Propex Malaga 5, Malaga 5E Installation & Operation Instructions

ELECTRODE SETTING

INSTALLATION

&

OPERATION

Malaga 5/5E

INSTRUCTIONS

Storage Water

Heater

All g

as appliances must be installed and/or commissioned
by persons registered with the Gas Safety Register (GB)
or the relevant national organisation.

Manufactured by:

Munster Simms Engineering

Distributed by:

PROPEX HEATSOURCE LTD

Unit 5, Second Avenue Business Park

,

Millbrook, Southampton,

United Kingdom, SO15 0LP

Tel: [phone]

Fax: [phone]

Website: www.propexheatsource.co.uk

E.mail: [email protected]

0120

Ref No: 180.119

ISSUE I

USER INSTRUCTIONS

Read the User Installation and Operation Instructions carefully before using this

WIRING DIAGRAM MALAGA 5/5E

product

.

This appliance isnot intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction concerning use of the
appliance by a person responsible for their safety. Children should be supervised to
ensure thatthey do no

t

p

lay with the appliance.

All warnings should be observed.

Incorrect use of the appliance and non observation of the installation and operator
instructions shall lead to the cancellation of the warrant

yand

exclusion of liabilit

y

y

y

claims. Only use the heater as directed by these instructions.

This symbol indicates that this appliance is suitable for use in Leisure
Accommodation Vehicles.

MALAGA 5/5E CONTROL LOOM

This

symbol

indicates

that

this

appliance

is

not

suitable

for

useinboats

.

CONTROL PANELS

Note: Malaga 5 (Gas only) does not have the white wire or the +12V “B” connection.

MALAGA 5/5E SWITCH PANEL CONNECTIONS

Malaga 5 E Control Panel

Malaga 5 Control Panel

MALAGA 5 /5E POWER LOOM

MALAGA 5E

MALAGA 5

-2 -

2 x 2 Position Switch
Green operation LED

Red lockout LED

1 x 2 Position Switch
Green operation LED

Red lockout LED

- 11 -

TECHNICAL DATA

• Dimensions Height – 250mm
Width – 285mm

OPERATION INSTRUCTIONS

• The Propex Malaga 5 is for use on L.P.G. only.

Depth –520mm

• Weight empty 9.3kg

• Nominal Water capacity 13 Litres

• Inward protrusion from wall 480mm

• HEATING TIMES Gas Approx. 43 Mins

15

o

C– 70oC Gas & Electric Approx. 28 Mins

On initial operation or when the system has been drained, refill the system with
water and flush out by turning on each hot tap until a steady flow of water is
obtained. If a water filter is fitted it should be changed at the recommended
intervals.

•

The Propex

Malaga 5E is for use on both L.P.G. and mains electricity

.

Electric OnlyApprox. 64 Mins

• Standby consumption Gas 98W

• WATER - Maximum supply pressure 1.3 BAR

Pressure relief valve setting 3.0 BAR
Working pressure 2.0 BAR

•

Check that all the gas and electricity supplies are turned on.

GAS – Switch to the gas position on the control panel. Initially no LED will come
on and there will be a 10 second delay. Ignition will then take place and the green
LED will stay on as long as the burner is alight. If the gas does not light first time,

GAS

Heat input

1.25kW / 91g/h

Injector Bray 960 / 40
Gas connection 8mm / 5/16 o.d.
Gas type Butane 28-30mBAR

Propane 37mBAR

Pressure category & pressure I

3+

(28-30/37)

theignitorw

illswitchoff,th

egasvalve w

illcl

ose andthere w

ill

bea60

secon

d

delay before it tries again.
Note – When the water has reached the preset temperature the green LED will
switch off. As the water cools or is drawn off, the heater will automatically start
the above sequence again. If the red LED starts flashing it indicates a fault
condition

,

see faultfindingand lockouts.

I

3B/P

(30)

• ELECTRICITY –Malaga 5 12V DC

Malaga 5E 12V DC + 230V AC element
Element 750W
Current consumption @ 12V 0.36A

,

g

ELECTRICITY – The Malaga 5E has a 230V, 750W immersion heating
element. The operation of the immersion heater is controlled by the same
thermistor that controls the gas burner. If you wish to use the immersion heater
operate the 230V switch on the control panel. The immersion heater can be used

Note: If connecting to mains water supply, a suitable water pressure regulator

must be connected to ensure that the maximum supply of water pressure
does not exceed 190kPa (1.9bar)

Clearances required for installation and servicing, as seen from the inside.

