andrews EC230/600, EC230/700, EC230/960, EC380/740, EC380/980 User guide

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Page 1

This manual must be kept with the appliance January 2012

Part No E864

ECOflo

Installation guide, operation and maintenance manual

High Efficiency Condensing Storage Water Heaters for Natural Gas and Propane (LPG)

EC230/600, EC230/700, EC230/960, EC380/740, EC380/980, EC380/1220, EC380/1400, EC380/1900

LEC230/600, LEC230/700, LEC230/960, LEC380/740, LEC380/980, LEC380/1220, LEC380/1400, LEC380/1900

Working towards a cleaner future

Page 2

INT ROD UCT ION

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

All installation and service on Andrews Water Heaters 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.

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

Tel: 0845 070 1055 Fax: 0845 070 1059 Email: [email protected] Website: www.andrewswaterheaters.com

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL ARE FOR USE WITH NATURAL GAS OR LPG (PROPANE) GAS ONLY

Page 3

SECTION 1 GENERAL AND SAFETY INFORMATION

General Information 4 British Standards and Codes of Practice 4 Health and Safety Regulations 1993 4 Effectiveness in Combating Legionella 5

SECTION 2 TECHNICAL DETAILS

Technical Data 6 Dimensions and Clearances 7

SECTION 3 INSTALLATION

Introduction 8

ocation 8

L Features 9–11 Component Specification 12

npacking 13

U Location 13 Gas Supply – Natural Gas 15 Gas Supply – Propane Gas 15 – 16 Electrical Supply 16 – 17 Flue System 18 – 27 Air Supply and Ventilation 28 Water Quality and Treatment 29 Water Connectors 30 – 32

CON TEN TS

PAGE

SECTION 4 COMMISSIONING

Filling the Heater with Water 33 Users Safety Guide 33 Air/Gas Mixture Adjustment 34 Natural Gas Models 34 Propane Gas Models 34 CO

Percentage 35

SECTION 5 OPERATING INSTRUCTIONS

General Instructions 36 Operating Sequence 36 Lighting Instructions 37 – 38 Temperature Stratification (Stacking) 38

SECTION 6 MAINTENANCE/SERVICE

Introduction 39 Pre-Service Operations 39 Annually 39 Maintenance Schedule 39 Correx Anodes 39 Flushing Water Heater 40 Draining Water Heater 40 Filling Water Heater 40 Sediment & Limescale 40 Replacing a Correx Anode 41 Drain Valve and Tank Access Panel 41 Cleaning the Storage Vessel 41 Restart 41 Combined Temperature/Pressure Relief Valve 42 Combustion System Inspection 42

SECTION 7 FAULT FINDING 43

SECTION 8 PARTS LISTS AND ILLUSTRATIONS 44 – 51

Page 4

SEC TIO N 1 • GENERAL AND SAFETY INFORMATION

GENERAL AND SAFETY INFORMATION

The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG 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.

BRITISH STANDARDS AND CODES OF PRACTICE

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).

LPGA Code of practice 7:

Storage of full and empty LPG cylinders and cartridges. Highly Flammable Liquids and Liquid Petroleum Gases Regulations

1972.

IGE/UP/10 Part 1 Edition 2:

Installation of Gas Appliances in Industrial and Commercial Premises.

Terms:

a. Andrews Water Heaters accepts no liability for any

damage resulting from failing to accurately follow the instructions.

b. When replacing parts during maintenance, only original

parts from Andrews Water Heaters should be used; these can be recognised by the name of the manufacturer printed on them.

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 5440:1990 Installation of flues and ventilation for gas

appliances of rated output not exceeding 60kW.

Part 1 Specification for installation of flues.

Part 2 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 6644 Installation of gas fired water boilers of

rated inputs between 60kW and 2mW

HEALTH AND SAFETY REGULATIONS 1993

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 are intended and in accordance with the instructions in this manual. Although the heaters have been manufactured with paramount consideration to safety, certain basic safety precautions highlighted in this manual must be observed by the user.

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

BS 7206:1990 Specification for unvented hot water

storage units and packages.

Page 5

EFFECTIVENESS IN COMBATING LEGIONELLA

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 Legionella 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 Legionella bacteria. These factors include stagnation, lukewarm conditions (20°C to 45°C) and the accumulation of debris, scale and corrosion in the base of tanks and calorifiers.

GENERAL AND SAFETY INFORMATION • SEC TIO N 1

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

Experiments were conducted to determine whether, following a substantial challenge by legionella pneumophilia. After overnight and stagnation, the system was rendered free from viable recoverable legionella. It was found that at 61°C, 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 legionella 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, temperatures as in the rest of the heater.

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

Page 6

SEC TIO N 2 • TECHNICAL DETAILS

TECHNICAL DETAILS

Model Reference – Natural Gas EC230/600 EC230/700 EC230/960 EC380/740 EC380/980 EC380/1220 EC380/1400 EC380/1900

Natural gas, category I ²H

Gas consumption G20

Heat input gross

Heat output

Supply pressure

Gross thermal efficiency (NG)

Model Reference – Propane LEC230/600 LEC230/700 LEC230/960 LEC380/740 LEC380/980 LEC380/1220 LEC380/1400 LEC380/1900

Propane, category I ³P

Gas consumption G31

Heat input gross

Heat output

Supply pressure

Gross thermal efficiency (propane)

Technical details (Natural Gas & Propane)

NOxLevel

Noise level (a)

Recovery rate thru’ 50°C

Storage recovery time @ 50°C rise

Concentric flue size (b)

Maximum flue run (concentric) (b)

Cold Inlet water connection

Hot outlet water connection

Drain port connection

Secondary return connection

Operating pressure (unvented)

Maximum working pressure (vented)

Maximum test pressure

Gas connection (gas cock supplied)

Electrical supply

Power consumption

Fuse

Weight empty

Weight full

Shipping weight

Shipping dimension

– depth 889mm 889mm 889mm 889mm 889mm 889mm 889mm 889mm

– width 819mm 819mm 819mm 819mm 819mm 819mm 819mm 819mm

– height 1664mm 1664mm 1664mm 2197mm 2197mm 2197mm 2197mm 2197mm

3.41m³/h 4.09m³/h 5.43m³/h 4.09m³/h 5.43m³/h 6.82m³/h 7.92m³/h 11.33m³/h

36.6 kW 43.9 kW 58.3 kW 43.9 kW 58.3 kW 73.2 kW 85.0 kW 118.7 kW

35.1 kW 41.3 kW 54.2 kW 43.0 kW 57.1 kW 71.0 kW 79.1 kW 116.0 kW

20 mbar 20 mbar 20 mbar 20 mbar 20 mbar 20 mbar 20 mbar 20 mbar

96% 94% 93% 98% 98% 97% 93% 94%

1.39m³/h 1.67m³/h 2.22m³/h 1.67m³/h 2.22m³/h 2.78m³/h 3.12m³/h 4.46m³/h

36.6 kW 43.9 kW 58.3 kW 43.9 kW 58.3 kW 73.2 kW 85.0 kW 117.2 kW

35.1 kW 41.3 kW 54.2 kW 43.0 kW 57.1 kW 71.0 kW 79.1 kW 111.2 kW

37 mbar 37 mbar 37 mbar 37 mbar 37 mbar 37 mbar 37 mbar 37 mbar

96% 94% 93% 98% 98% 97% 96% 94%

25ppm 25ppm 25ppm 25ppm 25ppm 25ppm 25ppm 25ppm

44mg/kW 44mg/kW 44mg/kW 44mg/kW 44mg/kW 44mg/kW 44mg/kW 44mg/kW

51dBA 51dBA 51dBA 51dBA 51dBA 51dBA 51dBA 51dBA

600 ltrs/hour 700 ltrs/hour 960 ltrs/hour 740 ltrs/hour 980 ltrs/hour 1220 ltrs/hour 1400 ltrs/hour 1900 ltrs/hour

23 mins 20 mins 14 mins 31 mins 23 mins 19 mins 16 mins 12 mins

100/150mm 100/150mm 100/150mm 100/150mm 100/150mm 100/150mm 100/150mm 100/150mm

16 metres 16 metres 16 metres 16 metres 16 metres 16 metres 16 metres 16 metres

1½”BSP 1½”BSP 1½”BSP 1½”BSP 1½”BSP 1½”BSP 1½”BSP 1½”BSP

¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP

3.5 bar 3.5 bar 3.5 bar 3.5 bar 3.5 bar 3.5 bar 3.5 bar 3.5 bar

10.3 bar 10.3 bar 10.3 bar 10.3 bar 10.3 bar 10.3 bar 10.3 bar 10.3 bar

20.7 bar 20.7 bar 20.7 bar 20.7 bar 20.7 bar 20.7 bar 20.7 bar 20.7 bar

¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP ¾”BSP 1”BSP

230V/50Hz 230V/50Hz 230V/50Hz 230V/50Hz 230V/50Hz 230V/50Hz 230V/50Hz 230V/50Hz

120W 120W 210W 120W 210W 210W 210W 210W

5amp 5amp 5amp 5amp 5amp 5amp 5amp 5amp

225kg 225kg 225kg 385kg 385kg 385kg 385kg 385kg

450kg 450kg 450kg 760kg 760kg 760kg 760kg 760kg

259kg 259kg 259kg 408kg 408kg 408kg 408kg 408kg

(a} Noise level measure at 2m from flue terminal.

(b) Reduce flue length by 1.2m for 90° bend, 0.7m for 45° and 1.5m for condense trap.

Page 7

TECHNICAL DETAILS • SECTION 2

ECOFLO MODELS EC230/600, EC230/700, EC230/960

359

1334

1080

1016

330

Flue exhaust/ c

ondense outlet

Cleanout a

ccess

ight side of plinth must not protrude

past edge of heater outer casing

330

150

1448

T&P Valve c

onnection

/4" BSP Gas connection

Combustion air inlet

/2" BSP Hot

water outlet

/2" BSP Cold

ater outlet

rain/secondary return connection

18 dia.

