installation guide, operation and service manual
Contents
1. Installation 1 Installation 2 Installation 3 Model RSC150 Flueing Option Installation 1 Installation 2 Installation 3 Type of flueing C31 C31 C11 Flue restrictor 45mm 50mm 60mm A lt 2 0 gt 0 5m lt 1 0m B lt 1 0m lt 1 0m Model RSC190 Flueing Option Installation 1 Installation 2 Installation 3 Type of flueing C31 C31 C11 Flue restrictor 48mm 55mm no restrictor required A lt 2 0 gt 0 5m and lt 1 0m RSC150 amp RSC190 Flue Fitting Instructions 1 Fit heater adaptor D1 to heater ensuring correct location on primary flue spigot from heater Use 4 self tapping screws provided 2 Fit flue restrictor ring D7 into heater adaptor D1 The correct size of restrictor for each heater model and installation is shown on page 5 Fit flue section D2 into heater adaptor D1 Fit elbow D4 into flue section D2 for horizontal flue runs Determine correct position of flue outlet and fit outer wall plate and inner wall plate Fit flue outlet guard if required Fixings not supplied 6 Fit horizontal terminal D3 or make up lengths of flue required see page 5 into elbow D4 Each joint must be secured with a sealed clamp D6 7 For vertical installations fit flue lengths required see page 5 into heater adaptor D1 8 Determine correct position of flue terminal and fit either D8 or D9 roof plates 9 Fit D5 ver2. When used in an unvented system the Andrews storage water heater will supply hot WATER water at a pressure of 3 5 bar 50 8 psi providing this pressure is available at the mains feed During conditions of no flow whilst the burner is operating the pressure of the CONNECTIONS system will rise to a maximum of 6 bar 87 0 psi UNVENTED SYSTEMS When testing the system it is recommended that a maximum test pressure of 8 62 bar 125 psi be employed The Andrews range of storage water heaters can be used on unvented hot storage water systems with the addition to the standard heater of an Unvented Systems Kit Part No B213 obtainable from Andrews Water Heaters All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with the requirement G3 of the Building Regulations Fig 4 p11 lists and illustrates the component parts of the Unvented Systems Kit Fig 5 p12 illustrates the general arrangement of the components The Wall Mounting Kit is available as an optional extra Item F4 must be fitted into the Temperature Relief port see Fig 6 p13 When assembling items F1 and F2 care must be taken to ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn
3. uk ANDREWS WATER HEATERS INSTALLATION ia GUIDE a OPERATION AND SERVICE MANUAL 4 Natural Gas Fired Storage Water Heaters Room Sealed Appliance MODELS RSC 150 RSC 190 Permanent Pilot Auto Ignition THIS MUST B WITH THE hd 2 E 4 July 2007 Part No E104 MANUAL E KEPT APPLIANCE amp PlumbNation the nation s favourite for v FREE SHIPPING v SECURE PAYMENTS on all orders over 100 to mainland UK shop online with confidence v FINANCE AVAILABLE v PRICE MATCH spread the cost with low interest rates always get the best deals available we have HUGE REDUCTIONS ON THOUSANDS OF ITEMS Boilers Bathroom suites eee siecle aaah 2 Pipes amp fittings 000 Wet rooms Cylinders Towel warmers Fires Bathroom furniture Renewable energy amp much more C un visit our website 2 7 plumbnation co uk 0844 800 3460 Copyright Andrews Water Heaters 2007 va ANDREWS WATER HEATERS Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters Andrews Storage Water Heaters have been designed and manufactured to comply with current International standards of safety In the interests of the health and safety of personnel and the continued safe reliable operation of the equipment safe working practices m
4. oe Er pui row VOLT FREE COMSAT ph OPTIONAL TIMER x To ensure long life and efficient reliable performance from Andrews water heaters it is essential that the water heater is installed and serviced in accordance with the manufacturers instructions Each water heater is fitted with one or more magnesium anode s which protect the tank from corrosion caused by electrolytic action within water systems The magnesium anodes are sacrificial and as such they erode as they offer protection Once the anode has eroded to less than 50 of its original diameter it may not offer sufficient protection The anodes should be inspected on an annual basis and replaced as necessary The frequency of which the anode needs replacing can vary and water quality can have a major influence on this Andrews offer Correx UP powered anodes as an alternative to the traditional magnesium anodes Correx UP anodes are made from titanium and are non sacrificial therefore they do not have a requirement for maintenance or replacement However the potentiostat which regulates the protective current supplied to the Correx UP anode has an indicator light which shows green when the anode is functioning correctly and red if a malfunction occurs Correx UP anodes are available as an optional extra on all models of Andrews storage water heaters and tanks In hard water areas scale formation can occur in hot water systems and water heaters and
