Coral Aquanox Installation Manual
Contents
1. 2 E FN a B CORAL F f CORAL ff QUANG aquanox j OG vas ex I H lis le IE A EZ A JJ S T am ea ea B 4 BP Ad IE AG sol x S Vn 3 5 B 5 B 5 v J Y Y Y v Fig 2 Dimensions and performance Auto fill versions shown Type Model Dimensions mm Total Coil Rating kW Hot Water Hot Water Reference Storage Capacity Itrs Capacity Itrs A C Volume Hot Primary volume of water v40 C V Water Coil Sawn of gt 40 0 Coil Store Store Store Store Temp Temp Temp Temp 75 C 85 C 75 C 85 C Direct 1204 mi sie 120 187 1450 801 900 175 33 11 146 190 180 264 L j NE p j 120 2 4 E pun pes DE s NE 215 Ed 1 1 1 1 Table 2 Dimensions and performance Note2. d Fig 3 Siting the Unit Schematics Indirect model IRA pua SS V AD rel UUUUU sd EE 2 metres is required for JUUUM expansion in pipework Kw Y before nearest cold Y draw off ews AAV Gas E Where expansion down the mains is not possible install an expansion vessel with a capacity not less than 1000ml 3 N SR A 2 metres is required for expansion in pipework before nearest cold a draw off SE ows Where expansion down the mains is not possible install an expansion vessel with a capacity not less than 1000ml P A Lock Shield Vat aaj Flow Setter Combined Isolation amp Check a um X lock Shield Valve SLI Thermostatic Radiator Valve cd me RE Aqua Stat b Single Check Valve X Drain Cock DE Automatic Bypass Valve ER Radiator Lock Shield Valve Room Stat Pressure Gauge Assembly DI Double Check Valve D lt Strainer Safety Valve sxpe Filing Loop Programmer Pq Thermostatic Mixing Valve X Double Reg Valve 0 T amp P Valve HW F
3. Address Cylinder Make and Model Cylinder Serial Number _ ttt ttt ttt tte ete ee tee et l lll l T L l 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 bar Has a strainer been cleaned of installation debris if fitted Yes _ No Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted What is the hot water thermostat set temperature C What is the maximum hot water flow rate at set thermostat temperature measured at high flow outlet l min Time and temperature controls have been fitted in compliance with Part L of the B
4. 26 SERVICE RECORD ee Ene ete deserto 27 GUARANTEE ges ee KAREE Re ge casa Ee RENE KERK ge kere en 28 TECHNICAL SUPPONRT Re Ee RNEER 28 penCHINGN THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS THE BENCHMARK SCHEME 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 The Benchmark Checklist can be used to demonstrate compliance with Building Regulations 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 for more information IMPORTANT NOTE TO USER PLEASE REFER TO THE USER INSTRUCTIONS SECTION ON PAGE 15 FOR IMPORTANT INFORMATION WITH RESPECT TO THE BENCHMARK SCHEME 2 Thank you for purchasing an Elson Thermal Store The thermal store is manufactured in the UK to the highest standards and has been designed to meet all the latest relevant
5. 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 The immersion heater s should be wired in accordance with Fig 6 The immersion heater s MUST be earthed The supply cable should be 1 5mm core flexible cable HOSBN4 F to BS EN 50525 2 21 2011 and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip DO NOT operate the immersion heaters until the cylinder has been filled with water Ensure the thermostat and thermal cut out sensing bulbs are pushed fully into the pockets on the element plate assembly PLUMBING CONNECTIONS Direct Thermal Stores require the following pipework connections Cold water supply to and from inlet Outlet to hot water draw off points Discharge pipework from visual indicator All connections are 22mm compression However 3 4 BSP parallel threaded fittings can be fitted to the primary coil connections if required 10 1 5mm 3 Core sheathed cable HOSBNA F Fig 6 Electrical connections direct schematic INSTALLATION INDIRECT SAFETY DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS Never attempt to replace the immersion heater s other than with the recommended authorised immersion heater s DO NOT BYPASS THE THERMAL CUT OUT IN ANY CIRCUMSTANCES
6. 1 Thermal store tested in conformance with the HWA Performance Specification for Thermal Stores E sae E INSTALLATION GENERAL WATER SUPPLY Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously It is recommended that the maximum water demand is assessed and the water supply checked to ensure this demand can be satisfactorily met Note A high mains water pressure will not always guarantee high flow rates Wherever possible the mains supply pipe should be 22mm We suggest the minimum supply requirements should be 0 15MPa 1 5 bar pressure and 20 litres per minute flowrate However at these values outlet flow rates may be poor if several outlets are used simultaneously The higher the available pressure and flow rate the better the system performance HARD WATER AREAS The building regulations 1 New dwellings L1B Existing dwellings and the requirements set out in the Domestic Building Services Compliance Guide specify that Where the mains total water hardness exceeds 200 parts per million provision should be made to treat the feed water to water heaters and the hot water circuit of combination boilers to reduce the accumulation of limescale To maintain the performance of the Thermal Store water heater and in orderto comply with this regulation the hardness of the mains water should be checked by the installer and if necessary fit
