control. Uncontrolled heat sources such as some AGA’s, back boilers, solid fuel stoves, etc are
NOT SUITABLE. Please contact our technical department for guidance. Connect the two port zone valve ( indirect only ) into the
primary flow pipework. The direction of flow arrow should be towards the primary flow connection. On twin coil solar cylinders we
have provided an extra thermostat boss should you wish to use it. Again a two port zone valve should be fitted (supplied).
For Solar products refer to pages 10-13.
SECONDARY CIRCULATION
Ultrasteel can be used with secondary circulation. An appropriate WRAS approved bronze circulator should be used in
conjunction with a non return valve to prevent backflow. On large secondary circulation systems it may be necessary to
incorporate an extra expansion vessel into the circuit to accommodate the increased system water volume. Secondary
circulation should be avoided on Direct electrically heated units being used on of f peak electricity tariffs.
A secondary return boss is fitted as standard on 210, 250 & 300L. On smaller sizes tee into the cold feed pipe above the drain.
IMMERSION HEATERS
Only immersion heaters with a thermal cutout may be used. To help ensure this the immersion heaters have a special 1¾“
thread. They are rated at 3 kW at 240 V and are of a low noise Incoloy construction. They have both a thermostat and a high limit
cutout. Please order the correct replacement via ourselves, fitting non-approved immersions may affect your guarantee. When
fitting, ensure the ‘O’ ring is positioned correctly on the head of the immersion heater and lubricate before fitting. Fit it by hand
until almost home then tighten gently as the ‘O’ rings will seal easily. The electrical supply to each immersion heaters must be
fused at 13A via a double pole isolating switch to BS 3456. The cable must be 2.5mm2 heat resistant (85°C HOFR) sheathed
flex complying to BS 6141:1981 Table 8. Do not operate the immersion heater/s until the unit is full of water. Do not operate the
immersion heater/s if any sterilisation liquid is in the cylinder as this will cause premature failure. Fit the immersion thermostat
4
(indirect only) into the thermostat pocket. Complete the wiring – use the appropriate wiring diagrams on page 6.
DISCHARGE ARRANGEMENT
Fig 3: Diagram of a typical discharge
pipe arrangement (extract from Building
Regulation G3 )
Note: The discharge will consist of
scalding water and steam. Asphalt,
roofing felt and non-metallic rainwater
goods may be damaged by such
discharges.
Note: It is not acceptable to
discharge straight into a soil pipe.
Position the inlet control group so that the discharge from both the two safety valves can be joined together via a 15mm end feed
Tee. (Fig.3) Connect the Tundish and route the discharge pipe. The discharge pipework must be routed in accordance with Part
G3 of schedule 1 of the Building Regulations. The information that follows is not exhaustive and if you are in doubt you should
seek advice. The two safety valves will only discharge water under fault conditions. When operating normally water will not be
discharged. The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted
as close as possible and within 500mm of the safety device e.g. the temperature relief valve. 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, be of metal and:
A) 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. discharge pipes between 9m and 18m equivalent resistance length
should be at least two sizes larger than the 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. Refer to diagram 1, Table 1 and the
worked example. An alternative approach for sizing discharge pipes would be to follow BS6700 Specification for design
installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.
B) Have a vertical section of pipe at least 300mm long, below the tundish before any elbows or bends in the pipework.
C) Be installed with a continuous fall.
WORKE D EX AMPL E
D) It is preferable for the discharge to be visible at both the tundish and the
final point of discharge but where this is not possible or practically difficult
there should be clear visibility at one or other of these locations. Examples of
acceptable discharge arrangements are:
1. Ideally below the fixed grating and above the water seal in a trapped gulley.
2. Downward discharges at a 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 play
or other wise come into contact with discharges, a wire cage or similar guard is positioned to
prevent contact whilst maintaining visibility.
3. Discharges at a 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 available ).
4. 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 6 systems so that any installation c an 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 storage
systems are installed where discharges from safety devices may not be apparent i.e. in
dwellings occupied by blind, infirm or disabled people, consideration should be given to the
installation of an electronically operated device to warn when discharge takes place.
The example be low is for G1/2 te mpera ture rel ief valv e with
a disch arge pipe (D2 ) having 4 N o. elbows and len gth of 7m
from the t undis h to the point of discharge.
