Elson Zircon 190 S Ind, Zircon 250 S Ind, Zircon 300 S Ind, Zircon 210 S Ind Installation & Servicing Instructions Manual

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Page 1

Pack Contents

• Zircon Solar unvented water heater incorporating immersion heater(s) & thermal controls

• Factory tted temperature/pressure relief valve (set at 90°C / 1 Mpa (10bar))

• Cold water combination valve assembly

• Expansion vessel & mounting bracket

• Tundish

• 2 Port motorised valve

• Compression nuts & olives

• Immersion heater spanner

• Installation & servicing instructions

• Guarantee card

IMPORTANT

Please read & understand all these instructions before commencing installation.

Please leave this manual with the customer for future reference.

Zircon Installation Manual

Unvented Solar Indirect Water Heaters

Installation & Servicing Instructions

Page 2

Introduction....................................................................2

General Requirements...................................................3

Installation General........................................................5

Installation Discharge....................................................7

Installation Solar...........................................................11

Installation Auxiliary Heating Coil................................12

Commissioning............................................................14

Maintenance................................................................15

User Instructions..........................................................16

Fault Finding & Servicing.............................................17

Spares.........................................................................18

Heat Loss.....................................................................19

Environmental Information...........................................19

Commissioning Check List..........................................20

Service Record............................................................21

Warranty......................................................................24

Technical Support........................................................24

Contents

The cylinder is a purpose designed unvented water

heater. The unit has a stainless steel inner vessel, which ensures an excellent standard of corrosion resistance. The outer casing is a combination of

resilient thermoplastic mouldings and plastic coated

corrosion proofed steel sheet. All products are insulated with CFC free polyurethane foam to give good heat loss performance. (see Table 06, page 19)

The unit is supplied complete with all the necessary

safety and control devices needed to allow connection to the cold water mains. All these components are preset and not adjustable.

This appliance complies with the requirements of the CE marking directive and is Kiwa approved to show compliance with Building Regulations (Section G3).

The following instructions are offered as a guide to installation which must be carried out by a competent plumbing and electrical installer in accordance with Building Regulation G3, The Building Standards (Scotland) Regulations 1990, or The Building Regulations (Northern Ireland).

NOTE: Prior to installation the unit should be stored in an upright position in an area free from excessive damp or humidity.

THE BENCHMARK SCHEME

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by

competent persons and that it meets the requirements

of the appropriate Building Regulations and relevant electrical qualications. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.

Introduction

Page 3

WALL

Min 250mm

IMPORTANT:

This appliance can be used by children aged from 8 years and above and persons with reduced physical sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

Children must be supervised to ensure they do not play with the appliance.

WARNING: Do not switch on if there is a possibility that the water in the heater is frozen.

Siting the Unit

The cylinder must be vertically oor mounted. Although location is not critical, the following points should be

considered:

• The cylinder should be sited to ensure minimum

dead leg distances, particularly to the point of most frequent use.

• Avoid siting where extreme cold temperatures will

be experienced. All exposed pipe work should be insulated.

• The discharge pipework from the safety valves must have minimum fall of 1:200 from the unit and terminate in a safe and visible position.

• Access to associated controls and immersion

heaters must be available for the servicing and maintenance of the system. Where these controls are installed against a wall a minimum distance of 250mm must be left (see Fig. 01, below).

• Ensure that the oor area for the cylinder is level and capable of permanently supporting the weight when full of water. (see Table 01)Water Supply

Water supply

Bear in mind that the mains water supply to the

property will be supplying both the hot and cold water requirements simultaneously.

It is recommended that the maximum water demand is assessed and the water supply checked to ensure this demand can be satisfactorily met.

Note: A high mains water pressure will not always

guarantee high ow rates.

Wherever possible the mains supply pipe should be 22mm. We suggest the minimum supply requirements should be 0.15MPa (1.5 bar) pressure and 20 litres per minute owrate. However, at these values outlet ow rates may be poor if several outlets are used simultaneously. The higher the available pressure and ow rate the better the system performance.

The cylinder has an operating pressure of 0.35MPa (3.5 bar) which is controlled by the cold water combination valve assembly. The cold water combination valve assembly can be connected to a maximum mains pressure of 1.6MPa (16 bar).

Outlet/Terminal Fittings (Taps, Etc)

The cylinder can be used with most types of terminal ttings. It is advantageous in many mixer showers to have balanced hot and cold water supplies. In these instances a balanced pressure cold water connection is available on the cold water combination valve assembly (see Fig. 02, page 5). Outlets situated higher

than the cylinder will give outlet pressures lower than

that at the heater, a 10m height difference will result in a 0.1MPa (1 bar) pressure reduction at the outlet. All ttings, pipework and connections must have a rated pressure of at least 0.6MPa (6 bar) at 80°C.

General Requirements

Table 01: Unit weights

Fig. 01: Siting the Unit

Type

Model

Reference

Nominal

Capacity

(litres)

Weight of

unit full

(Kg)

Weight

of unit

(Kg)

Solar

Indirect

190 S Ind 190 243 43

210 S Ind 210 264 50

250 S Ind 250 308 51

300 S Ind 300 367 58

Page 4

Limitations

The cylinder should not be used in association with any of the following:

• Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic control, unless additional and appropriate safety measures are installed.

• Ascending spray type bidets or any other class 1 back syphonage risk requiring that a type A air gap be employed.

• Steam heating plants unless additional and

appropriate safety devices are installed.

• Situations where maintenance is likely to be neglected or safety devices tampered with.

• Water supplies that have either inadequate pressure

or where the supply may be intermittent.

• Situations where it is not possible to safely pipe away any discharge from the safety valves.

• In areas where the water consistently contains a

high proportion of solids, e.g. suspended matter that could block the strainer, unless adequate ltration can be ensured.

