Fabdec EXCELSIOR User manual

UNVENTED WATER HEATERS
INSTALLATION MANUAL
INCLUDING SOLAR VESSELS
EXCELSIOR

T
echnical data & installation instructions for
Technical data & installation instructions for T
EXCELSIOR
direct & indirect unvented water
heaters including solar models.
Your water heater is made from Duplex Stainless Steel, which is one of the
toughest and best grades of steel currently available.
Each unit has been individually tested and inspected to industry standard.
Your water heater uses advances in technology and innovative techniques to
provide you with a high performance water heater at the best price possible.
The
EXCELSIOR
unvented water heater can be fed directly from the
mains water supply to provide high pressure hot water capable of meeting
the needs of the modern household.
EXCELSIOR
solar cylinders enable the use of alternative energy solutions
to be integrated into domestic water heating systems.
Built to the same exacting standards as the rest of our
EXCELSIOR
range,
they exceed market standards for insulation and build quality.
No other type of water heater can provide all of the benefi ts that can be
achieved from unvented units such as the
EXCELSIOR
unvented water
heater.
All
EXCELSIOR
unvented water heaters are covered by a 25 year
guarantee (please refer to manual for terms and conditions).
IMPORTANT NOTICE FOR INSTALLATION
READ THESE INSTALLATION AND MAINTENANCE
INSTRUCTIONS BEFORE COMMENCING
Unvented cylinders are designed to BS standard and installed
to relevant building regulations.
THE RELEVANT REGULATIONS ARE:
England & Wales - Building Regulation G3
Scotland - Technical Standard P3
Northern Ireland - Building Regulations P5
The information contained in these instrcutions referring
to connection of solar cylinders details how to connect the
EXCELSIOR
solar cylinder to a solar primary circuit. In order
EXCELSIOR solar cylinder to a solar primary circuit. In order EXCELSIOR
to control this primary circuit some other controls may be
necessary according to the requirements of each individual
system. Please refer to the relevant documentation for your
particular system for instructions on how to integrate these
controls with the
EXCELSIOR
solar cylinder.
EXCELSIOR solar cylinder.EXCELSIOR
On completion of the vessel installation and commissioning, the
Benchmark log book, included at the rear of this manual, must
be completed in full by the competent installer and left with the
household who should countersign to accept completion.
THIS MANUAL IS TO BE LEFT WITH THE USER
CONTENTS
Introduction
EXCELSIOR
Range p3
Specifi ers Guide
Range p3
Specifi ers Guide
Range p3
The law and unvented p3
The benefi ts of unvented systems p3
The benefi ts of
EXCELSIOR
unvented water heaters p3
EXCELSIOR
solar water heaters p3
Dimensions and performance
EXCELSIOR
Indirect and direct p4
EXCELSIOR
solar p5
Installation Instructions
solar p5
Installation Instructions
solar p5
Siting the
EXCELSIOR
unit p6
Storage & handling p6
Check water pressure and fl ow rates p6
Connecting the water supply p6
Cold water valve & drain tap p6
Pipework to taps p6
Taps and fi tting p6
Expansion vessel & immersion heater (
EXCELSIOR
solar) p7
Primary & Secondary circulation p8
Fitting the thermal cutout & primary connections P8
Wiring p9
Fitting immersion heaters P9
Tundish p10
External expansion vessel p10
Scale p10
G3 requirement p11
Discharge pipework p11
Commissioning the
EXCELSIOR
unit p12
Fault Finding p13
Part component references p14
Warranty p14
Diagrams
Warranty p14
Diagrams
Warranty p14
Dimensional data for the
EXCELSIOR
range p4
Typical installations p7
Secondary circulation connection p8
2 x 2 (S-plan) valve system p9
2 port valve + 3 port mid position valve (Y plan) p9
Immersion heater p9
Schematic discharge pipe arrangement p11
Internal expansion commissioing diagram p12
INTRODUCTION
The
EXCELSIOR
unvented water heater
is a high
quality stainless steel unvented cylinder to provide hot
water from a cold mains water supply of between 3 bar
and 12 bar. Reduced performance is available at lower
pressures although the units are not suitable for pressures
lower than 1.5 bar and a fl ow rate of less than 20 litres per
minute. The indirect heat exchange surfaces are designed
to provide a rapid heat up time. The unit comes complete
with all the necessary safety equipment to comply with
legislation governing the installation of such systems.
The
EXCELSIOR
solar unvented water heater
has been designed for use with all solar panels and ground
source heat pump systems requiring a storage and heating
vessel please ensure compatibility prior to installation.
SPECIFIERS GUIDE
THE LAW AND UNVENTED
THE LAW AND UNVENTED
THE LAW AND UNVENTED
THE LAW AND UNVENTED
It is legal to fi t an unvented unit into any property, UK water
byelaws were amended to allow this change.
There is no longer a requirement to have an old-fashioned
‘ Tank in the Roof’ system.