5. Flue Gas Volume 16m3 H 16m3 H Inlet amp Flow connections Rp BSP BSP Return connections Rp BSP Rp BSP Gas Connection Rp BSP Rp 4 BSP Maximum Working Pressure 10 bar 150 p s i 10 bar 150 p s i Maximum Test Pressure 20 6 bar 300 p s i 20 6 bar 300 p s i Burner Pressure 10 0 mBar 4 0 wg 10 0 mBar 4 0 wg Injector Diameter 2 87 mm 0 113 ins 3 05 mm 0 120 ins Flue Connection 80 125 80 125 Weight Empty 66 kg 145 Ibs 74 kg 163 Ibs Weight Full 216 kg 475 Ibs 264 kg 583 Ibs Shipping Weight 73 kg 162 lbs 82 kg 181 Ibs Shipping dimensions carton 1499 x 635 x 711 mm 59 x 25 x 28 in 1727 x 635 x 711 mm 68 x 25 x 28 in Maximum Test Pressure 20 6 bar 300 psi THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON Install in accordance with current British Standard Code of Practice 342 part 2 and British Standards 5440 5546 6644 6700 6798 and 6891 The location chosen for the heater must permit the provision of a satisfactory flue and an LOCATION adequate air supply A clearance of 300mm 2 should be left around the heater for fitting and servicing purposes and 762mm above the heater for removal of the flue baffle The above clearances are recommended for ease of servicing They can be reduced if necessary but a clearance of 30Omm 12 in must be left in front of heater for access to the burner and contro
6. used and to make available to users adequate information about their safe and proper operation REGULATIONS 1993 Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual Although the heaters have been manufactured with paramount consideration to safety the basic safety precautions highlighted in this manual must be observed by the user It is imperative that all users of the heater must be provided with all the information and instruction necessary to ensure correct and safe operation Water systems in buildings have been associated with outbreaks of Legionnaires Disease EFFECTIVENESS particularly in health care facilities where occupants are significantly more susceptible to infection IN COMBATING LEGIONELLAE In recognition of the risks in hospitals a Code of Practice for the Control of Legionellae in Health Care premises has been issued by the Department of Health 1991 Codes of Practice applicable to other premises have been published by other organisations principally the Health and Safety Executive HS G70 and the Chartered Institute of Building Services Engineers C1BSE TM13 All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria These factors include stagnation lukewarm conditions 20 C to 45 C and the accumu
7. Coil Replace if faulty PILOT LIGHTS BUT MAIN BURNER DOES NOT a Check for 24V AC at intermittent pilot ignition control terminal No 3 Replace control if faulty b Faulty Solenoid Coil Replace if faulty SECTION 8 PARTS LIST AND ILLUSTRATION RSC150 RSC190 Model RSC150 RSC190 Ref Part No Part No Description Qty A1 E080 E081 Data Plate 1 A2 E085 E086 Hot Outlet Nipple Anode 1 A3 E087 E088 Hydrojet Cold Inlet Dip Tube 1 4 247 247 3 4 NPT BSP Nipple 2 A5 C381 C381 Drain Cock 1 A6 C103 C103 3 4 Socket 1 A7 E089 E089 Combustion Chamber Seal Cover 1 A8 E090 E090 Cover Burner Access 1 A9 E091 E092 Flue Baffle 1 B1 E093 E094 Burner Assembly Comprising items B2 B3 B4 B5 B6 1 B2 E095 E095 Burner Supply Pipe 1 B3 E097 E097 Pilot Supply Pipe 1 B4 C126 C126 Thermocouple 1 B5 E099 E100 Injector 1 B6 E101 E101 Pilot Burner c w Jet Pipe Electrode amp Lead 1 B7 C252 C252 Pilot Burner Jet N18 1 B8 C514 C514 Piezo Ignitor 1 B9 C965 C965 Multifunctional Control White Rogers 1 B10 E016 E016 Thermostat Knob B11 C382 C382 Gas Cock 1 C1 E103 E103 Top Cover PARTS LIST AND ILLUSTRATION RSC150 RSC190 SECTION 8 Model RSC 150 RSC 190 Ref Part No Part No Description Oty D1 E072 E072 Heater Adaptor 1 D2 E069 E069 0 5m Flue 1 D3 E073 E073 Horizontal Terminal c w Wall Plates 1 D4 E071 E071 90 Bend 1 D5 E067 E067 Vertical Terminal 1 D6 E075 E075
8. Vented Systems Unvented Systems Gas Connections COMMISSIONING To Light the Burner To Shut Off the Burner To Check Main Burner Pressure To Light the Burner Auto Ignition To Shut Off the Burner Auto Ignition To Check Main Burner Pressure Auto Ignition OPERATION Operating Sequence ECO Energy Cut Off Auto Ignition SERVICING Burner Assembly Gas Control Valve Flueway Magnesium Anode Descaling Information FAULT FINDING SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL The Andrews Water Heater has been designed for use with NATURAL GAS only and is INFORMATION manufactured to give an efficient reliable and long service life To ensure the continued trouble free operation of your heater at maximum efficiency it is essential that correct installation commissioning operation and service procedures are carried out strictly in accordance with the instructions given in this manual By law installation and commissioning of the heater must be carried out by properly qualified personnel The heater s must be installed in accordance with the following requirements The current GAS SAFETY INSTALLATION AND USE REGULATIONS The current BUILDING REGULATIONS The WATER SUPPLY WATER FITTINGS REGULATIONS 1999 Additionally installation should be performed in accordance with all relevant requirements of the Gas Supplier Local Authority and recommendations of the British Standards and Codes of Practice detaile
