Santon PES170D, PES210D, PES260D, PES300D, PES190I Installation And Servicing Instructions

1

36 00 5945 Issue 04

UNVENTED MAINS PRESSURE SOLAR WATER HEATER

170, 190, 210, 250, 260 AND 300 LITRE

DIRECT AND INDIRECT MODELS

INSTALLATION AND SERVICING INSTRUCTIONS

PACK CONTENTS

Premier Plus unvented solar water heater incorporating immersion heater(s) and thermal controls
 Factory tted Temperature/Pressure Relief Valve  Cold Water Combination Valve Expansion
Vessel Expansion Vessel Mounting Bracket  Tundish Motorised Valve (Indirect models only)
 Compression nuts and olives Immersion heater spanner Installation Instructions

2

SANTON PREMIER PLUS SOLAR INSTALLATION AND SERVICING

INSTRUCTIONS.

PLEASE LEAVE THIS MANUAL WITH THE UNIT FOR FUTURE

REFERENCE.

CONTENTS

SECTION CONTENT PAGE

1 INTRODUCTION .................................................................................4

2 GENERAL REQUIREMENTS ............................................................ 5

3 INSTALLATION - GENERAL ................................................................ 6

4 INSTALLATION - SOLAR PRIMARY ...............................................11

5 INSTALLATION - DIRECT UNITS .......................................................11

6 INSTALLATION – AUXILLARY HEATING COIL ............................ 12

7 COMMISSIONING ..................................................................................14

8 MAINTENANCE ...................................................................................... 16

9 FAULT FINDING AND SERVICING .....................................................17

10 USER INSTRUCTIONS ..........................................................................19

11 GUARANTEE ........................................................................................... 20

3

TABEL 1: OPERATIONAL SUMMARY

IMPORTANT: PLEASE READ ALL THESE INSTRUCTIONS BEFORE
COMMENCING INSTALLATION

THE INFORMATION CONTAINED IN THESE INSTRUCTIONS DETAILS
HOW TO CONNECT THE PREMIER PLUS SOLAR CYLINDER TO A SO­LAR PRIMARY CIRCUIT. OTHER CONTROLS WILL BE NECESSARY TO
PROVIDE CONTROL OVER THE SOLAR PRIMARY CIRCUIT, REFER
TO THE INSTRUCTIONS SUPPLIED WITH THE SOLAR CONTROLS
AND ANCILLARY EQUIPMENT FOR DETAILS OF HOW TO INTEGRATE
THEM WITH THE PREMIER PLUS SOLAR CYLINDER.

Operating Pressure of Unit

16.0 ba r

3.5 b ar

Maximum water supply pressure to PRV

3.5 b ar

Expansion vessel charge pressure

6.0 b ar

Expansion valve setting
Nominal storage capacity

(see Section 2 Table 2)
Max. primary working pressure (Auxillary Coil)
Max. primary working pressure (Solar Coil)

3.0 b ar (indirects only)

6.0 b ar

Opening temperature of T&P Relief Valve

90°C

Opening pressure of T&P Relief Valve

10.0 b ar

4

Table 3: Standing heat losses

Table 2: Unit weights

1.0 INTRODUCTION

The Santon Premier Plus Solar is a purpose designed
unvented solar water heater. The unit has a stainless

steel inner vessel which ensures an excellent stan-

dard of corrosion resistance. The outer casing is a
combination of resilient thermoplastic mouldings and
corrosion proofed steel (Plastisol) sheet. All Premiers
are insulated with CFC/HCFC free polyurethane foam

to meet the latest European heat loss requirements

(see Table 3).

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 pre-adjusted.

NOTE: Prior to installation the unit should be stored in an upright position in an area free from excessive damp

or humidity.

This appliance complies with the requirements of
the CE marking directive and is KIWA approved to
show compliance with Building Regulations (Sec-

tion 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

Type

Model

reference

Nominal
capacity

(litres)

Weight of

unit full

(kg)

DIRECT PES170D 170 210

PES210D 210 259
PES260D 260 308
PES300D 300 362

INDIRECT PES190I 190 240

PES210I 210 264
PES250I 250 308
PES300I 300 367

per day

(kWh/24h)

per year

(kWh/365d)

190 1.52 555
210 1.70 621
250

300 2.28

Nominal

Capacity

(litres)

Standing Heat Loss

170 1.40 511

260 1.98 723

1.96 715

832

5

2.0 GENERAL REQUIREMENTS

2.1 COMPONENTS SUPPLIED

1. Premier Plus unvented solar water heater incor­porating immersion heater(s) and thermal controls

2. Factory tted Temperature/Pressure Relief Valve

3. Cold Water Combination Valve.

4. Expansion Vessel and mounting bracket.

5. Tundish.

6. Motorized Valve (Indirect models only).

7. Compression nuts and olives

8. Immersion heater key spanner

2.2 SITING THE UNIT

The Santon Premier Plus Solar must be installed verti­cally. Although location is not critical, the following

points should be considered:

• The Santon Premier Plus 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 servic-

ing and maintenance.

• Ensure that the base chosen for the Santon Pre­mier Plus Solar is level and capable of permanently
supporting the weight when full of water (see Table

2).

2.3 OUTLET/TERMINAL FITTINGS
(TAPS, ETC.)

The Santon Premier Plus Solar can be used with most
types of terminal ttings. 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 Cold

Water Combination Valve and the Premier Plus water
heater. Outlets situated higher than the Santon Premier
Plus 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.

