Hyco Powerflow User manual

Product Instruction anual
Powerflow
Unvented wate heate
30, 50 and 90 litres
v15.6/5
Powerflow_Layout 1 28/06/2015 10:09 Page 1

Thank you for purchasing a Powerflow series unvented electric water heater. The Powerflow is
suitable for hand washing and dishwashing where a number of hot water outlets are required
such as kitchens, schools, restaurants, washrooms and offices. The Powerflow is the ideal solution
for light industrial, commercial and light domestic hot water requirements. Please read and
understand these instructions before commencing installation, and leave them with the user
when installation is complete.
1. Impo tant safety points
Installation must be undertaken by a competent installer trained in the installation of unvented water
heating systems in accordance with building regulations G3.
Building regulations G3 requires a temperature and pressure relief valve to be factory fitted. This must
not be removed or blocked in any way.
Installation must comply with the latest edition of the IEE wiring regulations.
These units are very heavy. They must be securely fastened to a suitably strong wall using the fixings
supplied. Remember to allow for the weight of the water (one KG per litre of capacity) when assessing
the suitability of the wall.
2. Installation
Ove view
Components Checklist ✔
Expansion Vessel 3/4" BSP, precharge pressure 3.5 bar
Pressure Reducing Valve, factory set at 3 bar
Single Check Valve 15mm x 15mm compression
Pressure (expansion) Relief Valve 1/2" BSP male inlet, 1/2" BSP female discharge, factory set at 6 bar
Tundish 15mm x 22mm
•This unit must be installed vertically, with the pipes pointing downwards and the temperature and
pressure relief valve at the top.
•Ensure the wall is strong enough to support the heater, including the weight of the water when full.
•This heater is not suitable for outdoor installation.
•Do not install where there is any risk of freezing.
•The heater is bulky and heavy, Do not attempt to lift alone.
Powerflow_Layout 1 28/06/2015 10:09 Page 2

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 all the components supplied, components may be supplied loose or connected to a mainfold.
The manifold aids installation but does not alter the relative positions of the components.
•Do not remove the factory fitted temperature and pressure relief valve.
•Ensure in particular that there are no valves of any kind between the expansion relief vlave and the heater.
•Allow at least 400mm of space above and below the unity to permit for maintenance.
•Observe flow direction arrows on components.
Wall mounting
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.
Temperature and
Pressure Relief Valve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
Relief Valve
Expansion
Vessel
Check
Valve
Balanced
ColdWater
Draw O
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model
Vertical Bolt
Spacing A (mm)
Horizontal Bolt
Spacing B (mm)
PF30L 270320
PF50L 520320
PF90L 430320
Safety Device
Tundish
600mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief to Tundish
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)
from Tu n d i s h
Maximum resistance allowed,
expressed as a length of straight
pipe (I.E. no elbows or bends)
Resistance
created by each
elbow or bend
m8.0m9otpumm22mm512/1G
28mm up to 18m 1.0m
m4.1m72ot*mm53
Diagram 4
Element ange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
H
Diagram 3
WD
Temperature and
Pressure Relief Valve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
Relief Valve
Expansion
Vessel
Check
Valve
Balanced
ColdWater
Draw O
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model
Vertical Bolt
Spacing A (mm)
Horizontal Bolt
Spacing B (mm)
PF30LC
270320
PF50LC
520320
PF90LC
430320
Safety Device
Tundish
600mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief to Tundish
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)
from Tu n d i s h
Maximum resistance allowed,
expressed as a length of straight
pipe (I.E. no elbows or bends)
Resistance
created by each
elbow or bend
m8.0m9otpumm22mm512/1G
28mm up to 18m 1.0m
m4.1m72ot*mm53
Diagram 4
Element ange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
H
Diagram 3
WD
Powerflow_Layout 1 28/06/2015 10:09 Page 3

