Installation Manual
Contents
1. BSP BOSS COIL DN20 WITH 922MM PLAIN CONNECTIONS IMMERSION HEATER 1X BSP 3KW 1 PHASE TWIN THERMOSTAT INLET 22MM PLAIN CONNECTION WITH DIFFUSER BSP BOSS COIL DIMENSIONS mm CAPACITY Excelsior Solar Indirect Cylinder with external expansion BSP TEMPERATURE amp PRESSURE RELIEF VALVE OUTLET 22MM PLAIN CONNECTION BSP BOSS BSP BOSS AUX COIL DN20 WITH 22MM PLAIN CONNECTIONS TWIN THERMOSTAT SOLAR COIL DN20 WITH 22MM PLAIN CONNECTIONS IMMERSION HEATER 134 BSP 3KW 1 PHASE TWIN THERMOSTAT INLET 22MM PLAIN CONNECTION WITH DIFFUSER BSP BOSS 2 4 Excelsior Heat Pump Range Excelsior Heat Pump Cylinder single coil with external expansion OUTLET 22MM PLAIN CONNECTION BSP TEMPERATURE amp PRESSURE RELIEF VALVE BSP SENSOR CONNECTION COIL DN25 WITH 28MM PLAIN CONNECTIONS SEE TABLE FOR COIL CAPACITY TWIN THERMOSTAT INLET 22MM PLAIN CONNECTION IMMERSION HEATER 134 BSP 3KW 1 PHASE XX BSP SENSOR CONNECTION COIL CAPACITY Excelsior Heat Pump Cylinder twin coil with external expansion A N WN OUTLET 22MM PLAIN CONNECTION BSP TEMPERATURE amp PRESSURE RELIEF VALVE 3 BSP SENSOR CONNECTION COIL DN25 WITH 28MM PLAIN CONNECTIONS SEE TABLE FOR COIL CAPACITY TWIN THERMOSTAT IMMERSION HEATER 1X BSP 3KW 1 PHASE COIL DN20 WITH 22MM PLAIN CONNECTIONS SEE TABLE FOR COIL C2. Sleeved through wall Discharge below fixed grating Z Fixed grating at least 1 in 200 Trapped gully ENT al A ee tundish with continuous fall of 20 3 6 Commissioning Commissioning a newly installed cylinder with an internal or external air gap 1 Before turning on the mains supply to the cylinder a hot water tap should be opened preferably on the same floor or the floor below where the cylinder is located 2 Turn on the supply to the cylinder and fill until water runs from the open hot water tap 3 Close the hot water taps and bring the cylinder up to working pressure Draining Switch off electrical power to the immersion heaters and or shut down the boiler Close the stopcock valve to isolate the Excelsior unit Attach a hosepipe to the drain cock having sufficient length to take water to a suitable discharge point Open the drain cock Open the hot water tap nearest to the Excelsior unit If water fails to drain from the Excelsior unit vent the system by opening the temperature and pressure relief valve Scale In hard water areas lower water temperatures can result in less scale being deposited If a water softener is used it should be capable of flows of approximately 50Ltrs min this will maintain maximum performance of the Excelsior unit If no descaler or softener is used then the heating element s will need descaling periodically for maximum efficiency and t
3. installation Manual EXCELSIOR Unvented Water Heater SS mS n S m NS SS T ASKS SS i yy S lt mi T N mi S Water heating systems fabdec Contents Section 1 1 1 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 3 1 3 2 3 3 3 4 3 5 3 6 10 11 Title Introduction Specifier s Guide Standard Equipment Dimensions amp Performance Excelsior Direct amp Indirect Internal Excelsior Direct amp Indirect External Excelsior Solar Range Excelsior Heat Pump Range Excelsior Buffer Range Excelsior Horizontal Direct Range Excelsior Horizontal Indirect Range Installation Instructions Installation Requirements Recommended Installation Schematics Wiring Instructions Tundish Discharge Pipework Commissioning Warranty Servicing amp Maintenance Fault Finding Spare Parts Disposal Commissioning Checklist Service Record Contact Information Page 10 11 11 13 14 15 16 18 18 19 20 21 22 23 24 25 25 26 27 Rear cover 1 Introduction The Excelsior unvented water heater is a high quality stainless steel unvented cylinder which can provide hot water from a cold mains water supply of between 1 5 bar and 16 bar The indirect heat exchanger surfaces are designed to provide a rapid heat up time The unit comes complete with all the necessary safety equipment to comply with legislation governing the installation of such systems The Excels
