Ariston Unvented Hot Water Storage Cylinders User manual

Instructions for Installation,
Servicing and Use
LEAVE THESE INSTRUCTIONS WITH THE
END-USER
Unvented Hot
Water Storage
Cylinders
Country of destination: GB/IE
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TABLE OF CONTENTS 1. GENERAL INFORMATION
1.1 DELIVERY
2. INSTALLATION
2.1 WATER REGULATIONS
2.2 BUILDING REGULATIONS
2.3 HOW THE APPLIANCE WORKS
2.4 OVERALL DIMENSIONS
2.5 COLD WATER SUPPLY
2.6 SITING AND FIXING
2.7 CONNECTION OF MAINS WATER SUPPLY
2.8 COLD WATER COMBINATION VALVE
2.9 CONNECTION TO SERVICES
2.10 SECONDARY RETURN
2.11 DISCHARGE PIPEWORK
2.12 ELECTRICAL DIAGRAMS
3. COMMISSIONING
4. MAINTENANCE
4.1 PROTECH ANTI-CORROSION SYSTEM
4.2 THERMAL CUT-OUT(S)
4.3 IMMERSION HEATER(S)
4.4 UNVENTED CONTROLS
4.5 THERMOSTATS
4.6 MAINTENANCE
5. FAULT FINDING
6. TECHNICAL INFORMATION
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This manual is an integral and essential part of the product. It should be kept
with the appliance so that it can be consulted by the user and our authorised
personnel.
Please read carefully the instructions and notices about the appliance
contained in this manual, as they provide important information regarding the
safe installation, use and maintenance of the cylinder.
Failure to do so may invalidate the guarantee.
The Ariston range is available in the following options:
The Wall-hung ProTech range (50, 75, 100 litre models), which are supplied
as follows;
One box containing;
1) The cylinder with factory fitted temperature & pressure relief valve,
immersion heater and thermostat with thermal cut-out.
One box containing;
1) Unvented control pack (expansion vessel, 2 piece cold water combination
valve and tundish), instructions for installation, servicing and use and the
Benchmark Log Book).
The Contract ProTech floor-standing range (100, 125, 150, 200 and 300 litre
models), which are supplied as follows;
One box containing;
1) The cylinder with factory fitted temperature & pressure relief valve.
One box containing;
1) Unvented control pack (expansion vessel, 2 piece cold water combination
valve and tundish), motorised valve (indirect only). Immersion heater(s)
and thermostat(s) with thermal cut-out(s), cylinder thermostat with
thermal cut-out (indirect only), feet (x3), instructions for installation,
servicing and use and the Benchmark Log Book.
The High Capacity ProTech floor-standing range (500 litre models), which
are supplied as follows;
One box containing;
1) The cylinder with factory fitted temperature & pressure relief valve.
1) Unvented control pack (expansion vessel, 2 piece cold water combination
valve and tundish), motorised valve (indirect only). Immersion heater(s)
and thermostat(s) with thermal cut-out(s), cylinder thermostat with
thermal cut-out (indirect only), feet (x 3), instructions for installation,
servicing and use and the Benchmark Log Book.
The Classico and Primo floor-standing ranges (125, 150, 200 and 300 litre
models).
Are supplied with the following;
One box containing;
1) The cylinder with factory fitted temperature & pressure relief valve.
One box containing;
1) Unvented control pack (expansion vessel, 2 piece cold water combination
valve and tundish), motorised valve (indirect only). Immersion heater(s)
and thermostat(s) with thermal cut-out(s), cylinder thermostat with
thermal cut-out (indirect only), feet (x3), instructions for installation,
servicing and use and the Benchmark Log Book.
1. GENERAL
INFORMATION
1.2 DELIVERY
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2.3 HOW THE APPLIANCE
WORKS
2. INSTALLATION
These regulations (byelaws in Scotland) ensure a good supply of
wholesome water, and that only approved materials, pipes and fittings are
used to convey water.
These are a statutory document and take priority over all other regulations
and recommendations. The installation of an unvented hot water storage
cylinder is classified as a “Controlled Service” and Regulation G3 applies. To
meet the requirements of the Regulation, installation of an unvented system
should be undertaken by a “competent installer”.
All installations of unvented hot water storage systems having a capacity of
more than 15 litres should be notified to the relevant Local Authority by
means of building notice or by the submission of full plans. It is important to
note that it is a criminal offense to install an unvented hot water storage
system without notifying the Local Authority. The installation of the unvented
cylinder and hot water system must comply with BS 6700 and the HSE
Legionella Code of Practice.
