Page 1
Working towards
a cleaner future
RSC 150 / RSC 190
Permanent Pilot, Auto Ignition
Installation Guide, Operation & Service Manual
This manual must be kept with the appliance January 2011
Part No E104
Page 2
© Copyright Andrews Water Heaters 2007
Reproduction of any information in this publication by any method is not permitted
unless prior written approval has been obtained from Andrews Water Heaters.
Andrews Storage Water Heaters have been designed and manufactured to comply
with current International standards of safety. In the interests of the health and
safety of personnel and the continued safe, reliable operation of the equipment,
safe working practices must be employed at all times. The attention of U.K. users is
drawn to their responsibilities under the Health and Safety Regulations 1993.
All installation and service on the Andrews Water Heater must be carried out by
properly qualified personnel, and therefore no liability can be accepted for any
damage or malfunction caused as a result of intervention by unauthorised
personnel.
The Andrews Water Heaters policy is one of continuous product improvement, and
therefore the information in this manual, whilst completely up to date at the time of
publication, may be subject to revision without prior notice.
Further information and assistance can be obtained from:
Andrews Water Heaters
Wood Lane, Erdington, Birmingham B24 9QP
Tel: 0845 070 1055 Fax: 0845 070 1059
Sales: 0845 070 1056
Technical: 0845 070 1057
Service: 0845 070 1058
Email: [email protected]
www.andrewswaterheaters.co.uk
THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL
ARE FOR USE WITH NATURAL GAS ONLY
Page 3
CONTENTS
PAGE
SECTION 1 GENERAL AND SAFETY INFORMATION
General Information 2
British Standards and Codes of Practice 2
Health and Safety Regulations 1993 3
Effectiveness in Combating Legionellae 3
SECTION 2 TECHNICAL DATA 4
SECTION 3 INSTALLATION
Location 5
Flue Systems 5
Air Supply and Ventilation 6
Electrical Supply (Auto Ignition) 8
Water Connections 9
Water Quality & Treatment 9
Hydrojet Systems 9
Vented Systems 10
Unvented Systems 11
Gas Connections 14
SECTION 4 COMMISSIONING
To Light the Burner 15
To Shut Off the Burner 15
To Check Main Burner Pressure 15
To Light the Burner Auto Ignition 16
To Shut Off the Burner Auto Ignition 16
To Check Main Burner Pressure Auto Ignition 16
SECTION 5 OPERATION
Operating Sequence 17
ECO (Energy Cut-Off) 17
Auto Ignition 17
SECTION 6 SERVICING
Burner Assembly 18
Gas Control Valve 18
Flueway 19
Magnesium Anode 19
Descaling Information 19
SECTION 7 FAULT FINDING 20
SECTION 8 PARTS LISTS AND ILLUSTRATIONS 22
Page 4
GENERAL AND SAFETY INFORMATIONSECTION 1
GENERAL
INFORMATION
BRITISH
STANDARDS
AND CODES OF
PRACTICE
The Andrews Water Heater has been designed for use with NATURAL GAS only and is
manufactured to give an efficient, reliable and long service life.
To ensure the continued, trouble-free operation of your heater at maximum efficiency, it
is essential that correct installation, commissioning, operation and service procedures are
carried out strictly in accordance with the instructions given in this manual. By law,
installation and commissioning of the heater must be carried out by properly qualified
personnel.
The heater(s) must be installed in accordance with the following requirements;
The current GAS SAFETY (INSTALLATION AND USE) REGULATIONS
The current BUILDING REGULATIONS
The WATER SUPPLY (WATER FITTINGS) REGULATIONS 1999
Additionally, installation should be performed in accordance with all relevant
requirements of the Gas Supplier, Local Authority and recommendations of the British
Standards and Codes of Practice detailed below.
STANDARD RANGE
BS 6700: 1997 Specification for design, installation, testing and maintenance of
services supplying water for domestic use within buildings and their
curtilages. This standard supersedes the following British Standards
and Codes of Practice: CP99, CP310, CP324, 202, CP342 Part 2,
Centralised Hot Water Supply.
BS 5440:1990 Installation of flues and ventilation for gas appliances of rated output
not exceeding 60kW.
BS 6644 Installation of gas fired hot water boilers of rated inputs between
60kW and 2MW.
BS 5546:1990 Installation of gas hot water supplies for domestic purposes.
BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic
premises.
BS 7206:1990 Specification for unvented hot water storage units and packages.
I/M2 Purging procedures for 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).
BS 6798 Installation of gas fired hot water boilers of rated input not
exceeding 60kW.
NOTE: Consideration should be given to amendments or updates to
the above standards.
2
Page 5
GENERAL AND SAFETY INFORMATION SECTION 1
It is the duty of manufacturers and suppliers of products for use at work to ensure, so far
as is practicable, that such products are safe and without risk to health when properly
used and to make available to users, adequate information about their safe and proper
operation.
Andrews Water Heaters should only be used in the manner and purpose for which they
were intended and in accordance with the instructions in this manual. Although the
heaters have been manufactured with paramount consideration to safety, the basic safety
precautions highlighted in this manual must be observed by the user.
It is imperative that all users of the heater must be provided with all the information and
instruction necessary to ensure correct and safe operation.
Water systems in buildings have been associated with outbreaks of Legionnaires' Disease,
particularly in health care facilities where occupants are significantly more susceptible to
infection.
In recognition of the risks in hospitals, a Code of Practice for the Control of Legionellae
in Health Care premises has been issued by the Department of Health (1991). Codes of
Practice applicable to other premises have been published by other organisations,
principally the Health and Safety Executive (HS)(G70) and the Chartered Institute of
Building Services Engineers (C1BSE, TM13).