4. amp Handling If the cylinder is not being installed immediately it should remain in its protective wrapping with all pipe end protective caps in place to prevent damage Connecting the Water Supply Pipework is not supplied All pipework should be installed using good plumbing practice We recommend 22mm mains cold water supply is used Install a stop cock valve before the cold water inlet assembly on the incoming mains water supply so the unit can be isolated if required 11 Cold Water Valve The combined cold water valve supplied can be connected anywhere on the cold water mains prior to the unit It can be located at a point near to where the mains supply enters the premises if this is more convenient When installing the cold water valve ensure that the arrow is pointing in the same direction as the mains water supply flow when connecting see figures 5 and 6 The cold water balancing port on the valve allows you to connect the cold water mains to the rest of the property thus giving balanced pressure throughout If this facility is not required leave the cap on Check Water Pressure amp Flow Rates Fabdec suggests 1 5 bar pressure amp 20 litres minute flow rate to be the minimum requirements for satisfactory operation The unit will still operate below this but it will not be possible to run two or more outlets at the same time The mains supply must not exceed 3 bar If it does a special pressure reducing valve will be requi
5. CYLINDER AND SEPARATE HEAT SOURCE THE SOLAR SYSTEM IS CONFIGURED TO HEAT THE WATER TO ITS MAXIMUM ECONOMIC TEMPERATURE WHICH MAY VARY WITH AMBIENT TEMPERATURE AND WEATHER CONDITIONS THE IMMERSION MAY BE PROGRAMMED TO OPERATE DURING FIXED PERIODS OF THE DAY OR NIGHT IF THE HOT WATER RUNS COOL IT MAY BE NECESSARY TO MANUALLY SWITCH ON THE IMMERSION TO HEAT THE WATER PLEASE SEE THE RELEVANT INSTRUCTIONS FOR YOUR ALTERNATIVE ENERGY DEVICE 21 4 Warranty Fabdec Ltd guarantee the immersion s and controls for a period of 1 year from date of purchase excluding any failure caused by lime scale providing that they have been installed for their intended use by a competent person and have not been modified in any way In addition Fabdec Ltd guarantees domestic stainless steel inner hot water cylinders for a period of 25 years and commercial cylinders for 5 years from the date of purchase against faulty material or manufacture provided that a The vessel has been installed by a competent person in accordance with this manual and all current regulations and codes of practice in place at the time of installation b It has been used solely for the purpose of heating potable water that complies with current at the time of installation EU standards and is not fed with water from a private source C It had not been modified in any way d Ithas not been subjected to excessive pressure or electrolytic action from dissimilar materials or att
6. From table 1 overleaf Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from G1 2 temperature relief valve is 9m Subtract the resistance for 4 No 22mm elbows at 0 8m each 3 2m therefore the permitted length equates to 5 8m This 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 valve equates to 18m Subtract the resistance of 4 No 28mm elbows at Im each 4m Therefore the maximum permitted length equates to 14m As the actual length is m a 28mm D2 copper pipe will be satisfactory 19 Figure 13 Typical discharge pipe arrangement IMPORTANT THE DISCHARGE WILL CONSIST OF SCALDING WATER AND STEAM ASPHALT ROOFING FELT AND NON METALLIC RAINWATER GOODS MAY BE DAMAGED BY SUCH DISCHARGES Metal discharge pipe D1 from temperature relief valve to tundish Tundish 300mm min Table 1 Sizing of copper discharge pipe D2 for common temperature amp pressure relief valve sizes Valve outlet size Minimum size of Minimum size of Minimum resistance allowed Resistance created by discharge pipe D1 discharge pipe D2 expressed as a length of straight pipe each elbow or bend i e no elbows or bends Metal discharge pipe D2 from to 28mm 35mm ca Ur to 9m Om Safety device _ 7 e g temperature relief valve
7. and permanently marked to identify the product and performance standard e g as specified in the relevant part of BS 7291 1 2006 Thermostatic pipes and fittings for hot and cold water for domestic purposes and heating installations in buildings General Requirements Termination of discharge pipe 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 Examples of acceptable discharge arrangements are To a trapped gully with the end of the pipe below a fixed grating and above the water seal Downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility 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 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 The example below is for a G1 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length of 7m from the tundish to the point of discharge