ON/OFF Switch

Thermostat knob

NB: Unit must be installed on minimum 150 mm high plinth

100 mm clearance

lue exhaust outlet

210

500mm Clearance for

flue system

/4" BSP Gas connection

Combustion air inlet

T&P Valve connection

Flue exhaust/ c

ondense outlet

Cleanout access

T&P Valve connection

/4" BSP Gas

onnection

ombustion air inlet

/2" BSP Hot

water outlet

/2" BSP Cold

water outlet

Drain/secondary return connection

ON/OFF Switch

Thermostat knob

450mm service clearance

ECOFLO MODELS EC380/740, EC380/980, EC380/1220, EC380/1400, EC380/1900

1899

1857

1588

1524

330

Flue exhaust/ condense outlet

Cleanout access

Right side of plinth must not protrude past edge of heater outer casing

330

150

1972

T&P Valve connection

/4"BSP Gas connection

Combustion air inlet

/2"BSP Hot

water outlet

/2"BSP Cold

water outlet

Drain/secondary return connection

718 dia.

ON/OFF Switch

Thermostat knob

NB: Unit must be installed on minimum 150 mm high plinth

100 mm C

learance

lue exhaust outlet

210

500mm Clearance for

flue system

/4"BSP Gas connection

Combustion air inlet

T&P Valve connection

Flue exhaust/ condense outlet

Cleanout access

T&P Valve connection

/4"BSP Gas connection

Combustion air inlet

/2"BSP Hot water outlet

11/2"BSP Cold water outlet

Drain/secondary return connection

N/OFF Switch

Thermostat knob

50mm service clearance

Page 8

SEC TIO N 3 • INSTALLATION

INSTALLATION

INTRODUCTION

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 Supplier, Local Authority, Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1.

LOCATION

The location selected for installation of the water 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 plant room should be installed in the gas supply; it should be clearly identified and readily accessible for use at all times.

weight of the heater when filled with water, and should satisfy the requirements of the Local Authority & Building Regulations.

Any combustible material adjacent to the heater must be placed and shielded as to ensure that its temperature does not exceed 66°C (150°F).

All service clearances for the water heater must be maintained as specified in this Installation Manual.

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

The water heater must not be installed in any location which contains a bed, bath or shower. There must be easy access to the plant room and water heater at all times.

The water heater must be located in an area where leakage from the tank, water connections or the combination temperature and safety valve will not result in damage to the area adjacent to the water heater. When such locations cannot be avoided, a suitable drain tray must be installed under the water heater. The drain tray must be no deeper than 38mm (1.5in) and have a minimum length and width of 100mm (4in) wider than the heater. The drain tray must be piped to an adequate drain using 20mm (0.75in) diameter pipe, angled for proper drainage.

Access must be provided around the water heater to provide adequate clearance for its servicing and operation.

The floor and plinth on which the heater is installed must be flat, level and of sufficient strength to withstand the

Page 9

INSTALLATION • SECTION 3

FEATURES

ECOflo is the latest addition to the Andrews range of condensing storage water heaters and is designed for large domestic, commercial and industrial applications.

The high efficiency units incorporate Vitraglas

silica glass lined tanks to provide protection against the corrosive effect of hot water and therefore a longer working life.

The condensing glass-lined ultra high thermal efficiency storage water heater features a low NO

pre-mix power burner that is quiet in operation, a 98% gross efficiency that keeps running costs to a minimum and flueing arrangements that offer unsurpassed installation flexibility.

ECOflo – A NEW STANDARD IN CONDENSING STORAGE WATER HEATING

The ECOflo range comprises eight models in two storage capacities – 230/380 litres – with heat outputs ranging from 35kW to 79kW and recovery rates of up to 1400 litres/hour through a temperature rise of 50°C. A thermal efficiency rate of up to 98% gross puts ECOflo at the top of the class and leads to greater economy. In addition to outstanding performance characteristics, all ECOflo models can be flued either vertically or horizontally as room sealed balanced flue appliances, using concentric flue components supplied by Andrews, offering the ultimate in siting and installation flexibility. All models incorporate Correx Powered (maintenance free) Anodes as standard which substantially reduce service time and costs. The factory fitted Hydrojet® sediment reduction system on the cold inlet connection helps to prevent sediment build-up at the base of the tank, giving a longer and more efficient working life.

INSTALLATION

This water heater contains the following features:

MAIN POWER ON/OFF SWITCH

The front panel of this water heater has an illuminated ON/OFF switch, which is lit when the main power is turned on to indicate power to the water heater.

COMBUSTION SYSTEM

The ECOflo is equipped with a self-compensating, negative pressure pre-mix combustion system. As the blower operates, air is drawn in through the air intake and into a venturi, which pulls gas from the gas valve. The gas and air is then mixed in the combustion blower and sent

through the transition tube into the burner. The Hot Surface Ignition System (HSI) then ignites the gas/air fuel mixture to produce the flue products (combustion). The flame sensor signals the ignition module, (described below) that a flame is present.

IGNITION MODULE

The ignition module provides the timing for the combustion system. A sequence of operation (SOP) is described in “Section 5 – Operating Instructions.” As the combustion system progresses through the SOP, LED’s illuminate, allowing accurate trouble-shooting should the need arise. If a failure occurs, the system will “blink” the LED that corresponds to the failure as described in the “Section 6 – Troubleshooting Guide.”

ADJUSTABLE THERMOSTAT

The ECOflo is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for kitchen sinks, sluices, cleaners’ sinks and washdown applications can cause scald burns resulting in serious personal injury and/or death.

The temperature may be adjusted from approximately 27°C to 82°C. It is recommended that lower temperatures be used to avoid the risk of scalding. (Refer to the “Warnings” and the section on SCALDING in “Section 3 – Water Connections.”) It is further recommended, in all cases, that the water temperature be set for the lowest temperature, which satisfies hot water needs. This will also provide the most energy efficient operation of the water heater and minimises scale formation.

The top immersion well of the single bulb controller also contains the high limit (energy cut-off) sensor. The high limit switch interrupts the main burner gas flow should the water temperature reach approximately 93°C.

Should the high limit switch activate, it must be manually reset. This can be accomplished by depressing the red button on the control panel once the water temperature of the tank has dropped below 71°C.

Please contract Andrews Water Heaters (details listed on the Data Plate) if continued high limit switch operations occur.

CONDENSATE DRAIN

The ECOflo is a condensing type unit and requires a drain to be located in close proximity to allow the condensate to drain safely. The condensate drains from the unit at the base of the exhaust tee piece located near the bottom of the unit. The exhaust tee is provided with a 32mm dia connection. A condense siphon is supplied in the flue kit which should be connected to the 32mm connection at the base of the exhaust tee. The siphon outlet must be connected to a 40mm dia OD plastic waste system. If the

Page 10

SEC TIO N 3 • INSTALLATION

condense is allowed to build-up then the exhaust outlet will become blocked and cause improper operation of the water heater. The water heater will need to be raised off the floor, on a concrete slab or base, to utilise a low profile condensate pump to allow free drainage of condensate from the outlet fitting. The condensate plastic drain pipe installation should slope to a suitable drain.

CLEANOUT

All models are equipped with a cleanout opening to aid the removal of hard water deposits from the tank bottom. If this water heater operates under hard water conditions, the following should be performed at least every 3 months: Turn off water supply and drain the water heater. Remove the cleanout jacket cover and tank cover. When cleaning the tank, care must be taken to avoid trying to break deposits loose as this could damage the glass lining and shorten the life of the water heater. After cleaning, re-install the cleanout tank cover and jacket cover, and refill with water. Refer to the section, “Section 6 – Maintenance” in this Installation and Operating Instruction manual for the procedures for filling and draining the water heater.

ELECTRICALLY POWERED ANODES

All models are supplied complete with Andrews’ Correx Powered Anode system. The anodes are non-sacrificial and therefore do not require any maintenance or replacement. For this reason, the service clearance required above the water heater can be reduced quite significantly. Correx anodes require a permanent power supply, this is all pre-wired and the anode system can be located at the top of the heater, beneath the top cover.

SERVICE PANEL

The service panel is located behind the service panel access cover, which is located by the exhaust outlet tee piece near the bottom of the water heater. This panel contains a pressure switch to monitor for excess pressure in the exhaust pipe from a blocked vent condition. A collector high limit switch is used to monitor the ambient temperature between the first pass collector and the exhaust collector. This is a manually re-settable switch. If this switch continues to trip, please contact Andrews Water Heaters.

TECHNICAL DETAIL

Thermal Efficiency up to 98.0% – Fully condensing design.

Three Pass Flue System – The three pass flue system keeps the hot combustion gases moving at a high velocity. The combination of high turbulence and velocity causes an enormous rate of heat transfer into the water.

Low NOx Premix Power Burner – Developed for the ECOflo Range, a turbulent flame shoots down the submerged combustion chamber. This turbulence causes a thorough mixing of the gas and air for optimum combustion and high heat transfer efficiencies.

Submerged Combustion Chamber – Submerging the combustion chamber in the centre of the water storage tank minimizes radiant heat loss and improves efficiency.

Non-CFC foam insulation – Surrounds the tank surface, saving energy by reducing heat loss.

Electronic Controls – Adjustable electronic thermostat 27°-82°C recycling Energy Cut Off (E.C.O) shuts off all gas in event of an overheat condition.

Zero Inch Clearance – The ECOflo external jacket is cool to the touch and is approved for zero inches to combustibles for unsurpassed installation flexibility.

Vitraglas

lined tank – Andrews Water Heater tanks are

protected from the corrosive effects of hot water by an exclusive ceramic porcelain-like coating. Our high silica Vitraglas® lining provides a tough interior surface.

Electrically powered anodes – Each ECOflo product is supplied with a factory fitted Andrews Correx Powered Anode system. This significantly reduces service time due to the anodes being maintenance free.

Factory installed Hydrojet

Sediment Reduction

System – Cold inlet sediment reduction device made of

stainless steel for increased durability. Helps prevent sediment build up in tank.

ACCESS LID

Access for servicing the water heater from the top is easy. Remove the two latches and the metal screw at the front centre of the top to remove the lid for accessing the heater controls. The lid must be replaced and re-latched upon completion of servicing.

Factory installed dielectric fittings – All heaters are equipped with special water heater nipples for longer heater life. No special dielectric fittings to buy.

Flexible Venting – The ECOflo range can be flued vertically or horizontally with the Andrews 100/150mm concentric flue pipe system.

