andrews 24/39, 32/40, 40/61, 63/62, 84/87 User guide

This manual must be kept with the appliance January 2011

Part No E132

Gas Fired Storage
Water Heaters

Installation guide, operation
and service manual

Natural Gas

HI-FLO RANGE

Models 32/143, 65/173, 81/264, 62/341, 54/418, 54/440
Permanent Pilot, Auto Ignition with Flue Damper ‘E’/‘F’ Series

STANDARD RANGE

Models 24/39, 32/40, 40/61, 63/62, and 84/87
Permanent Pilot, Auto Ignition ‘G’ Series

Working towards
a cleaner future

© Copyright Andrews Water Heaters 2007

Reproduction of any information in this publication by any method is not permitted

unless prior written approval has been obtained from Andrews Water Heaters.

Andrews Storage Water Heaters have been designed and manufactured to comply

with current International standards of safety. In the interests of the health and

safety of personnel and the continued safe, reliable operation of the equipment,

safe working practices must be employed at all times. The attention of U.K. users is

drawn to their responsibilities under the Health and Safety Regulations 1993.

All installation and service on the Andrews Water Heater must be carried out by

properly qualified personnel, and therefore no liability can be accepted for any

damage or malfunction caused as a result of intervention by unauthorised

personnel.

The Andrews Water Heaters policy is one of continuous product improvement, and

therefore the information in this manual, whilst completely up to date at the time of

publication, may be subject to revision without prior notice.

Further information and assistance can be obtained from:

Andrews Water Heaters

Wood Lane, Erdington, Birmingham B24 9QP

Technical Helpline

Tel: [phone] Fax: [phone]

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL

ARE FOR USE WITH NATURAL GAS ONLY

CONTENTS

PAGE

SECTION 1 GENERAL AND SAFETY INFORMATION

General Information 2
British Standards 2
Health and Safety Regulations 1993 3
Legionellae in Water Heaters 3

SECTION 2 TECHNICAL DATA

Standard Range 4
Hi-Flo Range 5

SECTION 3 INSTALLATION

Introduction 6
Draught Diverter 6
Location 6
Gas Supply 7
Electrical Supply 8
Flue Systems 10
Air Supply and Ventilation 12
Water Quality and Treatment 14
Water Connections- Hydrojet System 15

Vented Systems, Standard Range 16
Unvented Systems, Standard Range 18
Vented Systems, Hi-Flo Range 20
Unvented Systems, Hi-Flo Range 23

SECTION 4 COMMISSIONING

Standard Range 26
Hi-Flo Range 28

SECTION 5 OPERATION

Standard Range 35
Hi-Flo Range 35

SECTION 6 SERVICING

Introduction 36
Burner Assembly, Standard Range 36
Burner Assembly, Hi-Flo Range 36
Gas Control Valve, Standard Range 37
Gas Control Valve, Hi-Flo Range 37
Flue Ways 37
Cleaning the Storage Vessel 38
Magnesium Anode(s) 38
Safety Valve 38

SECTION 7 REPLACING COMPONENTS, Hi-Flo RANGE

Gas Control Valve 40
Burner 40

SECTION 8 FAULT FINDING

Permanent Pilot Models - Standard and Hi-Flo Range 41
All Models 42
Auto Ignition Models, Hi-Flo Range 43

SECTION 9 PARTS LISTS AND ILLUSTRATIONS

Standard Range 45
Hi-Flo Range 46
Unvented Systems Kit 50
24V Auto System Kit 52

GENERAL AND SAFETY INFORMATIONSECTION 1

The Andrews Water Heater has been designed for use with NATURAL GAS only and is
manufactured to give an efficient, reliable and long service life.

To ensure the continued, trouble-free operation of your heater at maximum efficiency, it
is essential that correct installation, commissioning, operation and service procedures are
carried out strictly in accordance with the instructions given in this manual. By law,
installation and commissioning of the heater must be carried out by properly qualified
personnel.

The heater(s) must be installed in accordance with the following requirements;
The current GAS SAFETY (INSTALLATION AND USE) REGULATIONS
The current BUILDING REGULATIONS
The Water Supply (WATER FITTINGS) REGULATIONS 1999

Additionally, installation should be performed in accordance with all relevant
requirements of the Gas Supplier, Local Authority and recommendations of the British
Standards and Codes of Practice detailed below.

STANDARD RANGE

BS 6700: 1997 Specification for design, installation, testing and maintenance of

services supplying water for domestic use within buildings and their
curtilages. This standard supersedes the following British Standards
and Codes of Practice: CP99, CP310, CP324, 202, CP342 Part 2,
Centralised Hot Water Supply.

BS 5440 Installation of flues and ventilation for gas appliances of rated output

not exceeding 60kW.
Part 1:2000 Specification for installation of flues.
Part 2:2000 Specification for installation of ventilation for gas appliances.

BS 5546:1990 Installation of gas hot water supplies for domestic purposes.

BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic

premises.

BS 7206:1990 Specification for unvented hot water storage units and packages.

I/M2 Purging procedures for non-domestic gas installations.
I/M5 Soundness testing procedures for industrial and commercial gas

installations.
I/M11 Flues for commercial and industrial gas fired boilers and air heaters.
I/M16 Notes on installation of gas pipework

(excluding 25mm and below).
IGE/UP/10 Pt.1
Edition 2 Installation of Gas Appliances in Industrial and Commercial Premises

Hi-Flo RANGE

As STANDARD RANGE plus:
BS 6644: Installation of gas fired hot water boilers of rated inputs between

60kW and 2MW.

NOTE: Consideration should be given to amendments or updates to the

above standards.

GENERAL

INFORMATION

BRITISH

STANDARDS

AND CODES OF

PRACTICE

2

GENERAL AND SAFETY INFORMATION SECTION 1

It is the duty of manufacturers and suppliers of products for use at work to ensure, so far
as is practicable, that such products are safe and without risk to health when properly
used and to make available to users, adequate information about their safe and proper
operation.

Andrews Water Heaters should only be used in the manner and purpose for which they
were intended and in accordance with the instructions in this manual. Although the
heaters have been manufactured with paramount consideration to safety, certain basic
precautions specified in this manual must be taken by the user.

It is imperative that all users of the heater must be provided with all the information and
instruction necessary to ensure correct and safe operation.

Water systems in buildings have been associated with outbreaks of Legionnaires' Disease,
particularly in health care facilities where occupants are significantly more susceptible to
infection.

In recognition of the risks in hospitals, a Code of Practice for the Control of Legionellae
in Health Care premises has been issued by the Department of Health (1991). Codes of
Practice applicable to other premises have been published by other organisations,
principally the Health and Safety Executive (HS)(G70) and the Chartered Institute of
Building Services Engineers (CIBSE, TM13).

All Codes of Practice draw attention to the design and operation of water systems with
reference to avoidance of factors that favour colonisation by Legionellae bacteria. These
factors include stagnation, lukewarm conditions (20ºC to 45ºC) and the accumulation of
debris, scale and corrosion in the base of tanks and calorifiers.

Andrews Water Heaters has commissioned an independent evaluation of their products
to investigate their resistance to build-up of legionellae bacteria.

Experiments were conducted to determine whether, following a substantial challenge by
legionellae pneumophilia, after overnight and stagnation conditions, the system was
rendered free from viable recoverable legionellae. It was found that at 61ºC, following a
challenge of approximately 107 organisms per litre, within one hour, more than 99.999%
of organisms had been killed. After a subsequent stagnation period, sampling did not
reveal any residual contamination. The design of the base of the water heater precludes
legionellae colonisation, even after build-up of debris. The burner positioning ensures
that the water at the bottom of the heater reaches the same, or higher temperature as in
the rest of the heater.

Based on data obtained through experiment, the Andrews Water Heater can be described
as legionellae resistant as it is considered unlikely that, at the temperature tested, the
organism would colonise the water heater and present a possible health risk.

HEALTH AND
SAFETY
REGULATIONS
1993

EFFECTIVENESS
IN COMBATING
LEGIONELLAE

3

TECHNICAL DATASECTION 2

STANDARD

RANGE

4

Storage Capacity l 109 145 182 286 382

gal 24 32 40 63 84

Recovery thro' 44ºC/80ºF l/h 178 182 278 281 397

gal/h 39 40 61 62 87

Recovery thro' 56ºC/100ºF l/h 142 146 220 227 316

gal/h 31 32 49 50 70

Heat Input Gross kW 12 12.5 19 19 26

Btu/h 40,944 42,650 65,000 65,000 88,712

Heat Input Net kW 11 11.4 17 17 24

Btu/h 37,532 38,900 58,004 58,004 81,888

Gas NATURAL CAT I2H

Burner Gas Pressure mbar 10 10 10 10 10

ins wg. 4 4 4 4 4

Max. Gas Input Pressure mbar 35 35 35 35 35

ins wg. 14 14 14 14 14

Gas Flow Rate m

3

/h 1.12 1.16 1.78 1.78 2.43

ft

3

/h 39.4 41.22 62.86 62.86 85.71

Gas Connection Rc (in BSP Int) 1/2 1/2 1/2 1/2 1/2

Flue Gas Temp. ºC 200 205 195 160 125

Flue Gas Volume m3/h 17 18 26 31 37

Gas Injector Orifice Diameter mm 2.95 3.05 3.86 3.86 4.22

in 0.116 0.120 0.152 0.152 0.166

Flue Size (Secondary) mm 100 100 100 125 125

in 4 4 4 5 5

Cold Water Feed Connection R (in BSP/Exl) 1 1 1 1 11/4

Hot Water Flow Connection R (in BSP/Exl) 1 1 1 1 11/4

*Return Connection Rp (in BSP/Int) 3/4 3/4 3/4 3/4 3/4

Drain Port Size R (in BSP/Ext) 3/4 3/4 3/4 3/4 3/4

Max. Working Pressure bar 10.3 10.3 10.3 10.3 10.3

lbf/in

2

150 150 150 150 150

Max. Test Pressure bar 20.6 20.6 20.6 20.6 20.6

lbf/in

2

300 300 300 300 300

Weight Empty kg 43 57 65 110 181

lb 94 126 144 244 400

Weight Full kg 151 202 247 396 562

lb 334 446 544 874 1240

Shipping Weight kg 44 59 68 120 194

lb 98 131 150 264 428

Shipping Dimensions Depth mm 546 587 587 692 914

in 211/2 231/8 231/8 271/4 36

Shipping Dimensions Width mm 486 537 537 651 762

in 19 1/8 21 1/8 21 1/8 25 5/8 30

Shipping Dimensions Height mm 1194 1245 1499 1575 1829

in 47 49 59 62 72

ANDREWS MODEL NO. 24/39 32/40 40/61 63/62 84/87

TECHNICAL DATA SECTION 2

5

Storage Capacity l 145 295* 368* 282* 245* 245

gal 32 65 81 62 54 54

Recovery thro' 44ºC/80ºF l/h 649 786 1199 1549 1900 1998

gal/h 143 173 264 341 418 440

Recovery thro' 56ºC/100ºF l/h 517 629* 959 1239* 1520* 1598*

gal/h 114 138 212 273 334 352

Recovery thro' 72ºC/130ºF l/h 399 484* 730 953* 1169* 1223*

gal/h 88 106 162 210 257 270

Heat Input Gross kW 42.8 50 80 102 128 139

Btu/h

146,034 170,600 272,960 384,024 436,736 474,268

Heat Input Net kW 39 45 73 93 116 126

Btu/h

133,068 153,540 249,076 317,316 395,792 430,000

Gas NATURAL CAT I2H

Burner Gas Pressure mbar 6.8 6.8 6.8 6.8 6.8 N/A
Pernament Pilot ins wg. 2.73 2.73 2.73 2.73 2.73 N/A

