Elson 120zi User manual

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Pack Contents
Zircon unvented water heater incorporating immersion heater(s) & thermal controls•
Factoryttedtemperature/pressurereliefvalve(setat90°C/1Mpa(10bar))•
Coldwatercombinationvalveassembly•
Expansionvessel&mountingbracket•
Tundish•
2 Port motorised valve (indirect models only)•
Compressionnuts&olives•
Immersion heater spanner•
Installation & servicing instructions•
Guarantee card•
IMPORTANT
Pleaseread&understandalltheseinstructionsbeforecommencinginstallation.
Pleaseleavethismanualwiththecustomerforfuturereference.
Zircon Installation Manual
Unvented Direct & Indirect Water Heaters
Installation & Servicing Instructions

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INTRODUCTION............................................................2
GENERALREQUIREMENTS........................................3
INSTALLATIONGENERAL............................................5
INSTALLATIONDISCHARGE........................................7
INSTALLATIONDIRECT...............................................11
INSTALLATIONINDIRECT...........................................12
COMMISSIONING.......................................................14
MAINTENANCE...........................................................15
USERINSTRUCTIONS...............................................16
FAULTFINDING&SERVICING..................................17
SPARES.......................................................................18
HEATLOSS.................................................................19
ENVIRONMENTALINFORMATION.............................19
COMMISSIONINGCHECKLIST.................................22
SERVICERECORD.....................................................23
GUARANTEE...............................................................24
TECHNICALSUPPORT...............................................24
CONTENTS
The cylinder is a purpose designed unvented water
heater.Theunithasastainlesssteelinnervessel,
whichensuresanexcellentstandardofcorrosion
resistance.Theoutercasingisacombinationof
resilient thermoplastic mouldings and plastic coated
corrosionproofedsteelsheet.Allproductsare
insulatedwithCFCfreepolyurethanefoamtogive
goodheatlossperformance.(seeTable6,page19)
The unit is supplied complete with all the necessary
safetyandcontroldevicesneededtoallow
connectiontothecoldwatermains.Allthese
componentsarepresetandnotadjustable.
Thisappliancecomplieswiththerequirementsofthe
CEmarkingdirectiveandisKiwaapprovedtoshow
compliancewithBuildingRegulations(SectionG3).
Thefollowinginstructionsareofferedasaguide
toinstallationwhichmustbecarriedoutbya
competentplumbingandelectricalinstallerin
accordancewithBuildingRegulationG3,The
BuildingStandards(Scotland)Regulations1990,or
TheBuildingRegulations(NorthernIreland).
NOTE:Priortoinstallationtheunitshouldbestored
inanuprightpositioninanareafreefromexcessive
damporhumidity.
THEBENCHMARKSCHEME
Benchmarkplacesresponsibilitiesonboth
manufacturersandinstallers.Thepurposeisto
ensure that customers are provided with the correct
equipmentfortheirneeds,thatitisinstalled,
commissioned and serviced in accordance with the
manufacturer’sinstructionsbycompetentpersons
andthatitmeetstherequirementsoftheappropriate
BuildingRegulations.TheBenchmarkChecklistcan
beusedtodemonstratecompliancewithBuilding
Regulationsandshouldbeprovidedtothecustomer
forfuturereference.
Installersarerequiredtocarryoutinstallation,
commissioningandservicingworkinaccordance
withtheBenchmarkCodeofPracticewhichis
availablefromtheHeatingandHotwaterIndustry
CouncilwhomanageandpromotetheScheme.Visit
www.centralheating.co.ukformoreinformation.
IMPORTANTNOTETOUSER:PLEASEREFERTO
THEUSERINSTRUCTIONSSECTIONONPAGE16
FORIMPORTANTINFORMATIONWITHRESPECTTO
THEBENCHMARKSCHEME
INTRODUCTION