From Tabl e 1:
Maxi mum res istan ce allowed for a str aight l ength of 2 2mm
coppe r disch arge pi pe (D2 ) from a G1/2 tem perature reli ef
valve is : 9.0m Subt ract the resist ance for 4 No. 22mm
elbows a t 0.8m each = 3.2m Ther efore the maxi mum
permi tted le ngth equates to : 5.8m 5.8m is l ess tha n the
actual l ength o f 7m therefore calcu late the next largest si ze.
Maxi mum res istan ce allowed for a str aight l ength of 28 mm
pipe ( D2) fro m a G1/2 temper ature re lief val ve equates to:
14m As the actua l length is 7m, a 28mm (D2) copper pip e will
be satis factor y.
Table1
Sizing of coppe r disch arge pi pe ‘D2’ for a te mpera ture
relief v alve with a G1/2 outlet size (a s suppl ied) .
Size of
disch arge
pipewo rk
22mm Up to 9m 0.8m
28mm Up to 18m 1m
35mm Up to 27m 1.4m
Maxi mum
lengt h of
straig ht pipe
(no be nds or
elbows )
Deduc t the figu re below
from the m aximum
lengt h for each bend or
elbow in t he disc harge
pipe
5
WIRING DIAGRAM TWO 2 PORT ZONE VALVE (S-PLAN)
VARIANT DUAL THERMOSTAT WIRING
WIRING DIAGRAM 3 PORT MID POSITION VALVE (Y-PLAN) + 2 PORT VALVE
VARIANT DUAL THERMOSTAT WIRING
6
COMMISSIONING
FILLING
Check the pressure in the expansion vessel is 3 bar (45PSI), i.e. the same as the setting of the pressure reducing valve. The valve
is of the car tyre (Schrader) type. Check all the connections for tightness including any factory made connections such as the
immersion heater and the temperature and pressure relief valve. Before filling open the hot tap furthest away from the Ultrasteel
to let air out. Open the cold main isolation valve and allow the unit to fill. When water flows from the tap allow it to run for a short
while to flush through any dirt, swarf or flux residue. Close the tap and open every other hot tap in turn to purge all remaining air.
DIRECT UNITS
After filling with water and after sterilisation liquid has been purged, switch on the power to the immersion heaters and allow the
unit to start to heat. The immersion heater is supplied preset at 55°C. Turning fully to + sets to approx 65°C
INDIRECT UNITS
Consult the boiler manufacturers commissioning instructions and fill the primary circuit. Ensure the lever on the two port valve is
set to the filling position. When full move the lever back. Switch the programmer to Domestic Hot water (DHW) and allow the unit
to start to heat. Adjust the dial of the dual thermostat to between 55°C and 65°C as required.
STORAGE TEMPERATURE
The recommended storage temperature for both direct and indirect cylinders is 60-65°C. In hard water areas consideration should
be given to reducing this to 50-55°C. In many healthcare applications the guidance on Legionella control and safe water delivery
temperatures will require storing the water at 60-65°C, distributing at 50- 55°C and using thermostatic mixing valves to control the
final temperature.
For details consult the NHS Estates Guidance on safe hot water temperatures.
SAFETY VALVE CHECKS
During heat-up there should have been no sign of water coming from either the expansion relief valve or the temperature /
pressure relief valve. Now hold both of these safety valves fully open allowing as much water as possible to flow through the
tundish. Check that your discharge pipework is free from debris and is carrying the water away to waste efficiently Release the
valves and check that they reseat properly.
SERVICING
GENERAL
Servicing should only be carried out by competent installers and any spare parts used must be purchased from Albion. NEVER
bypass any safety devices or operate the unit without them being fully operational.
DRAINING
Isolate from the electrical supply to prevent the immersion heaters burning out. Isolate the unit from the cold mains. Attach a hose
to the draining tap ensuring it reaches to a level below the unit (This will ensure an efficient syphon is set up and the maximum
amount of water is drained from the unit). Open the hot tap closest to the unit and open the draining tap WARNING: WATER
DRAINED OFF MAY BE VERY HOT!
ANNUAL MAINTENANCE
Ultrasteel requires an annual service in order to ensure safe working and optimum performance. It is essential that the following
checks are performed by a competent installer on an annual basis. Commonly this is done at the same time as the annual boiler
service.
