PremierPlus Unvented Hot Water Cylinder
Contents
1. Boiler Pump NOTES 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 must be connected back to the mains earth supply Figure 2 Schematic wiring diagram basic 2 x 2 port valve system Terminal block 3 Zone valve DHW Zone valve HTG supplied OW OG amp gt 3 LN 1 O 3 7 8 10 5 D 5 Hneton pox 1 2 3 3 ONSOO DOE Programmer Room stat Boiler 2 Pump NOTES 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 must be connected back to the mains earth supply Figure 3 Schematic wiring diagram 3 port mid position system Control Housing Details Element Connections 123 LNG Indirect control 1 5mm 3 Core wiring HOFR sheathed cable Figure 4 Indirect wiring schematic 1 5mm 3 Core HOFR sheathed cable Figure 5 Direct wiring schematic 10 4 Description of the product 5 Before installation 4 1 General description This product is a purpose designed unvented 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 the2. 300 direct 5 300 direct BEN N w N as Si N on S w oO oO E Heat loss kWh in 24h Neon full o Max expansion vessel F pressure 0 35MPa 5 Expansion relief valve setting 0 6MPa 6 bar T amp P valve setting 1 0MPa 10 bar 90 C NTN z ai so 381815 Te x SIRS NIN so IS N wld on a Gla wN oO oan Red Ie Table 2 Technical data Direct Notes 1 Direct cylinders tested in accordance with EN 50440 for efficiency parameters 2 Heat up time from cold through 45 C based on a flow temperature of 80 C 2 C amp normal volume 3 2 Dimensions and connections Table 3 General dimensions table Direct Item 1008 1208 1508 170B 210B 250B 3008 YB 354 354 354 354 354 354 354 500 616 800 927 1184 1439 1754 D 784 906 1090 1216 1474 1726 2040 Table 4 General dimensions table Indirect 3 3 Electrical diagram s Terminal block DOPE Zone valve DHW Zone valve HTG Room stat supplied 6 6 O Br 6 2 2 2 TEN OD OOO DOG OO Junction box DODA D00 123 2 coeca Coa oT Programmer amp
3. C 140 150 F DO NOT bypass the thermal cut out s in any circumstances Temperature controls indirect units gt The cylinder units are fitted with an indirect thermostat and thermal cut out These controls must be wired in series with the 2 port motorised zone valve supplied to interrupt the flow of primary water around the heat exchanger coil when the control temperature has been reached gt The controls are located within the lower terminal housing along with the immersion heater thermostat The thermostat is factory set to give a water storage temperature of approx 55 C to 60 C gt Access to the thermostat can be made by opening the terminal housing cover DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE COVER gt Temperature adjustment is made by inserting a flat bladded screwdriver in the adjustment knob and rotating The minimum thermostst setting is 12 C The maximum thermostat setting is 72 C DO NOT bypass the thermal cut out s in any circumstances Operational faults Operational faults and their possible causes are detailed in the Fault Finding section p 23 of this book It is recommended that faults should be checked by a competent installer The air volume within the expansion vessel will periodically require recharging to ensure expanded water is accommodated within the system A discharge of water INTERMITTENTLY from the expansion valve will indicate the air volume has reduced to a point
4. direction gt The expansion relief valve should be installed with Expansion valve I outlet 15mm L Cold mains r connection A 4 22mm E N exchanger 88 C Expansion valve 7 Direction of flow Cold Water Combination Valve Jewe pre set 3 5 bar Expansion Vaive Outlet connection 22mm Pressure reducing valve cartridge 3 5bar Figure 8 3 bar pressure reducing valve 14 Expansion vessel The expansion vessel accommodates expansion that results from heating the water inside the unit gt The expansion vessel is pre charged at 3 5bar gt The expansion vessel must be connected between the expansion valve and the cylinder gt 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 gt It is recommended that the expansion vessel is adequately supported An expansion vessel wall mounting bracket is supplied for this purpose and should be fitted Secondary circulation If secondary circulation is required it is recommended that it be connected to the cylinder as shown see fig 9 below gt The secondary return pipe should be in 15mm pipe and inco
5. 10m height difference will result in a 1 bar pressure reduction at the outlet gt All fittings pipework and connections must have a rated pressure of at least 6 bar dependant on cylinder being fitted at 80 C gt It is advantageous in many mixer showers to have a balanced hot and cold water supply in these instantaces a balanced cold water connection should be placed between the cold water combination valve and the cylinder Limitations The cylinder should not be used in association with any of the following gt 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 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 In areas where the water supply contains chloride and levels that exceed 250mg I 5 3 Choice of l
6. gt Check water is discharged and that it flows freely through the tundish and discharge pipework gt Check valve reseats correctly when released gt Repeat the above procedure for the expansion relief valve Strainer gt Turn off the isolating valve prior to the Pressure Reducing Valve or the main stop cock to the system gt Open the lowest hot tap in the system to relieve the system pressure gt Using a spanner unscrew the pressure reducing cartridge and remove the moulded housing The strainer will be removed with the cartridge Wash any particulate matter from the strainer under clean running water gt Replace the strainer and screw the Pressure Reducing Valve cartridge into the moulded housing gt Close hot tap turn on isolating valve or main stop cock to the system Check for leaks gt Descaling immersion heater s gt Turn offthe mains water supply isolate the electrical supply and turn off boiler gt Attachahosepipe to the drain cock having sufficient length to take water to a suitable discharge point below the level of the unit gt Open a hot tap close to the unit and open drain cock to drain unit If water fails to drain vent the unit manually by opening the temperature and pressure relief valve gt Open the cover s to the immersion heater housing s and disconnect wiring from immersion heater s gt Unscrew the immersion heater backnut s and withdraw the immersion heater from the cyli