The maximum flue run length is sixteen metres from the appliance connector to the terminal.

Page 11

The overall length is reduced if an elbow or condensate trap is fitted (see below).

Determining required flue length –

1. Determine the total length of straight concentric flue pipe (in metres) required for the installation.

2. Add 1.2 metres of flue for every 90°C elbow.

3. Add 0.7 metres of flue for every 45°C elbow.

4. Add 1.5 metres for condensate trap.

5. Total flue length cannot exceed “Maximum Length” in the above paragraph.

NOTICE: Do not include the flue terminals in determining maximum flue installation length.

Three year limited warranty on storage tank

– Heavy gauge steel automatically formed, rolled and welded to assure a continuous seam for glass lining.

INSTALLATION • SECTION 3

One year limited warranty on parts

Page 12

SEC TIO N 3 • INSTALLATION

IGNITION SYSTEM COMPONENTS

Fenwal 35-655305-121 Hot Surface Ignition Control, CE listed. 3 Trials for Ignition, 15 second pre-purge timing, 15 second igniter heat up time, 4 second trial for ignition, 24 volt input to control.

Omron G2R-1A-T-AC24 relays (VDE listed) used for high voltage switching of hot surface igniter and combustion blower from the 24 volt outputs of the Fenwal control.

Saint Gobain 230 volt hot surface mini igniter.

Honeywell VK8115 gas valve (negative pressure regulator) with matched venturi sizes for mixing gas with combustion air.

EBM RG130 (36-6 and 43-9 kW/hr input sizes) and RG148 (58-3 through 85-0 kW/hr. inputs) pre-mix combustion blowers. 230 volts, 50/60 Hz.

Burner: Acotech (Bekaert Combustion Technology) Premix burner with stainless steel mesh outside knit.

Blocked Vent Pressure Switch: Honeywell IS20378-5770 normally closed pressure switch. Contacts open in the event of a severe blockage of the flue outlet.

2nd Pass Flue Collector: At the top of the tank, the flue gases from the 4” flue tubes collect in a heavy gauge steel collector to redirect the flue gases down eight 2” diameter flue tubes.

2” diameter flue tubes are glass lined on the inside as well as outside to prevent corrosion from flue gas condensate. Stainless steel flue baffles inside the 2” flue tubes turbulate the flue gases to aid heat transfer. Flue temperatures are reduced from 260-340°C from the second pass collector to 54°C or less in the flue exhaust.

3rd Pass Collector: The flue gases from the bottom of the 2” flue tubes are collected at the bottom of the tank in a stainless steel flue collector, where the exhaust gases and condensate exit out through a short Stainless Steel pipe extending outside the jacket that connects to the coaxial concentric flue system.

VENTING SYSTEM

A condensate tee with a silicone seal is connected to the plastic exhaust pipe and interfaces with the flue system. The tee connection has a 32mm condensate drainpipe connection to allow the siphon to be fitted. The waste pipe will then be taken from the siphon outlet to drain.

THERMOSTAT AND HIGH LIMIT CONTROLS

Honeywell L6189A 2043B aquastat. Temperature adjustment range: Below 40°C to maximum of 82°C (dial stop to limit maximum temperature). Differential set to 4°C Capillary bulb inserts into well in top of tank. Thermostat dial adjustable on top front section of water heater jacket.

Honeywell L6189C 2023 1 High limit control. Set point fixed to 93°C with screw. Mounted to control panel inside control compartment. Capillary bulb inserts into separate well in top of tank. Manual reset control button accessible through clearance hole in control panel.

HEAT EXCHANGER

Burner fires down into 8” diameter flue tube transferring the radiant heat from the burner flame into the tank water.

1st Pass Flue Collector: At the bottom of the tank, a refractory lined heavy gauge flue collector re-directs the flue gases from the 8” flue tube to pass through two 4” diameter flue tubes to the top of the tank.

4” diameter flue tubes have stainless steel baffles to turbulate the flue gases to improve heat transfer.

A section of aluminium flue pipe will run to the top of the water heater to connect to the air intake tee.

The intake tee adapts to the concentric flue pipe and has an elbow to connect to the combustion air intake pipe.

The 100/150 mm dia. Andrews’ concentric flue pipe will then run to the horizontal or vertical flue terminal.

Maximum concentric flue for this product is 16 metres. Each additional 90° elbow is equivalent to a reduction of

1.2 metres of straight flue pipe.

Each additional 45° elbow is equivalent to a reduction of

0.7 metres of straight flue pipe. If a condensate trap is installed, this is equivalent to a reduction of 1.5 metres of straight flue pipe.

WATER CONNECTIONS

Front hot and cold 1½” BSP (male) water supply connections.

GAS CONNECTIONS

¾” Gas Inlet Nipple for BSP connection to gas supply. 1” Gas Inlet Nipple for BSP connection to gas supply for the EC380/1900 model.

Page 13

INSTALLATION • SECTION 3

UNPACKING

INSPECT SHIPMENT CAREFULLY FOR ANY SIGNS OF DAMAGE

1. All equipment is carefully manufactured, inspected

and packed.

2. Any claims for damage or shortage in shipment must

be filed immediately with Andrews Water Heaters as detailed on the warranty card.

LOCATION

Locate water heater in front of final position before removing crate.

1. LOCATE so the flue installation connections will be as

short and direct as possible

2. THIS WATER HEATER IS NOT SUITABLE FOR

INSTALLATION ON A COMBUSTIBLE FLOOR. Do not install this water heater on carpeting.

3. FOR EVERY INSTALLATION, provide a solid level

elevated base such as concrete or other suitable pad to raise the water heater at least 150mm to provide a slope for the condensate waste to run to a suitable drain.

4. Minimum clearance to combustible material is 0” for

the Top, Sides and Rear of this water heater. However, it is recommended that at least 450mm from the Top, 600mm from the Front, 100mm from the Left Side and Rear, and 500mm from the Right Side edge of the water heater be provided for servicing and ease of installation. See Section 2, page 5 for diagram. Clearance for servicing may be reduced down to minimum clearance to combustible material, but service time and effort may be greatly increased.

REMOVE CRATE

1. Remove all banding and pry off crate sides carefully

so as not to damage the water heater.

2. Carefully roll/lift the water heater from the crate base.

MOVE WATER HEATER TO PERMANENT POSITION

by sliding or walking. Place on plinth/base as detailed previously.

LOCATION

KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, PETROL AND OTHER FLAMMABLE VAPOURS AND LIQUIDS.

This water heater MUST be installed indoors.

This water heater MUST be located in an area where the general public does not have access.

CHEMICAL VAPOUR CORROSION

Corrosion of the internal flue ways and concentric flue system will occur if air for combustion contains certain chemical vapours. Such corrosion may result in poor combustion and create a risk of asphyxiation, as well as reducing the life of the water heater. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals are corrosive. Products of this sort should not be stored near the water heater or outside by the air intake (if applicable).

SCALDING

This water heater can deliver scalding temperature water at any outlet in the system. Be careful whenever using hot water to avoid scalding injury. To protect against injury, you should install approved mixing valves in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

CAUTION

Do not drop water heater. Do not bump water

heater jacket against floor.

Do not bump exhaust flue pipe against crate or

other objects. This will damage the heater and

cause it to be inoperable or create nuisance

problems.

Page 14

Regulator set to give 37 mbar (14.86" wg) propane

as emergencey

ontrol at entry

1" Heavy steel sleeved pipe t

hrough wall

Steel liner sealed to pipe at inside end

Gas cock

egulator

ormally fitted at

ank

BULK SUPPLY TANK

Pigtail assembly

Automatic change-over device

Nipple

Propane cylinders must be outside the building

Cylinder regulator set to give 37 mbar (14.86" Wg) propane

Gas emergencey control at entry

1" heavy steel sleeved pipe through wall

Steel liner sealed to pipe at inside end

Gas cock

SEC TIO N 3 • INSTALLATION

TYPICAL PROPANE BULK STORAGE TANK INSTALLATION

Fig. 1

TYPICAL PROPANE CYLINDER INSTALLATION

Fig. 2

Important: These drawings show a schematic representation only and should not be used for installation purposes. Contact your gas supplier for authorised installation drawings.

Page 15

INSTALLATION • SECTION 3

APPROXIMATE TIME/TEMPERATURE SCALD CHART

The following chart details the relationship of water temperature and time with regard to scald injury. This may be used as a guide in determining the safest water temperature for the installation.

APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

8.8°C More than 5 minutes

51.6°C 1½ to 2 minutes

54.4°C About 30 seconds

57.2°C About 10 seconds

60.0°C Less than 5 seconds

62.8°C Less than 3 seconds

65.6°C About 1½ seconds

68.4°C About 1 second

CAUTION

The water heater and individual shutoff valve

must be disconnected from the gas supply

piping system during any pressure testing of the

system at test pressures in excess of

35mbar/14.0 in wg. The water heater must be

isolated from the gas supply piping system by

closing its manual shut off valve during any

pressure testing of the gas supply system at test

pressures equal or less than 35mbar/14.0 in wg.

The supply line must be capped when not

connected to the water heater.

GAS SUPPLY – NATURAL GAS

The installation of the gas supply must conform, depending on its 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 its authorised contractor.

The meter and service pipe should be checked by British Gas, or its 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.

Fit the service gas cock (supplied) to the gas connection on top of the water heater using a suitable jointing compound and connect to the gas supply.

The water heater is not intended for operation at higher than 35mbar (14.0 in wg) supply gas pressure. Higher gas supply pressures require supplemental reducing service regulator. Exposure to higher gas supply pressure may cause damage to the gas controls, which could result in fire or explosion. If overpressure has occurred, such as improper testing of gas lines or emergency malfunction of the supply system, the gas valve must be checked for safe operation.

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

GAS METER SIZE NATURAL GAS ONLY

Be sure that the gas meter has sufficient capacity to supply the full rate gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter. If the gas meter is too small, ask the gas company to install a larger meter having adequate capacity.

GAS PRESSURE REGULATION

Main line gas pressure to the water heater should be maximum 35mbar/14.0 in wg. The inlet gas pressure must not exceed the maximum value. In some installations, a regulator sized for the input rating of the water heater will need to be installed just ahead of the inlet gas connection to the water heater to reduce excess gas pressure or surges in gas pressure.