THE BENEFITS OF UNVENTED SYSTEMS
THE BENEFITS OF UNVENTED SYSTEMS
THE BENEFITS OF UNVENTED SYSTEMS
THE BENEFITS OF UNVENTED SYSTEMS
• A real Power Shower without the noisy pump
• No tanks in the roof
• No ball cocks to jam or leak
• All your water, hot and cold, is direct from the mains
• Site the
EXCELSIOR
unvented water heater wherever
convenient
• The
EXCELSIOR
fi lls your bath in minutes and will run two at
the same time (subject to good plumbing and fl ow rates)
• The
EXCELSIOR
can work off electricity (Economy 7),
alternative energy systems or any oil or gas fi red boiler (not
suitable for solid fuel boilers)
THE BENEFITS OF
EXCELSIOR
• Annual inspection as per warranty
• Duplex stainless steel
• High quality fi nish
• Low heat loss for maximum economy
• No sacrifi cial anode - low maintenance
EXCELSIOR
SOLAR
The
EXCELSIOR
solar range is available in four vessel capacities
in both direct electric or indirect models. Each cylinder has been
specifi cally designed for use with an alternative energy heating
system and includes a large corrugated coil that provides optimum
heat transfer from the alternative heat source to the water in the
cylinder.
The
EXCELSIOR
solar unvented water heater should only be
used as part of a solar or ground source heat pump installation and
confi gured as shown. Additional safety devices may be required if
the cylinder is operated with other heat sources.
STANDARD EQUIPMENT
STANDARD EQUIPMENT
STANDARD EQUIPMENT
STANDARD EQUIPMENT
Before commencing installation check that all the components of your
EXCELSIOR
unit are contained in the kit.
• 3kW Incoloy 825 heating element - incorporating thermostat 70
degrees Celsius and re-setable safety cut-out set at 80 degree Celsius
• Cold water control valve comprising line strainer, check valve &
appropriate pressure reducing valve
• Pressure relief valve with non-return valve set at 6 bar
• Tundish 15mm x 22mm Female x Female
• Temperature / Pressure relief valve set at 90 degrees Celsius and 7
bar pressure (factory fi tted)
• Motorised valve (indirect units only)
• Cylinder thermostat maximum setting 85 degrees Celsius (factory
fi tted to indirect units only)
• Thermal cut-out set to operate at 87 degrees Celsius, +/-3 degrees
(indirect units only)
• Expansion vessel, where required, with capacity to suit vessel size
Note: The solar range must always be
installed with an expansion vessel.
Standard indirect and direct units can
accommodate internal expansion and hence
do not require an external expansion vessel. In
this instance a 2 bar PRV should be fi tted. Where
external expansion is required the PRV should be a
3 bar version. Please refer to installation schematics.
2
3

DIMENSIONS & PERFORMANCE
EXCELSIOR
INDIRECT & DIRECT
EXCELSIOR - Direct Heat Exterior Reference
Dimensions
Reference
Volumes
Litres
A
B
C
D
E
130
957.5
196
182.5
331.5
388
150
1085.5
196
182.5
340
438
175
1242.5
196
182.5
252
489.5
215
1462
196
182.5
368.5
465.5
255
1752.5
196
182.5
388
484
305
2029
196
182.5
409.5
488.5
EXCELSIOR - Indirect Heat Exterior Reference Dimensions
Reference
Volumes
Litres
A
B
C
D
E
F
G
130
957.5
212.5
192.5
331.5
196.5
182.5
339
150
1085.5
212.5
192.5
341
196.5
182.5
339
175
1242.5
212.5
262.5
352
196.5
182.5
379.5
215
1462
212.5
262.5
368.5
196.5
182.5
379.5
255
1752.5
212.5
262.5
388
196.5
182.5
379.5
305
2029
212.5
262.5
388
196.5
182.5
379.5
EXCELSIOR - Performance
Nominal
Capacity
Litres
Heat up
Model IDH
mins
Heat up
Model DH
mins
Reheat
Model IDH
mins
Reheat
Model DH
mins
Heat loss in
24hrs
kw/hr
80
33
64
23
53
1.12
130
28
115
21
90
1.5
150
33
138
24
104
1.82
175
27
167
24
124
2.10
215
35
212
30
153
2.64
255
42
263
35
184
2.73
305
50
313
42
220
2.88
Slight variations may occur with changes to water mains supply
pressure.
Reheat times are those to heat 70% of the cylinder from cold.
Test carried out by the BBA, an independent testing agency.
The heat loss of each
EXCELSIOR
unvented unit while
maintaining the temperature of the stored water at 65 degrees
Celsius is given in the performance table opposite.
