Heatrae Sadia Megalife CLV190 User manual

Megalife Solar Vented Cistern Fed Water Heater
Installation manual
SOLAR INDIRECTDIRECT
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Megalife Product Guide
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Section Page
1 Introduction............................................... 2
2 General Requirements ............................. 4
3 Installation - General ................................ 5
4 Installation - Solar ..................................... 7
5 Installation - Auxillary Coil........................ 8
6 Commissioning ......................................... 11
7 User Instructions ....................................... 12
8 Maintenance ............................................. 13
9 Fault Finding & Servicing......................... 14
10 Dimensions & Specifications ................... 16
11 Guarantee.................................................. 19
12 Contacts .................................................... 20
Contents
Thank you for purchasing a Heatrae Sadia Megalife cistern fed solar vented water heater. The Megalife solar is manufactured
in the UK from top quality materials and meets all the latest relevant safety and constructional standards. The high grade
Duplex stainless steel cylinder offers exceptional strength and corrosion resistance and is backed by a 25 year cylinder
guarantee. Its performance and insulation levels meet the latest requirements of Building Regulation Part L.
The Megalife solar vented water heater must be fed from a cold water feed cistern located above the water heater and
hot outlets to be served. The unit must have a suitable vent pipe installed on the outlet that is arranged to discharge
over the cold water feed cistern.
The Megalife solar water heaters are supplied with a dedicated solar coil in the lower part of the cylinder which must be
connected to an indirect solar primary circuit. Various controls will be necessary to integrate the Megalife solar cylinder
into a solar primary circuit which are not supplied with the Megalife. Ensure that manufacturer’s instructions for any
ancillary solar primary circuit components are followed to ensure the correct integration of the Megalife solar into the
solar primary circuit.
In addition to the solar primary coil heat exchanger units also have an additional heat exchanger coil located in the
upper section of the cylinder for connection to an auxillary heat source such as a gas, oil or electric boiler. The units are
supplied fitted with a thermostat and over-temperature thermal cut-out for the control of the auxillary primary heat input
to the Megalife solar from the boiler selected. All models are supplied with one electric immersion heater for use as a
back up heat source should the auxillary primary heat source be switched off.
1: Introduction
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Megalife Product Guide
Please read and understand these instructions before starting work.
The information contained in these instructions details how to connect the Megalife Solar water
heater to a solar primary circuit. Other controls will be necessary to provide control over the primary circuit, refer
to the instructions supplied with the solar controls and ancillary equipment for details of how to integrate them
with the Megalife Solar unit.
Please leave this leaflet with the user following installation
G3 Requirements (extracts taken from G3 regulations)
(2) A hot water system, including any cistern or other vessel that supplies water to or receives expansion water from
a hot water system, shall be designed, constructed and installed so as to resist the effects temperature and pressure
that may occur either in normal use or in the event of such malfunctions as may reasonably be anticipated, and must be
adequately supported.
(3) A hot water system that has a hot water storage vessel shall incorporate precautions to:
(a) prevent the temperature of the water stored in the vessel at any time exceeding 100°C: and
(b) ensure that any discharge from safety devices and header tank is safely conveyed to where it is visible
but will not cause a danger to persons in or about the building.
In the Secretary of State’s view Requirement G3(3) will be met for a hot water storage system that has a vented stor-
age vessel if:
a. the storage vessel has a suitable vent pipe connecting the top of the vessel to a point open to the atmos-
phere above the level of the water in the cold water storage cistern and over it; and,
b. in addition to any thermostat, either the heat source, or the storage vessel is fitted with a device that will
prevent the temperature of the stored water at any time exceeding 100°C; and,
c. the hot water system has pipework that incorporates a provision for the discharge of hot water from the safety
devices to an appropriate place open to atmosphere where it will cause no danger to persons in or about
the building.
Vented hot water storage systems
3.12 Vented hot water storage systems should incorporate a vent pipe of an adequate size, but not less than 19mm
internal diameter, connecting the top of the hot water storage vessel to a point open to the atmosphere obove and over
the level of the water in the cold water storage sytem.
3.13 In addition to the vent pipe referred to in 3.12 and any thermostat provided to control the temperature of the
stored water to a desired temperature, vented hot water storage systems should incorporate either:
a. for all direct heated sources, a non-self-resetting energy cut-out to disconnect the supply of heat to the
storage vessel in the event of the storage system overheating: and,
for all indirect heat sources, an overheat cut-out to disconnect the supply of heat to the storage vessel in
the event of the stored water overheating so that the temperature of the stored water does not exceed
100°C.