• In areas where the water supply contains chloride

levels that exceed 250mg/l.

Important Note:

THE SOLAR CYLINDER MUST BE INCORPORATED INTO A FULLY PUMPED SOLAR PRIMARY CIRCUIT.

CONTROL OF THE SOLAR PRIMARY CIRCUIT IS ACHIEVED BY THE USE OF EXTERNAL CONTROLS

NOT SUPPLIED WITH THE UNIT. CONTROL MUST BE A PURPOSE DESIGNED SOLAR DIFFERENTIAL

TEMPERATURE CONTROLLER.

Checklist

• Unvented cylinder

• Cold control pack

- Tundish

- Combination valve

- Expansion vessel

- Tool - Element spanner

- Compression nuts & olives

- 2 Port motorised valve

• Literature pack

- Installation manual

- Guarantee card

Operational Summary

Maximum mains pressure 1.6MPa (16 bar) Operating pressure / PRV 0.35MPa (3.5 bar) Maximum design pressure 0.6MPa (6 bar) Expansion vessel charge pressure 0.35MPa (3.5 bar) Expansion relief valve setting 0.6MPa (6 bar) T&P relief valve setting 90-95°C/1.0MPa (10 bar) Maximum primary circuit pressure 0.3MPa (3 bar)

(Auxiliary coil)

Maximum primary circuit pressure 0.3MPa (3 bar)

(Solar coil)

Pressure drop (Auxiliary coil) 0.02MPa (0.2 bar) Pressure drop (Solar coil) 0.02MPa (0.2 bar) Storage capacity See Table 1 - page 3 Weight when full See Table 1 - page 3

All models in conformance with BS EN 12897:2006

Note: Although the primary coil pressure rating is 1.0Mpa (10 bar) the 2 port zone valve supplied with the cylinder is only rated 0.86MPa (8.6 bar). If the cylinder is to be plumbed into a system delivering 1.0MPa (10 bar) a suitable 2 port zone valve will have to be sourced.

Page 5

Pipe Fittings

All pipe ttings are made via 22mm compression ttings directly to the unit. The ttings are threaded 3/4”BSP male parallel, should threaded pipe connections be required.

Cold Feed

A 22mm cold water supply is recommended, however, if a 15mm (1/2”) supply exists, which provides sufcient ow, this may be used (although more ow noise may be experienced). A stopcock or servicing valve should be incorporated into the cold water supply to enable the cylinder and its associated controls to be isolated and serviced.

Cold Water Combination Valve Assembly

The 1-piece cold water combination valve assembly (see Fig. 02 opposite) can be located anywhere on the

cold water mains supply prior to the expansion vessel

(see Fig. 06 Page 10). The cold water combination valve is installed as a complete one-piece unit. The valve incorporates the pressure reducer, strainer, expansion valve and check valve. Ensure that the valve is installed with the direction of ow arrows pointing in the correct direction. No other valves should be placed between the cold water combination valve and the cylinder.

Drain Tap

A suitable drain tap should be installed in the cold water supply to the cylinder between the expansion valve (see Fig. 06 Page 10) and the heater at as low a level as possible. It is recommended that the outlet point of the drain pipework be at least 1 metre below the level of the heater (this can be achieved by attaching a hose to the drain tap outlet spigot).

Expansion Vessel

The expansion vessel accommodates expansion that

results from heating the water inside the unit. The expansion vessel is pre-charged at 0.35MPa (3.5 bar). The expansion vessel must be connected between

the expansion valve and the cylinder (see Fig. 06

Page 10). The location of the expansion vessel should

allow access to recharge the pressure as and when

necessary, this can be done using a normal car foot pump. It is recommended that the expansion vessel is adequately supported. An expansion vessel wall mounting bracket is supplied for this purpose and should be tted.

Secondary Circulation

If secondary circulation is required it is recommended that it be connected to the cylinder as shown (see

Fig. 03 below) The secondary return pipe should

be in 15mm pipe and incorporate a check valve to prevent backow. A suitable WRAS approved bronze circulation pump will be required. On large systems, due to the increase in system water content, it may be necessary to t an additional expansion vessel to the secondary circuit. This should be done if the capacity of the secondary circuit exceeds 10 litres.

Pipe capacity (copper):

15mm O.D. = 0.13 l/m (10 litres = 77m) 22mm O.D. = 0.38 l/m (10 litres = 26m) 28mm O.D. = 0.55 l/m (10 litres = 18m)

Outlet

The hot water outlet is a 22mm compression tting located at the top of the cylinder. Hot water distribution pipework should be 22mm pipe with short runs of 15mm pipe to terminal ttings such as sinks and basins. Pipe sizes may vary due to system design.

Installation General

Fig. 03: Secondary Circulation Connection

SECONDARY CIRCULATION PUMP

SECONDARY

RETURN

CHECK VALVE

SECONDARY RETURN CONNECTION

HOT OUTLET

Expansion valve (6bar)

Cold mains connection (22mm)

Expansion valve outlet (15mm)

Outlet connection (22mm)

Direction of ﬂow

Balanced take off port

Pressure reducing valve cartridge (3.5bar)

Fig. 02: Cold Water Combination Valve Assembly

Page 6

Fig. 04 General Dimensions

Notes:

1. Indirect cylinders tested in conformance with BS EN 12897:2006

2. Heat up time from cold through 45°C, with a primary ow rate 15ltrs/min at 80°C +/- 2°C.

Table 02: Dimensions and Performance

Type Model

Reference

Dimensions (mm) Solar

Volume

(ltrs)

Auxiliary

Volume

(ltrs)

Coil Rating (kW) Heat-up

Time

(mins)

Hot Water

Capacity (ltrs)