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 direction arrows on supplied valves.
•The drain valve must be fitted close to the COLD inlet to allow drain down if necessary.
•An isolating valve should be fitted UPSTREA 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.
Control valves may be supplied loosely connected for identification purposes, but these joins have
not been leak tested. This must be done at installation.
It is essential to also check the temperature pressure reflief valve connection to the heater for leaks.
Note that a leak from the temperature and pressure reflief vlve may not be immediately obvious, as
the connection is at the top of the heater and leaking water may in the first instance run down the
pipework and collect in the heater insulation.
Discharge pipe connections
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 UST terminate in a
safe, visible position.
In achieving this aim the G3 regulations strongly recommended that:
•The tundish is located within 500mm of the Temperature and Pressure Relief valve and it is wherever
possible oriented vertically. It must be visible to occupants and positioned away from electrical devices.
•The discharge pipe has a vertical fall of at least 300mm immediately below the tundish.
•The discharge pipe below the tundish is at least 22mm diameter (i.e. one size larger than the Temperature
and Pressure Relief valve outlet).
•The discharge pipe should be as straight and as short as is possible and positioned away from
electrical components.
Powerflow_Layout 1 28/06/2015 10:09 Page 4

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.
Electrical connections
•The heater is supplied pre-wired with appropriate cable.
•Electrical installation should conform to the latest edition of the IEE Wiring Regulations.
•Electrical supply should be capable of isolation via a user-accessible double pole isolation switch rated
for a 13A supply.
3. 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 the Temperature 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.
Temperature and
Pressure Relief Valve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
Relief Valve
Expansion
Vessel
Check
Valve
Balanced
ColdWater
Draw O
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model
Vertical Bolt
Spacing A (mm)
Horizontal Bolt
Spacing B (mm)
PF30L 270320
PF50L 520320
PF90L 430320
Safety Device
Tundish
600mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief to Tundish
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)
from Tu n d i s h
Maximum resistance allowed,
expressed as a length of straight
pipe (I.E. no elbows or bends)
Resistance
created by each
elbow or bend
m8.0m9otpumm22mm512/1G
28mm up to 18m 1.0m
m4.1m72ot*mm53
Diagram 4
Element ange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
H
Diagram 3
WD
Powerflow_Layout 1 28/06/2015 10:09 Page 5

Ensure the discharge pipe can cope with this flow rate continuously. Release the Temperature 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.
4. Ope ation
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.
aximum energy efficiency and product life is obtained avoiding very high temperature settings. The optimal
temperature setting balances these factors.
The maximum temperature settings is about 65 degrees, this can be excessively hot for some
situations. In situations where very young children, the elderly or other vulnerable people are
likely users a suitable thermostatic mixing valve should be fitted by your 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 interfere with any safety valves.
Beware that hot water discharged from safety valves could be very hot.
5. Maintenance
Draining the 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.
Note that a small quantity of water will remain in the tank. This residual water can be drained
by removing the heating element.
Electrical components
Always switch the electrical supply off before undertaking any maintence to the heater unit.
Servicing of electrial parts should only be undertaken by competent individuals.
Powerflow_Layout 1 28/06/2015 10:09 Page 6

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 parts take particular attention to ensure that the earthing connections
(green/yellow) to the element flange and thermostat housing are sound.
Thermal cut-out reset
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.
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 limescale are excluded from any warranty.
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.
Temperature and
Pressure Relief Valve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
Relief Valve
Expansion
Vessel
Check
Valve
Balanced
ColdWater
Draw O
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model
Vertical Bolt
Spacing A (mm)
Horizontal Bolt
Spacing B (mm)
PF30L 270320
PF50L 520320
PF90L 430320
Safety Device
Tundish
600mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief to Tundish
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)
from Tu n d i s h
Maximum resistance allowed,
expressed as a length of straight
pipe (I.E. no elbows or bends)
Resistance
created by each
elbow or bend
m8.0m9otpumm22mm512/1G
28mm up to 18m 1.0m
m4.1m72ot*mm53
Diagram 4
Element ange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
H
Diagram 3
WD
Powerflow_Layout 1 28/06/2015 10:09 Page 7

