Lochinvar CH 155 PG CE, CH 200 PG CE, CH 200 G CE, CH 100 PG CE, CH 155 G CE Installation, Commissioning, User & Maintenance Instructions

...

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These instructions must be read and understood before installing, commissioning, operating or maintaining the equipment.

IMPORTANT INFORMATION

0310570 March 2012

Installation, Commissioning, User & Maintenance Instructions

High Efficiency Water Heaters and Boilers

Charger

Direct Gas Fired Floor Standing Water Heater

with Permanent Pilot Ignition

Models:

CH 100 G CE CH 155 G CE CH

and PG CE and PG CE

200 G CE and PG CE CH 300 G CE and PG CE CH 400 G CE and PG CE CH 500 G CE and PG CE CH 600 G CE and PG CE

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Lochinvar Ltd

7 Lombard Way The MXL Centre Banbury Oxon OX16 4TJ

www.lochinvar.ltd.uk

High Efficiency Water Heaters and Boilers

Tel: +44 (0) 1295 269 981 Fax: +44 (0) 1295 271 640 Email: info@lochinvar.ltd.uk

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Read this manual carefully

Warning

Read this manual carefully before starting the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater.

Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by any means whatsoever without the prior written approval of the supplier.

The supplier reserves the right to modify specifications stated in this manual.

Trademarks

Any brand names mentioned in this manual are registered trademarks of their respective owners.

Liability

The supplier accepts no liability for claims from third parties arising from unauthorised use, use other than that stated in this manual, and use other than in accordance with the General Conditions registered at the Chamber of Commerce.

Refer further to the General Conditions. These are available on request, free of charge.

Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components, the manual may nonetheless contain errors and inaccuracies.

Should you detect any errors or inaccuracies in the manual, we would be grateful if you would inform us. This helps us to further improve our documentation.

Liability

In the event of problems with your gas, electricity or water supply connections, please contact the supplier/installation engineer of your installation.

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Instruction manual CH 5

Table of contents

1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

1.1 About the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 7

1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

1.6 Notation conventions- - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - - 9

2 Working principle of the water heater - - - - - - - - - - - - - 11

2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

2.2 General working principle of the water heater - - - - - - - - - - - - - - - 11

2.3 Water heater operating cycle - - - - - - - - - - - - - - - - - - - - - - - 13

2.4 Protection for the water heater - - - - - - - - - - - - - - - - - - - - - - 13

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 14

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.3 Ambient conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 19

3.5 Installation diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

3.6 Unvented water connections - - - - - - - - - - - - - - - - - - - - - - - 24

3.7 Vented water connections - - - - - - - - - - - - - - - - - - - - - - - - 25

3.8 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.9 Flue gas discharge- - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.10 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.11 Checking the supply pressure and burner pressure - - - - - - - - - - - - 30

4 Conversion to a different gas category - - - - - - - - - - - - 33

4.1 Conversion to a different gas category - - - - - - - - - - - - - - - - - - 34

5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

5.1 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 38

5.2 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 38

6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

6.1 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 40

6.2 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 40

7 The control panel- - - - - - - - - - - - - - - - - - - - - - - - 41

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

7.2 Control panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

7.3 Explanation of icons - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

7.4 On/off switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

7.5 Control thermostat - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

7.6 Weekly timer circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

7.7 Flue gas thermostat reset button - - - - - - - - - - - - - - - - - - - - - 42

8 Status of the water heater - - - - - - - - - - - - - - - - - - - 43

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

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8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

8.3 Power Anode status- - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

8.4 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

9 Starting the water heater - - - - - - - - - - - - - - - - - - - - 45

9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

9.2 Starting the appliance - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

9.3 The appliance's heating cycle - - - - - - - - - - - - - - - - - - - - - - - 45

10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 47

10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

10.2 Shutting the appliance down for a brief period ("OFF" mode) - - - - - - - - 47

10.3 Isolating the appliance from the mains - - - - - - - - - - - - - - - - - - - 47

10.4 Shutting the appliance down for a long period - - - - - - - - - - - - - - - 47

11 Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

11.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - - 50

11.3 Troubleshooting table - 'no hot water' - - - - - - - - - - - - - - - - - - - 51

11.4 CH Troubleshooting table - 'insufficient hot water' - - - - - - - - - - - - - 52

12 Performing maintenance - - - - - - - - - - - - - - - - - - - - 53

12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

12.2 Preparation for maintenance - - - - - - - - - - - - - - - - - - - - - - - 53

12.3 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 53

12.4 Gas-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 55

12.5 Finalising maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 56

13 Warranty (certificate) - - - - - - - - - - - - - - - - - - - - - - 57

13.1 General warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

13.2 Tank warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

13.3 Conditions for installation and use - - - - - - - - - - - - - - - - - - - - - 57

13.4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

13.5 Scope of the warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

13.6 Claims - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

13.7 Obligations of Lochinvar Ltd - - - - - - - - - - - - - - - - - - - - - - - - 58

14 Electrical diagram - - - - - - - - - - - - - - - - - - - - - - - 59

14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

15 Declaration of Conformity - - - - - - - - - - - - - - - - - - - 63

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1 Introduction

1.1 About the appliance

This manual describes how to install, service and use the CH appliance. The CH appliance is a gas-fired open boiler without fan. These Charger devices have a pilot flame ignition feature and flue gas discharge safety device

The CH is an appliance of type B

11B S

The information in this manual applies to types: CH 100, CH 155, CH 200, CH 300, CH 400, CH 500 and CH 600.

The water heater has been manufactured and equipped in accordance with the European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89). The water heaters are therefore compliant with the European Directive for Gas water heaters, and and are entitled to bear the CE mark.

Warning

Read this manual carefully before starting the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater.

1.2 What to do if you smell gas

Warning

If you smell gas:

No naked flames! No smoking!

Avoid causing sparks! Do not use any electrical equipment or switch, i.e. no telephones, plugs or bells!

Open windows and doors!

Shut off the mains gas supply valve!

Warn occupants and leave the building!

After leaving the building, alert the gas distribution company or your installation engineer.

1.3 Regulations

As the (end) user, installation engineer or service and maintenance engineer, you must ensure that the entire installation complies, as a minimum, with the official local:

• building regulations;

• energy supplier's directives for existing gas installations;

• directives and technical guidelines for natural gas installations;

• safety requirements for low-voltage installations;

• regulations governing the supply of drinking water;

• regulations governing ventilation in buildings;

• regulations governing the supply of air for combustion;

• regulations governing the discharge of products of combustion;

• requirements for installations that consume gas;

• regulations governing indoor waste water disposal;

• regulations imposed by fire service, power companies and municipality.

0063

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Furthermore, the installation must comply with the manufacturer's instructions.

Note

The installation is also subject to any later amendments and/or additions to all regulations, requirements and guidelines published on or prior to the moment of installation.

1.4 Target groups

The three target groups for this manual are:

• (end) users;

• installation engineers;

• service and maintenance engineers.

Symbols on each page indicate the target groups for whom the information is intended. See the table.

Target group symbols

Caution

This water heater is not intended for use by persons with reduced physical, sensory or mental capacities, or who lack the necessary experience or knowledge, unless the person responsible for their safety is supervising them or has explained to them how the water heater should be used.

Caution

This water heater is not intended to be used by children. Always supervise children, and ensure that they do not play with the water heater.

1.5 Maintenance

A service should be carried out at least once a year, both on the water side and on the gas side. Among other things, the service interval depends on the water quality, the average burning time per day and the set water temperature.

Note

To determine the correct service interval, it is recommended to arrange for the service and maintenance engineer to check the water heater on both the water and gas side within three months following installation. Based on this check, the best service interval can be determined.

Note

Regular maintenance extends the service life of the water heater.

Both the end user and the service and maintenance engineer are responsible for regular maintenance. They will need to establish clear agreements on this.

Note

If the water heater is not regularly serviced, the warranty will become void.

Symbol Target Group

(End) user

Installation engineer

Service and maintenance engineer

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1.6 Notation conventions

The following notation is used in this manual:

Note

Important information.

Caution

Ignoring this information can lead to the water heater being damaged.

