Redring DC3810 User's Manual
Contents
1. Discharge pipes must be left open to atmosphere not blocking the tundish The responsibility for supplying and fitting the discharge pipe from the tundish is that of the certified installer In general installation practice should be in accordance with the approved document G3 of schedule 1 of the building regulations 1991 VIZ 3 9 d 1 d 2 The discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge be of metal and Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i e discharge pipes between 9m and 18m equivalent resistance length should be at least larger than the nominal outlet size of the safety device between 18m and 27m at least 3 sizes larger and so on Bends must taken into account in calculating the flow resistance See Diagram and table on page 6 Have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework Be installed with a continuous fall Have discharges visible at both the tundish and the final point of discharge but where this is not possible or practically difficult there should be clear visibility at one or other of these locations Examples of acceptance discharge arrangements are Ideally below a fixed grating and above the water seal in a trapped gully Do2. DATE ADDRESS TEL NO REGISTRATION DETAILS Where applicable for unvented systems etc REG No ID SERIAL No etc APPLIANCE DETAILS MANUFACTURER MODEL CAPACITY LITRES SERIAL NO GENERAL INSTALLATION HAS A CHECK BEEN DONE FOR JOINT TIGHTNESS AND LEAKS YES NO HAS A CHECK BEEN DONE FOR ELECTRICAL SAFETY YES NO benchmark is supported by WATERHEATER MANUFACTURERS ASSOCIATION Storage Waterheater Installation Commissioning and Service Record Log Book To be retained by customer INSTALLER DETAILS APPLIANCE DETAILS COMMISSIONING RECORDS SERVICE INTERVAL RECORD IMPORTANT FAILURE TO INSTALL amp COMMISSION THIS APPLIANCE TO THE MANUFACTURER S INSTRUCTIONS MAY INVALIDATE THE WARRANTY This note does not affect your statutory rights
3. WHAT IS THE AVAILABLE BOILER FLOW TEMPERATURE C WHAT IS THE BOILER RETURN TEMPERATURE WHEN CYLINDER STORE IS SATISFIED BOILER PRIMARY SETTINGS IS THE VENT PIPE CORRECTLY INSTALLED YES NO WHAT IS THE STATIC HEAD IN METRES METRES WHAT IS THE CYLINDER THERMOSTAT SETTING 1 C ALL MAINS PRESSURE SYSTEMS WHAT IS INCOMING COLD WATER PRESSURE BAR HAS STRAINER IF FITTED BEEN CLEANED OF INSTALLATION DEBRIS YES NO HAS A WATER TREATMENT DEVICE BEEN FITTED YES NO IF YES TO ABOVE THEN WHAT TYPE UNVENTED SYSTEMS ONLY ARE T amp P AND EXPANSION VALVES FITTED AND DISCHARGE TESTED YES NO IS PRIMARY ENERGY CUT OUT FITTED NORMALLY 2 PORT VALVE YES NO WHAT IS OPERATING PRESSURE PRV SETTINGS BAR WHERE IS PRV SITUATED HAS STRAINER IF FITTED BEEN CLEANED OF INSTALLATION DEBRIS YES NO HAS EXPANSION VESSEL OR INTERNAL AIR GAP BEEN CHECKED YES NO WHAT IS THE CYLINDER THERMOSTAT SETTING C HAS THE SYSTEM BEEN EXPLAINED TO THE HOUSEHOLDER YES HAS THE SYSTEMS LITERATURE BEEN LEFT WITH THE HOUSEHOLDER YES NO ENGINEERS SIGNATURE CUSTOMERS SIGNATURE CUSTOMER DETAILS NAME ADDRESS TEL No INSTALLER DETAILS NAME DATE ADDRESS TEL NO REGISTRATION DETAILS Where applicable for unvented systems etc REG No ID SERIAL No etc COMMISSIONING ENGINEER DETAILS NAME
4. and opening hot tap Open the pressure and temperature relief valve to drain water from the top of the unit then close this valve Leaving the hot tap open and the main supply off pump the vessel using a schraeder valve connector via a footpump or motorised pump to 3 0 bar Remove pump open mains supply and close hot tap once water is running freely Run a hot tap and close If the pressure remains over 3 bar re calibrate the Pressure Reducing Valve and clean the strainer replacing if necessary Open the expansion valve cap to manually discharge water to ensure that it works making sure that it resets correctly Open the pressure and temperature relief valve cap to manually discharge water to ensure that it works making sure that it resets correctly In both cases ensure that discharge pipework is adequate to safely carry discharged water away If not check for blockages etc and clear Check that the controls of the hot water temperature do not allow the water to get hotter than 60 c STAINLESS INDIRECT UNIT WITH COMPONENT 1 D 3 4 Female boss for expansion vessel COLD MAIN IN THROUGH E THEN G D IS TEED OFF BETWEEN G AND THE UNIT HOT DRAW OFF TO TAPS 3 KW IMMERSION HEATER WITH MANUAL RE SET TEMPERATURE HIGH LIMIT CUT OUT TEMPERATURE AND PRESSURE RELIEF VALVE EXPANSION RELIEF VALVE PRESSURE REDUCING VALVE LINE STRAINER EXPANSION VESSEL SUPPLIED LOOSE NON RETURN VALVE PRIMARY CONNECTI