HEALTH AND
SAFETY
REGULATIONS
1993
EFFECTIVENESS
IN COMBATING
LEGIONELLAE
All Codes of Practice draw attention to the design and operation of water systems with
reference to avoidance of factors that favour colonisation by Legionellae bacteria. These
factors include stagnation, lukewarm conditions (20ºC to 45ºC) and the accumulation of
debris, scale and corrosion in the base of tanks and calorifiers.
Andrews Water Heaters has commissioned an independent evaluation of their products
to investigate their resistance to build-up of legionellae bacteria.
Experiments were conducted to determine whether, following a substantial challenge by
legionellae pneumophilia, after overnight and stagnation conditions, the system was
rendered free from viable recoverable legionellae. It was found that at 61ºC, following a
challenge of approximately 107 organisms per litre, within one hour, more than 99.999%
of organisms had been killed. After a subsequent stagnation period, sampling did not
reveal any residual contamination. The design of the base of the water heater precludes
legionellae colonisation, even after build-up of debris. The burner positioning ensures
that the water at the bottom of the heater reaches the same, or higher temperature as in
the rest of the heater.
Based on data obtained through experiment, the Andrews Water Heater can be described
as legionellae resistant as it is considered unlikely that, at the temperature tested, the
organism would colonise the water heater and present a possible health risk.
3
Page 6
DIMENSIONS
AND
CLEARANCES
Fig 1.
Appliance Dimensions
Including
Standard Flue Run
Dimensions
TECHNICAL DATASECTION 2
Recommended Service Clearance
E
Hot
A
C
K
180˚
I
Recommended Service Clearance
Minimum Service Clearance
H
F
Recommended Service Clearance
G
J
Concentric Flue
External Flue diameter 125mm (5”)
Internal Flue diameter 80mm (3”)
ANDREWS MODEL NO. RSC 150 RSC 190
SI Metric Imperial SI Metric Imperial
A Height of Heater 1264 mm 493⁄4in 1492 mm 583⁄4in
B Diameter 508 mm 20 in 508 mm 20 in
C Gas Connection 378 mm 147⁄8in 378 mm 147⁄8in
D Height to Centre of Flue 2118 mm 85in 2398 mm 94 in
E Service Clearance 1226 mm 48 in 1226 mm 48 in
F Standard Flue Run 750 mm 291⁄2in 750 mm 291⁄2in
G Height to Flue Centre 854 mm 331⁄2in 854 mm 331⁄2in
H Standard 90º Elbow 194 mm 75⁄8in 194 mm 75⁄8in
I Service Clearance 305 mm 12 in 305 mm 12 in
J Service Clearance (Front) 610 mm 24 in 610 mm 24 in
K We recommend that the flue outlet can be installed in any configuration through 180º as long as proper service clearances are observed.
L Water Connection GRS 200mm 77⁄8in 200mm 77⁄8in
M Flue Terminal 170mm 65⁄8in 170mm 65⁄8in
Storage Capacity 150 litres 33 gallons 190 litres 42 gallons
Recovery through 44˚C/80˚F 159 l/hr 35 gph 181 l/hr 40 gph
Recovery through 56˚C/100˚F 127 l/hr 28 gph 145 l/hr 32 gph
Heat Input 9.5 kW 32,414 Btu/hr 10.5 kW 35,826 Btu/hr
Heat Output 8.2 kW 27,978 Btu/hr 9.4 kW 32,073 Btu/hr
Gas Flow Rate 0.88 m3/hr 31.32 ft3/hr 0.98 m3/hr 34.62 ft3/hr
Gas family I2H Natural I2H Natural
Flue Gas Temp Approx 180ºC 180ºC
Flue Gas Volume 16m3/H 16m3/H
Inlet & Flow connections Rp3⁄4
Return connections Rp3⁄4
Gas Connection Rp1⁄2
Maximum Working Pressure
Maximum Test Pressure
10 bar 150 p.s.i. 10 bar 150 p.s.i.
20.6 bar 300 p.s.i. 20.6 bar 300 p.s.i.
3
⁄4 BSP Rp3⁄4
3
⁄4 BSP Rp3⁄4
1
⁄2BSP Rp1⁄2
Burner Pressure 10.0 mBar 4.0 wg. 10.0 mBar 4.0 wg.
Injector Diameter 2.87 mm 0.113 ins 3.05 mm 0.120 ins
Flue Connection 80/125 80/125
Weight Empty 66 kg 145 lbs 74 kg 163 lbs
Weight Full 216 kg 475 lbs 264 kg 583 lbs
Shipping Weight 73 kg 162 lbs 82 kg 181 lbs
Shipping dimensions carton 1499 x 635 x 711 mm 59 x 25 x 28 in 1727 x 635 x 711 mm 68 x 25 x 28 in
200mm
GRS
Cold
D
L
B
Return Via Drain Port
3
⁄4 BSP
3
⁄4 BSP
1
⁄2BSP
M
170mm
5
6
⁄8”
Maximum Test Pressure 20.6 bar/300 psi
4
Page 7
INSTALLATION SECTION 3
THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON
Install in accordance with current British Standard Code of Practice 342 part 2 and British
Standards 5440, 5546, 6644, 6700, 6798 and 6891.
The location chosen for the heater must permit the provision of a satisfactory flue and an
adequate air supply.