Warning

Failure to carefully read this information may lead to danger of personal

injury, and serious damage to the water heater.

1.7 Overview of this document

The table provides an overview of the contents of this document.

Contents of this document

Chapter Target groups Description

Working principle of the water heater

This chapter describes the working principle of the water heater.

Installation This chapter describes the installation activities to be

carried out before final commissioning.

Conversion to a different gas category

This chapter describes how to convert the water heater to a different gas category and/or family of gases.

Filling This chapter describes how to fill the water heater.

Draining This chapter describes how to drain the water heater.

The control panel This chapter describes the appliance's control panel, and

how to use it.

Status of the water heater This chapter describes the status (mode or condition) that

the water heater may have, and possible actions to take.

Starting the water heater This chapter describes how to start the water heater. The

general operating cycle of the water heater is also described.

Shutting down This chapter describes how to decommission the water

heater for a brief or long period of time.

Errors This chapter is mainly intended for the installation

engineer and the service and maintenance engineer. It describes appliance errors. A troubleshooting table of possible features, causes and solutions is provided. End users may also refer to this chapter for additional information about the appliance.

Performing maintenance This chapter sets out the maintenance tasks to be carried

out.

General warranty This chapter states the warranty terms and conditions.

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2 Working principle of

the water heater

2.1 Introduction

This chapter covers the following topics:

• General working principle of the water heater;

• Water heater operating cycle;

• Protection for the water heater;

• Safety of the installation.

2.2 General working principle of the water heater

Cut-away view of the water heater

Legend

Unused numbers are not applicable

2. hot water outlet

6. control panel

8. combustion chamber

9. anode

10. tank

11. heat exchanger

12. inspection and cleaning

opening

14. cold water inlet

15. drain valve

16. gas control valve

21. flame probe

22. chimney pipe

24. insulation layer

33. draught diverter

34. flue gas sensor

35. radiation

shield/condensation tray

36. bar burners/burner tray

37. flue gas thermostat

38. safety thermostat sensor

39. high-limit thermostat sensor

41. control thermostat

42. high-limit thermostat

43. safety thermostat

45. control thermostat sensor

51. pilot burner

52. spark igniter

IMD-1037 R0

38237

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Working principle of the water heater

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In this appliance, the cold water enters the bottom of the tank through the cold water inlet (26). The heat of combustion is conducted to the water by the combustion chamber (10) and flue tubes (4). The heated tap water leaves the tank through the hot water outlet (15). Once the appliance is completely filled with water, it will constantly be under mains water pressure. When hot water is drawn from the appliance, it is immediately replenished with cold water.

The appliance has an ignition probe that lights the pilot flame burner (12).

The gas required for combustion flows via the gas control (12) into the manifold. There are orifices in the manifold. The gas is injected into the burner bars at pressure from these orifices (29). The burner bars together form the burner tray. The injection of gas into the burner bars also draws in the primary air required for combustion. The narrow opening in the orifice causes the gas flow to accelerate. This in turn causes a partial vacuum. It is this partial vacuum that draws in the air (the Venturi effect). Additional air is drawn in through the opening in the burner tray.

When the gas/air mixture starts to flow, it is ignited by the pilot burner.

The flue gases generated by this combustion are led through the flue tubes (4). Flue baffles (5) are fitted inside the flue tubes. These retard the flow of the flue gases, thereby increasing the thermal efficiency of the appliance.

The flue gases are exhausted from the appliance via the draught diverter (2).

A radiation shield/condensation tray (11) is mounted below the burner tray. This prevents overheating of the floor area below the appliance, as well as serving as a collection tray for condensation water.

The insulation layer (6) prevents heat loss. The inside of the tank is enamelled to protect against corrosion. The anodes (3) offer extra protection.

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2.3 Water heater operating cycle

The entire appliance is regulated by a control thermostat. The control thermostat monitors the water temperature (T

water

). The appliance's heating

cycle is activated as soon as T

water

falls below the specified threshold value

set

). The value for T

set

can be adjusted using the control thermostat (±40°C to

±70°C).

As soon as T

water

drops below T

set

there is a demand, and the control thermostat closes, causing the main valve on the gas control to open. The gas mixes with the air it draws along. This mixture is ignited by the pilot burner and the water is heated. As soon as T

water

exceeds T

set

, demand ceases, the

thermostat opens again, and the heating cycle stops.

The control thermostat has a certain margin both when closing and opening. We refer to this margin as the hysteresis. The hysteresis cannot be adjusted.

2.4 Protection for the water heater

The burner control monitors the water temperature by means of thermostats and ensures safe combustion. This takes place using:

•the Gas control

•the Thermocouple

•the Water temperature protection

•the Flue gas backflow safeguard

2.4.1 Gas control

The gas control has 2 valves for safety purposes:

1. The main valve, which controls the gas supply to the burner tray and which is switched via the I/0/II switch circuit and the control, high-limit and flue gas thermostats. This circuit is powered by the supply voltage.

2. The safety valve, which controls the gas supply to the pilot burner and which is switched via the thermocouple circuit and the safety thermostat. This circuit is powered by the millivoltage from the thermocouple that is located in the pilot flame. Whenever the safety valve closes, the main valve also closes.

2.4.2 Thermocouple

1. To prevent gas flowing when there is no combustion, a thermocouple is fitted. As a result of the presence of the (permanent) pilot flame, the thermocouple maintains a millivoltage which keeps the gas control's safety valve open.

2. If the pilot flame goes out, this voltage disappears and the gas control's safety valve closes, interrupting the gas supply to the burner tray.

2.4.3 Water temperature protection

To ensure a safe water temperature is not exceeded, the high-limit thermostat sensor is installed at the top of the appliance. This is because stratification ('stacking') of the water temperature can mean that the temperature at the top of the appliance can be considerably higher than the set temperature for the hot water.

In the event that both the control and high-limit thermostats should fail, there is also a safety thermostat.

The table explains how the high-limit and safety thermostats respond to the sensors.

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Working principle of the water heater

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Temperature protection

2.4.4 Flue gas backflow safeguard

The flue gases are discharged to the outside via the draught diverter (33) and the flue (22). To prevent the flue gases from flowing back into the boiler room, the discharge ducting is monitored by a feature called the Thermal Reflux Safeguard (TRS). This uses a flue gas thermostat (37) with a flue gas thermostat sensor (34) that are located in the draught diverter. Under normal circumstances this sensor will register the ambient temperature.

However, if the chimney is not drawing sufficiently (for example, due to a blockage in the chimney), the flue gases will 'reflux' and flow back past the flue gas thermostat sensor. The sensor will then detect an excessive temperature and the flue gas thermostat will open. The demand will cease, and the burner control will immediately stop the heating cycle. The flue gas thermostat will also lock out. It must be manually reset before the appliance can resume operation .

2.5 Safety of the installation

In addition to the appliance's standard built-in safety monitoring, the appliance must also be protected by an expansion vessel, expansion valve, pressure reducing valve, non-return valve and a T&P valve.

The use of an expansion vessel, expansion valve and/or pressure reducing valve depends on the type of installation: unvented or vented.

2.5.1 Unvented installation

With an unvented installation, an expansion valve valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being caused to the enamelled coating (in the appliance) or to the tank. A nonreturn valve prevents excessive pressure buildup in the water supply system. This valve also prevents water from flowing backwards from the tank into the cold water supply system. The pressure reducing valve protects the installation against an excessively high water supply pressure (> 8 bar). These components are fitted to the cold water pipe (3.7 "Vented water connections").

2.5.2 Vented installation

With a vented installation, excess pressure is taken up by the open cold water head tank. The height of the head tank determines the working pressure in the water heater, which may not exceed 8 bar. The installation must also be fitted with a vent pipe from the hot water pipe, that opens into the cold water tank.

Ideally, the vent pipe should discharge into a separate tundish/drain or otherwise to the open cold water head tank. The water heater should also be fitted on the hot water side with a stop valve (3.6.3 "Hot water side").

Protection Description

High-limit thermostat If the high-limit thermostat sensor (39) detects a temperature greater than

84°C, the high-limit thermostat will open. The demand will cease, and the burner control will stop the heating cycle until the high-limit thermostat closes again. At that moment, the burner control resets the appliance, and the heating cycle resumes. The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the appliance.

