INSTALLATION MANUAL SOLARCYL
Contents
1. If problem still persists contact a competent engineer BER OSO FAULT FINDING GUIDE Hot water from taps is cold Low solar gain Is the programmer set to central heating or not switched on YES YES Activate boiler Insufficient hot water when boiler is used Is the boiler NO working Check and ls the nas eond motorised NO cylinder tee valve thermal operating cut out prooramme correctly operated Check wiring Check and or plumbing connections reset button If problem still persists contact a competent engineer plumber Excessive Hot water from taps Thermostat Solar controller set too high Reduce Temperature setting ls Thermostat wired NO as per layouts for NO S or Y plan installation Faul Check cylinder auty Th fat isswitchi Thermostat Connect wiring as Zeg op SC mg replace per instructions programmer amp hot water on Is 2 port motorised D valve closing when cylinder reaches temperature Wiring Fault Seek advice from electrician Check wiring on cylinder Thermostat If in doubt at any stage you must consult a qualified electrician BER NOTES ALTERNATIVE DISCHARGE Downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standings grassed2. Sensor Pocket Thermostat lBlele Nele Y Plan Wiring Layout A Honeywell 10 way junction box must be used in a Y plan system No other wiring centre is acceptable SOLAR BOILER UPPER ELECTRICAL BOX Thermostat Thermostat Zone Valve DHW supplied V4043H Mid Position Valve not supplied T6360B V4073A1039 TT n 2 3 2 Isolated Mains L N E Supply From rused spur 1 2 4 S Room stat 123 23 2 3 LINJE 4 3 1 L NJE LINJE ST6400 Boiler Pump The wiring plan shown is based on the use of a 10 way Junction Box Honeywell Part no 42002116 001 Junction Box terminal 8 is switched live and if needed terminal 10 is pump live FIGURE 4 SOLAR CONTROLLER WIRING ee Safety Cut out Reset Differential button Solar Controller Electrical spare parts Immersion Heater 71259 Immersion Heater Thermostat 80020 Coil Thermostats 80030 10 Honeywell ST 6400 Programmer 7 day FIGURE 1 Mains iH Blolal WINNI sle el ela s e n DHW Valve V4043H Y Plan System Schematic veS e 8 A
3. PLEASE LEAVE THIS MANUAL WITH THE OSO UNIT AFTER INSTALLATION Cs Oo SOLARCYL MOTWATEL IM SC2 INSTALLATION MANUAL This cylinder is manufactured and approved in accordance with EN 12897 2006 This manual gives detailed advice for installation and should be read carefully prior to fitting any unvented unit This OSO cylinder must be installed by a competent person and be installed in compliance with the OSO Installation and Maintenance Instructions all current legislation codes of practice and regulations governing the installation of unvented hot water cylinders in force at the date of installation Components supplied with the unit for site fitting See also page 2 for component list Multibloc valve includes pressure reducing valve line strainer balanced cold water take off for shower or bidet only check and expansion valve Tundish D H Health and Safety 1 2 F x 15x 15 tee plece Manual Handling Operations Regulations 1992 defines manual handling as any transporting or supporting of a Flexible hose load including the lifting putting down pushing pulling carrying or moving thereof by hand or bodily force The S 3 4 x 22mm Elbow Drain Cock Regulations set no specific requirements such as weight imits However common sense still has to be used S Blanking plug based on an ergonomic approach for each individual m e kt Motorised valve indirect only DIMENSIONS AND WEIGH
4. areas etc are acceptable pro viding that where children may play or otherwise come into contact with discharges a wire cage or similar guard is posi tioned to prevent contact whilst maintaining visibility Discharge at high level i e 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 Metal discharge pipe D1 from perati temperature relief valve to tundish FIGURE 4 Safety device e g temperature relief valve Tundish 300mm minimum Discharge pipe 02 from tundish with continuous fall See 3 56 Table 1 and worked example 3 61 gives alternative points of discharge water and 3m from any plastics guttering system that would collect such discharges tundish visible Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than 6 systems so that any installation discharging can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected For further information contact your Building Control Office or The British Board of Agr ment FIGURE 5 1 Secondary Return Fitting 2 Non Return Valve 3 Circulation Pump 4 Secondary Return Line 5 Balanced cold supply for showers or bidet only SECO