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.

GAS SUPPLY – PROPANE

Contact Calor Gas who will provide the appropriate type and size of LPG supply vessel and ensure its safe location and installation.

The installation of the gas supply must conform to LPGA Code of Practice, 22 LPG Piping Systems: Design and Installation, plus the requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

Andrews Water Heaters are unregulated and a second stage regulator must be installed to give an inlet pressure to the appliance as follows:

Page 16

SEC TIO N 3 • INSTALLATION

PROPANE: 37mbar (14.86 in wg)

LECTRICAL SUPPLY

hen using propane cylinders, connect a minimum

W number of 47kg cylinders, as listed below, together with a manifold before connecting to the union.

Use a minimum pipe size of ¾in bore.

wo 47kg Cylinders LEC230/600, LEC230/700

and LEC380/740

Three 47kg Cylinders LEC230/960 and

EC380/980

Four 47kg Cylinders LEC 380/1220 and

LEC380/1400

EC 380/1900

WARNING! PROPANE CYLINDERS MUST BE USED AND STORED IN ACCORDANCE WITH ‘THE HIGHLY FLAMMABLE LIQUIDS AND LIQUIFIED PETROLEUM GASES REGULATIONS 1972’, AND SHOULD COMPLY WITH LPGA CODE OF PRACTICE 7, ‘STORAGE OF FULL AND EMPTY LPG CYLINDERS AND CARTRIDGES’.

External wiring to the water heater(s) must be installed in

ccordance with current I.E.E. Regulations for the wiring

a of buildings and to any Local Regulations that may apply.

he ECOflo range is designed to operate from a 230V,

T single phase supply. The fuse rating is 5 amps.

he method of connection to the mains electrical supply

T should facilitate complete electrical isolation of the appliance, preferably by use of a fused double pole

witch or fused spur box serving only the heater. The

s disconnection of the supply shall have a contact separation of 3mm on all poles. The double pole switch

or the water heater electrical supply must be located

f where it can be easily reached under all circumstances.

The point of connection to the mains electrical supply should be readily accessible through a cable entry gland at the rear of the appliance on the combustion assembly surround.

Connect the electrical supply to the main control panel terminal block via the cable gland. Mains input cable should be 0.75mm² 3 core and should be connected to the mains supply as detailed above.

Mains Voltage: 230V – IP 20 Frequency: 50Hz Fuse: 5 Amps

Page 17

INSTALLATION • SECTION 3

Schematic

N.O.

Igniter relay

WBK

Flame sensor

Combustion blower relay

Blocked exhaust

P.S. N.C.

Collector limit N.C.T Stat ECO

Igniter relay coil

Combustion blower

230V

24V

Anodes

ON/OFF

Switch

GND

LED

MW1

HSI Control

Fenwal 35-309-121

Gas valve

Toggle switch light

N.O.

Igniter

Blower relay coil

Wiring diagram

GN/Y

N/Y

Y/BK

BLBL

GN/Y W

30V

.B.

orrex powered

anode control

Igniter 230V

Flame sensor

lower relay

Blocked exhaust

.S.

Collector limit

T Stat High limit

as valve

gniter relay

round T

.B.

ransformer

ombustion blower

230V

24V

4V 24V

Powered anodes

N/OFF

witch

GND

HSI Control

Fenwal 35-309-121

Page 18

SEC TIO N 3 • INSTALLATION

FLUE SYSTEMS

onventional Flue Option

Andrews Water Heaters’ ECOflo is a Balanced Flue, Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere. The flue system is a single concentric (pipe within pipe) design where the flue products are discharged through the inside flue tube and the combustion air supply surrounds the flue surrounded by the outside pipe. The flue system incorporates both combustion air supply and the flue exhaust. The flue system component which is outside the building, takes in the combustion air supply and discharges the flue products (whilst keeping them separate) is referred to as the ‘direct flue terminal’.

WARNING!

The direct flue systems MUST be properly installed. Failure to do so could results in property damage or personal injury. DO NOT install any damaged components. Contact Andrews Water Heaters for replacement parts. The flow of combustion air must not be restricted. Keep direct flue terminal openings clear of any objects likely to cause flow restriction.

Direct Flue Terminal

Shall terminate at least 1.5m (5ft) above any forced air inlet located on the same wall. This provision does not apply to the combustion air intake of a direct flue appliance or the circulating air inlet and flue gas discharge of listed outdoor appliances.

Shall be installed with at least a 300mm (12in) flue termination clearance from any air opening into a building.

The bottom of the direct flue terminal shall be located at least 300mm (12in) above ground.

Consideration should be given to the location of the flue terminal. The flue terminal should be located where the discharge of flue products does not cause a nuisance. Consideration should also be given with regard to noise that may be emitted by this flue system. In all cases the flue termination must meet the requirements of BS6644.

fresh air ducting (150mm) direct

Combustion via “T” piece

from outside, terminating with a suitable

xhaust

00mm

terminal.

The maximum ‘combined’ flue run is 32 metres.

NB: 100 mm flue section NOT available from BAXI Commercial.

Vertical option, maximum

verall run is 32 meters

The use of 90° and 45° bends will reduce the allowed overall length by 1.2m per 90° and 0.7m per 45° bend used along the flue run.

NOTE: The overall length does not include the 1m terminal. The 1m terminal is not to be included in determining the overall length of the flue.

Maximum Flue Distances (Horizontal or Vertical)

Number of 90° Elbows Maximum length of straight

pipe (excluding flue terminal) to exterior wall

0 16m (52ft 6in)

1 14.8m (48ft 6in)

2 13.6m (44ft 7in)

3 12.4m (40ft 7in)

NOTE: Each 45° elbow reduces the maximum flue distance by 700mm (2ft 3in).

IMPORTANT:

Do not exceed the flue distances or the number of elbows listed above. This may cause heater malfunction or unsafe conditions.

A suitable terminal guard must be fitted if less than 2 metres above ground level.

OPTIONAL CONVENTIONAL FLUE (OPEN FLUE)

This is an open flued arrangement where the air is drawn into the appliance from within the plant room (boiler house). Permanent ventilation is required to allow correct operation of the appliance (refer to BS 6644). Alternatively, the ventilation can be supplied by running

Page 19

HORIZONTAL AND VERTICAL FLUE KITS

INSTALLATION • SECTION 3

INSTALLATION PROCEDURE

2. Determine if additional flue components are required

for installation. Refer to the flue component information

Determine location of flue exit.

on pages 21 and 55 for available optional flue components.

1. The Horizontal or Vertical flue kit that has been delivered includes the components as listed below and on page 21. The concentric flue pipe system includes both the flue exhaust (inside pipe) and combustion air

3. Ensure that the flue terminal location complies with requirements described within this manual and the Local Codes of Practice.

(outside pipe). The flue pipe may be cut on the unflared end (end without gasket) as required for installation.

4. Measure the vertical and horizontal distance from the water heater flue connection to determine the number of components required.

HORIZONTAL FLUE KIT/FITTINGS PACK – 230 LITRE MODELS AWH PART No: B291 SUPPLIED COMPONENTS

Part Description Part Number

Exhaust Outlet Tee c/w Condense Outlet (82500) E860

100mm to Concentric Exhaust Connector (75412) E861

Air intake Tee Piece Connector (82501) E862

Condense Syphon (87436) E863

Horizontal Flue Terminal, 100/150mm (87990) E236

90° Elbow c/w clamp, 100/150 (87890) E205

Gas Cock – ¾”BSP C498

Drain Valve – ¾”BSP C381

Drain Valve Socket – ¾”BSP C103

Installation, Operation and Maintenance Manual E864

VERTICAL FLUE KIT/FITTINGS PACK – 230 LITRE MODELS AWH PART No: B293 SUPPLIED COMPONENTS

Part Description Part Number

Exhaust Outlet Tee c/w Condense Outlet (82500) E860

100mm to Concentric Exhaust Pipe (75412) E861

Air intake Tee Piece Connector (82501) E862

Condense Syphon (87436) E863

Vertical Flue Terminal, 100/150mm (87969) E866

Gas Cock – ¾”BSP C498

Drain Valve – ¾”BSP C381

Drain Valve Socket - ¾”BSP C103

Installation, Operation and Maintenance Manual E864

Page 20

SEC TIO N 3 • INSTALLATION

VERTICAL FLUE KIT/FITTINGS PACK – 380 LITRE MODELS AWH PART No: B292 SUPPLIED COMPONENTS

Part Description Part Number

xhaust Outlet Tee c/w Condense Outlet (82500) E860

100mm to Concentric Exhaust Pipe (75413) E865

Air intake Tee Piece Connector (82501) E862

Condense Syphon (87436) E863

Horizontal Flue Terminal, 100/150mm (87990) E236

90° Elbow c/w clamp, 100/150 (87890) E205

Gas Cock – ¾”BSP C498

Drain Valve – ¾”BSP C381

Drain Valve Socket – ¾”BSP C103

nstallation, Operation and Maintenance Manual E864

VERTICAL FLUE KIT/FITTINGS PACK – 380 LITRE MODELS AWH PART No: B294 SUPPLIED COMPONENTS

Part Description Part Number

Exhaust Outlet Tee c/w Condense Outlet (82500) E860

100mm to Concentric Exhaust Pipe (75413) E865

Air intake Tee Piece Connector (82501) E862

Condense Syphon (87436) E863

Vertical Flue Terminal, 100/150mm (87969) E866

Gas Cock – ¾”BSP C498

Drain Valve – ¾”BSP C381

Drain Valve Socket – ¾”BSP C103

Installation, Operation and Maintenance Manual E864

FLUE SYSTEMS

Optional Components for 100/150mm dia (concentric) Flue

Quantity Flue Length Part Description Part Number

1 1000mm (40in) Flue pipe with clamp E202

1 1000mm (40in) Cutable flue pipe with clamp E203

1 500mm (20in) Flue pipe with clamp E204

1 90° Elbow E205

1 45° Elbow E206

1 Flat roof flashing for vertical flue terminal with adjustable cap E207

1 Roof flashing for pitched roof to suit 150mm (6in) dia flue size E208

1 Wall clamp 150mm (6in) dia. E209

1 Flue condense trap E210

1 Syphon E211

1 Condensate trap pipe kit to syphon E261

Model EC230/600 EC230/700 EC230/960 EC380/740 EC380/980 EC380/1220 EC380/1400

Flue size (concentric) mm 100/150 100/150 100/150 100/150 100/150 100/150 100/150

Max flue run – room sealed (a) m 16 16 16 16 16 16 16

Reduce flue length by 1.2m for 90° bend, 0.7m for 45° bend and 1.5m for a condensate trap.