Burner Gas Pressure mbar 10 10 10 10 10
Auto Ignition ins wg. 4 4 4 4 4

Max. Gas Input Pressure mbar 35 35 35 35 35

ins wg. 14 14 14 14 14

Gas Flow Rate m3/h 4.0 4.68 7.44 9.48 11.94 13.14

ft

3

/h 141 164.76 263.58 336.24 421.98 465.06

Gas Connection Rc (in BSP Int) 3/4 3/4 3/4 3/4 3/4 3/4

Flue Gas Temp. ºC 117 140 150 195 185 215

Flue Gas Volume m

3

/h 62 73 116 149 186 202

Gas Injector Orifice Diameter mm 2.69 2.87 3.66 3.45 3.50 N/A
Permanent Pilot in 0.106 0.113 0.144 0.136 0.138 N/A

Gas Injector Orifice Diameter mm 2.40 2.58 3.25 3.18 N/A 3.26
Auto Ignition in 0.094 0.101 0.127 0.125 N/A 0.128

Flue Size (Secondary) mm 150 150 200 200 250 250

in 6 6 8 8 10 10

Cold Water Feed Connection R

(in BSP/Exl) 11/2 11/2 11/2 11/2 11/2 11/2

Hot Water Flow Connection R

(in BSP/Exl) 11/2 11/2 11/2 11/2 11/2 11/2

*Return Connection Rp

(in BSP/Int) 3/4 3/4 3/4 3/4 3/4 3/4

Drain Port Size R (in BSP/Ext) 3/4 3/4 3/4 3/4 3/4 3/4

Max. Working Pressure bar 10.3 10.3 10.3 10.3 10.3 10.3

lbf/in

2

150 150 150 150 150 150

Max. Test Pressure bar 20.6 20.6 20.6 20.6 20.6 20.6

lbf/in

2

300 300 300 300 300 300

Weight Empty kg 190 200 289 257 269 269

lb 419 441 637 566 594 594

Weight Full kg 335 495 656 538 514 514

lb 738 1091 1447 1186 1134 1134

Shipping Weight kg 199 223 316 282 293 293

lb 438 492 697 623 645 645

Shipping Dimensions Depth mm 902 914 914 914 914 914

in 35 1/2 36 36 36 36 36

Shipping Dimensions Width mm 768 762 762 762 762 762

in 30 1/4 30 30 30 30 30

Shipping Dimensions Height mm 1270 1960 2083 1960 1960 1960

in 50 77 82 77 77 77

ANDREWS MODEL NO. 32/143 65/173 81/264 62/341 54/418 54/440

Hi-Flo
RANGE

* If the water heater is to be

used on an unvented system,
the combined temperature/
pressure relief valve must be
fitted directly into the tank.
The secondary return is then
connected to the drain port
via a suitable tee.

INSTALLATIONSECTION 3

THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A
PROPERLY QUALIFIED PERSON

Installations must be carried out in accordance with Gas safety (Installation and Use)
Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations
1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire
Authorities and the current British Standards and Codes of Practice listed in Section 1.

The fittings pack supplied with the heater contains the items listed below.

1 - Installation and Service Manual.
1 - Coupler Socket 3⁄4in BSP.
1 - Gas Cock.
1 - Drain Cock.
1 - Flue Adaptor Socket (Where required).
2 - Cap End 11⁄2in BSP (Hi-Flo only).
2 - 11⁄2in x 3in Nipples (32/143 Model only).
1 - Warranty Card.

The draught diverter must be assembled with the legs provided.
Attach the legs to the draught diverter with the nuts and bolts provided.
Fit the draught diverter (1) as shown in Fig.1 to the water heater using the screws
provided. For Standard Range fit the draught diverter to the top of the water heater
using the location holes.

In some cases, it may be necessary to drill the fixing holes in the top cover to fit the
draught diverter to the water heater. By using the draught diverter as a template,
position carefully over the flueway and mark the hole positions to be drilled 4mm.

Fit the adaptor socket (2) and caulk into the draught diverter as shown in Fig. 1.

The location selected for installation of the heater must allow the provision of a
satisfactory flue, adequate air supply, drain facilities and must be well illuminated.

A purpose built boiler room or compartment is strongly recommended.

A manual valve for isolation of the boiler room should be installed in the gas supply;
it should be clearly identified and readily accessible for use at all times.

If a purpose built boiler room is not available, measures should be taken to protect the
heater from damage and prevent any extraneous matter from being stored on or around
the heater.
See BS 6644 Clauses 4, 5 and 6 for details.

INTRODUCTION

ASSEMBLING

THE DRAUGHT

DIVERTER

Fig. 1

Draught Diverter

Assembly

6

Top Connections

81/264 Only

Elbows must be used

Top Connections

65/173

LOCATION

INSTALLATION SECTION 3

The heater must not be installed in any location which contains a bed, bath or shower.

There must be easy access to the boiler room and heater at all times.

A clearance of 800mm (31

1

⁄2 in) for Hi-Flo and 300mm for Standard Range should be left

at the front of the heater for removal of the burner.

Clearances at the sides and rear of the heater should be at least 305mm (12 in).

Service clearances for removal of the anodes and flue baffles should be provided as
detailed below.

STANDARD RANGE

Models 24/39, 32/40, 40/61 762mm (30 in)
Model 63/62 1143mm (45 in)
Model 84/87 1270mm (50 in)

HI-FLO RANGE

Model 32/143 597mm (23

1

⁄2 in)
Model 81/264 1300mm (52 in)
Models 65/173, 62/341, 54/418, 54/440 1143mm (45 in)

The floor on which the heater is installed must be non-combustible, flat, level and of
sufficient strength to withstand the weight of the heater filled with water (see Section 2,
Technical Data) and should satisfy the requirements of the Local Authority and Building
Regulations.

NOTE:
If the heater is in an exposed position and out of use during a period of heavy frost, it is
recommended that the whole system is drained down to prevent damage due to the
formation of ice inside the storage vessel.

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST
ONLY BE USED WITH NATURAL GAS.

The installation of the gas supply must conform, depending on it's size, to the
requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

A gas meter will be connected to the service pipe by British Gas plc or it's authorised
contractor.

The meter and service pipe should be checked by British Gas or it's authorised contractor
to ensure that they are adequate to deal with the gas supply to the water heater(s) in
addition to any existing or additional requirements.

Gas Supply Cock, Standard Models

Fit the gas supply cock immediately upstream of the gas control thermostat using a
suitable jointing compound and connect to the gas supply. Do not apply heat in close
proximity to the gas thermostat as damage to the control will result. A pressure test point
nipple is fitted to the gas control thermostat at the gas inlet to test the incoming gas
pressure.

LOCATION

7

GAS SUPPLY

INSTALLATIONSECTION 3

Gas Supply Cock, Hi-Flo Models

Fig 2.
Fit the gas cock immediately upstream of the gas control valve using a suitable jointing
compound and connect to the gas supply. An inlet nipple complete with pressure test
point nipple is factory fitted to the gas control valve to avoid possible damage.

Where the water heater(s) is(are) installed in a boiler house or purpose built
compartment, a manually operated valve for the boiler house must be fitted in
accordance with the Gas Safety (Installation and Use) Regulations 1998. The valve must
be easily identified and readily accessible.

After installation, the system should be pressure tested for soundness and purged in
accordance with BS 6891 or IM/2 and IM/5 as appropriate.

HI-FLO MODELS - STANDARD RANGE MODELS

External wiring to the water heater(s) must be installed in accordance with current I.E.E.
Regulations for the wiring of buildings and to any Local Regulations that may apply.

The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply.
The fuse rating is 5 amps.

The method of connection to the mains electricity supply should facilitate complete
electrical isolation of the appliance, preferably by use of an unswitched shuttered socket
outlet in conjunction with a fused three pin plug, both complying with the requirements
of BS 1363.

Alternatively, a fused double pole switch or fused spur box serving only the heater may
be used.

The point of connection to the mains electricity supply should be readily accessible and
adjacent to the appliance.

Fig 3a and 3b.
Connect the electrical supply to the main control panel terminal block via the cable
glands in the base of the control panel. Mains input cable should be 0.75mm

2

, 3 core,

and should be connected to the mains supply as detailed above.

It is recommended that screen cable is used where the volt-free contacts are to be
connected from an external supply. This will eliminate the risk of possible interference
from nearby high voltage cables.

Data sheets available for Hi-Flo and Standard Range, Automatic Ignition Control System.
Contact Andrews Water Heaters.

GAS SUPPLY

ELECTRICAL

SUPPLY -

AUTO IGNITION

UNITS

8

Fig 2.

Gas Cock

BSP Thread U.P.T. Thread

Nipple

Gas Valve

INSTALLATION SECTION 3

9

Standard
Range

Hi-Flo Range

Fig 3a.

Fig 3b.

INSTALLATIONSECTION 3

Detailed recommendations for flue installation are given in BS 6644, BS5440 Pt 1 and
British Gas publication IM/11 - Flues for Commercial and Industrial Gas Fired Boilers and
Air Heaters.

The flue connection is designed for BS 835 type heavy duty flue, but light quality flue
pipe, mild steel or stainless steel sheet may be used using the appropriate adapter.
Flue pipes etc. shall be fitted socket-up to keep any condensate within flue and
appliance. Flues up to 200mm (8in) diameter should be fitted with a suitable British Gas
Certified terminal.

Fig 4a.
The terminal position is most important and must be at least 1000mm (40in) above roof
surfaces or at least 600mm (24in) above any parapet and clear of any adjacent
obstruction as well as being clear of any openable windows, ventilators or features which
could allow re-entry of flue products into the building. Pressure areas should also be
avoided to prevent blowdown. See recommendations in BS 6644. BS 5440 Part 1 also
provides useful additional advice.