5. and Expansion valve cartridge and seat Part strainer Part No REDC312100 3 Bar No RELC 102201 8 0 Bar Complete Expansion Valve Part No PREL 102300 8 0 Bar SPARE PARTS Expansion valve Pressure reducing valve Cartridge and seat Cartridge Part No Part No RELC 102201 REDC 312100 3 bar 8 0 Bar Expansion valve Part No PREL 102300 8 0 Bar Tundish Install theTundish in a vertical position within a maximum of 600mm from the temperature and Pressure Relief Valve drain connection Ensure the expansion relief pipework discharges through the tundish Tundish pipework must be 22mm with a minimum vertical length of 300mm below tundish Maximum permitted length of 22mm pipework is 9m Each bend or elbow is equivalent to 0 8m of pipework All pipework must have continuous fall and discharge in a safe visible position If any doubt refer to Building Regulation G3 6 ELECTRICAL INSTALLATION Immersion heaters SolarCyl Single coil is provided with twin immersion heaters The upper immersion heater is designed as an auxiliary heater to supplement the solar energy and will ensure the top section of the water heater is fully heated All SolarCyl units are supplied with an immersion heater at low level This immersion heater is to allow full heating of the entire cylinder should it be required for cleansing purposes The lower immersion heater should not be in regular use as this will severely compromise the
6. or altering the thermostat setting isolate electrical supply to the unit before removal of the lid 72 S Plan Wiring Layout UPPER ELECTRICAL BOX SOLAR BOILER Thermostat Thermostat Ee Terminal for Y plan System Zone Valve DHW supplied Zone Valve Htg Room stat not supplied Isolated Mains L N Supply From Fused Spur 123 ST6400 Boiler Pump The wiring plan shown is based on the use of a 10 way Junction Box Honeywell Part no 420021 16 001 Junction Box terminal 8 is switched live and if needed terminal 10 is pump live FIGURE 4 SOLAR CONTROLLER WIRING icant et Safety Ox x Cut out Reset button Differential Solar Controller Electrical spare parts O O Immersion Heater 71259 Immersion Heater Thermostat 80020 Coil Thermostats 80030 S Plan System Schematic Honeywell FIGURE 1 cen FIGURE 2 ST 6400 Programmer 7 day Mains L gt 1 L 1 Radiators UFH N 2 N 2 SE E 3 4 4 source 3 gt 6 Honeywell HTG Valve ST 6300 V4043H Senso FIGURE 3 Solar 5 L 1 Bl 2 IN p 2 Gr 1 Collector Or 10 4 gt 4 3 3 P 6 DHW Valve Pocket ST 6360 V4043H Room stat
7. solar efficiency of the cylinder Wiring instructions for the immersion heater is located on the reverse side of the lower lid Follow the wiring instructions connecting the live neutral and earth as indicated The electrical connection to the immersion heater must conform to current IEE wiring regulations The unit must be permanently connected to the electrical supply through a double pole linked switch with a minimum break capacity of 13 amps All internal wiring is factory mounted Each immersion heater has a working thermostat adjustable between 40 C 70 C A safety cut out is also incorporated within the thermostat and will operate at 85 C 3 C Should this happen press the reset button Important Before resetting the safety cut out or altering the thermostat setting isolate electrical supply to the unit prior to removal of the lid Ensure the lid to the electrical box is replaced correctly and the retaining screw is fitted Indirect Units upper coil Motorised valve To comply with regulations governing the installation of indirect unvented cylinders a motorised valve must be fitted in the primary flow Your OSO unit has been supplied with a two port motorised valve which will act as a positive energy cut out should the safety cut out operate The motorised valve will also control the temperature of the domestic stored water via the cylinder thermostat which is located in the upper electrical box The unit should be installed on a