1) Twist the cap of the expansion relief valve on the inlet control set and allow water to flow for 5 seconds. Release and make
sure it resets correctly. Repeat with the pressure / temperature relief valve. In both cases check that the discharge pipework is
carrying the water away adequately. If not check for blockages etc. and clear. WARNING: THE WATER DISCHARGED MAY BE
VERY HOT!
2) Check that any immersion heaters fitted are working correctly and that they are controlling the water at a temperature
between 55°C and 65°C.
3) Check the pressure in the expansion vessel is charged to 3 bar. Turn off the water supply to the unit and open a hot tap
first. The air valve on expansion vessel is a Schrader (car tyre ) type. Air or CO2 may be used to charge the expansion vessel.
4) Unscrew the head on the inlet control set and clean the mesh filter within.
5) The benchmark log book supplied with this unit should be updated at each service.
YOUR GUARANTEE MAY BE VOID WITHOUT PROOF OF ANNUAL SERVICING
SPARE PARTS
We carry the full range of spares listed below in stock. If you order before noon we will dispatch the same day for delivery the next
to most locations. Tel: 01924 376026.
TS201 - Inlet control set (pressure reducing valve, strainer and
expansion relief valve )
TS202 - Temperature & pressure relief valve
TS3 - Tundish
TS4 - Expansion relief valve (car tridge only)
TS105 - 2 port valve
TS207 - Dual thermostat
TS9 - Immersion heater ( same on all models )
TS212 - 12 litre Expansion Vessel ( 120 & 150 ltr sizes )
TS219 - 19 Litre Expansion vessel ( 180 , 210 & 250 ltr sizes)
TS224 - 24 litre expansion vessel ( 300 ltr size )
TS216 - Wall mounting bracket
TS214 - Expansion vessel hose ( ¾” M x ¾” F )
TS27 - Single control stat
TS28 - Single high limit stat
- Sensor pocket retaining plugs
7
FAULT FINDING
8
ABCDEF
22mm HOT
DRAWOFF
“
“
F PTRV BOSS
F STAT BOSS
SECOND
IMMERSION HEATER
(not always fitted. See table)
22mm SECONDARY
RETURN (not always fitted.
See table)
22mm COLD FEED WITH
DIP PIPE TO DEFLECTOR
IN BOTTOM OF CYLINDER
1
2
1
2
160mm
195mm
FDF
22mm HOT
DRAWOFF
“
F PTRV BOSS
22mm SECONDARY
RETURN (not always fitted.
See table)
22mm COLD FEED WITH
DIP PIPE TO DEFLECTOR
IN BOTTOM OF CYLINDER
1
2
TECHNICAL SPECIFICATIONS
Ultrasteel
Direct
PRODUCT
CODE
CAPACITY
(Litres)
HEIGHT DIAMETER D F WEIGHT
(Kg - EMPTY)
AUD 120 120 906 550 N/F 510 30 150
AUD 150 150 1093 550 N/F 610 35 185
AUD 180 180 1281 550 N/F 710 40 220
AUD 210 210 1469 550 1000 810 45 255
AUD 250 250 1719 550 1250 950 50 300
AUD 300 300 2032 550 1500 1100 55 355
All dim ensio ns are in m m and are of t he case d unit. N /F = not fi tted
Ultrasteel
Indirect
WEIGHT
(Kg-FULL)
PRODUCT
CODE
AUI 120 120 906 550 290 330 390 345 N/F N/F 35 155
AUI 150 150 1093 550 330 370 465 385 N/F N/F 40 190
AUI 180 180 1281 550 330 370 465 385 N/F N/F 45 225
AUI 210 210 1469 550 365 405 465 465 N/F 1150 50 260
AUI 250 250 1719 550 365 405 465 560 950 1400 55 305
AUI 300 300 2032 550 365 405 465 660 1100 1600 60 360
All dim ensio ns are in m m and are of t he case d unit. N /F = not fi tted
CAPACITY
(Litres)
HEIGHT DIAMETER A B C D E F WEIGHT
(Kg - EMPTY)
WEIGHT
(Kg-FULL)
9
ULTRASTEEL SOLAR UNVENTED
DIRECT SINGLE COIL CYLINDER
Detail for the installation of a Solar Unvented cylinder in an electric home.