A clearance of 3OOmm (l2in) should be left around the heater for fitting and servicing
purposes and 762mm (3Oin) above the heater for removal of the flue baffle. The above
clearances are recommended for ease of servicing. They can be reduced if necessary but a
clearance of 3OOmm (12 in) must be left in front of heater for access to the burner and
controls. The flue baffle clearance should also be maintained if possible to avoid servicing
problems.
The floor on which the heater is installed must be flat, level and of sufficient strength to
withstand the 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 so placed or shielded as to ensure
that its temperature does not exceed 66°C (150°F).
Detailed recommendations for flueing are given in British Gas Booklet IM/11 and
BS 5440 part 1. The following notes are intended to give general guidance:
• A horizontal or vertical flue kit is supplied with each heater. Flue fitting instructions on
page 6.
• Location. The siting of the flue terminal is not critical with respect to the performance of
the unit. However, areas where the discharge of combustion products would cause a
nuisance should be avoided. In accessible positions a suitable guard should be provided.
(see page 6).
• Route. The route of the flue is not critical, with three installation options available. See
below for permissible flue lengths. Where installation options 2 or 3 are used we
recommend that the flue outlet can be installed in any configuration through 180º as
long as proper service clearances are observed see fig.1 page 4.
LOCATION
FLUE SYSTEM
B
600mm
Wall
3.2 Mtrs.
Roof
Installation 2
500mm
B
1.2 Mtrs.
A
Installation 3
500mm
A
Installation 1
Model RSC150
Flueing Option Installation 1 Installation 2 Installation 3
Type of flueing C31 C31 C11
Flue restrictor Ø 45mm Ø 50mm Ø 60mm
A ≤ 2.0 - ≥ 0.5m and ≤ 1.0m
B-≤ 1.0m ≤ 1.0m
Model RSC190
Flueing Option Installation 1 Installation 2 Installation 3
Type of flueing C31 C31 C11
Flue restrictor Ø 48mm Ø 55mm no restrictor required
A ≤ 2.0 - ≥ 0.5m and ≤ 1.0m
B-≤ 1.0m ≤ 1.0m
Fig 2.
Typical Flue
Installations and
Permissable Flue
Lengths
5
Page 8
INSTALLATIONSECTION 3
RSC150 & RSC190 Flue Fitting Instructions
1. Fit heater adaptor D1 to heater ensuring correct location on primary flue spigot from
heater. (Use 4 self tapping screws provided).
2. Fit flue restrictor ring D7 into heater adaptor D1 The correct size of restrictor for
each heater model and installation is shown on page 5.
3. Fit flue section D2 into heater adaptor D1.
4. Fit elbow D4 into flue section D2 for horizontal flue runs.
5. Determine correct position of flue outlet and fit outer wall plate and inner wall plate.
Fit flue outlet guard if required. (Fixings not supplied).
6. Fit horizontal terminal D3 or make up lengths of flue required (see page 5) into
elbow D4. Each joint must be secured with a sealed clamp D6.
7. For vertical installations fit flue lengths required (see page 5) into heater
adaptor D1.
8. Determine correct position of flue terminal and fit either D8 or D9 roof plates.
9. Fit D5 vertical terminal through roof plate into vertical flue pipe.
10. Fit D6 sealed clamps on all joints.
11. On all installations the lengths of flue pipes may be cut to obtain correct length of
flue route required.
12. See parts list on page 20 for part numbers and description of flue available.
Components
Supplied In Flue Kits
AIR SUPPLY
AND
VENTILATION
D2
D6
D5
D4
D7
D6
D3
D10
D8
D9
D1
The following notes are intended to give general 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 Areas
Position of Air from room or Air direct from
Air Vents internal space outside
High Level 10cm2per kW 5cm2per kW
Low Level 10cm2per kW 5cm2per kW
In a Room or
Internal Space
No requirement for ventilation
6
Page 9
INSTALLATION SECTION 3
Note: - Both air vents must communicate with the same room or internal space or must
both be on the same wall to outside air.
Air vents should have negligible resistance and must not be sited in any position where they
are likely to be easily blocked or flooded or in any position adjacent to an extraction system
which is carrying flammable vapour.
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 or louvers should be so designed that high velocity air streams do not occur within
the space housing the heater(s).
IMPORTANT:
The vapours given off by halogen based compounds can, if drawn into the combustion air,
cause corrosion of the Storage Vessel and premature failure of the thermocouple.
If water heaters are to be installed, in locations where halogens are likely to be present they
should be isolated from such compounds and ventilated from and to outside,
uncontaminated atmosphere.
Some of the vulnerable areas are listed below -
(i) Hairdressing salons and adjoining rooms and basements.
(ii) Establishments where dry cleaning solutions are used or stored.
(iii) De-greasing plants using hydrocarbon solvents.
(iv) Premises where refrigerant gases are used or stored.
7
Page 10
INSTALLATIONSECTION 3
y
Brown Cable
ELECTRICAL
SUPPLY -
AUTO IGNITION
UNITS
External wiring to the water heater(s) must be installed in accordance with current
I.E.E. Regulations for the wiring of buildings and to any Local Regulations that may apply.
The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply.
The fuse rating is 5 amps.
The method of connection to the mains electricity supply should facilitate complete
electrical isolation of the appliance, preferably by use of an unswitched shuttered
socket outlet in conjunction with a fused three pin plug, both complying with the
requirements of BS 1363.
Alternatively, a fused double pole switch or fused spur box serving only the heater may
be used.
The point of connection to the mains electricity supply should be readily accessible and
adjacent to the appliance.
