elco Polywarm-Maxi PWC1-500 User manual

Polywarm-Maxi
PWC Indirect Hot Water Cylinders
and
PWB Buffer Vessels
Models PWC1 - 500, 800, 1000 & 1500
PWC2 - 500, 800, 1000 & 1500
Models PWB - 500, 800, 1000, 1500, 2000,
2500 & 3000
!
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Page 1 of 25
Installation and Operating Instructions

Index
Section Topic Page No
2. Technical data & dimensions ………………………………....……
3. Installation .................…………………………………………....…
4. Connections ……………………………................................…....
5. Primary coils circulation ………................................………....….
6. Self cleaning flux …………………................................……...….
7. Immersion heaters …………………................................……....
8. Hard water ………………………………………………………...…
9. Unvented systems ……………………………………………….....
10. Expansion vessels pre-charge pressure …………...........….…...
11. Expansion vessel capacity …………………………..........…....…
12. Safety relief valves discharge pipes ………………..........….…...
13. Tundish positioning & discharge ………………………................
14. Electrical installation............................... …………………...........
15. Electrical connections for optional powered anode………….…..
16. Electrical connections for optional immersion heaters .……...….
17. Typical installation schematics ………………………………….…
18. Commissioning ………………………………………………..….…
19. User instructions ………………………………………………....…
20. Regular maintenance …………………………………………....…
Draining the cylinder &/or buffer vessel ...............……………….
21.
Easy Control Panel ………………………………………………..
22.
In compliance with Directive 2014/68/EU (PED) and the Regulations 812/2013 and
814/2013 issued by Directive 2009/125/EC (ErP - EcoDesign Requirements for Energy
Related Products) and by Directive 2010/30/EC (Energy Labelling of Products), the
technical and heat loss specifications together with the energy categories are written on
the labels/technical sheets attached to the product. Such labels/technical sheets must
be considered as an integral part of these instructions for use.
The Indirect Hot Water Cylinders have been tested in compliance with standard EN
12897. All Hot Water Storage Tanks are manufactured in accordance with Article 4.3 of
PED and must not be CE marked. However the manufacturer guarantees the
production quality in accordance with EN ISO 9001
Page !of !2
25
1. Overview & Regulations ..…..………………………………....…… 3
5
14
14
14
14
14
14
15
15
15
15
16
16
16
17
19
20
22
22
21
22

1.1 Overview
The Polywarm-Maxi range of Indirect hot water cylinders and storage tanks are carbon
steel construction with a patented WRAS approved internal coating for UK commercial
(dhw) systems. The calorifier range consists of single and twin coil variants offering
enhanced dhw performance by linking the coils in series when using a single heat
source or connected separately when using two heat sources.
There are four models of calorifiers with storage capacities from 500 - 1500 litres.
There are seven models of storage tanks with capacities from 500 - 3000 litres.
Controls - external (non Elco supply) devices may be used to control the operation of
the system or alternatively the Elco Easy Control panel is designed for simple timed
control of the domestic hot water throughout the day (3 periods per day) whilst also
managing the Anti-Legionella function, system re-circulation pump and up to two heat
sources plus an immersion heater - refer to Easy Control instructions & section 22, for
further information.
1.2 Regulations
Attention is drawn to the following documents for best practice:
Statutory Instruments
Water Supply (Water Quality England & Wales) Regulations 2016 - as amended
The Public Water Supplies (Scotland) Regulations 2014 - as amended
The Water Supply (Water Fittings) Regulation (Northern Ireland) 2009 - as amended
British Standards
BS 6880 Part 1, 2 & 3 Code of Practice for low temperature hot water heating systems of output
greater than 45kW.
BS 7074 Part 1: Application, selection and installation of expansion vessels and ancillary
equipment for sealed water systems.
Part 2: Code of Practice for low and medium temperature hot water heating systems.
BS 7671 Requirements for electrical installations. IET Wiring Regulations. 17th edition.
BS 8550 Guide for the auditing of water quality sampling
BS 8558 Guide to the design, installation, and maintenance of services supplying water for
domestic use within buildings. Note: this document is complimentary to BS EN 806
BS 14743 Water conditioning equipment inside buildings. Softeners. Requirements for
performance, safety and testing
BS EN ISO 4126-1 Safety devices for protection against excessive pressure. Safety valves.
BS EN 806 Specification for installations inside buildings conveying water for human
consumption
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Page 3 of 25

