Keston SPA Installation Manual
Contents
1. approx NB Above figures assume constant primary coil flow of 82C and sufficient heat input to fully utilise the coil output SpaTwin figures assume both coils used concurrently with sufficient boiler power 1 Component Check List The following items accompany your Spa Unvented Storage Cylinder Combined control and overheat thermostat with manual cut out switch variable thermostat 30 70C and sensor Combined strainer pressure reduction valve 3 0 bar with stop tap check valve expansion relief valve 6 bar 3kW 230 VAC electric element with safety cut out switch and variable thermostat 1 75 BSP head 90C 7 bar 7Temperature and Pressure T amp P relief valve Discharge tundish Diagnostic gauge 2 Port Motorised Valve Expansion vessel hose and wall mounting kit Hot Outlet are Expansion A Vessel 1 with Wall Bracket Secondary Return Circuit Yria sia Flexible B amp Pressure 210 250 amp 300 L sizes Rellef Valve Hose Non Bronze Return Pump valve Enhanced Cold Connection Enhanced Cold Connection Dual p Stat fave o Cold Inlet Boiler SI 3 via Drain Flow Boller Return Immersion Heater Handling amp Storage Do not lift via valves or element bosses on unit Expansion vessels must not be dented lt Store unit away from excess heat or frost Always transport cylinders in the vertical position Location and Cylinder Mounti2. eestor d Uir sevmid tamu deere 16 eak aaehaanirelonam aar sergah raan a fom sf Wer ates Pantie da tr jaya eRe Kee adani tow o Pre Eee eas eS aa shel de vane eat Los bse Twin Coil Spa KESTON SPA UNVENTED CALORIFIER ee KESTON Racca Bessa fad s Air Camco Baad Eryna Braker Keer HELK Tae ar COS tet aT S Teat i Te The irre Ta Tie beraber GOs aecramrreor uan aar compa f di Da aeniea kk viise parcel bh tand maar baase Coe Ceia pi soit dee Leia ke mesrdee Asthnnty s awam ta imesh Yih raes san eaw derdia fli To ady ataca rts tapla Serie sete m a Pina wl as mme rman ier f pars tee pe ppe tok te leerrs oF eed DEE tr meter
3. water flow direction Restricted pipework Use larger diameter pipework Mains stopcock Operate stopcock or replace Sticking jumper in stop Replace stop cock Blocked filter Clean filter 2 Discharging cold Loss of expansion vessel Check and recharge vessel relief valve with hot tap open Defective pressure Replace pressure valve reducing valve Blocked or defective Operate expansion valve expansion relief valve mechanism to clear or replace Crossflow from cold supply Check mixer taps and fit check through mixer top or other valve on hot outlet from heater fittings j 3 Water is cold Boiler not switched on CARRY OUT PROCEDURE BELOW indirect Air locked primary flow Thermostat settings incorrect Cut out switch need reset Warnings Electric Models Always isolate the electrical supply before opening heating elements Confirm that power supply is reaching the elements If thermal cut out switches have operated press in the red button If this fails to heat the cylinder the element has failed and should be replaced Fit new element and reset thermal cut out With power to the element and the cut out reset check the voltage on thermal cut out output If this is incorrect replace cut out switch 11 12 Spares ITEM DESCRIPTION MODEL SPECIFICATION 1 2 inch Temperature and KSI 120 04 00 1 Pressure Relief Valve 3 4 inch pressure reduction valve KSI 125 06 00 0 2 expansion relief manifold 12 l
4. 00mm long below the tundish before any elbows or bends in the pipework c be installed with a continuous fall d have discharges visible at both the tundish and the final point of discharge but where this is not possible or is practically difficult there should be clear visibility at one or other of these locations Examples of acceptable discharge arrangements are i ideally below a fixed grating and above the water seal in a trapped gully ii Downward discharges at low level i e up to 100mm above external surfaces such as car parks hard standings grassed area 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 iii Discharges at high level e g into a metal hopper and metal down pipe with the end of the discharge clearly visible tundish visible or not or onto a roof capable of withstanding high temperature discharges of water 3m from any plastics guttering system that would collect such discharges tundish visible iv Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than 6 systems so that and installation discharging can be traced reasonable easily The single common discharge pipe should be at least on pipe size larger than the largest individual discharge pipe D2 to be connected If unvented hot water storage syst