Connect the electrical supply to the main control panel terminal block via the cable
glands in the base of the control panel. Mains input cable should be 0.75mm2, 3 core,
and should be connected to the mains supply as detailed above.
It is recommended that screen cable is used where the volt-free contacts are to be
connected from an external supply. This will eliminate the risk of possible interference
from nearby high voltage cables.
Auto Ignition
HT Lead
Maclaren Gas Block
Gas to Main Burner
Pilot Burner Assembl
” BSP
Gas Inlet ” BSP
10
9
8
7
6
5
4
3
2
1
EP6SX Automatic G as Burner Control Un it
Control Thermostat
Lock Out LED
Power “ON” Neon
Limit Thermostat
Custom PCB
Red Cable
Yellow Cable
Blue Cable
Time Switch Motor If Fitted
NOTE:
The Interlock con tact terminals 3&4 – 5&6
must be linked if no device is fitted
Earth Pin
Relay 2
Fuse 5 A
Black Cable
10
Volt Free
Output For
}
Over-Heat
9
8
Volt Free
Output For
}
Lock Out
7
6
Interlock
Contact 2
(Time Switch)
5
Interlock
4
Contact 1
(Additional
3
Combustion
Safeguard)
2
Neutral
1
Live Input
8
Page 11
INSTALLATION SECTION 3
To ensure long life and efficient, reliable performance from Andrews water heaters it is
essential that the water heater is installed and serviced in accordance with the
manufacturers instructions.
Each water heater is fitted with one or more magnesium anode(s) which protect the tank
from corrosion caused by electrolytic action within water systems. The magnesium
anodes are sacrificial and as such they erode as they offer protection. Once the anode
has eroded to less than 50% of its original diameter it may not offer sufficient protection.
The anodes should be inspected on an annual basis and replaced as necessary. The
frequency of which the anode needs replacing can vary and water quality can have a
major influence on this.
Andrews offer Correx™UP powered anodes as an alternative to the traditional
magnesium anodes. Correx™UP anodes are made from titanium and are non sacrificial,
therefore they do not have a requirement for maintenance or replacement. However, the
potentiostat, which regulates the protective current supplied to the Correx™UP anode,
has an indicator light which shows green when the anode is functioning correctly and red
if a malfunction occurs.
Correx™UP anodes are available as an optional extra on all models of Andrews storage
water heaters and tanks.
In hard water areas scale formation can occur in hot water systems and water heaters
and the higher the temperature of operation and the higher the volume of water used
the more problematic this scale build up can be. Water treatment is normally
recommended when the hardness reaches 100-150 ppm (7-10 degrees Clark) and above
- a number of water treatment devices are available. When specifying or installing
Andrews water heaters in hard water areas we would recommend that a specialist in this
area of operation is consulted.
WATER
CONNECTIONS
WATER QUALITY
AND TREATMENT
Contact Andrews Water Heaters for further information.
How the
system works
The upper “jet
ports” direct the flow
outward to begin the
dynamic mixing
action.
The lower “jet ports”
direct the flow
inward to increase
the turbulence.
HYDROJET
SYSTEM
The heater is fitted with
the Hydrojet Total
Performance System
incorporated in the cold
inlet dip tube. The tube is
designed to increase
turbulence and reduce
sediment build up, reduce
thermal stacking and
increase delivery.
9
Page 12
INSTALLATIONSECTION 3
WATER
CONNECTIONS
VENTED SYSTEMS
The water heater must be supplied from a cold water feed cistern and the hot water
supply pipe must be fitted with an open vent pipe in accordance with BS 5546. Local
regulations and bye-laws must be observed when installing the system but typical water
service layouts are shown in Fig. 3.
The cold water feed cistern must have an actual capacity greater than the hourly
recovery rate of the heater or heaters to which it is fitted, the minimum actual capacity
allowed for a feed cistern is 227 litres (50 gal).
The actual cistern capacity is the capacity to the normal water line of the cistern. All
cisterns used should be to the relevant British Standard and the distance from the normal
water line to the top of the cistern should be as laid down by the water authorities.
The cold water inlet and hot water outlet are identified on top of the heater. Connect the
cold water feed and hot water outlet to these nipples with union adaptors for ease of
servicing.
CAUTION - DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY
SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS. MAKE THE
CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER. A DRAIN
COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE
APPROPRIATE BOSS AS SHOWN ON THE DRAWING.
After installation of the water system open the main water supply valve, flush the system
and fill the heater. Open the hot taps to allow air to escape from the system. When the
system is free of air, close the taps and check for leaks at the control thermostat, drain
cock and pipe connections at the top of the heater.
Fig.3
Typical Installation -
Vented System
Hot Water
Service Pipe
Union
Adaptor
Secondary Return
Check Valve
Overflow
Stop Valve
Open Vent
Cold Water Feed
Cold Water Cistern
Cold Water
Inlet Valve
Flue
Gas Control Thermostat
10
Page 13
INSTALLATION SECTION 3
When used in an unvented system, the Andrews storage water heater will supply hot
water at a pressure of 3.5 bar (50.8 psi) providing this pressure is available at the mains
feed. During conditions of no flow, whilst the burner is operating, the pressure of the
system will rise to a maximum of 6 bar (87.0 psi).
When testing the system it is recommended that a maximum test pressure of 8.62 bar
(125 psi) be employed.
The Andrews range of storage water heaters can be used on unvented hot storage water
systems with the addition, to the standard heater, of an "Unvented Systems Kit" Part No.
B213 obtainable from Andrews Water Heaters.
All fittings and materials must be suitable for use with drinking water and listed in the
current Water Research Centre "Materials and Fittings Directory".