Flue materials, including jointing materials and fittings shall be asbestos-free, robust,
durable, corrosion resistant and non-combustible and shall comply with BS 5854 and
BS 715 or BS 4076 as appropriate, as well as being of a type accepted by the Local Gas
Authority.

When passing up through or adjacent to combustible materials, measures shall be taken
to prevent the temperature of the combustible material from exceeding 60ºC (150ºF).
The flue shall not be closer than 50mm (2in) to any combustible material except when
passing through, when it must be enclosed by a non-combustible sleeve and separated
from the sleeve by not less than 25mm (1in) air space.

Flues shall be of a size not less than specified in Section 2, Technical Data (i.e. nominal
flue size) and fitted so that there is no risk to persons in the building or from accidental
damage.

Fig 4b.
If using an existing brick chimney, it should be swept and checked for soundness before
connecting the flue and should take the shortest possible route and rise continuously to
the terminal avoiding the use of 90º bends where a change of direction is required.
Horizontal and very shallow runs of flue should be avoided since they impede the flow of
gases and increase local cooling

FLUE

SYSTEMS

10

Fig 4a.

Terminal

1000mm

40”

Minimum

Roof

Terminal

INSTALLATION SECTION 3

FLUE
SYSTEMS

11

Fig 4b.

Fig 5.

*A minimum of 600mm of vertical flue directly above the draught diverter should be
provided where possible on all natural draught flue installations. If this dimension cannot
be achieved please contact Andrews Water Heaters. Please note this is not required
where a common flue header is used on multiple installations.

Fig 5.
Common flues may be used on multiple installations only if all the heaters are of the
same burner system and fuel type and should be sized to ensure complete evacuation of
the flue products from the installation.

Where one flue is to be used more regularly or for longer periods than the others in the
group, it should be connected at the point nearest to the main flue. See BS 6644 Clause
20 for further information and recommendations on this as well as general flue
requirements.

Fit a flue clip or flange joint close to the diverter so that it is secure but can be
disconnected for servicing. The weight of the flue must be borne by securing clips, etc.
and not by the heater.

1. This flue run
must not be used

Split Flue Clip

600mm*

2 & 3 are recommended flue runs

Heater with
highest usage
fitted nearest to
main flue
(if applicable)

Each unit has an
atmospheric
burner system &
uses natural gas.

INSTALLATIONSECTION 3

AIR SUPPLY

AND

VENTILATION

12

Minimum Heights from Roof to Base of Flue Terminal

For all installations, please refer to the table below for calculating requirements. Detailed
recommendations for the air supply are given in BS 5440 Part 2, BS 6644 Clause 19
and IGE/UP/10 Pt.1.

The following notes are provided for general guidance only.

Ventilation shall prevent the heater environment from exceeding 32ºC (90ºF).
The purpose provided space in which the heater(s) are installed must have permanent air vents
communicating directly with the outside air, at high and low level. Where communication with the
outside air is possible only by means of high level air vents, ducting down to floor level for the lower
vents must be used.
For an exposed building, air vents must be fitted on at least two sides, preferably on all four sides.

Air vents should have negligible resistance and must not be sited in any position where they are likely
to- be easily blocked or flooded, or in any position adjacent to an extraction system which is carrying
flammable vapour.

Grilles or louvers should be so designed that high velocity air streams do not occur within the space
housing the heater(s).

The grilles should have a total minimum

free area for the water heater(s) in addition to any other

requirements as follows:-

Where the heater is to be installed in a room the following permanent
ventilation is required:

5cm

2

per kW in excess of 7kW net for installations up to 54kW net.

For installations exceeding 60kW the following permanent ventilation is required:

Low Level (inlet) 540cm

2

plus 5cm2per kilowatt in excess of 54kW total net input.

High Level (outlet) 270cm

2

plus 2.5cm2per kilowatt in excess of 54kW total net input.

Where the heater is to be installed in a compartment, permanent air vents are required in the
compartment at high and low level. These air vents must either communicate with a room or
internal space or be direct to outside air.

The minimum effective areas of the permanent air vents required in the
compartment are as follows;-

Not within 1.5m (5ft) of a

vertical surface of a

structure ≠ on the roof

Internal Route

On Ridge

Not on Ridge

Pitched

Flat

Pitch

exceeding

45º

Pitch not

exceeding

45º

At or

above

ridge
level

600 mm

(24 in)

above roof

intersection

600 mm

(2 ft)
above roof
intersection

With

parapet

Not

applicable

Without

parapet

250 mm

(10 in)

above roof

intersection

The base of
the terminal

should be

600 mm

(24 in)

above the

level of the

adjacent

roof edge

The base of the
terminal should

be 600 mm

(24 in) above

the level of

the top of the

structure

1m (3.3 ft)

above roof

intersection

1m (3.3 ft)
above roof

intersection

External

Route

Internal

Route

External

Route

Type of Roof

Within 1.5m (5ft) of a

vertical surface of a

structure ≠ on the roof

Air Vent Areas

Position of Air Vents Air from room or internal space Air direct from outside
High Level 10cm

2

per kW net 5cm2 per kW net

Low Level 20cm

2

per kW net 10cm2 per kW net

Note:- Both air vents must communicate with the same room or internal space or must both be on the

same wall to outside air.

INSTALLATION SECTION 3

AIR SUPPLY
AND
VENTILATION

13

IMPORTANT!

1. The effective area requirements specified in the table are related to the maximum
net input of the heater(s) and are equivalent to those specified in BS 6644 and
IGE/UP/10 Pt.1.

2. The free area of the grilles should not be less than the size of the recommended
ventilation opening.

3. The supply of air to a space housing the heater(s) by mechanical means should be:
(a) Mechanical inlet with natural extraction.
(b) Mechanical inlet with mechanical extraction.

NOTE! Natural inlet with mechanical extraction must not be used.

Where a mechanical inlet and mechanical extraction system is used, the design extraction
rate must not exceed one third of the design inlet rate.

All mechanical ventilation systems must be fitted with automatic gas shut off safety systems
which cut off the supply of gas to the heater(s) in the event of failure of either the inlet or
extract fans.

The requirements for air supply by mechanical ventilation are given in BS 6644 Clause 19.3.
and IGE/UP/10 Pt.1.

The permanent air vents shall be sited away from any extract fans. Where an extract fan is
fitted, check for spillage at the draught diverter as detailed in BS 5440 Part 1 Appendix B.
It may be necessary to increase the ventilation area to compensate for the extract fan.

4. The vapours emitted by halogen based compounds can, if drawn into the combustion
air, cause corrosion of the gas burner, thermocouple and storage vessel. Therefore, if
heaters are to be installed in locations where halogens are likely to be present, they
should be isolated from such compounds and ventilated from and to outside
uncontaminated atmosphere.

Some of the vulnerable areas are:
(a) Hairdressing salons and adjoining rooms and basements
(b) Establishments where dry cleaning solutions are used or stored.
(c) Degreasing plants using hydrocarbon solvents.
(d) Premises where refrigerant gases are used or stored.

INSTALLATIONSECTION 3

Where extreme conditions of water hardness exist, scale can form in any water heating
equipment, especially when the heater is working under conditions of constant heavy
demand and at high temperatures.

Each water heater is fitted with one or more magnesium anode(s) which protect the tank
from corrosion caused by electrolytic action. Magnesium anodes are sacrificial in that
they corrode as they protect. When the anode has eroded to less than 50% of it's
original diameter, it may not offer protection.The anodes should be inspected annually
and replaced as necessary. Frequency of anode replacement will vary dependent on water
quality.

Andrews Water Heaters offer CorrexTMUP powered anodes as an alternative to the
standard magnesium anodes. These anodes do not need maintenance or replacement.
The potentiostat which regulates the current to the CorrexTManode, features an indicator
light which shows green to indicate correct function and red to indicate malfunction.
An additional CorrexTMBEMS version is available, which provides a remote
warning signal.
These anodes are available as an optional extra on all Andrews heaters.

In hard water areas, scale formation can occur in hot water systems and hot water
heaters and the higher the temperature and volume of water used, the more problematic
the scale build-up can be. Water treatment is normally recommended when the hardness
reaches 100 - 150ppm (7 - 10 degrees Clark) and above. This problem can be minimised
by reducing the water temperature in the heater and by fitting suitable water pre­treatment equipment.

When installing Andrews Water Heaters in hard water areas we would recommend
that a water treatment specialist is consulted.

The following companies have supplied water treatment equipment in the UK for a
number of years to various establishments including those where Andrews water heaters
have been installed.

WATER

QUALITY AND

TREATMENT

14

WATER TECHNOLOGY LTD

Powke Lane Ind. Estate
Blackheath
Birmingham
B65 0AH

Contact

Gareth Morris
Tel: [phone]
Fax: [phone]

LIFF INDUSTRIES LTD

Bay Hall
Miln Road
Huddersfield
West Yorkshire HD1 5EJ

Contact

Ingrid Ashman
Tel: [phone]
Fax: [phone]

HYDROTEC (UK) LTD

Hydrotec House
Potts Place
West Street
Marlow
Buckinghamshire SL7 2LY

Contact

Mark Darvill
Tel: [phone]
Fax: [phone]

HYDROPATH (UK) LTD

2 Lenton Business Centre
Lenton Boulevard
Nottingham NG7 2BY

Contact

Glyn Appleby
Tel: [phone]

THE ENERGY SHOP

Thames House
89 St Leonards Road
Windsor
Berkshire SL4 3BZ

Contact

Patrick McCart
Tel: [phone]
Fax: [phone]

ECO SYSTEMS

Po Box 330
Walton on Thames
Surrey KT12 5YU

Contact

James Christie
Tel: [phone]

INSTALLATION SECTION 3

WATER
CONNECTIONS

15

Hydrojet System

The upper “jet
ports” direct the
flow outward to
begin the dynamic
mixing action.

The lower “jet
ports” direct the
flow inward to
increase the
turbulence.

The heater is fitted with the Hydrojet Total Performance System incorporated in the cold
inlet dip tube. The tube is designed to increase turbulence and reduce sediment build up,
reduce thermal stacking and increase delivery.

Mini
Hydrojet Inlet Nipple
(Side Cold Inlet
Connection)

All models now incorporate the
new Mini Hydrojet system on
cold inlet side connections.

This system ensures water is
directed onto the tank base
which minimises sediment build
up from day one of installation.

Heater Casing

Tank

INSTALLATIONSECTION 3

WATER

CONNECTIONS

16

Fig 6.