5. KESTON SPA UNVENTED STORAGE CYLINDERS SINGLE AND TWIN COIL MODELS Installation Instructions amp Performance Specification Single Coil Models Spa 120 litre Spa 150 litre Spa 210 litre Spa 300 litre Twin Coil Models SpaTwin 210 SpaTwin 300 Indirect Stainless Steel Cylinders with Ultra High Performance Fully Approved To Building Regulations G3 and L Issue 04 2007 WRAS Approved to the Water Regulations KESTON BOILERS LTD Specialists in high 34 WEST COMMON ROAD Efficiency Commercial HAYES BROMLEY amp Domestic Heating KENT BR2 7BX Equipment Tel 44 020 8462 0262 Fax 44 020 8462 4459 Email info keston co uk Web www keston co uk READ CAREFULLY BEFORE INSTALLATION INCORRECT INSTALLATION MAY INVALIDATE GUARANTEE CONTENTS PAGE 1 Component Check List 3 2 Handling and Storage 4 3 Location and Cylinder Mounting 4 4 Warnings 4 5 Markings and Specification 5 i 6 Connection Layout and Recommendations for 6 Pipework and Discharge Lines 7 Flushing and Commissioning 9 8 Electrical Specification and Wiring 9 9 Secondary Circulation 10 10 Scale Advice and Maintenance 11 11 Trouble Shooting and Maintenance 12 12 Spares 13 13 Safety amp Relevant British Standards 14 14 Tank Data Plate ji i Note to Installer Please leave Installation manual with Householder after installation INTRODUCTION The Keston Spa is a range of Duplex stainless steel u
6. ections 5 All electrical wiring should be carried out by a registered electrical contractor and must conform to IEE Wiring Regulations If a replacement immersion heater is required at any time do not fit an immersion heater s without thermal cut out s 5 Ensure unit is flushed for 3 minutes via hot tap before switching on Do not use excessive plumbers paste or flux which may damage the controls Do not switch on power until the unit is full of water Do not open electric elements unless power is switched off Position discharge tundish away from any electrical components Do not allow discharge pipes to kink or block in any way Markings and Specification Single Coil Spa 22mm Hot Drawoff _ 2 F PTRV Boss 22mm Secondary return not always fitted see table see table 1 2 F Stat Bosses 22mm Cold feed with dip pipe to deflector In bottom of cylinder MODEL CAPACITY WEIGHT DIMENSIONS in mm IMM Litres Empty Full Height Dia A B E D EEPE kW kg kg Spai20 120 35 155 906 gt 550 290 330 390 345 N F N F 3 Spa150 150 40 e 190 1093 550 330 370 465 385 N F N F 3 Spa 210 210 50 260 1469 550 365 405 465 465 N F 1150 3 Spa300 300 60 360 2032 550 365 405 465 660 1100 1600 6 Double Coil SpaTwin 22mm Hot Drawoff 1 2 F PTRV Boss 1 2 F Stat Bosses f ah Secondary return not always fitted 22mm Cold feed with dip pipe
7. ems 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 Discharge pipe D1 from temperature relief valve to tundi Safety device eg sh temperature relief valve va ivn pes Tundish E Temperature Relief Valve 2 Discharge pipe D2 from Fixed Grating Expansion Ber tundish with continuous fall E E Relief Valve 35 ma Trapped Gull 3 i EA Tundish in same lt r o viy E AR compartment as original N 300mm i s k wii i Pipe diameter below S tundish increased by one bs Pipe close to wall Temperature size h Relief Valve k 100MM e Sa max Expansion si d th Relief Valve Se Rate ee EN ray Pay pt ee i Inlet pipe pn EA Bal Alternative method at rs 25mm K A tundish 300mm i ih Nia sa TO a Alternative method of Oe toe EX termination at high level Pe Must be larger than inlet pipe H Se F POE e t Ka End of discharge pipe diameter of pipe must f be kept off wall Note The discharge will consist of scalding water and steam Asphalt roofing felt and nonmetallic rainwater goods may be damaged by such discharges 7 Flushing and Commissioning Ensure all pipe connections are tight including immersion heater s Check the immersion heater setting i