Anode & tank inspection
•It is possible to view the tank by removing the element to gain access. It is advisable the tank is inspected
at regular intervals for signs of corrosion.
•There is a magnesium anode fitted to most models of the Power flow.
•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.
•It is not normally necessary (or practical) to attempt to remove any scale from the tank walls.
•Rest element and follow commissioning instructions as per section 8.
afety valve checks
•The Temperature 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.
Expansion vessel
•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.
Powerflow_Layout 1 28/06/2015 10:09 Page 8

6. Specifications
Model
PF30LC PF50LC PF90LC
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
Maximum design pressure 6 bar
Expansion vessel charge pressure 3 bar
Expansion relief valve setting 6 bar
Pressure Reducing Valve 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
tanding heat losses(kW/h) 0.93 1.16 1.26
Height (mm) 620 915 930
Width (mm) 380 380 540
Depth (mm) 295 295 385
Tank Material tainless steel
Inlet / Outlet ½ ” B P male
Powerflow_Layout 1 28/06/2015 10:09 Page 9
*Units also available with 1kW element. Add suffix of 1KW to product code e.g. PF30LC1KW

T
emperature and
Pressure Relief Valve
POWERFLOW
Hot
Drain Cock To Drain (Waste)
Pressure
(Expansion)
Relief Valve
Expansion
Vessel
Check
Valve
Balanced
ColdWater
Draw O
Pressure
ReducingValve
Service
Valve
ColdWater
Mains
Diagram 1
B
A
Diagram 2
Model
Vertical Bolt
Spacing A (mm)
Horizontal Bolt
Spacing B (mm)
PF30L 270320
PF50L 520320
PF90L 430320
Safety Device
Tundish
600mm MAXIMUM
Metal Discharge Pipe (D1) from
Temperature Relief to Tundish
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)
from Tu n d i s h
Maximum resistance allowed,
expressed as a length of straight
pipe (I.E. no elbows or bends)
Resistance
created by each
elbow or bend
m8.0
m9
otpu
mm22mm51
2/1
G
28mm up to 18m 1.0m
m4.1m72ot*
mm53
Diagram 4
Element ange -
Remove to access anode
Thermostat
Thermal cutout -
Press here to reset
H
Diagram 3
W D
Powerflow_Layout 1 28/06/2015 10:09 Page 10

7. T oubleshooting
ymptom 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 No action needed.
as they are heated – this is normal Water will turn clear after
condition for pressurised systems standing for a few seconds.
Water discharged during Expansion vessel has lost its charge Re-pressurise vessel as
heating cycle only section 15.
Water discharged all the Either the pressure reducing valve is Replace appropriate valve.
time 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.
No / limited water flow Check mains water is turned on. Check pressure reducing
valve for grit.
ixing valves not working Unbalanced pressure. Ensure cold is tee-ed off
correctly after pressure
reducing valve so hot
and cold are at equal
pressure.
8. Gua antee and se vice policy
This product is guaranteed against faulty materials and manufacture for a period of one year from the date of
purchase. Hycowill in its sole discretion replace, repair or refund any faulty unit. Incorrect installation, frost
damage, and the consequences of limescale deposits are excluded. Consequential costs such as labour
charges or damage to fittings and surroundings are expressly excluded.
Powerflow_Layout 1 28/06/2015 10:09 Page 11

hyco.co.uk
Hyco anufacturing Ltd
Normandy Court
Express Way
Castleford, WF10 5NR
T 01924 225 200
F 01924 225 210
E [e-mail]
INFOR ATION FOR CORRECT DISPOSAL OF THE PRODUCT IN ACCORDANCE WITH THE
EUROPEAN DIRECTIVE 2002/96/E.
At the end of its working life this equipment must not be disposed of as household waste. It must be
taken to a local authority waste collection centre or to a dealer providing this service. Disposing of
electrical and electronic equipment separately enables its components to be recovered and recycled
to obtain significant savings in energy and resources. In order to underline the duty to dispose of
this equipment separately, the product is marked with a crossed out dustbin.
Powerflow_Layout 1 28/06/2015 10:09 Page 12