Cold Water
Inlet

T&P Valve Tapping
84/87 only

Drain & Secondary
Return Tapping

1

Hot Water
outlet

All connection sizes are
shown on page 4

T&P Valve Tapping

VENTED SYSTEMS, STANDARD RANGE

The water heater must be supplied from a cold water feed cistern and the hot water
supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and
BS 6644.

The Water Supply (Water Fittings) Regulations 1999 must be observed when installing
the system.

The cold water feed cistern must have an actual capacity greater than the hourly
recovery rate of the heater or heaters to which it is fitted, the minimum actual capacity
allowed for a feed cistern being 227 litres (50 gallons).

The actual cistern capacity is the capacity to the normal water line of the cistern.

All cisterns should be manufactured to the relevant British Standard.

The distance from the normal water line to the top of the cistern should comply with that
specified by the Water Authorities.

The cold water inlet and hot water outlet connection nipples are identified on top of the
heater.

Connect the cold water feed and hot water outlet to these nipples with union adaptors
for ease of servicing.

CAUTION!
DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED
JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS. MAKE THE CAPILLARY
JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER. A DRAIN COCK IS
SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE
BOSS AS SHOWN ON THE DRAWING.

After installation of the water system, open the main water supply valve, flush the system
and fill the heater.

Open the hot taps to allow air to escape from the system.

When the water is free of air, close the taps and check for leaks at the gas control
thermostat, drain cock and the pipe connections at the top of the heater.

All water connections for Standard Range are shown in Fig 6.

Typical water service layout for Standard Range single heater vented system is
shown in Fig. 6A.

Typical water service layout for Standard Range multiple heater vented system is
shown in Fig. 7.

INSTALLATION SECTION 3

17

Fig 6A.

Fig 7.

INSTALLATIONSECTION 3

UNVENTED SYSTEMS, STANDARD RANGE

Unvented Systems should be fitted by an Approved Installer
When used in an unvented system, the Andrews Water Heater will supply hot water at a
pressure of 3.5bar (50.8lbf/in2) provided that this pressure is available at the mains feed.
During conditions of no-flow, system pressure may rise to a maximum of 6bar (87lbf/in2)
whilst the burner is operating. When testing the system, it is recommended that a
maximum test pressure of 8.62bar (125lbf/in2) is employed.

Fig. 8
The heater can be used on unvented hot water storage systems, with the addition of an
Unvented Systems Kit, part number B171 available from Andrews Water Heaters. See Parts
List Page 51. The Wall Mounting Kit is available as an optional extra.

Item D4 must be fitted into the temperature relief port in the water heater tank.
D6 Adaptor - For use with D4 on heater models 40/61 63/62 & 84/87.
When assembling items D1 and D2, ensure that the flow arrows marked on the
components are pointing in the direction of flow i.e. towards the water heater.

The cold water for services may be drawn from the 22mm compression port on item D1
(a). The water pressure at this point will be similar to that available at the hot water outlet
of the water heater. If port (a) is not used, it should be sealed with the blanking plug
supplied.

If higher flow rates are required for the cold water services, a suitable tee fitting should be
fitted to the pipework, upstream of item D1.

The pipework fitted to the tundish outlet should be at least 28mm diameter and should be
terminated at a suitable drain (see Building Regulations 1991 Approved Document G3).

All fittings and materials must be suitable for use with drinking water and listed in the
current Water Research Centre "Materials and Fittings Directory".

Installation of unvented hot storage water systems must comply with Part G of Schedule 1
of the Building Regulations 1991.

Typical water service layout for Standard Range single heater unvented system is
shown in Fig 9.

Typical water service layout for Standard Range multiple heater unvented system is
shown in Fig 10.

WATER

CONNECTIONS

18

Fig 8.

INSTALLATION SECTION 3

WATER
CONNECTIONS

19

Fig 9.

Fig 10.

INSTALLATIONSECTION 3

VENTED SYSTEMS, Hi-Flo RANGE

The water heater must be fed from a cold water feed cistern or static water tank.

A safety valve must be fitted as specified in BS 6644 Clause 9.

The safety valve must be fitted either directly to an upper tank tapping or not further
than 1 metre along the outlet flow pipe of size not less than the safety valve.

There must be no valve separating the heater from the safety valve.

The size of the discharge pipe must be not less than the nominal size of the safety valve
outlet. It should be self-draining and any water discharged must be visible and create
no hazard to persons in or about the building.

A low pressure open vented system can be used or where the natural circulating pressure
is insufficient, pumped circulation can be employed.

The heater must be fitted with an open vent pipe which is not valved and which rises
continuously to the open vent. It should be sized with reference to Technical Data,
BS 6644 Clauses 9 and 10 and CP 342. Local Regulations and Bye-Laws must be
observed when installing the system.

Water draw-off dead legs should comply with CP 342 Part 2, Table 1 and BS 6700.

Fig. 11

Models 65/173, 81/264. Optional top inlet/outlet water connections

Select the cold/hot location required (i.e. top inlet/outlet or front inlet/outlet) and, using
a suitable jointing compound, blank off the two ports not required.

All Models. Front inlet/outlet water connections
Models 32/143. Optional rear inlet/outlet water connections

Assemble onto the 3/4 BSP thread, the 3/4 BSP coupler socket (1) and drain cock using a
suitable jointing compound. Select the Cold/Hot location required and using a suitable
jointing compound, blank off the two ports not required.

Models 32/143, 62/341, 54/418, 54/440

A 3/4 BSP thread connection is available at the top of the heater, this is suitable for a
Automatic Air Vent if required (Not supplied).

NOTE
When using a secondary return circuit, see Fig 11 for the locations of the return tappings.

It is recommended that all water connections be made to the heater(s) using union
fittings for ease of servicing. Pipe support intervals should comply with CP 342, Part 2
Table 4.

After Installation of the water system, open the main water supply valve, flush the system
and fill the heater. Open the hot taps to allow air to escape from the system. When the
system is free of air, close the taps and check for leaks at the gas control thermostats,
drain cock and pipe connections on the heater.

Typical water service layout for Hi-Flo Range single heater vented system is
shown in Fig 12.

Typical water service layouts for Hi-Flo Range multiple heater vented systems are
shown in Figs 13 and 14.

WATER

CONNECTIONS

20

INSTALLATION SECTION 3

WATER
CONNECTIONS

21

Fig 11.

Fig 12.

All connection sizes are
shown on page 5

Automatic Air Vent
32/143
62/341
54/418
54/440

Front
Cold Inlet/Hot Outlet
All Models

Drain &
Secondary Return
Tapping

Optional Rear
Cold Inlet/Hot Outlet
Tappings 32/143 only

T & P Valve Tapping

Optional Top
Cold Inlet/Hot Outlet
on models
65/173
81/264

INSTALLATIONSECTION 3

WATER

CONNECTIONS

22

Fig 13.

Fig 14.

INSTALLATION SECTION 3

WATER
CONNECTIONS

UNVENTED SYSTEMS, Hi-Flo RANGE

Unvented Systems should be fitted by an Approved Installer

When used in an unvented system, the Andrews Water Heater will supply hot water at a
pressure of 3.5bar (50.8lbf/in

2

) provided that this pressure is available at the mains feed.
During conditions of no-flow, system pressure may rise to a maximum of 6bar (87lbf/in2)
whilst the burner is operating. When testing the system, it is recommended that a
maximum test pressure of 8.62bar (125lbf/in2) is employed.

Fig. 15
The heater can be used on unvented hot water storage systems, with the addition of an
Unvented Systems Kit, part number B172 available from Andrews Water Heaters.
See Parts List Page 51. The Wall Mounting Assembly is available as an optional extra.

Item C4 must be fitted into the temperature relief port in the water heater tank.

When assembling items C1 and C2, ensure that the flow arrows marked on the
components are pointing in the direction of flow i.e. towards the water heater.

The cold water for services may be drawn from the 22mm compression port on item C1
(a). The water pressure at this point will be similar to that available at the hot water
outlet of the water heater. If port (a) is not used, it should be sealed with the blanking
plug supplied.

23

Fig 15.

C3

INSTALLATIONSECTION 3

If higher flow rates are required for the cold water services, a suitable tee fitting should
be fitted to the pipework, upstream of item C1.

The pipework fitted to the tundish outlet should be at least 28mm diameter and
should be terminated at a suitable drain (see Building Regulations 1991 Approved
Document G3).

All fittings and materials must be suitable for use with drinking water and listed in the
current Water Research Centre "Materials and Fittings Directory".

Installation of unvented hot storage water systems must comply with Part G of
Schedule 1 of the Building Regulations 1991.

Typical water service layout for Hi-Flo Range single heater unvented system is
shown in Fig 16.

Typical water service layouts for Hi-Flo Range multiple heater unvented systems
are shown in Figs 17 and 18.

WATER

CONNECTIONS

24

Fig 16.

INSTALLATION SECTION 3

WATER
CONNECTIONS

25

Fig 17.

Fig 18.

COMMISSIONINGSECTION 4

CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE
STORAGE VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER
RUNNING FROM ALL HOT TAPS.

Open the main gas supply cock after all connections to the gas control are completed
and test all connections, using proprietary leak detection fluid.

Lighting the Burner

1. Remove outer cover and slide inner cover to right. (On 63/62 and 84/87 Models, raise
the inspection port cover). Wait for 3 minutes for any unburnt gas to vent.

2. Turn the gas control knob to pilot.

3. Fully depress the gas control knob and the piezo igniter. With the pilot burner alight,
hold gas control knob in for 20 seconds. When gas control knob is released, the pilot
should remain lit. If not, repeat this operation.

4. Close and refit covers.

5. Set temperature indication dial to required temperature as follows:

Setting 0 1 2 3

Approx. Water
Temperature 104ºF (40ºC) 125ºF (52ºC) 143ºF (62ºC) 159ºF (71ºC)

6. Turn the gas control knob to ON and the burner should light. If not, wait for at
least 3 minutes and repeat from step 1.

STANDARD

RANGE

PERMANENT

PILOT MODELS

26

Fig 19.

COMMISSIONING SECTION 4

27

Fig 20.

Shutting Off The Burner

For long periods only (7 days or more) turn gas control knob to PILOT, depress slightly
and turn clockwise to OFF. Turn off the gas service cock. For shorter periods, leave the
heater under thermostat control.

NOTE! If the pilot goes out for any reason, turn off heater and wait for 3 minutes before
relighting.

Checking Main Burner Pressure

1. Turn burner OFF as above.

2. Remove brass cap from pressure adjustment port.

3. Release bleed screw A one turn and connect pressure gauge tube.

4. Light burner according to the preceding instructions.

5. Adjust burner pressure at screw B in accordance with data plate.
Turn screw clockwise to increase pressure and counterclockwise to decrease.