2.5 LIMITATIONS

The Premier Plus unvented solar water heater 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 pres-

sure 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 ltration can

be ensured.

6

3.0 INSTALLATION – GENERAL
(FIGS 3 & 5)

3.1 PIPE FITTINGS

All pipe ttings are made via 22mm compression
ttings directly to the unit. The ttings are threaded
3/4”BSP male parallel should threaded pipe connec-

tions be required.

3.2 COLD FEED

A 22mm cold water supply is recommended however,
if a 15mm (1/2”) supply exists which provides suf­cient ow this may be used (although more ow

noise may be experienced).

A stopcock or servicing valve should be incorporated
into the cold water supply to enable the Santon Premier
Plus Solar and its associated controls to be isolated

and serviced.

3.3 COLD WATER COMBINATION VALVE (FIG

1)

The Cold Water Combination Valve can be connected

anywhere on the cold water mains supply prior to the

Expansion Vessel (see Fig. 5). The Cold Water Combi­nation Valve is installed as a complete one-piece unit.
The valve incorporates the Pressure Reducer, Strainer,
Expansion Valve and Check Valve. Ensure that the
valve is installed with the direction of ow arrows

pointing in the right direction. No other valves should

be placed between the Cold Water Combination Valve
and the Premier Plus Solar unit. The Expansion Valve
connection must not be used for any other purpose.

3.5 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 Cold Water Combi-

nation Valve and the Santon Premier Plus 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.

NO TE: DO NOT USE THE PO TABLE
WATER EXPANSION VESSEL SUPPLIED
WITH THE PREMIER PLUS SOLAR FOR
ANY OTHER PURPOSE. IT IS NOT SUIT­ABLE FOR USE ON A SOLAR PRIMARY
CIRCUIT.

3.7 OUTLET

The hot water outlet is a 22mm compression tting
located at the top of the cylinder. Hot water distribu­tion pipework should be 22mm pipe with short runs
of 15mm pipe to terminal ttings such as sinks and
basins. Pipe sizes may vary due to system design.

3.4 DRAIN TAP

A suitable draining tap should be installed in the cold
water supply to the Premier Plus Solar unit between
the Cold Water Combination Valve 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).

3.6 SECONDARY CIRCULATION

If secondary circulation is required it is recommended

that it be connected to the Premier as shown in Fig.
2

The secondary return pipe should be in 15mm pipe
and incorporate a check valve to prevent backow.
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 t 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.

7

COLD MAINS
CONNECTION
(22mm)

EXPANSION
VALVE

EXPANSION
VALVE OUTLET
(15mm)

OUTLET
CONNECTION
(22mm) TO
PREMIER PLUS

PRESSURE REDUCING
VALVE / CHECK VALVE
HOUSING

FIG. 2 Secondary circulation connection

FIG. 1 Cold Water Combination Valve

SECONDARY RETURN
CONNECTION

CHECK VALVE

SECONDARY
CIRCULATION PUMP

OUTLET

SECONDARY
RETURN

FIG. 3 General Dimensions and features

370

433

412

29

A

B

C

D

E

8

9

2

1

3

4

7

5

10

6

F

20°

25°

30°

1 SOLAR PRIMARY RETURN
2 SOLAR PRIMARY FLOW
3 AUXILLARY BOILER RETURN
(INDIRECT MODELS ONLY)
4 AUXILLARY BOILER FLOW
(INDIRECT MODELS ONLY)
5 T&P VALVE
6 SECONDARY RETURN
7 BOOST IMMERSION HEATER
(DIRECT MODELS ONLY)
8 AUXILLARY CONTROL HOUSING
9 INLET
10 SOLAR CONTROL HOUSING

Ø

594

550

45°

81

A B C D E F

TYPE

DIMENSIONS (mm)

AUXILLARY

VOLUME

(litres)

AUXILLARY COIL

SURFACE

AREA

(sq.m)

RATING

(kW)

RECOVERY

(mins)

HEATING

TIME

DIRECT

(MINS)

SOLAR

SURFACE

AREA

(sq.m)

NOMINAL
CAPACITY

(litres)

E = DIRECT

B = INDIRECT

170

E

NOTES:

1. Recovery time based on heating 70% of auxillary volume through 45°C

2. Direct heating times assume use of lower element only and auxillary cylinder volume being heated.

1221

740 925 1.1

190 B

1372 803 923732 1019 1.1

120

0.61 11.9 22

120

126

210

E

1473

778 1184 1.1

140

1471000

210 B

1473 925 10951009 1184 1.1

120

0.68 18.3 17

260

E

1792

842 1440 1.1

170

1781072

300

E

2038

933 1715 1.1

200

2101409

250 B

1731 1072 12581160 1391 1.1

145

0.79 20.0 19

300 B

2038 1243 15731438 1715 1.1

175

0.79 20.0 22

8

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.
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.

3.8 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 tted 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 Agrement 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 either your local Build­ing Control Ofcer or Santon.

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 tted 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 ow resistance. Refer to Diagram
4, Table 4 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

nal point of discharge but where this is not possible
or is practically difcult there should be clear vis­ibility at one or other of these locations. Examples of

acceptable discharge arrangements are:

i. ideally below a xed 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 ats, the number served should

be limited to not more than 6 systems so that any
instalation discharging can be traced reasonably eas-

ily. 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, inrm 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, roong felt and non-metallic rainwater

goods may be damaged by such discharges.