8. fore 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 for 4 no 28mm elbows at 1 0m each 4m Therefore the maximum permitted length equates to 14m As the actual length is 7m a 28mm D2 copper pipe will be satisfactory The tundish should be vertical located in the same space as the Spa tank and fitted as close as possible and within 500mm of the temperature relief valve 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 be of metal and a 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 two sizes larger than the nominal outlet size of the safety device between 18m and 27m at least 3 sizes larger and so on Bends must be taken into account in calculating the flow resistance Refer to the worked example An alternative approach for sizing discharge pipes would be to follow BS6700 1987 Specification for design installation testing and maintenance of services supplying water for 8 domestic use within buildings and their curtilages Appendix E section E2 and table 21 b have a vertical section of pipe at least 3
9. iring Thermostat Control The cylinder control thermostat is mounted at the top of the unit in a housing with cable entry point The unit houses two thermostats a control thermostat and an overheat thermostat Operation of either thermostat must cease the supply of heat to the cylinder Remove the thermostat housing cover Wire the two thermostats inside in series to the hot water control valve as shown below Electrical Specification and Wiring Thermostat Control for additional heat source refer to the suppliers manual However the manual reset limit ther mostat should be used to isolate any further supply of heat to the Spa i 9 Secondary Circulation A pump is required together with a non return valve The pump should be fitted with isolating valves on either side and sited to minimise air accumulation away from the high point of the circuit An air bleed valve may be located at the high point o The return pipe should be fitted to the secondary return drain off tapping near the base of the cylinder A drain off cock not supplied should be fitted in line in the secondary return near the connection to the cylinder to facilitate drainage of the cylinder for maintenance purposes A non return valve not supplied must be fitted to prevent backflow Calculate the flow rate and pump size by determining the total heat loss in flow and return in watts Consideration should be given to the fitting of an additional
10. itre Expansion Vessel KSI 200 01 00 1 120 150 litre sizes 18 litre Expansion Vessel KSI 300 03 00 0 210 litre size 24 litre Expansion Vessel KSI 400 01 00 1 300 litre size Immersion Heater KSI 125 02 00 1 Control Thermostat KSI 125 03 02 0 Overhant Thermostat KSI 125 03 01 0 Motorized Valve 22mm KSI 125 07 00 2 Tundish KSI 125 10 00 0 Diagnostic Gauge Expansion Vessel Hose 13 Safety amp Relevant British Standards 1 2 inch male inlet 15mm comp outlet 90C 7 bar 2mm comp inlet 22mm comp outlet 3 bar supply 6 bar relief 3 4 inch male inlet 3 bar 3 4 inch male inlet 3 bar 3 4 inch male inlet 3 bar 3kW 2 25 inch male 80C cut out 1 75inch boss Adjustable 30 to 70C 80C Cut Out Manual Reset 22mm 2 port valve 15mm 22mm Compression Installation of this tank as an unvented hot water system falls within the scope of the Building Regulations 1995 Part G These require that installation of an unvented system shall be noti fied to the local authority Building Control Department also that the work must be carried out by a competent person as defined in the Approved Document G3 The Electricity at Work Regulations 1989 The manufacturers notes must NOT be taken in any way as overriding statutory obligations 13 Tank Data Plate Single Coil Spa PIM Ra ictteleeeaeteenaeiemeneeaitiiaiiameememeneemaeeee TAKAR Te Tha wr oer Nee 8 owe keda e swapa aed ei h nevetes rrie eeke Parked de
11. le from the tank p ide Do not vent the primary circuit from the boiler to the water heater system 8 Better performance will be obtained by using 22mm pipe limiting the number of elbows and fittings and using swept bends g Follow connection layout on page 3 Connect valves with flow in arrow direction marked on valve bodies 10 For indirect cylinders the control thermostat and overheat thermostat must be wired to the Motorized valve supplied or some other suitable device to shut off the flow to the coil that is approved by a member of EOTA or by a body with NACCB accreditation G The high efficiency coil of the Spa tanks offer a higher resistance to boiler water flow than other lower efficiency traditional cylinders Consideration should therefore be given to additional pump capacity or a coil flow return bypass arrangement Such a by pass may then be adjusted to balance cylinder and boiler flow accordingly Refer to the cylinder coil pressure drop curves below for pump selection 12 For twin coil models the boiler should be connected to the upper coil The lower coil should be used for the additional heat source such as solar thermal or heat pump Coil Pressure Drop Curves Pressure Drop Kps Water Flow Through Coil L sec How to drain the System 1 Switch off the electrical power to the immersion heater s and shut down the boiler Close the stop cock valve 2 Open a hot water tap on order to reduce pressure in the cy