(volume of water drawn off >40°C)

A B C D Solar Auxiliary

Solar

Indirect

190 S Ind 1401 1085 784 925 65 120 19 14.2 32 132

210 S Ind 1499 1186 1012 1026 85 120 19 15.0 25 196

250 S Ind 1752 1438 1143 1279 95 145 19 15.2 30 237

300 S Ind 2065 1752 1440 1592 120 175 19 17.4 32 265

373

415

SOLAR RETURN

SOLAR FLOW COLD INLET

HOT OUTLET

T&P VALVE

AUXILIARY RETURN

AUXILIARY FLOW

45°

25°

30°

45°

592

550

SOLAR CONTROL

AUXILLARY CONTROL

SECONDARY RETURN

Page 7

Discharge Pipework

It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed to where it is visible, but will not cause danger to persons in or about the building. The tundish and discharge pipes should be tted in accordance with the requirements and guidance notes of Building Regulation G3. The G3 Requirements and Guidance section 3.50

- 3.63 are reproduced in the following sections of this

manual. For discharge pipe arrangements not covered by G3 guidance advice should be sought from your local Building Control Ofcer. Any discharge pipe connected to the pressure relief devices (expansion valve and temperature/pressure relief valve) must be

installed in a continuously downward direction and in

a frost free environment.

Water may drip from the discharge pipe of the pressure relief device. This pipe must be left open to the atmosphere. The pressure relief device is to be

operated regularly to remove lime deposits and to

verify that it is not blocked.

G3 REQUIREMENT

“...there shall be precautions...to ensure that the hot water discharged from safety devices is safely conveyed to where it is visible but will not cause danger to persons in or about the building.”

The following extract is taken from the latest G3 Regulations

Discharge pipes from safety devices

Discharge pipe D1

3.50 Each of the temperature relief valves or combined

temperature and pressure relief valves specied in 3.13

or 3.17 should discharge either directly or by way of a manifold via a short length of metal pipe (D1) to a tundish.

3.51 The diameter of discharge pipe (D1) should be

not less than the nominal outlet size of the temperature relief valve.

3.52 Where a manifold is used it should be sized to

accept and discharge the total discharge form the discharge pipes connected to it.

3.53 Where valves other than the temperature and

pressure relief valve from a single unvented hot water system discharge by way of the same manifold that is used by the safety devices, the manifold should be

factory tted as part of the hot water storage system

unit or package.

Tundish

3.54 The tundish should be vertical, located in the same space as the unvented hot water storage system and

be tted as close as possible to, and lower than, the

valve, with no more than 600mm of pipe between the valve outlet and the tundish (see Fig. 05 page 9 ).

Note: To comply with the Water Supply (Water Fittings) Regulations, the tundish should incorporate a suitable air gap.

3.55 Any discharge should be visible at the tundish. In addition, where discharges from safety devices may not be apparent, e.g. in dwellings occupied by people with impaired vision or mobility, consideration should be given to the installation of a suitable safety device to warn when discharge takes place, e.g. electronically operated.

Discharge pipe D2

3.56 The discharge pipe (D2) from the tundish should:

(a) have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework (see Fig. 05 page 9); and (b) be installed with a continuous fall thereafter of at least 1 in 200.

3.57 The discharge pipe (D2) should be made of: (a) metal; or (b) other material that has been demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly and permanently marked to identify the product and performance

standard (e.g. as specied in the relevant part of BS

7291).

3.58 The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e. for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device; between 18 and 27m at least 3 sizes larger, and so on; bends must be taken into account in calculating

the ow resistance (see Table 03 page 9) and the

worked example.

Note: An alternative approach for sizing discharge pipes would be to follow Annex D, section D.2 of

BS 6700:2006 Specication for design, installation,

testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

3.59 Where a single common discharge pipe serves more than one system, it should be at least one pipe size larger than the largest individual discharge pipe (D2) to be connected.

Installation Discharge

Page 8

3.60 The discharge pipe should not be connected to

a soil discharge stack unless it can be demonstrated that the soil discharge stack is capable of safely withstanding temperatures of the water discharged, in which case, it should:

(a) contain a mechanical seal, not incorporating a water trap, which allows water into the branch pipe without allowing foul air from the drain to be ventilated through the tundish; (b) be a separate branch pipe with no sanitary appliances connected to it; (c) if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either

polybutalene (PB) to Class S of BS 7291-2:2006 or cross linked polyethylene (PE-X) to Class S of BS 7291-3:2006; and

(d) be continuously marked with a warning that no sanitary appliances should be connected to the pipe.

Note:

1. Plastic pipes should be joined and assembled

with ttings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043-1.

2. Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to the discharge stack.

Termination of discharge pipe

3.61 The discharge pipe (D2) from the tundish should

terminate in a safe place where there is no risk to persons in the vicinity of the discharge.

3.62 Examples of acceptable discharge arrangements

are:

(a) to a trapped gully with the end of the pipe below

a xed grating and above the water seal;

(b) downward discharges at low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility; and (c) discharges at high level: e.g. into a metal hopper and metal downpipe with the end of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges.

3.63 The discharge would consist of high temperature

water and steam. Asphalt, roofing felt and non-

metallic rainwater goods may be damaged by such discharges.

Worked Example of Discharge Pipe Sizing

Fig. 05: shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.

From Table 03: Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m. Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m

Therefore the permitted length equates to: 5.8m

5.8m is less than the actual length of 7m therefore calculate the next largest size.

Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valves equates to 18m. Subtract the resistance of 4 No. 28mm elbows at 1.0m each = 4.0m

Therefore the maximum permitted length equates to: 14m

As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

WARNINGS:

• Under no circumstances should the factory tted temperature/pressure relief valve be removed other than by a competent person. To do so will invalidate any guarantee or claim.