EXCELSIOR - SOLAR Direct Heat Exterior Reference Dimensions
Reference
Volumes
Litres
A
B
C
D
E
F
G
H
I
130
957.5
300.5
348
225.5
192.5
212.5
182.5
182.5
455
150
1085.5
300.5
398
225.5
192.5
212.5
182.5
182.5
513
175
1242.5
469
398
225.5
267.5
212.5
182.5
182.5
589
215
1462
590
398
225.5
267.5
212.5
182.5
182.5
589
255
1752.5
469
398
225.5
267.5
212.5
182.5
182.5
589
305
2029
5590
398
225.5
267.5
212.5
182.5
182.5
589
DIMENSIONS & PERFORMANCE
EXCELSIOR
SOLAR
EXCELSIOR SOLAR - Performance
Nominal
Capacity
Litres
Heat up
Model IDH
mins
Heat up
Model DH
mins
Reheat
Model IDH
mins
Reheat
Model DH
mins
Heat loss in
24hrs
kw/hr
175
18
20
13
14
1.78
215
21.5
24
16
17
2.19
255
25
28.5
19
20
2.31
305
30
34
22
24
2.51
EXCELSIOR - SOLAR Indirect Heat Exterior Reference Dimen-
sions
Reference
Volumes
Litres
A
B
C
D
E
F
G
H
130
957.5
182.5
212.5
192.5
505
192.5
301
225.5
150
1085.5
182.5
212.5
192.5
505
192.5
301
225.5
175
1242.5
182.5
212.5
267.5
579.5
262.5
469
225.5
215
1462
182.5
212.5
267.5
579.5
262.5
590
225.5
255
1752.5
182.5
212.5
267.5
579.5
262.5
590
225.5
305
2029
182.5
212.5
267.5
579.5
262.5
590
225.5
4
5
Indirect Heat
Direct Heat
Slight variations may occur with changes to water
mains supply pressure.
EXCELSIOR
solar data is based on a primary fl ow
temperature of 60 degrees Celsius and heating water
from 15 to 60 degrees Celsius. The immersion of
the cylinder or external boiler must be used to raise
the temperature to 60 degrees Celsius from the
maximum temperature achieved at any time by the
solar system.
Reheat times are those to heat 70% of the cylinder
from cold.
Test carried out by the BBA, an independent testing
agency.
The heat loss of each
EXCELSIOR
Unvented
unit while maintaining the temperature of the
stored water at 65 degrees Celsius is given in the
performance table opposite.
(Fig 3)
(Fig 1)
(Fig 2)
(Fig 4)
Solar - Direct Heat
Solar - Direct Heat
Solar - Indirect Heat
Solar - Indirect Heat
All measurements are in mm.
All measurements are in mm.

EXCELSIOR UNVENTED INSTALLATION INSTRUCTIONS
WARNING:
Under no circumstances must the factory fi tted temperature pressure relief valve
be removed. This will totally invalidate any guarantee or claim. The cold-water inlet valve assembly
must be fi tted or the
EXCELSIOR
unit will not perform satisfactorily.
EXCELSIOR unit will not perform satisfactorily.EXCELSIOR
DO NOT ATTEMPT TO VENT THE PRIMARY CIRCUIT THROUGH THE
EXCELSIOR
UNIT.
EXCELSIOR UNIT.EXCELSIOR
All boilers should be installed to manufacturers instructions and the primary circuit through the
EXCELSIOR
unit must be pumped.
SITING THE
SITING THE
SITING THE
SITING THE
EX
CELSIOR
UNIT
The unit can be placed anywhere convenient. Since it is
connected directly to the mains water supply it is equally
effi cient on any fl oor – ground, fi rst or second. Avoid areas
that may be subject to frost. Try to keep pipe runs as short as
possible for maximum economy, especially hot water discharge
pipes running down from the
EXCELSIOR
unit.
The unit can be fi tted into a conventional airing cupboard and
does not require any additional insulation.
ALL
EXCELSIOR
UNITS MUST BE STORED
VERTICALLY FOR INDOOR USE ONLY.
The water supply to the cylinder should be potable water direct
from a public mains supply with any water treatment equipment
functioning correctly.
CHECK WATER PRESSURE & FLOW
RATES
RATES
RATES
RATES
We suggest 1.5 bar pressure & 15 litres / minute fl ow rate to be
the minimum requirements for satisfactory operation. Below this
the unit will still operate but you will not be able to run two, or
more, outlets at the same time. 85% of all UK homes have more
than 2 bar pressure.
The mains supply must not exceed 16 bar. If it does a special
pressure-reducing valve will be required.
Consideration should be given to the routing of the discharge
pipe and the location of the solar panel or alternative energy
source.
STORAGE & HANDLING
If the cylinder is not being installed immediately, it should remain
in its carton with all pipe end protective caps in place to prevent
damage.
CONNECTING THE WATER SUPPLY
• Pipework is not supplied
• All pipework should be installed using good plumbing practice.
We recommend 22mm mains cold water supply is used.
• Install a Stop Cock Valve before the cold water inlet assembly
on the incoming mains water supply so the unit can be isolated
if required.
COLD WATER VALVE
The combined cold water valve (supplied) can be connected
anywhere on the cold water mains prior to the unit. It can even
be located at a point near to where the mains supply enters the
premises if this is more convenient. When installing the cold water
valve, ensure that the arrow is pointing in the same direction as
the mains water supply fl ow when connecting, see fi g 7 and 8.
The cold water balancing port, on the valve, allows you to
connect the cold water mains to the rest of the property thus
giving balanced pressure throughout. If this facility is not required
leave the cap on.
DRAIN TAP
A drain tap to drain the unit must be fi tted to the cold-water inlet
pipe somewhere between the
EXCELSIOR
unit
and the cold
water valve assembly and at as low a level as possible, see fi g. 7
and 8.