8. G Filling up Open a hot tap Open the cold water supply valve when water flows from hot tap close the tap Allow the system to stabilize for 5 minutes Open each hot water tap in turn to expel air from the system pipe work Check for leaks Manually operate Temperature and Pressure Relief Valve 5 to ensure free water flow through discharge pipe Turn knob to left NOahON Draining flushing 1 Turn off mains supply 2 Connect hose pipe to drain cock at base of cylinder 3 Open hot tap Open drain valve and open temperature amp pressure relief valve 4 Allow to drain Follow commissioning instructions above to refill SAFETY AND MAINTENANCE Safety Cut out The safety cut out operates if Wiring is incorrect The immersion heater thermostat or cylinder thermostat fails Thermostat is set too high Remember before resetting the safety cut out or altering the thermostat setting isolate electrical supply to the unit prior to removal of the electrical box lid Reduce thermostat setting and press the reset button After adjustments are completed ensure the lid to the electrical box is replaced correctly and the retaining screw is fitted If still out of operation contact installer RECOMMISSIONING INSTRUCTIONS Cold or tepid water discharge from tundish The tundish should be installed away from electrical devices Close cold water supply valve Open a hot tap Repressurise the expansion vessel air charge
9. NDARY RETURN HMOTWATER WA Lid All replacement parts must be supplied by OSO HOTWATER UK LIMITED To obtain the address of a local stockist contact OSO HOTWATER UK LTD E15 Marquis Court Team Valley Trading Estate Gateshead Tyne amp Wear NE11 ORU Phone 0191 482 0800 e Fax 0191 491 3655 e www oso hotwaier com E mail technical uk oso hotwater com e spareparts uk oso hotwater com e sales uk oso hotwater com
10. S yor a am FIGURE 2 Radiators UFH Automatic Pump flow Senso FIGURE 3 Solar Collector Sensor Pocket Sensor Pocket Thermostat FAULT No water flow from hot taps Water from hot taps is cold OSO FAULT FINDING GUIDE 1 2 POSSIBLE CAUSE Mains supply off Strainer blocked Cold water inlet Pressure Reducing Valve incorrectly fitted Low solar gain Immersion heaters not switched on Immersion heater thermal cut out has operated Programmer set to central heating or not switched on Boiler not working Cylinder thermal cut out has operated Indirect units only Motorised valve not operating correctly ik 2 REMEDY Check and open stopcock Turn off water supply Remove strainer and clean See Pressure Reducing Valve page 6 Installation Manual Check and refit as required see item 3 page 5 of installation manual Activate alternative power source Check and switch on Check and reset button See thermostat diagram page 9 and safety cut out on page 4 of installation manual Check and set to hot water Check boiler operation If fault suspected consult installer or boiler manufacturer As at No 2 Check wiring and or plumbing connections to motorised valve See pages 8 or 10 of the installation manual Intermittent water discharge Reduced internal expansion Thermal con
11. TS TABLE 1 Expansion vessel PRODUCTREF 197 250 300 380 HEIGHT 1150 1400 1600 2090 Components factory fitted DIAMETER 580 580 580 580 Immersion heater s WEIGHT EMPTY 50 54 57 83 R MAX WEIGHT FULL 241 297 339 454 Thermostats thermal cut out COIL SURFACE AREA Ne Temperature and pressure relief valve UPPER COIL 04 04 04 08 LOWER COIL 0 8 0 8 0 8 0 8 Installation details The OSO unvented unit is designed for use with supply pressure up to 16 bar For pressures over 16 bar an additional pressure reducing valve must be fitted in the supply pipe to the unit 142044 05 General Layout Fig 1 SOLARCYL TWIN COIL Twin Coil Single Immersion Heater Return 3 4 BSP Boiler Return 3 4 BSO Solar Flow 3 4 BSP Boiler Flow 3 4 BSP Solar 1 2A 355013 3 0 bar cartridge REDC 355013 2 Pressure Reducing Valve Multibloc Includes Item 4 Expansion valve 5 Temperature and Pressure Relief Valve e mmn iy i 7A Immersion Heater Thermostat 7B Thermostat Boiler 80030 ees _ Not supplied see Table 2 AD SOLARCYL SINGLE COIL Single Coil Twin Immersion Heater CUTAWAY KEY Fawon O C C E EIERE REES 20 Deepen D esered Rz TABLE 2 Size Lenght of tube 22 mm Exp vessel pre charge e 60 100 es COLD WATER SUPPLY 1 To obtain the best performance from your OSO unvented system it is advisable to feed the