7. 0 20 0 10 0 00 0 6 3 9 45 12 6 FDHW 13 86 15 75 DHW flow rate I min Fig 18 Pressure Loss Characteristics DHW Exchanger Pressure Loss bar Pressure Loss Characteristics of a Primary heat exchanger Coral Aquanox 0 40 0 35 0 30 0 25 0 20 0 15 0 10 0 05 0 00 0 7 5 11 25 15 FPHE 16 5 18 75 Primary flow rate l min Fig 19 Pressure Loss Characteristics Primary Heat Exchanger 20 FAULT FINDING amp SERVICING IMPORTANT After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located on page 27 of this document Servicing should only be carried out by competent persons in the installation and maintenance of water heating systems Any spare parts used MUST be authorised Elson parts Disconnect the electrical supply before removing any electrical equipment covers NEVER bypass any thermal controls or operate system without the necessary safety controls Water contained in the thermal store may be very hot especially following a thermal control failure Caution must be taken when drawing water from the unit SPARE PARTS A full range of spare parts are available for the Thermal Store Table 4 Page 22 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 FAULT FINDING
8. The fault finding chart Table 3 will enable operational faults to be identified and their possible causes rectified Any work carried out on the thermal store and its associated controls MUST be carried out by a competent installer In case of doubt contact service support see contact details on back page No hot water flow Water from hot tap is cold Water discharges from overflow visual Mains water supply off Check and open stop cock isolating valve Direct immersion heater not switched on Check and switch on Direct immersion heater thermal cut out Check reset by pushing button on thermal cut out Indirect programmer set to central heat Check set to domestic hot water programme ing only has operated Indirect motorised valve not connected 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 thermal cut out Check operation of indirect thermostat Check wiring and or plumbing connections to correctly motorised valve INTERMITTENTLY CONTINUALLY indicator Performance has detiorated Table 3 Fault Finding Chart The water level of the feed amp expansion tank has been set incorrectly Occasional small discharge is normal and is gen erally due to condensation Check the operation of the ball float valve inspect the float for leaks Check the ball valve
9. Ensure the two male spade terminations from the combined thermostat and thermal cut out are pushed firmly onto the corresponding terminations on the element plate assembly See Fig 7 In case of difficulty contact service support contact details available at the back of this booklet ELECTRICAL SUPPLY All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I E E Wiring Regulations 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 The immersion heater should be wired in accordance with Fig 7 The immersion heater MUST be earthed The supply cable should be 1 5mm core flexible cable HOSBN4 F to BS EN 50525 2 21 2011 and must be routed through the cable grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip DO NOT operate the immersion heaters until the cylinder has been filled with water Ensure the thermostat and thermal cut out sensing bulbs are pushed fully into the pockets on the element plate assembly PLUMBING CONNECTIONS Indirect Thermal Stores require the following pipework connections Cold water supply to and from inlet Outlet to hot water draw off points Discharge pipework from visual indicator Connection to the primary circuit All connections are 22mm compression However 3 A BSP parallel threaded fitting
10. and 27 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 Benchmark commissioning checklist page 26 to accept completion The Service Record should be filled in when any subsequent service or maintenance operation is carried out on the product USER INSTRUCTIONS WARNINGS IF STEAM DISCHARGES FROM THE OVERFLOW VISUAL INDICATOR SHUT DOWN THE BOILER OR IMMERSION HEATER S DO NOT TURN OFF ANY WATER SUPPLY CONTACT A COMPETENT INSTALLER FOR WATER HEATERS TO CHECK THE SYSTEM IF AFAULT IS SUSPECTED CONTACT ACOMPETENT INSTALLER FLOW PERFORMANCE When initially opening hot outlets a small surge in flow may be noticed as pressures stabilise This is quite normal with hot water 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 UNIT IMMERSION HEATER S Acombined 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 75 C Access to the thermostat can be made by opening the immersion heater cover DISCONNECT THE ELECTRICAL SUPPLY BEFORE OPENING THE CO