The ventilation requirements for room sealed flue systems are given on pages 29 and 30.

Page 21

INSTALLATION • SECTION 3

ECOflo 380/1900

HORIZONTAL FITTINGS PACK – Part No: B292

Part No. Description Qty

E910 Concentric measure point 1

860 Exhaust outlet Tee 1

E865 100mm concentric exhaust pipe 1

E862 Air intake “T” piece 1

E863 Condense syphon 1

E236 Horizontal terminal 100/150 mm 1

E205 90º elbow/clamp 1

G167 1" BSP M&F gas cock 1

G028

G029

C103AWH

⁄2" Drain cock 1

⁄4" x1⁄2" reducing bush 1

⁄4" drain valve socket 1

ECOflo 380/1900

VERTICAL FITTINGS PACK – Part No: B294

E910 Concentric measure point 1

E860 Exhaust outlet Tee 1

E865 100mm concentric exhaust pipe 1

E862 Air intake “T” piece 1

E863 Condense syphon 1

E866 Vertical terminal 100/150mm 1

G167 1" BSP M&F gas cock 1

G028

G029

C103AWH

GENERAL

⁄2" Drain cock 1

⁄4" x1⁄2" reducing bush 1

⁄4" drain valve socket 1

The terminal must be fitted with a guard if less than 2m

above ground level or in a position where it may cause Flue terminals must be installed in accordance with the Clean Air Act to ensure the results of combustion are properly dispersed. The drawing on page 25 shows some

injury to persons resulting from touching a hot surface.

Guards can be ordered with flue components, see table

on page 55. minimum clearances for the flue terminal. In addition, the flue terminal should be positioned where it will not cause a nuisance from noise or from the combustion waste accumulating. Please contact Andrews Technical Support Department if advice is needed for a particular installation.

WARNING:

The flue system must be properly installed.

Ensure the inner flue is securely sealed at all the

joints otherwise incomplete combustion may result.

If installed on a roof valley, the terminal should be at least 1m above the highest part of the roof structure and 2.5m from any adjacent structure.

Do not exceed maximum flue lengths including

elbows.

Page 22

E861 (230 Litre)

E865 (380 Litre)

E862

E860 E863

Condense syphon

Condense pipe to drain

SEC TIO N 3 • INSTALLATION

ECOflo 230 & 380 LITRE FLUE SYSTEMS

The ECOflo uses a concentric flue system,150mm outside diameter with an inner flue of 100mm diameter.

Flue components fit together with silicon sealing rings and the flues are retained with sealing clamps. Each heater can be ordered with either a horizontal or vertical flue kit. Flue assembly instructions are also included.

Prior to installing the concentric flue system and terminal, the following must be carried out:

1) Fit item E860 to the stainless steel exhaust outlet

connection on the appliance and ensure that the condense connection is at the base of the tee piece.

2) Fit item E862 to the PVC air intake connection on appliance and ensure that the open end is at the top of the tee piece.

3) Fit item E861 or E865 (depending on the model) to both previously fitted E860 and E862. Ensure that both connectors are located correctly. Secure the 100mm dia. vertical section of item E861 or E865 to heater outer casing with brackets supplied. Ensure that internal cable is not damaged during installation.

4) Fit item E863 condense syphon to 32mm connection at base of condense tee (E860).

5) Install 40mm OD plastic waste system from syphon outlet to suitable drain.

A minimum downward slope of between 3mm to 6mm per 300mm length of water pipe must be adhered to.

Page 23

ECOflo 230 & 380 VERTICAL/HORIZONTAL FLUE SYSTEMS

INSTALLATION • SECTION 3

Height of concentric section above heater 205mm Height of concentric sample point 115mm (+/– 5mm) Height of centre line of 90° bend 178mm (+/– 5mm) Total height to centre line of bend 500mm (+/– 10mm) Total height to centre line of bend including EC230 heater: 1948mm (+/– 10mm) Note: Total height to top of bend 573mm (+/– 10mm)

Total height to top of bend including EC230 heater 2021mm (+/– 10mm) Total height to centre line of bend including EC380 heater 2472mm (+/– 10mm) Total height to top of bend including EC380 heater 2525mm (+/– 10mm)

Heights are given from bottom of heater and EXCLUDE a plinth

Page 24

SEC TIO N 3 • INSTALLATION

FLUE SYSTEMS

Fig. 3

Terminal Positions with Minimum Distance mm

A Directly below an opening, air brick, opening window etc. 300

B Above an opening, air brick, opening window etc 300

C Horizontal to an opening, air brick, opening window etc. 300

D Below a gutter or sanitary pipework 75

E Below the eaves 200

F Below a balcony or carport roof 200

G Above ground, roof or balcony level 300

H From vertical drain/soil pipework 150

J From an internal or external corner 300

K From a surface or boundary facing the terminal 600

L Vertically from a terminal on the same wall 1500

M Horizontally from a terminal on the same wall (up to 70kW) 300

(above 70kW) 600

N From a terminal facing the terminal 1200

P From an opening in a carport (e.g. door, windows) into the building 1200

Q Above roof 500

R From a vertical structure on a roof 500

S Above flat roof 1000

Page 25

Flue terminal

Inner wall mount plate

4 Fixing screws (supplied)

Hole through wall

4 Wall anchors

Flue terminal

Outer wall mount plate

4 Fixing screws (supplied)

ole through wall

4 Wall anchors

Air intake openings (must face ground)

FLUE SYSTEMS

INSTALLING THE HORIZONTAL FLUE TERMINAL

INSTALLATION • SECTION 3

NOTE: The horizontal flue terminal supplied may be used through outside walls up to 600mm (24in) thick.

1. Horizontal flue Terminal (Through the Wall) supplied a) Cut an opening of at least 165mm (6.5in) diameter

through to the outside.

b) Slide the flue terminal through the wall opening to the

rib closest to the intake air openings of the terminal and even with the outside wall.

Fig. 4

c) Slide the outside wall plate over the flue terminal and

fasten to the wall with four screws. Depending on the wall construction, wall anchors may be required to reinforce the screws.

Fig. 2

d) Install inside wall plate on the inside wall and secure

with four screws. Depending on wall construction, wall anchors may be required to reinforce the screws.

Page 26

Flue terminal

Storm collar

Flat roof

Roof flashing (nail & seal to roof)

Flue terminal pipe

Flue pipe (from water heater)

SEC TIO N 3 • INSTALLATION

FLUE SYSTEMS

INSTALLING THE VERTICAL FLUE TERMINAL

2. Vertical Flue Terminal (Through the Roof) a) Determine the exact location where the roof flue

terminal will exit the roof, ensuring the flue system clears all obstructions. For pitched roofs, the flue cap must be the distance above the roof line as specified (300mm to base of Flue Clamp, minimum). The top of the roof terminal may extend up to 760mm (2.5ft) above the roof line as required.

b) Run the concentric flue system to the proper distance

below the roof sheathing required for the correct distance of the roof terminal above the roof surface. See the following sections on installing the rest of the flue system.

c) Cut a minimum 165mm (6.5in) diameter hole for the

flue centred in the desired location for the roof terminal, see Fig. 6.

d) Centre the roof flashing over the hole using either the

flat roof flashing or universal flashing for pitched roofs.

e) Slip the storm collar supplied with the roof flashing kit

over the outside of the flue terminal and align with the flue pipe end below roof opening. Insert the terminal into the flue pipe.

f) Fasten the roof flashing with nails. Seal the flue

terminal and flashing to the roof.

g) Install the gasketed clamp around the joint between

the flue terminal and flue pipe.

INSTALLING FLUE PIPING SECTIONS FOR BOTH APPLICATIONS

a) The coaxial flue pipe sections are designed to fit

tightly together and seal with the integral flue pipe seal and supplied pipe clamps. No silicone caulk or special tools are required.

b) All flue sections and fittings come complete with

silicone flue pipe gaskets and outside gasketed pipe clamps for making air tight connections between the flue pipe connections.

c) Raise the flue pipe to the flue terminal connection with

the gasketed end of the flue pipe towards the flue terminal. Insert the flue pipe into the flue terminal connection and grasp the end of the flue pipe while twisting and pushing the pipe until inserted all the way into the flue terminal.

d) Connect the outside pipes together using the

gasketed clamps provided. The flue pipes have ribs located near each end. When the flue piping is connected, the gasketed clamps shall cover the ribs and joints of the connecting flue tubes. Support each pipe section with hangers attached to the supporting joints in the wall or ceiling.

e) Continue connecting pipe sections together with

clamps and supporting with hangers.

Fig. 6

Page 27

Fit syphon (part No. E211) to condensate trap

40mm OD waste pipe to drain

Part No. E210 Condense “T”

Gasket end

ibs locked beneath

asketed clamp

traight end

(

ungasketed)

Fig. 7

INSTALLATION • SECTION 3

g) The last pipe section may be cut to fit the distance

required to reach the water heater flue connections. If a flue condensate trap is specified, install the supplied tap with crimped end into the gasketed end of the elbow (horizontal flue installations) and clamp the condensate tee and elbow together. Install the crimped end of the elbow into the flue connection of the water heater. On vertical installations, install the crimped end of the condensate trap directly onto the water heater flue connection.

IMPORTANT! In order for the condensate trap to collect and dispose of the condensate from the flue pipe, the flue system must have a downward slope of 21mm per metre (0.25in/ft) towards the condensate trap. The condensate trap must be installed as close as possible to the flue adaptor to prevent condensate from accumulating and draining back into the base of the water heater.

h) Carefully measure the length of straight flue pipe

needed, allowing for about 50mm (2in) insertion into the elbow. Mark the ungasketed end of the pipe to be cut and carefully make a straight cut on the outside pipe to the desired length. Make sure the inside tube is not cut. Cut the inside flue pipe about 50mm (2in) more than the outside pipe so that the flue pipe protrudes slightly beyond the outside pipe. Connect the flue pipe and clamp at each end.

i) Use the clamp supplied in the flue kit with the stepped

gasket to seal the elbow or condensate trap to the concentric flue connector.

j) Condensate disposal: Connect syphon (part no. E211)

to the 32mm slip joint condensate trap connector and install 40mm OD waste pipe suitable drain, (see fig.8).

