DeDietrich BP 150 Troubleshooting guide

EN
Independent domestic hot water tanks
BP 150...500
20 100
°C
M000734
Installation, User
and Service
Manual
300011515-001-E

Contents
1 Introduction ................................................................................................4
1.1 Used symbols .......................................................4
1.2 Abbreviations ........................................................4
1.3 General ..................................................................4
1.3.1 Manufacturer's liability .............................................4
1.3.2 Installer's liability .....................................................5
1.3.3 User's liability ..........................................................5
1.4 Homologations ......................................................6
1.4.1 Certifications ...........................................................6
1.4.2 Directive 97/23/EC ..................................................6
1.4.3 Factory test .............................................................6
2Safety instructions and recommendations ..............................................7
2.1 Safety instructions ...............................................7
2.2 Recommendations ................................................7
3Technical description ................................................................................8
3.1 General description ..............................................8
3.2 Technical characteristics .....................................8
3.2.1 Characteristics of the DHW calorifier ......................8
3.2.2 Specifications of the DHW sensor ...........................9
4 Installation ................................................................................................10
4.1 Regulations governing installation ...................10
4.2 Package list .........................................................10
4.2.1 Standard delivery ..................................................10
4.2.2 Accessories ...........................................................10
4.3 Choice of the location ........................................11
4.3.1 Data plate ..............................................................11
4.3.2 Location of the appliance ......................................11
4.3.3 Main dimensions ...................................................12
4.4 Levelling ..............................................................13
4.5 Hydraulic installation diagram ..........................13
4.5.1 Safety unit (For France ) .......................................14
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4.6 Hydraulic connections .......................................15
4.6.1 Hydraulic connection of the primary circuit (exchanger
circuit) ....................................................................15
4.6.2 Connecting the tank to the domestic water circuit
(secondary circuit) .................................................15
4.7 Electrical connections ........................................17
4.7.1 Recommendations ................................................17
4.7.2 Fitting the DHW sensor .........................................18
5 Commissioning ........................................................................................19
5.1 Putting the appliance into operation ................19
6 Checking and maintenance .....................................................................20
6.1 General instructions ...........................................20
6.2 Checking the magnesium anode .......................20
6.3 Safety valve or safety unit .................................20
6.4 Cleaning the casing material .............................20
6.5 Replacing the magnesium anode and
descaling .............................................................20
6.6 Maintenance form ...............................................22
7 Spare parts ................................................................................................23
7.1 General ................................................................23
7.2 Spare parts ..........................................................23
7.2.1 Domestic hot water tanks ......................................24
7.2.2 Options ..................................................................29
8 Warranty ....................................................................................................34
8.1 General ................................................................34
8.2 Warranty terms ...................................................34
Contents
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1 Introduction
1.1 Used symbols
In these instructions, various danger levels are employed to draw the
user's attention to particular information. In so doing, we wish to
safeguard the user's safety, obviate hazards and guarantee correct
operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of a dangerous situation causing slight physical
injury.
CAUTION
Risk of material damage.
Signals important information.
¼ Signals a referral to other instructions or other pages in the
instructions.
1.2 Abbreviations
4CFC: Chlorofluorocarbon
4DHW: Domestic hot water
1.3 General
1.3.1. Manufacturer's liability
Our products are manufactured in compliance with the requirements
of the various applicable European Directives. They are therefore
delivered with [ marking and all relevant documentation.
BP 150...500 1. Introduction
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In the interest of customers, we are continuously endeavouring to
make improvements in product quality. All the specifications stated in
this document are therefore subject to change without notice.
Our liability as the manufacturer may not be invoked in the following
cases:
4Failure to abide by the instructions on using the appliance.
4Faulty or insufficient maintenance of the appliance.
4Failure to abide by the instructions on installing the appliance.
1.3.2. Installer's liability
The installer is responsible for the installation and inital start up of the
appliance. The installer must respect the following instructions:
4Read and follow the instructions given in the manuals provided
with the appliance.