12. linder Leave the hot water tap open 3 Connect a hose to the draining tap ensuring it reaches a level below the unit this will ensure a siphon is established to drain the maximum amount of water CAUTION WATER DRAINED OFF MAY BE VERY HOT Discharge Pipework and Tundish Tundish must be visible Discharge pipe must be to fixed grating and not located to cause possible discharge injury to persons Typical Discharge Pipe Arrangement Table 1 Sizing of copper discharge pipe D2 for common temperature relief valve outlet sizes Valve Min size Min size of Maximum resistance allowed Resistance created Outlet of discharge discharge pipe as a length of straight pipe by each elbow or Size pipe D1 D2 from tundish i e no elbows or bends bend G1 2 15mm 22mm up to 9m 0 8m gt 28mm up to 18m 1 0m 35mm up to 27m 7 Am G3 4 22mm 28mm up to 9m 1 0m 35mm up to 18m 1 4m 42mm up to 27m 1 7m G1 28mm 35mm up to 9m 1 4m 42mm up to 18m 1 7m 54mm up to 27m 2 3m Worked example 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 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 elbows equates to 5 8m is less than the actual length of 7m there
13. n vented water heaters with ultra high performance coils for indirect heating The use of stainless steel for both coil and tank ensures long life and high strength ensuring high pressure performance The ultra high efficiency coils give rapid reheat and high volume hot water delivery The units are supplied with manifold type pressure regulating expansion relief valves preset to 3bar and with integral strainer However the manifold can be separated to two sections should you wish to install the pressure regulating valve at a remote location An expansion vessel is also supplied for connection to the cold supply Use of an external expansion vessel allows the entire volume of the tank to be used for water storage The units are also fitted with a 3kW electric immersion heater as standby heating and adjustable thermostat with overheat shut down to control the supply of indirect heat to the unit Operating Data Maximum Water Supply Pressure to pressure regulating valve 12 0 bar Operating Pressure of unit 3 0 bar Expansion Vessel Charge Pressure 3 0 bar Expansion Relief Valve Setting 6 0 bar Maximum Primary Working Pressure 3 5 bar Opening Temperature of T amp P Valve i 90C Opening Pressure of T amp P Valve 7 bar Performance Data s Model Spa Spat V Spa Spa Spa Twin Spa Twin 120 150 210 300 210 300 Re heat 15C 60C approx 23mins 25mins 35mins 44mins 18mins 22mins Re heat after 70 draw off 17mins 17mins 22mins 28 mins 11 mins 14 mins
14. ng Site the unit as close as possible to main points of usage Outlets above the Spa unit will reduce the outlet pressure by 0 1 bar for every 1m of height difference Avoid locating the unit where freezing temperatures may be experienced All expose pipework should be insulated Ensure unrestricted access to plumbing connections and top of expansion vessel Allow sufficient clearance for removal of immersion heater and valves In floor standing the unit place the unit on a load bearing surface sufficient for the weight of the unit when full of water The unit must be installed and transported vertically unless otherwise indicated on packaging Valves can be mounted in any orientation provided discharge downpipes can be run to drain in accordance with instructions see Tundish The discharge pipework should have a minimum fall of 1 200 from the unit z A drainage safe tray should be placed under the cylinder to facilitate servicing Warnings Boilers without thermostatic control such as and steam heating plant should not be used with this unit unless appropriate additional safety controls are installed Solid fuel boiler must not be used with any unvented unit Under no circumstances must the unit be filled or operated without the factory fitted TEP relief valve Do not fit a stop or check valve between the inlet safety group and the cylinder Do not apply heat to any component or any welding to cylinder or pipe conn
