RVR Energy Technology TML SF Installation And Operating Instructions Manual

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INSTALLATION AND OPERATING INSTRUCTIONS

TML SF WATER

HEATERS

ALT223

2

1.0 INTRODUCTION

1.1 Reading the Instructions

Please read and understand these instructions prior to installing the water heater.

Following installation and commissioning the operation of the heater should be explained to the
customer and these instructions left with them for future reference.

2.0 GUARANTEE

This water heater is guaranteed for a period of 5 years provided that:

- It has been installed in accordance with these instructions and all the necessary inlet controls and
safety valves have been fitted correctly.

- Any valves or controls are supplied or approved by RVR.

- The unit has not been tampered with and has been regularly maintained as detailed in these
instructions.

- The unit has been used only for heating potable water.

The unit is NOT guaranteed against damage by frost or due to the build up of scale.

This guarantee does not affect the statutory rights of the consumer.

Our policy is that of continuous improvement and development, therefore the right is reserved to
change specification without notice.

All water heaters must be installed by a competent and qualified person, in accordance with
relevant clauses of applicable standards and recommendations.

These include but may not be limited to the following:-

EN12897: 2006 Water Supply—Specification for indirectly heated unvented (closed)
storage water heaters.
All relevant Building Regulations
Local Water Bye Laws
IEE Wiring Regulations
Health & Safety legislation

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3.0 Technical Specifications

3.1 Capacity and Performance

Table 1 - Technical information

SF 300 SF 500 SF 800 SF1000 SF 1500 SF 2000

Nominal Capacity

Litres

300

500 800 1000 1500 2000

Max. DHW Pressure

bar

6

6 6 6 6 6

Max. Primary Pressure

bar

3

3 3 3 3 3

Max. Operating Temperature

C

95

95 95 95 95 95

Max. design pressure

bar

6

6 6 6 6 6

Heating capacity

kW

38.3 53.5 68.6 109.8 127.65 142.97

Primary Flow Rate

Litres/min

27.4

38.3 49.17 78.7 91.5 102.5

Coil Pressure Drop

kPa

3.97

9.85 19.2 27.5 39.15 42.2

Coil Water Content

Litres

10.5 14.7 18.9 21 25.9 29

4

3.2 Dimensions

Figure 1 - Location of connections on cylinder

Table 2– Dimensions of Water Heaters

a Anode

e

Thermometer
Probe

C Boiler Flow/Return
i Cold Water Inlet
q Inspection flange
r

Recirculation

u DHW Outlet

w

Electric Immersion
Heater

Lt Ø Ø Ext H tot a e C i u r W q Kg empty Kg full

500 650 750 1730 1¼" ½"

1"

1¼" 1¼" ½" 1½" 120/180 120 620

800 790 990 1810 1¼" ½"

1"

1½" 1½" 1" 1½" 120/180 162 962

1000 790 990 2210 1¼" ½"

1"

1½" 1½" 1" 1½ 120/180 195 1195

1500 1000 1200 2215 1¼" ½"

1"

2" 2" 1" 1½" 220/290 271 1771

2000 1100 1300 2525 1¼" ½"

1"

2" 2" 1" 1½" 220/290 385 2385

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3.3 Installation options

This water heater may be used in open vented water heating systems or in an unvented installations.

When used in unvented installations, the appropriate unvented kit supplied by RVR must be used.
This contains items 1,3,4,5 and 6 as shown in figure 3. Other items such as mixing valves and zone
valves are also available from RVR.

3.3.1 Unvented installations

Please see figure 2 for a general layout for an unvented water heater installation. The following
safety devices must be fitted to the unvented water heater:

Thermostatic control — Energy Cut Out Device

The normal water storage temperature is 60° C. The water heater thermostat should be wired to en­sure that the energy supply to the water heater is interrupted if the water temperature exceeds 60° C.

Temperature and Pressure Relief valve (T&P valve)
The T&P valve ensures that the temperature of the stored water cannot exceed 100

o

C by venting the

water heater under these conditions.

