Gah Itd 130 User manual

Technical and Installation manualechnical and Installation manual

echnical and Installation manualechnical and Installation manual

echnical and Installation manual

All Models

For owners, installers and service engineers

heating products

Important Health and Safety Information for Installers and Service Engineers

Health and Safety at Work Act 1974

Consumer Protection Act 1987

COSHH Regulations 1988

The following information is given as a requirement of the

above legislation.

Great care is taken by GAH (HEATING PRODUCTS) LIMITED to

ensure that Dualstream systems are designed and

manufactured to meet general safety requirements when

properly used and installed as recommended in this manual.

It is the responsibility of Users and Engineers to ensure that

adequate protective clothing and glasses are worn when

working with the Dualstream system.

SEALS AND INSULATIONSEALS AND INSULATION

SEALS AND INSULATION

Insulation and sealing materials are used in the construction of

the Dualstream cylinders. Units are sealed and when used in

the manner for which they are intended the insulating and

sealing materials do not present any known hazard. However

always observe the following recommendations:-

1. Avoid inhalation of fibres or dust, wear face mask.

2. Avoid eye contamination by fibres or dust - wear eye

protection.

3. As far as possible avoid any skin contact with Fibreglass

Insulation, Glass Rope, Mineral Wool, Insulation Pads and

Ceramic Fibre.

GAH (HEATING PRODUCTS) LIMITED will not accept

responsibility for any damage or personal injury caused

by not giving due consideration to the above safety

recommendations.

OTHER MATERIALSOTHER MATERIALS

OTHER MATERIALS

SEALANTS, ADHESIVES AND PAINTS

Sealants, Adhesives and Paints are used in the construction of

the Dualstream components. When used in the manner for

which they are intended they do not present any known hazard.

ELECTRICELECTRIC

ELECTRIC

All cylinders have electrical supply of 240V (enough to

endanger life) connected to the Immersion Heater.

Always isolate before adjustment, servicing and repair.

All electrical installation and maintenance of the Dualstream

must be carried out by a competent qualified installer.

All electrical work must be installed to the requirements of

these ‘User and Installation Instructions’.

Patents GB 2349908atents GB 2349908

atents GB 2349908atents GB 2349908

atents GB 2349908

©©

2012 GAH (HEATING PRODUCTS) L2012 GAH (HEATING PRODUCTS) L

2012 GAH (HEATING PRODUCTS) LTD.TD.

TD.TD.

TD.

DualstrDualstr

Dualstream is a Team is a T

eam is a Team is a T

eam is a Trademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L

rademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L

rademark of GAH (HEATING PRODUCTS) LTD.TD.

TD.TD.

TD.

Manual by Harber Technical Services Tel/Fax 01263 515444

E-mail:[email protected] www.harbertech.co.uk

GAH (Heating PrGAH (Heating Pr

GAH (Heating Products) Ltd.oducts) Ltd.

oducts) Ltd.oducts) Ltd.

oducts) Ltd.

Building 846

Bentwaters Parks

Rendlesham

Woodbridge

Suffolk IP12 2TW

Tel:el:

el:el:

el: 01394 42116001394 421160

01394 42116001394 421160

01394 421160

Fax:Fax:

Fax: 01394 42117001394 421170

01394 42117001394 421170

01394 421170

email: [email protected]

www.gah.co.uk

In pursuance of a policy of constant development, GAH (HEATING PRODUCTS) LIMITED

reserve the right to change any boiler part or design without notice, therefore certain

details included in this manual may not be correct at the time of printing. Any

modification and improvements detailed in this manual does not commit GAH to update

any system previously supplied.

Front cover shows typical components.

Manual Part No. ...................015-15011

Manual Ref ..........................CS10

Issue ...................................7a

Date ....................................25/02/2013

HTS REF GAH Dualstream 250213 (Aquabravo cylinders)