• The cold water combination valve assembly must be tted on the mains water supply to the cylinder.

• No control or safety valves should be tampered with or used for any other purpose.

• The discharge pipe should not be blocked or used for any other purpose.

• The tundish should not be located adjacent to any electrical components.

Page 9

Table 03: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes NOTE: The table below is based on copper tube. Plastic pipes may be of different bore and resistance. Sizes and maximum lengths of plastic should be calculated using data prepared for the type of pipe being used.

VALVE OUTLET SIZE

MINIMUM SIZE OF DISCHARGE PIPE D1

MINIMUM SIZE OF DISCHARGE PIPE D2 FROM TUNDISH

MAXIMUM RESISTANCE ALLOWED, EXPRESSED AS A LENGTH OF STRAIGHT PIPE (I.E. NO ELBOWS OR BENDS

RESISTANCE CREATED BY EACH ELBOW OR BEND

G 1/2 15MM 22mm

28mm 35mm

UP TO 9M UP TO 18M UP TO 27M

0.8M

1.0M

1.4M

G 3/4 22MM 28mm

35mm 42mm

UP TO 9M UP TO 18M UP TO 27M

1.0M

1.4M

1.7M

G 1 28MM 35mm

42mm 54mm

UP TO 9M UP TO 18M UP TO 27M

1.4M

1.7M

2.3M

600mm maximum

300mm

minimum

Safety device

(e.g. Temperature

relief valve)

Metal discharge pipe (D1) from

Temperature relief valve to tundish

Tundish

Discharge below

fixed grating

(Building Regulation

G3 section 3.61 gives

alternative points

of discharge)

Fixed grating

Trapped

gully

Discharge pipe (D2) from tundish,

with continuous fall. See Building

Regulation G3 section 3.56,

Table 03 and worked example

Figure 05: Typical Discharge Pipe Arrangment (Extract From Building Regulation G3 Guidance Section 5.50)

Page 10

Fig. 06: Typical SOLAR Installation - Schematic

To hot outlets

Solar

Primary ﬂow

Solar

Primary return

T&P relief

valve

Expansion

vessel

Balanced cold

water connection

(if required)

Cold water

combination

valve

Mains water

supply

Isolating valve

(not supplied)

Discharge

pipe

Tundish

Drain cock

(not supplied)

Secondary return

(if required)

use swept tee

Inlet

Boost element/

Auxillary

control housing

Solar controls housing

Auxillary

Primary return

Auxillary

Primary ﬂow

Solar

Primary return

Secondary Return Tapping (if required)

Page 11

Fig. 07: Solar Control Connections

Installation - Solar

Connection To Solar Primary Circuit

The lower (solar) coil of the SOLAR cylinder must be connected to a fully pumped solar primary circuit. The connections are suitable for 22mm copper pipe direct to the compression ttings provided. The connections are also threaded 3/4” BSP male parallel should BSP be required.

The solar primary circuit should have its own dedicated

circulating pump and safety controls which must be installed as per the manufacturer’s instructions.

Control of Solar Primary Circuit

Temperature control of the SOLAR cylinder must be carried out using a suitable proprietory solar controller/ programmer. The cylinder temperature sensing probe (supplied with the solar controller) should be fully inserted with the thermal cut-out probe into the pocket provided on the SOLAR cylinder.The cable must be secured using the cable clamps on the controls housing.

Connection to the solar controller should be in accordance with the manufacturers instructions. The solar controller should be programmed to give a cylinder temperature of approximately 60°C (maximum 70°C).

THERMAL CUT-OUT

PROBE

CONTROL ASSEMBLY

POWER SUPPLY TO

SOLAR CONTROLLER

L N E

SOLAR CONTROLLER

The solar controller and solar primary circulation

pump must be wired via the over-temperature cut-out mounted in the lower solar controls housing. This will

ensure that the heat input to the solar coil is interrupted

in the event of the cylinder over-heating (see Fig. 07 below). There must also be suitable check (non-return) valves installed in the solar primary ow and return to prevent the possibility of any thermo-syphoning if the solar circulation is stopped.

Page 12

Safety

DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS.

Never attempt to replace the immersion heater other than with the recommended authorised immersion

heater(s).

DO NOT BYPASS THE THERMAL CUT-OUT(S) IN ANY CIRCUMSTANCES. Ensure the two male spade terminations on the combined thermostat and thermal cut-out are pushed firmly onto the corresponding terminations on the element assembly.

In case of difculty contact service support; contact details available at the back of this booklet.

Electrical Supply

All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E Wiring Regulations.

Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact separation of at least 3mm in both poles.

The immersion heater should be wired in accordance with Fig 08 opposite. The immersion heaters MUST be earthed. The supply cable should be 1.5mm2 3 core HO5 VV-F sheathed and must be routed through the cable grip provided with the outer sheath of the cable rmly secured by tightening the screws on the cable grip.

DO NOT operate the immersion heaters until the

cylinder has been lled with water.

Ensure the thermostat and thermal cut-out sensing

bulbs are pushed fully into the pockets on the element plate assembly.

Plumbing Connections

Indirect cylinders require the following pipework connections.

• Cold water supply to and from inlet controls.

• Outlet to hot water draw off points.

• Discharge pipework from valve outlets to

tundish.

• Connection to the primary circuit. All connections are 22mm compression. However, 3/4”BSP parallel threaded ttings can be tted to the primary coil connections if required.

Boiler Selection

The boiler should have a control thermostat and non self-resetting thermal cut-out and be compatible with unvented storage water heaters.

Where use of a boiler without a thermal cut-out is unavoidable a “low head” open vented primary circuit should be used. The feed and expansion cistern head above the cylinder should not exceed 2.5m.

