Hyco powerflow series User manual

Hyco Manufacturing Ltd
California Drive
Whitwood
Castleford
WestYorkshire
WF10 5QH
Tel:[phone] Fax: [phone]
Web:www.hyco.co.uk
E-mail:[e-mail]
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17.USER INSTRUCTIONS
This water heater will store water at a temperature selected via the thermostat on the front of the heater.
To set the temperature turn the control clockwise to increase the temperature and anti-clockwise to decrease it.
The indicator light comes on when the unit is heating.
Maximum energy efficiency and product life is obtained avoiding very high temperature settings.The optimal temperature
setting balances these factors.
THE MAXIMUMTEMPERATURE SETTING ISABOUT 65 DEGREES.THIS CAN BE EXCESSIVELY HOT FOR SOME
SITUATIONS.IN SITUATIONSWHEREVERYYOUNG CHILDREN,THE ELDERLY OR OTHERVULNERABLE
PEOPLEARE LIKELY USERSA SUITABLETHERMOSTATIC MIXINGVALVE SHOULD BE FITTED BYYOUR
INSTALLER.
If there is any risk of frost the heater should be left switched on at it lowest heat setting.If the heater is to be left unused for
long periods,it should be drained.
This unit should be maintained in accordance with the instruction in the sections 12-16.
NEVER INTERFEREWITH ANY SAFETYVALVES.
BEAWARETHAT HOTWATER DISCHARGED FROM SAFETYVALVES COULD BEVERY HOT.
18.GUARANTEEAND SERVICE POLICY
This product is guaranteed against faulty materials and manufacture for a period of one year from the date of purchase.Hyco
will in its sole discretion repair,replace or refund any faulty unit. Incorrect installation and the consequences of limescale
deposits are excluded.Consequential losses such as damage to fittings or labour charges are excluded from this guarantee.
POWERFLOW Series
Unvented Electric Storage
Water Heaters
Installation & Operating Instructions Manual
These Instructions must be left with the user after installation.
Version 3.0 June 2009

HYCO POWERFLOW SERIES UNVENTED ELECTRIC STORAGEWATER HEATERS
1.INTRODUCTION &TECHNICAL SPECIFICATION
Thank you for purchasing a POWERFLOW Series Unvented Electric StorageWater Heater from Hyco Manufacturing Ltd.
To use this equipment safely please read this manual carefully.When the unit is installed,the operation and maintenance
section should be explained to the user of the equipment.
Do not proceed with installation or operation if there is sign of any damage to the product or the power cord.
If you have any queries regarding operation or installation please contact our technical department on 01977 517555.
READTHESE INSTRUCTIONS BEFORE ATTEMPTING INSTALLATION.
INSTALLATION MUST BE UNDERTAKEN BYA COMPETENT INSTALLERTRAINED INTHE INSTALLATION
OF UNVENTEDWATER HEATING SYSTEMS INACCORDANCE WITH BUILDINGS REGULATION G3.
BUILDING REGULATION G3 REQUIRES ATEMPERATUREAND PRESSURE RELIEFVALVETO BE FACTORY
FITTED.THIS MUST NOT BE REMOVED OR BLOCKED IN ANYWAY.
INSTALLATION MUST COMPLYWITHTHE LATEST EDITION OFTHE IEEWIRING REGULATIONS.
THESE UNITSARE VERY HEAVY.THEY MUST BE SECURELY FASTENEDTOA SUITABLY STRONGWALL
USINGTHE FIXINGS SUPPLIED.REMEMBER TOALLOW FORTHEWEIGHT OFTHEWATER (ONE KG PER
LITRE OF CAPACITY)WHENASSESSINGTHE SUITABILITY OFTHEWALL.
2.SPECIFICATIONS
3.INSTALLATION OVERVIEW
THIS UNIT MUST BE INSTALLEDVERTICALLY,WITHTHE PIPES POINTING DOWNWARDS ANDTHE
TEMPERATURE AND PRESSURE RELIEFVALVEATTHETOP.