3.9 WARNINGS

9

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
Regula tion G3 section 3.9d i-iv,
Table 4 and worked exam ple

300mm
minimum

500mm maximum

Metal discharge pipe (D1) from
Temperature relief valve to tundish

Tundish

Safety device
(e.g. Temperature
relief valve)

Table 4 Sizing of copper discharge pipe (D2) for common temperature relief valve outlet

FIG. 4 Typical discharge pipe arrangement (extract from Building Regulation G3 Guid­ance section 3.9)

• Underno circumstances should the factorytted

Temperature/Pressure Relief Valve be removed other
than by authorised Santon personnel. To do so will
invalidate any guarantee or claim.

• TheColdWaterCombinationValvemustbetted

to the mains water supply to the Premier Plus 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 out let size

Minimum size of

discharge pipe

D1

Minimum size of

discharge pipe

D2 from tundish

Maximum

resist ance

allowed, expr essed

as a lengt h of

st raight pipe (i.e.

no elbows or

bends)

Res istance

create d 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 27

m

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

10

1

2

GREEN/YELLOW

13 AMP MAINS

SUPPLY. 1.5mm

2

MIN. CABLE SIZE

TO INDIRECT SYSTEM

CONTROLS JUNCTION

BOX - SEE FIGS. 8/9

GREEN/

YELLOW

BROWN

BLUE

3

DIRECT THERMOSTAT

B

A

112

2

3

INDIRECT THERMOSTAT

INDIRECT THERMAL CUT-OUT

FIG. 5 Typical installation - schematic

FIG. 6 Electrical Connections (Schematic)

DIRECT MODELS AUXILLARY HEATING CONTROL

Note: On models tted with two elements each element must be wired indi­vidually in accordance with the diagram above.

THERMOSTAT

EARTH
CONNECTION

FUSED (13A) DOUBLE
POLE ISOLATING
SWITCH

1.5mm2 3 CORE

HOFR SHEATHED
CABLE

B

R

O

W

N

B

L

U

E

G

R

E

E

N

/ Y

E

L

L

O

W

A

B

11

5.0 INSTALLATION - DIRECT
UNITS

5.1 PLUMBING CONNECTIONS

Direct units require the following pipework connec­tions.

• Cold water supply to and from inlet controls.

• Outlet to hot water draw off points.

• Discharge pipew or k from valve outlets to

tundish.

5.2 ELECTRICAL SUPPLY (FIG. 6)

Premier Plus solar units are tted with two 3kW
immersion heaters (Except 170Ltr) as standard. It is

recommended that these should be wired via a suitable

controller to BSEN 60730. The Premier Plus Solar
MUST be earthed.

All wiring to the unit must be installed in accordance
with the latest IEE Wiring Regulations and the circuit
must be protected by a suitable fuse and double pole
isolating switch with a contact separation of at least
3mm in both poles. The Live and Neutral connections

are made directly onto the combined thermostat and
thermal cut-out located under the terminal cover(s)
mounted on the side of the unit. The Earth connec­tion should be made to the earth connection located to

the side of the immersion heater boss(es). The supply

cable must be routed through the cable gland located
on the unit casing beneath the terminal housing.

DO NOT operate the immersion heaters until the San-

ton Premier Plus Solar has been lled with water.

4.0 INSTALLATION - SOLAR PRI­MARY

4.1 CONNECTION TO PRIMARY CIRCUIT

The lower (solar) coil of the Premier Plus Solar must
be connected to a fully pumped solar primary circuit.
The connections are suitable for 22mm copper pipe
direct to the compression ttings provided. The con­nections are also threaded 3/4” BSP male parrallel
should BSP be required.
The solar primary circuit should have its own dedi­cated circulating pump and safety controls which must
be installed as per the manufacturers’ instructions.

4.2 CONTROL OF PRIMARY CIRCUIT

Temperature control of the Premier Plus Solar must
be carried out using a suitable proprietory Solar Con­troller/Programmer. The cylinder temperature sensing

probe (supplied with the solar controller) should be

fully insterted into the pocket provided on the Premier
Plus Solar and its cable secured using the cable clamps

on the controls housing. (see Fig.7)

Connection to the solar controller should be in ac-

cordance with manufacturers instructions. The solar

controller should be programmed to give a cylinder

temperature of approximately 60°C (maximum
70°C).

The solar controller and solar primary circulation

pump must be wired via the over-temperature thermal
cut-out mounted in the lower solar controls housing

(see Fig. 7). This will ensure that the heat input to
the solar coil is interrupted in the event of the cylin­der over-heating. There must also be suitable check
(non-return) valves installed in the solar primary ow
and return to prevent the possibility of any thermo­syphoning if the solar circulation is stopped.

5.3 SAFETY
DISCONNECT FROM THE MAINS SUPPLY
BEFORE REMOVING ANY COVERS.

Never attempt to replace the immersion heater(s)

other than with the recommended Santon immersion

heater(s).

DO NOT BYPASS THE THERMAL CUT-OUT(S)
IN ANY CIRCUMSTANCES. Ensure the two male

spade terminations on the underside of the combined
thermostat and thermal cut-out are pushed rmly onto

the corresponding terminations on the element plate
assembly.