7. least 1 in 200 3 57 The discharge pipe D2 should be made of a metal or b other material that has been demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly and permanently marked to identify the product and performance standard e g as specified in the relevant part of BS 7291 3 58 The discharge pipe D2 should 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 for discharge pipes between 9m and 18m the 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 See Fig 10 Table 5 and the worked example Note An alternative approach for sizing discharge pipes would be to follow Annex D section D 2 of BS 6700 2006 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages 3 59 Where a single common discharge pipe serves more than one system it should be at least one pipe size larger than the largest individual discharge pipe D2 to be connected 3 60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated that the soil discharge stack is
8. the event that the unit fails prematurely as a result of a proved manufacturing defect In order that this can be achieved full access to replace the unit is essential If it is found that access can not be achieved the warranty will be limited to the replacement of the unit only and subsequent labour charges would not be met under the warranty For installations outside of the United Kingdom please contact either the Heatrae Sadia Export Department on Tel 44 1603 420271 or Baxi International on Tel 44 1926 478323 for further details of the guarantee terms and conditions applicable This guarantee does not affect your statutory rights 27 HEATRAESADIA SMARTER CLEANER WARMER Electric Water Heating Co 2 Horsecroft Place Pinnacles Harlow Essex CM19 5BT Tel 0845 0553811 E Mail sales ewh co uk SPD Special Product Division Units 9 amp 10 Hexagon Business Centre Springfield Road Hayes Middlesex UB4 OTY Tel 020 8606 3567 Parts Center Tel 0344 292 7057 www partscenter co uk Newey amp Eyre Unit 3 5 Wassage Way Hampton Lovett Ind Estate Droitwich Worcestershire WR9 ONX Tel 01905 791500 Fax 01905 791501 UK Spares Ltd Unit 1155 Aztec West Almondsbury Bristol BS32 4TF Tel 01454 620500 Alternatively contact your local supplying merchant or wholesale branch or use our online stockist finder at www interpartspares co uk Please follow us online RS Be iv hot water AA ass
9. 60 C ROTATE SPINDLE CLOCKWISE FOR TEMPERATURE INCREASE r AND COUNTER CLOCKWISE N FOR TEMPERATURE DECREASE TEMPERATURE ADJUSTING SPINDLE 19 20 8 1 General A N WARNING gt If water discharges from the temperature pressure relief valve on the cylinder shut down the heat source Do not turn off any water supply Contact a competent installer for unvented water heaters to check the system gt Do not tamper with any of the safety valves fitted to the system If a fault is suspected contact a competent installer gt DO NOT bypass the thermal cut out s in any circumstances Benchmark The cylinder is covered by the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety efficiency and performance Benchmark is managed and promoted by the Heating and Hotwater Industry Council For more information visit www centralheating co uk Please ensure that the installer has fully completed the Benchmark Checklist page 26 of this manual and that you have signed it to say that you have received a full and clear explanation of its operation The installer is legally required to complete a commissioning checklist as a means of complying with the appropriate Building Regulations England amp Wales All installations must be notified to Local Area Building Control either directly or t
10. HEATRAESADIA SMARTER CLEANER WARMER PremierPlus Unvented Hot Water Cylinder Installation and User Manual Contents 1 Introduction use kai en 3 1 1 Gener l sen 28 31848 aisnkniik ee se 3 1 2 Symbols used E aa 3 1 3 Abbreviationsauu unsnassentnesinie nennt ae 3 DA Kiabilitieschssenassetestenteeetinn renden tte alsin 3 DE SATO LY Eee ee keit 4 2 1 General satety WaritinGs sii si tcsehdeeteh isa di desbeadad endo ete A E 4 2 2 Recommendations nennen 4 2 3 Speeilie satety ihstr ctions amateure nei 4 3 Technical specificati nSeries arns ien ieiet 5 32 lechnical data ena means 5 3 2 Dimensions and connections 7 3 3 Electrical diagramls 2 4 4eh8 e each 8 4 Description of the prodiens nea a E 10 4 1 General descriptifs sssini aaao ei a eiid nn 10 4 2 Operation Principle sessie apna eari kin een 10 4 3 Maim COMPONENKS sennie aa E e E R E N 10 AA St ndard delivery anasshanieenenansenn anna 10 5 Before installation ueeeneneeeneeneeneneneenenenenenennnenen 10 5 1 Installationregulationssunetasenenetiisinieiensgie kenn 10 5 2 Installation requirements nenne 10 5 3 Choicesot location near nennen une 11 6 Install tion e etarne nee antenne eine coed E 11 KGenelalen ensure engeren 11 6 2 Water Connect ONS iranse ei ai ini enai 12 6 3 Electiica Connection Sense aa ee a A tek ee cI A 18 6 4 Filling the installation neeneeeneneneneenen nennen 18 Fs COMMISSIONING l
11. Time and temperature controls have been fitted in compliance with Part L of the Building Regulations Type of control system if applicable Is the cylinder solar or other renewable compatible What is the hot water temperature at the nearest outlet All appropriate pipes have been insulated up to 1 metre or the point where they become concealed UNVENTED SYSTEMS ONLY Where is the pressure reducing valve situated if fitted What is the pressure reducing valve setting Has a combined temperature and pressure relief valve and expansion valve been fitted and discharge tested The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Are all energy sources fitted with a cut out device Has the expansion vessel or internal air space been checked THERMAL STORES ONLY What store temperature is achievable What is the maximum hot water temperature ALL INSTALLATIONS The hot water system complies with the appropriate Building Regulations The system has been installed and commissioned in accordance with the manufacturer s instructions The system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Sign