5. described in the manufacturer s instructions and in compliance with all the relevant codes of practice SERVICE 1 DATE ENGINEER NAME COMPANY NAME SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No TEL No ID SERIAL No ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No TEL No ID SERIAL No ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No ID SERIAL No COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No ID SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No TEL No ID SERIAL No ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE WHEN ALL OF THE ABOVE SERVICE HAVE BEEN COMPLETED PLEASE CONTACT YOUR SERVICE ENGINEER FOR AN ADDITIONAL SERVICE INTERVAL RECORD SHEET COMMISSIONING PROCEDURE INFORMATION IS THE PRIMARY SEALED OR OPEN VENTED SYSTEM Sealed Open IF SEALED THEN WHAT IS THE SYSTEM PRESSURE Hot Cold IF SEALED THEN WHAT IS THE CHARGE PRESSURE OF EXPANSION VESSEL
6. omm GUARANTEE Applied Energy Products Ltd guarantees the shell of the unit for 25 years The component parts including the expansion vessel are guaranteed for 2 years from date of purchase THE FOLLOWING INFORMATION IS IMPORTANT WITHOUT IT YOUR GUARANTEE MAY BE INVALID 1 Keep proof of purchase 2 Maintain log book on unit 3 Service annually 4 Ensure that installation has been carried out correctly by appropriately approved competent personnel following relevant Code of Practice 5 Installation must be in an appropriate location and use is restricted to potable water Please note that the extended guarantee is not transferable and rests with the original householder The above does not affect your statutory rights Every effort has been made to ensure that this information is correct Regulations may change and installers must adopt best current practice We reserve the right to alter or improve components or specification without notice We will endeavour to update web site details as changes happen TROUBLESHOOTING NO HOT WATER INDIRECT START I BOILER ON SWITCH ON 15 PROGRAMMER SWITCHED TO HOT WATER SET PROGRANME 15 MID POSITION VALVE IN CORRECT POSITION NE SET CHECK WIRING amp PLUMBING IS CORRECT 5 CONTROL TEMPERATURE SET AT 55 C 60 C RE SET gi IS ALL WIRING TO THE CONTROLS 0 REPLACE RE SET
7. ONS IMMERSION THERMOSTAT WITH HIGH LIMIT CUT OUT GAUGE umer gt STAINLESS DIRECT UNIT WITH COMPONENT 1 0 3 4 Female boss for expansion vessel COLD MAIN IN THROUGH E THEN G D IS TEED OFF BETWEEN G AND THE UNIT HOT DRAW OFF TO TAPS 3 KW IMMERSION HEATER WITH MANUAL RE SET TEMPERATURE HIGH LIMIT CUT OUT TEMPERATURE AND PRESSURE RELIEF VALVE EXPANSION RELIEF VALVE PRESSURE REDUCING VALVE LINE STRAINER EXPANSION VESSEL SUPPLIED LOOSE NON RETURN VALVE GUAGE nn m O w gt SIZING GUIDE amp SPECIFICATIONS CAPACITY NOM WEIGHT NOM WEIGHT INDIRECT APPLICATION DIRECT APPLICATION LITRES INDIRECT FULL DIRECT FULL HEAT UP TIME RE HEAT TIME HEAT UP TIME RE HEAT TIME TWIN BATH SINGLE BATH 3 BED gt me 2 BATH amp 2 SHOWERS TWIN BATH 20 1470 x 560 300kg 33mins 24mins 108mins 63mins 3 BATH amp 2 SHOWERS TWIN BATH amp SHOWER 20 1770960 360kg 319kg 36mins 26mins 155mins 100mins Heat up times through 50 C Re heat is 70 of volume COMPONENT SPECIFICATION amp REFERENCE NUMBERS DESCRIPTION SPECIFICATION PART NUMBER amm _ EXPANSION VESSEL UP TO 170 LITRE MODELS 3 0 BAR CHARGE 12 LITRE CAPACITY 97 392063 EXPANSION VESSEL FOR 200 amp 250 LITRE MODELS 3 0 BAR CHARGE 18 LITRE CAPACITY 97 392064 TUNDISH 1 2 X 22MM 97 392065 mmm
