Pullin Evolution Solar PES190, PES300D, PES210D, PES190I, PES210I Installation And Servicing Instructions
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UNVENTED MAINS PRESSURE SOLAR WATER HEATERS
100 TO 300 LITRE CAPACITY
DIRECT AND INDIRECT MODELS
INSTALLATION AND SERVICING INSTRUCTIONS
PACK CONTENTS
Pullin Evolution unvented solar water heater incorporating immersion heater(s) and thermal controls
Factory fitted temperature/pressure relief valve l Cold water combination valve assembly l Expansion vessel
and mounting bracket l Tundish l Motorised valve (indirect models only) l Compression nuts and olives
Immersion heater spanner l Installation instructions
IMPORTANT: PLEASE READ ALL THESE INSTRUCTIONS BEFORE
COMMENCING INSTALLATION
PLEASE LEAVE THIS MANUAL WITH THE CUSTOMER FOR
FUTURE REFERENCE
NOTE: Prior to installation the unit should be stored in
an upright position in an area free from excessive damp
or humidity.
INTRODUCTION
The Pullin Evolution Solar is a purpose designed
unvented solar water heater. The unit has a stainless
steel inner vessel, which ensures an excellent
standard of corrosion resistance. The outer casing is
a combination of resilient thermoplastic mouldings
and corrosion proofed steel sheet. All products are
insulated with CFC/HCFC free polyurethane foam to
meet the latest European heat loss requirements
(see Table 4).
The unit is supplied complete with all the necessary
safety and control devices needed to allow connection to the cold water mains. All these components
are preset and not adjustable.
This appliance complies with the requirements of the
CE marking directive and is Kiwa approved to show
compliance with Building Regulations (Section G3).
The following instructions are offered as a guide to
installation which must be carried out by a competent plumbing and electrical installer in accordance
with Building Regulation G3, The Building Standards
(Scotland) Regulations 1990, or The Building Regulations (Northern Ireland).
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Table 1: Unit weights
IMPORTANT NOTE:
THE PULLIN EVOLUTION SOLAR MUST BE INCORPORATED INTO A FULLY PUMPED SOLAR PRIMARY
CIRCUIT. CONTROL OF THE SOLAR PRIMARY IS
ACHIEVED BY THE USE OF EXTERNAL CONTROLS
NOT SUPPLIED WITH THE UNIT. CONTROL MUST BE
VIA A PURPOSE DESIGNED SOLAR HYDRAULIC
STATION AND SOLAR DIFFERENTIAL TEMPERATURE CONTROLLER.
GENERAL REQUIREMENTS
SITING THE UNIT
The Pullin Evolution Solar must be installed vertically.
Although location is not critical, the following points
should be considered:
• The Pullin Evolution Solar should be sited to
ensure minimum dead leg distances, particularly
to the point of most frequent use.
• Avoid siting where extreme cold temperatures
will be experienced. All exposed pipework should
be insulated.
• The discharge pipework from the safety valves
must have minimum fall of 1:200 from the unit
and terminate in a safe and visible position.
• Access to associated controls and immersion
heaters should be possible to allow for periodic
servicing and maintenance.
• Ensure that the base chosen for the Pullin Evolution Solar is level and capable of permanently
supporting the weight when full of water (see
Table 1).
The Pullin Evolution Solar has an operating pressure
of 3.5 bar that is controlled by the cold water combination valve assembly. The cold water combination
valve assembly can be connected to a maximum mains
pressure of 16 bar.
Wherever possible the mains supply pipe should be
22mm. We suggest the minimum supply requirements
should be 1.5 bar pressure and 20 litres per minute
flowrate. However, at these values outlet flow rates
may be poor if several outlets are used simultaneously.
The higher the available pressure and flow rate the
better the system performance.
OUTLET/TERMINAL FITTINGS (TAPS, ETC.)
The Pullin Evolution Solar can be used with most
types of terminal fittings. It is advantageous in many
mixer showers to have balanced hot and cold water
supplies. In these instances a balanced pressure
cold water connection should be placed between the
2 pieces of the cold water combination valve assembly (see Fig. 1). Outlets situated higher than the
Pullin Evolution Solar will give outlet pressures lower
than that at the heater, a 10m height difference will
result in a 1 bar pressure reduction at the outlet.
LIMITATIONS
The Pullin Evolution Solar should not be used in
association with any of the following:
• Solid fuel boilers or any other boiler in which
the energy input is not under effective thermostatic control unless additional and appropriate
safety measures are installed.