Figure 2 - Unvented System Schematic

Key

1 Anti Vacuum Valve
2 Mixing Valve
3 Tundish
4 Temperature & Pressure Relief Valve
5 Pressure Relief Valve
6 Expansion vessel
7 Non Return Valve
8 Check valve

6

Pressure Relief valve
This is the most important safety device. All unvented water heaters must be fitted with a Pressure
Relief Valve (Expansion valve) with a setting of 6 bars.

Pressure Reducing Valve
The cold water supply pressure must not exceed 3.5 bar. If the supply pressure is higher than this
then a pressure reducing valve should be fitted.

Expansion vessel
Expansion must be accommodated using an Expansion Vessel. The Expansion vessel must be
sized to accommodate the maximum expansion of the system and should be suitable for use with
potable water. The size of the expansion vessel is proportional to the volume of the DHW system.
The size of the vessel should be carefully calculated.

A rule of thumb for systems with a cold water supply pressure of 3.5 bars and a maximum heating
temperature of 60°C is that the volume of the expansion vessel should be at least 10% of the total
DHW system volume.

Backflow Prevention
To ensure all expansion takes place in the vessel, a Non Return Valve must be fitted on the cold wa­ter supply.

Anti Vacuum Valve
The Anti Vacuum Valve is installed to ensure that the water heater is vented and cannot collapse if
exposed to an internal negative pressure.

Mixing Valve
The mixing valve limits the temperature of the delivered water by mixing it with cold water as re­quired. The delivered water temperature should not exceed 50°C.

Failure to fit these essential safety devices will invalidate the warranty and
create a dangerous installation. This may lead to property damage, injury or
loss of life.

7

Open Vented Systems

Please see figure 3 for a gen­eral layout for an open vented
water heater installation. The
following safety devices must be
fitted to the water heater:

1. Feed and Vent cistern.

2. Thermostatic control — En­ergy Cut Out Device

The normal water storage tem­perature is 60° C. The water
heater thermostat should be
wired to ensure that the energy
supply to the water heater is
interrupted if the water tempera­ture exceeds 60° C.

The following safety devices
must be fitted to the water
heater when used in an open system:

1 Stop Valve: This allows the system to be isolated from the cold water supply.

2 Drain Valve: This allows the water heater to be drained for service or removal.

3 Blending (Mixing) Valve: The blending valve limits the temperature of the delivered water by

mixing it with cold water as required. The delivered water temperature should not exceed
50°C.

4 Zone Valve: The recommended water storage temperature is 60°C. The water heater ther-

mostat should be wired to ensure that the energy supply to the water heater is interrupted if
the water temperature exceeds 60°C. The zone valve is used for this purpose.

5 Cold Water Cistern: This is the cold water storage cistern. The Vent pipe is also returned to

the cistern.

6 Vent pipe: This is also referred to as the expansion pipe and is used to safely vent expansion

of the heated water.

Failure to fit these essential safety devices will invalidate the warranty and may cause a dangerous installation.

WARNING: All water heaters must be fitted with temperature control to ensure that the domestic water
is not heated to excessive temperatures.

A blending (mixing) valve must be fitted to all installations to ensure water does not exceed 50°C at the
point of use.

Figure 3 - Open Vented System Schematic

8

5.0 Discharge Pipes from Safety Valves

5.1 Tundish Installation

The discharge pipes must be routed to a tundish.

The pipe diameter must 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 2 sizes
larger than the nominal outlet size of the safety device. Between 18m and 27m at least 3 larger,
and so on.

Bends must be taken into account in calculating the flow resistance.

For more information please see table 3.

Tundish - The tundish must be positioned vertically within 500 mm of the unit, clearly visible to the
user and away from electrical devices. The minimum size of the discharge pipe downstream of the
tundish is given in TABLE 3.

Valve outlet
size

Minimum size of
discharge pipe D1

Minimum size of
discharge pipe
D2 from tundish

Maximum Resistance
allowed (expressed
as a length of
straight pipe)

Resistance cre­ated by each el­bow or bend

G 1/2 15mm 22mm

28mm
35mm

Up to 9m
Up to 18m
Up to 27m

0.8m

1.0m

1.4m

G 3/4 22mm 28mm

35mm
42mm

Up to 9m
Up to 18m
Up to 27m

1.0m

1.4m

1.7m

G 1 28mm 35mm

42mm
54mm

Up to 9m
Up to 18m
Up to 27m

1.4m

1.7m

2.3m

Table 3 – Discharge Pipe Sizing

4.0 Installation - General Requirements:

Check the load bearing capacity of any floors or walls to ensure that they can support the
weight of the water heater when filled to capacity. Refer to table 2 for full weight of the water
heater.