CONTENTSCONTENTS

CONTENTS

1 INTRODUCTION1 INTRODUCTION

1 INTRODUCTION

2 OPERA2 OPERA

2 OPERATOR CONTROLSTOR CONTROLS

TOR CONTROLSTOR CONTROLS

TOR CONTROLS

3 TECHNICAL INFORMA3 TECHNICAL INFORMA

3 TECHNICAL INFORMATIONTION

TIONTION

TION

5 COMMISSIONING5 COMMISSIONING

5 COMMISSIONING

7 F7 F

7 FAULAUL

AULAUL

AULT FINDINGT FINDING

T FINDINGT FINDING

T FINDING

CONTENTSCONTENTS

CONTENTS

Section 1 IntrSection 1 Intr

Section 1 Introductionoduction

oductionoduction

oduction

1-1 Introduction ---------------------------------------------- 2

1-2 System Layout ------------------------------------------- 3

1-3 System Requirements ------------------------------------ 4

Section 2 Operator ContrSection 2 Operator Contr

Section 2 Operator Controlsols

olsols

ols

2-1 Hot Water Temperature - Heating System ---------------- 7

2-2 Hot Water Temperature - Immersion Heater--------------- 7

2-3 Hot Water Overheating ----------------------------------- 8

2-4 Shut Off Valves ------------------------------------------ 10

2-5 Expansion Relief----------------------------------------- 11

2-6 Servicing ------------------------------------------------ 11

2-7 Protech Anti-corrosion System -------------------------- 11

Section 3 TSection 3 T

Section 3 Technical Informationechnical Information

echnical Informationechnical Information

echnical Information

3-1 Specifications ------------------------------------------- 12

3-2 Dimensions --------------------------------------------- 13

3-3 Wiring --------------------------------------------------- 16

Section 4 InstallationSection 4 Installation

Section 4 Installation

4-1 Building Control ----------------------------------------- 18

4-2 Installation ---------------------------------------------- 18

4-3 Expansion Discharge ------------------------------------ 21

4-4 Larger Systems ------------------------------------------ 23

4-5 System Pressure ---------------------------------------- 24

4-6 Parts Supplied - ----------------------------------------- 25

Section 5 CommissioningSection 5 Commissioning

Section 5 Commissioning

5-1 Commissioning Checks --------------------------------- 28

5-2 Handing Over ------------------------------------------- 29

Section 6 ServicingSection 6 Servicing

Section 6 Servicing

6-1 Routine Service ----------------------------------------- 30

Section 7 Fault FindingSection 7 Fault Finding

Section 7 Fault Finding

7-1 Fault Finding -------------------------------------------- 31

6 SERVICING6 SERVICING

6 SERVICING

4 INST4 INST

4 INSTALLAALLA

ALLAALLA

ALLATIONTION

TIONTION

TION

IMPORTANT

BEFORE STARTING THE INSTALLATION OF THE DUALSTREAM CHECK ALL COMPONENTS HAVE

BEEN DELIVERED AND ARE IN SATISFACTORY CONDITION.

1-1 Introduction

INTRODUCTION 1INTRODUCTION 1

INTRODUCTION 1

1-1.1 The Dualstream System

The Dualstream systems by GAH Heating Products have been developed as an advanced

solution for domestic hot and cold water installations. A Dualstream system will increase

the water volume and maintain the mains pressure to both the hot and cold supplies

when more than one outlet is in use at the same time.

Dualstream has been designed to function on the minimum standard for domestic water

supply as provided by local water authorities - which is 1 Bar at 9 litres per minute.

GAH offer full technical assistance and design service to enable the optimum Dualstream

system to be configured to overcome situations where poor mains supply and pressure

are considered a problem.

1-1.2 How the Dualstream system works

The system mainly comprises:- an unvented direct or indirect cylinder, an accumulator

(cold water storage vessel), a combination valve and an expansion relief valve.

The accumulator has an internal controlled butyl diaphragm, incoming cold water is

stored within this diaphragm at mains pressure. The air space between the diaphragm

and the accumulator case is pressurised, this balances the supply and maintains

pressure to the unvented hot water cylinder and cold outlets. When hot and cold water

outlets are turned on the stored water from the accumulator supplements water from the

incoming main, this results in consistent pressure and flow to all taps, showers and baths

when outlets are used simultaneously. Pressure will be sustained for as long as the

accumulator is holding sufficient volume of water.

1-1.3 System Comprises

1. An unvented hot water cylinder pre-plumbed with all valves and controls with easy

access pipe connections for quick, trouble-free installation.

2. Cylinder Thermostat and Thermal Cut-Out Thermostat.

3. An accumulator (cold water storage) and associated fittings which can be

positioned anywhere in the dwelling, outhouse or garage, refer to 4-2.6.

4. A Motorised Valve for connection to the heating systems flow to cylinder.

1-1.4 Dualstream System Features

1. All taps and showers are at maximum ‘System Pressure’.

2. Provide increased water flow rate to both hot and cold water outlets.

3. Suitable for properties with very low mains flow rates (9 litres per minute).

4. Balanced Hot and Cold water supply pressures.

5. Minimum pressure drop when more than one tap is in use.

6. More than 25% less pipework than traditional systems.

7. No loft storage tank - no risk of water stagnation.

8. Completely sealed system - wholesome water to all cold taps.

9. No tank filling noise.

10. Dualstream utilises GREEN TECHNOLOGY.

Note

For components supplied with system refer

to page 25.

Note

It is recommended to obtain the nominal

mains pressure and flow rate before

installing a Dualstream system, this will

enable the optimum system to be

configured to suit conditions.

Note

Direct cylinder heated by immersion

heater. Indirect cylinder heated by boiler

(also has immersion heater).

DualstrDualstr

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rademark of GAH (HEATING PRODUCTS) LTD.TD.

TD.TD.

TD.