8. port valve should be wired to the thermostat see Figure 7 or 8 depending on required configuration Connect the live supply to the thermo cut out and connect the brown wire of the two port valve to terminal 1 on the thermostat see Figure 11 Earth and Neutral supplies can be connected directly to the valve The orange wire of the two port valve should be connected to the central heating boiler and the cylinder thermostat set to 60 The power supply to the pump station should be connected via the lower valve Figure 11 Twin thermostat wiring 3 4 Tundish The tundish supplied must be fitted so it is visible to the occupier The discharge pipe must be 22mm copper pipe Regulations do not permit more than 3 x 90 degree bends between the Excelsior unit and the outflow Between the temperature amp pressure relief valve and the first 90 degree bend there must be a fall of at least 300mm The fall of the pipework must be continuous and the pipe should terminate in the gully or be bent backwards onto an outside wall in a place where discharge cannot be injurious to persons If you need to site the Excelsior unit in the middle of the house your discharge pipe to the tundish can be as far away as 9m which in most cases is enough to run the final discharge point After 9m increase the pipe size to a greater diameter than 22mm and accordingly for subsequent 9m lengths see table 1 Figure 12 Tundish Installation IMPORTANT REGULAR CHECKS SHOU
9. 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 Replacing air gap if lost during service internal air gap no expansion vessel 1 Turn off the mains supply to the unvented hot water cylinder 2 Open a hot water tap preferably on the same floor or the floor below where the cylinder is located 3 Operate the temperature and pressure relief valve until water stops flowing from tap 4 Close the hot water tap and temperature and pressure relief valve 5 Turn the mains supply back on and bring the cylinder up to working pressure Replacing air gap if lost during service external air gap expansion vessel fitted 1 Turn off the mains supply to the unvented hot water cylinder 2 Open a hot water tap preferably on the same floor or the floor below where the cylinder is located to relieve pressure Check pressure within expansion vessel Re pressurise to 3 0 bar if required Close the hot water tap e Turn the mains supply back on and bring the cylinder up to working pressure DENCHMAH THE OF QUALITY FOR THE INSTALLATION COMMISSIONING A SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 23 6 Fault Finding WARNING Disconnect electrical supply before removing any electrical equipment cover Fault Possible cause Remed The cylinder cools
10. the Building Regulations Type of control system if applicable Y Plan sPal Is the cylinder solar or other renewable compatible Yes wel 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 Signature To confirm satisfactory demonstration and receipt of manufacturer s literature SERVICE 1 Date Engineer Name Com Name Telephone Num
11. APACITY TWIN THERMOSTAT INLET 622MM PLAIN CONNECTION BSP SENSOR CONNECTION 2 5 Excelsior Buffer Range Excelsior Buffer Cylinder with external expansion BSP BOSS HEATING CAPACITY KW BSP TEMPERATURE amp PRESSURE RELIEF VALVE 2Z2MM PLAIN CONNECTIONS 4NO 1 BOSS FOR FITMENT OF IMMERSION HEATER 2 6 Excelsior Horizontal Direct Range Excelsior Horizontal Direct Cylinder with external expansion 34 BSP OUTLET 134 BSP IMMERSION BSP DRAIN PLUGGED HEATING CAPACITY INLET OUTLET TEMPERATURE amp PRESSURE RELIEF VALVE IMMERSION HEATERS SADDLE 2 7 Excelsior Horizontal Indirect Range BSP OUTLET BSP OUTLET Excelsior Horizontal Indirect Cylinder with external expansion B INLET Y T amp P OUTLET TEMPERATURE dg amp PRESSURE RELIEF VALVE IMMERSION HEATERS 134 BSP IMMERSION COIL HEAT HEATERS EXCHANGER 34 BSP COIL SADDLE W BSP DRAIN DRAIN PLUGGED HEATING DIMENSIONS mm CAPACITY m I I e ss s 6 ss ios 6 55 252 6 55 ss 5 6 55 152 os 6 5 208 Excelsior Horizontal Twin Coil Cylinder with external expansion INLET OUTLET TEMPERATURE er amp PRESSURE RELIEF VALVE 34 BSP COIL THERMOSTAT IMMERSION HEATERS 134 BSP IMMERSION HEATERS COIL HEAT 3A BSP COIL SADDLE BS
12. LD BE CARRIED OUT TO ENSURE THAT THE EXPANSION VESSEL IS ALWAYS CORRECTLY PRESSURISED TO 3 5 BAR From temperature amp pressure relieve valve From expansion relief valve Tundish D2 discharge pipe 18 3 9 Discharge Pipework G3 Requirement there shall be precautions to ensure that the hot water discharged from safety devices is safely conveyed to where it is visible but will not cause danger to persons in or about the building G3 Guidance Section 3 5 The discharge pipe D1 from the vessel up to and including tundish is generally supplied by the manufacturer of the hot water storage system Where otherwise the installation should include the discharge pipe s D1 from the safety device s In either case the tundish should be vertical located in the same space as the unvented hot water storage system and be fitted as close as possible to and lower than the safety device with no more than 600mm of pipe between the valve outlet and the tundish See Figure 13 The discharge pipe D2 The discharge pipe D2 from the tundish should Have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework see Figure13 Be installed with a continuous fall of at least 1 in 200 thereafter The discharge pipe D2 should be made of metal or other material that has been demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly
13. LER PUMP 16 Fitting the immersion heaters The heating element is fitted with a control thermostat which allows the water temperature to be set and a thermal cut out for safety see Figure 9 The unit is designed to screw into the 1 boss fitted to the unit An O ring is supplied as the seal and must be fitted against the flange of the element Take care not to cross thread and DO NOT use any other type of seal Replacement elements can be obtained through your authorised service agent Immersion Heater Excelsior Solar Secondary circuit connections MUST be made to the cylinder in accordance with the recommended installation diagram A drain cock should be fitted in the cold water inlet to facilitate draining of the cylinder Not supplied IMPORTANT ENSURE THAT THE IMMERSION HEATER THERMOSTAT IS SET TO A MAXIMUM OF 60 Figure 9 Immersion Heater Connections and Control Thermostat Settings Key connections A Live terminal B Neutral terminal E Protective Earth PE terminal Key approximate thermostat settings 1 16 2 35 3 45 2 55 preset position 5 68 C 3 Safety 85 C 5 Fitting the twin thermostat Figure 10 Cylinder Thermostat amp Thermal Cut out Connections Refer to wiring diagrams for correct installations Housing Twin Thermostat Insert probes through hole in housing Secure front face using self tapping screws provided 17 Two Port Valve The two
14. P DRAIN PLUGGED HEATING CAPACITY 10 3 Installation Instructions 3 1 Installation Requirements WARNING UNDER NO CIRCUMSTANCES MUST THE FACTORY FITTED TEMPERATURE PRESSURE RELIEF VALVE BE REMOVED THIS WILL INVALIDATE ANY GUARANTEE OR CLAIM THE COLD WATER INLET VALVE ASSEMBLY MUST BE FITTED OR THE EXCELSIOR UNIT WILL NOT PERFORM SATISFACTORILY DO NOT ATTEMPT TO VENT THE PRIMARY CIRCUIT THROUGH THE EXCELSIOR UNIT ALL EXTERNAL HEAT SOURCES SHOULD BE INSTALLED TO MANUFACTURERS INSTRUCTIONS AND THE PRIMARY CIRCUIT THROUGH THE EXCELSIOR UNIT MUST BE PUMPED Benchmark Scheme Checklist 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 The Benchmark Code of Practice is available from the Heating and Hot Water Industry Council who manage and promote the scheme Visit www centralheating co uk for more information Please ensure that the installer has fully completed the Benchmark Checklist on the inside back pages of the installation instructions supplied with the product 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 R
15. VALVE IMMERSION HEATER 134 BSP 3KW 1 PHASE INLET 622MM PLAIN CONNECTION WITH DIFFUSER IMMERSION HEATER 124 BSP 3KW 1 PHASE HEATING CAPACITY Excelsior Indirect Cylinder with internal expansion OUTLET 22MM PLAIN CONNECTION WITH DIP PIPE BSP TEMPERATURE amp PRESSURE RELIEF VALVE COIL DN20 WITH 022MM PLAIN CONNECTIONS SEE TABLE FOR COIL CAPACITY INLET 622MM PLAIN CONNECTION WITH DIFFUSER TWIN THERMOSTAT IMMERSION HEATER 1 BSP 3KW 1 PHASE COIL CAPACITY 2 2 Excelsior Direct and Indirect Cylinders External Excelsior Direct Cylinder with external expansion OUTLET 22MM PLAIN CONNECTION BSP TEMPERATURE amp PRESSURE RELIEF VALVE IMMERSION HEATER 1 BSP 3KW 1 PHASE IMMERSION HEATER 1 BSP 3KW 1 PHASE INLET 22MM PLAIN CONNECTION WITH DIFFUSER HEATING CAPACITY Excelsior Indirect Cylinder with external expansion OUTLET 22MM PLAIN CONNECTION BSP TEMPERATURE amp PRESSURE RELIEF VALVE TWIN THERMOSTAT COIL DN20 WITH 22MM PLAIN CONNECTIONS SEE TABLE FOR COIL CAPACITY IMMERSION HEATER 1 BSP 3KW 1 PHASE INLET 22MM PLAIN CONNECTION WITH DIFFUSER COIL CAPACITY 2 3 Excelsior Solar Range Excelsior Solar Direct Cylinder with external expansion uno T BSP TEMPERATURE amp PRESSURE RELIEF VALVE OUTLET 22MM PLAIN CONNECTION BSP BOSS IMMERSION HEATER 134 BSP 3KW 1 PHASE
16. able parts 25 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 Telephone Number Address Cylinder Make and Model Commissioned by print name _ GL Registered Operative ID Number Company Name Telephone Number Company Address a 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 circuit a sealed or open vented system 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 Time and temperature controls have been fitted in compliance with Part L of