• Ascending spray type bidets or any other class
1 back syphonage risk requiring that a type A air
gap be employed.
• Steam heating plants unless additional and appropriate safety devices are installed.
• Situations where maintenance is likely to be neglected or safety devices tampered with.
• Water supplies that have either inadequate pressure or where the supply may be intermittent.
• Situations where it is not possible to safely pipe
away any discharge from the safety valves.
• In areas where the water consistently contains
a high proportion of solids, e.g. suspended matter
that could block the strainer, unless adequate filtration can be ensured.
OPERATIONAL SUMMARY
Maximum mains pressure 16 bar
Operating pressure 3.5 bar
Expansion vessel charge pressure 3.5 bar
Expansion relief valve setting 6 bar
T&P relief valve setting 90°C/10 bar
Maximum primary circuit pressure
(auxillary coil) (indirect only) 3 bar
Maximum primary circuit pressure
(solar coil) 6 bar
Storage capacity See Table 1
Weight when full See Table 1
WATER SUPPLY
Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously. It is recommended that the
maximum water demand is assessed and the water
supply checked to ensure this demand can be satisfactorily met.
Note: A high mains water pressure will not always
guarantee high flow rates.
Type
Model
reference
Nominal
capacity
(litres)
Weight of
unit full
(kg)
DIRECT PES190D 190 235
PES210D 210 259
PES250D 250 302
PES300D 300 362
INDIRECT PES190I 190 240
PES210I 210 264
PES250I 250 308
PES300I 300 367
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INSTALLATION – GENERAL
(FIGS 3 & 5)
PIPE FITTINGS
All pipe fittings are made via 22mm compression
fittings directly to the unit. The fittings are threaded
3/4”BSP male parallel should threaded pipe connections be required.
COLD FEED
A 22mm cold water supply is recommended, however if a 15mm (1/2”) supply exists which provides
sufficient flow this may be used (although more flow
noise may be experienced).
A stopcock or servicing valve should be incorporated
into the cold water supply to enable the Pullin
Evolution Solar and its associated controls to be
isolated and serviced.
COLD WATER COMBINATION VALVE ASSEMBLY
(FIG 1)
The 2-piece cold water combination valve assembly
can be located anywhere on the cold water mains
supply prior to the expansion vessel (see Fig. 5) but
the two pieces do not have to be installed together.
The pressure reducing valve incorporates the
pressure reducer & strainer and the expansion valve
incorporates the expansion & check valves. Ensure
that the valves are installed in the correct order and
orientation. No other valves should be placed
between the expansion valve and the Pullin Evolution
Solar unit. A connection can be made between the
expansion and pressure reducing valves to provide a
balanced cold water connection. The expansion
valve connection must not be used for any other
purpose.
EXPANSION VESSEL
The expansion vessel accommodates expansion that
results from heating the water inside the unit. The
unit is pre-charged at 3.5 bar. The expansion vessel
must be connected between the expansion valve
(see Fig. 1) and the Pullin Evolution Solar (see Fig.
5). The location of the expansion vessel should allow
access to recharge the pressure as and when
necessary, this can be done using a normal car foot
pump. It is recommended that the expansion vessel
is adequately supported. An expansion vessel wall
mounting bracket is supplied for this purpose.
NOTE: DO NOT USE THE POTABLE WATER EXPANSION VESSEL SUPPLIED WITH THE PULLIN
EVOLUTION SOLAR FOR ANY OTHER PURPOSE. IT
IS NOT SUITABLE FOR USE ON A SOLAR
PRIMARY CIRCUIT.
SECONDARY CIRCULATION
If secondary circulation is required it is recommended
that it be connected to the Pullin Evolution Solar as
shown in Fig. 2. The secondary return pipe should be
in 15mm pipe and incorporate a check valve to prevent backflow. A suitable WRAS approved bronze circulation pump will be required. On large systems, due
to the increase in system water content, it may be
necessary to fit an additional expansion vessel to the
secondary circuit. This should be done if the capacity
of the secondary circuit exceeds 10 litres.
Pipe capacity (copper)
15mm o/d = 0.13 l/m (10 litres = 77m)
22mm o/d = 0.38 l/m (10 litres = 26m)
28mm o/d = 0.55 l/m (10 litres = 18m)
Secondary circulation is NOT recommended for direct
electric units being used on Off Peak electricity tariffs.
OUTLET
The hot water outlet is a 22mm compression fitting
located at the top of the cylinder. Hot water distribution pipework should be 22mm pipe with short runs
of 15mm pipe to terminal fittings such as sinks and
basins. Pipe sizes may vary due to system design.