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IMPORTANT:
THISAPPLIANCEISNOTINTENDEDFORTHE
USEBYPERSONS(INCLUDINGCHILDREN)
WITHREDUCEDPHYSICAL,SENSORY
ORMENTALCAPABILITIES,ORLACKOF
KNOWLEDGEANDEXPERIENCE,UNLESS
THEYHAVEBEENGIVENSUPERVISIONOR
INSTRUCTIONCONCERNINGTHEUSEOFTHE
APPLIANCEBYAPERSONRESPONSIBLEFOR
THEIRSAFETY.
CHILDRENMUSTBESUPERVISEDTOENSURE
THEYDONOTPLAYWITHTHEAPPLIANCE.
SITINGTHEUNIT
Thecylindermustbeverticallyoormounted.
Althoughlocationisnotcritical,thefollowingpoints
shouldbeconsidered:
Thecylindershouldbesitedtoensureminimum•
deadlegdistances,particularlytothepointof
mostfrequentuse.
Avoid siting where extreme cold temperatures•
willbeexperienced.Allexposedpipework
shouldbeinsulated.
Thedischargepipeworkfromthesafetyvalves•
musthaveminimumfallof1:200fromtheunit
andterminateinasafeandvisibleposition.
Access to associated controls and immersion•
heatersmustbeavailabletoprovideforthe
servicingandmaintenanceofthesystem.
Wherethesecontrolsareinstalledagainstawalla
minimumdistanceof250mmmustbeleft(see
Fig.1).
Ensurethattheoorareaforthecylinderislevel•
andcapableofpermanentlysupportingthe
weightwhenfullofwater.(seeTable1)
WATERSUPPLY
Bear in mind that the mains water supply to the
propertywillbesupplyingboththehotandcold
waterrequirementssimultaneously.
It is recommended that the maximum water
demand is assessed and the water supply
checked to ensure this demand can be
satisfactorily met.
Note: A high mains water pressure will not
always guarantee high ow rates.
Whereverpossiblethemainssupplypipeshould
be22mm.Wesuggesttheminimumsupply
requirementsshouldbe0.15MPa(1.5bar)pressure
and20litresperminuteowrate.However,at
thesevaluesoutletowratesmaybepoorif
severaloutletsareusedsimultaneously.Thehigher
theavailablepressureandowratethebetterthe
systemperformance.
Thecylinderhasanoperatingpressureof0.35MPa
(3.5bar)whichiscontrolledbythecoldwater
combinationvalveassembly.Thecoldwater
combinationvalveassemblycanbeconnectedtoa
maximummainspressureof1.6MPa(16bar).
OUTLET/TERMINALFITTINGS(TAPS,ETC.)
Thecylindercanbeusedwithmosttypesofterminal
ttings.Itisadvantageousinmanymixershowers
tohavebalancedhotandcoldwatersupplies.In
theseinstancesabalancedpressurecoldwater
connectionshouldbeplacedbetweenthe2pieces
ofthecoldwatercombinationvalveassembly(see
Fig.2).Outletssituatedhigherthanthecylinderwill
giveoutletpressureslowerthanthatattheheater,a
10mheightdifferencewillresultina0.1MPa(1bar)
pressurereductionattheoutlet.Allttings,pipework
andconnectionsmusthavearatedpressureofat
least0.6MPa(6bar)at80°C.
GENERAL REQUIREMENTS
Table1:Unitweights
Fig.1:SitingtheUnit
WALL
Min 250mm Min 250mm
Type Model
Reference
Nominal
Capacity
(litres)
Weightof
unitfull
(Kg)
Weight
ofunit
(Kg)
Indirect 120zi 120 147 27
150zi 150 182 32
170zi 170 204 34
210zi 210 250 40
250zi 250 294 44
300zi 300 352 52
Direct 120zd 120 144 24
150zd 150 178 28
170zd 170 201 31
210zd 210 247 37
250zd 250 289 39
300zd 300 349 49

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LIMITATIONS
Thecylindershouldnotbeusedinassociationwith
anyofthefollowing:
Solidfuelboilersoranyotherboilerinwhichthe•
energyinputisnotundereffectivethermostatic
control,unlessadditionalandappropriatesafety
measuresareinstalled.
Ascendingspraytypebidetsoranyotherclass•
1backsyphonageriskrequiringthatatypeAair
gapbeemployed.
Steamheatingplantsunlessadditionaland•
appropriatesafetydevicesareinstalled.
Situationswheremaintenanceislikelytobe•
neglectedorsafetydevicestamperedwith.
Watersuppliesthathaveeitherinadequate•
pressureorwherethesupplymaybe
intermittent.
Situationswhereitisnotpossibletosafelypipe•
awayanydischargefromthesafetyvalves.
In areas where the water consistently contains a•
highproportionofsolids,e.g.suspendedmatter
thatcouldblockthestrainer,unlessadequate
ltrationcanbeensured.
In areas where the water supply contains•
chloridelevelsthatexceed250mg/l.
OPERATIONAL SUMMARY
Maximummainspressure  1.6MPa(16bar)
Operatingpressure   0.35MPa(3.5bar)
Maximumdesignpressure  0.6MPa(6bar)
Expansionvesselchargepressure 0.35MPa(3.5bar)
Expansionreliefvalvesetting 0.6MPa(6bar)
T&Preliefvalvesetting  90-95°C/1.0MPa(10bar)
Maximumprimarycircuitpressure 1.0MPa(10bar)
(indirect only)
Pressuredrop(Primarycoil)  0.02MPa(0.2bar)
Storagecapacity   seeTable1
Weightwhenfull   seeTable1
IndirectModelsinconformancewithBSEN12897:2006