3.14 Vent pipes should discharge over a cold water storage cistern conforming to BS 417-2:1987. Specification for
galvanized low carbon steel cisterns, cistern lids, tanks and cylinders. Metric units; or BS 4213:2004 Cisterns for domestic
use. Cold water storage and combined feed and expansion (thermoplastic) cisterns up to 500 litres. Specification; as
appropriate.
3.15 The cold water storage cistern into which the vent pipe discharges should be supported on a flat, level, rigid
platform which is capable of safely withstanding the weight of the cistern when filled with water to the rim and fully
supporting the bottom of the cistern over the whole of its area. The platform should extend a minimum of 150mm in all
directions beyond the edge of the maximum of the cistern.
Note: When an existing metal cistern is replaced, or a plastic cistern is replaced by one with larger dimensions, the
existing support should be upgraded, as necessary, with one in accordance the paragraph 3.15.
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2: General Requirements
IMPORTANT : PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING THE MEGALIFE
SOLAR WATER HEATER. INCORRECT INSTALLATION MAY INVALIDATE GUARANTEE.
THIS APPLIANCE CAN BE USED BY CHILDREN AGED FROM 8 YEARS AND ABOVE AND PERSONS WITH REDUCED
PHYSICAL SENSORY OR MENTAL CAPABILITIES OR LACK OF EXPERIENCE AND KNOWLEDGE IF THEY HAVE
BEEN GIVEN SUPERVISORY OR INSTRUCTION CONCERNING USE OF THE APPLIANCE IN A SAFE WAY AND
UNDERSTAND THE HAZARDS INVOLVED. CHILDREN SHALL NOT PLAY WITH THE APPLIANCE. CLEANING AND
USER MAINTENANCE SHALL NOT BE MADE BY CHILDREN WITHOUT SUPERVISION.
WARNING: Do not switch on if there is a possibility that the water in the heater is frozen.
THE MEGALIFE MUST BE FED FROM A COLD WATER FEED CISTERN. A SUITABLE VENT PIPE MUST BE
INSTALLED.
2.1 Siting The Megalife (see Fig. 01, below)
The Megalife solar range of water heaters must only be installed as CISTERN FED VENTED units supplied from
a cold water feed cistern at an appropriate head height above the heater and outlet points. Ensure that the feed
cistern height above the heater does not exceed its maximum rated pressure of 40 metres (4 bar). The feed cistern
should comply with the requirements of Schedule 2 Section 7 Paragraph 16: Cold Water Services to the Water Supply
(Water Fittings) Regulations 1999 (previously Water Byelaw 30).
A vent pipe MUST be connected to the outlet of the heater. This must rise continuously and be arranged to discharge
into the feed cistern. The vent pipe must have a minimum bore diameter of 19mm.
DO NOT connect directly to the mains water supply.
DO NOT connect any pressure relief device or other valves to the vent pipe of this heater.
DO NOT install in a position where the heater is liable to be subject to frost conditions.
The Megalife solar unit must be vertically floor mounted or on a suitable plinth. It can be placed anywhere convenient
provided the vent pipe can be correctly installed. Ensure that the floor or supporting plinth is of sufficient strength
to support the “full” weight of the unit (refer to Table 04 on page 17 for unit weights). Ideally the heater should be
sited close to the point where hot water is required most frequently. Pipe runs should be kept as short as possible
for maximum economy. Access to associated plumbing connections, immersion heaters and indirect controls should
be possible for servicing and maintenance of the system.
2.2 Outlet/Terminal Fittings (taps, etc.)
The Megalife solar can be used in conjunction with most types of terminal fittings. In a cistern fed system the pressure
at the outlet fittings is due to the head height of the cold water feed cistern above the outlet point. When choosing
suitable fittings ensure they will operate at the pressure available at the outlet point.
Fig. 01: Siting the Unit
WALL
Min 250mm Min 250mm
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Megalife Product Guide
3: Installation - General
3.1 Pipe Fittings
All pipe connections to the Megalife solar are made via 22mm compression fittings directly to the unit (nuts and
olives supplied). The fittings are also threaded 3/4” BSP male parallel should threaded connections be required.
3.2 Cold Water Supply
A 22mm cold water supply is recommended from the cold water feed cistern. No other connection should be taken
from this supply. A servicing valve or stop valve with a fixed washer plate should be incorpoarted in a convenient
and accessible position in the cold feed pipe. The cold feed pipe should be connected to the heater connection
marked with a BLUE collar.