The immersion heater(s) are controlled through a thermostat which senses
the water temperature. The operating temperature can be pre-set by
adjusting the spindle in the head of the thermostat. In addition to the
thermostat there is a thermal cut-out incorporated if the thermostat fails and
the water temperature rises too high. Once the cut-out operates it can only
be re-set manually after the fault has been rectified.
Indirect models have dual thermal controls. In addition to the above there is
a separate cylinder thermostat and thermal cut-out for controlling the indirect
circuit. Again the thermal cut-out operates if the cylinder thermostat fails, by
disconnecting the live feed (call for hot water) from the programmer.
Classico (STD/STI) models have magnesium anodes provided to prevent
corrosion of the cylinder tank.
All High Capacity (STD/STI) 500 litre models, Wall-hung (ST) units and the
Contract (STD/STI) Floor-standing models utilise the ProTech anti-corrosion
system (electronic anode).
The factory fitted temperature & pressure relief valve at the top of the
cylinder is a safety device to back-up the thermostat(s) and thermal cut-
out(s). It works by sensing an excess in water temperature or pressure and
releasing the hot water into a discharge tundish and drain.
The cylinder will only work in the vertical position. The inlet pipe needs to
deliver cold water to the bottom of the tank. When water is heated it
expands. To accommodate this increase in volume an expansion vessel is
provided. A cold water combination valve is also provided in two pieces,
loose jointed for ease of installation. These comprise a combined line
strainer/pressure reducing valve and core non-return valve/expansion relief
valve.
The strainer prevents any debris entering the other controls. The pressure
reducer ensures the correct operation of the expansion vessel, and prevents
any damage to the control valves through too great a pressure.
The non-return valve ensures the water expansion is forced into the
expansion vessel and prevents contamination of the mains cold water
supply.The expansion relief valve will discharge expanded water to the
discharge tundish if the expansion vessel fails.
2.1 WATER REGULATIONS
2.2 BUILDING REGULATIONS
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It is important to ensure that the cold water main is capable of supplying the
increased demand which will be imposed on it. Hot and cold water are both
drawn off the same source of supply. Remember, there will not be a storage
tank to help compensate for variations in the demand on the system.
A minimum pressure of approximately 1.5 bar and 20 litres per minute is
required for satisfactory operation. 85% of UK dwellings have a mains
pressure above 2.0 bar.
NOTE:THE MAINS WATER SUPPLY MUST NOT EXCEED 16 BAR.
The cylinder should be left packed until it is time to install. When unpacking
the appliance follow the guidelines within the packaging and take care not to
damage the temperature and pressure relief valve.
The cylinder may be installed at any convenient position, as it is connected
to the mains cold water supply, it is equally effective on any floor, however,
consideration must be given to allow ease of access for maintenance
purposes.
However, do not install the unit in premises which may be subject to
freezing. Ensure that the floor load bearing strength is adequate to take the
weight of the cylinder when full of water (see TABLE 1).
The ST50, ST80 and ST100 ProTech models are wall mounted. All other
models are free standing. These are supplied with feet which are attached to
the heater via self-tapping screws which are also supplied. All units must be
installed in the VERTICAL POSITION.
For maintenance purposes leave at least 500 mm free space in front of the
unit, for access.
2.5 COLD WATER SUPPLY
2.4 OVERALL DIMENSIONS
2.6 SITING AND FIXING
DIRECT RANGE
Wall-hung
ST 50
ST 80
ST 100
Floor Standing
STD ProTech
STD / STD ProTech / ITD 125
STD / STD ProTech / ITD 150
STD / STD ProTech / ITD 210
STD / STD ProTech / ITD 300
500 STD ProTech
INDIRECT RANGE
STI / STI ProTech / ITI 125
STI / STI ProTech / ITI 150
STI / STI ProTech / ITI 210
STI / STI ProTech / ITI 300
500 STI ProTech
50 l
75 l
100 l
100 l
125 l
150 l
200 l
300 l
495 l
125 l
150 l
200 l
300 l
495 l
1/2”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4"
1”
3/4”
3/4”
3/4”
3/4”
1"
410
590
550
530
700
840
990
1215
1390
700
840
990
1215
1390
-
-
-
-
-
-
-
-
-
0.75
0.9
0.9
0.9
1.5
120
175
175
650
805
965
1280
1555
335
805
965
1280
1555
335
580
740
700
890
1045
1205
1525
1790
1870
1045
1205
1525
1790
1870
160
230
230
-
-
-
-
-
-
675
815
815
815
700
475
475
575
-
-
-
-
-
-
-
-
-
-
-
460
460
560
505
505
505
505
560
714
505
505
505
560
714
77
115
141
129
158/138*
190/164*
245/220*
385/331*
630
166/143**
201/171**
256/227**
395/337**
641
TABLE 1
Model Storage Units Pipe Size Coil Dimensions in mm Weight
Surface When Full
Capacity Inlet Outlet m2ABCDEFGH Kg
265
265
265
265
275
265
265
265
275
225
225
225
225
255
225
225
225
255
*ITD Models **ITI Models
ST ProTech
50-80-100
500 STD ProTech
500 STI ProTech
STD/STD ProTech/ITD
125-150-200-300
STI/STI ProTech/ITI
125-150-200-300
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SECONDARY
RETURN
COMBINATION
VALVE
EXPANSION RELIEF
PIPE
COLD
MAINS-IN
22mm
DRAIN
EXPANSION
VESSEL
PRESSURE + TEMPERATURE
RELIEF VALVE
HOT SUPPLY
22mm
TUNDISH
22mm
MAX. 100mm
FIG.2.2
2.7 CONNECTION OF MAINS
WATER SUPPLY
For floor standing models:
On the front of the unit there is a label to identify the connection ports.