In case of difculty contact Santon service,
Tel: [phone].

Cylinder Temperature

Control Probe Pocket

Cable Clamp

Solar Cylinder
Controls Housing
(cover not shown)

FIG. 7 Solar Coil Control Connections

Over-temperature

Cut-out

12

6.0 INSTALLATION - AUXILLARY
HEATING COIL

6.1 PLUMBING CONNECTIONS

Indirect units require the following pipework con­nections.

• Cold water supply to and from inlet controls.

• Outlet to hot water draw off points.

• Discharge pipew or k from valve outlets to

tundish

• Connection to the auxillary primary circuit.

Primary connections are 22mm compression. How­ever, 3/4”BSP parallel threaded ttings can be tted
to the primary coil connections if required.

6.2 ELECTRICAL SUPPLY (FIG. 6)

All Indirect units are tted with a 3kW immersion

heater and a combined thermostat and thermal cut-out
to control the primary heating source. The Premier

Plus Solar MUST be earthed.

All wiring to the unit must be installed in accordance
with the latest IEE Wiring Regulations and the supply
circuits must be protected by a suitable fuse and double
pole isolating switch with a contact separation of at
least 3mm in both poles. All connections are made to
the terminal block located under the terminal cover
mounted on the side of the unit. The supply cable(s)

must be routed through the cable grip(s) in the termi­nal housing.

DISCONNECT FROM MAINS SUPPLY BE­FORE REMOVING ANY COVERS. DO NOT
BYPASS THE THERMAL CUT-OUTS IN ANY
CIRCUMSTANCES. Ensure the thermostat and

thermal cut-out sensing bulbs are pushed fully into
the pockets on the element plate assembly.

6.3 BOILER SELECTION

The boiler should have a control thermostat and non
self-resetting thermal cut-out and be compatible with

unvented storage water heaters.

Where use of a boiler without a thermal cut-out is
unavoidable a “low head” open vented primary cir­cuit should be used. The Feed and Expansion cistern
head above the Premier Plus Solar should not exceed

2.5m.

6.4 AUXILLARY CIRCUIT CONTROL

The 2 port motorised valve supplied with the Premier
Plus Solar indirect units MUST be tted to the primary
auxillary circuit ow to the Premier Plus solar heat

exchanger and wired in series with the indirect ther-

mostat and thermal cut-out tted to the unit.

Primary circulation to the Premier Plus Solars heat
exchangers must be pumped, gravity circulation WILL
NOT WORK.

13

FIG. 8 Schematic wiring diagram - Basic 2 x 2 port valve system

FIG. 9 Schematic wiring diagram - 3 port mid position valve system. N.B. Must be used in
conjunction with 2 port zone valve supplied

Control terminal numbering may
differ from those shown. Refer to
instructions with controls

selected

A DOUBLE POLE ISOLATING
SWITCH MUST BE INSTALLED
IN THE MAINS SUPPLY.
ALL EARTH CONNECTIONS
BE CONNECTED BACK TO
THE MAINS EARTH SUPPLY

Control terminal numbering may
differ from those shown. Refer to
instructions with controls

selected

A DOUBLE POLE ISOLATING
SWITCH MUST BE INSTALLED
IN THE MAINS SUPPLY.
ALL EARTH CONNECTIONS
BE CONNECTED BACK TO
THE MAINS EARTH SUPPLY

NOTE: CONTROL CIRCUIT
FOR AUXILLARY HEATING
BOILER ONLY. SEPERATE
CONTROLS WILL BE RE­QUIRED FOR THE SOLAR

PRIMARY CIRCUIT

NOTE: CONTROL CIRCUIT
FOR AUXILLARY HEATING
BOILER ONLY. SEPERATE
CONTROLS WILL BE RE­QUIRED FOR THE SOLAR

PRIMARY CIRCUIT

14

7.0 COMMISSIONING

7.1 FILLING THE UNIT WITH WATER

• Check Expansion Vessel pre-charge pressure. The

vessel is supplied pre-charged to 3.5 bar to match the

control pressure of the Pressure Reducing Valve. The
pre-charge pressure is checked using a car tyre gauge

by unscrewing the plastic cap opposite the water con­nection.

• Check all connections for tightness including the

immersion heater(s). An immersion heater key spanner
is supplied for this purpose.

• Ensure the drain cock is CLOSED.

• Open a hot tap furthest from the Santon Premier

Plus Solar.

• Open the mains stop cock to ll the unit. When

water ows from the tap, allow to run for a few min­utes to thoroughly ush through any residue, dirt or
swarf, then close the tap.

• Open successive hot taps to purge the system of

air.

7.2 SYSTEM CHECKS

• Check all water connections for leaks and rectify

as necessary.

• Remove the Pressure Reducing Valve headwork

to access the strainer mesh, clean and re-t.

• Manually open, for a few seconds, each relief

valve in turn, checking that water is discharged and
runs freely through the tundish and out at the discharge

point.

• Ensure that the valve(s) reseat satisfactorily.

