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HPMONO/IND300

Grant HPMONO/IND125, HPMONO/IND250, HPMONO/IND150, HPMONO/IND400, HPMONO/IND300 Installation & User's Instructions

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Grant MonoWave System
Indirect Heat Pump Cylinder Range
Installation & User Instructions
Part No. DOC 74. Rev 04. January 2011
Storage Cylinder
2
Contents
Contents
1 Introduction &
General Requirements 3
1.1 Installation Requirements 3
1.2 Water Supply Requirements 3
1.3 Location 3
1.4 Storage and Handling 3
1.5 About Your New Cylinder 3
1.6 Open Vented Hot Water Systems 3
1.7 Taps and Fittings 3
1.8 Pipework Connections 3
1.9 Scaling 3
1.10 Insulation 3
1.11 Health and Safety 3
2 Technical Specifications 4
2.1 Technical Data 4
2.2 Dimensions 5
2.3 Connections and Controls 6
3 Primary Circuit Installation 7
3.1 Grant MonoWave HP Cylinders 7
3.2 Primary Connections 7
3.3 The 2-Port Valve 7
3.4 Hard Water Areas 7
4 Secondary Circuit Installation 8
4.1 Cold Water Inlet Manifold 8
4.2 Installation 8
4.3 Expansion Vessel 8
4.4 Temperature and Pressure Relief Valve 8
4.5 Hot Water Supply 8
4.6 Prevention of Scalding 8
4.7 Secondary Return 9
4.8 Tundish 9
4.9 Discharge Pipe 9
4.10 Discharge Pipe Arrangement 10
4.11 Discharge Pipe Sizing 10
4.12 Worked Example 10
5 Electrical Installation 11
5.1 Immersion Heater 11
5.2 Immersion Heater Wiring Instructions 11
5.3 Dual Thermostat 11
5.4 2-Port Valve 11
5.5 'S' Plan System 12
6 Commissioning, Draining
Down & Safety 13
6.1 Filling the Cylinder 13
6.2 Draining Down 13
6.3 Safety Cut-Out 13
6.4 Cold Water Discharge from Tundish 13
6.5 Hot Water Discharge from Tundish 13
6.6 Expansion Vessel 13
6.7 Customer Handover 13
7 Maintenance 14
7.1 Servicing and Maintenance 14
7.2 Manifold Assembly 14
7.3 Pressure Reducing Valve 14
7.4 Expansion Relief Valve Cartridge 14
7.5 Expansion Vessel 14
8 Fault Finding 15
8.1 Intermittent Water Discharge 15
8.2 Constant Water Discharge 16
8.3 No Flow from Hot water Taps 16
8.4 Cold Water Flow from Hot Water Taps 17
8.5 Excessive Hot Water from Taps 18
9 Spare Parts 19
9.1 Spare Parts 19
10 User Instructions 20
10.1 User Instructions 20
11 Warranty 21
11.1 The Grant Cylinder Warranty 21
11.2 Extended Warranty 22
1 Introduction & General Requirements
1.1 Installation Requirements
Thank you for purchasing a Grant unvented hot water storage cylinder from our Wave range. This installation manual must be read carefully before you begin installing the cylinder.
This cylinder must be installed by a competent person in compliance with all current legislation, codes of practice and local by-laws covering the installation of an unvented hot water cylinder. Please also make sure that any installation complies with the instructions contained in this installation instruction manual.
1.2 Water Supply Requirements
We recommend that your Grant Unvented cylinder is installed with an uninterrupted water supply.
Where possible the unit should be fed via a Ø22mm supply pipe. It requires a supply pressure of 1.5bar with a flow rate of at least 20 litres per minute as a minimum for it to function. Even with these rates, flow from the outlets will be disappointing if several outlets are used simultaneously. Generally speaking, the higher the supply pressure, the better the system will function. The cylinder control equipment is factory set to limit the incoming system operating pressure to 3bar. The maximum supply pressure into the pressure reducing valve (PRV) is 12bar.
1.3 Location
The unit is designed to be floor standing, vertically mounted, indoors, in a frost-free environment. When choosing a suitable location for the cylinder, consideration should be given to the routing of the discharge pipe to a convenient point and also the availability of an adequate power supply for connecting the immersion heater(s).
The cylinder may stand on any flat and level surface without any special foundation preparations, provided that it is sufficiently robust to support the full weight of the cylinder. (Refer to Technical specifications for weights).
The position of the cylinder should be such that easy access is provided for servicing the controls and replacing the immersion heater should the need arise.
Generally, pipe runs should be made as short as possible and lagged to prevent heat loss.
1.4 Storage and Handling
If the cylinder is not being installed immediately, it should remain in its carton to prevent damage. We recommend that the cylinder be transported to its installation position on a sack truck or similar whilst still within the carton.