8. OTES TYPICAL DISCHARGE PIPE ARRANGEMENT SAFETY DEVICE e g TEMPERATURE RELIEF VALVE METAL DISCHARGE PIPE pn FROM TEMPERATURE RELIE TO TUNDISH 500mm MAXIMUM TUNDISH 300mm MINIMUM METAL DISCHARGE PIPE D2 FROM TUNDISH WITH CONTINUOUS FALL SEE 3 9d i iv amp TABLE 1 DISCHARGE BELOW FIXED GRATING 3 9d GIVES ALTERNATIVE POINTS OF DISCHARGE 0 FIXED GRATING TRAPPED GULLY SIZING OF D2 COPPER DISCHARGE PIPE FOR COMMON TEMPERATURE RELIEF VALVE OUTLET SIZES VALVE MINIMUM SIZE OF MINIMUM SIZE OF MAXIMUMIRESISTANCE RESISTANCE OUTLET DISCHARGE PIPE DISCHARGE PIPE D2 RT ee E DUO SIZE 02 NO ELBOWS OR BENDS OR BEND up to 9m up to 18m up to 27m up to 9m up to 18m up to 27m up to 9m up to 18m up to 27m WORKED EXAMPLE The example below is for a 61 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length of 7m from the tundish to the point of discharge From Table 1 Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a G1 2 temperature relief valve is 9 0m Subtract the resistance for 4 No 22mm elbows at 0 8m each 3 2m Therefore the maximum permitted length equates to 5 8m 5 8m is less than the actual length of 7m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28mm pipe D2 from a 61 2 temperature relief valve equate
9. REDRING LWSS STAINLESS STEEL UNVENTED WATER STORAGE HEATER INSTALLATION COMMISSIONING MAINTENANCE W 9 RAS 04 THIS UNIT IS SUPPLIED BY APPLIED ENERGY PRODUCTS LTD TEL 08709 000430 APPLIED ENERGY PRODUCTS LTD STAINLESS STEEL UNVENTED HOT WATER STORAGE UNITS Please read the following carefully before installation of the product You should be competent to install the unvented system as defined by the regulations Special attention must be paid to maintenance and service Please keep the unit packaged until you are ready to commence installation Store the unit in a dry area keep it vertical and ensure that all safety components are kept in the box IT IS A REQUIREMENT THAT THIS UNIT IS SERVICED AND MAINTAINED ANNUALLY THE BENCHMARK LOG BOOK MUST BE COMPLETED AND UPDATED FAILURE TO DO SO WILL INVALIDATE GUARANTEES THE DIRECT amp INDIRECT UNITS DIRECT INDIRECT EXPANSION EXPANSION VESSEL VESSEL SUPPLIED LOOSE SUPPLIED LOOSE PRESSURE AND TEMPERATURE RELIEF VALVE HOT DOMESTIC PRESSURE AND WATER TEMPERATURE RELIEF VALVE HOT DOMESTIC WATER PRIMARY INSULATION TAPPINGS INSULATION IMMERSION HEATERS DUAL THERMOSTAT IMMERSION HEATER COLD MAINS VIA GROUPSET COLD MAINS VIA GROUPSET INSTALLING THE LWSS UNIT Choose a flat even surface Wooden bearers are not essential as the unit sits on a ring stand The unit must be installed vertically Please i
10. THERMOSTAT TROUBLESHOOTING NO HOT WATER DIRECT START SWITCH ON ELEMENTS 15 CONTROL TEMPERATURE SET RE SET AT55 C 60 C HAS HIGH LIMIT TRIPPED REPLACE ELEMENT CHECK WIRING LINKS CONTINUITY AND RE SET TROUBLESHOOTING POOR WATER FLOW AT HOT TAPS START WATER SERVICE INCOMING MAINS SUPPLY FLOW PRESSURE ADEQUATE CHECK BY SUPPLY COMPANY REQUIRED CLEAN IN LINE OR REPLACE STRAINER IN PRV STRAINERS DIRTY AS APPROPRIATE YES SERVICE REPLACE PRV AS APPROPRIATE SYSTEM FREE FROM RESTRICTIONS BLOCKAGES CLEAR OBSTRUCTIONS TROUBLESHOOTING WATER DISCHARGING INTO TUNDISH START 15 PRESSURE DOWNSTREAM OF TPRV CORRECT NO NO CLEAN OR REPLACE 15 VALVE SEAL AND SEAT CLEAN AS REQUIRED amp UNDAMAGED 15 HEATER OPERATING AT LESS THAN 60 C 15 EXPANSION VESSEL CHARGE CORRECT NO RECOMMISSION EXPANSION LEVEL REPLACE 15 ERV TPRV ERV TPRV DISCHARGING RESET TEMPERATURE RE CALIBRATE PRV SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate Service Interval Record below SERVICE PROVIDER Before completing the appropriate Service Interval Record below please ensure you have carried out the service as
11. and 24 hour programming Y PLAN Room Stat Cylinder Stat Mid Position Valve RMT 230 ITD Dual Stat HS3 RDN XI 1 2 3 HE N L Junction Box FP75 or CP15 Programmer Basic Boiler COMMISSIONING INSTRUCTIONS BEFORE FILLING CHECK EXPANSION VESSEL CHARGE IS AT 3 0 BAR Open all terminal fittings on the domestic hot water circuit Open the main supply to the unit Flush through until all air is expelled Close hot outlets and open all cold outlets connected to the tee after the pressure control valve Flush through until all air is expelled The system is now full of water Check for any leaks on pipework or joints or components such as immersion heaters etc It is the responsibility of the installer to check all fittings including those that are fitted to the unit Switch on power and heat up via immersion heater and or boiler Your system should be ready for use MAINTENANCE Maintain annually and carry out the following checks Clearly up date the Benchmark Log Book at each service GUARANTEES ARE VOID WITHOUT SERVICE RECORDS 1 Check incoming pressure is controlled at 3 bar maximum The gauge reading clearly demonstrates this Expansion vessels must be maintained annually The charge should be checked with an accurate pressure gauge and maintained at 3 0 bar If the reading is less than 3 0 bar to recharge the vessel ensure that the unit is decommissioned by turning off the water supply