4Carry out installation in compliance with the prevailing legislation
and standards.
4Perform the initial start up and carry out any checks necessary.
4Explain the installation to the user.
4If a maintenance is necessary, warn the user of the obligation to
check the appliance and maintain it in good working order.
4Give all the instruction manuals to the user.
1.3.3. User's liability
To guarantee optimum operation of the appliance, the user must
respect the following instructions:
4Read and follow the instructions given in the manuals provided
with the appliance.
4Call on qualified professionals to carry out installation and initial
start up.
4Get your fitter to explain your installation to you.
4Have the required checks and services done.
4Keep the instruction manuals in good condition close to the
appliance.
This appliance is not intended to be used by persons (including
children) whose physcial, sensory or mental capacity is impaired or
persons with no experience or knowledge, unless they have the
benefit, through the intermediary of a person responsible for their
safety, of supervision or prior instructions regarding use of the
appliance. Care should be taken to ensure that children do not play
with the appliance.
1. Introduction BP 150...500
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1.4 Homologations
1.4.1. Certifications
This product complies to the requirements to the european directives
and following standards:
42006/95/EC Low Voltage Directive.
Reference Standard: EN 60.335.1.
42004/108/EC Electromagnetic Compatibility Directive.
Reference Standards: EN 50.081.1, EN 50.082.1, EN 55.014
1.4.2. Directive 97/23/EC
This product conforms to the requirements of european directive 97 /
23 / EC, article 3, paragraph 3, on pressure equipment.
1.4.3. Factory test
Before leaving the factory, each appliance is tested for the following:
4Water tightness
4Air tightness
4Electrical safety.
BP 150...500 1. Introduction
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2 Safety instructions and
recommendations
2.1 Safety instructions
CAUTION
Before any work, switch off the mains supply to the
appliance.
CAUTION
In order to limit the risk of being scalded, the installation of
a thermostatic mixing valve on the domestic hot water flow
piping is compulsory.
2.2 Recommendations
CAUTION
Do not neglect to service the appliance. Service the
appliance regularly to ensure that it operates correctly.
WARNING
Only qualified professionals are authorised to work on the
appliance and the instalation.
WARNING
Heating water and domestic water must not come into
contact with each other. Domestic water must not circulate
via the exchanger.
4To take advantage of the guarantee, no modifications must be
made to the appliance.
4To reduce heat losses as much as possible, insulate the pipes.
Casing components
Only remove the casing for maintenance and repair operations. Put
the casing back in place after maintenance and repair operations.
Instructions stickers
The instructions and warnings affixed to the appliance must never be
removed or covered and must remain legible during the entire lifespan
of the appliance. Immediately replace damaged or illegible
instructions and warning stickers.
2. Safety instructions and recommendations BP 150...500
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3 Technical description
3.1 General description
DHW calorifiers BP 150...500 can be connected to central heating
boilers used for heating domestic hot water.
Main parts:
4The tanks are made of high quality steel lined with food quality
standard enamel vitrified at 850°C, which protects the tank from
corrosion.
4The heat exchanger welded into the tank is made of smooth
tubing, the external surface of which, which is in contact with
domestic water, is enamelled.
4The appliance is highly insulated with CFC-free polyurethane
foam, which reduces thermal losses to a minimum. The insulating
material can be easily detached from the tank. This measure
facilitates the recycling of materials.
4The outside casing is made of painted steel sheeting.
4The tank is protected against corrosion by a magnesium anode
which should be checked every 2 years and replaced if need be.
The tanks with the greatest capacity (BP 300, BP 400, BP 500)
are fitted with 2 protection anodes.