7.3 SOLAR PRIMARY CIRCUIT

Fill the solar primary circuit following the instruc­tions provided with the solar hydraulic controls. The

cylinder temperature control probe supplied with the

solar controller must be fully inserted into the pocket

in the lower controls housing and the cable securely

clamped. Heating by the solar primary circuit is con­trolled by the solar controller, refer to the manufactur­ers installation instructions for details of how to set
up and connect the solar primary circuit. The solar

controller should be programmed to give a maximum

storage temperature in the Premier Plus Solar of 70oC,
60oC is recommended to minimise scaling.

7.5 Secondary Heating Coil

Fill the indirect secondary circuit following the boiler
manufacturer’s commissioning instructions. To ensure
the Premier Plus Solar auxillary heat exchanger is
lled, the 2 port motorised valve (supplied) should be

manually opened by moving the lever on the motor

housing to the FLUSHING ONLY setting. When the
circuit is full return the lever to the NORMAL USE
position. Switch on the boiler, ensure the programmer
is set to Domestic Hot Water and allow the Premier
Plus Solar to heat up to a normal working temperature
(60oC recommended, approximately graduation 4 on
the thermostat). If necessary the temperature can be
adjusted by inserting a at bladed screwdriver in the
adjustment knob (located on top of the thermostat
mounting bracket - see Fig.9) and rotating. The mini­mum thermostat setting is 10oC. The adjustment range
1 to 5 represents a temperature range of 30o to 70oC.
Check the operation of the indirect thermostat and 2
port motorised valve and that no water has issued from
the Expansion Relief Valve or Temperature/Pressure
Relief Valve during the heating cycle.

7.6 BENCHMARKTM LOG BOOK

On completion of the installation and commissioning
of the Premier Plus Solar the BenchmarkTM “Installa­tion, Commissioning and Service Record Log Book”
should be completed and signed off by the competent

installer or commissioning engineer in the relevant
sections.

The various system features, location of system con­trols, user instructions and what to do in the event of
a system failure should be explained to the customer.
The customer should then countersign the Bench­markTM log book to accept completion.
The log book should be left with the customer along
with these instructions. The log book includes sections
that should be lled out when any subsequent service

or maintenance operation is carried out on the Premier
Plus system.

7.4 DIRECT UNITS

Switch on electrical supply to the immersion heater(s)
and allow the Premier Plus Solar to heat up to normal
working temperature (60ºC recommended, approxi­mately graduation 4 on the thermostat). If necessary
the temperature can be adjusted by inserting a at
bladed screwdriver in the adjustment knob on top of

the immersion heater thermostat and rotating.

The adjustment range 1 to 5 represents a tempera­ture range of 10o to 70oC. Check the operation of
thermostat(s) and that no water has issued from the
Expansion Relief Valve or Temperature/Pressure
Relief Valve during the heating cycle.

15

FIG. 10 Indirect thermostat and thermal
cut-out

CABLE CLAMPS

TERMINAL BLOCK

INDIRECT
THERMOSTAT

THERMOSTAT
ADJUSTMENT

INDIRECT
THERMAL
CUT-OUT

INDIRECT THERMAL
CUT-OUT RESET
BUTTON

NOTE:
THE HOUSING COVER AND ELEMENT ASSEMBLY
HAVE BEEN REMOVED FROM THIS VIEW FOR CLAR­ITY

16

Carefully remove any scale from the surface of the
element(s). DO NOT use a sharp implement as dam­age to the element surface could be caused. Ensure
sealing surfaces are clean and seals are undamaged,
if in doubt t a new gasket.

Replace immersion heater(s) ensuring the lower (right

angled) element hangs vertically downwards towards

the base of the unit. It may be helpful to support the

immersion heater using a round bladed screwdriver

inserted into one of the thermostat pockets whilst
the backnut is tightened. Replace thermostat (Direct
models) or thermostat capillaries into pocket (Indirect
models), rewire, check, close and secure immersion

heater housing cover(s).

8.5 PREMIER PLUS SOLAR EXPANSION VESSEL
CHARGE PRESSURE

Remove the dust cap on top of the vessel. Check the
charge pressure using a tyre pressure gauge. The pres-

sure (with system de-pressurised) should be 3.5bar.

If it is lower than the required setting it should be
re-charged using a tyre pump (Schrader valve type).
DO NOT OVER CHARGE. Re-check the pressure

and when correct replace the dust cap.

8.6 RE-COMMISSIONING

Check all electrical and plumbing connections are se­cure. Close the drain cock. With a hot tap open, turn on
the cold water supply and allow unit to rell. DO NOT

switch on the immersion heater(s) or boiler until the

unit is full. When water ows from the hot tap allow
to ow for a short while to purge air and ush through

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

When completely full and purged check system for
leaks. The heating source (immersion heater(s), boiler

or solar primary circuit) can then be switched on.

8.7 BENCHMARKTM LOG BOOK

On completion of any maintenance or service of the
Premier Plus the BenchmarkTM “Installation, Com­missioning and Service Record Log Book” should be
lled in to record the actions taken and the date the
work was undertaken.

8.3 STRAINER

Turn off the cold water supply, boiler and immer­sion heaters. The lowest hot water tap should then
be opened to de-pressurise the system. Remove the
Pressure Reducing Valve by unscrewing it housing.
Pull the Reducing Valve cartridge from the Check
Valve housing to access the strainer mesh. Wash any
particulate matter from the strainer under clean water.
Re-assemble ensuring the seal is correctly tted, DO
NOT use any other type of sealant.

