andrews Maxxflo CWH30/200 User manual

M6500 Rev B
INSTALLATION OPERATION AND MAINTENANCE MANUAL
MAXXflo
High Efficiency Condensing Stainless Steel Storage Water heaters
High Efficiency Condensing Stainless Steel Storage Water heaters
Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference
CWH30/200, CWH30/300, CWH60/200, CWH60/300,
CWH90/200, CWH90/300, CWH120/200, CWH120/300
E281B

MAXXflo Water Heater
22
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 must be employed at
all times. e attention of UK users is drawn to their responsibilities under the Health and Safety
Regulations.
All installation and service on Andrews Water Heaters must be carried out by competent qualified
personnel and, therefore, no liability can be accepted for any damage or malfunction caused as a
result of intervention by unauthorised personnel.
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: [phone]
Fax: [phone]
Email: [email protected]
Website: www.andrewswaterheaters.co.uk
Twitter: @AndrewsWH
THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL
ARE FOR USE WITH NATURAL GAS OR LPG (PROPANE) GAS ONLY
Copyright Andrews Water Heaters

MAXXflo Water Heater
33
PAGE
SECTION 1 GENERAL AND SAFETY INFORMATION
General Information 4
British Standards and Codes of Practice 4
Health and Safety Regulations 1993 4
Legionellae in Water Heaters 5
SECTION 2 TECHNICAL DETAILS
Technical Details – CWH30/60/90/120 5
Technical Parameters 6
Product Fiche 7
Heater Dimensions – 200 litre model 7
Heater Dimensions – 300 litre model 8
SECTION 3 INSTALLATION
Description 10
Location 10
Water Quality and Treatment 11
Water Connections 11
Condense Drain 12
Typical Installations – CWH30/60 & CWH90/120 13
Gas Supply – Natural Gas 14
Gas Supply – Propane 14
Typical Bulk Storage Vessel Installation 15
Typical Cylinder Installation 15
Electrical Supply 16
Electrical Connection 16
Wiring Diagram 17
Temporary Water Heater Temperature Change 18
Circulation Pump and Storage Tanks 18
HWST Tank Dimensions and Wiring Diagram 19
Flue Systems 20
Flue Systems – CWH 30 & 60 21
Alternative Flue Systems – CWH 30 & 60 22
Standard Flue System Dimensions – CWH 30 & 60 23
Flue Systems – CWH 90 & 120 24
Alternative Flue Systems – CWH 90 & 120 25
Standard Flue System Dimensions – CWH 90 & 120 26
Flue System Positions and Distances 27
Flue System – Horizontal and Vertical Terminations 28
Air supply and ventilation – Concentric Flue Systems 28
Air supply and ventilation – concentric and conventional flue systems 30
Air supply and ventilation – conventional flue systems 31
Heat exchanger configuration 32
Control panel 32
SECTION 4 WATER TEMPERATURE SETTINGS
Temperature setting 33
Adjusting temporary temperature change 33
SECTION 5 INSTRUCTIONS FOR COMMISSIONING
Filling the water heater 34
Commissioning – natural gas and propane 34
CO2adjustment 34
Control and adjustment at full load 35
Control and adjustment at low load 35
Decommissioning 35
SECTION 6 FAULT CODES
Fault codes 36
Blocking faults 36
Lockout faults 36
SECTION 7 MAINTENANCE
Annual maintenance checks 37
SECTION 8 PARTS LIST
External, Internal & cylinder spares 38
Flue and old issue spares 40
SECTION 9 DISMANTLING DISPOSAL AND RECYCLING 43
CONTENTS

MAXXflo Water Heater
44
GENERAL AND SAFETY INFORMATION
e Andrews Water Heater has been designed for use with NATURAL GAS OR LPG and is 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.
e heater(s) must be installed in accordance with the following requirements:
• e current GAS SAFETY (INSTALLATION AND USE) REGULATIONS
• e current BUILDING REGULATIONS
• e WATER SUPPLY (WATER FITTINGS) REGULATIONS
•
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 which should include the following:
• BS EN 806 (Parts 1 - 5) Specifications for installations inside buildings conveying water for human consumption.
General design, pipe sizing, installation, operation and maintenance.
• BS 5440-1 Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net. Specification for
installation of gas appliances to chimneys and for maintenance of chimneys.
• BS 5440-2 Flueing and ventilation for gas appliances of rated input not exceeding 70 kW net. Specification for the
installation and maintenance of ventilation provision of gas appliances.
• BS 5546 Specification for installation of gas hot water supplies for domestic purposes. Using gas-rated appliances of
rated input not exceeding 70 kW net.
• BS 6891 Installation of low pressure gas pipework of up to 35mm in domestic premises.
• BS 6644 Installation of gas fired water boilers of rated inputs between 70kW and 1.8MW
• BS EN 12897 Water supply. Specification for indirectly heated unvented (closed) storage water heaters
• IGE/UP/1A, 1B Strength/tightness testing and direct purging
• IGE/UP/2 Installation pipework
• IGE/UP/10 - 1 (Edition 4): Installation of gas appliances in industrial and commercial premises.
Andrews Water Heaters accepts no liability for any damage resulting from failing to accurately follow the instructions.
When replacing parts during maintenance, only original parts from Andrews Water Heaters should be used; these can be
recognised by the name of the manufacturer printed on them.
HEALTH AND SAFETY REGULATIONS
It is the duty of manufacturers and suppliers of products for use at work to ensure, so far as is practicable, that such products
are safe and without risk to health when properly used, and to make available to users adequate information about their safe
and proper operation.
Andrews Water Heaters should only be used in the manner and purpose for which they are intended and in accordance with
the instructions in this manual. Although the heaters have been manufactured with paramount consideration to safety, certain
basic safety precautions highlighted in this manual must be observed by the user.
It is imperative that all users of the heaters must be provided with all the information and instruction necessary to ensure
correct and safe operation.
EFFECTIVENESS IN COMBATING LEGIONELLA
Water systems in buildings have been associated with outbreaks of Legionnaires’ Disease, particularly in health care facilities
where occupants are significantly more susceptible to infection.
In recognition of the risks in hospitals, a Code of Practice for the Control of Legionella in Health Care premises has been issued
by the Department of Health. Codes of Practice applicable to other premises have been published by other organisations,
principally the Health and Safety Executive and the Chartered Institute of Building Services Engineers (CIBSE).
All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that
favour colonisation by Legionella bacteria. ese factors include stagnation, lukewarm conditions (20°C to 45°C) and the
accumulation of debris, scale and corrosion in the base of tanks and calorifiers.
e MAXXflo range has a Legionella flushing programme – see page 15 (terminals BTI – BT2)
SECTION 1 • GENERAL AND SAFETY INFORMATION