3.3 Drain Tap
A suitable draining tap should be installed at the lowest point of the cold feed pipe between the cold water service
valve and the heater to facilitate draining the heater.
3.4 Outlet Pipework
The outlet pipework should be connected to the heater connection marked with a RED collar in the centre of the
top cover. The vent pipe must be teed into the outlet pipe (see section 3.5 below). Outlets above the heater can be
teed off the vent pipe. Ideally the pipework from the heater to the outlet fittings should be in 22mm pipe with short
runs of 15mm pipe to the terminal fittings. Pipe sizes may vary due to system design.
3.5 Vent Pipe
A vent pipe MUST be connected to the outlet of the heater.
The vent pipe must rise continuously and be arranged to discharge into the cold water feed cistern.
The vent pipe must have a minimum bore diameter of 19mm.
No valves should be fitted to the vent pipe. It is not acceptable to replace the vent pipe with a pressure relief
device.
The hot water distributing pipes can be teed off the vent pipe. If fitting a shower booster pump particular attention
should be made to the manufacturer’s instructions regarding the positioning of the hot water tapping to prevent
air entrainment via the vent pipe.
3.6 Secondary Circulation
If secondary circulation is required it is recommended that it be connected to the Megalife cylinder as shown in Fig.
02, below. A 1/2” BSP female threaded boss is provided (supplied blanked with a 1/2” BSP plug) for the connection
of a secondary circulation return pipe.
The secondary return pipe should be in 15mm pipe and incorporate a check valve to prevent backflow. A suitable
WRAS approved bronze circulation pump will be required.
Fig. 02: Sectondary Circulation Connection
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OUTLET/VENT
(HOT)
COLD
HOT
COLD
HOT
INLET WATER SUPPLY
CISTERN TANK
COLD
MAINS
SUPPLY
MAX HEAD 40m
VENT PIPE
Stop Valve
OVERFLOW PIPE
Fig. 03: Typical Vented Solar Installation - Schematic
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Megalife Product Guide
4: Installation - Solar Primary
4.1 Connection To Solar Primary Circuit
The lower (solar) coil of the Megalife solar must be connected to a fully pumped solar primary circuit. The connections
are suitable for 22mm copper pipe direct to the compression fittings provided. The connections are also threaded
3/4” BSP male parallel should BSP connections be required.
The solar primary circuit must have its own dedicated circulating pump, thermal and safety controls which must be
installed as per the manufacturers instructions.
4.2 Control Of Solar Primary Circuit
Temperature control of the Megalife solar must be carried out using a suitable proprietary solar differential
temperature controller. The cylinder temperature sensing probe (supplied with the solar controller) should be fully
inserted with the thermal cut-out probe into the pocket provided on the Solar cylinder.The cable must be secured
using the cable clamps on the controls housing..
The solar differential temperature controller will control the operation of the solar pumped primary circuit to transfer
heat from the solar collector panels to the cylinder via the lower solar primary coil heat exchanger; refer to the
maunfacturer’s installation instructions supplied with the controls selected for details of how to install the ancillary
solar primary circuit equipment. The solar controller and solar primary circulation pump must be wired via the over-
temperature cut-out mounted in the solar controls housing (see Fig 04, below). There must also be suitable check
(non-return) valves installed in the solar primary flow and return to prevent the possibility of any thermo-syphoning
if the solar circulation is stopped.
Connection to the solar differential temperature controller should be in accordance with the manufacturer’s
instructions. The controller should be set to give a recommended cylinder temperature of approx. 60oC. The maximum
setting should not exceed 70oC otherwise nuisance operation of the thermal cut-outs may occur.
THERMAL CUT-OUT
PROBE
CONTROL ASSEMBLY
POWER SUPPLY TO
SOLAR CONTROLLER
L
N
E
SOLAR CONTROLLER
Fig. 04: Electrical connection - Solar
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5: Installation - Auxillary Coil (Indirect Units)
5.1 Boiler Selection
The Auxillary coil on the Megalife solar indirect models are suitable for use with most gas, oil or electric boilers. The
boiler used can either be a sealed system or open vented type. The maximum primary circuit pressure is 3.5 bar. If
an open vented type boiler is used it must be fed from a separate boiler feed and expansion cistern, it MUST NOT
be fed from the Megalife solar cold water feed cistern.
The auxilary primary flow from the boiler MUST be pumped. Gravity circulation will not work due to the special design
of the primary heat exchanger. It is recommended that an air bleed point or automatic air vent is incorporated in the
primary return pipework close to the Megalife solar unit to aid in bleeding air from the primary heating coil.