PIPEWORK TO TAPS
Ideally a 22mm pipe run should supply the outlets throughout
the property with short lengths (max 1 metre) runs of 15mm
going to baths, showers, and basin taps. Smaller bore pipe can be
used to suit taps.
TAPS & FITTINGS
All taps and fi ttings incorporated into the unvented system
should have a rated operating pressure of 7 bar or above.
INLET GROUP
The inlet group will vary according to whether the vessel is
fi tted as internal or external expansion, see fi g. 7 and 8.
RECOMMENDED INSTALLATION SCHEMATICS
6
7
(Fig 5)
EXTERNAL EXPANSION SCHEMATIC
(Fig 6)
INTERNAL EXPANSION SCHEMATIC
(Fig 7)
INLET GROUP INTERNAL
EXPANSION
(Fig 8)
INLET GROUP EXTERNAL
EXPANSION

INSTALLATION INSTRUCTIONS
PRIMARY CIRCUIT
PRIMARY CIRCUIT
PRIMARY CIRCUIT
PRIMARY CIRCUIT
The motorised valve supplied and the thermal cut-out (Hi limit stat)
must be fi tted to the primary fl ow. Use compression fi ttings only.
Operation of the cut-out and motorised valve
To comply with BBA regulations and to prevent the temperature
reaching 100 degrees Celsius the thermal cut-out supplied must
be fi tted.
The thermal cut-out is wired in series to the cylinder thermostat.
When the thermal cut-out senses an abnormal rise in
temperature in the primary fl ow the electrical supply to the
motorised valve will be cut, and the valve will be in the closed
position thus cutting of the primary water from the boiler to
the indirect coil in the cylinder. If this occurs it must be reset
manually. If the thermal cut-out operates check the cylinder stat
and / or boiler stat.
SECONDARY RETURN
SECONDARY RETURN
SECONDARY RETURN
Secondary circuit connections
MUST
be made to the cylinder
in accordance with the recommended installation diagram. A
drain cock (not supplied) should be fi tted in the cold water inlet
to facilitate draining of the cylinder.
This is particularly easy to fi t on the
EXCELSIOR
units; and
is illustrated in Fig.9 opposite. A swept tee (not supplied)
is needed for all indirect models if secondary circulation is
required and is fi tted as per the illustration. A non-return valve
(not supplied) must also be fi tted to prevent backfl ow. A pump
will be required to circulate the hot water (not supplied). The
return feed is in 15mm pipe and all work can be done on site.
PRIMARY CIRCUIT
PRIMARY CIRCUIT
PRIMARY CIRCUIT
(
EXCELSIOR
(EXCELSIOR (
SOLAR)
EXCELSIOR
solar cylinders are suitable for connecting to
a solar collector system and, where a twin coil is present
(INDIRECT) to a gas or oil central heating boiler.
SOLID FUEL OR WOOD BURNING BOILERS AND
GRAVITY CIRCULATION SYSTEMS MUST NOT
BE USED ON THE PRIMARY CIRCUIT OF AN
UNVENTED HOT WATER SYSTEM.
The cylinder should be installed in accordance with the solar
installation instructions for connection to the primary fl ow and
return.
The
EXCELSIOR
solar range must only be connected to solar
installations containing a hydraulic station with two non-return
valves (one in the fl ow to the collector and one in the return)
such as the
EXCELSIOR
Solar Eclipse System
.
This will prevent
. This will prevent .
thermal siphoning of the heat transfer fl uid when the pump is
switched off. Where two non-return valves are not present or
hydraulic station is not used in the solar system, a second two-
port valve must be installed into the fl ow of the solar coil and
wired to the lower two-port valve.
SECONDARY CIRCULATION
SECONDARY CIRCULATION
SECONDARY CIRCULATION
(
(
(
EXCELSIOR
(EXCELSIOR (
SOLAR)
EXCELSIOR SOLAR)EXCELSIOR
The temperature and pressure relief valve (factory fi tted) should
not be removed from the cylinder or tampered with in any way.
The valve is pre-calibrated to lift at 7 bar or 90 degrees Celsius
and any attempt to adjust it will invalidate the warranty and
could affect the safety performance of the unit.
IMPORTANT. If a secondary circulation
circuit is installed then a larger expansion
vessel may be required to handle the
increase in water volume. Calculate the additional
water volume and contact our customer services
department regarding suitable vessel sizes.
8
The
EXCELSIOR
solar is supplied with one two-port
motorised valve which should be connected in the fl ow to the
auxiliary coil and wired to the upper twin thermostat of the
cylinder.
Solar Pump - the lower twin thermostat should be connected in
line with the solar pump power supply.
(Fig 9)
Check valve
Secondary
(Fig 9)
Secondary
(Fig 9)
Return
Secondary
circulation
pump
Cold water supply
Swept tee
Cold inlet
connection
WARNING:
All electrical wiring should be carried out by a competent electrical contractor
and must conform to the latest IEE wiring regulations.
Do not switch the power on until the unit has been fi lled with water and all wiring has been earthed.
See Fig 10, 11 and 12.