Note: On all flue installations, for distances over

1.5 metres, we recommend that a condensate trap

is fitted.

Fig. 8

Page 28

SEC TIO N 3 • INSTALLATION

AIR SUPPLY AND VENTILATION

CONCENTRIC FLUE SYSTEMS

The following notes are intended to give guidance: Where the heater is to be installed in a room, NO VENTS ARE REQUIRED.

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:

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

Air Vents Areas

Consideration must be given to the position of the high level ventilation opening. A high level vent must not be sited within 300mm measured vertically of the flue terminal.

Grilles and louvres 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:

• Low level (inlet)

540cm² plus 5cm² per kilowatt in excess of 54kW total net input.

• High level (outlet)

270cm² plus 2.5cm² per kilowatt in excess of 54kW total net input.

Position of Air Vents Air from Room for Internal Space Air Direct from Outside

High Level 10cm² per kW Net input 5cm² per kW Net input

Low Level 10cm² per kW Net input 5cm² per kW Net input

In a Room or Internal Space No requirement for Ventilation No requirement for Ventilation

Note: Both air vents must communicate with the same

room or internal space or must both be on the same

wall to outside air.

IMPORTANT:

1. The effective area requirements specified in the table are related to the maximum heat input of the heater(s), and are equivalent to those specified in BS6644.

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.

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

The requirements for air supply by mechanical ventilation are given in BS6644 Clause 19.3. and in IGE/UP/10 Pt.1.

mechanical means should be;

(a) Mechanical inlet with natural extraction. (b) Mechanical inlet with mechanical extraction.

The permanent air vents shall be sited away from the extractor fans. It may be necessary to increase the ventilation area to compensate for the extractor fan.

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.

Page 29

Tank Heater casing

WATER QUALITY AND TREATMENT

INSTALLATION • SECTION 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.

In hard water areas, scale formation can occur in hot water systems and hot water heaters. 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 pre-treatment equipment.

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

Each Andrews ECOflo Water Heater includes two factory fitted Correx™ Powered Anodes as standard. These

anodes do not need maintenance or replacement.

The potentiostat which regulates the current to the Correx™ anode features an indicator light which shows green to indicate the correct function and red to indicate a malfunction. The anodes and potentiostat are available as spare parts if required, (see page 52 for part numbers).

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

Fig. 9

All models now incorporate the new 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.

Page 30

Hot water service

Overflow

Open vent Stop valve

Cold water feed

Cold water cistern

Cold water

inlet valve

Secondary return

Bronze pump

Check valve

SEC TIO N 3 • INSTALLATION

WATER CONNECTIONS

VENTED SYSTEMS

The water heater can 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.

Minimum 1 bar water pressure is required to allow correct operation.

The safety valve must be fitted either directly to an upper tank tapping or not further than one metre along the outlet flow pipe, 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 not be less than the nominal size of the safety valve outlet. It should be selfdraining. 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.

Front Cold inlet / Front Hot outlet water connections

Assemble onto the 1½” hot water outlet (front) the required fitting using a suitable jointing compound.

Assemble onto the ¾ BSP thread, the ¾ BSP coupler socket and drain cock using a suitable jointing compound.

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

NOTE: When using a secondary return circuit, see Fig. 10 for the location of the return tapping.

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 thermostats, drain cock and pipe connections on the heater.

Fig. 10

Page 31

INSTALLATION • SECTION 3

Cold water inlet of water heater

C3 Expansion valve

C6 Tundish

C1 Combined pressure reducing valve/strainer

Balanced cold water take-off (if required)

Cold water inlet

(a)

NB: Tees, elbows,stop valves and pipework not supplied

C8 Wall bracket assembly

C7 Hose assembly

The wall mounting assembly C7 & C8

is available as an

optional extra

OPTIONAL PARTS

5 Temperature/pressure

relief valve

C2 Check valve assembly

WATER CONNECTIONS

UNVENTED SYSTEMS

Unvented Systems should be fitted by an Approved Installer.

The water heater can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit, part number B290, available from Andrews Water Heaters.

See Parts List on page 44. The wall bracket assembly (shown below) is available as an optional extra (AWH

Part No – B173).

When used in an unvented system, the ECOflo will supply hot water at a pressure of 3.5bar (51lbf/in²), provided that this pressure is available at the mains feed. During conditions of no-flow, system pressure may rise to a maximum of 6 bar (87lbf/in²) whilst the burner is operating. When testing the system, it is recommended that a maximum test pressure of 8.6 bar (125lbf/in²) is employed.

The expansion vessel C4 supplied is suitable for the stored volume of the water heater. FOR SYSTEMS WITH LARGER PIPE VOLUMES OR ADDITIONAL STORAGE, EXPANSION VESSELS WITH MORE CAPACITY ARE AVAILABLE – CONTACT THE ANDREWS SALES OFFICE FOR FURTHER DETAILS.

The combined temperature and pressure relief valve C5, must be installed into the horizontal 1” dia. male tapping. A 1” dia. socket (not supplied) is required as the T&P valve is also a male fitting. The discharge pipe from items C3 and C5 must be connected into tundish C6.

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 C2(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.

Fig. 11

Page 32

Cold Water Inlet Valve

Secondary Return Pipe

Hot Water Service

Check ValveBronze

Pump

To D rain

Balanced Cold Water Ta ke Off

(Optional)

SEC TIO N 3 • INSTALLATION

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 one size larger than the outlet pipe of the safety device and should be terminated at a suitable drain. (See Building Regulations 1992 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 storage hot water systems must comply with Part G3 of the Building Regulations 1992.

Typical water service layout for unvented system is shown in Fig 12.

Fig. 12

Page 33

COMMISSIONING

COMMISSIONING • SECTION 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. Test all connections, using propriety leak detection fluid.

Filling the Heater with Water

1. Close the water heater drain valve.

2. Open the cold water supply valve.

3. Open several hot water taps to allow air to escape

from system.

4. When a steady stream of water flows from the taps,

the heater is filled.

5. Close the taps and check for leaks at the drain valve,

temperature/pressure relief valve and the hot and cold water connections.

USER’S SAFETY GUIDE

For your safety, read this section prior to lighting the appliance.

WARNING

1. Always follow manufacturer’s 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 around 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 gas appliance.

Page 34

SEC TIO N 4 • COMMISSIONING

AIR/GAS MIXTURE ADJUSTMENT

The water heater gas/air mixture is adjusted at the factory for the proper mixture for optimum combustion and ignition for the type of gas listed on the rating label. The water heater should operate properly without requiring adjustment with the gas type shown on the rating label. The following is a guide for the correct mixture adjustment settings in case the gas content is different from the rating label or ignition is not satisfactory. A combustion analyser is necessary for making gas/air mixture adjustments to determine the correct setting.

The water heater cannot be converted from natural to L.P. gas or L.P. gas to natural gas, without changing the gas valve/venturi assembly. Using L.P. gas on a water heater set up for natural gas will result in rough ignitions and dangerous levels of carbon monoxide.

Do not attempt to adjust the venturi screws without a properly calibrated CO²/CO combustion analyser. Making the mixture richer without an analyser to monitor the adjustments can result in dangerous levels of carbon monoxide.

G20 (NATURAL GAS, MOSTLY METHANE) FAMILY

The venturi screw depth, when measured with a set of callipers (see fig. 13), should be approximately 13.0 –

13.5mm. The CO² range should be set as detailed in

Table 1.

The CO content should be less than 50ppm. If the CO² content is above the correct percentage, turn the venturi screw (see fig. 14), clockwise half a turn and recheck combustion. Repeat, if necessary, until the correct reading is achieved. Turn the venturi screw anticlockwise if the CO² reading is less than the stated figure or the ignitions are not smooth.

PROPANE GAS MODELS

The burner assembly is factory adjusted for Propane Gas on LPG models. The nominal venturi screw setting is the same as G20 Natural Gas, i.e. 13.0 – 13.5mm screw depth. A gas inlet orifice is used on LPG models to use the same venturi screw setting. The CO² range for propane should be set as shown in Table 1, and adjustment carried out as detailed above. The CO content should be less than 50ppm.

Fig. 13

Measurement of venturi screw depth with vernier calipers.

Page 35

COMMISSIONING • SECTION 4

Adjust gas mixture by turning venturi screw (see procedure on previous page).

Fig. 14

CO² PERCENTAGE

Model Reference Input rating Combustion Flue Gas Volume Vent Temperature

kW/hr CO2/CO Cubic metres/hr °C

EC230/600 36.6 11.0%/10 ppm 40 50 – 60

EC230/700 43.9 10.3%/20 ppm 49 50 – 60

EC230/960 58.6 9.7%/10 ppm 63 55 – 60

EC380/740 43.9 10.4%/15 ppm 49 45 – 50

EC380/980 58.6 9.8%/15 ppm 63 50 – 55

EC380/1220 73.2 10.6%/15 ppm 75 50 – 60

EC380/1400 85 11.0%/15 ppm 86 55 – 60

EC380/1900 118.7 11.0%/15 ppm 117 55 – 60

Page 36

SEC TIO N 5 • OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

WARNING

Water heaters are heat-producing appliances. To avoid damage or injury, there must be no materials stored against the water heater or flue system and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and flue system. UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.

Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, air supply, flueing, gas supply and electrical work are required.

Light the unit in accordance with the operating instructions label attached to the water heater.

Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate. Over firing could result in damage or sooting of the water heater.

If the unit is exposed to the following, do not operate water heater until all corrective steps have been made by a factory authorized, independent service contractor or qualified service professional.

1. Flooding to or above the level of the burner controls

2. External firing

3. Damage

4. Firing without water

5. Sooting

NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE WATER HEATER (UNVENTED INSTALLATIONS ONLY).

GENERAL INSTRUCTIONS

TO FILL THE WATER HEATER

1. Close the water heater drain valve by turning the knob or valve stem clockwise. If alternative water connections are provided but not used, make certain they are plugged (i.e. side connections).