8.4 DESCALING IMMERSION HEATER(S)

Before removing the immersion heater(s) the unit

must be drained. Ensure the water, electrical supply,
boiler and solar primary circuit are OFF before
draining. Attach a hosepipe to the drain cock having

sufcient length to take water to a suitable discharge
point below the level of the unit. Open a hot tap close
to the unit and open drain cock to drain unit.

Direct models:

Open the cover(s) to the immersion heater housing(s)

and disconnect wiring from the thermostat mounted on
top of the immersion heater(s). Remove the thermostat
by carefully pulling outwards from the immersion
heater. Unscrew immersion heater backnut(s) and
remove immersion heater from the unit. A key spanner
is supplied with the Premier Plus Solar unit for easy
removal/tightening of the immersion heater(s). Over
time the immersion heater gasket may become stuck
to the mating surface. To break the seal insert a round
bladed screwdriver into one of the pockets on the im-

mersion heater and gently lever up and down.

8.0 MAINTENANCE

8.1 MAINTENANCE REQUIREMENTS

Unvented hot water systems have a continuing main­tenance requirement in order to ensure safe working
and optimum performance. It is essential that the
Relief Valve(s) are periodically inspected and manu­ally opened to ensure no blockage has occurred in
the valves or discharge pipework. Similarly cleaning
of the strainer element and replacement of the air in
the Expansion Vessel will help to prevent possible
operational faults.

The maintenance checks described below should be
performed by a competent installer on a regular basis,

e.g. annually to coincide with boiler maintenance.

8.2 SAFETY VALVE OPERATION

Manually operate the Temperature/Pressure Relief
Valve for a few seconds. Check water is discharged
and that it flows freely through the tundish and
discharge pipework. Check valve reseats correctly

when released. NOTE: Water discharged may be
very hot!

Repeat the above procedure for the Expansion
Valve.

Indirect models:

Open the cover(s) to the immersion heater housing(s)

and disconnect wiring from immersion heater(s). Re­move thermostat capillary sensors from the pockets
on the immersion heater. Unscrew immersion heater
backnut(s) and remove immersion heater from the
unit. A key spanner is supplied with the Premier Plus
Solar unit for easy removal/tightening of the immer­sion heater(s). Over time the immersion heater gasket
may become stuck to the mating surface. To break
the seal insert a round bladed screwdriver into one of
the pockets on the immersion heater and gently lever

up and down.

17

9.0 FAULT FINDING AND
SERVICING

9.1 IMPORTANT

• Servicing should only be carried by authorised

Santon Service Engineers or Agents or by competent

installers in the installation and maintenance of un-

vented water heating systems.

• Any spare parts used MUST be authorised Santon

parts.

• Disconnect the electrical supply before removing

any electrical equipment covers.

• NEVER bypass any thermal controls or operate

system without the necessary safety valves.

• Water contained in the Premier Plus Solar unit

may be very hot, especially following a thermal

control failure. Caution must be taken when drawing

water from the unit.

9.2 SPARE PARTS

A full range of spare parts are available for the Premier

Plus range. Refer to the Technical Data label on the

unit to identify the model installed and ensure the

correct part is ordered.

Description Part no.

Immersion heater (lower) 95 606 946
Immersion heater (upper) 95 606 947
Immersion heater gasket 95 611 822
Immersion heater backnut 95 607 869
Solar temperature probe pocket plate 95 607 064
Immersion heater key 95 607 861
Tundish 95 605 838
Expansion valve cartridge - 6bar 95 605 864
Expansion valve complete - 6bar 95 607 030
Cold water combination valve complete 95 605 022
Cold water combination valve body 95 605 030
Check valve housing 95 605 028
Pressure reducing valve cartridge 3.5bar 95 607 029
Pressure reducing valve housing 95 605 027
Temperature/Pressure Relief Valve 95 605 810
Expansion vessel 12 litre (100, 120
and 150 litre models) 95 607 863
Expansion vessel 18 litre (170 and

Cold Water Combination Valve - Exploded view

210 litre models) 95 607 864
Expansion vessel 25 litre (250 and
300 litre models) 95 607 612
Indirect Thermal cut-out (for Solar Coil) 95 612 698

Direct units only

Combined thermostat and thermal

cut-out 95 612 599
Terminal cover 95 607 836

Indirect units only

Indirect thermostat 95 612 697
Indirect Thermal cut-out 95 612 698
Motorised valve 2 port 95 605 819
Terminal housing 95 607 865
4 Way terminal block 95 607 902

Cable
Gland

Combined

Thermostat &

Thermal Cut-out

- Direct models

Spare Part No:

95 612 599

Expansion Valve

Cartridge

Spare Part No.
95 605 864

Expansion Valve

Complete (6 bar)

Spare Part No.
95 607 030

Valve Body
Spare Part No.
95 605 030

Check Valve
Housing
Spare Part No.
95 605 028

Pressure Reducing
Valve Housing
Spare Part No.
95 605 027

Pressure Reducing
Valve Cartridge

(3.5 bar)

Spare Part No.
95 607 029

Strainer Mesh

Housing Securing
Screws (4 off)

Cold Water Combination Valve Complete
Spare Part No. 95 605 022

Indirect thermostat
Spare Part No:
95 612 697

Indirect Thermal Cut-out
Spare Part No:
95 612 698

4 Way Terminal Block
Spare Part No:
95 612 697

18

9.3 FAULT FINDING

The Fault Finding chart below will enable opera­tional faults to be identied and their possible causes
rectied. Any work carried out on the Premier Plus

unvented solar water heater and its associated con-

trols MUST be carried out by a competent installer
for unvented water heating systems. In case of doubt
contact the Santon Service Department (see contact
details at foot of page 20).