9. and at gas inlet to appliance f Check cold inlet dip tube to see if it is broken or missing see Fig 10 PILOT FLAME a Try to light burner as detailed in lighting instructions IS OUT b Pilot will not light wait 3 mins and try again then see below a Check gas available b Check thermocouple replace if necessary Check inlet gas pressure as this may be too high or too low Inlet gas pressure to heater multifunctional control should be 17 5 mbar 7 Wg to 25 mbar 10 Wg d Pilot jet blocked clean or replace pilot jet e Faculty magnet replace multifunctional control f E C O safety thermostat operating at too low a temperature Replace multifunctional control BURNER WILL a Water already at correct temperature NOT LIGHT b Replace multifunctional control PILOT ESTABLISHED a Check pilot pipe for loose joints THERMOCOUPLE b Check that correct amount of fresh air ventilation is available BURNS OUT c Check that flue is clear and is correctly designed and fitted FREQUENTLY d Check for presence of halogen vapours see page 7 HEATER SOOTING YELLOW FLAME a Clean burner and injector b Flue obstruction clean flueways c Check flue design and termination position POOR d Check burner pressure COMBUSTION e Check for correct ventilation WATER a Reset thermostat to lower temperature TEMPERATURE b If water temperature is still too high replace
10. and the piezo ingnitor With the pilot burner alight hold the gas control knob for 20 seconds When the gas control knob is released the pilot should remain lit if not repeat the operation The pilot can be seen through the sight glass on the inner cover 4 Replace outer cover Set the temperature indication dial to the required temperature see below 6 Turn the gas control knob to ON the burner should now light if not repeat the operation see below UT Thermostat Setting 0 1 2 3 Approx Water Temperature a 104 F 40 C 125 F 143 F 62 C 159 F 71 C Correct size and shape CN of the pilot flame Note European Symbols 30 mm OFF Q PILOT X lt P ON 9 a J For long periods only eg holidays or periods of 7 days or more turn the gas control knob to PILOT position depress slightly and turn clockwise to OFF Turn off the gas service cock For shorter periods eg less than 7 days leave the heater under the control of the thermostat N B If the pilot should become extinguished for any reason turn off the appliance and wait three minutes before attempting to relight 1 Turn burner OFF as above 2 Remove brass cap from burner adjustment port see below 3 Release bleed screw A one turn and connect pressure gauge tube 4 Light burner according to the preceding instructions 5 Adjust burner pressure at screw B in accordance with data
11. Clamp with Seal 2 D7 E074 Flue Restrictor 45mm Vertical 1 D7 E076 Flue Restrictor 60mm Horizontal 1 D7 E077 Flue Restrictor 48mm Vertical 1 D7 E078 Flue Restrictor 50mm 1 D7 E107 Flue Restrictor 55mm 1 D8 E065 E065 Flat Roof Plate 1 D9 E066 E066 Angled Roof Plate 1 D10 E105 E105 Horizontal Flue Outlet Terminal Guard 1 Note Straight lengths of flue can be supplied to suit each installation requirements as shown on page 6 See below Part No Description E064 1m Flue E070 1m Cutable Flue E068 Wall Clamp E308 45 Elbow SECTION 8 PARTS LIST AND ILLUSTRATIONS 24 Volt Auto System Kit B217 24 Volt Auto Part No Description Qty System Kit B217 24 Volt Auto System Kit Complete 1 Standard Range 1 On Off Switch 1 C641 Mains Indicator Light 1 E113 Intermittent Pilot Ignition Control 1 E115 Transformer 1 E116 Limit Thermostat 1 E117 Control Thermostat 1 E120 Control Thermostat Knob 1 E114 Gas Valve 1 E126 Solenoid Coil 2 E127 Pilot Assembly 1 E128 Ignition flame Probe 1 E135 HT Lead 24 1 I mn ANDREWS WATER HEATERS Andrews Water Heaters Wood Lane Erdington Birmingham B24 9QP Tel 0845 070 1055 Fax 0845 070 1059 Sales 0845 070 1056 Technical 0845 070 1057 Service 0845 070 1058 Email andrews andrews waterheaters co uk www andrewswaterheaters co uk
12. Consideration must be given to the position of the high level ventilation opening A high level vent must not be sited within 300mm measured vertically of the flue terminal Grilles or louvers should be so designed that high velocity air streams do not occur within the space housing the heater s IMPORTANT The vapours given off by halogen based compounds can if drawn into the combustion air cause corrosion of the Storage Vessel and premature failure of the thermocouple If water heaters are to be installed in locations where halogens are likely to be present they should be isolated from such compounds and ventilated from and to outside uncontaminated atmosphere Some of the vulnerable areas are listed below i Hairdressing salons and adjoining rooms and basements ii Establishments where dry cleaning solutions are used or stored iii De greasing plants using hydrocarbon solvents iv Premises where refrigerant gases are used or stored ELECTRICAL External wiring to the water heater s must be installed in accordance with current SUPPLY Regulations for the wiring of buildings and to any Local Regulations that may apply AUTO IGNITION The Auto Ignition Heater is designed to operate from a 220 240V 1Phase supply UNITS The fuse rating is 5 amps The method of connection to the mains electricity supply should facilitate complete electrical isolation of the appliance preferably by use of an unswitched shuttered s