5
PIPEFITTINGS
Allpipettingsaremadevia22mmcompression
ttingsdirectlytotheunit.Thettingsarethreaded
3/4”BSPmaleparallel,shouldthreadedpipe
connectionsberequired.
COLDFEED
A22mmcoldwatersupplyisrecommended,however,
ifa15mm(1/2”)supplyexists,whichprovidessufcient
ow,thismaybeused(althoughmoreownoise
maybeexperienced).
Astopcockorservicingvalveshouldbeincorporated
intothecoldwatersupplytoenablethecylinderand
itsassociatedcontrolstobeisolatedandserviced.
COLDWATERCOMBINATIONVALVEASSEMBLY
The2-piececoldwatercombinationvalveassembly
(seeFig.2)canbelocatedanywhereonthecold
water mains supply prior to the expansion vessel
(seeFig.6Page10)butthetwopiecesdonothave
tobeinstalledtogether.
The pressure reducing valve incorporates the
pressure reducer and strainer and the expansion valve
incorporatestheexpansionandcheckvalves.Ensure
that the valves are installed in the correct order
andorientation.Noothervalvesshouldbeplaced
betweentheexpansionvalveandthecylinder.A
connectioncanbemadebetweentheexpansionand
pressurereducingvalvestoprovideabalancedcold
waterconnection.Theexpansionvalveconnection
mustnotbeusedforanyotherpurpose.
DRAIN TAP
Asuitabledrainingtapshouldbeinstalledinthecold
watersupplytothecylinderbetweentheexpansion
valve(seeFig.6Page10)andtheheaterataslowa
levelaspossible.Itisrecommendedthattheoutlet
pointofthedrainpipeworkbeatleast1metrebelow
theleveloftheheater(thiscanbeachievedby
attachingahosetothedraintapoutletspigot).
EXPANSIONVESSEL
The expansion vessel accommodates expansion
thatresultsfromheatingthewaterinsidetheunit.
Theexpansionvesselispre-chargedat0.35MPa
(3.5bar).Theexpansionvesselmustbeconnected
betweentheexpansionvalveandthecylinder(see
Fig.6Page10).Thelocationoftheexpansion
vessel should allow access to recharge the pressure
asandwhennecessary,thiscanbedoneusing
anormalcarfootpump.Itisrecommendedthat
theexpansionvesselisadequatelysupported.An
expansionvesselwallmountingbracketissupplied
forthispurposeandshouldbetted.
SECONDARYCIRCULATION
Ifsecondarycirculationisrequireditisrecommended
thatitbeconnectedtothecylinderasshown (see
Fig.3page5)via a swept tee joint into the cold
feedtotheunit.Asweptteejointisavailableasan
accessory(ordercodeno.5133565).
Thesecondaryreturnpipeshouldbein15mmpipe
andincorporateacheckvalvetopreventbackow.
AsuitableWRASapprovedbronzecirculation
pumpwillberequired.Onlargesystems,dueto
theincreaseinsystemwatercontent,itmaybe
necessarytotanadditionalexpansionvesseltothe
secondarycircuit.Thisshouldbedoneifthecapacity
ofthesecondarycircuitexceeds10litres.
Pipe capacity (copper):
15mmO.D.=0.13l/m(10litres=77m)
22mmO.D.=0.38l/m(10litres=26m)
28mmO.D.=0.55l/m(10litres=18m)
NOTE:SecondarycirculationisNOTrecommendedfor
directelectricunits.
OUTLET
Thehotwateroutletisa22mmcompressiontting
locatedatthetopofthecylinder.Hotwaterdistribution
pipeworkshouldbe22mmpipewithshortrunsof
15mmpipetoterminalttingssuchassinksand
basins.Pipesizesmayvaryduetosystemdesign.
INSTALLATION GENERAL
Fig.2:Coldwatercombinationvalveassembly
Fig.3:Secondarycirculationconnection