Safety thermostat If the safety thermostat sensor (38) detects a temperature greater than 93°C,

the safety thermostat will open. The demand will cease, and the burner control will immediately stop the heating cycle. A lockout error of the burner control takes place. It must be manually reset before the appliance can resume operation .

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2.5.3 T&P valve

A T&P valve is only mandatory in an unvented installation. However, the supplier also recommends the use of a T&P valve in vented installations.

A T&P (Temperature and Pressure Relief) valve monitors the pressure in the tank and the water temperature at the top of the tank. If the pressure in the tank becomes excessive (> 10 bar) or the water temperature is too high (> 97°C), the valve will open. The hot water can now flow out of the tank. Because the appliance is under water supply pressure, cold water will automatically flow into the tank. The valve remains open until the unsafe situation has been rectified. The appliance is fitted standard with a connecting point for a T&P valve (3.6.3 "Hot water side").

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Instruction manual CH 17

3 Installation

Warning

The installation must be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire brigade.

The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations").

3.1 Introduction

This chapter describes the installation activities to be carried out before the appliance may be started up (9 "Starting the water heater"), in particular:

• Packaging;

• Ambient conditions;

• Technical specifications;

• Vented water connections;

• Gas connection;

• Flue gas discharge;

• Electrical connection;

• Checking the supply pressure and burner pressure.

For a possible conversion to a different gas category, see conversion (4 "Conversion to a different gas category").

3.2 Packaging

To avoid damaging the water heater, remove the packaging carefully.

We recommend unpacking the water heater at or near its intended location.

Caution

The water heater may only be manoeuvred in an upright position. Take care that the water heater is not damaged after unpacking.

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18 Instruction manual CH

3.3 Ambient conditions

Caution

The water heater may not be used in rooms where chemical substances are stored or used due to the risk of explosion, and corrosion of the water heater. Some propellants, bleaching agents and degreasing agents etc. disperse vapours that are explosive and/or cause accelerated corrosion. If the water heater is used in a room in which such substances are present, the warranty will be void.

CH appliances are open appliances and may only be installed in an open boiler room. They are type B

11B S

3.3.1 Air humidity and ambient temperature

The boiler room must be frost-free, or be protected against frost. The table shows the ambient conditions that must be adhered to for correct functioning of the electronics present in the water heater to be guaranteed.

Air humidity and ambient temperature specifications

3.3.2 Maximum floor load

Allow for the appliance's weight with respect to the maximum floor load; refer to the table.

Weight of the appliance filled with water

Air humidity and ambient temperature

Air humidity max. 93% RH at +25°C

Ambient temperature Functional: 0 <

T < 60°C

Weight (kg) of the appliance filled with water

CH 100 507

CH 155 507

CH 200 510

CH 300 581

CH 400 576

CH 500 525

CH 600 526

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3.3.3 Working clearances

For access to the appliance, it is recommended that the following clearances are observed (see figure):

• AA: around the appliance's control column and cleaning openings: 100 cm.

• BB: all sides of the appliance: 50 cm.

• Above the appliance (room to replace the anodes):

- 100 cm if using fixed anodes, or

- 50 cm if using flexible anodes.

If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered.

Note

When installing the appliance, be aware that any leakage from the tank and/or connections can cause damage to the immediate environment or floors below the level of the boiler room. If this is the case, the appliance should be installed above a wastewater drain or in a suitable metal leak tray.

The leak tray must have an appropriate wastewater drain and must be at least 5cm deep with a length and width at least 5cm greater than the diameter of the appliance.

Working clearances

IMD-0275 R2

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Installation

20 Instruction manual CH

3.4 Technical specifications

The water heater is supplied without accessories. Check the dimensions (3.4 "Technical specifications"), gas data (3.4.3 "Gas data") and other specifications (3.4.2 "General and electrical specifications") of any accessories you plan to use.

3.4.1 Dimensions of the water heater

Plan and elevation of the water heater

Legend

See the table.

10º

37º 45º

IMD-0145 R3

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Instruction manual CH 21

Dimensions (all measurements in mm unless otherwise indicated)

3.4.2 General and electrical specifications

General and electrical specifications

Size Description CH

100CH155CH200

CH 300CH400CH500CH600

A Overall height 1910 1910 1890 2155 2155 1950 2145

B Height of top of appliance 1700 1700 1700 1900 1900 1735 1810

D Appliance diameter 710 710 710 710 710 710 710

F Width 800 800 800 800 800 800 800

G Diameter of flue gas discharge 130 130 150 180 180 200 250

K Height of gas connection 145 145 145 145 145 145 145

M Height of cold water supply 505 505 505 505 505 515 590

N Height of hot water outlet 1545 1545 1545 1750 1750 1580 1655

P Height of cleaning opening 670 670 670 670 670 680 765

R Height of drain valve connection 440 440 440 453 455 465 540

S Height of T&P valve connection 1490 1490 1490 1700 1700 1535 1600

1 Cold water supply connection (external) R1

/2R11/2R11/2R11/2R11/2R11/2R11/

2 Hot water outlet connection (internal) Rp11/2Rp11/2Rp11/2Rp11/2Rp11/2Rp11/2Rp11/

3 Gas control connection (internal) Rp3/4Rp3/4Rp3/4Rp3/4Rp3/4Rp3/4Rp1

4 Drain valve connection (internal) Rp1

/2Rp11/2Rp11/2Rp11/2Rp11/2Rp11/2Rp11/

5 T&P valve connection (internal) 1 - 11.5

NPT

1 - 11.5 NPT

6 Cleaning/inspection opening Ø 100 Ø 100 Ø 100 Ø 100 Ø 100 Ø 100 Ø 100

DESCRIPTION Unit CH

100

CH 155

CH 200

CH 300

CH 400

CH 500

CH 600

Contents litres 309 309 298 357 335 278 253

Maximum working pressure bar 8 8 8 8 8 8 8

Empty weight kg 198 198 212 224 241 247 273

Heating time ΔT=45

C minutes 38 30 23 25 17 11 8

Number of anodes - 2 2 2 2 3 3 4

Number of bar burners/orifices

- 3344779

Number of flue tubes/flue baffles

- 557691216

Electrical power consumption W 30 30 30 30 30 30 30

Supply voltage (-15% +10% VAC)

volts 230 230 230 230 230 230 230

Mains frequency Hz (±1Hz) 50 50 50 50 50 50 50

IP class - 30 30 30 30 30 30 30

Page 22

Installation

22 Instruction manual CH

3.4.3 Gas data

Gas data

Description II

2H3+

Unit CH

100

CH 155

CH 200

CH 300

CH 400

CH 500

CH 600

Gas category 2H: General

Orifice diameter mm 2.90 3.20 3.20 3.30 2.95 3.20 3.30

(1) = Blank plate (2) = Burner pressure

regulator (3) = High/low regulator

1, 2 or 32222222

G20 - 20 mbar

Nominal load (gross calorific value)

kW 33.9 42.1 53.4 59.9 83.2 102.5 128.4

Nominal output kW 25.6 31.9 40.4 45.3 62.9 77.6 97.1

Supply pressure mbar 20 20 20 20 20 20 20

Burner pressure mbar 8.5 8.6 7.8 8.5 8.5 9.2 7.8

Gas consumption

(*)

m3/h 3.2 4.0 5.1 5.7 7.9 9.8 12.2

General 3+

Orifice diameter mm 1.6 1.7 1.6 1.75 1.50 1.70 1.75

(1) = Blank plate (2) = Burner pressure regulator (3) = High/low regulator

1, 2 or 31111111

G30 - 30 mbar (butane)

Nominal load (gross calorific value)

kW 33.9 42.2 53.4 59.2 80.8 100.1 127.5

Nominal output kW 26.3 32.7 41.4 45.9 62.6 77.6 98.8

Supply pressure mbar 30 30 30 30 30 30 30

Burner pressure

(†)

mbar-------

Gas consumption

(*)

kg/h 2.5 3.1 3.9 4.3 5.9 7.3 9.3

G31 - 37 mbar (propane)

Nominal load (gross calorific value)

kW 33.1 41.4 52.8 58.2 78.4 98.3 125.5

Nominal output kW 25.6 32.0 40.8 45.0 60.6 75.9 97.0

Supply pressure mbar 37 37 37 37 37 37 37

Burner pressure

(†)

mbar-------

Gas consumption

(*)

kg/h 2.4 3.0 3.8 4.2 5.6 7.0 9.0

(*) Based on 1013.25 mbar and 15 °C. (†) If using a blank plate instead of a burner pressure regulator, it is assumed that the burner pressure is equal to

the supply pressure. In practice, however, the burner pressure will be lower.