12. ct gap separation Appropriate wiring for the electrical load must be used The twin immersion heaters supplied with direct units can be switched to utilise low tariff electricity supply Do not switch on until the unit is full of water Immersion heaters are supplied fitted in the body of the unit Always ensure that the joints are watertight on commissioning The thread is non standard Order replacements using reference number on page 14 Do not fit an immersion heater without a high limit thermostat Immersion heaters fitted are designed for domestic use only either utilising low tariff electricity and occasional boost or for switched periods during the day Immersion heaters must meet BS EN 60730 2 1 Units must be earth bonded The fuse rating for 6kw loading is 25 amps for the 3kw indirect model the fuse rating is 13 amps ALWAYS CONSULT THE REGULATIONS INDIRECT INSTALLATIONS The indirect pattern products are supplied with dual thermostats with sensing probes and with a motorised two port valve The thermostat has to be wired in order to control the water temperature in the system and if the high limit is tripped to operate the two port valve in such a way as to route primary water back to the boiler and isolate the cylinder see diagram NB By pass must be fitted BOILER in accordance with boiler CIRCS manufacturer s instructions 22mm VALVE WIRING INSTALLATION The wiring diagram for Danfoss systems is give
13. n as guidance For modified Danfoss Randall Y S and W plan systems when used in conjunction with unvented water storage systems Programmers recommended are FP715 7 5 and 2 day programming and the CP15 5 2 and 24 hour programming W PLAN Diverting Valve Room Stat Cylinder Stat HS3D RMT 230 ITD Dual Stat p High Mn ITD Dual Stat 10 0000 45 41 4L AL JL Power L Dab Junction Box HP22 FP75 or CP15 Basic Boiler 2 Port Valve Programmer WIRING INSTALLATION The wiring diagram for Danfoss systems is given as guidance For modified Danfoss Randall Y S and W plan systems when used in conjunction with unvented water storage systems Programmers recommended are FP715 7 5 and 2 day programming and the CP15 5 2 and 24 hour programming S PLAN Room Stat Zone Valve Htg Zone Valve DHW HP22 RMT 230 HP22 2 ITD Dual Stat Control BEI 00000000 1 2 3 4 5 6 7 8 9 10 2E JE KIK 2E 2E 7L 22 Junction Box 2 3 2 3 1 44 00 i P Htg Dh ump Bud FP75 or CP15 Programmer Basic Boiler WIRING INSTALLATION The wiring diagram for Danfoss systems is given as guidance For modified Danfoss Randall Y S and W plan systems when used in conjunction with unvented water storage systems Programmers recommended are FP715 7 5 and 2 day programming and the CP15 5 2
14. nstall in an area that will be accessible in the future When first fixing take into account that the connections and controls will be front facing to facilitate access Check that the floor will support the unit when it is full of water See page 14 for weights COLD FEED Minimum mains pipework of 25mm MDPE or 22mm copper is advised If 15mm copper or Te lead is the only mains feed then the decision to install rests with the installer or specifier of the product Flow rates will be compromised even at appropriate pressures ensure that you have at least 18 litres per minute at the bath tap Maximum inlet pressure is 12 bar If multiple bath filling or showering is required mains feed may need to be 32mm MDPE or 28mm copper The unit operates at 3 bar and pressures from 2 bar upwards are suitable Lower pressure will result in a fall in flow rate A flow rate of 20 litres per minute is a minimum requirement for single bath applications and must rise proportionately for greater demands Please also take into account any fitting that could restrict flow such as water meters softeners etc Connection to the unit Use 22mm compression for all connections Use gunmetal DZR or brass fittings noting local water conditions COLD MAINS COMPONENT LAYOUT T EXPANSION VESSEL COLD TAPS Q OPTIONAL PRESSURE REDUCING VALVE FILTER 2 DRAIN POINT No valve is to be fitted between the expansion valve and the cylinder except a drain poi