1.5 About Your Cylinder
MonoWave HP indirect cylinders have one coil specifically designed for connection to an air source heat pump, such as the Grant Aerona range. If a source such as Solar Thermal or another make of heat pump is to be connected, please refer to the manufacturers installation instructions for more information.
The coil must be connected using a 2-port motorised valve (for solar installations a high temperature 2-port or solenoid valve must be used) to shut off the flow from the primary source and electrically interlocked with the heat source via the cylinder control and limit thermostat.
Failure to do so will invalidate all warranties and will be in breach of The Building Regulations Approved Document G3 (2010).
More information on electrical wiring is given on page 11.
MonoWave HP indirect cylinders are also supplied fitted with a 3kW electric immersion heater (two are supplied with the 300 and 400 models).
Refer to page 11 for further details on immersion heaters.
1.6 Open Vented Hot Water Systems
If required, your Grant MonoWave HP Cylinder can be used as part of an Open Vented hot water system, i.e. fed from a cold water storage cistern and fitted with an Open Vent pipe, provided the maximum head does not exceed 30m.
When used in this way, it will not be necessary to install the expansion vessel and cold inlet manifold supplied with the cylinder.
Introduction &
General Requirements
3
Note: The Temperature and Pressure
relief (T&P) valve should be left connected to the cylinder (as supplied). As it may still operate due to temperature it should be connected in the correct manner – refer to guidance given in Section 4 of these Instructions.
1.7 Taps and Fittings
All taps and fittings incorporated in the unvented system should have a rated operating pressure of 7 bar or above.
1.8 Pipework Connections
All Pipework connections to the cylinder must be made in accordance with Figures 2-3 or 2-4 as appropriate.
1.9 Scaling
In hard water areas scaling will form inside the cylinder and this will reduce both the performance and working life of the cylinder. Where the total hardness exceeds 125ppm a high capacity water softener, or suitable water conditioner, should be installed in the incoming cold water supply to the cylinder.
It is recommended that the water temperature control thermostats (on the immersion heaters and dual thermostats) fitted to the cylinder be set no higher than 60°C to minimise scale build up.
1.10 Insulation
All Grant Cylinders are insulated with 40mm thick CFC/HFC free, fire retardant, polyurethane foam injected between the stainless steel cylinder and the outer casing. This polyurethane foam has a Global Warming Potential (GWP) of less than 3 and an Ozone Depletion Potential (ODP) of 0.
1.11 Health and Safety
The information supplied in the table in Section 2 Technical Specification will help you assess the safest way to manoeuvre your cylinder into position. Please use the table to find the empty weight of your cylinder and then consider how you can safely move it into its final position.
Please leave this manual with the householder after installation.
2 Technical Specifications
Technical
Specifications
4
2.1 Technical Data
MonoWave HP Indirect Cylinders
Model Number 125 150 170 200 250 300 400
Storage capacity (litres) 125 150 170 200 250 300 400 Overall diameter (mm) 580 580 580 580 580 580 580 Overall height - with expansion vessel on cold supply (mm) 800 890 1075 1230 1480 1745 2110 Weight empty (kg) 30 32 45 49 59 68 76 Weight full (kg) 155 182 215 249 309 368 476 Secondary return connection (mm) 22 22 22 22 22 22 22 Cold feed/hot draw-off connections (mm) 22 22 22 22 22 22 22 Primary coil connections (mm) 22 22 22 22 22 22 22 Primary coil length (m) 11.68 13.90 13.90 23.36 23.36 27.80 27.80 Primary coil surface area (m2) 1.5 2.0 2.0 3.5 3.5 4.0 4.0 Primary coil pipe diameter (mm) 22 22 22 22 22 22 22 Maximum water supply pressure (bar) 12 12 12 12 12 12 12 System operating pressure - pre-set (bar) 3 3 3 3 3 3 3 Expansion vessel charge pressure (bar) 3 3 3 3 3 3 3 Expansion relief valve pressure (bar) 6 6 6 6 6 6 6 Temp & pressure relief valve lift pressure (bar) 7 7 7 7 7 7 7 Temp & pressure relief valve lift temperature (°C) 90 90 90 90 90 90 90 Maximum primary circuit working pressure (bar) 3 3 3 3 3 3 3
Performance:
Primary coil rating (kW) 24.0 27.8 27.8 47.0 47.0 56.6 56.6 24 hr standing loss (kW)* 1.70 1.92 2.04 2.45 2.69 2.71 2.94
Check list:
Cylinder assembly 125 litre 1 - - - - - ­Cylinder assembly 150 litre - 1 - - - - ­Cylinder assembly 170 litre - - 1 - - - ­Cylinder assembly 200 litre - - - 1 - - ­Cylinder assembly 250 litre - - - - 1 - ­Cylinder assembly 300 litre - - - - - 1 ­Cylinder assembly 400 litre - - - - - - 1 Expansion vessel 12 litre 1 1 - - - - ­Expansion vessel 19 litre - - 1 1 - - ­Expansion vessel 24 litre - - - - 1 1 ­Expansion vessel 35 litre - - - - - - 1 Expansion vessel hose (3/4" BSPF x 3/4" BSPM) c/w washer 1 1 1 1 1 1 1 Expansion vessel wall bracket and band 1 1 1 1 1 1 1 Adaptor (1" BSPF x 3/4" BSPM) - - - - - - 1
1
/2" Temp & pressure relief valve (7 bar 90ºC) factory-fitted 1 1 1 1 1 1 1 Tundish 15/22mm 1 1 1 1 1 1 1 Drain cock (1/2" end feed) 1 1 1 1 1 1 1 Inlet manifold (3 bar pressure reducing valve & 6 bar exp. relief valve) 1 1 1 1 1 1 1 2-port motorised valve 22mm 1 1 1 1 1 1 1 Dual thermostat (Control 25-65ºC High limit 90ºC) 1 1 1 1 1 1 1 Immersion heater 3 kW (13/4" boss) factory-fitted 1 1 1 1 1 2 2
* Test carried out at 60˚C.