11. man lift Upon installation it will be necessary to get assistance when lifting or manoeuvring the product into place Use of mechanical lifting aids may be necessary DO NOT LIFT THE APPLIANCE BY THE ATTACHED PIPEWORK OR ANCILLARY COMPONENTS SITING THE UNIT The Thermal Store must be vertically floor mounted Although location is not critical the following points should be considered The Thermal Store 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 Access to associated controls and immersion heaters must be available to provide for the servicing and maintenance of the system Where these controls are installed against a wall a minimum Wall distance of 300mm must be left see Fig 3 For the autofill versions a minimum distance of 225mm must be left free above the unit in order to comply with the access requirements of the water regulations This requirement is for replacement of the ball float valve if necessary Ensure that the floor area for the Thermal Store is level and capable of permanently supporting the weight when full of water see Table 1 Page 3 N Min 300mm Y maintenance access Min 225mm Hot Outlet Adjustable 180 Access for float valve maintenance Auto fill version only
12. or temperature pressure relief valve during the heating cycle INDIRECT UNITS Open the cover s to the immersion heater housing s and disconnect wiring from immersion heater s thermostat s Remove thermostat by carefully pulling outwards 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 cylinder unit for easy removal tightening of the immersion heater s Over time the immersion heater gasket may become stuck to the mating surface To 16 break the seal insert a flat bladed screwdriver into one of the pockets on the immersion heater and gently lever up and down 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 fit a new gasket part number 95 611 822 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 capillaries into pocket Replace the immersion heater thermostat by carefully plugging the two male spade terminations on the underside of the thermostat head into the correspon
13. working temperature 75 C recommended approximately graduation 4 on the thermostat If necessary the temperature can be adjusted by inserting a flat 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 37 C to 85 C Check the operation of thermostat s INDIRECT UNIT Fill the indirect primary circuit following the boiler manufacturer s commissioning instructions To ensure the cylinder primary heat exchanger is filled the 2 port motorised valve 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 Switch on the boiler ensure the programmer is set to Domestic Hot Water and allow the cylinder to heat up to a normal working temperature 75 C recommended approximately graduation 5 on the thermostat If necessary the temperature can be adjusted by inserting a flat bladed screwdriver in the adjustment knob and rotating The minimum thermostat setting is 12 C The adjustment range 1 to 5 represents a temperature range of 37 C to 85 C Check the operation of the indirect thermostat and motorised valve during the heating cycle BENCHMARK LOG BOOK On completion of the installation and commissioning procedures detailed in this manual the Benchmark Installation Commissioning and Service Record Log pages 26
14. Coral Aquanox Installation Manual Thermal Store Direct amp Indirect Water Heaters Installation amp Servicing Instructions Es rf CORAL Y MN E AQUANOL a H Pack Contents Coral Aquanox vented water heater incorporating immersion heater s amp thermal controls Visual discharge indicator Compression nuts amp olives Immersion heater spanner Installation amp servicing instructions Guarantee card Blending valve insulation kit IMPORTANT Please read amp understand all these instructions before commencing installation Please leave this manual with the user for future reference CONTENTS INTRODUCTION INTRODUCTION tinens eter neret entes 2 TECHNICAL 3 INSTALLATION GENERAL seen 6 MANUAL FILL VERSION a 13 COMMISSIONING trei tette a salsa 14 USER INSTRUGTIONYS tenuit 15 cii rr i eene 16 PERFORMANGE eset See 18 FAULT FINDING amp 21 SPARES RR ER ER a e 22 HEAT LOSS RA RE EE 24 ENVIRONMENTAL INFORMATION 24 COMMISSIONING CHECK L_LIST
15. EFERENCE THIS APPLIANCE IS NOT INTENDED FOR THE USE BY PERSONS INCLUDING CHILDREN WITH REDUCED PHYSICAL SENSORY OR MENTAL CAPABILITIES OR LACK OF KNOWLEDGE AND EXPERIENCE UNLESS THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING THE USE OF THE APPLIANCE BY A PERSON RESPONSIBLE FOR THEIR SAFETY CHILDREN MUST BE SUPERVISED TO ENSURE THEY DO NOT PLAY WITH THE APPLIANCE kiwa approved product LIMITATIONS TECHNICAL SPECIFICATION The Thermal Store water heater should not be used in association with any of the following OPERATIONAL SUMMARY Solid fuel boilers or any other boiler in which the Total storage volume V 120ltrs energy input is not under effective thermostatic 150ltrs control unless additional and appropriate safety 175ltrs measures are installed 210ltrs Ascending spray type bidets or any other class Maximum mains pressure 0 5MPa 5 bar 1 back syphonage risk requiring that a type A air gap be employed Heat Loss 1201 1 75kWh 24h 150lt 2 02KWh 24h Steam heating plants unless additional and 175 2 23kWh 24h appropriate safety devices are installed 210 2 49kWh 24h Situations where maintenance is likely to be Store thermostat settings 12 85 C neglected or safety devices tampered with 4 6 C Water supplies that have either inadequate pressure Overheat thermostat settings 96 C 2 5 C or where the supply may be intermittent Maximum working pressure for areas where t