3.2 Technical characteristics
3.2.1. Characteristics of the DHW calorifier
BP 150 BP 200 BP 300 BP 400 BP 500
Primary circuit (heating water)
Maximum operating temperature °C 90 90 90 90 90
Maximum operating pressure bar 10 10 10 10 10
Exchanger capacity l 5.7 8.0 11.2 14.9 21.1
Exchange surface m20.84 1.19 1.67 2.22 3.14
Secondary circuit (domestic water)
Maximum operating temperature °C 90 90 90 90 90
Maximum operating pressure bar 10 10 10 10 10
Water content l 150 200 300 400 500
Weight
Shipping weight - DHW tank package kg 88.5 107.5 155 238 290
Performances related to the boiler type
Power exchanged(1) kW 33 44 55 70 93
(1) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 45 °C - Primary flow rate: 3 m3/h
(2) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 40 °C - Domestic hot water storage: 40 °C
BP 150...500 3. Technical description
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BP 150 BP 200 BP 300 BP 400 BP 500
Flow per hour (∆T = 35 °C(1) l/h 810 1080 1350 1720 2290
Specific flow (∆T = 30°C) (10 minutes)(2) l/h 220 325 510 580 800
Maintenance consumption (ΔT=45K) kWh/24h 1.5 1.9 2.6 2.9 3.0
(1) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 45 °C - Primary flow rate: 3 m3/h
(2) Primary temperature: 80 °C - Domestic cold water inlet: 10 °C - Domestic hot water outlet: 40 °C - Domestic hot water storage: 40 °C
3.2.2. Specifications of the DHW sensor
Temperature in °C 10 20 25 30 40 50 60 70 80
Resistance in ohm 19691 12474 10000 8080 5372 3661 2536 1794 1290
3. Technical description BP 150...500
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4 Installation
4.1 Regulations governing installation
CAUTION
Installation of the appliance must be done by a qualified
engineer in accordance with prevailing local and national
regulations.
CAUTION
France: The installation must comply in all matters to the
standards and rules which govern the work and
interventions in individual and collective homes, and other
constructions.
4.2 Package list
4.2.1. Standard delivery
The delivery includes:
4One DHW tank.
4One installation, use and service manual.
BP 150 BP 200 BP 300 BP 400 BP 500
DHW tank package EC 400 EC 401 EC 402 EC 403 EC 404
4.2.2. Accessories
Various options are available depending on the configuration of the
installation:
BP 150 BP 200 BP 300 BP 400 BP 500
Impressed current anode AJ 38 AJ 38 AJ 38 AM 7 AM 7
Titanium anode(1) EC 414 EC 414 - - -
Single phase shielded resistor
2.2 kW EC 410 - - - -
Multi-voltage shielded resistor
3.3 kW - - EC 412 - -
(1) The titanium anode can only be fitted to the DHW tank if this is connected to a boiler equipped with a Diematic 3 control panel which
incorporates the TAS ® function.
(2) The EG 88 steatite heating resistance must be accompanied by the installation of the AJ 38 impressed current anode in the top buffer tank
in order to ensure adequate protection of the tank against corrosion.
BP 150...500 4. Installation
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BP 150 BP 200 BP 300 BP 400 BP 500
Multi-voltage shielded resistor
4.5 kW - - - EC 413 EC 413
Multi-voltage steatite heating
resistance 2.4 kW - EC 411 - - -
Multi-voltage steatite heating
resistance 3 kW - - EG 88(2) - -
SLA2 control system for load
pump EC 320 EC 320 EC 320 EC 320 EC 320
(1) The titanium anode can only be fitted to the DHW tank if this is connected to a boiler equipped with a Diematic 3 control panel which
incorporates the TAS ® function.
(2) The EG 88 steatite heating resistance must be accompanied by the installation of the AJ 38 impressed current anode in the top buffer tank
in order to ensure adequate protection of the tank against corrosion.
WARNING
4The impressed current anode and the shielded
electrical resistor cannot be fitted simultaneously.
4Respect the recommended anode / electrical resistor
combinations as the electrical resistor is combined
with a magnesium anode which, with the anode in the
top section already in place, is calculated to protect
the enamelled tank correctly.