Primary Circuit Control

The 2 port motorised valve supplied with the cylinder

MUST be tted on the primary ow to the cylinder heat

exchanger (coil) and wired in series with the indirect

control thermostat and thermal cut-out tted to the unit. (see Fig. 08 below). Primary circulation to the cylinder heat exchanger (coil) must be pumped; gravity circulation WILL NOT WORK.

Space and Heating Systems Controls

The controls provided with the cylinder will ensure the

safe operation of the unit within the central heating system. Other controls (eg. room thermostat and timer) will be necessary to control the space heating

requirements and times that the system is required to

function.The cylinder is compatible with most heating

controls, examples of electrical circuits are shown in Figs. 09 and 10 (Page 13). However, other systems

may be suitable, refer to the controls manufacturers’ instructions, supplied with the controls selected, for alternative system wiring schemes.

Installation -

Auxiliary Heating Coil

Fig. 08: Electrical Connections

1 2 3

Control Housing Details

Element Connections

1.5mm² 3 Core HO5 VV-F sheathed cable

Indirect control wiring

Page 13

Fig. 09: Schematic Wiring Diagram - Basic 2 x 2 port valve system ( ‘S’ plan )

Fig. 10: Schematic Wiring Diagram - 3 port mid position valve system, ( ‘Y’ plan ). N.B. Must be used in conjunction

with 2 port zone valve supplied

NOTES: Control terminal numbering may differ from those shown. Refer to instructions with controls selected. A double pole isolating switch must be installed in the mains supply. All earth connections must be connected back to the mains earth supply.

L1N

HTGONDHW

L2N

5 6 7 8 9 10

2 3

5 6 7 8 9 10

(Supply)

2 3

Bl20 GY

G1Br Bl20

3 2

Programmer Boiler Pump

Zone valve (HTG)

Cylinder terminal block

Room stat

Zone valve (DHW)

(supplied)

Junction box

L1N

HTGONDHW

L2N

5 6 7 8 9 10

2 3

5 6 7 8 9 10

(Supply)

2 3

Bl20 GY

G1Br Bl20

Programmer Boiler Pump

3 Port Zone valve

Cylinder terminal block

3 2

Room stat

Zone valve (DHW)

(supplied)

Junction box

DHW OFF

Page 14

Filling The Unit With Water

Ensure that all ttings and immersion heaters are correctly tted and tightened. An immersion heater key

is provided to aid tightening the immersion heater(s)

• Check expansion vessel pre-charge pressure. The

vessel is supplied precharged to 0.35MPa (3.5 bar) to match the control pressure of the pressure reducing valve. The precharge pressure is checked using a car tyre gauge by unscrewing the plastic cap opposite the water connection.

• Check all connections for tightness including the immersion heater(s). An immersion heater key spanner is supplied for this purpose.

• Ensure the drain cock is CLOSED.

• Open a hot tap furthest from the cylinder.

• Open the mains stop cock to ll the unit. When

water ows from the tap, allow to run for a few minutes to thoroughly ush through any residue, dirt or swarf, then close the tap.

• Open successive hot taps to purge the system

of air.

System Checks

• Check all water connections for leaks and rectify as necessary.

• Turn off mains water supply.

• Remove the pressure reducing valve head work to

access the strainer mesh, clean and re-t.

• Turn mains water supply on.

• Manually open, for a few seconds, each relief

valve in turn, checking that water is discharged and runs freely through the tundish and out at the discharge point.

• Ensure that the valve(s) reseat satisfactorily.

Solar Primary Circuit

Fill the solar primary circuit following the instructions provided with the solar hydraulic controls. The cylinder temperature control probe supplied with the solar controller must be fully inserted into the pocket in the lower controls housing and the cable securely clamped. Heating by the solar primary circuit is controlled by the solar controller; refer to the manufacturer’s installation instructions for details of how to set up and connect the solar primary circuit. The solar controller should be

programmed to give a maximum storage temperature

in the cylinder of 70°C, (60°C is recommended to minimise scaling).

Secondary heating coil

Fill the secondary circuit following the boiler manufacturer’s commissioning instructions. To ensure the cylinder primary heat exchanger is lled, the 2 port motorised valve (supplied) should be manually opened by moving the lever on the motor housing to the MANUAL setting. When the primary circuit is full return the lever to the AUTOMATIC position.

Switch on the boiler, ensure the programmer is set to

Domestic Hot Water and allow the cylinder to heat up to

a normal working temperature (60°C recommended). If necessary the temperature can be adjusted by inserting a at bladed screwdriver in the adjustment knob (located on front of the thermostat mounting bracket - (see Fig.11 below) and rotating. The minimum thermostat setting is 10°C.

The adjustment represents a temperature range of 10°C to 72°C.

Check the operation of the indirect thermostat and 2 port motorised valve and that no water has emitted from the expansion relief valve or temperature/pressure relief valve during the heating cycle.

Benchmark Log Book

On completion of the installation and commissioning procedures detailed in this manual the Benchmark Installation, Commissioning and Service Record Log, pages 20 and 21 should be completed and signed off by the competent installer or commissioning engineer in the relevant sections. The various system features, location of system controls, user instructions and what to do in the event of a system failure should be explained to the customer. The customer should then countersign the BenchmarkTM Commissioning Checklist (page 20) to accept completion. The service record should be lled in when any subsequent service or maintenance operation is carried out on the product.