16. VER S Temperature adjustment is made by inserting a flat bladed screwdriver in the slot on the adjustment spindle on top of the thermostat and rotating The adjustment range 1 to 5 represents a temperature range of 37 C to 85 C 75 C will be approximately position 4 If in any doubt contact a competent electrician DO NOT bypass the thermal cut out s in any circumstances TEMPERATURE CONTROLS INDIRECT UNIT The Thermal Store units are fitted with an indirect control thermostat and thermal cut out These controls must be wired in series with the motorised zone valve to interrupt the flow of primary water around the heat exchanger coil when the control temperature has been reached The controls are located within the terminal housing along with the immersion heater thermostat The thermostat is factory set to give a water storage temperature of approx 75 C 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 flat bladed screwdriver in the adjustment spindle and rotating The minimum thermostat setting is 12 C The adjustment range 1 to 5 represents a temperature range of 37 C to 85 C 75 C will be approximately position 4 If in any doubt contact a competent electrician An immersion heater is also provided for use should the indirect heat source be shut down for any reason The immersion heater cont
17. a proprietary scale reducer or water softener to the cold water supply refer to the manufacturers instructions for installation for guidance Please consult the local water authority for additional advice on water quality if required INHIBITOR The use of a corrosion inhibitor is recommended to prolong the performance and efficiency of the Thermal Store Checking the concentration of corrosion inhibitor in the Thermal Store is essential dose appropriately according to the size of the Thermal Store volume in accordance with the inhibitor manufacturer s guidelines Please refer to BS 7593 2006 Code of practice for treatment of water in domestic hot water central heating systems PIPE FITTINGS The cold feed is made via 22mm copper pipe spigot Primary coil pipe fittings are made via 22mm compression fittings directly to the unit The fittings are threaded 3 4 BSP male parallel should threaded pipe connections be required COLD FEED A 22mm cold water supply is recommended however if a 15mm 1 2 supply exists which provides sufficient flow this may be used although more flow noise may be experienced A stopcock or servicing valve should be incorporated into the cold water supply to enable the Thermal Store and its associated controls to be isolated and serviced OUTLET The hot water outlet is a 22mm compression fitting located at the thermostatic mixer valve TMV2 Hot water distribution pipework should be 22mm p
18. ctions indirect schematic 11 CYLINDER TERMINAL BLOCK BOILER PROGRAMMER 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 Fig 8 Schematic wiring diagram Basic 2 x 2 port valve system CYLINDER TERMINAL BLOCK L N MI amp OIO OO JUNCTION BOX 2101019101006 ROOM STAT BOILER 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 Fig 9 Schematic wiring diagram 3 port mid position valve system N B Must be used in conjunction with 2 port zone valve supplied 12 MANUAL FILL VERSION MANUAL FILL The store is provided with a flexible temporary filling loop which MUST be disconnected after installation to comply with the requirements of the Water Supply Water Fittings Regulations 1999 The feed amp expansion header tank water level should be checked regularly If required fill with clean cold water via the filling loop to the appropriate level as shown on the sight glass Do not overfill the tank Ensure that the header tank lid is securely replaced this reduces the amount of water lost through e
19. ding terminations on the element Rewire check close and secure immersion heater housing cover s 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 refill DO NOT switch on the immersion heater s or boiler until the unit is full When water flows from the hot tap allow it to flow for a short while to purge air and flush through any disturbed particles Close the hot tap and then open successive hot taps in the system to purge any air When completely full and purged check the system for leaks The heating source immersion heater s or boiler can then be switched on INHIBITOR The use of a corrosion inhibitor is required to maintain the performance and cylinder guarantee of the Thermal Store Checking the concentration of the corrosion inhibitor in the Thermal Store is essential to prevent corrosion Dose appropriately according to the size of the volume in accordance with the inhibitor manufacturer s guidelines Please refer to BS 7593 2006 Code of practice for treatment of water in domestic hot water central heating systems Step 1 Drain feed amp expansion tank Step 2 Release feed amp expansion Step 3 Remove feed amp expansion tank note drain tank only tank pipe connections fixing bolt amp slide forwards to remove F