This Handbook has been compiled to assist in the Installation and Operation of GAH (HEAThis Handbook has been compiled to assist in the Installation and Operation of GAH (HEA

This Handbook has been compiled to assist in the Installation and Operation of GAH (HEATINGTING

TINGTING

TING

PRODUCTS) LIMITED Dualstream domestic hot and cold water system.PRODUCTS) LIMITED Dualstream domestic hot and cold water system.

PRODUCTS) LIMITED Dualstream domestic hot and cold water system.

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’ supplied with Accumulator..

After installation the Installer of the system should give full operating instructions to the householder for the DualstrAfter installation the Installer of the system should give full operating instructions to the householder for the Dualstr

After installation the Installer of the system should give full operating instructions to the householder for the Dualstreameam

eameam

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System. This User and Installation Instructions must be left for the end userSystem. This User and Installation Instructions must be left for the end user

System. This User and Installation Instructions must be left for the end user..

OUTSIDE

TAP

WATER

SOFTENER

BOILER

FLOW

BOILER

RETURN

CHECK VALVE

COMBINATION

VALVE

HOT WATER

SUPPLY TO

TAPS

EXPANSION

DISCHARGE

HTPV

DRAIN

ACCUMULATOR

UNVENTED

CYLINDER

BALANCED

COLD SUPPLY

TO TAPS

INCOMING

MAINS

SUPPLY

SINGLE

CHECK

VALVE

TUNDISH

PRV

HEATING

SYSTEM

FILL

KITCHEN

SINK COLD

TAP

PRESSURE

REDUCING

VALVE

EXPANSION

VESSEL

INTRODUCTION 1INTRODUCTION 1

INTRODUCTION 1

Fig. 1-2a Schematic Installation - Standard Arrangement

All installations must comply with relevant regulations - refer to section 4-1.

1-2 System Layout

Fig. 1:2a shows a typical configuration of a Dualstream system with the accumulator and

hot water cylinder installed within close proximity of each other.

The Combination Valve comprises a non return valve, a pressure reducing valve and a

pressure relief valve (PRV). The pressure reducing valve limits the supply to the cylinder

at a pressure of 3.5 Bar.

A separate pressure reducing valve, set at 3.5 Bar is supplied, this should be installed to

limit the incoming main pressure. To maintain maximum mains pressure to the kitchen

tap and outside taps it can be fitted following these draw offs, when applicable. Failure to

fit the pressure reducing valve as specified will invalidate warranty.

A Single Check Valve is supplied, if one is not already fitted, this should be fitted to the

mains supply prior to any connections or take offs to prevent back flow and to maintain

accumulator pressure.

Supply to all the cold taps and outlets is taken from the Tee fitting at the base of the

accumulator.

Supply to the hot taps and outlets is taken from the cylinder in the traditional manner.

Provision must be made, as applicable, for:- outside tap, boiler/heating system fill and

water softener.

The cylinder HTPV Valve and the combination valve PRV should be plumbed to the

tundish (supplied), installation must comply with building regulations.

Three full bore lever valves are supplied, it is recommended to install these, one each:-

incoming mains to combination valve, hot supply from cylinder, cold supply from

accumulator.

Note

Alternative system layouts are possible

consult GAH Heating Products.

IMPORTANT

Both pressure reducing valves

must be set to the same pressure.

PRIMARY HEAT

SOURCE (SOLAR)

FLOW

HOT WATER

SUPPLY TO

TAPS

HTPV

DRAIN

ACCUMULATOR

UNVENTED

TWIN COIL CYLINDER

BALANCED

COLD SUPPLY

TO TAPS

AUXILIARY HEAT

SOURCE (BOILER)

FLOW

AUXILIARY HEAT

SOURCE (BOILER)

RETURN

PRIMARY HEAT

SOURCE (SOLAR)

RETURN

EXPANSION

VESSEL

INTRODUCTION 1INTRODUCTION 1

INTRODUCTION 1

Note

The accumulator model is designated as

its gross volume, the actual water content

of the accumulator is up to 65% of its gross

volume.

1-3.1 Sizing of System

The size of the Dualstream system is determined by the capacity of the accumulator and

cylinder models selected. As the accumulator provides the pressure for the system it is

important that this is of adequate size.

The accumulator water content is up to 65% of its gross volume.

When sizing the Dualsteam system close consideration should be given to the following:-

1. Incoming mains supply pipe size.

2. Incoming mains flow and static pressure.

3. House type, building height and number of occupants.

4. Typical daily water usage and peak demands.

5. Number of bathrooms and total number hot and cold water outlets

6. Types of shower, taps and baths and the volume and pressure of water to operate

them.

1-3 System Requirements

Fig. 1-2c Twin Coil Cylinder Application

All installations must comply with

relevant regulations - refer to

section 4-1.