12. a m2 0 58 0 58 Coil rating kW 15l min 15 2 el 24 Kr mins onen e ondea p 210 indirect g 250 indirect p 300 indirect oO Pin I 300 indirect oO NI N oO SQ so oO SQ no oO SQ so oO N no g zl g g o BBA 250 indirect 2 5 411 1 1 18 1 1 4 1 5 7 9 8 8 18 8 afe ele elelee Heat low Wh n 2an 7 414 1125 ERI 125 Weight empty kg s a a s a oloo al gt fefefe moroa alel gt fefefe moria Max supply pressure 1 6MPa 16 bar Max design pressure 0 8MPa 8 bar Max operating pressure PRV 0 35MPa 3 5 bar T amp P valve setting 1 0MPa 10 bar 90 C Expansion relief valve setting 0 6MPa 6 bar i Maximum primary pressure 1 0MPa 10 bar Presure drop across coil 0 02MPa 0 2bar Table 1 Technical data Indirect Notes 1 2 3 Indirect cylinders tested in accordance with BS EN 12897 2006 Heat up time from cold through 45 C based on a flow temperature of 80 C 2 C amp normal volume Although the primary coil pressure rating is 1 0MPa 10bar the 2 port zone valve and coil compression nuts supplied with the cylinder is only rated 0 86MPa 0 86 bar If the cylinder is to be plumbed into a system delivering 1 0MPa 10 bar a suitable 2 port zone valve and the coil compression nuts supplied will have to be sourced Max direct kW rating 240v Direct heat time based on max kW rating in mins ef odrect 210 direct 250 direct
13. ature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC benchmari THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk 25 SERVICE RECORD It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Email Address Email Address Comments Comments SERVICE 03 Signature SERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Email Address Email Address Comments Comments SERVICE 05 Signature SERVICE 06 Engineer name Engineer name Company name Company name Telephone No Telephone No Email Address Email Add
14. capable of safely withstanding temperatures of the water discharged in which case it should a contain a mechanical seal not incorporating a water trap which allows water into the branch pipe 15 16 without allowing foul air from the drain to be ventilated through the tundish b be a separate branch pipe with no sanitary appliances connected to it c if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either polybutylene PB to Class S of BS 7291 2 2006 or cross linked polyethylene PE X to Class S of BS 7291 3 2006 and d be continuously marked with a warning that no sanitary appliances should be connected to the pipe Note 1 Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043 1 2 Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to the discharge stack Termination of discharge pipe 3 61 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 3 62 Examples of acceptable discharge arrangements are a to a trapped gully with the end of the pipe below a fixed grating and above the water seal b downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standings grasse
15. d areas etc are acceptable providing that a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility and c discharges at high level e g into a metal hopper and metal downpipe with the end of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges 3 63 The discharge would consist of high temperature water and steam Asphalt roofing felt and non metallic rainwater goods may be damaged by such discharges Worked example of discharge pipe sizing Fig 10 shows 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 5 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 Maxim
16. d system or open vented type maximum primary pressure 3 bar The primary flow from the boiler must be pumped Gravity circulation will not work due to the special design of the primary heat exchanger It is recomended that an air bleed point or automatic air vent is incorporated in the primary return pipework close to the unvented system The boiler cannot be vented through the cylinder WALL N Min 250mm Min 250mm Figure 6 Acess schematic not to scale 11 i Balanced cold Cold water To hot outlets T amp P relief Expansion ee water connection combination valve vessel p E if required valve Boost element control housing PP120E to PP300E models only Isolating valve not supplied Mains water l Element controls housing a Secondary return if required use swept tee Primary return lt LS gt Primary flow 7 Discharge pipe NOTE Primary heating coil fitted on PP100B to PP300B models only Drain cock not supplied Tunaishi Inlet Figure 7 Typical installation schematic not to scale 6 2 Water connections N WARNING gt 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 gt The cold water combination valve assembly must be fitted on the mains water supply to th
17. e cylinder gt No control or safety valves should be tampered with or used for any other purpose gt The discharge pipe should not be blocked or used for any other purpose gt The tundish should not be located adjacent to any electrical components Refer to the installation schematic fig 7 above for details on the pipework layout Specific details for the discharge pipework layout is also provided in figure 10 on page 18 12 supply All pipe fittings are made via 22mm compression fittings directly to the unit nuts and olives supplied The fittings are also threaded 3 4 BSP male parallel should threaded pipes connections be required A stopcock or servicing valve should be incorporated into the cold water supply to enable the cylinder to be isolated from the mains supply for maintenance or servicing A suitable draining tap should be installed in the cold water supply to the cylinder between the expansion 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 Cold water control pack A N CAUTION gt Flush supply pipework before connection to remove all flux and debris prior to fitting the inlet controls Failure to do this may result in irreparable damage to the controls and will invalidate any warranty the disc
18. en be switched on Expansion vessel charge pressure gt Remove the dust cap on top of the vessel Check the charge pressure using a tyre pressure gauge The pressure system de pressured should be 0 35MPa 3 5 bar 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 21 22 10 Troubleshooting N WARNING Do not tamper with any of the safety valves or controls supplied with the cylinder as this will invalidate any guarantee 10 1 Fault finding Important gt After servicing complete the relevant Service Interval Record section ofthe Benchmark Checklist located on pages 25 and 26 of this document gt Servicing should only be carried out by competent persons in the installation and maintenance of unvented water heating systems gt Any spare parts used MUST be authorised parts gt Disconnect the electrical supply before removing any electrical equipment covers gt NEVER bypass any thermal controls or operate system without the necessary safety valves gt Water contained in the cylinder may be very hot especially following a thermal control failure Caution must be taken when drawing water from the unit The fault finding chart table 6 below will enable operational faults to be identified and their possible causes rectified Any work carried out on the unven