Please check this before making any connection to the unit.
For units up to 300 litres it is recommended that all mains cold water supply
pipe work is a minimum of 22mm, with the exception of model ST 50
ProTech where 15mm can be used. For 500 litre models the supply should
be 28mm. An isolating valve should be installed between the cold water
supply and the cylinder for servicing. ALL PIPEWORK MUST BE FLUSHED
TO AVOID DAMAGE TO THE CONTROL VALVES.
Please refer to FIGS. 2.1, 2.2, 2.3, 2.4, 2.5 for a suggested installation layout.
STD PROTECH 100
STD/STD PROTECH/ITD 125-150-210-300 DIRECT
COMBINATION
VALVE
EXPANSION
RELIEF
PIPE
COLD
MAINS-IN
15/22mm
EXPANSION
VESSEL
PRESSURE + TEMPERATURE
RELIEF VALVE
HOT SUPPLY
15/22mm
TUNDISH
15mm
22mm
MAX. 100mm
FIG. 2.1
ST PROTECH 50-80-100
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RETURN
FLOW
SECONDARY
RETURN
COMBINATION
VALVE
EXPANSION RELIEF
PIPE
COLD
MAINS-IN
22mm
DRAIN
EXPANSION
VESSEL
PRESSURE + TEMPERATURE
RELIEF VALVE
ZONE
VALVE
HOT SUPPLY
22mm
TUNDISH
22mm
MAX. 100mm
FIG.2.3
STI/STI PROTECH/ITI 125-150-210-300 INDIRECT
SECONDARY
RETURN
COMBINATION
VALVE
EXPANSION RELIEF
PIPE
COLD
MAINS-IN
28mm
DRAIN
EXPANSION
VESSEL
PRESSURE + 
TEMPERATURE
RELIEF VALVE
HOT SUPPLY
28mm
TUNDISH
22mm
MAX. 100mm
FIG. 2.4
500 STD PROTECH
RETURN
FLOW
SECONDARY
RETURN
COMBINATION
VALVE
EXPANSION RELIEF
PIPE
COLD
MAINS-IN
28mm
DRAIN
EXPANSION
VESSEL
PRESSURE + 
TEMPERATURE
RELIEF VALVE
ZONE
VALVE
HOT SUPPLY
28mm
TUNDISH
22mm
MAX. 100mm
FIG.2.5
500 STI PROTECH
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The cold water combination valve can be connected either close by
the unit or alternatively it may be installed in a remote position from
the unit as there is no requirement to site it in close proximity to the
cylinder. This allows a flexible and convenient installation. However, it
is important to note allowances for the discharge pipe work from the
expansion relief valve must be accounted for.
A balancing port is supplied on the 22mm valves (for units above 50
litres) and 28mm valves (for 500 litres units) allowing balanced cold
water supply to the rest of the building giving constant results for
mixer and shower valves. If the facility is not needed a plug is
supplied. Refer to FIG. 2.7 and FIG. 2.8
Although this facility is not built into the 15mm valve (supplied with
model ST50), a tee piece may be inserted between the two
components giving the same result. Refer to FIG. 2.6
NOTE!
THERE SHOULD BE NO OTHER VALVES FITTED BETWEEN THE CYLINDER AND
THE EXANSION VALVE.