The boiler should be fitted with adequate thermal control. This will normally include a primary flow thermostat and a
safety over temperature cut-out. The boiler flow temperature should usually be set to 82oC (maximum flow temperature
to primary heat exchanger 90oC).
The boiler cannot be vented through the Megalife solar unit.
5.2 Indirect Thermal Controls
Control of the storage temperature when indirectly heated is provided by the fitted cylinder thermostat. The control is
located under the white plastic cover located to the right of the indirect coil connections. If necessary the temperature
can be adjusted by inserting a flat bladed screwdriver in the adjustment knob and rotating. The minimum thermostat
setting is 10°C. Adjustment represents a temperature range of 10°C to 72°C (See Fig. 05, page 9). If in any doubt
contact a competent electrician.
5.3 Wiring
All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E.
Wiring Regulations.
The Megalife solar indirect thermostat and thermal cut-out are factory pre-wired. It is recommended that these controls
are wired in series with a suitable 2 or 3 port motorised valve to control the primary flow through the heater coil. Wiring
to external controls is made via the terminal block fitted. The cable should be routed through the aperture in the
terminal cover and secured using the cable grip provided. The indirect thermal cut-out MUST NOT be bypassed.
5.4 Heating System Controls
The controls provided with the Megalife solar will ensure the safe operation of the Megalife solar when heated
by an auxillary heat source. Additional controls will be required for the control of the solar primary heating circuit.
Other controls will be necessary to control the space heating requirements and times that the system is required to
function. Depending on the auxillary boiler selected, heating circuit design and controls used it may be beneficial
to incorporate a system by-pass in the auxillary heating system pipework.
The Megalife solar is compatible with most heating controls, examples of electrical circuits are given in Fig’s 06 and
07, page 10. However, other systems may be suitable, refer to the controls manufacturers’ instructions, supplied with
the controls selected, for alternative system wiring schemes.
5.5 Immersion Heater
The Megalife solar indirect units are supplied with an immersion heater which can be used as an alternative heat
source should the boiler supply need to be isolated from the Megalife solar unit. Refer to Fig. 05 page 9 for details
of the wiring and operation of the immersion heater.
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Megalife Product Guide
Fig. 05: Electrical connection (indirect schematic) and temperature adjustment
LN
1 2 3
Element Connections
1.5mm2 3 Core
HOFR sheathed
cable
Indirect control
wiring
SPINDLE POSITIONS
= MINIMUM TEMP 10ºC = MAXIMUM TEMP 72ºC
= APPROX 60 °C
ROTATE SPINDLE CLOCKWISE FOR TEMPERATURE INCREASE
AND COUNTER CLOCKWISE FOR TEMPERATURE DECREASE
THERMAL CUT-OUT RESET BUTTON
TEMPERATURE ADJUSTING
SPINDLE
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Fig. 06: Schematic wiring diagram - Basic 2 x 2 port valve system
Fig. 07: Schematic Wiring Diagram - 2 port valve in conjunction with 3 port mid position valve system. (Y plan).
NOTES: Control terminal numbering may differ from those shown.
Refer to instructions with controls selected.
A double pole isolating switch must be installed in the mains supply.
All earth connections must be connected back to the mains earth supply.
L
1
N
23
HTG
ON
DHW
ON LN
23
1
L
2
N
345 6 7 8 9 10
12 3 45 6 7 8 9 10
(Supply)
12 3
G
1
Br Bl
2
0GY
3
G
1
Br Bl
2
0
13 2
2
L
N
Programmer Boiler Pump
Zone valve (HTG)
Cylinder terminal block
Room stat Zone valve (DHW)
Junction box
3
2
3
L
1
N
23
HTG
ON
DHW
ON LN
23
1
L
2
N
345 6 7 8 9 10
12 3 45 6 7 8 9 10
(Supply)
12 3
GWBl
2
0GY
3
G
1
Br Bl
2
0
L
N
Programmer Boiler Pump
3 Port Zone valve
Cylinder terminal block
13 2
2
Room stat
Zone valve (DHW)
(supplied)
Junction box
NOTES: Control terminal numbering may differ from those shown.
Refer to instructions with controls selected.
A double pole isolating switch must be installed in the mains supply.
All earth connections must be connected back to the mains earth supply.
3
DHW
OFF
2
3
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Megalife Product Guide
6: Installation - Commissioning
6.1 Filling The Megalife Solar With Water
• Ensurethatallttingsandimmersionheater(s)arecorrectlyttedandtightened.