19. erature and pressure relief valve be tampered with or removed your guarantee will be invalidated The water heater has not been modified in anyway other than by our approved engineers The water heater has only been used for the storage of wholesome sanitary water max 250mgj l chloride e The water heater unit has not been subjected to excessive pressure beyond the guidelines detailed in the installation instructions e The water heater unit has not been subjected to frost nor has it been tampered with or been subject to misuse or neglect No factory fitted parts have been removed for un authorised repair or replacement The Benchmark commisioning checklist service record included in this product guide has been completed e Regular maintenance has been carried out by a competent person in accordance with the requirements set in the maintenance section of the installation manual and any replacement parts used should be approved spare parts e Within 60 days of purchase the owner completes and returns the certificate supplied to register the product Evidence of purchase and date of supply must be submitted upon making a claim e The guarantee is not valid outside of the United Kingdom The warranty does NOT cover Consequential damages or profit loss which may arise from a defect Warranty claims have no delaying effect on the payment dates and other demands Your water heater warranty covers you for a direct replacement and labour in
20. f demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer name Telephone number Address Cylinder Make and Model Cylinder Serial Number Commissioned by PRINT NAME Registered Operative ID Number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable ALL SYSTEMS PRIMARY SETTINGS indirect heating only Is the primary circuit a sealed or open vented system Sealed What is the maximum primary flow temperature ALL SYSTEMS What is the incoming static cold water pressure at the inlet to the system Has a strainer been cleaned of installation debris if fitted Is the installation in a hard water area above 200ppm If yes has a water scale reducer been fitted What type of scale reducer has been fitted What is the hot water thermostat set temperature What is the maximum hot water flow rate at set thermostat temperature measured at high flow outlet
21. gulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk 2 for more information 1 Introduction 1 _ A N WARNING A 1 General The following instructions are offered as a guide to the user and installer The installation must be carried out by a competent plumbing and electrical installer in accordance with Building Regulation G3 England and Wales Technical Standard P3 Scotland or Building Regulation P5 Northern Ireland and the Water Fitting Regulations England and Wales or Water Byelaws Scotland 2 Symbols used In these instructions various risk levels are employed to draw the user s attention to particular information In doing so we wish to safeguard the user avoid hazards and guarantee the correct operation of the appliance DANGER Risk of a dangerous situation causing serious physical injury Risk of dangerous situation causing slight physical injury CAUTION Risk of material damage ignals important information 1 1 S 3 Abbreviations gt T amp P Temperature amp Pressure relief valve gt PRV Pressure Reducing Valve gt Prv Pressure relief valve 4 Liabilities Manufacturers liability Ou
22. harge pipework in either the horizontal position or facing downwards Where discharge pipework is difficult to attain the local building control officer from the local council should be sought for advice as this falls under G3 guidelines and is not down to the manufacturer of unvented systems Primary circuit control gt The 2 port motorised valve supplied with the cylinder MUST be fitted on the primary flow to the cylinder heat exchanger and wired such that in the event of the cylinder overheating it will close the primary circuit The cold water combination valve can be connected gt Primary circulation to the cylinder heat exchanger anywhere on the cold water cylinder supply prior to must be pumped gravity circulation WILL NOT the expansion vessel WORK No other valves should be placed between the gt Itis recommended that an air bleed or automatic cold water combination valve and the cylinder air vent is incorporated in the primary return pipe The cold water combination valve is installed as a work close to the unit complete one piece unit the valve incorporates gt Boiler flow temperature should be set to 82 the pressure reducer strainer expansion valve and maximum flow temperature to primary heat check valve gt The pressure setting is set to 3 5 bar gt The valve can be fitted in any orientation to suit the installation as long as the valve is installed with the direction of flow arrows pointing in the correct
23. hrough a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer who should on receipt write the Notification Number on the Benchmark Checklist This product should be serviced regularly to optimise its safety efficiency and performance The service engineer should complete the relevant Service Record on the Benchmark Checklist after each service The Benchmark Checklist may be required in the event of any warranty work Flow performance When initially opening hot outlets a small surge in flow 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 Temperature controls direct units immersion heater s gt All immersion heaters are fitted with a combined thermostat and thermal cut out located under the terminal cover mounted on the side of the product gt Access to the thermostat can be made by opening the immersion heater cover DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE COVER S gt Temperature adjustment is made by inserting a flat bladed screwdriver in the slot on the adjustment disc on top of the thermostat and rotating The adjustment represents a temperature range of 12 C to 72 C Figure 11 page 20 gt Maximum working temperature is 72 C 154 F In very hard water areas limit to 60 65