12. at least 80 cm of free space in front of the water heater to ensure easy access for servicing and maintenance Protection from frost If the water heater is in danger of being exposed to frost while not operating under electric power the unit must be drained to avoid damage Make sure the electric power is turned off before draining otherwise the heating elements can be damaged and the warranty is void Draining instructions see Commissioning on page 4 Cold water inlet control Multibloc See Page 2 Items 3 4 This combination consists of a pressure reducing valve with integral strainer check valve and expansion valve with stainless steel seat The pressure settings are set and locked in the factory and are shown on the top of each valve For optimum performance the following installation instructions should be complied with Installation 1 Cold water supply to be 22mm nominal size 2 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 the warranty 3 The MULTIBLOC can be fitted in any orientation to suit the installation as long as it is fitted in the correct flow direction Check the flow arrows on the side of the body 4 The expansion valve should be either horizontal or pointing downwards If fitted upwards debris may be deposited on the seat and cause fouling of the seat when t
13. he valve operates Check direction of flow arrows 5 The black plastic plugs in the body are pressure gauge connections to enable pressure monitoring to be carried out should the system develop a fault It is recommended that these be accessible the pressure reducing valve has two only one need be accessible 6 Expansion relief drain pipework must be connected to a safe visible discharge point via a tundish and the pipework must have a continuous fall 7 The pressure reducing valve has two outlets the second one is for a balanced cold water supply to a shower or a bidet over rim type only ascending spray type requires type AA AB or AD air gap Major shower manufacturers advise fitting a mini expansion vessel in the balanced cold supply to accommodate thermal expansion and prevent tightening of shower controls Using the balanced cold connection to feed bath taps can reduce the flow available to the unvented cylinder If not required the balanced cold supply is blanked off The Benchmark Log Book enclosed with the cylinder should be completed after commissioning of the system and handed to the customer for future use TABLE 4 Size Weight Weight Heat up mins Rating kW Heat loss Primary Hot water capacity I litres empty full lower upper coil lower uppercoil kWh 24h flow rate lower upper coil 37 30 16 1 10 8 15 Vmin 80 C 195 108 so La o au memo 21 Dani ang o s so ss manos 23 15 min aorc
14. ing the balanced cold connection to feed bath taps can reduce the flow available to the unvented cylinder Major shower manufacturers advise fitting a mini expansion vessel in the pipework to accommodate thermal expansion and prevent tightening of shower controls 12 Connect the cold supply to the Multibloc 3 13 Fit the expansion vessel to the wall close to the water heater using the enclosed mounting bracket Connect the expansion vessel hose to the T piece in the cold feed pipe to the cylinder The expansion vessel is supplied with the OSO unit fit as shown on page 2 wr Oo OM Em e Hot water supply 14 Connect the hot water supply pipe to the outlet 9 Ensure connection is water tight Secondary return optional 15 Connect secondary return if required to fitting according to diagram on page 16 Discharge pipe 16 Connect the discharge pipe from the tundish 6 This must have a continuous fall and be fitted in accordance with The Building Regulations see page 16 The tundish should be installed away from electrical devices Boiler Primaries Primary flow amp return and motorised valve 17 The boiler primary flow and return connections should be made to the upper coil connections unit The motorized valve can be connected to either the primary flow or return pipe The primary flow and return fittings are 3 4 BSP female The valve has 22mm x copper connections The direction of primary flow in the boiler coil is b