Installation of unvented hot storage water systems must comply with the requirement
G3 of the Building Regulations.
Fig.4 p11 lists and illustrates the component parts of the Unvented Systems Kit.
Fig.5 p12 illustrates the general arrangement of the components. The Wall Mounting Kit
is available as an optional extra.
Item F4 must be fitted into the Temperature Relief port (see Fig. 6, p13)
When assembling items F1 and F2 care must be taken to ensure that the flow arrows
marked on the components are pointing in the direction of flow i.e. towards the water
heater.
WATER
CONNECTIONS
UNVENTED
SYSTEMS
The cold water for services may be drawn from the 22mm compression port on item
F1(a). The water pressure at this point will be similar to that available at the hot water
outlet of the water heater. If port (a) is not used it should be sealed with the blanking
plug supplied.
If higher flow rates are required for the cold water services a suitable "tee" fitting should
be included in the pipework upstream of item F1.
The discharge pipe from the tundish should be of suitable metal and be at least one pipe
size larger than the outlet pipe on the safety devices.
(See Building Regulations Approved Document G3).
11
Page 14
INSTALLATIONSECTION 3
F3
F8
F4
F1
(a)
F2
F7
Fig. 4
Unvented
Systems Kit
F5
Ref Part No. Description Qty
B213 Complete Unvented System Kit
F1
F2
F3
F4
F5
F6
F7
F8
C780
C781
E319
E320
E321
E322
B229
C788
E323
F6
Comprises
Pressure Reducing Valve
Expansion Valve / Check Valve
Expansion Vessel
Temperature / Pressure Relief Valve
3
⁄4”x1⁄2” Reducing Bush
Tundish
Expansion Vessel Wall Mounting Kit (Optional)
Comprises
Hose Assembly
Wall Bracket Assembly
1
1
1
1
1
1
1
1
1
1
12
Page 15
INSTALLATION SECTION 3
WATER
CONNECTIONS
FF44
Tempera
Pressure Relief
Valve
Reduc
ture/
Cold Water
Inlet to Water
FF55
ing Bush
FF33
ansion Vessel
Exp
Heater
FF22
Ch
Expansion
Valve
eck Valve/
Balanced Cold
Water Take-off
(if required)
FF11
essure
Pr
Reducing
Valve/
Strainer
FF88
l Bracket Assembly
Wal
FF77
e Assembly
Hos
FF66
Tun
dish
Cold Water Feed
NB. Tees, elbows, stop valve and pipework not supplied.
Fig.5
Unvented Systems Kit,
Correct Sequence
13
Page 16
WATER
CONNECTIONS
INSTALLATIONSECTION 3
F3
Fig. 6
Typical Installation,
Unvented System
Hot water service
Secondary Return
Check Valve
F1
F5
F4
Cold Water Take Off
F2
F6
Cold Water Inlet
To drain
GAS
CONNECTIONS
THE APPLIANCE MUST ONLY BE USED WITH NATURAL GAS.
The installation of the gas supply should conform to the requirements of IM/16 published
by British Gas p.l.c. or BS 6891. Jointing compound used must conform to BS 6956 Pt 5.
CAUTION - DO NOT APPLY HEAT IN CLOSE PROXIMITY TO THE GAS CONTROL
THERMOSTAT AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL.
Fit a 1/2, gas supply cock immediately upstream of the gas control thermostat and
connect to the gas supply. Pressure test the gas installation for soundness. If any doubt
exists as to size of gas supply pipe, consult your local Gas Region.
It is recommended that a pressure test point is fitted on the input next to the gas supply
valve.
14
Page 17
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 thermostat are
complete, and test all connections with soap solution.
1. Remove outer cover wait 3 minutes for any unburnt gas to vent.
2. Turn the gas control knob to pilot. (see below)
3. Fully depress the gas control knob and the piezo ingnitor. With the pilot burner alight,
hold the gas control knob for 20 seconds. When the gas control knob is released the
pilot should remain lit, if not repeat the operation. The pilot can be seen through the
sight glass on the inner cover.
4. Replace outer cover.
5. Set the temperature indication dial to the required temperature. (see below)
6. Turn the gas control knob to ON, the burner should now light, if not repeat the
operation. (see below)
Thermostat
Setting
Approx. Water
Temperature
0123
104°F 40°C 125°F 52°C 143°F 62°C 159°F 71°C
Correct size and shape
of the pilot flame
30 mm
Note European Symbols:
OFF :
PILOT :
ON :
GAS
CONNECTIONS
TO LIGHT
THE BURNER
Fig.7
Lighting Instructions
For long periods only, eg. holidays or periods of 7 days or more, turn the gas control
knob to ‘PILOT’ position, depress slightly and turn clockwise to ‘OFF’. Turn off the gas
service cock.
For shorter periods, eg. less than 7 days, leave the heater under the control of the
thermostat.
N.B. If the pilot should become extinguished for any reason, turn off the appliance, and
wait three minutes before attempting to relight.
1. Turn burner OFF as above.
2. Remove brass cap from burner adjustment port. (see below).
3. Release bleed screw A one turn and connect pressure gauge tube.
4. Light burner according to the preceding instructions.
5. Adjust burner pressure at screw B in accordance with data plate.
Turn screw clockwise to increase pressure and anticlockwise to decrease pressure.