• Openthehighesthottapinthesystem.
• Openthemainscoldwatersupplytothecoldwaterfeedcistern.
• Opentheservicevalveorstopvalvettedinthecoldfeedpipetotheunit.Allowtheunittoll.Whenwater
flows from the hot tap allow to run for a few minutes to flush through any dirt or swarf, then close tap.
• Allowcoldwaterfeedcisterntolltothewaterline.Adjusttheoatvalveifnecessary.
• Opensuccessivehottapstopurgeanyairfromthesystem.
• Checkallconnectionsforleaksandrectifyasnecessary.
DO NOT SWITCH ON ANY OF THE HEAT SOURCES UNTIL THE UNIT HAS BEEN FULLY FILLED WITH WATER.
6.2 Solar Primary Circuit
Fill the solar primary circuit following the instructions provided with the solar hydraulic controls. The cylinder
temperature control sensor probe supplied with the solar differential temperature controller must be inserted into
the pocket in the lower controls housing and its cable securely clamped.
Heating by the solar primary circuit is controlled by the solar differential temperature controller, refer to the
manufacturers installation instructions for details of how to set up and commission the solar primary circuit. The solar
controller should be programmed to give a maximum storage temperature in the Megalife solar of 70oC although
60oC is recommended to minimise scaling.
6.3 Auxillary Heating Coil Units
Fill the auxillary primary (indirect) circuit following the boiler manufacturer’s commissioning instructions. To ensure
the primary heating coil in the Megalife solar is filled any motorised valve fitted to control the primary flow to the
Megalife solar auxillary primary heating coil should be manually opened by moving the lever on the motor housing
to the MAN OPEN setting. When the primary circuit is full return the lever to the AUTO position. Vent any air by
opening the air bleed.
When the system is full switch on the boiler, ensure the programmer is set to Domestic Hot Water. Allow the Megalife
solar unit to heat up and check that the indirect thermostat and any motorised valve connected operate correctly.
A storage temperature of approx. 60oC is recommended.
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7: Installation - User Instructions
7.1 Temperature Control
Solar Primary Circuit
Temperature control when heating by the solar primary circuit will be controlled by the external solar differential
temperature controller. The controller should be set to give a water storage temperature of approx. 60oC, however it can
be set to other temperatures. This will usually have been done during installation. A maximum of 70oC is recommended
to avoid nuisance operation of the thermal cut-outs fitted to the unit. Adjustment is made at the solar differential
temperature controller, refer to the manufacturer’s instructions for details of how to make any adjustments.
Changes to the operating temperature differential set points can affect the efficiency of the operation of the solar
heating circuit, it is recommended that any changes made are carried out by a competent solar water heating
installation engineer.
Immersion Heaters
A combined thermostat and thermal cut-out is provided for each immersion heater. The thermostat is factory set
to give a water storage temperature of approx. 60oC, however it can be set to control between 10oC and 72oC. This
will usually have been done during installation. Adjustments can only be made by opening the terminal cover(s),
DO NOT remove the cover(s) without first switching off the electrical supply. The temperature adjustment is
made by inserting a flat bladed screwdriver in the slot in the spindle on top of the thermostat and rotating (see Fig.
05, page 9).
If in any doubt consult a competent electrician.
Auxiliary Heating Coil
All units are fitted with an indirect thermostat. The thermostat is factory set to give a water storage temperature
of approx. 60oC, however it can be set to control between 10oC and 72oC, this will usually have been done during
installation. Adjustments can only be made by opening the terminal cover. DO NOT remove the cover without
first switching off the electrical supply. Temperature adjustment is made by inserting a flat bladed screwdriver in
the adjustment spindle located on the front of the thermostat mounting bracket (see Fig. 05, page 9) and rotating.
At the minimum position the temperature will be approx. 10oC.
If in any doubt consult a competent electrician.
DO NOT bypass the thermal cut-out in any circumstances.
7.2 FLOW PERFORMANCE
As with any cistern fed vented system the pressure obtained at the outlet points is due to the height (head) of the
cold water fed cistern above the outlet. Outlet points with a low head may give lower flow rates than those located at
a lower level within the property. When several hot outlets are opened simultaneously some loss of flow from outlets
with a low head or located some distance from the Megalife solar may occur. This a function of the system design
and does not necessarily indicate a fault with the water heater.