6. Turn burner OFF as described above. Remove pressure gauge tube and tighten
screw A.

7. Refit brass cap to pressure adjustment port.

COMMISSIONINGSECTION 4

Lighting the Burner

Open the main gas supply cock after all connections to the gas control are completed
and test all connections using a manometer. Purge air from pipework and ensure there
are no loose connections to burner or pilot pipe. NOTE! The gas control will be damaged
if inlet pressure exceeds 35mbar (14in Wg).

1. Ensure gas supply is on.

2. Turn gas control knob to PILOT position.

3. Depress knob and activate piezo igniter.

4. Keep knob pressed in for a further 40 seconds after pilot lights, then release knob and
check that pilot remains lit. If not, turn off then wait 3 minutes before repeating from
step 2. Observe via the view port.

5. Turn control knob to ON and turn control thermostat dial to required water
temperature. The burner will now light.

6. Check pilot and gas connections for soundness with leak detection fluid whilst burner
is alight. Turn off, seal any leakages, then re-test.

WARNING! if pilot goes out, do not attempt to relight gas until at least 3 minutes have
elapsed. If gas supply has been interrupted and immediately reconnected, unburnt gas
will pass into the combustion chamber due to operation of the thermopile. Do not
attempt to re-light for at least 5 minutes to allow unburnt gas to disperse. Ventilate the
area if possible.

HI-FLO RANGE

PERMANENT

PILOT MODELS

28

Fig 21.

COMMISSIONING SECTION 4

29

Fig 22.

Shutting Off The Burner

For long periods only, (7 days or more) turn control knob to PILOT, partially depress
knob, then turn clockwise to OFF. Turn off gas service cock. For shorter periods leave
heater under thermostat control.

Checking Main Burner Pressure

1. Turn gas control knob to OFF.

2. Release bleed screw A and connect pressure gauge tube.

3. Light burner as described above.

4. Remove valve cap from port B and adjust pressure using exposed screw in accordance
with data plate.
Turn screw clockwise to increase pressure and counterclockwise to decrease.
If possible, check gas rate (see Technical Data) with meter and watch.
Refit valve cap to port B.

5. Turn gas control to PILOT. Remove pressure gauge tube and tighten bleed screw A.

6. Turn gas control knob to ON and light burner as described above.

COMMISSIONINGSECTION 4

Lighting the burner

1. Ensure gas supply is on.

2. Set thermostat control knob to the required water temperature. (See below).

3. Ensure time switch if fitted is in the ON position.

4. Move electrical ON/OFF switch to ON and the burner will light.

5. Check pilot and main gas connections at gas control valve using leak detection fluid
whilst burner is alight. Turn OFF, seal any leakages then re-test.

Shutting OFF burner

To shut OFF the burner move switch to OFF then turn OFF the gas service cock.

The water heater should only be turned OFF for long periods, eg holidays, or in an
emergency. Otherwise the heater should be left to operate under normal thermostat
control.

NB. When using a time control ensure the heater is not turned OFF before the final
water draw off occurs. This will ensure the water in the tank is left in a hot condition.

STANDARD

RANGE

AUTO IGNITION

MODELS

30

Fig 23.

Thermostat Control
Knob

On/Off Switch

Gas Control valve

THERMOSTAT SETTING

APPROX WATER TEMP.

1 2 3

104ºF 40ºC 131ºF 55ºC 158ºF 70ºC

COMMISSIONING SECTION 4

31

Fig 24.

Checking main burner pressure

1. Turn gas supply OFF.

2. Release bleed screw A and connect pressure gauge tube (See Fig. 24)

3. Light burner as described previously.

4. Remove cap from port B and adjust pressure using exposed screw in accordance with

data plate (See Fig. 24)

5. Shut OFF burner as described previously. Remove pressure gauge tube and tighten

bleed screw A.

6. Re-light burner as described previously.

B

A

COMMISSIONINGSECTION 4

Hi-Flo RANGE

AUTO IGNITION

MODELS

32

Fig 25.

A

Pink MV
Black PV-MV
Purple PV

Gas control
Knob

B

Lighting the Burner

1. Ensure gas supply is ON.

2. Turn gas control knob to ON position.

3. Using control thermostat, select required water temperature.

4. Move electrical ON/OFF switch to ON. After a delay of about 10 seconds, the burner
will light.

5. Check pilot and main gas connections at gas control valve using leak detection fluid
whilst burner is alight. Turn off, seal any leakages, then re-test.

Shutting Off The Burner

For long periods only, (7 days or more) move electrical ON/OFF switch to OFF, then
turn gas control knob to OFF. Turn off gas service cock. For shorter periods, leave
heater under thermostat control.

Checking Main Burner Pressure

1. Turn gas control knob to OFF.

2. Release bleed screw A and connect pressure gauge tube.

3. Light burner as described previously.

4. Remove valve cap from port B and adjust pressure using exposed screw in accordance
with data plate.
Turn screw clockwise to increase pressure and counterclockwise to decrease.
If possible, check gas rate (see Technical Data) with meter and watch. Refit valve cap
to port B.

5. Turn gas control to PILOT. Remove pressure gauge tube and tighten bleed screw A.

6. Turn gas control knob to ON and light burner as described above.

COMMISSIONING SECTION 4

33

Check correct shape and size of Pilot Flame
No adjustment is provided for the pilot. The restrictor C on the gas control (see Fig. 22)
should be turned fully conterclockwise to the fully open position.

When viewed from the front of the heater, the pilot flame should appear as shown in the
illustration above.

Checking for Spillage at the Draught Diverter

If an extract fan is fitted, carry out a spillage check as set out in BS 5440 Part 1,
Appendix B. If spillage does occur, increase the ventilation area until the products clear
well. If an openable window is in the boiler house or room containing the heater(s), turn
on the extract fan and heater(s). Open the window fully, and, using a stiff card,
gradually reduce the opening until the appliance(s) just spills. Then increase the opening
until the products clear well. Measure the opening for the additional area required.

When satisfactory commissioning and testing has been achieved, hand this manual to the
User or Purchaser and explain the method of economic and efficient operation.

Explain that:

1. Other than for long shutdown periods, the heater must be left operating normally.

2. It is important that the control thermostat is set at the lowest temperature consistent
with the user's needs.

Ensure that the user or purchaser is fully conversant with the lighting, shutdown and
general operating procedures, including the emergency procedure. (see p.34).

Advise that any air vents must be kept clear and items must not be placed or stored in
the vicinity of the heater.

Advise of precautions necessary to prevent damage to the heater and systems in the
event of the system remaining inoperative during frost conditions.

Advise the user or purchaser that for continued efficient and safe operation of the heater,
it is important that magnesium anodes are inspected annually and that adequate servicing
is carried out at regular intervals by the installer or by the local gas authority.

HI-FLO
RANGE

PERMANENT
PILOT MODELS

INSTRUCTING
THE USER

ALL STANDARD
AND Hi-Flo
MODELS

Fig 26.

COMMISSIONINGSECTION 4

For your safety read before lighting the appliance

WARNING

1. Always follow manufacturers instructions when lighting the appliance. Failure to
do
so may result in damage to property, personal injury or loss of life

.

2. Before lighting check all round the appliance area for gas. Be sure to check at
low level because some gas (i.e. LPG) is heavier than air and will settle on the
floor.

3. Do not make

any attempt to re-light the appliance if the main burner has
extinguished. Wait at least 5 minutes to allow for any unburnt gas to disperse.
Ventilate the area if possible.

FOR YOUR SAFETY IF YOU SMELL GAS

1. Turn off gas supply and open windows.

2. Do not operate electrical switches.

3. Extinguish any naked flames.

4. Contact gas supplier if the smell of gas persists.

FOR YOUR SAFETY

Do not store or use petrol, aerosol or other flammable vapours or liquids in the
vicinity
of this or any other atmospheric gas appliance.

WARNING

Hotter water increases the risk of scalding. Before changing the temperature refer
to instruction manual or data label. Hot water can produce third-degree burns in:
6 seconds at 140ºF (60°C)
30 seconds at 130°F (54°C)

USERS

SAFETY

GUIDE

34

OPERATION SECTION 5

STANDARD
RANGE

HI-FLO
RANGE

HI-FLO AND
STANDARD
RANGE
AUTO IGNITION

35

When properly installed and adjusted, the heater will require minimal attention.
Should it become necessary to completely drain the heater, close the cold water inlet valve
and open a hot water tap to allow air to enter the system. Fit a suitable hose to the drain
cock and open.

Whenever the heater is filled with cold water, condensation will form on the storage vessel
surfaces when the burner is lit. This is normal and will disappear when the heater warms up.

The gas control fitted to the heater has a built-in limit thermostat (ECO). In the event of
high water temperature, the gas supply will be shut off automatically.
The high temperature condition must be identified and rectified before the heater is relit.
The gas control is fitted with a recycling type ECO. This means that, once the water has
cooled sufficiently, the ECO circuit will close and allow the heater to be relit.
A replacement gas control valve must be an identical model with the same code number.

Permanent Pilot Models, Operating Sequence

1. With the pilot lit, the solenoid coil holds the inlet gas port on the gas valve open.

2. The knob on the gas valve is set to the ON position.

3. The control thermostat is set to the desired water temperature, 49ºC to 82ºC (120ºF to
180ºF). To set the thermostat, remove the outer cover and turn the adjustment dial to the
required temperature.

4. The thermostat should now be in a closed position allowing the current generated by the
pilot-energised thermopile to open the main burner valve.

5. The gas valve has a slow burning feature. Burners will light several seconds after setting
the thermostat.

6. Burners will continue to heat water until the preset temperature is reached. As the
thermostat opens, the thermopile current is interrupted and the main gas valve will close.

Auto-Ignition Units, Operating Sequence. Hi-Flo and Standard Range

1. When the control thermostat senses too-cool water, a signal is sent to the control
sequence unit.

2. The flue damper unit is de-energised and thus allowed to open. (Hi-Flo only).

3. When the flue damper is fully open, gas is allowed to pass to the pilot and simultaneous
ignition begins. (Hi-Flo only).

4. When the pilot flame is established, the main gas solenoid is allowed to slowly open and
the main burners or burner is lit.

5. When the control thermostat is satisfied, both pilot and main gas solenoids are closed.

6. The damper motor is energised and the damper closes. (Hi-Flo only).

ECO (Energy Cut-Off)

The heater is equipped with an ECO (Energy Cut-Off) device, fitted to the control
thermostat. It is a temperature sensitive switch which opens at high temperature, shutting off
gas to the burners, including the pilot in an overheat condition. If the pilot goes out and is
associated with high water temperature, the ECO is probably operational and the cause of
overheating should be investigated.