Page 23

Instruction manual CH 23

3.5 Installation diagram

The figure shows the Installation diagram. This diagram is referred to in the sections describing the actual connection procedure.

Installation diagram

Legend

Unused numbers are not applicable

1. pressure reducing valve

(mandatory)

3. T&P valve (mandatory)

4. stop valve (recommended)

5. non-return valve (mandatory)

6. circulation pump (optional)

7. top to bottom circulation

pump (optional)

9. drain valve

10. manual gas valve

(mandatory)

11. service stop valve

(mandatory)

12. temperature gauge

(recommended)

14. draw-off points

15. expansion valve (mandatory)

16. expansion vessel

(mandatory)

17. 3-way aeration valve

(recommended)

18. cold water head tank

19. float switch A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

Page 24

Installation

24 Instruction manual CH

3.6 Unvented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.6.1 Cold water side

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side as required by the applicable regulations (1.3 "Regulations").

2. The maximum working pressure of the water heater is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve (1).

3. Fit a non-return valve (5) and an expansion vessel (16).

4. Fit an expansion valve (15) and connect the overflow side to an open waste water pipe.

3.6.2 Shunt pipe

You can connect a top to bottom circulation pump to prevent stacking of the water in the water heater.

1. Optional: Depending on the draw-off pattern, fit a shunt pipe (Ø 22 mm), a stop valve (11) and a top-to-bottom circulation pump (7).

2. Fit a non-return valve (5).

3. Fit a stop valve (11).

3.6.3 Hot water side

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes prevents unnecessary energy loss.

1. Optional: fit a temperature gauge (12) so you can check the temperature of the tap water.

2. Fit the T&P valve (3).

3. Fit a stop valve (11) in the hot water outlet pipe for servicing.

3.6.4 Drain valve

1. Fit the standard drain valve supplied (9).

2. If desired, fit a circulation pipe (3.6.5 "Circulation pipe"). Otherwise, fit the sealing nut and gasket (C) supplied with the drain valve, as per the diagram.

Page 25

Instruction manual CH 25

3.6.5 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort, and reduces water wastage.

1. Fit a circulation pump (6) of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation piping to the T-piece on the drain valve (9) as per the drain valve diagram (3.6.4 "Drain valve").

3.7 Vented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.7.1 Cold water side

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the water heater, as required by applicable regulations.

3.7.2 Shunt pipe

You can connect a top to bottom circulation pump to prevent stacking of the water in the water heater.

1. Optional: Depending on the draw-off pattern, fit a shunt pipe (Ø 22 mm), a stop valve (11) and a top-to-bottom circulation pump (7).

2. Fit a non-return valve (5).

3. Fit a stop valve (11).

IMD-0122 R1

Page 26

Installation

26 Instruction manual CH

3.7.3 Hot water side

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes prevents unnecessary energy loss.

1. Fit the T&P valve (3).

2. Optional: fit a temperature gauge (12) so you can check the temperature of the tap water.

3. Fit a stop valve (4) in the hot water outlet pipe for servicing.

4. If a circulation pipe is required, continue by installing the circulation pipe (3.6.5 "Circulation pipe").

3.7.4 Drain valve

1. Fit the standard drain valve supplied (9).

2. If desired, fit a circulation pipe (3.6.5 "Circulation pipe"). Otherwise, fit the sealing nut and gasket (C) supplied with the drain valve, as per the diagram.

3.7.5 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is required at draw-off points, a circulation pump can be installed. This improves comfort, and reduces water wastage.

1. Fit a circulation pump (6) of the correct capacity for the length and resistance of the circulation system.

2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation piping to the T-piece on the drain valve (9) as per the drain valve diagram (3.6.4 "Drain valve").

IMD-0122 R1

Page 27

Instruction manual CH 27

3.8 Gas connection

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

Caution

Make sure that the diameter and length of the gas supply pipe are large

enough to supply sufficient capacity to the water heater.

See (D) in the installation diagram (3.5 "Installation diagram").

1. Fit a manual gas valve (10) in the gas supply pipe.

2. Blow the gas pipe clean before use.

3. Close the manual gas valve.

4. Fit the gas supply pipe to the gas control valve.

Warning

After fitting, check for leaks.

3.9 Flue gas discharge

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

Fit a vertical chimney pipe (2) of at least 0.5 metres length to the opening of the draft diverter, before fitting the rest of the chimney materials according to current regulations (1.3 "Regulations").

Installing the draught diverter

Legend

1 draught diverter 2 flue gas discharge

>0,5m

IMD-0148 R2

Page 28

Installation

28 Instruction manual CH

Note

Use flue gas discharge materials that comply with the

regulations (1.3 "Regulations").

Note

Make sure that the chimney discharges into an area approved for this type

of appliance.

3.10 Electrical connection

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.10.1 Introduction

Topics covered in this paragraph, in sequence:

• Preparations;

• Connecting the mains power;

• Weekly timer circuit;

3.10.2 Preparations

The figure shows a view of the terminal block, and the table explains the relevant connections.

Connector block

Legend

A. screws B. cover C. terminal block

IMD-0150 R1

Page 29

Instruction manual CH 29

1. In preparation, first remove the protective cover from the control column:

2. Undo the 4 screws (1).

3. Remove the protective cover (2) from the electrical part.

The connector block (C) is now visible.

Note

Consult the Electrical diagram for the electrical component connections.

Terminal block

3.10.3 Connecting the mains power

The water heater is supplied without a power cable and isolator.

Note

In order to receive electrical power, the water heater has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the water heater. The power cable must have cores of at least 3 x 1.0 mm 2 .

Warning

Leave the water heater electrically isolated until you are ready to

commission it.

1. Feed the power cable through the metric strain relief in the top of the control

column.

2. Connect the earth ( ), live (L

) and neutral (N) of the power cable to

terminals 1 to 3 of the connection block according to the table.

3. Tighten the strain relief so that the cable is clamped.

4. If you do not need to make any more connections, then fit the protective

cover back on the control column.

5. Connect the power cable to the isolator.

3.10.4 Weekly timer circuit

1. Cut the image of the weekly timer from the operating panel.

2. Place the weekly timer in the opening thus created.

3. Connect the cables to points 10 (N), 12 (L) and 14 (L) using wire end

sheaths.

4. Connect the cable with the crimped terminal clip onto position B4 on the

ON/OFF switch.

5. If you do not need to make any more connections, then fit the protective

cover back on the control column.

Mains power

Flue gas

discharge

safety

Week timer circuit

N NNLLLL

1234567891011121314

Page 30

Installation

30 Instruction manual CH

3.11 Checking the supply pressure and burner pressure

Note

Before starting the appliance and/or checking the supply pressure and

burner pressure, you must fill (5 "Filling") the appliance.

Caution

Before starting up for the first time or after conversion, you must always

check the supply pressure and burner pressure.

Note

The easiest way to check the gas pressures is by using two pressure

gauges. This procedure assumes that these two gauges are available.

Legend Unused numbers are not applicable

4. burner pressure controller

5. blank plate

6. supply pressure nipple

7. gas control

8. manifold test nipple

9. sealing screw

10. burner pressure adjustment

screw

Gas control for CH

Page 31

Instruction manual CH 31

Reading off and adjusting

1. Isolate the appliance from the mains power (10.3 "Isolating the appliance

from the mains").

2. To check the supply pressure, test nipple (6) is used. The manifold test nipple (8) is used for measuring the burner pressure. Sealing screws are located inside the test nipples. Loosen both sealing screws by a few turns. Do not completely loosen them; they can be difficult to retighten.