20. ectly fitted and tightened An immersion heater key is provided to aid tightening the immersion heater s AUTO FILL UNIT Check all connections for tightness including the immersion heater s An immersion heater key spanner is supplied for this purpose Ensure that both drain cocks are CLOSED Open a hot tap furthest from the Thermal Store Open the mains stop cock to fill the unit When water flows from the tap allow to run for a few minutes to thoroughly flush through any residue dirt or swarf then close the tap Open successive hot taps to purge the system of air The Thermal Store will continue to fill via the ball valve located in the feed amp expansion header tank This will stop when the cylinder store is full Set the level of water in the cistern by adjusting the height of the ball float using the internal water height gauge as shown in Fig 11 page 13 MANUAL FILL UNIT Check all connections for tightness including the immersion heater s An immersion heater key spanner is supplied for this purpose Ensure that both drain cocks are CLOSED Open a hot tap furthest from the Thermal Store Open the mains stop cock to fill the unit When water flows from the tap allow to run for a few minutes to thoroughly flush through any residue dirt or swarf then close the tap Open successive hot taps to purge the system of air The filling loop is used for introducing mains wat
21. er into the cylinder for filling and topping up purposes The filing loop has an isolating valve at each end To introduce water into the system undo one of these valves completely and gently open the other valve to control the rate of flow of water into the cylinder Introduce water until the sight gauge on the feed amp expansion tank is level with the bottom fill line as shown in Fig 12 page 13 Turn both valves off fully The temporary filling loop should be disconnected after installation to comply with the requirements of the Water Supply Water Fittings Regulations 1999 The feed amp expansion header tank water level should be checked regularly If required fill with clean cold water via the filling loop to top up SYSTEM CHECKS Upon commissioning a competent engineer should 14 Check all water connections for leaks and rectify as necessary Check water pressure maximum 5 0bar e Check operation of all service valves Check operation of the blending valve and test that the water temperature hot flow mix is at 55 C when the store temperature is operating at 75 C e Check operation of the immersion heater thermostats and settings Complete the service record at the back of the commissioning booklet provided to comply with the manufacturers guarantee and Benchmark requirements DIRECT UNIT Switch on electrical supply to the immersion heater s and allow the cylinder to heat up to normal
22. he water consistently contains DHW heat exchanger 0 5MPa 5 bar high proportion of solids e g suspended matter that could block the blending valve unless adequate filtration can be ensured Pressure Loss F aw 0 5 bar at 12 6ltrs min In areas where the water supply contains chloride levels that exceed 200mg I DHW Volume 120ltrs 115ltrs Volume of water gt 40 C 150Itrs 123ltrs 75 C store temp at 175ltrs 146ltrs 12 6ltrs min 210ltrs 168ltrs Nominal Weight Model Capacity of unit DHW Outlet temperature setting 55 C TMV2 Reference litres empty adj 35 60 C Kg ER indirect aximum working pressure for Primary heat exchanger 1 0MPa 10 bar 758 175 57 239 Thermal rating of Primary ne es ew Direct Pressure Loss Frye 0 2 bar at 15ltrs min Table 1 Unit weights Ingress Protection IPX2 Electrical rating 3kW 240V ac Weight when full See Table 1 Fig 1 Key Features Primary Coil Flow Connection 3 4 22 compression Primary Coil Return Connection 3 4 22mm compression Electrical Connection Housing IPX2 Visual Discharge Indicator 22 x 28mm compression Feed amp Expansion Header Tank Feed amp Expansion Header Tank Lid Blending Valve Insulation Cover 8 Hot Outlet TMV2 22mm compression 9 Cold Supply Inlet 22mm compression
23. hloride levels in the water supply or incorrect disinfection methods Maximum permissible chloride level 200mg l PPM Evidence of purchase and date of supply may be required The guarantee is transferable This guarantee does not affect your statutory rights Servicing heateam heateam is BDR Thermea s very own service division With us on your side you can be sure that your customers are in the very best of hands Totally committed to quality and safety heateam is open 7 days a week for 363 days a year and offers Dedicated Trade Advice Line our helpful and qualified specialists are always on hand to help you with even the most complex technical query Installer Priority Call Outs our 280 strong team of specifically trained expert heating engineers covers the UK no one is better qualified to look after Elson s products for the duration of the guarantee Fully Stocked Vans a nationwide fleet of vans fully stocked with spare parts meaning we can repair our appliances on the first visit 95 of call outs Exclusive Service Plans heateam also offer Elson s customers a range of exclusive annual service plans Opening Times Monday Friday 8am 6pm weekends and Bank Holidays 8 30am 2pm excluding Christmas Day and New Year s Day Simply call 0844 335 8819 or visit our website at www heateam co uk Spares For all technical support replacement parts amp service issues please contact E