Note: - BS6700- The Design, Installation, Testing and Maintenance of Services supplying water
for domestic use within buildings. This document has been superseded by BS EN 806
Electrical Standards:- BS 3456 Part 201, EN 60335 Part 1
CP 342-2 Code of practice for centralised hot water supply. Buildings other than individual
dwellings.
The Health and Safety Commission (HSC) approved code of practice and guidance document
L8 - HSG274: Legionnaires disease. Technical Guidance.
CIBSE Publications
CIBSE Guide G Public Health Engineering "
CIBSE TM13: Minimising the risk of Legionnaires’ disease."
CIBSE Guide H Building Control Systems."
CIBSE Guide Energy Efficiency in Buildings."
CIBSE Commissioning Code B: 2002.
ICOM Publication - Water quality consideration for non domestic hot water systems
Department of Health
Health Technical Memorandum (HTM) 04-01: The control of Legionella, hygiene, ‘safe’
hot water, cold water and drinking water systems.
Part A Design, installation and testing."
Part B Operational Management Department of Health (DH). Addendum
Pseudonomas aeruginosa - advice for augmented care units.
HTM 04-04 The Control of Legionella in Health Care Premises- Code of Practice:2006
General Requirements
All connections to the local water main must comply with Water Supply (Water Fittings)
Regulations 1999 (as amended). Compliance with the Regulations can be demonstrated by
certification from notified body organisations such as WRAS or KIWA.
Unvented Systems
Building Regulations - use of unvented hot water storage systems with volumes exceeding 15
litres. G3 (England & Wales), P3 (Scotland) & P2 (Northern Ireland)
The unvented system components allows the storage vessel to be fed directly from the mains
cold water supply, or from a booster pump set, without the need for feed and expansion tanks.
The unvented system components should be approved and comply with the Water Supply
(Water Fittings) Regulations 1999 (as amended), including a suitably sized temperature and
pressure (T&P) relief valve, which locates directly into the top portion of the storage vessel .
DISPOSAL
At the end of the technical life cycle of this product, all metal components must be
delivered to operators authorised in the collection of metals for recycling, while all non
metal components must be delivered to suitably authorised agents. The disposal of
products must be managed in accordance with local regulations and must never be
managed as household waste.
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Page 4 of 25

2
Technical data & dimensions
2
.1 Polywarm-Maxi PWC1 Indirect Cylinders
Page
ITEM
No.
DESCRIPTION
1
Drain
2
Domestic cold water inlet
3
Primary circuit return
4
1/2”BSP tapping for
instrumentation
5
Blind inspection flange
6
Primary circuit flow
7
1
1/4
”BSP connection for
magnesium anode
8
Connection for immersion
heater
10
1/2”BSP tapping for
instrumentation
11
Re-circulation
13
T&P valve
15
Domestic hot water outlet
1
!
of
!
5
25
(
15
)
D
e
D
f
H
1
1
(
11
)
H
13
(
1
3
)
H
4
(
5
)
0
H
6
(
6
)
H
3
(
3
)
H
2
(
2
)
(
2
)
(
3
)
(
6
)
(
11
)
(
5
)
(
7
)
(
4
)
(
8
)
(
13
)
(
1
)
(
15
)
H
1
(
1
)
(
10
)
H
8
(
8
)
H
7
(
7
)
(
10
)
500 LITERS
0
H
1
(
1
)
800 - 1000 LITERS
H
1
(
1
)
0
1500 LITERS
H
4
(
4
)

2.1.2 Dimensions
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Page 6 of 25
1
Note:
- 1500 Model has
two ‘grips’ on the bottom
which allow the use of
forklift when handling and
drain pipe already fitted.
Note:
500 model - Hard foam insulation applied to tank
All other models -
Removable soft fleece insulation.
Unvented models require necessary safety equipment:
SRV/PRV (Safety relief & pressure reducing valve
including check valve), external expansion vessel,
tundish and a T&P (Temperature and Pressure) relief
valve.
These are supplied separately in the Unvented Kit.-
refer to section 9.
2.1.3 Performance data
MODEL
ABOVE
BEHIND
SIDE
INFRONT
PWC1&2
MINIMUM CLEARANCES (mm)
500
500
400
200
750
800
500
400
200
950
1000
500
400
200
1050
1500
500
400
200
1150