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8: Installation - Maintenance
8.1 Maintenance Requirements
The Megalife solar has been designed and manufactured to require very little maintenance. However, to ensure
the continued optimum performance of the Megalife solar it should be periodically maintained. This is of particular
importance in hard water areas where limescale can build up on hot surfaces and eventually affect the heating efficiency
of either the immersion heater(s) or primary heating coil. Maintenance should be carried out by a competent person
and any replacement parts used should be authorised Heatrae Sadia Megalife solar spare parts.
In hard water areas consideration should be given to periodically descaling the immersion heater elements. To do
this the Megalife solar unit will need to be drained, 8.2 and 8.3 below detail how to drain the unit and remove the
immersion heater(s).
8.2 Draining The Megalife Unit
Switch off the electrical supply to the immersion heater, shut down the auxillary boiler on indirect units and shut
down the solar primary circuit. Turn off the cold water supply to the Megalife solar unit by shutting the service valve
in the cold water feed pipe from the feed cistern. Attach a hosepipe to the drain cock having sufficient length to take
water to a suitable discharge point below the level of the unit, at least one metre below the unit is recommended.
Open drain cock.
8.3 Descaling Immersion Heater(s)
Switch off the electrical supply prior to removing the control cover.
Open the cover(s) to the immersion heater housing and disconnect wiring from immersion heater. Remove the
thermostat capillaries by carefully pulling outwards from the immersion heater. (Note which order they are fitted).
Remove the terminal shroud. Unscrew immersion heater backnut(s) and remove immersion heater from the unit. A
key spanner is supplied with the Megalife solar unit for easy removal/tightening of the immersion heater(s). Over
time the immersion heater gasket may become stuck to the mating surface. To break the seal insert a round bladed
screwdriver into one of the pockets on the immersion heater and gently lever up and down.
Carefully remove any scale from the surface of the element. DO NOT use a sharp implement as damage to the
element surface could be caused. Ensure sealing surfaces are clean and seals are undamaged, if in doubt fit a new
gasket. Replace immersion heater ensuring the (right angled) element hangs vertically downwards towards the base
of the unit. It may be helpful to support the immersion heater using a round bladed screwdriver inserted into one
of the thermostat pockets whilst the backnut is tightened. Replace the terminal shroud. Replace the thermostat
capillaries into the capliilary pockets, taking care to put the curly tail capillary in first.
Rewire the immersion heater(s) in accordance with Fig. 05, page 9 . Check, close and secure terminal cover.
8.4 REFILLING SYSTEM
DO NOT switch on the immersion heater, auxillary boiler or solar primary circuit until the system has been completely
refilled.
Close the drain tap. With the highest hot tap in the system open, turn on the service valve in the cold water feed pipe.
When water emits from the hot tap allow to flow for a short while to purge air and to flush through any disturbed
particles. Close hot tap and then open successive hot taps in system to purge any air. The electrical supply can now
be switched on.
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9.1 Important
i) Servicing should only be carried out by competent installers in the installation and maintenance of water
heating systems.
ii) Any spare parts used MUST be authorised Heatrae Sadia parts.
iii) Disconnect the electrical supply before removing any electrical equipment covers.
iv) NEVER bypass any thermal controls or operate system without the necessary safety controls.
v) Water contained in the Megalife solar unit may be very hot, especially following a thermal control failure.
Caution must be taken when drawing water from the unit.
9.2 Spare Parts
A full range of spare parts are available for the Megalife solar range. Refer to the technical data label on the unit to
identify the model installed and ensure the correct part is ordered.
9: Fault Finding and Servicing
29
6
4
5
8
3
1
Fig. 08: Spares
10
Item Description Part Number
1 Immersion heater (lower) 95 606 984
2 Immersion heater gasket 95 611 822
3 Immersion heater backnut 95 607 869
4
Direct combined thermostat and thermal cut-out
(spade terminals including wires and terminal block).
Direct combined thermostat and thermal cut-out
(spade terminals NO wires or terminal block).
95 612 720
95 612 721
5
Indirect combined thermostat and thermal cut-out
(spade terminals including wires and terminal block).
Indirect combined thermostat and thermal cut-out
(spade terminals NO wires or terminal block).
95 612 719
95 612 722
6 6 way terminal block 95 607 933
7 Immersion heater key 95 607 861
8 Terminal cover 95 614 095
9 Terminal Shroud 95 606 993
10 Solar temperature probe pocket 95 607 064
Table 01: Spares
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Megalife Product Guide
9.3 Fault Finding
The fault finding chart below will enable operational faults to be identified and their possible causes rectified. Any work
carried out on the Megalife solar water heater and its associated controls MUST be carried out by a competent installer
for water heating systems. In case of doubt contact the Heatrae Sadia Service Department (see back page).