IMMERSION HEATER
IMMERSION HEATER
IMMERSION HEATER
IMMERSION HEATER
(
(
(
EXCELSIOR
(EXCELSIOR(
SOLAR)
For direct solar (single coil) cylinders, the immersion heater
should be connected and suitably controlled to bring the water
temperature to 60 degrees Celsius following heating by the
alternative energy source.
FITTING IMMERSION HEATERS
FITTING IMMERSION HEATERS
FITTING IMMERSION HEATERS
FITTING IMMERSION HEATERS
These are supplied as standard. An O ring is supplied as the seal
and must be fi tted against the fl ange of the element. Take care
not to cross thread and
DO NOT
use any other type of seal.
As our heating element is Incoloy 825 and is fi tted with a
cut-out and thermostat for safety, a non-standard 1
3
/
4
”
boss
” boss ”
is fi tted to the unit. Replacement elements can be obtained
through your authorised service agent.
IMPORTANT: ensure that the immersion
heater thermostat is set to 60 degrees
Celsius.
9
WIRING INSTRUCTIONS
(Fig 10)
2 PORT
(Fig 11)
3 PORT
LNE
L N E
Mains isolater
supply 240V.50HZ
Fuse 5 AMP
Room thermostat
Room thermostat
Programmer
Programmer
Boiler
Boiler
Pump
Pump
(2-Port (DHW)
Thernostat
Cut out
3-Port mid postn
Room thermostat
Programmer
Boiler
Pump
(2-Port (DHW)
Thernostat
Cut out
2-Port (HGT)
LNE
Mains isolater
supply 240V.50HZ
Fuse 5 AMP
(Fig 12)

WIRING INSTRUCTIONS
TWO PORT VALVE
The two port valve should be wired to the thermostat as per
Fig 10 or 11 depending on required confi guration. Connect the
live supply to the thermal cut-out and connect the brown wire
of the two port valve to terminal 2 on the thermostat. Earth
and Neutral supplies can be connected directly to the valve.
The orange wire of the two port valve should be connected to
the central heating boiler and the cylinder thermostat set to 60
degrees Celsius. The power supply to the pump station should be
connected via the lower valve.
TUNDISH, EXTERNAL EXPANSION & SCALE
FITTING THE THERMAL CUT-OUT &
FITTING THE THERMAL CUT-OUT &
FITTING THE THERMAL CUT-OUT &
FITTING THE THERMAL CUT-OUT &
PRIMARY CONNECTIONS
PRIMARY CONNECTIONS
PRIMARY CONNECTIONS
PRIMARY CONNECTIONS
The motorised valve supplied and the thermal cut-out (Hi limit
stat) must be fi tted to the primary fl ow. Use compression fi ttings
only.
Operation of the cut-out and motorised valve; to comply with
BBA regulations and to prevent the temperature reaching 100
degrees Celsius the thermal cut-out supplied must be fi tted.
The thermal cut-out is wired in series to the cylinder
thermostat. When the thermal cut-out senses an abnormal rise
in temperature in the primary fl ow the electrical supply to the
motorised valve will be cut, and the valve will be in the closed
position thus cutting of the primary water from the boiler to
the indirect coil in the cylinder. If this occurs it must be reset
manually. If the thermal cut-out operates check the cylinder stat
and or boiler stat.
DISCHARGE PIPEWORK
TUNDISH
TUNDISH
TUNDISH
TUNDISH
The tundish supplied must be fi tted so it is visible to the
occupier. The discharge pipe must be 22mm copper pipe.
Regulations do not permit more than 3 x 90-degree bends
between the
EXCELSIOR
unit and the outfl ow. Between the
temperature & pressure relief valve and the fi rst 90-degree bend
there must be a fall of at least 300mm. The fall of the pipework
must be continuous and the pipe should terminate in the gully
or be bent backwards onto an outside wall, in a place where
discharge cannot be injurious to persons.
If you need to site the
EXCELSIOR
unit in the middle of the
house your discharge pipe to the tundish can be as far away as
9m, which in most cases is enough to run the fi nal discharge
point. After 9m, increase the pipe size to a greater diameter
than 22mm and accordingly for subsequent 9m lengths, see table
1 on page 12.
EXTERNAL EXPANSION VESSEL
EXTERNAL EXPANSION VESSEL
This smaller tank is connected to the cold-water inlet side of
the vessel. Mount the tank according to separate manufacturers
instructions provided with the External Expansion vessel.
See fi g 8 page 7.
A suitable expansion vessel with a pre-charge pressure of 3
bar is supplied with the
EXCELSIOR
solar. The expansion
vessel should be Tee’d off between the pressure relief valve
and the cylinder (see installation diagram) and should always
be positioned with the entry point at the bottom. Installation
should always be by means of a standard T connector ensuring
no other valve is between this and the cylinder. Adjust the
pressure to 3.5 bar.
SCALE
In hard water areas lower water temperatures can result in less
scale being deposited.
If a water softener is used it should be capable of fl ows
of approximately. 50 lt/min, this will maintain maximum
performance of the
EXCELSIOR
unit.
If no descaler or softener is used then the heating element(s)
will need descaling periodically for maximum effi ciency.