24. ins water supply gt Do not switch on if there is a possibility that the water in the cylinder is frozen N CAUTION Do not operate immersion heaters until the cylinder has been filled with water 2 2 Recommendations A N WARNING N When handling the unit take appropriate precautions for the weight of the unit Weights can be found in section 3 table 1 amp 2 page 5 amp 6 CAUTION Annual maintenance is recommended by a competent person having training are permitted to work on the appliance A K gt ING If water discharges from the temperature pressure relief valve on the cylinder shut down the boiler immersion heaters 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 system If a fault is suspected contact a competent installer DO NOT bypass the thermal cut out s in any circumstances The HWA Charter Statement requires that all members adhere to the following gt gt gt gt To supply fit for purpose products clearly and honestly described To supply products that meet or exceed appropriate standards and building and water regulations To provide pre and post sales technical support To provide clear and concise warranty details to customers 3 Technical specifications 3 1 Technical data Max direct kW rating 240v 3 3 Coil surface are
25. isse eanne erin dian ieo noana sed AEEA EE E E E EAEE aai Sa 19 EE E E E eden dia deena ahead 19 7 2 Checklist before COMMISSIONING neneneeneenenneeenenenenee 19 7 3 GOMMISSIONING procedure siensia eaaa 19 8 QD STATON assesses pati Sa a e r E e E A E A S 20 8 1 General kerspunisioasononos an r aE a No aaa ENEN 20 2 Maintenance een a E E 21 PAE T E E E E Settee stestee cagestactaes abel 21 9 2 Standard inspection amp maintenance Operations 21 10 Troubleshooting pi a EE 22 10 1 Faultiinding ea ea Rettet 22 11 Decommissiening z 4 5 eher 23 11 1 Decommissioning proced re nansssenkinekentenan aueh 23 12 1 Spare parts list a 8 4 8 23 Benchm rtk checklist n 2 2aien21e 22 ernannt 25 Commissioning amp service records neeneneneeeneensenenen nen 26 Warranty areenaan 27 benchmari THE BENCH MARK SCHEME THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations and relevant electrical qualifications The Benchmark Checklist can be used to demonstrate compliance with Building Re
26. low gt Building Regulations G3 gt The Building Standards Scotland gt The Building Regulations Northern Ireland gt E E Electrical Regs gt UK Water Regulations 5 2 Installation requirements Water supply In an unvented system the pressure and flowrate is directly related to the incoming water supply For this reason it is recommended that the maximum water demand is assessed and the water supply checked to ensure this demand can be satisfactorily met gt We suggest the minimum supply requirements should be 0 15MPa 1 5 bar pressure and 20 litres per minute flow rate However at these values outlet flow rates may be poor if several outlets are used simultaneously gt A 22mm cold water supply is recommended however if a smaller supply exists which provides sufficient flow this may be used although more flow noise may be experienced gt The higher the available pressure and flow rate the better the system performance gt See table 1 amp 3 on pages 5 amp 6 for cylinder operating pressures This is controlled by the cold water combination valve assembly gt The water supply must be of wholesome water quality Fluid Category 1 as defined by the Water Supply Regulations 1999 Outlet terminal fittings taps etc gt The cylinder can be used with most types of terminal fittings gt Outlets situated higher than the cylinder will give outlet pressures lower than that at the heater a
27. m the cylinder Open the mains stop cock to fill the unit When water discharges from the tap alow to run for a few minutes to throughly flush through any residue dirt or swarf then close the tap Open successive hot taps to purge the system of air 7 Commissioning 7 1 General After filling the installation with water in the previous section please follow the following steps to complete the installation of the unit N WARNING DO NOT operate the immersion heaters or primary circuit until the cylinder has been filled with water 7 2 Checklist before commissioning gt Check all water connections for leaks and rectify as necessary Turn off mains water supply Remove the pressure reducing valve head work to access the strainer mesh clean and re fit Turn the water supply back on 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 Commissioning procedure Direct units gt Switch on electrical supply to the immersion heater s and allow the cylinder to heat up to normal working temperature 60 65 C recommended THERMAL CUT OUT RESET BUTTON Figure 11 Direct controls gt If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment spindle on front of the im
28. mersion heater thermostat and rotating The adjustment represents a temperature range of 12 C to 72 C gt Check the operation of thermostat s and that no water has discharged from the expansion relief valve or temperature pressure relief valve during the heating cycle Indirect units gt Fill the indirect primary circuit following the boiler manufacturer s commissioning instructions gt To ensure the cylinder primary heat exchanger is filled the 2 port motorised valve supplied should be manually opened by moving the lever on the motor housing to the MANUAL setting When the primary circuit is full return the lever to the AUTOMATIC position gt Switch on the boiler ensure the programmer is set to Hot Water and allow the cylinder to heat up to a normal working temperature 60 65 C recommended gt If necessary the temperature can be adjusted by inserting a flat bladded screwdriver in the adjustment knob and rotating The minimum thermostst setting is 10 C The maximum thermostat setting is 72 C A WARNING gt Ifthe unit is to be left unused following installation and commissioning e g unocupied properties the water heater should be drained or regularly flushed through with fresh mains water once a week gt When placing the unit into service the procedure for filling the unit and the system checks above should be observed SPINDLE POSITIONS D MINIMUM TEMP G MAXIMUM TEMP ON APPROX