1-2.3 Typical Twin Coil Cylinder Layout

SOLAR COLLECTORS

SOLAR SYSTEM

CONTROL

TWIN COIL

CYLINDER

AUXILIARY HEAT

SOURCE (BOILER)

TYPICAL SOLAR WATER HEATING SYSTEM

GAH (Heating Products) Ltd. supply a range of Solar

Water Heating Systems that compliment the GAH

Dualstream System.

For further details consult GAH.

INTRODUCTION 1INTRODUCTION 1

INTRODUCTION 1

Note

The accumulator model is designated as

its gross volume, the actual water content

of the accumulator is up to 65% of its gross

volume.

GAH offer a range of quality Water

Softeners, for information contact

GAH (HEATING PRODUCTS).

GAH offer full technical assistance and design service to enable the optimum Dualstream

system to be configured to overcome situations where poor mains supply and pressure

are considered a problem.

1-3.2 Central Heating System

The Dualstream system does not affect the central heating installation. However

consideration has to be given to the best method of connection and control of the heating

system to the indirect cylinder.

1-3.3 Scale Protection

IMPORTANT All installations should have a scale protection device fitted

and in areas known to have hard water, a water softening device is

strongly recommended.

GAH recommend and promote the use of scale prevention devices and water softeners in

areas that are known to have hard water. Installed correctly they prolong the life of

equipment and help prevent lime-scale formation in the pipework. Water Softeners

provide the advantages of soft water, as well as preventing scale build up on taps and

shower heads.

Water softeners and any mains fed system must be of adequate capacity and should be

installed with suitably sized hoses to prevent any possibility of flow reduction.

1-3.4 Frost Protection

When planning the installation location of both the accumulator and the unvented

cylinder consideration must be given to the risk of frost and the use of frost protection.

The design of the accumulator gives it a degree of frost protection enabling it to be

located within the dwelling, loft space or garage without further protection.

The cylinder can also be installed within the dwelling or loft space without further

protection.

Cylinders or accumulators must have frost protection when they are installed where low

temperatures could be a potential problem. Cylinders can be protected by a frost

thermostat.

To comply with Building Regulations all necessary pipework must be suitably lagged.

The following chart is given as a guide only.

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WATER

HEATER

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

2-1 Hot Water Temperature - Heating System

Fig. 2-1a Typical Hot Water Control

2-1.1 Hot Water Control - Heating System

When the hot water is heated by the heating system the temperature of the hot water at

the taps is controlled by the Cylinder Thermostat. This controls a motorised valve that

opens and closes the flow from the heating system.

The temperature range is 30°C to 85°C.

Recommended setting is 60°C.

CYLINDER

THERMOSTAT

IMMERSION HEATER

MOTORISED VALVE

FLOW FROM

HEATING

SYSTEM

THERMAL CUT-OUT

SAFETY THERMOSTAT

2-2.1 Hot Water Control 125, 150, 210 & 300 Cylinders

When the hot water is heated by the electric Immersion Heater the temperature of the hot

water at the taps is controlled by the Immersion Heater Thermostat. This is located under

the black Immersion Heater cover.

The temperature range is 30°C to 85°C.

Recommended setting is 60°C.

Fig. 2-2a shows the approximate setting position for 60°C.

The Immersion Heater has a Thermal Cut-Out, refer to 2:3.1.

WARNING

ALWAYS ISOLATE THE IMMERSION HEATER BEFORE REMOVING COVER.

When the cover is removed electrical live terminals are exposed.

DOUBLE POLE SWITCH

Note

For 500 Cylinders see 2-2.2.

Fig. 2-2a Immersion Heater Thermostat

ADJUSTMENT

2-2 Hot Water Temperature - Immersion Heater

LOWER HIGHER

SHOWN AT 60° APPROX.

RESET

2-3 Hot Water Overheating

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

2-3.1 Water Heated by Heating System

When the hot water is heated by the heating system a Thermal Cut-Out Thermostat

prevents the water within the cylinder overheating.

In the event of the water temperature within the cylinder reaching 90°C the thermostat will

trip and close the motorised valve shutting off the flow from the heating system - see fig.

2-3a.

The Thermal Cut-Out Thermostat is a manual reset type, this means it has a button that

pops out when the thermostat has been tripped by overheating.

To reset the system after overheating allow time for the water to cool, or run off some hot

water, then remove the plastic cap and press the Thermal Cut-Out Thermostat manual

reset button.

If the Thermal Cut-Out Thermostat trips more than once, switch off the heating system

and Immersion Heater and contact your installer.

2-3.2 Water Heated by Immersion Heater

When the hot water is heated by the Immersion Heater its integral Thermal Cut-Out

Thermostat prevents the water within the cylinder overheating.

The Immersion Heater Thermal Cut-Out Thermostat is a manual reset type, this means it

has a small button that pops up when the thermostat has been tripped by overheating.