10
11
G3 REQUIREMENT
‘...there shall be precautions...to ensure that the hot water
discharged from safety devices is safely conveyed to where it
is visible but will not cause danger to persons in or about the
building.’
G3 GUIDANCE SECTION 3.9
The discharge pipe (D1) from the vessel up to and including
tundish is generally supplied by the manufacturer of the hot
water storage system. Where otherwise the installation should
include the discharge pipe(s) (D1) from the safety device(s). In
either case the tundish should be vertical located in the same
space as the unvented hot water storage system and be fi tted as
close as possible and within 500mm of the safety device e.g the
temperature relief valve.
The discharge pipe (D2) from the tundish should terminate in a
safe place where there is no risk to persons in the vicinity of the
discharge, preferably be of metal and:
a. 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 ie. discharge
pipes between 9m and 18m equivalent resistance length
should be at least two sizes larger, than the nominal outlet
size of the safety device between 18 and 27m, at least 3
sizes larger and so on. Bends must be taken into account in
calculating fl ow resistance. Refer to Table 1 overleaf and fi g. 6.
An alternative approach to sizing discharge pipes would be to
follow BS 6700:1987 specifi cation for design installation, testing
and maintenance of services supplying water for domestic use
within buildings and their curtilages, Appendix E, section E2 and
table 21.
b. have a vertical section of pipe at least 300mm long, below the
tundish before any elbow or bends in the pipework.
c. be installed with a continuous fall.
d. have discharges visible at both the tundish and the fi nal point
of discharge but where this is not possible or is practically
diffi cult there should be clear visibility at one or other of
these locations.
Examples of acceptable discharge arrangements are:
i) ideally below a fi xed grating and above the water seal in a
trapped gully.
ii) downward discharges at low level; i.e. up to 100mm above the
external surfaces such as car parks, hard standings, grassed
areas etc. 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; e.g 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 and 3m from any
plastics guttering system that would collect such discharges
(tundish visible.)
iv) where a single pipe serves a number of discharges, such as in
blocks of fl ats, the number served should be limited to not
more than 6 systems so that any installation discharging can
be traced reasonably easily. The single common discharge
pipe should be at least one pipe size larger than the largest
individual discharge pipe (D2) to be connected. If unvented
hot water storage systems are installed where discharges
from safety devices may not be apparent i.e. in dwellings
occupied by blind, infi rm 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, roofi ng
felt and non-metallic rainwater goods may
be damaged by such discharges.
WORKED EXAMPLE OF DISCHARGE
PIPE SIZING
The example below is for a G1/2 temperature 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 1: (overleaf)
Maximum resistance allowed for a straight length of 22mm copper
discharge pipe (D2) from G1/2 temperature relief valve is 9.0m
Subtract the resistance for 4 No 22mm elbows at 0.8m each = 3.2m
Therefore the permitted length equates to 5.8m, 5.8m is less than
the actual length of 7m therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe
(D2) from a G1/2 temperature relief valve equates to 18m
Subtract the resistance of 4 No 28mm elbows at 1.0m each =
4.0m
Therefore the maximum permitted length equates to 14m
As the actual length is 7m a 28mm (D2) copper pipe will be
satisfactory.
(Fig 14)
28mm
Tundish
22mm
22mm
Pressure
Pressure
relief
valve
15mm
T & P Valve
IMPORTANT: regular checks should be
carried out to ensure that the expansion
vessel is correctly pressurised to 3.5 bar
at all times.
(Fig 13)
(Fig 13)

Table 1 – Sizing of copper discharge pipe (D2) for common T&P relief valve sizes
Valve outlet Size
Minimum size of discharge
pipe D1
Minimum size of discharge
pipe D2
Maximum resistance allowed,
expressed as a length of straight
pipe (i.e: no elbows or bends)
Resistance created by each
elbow or bend
G1/2
15mm
22mm
up to 9m
0.8m
28mm
up to 18m
1.0m
35mm
up to 27m
1.4m
G3/4
22mm
28mm
up to 9m
1.0m
35mm
up to 18m
1.4m
42mm
up to 27m
1.7m
G1
28mm
35mm
up to 9m
1.4m
42mm
up to 18mm
1.7m
54mm
up to 27m
2.3m
COMMISSIONING
FAULT FINDING
12
13
USERS INSTRUCTIONS
USERS INSTRUCTIONS
USERS INSTRUCTIONS
USERS INSTRUCTIONS
Your
EXCELSIOR
unvented hot water duplex stainless cylinder
has been designed to
give many years of trouble free service and
is made from hygienic high grade steel. It includes a 3kW electric
immersion heater which heats the water to 60°C once
pre-heating of the solar system is completed (
EXCELSIOR
solar only).
The fl ow temperature of the hot water can be set to your
requirements on the immersion heater ideally 60°C. Higher
temperatures can cause tripping of the high limit thermostat and
introduces more energy loss from the cylinder.
When a hot tap is turned on there may be a short surge of
water, this is quite normal with unvented systems and does not
mean there is a fault.
When you fi rst fi ll a basin the water may sometimes appear
milky. This is due to very tiny air bubbles in the water which will
clear very quickly.