24. ig 13 Header Tank Removal Step 1 Drain feed amp expansion tank Step 2 Release connection pipe remove note drain tank only rear tank by unhooking and lifting Fig 13a 210litre Header Tank Removal 17 PERFORMANCE DHW Performance of a thermal store Coral Aquanox 120ltr 60 4 DHW outlet temperature C 10 100 120 140 160 180 Draw off volume I Fig 14 120ltr Hot Water Performance DHW Performance of a thermal store Coral Aquanox 150ltr 60 4 200 50 40 4 DHW outlet temperature C Co 10 0 0 20 40 60 80 100 120 140 160 180 Fig 15 150ltr Hot Water Performance 18 Draw off volume 1 200 DHW Performance of a thermal store Coral Aquanox 175ltr DHW outlet temperature C 0 20 40 60 80 Fig 16 175ltr Hot Water Performance 100 120 140 160 180 Draw off volume 1 DHW Performance of a thermal store Coral Aquanox 210ltr 200 220 240 DHW outlet temperature C 0 20 40 60 80 Fig 17 210ltr Hot Water Performance 100 120 140 160 180 200 Draw off volume I 220 240 260 280 19 Pressure Loss bar Pressure Loss Characteristics of DHW heat exchanger Coral Aquanox 0 90 0 80 0 70 0 60 0 50 0 40 0 30
25. ipe with short runs of 15mm pipe to terminal fittings such as sinks and basins Pipe sizes may vary due to system design The Thermal Store can be used with most types of terminal fittings It is advantageous in many mixer showers to have balanced hot and cold water supplies In these instances a balanced pressure cold water connection should be placed between the cold water supply inlet and Thermal Store cold feed connection A minimum distance of 2 mtrs to the first cold water draw off take must be observed see Fig 4 page 8 Outlets situated higher than the thermal Store will give outlet pressures lower than that at the heater a 10m height difference will result in 0 1MPa 1 bar pressure reduction at the outlet All fittings pipework and connections must have a rated pressure of at least 0 5MPa 5 bar at 80 C DOMESTIC HOT WATER BACK EXPANSION During a heating cycle the expansion of water in the DHW heat exchanger must be accommodated Expansion back into the mains may not always be possible For example a double check valve may be fitted in the mains supply If required the minimum expansion vessel size recommended is 1ltr This must be fitted upstream of the DHW exchanger as shown in the schematic Figure 4 Page 8 Any method or product used for accommodating the expansion must comply with the Water Regulations and relevant standards MANUAL HANDLING GUIDANCE The appliance exceeds the recommended weight for a one
26. lectric 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 0845 270 9800 www partscenter co uk Newey amp Eyre Specialists Products Division Please contact your local branch UK Spares Ltd Tower Lane Warmley Bristol BS30 8XT Tel 0117 961 6670 www uk spares com Advanced Water Company Ltd Unit 5D Enterprise Way Vale Park Evesham Worcestershire WR11 1GS Tel 01386 760 066 Policy Statement The policy of ELSON is one of continuous product development and as such we reserve the right to change specifications without notice Elsy amp Gibbons Fifers Lane Norwich Norfolk NR6 6XB T 0844 335 8819 F 0844 871 1528 E elson service heateam co uk W elsonhotwater co uk 90002503 PART OF BDR THERMEA 36006142 issue 01
27. lexible Connection Air Separator AGD Anti Gravity Dip AN Pressure Reducing Valve D Angle pattern Drain Cock Automatic Air Vent Flow Meter Y Tundish Safety Discharge Vessel X Isolation Valve Expansion Vessel py 2 Port Motorised Valve n Stop Cock Temperature Sensor F Immersion Heater The hydraulic schematics within this document are for guidance only and do not constitute system design Some components may not be detailed for clarity purposes Fig 4 Technical Hydraulic Schematics Fig 5 Blending Valve Insulation INSTALLATION DIRECT SAFETY DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS Never attempt to replace the immersion heater s other than with the recommended immersion heater s DO NOT BYPASS THE THERMAL CUT OUT S IN ANY CIRCUMSTANCES Ensure the two male spade terminations from the combined thermostat and thermal cut out are pushed firmly onto the terminations on the element plate assembly See Fig 6 In case of difficulty contact service support contact details available at the back of this booklet ELECTRICAL SUPPLY All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I E E Wiring Regulations
28. ment INSPECTION The immersion heater boss can be used as an access for inspecting the cylinder internally Ensure the unit is drained before removal of immersion heater DE SCALING THE DHW EXCHANGER The hot water heat exchanger may be de scaled in the field by a qualified technician using a high pressure de scaling pump and suitable acidic de scaling chemical e g Fernox DS3 The store must be cooled to between 30 and 40 C before commencing the de scaling This must be carried out by a skilled person because of the specialist equipment needed DE SCALING IMMERSION HEATER S Before removing the immersion heater s the unit must be drained Ensure the water electrical supply and boiler are OFF before draining Attach a hosepipe to the drain cock having sufficient 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 the drain cock to drain the unit DIRECT UNITS Switch on electrical supply to the immersion heater s and allow to heat up to normal working temperature 75 C recommended approximately graduation 4 on the thermostat If necessary the temperature can be adjusted by inserting a flat 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 12 C to 68 C Check the operation of thermostat s and that no water has issued from the expansion relief valve