DRAIN TAP
A suitable draining tap should be installed in the cold
water supply to the Pullin Evolution Solar unit
between the expansion valve (see Fig. 1) and the
heater at as low a level as possible. It is recommended that the outlet point of the drain pipework
be at least 1 metre below the level of the heater
(this can be achieved by attaching a hose to the
drain tap outlet spigot).
Fig. 1: Cold water combination valve assembly
Fig. 2: Secondary circulation connection
SECONDARY
CIRCULATION
PUMP
SECONDARY
RETURN
CHECK
VALV E
OUTLET
T&P RELIEF
VALV E
SECONDARY
RETURN
CONNECTION
INLET
OUTLET
EXPANSION
VALV E
OUTLET
PRESSURE
REDUCING
VALV E
CARTRIDGE
& STRAINER
DIRECTION OF FLOW
BALANCED COLD
WATER CONNECTION
(NOT SUPPLIED)
EXPANSION VALVE
PRESSURE REDUCING VALVE
CHECK
VALV E
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Fig. 3: General Dimensions and features
190
9
1372 950 740 1019 1.1 110 115
190
9
1372 732 803 923 1019 1.1 110 0.61 11.9 20
210
9
1473 1000 759 1184 1.1 130 136
210
9
1473 892 808 1095 1184 1.1 130 0.68 15.2 20
250
9
1731 1072 773 1391 1.1 163 171
250
9
1731 1160 883 1258 1391 1.1 163 0. 79 15.2 23
300
9
2038 1409 870 1715 1.1 198 208
300
9
2038 1438 1023 1573 1715 1.1 198 0. 79 17.4 25
NOTES:
SOLAR
SURFACE
AREA (m²)
FE
NOMINAL
CAPACITY
(lit res)
TYPE DIMENSIONS (mm)
ABCD
2. Direct heating t imes as sume us e of lower element only and auxillary cy linder volume being heated
SURFACE
AREA (m²)
RATING
(kW )
RECOVERY
(mins )
1. Recovery time based on heating 70% of auxillary volume through 45°C
AUXILLARY
VOLUME
(lit res)
AUXILLARY COIL HEATING
TIME DIRE CT
(mins )DIRECT INDIRE CT
370
433
D
C
B
A
29
412
E
F
SOLAR
PRIMARY
RETURN
SOLAR
PRIMARY
FLOW
AUX. BOILER RETURN
(INDIRECT ONLY)
AUX. BOILER RETURN
(INDIRECT ONLY)
AUX. BOILER FLOW
(INDIRECT ONLY)
T&P VALVE
SECONDARY
RETURN
BOOST IMM. HTR.
(DIRECT ONLY)
INLET
AUX. CONTROL
HOUSING
SOLAR CONTROL
HOUSING
Ø550
20°
75°
90°
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Worked example of discharge pipe sizing
The example below is for a G1/2 temperature relief
valve with a discharge pipe (D2) having 4 No. elbows
and length of 7m from the tundish to the point of
discharge.
From Table 4:
Maximum resistance allowed for a straight length of
22mm copper discharge pipe (D2) from a G1/2
temperature relief valve is 9.0m.
DISCHARGE PIPEWORK
It is a requirement of Building Regulation G3 that any
discharge from an unvented system is conveyed to
where it is visible, but will not cause danger to
persons in or about the building. The tundish and
discharge pipes should be fitted in accordance with
the requirements and guidance notes of Building
Regulation G3. The G3 Requirements and Guidance
section 3.9 are reproduced in the following sections.
Information Sheet No. 33 available from the British
Board of Agrément gives further advice on discharge
pipe installation. For discharge pipe arrangements
not covered by G3 Guidance or BBA Info Sheet No.33
advice should be sought from your local Building
Control Officer.
G3 REQUIREMENT
“...there shall be precautions...to ensure
that the hot water discharged from safety
devices is safely conveyed to where it is
visible but will not cause danger to
persons in or about the building.”
G3 GUIDANCE SECTION 3.9
The discharge pipe (D1) from the vessel up
to and including the tundish is generally
supplied by the manufacturer of the hot
water storage system. Where otherwise,
the installation should include the
discharge pipe(s) (D1) from the safety
device(s). In either case the tundish
should be vertical, located in the same
space as the unvented hot water storage
system and be fitted as close as possible
and within 500mm of the safety device e.g.
the temperature relief valve.