17. ack from any salt deposits e It has been installed indoors in a frost free environment f The cylinder is connected to a public water supply maintained by a local water authority g The warranty card is completed and returned to Fabdec Ltd within 90 days of installation h Theunit has been serviced annually i The log book has been filled in after each annual service This warranty is not transferable and does not include claims due to frost or lime scale damage This guarantee does not cover a procedure of flushing the system not in accordance to the WRAS guidelines pertaining to BS 6700 Proof of purchase will be required for any claim This guarantee does not affect your statutory rights 22 9 Servicing amp Maintenance Servicing and maintenance should only be carried out by a competent unvented hot water installer or Fabdec Ltd authorised personnel Before any work is carried out on the installation it must be isolated from the electricity supply Both the primary and secondary systems will contain very hot water that will scald therefore care should be taken when opening any joints seals or valves Only use spare parts authorised by Fabdec Ltd The use of other parts will invalidate the warranty Excelsior cylinders utilising internal expansion will require checking periodically to ensure the air gap is sufficient If the air gap requires replenishing follow the steps listed in the Commissioning section This product
18. ary water from the boiler to the indirect coil in the cylinder If the thermal cut out operates it must be reset manually Check the cylinder stat and or boiler stat Primary Circuit Excelsior Solar Excelsior solar cylinders are suitable for connecting to a solar collector system and where a twin coil is present indirect to a gas or oil central heating boiler WARNING SOLID FUEL OR WOOD BURNING BOILERS AND GRAVITY CIRCULATION SYSTEMS MUST NOT BE USED ON THE PRIMARY CIRCUIT OF AN UNVENTED HOT WATER SYSTEM The cylinder should be installed in accordance with the solar installation instructions for connection to the primary flow and return The Excelsior Solar range must only be connected to solar installations containing a hydraulic station with two non return valves one in the flow to the collector and one in the return This will prevent thermal siphoning of the heat transfer fluid when the pump is switched off Where two non return valves are not present or a hydraulic station is not used in the solar system a second two port valve must be installed into the flow of the solar coil and wired to the lower two port valve The Excelsior Solar is supplied with one two port motorised valve which should be connected in the flow to the auxiliary coil and wired to the upper twin thermostat of the cylinder Solar pump The lower twin thermostat should be connected in line with the solar pump power supply The factory fitted temperature and pressu
19. ber Comments SERVICE 3 Date Engineer Name Company Name Telephone Number Comments SERVICE 5 Date Engineer Name Company Name Telephone Number Comments SERVICE 7 Date Engineer Name Company Name Telephone Number Comments SERVICE 9 Date Engineer Name Company Name Telephone Number Comments SERVICE 2 Date Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Engineer Name Company Name Telephone Number Comments SERVICE 6 Date Engineer Name Company Name Telephone Number Comments SERVICE 8 Date Engineer Name Company Name Telephone Number Comments SERVICE 10 Date Engineer Name Company Name Telephone Number Comments Tero 108 010 11 Fabdec Ltd Grange Road Ellesmere Shropshire SY12 9DG Tel 44 0 1691 627200 Fax 44 0 1691 627222 Email sales fabdec com fabdec excelsior Installation 03 14 Fabdec GmbH Gerhardstrasse 5 45892 Gelsenkirchen Germany Tel 49 0 209 700 900 Fax 49 0 209 70090 20 Email germany fabdec com Fabdec LLC October Embankment 12 building 2 193091 Saint Petersburg Russia Tel 7 812 715 0102 or 7 921 977 5936 Email russia fabdec com
20. down overnight One pipe circulation in the case of Install a non return valve as close as short pipe networks with low pressure possible to the cylinder loss Primary heating is not working Boiler Air trapped in heat exchanger Vent air from heat exchanger circuit runs for a short period goes off then comes on again This is repeated until Heat exchanger surface too small Check data for boiler and cylinder The the cylinder reaches its target problem may be solved by increasing temperature the flow from boiler Only cold or lukewarm water comes Programmer set to heating only or not Set programmer to call for hot water out of taps switched on for hot water on demand Central heating boiler malfunction Check boiler operation If faulty consult manufacturers instruction manual High limit thermostat has tripped Check and re set The cause will need to be identified Pump malfunction Check wiring and or plumbing connections to pump If only cold water comes out of taps Check connections and have them hot and cold pipes may have been changed if necessary connected up incorrectl Intermittent water discharge through Expansion vessel has lost its charge Follow steps listed in Service amp tundish on warm up pressure vessels with external maintenance section expansion only Internal air gap needs replenishing Follow steps listed in Servicing amp maintenance section Continuous water discharge Pressure reducing valve PRV not Check pressure fr