3. Connect a pressure gauge to the manifold test nipple (8).

4. Open the gas supply and bleed the air from the mains gas supply via test nipple (6).

5. Connect a pressure gauge to the manifold test nipple (6) when gas starts to flow from this nipple.

6. Switch on the power to the appliance using the isolator on the appliance.

7. Set the control thermostat to the maximum temperature and start the appliance running by setting the ON/OFF switch to position I.

8. The heating cycle will start, and after a short time the burner tray will ignite.

9. After the burner tray has ignited, wait approximately 1 minute before reading the dynamic pressures.

Note

If the burner pressure is not correct and the appliance is fitted with a blank

plate or high-low control, you will not be able to adjust the pressure. In this case, consult your installation engineer or supplier. If the appliance is indeed fitted with a burner pressure regulator, the pressure can be adjusted ( "Adjusting

the pressure").

10. Adjust the burner pressure by turning the adjusting screw (10), depending on the correction required:

- Adjustment screw anticlockwise: burner pressure decreases.

- Adjustment screw clockwise: burner pressure increases.

11. Cover the opening of the adjusting screw and check the burner pressure against the value given in the gas data table (3.4.3 "Gas data").

12. If the pressure reading is not correct, repeat the burner pressure adjustment until the correct pressure is reached.

13. Fit the cap (9) back on the burner pressure regulator.

14. Shut off the gas supply.

15. Disconnect the two pressure gauges and retighten the sealing screws in the test nipples.

Note

Before starting the appliance up, take time to fill in the warranty card

supplied with the appliance. This enables us to guarantee the quality of our systems and further enhance our warranty procedure.

16. Please return this card as soon as possible. Your customer will then receive a warranty certificate with our warranty conditions.

Page 32

Installation

32 Instruction manual CH

Adjusting the pressure

1. Remove the cap (2) from the burner pressure regulator.

2. Depending on the correction required, correct the burner pressure by turning adjustment screw (3):

- Adjustment screw anticlockwise: burner pressure decreases.

- Adjustment screw clockwise: burner pressure increases.

3. Cover the opening of the adjusting screw and check the burner pressure against the value given in thegas data table (3.4.3 "Gas data").

4. If the pressure reading is not correct, repeat the burner pressure adjustment until the correct pressure is reached.

5. Fit the cap (2) back on the burner pressure regulator.

Finalising

1. Shut off the gas supply.

2. Disconnect the two pressure gauges and retighten the sealing screws in the test nipples.

3. Replace the cover.

Page 33

Instruction manual CH 33

4 Conversion to a

different gas category

Caution

The conversion may only by carried out by a competent person.

If the appliance has to operate on a different family of gases (liquid petroleum gas or natural gas) or other gas category, other than that for which the appliance has been configured at the factory, then the appliance will have be adapted using a special conversion kit.

Caution

You must check the supply pressure and burner pressure once the

conversion is complete.

Exchanging orifices

Legend

1. cover plate

2. locking strips

3. orifice with stamped figures

Page 34

Conversion to a different gas category

34 Instruction manual CH

4.1 Conversion to a different gas category

1. Isolate the appliance from the power supply (10.3 "Isolating the appliance

from the mains").

2. Shut off the gas supply.

Caution

The burner may be hot.

3. Unscrew the cover plate (1) from the burner support.

4. Use a suitable tool to remove the retaining strips (2). Note that the retaining strips have very sharp edges. Withdraw the retaining strips straight upwards.

Note

The radiation shield / condensation tray can be temporarily loosened to

simplify disassembly of the burner.

5. Remove the burners one by one from their brackets at the front. To do this, you first move them away from you and then downwards. The orifices will now be accessible

6. Remove the orifices.

7. Select and fit the correct orifices from the conversion kit, based on the gas data table (3.4.3 "Gas data"). The orifice diameter is stamped on the orifice itself, see (3).

8. Re-fit the burners back in their original position.

9. Re-fit the retaining strips.

10. If the radiation shield / condensation tray was loosened, re-fasten it.

11. Check whether there is a burner pressure regulator (1) attached to the gas control, or simply a blank plate (5).

Note

If the supply pressure for a gas category is the same as the burner pressure (see the gas data table (3.4.3 "Gas data")) then the gas control must be fitted with a blank plate with cork gasket. A burner pressure that deviates in comparison to the supply pressure requires the use of a burner pressure regulator with rubber gasket. Each conversion kit contains all the necessary components.

12. If the blank plate or burner pressure regulator need to be replaced:

- If necessary, remove the blank plate or burner pressure regulator (5) or burner pressure regulator (1).

- If necessary, fit the blank plate or burner pressure regulator supplied with the conversion kit.

13. Check the supply pressure and burner pressure (3.11 "Checking the supply

pressure and burner pressure").

14. Remove the sticker showing the new gas category from the conversion kit, and attach it below the appliance's rating plate. This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied.

15. Start the appliance (9 "Starting the water heater").

Page 35

Instruction manual CH 35

Legend Unused numbers are not applicable

4. burner pressure controller

5. blank plate

6. supply pressure nipple

7. gas control

8. manifold test nipple

9. sealing screw

10. burner pressure adjustment screw

Gas control for CH

Page 36

Conversion to a different gas category

36 Instruction manual CH

Page 37

Instruction manual CH 37

gis

5 Filling

Installation diagram

Legend

Unused numbers are not applicable

1. pressure reducing valve (mandatory)

3. T&P valve (mandatory)

4. stop valve (recommended)

5. non-return valve (mandatory)

6. circulation pump (optional)

7. top to bottom circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve (mandatory)

12. temperature gauge (recommended)

14. draw-off points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. cold water head tank

19. float switch

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

Page 38

Filling

38 Instruction manual CH

gis

5.1 Filling unvented installations

To fill the water heater, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the water heater.

5. Completely fill the water heater. When a full water jet flows from the nearest draw-off point, the water heater is full.

6. Bleed the entire installation of air, for example by opening all draw-off points.

7. The appliance is now under water supply pressure. There should be no water coming out of the expansion valve (15) or out of the T& valve (3). If there is, the cause might be:

- The T&P valve is defective or incorrectly fitted.

- The water supply pressure is greater than the specified 8 bar.

Rectify this by fitting a pressure reducing valve (1).

- The expansion valve in the protected cold supply set-up is defective or

incorrectly fitted.

5.2 Filling vented installations

To fill the water heater, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the water heater.

5. Completely fill the water heater. When a full water jet flows from the nearest draw-off point, the water heater is full.

6. Bleed the entire installation of air, for example by opening all draw-off points.

7. The water heater is now under water supply pressure. There should be no water coming out of the T&P valve (3). If this does happen, the T&P valve might be defective or incorrectly fitted.

Page 39

Instruction manual CH 39

gis

6 Draining

Installation diagram

Legend

Unused numbers are not applicable

1. pressure reducing valve (mandatory)

3. T&P valve (mandatory)

4. stop valve (recommended)

5. non-return valve (mandatory)

6. circulation pump (optional)

7. top to bottom circulation pump (optional)

9. drain valve

10. manual gas valve (mandatory)

11. service stop valve (mandatory)

12. temperature gauge (recommended)

14. draw-off points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. cold water head tank

19. float switch

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

Page 40

Draining

40 Instruction manual CH

gis

6.1 Draining unvented installations

Some service activities require the water heater to be drained. The procedure is as follows:

1. Shut down the appliance by setting the ON/OFF switch on the control panel to position 0.

2. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0.

3. Shut off the gas supply (10).

4. Close the stop valve (11) in the hot water pipe.

5. Close the supply valve of the cold water supply (A).

6. Open the drain valve (9).

7. Bleed the appliance (or installation) so that it drains completely.

6.2 Draining vented installations

Some service activities require the water heater to be drained. The procedure is as follows:

1. Shut down the appliance by setting the ON/OFF switch on the control panel to position 0.

2. Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0.

