Main Solar 190 S Ind User manual

36006095_issue_08
Installation Manual
Unvented Solar Indirect Water Heaters Installation & Servicing
Instructions

Pack Contents
●Solar unvented water heater incorporating immersion heater(s) & thermal controls
●Factory fitted temperature/pressure relief valve (set at 90°C / 1 Mpa (10bar))
●Cold water combination valve assembly

●Expansion vessel & mounting bracket
●Tundish
●2 Port motorised valve
●Compression nuts & olives
●Immersion heater spanner
●Installation & servicing instructions
●Guarantee card
IMPORTANT
Please read & understand all these instructions before commencing installation. Please leave this manual
with the customer for future reference.
page 1
Contents
Introduction
General Requirements
Installation General
Installation Discharge
Installation Solar
Installation Auxiliary Heating Coil
Commissioning
Maintenance
User Instructions
Fault Finding & Servicing

Spares
Heat Loss
Environmental Information
Commissioning Check List.
Service Record
Guarantee
Technical Support
Introduction
The cylinder is a purpose designed unvented water heater. The unit has a stainless steel inner vessel,
which ensures an excellent standard of corrosion resistance. The outer casing is a combination of resilient
thermoplastic mouldings and plastic coated corrosion proofed steel sheet. All products are insulated with
CFC free polyurethane foam to give good heat loss performance. (see Table 6)
The unit is supplied complete with all the necessary safety and control devices needed to allow
connection to the cold water mains. All these components are preset and not adjustable.
This appliance complies with the requirements of the CE marking directive and is Kiwa approved to show
compliance with Building Regulations (Section G3).
The following instructions are offered as a guide to installation which must be carried out by a competent
plumbing and electrical installer in accordance with Building Regulation G3, The Building Standards
(Scotland) Regulations 1990, or The Building Regulations (Northern Ireland).
NOTE: Prior to installation the unit should be stored in an upright position in an area free from excessive
damp or humidity.
The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that
customers are provided with the correct equipment for their needs, that it is installed, commissioned
and serviced in accordance with the manufacturer's instructions by competent persons and that it meets
the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to
demonstrate compliance with Building Regulations and should be provided to the customer for future
reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the
Benchmark Code of Practice which is available from the Heating and Hot water Industry Council who
manage and promote the scheme. Visit www.centralheating.co.uk for more information.
IMPORTANT NOTE TO USER: PLEASE REFER TO THE USER INSTRUCTIONS SECTION FOR
IMPORTANT INFORMATION WITH RESPECT TO THE BENCHMARK SCHEME
page 2
General Requirements
IMPORTANT:
IMPORTANT: 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.
Siting the Unit
The cylinder must be vertically floor mounted. Although location is not critical, the following points
should be considered:
●The cylinder should be sited to ensure minimum dead leg distances, particularly to the point of
most frequent use.
●Avoid siting where extreme cold temperatures will be experienced. All exposed pipe work should
be insulated.
●The discharge pipework from the safety valves must have minimum fall of 1:200 from the unit
and terminate in a safe and visible position.
●Access to associated controls and immersion heaters must be available for the servicing and
maintenance of the system. Where these controls are installed against a wall a minimum distance
of 250mm must be left (see Fig. 01, below).
●Ensure that the floor area for the cylinder is level and capable of permanently supporting the
weight when full of water. (see Table 01)

Fig. 01: Siting the Unit
Type Model Reference Nominal Capacity
(litres)
Weight of unit full
(Kg)
Weight of unit
(Kg)
190 S Ind 190 243 43
210 S Ind 210 264 50
250 S Ind 250 308 51
Solar
Indirect
300 S Ind 300 367 58
Table 01: Unit weights
Water Supply
Bear in mind that the mains water supply to the property will be supplying both the hot and cold water
requirements simultaneously.
It is recommended that the maximum water demand is assessed and the water supply checked to
ensure this demand can be satisfactorily met.
Note: A high mains water pressure will not always guarantee high flow rates.