6. Turn burner OFF. Remove pressure gauge tube and tighten screw A.
7. Replace brass cap in burner pressure adjustment port. (see below).
B
A
TO SHUT OFF
THE BURNER
TO CHECK
MAIN BURNER
PRESSURE
Fig. 8
Burner Pressure
Adjustment
15
Page 18
COMMISSIONINGSECTION 4
LIGHTING THE
BURNER
AUTO IGNITION
Thermostat Control
Knob
Gas Control valve
1. Ensure gas supply is on.
2. Set thermostat control knob to the required water temperature. (See below).
3. Ensure time switch if fitted is in the ON position.
4. Move electrical ON/OFF switch to ON and the burner will light.
5. Check pilot and main gas connections at gas control valve using leak detection fluid
whilst burner is alight. Turn OFF, seal any leakages then re-test.
Shutting OFF burner
To shut OFF the burner move switch to OFF then turn OFF the gas service cock.
On/Off Switch
The water heater should only be turned OFF for long periods, eg holidays, or in an
emergency. Otherwise the heater should be left to operate under normal thermostat
control.
NB. When using a time control ensure the heater is not turned OFF before the final
water draw off occurs. This will ensure the water in the tank is left in a hot condition.
THERMOSTAT SETTING
APPROX WATER TEMP.
Checking main burner pressure
1. Turn gas supply OFF.
2. Release bleed screw A and connect pressure gauge tube.
3. Light burner as described previously.
4. Remove cap from port B and adjust pressure using exposed screw in accordance with
data plate.
5. Shut OFF burner as described previously. Remove pressure gauge tube and tighten
bleed screw A.
6. Re-light burner as described previously.
104ºF 40ºC 131ºF 55ºC 158ºF 70ºC
123
16
B
A
Page 19
OPERATION SECTION 5
When properly installed and adjusted the Heater will require the minimum of attention.
Should it become necessary to completely drain the heater, close the cold water inlet
valve, open a hot water tap to allow air to enter the system. Fit a suitable hose to the
drain cock and open.
Whenever the Heater is filled with cold water, condensation will form on the cold storage
vessel surfaces when the burner is lit. Condensation is normal and does not indicate a
leak. It will disappear when the storage vessel becomes heated.
The gas control fitted to this heater has a built in limit thermostat (ECO). In case of high
water temperature the gas supply will be automatically shut off. The reason for such a
high temperature must be investigated and corrected before the heater is relit.
The gas control is fitted with a recycling type ECO, this means that once the water
temperature has cooled sufficiently the ECO circuit will close and allow the heater to be
relit. If the gas control has to be changed it must be replaced with an identical model
having the same code number.
1. When the thermostat senses too-cool water, a signal is sent to the control sequence unit.
2. The pilot solenoid coil is energised and thus allowed to open. Gas is allowed to pass to
the pilot and ignition begins.
3. When the pilot flame is established, the main gas solenoid is energised and allowed to
open and the main burner is lit.
4. When the control thermostat is satisfied, both pilot and main gas solenoids are closed.
Temperature Stratification (Stacking)
When small amounts of hot water are drawn repeatedly, the thermostat responds to each
feed of cold water and activates the main burners. Each time this occurs, more heat may
be put back in the tank than was drawn off. As this continues, water in the upper level of
the tank gets hotter than the thermostat setting. This hotter water does not mix
completely with the cold inlet water but rises in a 'chimney effect' to the top of the tank.
Many repetitions of this over a short time period result in accumulation of excessively hot
water in the upper part of the tank, even when the thermostat control is within limits. This
is known as stacking.
If in doubt contact Andrews Water Heaters.
AUTO
IGNITION
UNITS
17
Page 20
SERVICINGSECTION 6
Whilst giving the following instructions for the care of the Andrews Water Heater, we
would recommend that an arrangement is made with your local gas region or installer to
carry out periodic checks of the appliance to ensure trouble free operation and continued
satisfaction.
BURNER
ASSEMBLY
The burner assembly should be cleaned and checked annually as follows:-
1. Depress slightly the gas control knob and turn to "OFF". Remove the outer burner
cover and the inner door. Remove the IO fixing screws to remove the inner cover.
2. Disconnect from the bottom of the control valve the ‘pilot tube, thermocouple and
main burner supply tube. Withdraw the burner assembly from the heater.
3. Remove the screw securing the pilot assembly to the main burner.
4. Remove the gland nut connecting the pilot tube to the pilot assembly. Withdraw the
pilot tube and remove the pilot restrictor from the end. Clean the pilot restrictor with
acetone and blow through the pilot burner with compressed air.
5. Remove the two screws securing the main burner supply tube to the bottom of the
burner to gain access to the main jet. Remove the main jet and clean with acetone.
Blow through the main burner with compressed air.
DO NOT ATTEMPT TO CLEAN ORIFICES WITH SHARP METALLIC OBJECTS, IF
NECESSARY, USE A WOOD SPLINTER TO CLEAR.
6. Re-assemble in the reverse order of steps 2 to 5 but note:
i) Be sure to engage the rear section of the main burner supply pipe in its location
bracket on the base pan of the heater.
ii) DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION, SCREW IN
FINGER TIGHT AND TIGHTEN A FURTHER 1/4 TURN USING A SPANNER.
7. Turn the control knob to "PILOT" and depress. Using a leak detection fluid check the
joints at both ends of the pilot supply tube. Seal if necessary.
8. Allow 3 minutes for any unburnt gas to disperse and light the pilot flame, check that
the flame is correct, see Fig. 7 and turn the control knob to ‘ON’, the main burner will
light.
9. Check the main burner tube connection at the control valve with leak fluid and seal if
necessary. Replace the outer cover.