General
When installing this product it is essential the overall installation meets all current legislation including, in particular, the high limit
isolation requirements of Building Regulation G3. This document is designed to assist in achieving that aim.
Water
The potable water connection and tundish discharge connection are to be connected in exactly the manner described in Pages 1
to 7 of this manual.
Immersion Heaters
The standard issue immersion heaters are designed for domestic usage where the lower heater is connected to a low rate off
peak tariff and the upper heater used for occasional top up purposes. Heaters of this nature are not designed to be permanently
live. For usage outside of domestic parameters Titanium immersion elements are recommended.
Solar Connections
The flow and return from the solar heat source are to be connected to the indirect coil. Either primary coil connection (A) may be
utilised as the flow or return. The solar sensor, supplied as part of the solar controls, inserts into Pocket B and is held in-situ with
the black sensor pocket retaining bung provided. It is necessary to mount the solar pump in the return pipework with the Danfoss
HP22 two port valve (supplied with the cylinder) installed between the cylinder and the pump. This valve is of the powered open,
sprung closed design and is wired through the Danfoss ITL100 high limit stat which inserts into Pocket F. Two wiring options for
high limit isolation are provided in fig 1 and fig 2. The superior option is fig 2 which disconnects the pump movement as well as
providing valve closure. (see pages 11 & 12)
ULTRASTEEL SOLAR UNVENTED
INDIRECT TWIN COIL CYLINDER
Indirect, twin coil, units can be installed in two separate formats:
a) In a solar powered system with a fossil fuel boiler.
b) In a system with two independent fossil fuel boilers.
With either format it is essential the overall installation meets all current legislation including, in particular, the high limit isolation
requirements of Building Regulation G3. This document is designed to assist in achieving this aim.
UPPER COIL
The upper coil is connected to the fossil fuel boiler as per the instructions for the Ulrasteel Unvented Indirect single coil model with
the Danfoss ITD100 control and high limit thermostat inserted into pocket D (lower diagram page 12). The wiring requirements are
as depicted on page 11.
LOWER COIL: SOLAR INSTALLATION
In a solar powered system the lower coil is connected to the solar heat source. Either primary coil connection may be utilised
as the flow or return. The solar cylinder sensor, supplied as part of the solar controls, inserts into pocket B (fig. page 12). It is
necessary to mount the solar pump in the return pipework with the Danfoss HP22 two port valve (supplied with the cylinder)
installed between the cylinder and the pump. This valve is of the powered open, sprung closed design and is wired through the
Danfoss ITL100 high limit stat which inserts into pocket F (lower diagram page 12). Two wiring options for high limit isolation are
provided in fig. 1 and fig. 2 page 11. The Danfoss ITC100 control thermostat is not required in a solar installation.
10
LOWER COIL: TWO BOILER INSTALLATION
Where the lower coil is to be used with a fossil fuel boiler, the pipework requirements are as per that of a Ulrasteel Indirect single
coil cylinder described earlier in this book. Electrically the ITC100 inserts into Pocket B (fig. Page 12) to control the boiler input and
the Danfoss ITL100 limit stat into Pocket F (lower diagram page 12). The Danfoss HP22 two port valve may be installed into either
the flow or return pipework. Wiring of the ITC100 and ITL100 are as per the wiring detail using the ITD100 on page 6.