29. nce with the latest E E Wiring Regulations gt Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact separation of at least 3mm in both poles DO NOT operate the immersion heaters until the cylinder has been filled with water The immersion heater s should be wired in accordance with fig 4 amp 5 page 10 Space and heating systems controls gt The controls provided with the cylinder will ensure the safe operation of the unit within the central heating system Other controls will be necessary to control the space heating requirements and times that the system is required to function The cylinder is compatible with most heating controls examples of electrical circuits are shown in figs 2 and 3 page 9 However other systems may be suitable refer to the controls manufacturers instructions supplied with the controls selected for alternative system wiring schemes 6 4 Filling the installation gt w Check expansion vessel pre charge pressure The vessel is supplied precharged to 3 5 bar to match the control pressure of the pressure reducing valve The precharge pressure is checked using 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 fro
30. nder A key spanner is supplied with the product for easy removal and 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 shafted screwdriver into one of the pockets on the immersion heater and gently lever up and down Take care when lifting the immersion heater out of the cylinder and work within safe working practices gt Carefully remove any scale from the surface of the element s N CAUTION DO NOT use a sharp implement as damage to the element surface could be caused gt Ensure sealing surfaces are clean and seals are undamaged if in doubt fit a new gasket spare part number 95 611 822 gt Replace immersion heater s making sure not to trap the gasket gt Rewire check close and secure immersion heater housing cover s Re commissioning gt Check all electrical and plumbing connections are secure Close the drain cock gt With a hot tap open turn on the cold water supply and allow unit to refill DO NOT switch on the immersion heater s or boiler until the unit is full gt When water flows from the hot tap allow to flow for a short while to purge air and flush through any disturbed particles gt Close hot tap and then open successive hot taps in system to purge any air gt When completely full and purged check system for leaks gt The heating source immersion heater s or boiler can th
31. ocation The cylinder must be vertically floor mounted Although location is not critical the following points should be considered The cylinder 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 pipe work 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 must be available for the servicing and maintenance of the system Where these controls are installed against a wall a minimum distance of 250mm must be left Ensure that the floor area for the cylinder is level and capable of permanently supporting the weight when full of water see table 1 amp 3 page 5 amp 6 for weights Prior to installation the unit should be stored and transported in an area free from excessive damp or humidity The Unit should be stored in a frost free environment 6 Installation 6 1 General After reading the previous sections in this booklet and choosing a good location for the unit please install paying attention to the following hydraulic electrical and commissioning sections Boiler selection gt The boiler should have a control thermostat and non self resetting thermal cut out and be compatible with unvented storage water heaters Can be a seale
32. ociation CHARTER MEMBER SPECIFICATION ADVICE HOTLINE t 01603 420220 e specifier heatraesadia com AFTER SALES SERVICE t 0344 871 1535 e heatraesadiaservice heateam co uk w heatraesadia com app 30 YEAR WARRANTY AS OUR NATIONWIDE NETWORK OF CUSTOMER SUPPORT ENGINEERS Heatrae Sadia has its very own dedicated nationwide network of highly trained customer support engineers so you can have peace of mind that we re always here to help PRODUCT RANGE Full specification details on all our products are available to download from our website To support our corporate responsibility and sustainability charters and reduce our printed material we encourage you to download product brochures from our website In designing these files we have taken into account the need to access data on screen If you would like to receive a printed copy of our full product catalogue please call our literature hotline on 01603 420127 Heatrae Sadia Heating may introduce modifications to their products from time to time Consequently the details given in this brochure are subject to alteration without notice PN 7032982 Issue 1 Heatrae Sadia 2015
33. r products are manufactured in compliance with the requirements of the various applicable European Directives This appliance complies with the requirements of the CE marking directive In the interest of UK customers we are continuously endeavouring to make improvements in product quality All the specifications stated in this document are therefore subject to change without notice Our liability as the manufacturer may not be invoked in the following cases gt Failure to abide by the instructions on using the appliance gt Faulty or insufficient maintenance of the appliance gt Failure to abide by the instructions on installing the product Installer s liability The installer is responsible for the installation and the commissioning of the appliance The installer must respect the following instructions gt Read and follow the instructions given in the manuals provided with the appliance gt Carry out installation in compliance with the prevailing legislation and standards gt Perform the initial start up and carry out any checks necessary gt Complete the commissioning checklist gt Explain the installation to the user gt If maintenance is necessary warn the user of the obligation to check the appliance and maintain it in good working order gt Give all the instruction manuals to the user Users liability To guarantee optimum operation of the appliance the user must respect the following in
34. r set to high Water discharges Continually from expansion f Thermal control failur Water discharges ee tual from T amp P relief valve Oxygenated water Milky water Table 6 Fault finding chart Cold water combination valve pressure valve reducer not working correctly Expansion valve seat damaged CAUTION Water will be very hot See Maintenance section p 22 for re charging of expansion vessel procedure Check pressure from cold water combination valve If greater than 3 5bar replace pressure reducing valve cartridge Remove expansion valve cartridge check condition of seat If necessary fit new expansion valve Switch off power to immersion heater s and shut down boiler DO NOT turn off water supply When discharge stops check all thermal controls replace if faulty Water from a pressurised system releases oxygen bubbles when flowing The milkiness will disappear after a short while Beer Environmental information 11 Decommissioning 11 1 Decommissioning procedure Products are manufactured from many recyclable materials At the end of their useful life they should be gt Isolate electrical supplies and make safe disposed of at a Local Authority Recycling Centre in gt Isolate the water supply order to realise the full environmental benefits gt Drain the cylinder gt Drain the primary circuit indirect only Insulation is by means of an approved CFC HCFC free gt Remove cylinder polyurethane foam wi