Enough space should be left at the top and sides of the unit for pipe connections and access to the
safety controls and valves. Refer to figure 1 and the dimensions table 2 to determine a suitable posi­tion for the heater.

DO NOT install the water heater where the unit may freeze.

Refer to the section Installation Options to determine which valves and accessories are required.
Plumb the valves as shown in the relevant diagrams ( Figures 2 & 3). An isolating valve must be
fitted on the cold water supply to the heater.

Do not use solder joints as this will damage the heater and may prevent servicing under warranty.

9

The discharge pipework from the tundish:

Must fall continuously through its length.

Must be of a heat resistant material, e.g. metal.

Must not be fitted with any valves or taps.

Must discharge to a safe visible position, e.g. onto the surface of an external wall or into a gulley.

Must have a minimum of 300 mm straight pipework directly from the tundish.

Note: Where children may play or otherwise come into contact with discharges, a wire
cage or similar guard must be positioned to prevent contact whilst maintaining visibility.

The diagrams on this page show recommended methods of routing and terminating the discharge
pipe safely. 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 tundish installation can be
traced easily.

If a single common discharge pipe is used then it should be at least one pipe size larger than the
largest individual discharge pipe to be connected. If the system is 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.

Figure 4 - Discharge Pipe routing

Figure 5 - Tundish installation

5.2 High Level Termination of Discharge

At high level, discharge onto a roof is acceptable providing the roof is capable of withstanding high
temperatures and there is a distance of 3 m from any plastic guttering systems that would collect
such discharge.

Note: The discharge may consist of scalding water and steam. Asphalt, roofing felt and non-metallic
materials may be damaged by such discharges.

Tundish

D1

D2

300mm

minimum

Tundish

300mm

minimum

D1

D2

Pipe close to wall t o
allow water to fan out
safely

100mm max.
70mm min.

Ground level

Gulley if

available

Tundish

300mm

minimum

D1

D2

Type ‘A’
Air Gap

End of pipe

clearly visible

Option A Option B Option C

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5.3 Discharge Pipe Sizing Example

This example shows how to select pipe diameter for a given discharge pipe.

For this example we will assume we are using a G½ temperature relief valve and require 4 elbows in
the discharge pipe run. The length of the pipe run from tundish to point of discharge is 7 metres.

Begin by calculating whether 22mm pipe would be sufficient

Consult Table 3 and look up the maximum resistance allowed for this pipe size (9 metres)

Consult Table 3 and look up the resistance of an elbow in this pipe size (0.8 m) As we have 4 el­bows or bends, multiply (0.8m * 4m) = 3.2m

Subtract the resistance of the elbows from the maximum resistance (9m—3.2m) = 5.8m.

Is your length of pipe run less than or equal to the maximum permissible resistance for this pipe run?

6.0 Installation - Electrical Requirements

WARNING: This water heater must be earthed

The water heater is fitted with a control thermostat as shown in figure 6. It is essential that the en­ergy source to the water heater is under the control of this device.

Figure 6—Thermostat Control

The water heater may be optionally fitted with an electrical immersion heater. Ensure that any elec­tric immersion heater is fitted with a high limit and control thermostat.

Where an immersion heater is fitted, the following information is relevant.

Disconnect the electrical supply before removing the terminal cover. Installation must be in accor­dance with the current I.E.E. Wiring Regulations.

The electricity supply should be fused to protect the immersion heater circuit and it should be possi­ble to isolate it via a double pole isolating switch with a contact separation of at least 3mm in both
poles.

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7.0 Maintenance Procedures

The water heater should be inspected and serviced annually. As a minimum, check operation
of both pressure relief valve and T&P valve, check system for leaks, check expansion vessel
and check operation of thermostat.