Temperature Stratification (Stacking)

When small amounts of hot water are drawn repeatedly, the thermostat responds to each
feed of cold water and activates the main burners. Each time this occurs, more heat may be
put back in the tank than was drawn off. As this continues, water in the upper level of the
tank gets hotter than the thermostat setting. This hotter water does not mix completely with
the cold inlet water but rises in a 'chimney effect' to the top of the tank. Many repetitions of
this over a short time period result in accumulation of excessively hot water in the upper part
of the tank, even when the thermostat control is within limits. This is known as stacking.

To counter this condition, an upper thermostat phial is fitted (not on Model 32/143) which
senses abnormally hot water and shuts down the main burner until the water cools. Most
modern commercial pipe installations include a circulating pump which keeps hot water
moving continuously throughout the heater. This stabilises temperatures in the water heater
tank and throughout the pipe system.

SERVICINGSECTION 6

Servicing must be carried out by a properly qualified person.

Whilst giving these instructions for the care of the Heater, it is recommended that checks
are carried out by the installer or local gas authority, at least annually. Ensure good
ventilation by keeping the heater free of extraneous materials and clear of dust and lint.
Keep pipework, flue and tops of heaters clear of any combustible materials. A water
softener or lime inhibitor should be employed in hard water areas. The heater should be
inspected every few months via the hand hole cleanout and lime or silt deposits removed.
Failure to do so will shorten heater life and may invalidate the warranty.

NOTE! The cleanout hole gasket must be renewed whenever the cover is removed.

(See parts lists pages 46-49)

Before servicing, carry out the following operations.

1) Turn off the gas service cock.

2) Turn off the cold water supply to the heater.

3) Turn on the hot water draw-off taps served by the water heater, or, for multiple
installations, turn off the hot water outlet connection valve and secondary return valve.

4) Drain down using the drain valve on the heater.

The burner assembly should be checked and cleaned annually.

1. Depress gas control knob and turn to OFF. Remove outer burner cover and slide inner
door to the right. On models 63/62 and 84/87, remove two screws to release the
inner cover.

2. Disconnect pilot tube, thermocouple and main burner supply tube from bottom of control
valve. Withdraw burner assembly from heater.

3. Remove screw securing pilot assembly to main burner.

4. Remove gland nut securing pilot tube to pilot assembly. Withdraw pilot tube and remove
pilot restrictor. Clean pilot restrictor with acetone and blow through pilot burner with
compressed air.

5. Remove two screws securing main burner supply tube to bottom of burner to gain access
to main jet. Remove main jet and clean with acetone. Blow through main burner with
compressed air.

CLEAN ORIFICES WITH WOOD SPLINTER. DO NOT USE SHARP METALLIC OBJECTS.

6. Re-assemble in reverse order of steps 2 - 5, but note:
i) Be sure to engage rear section of main burner supply pipe in it's location bracket on
base pan of heater.

ii) DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION. SCREW IN FINGER
TIGHT THEN TIGHTEN A FURTHER 1/4 TURN USING A SPANNER.

III) Replace and secure inner cover with two screws on Models 63/62 and 84/87.

7. Turn gas control knob to PILOT and depress. Using leak detection fluid, check joints at
both ends of the pilot supply tube. Seal if necessary. DO NOT EXAMINE WITH A NAKED
FLAME.

8. Allow 3 minutes for unburnt gas to disperse. Light the pilot and check flame is correct.
(see Fig. 19, p26). Slide inner door to left (on Models 63/62 and 84/87, lower the
inspection port) and turn gas control knob to ON. The main burner will light.

9. Check main burner connection tube at control valve with leak detection fluid and seal if
necessary. Replace outer cover.

The burner assembly should be checked and cleaned annually.

NOTE! Models 62/341, 54/418 and 54/440 are fitted with an anchor bracket between the
burner manifold and heater body. Take out 2 screws to remove.

1. Turn gas control valve knob to OFF and disconnect union joint from gas service cock.

2. Disconnect thermostat connections (black, red and white wires) from gas control valve.

3. Remove two screws and slide out burner assembly.

4. Disconnect pilot tube and thermopile connections from gas valve. Remove two screws
and withdraw pilot/thermopile assembly.

5. Unscrew two wing nuts and remove draught shield. Remove four screws and disconnect
manifold from burner tray.

6. Clean burners by brushing internally and externally and by blowing through with
compressed air. Do not remove individual burners from the burner tray.

7. Remove the burner and pilot injectors and clean with acetone. CLEAN ORIFICES WITH

WOOD SPLINTER. DO NOT USE SHARP METALLIC OBJECTS.

INTRODUCTION

PRE-SERVICE

OPERATIONS

BURNER

ASSEMBLY

STANDARD

RANGE

BURNER

ASSEMBLY

HI-FLO RANGE

36

SERVICING SECTION 6

GAS CONTROL
VALVE

STANDARD
RANGE

GAS CONTROL
VALVE

HI-FLO RANGE

FLUE WAYS

STANDARD
RANGE

FLUE WAYS

HI-FLO RANGE

37

8. Re-assemble in reverse order but note:
i) The flueways and combustion chamber must be cleaned first.
ii) Use an approved jointing compound when re-fitting burner injectors.

9. Light heater in accordance with lighting instructions. All gas joints must be checked
using leak detection fluid. Turn off and seal any leakages.

DO NOT EXAMINE WITH A NAKED FLAME.

10. Re-light the heater and set the thermostat to the user's requirements.

The gas control valve should be checked and serviced by a qualified person, fully
conversant with this item.

The gas control valve should be cleaned and checked. Remove any debris from the valve
inlet filter using a soft brush or by blowing with low pressure air.
After servicing, check:-

1. Soundness of any gas joints broken or disturbed and seal any leaks.

2. Burner pressure/gas rate at maximum thermostat setting.

3. Operation of heater is correct. Reset controls to user's requirements.

The flue ways should be checked and cleaned annually.

1. Remove burner as described in Burner Assembly, Standard Range.

2. Remove split flue clip from flue and lift off draught diverter.

3. Inspect and clean secondary flue installation as necessary.

4. Lift out baffle from inside central flue way. (not Model 84/87)

5. Clean flue way with a brush and remove deposits from underside of storage vessel and
from flue baffle.

6. Re-assemble in reverse order. Be sure to engage rear section of main burner supply
pipe in it's location bracket on base pan of heater. DO NOT OVERTIGHTEN THE
THERMOCOUPLE CONNECTION. SCREW IN FINGER TIGHT THEN TIGHTEN A
FURTHER 1/4 TURN USING A SPANNER.

7. Re-light heater and carry out relevant commissioning procedures as detailed
in Section 4.

The flue ways should be checked and cleaned annually.

1. Remove burner as described in Burner Assembly, Hi-Flo Range.

2. Remove the split clamp and raise the flue system to clear the draught diverter socket.

3. Remove securing screws and remove top cover complete with draught diverter and
adaptor ring.

4. Remove top insulation and keep safe.

5. Remove flue collector cover.

6. Remove flue baffles and brush flue tube using 75mm diameter brush with minimum
length of 1.4m.

7. Remove deposits from tank top and burner compartment. Replace baffles.

8. Re-assemble collector cover, insulation, top cover, flue system and burner assembly.

9. Carry out relevant commissioning procedures as detailed in Section 4.

NOTE! For models 65/173 and 81/264, where top inlet/outlet connections are used,
both hot and cold connections must be disconnected before removing the top cover.

Fig 27.

SERVICINGSECTION 6

The storage vessel should be checked and cleaned annually.

Scale formation in the base of the vessel may occur, particularly in hard water areas and is
normally associated with high usage and high water temperatures. It is characterised by a
rumbling noise when the main burner is lit. Scale formation in the base of the vessel will
affect the efficiency of the water heater and reduce the life of the storage vessel.

It should be noted that the failure of the storage vessel due to scale formation on the
base will not be covered by the terms of the warranty.

Any scale formation which cannot be removed by normal means of cleaning should be
removed by chemical descaling. See below.

DESCALING

When descaling the heater, attention is drawn to the following guidelines.

CAUTION!
DUE TO THE CORROSIVE NATURE OF DESCALING FLUID, IT IS ESSENTIAL THAT
SUITABLE PROTECTIVE CLOTHING IS USED AND ADEQUATE VENTILATION
AVAILABLE.

1. Turn gas control to OFF and isolate gas supply.

2. Close water inlet valve and drain heater tank.

3. Remove magnesium anode(s). It is recommended that new anode(s) is(are) fitted.

4. Add suitable hydrochloric acid based descale fluid. The requirement is normally 5 litres
for Standard Models and 10 litres for Hi-Flo Models, or more dependant on amount of
limescale present.

5. After a minimum of one hour, restore gas supply and turn on main gas burner for 2
minutes maximum.

6. Isolate gas supply and drain descale fluid through drain port.

7. Open cold water feed valve and fill heater tank.

8. Drain and flush out heater for 20 minutes minimum.

9. Replace anode(s).

10. Restore gas supply and re-light heater.

IMPORTANT

Remove CorrexTManode(s) if fitted and plug off the connections using 3/4” BSP plugs. (Hi­Flo models only). Re-fit the CorrexTManode(s) when the descaling operation is complete.

Magnesium sacrificial anode(s) is (are) fitted to the top of the storage vessel.
The anode(s) will prevent corrosion of the storage vessel. Anode condition should be
checked annually and replaced if excessive wear is present. We recommend that the
anode(s) are replaced annually

1. Withdraw each anode using a 1

1

⁄16 in AF socket spanner. A new anode measures 21mm

diameter.

2. An anode should be replaced, if, at any point along it's length, the diameter is reduced to
half, or less of original. Particular attention should be paid to the ends.

3. If the anode is encrusted with limescale, it should be either wire brushed to reveal bright
metal or replaced.

Where CorrexTManodes are fitted, no maintenance is necessary.

Check the condition and operation of the safety valve as described below.

During Servicing

Examine the safety valve for deposits or let-by. Clean or replace as necessary.

When Re-Commissioning

Operate the safety valve, ensuring no let-by when the valve is reset and reseated.

NOTE! For adjustable valves, reduce the rating until the valve operates and gives full flow.
Reset the valve and check for let-by. For lever operation valves, operate lever and check
for let-by when reseated.

Re-light and carry out commissioning checks as detailed in Section 4, Commissioning.
Set the thermostat control to the required user setting.