4.3 Choice of the location
4.3.1. Data plate
The nameplate affixed to the tank provides important information
regarding the appliance: serial number, model, etc.
CAUTION
The rating plate must be accessible at all times.
4.3.2. Location of the appliance
CAUTION
Put the appliance in a frost-free location.
4Place the appliance as close as possible to draw-off points in order
to minimise energy losses through the pipes.
4Place the appliance on a base frame to facilitate cleaning of the
premises.
4. Installation BP 150...500
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4.3.3. Main dimensions
M000735A BP 300 - 400 - 500 BP 150 BP 200
BP 150
BP 200
BP 300
BP 400
BP 500
ADomestic hot water outlet G 1 G 1¼
ZExchanger inlet G 1 G 1
ECirculation G ¾ G ¾
RDomestic cold water inlet G 1 G 1¼
TExchanger outlet G 1 G 1
YDrain opening G 1 G 1
UMagnesium anode
aDomestic hot water sensor
(1) Adjustable feet
G : Exterior cylindrical threading, sealed by sheet gasket
BP 150 BP 200 BP 300 BP 400 BP 500
A80 80 80 93 95
B216 216 216 232 232
C296 296 296 330 330
D521 651 626 785 817
E661 796 996 1012 1192
F- 976 1516 1535 1494
G (Ø) 600 600 600 650 750
H935 1215 1755 1785 1763
J978 - - - -
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4.4 Levelling
Levelling is done using the adjustable feet located on the base of the
domestic hot water tank:
4BP 150 - BP 200 - BP 300: 3 adjustable feet
4BP 400 - BP 500: 4 adjustable feet
(1) Adjustment range: 30 mm
4.5 Hydraulic installation diagram
1Heating flow
2Heating return
33-bar safety valve
4Pressure gauge
7Automatic air vent
9Isolating valve
16 Expansion vessel
M000736-B
30
M000737
4. Installation BP 150...500
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17 Drain cock
18 Filling the heating circuit
24 DHW tank heat exchanger primary inlet
25 DHW tank heat exchanger primary outlet
26 DHW pump
27 Non-return valve
28 Domestic cold water inlet
29 Pressure reducer
30 Safety unit
7-bar safety valve
32 D.H.W. loop back pump
51 Thermostatic valve
54 End of the discharge pipe free and visible 2 to 4 cm above
the flow funnel
56 Circulation
57 Domestic hot water outlet
64 Circuit A: direct heating circuit (example: radiators)
4.5.1. Safety unit (For France )
9Isolating valve
28 Domestic cold water inlet
29 Pressure reducer
30 Safety unit
54 End of the discharge pipe free and visible 2 to 4 cm above
the flow funnel
nDetails of the safety unit
aCold water inlet with an integrated non-return valve
bConnection to the DHW tank cold water inlet
cStop cock
d7-bar safety valve
eDrain opening
C000711-D
a
b
c
d(54)
2 cm
e
28 30
9 29
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4.6 Hydraulic connections
4.6.1. Hydraulic connection of the primary circuit
(exchanger circuit)
¼ See diagram : "Hydraulic installation diagram", page 13.
For the hydraulic connection of 150 l to 300 l tanks and the boiler (right
or left), we offer optional hydraulic connection kits.
For connection using these kits, refer to the instructions
delivered with them.
4.6.2. Connecting the tank to the domestic water
circuit (secondary circuit)
When making the connections, it is imperative that the standards and
corresponding local directives are respected.
nSpecific precautions
Before making the connection, rinse the drinking water inlet
pipes in order not to introduce metal or other particles into the
appliance's tank.
nProvision for Switzerland
Make the connections according to the instructions of the Société
Suisse de l'Industrie du Gaz et des Eaux. Comply with local
instructions from water distribution plants.
nSafety valve
CAUTION
In accordance with safety rules, a safety valve sealed at
7 bar is fitted to the domestic cold water inlet on the DHW
tank.
France: We recommend NF-marked hydraulic membrance safety
control units.