WIRING DIAGRAM:
SOLAR HIGH LIMIT CONTROL
11
TECHNICAL SPECIFICATIONS
AB GCDEF
22mm HOT DRAWOFF
SECONDARY RETURN
(not always fitted)
22mm COLD FEED
WITH DIP PIPE
TO DEFLECTOR
IN BOTTOM
OF CYLINDER
25.0015.0
0
45.0
0
45.0
0
35.0
0
“
F PTRV BOSS
1
2
“
F PTRV BOSS
1
2
AB HGCDEF
22mm HOT DRAWOFF
SECONDARY RETURN
(not always fitted)
22mm COLD FEED
WITH DIP PIPE
TO DEFLECTOR
IN BOTTOM
OF CYLINDER
25.0015.0
0
45.0
0
45.0
0
35.0
0
“
F PTRV BOSS
1
2
“
F PTRV BOSS
1
2
Ultrasteel
Solar
Direct
PRODUCT
CODE
CAPACITY
(Litres)
HEIGHT DIAMETER A B C D E F G WEIGHT
(Kg - EMPTY)
AUSD 180 180 1281 550 290 345 445 710 N/F 1080 390 45 225
AUSD 210 210 1469 550 365 420 500 810 1150 1268 465 50 260
AUSD 250 250 1719 550 365 420 575 950 1400 1518 465 55 305
AUSD 300 300 2032 550 365 420 670 1100 1600 1831 465 60 360
All dim ensio ns are in m m and are of t he case d unit. N /F = not fi tted
Ultrasteel
Solar
Indirect
WEIGHT
(Kg-FULL)
CODE
AUSI 180 180 1281 550 290 345 674 729 N/F 1080 390 725 50 230
AUSI 210 210 1469 550 365 420 779 834 1150 1268 465 830 55 265
AUSI 250 250 1719 550 365 420 854 909 1400 1518 465 905 60 310
AUSI 300 300 2032 550 365 420 979 1034 1600 1832 465 1030 65 365
PRODUCT
All dim ensio ns are in m m and are of t he case d unit. N /F = not fi tted
12
CAPACITY
(Litres)
HEIGHT DIAMETER A B C D E F G H WEIGHT
(Kg - EMPTY)
WEIGHT
(Kg-FULL)
ALBION ULTRASTEEL
SOLAR UNVENTED CYLINDERS
Al bi on Ul tr astee l Solar c ylind ers h ave be en de sig ned spe cif ica lly
with Solar ap plications i n mi nd. Featu ring a purpose d esign ed
sola r coi l wh ich all ows maximu m heat transfe r of sol ar en ergy
into th e stored water, t he c yli nders a re s uit able fo r us e with
a w ide ran ge of sol ar s ystems now avai lable i n th e UK a nd are
an effi cie nt a nd envi ro nme ntall y fri end ly way of prov iding
dome stic hot water. U ltras te el So lar cyl inder s als o of fer the
bene fit of ma ins pre ssure hot water – power f ul shower s and fas t
fi ll ing bat hs .
Ultr aste el So lar C ylind ers a re d esi gne d to acc ept hea t in put f ro m a re newab le/sus taina ble ( ie: Sola r) h eat sou rce.
Where th is inpu t doe s not fully m eet the desire d te mpera tu re a g uar anteed qu antit y of water c an be h eate d to a n ac cep table
temperature by the hous eho lde rs tradit ional h eat sou rc e of g as, oil or el ect ricit y.
Th e Do mes tic Heati ng Comp lia nce Gui de docu men t L1A and L1B provid es exce ll ent adv ice i n sizin g bo th c ylind er de signa te d solar
area s and hea t exch ang ers to t he s urface a rea of the sola r col lectors. Us ing thi s guide A lbion a re able to of fer siz ing adv ice for
specificatio n.
Ultr aste el So lar cyl ind ers are avail abl e in a r ange of sizes f rom
180 to 300 litres a nd in Dir ect or Indi rec t ve rsions. Ultras te el
Sola r cylin der s are man ufactur ed from h igh grade D upl ex
stai nle ss ste el an d come wi th a 25 year f ully transfe ra ble
Guar antee o n th e in ner c ontai ner.
Water Capacities
Model Designated solar area Fossil fuel area Total Capacity
180 55 125 180
210 65 145 210
250 75 175 250
300 100 200 300
Lower (Solar) Coil Specification
Model Surface Area (m2) Fluid Content (litres)
180 0.670 3.687
210 0.878 4.826
250 0.878 4.826
300 0.878 4.826
NB: The total detail of compliance guide document
should be consulted prior to specifying product or
commencing design.
Maximum Nett Surface Area of Collector panel (m2)
As detailed in domestic compliance guide.
Model Solar Pump speed
< 0.5LPM > 0.5LPM
180 3.35 6.70
210 4.39 8.78
250 4.39 8.78
300 4.39 8.78
In addition our insulation process offers benefits to the
‘green’ specifier.
Ozone Depletion Potential (ODP) ZERO
Global Warming Potential (GWP) ONE
13
NOTES
14
GUARANTEE
The Ultrasteel’s stainless steel vessel carries
a 25 year guarantee against faulty materials or
manufacture provided that:
It has been correctly installed as per this
•
document and all the relevant standards,
regulations and codes of practice in force
at the time.