21. e to Strainer safe position Balanced cold water draw off ee ee ce 6 Isolating valve lt Cold mains 14 Figure 4 Combination Valve Pressure reducing valve Water flow Water 4 Connection for Balanced take expansion vessel off port Figure 5 Inlet Group External Expansion Expansion relief valve Pressure II Safety valve reducing valva set at 6 Bar set at 3 Bar s B Expansion vessel To water Mig or HM SIE Balanced Drain cock Flexible hose Figure 6 Inlet Group Internal Expansion Expansion relief valve Pressure Safety valve reducing valve set at6 Bar set at2 Bar To 4 tundish Balanced take off port 15 3 3 Wiring Instructions WARNING ALL ELECTRICAL WIRING SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICAL CONTRACTOR AND MUST CONFORM TO THE LATEST IEE WIRING REGULATIONS DO NOT SWITCH THE POWER ON UNTIL THE UNIT HAS BEEN FILLED WITH WATER AND ALL WIRING HAS BEEN EARTHED SEE FIGURES 7 8 9 amp 10 Figure 7 S Plan Wiring Diagram TWIN STAT 2 PORT VALVE 2 PORT VALVE ROOM STAT T yi IH a Liva e I Earth S PLAN E E 2x2 PORT z ZONE VALVE d 1 l PROGRAMMER BOILER PUMP Figure 8 Y Plan Wiring Diagram w s ROOM STAT 2 PORT VALVE mi Mi if W L Uwe PN dmm Y PLAN 2 PORT amp tele 3 PORT n ZONE VALVE 2 iji iu PROGRAMMER BOI
22. egulations England and 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 THE OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND WATER SYSTEMS Siting the Excelsior unit Note Excelsior cylinders are designed for indoor use only The unit can be placed anywhere convenient Since it is connected directly to the mains water supply it is equally efficient on any floor ground first or second Avoid areas that may be subject to frost Try to keep pipe runs as short as possible for maximum economy especially hot water discharge pipes running down from the Excelsior unit The unit can be fitted into a conventional airing cupboard and does not require any additional insulation The water supply to the cylinder should be potable water direct from a public mains supply with any water treatment equipment functioning correctly Vertical cylinders If installing a vertical cylinder ensure it is fixed securely in an upright position for correct operation Horizontal cylinders If installing a horizontal cylinder ensure it is fixed securely with the temperature and pressure relief valve positioned at the top for correct operation Storage
23. ior Solar and Heat Pump unvented water heaters have been designed for use with all solar panels and ground or air source heat pump systems requiring a storage and heating vessel please ensure compatibility prior to installation 1 1 Specifier s Guide The Law amp Unvented It is legal to fit an unvented unit into any property There is no longer a requirement to have an old fashioned Tank in the Roof system The Benefits of Excelsior Duplex stainless steel High quality finish Low heat loss for maximum economy No sacrificial anode low maintenance The Benefits of Unvented Systems The Excelsior fills a bath in minutes and can run two at the same time The Excelsior can work off electricity Economy 7 or alternative energy systems A power shower without the noisy pump No tanks in the roof No ball cocks to jam or leak All your water hot and cold direct from the mains Site the Excelsior unvented water heater wherever convenient not suitable for solid fuel boilers refer to Siting the Excelsior unit in section 3 1 Excelsior Solar The Excelsior solar range is available in many vessel capacities in both direct electric or indirect models Each cylinder has been specifically designed for use with an alternative energy heating system and includes a large corrugated coil heat exchanger that provides optimum heat transfer from the alternative heat source to the water in the cylinder The Excelsior solar unvented water hea