35. ress Comments Comments SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Email Address Email Address Comments Comments SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Email Address Email Address Comments Comments Signature Guarantee Terms and Conditions WARNING Should the factory fitted temperature and pressure relief valve be tampered with or removed your guarantee will be invalidated Neither the Distributor nor Manufacturer shall be responsible for any consequential damage howsoever caused Warranty Terms Heatrae Sadia warranty guarantees the water heater cylinder against faulty manufacture or materials for a period of two years from the date of purchase including parts and labour This two year warranty is extended to five years for the cold water control valve and to 30 years for the stainless steel inner vesssel These guarantees are valid provided that e The water heater has been installed by a competent engineer and as per the instructions contained in the installation manual and all relevant Codes of Practice and Regulations in force at the time of installation Any disinfection has been carried out in accordance with BS EN 806 5 2012 Should the factory fitted temp
36. rmoplastic mouldings and pre coated steel All products are insulated with CFC free polyurethane foam to give good heat loss protection 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 should not be tampered with 4 2 Operation principle The unvented cylinder is used to heat and store hot water for use in domestic intallations Depending on the model the water can be heated directly using Immersion heater s or indirectly through a coil in the unit using an indirect heat source 4 3 Main connections See Figures 7 Main Schematic on page 13 4 4 Standard delivery The delivery includes gt Cylinder Factory fitted immersion heater s and thermal controls Factory fitted Temperature and Pressure Relief Valve set at 90 C 1 Mpa 10bar Factory fitted indirect thermostat and thermal cut out gt Literature pack Instructions inc benchmark commissioning checklist amp service record gt Cold water control pack Combination valve inc pressure reducing valve pressure relief valve and check valve Expansion vessel and mounting bracket Tundish Nuts amp Olives gt 2 port zone valve indirect only 5 1 Installation regulations A N WARNING Installation of the appliance must be carried out by a qualified engineer in accordance with prevailing and national regulations as listed be
37. rporate a check valve to prevent backflow gt A suitable WRAS approved bronze circulation pump will be required gt 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 Cold Swept supply tee Secondary return Cold inlet Check N circulation connection valve pump Figure 9 Secondary circulation schematic Pipe capacity copper 15mm O D 0 13 I m 10 22mm O D 0 38 I m 10 28mm O D 0 55 l m 10 Note Plastic pipe capaciti thicker wall sections In direct electric instal circulation is required be paid by the installer water temperature guide itres 77m itres 26m itres 18m es may be reduced due to ations where a secondary particular attention should to maintain the returning ines state that a minimum of 55 C return temperature is advisable Factors such as but not limited to secondary circulation flow rates minimising heat loss of all secondary circuit pipework and timed operation during periods of high demand are critical to the correct operation and longevity of the heating element s and thermostats Discharge 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
38. structions gt Read and follow the instructions given in the manuals provided with the appliance Call on qualified professionals to carry out installation and initial start up gt Get your installer to explain your installation to you Have your required checks and services done gt Keep the instruction manuals in good condition and close to the appliance w This appliance can be used by children aged from 8 years and above and persons with reducedphysicalsensoryormentalcapabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved Children shall not play with the appliance Cleaning and user maintenance shall not be made by children without supervision Children must be supervised to ensure they do not play with the appliance 2 3 Specific safety instructions 2 Safety 2 1 General safety warnings N DANGER This cylinder is unvented and as such becomes pressurised when in operation Thecombination of pressurisation and hot water could lead to serious physical injury if the safety instructions in this manual are not adhered to JAN WARNING gt Only competent persons received adequate and the installation gt Do not tamper with any of the safety valves or controls supplied with the cylinder gt Before any work switch off the mains supply to the appliance and the ma
39. ted water heater and its associated controls MUST be carried out by a competent installer for unvented water heating systems In case of doubt contact service support Spare Parts A full range of spare parts are available for the cylinder range table 7 page 24 Refer to the technical data label on the unit to identify the model installed and ensure the correct part is ordered You will need to quote the serial number which is printed on the data label Mains water Mains watersupply off Mains watersupply off Check and open Check and open stop cock cock No torwateriow Strainer blocked Turn off water supply Remove strainer and clean Cold water combination valve incorrectly Check and refit as required fitted Direct immersion heater not switched on Check and switch on Direct immersion heater thermal cut out Check reset by pushing button on thermostat has operated Water from hot tap is cold Indirect programmer set to central Check set to domestic hot water programme heating only Indirect boiler not working Check boiler operation If fault is suspected consult boiler manufacturer s instructions Indirect thermal cut out has operated Check reset by pushing button on thermostat Check operation of indirect thermostat Indirect motorised valve not connected Check wiring and or plumbing connections to correctly motorised valve Intermittently Expansion vessel charge pressure has reduced below 3 5bar o