15
Domestic hot water outlet
Polywarm-Maxi PWC2 (twin coil) Indirect Cylinders
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Page 7 of 25
ITEM
No.
DESCRIPTION
1
Drain
8
Connection for immersion heater
2
Domestic cold water inlet
9
Upper coil return
3
Primary circuit return
10
1/2”BSP tapping for instrumentation
4
1/2”BSP tapping for instrumentation
11
Re-circulation
5
Blind inspection flange
12
Upper coil flow
6
Primary circuit flow
13
T&P valve
7
1/2”BSP tapping for instrumentation
14
2
.2.1
(15)
De
Df
H11(11)
H13 (13)
H4
(
5
)
0
H6(6)
H3(3)
H2(2)
H1(1)
H10(10)
H12(12)
H9(9) H8(8)
H7(7)
H14
(14)
500 LITERS
(
2
)
(3) (6) (11)(5) (7)
(4) (8) (10)
(
14
)
(1)
(
15
)
(9) (12)
(1
3
)
0
H1(1)
800 - 1000 LITERS
1
H1(1)
0
1500 LITERS
Connections
H
4
(
4
)
1/2”BSP tapping for instrumentation

2
.2.2 Dimensions
! !
Page 8 of 25
MODEL
ABOVE
BEHIND
SIDE
INFRONT
PWC1&2
MINIMUM CLEARANCES (mm)
500
500
400
200
750
800
500
400
200
950
1000
500
400
200
1050
1500
500
400
200
1150
1
Note:
- 1500 Model has two
‘grips’ on the bottom which
allow the use of forklift when
handling and
drain pipe already fitted.
Note:
500 model - Hard foam insulation applied to tank
All other models -
Removable soft fleece insulation.
Unvented models require necessary safety equipment:
SRV/PRV (Safety relief & pressure reducing valve
including check valve), external expansion vessel,
tundish and a T&P (Temperature and Pressure) relief
valve.
These are supplied separately in the Unvented Kit.-
refer to section 9.

2.2.3
Performance data
! !
Page
9
of
25

2.3.1 Polywarm-Maxi PWB Buffer Vessels
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Page 10 of 25
H1(15)
2000 - 2500 - 3000 LITERS
ITEM
No.
DESCRIPTION
1
Drain
2
Domestic cold water inlet
3
Flow to external heat
source
5
Blind inspection flange
7
1/2”BSP tapping for
instrumentation
8
9
1/2”BSP tapping for
instrumentation
10
Connection for immersion
heater
11
Re-circulation
12
T & P valve
13
Alternative return from
external heat source
source
14
Domestic hot water outlet
15
Drain 1”BSP (only
models >1000L)
1
H15 (9)
H7 (8)
0
H
1
7
(
1
3
)
D
e
(
14
)
H16(10)
H6(7)
H4(5)
H
2
(
2
)
H1(1)
FROM 500 TO 1500 LITERS
(
1
)
(
2
)
(
11
)
(
7
)
(
1
0
)
(
1
2
)
(
5
)
(
8
)
(
9
)
(
3
)
(
1
3
)
(
14
)
Connections
H
1
7
(
11
)
H
2
(
3
)
H
1
7
(
12
)
Return from external heat
D
f

2.3.2 Dimensions
! !
Page 11 of 25
Note:
- 1500 - 3000L
Models have two
‘grips’ on
the bottom which allow the use of a forklift when
handling and drain pipe already fitted.
Note:
500 model - Hard foam insulation applied
to tank
All other models - Removable soft fleece
insulation.
Unvented models require necessary safety
equipment: SRV/PRV (Safety relief & pressure
reducing valve including check valve), external
expansion vessel, tundish and a T&P
(Temperature and Pressure) relief valve.
These are supplied separately in the Unvented
Kit.- refer to section 9.
MODEL
ABOVE
BEHIND
SIDE
INFRONT
PWB
MINIMUM CLEARANCES (mm)
500
500
200
400
750
800
500
200
400
750
1000
500
200
400
750
1300
500
200
400
750
1500
500
200
400
750
2000
500
200
400
750
2500
500
200
400
750
3000
500
200
400
750
1