DO NOT TAMPER WITH ANY OF THE
SAFETY VALVES OR CONTROLS SUP­PLIED WITH THE PREMIER PLUS AS
THIS WILL INVALIDATE ANY GUAR­ANTEE

TABLE 5 Fault Finding Chart

WARNING

F A U L T

No hot water o w

2. S trainer blo cked
s tra iner and cl ean (s ee S ec tion 8.3)

3. Co ld W ater C om bi nation V alve

in co rrec tly tted

3. Check and re t as require d

W ater from h ot taps is col d

s wit che d on

1. Check and s witch on

2. DIR ECT im m ers ion heate r

therm al c ut -out has operat ed

2. Check. R es et b y pushing butt on.

3. INDIRE CT program mer s et t o

Central Heat ing only

3. C heck. S et t o a Do mes ti c Hot
W ate r p rogram me

4. INDIRE CT boiler not work ing
s us pect ed c onsult boile r
m a

nufa c turer's in struc tions

5. INDIRE CT therm al cut -out has

operat ed

5. Check. R es et b y pushing butt on on
c ut-out. C heck opera tion o f indirec t
therm os tat

6. INDIRE CT m otoris ed valve not

c onnected correc tly

6. C heck wiri ng and/or p lum bing
c onnect ions to m ot oris ed valve (s ee
F ig . 8 or 9)

7. S O LA R Ins uc ient Sol ar Gai n,

with no aux illa ry heat ing s witc hed
on

7. Check auxill ary heat s ourc e is
s wit ched o n and i s c ontroled to p rovid e
heat gain if no s olar out put is a va ilable .

W ater di schar

ges

from E xpans ion V alve

pressu re has reduc ed below

3.5bar

1. S ee S ec tion 8.5 for re-c harging
proc edure

2. CO NTINUA LLY

a. Co ld W ater C om bi nation V alve
P ressu re Reduc er not w ork ing
c orrec tly

a. Check pre ssure from C old W a ter
Com bination V al ve . If greater th an

3.5bar repla c e P ressu re Re duce r
c art ridge

b. E x pansi on V alve seat
dam aged.

b. Re move E x pansion V alve c artridge.
Check c on dit ion of seat . If nec essary
t new E xpans ion V al ve cartridge.

W ater di scharges from T&P
Relie f V alve

1. Therm a l

c ontrol fa ilure N OTE

wat er wil l be ve ry hot

1. S wit ch o powe r to im mers ion
heater(s ), s hut dow n bo ile r and s hut
down so lar p rim ary c ircui t. DO N OT
turn o  w ater s upply . W hen d ischarge
s tops c heck all therm al controls ,
repla ce if faulty .

"M ilky" wat er O xygenated wa te r

releas es o xygen bubble s w hen owing.
The m ilk iness will dis appear after a
s hort whi le.

P OS S IB L E C AU S E

R E M E D Y

1. C heck and open s top c oc k1. M ain s suppl y o

2. Tu rn o wa ter s upply . R em ove

1. DIR ECT im m ers ion heate r not

4. C heck boiler operation. If fault is

1. INTE RM ITTE NTLY

E xpans ion Vesse l c harge

W ate r from a pre ssurised system

19

10.0 USER INSTRUCTIONS

10.1 WARNINGS
IF WATER ISSUES FROM THE TEMPERA­TURE/PRESSURE RELIEF VALVE ON THE
SANTON PREMIER PLUS SOLAR SWITCH
OFF ELECTRICAL SUPPLY TO THE IMMER­SION HEATER(S) (DIRECT UNITS),SHUT
DOWN THE BOILER (INDIRECT UNITS) AND
SHUT DOWN THE SOLAR PRIMARY CIRCUIT.
DO NOT TURN OFF ANY WATER SUPPLY.
CONTACT A COMPETENT INSTALLER FOR
UNVENTED WATER HEATERS TO CHECK
THE SYSTEM.

DO NOT TAMPER WITH ANY OF THE SAFETY
VALVES FITTED TO THE SANTON PREMIER
PLUS SYSTEM. IF A FAULT IS SUSPECTED
CONTACT A COMPETENT INSTALLER.

10.2 TEMPERATURE CONTROLS - SOLAR

Temperature control of the solar primary coil is by
means of solar differential temperature controller.
This will usually have been set during commissioning
to give a storage temperature of approximately 60oC.
Refer to user instructions supplied with the controller
for details of how to adjust this if required.

10.3 TEMPERATURE CONTROLS – DIRECT

UNIT IMMERSION HEATER(S)

A combined adjustable thermostat and thermal cut-out
is provided for each immersion heater. The thermostat
is factory set to give a water storage temperature of

approx. 55o to 60oC. Access to the thermostat can be

made by opening the immersion heater cover - DIS­CONNECT THE ELECTRICAL SUPPLY BEFORE
OPENING THE COVER(S). Temperature adjustment
is made by inserting a at bladed screwdriver in the
slot on the adjustment disc on top of the thermostat
and rotating. The adjustment range 1 to 5 represents
a temperature range of 10o to 70oC (60oC will be
approximately position 4). If in any doubt contact a

competent electrician.