Commisioning

Fig. 11: Indirect Thermostat and Thermal Cut-out

SPINDLE POSITIONS

= MINIMUM TEMP 10ºC

= MAXIMUM TEMP 72ºC

= APPROX 60 °C

ROTATE SPINDLE CLOCKWISE FOR TEMPERATURE INCREASE AND COUNTER CLOCKWISE FOR TEMPERATURE DECREASE

THERMAL CUT-OUT RESET BUTTON

TEMPERATURE ADJUSTING SPINDLE

Page 15

Maintenance Requirements

Unvented hot water systems have a continuing

maintenance requirement in order to ensure safe working and optimum performance. It is essential that the relief valve(s) are periodically inspected and manually opened to ensure no blockage has occurred in the valves or discharge pipework.

Similarly cleaning of the strainer element and replacement of the air in the expansion vessel will help to prevent possible operational faults.

The maintenance checks described below should be performed by a competent person on a regular basis, e.g. annually to coincide with boiler maintenance.

After any maintenance, please complete the relevant Service Interval Record section of the Benchmark Checklist on Page 21 of this document.

Inspection

The immersion heater boss can be used as an access for inspecting the cylinder internally.

Safety Valve Operation

Manually operate the temperature/pressure relief valve for a few seconds. Check water is discharged and that it ows freely through the tundish and discharge pipework. Check valve reseats correctly when released.

NOTE: Water discharged may be very hot!

Repeat the above procedure for the expansion relief valve.

Strainer

Turn off the cold water supply, boiler and immersion heaters. The lowest hot water tap should then be opened to de-pressurise the system. Remove the

pressure reducing cartridge to access the strainer

mesh. Wash any particulate matter from the strainer under clean water. Re-assemble ensuring the seal is correctly fitted. DO NOT use any other type of sealant.

Descaling Immersion Heater

Before removing the immersion heater the unit must be drained. Before draining ensure the water, electrical

supply and boiler are OFF. Attach a hosepipe to the

drain cock having sufcient length to take water to a suitable discharge point below the level of the unit. Open a hot tap close to the unit and open drain cock to drain unit. Remove the cover to the immersion heater

housing and disconnect wiring from immersion heater. Carefully remove the thermostat capillaries. Note. the order of the capillaries within the pocket. Remove the terminal shroud. Unscrew immersion heater backnut and remove immersion heater from the unit. A key spanner is supplied with the cylinder unit for easy removal/tightening of the immersion heater.

Over time the immersion heater gasket may become stuck to the mating surface. To break the seal insert a round bladed screwdriver into one of the pockets on the immersion heater and gently lever up and down.

Carefully remove any scale from the surface of the element. DO NOT use a sharp implement as damage to the element surface could be caused. Ensure sealing surfaces are clean and seals are undamaged, if in doubt t a new gasket (part number 70 351 65).

Replace immersion heater ensuring the (right angled)

element hangs vertically downwards towards the base of the unit. It may be helpful to support the immersion heater using a round bladed screwdriver inserted into one of the thermostat pockets whilst the backnut is tightened. Replace the terminal shroud. Connect wiring to element. Check, and close and secure immersion heater housing cover.

Expansion Vessel Charge Pressure

While system is de-pressurised check expansion vessel charge pressure. Remove the dust cap on top of the vessel. Check the charge pressure using

a tyre pressure gauge. The pressure (with system de-

pressurised) should be 0.35MPa (3.5 bar). If it is lower than the required setting it should be re-charged using a tyre pump (Schrader valve type). DO NOT OVERCHARGE. Re-check the pressure and when correct replace the dust cap.

Re-commissioning

Check all electrical and plumbing connections are secure. Close the drain cock. DO NOT switch on

the immersion heater(s) or boiler while the unit is empty. With a hot tap open, turn on the cold water

supply and allow unit to rell. When water ows from the hot tap allow to ow for a short while to purge air and ush through any disturbed particles. Close hot tap and

then open successive hot taps in system to purge any

air. When completely full and purged check system for leaks. Replace and secure immersion heater housing cover. The heating source (immersion heater or boiler) can then be switched on.

Maintenance

Page 16

User instructions

Warnings

IF WATER DISCHARGES FROM THE TEMPERATURE/ PRESSURE RELIEF VALVE ON CYLINDER SHUT DOWN THE BOILER. ISOLATE ELECTRICAL SUPPLY TO THE IMMERSION HEATER. DO NOT TURN OFF ANY WATER SUPPLY. CONTACT A COMPETENT INSTALLER FOR UNVENTED WATER HEATERS TO CHECK THE SYSTEM.

DO NOT TAMPER WITH ANY OF THE SAFETY VALVES FITTED TO THE SYSTEM. IF A FAULT IS SUSPECTED CONTACT A COMPETENT INSTALLER.

Benchmark

The cylinder is covered by the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety, efciency and performance.

Benchmark is managed and promoted by the Heating and Hotwater Industry Council. For more information visit www.centralheating.co.uk.

Please ensure that the installer has fully completed the Benchmark Checklist (Pages 20 & 21) of this manual

and that you have signed it to say that you have received

a full and clear explanation of its operation. The installer is legally required to complete a commissioning checklist as a means of complying with the appropriate Building Regulations (England & Wales).

All installations must be notied to Local Area Building Control either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certicate will then be issued to the customer who should, on receipt, write the Notication Number on the Benchmark Checklist.

This product should be serviced regularly to optimise its safety, efciency and performance. The service

engineer should complete the relevant Service Record

on the Benchmark Checklist after each service.

The Benchmark Checklist may be required in the event of any warranty work.

Flow Performance

When initially opening hot outlets a small surge in

ow may be noticed as pressures stabilise. This is quite normal with unvented systems. In some areas cloudiness may be noticed in the hot water. This is due to aeration of the water, is quite normal and will quickly clear.

Temperature Controls - Solar

Temperature control of the solar primary coil is by means of solar differential temperature controller. This will usually have been set during commissioning to give a storage temperature of approximately 60°C. Refer to user instructions supplied with the controller for details of how to adjust this if required.