4Integrate the safety valve in the cold water circuit.
4Install the safety valve close to the tank in a place which is easy
to access.
4. Installation BP 150...500
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nSize
The safety device and its connection to the DHW tank must be of at
least the same diameter as the domestic cold water supply pipe of
the tank domestic circuit.
No isolating devices should be located between the valve or safety
device and tank.
The safety device drain pipe must have a uniform and sufficient
gradient and its diameter must be at least equal to that of the outlet
opening of the safety device (to prevent the flow of water being
hindered if the pressure is too high).
The outlet pipe in the valve or safety assembly must not be blocked.
Germany: Define the dimensions of the safety valve in accordance
with the DIN 1988 standard.
Capacity (litres)
Dimension of the valve
Min. dimension of the inlet
connection
Heating output
(kW) (max)
< 200 R or Rp 1/2 75
200 to 1000 R or Rp 3/4 150
Fit the safety valve above the tank to avoid draining the tank during
servicing.
Install a drainage valve at the lowest point on the tank.
nIsolating valves
Hydraulically isolate the primary and secondary circuits using stop
valves to facilitate maintenance operations on the unit. The valves
make it possible to carry out maintenance on the tank and its
components without draining the entire installation.
These valves are also used to isolate the tank unit when conducting
a pressurised check on the leak tightness of the installation if the test
pressure is greater than the admissible operating pressure.
CAUTION
If the mains pipes are made of copper, fit a sleeve made
of steel, cast iron or any other insulating material between
the tank's hot water outlet and the pipes to prevent
corrosion to the connection.
nConnecting the domestic cold water
Make the connection to the cold water supply according to the
hydraulic installation diagram.
¼ Refer to the installation and maintenance instructions of the
boiler.
Install a water drain in the boiler room and a "funnel-siphon" for the
safety unit.
The components used for the connection to the cold water supply
must comply with the prevailing standards and regulations in the
country concerned. Fit a one-way valve to the domestic cold water
circuit.
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nPressure reducer
If the mains pressure exceeds 80% of the valve or safety unit setpoint
(e.g.: 5.5 bar for a safety unit set at 7 bar), a pressure reducer must
be fitted upstream of the appliance. Install the pressure reducer
downstream the water meter in such a way as to ensure the same
pressure in all of the installation pipes.
nDomestic hot water circulation loop
To guarantee the availability of hot water as soon as the taps are
turned on, a circulation loop between the draw-off points and the
recirculation pipes in the DHW tank can be installed. A non-return
valve must be included in this loop.
nMeasures to take to prevent hot water flow reversal
Fit a one-way valve to the domestic cold water circuit.
4.7 Electrical connections
4.7.1. Recommendations
WARNING
Only qualified professionnals may carry out electrical
connections, always with the power off.
4. Installation BP 150...500
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4.7.2. Fitting the DHW sensor
D000882
13 2
4
5
3
BP 150...500 4. Installation
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5 Commissioning
5.1 Putting the appliance into operation
CAUTION
Initial commissioning must be done by a qualified
professional.
1. Flush the domestic circuit and fill the tank through the cold water
inlet tube.
2. Open a hot water tap.
3. Completely fill the DHW tank via the cold water inlet pipe, leaving
the hot water valve open.
4. Close the hot water valve when the water flow is regular, without
noise in the pipes.
5. Degas all DHW pipes by repeating steps 2 to 4 for each hot water
tap.
Carefully degas the DHW tank and the distribution network
in order to eliminate noises and hammering caused by
trapped air moving in the pipes during draw-off.
6. Vent the tank exchanger circuit using the bleed valve provided for
this purpose.
7. Check the safety devices (particularly the valve or safety unit),
referring to the instructions provided with these components.
CAUTION
"During the heating process, a certain amount of water
may flow through the valve or safety unit; this is caused by
water expansion. This phenomenon is completely normal
and must in no event be hindered".
5. Commissioning BP 150...500
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