13. ING APPROX WATER TEMP Checking main burner pressure 1 Turn gas supply OFF 2 Release bleed screw A and connect pressure gauge tube 3 Light burner as described previously 4 Remove cap from port B and adjust pressure using exposed screw in accordance with data plate 5 Shut OFF burner as described previously Remove pressure gauge tube and tighten bleed screw A 6 Re light burner as described previously OPERATION SECTION 5 When properly installed and adjusted the Heater will require the minimum of attention Should it become necessary to completely drain the heater close the cold water inlet valve open a hot water tap to allow air to enter the system Fit a suitable hose to the drain cock and open Whenever the Heater is filled with cold water condensation will form on the cold storage vessel surfaces when the burner is lit Condensation is normal and does not indicate a leak It will disappear when the storage vessel becomes heated The gas control fitted to this heater has a built in limit thermostat ECO In case of high water temperature the gas supply will be automatically shut off The reason for such a high temperature must be investigated and corrected before the heater is relit The gas control is fitted with a recycling type ECO this means that once the water temperature has cooled sufficiently the ECO circuit will close and allow the heater to be relit If the gas control has to be changed
14. ance to ensure trouble free operation and continued satisfaction BURNER The burner assembly should be cleaned and checked annually as follows ASSEMBLY 1 Depress slightly the gas control knob and turn to OFF Remove the outer burner cover and the inner door Remove the IO fixing screws to remove the inner cover 2 Disconnect from the bottom of the control valve the pilot tube thermocouple and main burner supply tube Withdraw the burner assembly from the heater 3 Remove the screw securing the pilot assembly to the main burner 4 Remove the gland nut connecting the pilot tube to the pilot assembly Withdraw the pilot tube and remove the pilot restrictor from the end Clean the pilot restrictor with acetone and blow through the pilot burner with compressed air 5 Remove the two screws securing the main burner supply tube to the bottom of the burner to gain access to the main jet Remove the main jet and clean with acetone Blow through the main burner with compressed air DO NOT ATTEMPT TO CLEAN ORIFICES WITH SHARP METALLIC OBJECTS IF NECESSARY USE A WOOD SPLINTER TO CLEAR 6 Re assemble in the reverse order of steps 2 to 5 but note i Be sure to engage the rear section of the main burner supply pipe in its location bracket on the base pan of the heater i DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION SCREW IN FINGER TIGHT AND TIGHTEN A FURTHER 1 4 TURN USING A SPANNER 7 Turn the control knob to PILOT and depre
15. d below BRITISH STANDARD RANGE STANDARDS BS 6700 1997 Specification for design installation testing and maintenance of AND CODES OF services supplying water for domestic use within buildings and their PRACTICE curtilages This standard supersedes the following British Standards and Codes of Practice CP99 CP310 CP324 202 CP342 Part 2 Centralised Hot Water Supply BS 5440 1990 Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW BS 6644 Installation of gas fired hot water boilers of rated inputs between 60kW and 2MW BS 5546 1990 Installation of gas hot water supplies for domestic purposes BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic premises BS 7206 1990 Specification for unvented hot water storage units and packages I M2 Purging procedures for industrial and commercial gas installations 1 M11 Flues for commercial and industrial gas fired boilers and air heaters I M16 Notes on installation of gas pipework excluding 25mm and below BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 60kW NOTE Consideration should be given to amendments or updates to the above standards GENERAL AND SAFETY INFORMATION SECTION 1 It is the duty of manufacturers and suppliers of products for use at work to ensure so far HEALTH AND as is practicable that such products are safe and without risk to health when properly SAFETY