15. nt It is recommended that a stop cock is fitted to the above to facilitate servicing Install before the pressure reducing valve Always fit a drain tap in an appropriate position for drain down as low as possible DON T USE MONOBLOC MIXERS IF THE COLD SERVICE IS UNEQUALISED AS IT WILL BACK PRESSURISE THE UNIT AND RESULT IN DISCHARGE EXPANSION VALVE DISCHARGE PRESSURE AND TEMPERATURE RELIEF VALVE COLD FEED Both the pressure and temperature 22mm relief valve fitted to the unit and the expansion valve supplied loose must be arranged to comply with G3 regulations and each discharge into an open visible tundish A 300mm vertical drop of 22mm TUNDISH diameter pipe must be fitted to the tundish NB THE TUNDISH AND DRAIN MUST BE POSITIONED AWAY FROM ELECTRICAL DEVICES Y 22mm ALWAYS CONSULT THE REGULATIONS IMPORTANT Discharge arrangements are the responsibility of the installer and reference to current building regulations should always be made Applied Energy Products Ltd offers the foregoing as guidelines only The main purpose of discharge pipework is to allow full flow from relief valves to be accumulated and safely routed to a point outside the building at low level GUIDANCE NOTES TUNDISH DISCHARGE The unit is supplied with two mechanical safety devices An expansion relief valve supplied loose and a temperature pressure relief valve fitted to the unit both discharging into a tundish supplied loose
16. s to 18m Subtract the resistance for 4 No 28mm elbows at 1 0m each 4 0m e Therefore the maximum permitted length equates to 14m As the actual length is 7m a 28mm D2 copper pipe will be satisfactory INSTALLATION HOT WATER OUTLETS Dynamic pressure always drops across a system when more than one outlet is opened The unit has a working pressure of 3 bar Good system design should take this into consideration amp pipe sizing should be in line with current good practice In hard water areas a reduced operating temperature will help to prevent premature scaling EXPANSION VESSEL The vessel supplied loose screws onto the top of the unit It is sized appropriately and includes some allowance for pipework Check the charge is at 3 0 bar before commissioning The expansion vessel can also be fitted remotely between the unit and the check valve on the cold supply or by adaptor to the top female fitting on the cylinder PRIMARY CIRCUITS The maximum primary pressure is 3 5 bar The boiler must have a mechanical high limit thermostat Solid fuel boilers cannot be used If the primary circuit is sealed an additional expansion vessel must be fitted If a secondary circuit is connected an additional expansion vessel may be required ELECTRICAL CONNECTIONS Immersion heaters are rated 3kw at 240v 2 76kw at 230v incolloy elements with a thermal energy cut out and must be connected via double pole switches with a 3mm conta
17. wnward discharges at a low level i e up to 100mm above external surfaces such as car parks hard standings grassed areas etc are acceptable providing that where children may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility Continued GUIDANCE NOTES d 3 Discharges at high level e g in to metal hopper and metal down pipe with the end of the discharge pipe clearly visible tundish visible or not or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges tundish visible d 4 Where a single pipe serves number of discharges such as in a block of flats the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected If unvented hot water storage systems are installed where discharges from safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device to warn when discharge takes place NOTE The discharge will consist of scalding water and steam Asphalt roofing felt and non metallic rainwater goods may be damaged by such discharges GUIDANCE N
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