The discharge pipe (D2) from the tundish
should terminate in a safe place where
there is no risk to persons in the vicinity of
the discharge, preferably be of metal and:
a. be at least one pipe size larger than the
nominal outlet size of the safety device
unless its total equivalent hydraulic
resistance exceeds that of a straight pipe
9m long i.e. discharge pipes between 9m
and 18m equivalent resistance length
should be at least two sizes larger than
the nominal outlet size of the safety
device, between 18 and 27m at least 3
sizes larger , and so on. Bends must be
taken into account in calculating the flow
resistance. Refer to Diagram 1, Table 1 and
the worked example.
An alternative approach for sizing discharge pipes would be to follow BS
6700:1987 Specification for design installation, testing and maintenance of services supplying water for domestic use
within buildings and their curtilages,
Appendix E, section E2 and table 21.
b. have a vertical section of pipe at least
300mm long, below the tundish before
any elbows or bends in the pipework.
c. be installed with a continuous fall.
d. have discharges visible at both the
tundish and the final point of discharge
but where this is not possible or is practically difficult there should be clear
visibility at one or other of these locations.
Examples of acceptable discharge arrangements are:
i. ideally below a fixed grating and
above the water seal in a trapped gully.
ii. downward discharges at low level;
i.e. up to 100mm above external surfaces
such as car parks, hard standings,
grassed areas etc. are acceptable providing that where children may play or
otherwise come into contact with discharges a wire cage or similar guard is
positioned to prevent contact, whilst
maintaining visibility.
iii. discharges at high level; e.g. into a
metal hopper and metal down pipe with
the end of the discharge pipe clearly
visible (tundish visible or not) or onto a
roof capable of withstanding high temperature discharges of water and 3m
from any plastics guttering system that
would collect such discharges (tundish
visible).
iv. where a single pipe serves a number
of discharges, such as in blocks of flats,
the number served should be limited to
not more than 6 systems so that any
instalation discharging can be traced
reasonably easily. The single common
discharge pipe should be at least one
pipe size larger than the largest individual discharge pipe (D2) to be connected. If unvented hot water storage
systems are installed where discharges
from safety devices may not be apparent i.e. in dwellings occupied by blind,
infirm or disabled people, consideration
should be given to the installation of an
electronically operated device to warn
when discharge takes place.
Note: The discharge will consist of
scalding water and steam. Asphalt, roofing felt and non-metallic rainwater
goods may be damaged by such discharges.
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Subtract the resistance for 4 No. 22mm elbows at
0.8m each = 3.2m
Therefore the permitted length equates to: 5.8m
5.8m is less than the actual length of 7m therefore
calculate the next largest size.
Maximum resistance allowed for a straight length of
28mm pipe (D2) from a G1/2 temperature relief
valves equates to 18m.
Subtract the resistance of 4 No. 28mm elbows at
1.0m each = 4.0m
Therefore the maximum permitted length equates
to: 14m
As the actual length is 7m, a 28mm (D2) copper pipe
will be satisfactory.
WARNINGS
• Under no circumstances should the factory fitted temperature/pressure relief valve be removed
other than by a competent person. To do so will
invalidate any guarantee or claim.
• The cold water combination valve assembly must
be fitted to the mains water supply to the Pullin
Evolution Solar unit.
• No control or safety valves should be tampered
with.
• The discharge pipe should not be blocked or
used for any other purpose.
• The tundish should not be located adjacent to
any electrical components.
Valve outlet size
Min imum size of
discharge pipe
D1
Min imum size o f
discharge pipe
D2 from tundish
Ma ximum
resistance
allowed, expressed
as a length of
straight pipe (i.e.
no elbows or
bends)
Resistance
created by each
elbow or bend
G1/2 15mm
22mm
28mm
35mm
up to 9m
up to 18m
up to 27m
0.8m
1.0m
1.4m
G3/4 22mm
28mm
35mm
42mm
up to 9m
up to 18m
up to 27m
1.0m
1.4m
1.7m
G1 28mm
35mm
42mm
54mm
up to 9m
up to 18m
up to 27m
1.4m
1.7m
2.3m
Table 2: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes
Fixed grating
Discharge below
fixed grating
(Building Regulation
G3 section 3.9d gives
alternative points
of discharge)
Trapped
gully
Discharge pipe (D2) from tundish,
with continuous fall. See Building
Regulation G3 section 3.9d i-iv,
Table 4 and worked example
300mm
minimum
500mm maximum
Metal discharge pipe (D1) from
Temperature relief valve to tundish
Tundish
Safety device
(e.g. Temperature
relief valve)
Fig.4: Typical discharge pipe arrangement (extract from Building Regulation G3 Guidance section)
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