15. n S or Y plan system Cylinder temperature control can also be achieved via the solar thermostat when the boiler is not operational Please follow the instructions carefully All electrical connections must conform to current IEE wiring regulations The working thermostat is adjustable between 40 C 70 C A safety cut out is also incorporated within the thermostat and will operate at 85 C 3 C Should the safety cut out be brought into operation the motorised valve will operate and close down the primary flow to the cylinder To reset the safety cut out and the motorised valve the reset button must be pressed in see fig 4 page 8 Lower Solar coil Heat sources to unvented hot water cylinders must be controlled by a thermal cut out as well as a thermostat The OSO Solarcyl is supplied both with bosses for solar sensor pockets and the pockets themselves The top half of the thermostats fitted to the cylinder is a thermal cut out The solar controller not supplied and solar sensor point should be wired through the OSO thermal cut out See fig 4 pages 8 amp 10 Please note that the direction of flow in the solar coil is reversed compared to the boiler coil If the cylinder is not being used for solar use connect the boiler to the lower coil with the primary flow in a bottom to top direction OSO Hotwater UK Limited can not be responsible if alternative wiring plans are used Important Before resetting the safety cut out
16. omg so e sa es manea a2 Lane em Note Temperature rise is from 15 to 60 C Coil heating E based on a primary flow rate of 15 l min at 80 C 5 MAINTENANCE It is recommended that annually a competent person a Inspects and cleans the line strainer b Checks the operation of the expansion relief valve and temperature amp pressure relief valve c Recommissions the cylinder in accordance with the instructions on page 4 Corrosion resistance Duplex stainless steel is naturally corrosion resistance to mains water supply No specific mainte nance is required to maintain this resistance Please see guarantee terms for permissable water content Please note OSO cylinders are not guaranteed for use with a private water supply The immersion heater can be removed to provide visual inspection access to the cylinder Pressure reducing valve Expansion relief cartridge 1 Isolate the cold water supply and open a 1 Isolate the cold water supply and open a ground floor cold tap ground floor cold tap 2 Unscrew the pressure reducing cartridge 2 Unscrew blue expansion relief headwork 3 Clean the filter mesh and the cartridge from valve body under running water 3 Clean valve seat face and seating do not 4 Replace cartridge ensuring that strainer is scratch or damage either seat face or seating correctly located and reassemble the unit 4 Refit in reverse order Do not overtighten Pressure Reducing Valve cartridge
17. ottom to top The maximum operating temperature of the primary flow would typically be 82 C 18 For electrical connection of the motorised valve and immersion heater please read Electrical Installation Instructions Pages 7 11 Solar Primaries 19 The Solar flow and return connections should be made to the lower coil connections Temperature control from the Solar circuit is achieved using a differential solar controller This controller must be wired in series through the thermal cut out on the OSO thermostat see figure 4 pages 9 amp 11 If Solar Collectors are to be installed at a later date then connect the boiler primaries to the lower coil The driection of solar primary flow in the solar coil is top to bottom 20 The solar circuit must be installed with a solar hydraulic station which must incorporate a pump and non return valves in both flow and return within the solar circuit This system will prevent thermal siphoning when the pump is not active 3 21 Temperature sensors for the cylinder provided with the differential controller should be inserted into the pockets provided see pt 5 above 22 There is no maximum primary temperature from the solar system and primary temperatures in excess of 100 C are not unusual All components on the solar circuit must be suitable for these higher temperatures Should the solar circuit be installed incorrectly then all approvals and guarantees of the cylinder are invalid COMMISSIONIN