2.3.3
Performance data
! !
Page 12 of 25
1
1
2.3.4 Unvented kits

3 Installation
3.1 Handling
Care should be taken when handling the Polywarm-Maxi cylinders to avoid damage to
the outer insulation.
Models 800 and larger, are supplied with lifting points on the top of the cylinder and
models 1500L and larger are fitted with cutouts in the base support ring to
accommodate fork lift truck access.
3.2 Position
The position chosen for installation must be capable of supporting the unit when full of
water and it is important to ensure that the unit is level, true and vertical to avoid the
possibility of difficulties with air trapping and or locking in primary coils.
4 Connections
Care must be taken when making pipe connections to the tank to avoid any undue
loading of connections. Pipework must be adequately supported to avoid any undue
loading being applied to the cylinder and its connection points.
Note: ensure that any redundant tappings are capped off prior to filling the system.
After a few days of operation it is good practice to check the integrity of all joints
including the tightness of the inspection flange bolts, accessible by removing the cover.
5 PWC1 & 2 models - Primary Coils
Circulation through primary coils should always be pumped, refer to the technical data
for flow rates. The PWC range is not suitable for gravity circulation.
6 Self cleaning fluxes
If any joints on copper pipes local to the cylinder are soldered, then avoid excessive use
of self cleaning fluxes.
7 Installation of Immersion Heaters
It is important to ensure that any immersion heaters are installed with the temperature
control and high limit thermostats located so that they are positioned above the heating
elements and can detect the heat input from the heating elements.
! !
Page 13 of 25
3.3 Installation and Maintenance
Make sure that the premises where the storage tank(s) are to be installed have suitable
openings to allow their free passage to the outside without any need for demolition.
The warranty does not cover any costs de-rived from a failure to observe this point.

9 Unvented Systems
If the installation is to be of the “unvented” type, the cylinder will have been supplied
with a group of safety controls (loose) which must be installed (see Fig. 9 & Figs 16)
10 Expansion Vessel pre-charge Pressure
It is the responsibility of the installer to check the air pre-charge pressure before
installation and adjust as necessary to 3.5bar.
11 Expansion Vessel Capacity
The capacity of the expansion vessel supplied as part of the unvented kit, is nominally
sized to accommodate the capacity of the cylinder with which it was supplied plus a
nominal system pipework volume of approximately 17.5% of the cylinder capacity. If the
system pipework capacity exceeds the allowance described above, then appropriately
sized additional potable water expansion vessels will need to be obtained and installed.
! !
Page 14 of 25
Figure 9 - Example Unvented valve block
8 Hard Water
In known hard water areas the use of scale prevention measures is recommended.
Ensure compatibility with stainless steel material. No warranty is provided for
components such as immersion heaters that are damaged through scale build up.

"
! !
13 Tundish Positioning & Discharge
The tundish should be
vertical,
located
in
the same
space
as the unvented hot water
storage system
and be fitted as close as
possible
and
within
500mm of the
safety
device (i.e. the temperature pressure relief valve) and must be away from any electrical
device.
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, according to Building Regulation G3.
Note:
The discharge will consist of scalding water and steam. Asphalt, roofing felt and
non-metallic rain water
goods may
be
damaged by
such
discharges.
Where children
may play
or otherwise come
in
contact
with
discharges,
a wire
cage
or similar
guard
must be positioned to prevent contact whilst maintaining visibility.
14 Electrical installation
Wiring
should be carried
by
a
competent
electrician
in
accordance
with
the current
edition of the IEE Regulations.
Thermostats used will have a maximum switching capability (typically 16A / 230V).
If
loadings
are
in
excess of this
figure,
a
suitably
rated contactor or
relay
must be
interposed.
An
appropriately
rated isolator and fuses should be installed to
protect
the control and
load circuits.
15. Electrical connections for optional powered anode
In areas of the country that have particularly soft water and therefore poor conductivity
of the water, less than 200 micro-siemens per cm, such as Scotland, Devon and
Cornwall, then magnesium sacrificial anodes may not be fully effective in providing
protection against corrosion. The optional electrical anode protection system is effective
in providing protection in any water conditions.
It
is essential that the
powered
anode is
provided
with
a
permanent
live
supply
from a
fused spur adjacent to the tank.
Installation
-
follow the manufacturers instructions
supplied
with
the unit. The
requirements for the electrical supply are 230v / 50Hz / 3A.
Wiring - ensure that the fused spur is non switchable (permanent live).
Ensure that the cable connecting the element to the control panel is suitably protected
and routed providing protection from inadvertent disconnection.
Page 15 of 25
12 Safety Relief Valve Discharge Pipes
It is a requirement of the Building Regulations that any discharge from an unvented
system is conveyed safely to a point that is visible but will not constitute a hazard or
danger to persons in or about the building.
It is the responsibility of the installer to supply and install discharge pipes and suitable
tundishes, in accordance with the requirements of the Building Regulations.