Technical
Specifications
5
Figure 2-2: MonoWave HP indirect cylinder dimensions
Dims Model (mm) 125 150 170 200 250 300 400
A 210 210 210 210 210 210 210
B N/A N/A N/A N/A N/A 872 1015
C 460 500 635 765 1020 1290 1550
D 580 670 855 915 1260 1525 1890
E 740 830 1025 1170 1430 1695 2050
F 800 890 1075 1230 1480 1745 2110
Dia 580 580 580 580 580 580 580
MonoWave HP Indirect Cylinder Dimensions
2.2 Dimensions
Dia
ABCDEF
40˚ 30˚
22mm Hot water
draw off
1
/2" T & P Relief
valve (factory fitted)
22mm Heat pump
flow
22mm Heat pump
return
22mm Secondary
return
Immersion heater
(factory fitted) on
300 & 400
models only
22mm Cold water
inlet
Immersion heater
(factory fitted)
Heat pump stat
pocket
0˚30˚
2 Technical Specifications
Technical
Specifications
6
Figure 2-3: MonoWave HP indirect cylinders
- 125, 150, 170, 200 & 250
Figure 2-4: MonoWave HP indirect cylinders
- 300 & 400
2.3 Connections and Controls
Item Description Connection Size
1 Hot water draw off 22mm
2 T & P valve connection
1
/2" BSPF
3 Secondary return 22mm compression
4 Heat pump return tapping 22mm compression
5 Dual stat pocket -
6 Cold water inlet 22mm compression
7 Heat pump flow tapping 22mm compression
8 Immersion heater c/w control
& limit thermostat (factory fitted)
1
3
/4" BSPF
8A Immersion heater c/w control
& limit thermostat (factory fitted) 1
3
/4" BSPF
300 & 400 only
9 Pressure reducing valve - 3 bar -
Item Description Connection Size
10 Balanced cold supply connection 22mm compression
11 Expansion relief valve - 6 bar 15mm compression
12 Temperature & Pressure relief
valve - 90°C/7 bar 15mm compression
13 Tundish 15/22mm
compression
14 Discharge pipe
(not supplied with cylinder) -
15 Mains water supply pipe
(not supplied with cylinder) -
16 Drain cock
(supplied with cylinder) -
Note:
Pipework between items 11 and 12 not supplied with cylinder.
1
9
10
11
12
17 17
1415
16
24
7
3
5
8
6
1
9
10
11
12
1415
16
24
7
3
56
8
8A
Primary Circuit
Installation
7
3 Primary Circuit Installation
Indirect models only
3.3 The 2-Port Valve
To prevent gravity circulation when the boiler or heat pump switches off, the 2-port motorised valve supplied with the unvented hot water kit, must be fitted in the primary flow pipe to the cylinder and wired in accordance with Figure 5-3 for a Grant Aerona heat pump to comply with current legislation.
For other makes of heat pump please check with the heat pump manufacturer for connection details.
3.4 Hard Water Areas
If the cylinder is to be used in a hard water area, we recommend that the primary flow temperature be limited to 75ºC. This will help reduce the migration of suspended solids in the water and help prevent the build up of lime scale.
3.1 Grant MonoWave HP Cylinders
Grant MonoWave HP indirect cylinders are specifically designed for connection to most fully pumped Air Source Heat Pump systems (such as the Grant Aerona Heat Pump range) - either open vented or sealed systems having a maximum working pressure of 3 bar and a maximum working temperature of 90ºC.