2.8 COLD WATER
COMBINATION VALVE
15mm
COLD
MAINS IN
15mm
TO CYLINDER
3/4” B.S.P
. CONNECTIONS
FOR EXPANSION VESSEL
EXPANSION RELIEF
VALVE (SET AT 6 BAR)
NON-RETURN
VALVE (WITHIN HOUSING)
TEE PIECE
FOR BALANCED
COLD WATER
TAKE OFF
(NOT SUPPLIED)
SERVICEABLE 1/2” PRESSURE
REDUCING CARTRIDGE AND
LINE STRAINER
For Model ST 50
FIG. 2.6
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22mm COLD
MAINS IN
22mm COLD
MAINS IN
22mm TO WATER HEATER
3/4” B.S.P. CONNECTION
FOR EXPANSION VESSEL
22mm TO CYLINDER
NON-RETURN VALVE
(WITHIN HOUSING)
22mm BALANCED COLD WATER TAKE OFF
WITH NON-RETURN VALVE
15mm EXPANSION RELIEF
OUTLET TO TUNDISH
SERVICEABLE 3/4” PRESSURE REDUCING
CARTRIDGE AND LINE STRAINER
(SET AT 3.5 BAR)
EXPANSION RELIEF VALVE
(SET AT 6 BAR)
3.5
6 BAR
For 500 litre
Models
28mm COLD
MAINS IN 28mm TO
CYLINDER
SERVICEABLE 1” PRESSURE REDUCING
CARTRIDGE AND LINE STRAINER
(SET AT 3.5 BAR)
3/4” B.S.P
. CONNECTION
FOR EXPANSION VESSEL
EXPANSION RELIEF VALVE
(SET AT 6 BAR)
1” BALANCED COLD WATER TAKE OFF
WITH NON-RETURN VALVE
FIG. 2.7
FIG.2.8
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2.9 CONNECTION TO SERVICES It is recommended that a 22mm pipe run should supply the outlets
throughout the building, especially to baths and showers. Short runs of
15mm pipe may be used to connect basins and sinks.
On floor-standing models a secondary return may be fitted (consult the label
on the face of the unit for the correct location). A non-return valve (not
supplied) must be fitted to prevent back flow and a bronze pump will be
needed in conjunction with a pipe thermostat to circulate the hot water (both
not supplied).
NOTE:an extra expansion vessel may be required where the additional
volume of the secondary return exceeds the capacity of the expansion
vessel supplied.
NOTE!
THE SAFETY RELIEF VALVES MUST NOT BE USED FOR ANY OTHER PURPOSE
1) The tundish must be vertical and fitted within 500mm of the temperature
& pressure relief valve and must be located with the cylinder. The tundish
must also be in a position visible to the occupants, and positioned away
from any electrical devices. 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 and to be of metal.
2) Discharge pipes from the temperature & pressure relief and expansion
relief valve may be joined together.
3) The pipe diameter must be at least one pipe size larger than the nominal
outlet size of the safety device unless it's 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 2 sizes larger than the nominal outlet size of the safety
device.Between 18m and 27m at least 3 larger, and so on.
Bends must be taken into account in calculating the flow resistance.
See FIG. 2.9 and TABLE 2.
4) The discharge pipe must have a vertical section of pipe at least 300mm
in length, below the tundish before any elbows or bends in the pipework.
5) The discharge pipe must be installed with a continuous fall.
6) The discharge must be 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 are:
i) Ideally below a fixed grating and above the water seal in a trapped
gully.
ii) Downward discharges at a low level; i.e. up to 100mm above
external surfaces such as car parks, hard standings, grassed
areas etc. These 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; I.e. into a 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 3m from any plastic guttering
systems that would collect such a discharge (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 any installation can be traced reasonably
easily.The single common discharge pipe should be at least one
pipe size large than the largest individual discharge pipe to be
2.10 SECONDARY RETURN
2.11 DISCHARGE PIPEWORK
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connected. If unvented hot water storage systems are installed
where discharges from safety devices may not be apparent i.e. in
dwellings occupied by the 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
500mm Max.
300mm
Min.
Temperature & pressure
relief valve
Metal discharge pipe (D1) from
temperature & pressure relief valve.
to tundish.
Metal discharge pipe (D2) from tundish
with continuous fall. See Table 2 and worked
example.
Tundish
Fixed grating
Trapped gulley
Discharge below
fixed grating.
(see page 10 for
alternative points
of discharge).

Valve outlet size Minimum size of
discharge pipe D1* Minimum size of discharge pipe D2*
from tundish
Maximum
resistance allowed,
expressed as a
length of pipe (i.e.
no elbow or bends)
Resistance created
by each elbow or
bend
G 1/2 15mm 22mm
28mm
35mm
Up to 9m
Up to 18m
Up to 27m
0.8m
1.0m
1.4m
G 3/4 22mm 28mm
35mm
42mm
Up to 9m
Up to 18m
Up to 27m
1.0m
1.4m
1.7m
G 1 28mm 35mm
42mm
54mm
Up to 9m
Up to 18m
Up to 27m
1.4m
1.7m
2.3m
TABLE 2. Sizing of copper discharge pipe “D2” for common temperature valve outlet sizes.
be damaged by such discharges.