Table 02: Fault Finding
Fault Possible Cause Remedy
No hot water flow 1. No water in cold feed cistern
2. Service valve in cold water feed pipe
from cistern turned off
3. Air lock in system
4. Inadequate head between outlet
and cold water feed cistern
1. Check water supply to cold cistern
2. Turn on services valve
3. Check pipework layout for possible air lock-
ing points, recify as necessary
4. Check minimum head requirement of outlet
fitting
Hot water flow gradu-
ally decreases
1. Outlet flow rate exceeds inlet flow to
cold water feed cistern
2. Flow starvation caused by opening
further outlets
1. Install higher flow float valve. Consider
larger cold water cistern storage capacity
2. Check pipe sizings and layout. Consider
restricting flow rate through lower taps
Water from tap is cold 1. INDIRECT programmer set to central
heating only
2. INDIRECT boiler not working
3. INDIRECT thermal cut-out has oper-
ated
4. INDIRECT motorised valve not con-
nected correctly
5. Solar, insufficient solar gain with no
auxillary heating switched on
1. Check, set to domestic hot water pro-
gramme
2. Check boiler operation. If fault is suspected
consult boiler manufacturer’s instructions
3. Check, reset by pushing button on cut-out.
Check operation of indirect thermostat
4. Check wiring and/or plumbing connections
to motorised valve (see figs 5 & 6, page 10)
5. Check auxillary heat source is switched on
and is controlled to provide heat gain if no
solar output is available
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Megalife Product Guide
16
10: Dimensions and Specifications
Fig. 09: Dimensions
A
415
C
29
373
B
25°
45°
30°
592
Ø
550
SECONDARY RETURN
HOT OUTLET
COLD INLET
SOLAR
CONTROL
AUXILLARY
CONTROL
AUXILLARY
FLOW
AUXILLARY
RETURN
PRIMARY
FLOW
PRIMARY
RETURN
Table 03: Dimensions
NOTE
Coil heating performance based on a primary flow rate of 15l/min at 80 °C ± 2 °C
Temperature rise is from 15 °C to 60 °C
Indirect units tested to BS EN 12897:2006
Type Model
Reference
Dimensions (mm) Solar Auxiliary Coil
Solar
Surface
Area (sq
m)
Solar
Coil
Rating
(kW)
Rating
(kW)
Auxillary
Volume
Hot Water Capacity
(ltrs)
(volume of water drawn
off (40°C)
A B C
Solar
Indirect
190 SV Ind 1373 784 926 1.1 19 14.7 120 132
210 SV Ind 1477 1011 1025 1.1 19 15.0 120 136
250 SV Ind 1732 1141 1278 1.1 19 16.2 145 166
300 SV Ind 2046 1438 1591 1.1 19 18.8 175 181
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17
Megalife Product Guide
Table 04: Unit weights
Table 05: Standing heat loss
Type Model
Reference
Nominal
Capacity
(litres)
Weight of
unit full
(Kg)
Weight
of unit
(Kg)
Solar
Indirect
190 SV Ind 190 243 43
210 SV Ind 210 264 50
250 SV Ind 250 308 51
300 SV Ind 300 367 58
Nominal
Capacity
(Litres)
Standing Heat Loss
per day
(kWh/24h)
per year
(kWh/365d)
190 1.52 555
210 1.70 621
250 1.98 723
300 2.31 843
Indirect
Model(s) CLV190 CLV210 CLV250 CLV300
Energy efficiency class C C C C
Storage volume V in litres 190 210 250 300
Standing loss in W 80.0 81.7 82.5 96.3
Table: Technical parameters in accordance with European Commission regulations 814/2013 and 812/2013
Table: Figures measured in accordance with KIWA Test Criteria
for compliance with UK Building and Water Regulations
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Megalife Product Guide
18
Outline Specifications
Maximum working head 40 metres 0.4MPa (4 bar)
Immersion heater rating (a.c. supply only) 3kW @ 240V ~ 50Hz
2.8kW @ 230V ~ 50Hz
Maximum primary circuit pressure 0.3MPa (3 bar)
Rated pressure 0.2MPa (2.0 bar)
Pressure drop across coils 0.02MPa (0.2bar)
Outer casing:
White textured plastic coated corrosion proofed steel
Water container:
Duplex stainless steel (grade 1.4362 to EN10088). 100% pressure tested to 15 bar.