DO NOT bypass the thermal cut-out(s) in any
circumstances.

10.4 TEMPERATURE CONTROLS – INDIRECT

UNITS (Fig. 9)

The Santon Premier Plus Solar Indirect units are t­ted with an Indirect Thermostat and Thermal Cut-out.
These controls must be wired in series with the 2 port
motorised zone valve supplied to interupt the ow of

primary water around the heat exchanger coil when the

control temperature has been reached. The controls are

located within the upper grey terminal housing along

with the immersion heater thermostat. The thermostat
is factory set to give a water storage temperature of

approx. 55o to 60oC. Access to the thermostat can be

made by opening the terminal housing cover - DIS­CONNECT THE ELECTRICAL SUPPLY BEFORE
OPENING THE COVER. Temperature adjustment
is made by inserting a at bladed screwdriver in the
adjustment knob and rotating. The minimum ther­mostat setting is 10oC. The adjustment range 1 to 5
represents a temperature range of 30o to 70oC (60oC
will be approximately position 4). If in any doubt

contact a competent electrician.

On indirect units an immersion heater is also provided

for use should the indirect heat source be shut down
for any purpose. The immersion heater control tem-

perature is set using the immersion heater (Direct)

thermostat, see section 10.3 for details.

DO NOT bypass the thermal cut-out(s) in any
circumstances.

10.4 FLOW PERFORMANCE

When initially opening hot outlets a small surge in

ow may be noticed as pressures stabilise. This is
quite normal with unvented systems. In some areas
cloudiness may be noticed in the hot water. This is
due to aeration of the water, is quite normal and will
quickly clear.

10.5 OPERATIONAL FAULTS

Operational faults and their possible causes are de­tailed in Section 9.0. It is recommended that faults
should be checked by a competent installer.

The air volume within the expansion vessel will peri-

odically require recharging to ensure expanded water

is accommodated within the unit. A discharge of water
INTERMITTENTLY from the Expansion Valve will

indicate the air volume has reduced to a point where
it can no longer accommodate the expansion.

20

SANTON

Hurricane Way, Norwich, Norfolk, NR6 6EA

Tel: [phone]

Service

Tel: [phone]
Fax: [phone]
E-mail: [e-mail]

Specication

Tel: [phone]
Fax: [phone]
E-mail: speci[e-mail]

11.0 GUARANTEE

This product is guaranteed against faulty materials
and manufacture for a period of 25 years from date
of purchase (with the exception of the Expansion

Vessel which is guaranteed for a period of 5 years

andvalves,ttingsandelectricalpartswhichare

guaranteed for a period of 2 years) provided that:

• The unit has been installed in accordance with the
Installation and Service instructions and all relevant
Codes of Practice and Regulations in force at the time
of installation, and that all necessary inlet controls and
safety valves have been tted correctly.

• Any valves and controls are of the Santon recom­mended type and specication.

• It has only been used for the storage of potable

water.

• The unit has not been modied or tampered with
in any way, and has been regularly maintained as
detailed in the Installation and Service instructions.

• Within 60 days of installation, the user completes
and returns any Certicate of Registration that may

be supplied with the unit in order to register the prod­uct.

The unit is not guaranteed against damage by frost, and

the inner container with integral immersion heater(s)
is not guaranteed against excessive scale build-up.

Periodic loss of charge pressure from the Expan­sion Vessel is normal (indicated by an intermittent
discharge of water from the Expansion Valve) and
is not covered under the product guarantee. Refer to
Section 8.5 for details on how to restore the Expansion
Vessel charge pressure.

This guarantee is not valid for installations outside
the United Kingdom and the Republic of Ireland. For

installations outside these territories please contact

either the Santon Export Department (Tel: +44 1603

420191) or Baxi International (Tel: [phone])
for further details of the gaurentee terms and condi-

tions applicable.

This guarantee does not affect your statutory rights.

ENVIRONMENTAL INFORMATION

Santon products are manufactured from many recyclable
materials. At the end of their useful life they should be
disposed of at a Local Authority Recycling Centre in order
to realise the full environmental benets.

Insulation is by means of an approved CFC/HCFC free
polyurethane foam with an ozone depletion factor of
zero.

The policy of Santon is one of continuous product development and, as such, we reserve the right to change
specications without notice.

For the fast and efcient supply of spares
please contact the stockists listed below.

Electric Water Heating Co.

2 Horsecroft Place, Pinnacles, Harlow,
Essex, CM19 5BT
Tel: [phone]
E-mail: [e-mail]

SPD

Special Products Division, Units 9 & 10, Hexagon
Business Centre, Springeld Road, Hayes, Middle­sex, UB4 0TY
Tel: [phone]

Parts Center

Network 65 Business Park, Bentley Wood Way,
Burnley, Lancashire, BB11 5ST
Tel: [phone]
www.partscenter.co.uk

Newey & Eyre

Specialist Products Division

Please contact your local branch

UK Spares Ltd.

Tower Lane, Warmley, Bristol, BS30 8XT
Tel: [phone]

William Wilson Ltd.

Unit 3A, 780 South Street, Whiteinch,
Glasgow, G14 0SY
Tel: [phone]

12.0 SPARES STOCKISTS