To reset the system after overheating switch off the Immersion Heater, allow time for the

water to cool, or run off some hot water.

WARNING

ALWAYS ISOLATE THE IMMERSION HEATER BEFORE REMOVING COVER.

When the cover is removed electrical live terminals are exposed.

Fig. 2-2b 500 Immersion Heater

Adjustment

2-2.2 Hot Water Control - 500 Cylinders

When the hot water is heated by the electric Immersion Heater the temperature of the hot

water at the taps is controlled by the Immersion Heater Thermostat which has an

adjusting knob located on top of the plastic Immersion Heater cover.

The temperature range is 30°C to 85°C.

Recommended setting is 60°C.

Fig. 2-3a Thermal Cut-Out Thermostat

MANUAL RESET

BUTTON

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

Fig. 2-3b 125, 150, 210 & 300 Immersion Heater Thermal Cut-Out

THERMAL CUT-OUT RESET

'BIPOLAR SAFETY'

Fig. 2-3c 500 Immersion Heater Thermal Cut-Out

THERMAL

CUT-OUT RESET 'S'

If the Immersion Heater Thermal Cut-Out Thermostat trips more than once, switch off the

Immersion Heater and contact your installer.

To reset 125,150, 210 & 300 Cylinders

Isolate the Immersion Heater.

Remove the Immersion Heater cover and using a small screwdriver, press the 'Bipolar

Safety' reset button - see fig. 2-3b.

To reset 500 Cylinder

Isolate the Immersion Heater.

Remove the Immersion Heater cover and using a small screwdriver, press the 'S' reset

button - see fig. 2-3c.

COLD WATER

SHUT OFF

VALVE

HOT WATER

SHUT OFF

VALVE

SUPPLY WATER

SHUT OFF VALVE

OUTSIDE

TAP

WATER

SOFTENER

BOILER

FLOW

BOILER

RETURN

EXPANSION

DISCHARGE

HTPV

DRAIN

ACCUMULATOR

UNVENTED

CYLINDER

BALANCED

COLD SUPPLY

TO TAPS

INCOMING

MAINS

SUPPLY

SINGLE

CHECK

VALVE

PRV

HEATING

SYSTEM

FILL

KITCHEN

SINK COLD

TAP

PRESSURE

REDUCING

VALVE

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

2-4 Shut Off Valves

The Dualstream installation will have a number of shut off valves, the location of these

will be dependent on the installation - fig. 2-4a shows a typical layout.

2-4.1 Stop Cock

Normally located at the point where the mains supply enters the dwelling.

Shuts off the mains water supply to the dwelling.

2-4.2 Single Check Valve (If fitted)

Normally located after the Stop Cock. Prevents water back feeding to main.

Shuts off the mains water supply to the dwelling.

2-4.3 Cold Water Shut Off Valve

Normally located in the cold feed close to the accumulator.

Shuts off the cold water to the taps.

2-4.4 Supply Water Shut Off Valve

Normally located where the cold supply connects to the combination valve on the

cylinder.

Shuts off the cold supply to the Dualstream system.

2-4.5 Hot Water Shut Off Valve

Normally located where the Domestic Hot Water feed comes from the cylinder.

Shuts off the hot water to the taps.

Note

When opening the stop cock turn the valve

fully open then close ½ turn, this prevents

the valve sticking.

Fig. 2-4b Valves

OPEN

CLOSED

Fig. 2-4a Typical Shut Off Valve Locations

IMPORTANT Before closing ANY valve:-

1. Switch OFF the Electric Immersion Heater.

2. Turn OFF the Heating System.

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

The Dualstream installation has a TPR Valve normally mounted on the cylinder. In the

event of the pressure within the system becoming too high, the TPR Valve will vent.

A Tundish will be fitted in the system, this should be located in the same space or

compartment as the hot water cylinder. This device provides an air break when pressure

is being vented.

When pressure is being vented water/steam will be evident at the Tundish and from the

discharge pipe of the Tundish.

Water will normally only discharge when there is an increase in pressure caused by loss

of air pressure in the accumulator.

In the event of water/steam being seen at the discharge pipe or Tundish do the following:-

1. Turn ON a hot tap to relieve the pressure.

2. Turn OFF the Electric Immersion Heater.

3. Turn OFF the Heating System.

4. Investigate possible cause for high pressure e.g.:-

i Cylinder Thermostat is set too high.

ii Restriction in hot water pipework.

iii Loss of air pressure in the accumulator resulting in no expansion.

5. Contact the installer before restarting the system.

Fig. 2-5a Tundish

Note

At least the Tundish or discharge pipe

should remain in view, do not box in or

cover up either.

It is recommended the system is inspected by an approved engineer once per year.

The service procedure is included in section 6-1.1.

AIR BREAK

DISCHARGE PIPE

Note

For more information see 4-3

2-5 Expansion Relief

2-6 Servicing

2-7 Protech Anti-corrosion System - 500 only

Fitted to TDI 500 & TDD 500 non stainless steel cylinders only.