40. th an ozone depletion factor of gt Cap pipework zero 12 Spare parts 12 1 Spare parts list A full range of spare parts are available for the cylinder range Refer to the Technical Data label on the unit to identify the model installed and ensure the correct part is ordered DESCRIPTION Immersion heater lower Immersion heater upper Immersion heater gasket Immersion heater backnut Immersion heater key not shown Tundish not shown Expansion valve bar Cold water combination valve complete Cold water combination body Pressure reducing valve cartridge 3 5 bar Temperature Pressure Relief Valve Expansion vessel 12 litre 100 120 and 150 litre models not shown 95607863 Expansion vessel 18 litre 170 and 210 litre models not shown Expansion vessel 24 litre 250 and 300 litre models not shown Blanking plate assembly not shown Nut amp olive pack 4 of each not shown Direct combined Thermostat and Thermal cut out Indirect combined Thermostst and Thermal cut out 19 Table 7 Spares 4 a 6 8 Ea 23 24 Outlet Connection 22mm A m s s ll 15mm Cold Mains Connection 22mm Figure 12 Exploded view of cold water combination valve Figure 13 Cylinder exploded view MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means o
41. 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 50 3 63 are reproduced in the following sections of this manual For discharge pipe arrangements not covered by G3 Guidance advice should be sought from your local Building Control Officer Any discharge pipe connected to the pressure relief devices expansion valve and temperature pressure relief valve must be installed in a continuously downward direction and in a frost free environment Water may drip from the discharge pipe of the pressure relief device This pipe must be left open to the atmosphere The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked 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 The following extract is taken from the latest G3 Regulations Discharge pipes from safety devices Discharge pipe D1 3 50 Each of the temperature relief valves or combined temperature and pressure relief valves specified in 3 13 or 3 17 should discharge either directly or by way of a manifold via a short length of metal pipe D1 to a tundish 3 51 The diameter of discharge pipe D1 should be not less than the nominal o
42. um Resistance Allowed Expressed As A Length Of Straight Pipe I E No Elbows Or Bends Minimum Size Of Discharge Pipe D2 From Tundish Resistance Created By Each Elbow Or Bend Valve Minimum Size Of Outlet Size Discharge Pipe D1 Table 5 Sizing of copper discharge pipe D2 for common temperature relief valve outlet sizes Safety device e g Temperature relief valve Metal discharge pipe D1 from Temperature relief valve to tundish 300mm minimum Tundish Discharge below fixed grating Building Regulation G3 section 3 61 gives alternative points of discharge Fixed grating Discharge pipe D2 from tundish with continuous fall See Building Regulation G3 section 3 56 Table 5 and worked example Trapped gully Figure 10 Typical discharge pipe arrangement extract from Building Regulation G3 Guidance Section 3 50 17 18 6 3 Electrical connections In case of difficulty contact service support contact details are available on page 26 of this booklet gt WARNING gt Disconnect from the mains electrical supply before removing any covers gt Never attemptto replace the immersion heater s other than with genuine manufacturers components Using other manufacturers components may invalidate the warranty on the cylinder gt DO NOT bypass the thermal cut out s in any circumstances All electrical wiring should be carried out by a competent electrician and be in accorda
43. utlet size of the temperature relief valve 3 52 Where a manifold is used it should be sized to accept and discharge the total discharge from the discharge pipes connected to it 3 53 Where valves other than the temperature and pressure relief valve from a single unvented hot water system discharge by way of the same manifold that is used by the safety devices the manifold should be factory fitted as part of the hot water storage system unit or package Tundish 3 54 The tundish should be vertical located in the same space as the unvented hot water storage system and be fitted as close as possible to and lower than the valve with no more than 600mm of pipe between the valve outlet and the tundish see fig 10 Note To comply with the Water Supply Water Fittings Regulations the tundish should incorporate a suitable air gap 3 55 Any discharge should be visible at the tundish In addition where discharges from safety devices may not be apparent e g in dwellings occupied by people with impaired vision or mobility consideration should be given to the installation of a suitable safety device to warn when discharge takes place e g electronically operated Discharge pipe D2 3 56 The discharge pipe D2 from the tundish should a have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework see fig 10 and b be installed with a continuous fall thereafter of at
44. where it can no longer accommodate the expansion This will require a suitably qualified person to check the expansion vessel pressure and no attempt should be made to re pressurize the expansion vessel by the end user 9 Maintenance 9 1 General 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 Maintenance of this appliance should only be carried out by a suitably qualified person Failure to do so could invalidate the warranty 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 person on a regular basis e g annually to coincide with boiler maintenance After any maintenance please complete the relevant Service Interval Record section of the Benchmark Checklist on page 26 of this document 9 2 Standard inspection amp maintenance operations Inspection The immersion heater boss can be used as an access for inspecting the cylinder internally Safety valve operation N CAUTION Water discharged may be very hot gt Manually operate the temperature pressure relief valve for a few seconds
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