15. s not above 60C and that the live and neutral connec tions are correct Open a hot tap farthest from the unit Open the mains stop cock to fill the unit Flush for three minutes Close off taps and check pipework for leaks Switch on electricity to the immersion heater s or switch on the boiler Refer to boiler manu facturer s instructions or commissioning Bring the unit to approx 65C Check that water does not discharge via the Tundish pipework during heating Cut out Immersion Heater Wiring Connect Live to Connect Earth thermostat Heat resisting cable Connect Neutral from Double Pole isolating switch Hand guarantee card to user 8 Electrical Specification amp Wiring Immersion Heater Element terminals are marked N Neutral and L Live Ensure earth connection of 3 wire supply is connected to earth Recommended supply for 3kW element is 2 5mm cable to BS6141 A 16 Amp timer is recommended for 3kW elements The unit is not fitted with a fuse All heating elements operate on a 230 VAC 50Hz mains supply Do not fit immersion heater s without thermal cut out s FUSE RATING The fuse rating for two 3kW immersion heaters wired separately from the main fuseboard should be 15 Amps Electrical Wiring Drawing Cylinder Thermostat Fromulinecion Motorised Valve DHW Output Green Yellow Grey Orange To Boiler Electrical Specification and W
16. to deflector in bottom of cylinder 22mm ow ow Primary Coil ser Connections us MODEL CAPACITY WEIGHT DIMENSIONS in mm IMM Litres Empty Full Height Dia A B CE ES GASH kW kg kg SpaTwin210 210 55 265 1469 550 365 420 779 834 11501268 465 830 3 SpaTwin300 300 60 365 2032 550 365 420 979 1034 1600 1832 4651030 3 6 Connection Layout amp Recommendations The performance of any unvented mains fed cylinder is always limited by the supply of mains water to the unit A high static mains pressure is not a guarantee of adequate supply The static mains supply pressure should be measured as well as the size of the supply pipe Unvented mains fed cylinders should not be used where the water supplies have inadequate pressure flow rate or where the supply may be intermittent 1 For cylinder sizes up to 300 litres a suggested supply pressure of 1 bar or more is desirable 2 For cylinders of 200 litres or below with water pressure below 1 5 bar use 22mm supply and distribution pipework 3 Use 22mm pipe distribution up to the first branch connection 4 For 300 litres and over use 28mm or larger pipework If long pipe runs are required extra expansion vessel capacity may be necessary All hot pipework should be insulated 6 Use the balanced cold take off connection of the pressure reduction valve to ensure satisfactory shower performance However it should be noted that this will reduce the total available regulated flow availab
17. vessel where excessively large secondary loop circuits are used Required flow rate Total Watts litres second 4186 x 1000 xT where T temperature difference between flow and return normally the desirable drop is 5C and the hot water temperature should be 60C 10 Scale Advice and Maintenance In areas of hard water high storage temperatures above 50C will result in scale deposition Itis advisable to set the thermostat to the required level and fit a water softener or scale inhibitor capable of the required circuit flowrate in the cold supply line Maintenance The valve easing gear on the pressure and temperature relief valve must be operated at least once every 6 months The charge pressure of the expansion vessel should be checked annually with a pressure gauge at the top and with a hot tap open and the cold supply turned off Recharge with clean dry air to 3 5 bar Clean the pressure reducing valve filter every 2 years or of flow from water heater begins to deteriorate 11 Trouble Shooting amp Fault Guide WARNINGS If hot water discharges at tundish do not turn off supply main Switch off power to electric elements and shut down heating boiler indirect models The cause of this could be a failure of the safety controls and you should immediately contact your installer or our service operator i SYMPTOMS POSSIBLE CAUSES ACTION 1 No or low flow Poor mains pressure Check that all arrows on valves are in
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