The Protech unit is an electronic anti-corrosion protection system which improves the life

of the cylinder.

The Protech unit must be permanently connected to a 240V supply at all times.

The unit has a RED and a GREEN light on the front.

The GREEN light should be on at all times, this indicates proper operation.

When the RED light is on it indicates improper operation which could be:-

1. A short circuit between the electrode and the cylinder.

2. One of the electrodes is not connected.

3. There is no water in the cylinder.

Consult the installer if the RED light is on.

Fig. 2-7a Protech Unit

3-1 Specifications

3-1.1 Cylinders

*500 Cylinders the Immersion Heaters can be converted to 3 Phase - consult GAH for further information.

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nim:h)%07()tnemeleelgniS(emiTtaeheRtceriDnim:h30:242:271:365:430:242:271:393:365:4--

raberusserPyramirPmumixaMraB5.35.35.35.35.35.35.35.35.35.35.35.35.3

)diulfgnitaeh(erutarepmeTgnitarepOmumixaMCº---- 585858585858585858

rabmlioCyramirPhguorhTporDerusserPraBm---- 671681832262832

etaRwolFyramirPh/3m ---- 9.09.09.09.09.0

)h/3m9.0etarwolF(gnitaRregnahcxEtaeHWk ---- 82.7164.710.4295.421.628.130.020.020.02

aerAecafruSlioC²m---- 76.087.098.098.098.05.157.057.057.0

)h/3m9.0etarwolF(gnitaRregnahcxEtaeHraloSWK---------- 0.720.720.72

)rewol(aerAecafruSlioCraloS²m---------- 1.11.11.1

**emiTtaeheRnim ---- 5203531494429243

nim)%07(emiTtaeheRtceridnInim ---- 8122421343710242

)h42nihWk(ssoLtaeHWk04.186.139.172.204.186.139.162.213.231.192.194.1

thgieWtteNgk720314068203349456031350666

)PDO(laitnetoPnoitelpeDenozO)PDO(0000000000000

)PWG(laitnetoPgnimraWlabolG)PWG5<5<5<5<5<5<5<5<5<5<5<5<5<

dradnatSgnitseT 6002:79821NEecnadroccanignitseT

scirtcelE

esahpelgnis-VylppuSlacirtcelEtloV042042042042042042042042042042*042042042

WkgnitaRretaeHnoisremmIWk3+33+33+33+3333336333

epyTretaeHnoisremmI)1()1()1()1()1()1()1()1()1()1()1()1(

eziSelbaC²mm5.2x25.2x25.2x25.2x25.25.25.25.25.265.25.25.2

nim:h)%001()tnemeleelgniS(emiTtaeheRtceriDnim:h64.291:315:491:764:291:315:465:591:7---

nim:h)%07()tnemeleelgniS(emiTtaeheRtceriDnim:h30:242:271:365:430:242:271:393:365:4-

eziSelbaChcetorP²mm --------- 5.1 ---

esuFelbaChcetorPpma ---------3---

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-1.2 Accumulator

Membrane .................................................................................... Butyl for potable water

Maximum pressure ............................................................................................. 7.0 Bar

Minimum pressure ....................................................................................... 0.5/0.8 Bar

Factory set pressure ............................................................................................... 2 Bar

3-1.3 Pipes

All pipes should be sized to suit application.

Suitable types:-

Copper Pipe EN1057 Kite marked

Plastic Pipe BS 7291 Kite marked WRAS approved

Soldered copper fittings EN 1254-1 BS864 Part 2 WRAS approved

Compression type fittings EN 1254-2 WRAS approved

Push fit fittings BS7291 pt1/pt2 WRAS approved must be specified as

suitable for sealed systems.

IMPORTANT

Plastic pipe and fittings should not

be used within 1m of the cylinder.

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-2 Dimensions

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-2.1 Accumulator Dimensions

* Water content is up to 50-55% of the accumulator volume.

Total weight = weight empty + water content @ 1kg/litre.

Fig. 3-2a Accumulator Dimensions

rotalumuccA

ledoM

eziS

)yticapaCssorG(

mumixaM*

tnetnoCretaW DØH

muminimdednemmoceR

.deriuqerecaps

ytpmEthgieW

001

sertil55otpumm014mm098mm099gk3.61

002

071

sertil09otpumm535mm049mm0401gk4.03

042

sertil031otpumm535mm5121mm5131gk2.73

003

013

sertil061otpumm535mm0051mm0061gk5.44

005

054

sertil042otpumm866mm0351mm0361gk5.96

ØD

PRE-CHARGE VALVE - SCHRAEDER

BASE VENTED TO PREVENT

CONDENSATION & FLOOR FIXING

100 Essential

Access

NIAMFOEZISAA

AABB

mm82mm82mm82

mm22mm82mm22

mm51mm82mm51

‘TEE’ FITTING

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-2.2 Standard Direct and Indirect Cylinder Dimensions

45°

ØB

HOT WATER TO

TAPS -28mm

COLD SUPPL

-28mm

BOILER

FLOW -28mm

BOILER

RETURN -28mm

800

TPRV

500 maximum

EXPANSION

DISCHARGE

INDIRECT CYLINDERS

130,150, 215 & 305

500 CYLINDERS

COMPRESSION FITTINGS ARE SUPPLIED TO ADAPT THE

CYLINDER TAPPINGS TO THE PIPE SIZES SHOWN.