WORKED EXAMPLE
The example below is for a G 1/2temperature & pressure 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 2;
Maximum resistance allowed for a straight length of 22mm copper discharge
pipe (D2) from G 1/2temperature & pressure valve is 9m. Subtract the resistance
for 4 no. 22mm elbows at 0.8m each = 3.2m. Therefore the maximum permitted
length equates to: 5.8m. As 5.8m is less than the actual length of 7m therefore
FIG. 2.9
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calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe (D2) from G 1/2
temperature & pressure valve equates to: 18m. Subtract the resistance for 4 no.
28mm elbow 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.
WARNINGS
The outlet from the temperature & pressure relief valve must not be used for
any other purpose. This also applies to the expansion relief valve. No other
valve is to be fitted between the cold water combination valve and the
cylinder.
The temperature & pressure relief valve must not be removed in any
circumstances. Any of the above will totally invalidate the guarantee.
2.12 ELECTRICAL
CONNECTION
The electrical installation must be in accordance with the current I.E.E.
wiring regulations.
PROTECH ELECTRONIC ANTI-CORROSION SYSTEM
IMPORTANT:The ProTech anti-corrosion system MUST be permanently
connected to a 240V electricity supply see FIG 2.10.
240V~
Electronic anode
Anode circuit
N1L
The ProTech system, an exclusive solution, is an electronic anti-corrosion
protection system which ensures maximum longevity of the appliance,
regardless of water quality.The electronic circuit creates a difference in
potential between the hot water tank and the titanium electrode, thereby
guaranteeing optimum protection of the tank and preventing corrosion.
To ensure the proper operation of the protection system, IT MUST BE
PERMANENTLY CONNECTED TO A FUSED NON-SWITCHED 240V, 3A
ELECTRICITY SUPPLY even in the event of shut-down of the system. To
FIG. 2.10
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prevent risk to the appliance’s lifespan when disconnecting the protection
system for an extended period of time, it is necessary to drain the appliance
beforehand.
In addition to the 240V network, the electronic circuit is also connected to
the tank, which is to be protected, and to the titanium protection electrode,
INFORMATION FOR THE END USER
Proper operation of the protection system is shown by a continuous green
L.E.D, indicating that the circuits terminals are being supplied with electricity.
In the event of failure, a red L.E.D. indicates that there is a short-circuit
between the electrode and the cylinder tank, that one of the leads (tank or
electrode) is disconnected or that there is no water in the cylinder.
Your appliance is thus properly protected when the green L.E.D. is
illuminated and the red L.E.D. is off. Should this not be the case, please
contact your installer.
FITTING IMMERSION HEATER(S) (100 - 300 litre foor standing only)
These are supplied with but not fitted to 100 - 300 floor-standing models. A
sealing gasket is supplied with each element, however the use of a suitable
sealing compound is recommended to ensure a correct seal. Care must be
taken not to cross thread the immersion heater(s) when fitting. Each
immersion heater is supplied with a regulation thermostat and manual reset
thermal cut-out. This will activate if the regulation thermostat fails. Under no
circumstances should this be by-passed. The immersion heaters supplied
are rated at 3kW, there are 4kW upgrade kits available on request, (the part
number for which is 925392). Should the immersion heater(s) be ugraded to
the 4kW immersion, the electrical circuit and fuse must be checked to
ensure suitability with the higher output. Although the immersion heaters
are a standard 21/4” thread, they must not be substituted with anything but an
original Ariston spare part.
NOTE!
THE IMMERSION HEATERS MUST NOT BE FITTED WITHOUT THE THERMOSTAT/THERMAL
CUT-OUT.
DIRECT SYSTEMS
A mains supply of 240V, 3kW (13 amps) is required. Heat resistant cable,
round 3 or 4 core 2.5mm2(to BS6141 table 8) must be used to connect the
electrical supply through the Economy 7 time control switch using either
system ‘A’ or ‘B’ as illustrated in FIG. 2.11.
SYSTEM A SYSTEM B
FIG.2.11
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The thermostat(s) on the immersion heater(s) should be adjusted to trip at
60°C. This is the ideal temperature to prolong element life in hard water
areas. Scale on the sheath builds up more rapidly at temperatures above
this causing the element to overheat and premature failure can occur. Higher
temperatures without additional controls would result in scalding.
In addition to the thermostat the thermal cut-out will switch power off to the
element should the thermostat malfunction, causing an excessive rise in
water temperature. The thermal cut-out can be reset manually after the fault
has been corrected.