1
Model PF30L PF50L PF90L
Maximum water pressure to pressure reducing valve 12 bar
Power (kW) 3.0
Voltage (V) 230V ~ 50 Hz
Current (A) 13A
Capacity (Litres) 30 50 90
Operating Pressure 3 bar
Expansion vessel charge pressure 3 bar
Expansion relief valve setting 6 bar
Pressure ReducingValve setting 3 bar
Temperature and Pressure Relief 7 Bar 90 degrees C
Minimum recommended pressure 0.8 bar
Immersion heater specification Hyco PFEL30 EN60335 x 1
Weight empty (kg) 9 13 24
Weight full (kg) 39 63 114
Heat up time (from 13°C to 60°C) in minutes 21 40 86
Reheat time (70% contents to 60°C) in minutes 16.5 28 57
Height (mm) 620 915 930
Width (mm) 380 380 540
Depth (mm) 295 295 385
Tank Material Stainless steel
Inlet/Outlet ½ ” BSP male
Components Checklist ✔
ExpansionVessel 3/4" MBSP, precharge pressure 3.5 bar
■
Pressure ReducingValve, factory set at 3 bar
■
Single CheckValve 15mm x 15mm compression
■
Pressure (expansion) ReliefValve 1/2" BSP male inlet, 1/2" BSP female discharge,factory set at 6 bar
■
Tundish 15mm x 22mm
■
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13.MAINTENANCE -ANODE INSPECTION (Continued)
It is not normally necessary (or practical) to attempt to remove any scale from the tank walls.
Refit element and follow commissioning instructions as per section 8.
14.MAINTENANCE - SAFETYVALVE CHECKS
TheTemperature and Pressure relief and expansion relief valve relieve any dangerous pressure or temperature build up that
may arise as a consequence of abnormal operation.
BOTH valves should be tested periodically by twisting the cap and checking that water flows freely.The water flow should
cease when the valve is released.
The pressure reducing valve contains a wire mesh gauze that may become clogged over time.To clean, close off mains water
and open a hot outlet to drain the system of water.
Unscrew the plastic top of the pressure reducing valve from the brass housing and remove complete mechanism including
wire mesh.Rinse mesh to remove grit,scale etc as necessary and replace.
Re-commission system following instructions as per section 8.
15.MAINTENANCE – EXPANSIONVESSEL
Water expands when it is heated.The expansion vessel accommodates expanded water during the heating cycle via a
pressurised diaphragm arrangement so that water is not wasted.
The vessel is supplied already pressurised to 3 bar.Over time the pressure may be lost and water may be discharged during
the heating cycle.
The pressure should be checked using a standard car tyre foot pump or similar device.The pressure should be re-set to 3 bar.
16.TROUBLESHOOTING
Symptom Likely Fault(s) Remedy
Water not heating Thermal cut-out needs re-setting Reset as section 11.
Element failure Replace
Thermostat failure Replace
Thermal cut-out failure Replace
Electrical supply failure Check supply is present
Water too hot Thermostat set too high Reduce setting
Fit thermostatic mixing valve
Water milky coloured Dissolved gases coming out of solution as they are heated –
this is normal condition for pressurised systems No action needed.Water will turn clear after standing for a
few seconds.
Water discharged during
heating cycle only Expansion vessel has lost its charge Re-pressurise vessel as section 15.
Water discharged all the
time Either the pressure reducing valve is failing to reduce the water pressure to 3 bar approx, or one of the safety valves
is operating at below is nominal level.
To differentiate measure the water pressure downstream
of the pressure reducing valve.If the pressure is more than
about 4 bar, replace the pressure reducing valve.
If the pressure is less than 4 bar,replace the safety valve
that is opening.
Replace appropriate valve.
No/limited water flow Check mains water is turned on. Check pressure reducing valve
for grit.
Mixing valves not working
correctly Unbalanced pressure. Ensure cold is tee-ed off after pressure reducing valve so hot
and cold are at equal pressure.

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10.MAINTENANCE - ELECTRICAL COMPONENTS
ALWAYS SWITCHTHE ELECTRICAL SUPPLY OFF BEFORE UNDERTAKINGANY MAINTENANCETOTHE
HEATER UNIT.
SERVICING OF ELECTRICAL PARTS SHOULD ONLY BE UNDERTAKEN BY COMPETENT INDIVIDUALS.
All maintainable electrical components are located under a plastic cover that is next to the inlet and outlet pipes and held in
position with two small screws.Remove screws and lower cover to provide access to components.See diagram below for
electrical parts identification.
IF REPLACING ELECTRICAL PARTSTAKE PARTICULARATTENTIONTO ENSURETHATTHE EARTHING
CONNECTIONS (GREEN/YELLOW)TOTHE ELEMENT FLANGEANDTHERMOSTAT HOUSING ARE SOUND.
11.MAINTENANCE -THERMAL CUT-OUT RE-SET
This unit contains a manually re-settable thermal cut-out that will switch the power off if the temperature reaches an
abnormally high level.To reset the cut-out the press button as shown in Diagram 4.