Wherever possible the mains supply pipe should be 22mm. We suggest the minimum supply requirements
should be 0.15MPa (1.5 bar) pressure and 20 litres per minute flowrate. However, at these values outlet
flow rates may be poor if several outlets are used simultaneously. The higher the available pressure and
flow rate the better the system performance.
The cylinder has an operating pressure of 0.35MPa (3.5 bar) which is controlled by the cold water
combination valve assembly. The cold water combination valve assembly can be connected to a
maximum mains pressure of 1.6MPa (16 bar).
Outlet/Terminal Fittings (Taps, Etc)
The cylinder can be used with most types of terminal fittings. It is advantageous in many mixer
showers to have balanced hot and cold water supplies. In these instances a balanced pressure cold water
connection should be placed between the expansion vessel connection and the cold water combination
valve assembly (see Fig. 02). Outlets situated higher than the cylinder will give outlet pressures lower
than that at the heater, a 10m height difference will result in a 0.1MPa (1 bar) pressure reduction at the
outlet. All fittings, pipework and connections must have a rated pressure of at least 0.6MPa (6 bar) at
80°C.
page 3
Limitations
The cylinder should not be used in association with any of the following:
●Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic
control, unless additional and appropriate safety measures are installed.
●Ascending spray type bidets or any other class 1 back syphonage risk requiring that a type A air
gap be employed.
●Steam heating plants unless additional and appropriate safety devices are installed.
●Situations where maintenance is likely to be neglected or safety devices tampered with.
●Water supplies that have either inadequate pressure or where the supply may be intermittent.
●Situations where it is not possible to safely pipe away any discharge from the safety valves.
●In areas where the water consistently contains a high proportion of solids, e.g. suspended matter
that could block the strainer, unless adequate filtration can be ensured.
●In areas where the water supply contains chloride levels that exceed 250mg/l.
Important Note:
THE SOLAR CYLINDER MUST BE INCORPORATED INTO A FULLY PUMPED SOLAR
PRIMARY CIRCUIT.
CONTROL OF THE SOLAR PRIMARY CIRCUIT IS ACHIEVED BY THE USE OF EXTERNAL
CONTROLS NOT SUPPLIED WITH THE UNIT. CONTROL MUST BE A PURPOSE DESIGNED
SOLAR DIFFERENTIAL TEMPERATURE CONTROLLER.
Checklist
●Unvented cylinder
●Cold control pack

- Tundish
- Combination valve
- Expansion vessel
- Tool
- Element spanner
- Compression nuts & olives
- 2 Port motorised valve
●Literature pack
- Installation manual
- Guarantee card
Operational Summary
Maximum mains pressure 1.6MPa (16 bar)
Operating pressure / PRV 0.35MPa (3.5 bar)
Maximum design pressure 0.6MPa (6 bar)
Expansion vessel charge pressure 0.35MPa (3.5 bar)
Expansion relief valve setting 0.6MPa (6 bar)
T&P relief valve setting 90-95°C/1.0MPa (10 bar)
Maximum primary circuit pressure (Auxiliary coil) 0.3MPa (3 bar)
Maximum primary circuit pressure (Solar coil) 0.3MPa (3 bar)
Pressure drop (Auxiliary coil) 0.02MPa (0.2 bar)
Pressure drop (Solar coil) 0.02MPa (0.2 bar)
Storage capacity See Table 1

Weight when full See Table 1
All models in conformance with BS EN 12897:2006
Note: Although the primary coil pressure rating is 1.0Mpa (10 bar) the 2 port zone valve supplied
with the cylinder is only rated 0.86MPa (8.6 bar). If the cylinder is to be plumbed into a system
delivering 1.0MPa (10 bar) a suitable 2 port zone valve will have to be sourced.
page 4
Installation General
Pipe Fittings
All pipe fittings are made via 22mm compression fittings directly to the unit. The fittings are threaded
3/4" BSP male parallel, should threaded pipe connections be required.
Cold Feed
A 22mm cold water supply is recommended, however, if a 15mm (1/2") supply exists, which provides
sufficient flow, this may be used (although more flow noise may be experienced). A stopcock or servicing
valve should be incorporated into the cold water supply to enable the cylinder and its associated controls
to be isolated and serviced.
Cold Water Combination Valve Assembly
The 1-piece cold water combination valve assembly (see Fig. 02) can be located anywhere on the cold
water mains supply prior to the expansion vessel (see Fig. 06). The cold water combination valve is
installed as a complete one-piece unit. The valve incorporates the pressure reducer, strainer, expansion
valve and check valve. Ensure that the valve is installed with the direction of flow arrows pointing in the
correct direction. No other valves should be placed between the cold water combination valve and the
cylinder.
Drain Tap
A suitable drain tap should be installed in the cold water supply to the cylinder between the expansion
valve (see Fig. 06) and the heater at as low a level as possible. It is recommended that the outlet point of
the drain pipework be at least 1 metre below the level of the heater (this can be achieved by attaching a
hose to the drain tap outlet spigot).
Expansion Vessel
The expansion vessel accommodates expansion that results from heating the water inside the unit. The
expansion vessel is pre-charged at 0.35MPa (3.5 bar). The expansion vessel must be connected between
the expansion valve and the cylinder (see Fig. 06). The location of the expansion vessel should allow
access to recharge the pressure as and when necessary, this can be done using a normal car foot pump. It