16. es elbows stop valve and pipework not supplied Unvented Systems Kit KE E Correct Sequence WATER 7 CONNECTIONS Hot water service Cold Water Take Off gt He al Cold Water Inlet Check Valve Fig 6 Y Typical Installation To drain Unvented System XC y GAS THE APPLIANCE MUST ONLY BE USED WITH NATURAL GAS CONNECTIONS The installation of the gas supply should conform to the requirements of IM 16 published by British Gas p l c or BS 6891 Jointing compound used must conform to BS 6956 Pt 5 CAUTION DO NOT APPLY HEAT IN CLOSE PROXIMITY TO THE GAS CONTROL THERMOSTAT AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL Fit a 1 2 gas supply cock immediately upstream of the gas control thermostat and connect to the gas supply Pressure test the gas installation for soundness If any doubt exists as to size of gas supply pipe consult your local Gas Region It is recommended that a pressure test point is fitted on the input next to the gas supply valve CAUTION DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER WITH WATER RUNNING FROM ALL HOT TAPS Open the main gas supply cock after all connections to the gas control thermostat are complete and test all connections with soap solution 1 Remove outer cover wait 3 minutes for any unburnt gas to vent 2 Turn the gas control knob to pilot see below 3 Fully depress the gas control knob
17. from the 22mm compression port on item F1 a The water pressure at this point will be similar to that available at the hot water outlet of the water heater If port a is not used it should be sealed with the blanking plug supplied If higher flow rates are required for the cold water services a suitable tee fitting should be included in the pipework upstream of item F1 The discharge pipe from the tundish should be of suitable metal and be at least one pipe size larger than the outlet pipe on the safety devices See Building Regulations Approved Document G3 Fig 4 Unvented Systems Kit Ref Part No Description Qty B213 Complete Unvented System Kit 1 Comprises F1 C780 Pressure Reducing Valve 1 F2 C781 Expansion Valve Check Valve 1 F3 E319 Expansion Vessel 1 F4 E320 Temperature Pressure Relief Valve 1 F5 E321 3a x Reducing Bush 1 F6 E322 Tundish 1 B229 Expansion Vessel Wall Mounting Kit Optional 1 Comprises F7 C788 Hose Assembly 1 F8 E323 Wall Bracket Assembly 1 7 N WATER CONNECTIONS Balanced Cold F3 Water Take off Expansion Vessel if required 4 Temperature Pressure Relief Valve 1 Cold Water Inlet to Water Heater F2 Check Valve Expansion Valve F1 Pressure F5 Reducing Reducing Bush Valve Strainer F6 Tundish A Cold Water Feed i 1 5 NB Te
18. ing when the burner is lit and should be rectified by chemical descaling DESCALING When descaling the water storage heater your attention is drawn to the following guidelines SAFETY FIRST DUE TO THE CORROSIVE NATURE OF THE DESCALE FLUID IT ITS ESSENTIAL THAT SUITABLE PROTECTIVE CLOTHING EQUIPMENT IS USED AND ADEQUATE VENTILATION IS AVAILABLE WHEN DESCALING 1 Turn gas control on water heater to OFF position and isolate the gas supply 2 Close water inlet valve and drain heater tank 3 Remove magnesium sacrificial anode s Note It is recommended that a new anode s is fitted 4 Add suitable hydrochloric based descale acid the requirement is normally 5 litres for standard range or more dependent on the amount of limescale present 5 After a minimum of one hour restore gas supply and turn on main gas burner for 2 minutes MAXIMUM 6 Isolate gas supply and drain off descale fluid through drain port 7 Open cold water feed valve and fill heater tank 8 Drain and flush out heater for minimum of 30 minutes 9 Replace anodes 10 Replace gas supply and re light heater sero CTD Fig 10 Removal of Cold Inlet Dip Tube amp Hot Outlet Nipple Anode FAULT WATER DOES NOT ACTION a Check gas cock is open b Check water valves are open PILOT WILL NOT BEN c Check that pilot is alight d Check thermostat setting Reset to higher temperature e Check gas pressures at burner
19. it must be replaced with an identical model having the same code number 1 When the thermostat senses too cool water a signal is sent to the control sequence unit AUTO 2 The pilot solenoid coil is energised and thus allowed to open Gas is allowed to pass to the pilot and ignition begins IGNITION 3 When the pilot flame is established the main gas solenoid is energised and allowed to UNITS open and the main burner is lit 4 When the control thermostat is satisfied both pilot and main gas solenoids are closed Temperature Stratification Stacking When small amounts of hot water are drawn repeatedly the thermostat responds to each feed of cold water and activates the main burners Each time this occurs more heat may be put back in the tank than was drawn off As this continues water in the upper level of the tank gets hotter than the thermostat setting This hotter water does not mix completely with the cold inlet water but rises in a chimney effect to the top of the tank Many repetitions of this over a short time period result in accumulation of excessively hot water in the upper part of the tank even when the thermostat control is within limits This is known as stacking If in doubt contact Andrews Water Heaters Whilst giving the following instructions for the care of the Andrews Water Heater we would recommend that an arrangement is made with your local gas region or installer to carry out periodic checks of the appli