It has not been modified in any way, other
•
than by Albion.
It has not been misused, tampered with or
•
subjected to neglect.
It has only been used for the storage of
•
potable water.
It has not been subjected to frost damage.
•
The unit has been serviced annually.
•
The benchmark log book has been filled in
•
after each annual service.
The guarantee period starts from the date of
•
purchase and no registration is required.
The extended guarantee is not transferable,
•
and rests with the original householder.
The system is fed from a public water
•
supply.
EXCLUSIONS –THE GUARANTEE DOES NOT
COVER
The effects of scale build up.
Any labour charges associated with replacing the unit or its
parts. Any consequential losses caused by the failure or
malfunction of the unit.
GUIDANCE IN THE EVENT OF A PROBLEM
If you have a problem in the first year contact the plumber who
fitted the unit. Thereafter contact the plumber who carries out
the annual servicing for you. If your Ultrasteel develops a leak
we will supply you with a new one. We ask for an nominal upfront payment to prevent fraud. We will require the original
unit to be returned to us for inspection along with a copy of
your benchmark log book. If it is confirmed that it has failed
within the terms of the warranty your upfront payment will be
refunded.
If a component part fails within the two year guarantee period
we will send you a new one without any upfront charge. Credit
card details may be taken to prevent fraud. We ask you to
post the faulty part back to us within one month by recorded
delivery.
If you do not return the part we will charge you for it and for the
postage and packing. If your part fails after two years service,
we will ask for upfront payment.
Please note that invoices for servicing may be
requested to prove that the unit has been
serviced annually.
All the components fitted to / or supplied with
the Ultrasteel carry a 2 year guarantee.
USER INSTRUCTIONS
Your stainless system is automatic in normal use and requires only annual servicing. You should employ an competent installer to
perform the annual servicing. Normally this is timed to coincide with the annual boiler service.
IF WATER IS FLOWING FROM THE SAFETY VALVES THROUGH THE TUNDISH THIS INDICATES
A FAULT CONDITION AND ACTION IS NEEDED.
If this water is hot turn the boiler and / or the immersion heater off. Do not turn off the water until the discharge runs cool. The
discharge may also stop.
CALL A COMPETENT PLUMBER OUT TO SERVICE THE UNIT.
Tell them you have a fault on an unvented cylinder. We stock all the spare parts they may need.
15
Albion Water Heaters Ltd, Station Road, Caythorpe, Nr. Grantham, Lincolnshire NG32 3EW
T: 01400 272726 F: 01400 273508 www.albionwaterheaters.com
kingspanhws.com
Specification summary...
Materials
Inner shell - Duplex Stainless Steel
Coil - 22mm Diameter Stainless Steel
Bosses - Stainless Steel
Every Ultrasteel cylinder is water tested to a pressure of 15 bar.
Insulation
Fire retardant polyurethane foam, nominal thickness 50mm.
The foam is CFC-Free and HCFC-Free.
The foam has an Ozone Depletion Potential of ZERO and a Global Warming
Potential of One.
Casework
Zintec corrosion proofed steels throughout
Durable.
Anode
None fitted/none required
Expansion Vessel
12 Litre size with 120 and 150 Litre models
18 Litre size with 180, 210 and 250 Litre models
25 Litre size with 300 Litre model
Control Settings
Pressure Reducing Valve - 3 Bar
Expansion Relief Valve - 6 Bar
Pressure and Temperature Relief Valve - 7 Bar/90°C
High Limit Thermostat in Dual Thermostat - 85°C
High Limit Thermostat in Immersion Heater - 85°C
Immersion Heater
1
3
/4” BSP Parallel Threaded Head
Long Life Incoloy Sheathed Low Noise Element 14” Long
Long Life Incoloy Sheathed Thermostat Pocket 11” Long
Brazed Construction
11” Combined Thermostat and Safety Cut-Out
Element Rating 3Kw at 240V A/C
Approvals
WRAS Approved to the Water Regulations
WRC-NSF Approved to Building Regulations G3 & L
CE Compliant and fitted with a BEAB Approved
Immersion Heater
Guarantee Terms
The Stainless Ultrasteel’s stainless steel vessel carries a 25 year guarantee against faulty
materials or manufacture provided that:
It has been correctly installed as per the Installation Instructions and all the relevant
standards, regulations and codes of practice in force at the time.