WARNING:
If cold/warm water exits from the
temperature and pressure relief valve
(TPV) or from the pressure relief valve (PRV)
call your installer or the
EXCELSIOR
customer
service centre. If very hot water exits from
either valve switch off the heat source
immediately and isolate the electricity supply to
the cylinder and separate heat source.
The solar system is confi gured to heat the water
to its maximum economic temperature which
may vary with outside temperature and weather
conditions. The immersion may be programmed
to operate during fi xed periods of the day or
night.
If the hot water runs cool it may be necessary to
manually switch on the immersion to heat the
water – please see the relevant instructions for
your alternative energy device.
Fault Possible cause Remedy
Fault Possible cause Remedy
No hot water
No hot water
1. Mains supply off 1. Open stopcock
2. Strainer blocked 2. Turn water supply off, remove
2. Strainer blocked 2. Turn water supply off, remove
strainer and clean. (see 10.6)
strainer and clean. (see 10.6)
3. Pressure reducing valve 3. Re-fi t with arrow pointing in
3. Pressure reducing valve 3. Re-fi t with arrow pointing in
(PRV) fi tted the wrong way direction of fl ow
(PRV) fi tted the wrong way direction of fl ow
Water from hot taps is cold
Water from hot taps is cold
1. Programmer set to heating 1. Set programmer to call
only or not switched on for hot water
only or not switched on for hot water
2. Central heating boiler malfunction 2. Check boiler operation if faulty consult your
2. Central heating boiler malfunction 2. Check boiler operation if faulty consult your
boiler manufacturers instructions
boiler manufacturers instructions
3. High limit thermostat has tripped 3. Check and re-set
3. High limit thermostat has tripped 3. Check and re-set
4. Pump malfunction 4. Check wiring and/or plumbing
4. Pump malfunction 4. Check wiring and/or plumbing
connections to pump
connections to pump
Intermittent water discharge
Intermittent water discharge
1. Expansion vessel has lost its 1. Turn off stopcock open a hot
through tundish on warm-up
charge pressure water tap check vessel charge
pressure and recharge to 3 bar
pressure and recharge to 3 bar
Continuous water discharge
Continuous water discharge
1. Pressure reducing valve (PRV) 1. Check pressure from PRV if
not working greater than 3.5 bar replace cartridge
not working greater than 3.5 bar replace cartridge
2. Expansion relief valve not seating correctly 2. Manually lift the valve once or
2. Expansion relief valve not seating correctly 2. Manually lift the valve once or
twice to clear any debris from the
twice to clear any debris from the
seat otherwise replace valve
seat otherwise replace valve
3. Temperature and pressure relief 3. Manually lift the valve once or
3. Temperature and pressure relief 3. Manually lift the valve once or
valve not seating correctly twice to clear any debris from the
valve not seating correctly twice to clear any debris from the
seat otherwise replace valve.
seat otherwise replace valve.
Fault Possible cause Remedy
1. Mains supply off 1. Open stopcock
2. Strainer blocked 2. Turn water supply off, remove
strainer and clean. (see 10.6)
3. Pressure reducing valve 3. Re-fi t with arrow pointing in
(PRV) fi tted the wrong way direction of fl ow
1. Programmer set to heating 1. Set programmer to call
only or not switched on for hot water
2. Central heating boiler malfunction 2. Check boiler operation if faulty consult your
boiler manufacturers instructions
3. High limit thermostat has tripped 3. Check and re-set
4. Pump malfunction 4. Check wiring and/or plumbing
connections to pump
charge pressure water tap check vessel charge
pressure and recharge to 3 bar
not working greater than 3.5 bar replace cartridge
2. Expansion relief valve not seating correctly 2. Manually lift the valve once or
twice to clear any debris from the
seat otherwise replace valve
3. Temperature and pressure relief 3. Manually lift the valve once or
valve not seating correctly twice to clear any debris from the
seat otherwise replace valve.
Fault Possible cause Remedy
1. Mains supply off 1. Open stopcock
2. Strainer blocked 2. Turn water supply off, remove
strainer and clean. (see 10.6)
3. Pressure reducing valve 3. Re-fi t with arrow pointing in
(PRV) fi tted the wrong way direction of fl ow
1. Programmer set to heating 1. Set programmer to call
2. Central heating boiler malfunction 2. Check boiler operation if faulty consult your
boiler manufacturers instructions
3. High limit thermostat has tripped 3. Check and re-set
4. Pump malfunction 4. Check wiring and/or plumbing
connections to pump
1. Expansion vessel has lost its 1. Turn off stopcock open a hot
charge pressure water tap check vessel charge
pressure and recharge to 3 bar
1. Pressure reducing valve (PRV) 1. Check pressure from PRV if
not working greater than 3.5 bar replace cartridge
2. Expansion relief valve not seating correctly 2. Manually lift the valve once or
twice to clear any debris from the
seat otherwise replace valve
3. Temperature and pressure relief 3. Manually lift the valve once or
valve not seating correctly twice to clear any debris from the
seat otherwise replace valve.