29. ncil 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 through 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 15 MAINTENANCE MAINTENANCE REQUIREMENTS Thermal store hot water systems have a continuing maintenance requirement in order to ensure safe working and optimum performance 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 27 of this docu
30. rol temperature is set using the immersion heater thermostat 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 of this book It is recommended that faults should be checked by a competent installer ELECTRIC TARIFFS Direct units are designed to use predominantly low tariff electricity but with a boost switch during normal tariff periods The thermal store is designed to heat water to 75 C At this temperature performance is maintained with minimal heat loss keeping running costs to a minimum BOOST ELEMENT During periods of prolonged hot water draw off or during cold weather conditions the use of the boost element may be more common If the inlet cold water temperature is very low more energy will be required to heat the store The boost element will ensure hot water delivery when the indirect heat store is not available for any reason HOLIDAY It is safe to turn off the power to the Thermal Store and shut off the water supply if you go on holiday THE BENCHMARK SCHEME Elsy amp Gibbons is a licensed member of 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 Cou
31. s can be fitted to the primary coil connections if required BOILER SELECTION The boiler should have a control thermostat and non self resetting thermal cut out and be compatible with thermal 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 Thermal Store should not exceed 2 5m PRIMARY CIRCUIT CONTROL A motorised valve MUST be fitted on the primary flow to the cylinder heat exchanger and wired in series with the indirect control thermostat and thermal cut out fitted to the unit Primary circulation to the Thermal Store heat exchanger must be pumped gravity circulation WILL NOT WORK SPACE AND HEATING SYSTEMS CONTROLS Controls will be required 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 see Fig 9 below The Thermal store is compatible with most heating controls examples of electrical circuits are shown in Figs 8 and 9 Page 12 However other systems may be suitable refer to the controls manufacturers instructions supplied with the controls selected for alternative system wiring schemes Element Connections Indirect control 1 5mm 3 Core wiring 1 sheathed cable HOSBNA F Fig 7 Electrical conne
32. safety specifications The Elson Coral Aquanox thermal store is an Open Vented Hot Water only Thermal Store HWTS The stored energy in a Hot Water only Thermal Store is only used indirectly via a natural convection hot water heat exchanger for producing instantaneous domestic hot water The storage vessel of an open vented thermal store is open to atmosphere and it uses primary water to store thermal energy The thermal store is a purpose designed vented water heater Hot water is delivered at mains water pressure The unit has a stainless steel vessel which ensures an excellent standard of corrosion resistance The outer casing is a combination of resilient thermoplastic mouldings and plastic coated corrosion proofed steel sheet All products are insulated with CFC free polyurethane foam to give good heat loss performance see Table 5 page 24 This appliance complies with the requirements of the CE marking directive and is KIWA approved to show compliance with Water Regulations NOTE Prior to installation the unit should be stored in an upright position in an area free from excessive damp or humidity IMPORTANT THE THERMAL STORE MUST BE INSTALLED AND COMMISSIONED BY A COMPETENT PERSON PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING THE THERMAL STORE FOLLOWING INSTALLATION AND COMMISSIONING THE OPERATION OF THE THERMAL STORE SHOULD BE EXPLAINED TO THE USER AND THESE INSTRUCTIONS LEFT WITH THEM FOR FUTURE R
33. seat for damage Isolate the ball float valve if the water continues to discharge there may be a leak in the internal DHW heat exchanger coil GRADUALLY Check for scale build up in the DHW heat ex changer SUDDENLY Check the operation of the blending valve 21 SPARES The following comprehensive list of spare parts is available for your Elson Thermal Store water heater Please refer to the rating label on the Elson Thermal Store water heater before ordering to ensure the correct spare is obtained Item Description Part Number Number Direct thermostat amp thermal cut out thermal cut out a 6 way terminal block 95607955 9 sWayteminalbiock 95607932 14 Thermostatic mixing vave 95605089 Blending valve cover assembly 3pcs ES Immersion heater key spanner not shown 21 Sight glass not shown 95614 136 22 Motorised port 95 605 049 not shown Table 4 Spares Parts List 22 Figure 20 Exploded Spares Diagram 23 HEAT LOSS Standing Heat Loss per day per year KWh 24h KWh 365d Nominal Capacity Litres 460 54 531 59 586 86 655 28 Table 5 Standing heat losses DESIGN To minimise heat loss a 60mm thick void free layer of high performance polyurethane foam fills the space between the inner vessel and outer casing for maximum insulation efficiency and compliancy with future European wide legi
34. sfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer pen China THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE 1 Date Engineer Name Company Name SERVICE 2 Date Engineer Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 3 Date Engineer Name SERVICE 4 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 5 Date Engineer Name SERVICE 6 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 7 Date Engineer Name SERVICE 8 Date Engineer Name Company Name Telephone Number Company Name Telephone Number Comments Comments Signature SERVICE 9 Date Engineer Name Signat
35. slation The Coral Aquanox is supplied with an innovative casing which insulates the blending valve The carefully injection moulded one piece insulation can be fitted after installation for ease of plumbing The base is fully insulated and the unit stands on three moulded feet to minimise heat loss to the supporting floor Immersion heaters and controls are fully integrated with no large external bosses to radiate heat RECOMMENDATIONS To minimise the standing heat loss it is recommended that all exposed hot water pipework is insulated This will keep hot water hotter for longer and save energy 24 ENVIRONMENTAL 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 benefits Insulation is by means of an approved CFC HCFC free polyurethane foam with an ozone depletion factor of zero NOTES 25 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 of 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
36. uilding Regulations Yes Type of control system if applicable Y Plan S Plan L Other 1 Is the cylinder solar or other renewable compatible Yes No What is the hot water temperature at the nearest outlet All appropriate pipes have been insulated 1 metre or the point where they become concealed Yes UNVENTED SYSTEMS ONLY Where is the pressure reducing valve situated if fitted What is the pressure reducing valve setting M bar Has a combined temperature and pressure relief valve and expansion valve been fitted and discharge tested Yes No The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes Are all energy sources fitted with a cut out device Yes No Has the expansion vessel or internal air space been checked Yes No 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 Yes The system has been installed and commissioned in accordance with the manufacturer s instructions Yes The system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm sati
37. ure SERVICE 10 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature Sales amp Support Guarantee On site service support including parts and labour for 12 months from date of installation After the initial 12 months a guarantee will apply for a further four years for the stainless steel inner vessel only During this four year period in the event of a cylinder leak a replacement product will be issued provided that the replacement is carried out by one of our heateam engineers for which reasonable labour charges will apply The guarantee is valid provided that Ithas been correctly installed as per the instructions contained in the instruction manual and all relevant Codes of Practice and Regulations in force at the time of installation The Benchmark Checklist has been completed upon commissioning and the Benchmark Service Record is completed for each service It has not been modified in any way other than by ELSON It has not been frost damaged It has not been tampered with or been subjected to misuse or neglect The fault is not scale related Within 60 days of installation the user completes and returns the certificate supplied along with the proof of purchase to register the product It has been installed in the United Kingdom The fault is not caused by high c
38. vaporation during operation If the level in the feed and expansion tank should drop between services the flexible filling loop should be attached and the valve opened to let water slowly into the header tank This should be filled to the line indicated on the side of the units header section The filling loop should then be disconnected In the event of leak the only water that can be lost is the water held within the Thermal Store at that time Z a Eg j LY N L Y mg Sonn NI 8 Fig 10 Manual fill Version 2 NN Fill level of header tank with internal indicator Fig 11 Autofill Water Level a Upper Limit CORA MOX In A AQU Lower Limit Filling loop Fig 12 Manual fill Water Level 13 COMMISSIONING FILLING THE UNIT WITH WATER Ensure that all fittings and immersion heaters are corr
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