Maintenance
- the system is maintenance free but the status must be checked every
month. This can be done by checking the Pilot LED fitted into the control box.
•
Pilot lamp green - mains voltage is present and the system is ready for operation
•
Pilot lamp OFF - no mains voltage. Intervention required
•
Pilot lamp flashing red - there is a fault. Intervention required. Refer to manufacturers
instructions.
16 Electrical connections for optional immersion heaters
Installation
- When fitting the immersion heater to the tank, ensure that the thermostat
or cut-out is located at the top of the element bundle and that there is sufficient room in
front of the tank to allow removal of the element. Check the immersion heater joint to
the tank ensuring that there are no leaks.
Wiring -
Prior to wiring up the immersion heater, check that the mains supply available
corresponds to the rating on the heater data plate and that the rating of any cables,
fuses and contactors are suitable for the electrical load and that an earth is connected
to the heater - refer to Fig 14.
Check that the thermostat safety cut-out is correctly wired to ensure complete shutdown
of the heater ie. in series with the coil of the main contactor.
Operation -
Ensure that the element is immersed in the water as this includes a
thermostat to sense the water temperature. In the event of a shutdown due to
overheating, the main isolator must be switched off before checking the system, the
water level should be checked and the system inspected. When satisfied, reset the
cutout.
Maintenance -
The immersion heater must be electrically isolated before removing the
terminal cover. Periodically inspect the element to check for any deposit build up on the
element.
Page !of !
16 25
Operation -the hot water system must be exercised at least every two months to
ensure that gas is not allowed to build up in the tank. The system must not be
disconnected from the mains electrical supply whilst the tank is full of water as this will
compromise the corrosion protection. This is particularly important during prolonged
shut down periods (holidays).

Page !of !
17 25
Figure 16 - Immersion heater wiring diagrams

17 Typical Installation Schematics
! !
Figure 17.2 - Typical Unvented Indirect Cylinder Schematic
Page 18 of 25
Figure 17.1 - Typical Open Vented Indirect Cylinder Schematic
Feed &
Expansion
Tank
Open Vent
1
2
3
6
8
9
13
11
10
16
14
15
17
Cold water booster
pump set
17
12
1
1
9
8
7
2
3
6
4
5
10
11
15
18
14
2
2
2
2
13
6
2
2
1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve
(not of Elco supply)
Legend
Legend

Page !of !
25
Figure 17.3 - Typical Open Vented Indirect Cylinder Schematic
Figure 17.4 - Typical Unvented Indirect Cylinder Schematic
Feed &
Expansion
Tank
Open Vent
1
2
3
6
8
19
11
16
14
17
Cold water booster
pump set
17
12
1
1
19
8
7
2
3
6
4
5
10
11
18
14
2
2
2
2
13
6
2
2
15
14
15
13 10
2
2
6
18
15
14
15
1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve
(not of Elco supply)
19. Inox Maxi SSC2
1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve
(not of Elco supply)
19. Inox Maxi SSC2
Legend
Legend
19

Page !of !
20 25
Figure 17.5 - Typical Unvented Water Heater and Buffer Vessel Schematic
Figure 17.6 - Typical Unvented Packaged Plate Heat Exchanger and Buffer Vessel
Schematic
1
23
8
7
2
3
6
4
5
13
11
12
17
10
12
Trigon XL
Water
Heater
P
20
21
1
23
8
7
2
3
6
4
5
13
11
12
17
10
22
20
21
2
2
2
2
2
2
2
2
6
1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure
relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve
(not of Elco supply)
19. Inox Maxi SSC2
20. Double regulating valve
21. Loading pump
22. Packaged plate heat
exchanger set
23. Inox Maxi HSB Tank
Legend