20. lation of debris scale and corrosion in the base of tanks and calorifiers Andrews Water Heaters has commissioned an independent evaluation of their products to investigate their resistance to build up of legionellae bacteria Experiments were conducted to determine whether following a substantial challenge by legionellae pneumophilia after overnight and stagnation conditions the system was rendered free from viable recoverable legionellae It was found that at 61 C following a challenge of approximately 107 organisms per litre within one hour more than 99 999 of organisms had been killed After a subsequent stagnation period sampling did not reveal any residual contamination The design of the base of the water heater precludes legionellae colonisation even after build up of debris The burner positioning ensures that the water at the bottom of the heater reaches the same or higher temperature as in the rest of the heater Based on data obtained through experiment the Andrews Water Heater can be described as legionellae resistant as it is considered unlikely that at the temperature tested the organism would colonise the water heater and present a possible health risk SECTION 2 TECHNICAL DATA DIMENSIONS N AND CLEARANCES 170mm 6 F E 5 3 Fig 1 i 2 Appliance Dimensions Including 2 8 Standard Flue Run 5 8 Dimensions v Concentric Flue Minim
21. ls The flue baffle clearance should also be maintained if possible to avoid servicing problems The floor on which the heater is installed must be flat level and of sufficient strength to withstand the weight of the heater when filled with water and should satisfy the requirements of the Local Authority amp Building Regulations Any combustible material adjacent to the heater must be so placed or shielded as to ensure that its temperature does not exceed 66 C 150 F Detailed recommendations for flueing are given in British Gas Booklet IM 11 and FLUE SYSTEM BS 5440 part 1 The following notes are intended to give general guidance A horizontal or vertical flue kit is supplied with each heater Flue fitting instructions on page 6 Location The siting of the flue terminal is not critical with respect to the performance of the unit However areas where the discharge of combustion products would cause a nuisance should be avoided In accessible positions a suitable guard should be provided see page 6 Route The route of the flue is not critical with three installation options available See below for permissible flue lengths Where installation options 2 or 3 are used we recommend that the flue outlet can be installed in any configuration through 180 as long as proper service clearances are observed see fig 1 page 4 4 ES Fig 2 Typical Flue Installations and Permissable Flue Lengths 3 2 Mtrs 1 2 Mtrs
22. multifunctional control TOO HIGH WATER a Reset to higher temperature TEMPERATURE b Check gas pressures at burner and at gas inlet to appliance TOO LOW a Check gas pressures at burner and at gas inlet to appliance NOT ENOUGH b Check amount of water being used against recovery rate given on HOT WATER Data Plate 10 WATER DRIPPING FROM BASE OF HEATER a Check if water stops dripping when water in heater is hot If water stops problem is condensation caused by incorrectly designed flue or by tank cooling excessively i e more hot water being used than recovery rate of the heater b If water continues to drip when heater is hot Problem is a leaking joint or storage vessel 11 RUMBLING NOISE KETTLING a Scale formation in heater consult water treatment specialist Heater must be descaled and suitable water treatment provided to avoid problem re occurring 7 Disconnect pipe fittings and turn nipple anti clockwise to remove EN X Cm rl T zd i pid j E ia er 8 FAULT ACTION siad IGNITION NO a Check gas service cock is open UNITS IGNITION AT PILOT b Electrical ON OFF switch is not ON c Power to unit interrupted d Thermostat set too low e Check ECO for failure Reset f Check for 24V AC at intermittent pilot ignition control terminal No 1 Replace control if faulty g Faulty Solenoid
23. ocket outlet in conjunction with a fused three pin plug both complying with the requirements of BS 1363 Alternatively a fused double pole switch or fused spur box serving only the heater may be used The point of connection to the mains electricity supply should be readily accessible and adjacent to the appliance Connect the electrical supply to the main control panel terminal block via the cable glands in the base of the control panel Mains input cable should be 0 75mm 3 core and should be connected to the mains supply as detailed above It is recommended that screen cable is used where the volt free contacts are to be connected from an external supply This will eliminate the risk of possible interference from nearby high voltage cables g N 1 E I On i BK a 2 gm D au ia La T HE 1 Pr E je E Bj s v t tom xl u r 1 i i dg 55 1 m MG n TRA t LH n 1 Bb l Laar ETAT Ps TOT i pos Hoo WE E T idi i TN wr 1 4 ee cr m E S 6 EN sg PROT Aaa TIT 5 29 He le 4 1 pe 3 T D is ta va ovn Ot Fri Fre A a Bp HEEL i i E Lm