3. Shut off the gas supply (10).

4. Close the stop valve (11) in the hot water pipe.

5. Close the stop valve (4) between the cold water head tank and the cold water inlet.

6. Open the drain valve (9).

7. Bleed the appliance (or installation) so that it drains completely.

Page 41

Instruction manual CH 41

gis

7 The control panel

7.1 Introduction

Topics covered in this chapter, in sequence:

• Control panel

• Explanation of icons

• On/off switch

• Control thermostat

• Weekly timer circuit;

• Flue gas thermostat reset button.

7.2 Control panel

This figure shows the control panel.

The control panel

The control panel comprises:

• an ON/OFF switch (with positions I/0/II);

• a control thermostat with rotary knob;

• a weekly timer (optional);

• a Power Anode indicator LED (optional).

7.3 Explanation of icons

The table explains the meanings of the icons.

Icons and their meaning

7.4 On/off switch

Using the ON/OFF switch, set the appliance to the ON mode (position 'I'), OFF mode (position '0'), or the weekly program mode (position 'II'). See 'Operating

modes'.

The appliance remains live, even when in the OFF mode. This ensures that the frost protection remains activated.

Note

To isolate the appliance electrically, you must use the isolator between the appliance and the mains power supply.

7.5 Control thermostat

Use the rotary knob on the control thermostat to set the desired water temperature to between ±40°C and ±70°C. The knob rotates over a scale of 1 to 4. The table shows the temperatures corresponding to each position.

Temperature setting

Name Meaning

ON/OFF switch Sets appliance mode

to 'ON', 'Week Program' or 'OFF'.

Temperature control

Set water temperature (Tset)

1 weekly timer Sets the weekly water

heating program

2 Power Anode

indicator lamp

Shows Power Anode status

Position Temperature

1 approx. 40°C

2 approx. 50?

3 approx. 60?

4 approx. 70?

Page 42

The control panel

42 Instruction manual CH

gis

7.6 Weekly timer circuit

Optionally, you can use the week timer to program when the appliance must fulfil demand. Set the ON/OFF switch to the 'II' position to activate the weekly timer circuit.

Weekly timer

The weekly disk (2) of the timer (1) is divided into seven one-day segments: 'Monday' through 'Sunday'. Each day is divided into 12 segments of 2 hours each by the setting tabs (5).

To set a two-hour period during which the appliance must respond to demand, press the tab for that period outwards.

The current time can be read from the (12-hour) clock hands (3).

Set the day and time as follows: to set roughly, turn the week disk (2) in the direction of the arrow until the current day of the week is aligned with the marker arrow; for fine setting, turn the large hand clockwise until the current time is set. The manual switch (4) must always be in the central position (this activates the timer program).

7.7 Flue gas thermostat reset button

A malfunction in the flue gas discharge, e.g. a blockage in the chimney, can lead to the flue gas thermostat locking out. This state is evident when the push button on the flue gas thermostat has been activated (refer to the figure). Once the cause has been removed, and the sensor has cooled down sufficiently, press this push button to reset (if the sensor is not sufficiently cooled down, the flue gas thermostat will immediately lock out again). The appliance will then automatically start up again, if there is demand. If this is not the case, please consult the error condition summary (11 "Errors").

Note

The draught diverter may be hot.

Flue gas thermostat reset button

Legend

1timer 2 weekly disc 3 pointers 4 manual switch 5tabs

IMD-0474 R0

IMD-0151 R1

Page 43

Instruction manual CH 43

gis

8 Status of the water

heater

8.1 Introduction

Topics covered in this chapter, in sequence:

• Operating modes;

• Power Anode status;

• Error conditions.

8.2 Operating modes

When running, the appliance has three basic operating modes, namely:

• ISOLATED

In this mode the appliance is off and all components are electrically dead.

- The isolator (switch between the appliance and the power supply) is turned off.

- On the control panel, the on/off switch is at position 0.

• OFF

In this mode, the frost protection is activated.

- The isolator is set to position I.

- On the control panel, the on/off switch is at position 0.

• ON

In this mode the appliance continuously fulfils demand. On the control panel:

- the on/off switch is in position I

- The water temperature can be set using the rotary button on the control thermostat (7.5 "Control thermostat").

8.3 Power Anode status

If the appliance is fitted with a Power Anode, there is an extra indicator lamp on the operating panel. Depending on the status of the appliance, this lamp will be lit either green or red, or it will be off:

• Green

This state indicates that the Power Anode is working correctly.

• Red

This state indicates an error, and the Power Anode is not working.

• Off

This state indicates that the Power Anode is not working.

Note

If there is an error with the Power Anode (red), or if the Power Anode is not working (off), this will have no effect on the hot water supply.

8.4 Error conditions

If the appliance has an error, heat demand will be (temporarily) ignored. There are various types of errors, divided into three groups:

• Gas control lockout errors

In this case the gas control's safety valve is closed,

as a result of which the pilot flame is extinguished.

Once this error has been rectified, the pilot flame

must be re-lit (9.2 "Starting the appliance").

• Blocking errors

In this case the gas control's main valve is closed.

Despite a possible demand, combustion is

stopped although the pilot flame remains ignited.

These conditions disappear automatically once

the cause of the error has been eliminated. The

appliance then starts running again

spontaneously.

• Lockout error from the flue gas thermostat

This error condition has much the same

characteristics as a 'Blocking error'. The difference

here is that the lockout (push button) for the flue

gas thermostat in the draught diverter is

activated (7.5 "Control thermostat"). After

removing the cause, the push button must be

pressed to re-start the appliance.

The cause of the error cannot be seen on the control panel. For a detailed overview of error conditions, please refer to the 'Errors (11 "Errors")'.

If you as an end user come across the appliance when it is in an error status, you can attempt to start the device up (9.2 "Starting the appliance").

However, if the error returns or occurs several times in a short time, you must contact your service and maintenance engineer.

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9 Starting the water

heater

9.1 Introduction

Topics covered in this chapter, in sequence:

• Starting the appliance.

• The appliance's heating cycle.

9.2 Starting the appliance

Start the water heater as follows:

1. Fill the water heater (5 "Filling").

2. Open (3.5 "Installation diagram") the manual gas valve.

3. Switch on the power to the water heater using the isolator between the water heater and the power supply.

4. Begin the ignition procedure by pressing and holding the white button (1) on the gas control while repeatedly pressing the piezo igniter (2) until the pilot flame ignites. See the figure. The pilot flame can be seen through the inspection window above the burner tray.

Gas control

5. Keep the white button pressed in for about 30 seconds before carefully releasing it. The pilot flame should now stay lit.

6. Set the appliance in the "ON" mode by setting the on/off switch on the control panel to position I.

7. Set the desired water temperature using the control thermostat (7.5 "Control thermostat").

If there is a heat demand, the appliance will run through the heating cycle (9.3 "The appliance's

heating cycle").

Warning

If the pilot flame goes out during the heating cycle or ignition procedure, you must wait 5 minutes before repeating the ignition procedure.

9.3 The appliance's heating cycle

The appliance's heating cycle is activated when the measured water temperature (T

water

) falls below the

threshold value (T

set

). T

set

can be adjusted using the

control thermostat, for example position 3 (± 60°C).

The heating cycle runs successively through the following states:

1. HEAT DEMAND;

2. IGNITION;

3. RUNNING

The complete cycle is explained in the example set out below.

1. The control thermostat sensor measures the water

temperature (T

water

). If T

water

drops below the set

temperature (T

set

), there is demand and the control thermostat will close. This will cause the gas control to open.

2. Once the gas control is open, the pilot burner will ignite the gas flow.

3. The appliance is now running. This means that actual heating has started. When the water reaches the set temperature, the demand ceases. The gas control closes and the burner tray is extinguished (the pilot flame stays lit).

4. The appliance is now said to be in an idle state, waiting until T

water

once again falls below T

set

With any subsequent heat demand, the heating cycle will resume from step 1.

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10 Shutting down

10.1 Introduction

You can:

• Shutting the appliance down for a brief period

("OFF" mode)

• Isolating the appliance from the mains

• Shutting the appliance down for a long period.

10.2 Shutting the appliance down for a brief

period ("OFF" mode)

To shut down the appliance for a brief period, you can set the appliance in 'OFF mode'. Activate frost protection by switching the on/off switch on the control panel to the 0 position. The pilot flame will remain on.