12.MAINTENANCE – DE-SCALING PROCEDURE
If scale is allowed to build up heater performance will suffer and the life of the product will be reduced.
THE EFFECTS OF LIMESCALEARE EXCLUDED FROMANYWARRANTY.
To de-scale the heater,gain access to the element following the instructions set out in section 10.
Remove thermostat and thermal cut-out bulbs from respective pockets and unscrew the 6 nuts holding the element flange in
position.Withdraw element.
Remove scale carefully.If necessary,dip element in a de-scaling solution available from DIY or plumbing outlets.Do not allow
electrical connections to become wet.
It is not normally necessary (or practical) to attempt to remove any scale from the tank walls.
Refit element and follow commissioning instructions as per section 8.
13.MAINTENANCE –ANODE INSPECTION
There is a magnesium anode fitted to most models of the Powerflow.
It is a grey magnesium cylinder fitted to the element base and its role is to reduce the rate of corrosion of the tank.
It should be inspected periodically and replaced if there are signs of disintegration from a solid metallic structure.
To access the anode,follow instructions in section 10.
Remove scale carefully.If necessary,dip element in a de-scaling solution available from DIY or plumbing outlets.Do not allow
electrical connections to become wet.
Diagram 4
Element flange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
3.INSTALLATION OVERVIEW (Continued)
ENSURETHE WALL IS STRONG ENOUGH TO SUPPORTTHE HEATER,INCLUDINGTHEWEIGHT OF THE
WATERWHEN FULL.
THIS HEATER IS NOT SUITABLE FOR OUTDOOR INSTALLATION.
DO NOT INSTALLWHERETHERE ISANY RISK OF FREEZING.
Plan your installation carefully and choose a suitable position for the heater, allowing suitable space for accessories such
expansion vessels,pipework and subsequent maintenance.
See schematic Diagram 1 for the correct relative positions of the components.
FIT ALLTHE COMPONENTS SUPPLIED.COMPONENTS MAY BE SUPPLIED LOOSE OR CONNECTEDTOA
MANIFOLD.THE MANIFOLDAIDS INSTALLATION BUT DOES NOTALTERTHE RELATIVE POSITIONS OF
THE COMPONENTS.
DO NOT REMOVETHE FACTORY FITTEDTEMPERATUREAND PRESSURE RELIEFVALVE.
ENSURE IN PARTICULARTHATTHEREARE NOVALVES OFANY KIND BETWEENTHE EXPANSION RELIEF
VALVEANDTHE HEATER.
ALLOWAT LEAST 400MM OF SPACEABOVEAND BELOWTHE UNITTO PERMIT FOR MAINTENANCE.
OBSERVE FLOW DIRECTIONARROWS ON COMPONENTS.
4.MOUNT ONWALL
Drill holes for supplied heavy duty bolts to wall at the spacings shown in the table below (also See Diagram 2).
Insert bolt hooks and tighten ensuring that they are secure then hang heater on the protruding hooks.
2
Temperature and Pressure ReliefValve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
ReliefValve Expansion
Vessel
CheckValve
Balanced
ColdWater
Draw Off
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model Vertical Bolt Spacing A (mm) Horizontal Bolt Spacing B (mm)
PF30L 270 320
PF50L 520 320
PF90L 430 320

5.MAKE HEATER PLUMBING CONNECTIONS
Connect ALL the plumbing valves in the sequence shown in diagram 1.
The cold water inlet to the heater is marked BLUE and the hot water outlet is marked RED.
OBSERVE FLOW DIRECTIONARROWS ON SUPPLIEDVALVES.
The drain valve must be fitted close to the COLD inlet to allow drain down if necessary.
An isolating valve should be fitted UPSTREAM of all of the valves to allow the heater to be maintained without impacting on
other facilities.
Do NOT fit a service or other valves between the heater and the pressure relief (safety) valve as this could impede its
correct operation.
The pressure reducing valve is factory set at 3 bar.If a balanced cold water draw off is required this should be tee-ed off
down stream of this valve.
A balanced cold water feed is recommended as it ensures hot and cold water is supplied at the same pressure. Some mixer
taps and thermostatic showers require hot and cold water to be to be at the same pressure for correct operation.
The expansion vessel supplied must be supported using a bracket or similar fixing.Do not rely on the pipework alone – it will
not be strong enough.The orientation of the vessel is not important.
When all valves are correctly fitted, open a hot tap and wait until the water flow is steady and without traces of air. Close the
tap to allow the system to reach full pressure and carefully check system for leaks.