24. plate Turn screw clockwise to increase pressure and anticlockwise to decrease pressure Turn burner OFF Remove pressure gauge tube and tighten screw A Replace brass cap in burner pressure adjustment port see below NO GAS CONNECTIONS TO LIGHT THE BURNER Fig 7 Lighting Instructions TO SHUT OFF THE BURNER TO CHECK MAIN BURNER PRESSURE Fig 8 Burner Pressure Adjustment LIGHTING THE BURNER AUTO IGNITION a Thermostat Control ED E ET A On Off Switch kn i E BR Gas Control valve ud a zz SED ee x eT T Ensure gas supply is on Set thermostat control knob to the required water temperature See below Ensure time switch if fitted is in the ON position Move electrical ON OFF switch to ON and the burner will light Check pilot and main gas connections at gas control valve using leak detection fluid whilst burner is alight Turn OFF seal any leakages then re test gt Shutting OFF burner To shut OFF the burner move switch to OFF then turn OFF the gas service cock The water heater should only be turned OFF for long periods eg holidays or in an emergency Otherwise the heater should be left to operate under normal thermostat control NB When using a time control ensure the heater is not turned OFF before the final water draw off occurs This will ensure the water in the tank is left in a hot condition THERMOSTAT SETT
25. s fitted the minimum actual capacity allowed for a feed cistern is 227 litres 50 gal The actual cistern capacity is the capacity to the normal water line of the cistern All cisterns used should be to the relevant British Standard and the distance from the normal water line to the top of the cistern should be as laid down by the water authorities The cold water inlet and hot water outlet are identified on top of the heater Connect the cold water feed and hot water outlet to these nipples with union adaptors for ease of servicing CAUTION DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS MAKE THE CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER A DRAIN COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE BOSS AS SHOWN ON THE DRAWING After installation of the water system open the main water supply valve flush the system and fill the heater Open the hot taps to allow air to escape from the system When the system is free of air close the taps and check for leaks at the control thermostat drain cock and pipe connections at the top of the heater e Stop Valve Open Vent N Cold Water Feed Cold Water Cistern Cold Water Inlet Valve Hot Water Service Pipe Union Adaptor ANDREWS Gas Control Thermostat Secondary Return Fig 3 Typical Installation Vented System Check Valve
26. ss Using a leak detection fluid check the joints at both ends of the pilot supply tube Seal if necessary 8 Allow 3 minutes for any unburnt gas to disperse and light the pilot flame check that the flame is correct see Fig 7 and turn the control knob to ON the main burner will light 9 Check the main burner tube connection at the control valve with leak fluid and seal if necessary Replace the outer cover GAS This should be checked and serviced by an engineer fully conversant with every aspect of this piece of equipment CONTROL VALVE To remove gas control first drain appliance disconnect gas pipe union and turn Fic 9 control anti clockwise taking 15 care not to damage threads Replacement of knobs or the valve itself Gas Control The burner should be checked annually The flueway and baffle should be checked if FLUEWAY sooting occurs and if necessary cleaned as follows 1 Depress slightly the gas control knob and turn to OFF Remove outer burner cover and inner cover Remove the fixing screws to remove the inner cover Disconnect burner gas tube pilot tube and thermocouple at gas control Remove burner assembly complete with pipes and thermocouple lead Remove flue assembly and flue box on heater to reveal flue baffle Inspect and clean the secondary flue installation as necessary Lift out the baffle from inside the central flueway Clean the flueway with a brush and clean an
27. the higher the temperature of operation and the higher the volume of water used the more problematic this scale build up can be Water treatment is normally recommended when the hardness reaches 100 150 ppm 7 10 degrees Clark and above a number of water treatment devices are available When specifying or installing Andrews water heaters in hard water areas we would recommend that a specialist in this area of operation is consulted Contact Andrews Water Heaters for further information am the system works The upper jet ports direct the flow outward to begin the dynamic mixing action The lower jet ports direct the flow inward to increase the turbulence WATER CONNECTIONS WATER QUALITY AND TREATMENT HYDROJET SYSTEM The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet dip tube The tube is designed to increase turbulence and reduce sediment build up reduce thermal stacking and increase delivery WATER The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 Local CONNECTIONS regulations and bye laws must be observed when installing the system but typical water VENTED SYSTEMS service layouts are shown in Fig 3 The cold water feed cistern must have an actual capacity greater than the hourly recovery rate of the heater or heaters to which it i