2. Open the cold water supply shut-off valve.

3. Open several hot water taps to allow air to escape from the system.

4. When a steady stream of water flows from the taps, the water heater is filled. Close the taps and check for water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

SEQUENCE OF OPERATION

1. A call for heat from thermostat

2. Blower ON

3. Pressure switch contacts closed (no exhaust pipe blockage)

4. Blower pre-purge

5. Igniter warm-up

6. Main burner ON

7. Flame signal confirmed

8. Thermostat satisfied

9. Main burner OFF

10. Blower post-purge

Page 37

LIGHTING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE LIGHTING

ARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life

. This appliance does not have a pilot.

t is equipped with an ignition device

I which automatically lights the burner.

o not try to light the burner by hand.

. BEFORE OPERATING smell all

around the appliance for gas. Be sure

o smell near to the floor because

t some gas is heavier than air and will

ettle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance

•

• Do not touch any electric switch

OPERATING INSTRUCTIONS • SECTION 5

Do not use any telephone in the

• uilding

• If you cannot reach your gas upplier, call the fire brigade.

. Turn off mains power to the water

heater.

. Do not use this appliance if any part

has been under water. Immediately call a qualified service technician to inspect the appliance. Replace any

art of the control system and any gas

p control which has been under water.

. STOP! read the safety information

bove on this label.

. Set the thermostat to lowest setting.

3. Turn off all electrical power to the ppliance.

4. This appliance does not have a pilot.

It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

. Turn off the main power switch.

. Wait 5 minutes to clear out any gas. If

ou smell gas, STOP! Follow “B” in the

afety information above on this label.

s If you do not smell gas go to the next step.

7. Set the thermostat to the desired setting.

8. Turn on main power.

TO TURN OFF GAS TO THE APPLIANCE

LIGHTING INSTRUCTIONS

1. Set the thermostat to lowest setting. 2. Turn off main power switch

Fig. 15

Page 38

SEC TIO N 5 • OPERATING INSTRUCTIONS

TEMPERATURE ADJUSTMENT

During the winter season or any cold period, you may desire a higher temperature setting to adjust for the cold incoming water. This adjustment, however, may cause additional condensation to form on the colder tank surface. This does not mean the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed.

Condensation does not mean your tank is leaking. Most of reported tank leaks on installation’s are proven to be condensation. To avoid unnecessary inconvenience and expense, make sure the tank is actually leaking before contacting Andrews Water Heaters.

CAUTION

This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or if the gas supply fails to shut off, turn off the manual gas control valve to the appliance and call a qualified service company.

BURNER FLAME CHECK

If the water heater is to remain idle for 30 days or more, or is subjected to freezing temperatures while shut off, the water heater and piping should be fully drained and the drain valve should be left fully open. Refer to the relevant section of the Installation and Operating Instructions Manual for the procedure on draining the water heater.

When properly installed and adjusted, the heater will require minimal attention. Should it become necessary to completely drain the heater, follow instructions given in Section 4, Commissioning.

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 burner in an overheat condition. When the water has cooled sufficiently, the manual reset on the ECO needs to be depressed to allow the heater to be re-lit. If the burner shuts down 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. The 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 results 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 which senses abnormally hot water and shuts down the main burner until the water cools. Most modern commercial pipe installations include a pumped secondary return system which keeps hot water moving continuously throughout the heater. This stabilises temperatures in the water heater tank and throughout the pipe system.

Fig. 16

Page 39

MAINTENANCE/SERVICE

MAINTENANCE / SERVICE • SE CTI ON 6

INTRODUCTION

Servicing must be carried out by a properly qualified person.

Whilst giving these instructions for the care of the ECOflo, it is recommended that checks are carried out by the installer or local gas service engineer 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 scale inhibitor should be employed in hard water areas. The heater should be inspected every few months via the hand hole cleanout and scale or silt deposits removed. Failure to do so will shorten heater life and may invalidate the warranty.

PRE-SERVICE OPERATIONS

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.

ANNUALLY

Annual checks of the ignition systems, temperature controls and any other controls are necessary to ensure continued safe and efficient operation.

The entire combustion system must be sealed for this water heater to function correctly. Ensure that the burner access panel is kept tightly sealed. The combustion air supply tee piece at the side of the heater must be tightly clamped to the elbow and concentric flue adaptor. Replace any damaged parts.

The entire exhaust flue system and combustion air supply must be inspected at least annually for integrity of all joints and gaskets.

GENERAL

KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, PETROL AND OTHER FLAMMABLE VAPOURS AND LIQUIDS.

Water heater maintenance includes periodic tank flushing and cleaning, and removal of lime scale. The unit should be inspected and adjusted to maintain proper combustion. Refer to Fig. 17 below, “Suggested Maintenance Schedule”. A periodic inspection of the flue installation system should be made.

MAINTENANCE SCHEDULE

Following are the instructions for performing some of the recommended maintenance. Unit inspection and adjustment should be performed by a competent qualified engineer.

COMPONENT OPERATION INTERVAL REQUIRED

Tank Sediment Removal Every 6 months Flushing

Relief Valve Check Operation Every 6 months Proper Operation

Exhaust & Air Intake System Inspect Every 3 months Joints should be sealed

Ignition System Inspect Annually Clean off dust and dirt

Flue Vent Terminal Clean Inlet Screen As Required Soft Brush

Flue Terminal – Free of Shrubs Monthly Remove object Horizontal or Vertical & Debris that caused restriction

Combustion System Inspect Monthly Confirm S-OP

Condensate Waste Pipe Inspect Monthly Remove restriction

CORREX POWERED ANODES

As Correx Powered Anodes are fitted as standard to this appliance, no maintenance is necessary.

Page 40

SEC TIO N 6 • MAINTENANCE / SERVICE

FLUSHING WATER HEATER

1. Turn OFF the water heater electrical disconnect switch.

2. Open the drain valve and allow water to flow until it runs clean.

3. Close the drain valve when finished flushing.

4. Turn ON the water heater electrical disconnect switch.

DRAINING WATER HEATER

The water heater must be drained if it is to be shut down and exposed to freezing temperatures. Maintenance and service procedures may also require draining the water heater.

1. Turn off the water heater electrical disconnect switch.

2. Connect a hose to the drain valve.

3. Locate hose’s discharge in an area where hot water will not cause any damage or injury.

4. Close the cold water inlet valve to water heater.

5. Open a nearby hot water tap to vent the system.

6. Open the heater drain valve.

7. If the water heater is being drained for an extended shutdown, it is suggested the drain valve be left open during this period.

FILLING WATER HEATER

1. Close the water drain valve by turning the knob or valve stern clockwise. If alternative water connections are provided but not used, make certain they are plugged (i.e. side connections).

2. Open the cold water supply shut-off valve.

3. Open several hot water taps to allow air to escape from the system.

4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

SEDIMENT AND LIMESCALE

Waterborne impurities consist of the particles of soil and sand, which settle out and form a layer of sediment on the bottom of the tank.

The amount of calcium carbonate (scale) released from water is in direct proportion to water temperature and usage. The higher the water temperature or water usage, the more scale deposits are dropped out of the water. This is the limescale, which forms in pipes, water heaters and on cooking utensils.

Scale accumulation not only reduces the life of the equipment but also reduces efficiency of the water heater and increases fuel consumption.

The usage of water softening equipment greatly reduces the hardness of the water. However, this equipment does not always remove all of the hardness (scale). For this reason it is recommended that a regular schedule of de-scaling be maintained.

The depth of the build-up should be measured periodically. Water heaters will have about 3 inches of scale build-up when the level of scale has reached the bottom of the cleanout opening or about 1 inch of scale build-up if it has reached the drain valve opening. A schedule for de-scaling should be set up, based on the amount of time it would take for a ½ inch build-up of scale.

Example: Initial inspection shows ½ inch of scale accumulation. Therefore, the water can be de-scaled once a year.

TO REMOVE SEDIMENT AND LIMESCALE

1. Drain the heater. Refer to DRAINING THE WATER instructions in this section.

2. Remove outer cover plate from lower side of water heater jacket.

3. Remove cover and gasket from cleanout opening.

4. Remove lime scale or sediment taking care not to damage the glass-lining.

5. Inspect cleanout plate gasket: Replace gasket if necessary (refer to parts list on page 52).

6. Install gasket and cleanout plate. Be sure to draw plate up tight by tightening bolts securely.

7. Close the drain valve. Open a hot water fixture to allow air to escape. Open the cold water supply to water heater and allow the tank to fill. Follow the lighting instructions.

8. Check for water leakage.

9. Install outer jacket cover plate.

Page 41

MAINTENANCE / SERVICE • SE CTI ON 6

TO REPLACE A CORREX ANODE

The Correx Powered Anodes on this water heater are easily accessible from the top of the water heater, under the insulation, towards the front of the appliance by the burner assembly, making replacement (if necessary) simple and quick. Use the following procedure to replace the anodes.

1. Drain the heater. Refer to DRAINING THE WATER HEATER instructions in this section.

2. Flush the heater. Refer to FLUSHING THE WATER HEATER instructions in this section.

3. Remove the combustion surround top by unlatching.

4. Locate the hexagonal head of the anode(s) beneath the tank insulation.

5. Remove the anode using a socket of the appropriate size. Do not use an impact wrench.

6. Replace the anode as required. No pipe tape or sealant is required when reinstalling the anode.

7. Close the drain valve. Open a hot water fixture to allow air to escape. Open the cold water supply to water heater and allow the tank to fill.

8. Check your anode and drain valve for leaks.

9. Replace insulation previously removed.

10. Replace combustion surround top and latch it

securely in place.

11. Follow the lighting instructions.

DRAIN VALVE AND TANK ACCESS PANEL

The water heaters are equipped with a ¾ inch drain valve. An access panel covers the cleanout opening in the tank, which is sealed by a gasket and cover.

CLEANING THE STORAGE VESSEL

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 10 litres or more dependent on the amount of limescale present.

5. After a minimum of one hour, restore gas supply and turn on main gas burner for 2 minute 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 Correx Powered Anodes if fitted and plug off the connections using ¾” BSP plugs.

Re-fit the Correx Powered Anodes when the descaling operation is complete.