7.1 Draining and Refilling the System

Draining

1. Switch off electrical power to immersion heater(s) and/or shut down the boiler.

2. Close the Stop Valve.

3. Open a hot water tap in order to reduce pressure in the water heater.

4. Drain from the drain cock at the base of the water heater.

Refilling

1. DO NOT switch on the immersion heaters or boiler until the system has been completely refilled.

2. Close the drain valve.

3. With hot tap open, turn on pumped cold water supply. When water flows from the hot tap allow to
flow for a short while to purge air and to flush through any disturbed particles.

4. Close hot tap and then open successive hot taps in system to purge any air.

The electrical supply can now be switched on.

7.2 Checking the expansion vessel

The charge pressure of the expansion vessel should be checked annually.

Method

Switch off power to immersion heater(s) and shut down boiler.

Close the Stop Valve.

Open a hot water tap in order to reduce pressure in the cylinder.

Remove the black cap on the end of the expansion vessel. Check the pressure with a good quality
tyre gauge.

The charge pressure can then be checked against the vessel nameplates by using a good tyre
gauge. If it is low then replenish it by using a nitrogen gas bottle with regulating valve, or a foot
pump. The pressure will normally be set to 3.5 bar.

Any fluid escaping from the expansion vessel valve indicates a leaking diaphragm and the vessel
should be replaced.

7.3 Checking the operation of safety valves

Manually operate the valve lever on the Temperature & Pressure Relief Valve for a few seconds.

Check that water is discharged and that it flows freely through the tundish and discharge pipework.

Check that the valve reseats correctly when released.

Repeat the procedure for the Expansion Relief Valve.

Note: The water discharged may be very hot.

Important

: After servicing, preliminary electrical system checks must be carried out to ensure elec-

trical safety (i.e. polarity, earth continuity, resistance to earth and short circuit).

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8.0 Commissioning

It is important to follow the steps outlined below during commissioning.

Do not switch on the electrical supply, solar station or boiler until the unit has been filled with water
and checked for leaks.

Check that all installation, electrical and discharge pipe requirements have been met.

Check that all water and electrical connections are tight and properly connected.

Check charge pressure of expansion vessel.

Open a hot water tap, turn on mains water supply to the heater.

Allow unit to fill and leave hot tap running for a short while to purge any air and flush out the pipe­work. Close the hot tap and check the system for leaks.

Manually test the operation of the Temperature/Pressure Relief Valve and Pressure Relief Valve.
Ensure water flows freely from the valve(s) and through the discharge pipes.

Switch on the electrical supply and boiler.

Verify that water is heated and that the thermostatic controls work correctly.

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9.0 Troubleshooting

FAULT POSSIBLE CAUSES REMEDIAL MEASURES

Water not heating

Electrical supply fault

Check electrical supply. Verify the
operation of boiler and controls.

Thermal cut-out tripped

Check cut-out. If it has activated
then reset and check thermostat
operation. If necessary replace
thermostat/thermal cut-out (see
Wiring Diagram)

Thermostat fault

Check thermostat operation, re­place if necessary

Discharge of water
from Pressure Relief
Valve (continuously) Excessive supply water pressure

Fit Pressure Reducing Valve (see
section Installation Options)

Discharge of water
from Pressure Relief
Valve (intermittently) Inadequate expansion in system

Check expansion vessel size and
precharge pressure.

Water supply pressure exceeds 3.5 bar

Fit a pressure reducing valve with
integral line strainer (see section
Installation Options)

Water or steam from
Pressure Relief Valve

Thermostat and thermal cut-out fault

Replace thermostat and thermal
cut-out

No water flow

Inlet valves incorrectly fitted

Check all valves are correctly in­stalled in accordance with flow
direction arrows

Supply water not turned on Check water supply is on

Blockage in water supply

Check for obstructions. If a pres­sure reducing valve is fitted check
strainer is not blocked.

Milky water Oxygenated water

Water from a pressurised system
releases oxygen bubbles when
flowing. The milkiness will disap­pear after a short time.

Failure of Pressure Relief Valve

Check valve is seating properly.
Replace if necessary.

Table 4 - Faults and remedial measures

14

Manufacturer details:
TML

64010 CIVITELLA DEL TRONTO (TE)

ITALY

TML Single coil instructions 060510