CONTROLVALVES MAY BE SUPPLIED LOOSELY CONNECTED FOR IDENTIFICATION PURPOSES,BUTTHESE
JOINS HAVE NOT BEEN LEAKTESTED.THIS MUST BE DONEAT INSTALLATION.
IT IS ESSENTIALTOALSO CHECKTHETEMPERATURE PRESSURE RELIEFVALVE CONNECTIONTOTHE
HEATER FOR LEAKS. NOTETHATA LEAK FROMTHETEMPERATURE AND PRESSURE RELIEFVALVE MAY NOT
BE IMMEDIATELY OBVIOUS,ASTHE CONNECTION ISATTHETOP OFTHE HEATERAND LEAKINGWATER
MAY INTHE FIRST INSTANCE RUN DOWNTHE PIPEWORKAND COLLECT INTHE HEATER INSULATION.
6.DISCHARGE PIPE CONNECTIONS (SEE DIAGRAM 3,PAGE 4)
This product falls within the scope of Building Regulation G3 which stipulates certain conditions relating to the way any water
discharge from relief valves is transported away.
These conditions are designed to ensure that any discharge will not present a hazard to people or to property,and that any
discharge is clearly visible so that the underlying cause is likely to be rectified promptly.
The essential requirement of G3 in relation to water discharge is that the discharge pipe MUST terminate in a safe,visible
position.
In achieving this aim the G3 regulations strongly recommended that:
1. The tundish is located within 500mm of theTemperature and Pressure Relief valve and it is wherever possible oriented
vertically. It must be visible to occupants and positioned away from electrical devices.
2. The discharge pipe has a vertical fall of at least 300mm immediately below the tundish.
3. The discharge pipe below the tundish is at least 22mm diameter (i.e.one size larger than theTemperature and Pressure
Relief valve outlet).
4. The discharge pipe should be as straight and as short as is possible and positioned away from electrical components.
Diagram 3 illustrates an acceptable discharge pipe arrangement.The table below the diagram specifies how the maximum
acceptable pipe length from the tundish to the final outlet depends on the pipe diameter and the number of bends (reference
the chart on page 4 for pipe sizing).
For example in 22mm copper with no bends the pipe could be up to 9m long.With two bends present the maximum length
drops to 9.0m - (2 x 0.80m) = 7.4m.
7.ELECTRICAL CONNECTIONS
The heater is supplied pre-wired with appropriate cable.
Electrical installation should conform to the latest edition of the IEEWiring Regulations.
Electrical supply should be capable of isolation via a user-accessible double pole isolation switch rated for a 13A supply.
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8.COMMISSIONING
Visually re-confirm all plumbing and electrical connections are sound.
• Open a hot water tap and turn on mains water supply to the Powerflow heater
• Allow unit to fill and leave tap running for a short time to flush out the pipework and purge any air from the system
before closing the hot tap and checking the system for any leaks.
Check the operation of theTemperature and Pressure relief valve located at the top of the heater twisting the knob at the
top of the valve.This lifts the valve seat and water will flow rapidly and be visible at the tundish.Ensure the discharge pipe can
cope with this flow rate continuously.Release theTemperature and Pressure relief valve.The flow should stop completely.
Open the expansion relief valve and likewise check that water flows freely through the discharge pipe,that the discharge pipe
can cope with the flow rate and that the water flow ceases when the valve is released.
Switch on the electrical supply and select an appropriate heater setting on the thermostat knob (the thermostat is adjustable
in the approximate range 20°C to 65°C.
The neon indicator light comes on when the element is heating.
9.DRAININGTHE UNIT
To drain the unit disconnect electrical supply and close service valve on cold inlet.
Open the drain cock on cold inlet and open a hot water outlet to enable air to replace draining water.
NOTETHATA SMALL QUANTITY OFWATERWILL REMAIN IN THETANK.THIS RESIDUALWATER CAN
ONLY BE DRAINED BY REMOVINGTHE HEATING ELEMENT.
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Diagram 3
Safety Device
Tundish
500mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief toTundish
Discharge Below
Fixed Grating
300mm MINIMUM
Metal Discharge Pipe (D2) from
Tundish with Continuous Fall
Fixed Grating
Trapped Gully
Sizing of D2 Copper Discharge pipe for common temperature relief valve outlet size
Valve
outlet
size
Minimum size of
discharge pipe (D1) Minimum size of discharge pipe (D2)
fromTundish
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
25mm * to 27m 1.4m