28. tical terminal through roof plate into vertical flue pipe 10 Fit D6 sealed clamps on all joints 11 On all installations the lengths of flue pipes may be cut to obtain correct length of flue route required 12 See parts list on page 20 for part numbers and description of flue available a Components Supplied In Flue Kits AIR SUPPLY he following notes are intended to give general guidance AND Where the heater is to be installed in a room NO VENTS ARE REQUIRED VENTILATION where the heater is to be installed in a compartment permanent air vents are required in the compartment at high and low level These air vents must either communicate with a room or internal space or be direct to outside air The minimum effective areas of the permanent air vents required in the compartment are as follows Air Vents Areas Position of Air from room or Air direct from Air Vents internal space outside High Level 10cm per kW 5cm per kW Low Level 10cm per kW 5cm per kW In a Room or ere Internal Space No requirement for ventilation Note Both air vents must communicate with the same room or internal space or must both be on the same wall to outside air Air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour
29. um Service Clearance External Flue diameter 125mm 5 Return Via Drain Port er Internal Flue diameter 80mm 3 P ANDREWS MODEL NO i RSC 150 RSC 190 SI Metric Imperial SI Metric Imperial Height of Heater 1264 mm 494in 1492 mm 58 in Diameter 508 mm 20 in 508 mm 20 in Gas Connection 378 mm 1476 378 14 in Height to Centre of Flue 2118 mm 85in 2398 mm 94 in Service Clearance 1226 mm 48 in 1226 mm 48 in Standard Flue Run 750 mm 29 in 750 mm 2916 Height to Flue Centre 854 mm 33 in 854 mm 33 in I 9 gt Standard 90 Elbow 194 mm 7 194 7 Service Clearance 305 mm 12 in 305 mm 12 in Service Clearance Front 610 mm 24 in 610 mm 24 in K We recommend that the flue outlet can be installed in any configuration through 180 as long as proper service clearances are observed L Water Connection GRS 200mm 7 200 7 M Flue Terminal 170mm 6 in 170mm 6 in Storage Capacity 150 litres 33 gallons 190 litres 42 gallons Recovery through 44 C 80 F 159 35 gph 181 I hr 40 gph Recovery through 56 C 100 F 127 hr 28 gph 145 I hr 32 gph Heat Input 9 5 kw 32 414 Btu hr 10 5 kW 35 826 Btu hr Heat Output 8 2 kW 27 978 Btu hr 9 4 kW 32 073 Btu hr Gas Flow Rate 0 88 m3 hr 31 32 ft3 hr 0 98 m3 hr 34 62 ft3 hr Gas family DH Natural Natural Flue Gas Temp Approx 180 C 180 C
30. ust be employed at all times The attention of U K users is drawn to their responsibilities under the Health and Safety Regulations 1993 All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst completely up to date at the time of publication may be subject to revision without prior notice Further information and assistance can be obtained from Andrews Water Heaters Wood Lane Erdington Birmingham B24 9QP Tel 0845 070 1055 Fax 0845 070 1059 Sales 0845 070 1056 Technical 0845 070 1057 Service 0845 070 1058 Email andrews andrews waterheaters co uk www andrewswaterheaters co uk THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL ARE FOR USE WITH NATURAL GAS ONLY 2 SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 GENERAL AND SAFETY INFORMATION General Information British Standards and Codes of Practice Health and Safety Regulations 1993 Effectiveness in Combating Legionellae TECHNICAL DATA Location Flue Systems Air Supply and Ventilation Electrical Supply Auto Ignition Water Connections Water Quality amp Treatment Hydrojet Systems
31. y deposit from the underside of the storage vessel bottom and from the flue baffle Re assemble in the reverse order IT IS IMPORTANT THAT THE BURNER IS CORRECTLY LOCATED IN THE BURNER SUPPORT BRACKET ON BASE OF COMBUSTION CHAMBER DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION Screw in hand tight and tighten an extra 1 4 turn with a spanner 9 Re light and carry out commissioning check as above MOU BRUN IMPORTANT A magnesium sacrificial anode is fitted into the top of he water storage vessel MAGNESIUM The function of the anode is to provide additional corrosion protection for the inside of the ANODE vessel The condition of the anode should be checked at least annually during servicing The original diameter of the anode is 22mm 7 8 If at any point along its length the anode is eroded to half or less of the original diameter it should be replaced with new Particular attention should be paid to the extreme ends The anode hot outlet nipple can be unscrewed from the top of the heater see page 20 If the anode is encrusted with limescale it should be either cleaned by wire brushing to reveal bright metal or replaced Where correx anodes are fitted no anode maintenance is required CLEANING THE STORAGE VESSEL Scale formation in the base area of the storage vessel which may occur in hard water areas It is usually associated with high usage and high water temperatures It is characterised by a rumbling noise kettl
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