10.3 Isolating the appliance from the mains

The appliance may only be isolated from mains power in the correct way. The correct procedure is as follows:

1. Shut down the appliance by putting the ON/OFF switch to position 0.

2. Isolate the appliance from the power supply by setting the isolator between the appliance and the mains power supply to position 0.

3. The pilot flame will remain on, but you can extinguish it if required by pressing the red button (3) on the gas control (see the figure).

Gas control

Note

The "OFF" and "Isolated" operating modes are advisable only if there is no risk of frost. If frost can be expected, you will need to drain the appliance, see

Shutting the appliance down for a long period.

10.4 Shutting the appliance down for a long period

If the device is to be shut down for a longer period, you must drain the appliance (6 "Draining").

IMD-0516 R0

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Shutting down

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11 Errors

11.1 Introduction

This chapter covers the following errors:

• Gas smell

• Water leakage

• Explosive ignition.

• Poor flame profile.

• Power Anode.

• No hot water

• Insufficient hot water

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11.2 Troubleshooting table for general errors

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

General faults and failures

Feature Cause Measure Comment

Gas smell Gas leak

Warning

Close the main gas valve at once.

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

Note

Immediately contact your installation engineer or local gas

company.

Water leakage Leakage from a water

connection (threaded)

Tighten the threaded connection If the leak persists, consult your installation engineer

Leakage from another nearby water water heater or pipe segment

Trace the leak

Leakage from the water heater tank

Consult the supplier and/or manufacturer

Condensation Before drawing off (too much) hot tap water, wait until the water in

the heater has reached the set temperature.

Explosive ignition

Poor flame profile

Incorrect supply pressure and/or burner pressure

Set the correct supply pressure and/or burner pressure. (3.11 "Checking the supply pressure and burner

pressure")

If ignition is not improved, consult your installation engineer.

Contaminated burner Clean the burner(s) (12.4.2 "Clean the burner(s)")

Contaminated orifice Clean the orifice(s) (12.4.3 "Clean the orifice(s)")

Inadequate air supply Improve the air supply by better ventilating the boiler room.

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11.3 Troubleshooting table - 'no hot water'

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

No hot water

Power Anode If the error cannot be rectified, contact your installation engineer

• Indicator lamp is red

• Anodes not making contact with the water

• Break in one of the cables

• Anode poorly earthed

4. Check to see that all connections have been made properly

5. Check that the Power Anode is properly connected; see Electrical Diagram (14 "Electrical diagram").

6. Check to see that all connections have been made properly

7. Check all cables for breaks and replace if any are found.

• Indicator lamp is off No electrical supply to the potentiostat

Check the electrical supply

Feature Cause Measure Comment

No ignition (pilot flame LIT)

No supply voltage present

1. Check whether the isolator is ON.

2. Check whether there is power to the isolator

The measured voltage must be 230 V

AC (-15%, +10%)

If ignition is not improved, consult your installation engineer.

Pilot flame OUT Pilot flame blown out 1. Start the appliance up (9 "Starting the water heater") If the error cannot be resolved or is persistent, contact your

installation engineer

No gas 1. Check that the gas valve is open

2. Check whether the gas control is opening (clicking of the gas control)

3. Check the leads of the gas control

The safety thermostat has cut out without apparent reason.

1. The safety thermostat has cut out correctly:

- Check whether the control thermostat is working

- Check whether the high-limit thermostat is working

- Check that the circulation pump (if present) is working

2. The safety thermostat has cut out without apparent reason:

- Check whether the thermostat is defective

- Check whether the sensor of the thermostat is defective

Feature Cause Measure Comment

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52 Instruction manual CH

11.4 CH Troubleshooting table - 'insufficient hot water'

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

Insufficient hot water

Feature Cause Measure Comment

Insufficient hot water Water temperature

setting (T

set

) is too low

1. Set the control thermostat (7.5 "Control thermostat") to a higher value

Hot water supply is used up

1. Reduce hot water consumption and give the water heater time to heat up.

2. If this error persists, check whether the high-limit thermostat is switching.

If this is the case, check that the circulation and/or top to bottom circulation pump are working.

If the error has not been rectified, and no other cause can be found, isolate the appliance from the mains (10.3 "Isolating the appliance

from the mains"), shut off the manual gas valve and alert your

installation engineer.

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12 Performing

maintenance

12.1 Introduction

Caution

Maintenance may only be performed by a qualified service and

maintenance engineer.

At each service, the appliance undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order.

1. Water-side maintenance

2. Water-side maintenance

3. Gas-side maintenance

4. Finalising maintenance

Note

To order spare parts, it is important to write down the appliance type and model, and the full serial number of the appliance. These details can be found on the rating plate. Only by ordering with this information can you be sure to receive the correct spare parts.

12.2 Preparation for maintenance

To test whether all components are still working properly, complete the following steps:

5. Check the supply and burner pressures (3.11 "Checking the supply

pressure and burner pressure") and adjust them if necessary.

6. Also check that this is running properly during the The appliance's heating

cycle.

7. Check that all components of the chimney flue system are properly attached.

8. Test the operation of the overflow valve of the protected cold supply setup. The water should spurt out.

9. Test the overflow operation of the T&P valve. The water should spurt out.

10. Check the drainage pipes from the discharge points of all valves and remove any scale deposits that may be present.

11. Drain the appliance (6 "Draining").

12.3 Water-side maintenance

12.3.1 Introduction

The following steps must be carried out on the water side:

1. Checking the anodes.

2. Descaling and cleaning the tank.

12.3.2 Checking the anodes

Timely replacement of the anodes extends the service life of the appliance. The appliance's anodes must be replaced as soon as they are 60% or more used up (take this into consideration when determining the maintenance frequency).

1. Disconnect the plug of the flue gas thermostat from the connector on the appliance.

2. Disconnect the draught diverter from the flue gas discharge.

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3. Unscrew the screws from the lid on top of the appliance.

4. Remove the lid from the appliance, including the draught diverter.

5. Remove the sealing ring from the appliance.

6. Loosen the anodes using suitable tools.

7. Check the anodes, and if necessary, replace them.

8. Now also check the flue baffles (12.4.4 "Checking the flue baffles"). Replace them, if necessary.

9. Place a new sealing ring on the rim of the tank and re-fit the lid.

10. Insert the plug of the flue gas thermostat into the connector on the appliance.

Note

You can also use low-maintenance anodes ('Power Anodes') with this appliance. These are available as an accessory and can be ordered separately. Please refer to the instructions with these anodes for how to use them, or discuss it with the installer.

12.3.3 Descaling and cleaning the tank

Scale and lime build-up prevent effective conduction of the heat to the water. Periodic cleaning and descaling prevents build-up of these deposits. This increases the service life of the water heater, and also improves the heating process.

Take the rate of scale formation into account when deciding on the service interval. Scale formation depends on the local water composition, the water consumption and the water temperature setting. A water temperature setting of maximum 60°C is recommended for the prevention of excessive scale build-up.

To guarantee a good, watertight seal around the cleaning opening, replace the gasket (6), the O-ring (7), washers (4), bolts (3) and if necessary the lid (5) with new parts before reassembly (see diagram). A special set is obtainable from the supplier/manufacturer.

To simplify descaling and cleaning of the tank, the appliance is equipped with two cleaning openings.

1. Remove the cover plate (1) on the outer jacket (see the figure).

2. Carefully remove the insulation (2) and set it to one side. This will be needed

again later.

IMD-0235 R2

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Instruction manual CH 55

3. Undo the bolts.

4. Remove the lid, the gasket and the O-ring.

5. Inspect the tank and remove the loose scale deposits and contamination.

6. If the scale cannot be removed by hand, descale the appliance with a descaling agent. Contact the supplier/manufacturer for advice on what descaling agent to use.

7. Close the cleaning opening. To avoid damage to the tank, tighten the bolts that fasten the lid with a torque no greater than 50 Nm. Use suitable tools for this. To seal the cleaning opening properly, we recommend tightening the bolts in the sequence shown in the diagram.