TYPICAL PIPE ARRANGEMENTS SHOWN

Fig. 3-2b Standard Cylinder Dimensions

ledoMrednilyC lanimoN

yticapaC

lioC

ecafruS

lioC

gnitaR ABØCDE thgieW

ytpmE

thgieW

lluF

031IDT

l6.421²m76.0Wk82.71189055Ø942244867gk82gk251

051IDT

l2.641²m87.0Wk64.719011055Ø942244698gk03gk671

512IDT

l5.902²m98.0Wk00.428051055Ø9422155921gk34gk252

552IDT

l3.352²m98.0Wk95.420771055Ø9422153651gk94gk303

503IDT

l4.692²m98.0Wk01.622502055Ø9422159381gk56gk263

005IDT

l594²m5.1Wk8.130781417Ø032007- gk941gk146

031DDT

l7.621--189055Ø--867gk72gk451

051DDT

l1.151--9011055Ø--698gk03gk181

512DDT

l7.112--8051055Ø--5921gk14gk352

503DDT

l8.992--2502055Ø--9381gk06gk063

005DDT

l594--0781417Ø --- gk031gk036

32.5°32.5°

ØB

COLD SUPPL

-22mm

BOILER

FLOW

-22mm

BOILER

RETURN

-22mm

EXPANSION

DISCHARGE

500 maximum

TPRV

90°

HOT WATER

TO TAPS - 22mm

22mm

TPRV

32.5°32.5°

ØB

COLD SUPPL

-22mm

EXPANSION

DISCHARGE

500 maximum

TPRV

90°

HOT WATER

TO TAPS - 22mm

22mm

TPRV

DIRECT CYLINDERS

130,150, 215 & 305

ØB

HOT WATER TO

TAPS -22mm

COLD SUPPL

-22mm

PRIMAR HEAT

SOUCE FLOW

(SOLAR)

BOILER RETURN -22mm

EXPANSION

DISCHARGE

500 maximum

TPRV

BOILER FLOW -22mm

PRIMAR HEAT

SOUCE RETURN

(SOLAR)

40°

10°

rednilyC ledoM lanimoN

yticapaC

)raloS(lioCmottoBlioCpoT thgieW

ytpmE

thgieW

lluF

ecafruSgnitaRecafruSgnitaR

512ISTI

sertil512²m1.1W0.72²m57.0Wk0.02gk35gk072

552ISTI

sertil552²m1.1Wk0.72²m57.0Wk0.02gk06gk513

503ISTI

sertil503²m1.1Wk0.72²m57.0Wk0.02gk66gk073

3-2.3 Indirect Twin Cylinder Dimensions

COMPRESSION FITTINGS ARE SUPPLIED TO ADAPT THE

CYLINDER TAPPINGS TO THE PIPE SIZES SHOWN.

Fig. 3-2c Twin Cylinder Dimensions

rednilyC ledoM

SNOISNEMID

ABØCDEFG

512ISTI 5841875Ø0853480621312184

552ISTI 3571875Ø0853488251312184

503ISTI 9202875Ø0853484081312184

TWIN COIL CYLINDER ARE USED FOR SOLAR

WATER HEATING APPLICATIONS SEE 1-2.3

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-3 Wiring

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-3.1 Immersion Heater - 500 Cylinders

Fig. 3-3a Immersion Heater Wiring Diagram - 500 Cylinder

500 cylinders have three 2kW immersion heater elements (total 6kW) and must

be wired using 3 x 2.5mm² 20amp 3-core Heat Resistant Cables as shown.