24. o prevent damage User Instructions Fabdec Limited 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 Your Excelsior unvented hot water cylinder has been designed to give many years of trouble free service and is made from hygienic high grade stainless steel Where applicable it includes a 3kW electric immersion heater which heats the water to 60 once pre heating of the solar system is completed Excelsior Solar only The flow temperature of the hot water can be set to your requirements on the immersion heater ideally 60 maximum Higher temperatures can cause tripping of the high limit thermostat and introduce more energy loss from the cylinder When a hot tap is turned on there may be a short surge of water this is quite normal with unvented systems and does not mean there is a fault When you first fill a basin the water may sometimes appear milky This is due to very tiny air bubbles in the water which will clear very quickly WARNING IF COLD WARM WATER EXITS FROM THE TEMPERATURE AND PRESSURE RELIEF VALVE TPV OR FROM THE PRESSURE RELIEF VALVE PRV CALL YOUR INSTALLER OR THE EXCELSIOR CUSTOMER SERVICE CENTRE IF VERY HOT WATER EXITS FROM EITHER VALVE SWITCH OFF THE HEAT SOURCE IMMEDIATELY AND ISOLATE THE ELECTRICITY SUPPLY TO THE
25. om PRV Replace functioning properly cartridge if necessary Expansion relief valve not seating Manually lift the valve once or twice to correctly clear debris from the seat If this does not cure problem replace valve Temperature amp pressure relief valve Manually lift the valve once or twice to not seating correctly clear debris from the seat If this does not cure problem replace valve 24 7 Spare parts When ordering spare parts please contact Fabdec Sales Department and quote the part number required Description Fabdec Part Number Expansion vessel 12 Litre 951920 19 Litre 951921 24 Litre 951922 Expansion vessel bracket 951918 T amp P valve 7 bar 90 C 952318 15 22mm straight tundish 951917 3Kw Immersion heater 953409 22mm combination valve group 2 bar 953348 22mm combination valve group 3 bar 953349 22mm 2 port motorised valve 951878 Twin thermostat 951879A Twin thermostat pocket pre 2009 vessels 953356 Solar sensor pocket 9533565 Flexible hose 1000mm 951919 8 Disposal Disposal of packaging Those responsible for installing the cylinder are responsible for disposal of any transport packaging Observe national regulations Cylinder disposal You must not dispose of the cylinder or any of its accessories in normal domestic rubbish The cylinder and accessories must be disposed of in accordance with national regulations Recycling used parts Both the cylinder and transport packaging contain many recycl
26. re relief valve should not be removed from the cylinder or tampered with in any way The valve is pre calibrated to open at 7 bar or 90 C and any attempt to adjust it will invalidate the warranty and could affect the safety performance of the unit 12 Secondary Return where applicable Some Excelsior cylinders are fitted with a secondary return connection Secondary circuit connections must be made to the cylinder in accordance with the recommended installation diagram A drain cock not supplied should be fitted in the cold water inlet to facilitate draining of the cylinder see Figure 1 A swept tee is needed for all indirect models if secondary circulation is required and is fitted as per the illustration A non return valve must also be fitted to prevent backflow A pump will be required to circulate the hot water The return feed is in 15mm pipe and all work can be done on site not supplied IMPORTANT IF A SECONDARY CIRCULATION CIRCUIT IS INSTALLED THEN A LARGER EXPANSION VESSEL MAY BE REQUIRED TO HANDLE THE INCREASE IN WATER VOLUME CALCULATE THE ADDITIONAL WATER VOLUME AND CONTACT OUR CUSTOMER SERVICES DEPARTMENT REGARDING SUITABLE VESSEL SIZES Figure 1 Secondary Return l Secondary circulation pump Non return valve Check valve Cold inlet connection gt Cold water supply gt Swept tee Drain cock External Expansion Vessel where applicable This smaller tank is connected to the cold wa
27. red Consideration should be given to the routing of the discharge pipe and the location of the solar panel or alternative energy source where applicable Drain Tap A drain tap to drain the unit must be fitted to the cold water inlet pipe between the Excelsior cylinder and the cold water valve assembly at its lowest level possible see figures 2 3 and 5 Pipework to Taps Ideally a 22mm pipe should supply the outlets throughout the property with short lengths max 1 metre runs of 15mm going to baths showers and basin taps Smaller bore pipe can be used to suit taps Taps amp Fittings All taps and fittings incorporated into the unvented system should have a rated operating pressure of 7 bar or above Inlet Group The inlet group will vary depending on whether the vessel is fitted as internal or external expansion see figures 2 3 5 and 6 Primary Circuit The motorised valve supplied and the thermal cut out high limit stat must be fitted to the primary flow Use compression fittings only Operation of the cut out amp motorised valve To comply with regulations and to prevent the temperature reaching 100 C the thermal cut out supplied must be fitted The thermal cut out is wired in series to the cylinder thermostat When the thermal cut out senses an abnormal rise in temperature in the primary flow the electrical supply to the motorised valve will be cut and the valve will return to the closed position This will cut off the prim