DO NOT bypass the thermal cut-out(s) in any circumstances.

Temperature Controls

The cylinder units are tted with an indirect control thermostat and thermal cut-out. These controls must be wired in series with the 2 port motorised zone valve supplied to interrupt the ow of primary water around

the heat exchanger coil when the control temperature

has been reached. The controls are located within

the upper terminal housing along with the immersion

heater thermostat. The thermostat is factory set to give a water storage temperature of approx. 55°C to 60°C. Access to the thermostat can be made by opening the terminal housing cover - DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE COVER. Temperature adjustment is made by inserting a at bladed screwdriver in the adjustment knob and rotating. The minimum thermostat setting is 10°C. The adjustment represents a temperature range of 10°C to 72°C (60°C recommended) ( Fig. 11, page 14). If in any doubt contact a competent electrician.

An immersion heater is also provided for use should the indirect heat source be shut down for any purpose. The

immersion heater control temperature is set using the

immersion heater thermostat.

DO NOT bypass the thermal cut-out(s) in any circumstances.

Operational Faults

Operational faults and their possible causes are detailed in the Fault Finding section of this book. It is recommended that faults should be checked by a competent installer. The air volume within the

expansion vessel will periodically require recharging to ensure expanded water is accommodated within

the unit. A discharge of water INTERMITTENTLY from

the expansion valve will indicate the air volume has reduced to a point where it can no longer accommodate

the expansion.

Page 17

Important

• After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located on page 21 of this document.

• Servicing should only be carried out by competent persons in the installation and maintenance of unvented water heating systems.

• Any spare parts used MUST be authorised parts.

• Disconnect the electrical supply before removing any electrical equipment covers.

• NEVER bypass any thermal controls or operate system without the necessary safety valves.

• Water contained in the cylinder may be very hot, especially following a thermal control failure. Caution must be taken when drawing water from the unit.

Fault Finding & Servicing

Table 04: Fault Finding Chart

Fault Possible Cause Remedy

No hot water ow

Mains supply off Check and open stop cock

Strainer blocked Turn off water supply. Remove strainer and

clean

Cold water combination valve incorrectly tted

Check and ret as required

Water from hot tap

is cold

Direct immersion heater not switched on Check and switch on

Direct immersion heater thermal cut-out has operated

Check, reset by pushing button on thermostat

Indirect programmer set to central heating only

Check, set to domestic hot water programme

Indirect boiler not working Check boiler operation. If fault is suspected

consult boiler manufacturer’s instructions

Indirect thermal cut-out has operated Check, reset by pushing button on thermostat

Check operation of indirect thermostat

Indirect motorised valve not connected correctly

Check wiring and/or plumbing connections to

motorised valve

Water discharges

from expansion

valve

INTERMITTENTLY

Expansion vessel charge pressure has

reduced below 3.5 bar, or set to high

See maintenance section for re-charging of

expansion vessel procedure

CONTINUALLY Cold water combination valve pressure reducer not working correctly.

Expansion valve seat damaged

Check pressure from cold water combination valve. If greater than 3.5 bar replace pressure

reducing valve

Remove expansion valve cartridge, check condition of seat. If necessary t new expansion

valve

Water discharges

from T&P relief

valve

Thermal control failure

NOTE: water will be very hot

Switch off power to immersion heater(s) and shut down boiler DO NOT turn off water supply. When discharge stops check all thermal controls, replace if faulty

Milky water

Oxygenated water Water from a pressurised system releases

oxygen bubbles when owing. The milkiness will disappear after a short while

Spare Parts

A full range of spare parts are available for the

cylinder range (Table 05 Page 18). Refer to the technical data label on the unit to identify the model installed and ensure the correct part is ordered. You will need to quote the serial number, which is printed on the data label.

Fault Finding

The fault nding chart (Table 04 below) will enable operational faults to be identied and their possible causes rectied. Any work carried out on the unvented water heater and its associated controls MUST be carried out by a competent installer for unvented water heating systems. In case of doubt contact service

support (see contact details on back page).

Warning

DO NOT TAMPER WITH ANY OF THE SAFETY VALVES OR CONTROLS SUPPLIED WITH THE CYLINDER AS THIS WILL INVALIDATE ANY GUARANTEE.

Page 18

Spares

Table 05: Spares

Fig. 12: Solar Cylinder Spares Diagram

Item

Number

Description Part Number

1 Immersion heater 95 606 961

2 Immersion heater gasket 70 351 65

3 Immersion heater backnut 95 607 869

4 Immersion heater key

spanner

95 607 861

5 Tundish 95 605 838

6 Cold water combination

valve - complete

70 344 68

7 Direct combined thermostat

and thermal cut-out

95 612 717

8 Indirect combined thermo-

stat and thermal cut-out

95 612 716

9 Thermal cut-out 95 612 698

10 Terminal cover 77 008 62

11 6 way terminal block 95 607 933

12 Accessory kit - Indirect

(without expansion vessel)

95 607 968

13 Solar pocket assembly 95 607 064

14 Expansion vessel - 24 litre 95 607 612

15 3 way terminal block 95 607 932

16 Temperature / pressure

relief valve

95 605 810

17 Pressure reducing catridge

3.5 Bar

70 360 63

Page 19

Table 06: Standing heat losses (based on an ambient air

temperature of 20°C and a stored water temperature of 65°C)

Products are manufactured from many recyclable materials. At the end of their useful life they should be disposed of at a Local Authority Recycling Centre in order to realise the full environmental benets.

Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone depletion factor of zero.

WEEE Declaration

Disposal of Waste Equipment by Users in Private Household in the European Union.