GAS
CONTROL
VALVE
Fig. 9
Replacement of
Gas Control
18
This should be checked and serviced by an engineer fully conversant with every aspect of
this piece of equipment.
To remove gas control, first
drain appliance, disconnect
gas pipe union and turn
control anti clockwise, taking
care not to damage threads,
knobs or the valve itself.
Page 21
SERVICING SECTION 6
The burner should be checked annually. The flueway and baffle should be checked if
sooting occurs and if necessary cleaned as follows:-
1. Depress slightly the gas control knob and turn to "OFF". Remove outer burner cover
and inner cover. Remove the fixing screws to remove the inner cover.
2. Disconnect burner gas tube, pilot tube and thermocouple at gas control.
3. Remove burner assembly complete with pipes and thermocouple lead.
4. Remove flue assembly and flue box on heater to reveal flue baffle.
5. Inspect and clean the secondary flue installation as necessary.
6. Lift out the baffle from inside the central flueway.
7. Clean the flueway with a brush and clean any deposit from the underside of the
storage vessel bottom and from the flue baffle.
8. Re-assemble in the reverse order.
IT IS IMPORTANT THAT THE BURNER IS CORRECTLY LOCATED IN THE BURNER
SUPPORT BRACKET ON BASE OF COMBUSTION CHAMBER. DO NOT OVERTIGHTEN
THE THERMOCOUPLE CONNECTION.
Screw in hand tight and tighten an extra 1/4 turn with a spanner.
9. Re-light and carry out commissioning check as above.
IMPORTANT
A magnesium sacrificial anode is fitted into the top of he water storage vessel.
The function of the anode is to provide additional corrosion protection for the inside of the
vessel. The condition of the anode should be checked, at least annually, during servicing.
The original diameter of the anode is 22mm (7/8"), If at any point along its length, the
anode is eroded to half, or less, of the original diameter it should be replaced with new.
Particular attention should be paid to the extreme ends. The anode/hot outlet nipple can
be unscrewed from the top of the heater (see page 20). If the anode is encrusted with
limescale it should be either cleaned by wire brushing to reveal bright metal or replaced.
FLUEWAY
MAGNESIUM
ANODE
Where correx anodes are fitted no anode maintenance is required.
CLEANING THE STORAGE VESSEL
Scale formation in the base area of the storage vessel which may occur in hard water
areas. It is usually associated with high usage and high water temperatures. It is
characterised by a rumbling noise (kettling) when the burner is lit and should be rectified
by chemical descaling.
DESCALING
When descaling the water storage heater your attention is drawn to the following
guidelines.
SAFETY FIRST
DUE TO THE CORROSIVE NATURE OF THE DESCALE FLUID IT ITS ESSENTIAL THAT
SUITABLE PROTECTIVE CLOTHING EQUIPMENT IS USED AND ADEQUATE VENTILATION
IS AVAILABLE WHEN DESCALING.
1. Turn gas control on water heater to ‘OFF’ position and isolate the gas supply.
2. Close water inlet valve and drain heater tank.
3. Remove magnesium sacrificial anode (s).
Note: It is recommended that a new anode(s) is fitted.
4. Add suitable hydrochloric based descale acid, the requirement is normally 5 litres for
standard range 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
minutes (MAXIMUM).
6. Isolate gas supply and drain off descale fluid through drain port.
7. Open cold water feed valve and fill heater tank.
8. Drain and flush out heater for minimum of 30 minutes.
9. Replace anodes.
10.Replace gas supply and re-light heater.
19
Page 22
FAULT FINDINGSECTION 7
FAULT
1. WATER DOES NOT
GET HOT
2. PILOT FLAME
IS OUT
3. PILOT WILL NOT
STAY ON
4. BURNER WILL
NOT LIGHT PILOT
ESTABLISHED
5. THERMOCOUPLE
BURNS OUT
FREQUENTLY
6. HEATER SOOTING,
YELLOW FLAME
(POOR
COMBUSTION)
7. WATER
TEMPERATURE
TOO HIGH
ACTION
(a) Check gas cock is open.
(b) Check water valves are open.
(c) Check that pilot is alight.
(d) Check thermostat setting. (Reset to higher temperature).
(e) Check gas pressures at burner and at gas inlet to appliance.
(f) Check cold inlet dip tube to see if it is broken or missing (see Fig. 10).
(a) Try to light burner as detailed in lighting instructions.
(b) Pilot will not light wait 3 mins and try again then see below.
(a) Check gas available.
(b) Check thermocouple, replace if necessary.
(c) Check inlet gas pressure as this may be too high or too low.
Inlet gas pressure to heater multifunctional control should be 17.5
mbar (7”Wg) to 25 mbar (10”Wg).
(d) Pilot jet blocked, clean or replace pilot jet.
(e) Faculty magnet, replace multifunctional control.
(f) E.C.O. safety thermostat operating at too low a temperature. Replace
multifunctional control.
(a) Water already at correct temperature.
(b) Replace multifunctional control.
(a) Check pilot pipe for loose joints.
(b) Check that correct amount of fresh air ventilation is available.
(c) Check that flue is clear and is correctly designed and fitted.
(d) Check for presence of halogen vapours (see page 7).
(a) Clean burner and injector.
(b) Flue obstruction, clean flueways.
(c) Check flue design and termination position.
(d) Check burner pressure.
(e) Check for correct ventilation.
(a) Reset thermostat to lower temperature.
(b) If water temperature is still too high replace multifunctional control.