THERMAL
CUT-OUT
L2
N
L1
N
THERMOSTAT
DAY ELEMENT
3 kW 240V
~
NIGHT ELEMENT
3 kW 240V ~
ECONOMY 7
THERMAL
CUT-OUT THERMOSTAT
THERMAL
CUT-OUT
L1
N
THERMOSTAT
ELEMENT
3 kW
240V
~
Single Element
2.11 ELECTRICAL DIAGRAM Should the Economy 7 system not to be used, a separate 13 amp supply to
each element will be required. Through a double pole fused isolating switch
having a contact gap of at least 3mm on each pole.The immersion heater
shall be installed with 85°C rubber insulated HOFR-sheathed flexible cable
complying with Table 8 of BS 6141: 1991. Make the connection(s) to the
immersion heater(s) as per FIG. 2.12 and FIG. 2.13. For High Capacity 500
litre models consult the wiring diagram on the reverse of the inspection
panel.
FIG. 2.12
FIG. 2.13
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INDIRECT SYSTEMS
For models up to 300 litres a mains supply of 240V, 3kW (13 amps) will be
required for the direct immersion heater. heat resistant cable, round 3 core
2.5mm2(to BS) must be used. For High Capacity 500 litre models consult
the wiring diagram on the reverse of the inspection panel.
For indirect controls a 240V, 3 amp supply is required.
On floor standing models it is necessary to fit the thermostat using P.T.F.E
tape (Please consult the label on the face of the unit for the correct location
in both cases).
The cables must be clamped in position (as previously stated) and the
control thermostat should be set at 60°C for the reasons above. In addition
to the thermostat there is a thermal cut-out should the thermostat fail. Refer
to FIG. 2.14.
The indirect coil must not be connected to an uncontrolled heat source e.g.
solid fuel and must be connected to a thermostatically controlled appliance.
WIRING SCHEME FOR 2 X2 PORTMOTORISED VALVES
T6360B
ROOM
THERMOSTAT
14
35
22
OR
CM 41
CM 51
A
B1
5
V4043H
HEATING VALVE
BROWN
5
BLUE
2
GREY
1
ORANGE
10
GREEN/YELLOW
3
V4043H
HOT WATER VALVE
BROWN
8
BLUE
2
GREY
1
ORANGE
10
GREEN/YELLOW
3
Honeywell ST 699B 1002 63NL Link L-5-8 ST 6400/ST 6300 ST 6200 3 4 N L Drayton Tempus 7 3 4 N L
Horstmann 425, 525, 527 1 4 E N L Link L-2-5 Landis & Gyr RWB2 3 4 N L Glowworm Mastermind Landis & Gyr RWB20 3 4 N L Microgyr Potterton Miniminder 3 4 N L
Potterton EP2000/3000 - 3 4 N L
Link L-5 EP2001/3001 Randall 102/102 E 1 2 E 5 6 Link 3-6 Randall 4033 42E76 Link 1-6 Randall 701, 702 31E N L Link L-6-5 Sangamo M5 18 E 4 3 Link 1-6 Sangamo 410 Form 1 18E4 3
Link 3-6
PROGRAMMER
6 4 3 2 1
Pegler Sunvic 2 5 E N L SP 50/100 (Link L-3) Switchmaster 1 4 N L
Symphony, Sonata Switchmaster 400, 600 3 1 N L
SWITCHMASTER 805, 900
3 1 N L
Sunvic ET 1451 7 4 E 1 2 Link 2-3-6 Sunvic DHP 2201 6 3 E 1 2 Towerchron FP 610 2 1 Link 1-5/4-7-9 Towerchron MP 610 2 1 Link 1-4/6-11 Towerchron 2000 HW HTG N L
ON ON
ACL LS522, LS722 3 4 N L
Randall 922, 972 36 E N L
Link L-2-5 Randall 3020 P 4 2 E N L
and 3060
PROGRAMMER
64 3 2 1
1
Cylinder
thermostat
Thermal
cut-out
ELEMENT
3 kW 240V ~
Thermal
cut-out
Thermostat
18
6
Not
used
L1
240V~
N
P
2
P
2
240V
MAINS INPUT (3 AMP)
L1
N2
E3
240V
MAINS INPUT (13 AMP)
E
L
N
• 1
• 2
• 3
• 4
• 5
• 6
• 7
• 8
• 9
• 10
TYPICAL
JUNCTION BOX
FIG. 2.14
Basic Boilers (see Page 16) LENL N E
Baxi Solo 2 30PF To 80PF PL SL E N L L N E
and 30RS to 60RS Glowworm Economy Plus 7 SL E N L L N E
(remove link SL-9) Glowworm Spacesaver KFB50 9 12 E N L L N E
(remove link 12-7) Glowworm Ultimate SS P SL E N L L N E
(remove link SL - 4) Glowworm Fuelsaver 100FF P SL ENLL N E
(remove link 7 - 12) Halstead Best range 21E N L L N E
Halstead Balmoral range 9 6 E N 12 L N E
Halstead Blenheim range LP 2 E N L L N E
Ideal Mexico Super 2 PL LB E N L L N E
Myson Apollo PL ON E N L L N E
(remove all links) Potterton Profile/Suprima PL SL E N L L N E For ARISTON, Vaillant, Vokèra, Burco Maxol and other makes, refer
to manufacturers instructions.