COMMISSIONING A NEWLY INSTALLED
COMMISSIONING A NEWLY INSTALLED
COMMISSIONING A NEWLY INSTALLED
COMMISSIONING A NEWLY INSTALLED
UNVENTED CYLINDER WITH AN
UNVENTED CYLINDER WITH AN
UNVENTED CYLINDER WITH AN
UNVENTED CYLINDER WITH AN
INTERNAL AIR GAP
INTERNAL AIR GAP
INTERNAL AIR GAP
INTERNAL AIR GAP
1. Before turning on the mains supply to the cylinder a hot
water tap should be opened, preferable on the same fl oor or
the fl oor below where the cylinder is located.
2. Turn on the supply to the cylinder and fi ll until water runs
from the open hot water tap.
3. Turn off the supply to the cylinder and wait for the water to
stop running from the open hot water tap.
4. Operate the temperature and pressure relief valve until
water stops fl owing.
5. Close the hot water tap and temperature and pressure relief
valve.
6. Connect an air pump to the Schrader valve, located on the
pressure reducing water inlet valve.
7. Open the shut-off valve
8. Pump air into the Schrader valve until a pressure of .7 bar is
reached.
9. Remove the pump and close the shut-off valve.
10. Turn the mains supply back on and bring the cylinder up to
working pressure.
REPLACING AIR SPACE IF LOST
DURING SERVICE
1. Turn off the mains supply to the unvented hot water cylinder
2. Open a hot water tap, preferable on the same fl oor or the
fl oor below where the cylinder is located.
3. Operate the temperature and pressure relief valve until
water stops fl owing.
4. Close the hot water tap and temperature and pressure relief
valve.
5. Connect an air pump to the Schrader valve, located on the
pressure reducing water inlet valve.
6. Open the shut-off valve
7. Pump air into the Schrader valve until a pressure of 1.2 bar is
reached.
8. Remove the pump and close the shut-off valve.
9. Turn the mains supply back on and bring the cylinder up to
working pressure.
DRAINING
DRAINING
DRAINING
DRAINING
Switch off electrical power to the immersion heaters and/or
shut down the boiler. Close the stopcock valve to isolate the
EXCELSIOR
unit.
Attach hosepipe to the drain cock having suffi cient length to
Attach hosepipe to the drain cock having suffi cient length to
take water to a suitable discharge point.
take water to a suitable discharge point.
Open drain cock.
Open hot water tap nearest
Open hot water tap nearest
EXCELSIOR
unit.
If water fails to drain from the
If water fails to drain from the
EXCELSIOR
unit, vent the sys-
tem by opening the temperature and pressure relief valve.
tem by opening the temperature and pressure relief valve.
(Fig 15)
INTERNAL EXPANSION
COMMISSIONING DIAGRAM
COMMISSIONING DIAGRAM
WARNING:
disconnect electrical supply before removing any electrical equipment cover.

WARRANTY
CONTACTS
SERVICING & MAINTENANCE
fabdec Ltd guarantee all electrical and mechanical controls supplied with the cylinder excluding the immersion for a period of 5 years
from the date of purchase provide that they have been installed for their intended use by a competent person and have not been
modifi ed in any way. The immersion(s) are guaranteed for a period of 2 years, excluding any failure caused by lime-scale.
In addition fabdec Ltd guarantees the stainless still inner hot water cylinder for a period of 25 years from the date of purchase
against faulty material or manufacture provided that:
(a) The vessel has been installed by a competent person in accordance with this installation manual and all current regulations and
codes of practice in place at the time of installation.
(b) It has been used solely for the purpose of heating potable water that complies with current (at the time of installation)
EU standards and is not fed with water from a private source.
(c) It had not been modifi ed in any way.
(d) It has not been subjected to excessive pressure or electrolytic action from dissimilar materials, or attack from any salt deposits.
(e) It has been installed indoors in a frost-free environment.
(f) The cylinder is connected to a public water supply maintained by a local water authority.
(g) The warranty card is completed and returned to fabdec Ltd within 90 days of installation.
This warranty is not transferable. This warranty does not include claims due to frost or lime scale damage. Proof of purchase will be
required against any claim. This guarantee does not affect your statutory rights.
EXCELSIOR
fabdec Ltd
Grange Road
Ellesmere
Shropshire
SY12 9DG
UK
TEL: [phone]
SALES/SERVICE TEL: [phone]
FAX: [phone]
Email: excelsior[email protected]
Website: www.fabdec.com
Servicing and maintenance should only be carried
out by a competent unvented hot water installer or
fabdec Ltd authorised personnel.
Before any work whatsoever is carried out on the
installation, it must be isolated from the electricity
supply.
Both the primary and secondary systems will
contain very hot water that will scald, therefore
care should be taken when opening any joints, seals
or valves.
Only use spare parts authorised fabdec Ltd.
The use of other parts will invalidate the warranty.
EXCELSIOR
operating using internal expansion will
require period checking and recommissioning of the
internal air gap - please see commission procedure
for details.
Spare parts:
Expansion Vessel 24 litre
19 litre
Expansion Vessel Bracket 24 litre
19 litre
T&P valve 7bar 90°C
15 - 22mm straight tundish
3Kw Immersion heater
22mm pressure reducing valve kit
22mm 2-port motorised valve
Twin thermostat
For further assistance please contact the fabdec Ltd.
14