Fig. 10
Removal of
Cold Inlet Dip Tube
& Hot Outlet
Nipple/Anode
8. WATER
TEMPERATURE
TOO LOW
9. NOT ENOUGH
HOT WATER
10.WATER DRIPPING
FROM BASE OF
HEATER
11.RUMBLING NOISE
(KETTLING)
Disconnect pipe fittings and turn nipple anti clockwise to remove.
(a) Reset to higher temperature.
(b) Check gas pressures at burner and at gas inlet to appliance.
(a) Check gas pressures at burner and at gas inlet to appliance.
(b) Check amount of water being used against recovery rate given on
Data Plate.
(a) Check if water stops dripping when water in heater is hot. If water
stops problem is condensation caused by incorrectly designed flue or
by tank cooling excessively i.e. more hot water being used than
recovery rate of the heater.
(b) If water continues to drip when heater is hot. Problem is a leaking
joint or storage vessel.
(a) Scale formation in heater, consult water treatment specialist. Heater
must be descaled and suitable water treatment provided to avoid
problem re-occurring.
20
Page 23
FAULT FINDING SECTION 7
FAULT ACTION
NO (a) Check gas service cock is open.
IGNITION AT PILOT (b) Electrical ON/OFF switch is not ON.
(c) Power to unit interrupted.
(d) Thermostat set too low.
(e) Check ECO for failure. Reset.
(f) Check for 24V AC at intermittent pilot ignition control
terminal No. 1. Replace control if faulty.
(g) Faulty Solenoid Coil. Replace if faulty.
PILOT LIGHTS BUT (a) Check for 24V AC at intermittent pilot ignition control
MAIN BURNER terminal No. 3. Replace control if faulty.
DOES NOT (b) Faulty Solenoid Coil. Replace if faulty.
AUTO
IGNITION
UNITS
21
Page 24
PARTS LIST AND ILLUSTRATION RSC150/RSC190SECTION 8
Model RSC150 RSC190
Ref Part No. Part No. Description Qty
A1 E080 E081 Data Plate 1
A2 E085 E086 Hot Outlet Nipple / Anode 1
A3 E087 E088 Hydrojet Cold Inlet Dip Tube 1
A4 C247 C247 3/4” NPT/BSP Nipple 2
A5 C381 C381 Drain Cock 1
A6 C103 C103 3/4” Socket 1
A7 E089 E089 Combustion Chamber Seal Cover 1
A8 E090 E090 Cover Burner Access 1
A9 E091 E092 Flue Baffle 1
B1 E093 E094 Burner Assembly Comprising items B2,
B3, B4, B5, B6 1
B2 E095 E095 Burner Supply Pipe 1
B3 E097 E097 Pilot Supply Pipe 1
B4 C126 C126 Thermocouple 1
B5 E099 E100 Injector 1
B6 E101 E101 Pilot Burner c/w Jet, Pipe, Electrode & Lead 1
B7 C252 C252 Pilot Burner Jet N18 1
B8 C514 C514 Piezo Ignitor 1
B9 C965 C965 Multifunctional Control, White Rogers 1
B10 E016 E016 Thermostat Knob
B11 C382 C382 Gas Cock 1
C1 E103 E103 Top Cover
B10
B2
B4
B11
B9
B3
A5
B5
B1
A6
C1
A1
B6
A4
A3
A2
A4
A9
B8
22
B7
A8
A7
Page 25
PARTS LIST AND ILLUSTRATION RSC150/RSC190 SECTION 8
Model RSC 150 RSC 190
Ref Part No. Part No. Description Qty
D1 E072 E072 Heater Adaptor 1
D2 E069 E069 0.5m Flue 1
D3 E073 E073 Horizontal Terminal c/w Wall Plates 1
D4 E071 E071 90˚ Bend 1
D5 E067 E067 Vertical Terminal 1
D6 E075 E075 Clamp with Seal 2
D7 E074 Flue Restrictor 45mm (Vertical) 1
D7 E076 Flue Restrictor 60mm (Horizontal) 1
D7 E077 Flue Restrictor 48mm (Vertical) 1
D7 E078 Flue Restrictor 50mm 1
D7 E107 Flue Restrictor 55mm 1
D8 E065 E065 Flat Roof Plate 1
D9 E066 E066 Angled Roof Plate 1
D10 E105 E105 Horizontal Flue Outlet Terminal Guard 1
Note:
Straight lengths of flue can be supplied to suit each installation requirements as shown on
page 6 See below.
Part No.
Description
E064 1m Flue
E070 1m Cutable Flue
E068 Wall Clamp
E308 45º Elbow
D4
D5
D8
D9
D3
D6
D1
D6
D7
D2
D10
23
Page 26
PARTS LIST AND ILLUSTRATIONSSECTION 8
24 Volt Auto System
Kit B217
24 Volt Auto
System Kit
Standard Range
Part No. Description Qty
1e (nat gas)telpmoC tiK metsyS otuA tloV402712B
C521 On/Off Switch 1
1thgiL rotacidnI sniaM146C
G122
E115 Transformer 1
E116 Limit Thermostat 1
E117 Control Thermostat 1
G059 230 volt Gas Valve 1
E126 230 volt Solenoid Coil 2
E127 Pilot Assembly (nat gas) 1
E128 Ignition/Flame Probe 1
E135 HT Lead 24” 1
1EP6 Control Module
1bonK tatsomrehT lortnoC021E
24
Page 27
NOTES
25
Page 28
NOTES
26
Page 29
Baxi Commercial Division
Wood Lane, Erdington,
Birmingham B24 9QP
Email: [email protected]
www.andrewswaterheaters.co.uk
Sales:
0845 070 1056
Technical:
0845 070 1057
Loading...