CLEANING THE

STORAGE

VESSEL

ALL MODELS

MAGNESIUM

ANODE(S)

ALL MODELS

SAFETY

VALVE

HI-FLO RANGE

RESTART

ALL MODELS

38

REPLACING COMPONENTS, Hi-Flo RANGE SECTION 7

GAS CONTROL
VALVE

USER­ADJUSTABLE
CONTROL
THERMOSTAT
WITH LIMIT
SENSOR PHIAL
AND OVERHEAT
ECO

39

NOTE! Models 62/341, 54/418 and 54/440 are fitted with an anchor bracket between
the burner manifold and the heater body. Remove two screws to release the anchor
bracket.

1. Turn gas control knob and gas service cock to OFF.

2. Disconnect pilot feed pipe, thermocouple and thermostat leads from gas valve.

3. Disconnect union joint from gas service cock.

4. Unscrew two wing nuts and remove draught shield. Remove four screw located at
each end of the burner manifold and withdraw gas control/burner manifold as a unit.

5. Unscrew the control valve from the burner manifold noting position of the parts.

6. Remove gas service cock union from the control valve.

7. Re-assembly is reverse of above. The joints between the gas cock union and the
control valve to burner manifold must be made using an approved jointing compound
suitable for natural gas. The gas valve must be fitted so that it is square relative to the
centre line of the injectors.

8. Re-commission the heater as detailed in Section 4, Commissioning.

NOTE! These instructions apply to all models but Model 32/143 is not fitted with a limit
sensor phial.

1. Turn off the gas control and the service cock.

2. Drain the heater.

3. Remove front cover from control thermostat.

4. Disconnect black, red and white leads and withdraw.

5. Remove phial guard by removing two screws.

6. Remove the clips locating the thermostat capillary.

7. Unscrew gland nut securing limit phial and pull out the phial.

8. Rotate control thermostat/limit phial unit anti-clockwise using a smooth jawed spanner
and withdraw.

9. Re-assembly is reverse of above. The joint between control thermostat and tank must
be made using an approved jointing compound.

10. Re-commission the heater as detailed in Section 4, Commissioning.

REPLACING COMPONENTS, Hi-Flo RANGESECTION 7

2. Disconnect thermopile and pilot supply pipe from gas control valve.

3. Remove two screws and withdraw burner assembly.

4. Remove two screws and withdraw pilot assembly.

5. Unscrew gland nut securing thermopile to it's bracket and withdraw.

6. Unscrew pilot feed pipe nut and withdraw pipe. The pilot injector will be left in the pilot
burner and may be withdrawn by inverting the burner and allowing it to fall out.

7. Re-assemble pilot assembly and connect pilot pipe only to gas control valve with the pilot
assembly outside the heater. Turn on gas service cock. Turn gas control to PILOT and
press knob, whilst testing pilot connection at gland nut for soundness with leak detection
fluid. Seal any leakages and re-test. Turn gas control valve and service cock to OFF.

8. Re-assembly is reverse of steps 2 to 5.

9. Light the heater in accordance with lighting instructions. All gas joints must be checked
for soundness using leak detection fluid. Turn off and seal any leakages. DO NOT
EXAMINE WITH A NAKED FLAME.

10. Re-light the heater and set thermostat to user's requirements.

NOTE! Models 62/341, 54/418 and 54/440 are fitted with an anchor bracket between the
burner manifold and the heater body. Remove two screws to release the anchor bracket.

1. Turn off the gas control and the service cock. Disconnect union joint on service cock.

2. Disconnect thermostat connections (black, red and white wires) from gas control valve.

3. Remove two screws and slide out burner assembly.

4. Disconnect pilot tube and thermopile connections from gas valve. Remove two screws
and withdraw pilot/thermopile assembly.

5. Remove two screws to remove burner manifold and draught shields.

6. Remove two screws and remove burner fixing bracket.

7. Draw burner forwards to clear it's rear location slot. Replace with new burner.

8. Re-assembly is the reverse of steps 2 to 5.

9. Light the heater in accordance with the lighting instructions. All gas joints must be
checked for soundness using leak detection fluid. Turn off and seal any leakages. DO
NOT EXAMINE WITH A NAKED FLAME.

10. Re-light the heater and set thermostat to user's requirements.

THERMOPILE/

PILOT

BURNER/PILOT

RESTRICTOR

BURNER

40

FAULT FINDING SECTION 8

PERMANENT
PILOT MODELS

STANDARD AND
HI-FLO RANGES

41

FAULT ACTION

WATER DOES (a) Check gas service cock is open.
NOT GET HOT (b) Check water valves are open

(c) Check pilot is alight
(d) Check thermostat setting. reset to higher temperature)
(e) Check gas pressures at burner and at gas inlet to appliance.
(f) Standard Range. Check cold dip inlet tube for damage.

PILOT FLAME (a) Try to light burner.
FAILURE (b) Pilot will not light. Wait 3 minutes then try again.

NOTE: If pilot flame has failed and water is overtemperature,
ECO may operated. In which case, determine cause of
overheating.

PILOT WILL NOT (a) Check gas is available
STAY ON (b) Check thermopile and ECO connections. Replace if necessary.

(c) Check if inlet gas pressure is too high or too low. Pressure to

multifunctional control should be 17 mbar (7in WG) to 25

mbar (10in Wg).
(d) Pilot jet blocked. Clean or replace pilot jet.
(e) Faulty magnet coil. Replace multifunctional control.
(f) ECO safety thermostat operating at too low a temperature.

Replace faulty control.

BURNER WILL NOT (a) Thermostat setting too low.
LIGHT (b) Gas control knob not set to ON.
PILOT ESTABLISHED (c) Check thermostat for failure to close.

(d) Check gas control valve.

THERMOPILE / (a) Check pilot connection for loose joints.
THERMOCOUPLE (b) Check correct ventilation is available.
BURNS OUT (c) Check flue is clear and is correctly designed and flue terminal
FREQUENTLY is correctly positioned.

(d) Check for presence of halogen compounds.

FAULT FINDINGSECTION 8

ALL MODELS

42

FAULT ACTION

HEATER SOOTING, (a) Check gas burner pressure and injector size. If possible,
YELLOW FLAME check heat input with meter and watch.
(POOR COMBUSTION) (b) Clean burners and injectors.

(c) Flue obstruction. Clean flue ways.
(d) Check flue design and termination position.
(e) Check for correct ventilation.

WATER TEMPERATURE (a) Reset thermostat to lower temperature.
TOO HIGH (b) Thermostat faulty. Check and replace if necessary.

(c) Main gas valve not closing. Clean or replace.

WATER TEMPERATURE (a) Reset thermostat to higher temperature.
TOO LOW (b) Check gas pressures at burner and at gas inlet to heater.

(c) Thermostat faulty. Check and replace if necessary.

NOT ENOUGH (a) Check gas pressures at burner and at gas inlet to heater.
HOT WATER (b) Check amount of water being used against recovery rate

given on data plate. If usage too high, more heating
capacity needed.

WATER DRIPPING (a) Check if this stops when water in heater is hot. If yes, then
FROM BASE OF condensation is the problem caused by incorrectly designed
HEATER flue or by tank cooling excessively, i.e. more hot water

being used than recovery rate of heater. If so, more
heating capacity needed.

(b) If water continues to drip when heater is hot, problem is

leaking joint or storage vessel.

RUMBLING NOISE (a) Scale formation in heater, consult water treatment

specialist. Heater must be descaled and suitable water
treatment provided to avoid re-occurrence.

FAULT FINDING SECTION 8

AUTO
IGNITION
UNITS

HI-FLO
MODELS

43

FAULT ACTION

CONTINUOUS (a) Check gas service cock is open.
IGNITION NO (b) Check gas control knob is ON.
PILOT FLAME (c) Check ECO for failure.

PILOT LIGHTS BUT (a) Main gas valve not energised, opal light is on. Check for
MAIN BURNER loose contacts.
DOES NOT (b) Check for 24V AC at intermittent pilot ignition control

terminal No. 3. Replace control if faulty.

(c) Check for 24V AC at main gas valve terminals.

Replace valve if faulty.

FLUE DAMPER (a) Faulty damper unit- replace.
REMAINS OPEN (b) Power is being interrupted to the unit.
WHEN BURNER IS OFF

NO (a) Electrical ON/OFF switch is not ON.
IGNITION AT PILOT (b) Thermostat set too low.

(c) Power to unit interrupted.
(d) Flue damper not open - faulty unit, replace.

AUTO
IGNITION
UNITS

STANDARD
RANGE

FAULT ACTION

NO (a) Check gas service cock is open.
IGNITION AT PILOT (b) Electrical ON/OFF switch is not ON.

(c) Power to unit interrupted.
(d) Thermostat set too low.
(e) Check ECO for failure. Reset.
(f) Check for 24V AC at intermittent pilot ignition control

terminal No. 1. Replace control if faulty.

(g) Faulty Solenoid Coil. Replace if faulty.

PILOT LIGHTS BUT (a) Check for 24V AC at intermittent pilot ignition control
MAIN BURNER terminal No. 3. Replace control if faulty.
DOES NOT (b) Faulty Solenoid Coil. Replace if faulty.

PARTS LIST AND ILLUSTRATIONSSECTION 9

44

STANDARD Models

24/29, 32/40, 40/61,

63/62

STANDARD Model

84/87

A12

A4

C1

A13

A14

C5

C4

A8

A9

B11

B2

B3

B5

B7

B12

B1

C3

B13

B6

B8

B9

A10

A2

A12

A3

A1

B10

B4

B6

A15

A7

C2

A6

C3

A16

A16

63/62 only

63/62 only

A1

A3

A5A2

A1

A12

A4

C1

A2

A11

A13

A14

A15

C3

A9

A8

C8

A6

A7

A9

A8

A10

B1

B7

B13

B12

B11

B5

B2

B3

B9

B6

B8

B4

B6

B10

A16

PARTS LIST AND ILLUSTRATIONS SECTION 9

STANDARD MODELS

45

24/39 32/40 40/61 63/62 84/87

Part Numbers Description Qty

A1 C654 C654 C654 C657 C657 Adaptor Ring 1
A2 C653 C653 C655 C656 C658 Draught Diverter 1
A3 C285 C285 C285 C285 C690 Hot Outlet Nipple 1
A4 C286 C292 C293 C293 C691 Cold Inlet Dip Tube 1
A5 C641 C641 C641 C641 C641 Plug Return Connection 1
A6 C381 C381 C381 C381 C381 Drain Cock 1
A7 C103 C103 C103 C103 C103 Socket Coupler 3/4" 1
A8 C449 C449 C449 C660 C660 Cover, Combustion Chamber 1
A9 C450 C450 C451 C329 C329 Cover, Burner Access 1
A10 C701 C702 C703 C704 C705 Data Badge 1
A11 C671 C671 C672 C673 - Flue Baffle 1
A12 C333 C333 C333 C333 - Service Magnesium Anode 1
A12 - - - - C333 Service Magnesium Anode 2
A13 N/A N/A N/A C299 C299 Cleanout Pad Seal 1
A14 N/A N/A N/A C300 C300 Cleanout Pad 1
A15 N/A N/A N/A C301 C301 Cleanout Pad Cover 1
A16 C247 C247 C247 C247 - Nipple 3/4” NPT x 3/4”BSP 1
A16 - - - - C247 Nipple 3/4” NPT x 3/4”BSP 2
B1 E145 E146 E147 E148 E003 Burner Assy. comprising 1

items B2, B3, B5, B7, B12
B2 C405 C406 C406 C407 C407 Pilot Supply Pipe 1
B3 C993 C994 C994 C996 C997 Burner Supply Pipe 1
B4 C965 C965 C965 C966 C974 Multifunctional Control 1
B5 C684 C684 C684 C684 C684 Thermocouple 1
B6 C136 C136 C136 C136 C136 Pressure Test Nipple 1
B7 C679 C680 E149 E149 C683 Injector 1
B8 C382 C382 C382 C382 C382 Gas Cock 1
B9 E016 E016 E016 E016 E016 Control Knob 1
B10 C112 C112 C112 C112 C112 Knob 1
B11 E507 E507 E507 E507 C252 Pilot Burner Jet Type N18 1
B12 C685 C686 C686 C687 C688 Pilot Burner c/w Jet, Pipe 1