BOILER PUMP
910 321910 2 3
Based on Honeywell Controls
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BASIC BOILER LIST
Baxi Bermuda range
Boston RS and OF range
Glowworm Complheat
Hideaway range 65 - 80
Ultimate 40 - 80
30B - 80B, 30CF - 60CF
Halstead Buckingham range
Potterton Kingfisher range
Statesman range (oil fired)
Caradon Ideal Classic range
Mexico Super range
Mexico Slimline range
Newflame Boilers Backboiler range
Condensing Boiler List
CARADON IDEAL Minimiser FF30 - FF80 L E N
GLOWWORM Energysaver (Remove link SL-9) PL SL E N L
KESTON LEN
POTTERTON Envoy 30F - 80F PL SL E N L
refer to
VAILLANT VU 186, 226 manufacturers
instructions
Boiler Connections 2 Motorised valves 2 way (see Fig. 2.14) 9 10 3 2 1
Pump Connections 2 Motorised valves 2 way (see FIG.2.14)9 3 2
WARNING : THE APPLIANCE MUST BE EARTHED.
The earth continuity conductor of the electrical installation must be
effectively connected to all exposed parts of other appliances and services
in the room in which the water heater is to be installed, conformity with the
I.E.E. wiring regulations.
NOTE:Do not switch on the immersion heater or fire the boiler until the
cylinder is full of water.
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3. COMMISSIONING Check for obvious signs of damage to the cylinder and controls, and also
that the controls fitted correspond with the references quoted in these
instructions.
Ensure that the Drain Cock at the base of the appliance is closed before
commencing.
1) ProTech Models Only.Ensure that the ProTech anti-corrosion system is
connected to the electrical supply;
2) Open all outlet taps;
3) Turn on mains water supply and allow the water heater to fill;
4) Ensure that the hot water system is flushed in accordance with BS 6700;
5) Close taps in turn after having purged the system of air;
6) Check for leaks around the controls and immersion heaters and again
after the unit has heated up;
7) Check that no water is passing to waste through the relief valves;
8) Ensure that the line strainer (situated in the pressure reducing valve) is
clear of installation debris and clean if necessary;
9) Test the operation of the temperature & pressure relief and expansion
valves by lifting/turning the manually operated test lever/cap and
observing that water flows through freely and safely to waste;
10) Check that the pressure in the expansion vessel is correct;
11) Check that the discharge pipe is plumbed so that it falls continuously
and that no taps, valves or other shut off devices are installed in the
pipe;
12) Check that all thermostats are set at 60°C;
13) DIRECT UNITS. Switch on immersion heater(s) and allow unit to heat
up. Check operation of Thermostat(s);
14) INDIRECT UNITS. Fill the indirect (primary) circuit following the boiler
instructions. Switch on the boiler, ensure that the programmer is in the
domestic hot water position. Allow unit to heat up and check operation of
indirect thermostat on motorised valve(s);
15) Check the temperature of the hot water at the nearest outlet and record
in the Benchmark Log Book;
16) Demonstrate operation to user, including operation of temperature &
pressure relief valve and what to do if it operates;
17) Give this manual along with the completed Benchmark Log Book to the
user to retain for future reference and make the customer aware that
periodic checks of the equipment are essential for safety.
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4.2 THERMAL CUT-OUT(S)
4.3 IMMERSION HEATER(S)
4.4 UNVENTED CONTROLS
4. MAINTENANCE To ensure efficient safe operation, it is recommended that the appliance is
serviced annually by a competent person.
After servicing, preliminary electrical system checks must be carried out to
ensure electrical safety (i.e. polarity, earth continuity, resistance to earth and
short circuit).
WARNING: SWITCH OFF THE POWER SUPPLY BEFORE WORKING ON
THE APPLIANCE.
Trouble-shooting:
1) The green L.E.D. is NOT on:
- Check to see that the circuits electric plug is connected (if not,
connect);
- Check to see that the P.C.B, is supplied with electricity (if not, replace
the supply cable);
- Check to see that 230 V electricity is supplied (if not, ensure that 230 V
is supplied);
- If all these checks fail to locate the problem, replace the electronic
circuit (installer).