MAXXflo Water Heater
55
TECHNICAL DETAILS • SECTION 2
Model Reference CWH 30/200 60/200 90/200 120/200
30/300 60/300 90/300 120/300
Input gross Hs min/max 6.7–31.1 kW 13.4–62.2 kW 20.1–93.3 kW 26.8-124.4 kW
Input nett Hi min/max 6.0–28.0 kW 12.0–56.0 kW 18.0-84.0 kW 24.0-112.0 kW
Output (tank set point : 60°C) 6.5–30.5 kW 13.0–61.0 kW 19.5-91.6 kW 26.0-122.1 kW
Natural Gas, G20
Gas Consumption 2.96 m3/h 5.93 m3/h 8.89 m3/h 11.85 m3/h
Minimum Gas Supply Pressure 18 mbar 18 mbar 18 mbar 18 mbar
Propane, G31
Gas Consumption 2.18 Kg/h 4.35 Kg/h 6.53 Kg/h 8.71 Kg/h
Minimum Gas Supply Pressure 37 mbar 37 mbar 37 mbar 37 mbar
Efficiency (gross) 98% 98% 98% 98%
Efficiency (nett) 109% 109% 109% 109%
Standby Heat Loss 780 Mj per month
NOxlevel @ 0% O225ppm 25ppm 25ppm 25ppm
NOxlevel @ 0% O244mg/kWh 44mg/kWh 44mg/kWh 44mg/kWh
Noise level LWA 49dB 49dB 49dB 49dB
Ionisation current – max 6.0A 6.0A 6.0A 6.0A
Ionisation current – min 4.0A 4.0A 4.0A 4.0A
HSI resistance 1.0 – 1.4 k1.0 – 1.4 k1.0 – 1.4 k1.0 – 1.4 k
Max recovery thru 50°C 480 l/h 960 l/h 1440 l/h 1920 l/h
Max recovery thru 56°C 429 l/h 856 l/h 1284 l/h 1712 l/h
Time to recover tank thru 50°C rise
200 litre capacity 25 mins 13 mins 9 mins 7 mins
300 litre capacity 38 mins 19 mins 13 mins 10 mins
Flue size (concentric) Int/External 80/125 80/125 130/200 130/200
Flue Size (conventional) 80 80 130 130
Max flue run – concentric * 14 12 14 14
Max flue run – conventional ** 50 20 50 40
Max flue static pressure 140 Pa 140 Pa 140 Pa 140 Pa
Inlet/Outlet connections 1½” BSP 1½” BSP 1½” BSP 1½” BSP
Return connection 1” BSP 1” BSP 1” BSP 1” BSP
Nominal operating water pressure 3.5 bar 3.5 bar 3.5 bar 3.5 bar
Maximum water pressure 6.0 bar 6.0 bar 6.0 bar 6.0 bar
Minimum water pressure 1.0 bar 1.0 bar 1.0 bar 1.0 bar
Gas connection (gas cock supplied) 3/4” 3/4” 3/4” 3/4”
Electrical supply All models: 230/50V/Hz
Power consumption 170 W 340 W 510 W 680 W
Weight – empty (200 litre) 155 kg 170 kg 185 kg 200 kg
Weight – empty (300 litre) 165 kg 180 kg 195 kg 210 kg
Weight – full (200 litre) 355 kg 370 kg 385 kg 400 kg
Weight – full (300 litre) 465 kg 480 kg 495 kg 513 kg
Shipping weight (200 litre) 178 kg 193 kg 208 kg 213 kg
Shipping weight (300 litre) 188 kg 203 kg 218 kg 233 kg
Shipping depth 1040 mm 1040 mm 1040 mm 1040 mm
Shipping width 880 mm 880 mm 880 mm 880 mm
Shipping height (200 litre) 1653 mm 1653 mm 1653 mm 1653 mm
Shipping height (300 litre) 2077 mm 2077 mm 2077 mm 2077 mm
* Reduce flue length by 1.2m for 90° bend, 0.7m for 45° bend and 1.5m for condensate trap
** Reduce flue length by 4m for 90° bend, 2m for 45° bend and 4m for condensate trap
e MAXXflo range features stainless steel tanks with external heat exchanger(s) and fully automatic electronic control with
BEMS interface as standard. e heaters must be installed with a minimum water pressure of 1 bar. e heaters are factory
fitted with temperature and pressure relief valve(s). A gas cock, water draw-off cock and comprehensive instruction manual are
also included. e water heaters can be fitted with concentric flue for room sealed applications; horizontal or vertical flue kits
must be ordered separately – see pages 20 and 25.
Conventional flue, suitable for condensing applications can be used if the plantroom is ventilated.