18. to its set level Close hot tap Open the cold water supply valve A np gie Hot water discharge from tundish This indicates a malfunction of a thermal cut out operating thermostat or the combined temperature and pressure relief valve Turn off the electrical supply to the immersion heater and also isolate an indirect unit from the boiler Contact the installer or competent engineer TABLE 3 Size Max design Operating pressure Pressure drop primary heater Temp pressure Safety valve Exp vessel litres pressure CW feed amp coils lower amp upper relief valve Pressure conn capacity cw in 2 bar coils 2 5 6 lower 0 2 bar upper 0 1 bar 90 95 C 10 bar 8 bar 15mm 1 2 cw in 2 bar coils 2 5 6 lower 0 2 bar upper 0 1 bar 90 95 C 10 bar 8 bar 15mm 1 2 cw in 2 bar coils 2 5 6 lower 0 2 bar upper 0 1 bar 90 95 C 10 bar 8 bar 15mm 1 2 cw in 2 bar coils 2 5 6 lower 0 2 bar upper 0 1 bar 90 95 C 10 bar 8 bar 15mm 1 2 INSTALLATION AND SERVICING INSTRUCTIONS Positioning the unit The water heater should be fitted level on a hard surface with sufficient load strenght to take the full weight of the cylinder see table 1 page 1 Adjustable feet are fitted to ensure the unit can be adjusted to a level position There is no limitations regarding the fitting distance from walls etc but it is strongly recommended to ensure easy access to all pipe fittings etc There should be
19. trol failure Note Water will be hot ba Repressurize expansion vessel Follow recommissioning instructions on page 4 Switch off power to immersion heater s and boiler supply to the unit When discharge has stopped check thermal controls replace it faulty Contact a competent person Continuous water discharge Cold water inlet Pressure Reducing Valve not working Temperature and pressure relief valve faulty Expansion relief valve not working correctly Check pressure from valve if greater than 2 1 bar replace See page 6 of installation manual As No 2 of above Check and replace if faulty See page 6 of installation manual NOTE Disconnect electrical supply before removing any electrical equipment covers il OSO FAULT FINDING GUIDE Intermittent water discharge Reduced expansion volume Thermal control failure YES YES Repressurize expansion ves Switch off power to sel Follow recommissioning immersion heaters and instructions on page 4 boiler supply to the unit When discharge has stopped check thermal controls and replace as necessary If problem still persists contact a competent engineer plumber No water flow from hot taps Mains supply off NO Line strainer NO Cold water PRV blocked incorrectly fitted YES YES YES Open supply Clear line Check and refit valve strainer as required
20. unit with an uninterrupted supply Before connecting to the multibloc flush the cold supply pipework of all flux and debris Locate the water heater in a suitable position to facilitate the installation of the cold water supply discharge fittings and pipework Also take into account access to the immersion heaters and the commissioning valve Fit the combined male elbow drain cock to cold supply point 13 so that the compression fitting is vertical Fit the blanking plug 12 to the secondary return fitting If secondary return is to be used see point 16 Fit the female outlet of the tee piece to the temperature and pressure relief valve 5 with the horizontal connection facing right at approx 45 Fit the tundish 6 to the tee piece using a short length of 15mm copper tube Fit the length of copper tube 22mm specified in Table 2 to the cold feed elbow see 4 above to include a T piece 20 for expansion vessel flexible hose Fit the pressure reducing valve 3 to the top of the copper tube see 8 above so that the black knob is facing right 10 Connect the flexible hose to the 1 2 outlet of the expansion valve 4 and the horizontal outlet of the tee piece see 6 above Discard compression nut amp ring 11 If a balanced mains pressure cold water supply is required to a shower or bidet over rim type only remove the blanking cap from the pressure reducing valve 3 and connect to the shower or bidet cold supply Us
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