2) The red L.E.D. is on:
- Check to see that the tank is filled with water (if not, fill it before
carrying out the following checks);
- Check to see that the clip-on circuit connector is in the proper position
(if not, position correctly);
- Check to see that the electrodes connection lead is property connected
(to check this, gently pull on it) (if not, replace the electrode);
- Check to see that the connection lead to the tank is properly connected
to the tank (if not, connect properly); .
-Check to see that the two leads from the clip-on circuit connector are
not damaged, stripped, etc. (if so, replace the electrode);
-If all these checks fail to locate the problem, replace the electronic
circuit.
NOTE:To replace the P.C.B, there is no need to drain the cylinder;
1) Disconnect the two supply cables from the P.C.B. to the supply terminal;
2) Disconnect the clip-on circuit connector and polarising slot which
connects the circuit to the tank and the electrode;
3) Disconnect the P.C.B. from its supporting plate (plastic clips in the 4
corners) and;
4) Replace the defective circuit with a new one, then re-install in reverse
order to the above.
If the thermal cut-out has operated the cause must be found before resetting
(see section 5).
Should the immersion heater(s) become scaled, we would recommend that
the immersion heaters be replaced, also ensure that the thermostat is set
below 60OC to prevent further scale formation.
Check controls as per the following:
1) Line strainer - with the water supply turned off remove screen from
strainer and clean of any detritus;
2) Expansion vessel - with the water supply turned off and taps open, check
expansion vessel pressure and top up as necessary;
3) Temperature & pressure relief valve - with the water supply turned on,
check manually by lifting the test lever/turning the test knob (ensure valve
closes after testing)
;
4.1 PROTECH
ANTI-CORROSION SYSTEM
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4) Expansion relief valve - check manually by turning the test knob (ensure
valve closes after testing) ;
5) Discharge pipes (D1) - from both temperature & pressure relief and
expansion relief valve for obstructions;
6) Tundish & discharge pipe (D2) - open either valve gradually to produce a
full bore discharge into tundish and D2 without any back pressure;
7) Pressure reducing valve - check that the correct outlet pressure is being
maintained by recording the pressure at an in-line terminal fitting i.e. tap.
Ensure that all thermostats adjusted for the correct temperature setting, this
should be between 60 and 65°C.
To ensure efficient safe operation, it is recommended that the appliance is
serviced annually by a competent person.
After servicing, preliminary electrical system checks must be carried out to
ensure electrical safety (i.e. polarity, earth continuity, resistance to earth and
short circuit).
To drain the cylinder it is necessary to proceed as follows:
1) Close the mains supply service valve;
2) Open hot water taps;
3) Attach a hose and open the drain cock and allow the cylinder to empty.
Magneisum Anodes (Classico model only)
No longer than every 12 months, the installer should check the magnesium
anti-corrosion anodes (consult the label on the face of the unit for the correct
location). Assessment of the condition of the bottom anode (where fitted)
can be made by judging the condition of the top anode.
Removal of anodes;
1) Close the mains supply service valve;
2) Open hot water taps;
3) Attach a hose and open the drain cock and allow the cylinder to empty;
4) The anodes are removed by unscrewing;
EXAMINE THE ANODES AND REPLACE IF THE DIAMETER IS LESS
THAN 10mm.
The use of an approved P.T.F.E. sealing tape is recommended to ensure
watertight connection for anodes.
Thermal Cut-out(s)
If the thermal cut-out has operated the cause must be found before
resetting.
Immersion Heater(s)
Should the immersion heater be scaled, we would recommend it be
replaced.
4.5 THERMOSTATS
4.6 MAINTENANCE
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Unvented Controls(s)
Check controls as per the following:
1) Line strainer - with the water supply turned off remove screen from
strainer and clean of any detritus;
2) Expansion vessel - with the water supply turned off and taps open, check
expansion vessel pressure and top up as necessary;
3) Temperature & pressure relief valve - with the water supply turned on,
check manually by lifting the test lever/turning the test knob (ensure valve
closes after testing) ;
4) Expansion relief valve - check manually by turning the test knob (ensure
valve closes after testing)
;
5) Discharge pipes (D1) - from both temperature & pressure relief and
expansion relief valve for obstructions;
6) Tundish & discharge pipe (D2) - open either valve gradually to produce a
full bore discharge into tundish and D2 without any back pressure;
7) Pressure reducing valve - check that the correct outlet pressure is being
maintained by recording the pressure at an in-line terminal fitting i.e. tap.
Thermostats
Ensure that all thermostats adjusted for the correct temperature setting, this
should be between 60 and 65°C.
NOTE!
WHERE THERE IS A POSSIBILITY OF SCALE FORMING,IT IS RECOMMENDED TO ADJUST
THE THERMOSTAT TO BELOW 60OC
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