28. rised valve indirect units only 2 Dimensions and Performance The diagrams on the following pages show the standard range of Excelsior vessels All dimensions are in millimeters unless otherwise stated Tolerance 10mm All unvented installations must comply with local building regulations England amp Wales G3 Building Regulations Scotland Technical Standard P3 Northern Ireland Building Regulation P5 Excelsior coil data is based on a max primary flow temperature of 80 Water flow and return temperature differential of 20 It is recommended that the back pressure in the coil is restricted to 0 3bar See table below for flow rates Coil information Coil size Maximum coil output Approximate coil surface Approximate coil volume Recommended flow rates kW area sq m Ltrs through coil Ltrs Min DN20 14 054 D720 4 2 DN20 20 07 3 3230 AJ X AZ A9 19 JV DN20 30 x 1100 40 4165 DN25 54 20 3095 28 DN25 81 __ 80 145 235 Note The vessel working volume is the gross volume minus the displaced volume of any coil heat exchanger or internal air gap 2 1 Excelsior Direct and Indirect Cylinders Internal Excelsior Direct Cylinder with internal expansion OUTLET 622MM PLAIN CONNECTION WITH DIP PIPE BSP TEMPERATURE amp PRESSURE RELIEF
29. ter inlet side of the vessel Mount the tank according to separate manufacturer s instructions provided with the external expansion vessel A suitable expansion vessel with a pre charge pressure of 3 5 bar is supplied with Excelsior cylinders with external expansion The expansion vessel should be Tee d off between the pressure relief valve and the cylinder see figure 2 and should always be positioned with the entry point at the bottom Installation should always be by means of a standard T connector ensuring no other valve is between this and the cylinder Adjust the pressure to 3 0 3 5 bar 13 3 2 Recommended Installation Schematics Figure 2 Installation Schematic External Expansion Hot water draw off 1 Temperature amp Pressure relief valve T amp P 2 Motorised valve 3 Tundish 4 Expansion vessel 3 5 Drain valve 6 Combination valve consisting S Non return valve Check valve Expansion relief valve Safety valve Pressure reducing valve 3 Bar Discharge pipe to Strainer safe position Balanced cold water draw off SS Dre e 7 Isolating valve lt Cold mains Figure 3 Installation Schematic Internal Expansion Hot water draw off 1 Temperature amp pressure relief valve T amp P 2 Motorised valve 3 Tundish C3 4 Drain valve 9 Combination valve consisting S Non retum valve Check valve Expansion relief valve Safety valve Pressure control valve 2 Bar Discharge pip
30. ter should only be used as part of a solar installation and configured as shown Additional safety devices may be required if the cylinder is operated with other heat sources Excelsior Heat Pump The Excelsior Heat Pump range has been specifically designed to optimise the output from the heat pump It is fitted with a corrugated coil heat exchanger that has a larger diameter than that used on the standard Excelsior cylinders Always ensure the correct type of cylinder is paired with the renewable heat source Failure to do this may result in the system being inefficient and in extreme cases cause failure of components Consult the heat pump solar installation manual prior to cylinder installation 1 2 Standard Equipment Check that all the components of your Excelsior unit are contained in the kit prior to installation Your Excelsior should include the following 3kW heating element incorporating control thermostat and re settable safety cut out Combination control valve comprising Line strainer non return check valve pressure reducing valve amp expansion relief valve Tundish 15mm female x 22mm female Temperature Pressure relief valve set at 90 and 7 bar pressure factory fitted Cylinder thermostat temperature control setting 30 70 indirect units only Thermal cut out set to operate at 82 5 indirect units only Expansion vessel with capacity to suit vessel size external expansion units only Moto
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