This symbol on the product indicates that this product must not be disposed of with your other household waste. Instead, it is your responsibility to dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical equipment. The separate collection and recycling of your waste equipment at the time of disposal will help to conserve

natural resources and ensure that it is recycled in a

manner that protects human health and the environment. For more information about where you can drop off your waste equipment for recycling, please contact your local city ofce, your household waste disposal service or the company where this product was purchased.

Heat Loss Environmental

Nominal

Capacity

(Litres)

Standing Heat Loss

per day

(kWh/24h)

per year

(kWh/365d)

190 1.65 642

210 1.75 664

250 1.98 670

300 2.31 843

Table: Technical parameters in accordance with European Commission regulations 814/2013 and 812/2013

Model(s) 190 210 250 300

Energy efﬁciency class C C C C

Storage volumes V in Litres 190.0 210.0 250.0 300.0

Standing loss in W 80.0 81.7 82.5 96.3

Table: Figures measured in accordance with KIWA Test Criteria for compliance with UK Building and Water

Regulations

Page 20

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

Customer name: Telephone number:

Address:

Cylinder Make and Model

Cylinder Serial Number

Commissioned by (PRINT NAME): Registered Operative ID Number

Company name: Telephone number:

Company address:

Commissioning date:

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system? Sealed Open

°C

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system? bar

Yes No

Is the installation in a hard water area (above 200ppm)? Yes No

Yes No

What is the hot water thermostat set temperature? °C

I/min

Yes

Type of control system (if applicable) Y Plan S Plan Other

Is the cylinder solar (or other renewable) compatible? Yes No

What is the hot water temperature at the nearest outlet? °C

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes

UNVENTED SYSTEMS ONLY

What is the pressure reducing valve setting? bar

Yes No

The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes

Yes No

Has the expansion vessel or internal air space been checked? Yes No

THERMAL STORES ONLY

What store temperature is achievable? °C

What is the maximum hot water temperature? °C

ALL INSTALLATIONS

The hot water system complies with the appropriate Building Regulations Yes

The system has been installed and commissioned in accordance with the manufacturer’s instructions Yes

The system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

www.centralheating.co.uk

Page 21

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE RECORD

SERVICE 01

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 03

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 05

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 07

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 09

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 02

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 04

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 06

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 08

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

SERVICE 10

Date:

Engineer name:

Company name:

Telephone No:

Comments:

Signature

Email Address:

Email Address: Email Address:

Page 22

NOTES

Page 23

NOTES

Page 24

Fifers Lane, Norwich, Norfolk NR6 6XB

T: 0344 335 8819 F: 0344 871 1528 E: [email protected] W: elsonhotwater.co.uk

36006103_issue_06

Sales & Support

Policy Statement

The policy of ELSON is one of

continuous product development

and, as such, we reserve the right to change specications without notice.

Warranty

On site service support including

parts and labour for 12 months from date of installation. After the initial 12 months, a guarantee will apply for a further 24 years for the stainless steel inner vessel only. During this 24 year period, in the event of a cylinder leak, a replacement product will be

issued provided that the replacement

is carried out by one of our heateam engineers, for which reasonable labour charges will apply.

The Warranty is valid provided that:

• It has been correctly installed as

per the instructions contained in the instruction manual and all

relevant Codes of Practice and Regulations in force at the time of installation.

• The Benchmark Checklist has been completed upon

commissioning and the

Benchmark Service Record is completed for each service.

• It has not been modied in any way, other than by ELSON.

• It has not been frost damaged.

• It has only been used for the

storage of potable water.

• It has not been tampered with or been subjected to misuse or neglect.

• The fault is not scale related.

• Within 60 days of installation the user completes and returns the

certicate supplied along with the proof of purchase to register the product.

• It has been installed in the United Kingdom.

• The fault is not caused by high chloride levels in the water supply

or incorrect disinfection methods.

Evidence of purchase and date of supply may be required. The guarantee is transferable. This guarantee does not affect your statutory rights.

Servicing

Baxi Customer Support

Baxi Customer Support is Elson’s service division. With us on your side, you can be sure that your customers are in the very best of hands. Totally committed to quality and safety, Baxi Customer Support is open 7 days a week, 363 days a year.

*excluding Christmas Day and New Year’s Day.

Simply call 0344 335 8819 or contact us at [email protected]

• Dedicated Trade Advice

Line - our helpful and qualied

specialists are always on hand to help you with even the most

complex technical query.

• Installer Priority Call-Outs - our

280 strong team of specically

trained expert heating engineers

covers the UK, no one is better qualied to look after Elson’s products for the duration of the guarantee.

• Fully Stocked Vans - a

nationwide eet of vans, fully stocked with spare parts -

meaning we can repair our

appliances on the rst visit 95% of call-outs.

• Exclusive Service Plans -

heateam also offer Elson’s customers a range of exclusive annual service plans.

Opening Times: Monday-Friday 8am6pm, weekends and Bank Holidays*

8.30am-2pm.

*excluding Christmas Day and New Year’s Day.

Spares

For all technical support, replacement

parts & service issues please contact:

Electric Water Heating Co. 2 Horsecroft Place, Pinnacles, Harlow, Essex CM19 5BT Tel: 0845 0553811 E-mail: [email protected]

SPD

Special Product Division, Units 9 & 10 Hexagon Business Centre, Springeld Road, Hayes, Middlesex UB4 0TY Tel: 020 8606 3567

Parts Center Tel: 0845 270 9800 www.partscenter.co.uk

Newey & Eyre Specialists Products Division

Please contact your local branch

UK Spares Ltd Tower Lane, Warmley, Bristol BS30 8XT Tel: 0117 961 6670 www.uk-spares.com

Advanced Water Company Ltd Unit 5D, Enterprise Way, Vale Park, Evesham, Worcestershire WR11 1GS Tel: 01386 760 066