Left Hand Side 240mm
Ri

g

ht Hand Side 100m

m

on

its

ownorsimultaneously

with

the

gas

burnertoachieve

a

quicker

heat

up

time.

Note – A 12V DC supply must be connected at all times.

SWITCHING OFF THE APPLIANCE – If the appliance is not in use it should

When not in use the

g

Top 5mm

PRESSURE RELIEF/DRAIN VALVE

b

e switched off using the controlpanel. If the heateris notgoing tobeusedfora

long period of time the tank should be drained and gas supply isolated.

WATER – This appliance must not

be connected directly to the mains water

supply.

heater should be drained
using the drain valve as
per the diagram.

- 10 -

BATTERY – The h eater is designed to operate on a 12V DC supply. Should the
supply drop below 10V or rise above 15V, the gas valve will switch off and a
fault code of 3 flashes will be displayed on the control panel.

-3 -

WINTER OPERATION – When using the heater in winter ensure the flue is
not blocked by snow or fallen leaves etc. When not in use make sure the heater

FAULT FINDING & LOCKOUTS

The heater is equipped with an electronic diagnostic system which will detect
fault conditions ranging from poor gas or DC supply to internal heater

is

drained

,

especially

during

the

winter

months

.

ENERGY FAILURE – in the event of an energy failure isolate the gas supply.
When the energy supply has been restored clear any lockouts which may have
occurred and continue normal operation.

malfunctions

.

In

the

eventofa

failure,the

red

LEDonthe

control

panel

will

flash

a number of times, pause, and repeat until switched off. Count the number of
flashes and refer to the table below.

Number

of Flashes

Fault Remedy

BLOWN

FUSE

–TheMalaga

MK5/5E

i

sequippedwitha

2

A

replaceablefuse
to protect the PCB in the event of an overload on the 12V circuit. This is easily
replaced and the location of the fuse is outlined on page 11.

1

No Flame

Detected

Check gas supply making sure there is gas in
the bottle and no blockage in the gas line.
Ensure propane is used at temperatures below
+5°C. Clear lockout as described below.

MAINTENANCE

To clean and sterilise inside the water heater use diluted sterilising fluid and
fully rinse through with clean water afterwards. The outside of the appliance
should not normally require cleaning. If it does, isolate the electrical supplies
and wipe down with a soft, damp cloth only. Allow to fully dry before

2 Overheat

Check there is water in the appliance. We

recommend you wait at least 5 to 10 minutes to
allow the heater to cool before clearing lockout
as described below.

Minimum operating voltage is 10V, maxi mum

reconnecting

the

electrical

supplies

.

If descaling of this appliance is required, this can be done using ‘Kettle Klear’ or
an equivalent product and fully rinse through with clean water afterwards.
The appliance should be checked and maintained (if required) periodically by a
competent person within a maximum of 2 years according to the practice in the

3

Low/High

Supply Voltage

is 15V, when measured at the heater. Check
battery voltage. If between 10V and 15V,
check connections between heater and battery.
Check alternator or external battery charging.
Clear lockout as described below.

country where it is used and these instructions.

We recommend annual testing of gas soundness and combustion by an
accredited LPG gas engineer.

5

Other / internal

fault

Attempt to clear lockout as detailed below. If
this fails, contact Propex directly.

Clearing Lockouts

Lockouts are cleared by moving the switch from on position to off position then

The

centre

pageofthis

booklet

showsanexploded

diagram

of

the

appliance

to

aid maintenance.

back

to the onposition. The complete sequence of switch movements mus

t

b

e
completed within 2.5 seconds for a lockout to be successfully cleared. If there is
air in the gas line, e.g. after a gas bottle change, the water heater may require
several attempts before it lights. If this does not clear the Overheat lock out
remove the front cover exposing the PCB and press the red button on the manual

-9 -

reset

overheat

thermostat

.

Note: A cycling of the power supply to the unit will not clear a lockout.
If problems persist contact Propex Heatsource Ltd on 023 8058 2555

-4 -

CONNECTING THE W ATER HEATER

When installing a non return valve should be fitted if necessary.

1. WATER: The Malaga 5 is fitted with 12mm plain stems to which a suitable

INSTALLATION INSTRUCTIONS

A competent person should install the appliance in accordance with the
appliance installation instructions and should consider any relevant

12mmpush

fit

connectors

shouldbefitted.Alternatively

you

can

also

use

12

mm I.D. reinforced, food quality, opaque or equivalent pipe with hose clips. It is
important that the hot and cold connections are connected correctly and if the
plastic inlet connection is removed, only a plastic replacement should be used.