Electrode and Lead
B13 C514 C514 C514 C514 C514 Piezo Igniter 1
C1 C464 C465 C465 C466 C670 Top Cover Outer Jacket 1
C2 C416 C417 C417 C668 B669 Base Assy. c/w Radiation Pan 1
C3 C689 C689 C689 C689 C689 Special Screw 10
C4 C661 C662 C662 C663 C664 Combustion Chamber 1
C5 N/A N/A N/A C698 C698 Leg 3

Model
Ref.

46

PARTS LIST AND ILLUSTRATIONSSECTION 9

Hi-Flo Model

32/143

Hi-Flo Models

65/173 and 81/264

PARTS LIST AND ILLUSTRATIONS SECTION 9

HI-FLO MODELS

47

Model 32/143 65/173 81/264

Ref. Part Numbers Description Qty

A1 E023 C500 C501 Draught Divider 1
A2 C333 C333 C333 Service Magnesium Anode 2
A3 C334 C334 - Flue Connector, 150mm, BS 835 1
A3 - - C432 Flue Connector, 200mm, BS 835 1
A4 C381 C381 C381 Drain Cock, BS 2879, 3/4" 1
A5 C103 C103 C103 Socket Coupler, 3/4" 1
A6 E021 C475 C476 Data Badge 1
A7 C533 C536 C540 Flue Baffle 8
A8 C235 C235 C235 Andrews Label 1
A9 N/A C479 C479 Hot Outlet Connection, 1 1/2" BSP 1
A10 N/A E056 E055 Hydrojet Cold Inlet Connection 1

(top) 1 1/2" BSP
A11 C486 C486 C486 Top Cover 1
A12 C488 C488 C488 Insulation Pad 1
A13 E391 C489 C489 Flue Box Top Cover 1
A14 C299 C299 C299 Cleanout Pad Seal 1
A15 C300 C300 C300 Cleanout Pad 1
A16 C301 C301 C301 Cleanout Pad Cover 1
A17 C247 C247 C247 Drain Tapping Connector, 3/4 BSP 1
A19 C534 C534 C534 Nipple, 1 1/2 " BSP 4
A20 E050 E050 E050 Hydrojet Cold Inlet Connection 1

(side) 1 1/2" BSP
B1 E031 C537 C541 Burner Assy. comprising items 1

B2 - B6 and B8 - B9
B2 C503 C503 C503 Burner Bar 5
B3 C505 C505 C505 Burner Manifold 1
B4 E017 / E552 - - Injector 2.69mm (P.P.) / 2.40mm (A.I.) 5
B4 - C538 / E551 - Injector 2.87mm (P.P.) / 2.58mm (A.I.) 5
B4 - - C542 / E553 Injector 3.66mm (P.P.) / 3.25mm (A.I.) 5
B5 C507 C507 C507 Pilot Assy. c/w injector and electrode 1
B6 C508 C508 C508 Pilot Supply Pipe 1
B7 C252 C252 C252 Pilot Injector 1
B8 C552 C552 C552 Thermopile 1
B9 C511 C511 C511 Multifunctional Valve 1
B10 C512 - - Control Thermostat/Overheat ECO 1
B10 - C539 C539 Control Thermostat with remote 1

phial and ECO
B12 C513 C559 C559 Lead Assy. 1

Thermostat to Gas Valve 1
B13 C136 C136 C136 Pressure Test Nipple 1
B14 C514 C514 C514 Piezo Igniter 1
B16 C498 C498 C498 Gas Cock 3/4" BSP FxF 1
B17 E418 E418 E418 Pilot Shield 1
C1 C480 C480 C480 Flue Damper Assy. 6” 1
C2 Control Box Assy. complete 1
C8 Gas Control Valve 1
C9 C970 C969 C969 Damper Harness 1
C10 Pilot Assembly 1

P.P. = Permanent Pilot
A.I. = Auto Ignition

PARTS LIST AND ILLUSTRATIONSSECTION 9

48

Hi-Flo Models 62/341

and 54/418/440

PARTS LIST AND ILLUSTRATIONS SECTION 9

HI-FLO MODELS

49

Model 62/341 54/418/440

Ref. Part Numbers Description Qty

A! C501 C548 Draught Diverter 1
A2 C333 C333 Service Magnesium Anode 2
A3 C432 - Flue Connector, 200mm, BS 835 1
A3 - C335 Flue Connector, 250mm, BS 835 1
A4 C381 C381 Drain Cock, BS 2879, 3/4" 1
A5 C103 C103 Socket Coupler, 3/4" 1
A6 C474 C473/C492 Data Badge 1
A7 C543 - Flue Baffle 11

- C543 Flue Baffle 16
A8 C235 C235 Andrews Label 1
A11 C487 C554 Top Cover 1
A12 C488 C488 Insulation Pad 1
A13 C490 E392 Flue Box Top Cover 1
A14 C299 C299 Cleanout Pad Seal 1
A15 C300 C300 Cleanout Pad 1
A16 C301 C301 Cleanout Pad Cover 1
A17 C247 C247 Drain Tapping Connector, 3/4 BSP 1
A19 C534 C534 Nipple, 1 1/2 " BSP 4
A20 E050 E050 Hydrojet Cold Inlet Connection 1

(side) 1 1/2" BSP

B1 C544 C549 Burner Assy. comprising items 1

B2 - B6 and B8 - B9
B2 C503 C503 Burner Bar 7-9
B3 C545 C550 Burner Manifold 1
B4 C546 / E550 - Injector 3.45mm (P.P.) / 3.18mm (A.I.) 7

- C551 Injector 3.60mm (P.P.) 9

- E549 Injector 3.26mm (A.I.) 9
B5 C507 C507 Pilot Assy. c/w injector and electrode 1
B6 C547 C547 Pilot Supply Pipe 1
B7 C252 C252 Pilot Injector 1
B8 C552 C552 Thermopile 1
B9 C511 C511 Multifunctional Valve 1
B10 C539 C539 Control Thermostat with remote 1

phial and ECO

B12 C560 C560 Lead Assy. 1

Thermostat to Gas Valve 1
B13 C136 C136 Pressure Test Nipple 1
B14 C514 C514 Piezo Igniter 1
B16 C498 C498 Gas Cock 3/4" BSP FxF 1
B17 E418 E418 Pilot Shield 1
C1 C481 C482 Flue Damper Assy. 8”- 10” 1
C2 Control Box Assy. complete 1
C8 Gas Control Valve 1
C9 C969 C969 Damper Harness 1
C10 Pilot Assembly 1

P.P. = Permanent Pilot
A.I. = Auto Ignition

A11

PARTS LIST AND ILLUSTRATIONSSECTION 9

50

Unvented Systems Kit -

Hi-Flo Range

Unvented Systems Kit -

Standard Range

PARTS LIST AND ILLUSTRATIONS SECTION 9

51

Unvented
Systems Kit -

Standard Range

Ref. Part No. Description Qty

B171 Unvented Systems Kit Complete 1
D1 C780 Pressure Reducing Valve/Strainer 1
D2 C781 Check Valve / Expansion Valve 1
D3 C782 Expansion Vessel 1
D4 E462 Temperature/Pressure Relief Valve 1
D5 C783 Tundish 1
D6 C772 Adaptor 1

B173 Wall Mounting Kit for Expansion Vessel
D7 Hose Assembly 1
D8 Wall Bracket Assembly 1

Unvented
Systems Kit -

Hi-Flo Range

Ref. Part No. Description Qty

B172 Unvented Systems Kit Complete 1
C1 C784 Pressure Reducing Valve/Strainer 1
C2 C785 Check Valve 1
C3 C782 Expansion Vessel 1
C4 C380 Temperature/Pressure Relief Valve 1
C5 C384 Tundish 1
C6 C786 Expansion Valve 1

B173 Wall Mounting Kit (Optional)
C7 Hose Assembly 1
C8 Wall Bracket Assembly 1

PARTS LIST AND ILLUSTRATIONSSECTION 9

52

24 Volt Auto System

Kit B258

24 Volt Auto System

Kit B217

PARTS LIST AND ILLUSTRATIONS SECTION 9

53

Part No. Description Qty

1e (nat gas)telpmoC tiK metsyS otuA tloV402712B

C521 On/Off Switch 1

1thgiL rotacidnI sniaM146C
1EP6 Control Module

G122

E115 Transformer 1
E116 Limit Thermostat 1
E117 Control Thermostat 1

1bonK tatsomrehT lortnoC021E
G059 230 volt Gas Valve 1
E126 230 volt Solenoid Coil 2
E127 Pilot Assembly (nat gas) 1
E128 Ignition/Flame Probe 1
E135 HT Lead 24” 1

24 Volt Auto
System Kit

Standard Range

Part No. Description Qty

1 tiK metsyS otuA tloV 402852B
E839 Pilot assembly 1
C521 On/Off Switch 1
C531 Label - Andrews 1
C644 Label - Warning 1
C989 Label - On/Off 1

Label - Wiring 1

Z090 Gas Control Valve 1

1draob tiucriclortnoC966E

24 Volt Auto
System Kit

Hi-Flo Range

NOTES

54

Baxi Commercial Division

Wood Lane, Erdington,
Birmingham B24 9QP
Email: [e-mail]
www.andrewswaterheaters.co.uk

january 2011

Sales:

0845 070 1056

Technical:

0845 070 1057