12.4 Gas-side maintenance

12.4.1 Introduction

The following steps must be carried out on the gas side:

1. Clean the burner(s).

2. Clean the orifice(s).

3. Checking the flue baffles.

12.4.2 Clean the burner(s)

1. Detach the burner(s)

2. Remove all contamination present on the burner(s).

3. Fit the burner(s)

12.4.3 Clean the orifice(s)

1. Detach the orifice(s)

2. Remove all contamination present in the orifice(s).

3. Fit the orifice(s)

12.4.4 Checking the flue baffles

Warning

The flue baffles can be hot.

1. Remove the flue baffles from the appliance.

2. Check the flue baffles for the presence of corrosion, removing this if necessary.

3. Check the flue baffles for wear, and replace the flue baffles if necessary.

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12.5 Finalising maintenance

To finalise the maintenance, carry out the following steps:

1. Fill the appliance (5 "Filling").

2. Start the appliance up (9 "Starting the water heater")

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13 Warranty (certificate)

13.1 General warranty

If within 1 (one) year of the invoice date or commissioning date of a water heater supplied by Lochinvar Ltd, following verification, and at the sole discretion of Lochinvar Ltd, an assembly or part (with exclusion of the tank) proves to be defective or fails to function correctly due to manufacturing and/or material defects, then Lochinvar Ltd shall repair or replace this assembly or part.

13.2 Tank warranty

If within 3 (three) years of the invoice date or commissioning date of a water heater supplied by Lochinvar Ltd, following verification, and at the sole discretion of Lochinvar Ltd, the enamel-lined steel tank proves to be leaking due to rust or corrosion occurring on the water side, then Lochinvar Ltd shall offer to replace the defective water heater with an entirely new water heater of equivalent size and quality The warranty period given on the replacement water heater shall be equal to the remaining warranty period of the original water heater that was supplied.

13.3 Conditions for

installation and use

The warranty set out in articles 1 and 2 will apply solely under the following conditions:

a. The water heater is installed under strict adherence to Lochinvar Ltd

installation instructions for the specific model, and must be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, I.E.E. Regulations and the byelaws of the local water undertaking. The installation should also be in accordance with any relevant requirements of the local gas distributor and local authority.

b. The water heater remains installed at the original site of installation.

c. The water heater is used exclusively with drinking water, which at all

times can freely circulate (a separately installed heat exchanger is mandatory for heating saline water or corrosive water).

d. The tank is safeguarded against harmful scaling and lime build-up by

means of periodic maintenance.

e. The water temperatures in the heater do not exceed the maximum

setting of the thermostats, which form a part of the water heater.

f. The water pressure and/or heat load do not exceed the maximum values

stated on the water heater rating plate.

g. The water heater is installed in a non-corrosive atmosphere or

environment.

h. The water heater is connected to a protected cold supply arrangement,

which is: approved by the relevant authority; with sufficient capacity for this purpose; supplying a pressure no greater than the working pressure stated on the water heater; and where applicable by a likewise approved temperature and pressure relief valve, fitted in accordance with installation instructions of Lochinvar Ltd applying to the specific model of water heater, and further in compliance with Building Regulations, local authority installation byelaws and the Water Supply (Water Fittings) Regulations 1999 .

i. The water heater is at all times fitted with cathodic protection. If sacrificial

anodes are used for this and these anodes have reduced in size by more than 40% at any point along their length or if they are severely pitted, new anodes should be fitted. Particular attention should be paid to the ends of each anode to ensure excessive localized depletion has not

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occurred. Where anodes are covered with particles they should be cleaned; for reference, when new, the anode has a diameter of 21 mm. When power anodes are used, it is important to ensure that they continue to work properly.

13.4 Exclusions

The warranty set out in articles 1 and 2 will not apply in the event of:

a. damage to the water heater caused by an external factor;

b. misuse, neglect (including frost damage), modification and incorrect

and/or unauthorized use of the water heater;

c. contaminants or other substances having been allowed to enter the tank;

d. any attempts at repair to a defective water heater other than by an

approved service engineer.

13.5 Scope of the warranty

The obligations of Lochinvar Ltd pursuant to the specified warranty are limited to free delivery from the warehouse of the replacement assemblies, parts or water heater, respectively. Labor, installation and any other costs associated with the replacement will not be accepted by Lochinvar Ltd.

13.6 Claims

A claim on grounds of the specified warranty must be submitted to the dealer from whom the water heater was purchased, or to another authorized dealer of Lochinvar Ltd. Inspection of the water heater as referred to in articles 1 and 2 shall take place in one of the laboratories of Lochinvar Ltd

13.7 Obligations of Lochinvar Ltd

Lochinvar Ltd grants no other warranty or guarantee over its water heaters nor the (assemblies or parts of) water heaters supplied for replacement, other than the warranty expressly set out in these conditions.

Under the terms of the supplied warranty, Lochinvar Ltd is not liable for damage to persons or property caused by (assemblies or parts, or the glass-lined steel tank of) a (replacement) water heater that it has supplied.

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14 Electrical diagram

14.1 Introduction

This chapter shows the electrical diagram(s) and accompanying legend.

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Electrical diagram

60 Instruction manual CH

1 = brown, 2 = blue, 3 = yellow/green, 4 = black, 5 = white

0305906 R0

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Instruction manual CH 61

TERMINAL STRIP CONNECTIONS:

Earth

N Neutral

LPhase

Phase input of thermal reflux safeguard

Phase input of controller

COMPONENTS:

A ON/OFF switch

B Control thermostat

C High-limit thermostat

D Safety thermostat

E Gas control

F Eye terminal (for earthing to the Jacket)

G Thermal reflux safeguard

OPTIONAL COMPONENTS

H Control isolator

J CORREX Power Anode control

K Weekly timer circuit

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Electrical diagram

62 Instruction manual CH

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Instruction manual CH 63

15 Declaration of

Conformity

Commerc ial Ga s Fired Storage Water Heater

CH 10 0, CH 155, CH 2 00, CH 300, CH 40 0, CH 500 , CH 600

Gas Appl iance Directi ve - 90 /396/ EC

Low Volta ge Dir ec tiv e - 2006/9 5/ EC

EMC Direct ive - 20 04/10 8/EC

Standa rds used:

- EN 89: 19 99

- EN50 165 : 19 97

Standa rds used:

- EN60 335 -1: 1994

- EN50 165 : 19 97

Standa rds used:

- EN55 014 -1: 1993

- EN55 014 -2: 1997

- EN 61000 -3-2: 19 95

- EN 61000 -3-3: 19 95

- EN50 165 : 19 97

M arc h 1 , 2012

EEC - Declaration of Conformity

Supplier:

hereby d eclare s that the follow ing produc ts:

Product description:

Product models:

on the assu mption that the installat ion instruc tions have be en followe d are compl iant to:

as stated in the EC type-exami nation repor t by KIWA -Gastec Certificat ion BV, the Nethe rlan ds.

Co mpany: Dat e: Sign atu re:

D . J. P epper

M ana ging Dir ector

Loc hin va r Lim i te d

7 Lo m ba r d Way The M XL Cen tr e Banbury - United Kingdom

Lochinvar Limited

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Declaration of Conformity

64 Instruction manual CH

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Instruction manual CH 65

Index

ambient conditions 18 ambient temperature 18

burner pressure 30

connecting the circulation pipe 25, 26 connecting the cold water side 24, 25 connecting the hot water side 24 control thermostat 41 conversion to a different gas category 33

document contents 9 draining 39

electrical connection 28

filling 37 flame probe 14

gas category, conversion to different 33 gas connection 27 general specifications 3

humidity 18

installation diagram 23 installation engineer 8, 9 isolator 29

join

circulation pipe 25, 26 cold water side 24, 25 electrical 28, 29 gas 27 hot water side 24 shuntleiding 24, 25

liability 3

mains power 29 maintenance

anode 54 burner 55 finalizing 56 gas-side 55 orifice 55 performing 53 water-side 53

notation conventions 9

operating cycle 13

packaging 17 protection 13

scale 54 service 8 service engineer 8 shutting down

electrically isolating 47

long period 47 specifications 19 supply pressure 30 symbol

installation engineer 8

service engineer 8

user 8

target groups 8 top to bottom circulation pump 24, 25 trademarks 3

user 8

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0310 570 1.0 UK

Index

Instruction manual CH