IMPORTANT: The hot water outlet connection at the top of the tank must not

regulations

in

the

country

where

the

appliance

is

installed

.

For

this

appliance in Europe the standard is BS EN 1949:2002 (Specification for
the installation of LPG systems for habitable purposes in leisure
accommodation vehicles and in other road vehicles).

Installation and servicing of this appliance must only be carried out by

p

ersons registered with the Gas SafetyRegister(GB),or the relevant

b

e removedas

thish

ouses an a

dditi

ona

l

int

erna

l

tubewhich

p

rovidestheair

space for expansion inside the tank. The water pressure must not exceed 1.3 bar.

ALSO do not connect this appliance to a mains water supply.
Drain/Pressure Relief Valve – Drill the appropriate sized hole in the floor

close to the heater and run a piece of hose from the drain port, through the hole

pgyg(),

national organisation.

Prior to installation check the compatibility of the data plate information
with the LPG supply requirements of the vehicle.

This appliance must be installed in accordance with the current regulations.

to the outside. Seal round the hole with silicone orsimilarsealant.
Water Systems – The heater will work satisfactorily on either system where the
pump is controlled by a tap, micro-switch or pressure switch.

2. GAS: The gas fitting is 8mm (5/16”) and a suitable compression fitting is
required. An isolation tap should be fitted near to the heater and any

In

the

United

Kingdom

the

installation

mustbein

accordance

withBS6501

Pt 1 1978, BS5482 Pts 1 & 2 1977 and BS5440 Pt 2 1990.
The Malaga 5 Water Heater is designed to be floor mounted and flues

through a vertical section on an external wall. Normally the heater would be
fitted in a bed-box or locker allowing access to the heater with suitable room
fo

r

service andinspection. Structural sections within the vehicle shouldno

t

unsupporte

d

pi

pe-worksecured.

It

i

s recommende

d

that

agasdropholebe
positioned near to the heater and that all connections are carried out by a
registered person (see Installation section on page 3) .

3. ELECTRICITY: Fit the control panel in the chosen position and route the
loom down to the heater and plug into the PCB at CN27 & CN26. Connect the 2

p

be damaged. The flue terminal should not be fitted at the side of the
caravan/motor home where an awning may be fitted.

FLUE – Using masking tape, fix the template to the inside of the vehicle and
drill a pilot hole at position X. Remove the template and tape it to the outside
of the vehicle ensurin

g

thatthe template is square and thatthe centre lines u

p

core

loomtothe12v

supplyatCN24and

routetothe

heater

making

sure

the

polarity is correct. NOTE there is one less core on the loom used on the Malaga
5 and is supplied with a single on/off switch, whereas the Malaga 5E has 2 x 2
position switches to allow independent operation of gas or electric.

Malaga 5E only – The 3 core mains cable should be connected to a 230V AC –
5am

p

doublepole fused spur.

g

pqp

with the hole drilled from the inside.
Drill a 10mm hole at positions A and, using a jigsaw, cut out the hole. The
hole in the wall must be battened to secure inner and outer skins.
Note: When battening the finished hole must be 240mm x 135mm. Run a
bead of silicon rubber, or similar sealant, around edge of the rear side of the

ppp

Note: This appliance must be earthed.

flue

terminal

,

position

into

cut-outinwall

and

secure

with6screws

(No.8

x

¾”) provided and remove excess sealant. Clip the top of the flue cover onto
the flue terminal and secure with 2 screws (No. 6 x ½”) provided.

WATER HEATER – Remove the floor covering (e.g. carpet etc) from the
area where the heater will stand – 450mm inward from the wall and 320mm

-8 -

wide.Drawalineonthe

floor

from

the

centreofthe

flue,570mminto

the

vehicle. Slide the heater through the flue seals until the stop position is
reached. Make sure both flue and air intake pass through the lip seals.
Measure 115mm from right hand side of rear foot and line up with line on
floor – screw heater to the floor.

-5 -

EXPLODED DIAGRAM OF MALAGA 5/5E

This diagram is to be used for reference when carrying out any maintenance on the appliance

.

Note: “ELECTRIC ELEMENT & THERMOSTAT” is only present on Malaga 5E. Malaga 5 will have a blanking plate in place of this

.

-6 - -7 -