If you are in any doubt over the suitability of an Air Source Heat Pump (other than a Grant Aerona heat pump) for use with the cylinder, consult the heat pump manufacturer.
IMPORTANT
Solid fuel or wood burning boilers and gravity circulation systems must not be used on the primary circuit of an unvented hot water system.
3.2 Primary Connections
1. The primary flow and return connections from the heat pump should be made to the flow and return connections of the cylinder. Refer to either Figures 2-3 or 2-4 as appropriate.
The motorised valve (supplied) must be fitted into the primary flow. The primary flow and return fittings are 22mm compression. The valve has 22mm compression connections.
2. Locate the dual thermostat in the stainless steel pocket (refer to either Figures 2-3 or 2-4, as appropriate, for location) and secure using the retaining screws on the thermostat housing.
3. Any automatic or manual air vent fitted to vent air from the upper coil should be installed on the primary flow pipe to the coil.
Secondary Circuit
Installation
8
4 Secondary Circuit Installation
4.1 Cold Water Inlet Manifold
This manifold contains a pressure reducing valve (with integral strainer), double check valve, expansion valve with a stainless steel seat. The pressure reducing valve is factory set. The set pressure is shown on top of the valve. Maximum inlet pressure to valve is 12 bar.
4.2 Installation
1. Cold water supply to be 22mm nominal size.
2. Flush supply pipework before
connection to remove all flux and debris prior to fitting the inlet controls. Failure to do this may result in irreparable damage to the controls and will invalidate the warranty. Once the pipework is flushed connect the cold supply to the Inlet manifold.
3. The manifold can be installed in any position as long as it is installed in the correct flow direction. Refer to the arrows on the side of the body. Make sure that the head of the expansion relief valve is offset from the cylinder for ease of access.
4. The expansion relief valve should be either horizontal or upright - if fitted inverted, debris may be deposited on the seat and cause fouling of the seat when the valve operates. Check direction of flow arrows.
5. The black plastic plug in the body is a pressure gauge connection to enable pressure monitoring to be carried out, should the system develop a fault. It is recommended that this be accessible.
4.3 Expansion Vessel
A suitable expansion vessel with a pre­charge pressure of 3bar is supplied for fitting to all cylinders.
The supplied expansion vessel must be connected into the cold water supply, between the expansion relief valve (in the inlet manifold) and the cylinder using the flexible hope provided. The expansion vessel must be positioned with the entry point at the bottom. No valve should be fitted between the expansion vessel and cylinder.
The air charge pressure in the expansion vessel must be regularly checked (e.g. at every service) and topped up as necessary. The correct air charge pressure is 3.0bar.
Refer to Sections 7.1 and 7.5 for further details.
4.4 Temperature and Pressure Relief Valve
The temperature and pressure relief valve (T&P Valve) is supplied factory fitted to the cylinder. The T&P valve must not be removed from the cylinder or tampered with in any way. The valve is pre-set to lift at 7bar or 90°C and any attempt to adjust it will invalidate the warranty.
4.5 Hot Water Supply
Connect the hot water supply pipe to the top outlet (1) of the cylinder.
4.6 Prevention of Scalding
Building Regulations Approved Document G (Part G3) requires that the hot water temperature supplied to a bath should be limited to a maximum of 48°C by using an in-line blending valve (not supplied with the cylinder) with a maximum temperature stop. The length of the supply pipe between the blending valve and the bath hot water outlet should be kept to a minimum to prevent the colonisation of waterborne pathogens (e.g. legionella). Refer to Approved Document G for further details.
6. Expansion relief drain pipework must be connected to a safe visible discharge point via a tundish and the pipework must have a continuous fall. Connect the Expansion Relief valve outlet into the discharge pipe from the Temperature and Pressure Relief valve using a 15mm copper pipe and tee piece (not supplied). Fit the Tundish below this tee piece using a short length of copper pipe. Refer to Sections 4.7, 4.8 and 4.9 for further information on Tundish and Discharge pipe.
7. The pressure reducing valve has two outlets, the second one is for a balanced cold water supply, to a shower or a bidet (over rim type
only, ascending spray type requires type AA, AB or AD air gap). Major shower manufacturers advise fitting a mini expansion vessel in the balanced cold supply to accommodate thermal expansion and prevent tightening of shower controls. If the dwelling has a shower mixing valve (manual or thermostatic) or a Bidet (over rim type) use the cold water supply from the Balanced Cold water connection on the Inlet Manifold for these outlets. Do not use the balanced cold connection to supply bath taps as this can reduce the flow of water available to the cylinder.
If the balanced cold water outlet is not required, blank off the port.
The Benchmark book enclosed with the cylinder should be completed after commissioning of the system.
The cylinder must be registered with Grant UK within 30 days of installation. Refer to Section 11 for further details on the Cylinder Warranty.
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