134

THERMOSTAT

With Thermal Safety

Device

HEATING

ELEMENTS

BOTH PHIALS ARE

INSERTED IN THIS HOLE

L1 L2 L3

EARTH

TERMINAL

3 x 2.5mm² 20A 3-CORE

HEAT RESISTANT CABLE

green/ yellow

blue

brown

642

531

3 x 2kW

HEATING

ELEMENTS

3 x 2.5mm² 20A 3-CORE

HEAT RESISTANT CABLE

45 AMP

DOUBLE POLE SWITCH

THERMOSTAT

With Thermal Safety Device

blue

brown

mm² 32A 3-CORE 3 x LIVE WIRES

supplied

AMP TAG CONNECTIONS

IMPORTANT

ENSURE ALL TERMINALS

ARE TIGHT AND CORRECT

TECHNICAL INFORMATECHNICAL INFORMA

TECHNICAL INFORMATION 3TION 3

TION 3TION 3

TION 3

3-3.3 Cylinder Thermostats

3-3.4 Protech Anti-corrosion System (500 non stainless steel only)

Fig. 3-3c Cylinder Thermostats Wiring Diagram - 125, 150, 210 and 300 Cylinders

Brown / Red Blue / Black

Anode circuit

Electronic anode

240V 3amp

PERMANENT SUPPLY

Fig. 3-3d Protech Anti-corrosion System Wiring Diagram

Not required.

Can be used for

hot water heated light

SWITCHED LIVE from

BOILER/HEATING CONTROLS

blue

green/yellow

orange

brown

orange

NOT USED

or BOILER

or PUMP

depending on

system grey

HONEYWELL

V4043H

Normally Closed

FLOW FROM BOILER

NEUTRAL

EARTH

HIGH LIMIT

THERMOSTAT

Normally Closed

CYLINDER

THERMOSTAT

Normally Closed

3-3.2 Immersion Heater - 125, 150, 210 and 300 Cylinders

Fig. 3-3b Immersion Heater Wiring Diagram - 125, 150, 210 and 300 Cylinders

LIVE (brown)

EARTH (green yellow)

NEUTRAL (blue)

THERMOSTAT

ADJUSTMENT

LIVE

NEUTRAL

blue

brown

green/yellow

DOUBLE POLE

SWITCH

THERMOSTAT

IMMERSION HEATER

2.5mm 20A 3-CORE

HEAT RESISTANT CABLE

4-1 Building Control

INSTINST

INSTALLAALLA

ALLAALLA

ALLATION 4TION 4

TION 4TION 4

TION 4

4-2 Installation

Note

In some areas it is a criminal offence to

install an unvented hot water storage

system without notifying the local authority,

or without the relevant licence.

To install a Dualstream System the installer must be fully competent, suitably qualified

and hold a relevant unvented certificate and any applicable licence that may be required

by the local inspectorate for installation of an unvented hot water storage system.

In some areas the Local Authority may require notification by means of a building notice

or by the submission of full plans for the proposed installation of an unvented hot water

storage system.

4-1.1 Regulations

The WW

Water Bye-lawsater Bye-laws

ater Bye-lawsater Bye-laws

ater Bye-laws and CurrCurr

CurrCurr

Current Building Rent Building R

ent Building Rent Building R

ent Building Regulationsegulations

egulationsegulations

egulations (paying particular attention to G3

and Part L 1 & 2) and HSEHSE

HSEHSE

HSE requirements should be considered when installing a

Dualstream System.

4-1.2 Electrical Regulations

All wiring should carried out to and comply with the currAll wiring should carried out to and comply with the curr

All wiring should carried out to and comply with the current IEE Wiring Rent IEE Wiring R

ent IEE Wiring Rent IEE Wiring R

ent IEE Wiring Regulations.egulations.

egulations.egulations.

egulations.

All electrical work must comply with any rAll electrical work must comply with any r

All electrical work must comply with any relevant relevant r

elevant relevant r

elevant regulations that apply at the time ofegulations that apply at the time of

egulations that apply at the time ofegulations that apply at the time of

egulations that apply at the time of

the installation.the installation.

the installation.

4-1.3 Electrical Work

All electrical installation and maintenance of the Dualstream must be carried out by a

competent qualified installer.

All electrical work must be installed to the requirements of these ‘User and Installation

Instructions’.

4-2.1 Unvented Hot Water Cylinder

The cylinder may be installed at any convenient above ground location within the

dwelling. As Dualstream is a sealed system, the cylinder is equally effective on any floor.

The cylinder must always be installed vertically.

Avoid positioning the cylinder where it may be subjected to frost.

The floor must give adequate support to the filled cylinder.

Cylinders with legs are supplied with self-tapping screws for floor fixing.

For maintenance purposes leave at least 500mm at the front of the cylinder.

The cylinder may be installed below ground i.e. in a basement, providing that the

expansion relief discharge pipe is plumbed to a metal receptacle with a suitable pump

and switch arrangement, current Building Regulations give details of this. An alternative

is to use a Hepworth HepvO Self Sealing Waste Valve, this must be installed to the

manufacturers specification and building regulations.

4-2.2 Cylinder Thermostat

The combined Cylinder Thermostat and Thermal Cut-Out Thermostat supplied should be

inserted into the socket provided in the cylinder. A screw is provided to clamp the unit in

place.

Wire the unit as wiring diagram 3-3c.

Fig. 4-2a Cylinder Thermostat

Note

GAH offer full unvented training packages

contact GAH (HEATING PRODUCTS).

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