RESTART

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

Page 42

SEC TIO N 6 • MAINTENANCE / SERVICE

COMBINED TEMPERATURE / PRESSURE RELIEF VALVE

At least twice a year, the temperature and pressure relief valve should be checked to ensure that it is in operating condition. To check the relief valve, lift the lever at the end of the valve several times. The valve should sit properly and operate freely.

If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new valve of the recommended size as necessary. A thorough inspection of the valve should be performed at least every three years by removing the temperature and relief valve from the tank. Do not attempt to repair the valve as this could result in improper operation and a tank explosion. In areas with poor water conditions, it may be necessary to inspect the T&P valve more often than the recommended maintenance schedule.

CAUTION

COMBUSTION SYSTEM INSPECTION

Inspect the operation of the combustion system monthly. Use the following procedure to inspect the combustion system.

1. Turn off the main power switch of the water heater.

2. Adjust the thermostat to the Min. setting.

3. Remove the top of the combustion surround by unlatching it.

4. While observing the ignition module, turn on the main power switch.

5. Adjust thermostat to the Max. setting.

6. Watch the LED’s light as the controller goes through the S-OP as previously described.

7. Upon ignition, observe the main burner flame.

8. Readjust thermostat to previous setting.

9. Replace combustion surround top and latch it securely in place.

Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the discharge to an open drain. Failure to take this precaution could mean contact with extremely hot water passing out the valve during this checking operation.

If the temperature and pressure relief valve on the water heater discharges periodically or continuously, it may be due to thermal expansion of water in a closed water supply system or due to a faulty relief valve.

Thermal expansion is the normal response of water when it is heated. In a closed system, thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equalled. The relief valve will then open allowing some water to escape, slightly lowering the pressure.

Page 43

FAULT FINDING

FAULT FINDING • SECTION 7

MAIN POWER LIGHT IS NOT LIT

Make sure that the water heater is plugged in.

When the switch is on, is there 230V between L1 and N on the terminal block? If not, check for loose wire connections on the “Power Switch Wire Harness.” If connections are ok, replace the switch.

If there is voltage between L1 and N, the light on the switch is burnt out. Replace switch.

THERMOSTAT DOES NOT CALL FOR HEAT

Make sure that the temperature of the tank is cool.

If the thermostat does not call for heat, check the PRIMARY voltage across the “Transformer”. If there is voltage across the PRIMARY, check the voltage across the SECONDARY leads of the “Transformer”.

Install a jumper wire from N.O. terminal to the COM terminal on the “Thermostat PC Board.” If the thermostat calls for heat after installing a jumper wire, replace the “Thermostat Sensor Probe”.

If the ‘Sensor Probe’ is replaced and the unit still does not operate, check “Potentiometer” for the proper resistance. If the readings are correct, replace the “Thermostat PC Board”. Otherwise, replace the “Potentiometer.”

IGNITION MODULE “POWER” LED IS NOT LIT

Check for 230 VAC at the ignition module on “230 VAC IN.” If there is voltage, check the secondary (24 volt terminals) voltage across the transformer as previously described. If there is no voltage from the secondary plug from the transformer, replace the transform or wire harness. If the control has 230 and 24 volt input, replace the control.

IGNITOR DOES NOT GLOW

Is there voltage to the “Hot Surface Ignitor”? Check for 230VAC to the ignitor from the ignition module when the ignition LED is lit. If not voltage to the ignitor, replace ignition control or the ignitor relay.

Check the resistance value across the “Hot Surface Ignitor”. If over 2000 ohms, then replace hot surface ignitor.

MAIN VALVE DOES NOT TURN ON

Put your hand on the gas valve – can you feel it energize? If not, check the voltages at the ignition module across pins MV on the plug GND.

If there is a 24 VAC problem, check to see if the “Rectifier Harness” is secure. If it is secure, replace the “Gas Valve”.

If you can feel the gas valve energize, check the main gas supply is not in the off position.

BURNER FLAME KEEPS GOING OUT

Is there minimum gas supplied to water heater as stated on the rating plate? If not, increase the supply pressure to the water heater.

Measure the mircoAmps through the flame sensor using a multimeter. Is there at least 4 microAmps? If not, replace the “Flame Sensor” or flame sensor wire.

THERMOSTAT DOES NOT SATISFY

Is the tank temperature above the temperature set point?

Does the T&P relief valve leak? If yes, replace “Thermostat PC Board.”

BLOWER DID NOT POST PURGE

BLOWER DOES NOT ENERGIZE

Check for voltage to the blower leads. If 230 volts is present, replace the blower. If no voltage is present, check the blower relay, thermostat/high limit switch and collector unit switch. If the limit switch trips, call our technical support department.

Check “Pressure Switch” (exhaust pressure switch) as previously mentioned.

Check “Collector Limit Switch” as previously mentioned.

If the above switches are functioning, please contact the Technical Support Department at Andrews Water Heaters for further assistance.

Page 44

SEC TIO N 8 • PARTS LIST AND ILLUSTRATIONS

PARTS LIST AND ILLUSTRATIONS

Part Ref. Description Part Number Qty

1 Control Thermostat E883 1

2 Baffle 4” Flue E881 2

3 Mag. Rod Assembly – 230 C288 1

4 Correx Anode Z091 2

5 Baffle 2” Flue – 230 E879 8

6 Baffle 2” Flue – 380 E880 8

7 Plastisert Nipple 1½” NPT E875 1

9 Nipple E874 1

10 Outer Door Service Panel E899 1

11 Exhaust Pressure Switch E909 1

12 Cleanout Access Cover C300 1

13 Cleanout Gasket C694 1

14 Screw 5/16 – 18 x 3/4 HH Grade 5 E483 6

15 Cold Water Inlet (Hydrojet) Assembly E876 1

16 EF Burner Assembly: 600/700/960/740/980 Z079 1

17 EF Burner Assembly: 1200/1400/1900 Z080 1

Plug E902 1

ECO Switch – High Temperature E878 1

Page 45

PARTS LIST AND ILLUSTRATIONS • SECTION 8

16 17

Page 46

SEC TIO N 8 • PARTS LIST AND ILLUSTRATIONS46PARTS LIST AND ILLUSTRATIONS • SECTION 8

COMBUSTION SURROUND ASSEMBLY

Part Ref. Description Part Number Qty

1 Ignition Control Assembly E885 1

2 Switch Main Power E884 1

Potentiometer E889 1

High Limit Thermostat E886

COMBUSTION ASSEMBLY

Part Ref. Description Part Number Qty

4 Blower – EBM 600/700/740 E892 1

5 Blower – EBM 960/980/1220/1400 E893 1

5A Fan Assembly 1900 Z040 1

Gasket & Screw E898 1

7 Gas Valve 600 E894 1

8 Gas Valve 700/740/960/980 E895 1

9 Gas Valve 1220 E896 1

10 Gas Valve 1400 E897 1

10A Gas valve 1900 G125 1

11 Gasket Flame Sensor E891 1

12 Flame Sensor E890 1

13 Hot Surface Ignitor E877 1

14 Burner Mounting Gasket E882 1

14A Blower Transition Gasket Z082 1

LPG Gas Valve 600 E901 1

LPG Gas Valve 700/740/960/980 E902 1

LPG Gas Valve 1220 E903 1

LPG Gas Valve 1400 E904 1

LPG Gas Orifice 600 E905 1

LPG Gas Orifice 700/740/960/980 E906 1

LPG Gas Orifice 1220 E907 1

LPG Gas Orifice 1400 E908 1

14B Burner Gasket G168 1

IGNITION CONTROL ASSEMBLY

Part Ref. Description Part Number Qty

15 Electronics Control Module E887 1

16 Transformer – 120/24 VAC E888 1

LPG GAS VALVE & FAN ASSEMBLY

Part Ref. Description Part Number Qty

18 LPG gas valve & fan assembly (Model no 230/600) Z084 1

18 LPG gas valve & fan assembly (Model no 230/700, 380/740) Z085 1

18 LPG gas valve & fan assembly (Model no 230/960, 380/980) Z086 1

18 LPG gas valve & fan assembly (Model no 380/1220) Z087 1

18 LPG gas valve & fan assembly (Model no 380/1400) Z088 1

18 LPG gas valve & fan assembly (Model no 380/1900) Z089 1

Page 47

Combustion assembly

Combustion surround assembly

Ignition control assembly

Page 48

SEC TIO N 8 • PARTS LIST AND ILLUSTRATIONS

ECOflo Concentric Flue Component List (100/150mm dia.)

Part Ref. Description Part Number

1 90° Elbow with Clamp E205

2 1000mm Flue with Clamp E202

3 Horizontal Flue Terminal E236

4 Wall Clamp (not shown) E209

1000mm Cutable Flue with Clamp E203

6 500mm Flue with Clamp E204

7 Condensate Trap Tee E210

8 Flat Roof Plate E207

9 Angled Roof Plate E208

10 Horizontal Flue Outlet Terminal Guard E105

11 45° Elbow with Clamp E206

Note: Extra lengths of flue and elbows can be supplied to suit each installation requirement.

Page 49

PARTS LIST AND ILLUSTRATIONS • SECTION 8

Page 50

SEC TIO N 8 • PARTS LIST AND ILLUSTRATIONS

ECOflo Unvented System Kit B290 – Parts List

art ref. Part Number Description Qty

C1 C784 Combined Pressure Reducing Valve/Strainer 1

C2 C785 Check Valve Assembly 1

C3 C786 Expansion Valve 1

C4 C782 Expansion Vessel (25 Litre) 1

C5 C380 Temperature/Pressure Relief Valve 1” 1

C6 C384 Tundish from Expansion Valve and T/P Valve 1

B173 Expansion Vessel Wall Mounting Kit (Optional)

C7 C788 Hose Assembly 1

8 C787 Wall Bracket Assembly 1

N/A E923 Plinth 150mm

Page 51

Unvented system kit components

PARTS LIST AND ILLUSTRATIONS • SECTION 8

Page 52

” R R hRjjmso

Baxi Commercial Division

Wood Lane, Erdington, Birmingham B24 9QP

Publication Date: SEPT2012

Sales:

0845 070 1056

Email: [email protected] www.andrewswaterheaters.co.uk

Technical:

0845 070 1057