It has not been modified in any way, other than by Albion.
It has not been misused, tampered with or subjected to neglect.
The system is fed from the public mains water supply.
It has only been used for the storage of potable water.
It has not been subjected to frost damage.
The unit has been serviced annually.
The benchmark log book has been filled in after each annual service.
The guarantee period starts from the date of purchase and no registration is required.
Please note that invoices for servicing may be requested to prove that the unit
has been serviced annually.
All the components fitted to/or supplied with the Stainless HE carry a
2 year guarantee.
Exclusions –The Guarantee does not cover
The effects of scale build up.
Any labour charges associated with replacing the unit or its parts.
Any consequential losses caused by the failure or malfunction of the unit.
Kingspan Hot Waters Systems have a policy of continuous product development
and may introduce product modifications from time to time. As a consequence
details given in this brochure are subject to alteration without notice.
Albion is a market leader in the manufacture
and supply of quality hot water systems.
Albion Water Heaters Ltd, part of Kingspan group, is a major
manufacturer of domestic hot water storage systems in the UK
and offers the trade products backed by the service and technical
development skills that only a company of its size can.
All sites are licensed to British standards quality assurance BS EN
ISO 9001 : 2000 and Albion is a BSi registered firm. This means
that all manufacturing plants are monitored by an independent
inspectorate and that the quality systems employed by Albion meet
the stringent requirements set down.
Specifiers, stockists and users can depend on Albion for
consistent quality and supply. Albion continues to develop
energy saving and innovative hot water products for domestic
and commercial applications.
ALBION IS A MARKET LEADER IN THE
MANUFACTURE AND SUPPLY OF QUALITY HOT
WATER SYSTEMS.
Specification summary...
Material s
OHSAS 18 001
Inner shell - Duplex Stainless Steel
Coil - 22mm Diameter Stainless Steel
Bosses - Stainless Steel
Every Ultrasteel cylinder is water tested to a pressure of 15 bar.
Insulation
Fire retardant polyurethane foam, nominal thick ness 50mm.
The foam is CFC-Free and HCFC-Free.
The foam has an Ozone Depletion Potential of ZERO and a Global Warming
Potential of O ne.
Casework
Zintec corrosion proofed steels throughout
Durable, metallic finish outer casing.
Anod e
None fitted/none required
Expansion Vessel
12 Litre size with 120 and 150 Litre models
19 Litre size with 180, 210 and 250 Litre models
24 Litre size with 300 Litre model
Control Setti ngs
Pressure Reducing Valve - 3 Bar
Expansion Relief Valve - 6 Bar
Pressure and Temperature Relief Valve - 7 Bar/90°C
High Limit Thermostat in Dual T hermostat - 85°C
High Limit Thermostat in Immersion Heater - 85°C
Immersion Heater
13/4” BSP Parallel Threaded Head
Long Life Incoloy Sheathed Low Noise Eleme nt 14” Long
Long Life Incoloy Sheathed Thermostat Pocket 11” Long
Brazed Construction
Combined Thermostat and Safety Cut-Out
Element Rating 3Kw at 240V A/C
Approvals
WRAS Approved to the Water Regulations
WRC-NSF Approved to Building Regulations G3 & L
CE Compliant and fitted with a BEA B Approved
Immersion Heater
Kingspan Hot Waters Systems have a policy of continuous product development
and may introduce produ ct modificatio ns from time to time. As a consequenc e
details given in this bro chure are subject to alteration without notice.
Albion Water Heaters Ltd, part of Kingspan group, is a major
manufacturer of domestic hot water storage systems in the UK
and offers the trade products backed by the service and technical
development skills that only a company of its size can.
All sites are licensed to British standards quality assurance BS EN
ISO 9001 : 2000 and Albion is a BSi registered firm. This means
that all manufacturing plants are monitored by an independent
inspectorate and the quality systems employed by Albion meet
the stringent requirements set down.
Specifiers, stockists and users can depend on Albion for
consistent quality and supply. Albion continues to develop
energy saving and innovative hot water products for domestic
and commercial applications.
Issue 01
June 2008
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