Thermal insulation:
HCFC/CFC free (ODP Zero) fire retardant expanded polyurethane foam. Nominal thickness 50mm.
Immersion heater:
Alloy sheathed element and thermostat pocket in Duplex stainless steel plate.
Pipe connections:
All connections accept 22mm outside diameter pipe - compression nuts and olives supplied. Thread rate is 3/4” BSP
male parallel to accept standard 3/4” BSP female fittings if required. Secondary return tapping thread rate is 1/2” BSP
female parallel to accept standard 1/2”BSP male fittings if required (supplied plugged).
Safety features:
Manually resettable thermal cut-out on heating element thermostat.
Manually resettable thermal cut-out for primary heating. Must be wired in conjunction with a suitable motorised valve
located within the primary heating circuit (not supplied).
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19
Megalife Product Guide
Goods are guaranteed and sold subject to our standard conditions of sale. A copy of these conditions will be supplied
on application.
11.1 Guarantee Terms
Heatrae Sadia guarantee the Megalife solar immersion heater for a period of two years from the date of purchase,
with the exception of damage due to scaling.
Electrical parts and thermal controls are guaranteed for a period of two years, from the date of purchase.
The stainless steel vessel is guaranteed for a period of 25 years against faulty manufacture or materials provided
that :-
• It has been installed by a competent installer and as per the instructions contained in this manual and all relevant
Codes of Practice and Regulations in force at the time of installation.
• It has not been modified in any way other than by Heatrae Sadia Heating.
• It has only been used for the storage of potable water.
• It has not been installed in a location liable to be subjected to frost, nor has it been tampered with or been
subjected to misuse or neglect.
• The fault is not scale related.
• The fault is not caused by high chloride levels in the water supply or incorrect disinfection methods.
• No factory fitted parts have been removed for unauthorised repair or replacement.
• Within 60 days of purchase the user completes and returns the certificate supplied along with proof of purchase to
register the product.
• Evidence of purchase and date of supply must be submitted.
This guarantee is not valid for installations outside the United Kingdom and the Republic of Ireland. For installations
outside these territories please contact either the Heatrae Sadia Heating Export Department (Tel: [phone])
or Baxi International (Tel: [phone]) for further details of the guarantee terms and conditions applicable.
This guarantee does not affect your statutory rights.
Environmental Information
This product is made from many recyclable materials, therefore at the end of its useful life it should be disposed of
at a Local Authority Recycling Centre in order to realise the full environmental benefits.
Insulation is by means of an approved HCFC and CFC free polyurethane foam.
WEEE Declaration
Disposal of Waste Equipment by Users in Private Household in the European Union.
This symbol on the product indicates that this product must not be disposed of with your other household waste.
Instead, it is your responsibility to dispose of your waste equipment by handing it over to a designated collection
point for the recycling of waste electrical equipment. The separate collection and recycling of your waste equipment
at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects
human health and the environment. For more information about where you can drop off your waste equipment for
recycling, please contact your local city office, your household waste disposal service or the company where this
product was purchased.
The pace of product development is such that we reserve the right to change product specifications without notice.
We do, however, strive to ensure that all information in this leaflet is accurate at the time of publication
11: Guarantee
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Heatrae Sadia, Hurricane Way, Norwich,
Norfolk, NR6 6EA, United Kingdom
After Sales Service
T: 0344 871 1535 F: 0344 871 1528
E: [email protected]
www.heatraesadia.com
SPARES STOCKISTS:
Advanced Water Company Ltd
Unit D5 Enterprise Way
Vale Park, Evesham
Worcs, WR11 1GS
T: 01386 760066
F: 01386 760077
Electric Water Heating Co
2 Horsecroft Place, Pinnacles,
Harlow, Essex, CM19 5BT
T: 0845 055 3811
E: [email protected]
SPD
Units 9 & 10 Hexagon Business Centre
Springeld Road, Hayes,
Middlesex, UB4 0TY
T: 020 8606 3567
Parts Center
T: 0845 270 9800
W: www.partscenter.co.uk
Newey & Eyre
Unit 3/4/5 Wassage Way
Hampton Lovett Industrial Estate
Droitwich, Worcestershire, WR9 0NX
T: 01905 791500
F: 01905 791501
UK Spares Ltd
Unit 1155, Aztec West,
Almondsbury, Bristol, BS32 4TF
T: 01454 620500
Alternatively contact your local supplying
merchant or wholesale branch.
36005941_issue_07
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