is recommended that the expansion vessel is adequately supported. An expansion vessel wall mounting
bracket is supplied for this purpose and should be fitted.
Secondary Circulation
If secondary circulation is required it is recommended that it be connected to the cylinder as shown (see
Fig. 03) 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. On large systems, due
to the increase in system water content, it may be necessary to fit an additional expansion vessel to the
secondary circuit. This should be done if the capacity of the secondary circuit exceeds 10 litres.
Pipe capacity (copper):
15mm O.D. = 0.13 l/m (10 litres = 77m)
22mm O.D. = 0.38 l/m (10 litres = 26m)
28mm O.D. = 0.55 l/m (10 litres = 18m)
Outlet
The hot water outlet is a 22mm compression fitting located at the top of the cylinder. Hot water
distribution pipework should be 22mm pipe with short runs of 15mm pipe to terminal fittings such as
sinks and basins. Pipe sizes may vary due to system design.
Fig. 02: Cold Water Combination Valve Assembly

Fig. 03: Secondary Circulation Connection
page 5

Fig. 04 General Dimensions
Type Model
Reference
Dimensions (mm) Solar
Volume
Auxiliary
Volume
Coil
Rating (kW)
Heat-
up
Time
Hot Water
Capacity
(ltrs)

A B C D
(ltrs) (ltrs)
Solar Auxiliary
(mins) (volume of
water drawn
off
>40°C)
190 S
Ind 1401 1085 784 925 65 120 19 14.2 32 132
210 S
Ind 1499 1186 1012 1026 85 120 19 15.0 25 196
250 S
Ind 1752 1438 1143 1279 95 145 19 15.2 30 237
Solar
Indirect
300 S
Ind 2065 1752 1440 1592 120 175 19 17.4 32 265
Table 02: Dimensions and Performance
Notes:
1. Indirect cylinders tested in conformance with BS EN 12897:2006
2. Heat up time from cold through 45°C, with a primary flow rate 15ltrs/min at 80°C +/- 2°C.
page 6
Installation Discharge
Discharge Pipework
It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed
to where it is visible, but will not cause danger to persons in or about the building. The tundish and
discharge pipes should be fitted in accordance with the requirements and guidance notes of Building
Regulation G3. The G3 Requirements and Guidance section 3.50 - 3.63 are reproduced in the following
sections of this manual. For discharge pipe arrangements not covered by G3 guidance advice should be
sought from your local Building Control Officer. Any discharge pipe connected to the pressure relief
devices (expansion valve and temperature/pressure relief valve) must be installed in a continuously
downward direction and in a frost free environment.
Water may drip from the discharge pipe of the pressure relief device. This pipe must be left open to the
atmosphere. The pressure relief device is to be operated regularly to remove lime deposits and to verify
that it is not blocked.
G3 REQUIREMENT "...there shall be precautions...to ensure that the hot water discharged from safety
devices is safely conveyed to where it is visible but will not cause danger to persons in or about the
building."
The following extract is taken from the latest G3 Regulations

Discharge pipes from safety devices
Discharge pipe D1
3.50 Each of the temperature relief valves or combined temperature and pressure relief valves specified in
3.13 or 3.17 should discharge either directly or by way of a manifold via a short length of metal pipe (D1)
to a tundish.
3.51 The diameter of discharge pipe (D1) should be not less than the nominal outlet size of the
temperature relief valve.
3.52 Where a manifold is used it should be sized to accept and discharge the total discharge form the
discharge pipes connected to it.
3.53 Where valves other than the temperature and pressure relief valve from a single unvented hot water
system discharge by way of the same manifold that is used by the safety devices, the manifold should be
factory fitted as part of the hot water storage system unit or package.
Tundish 3.54 The tundish should be vertical, located in the same space as the unvented hot water storage
system and be fitted as close as possible to, and lower than, the valve, with no more than 600mm of pipe
between the valve outlet and the tundish (see Fig. 05).
Note: To comply with the Water Supply (Water Fittings) Regulations, the tundish should incorporate a
suitable air gap.
3.55 Any discharge should be visible at the tundish. In addition, where discharges from safety devices
may not be apparent, e.g. in dwellings occupied by people with impaired vision or mobility, consideration
should be given to the installation of a suitable safety device to warn when discharge takes place, e.g.
electronically operated.
Discharge pipe D2
3.56 The discharge pipe (D2) from the tundish should:
(a) have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the
pipework (see Fig. 05);
and
(b) be installed with a continuous fall thereafter of at least 1 in 200.
3.57 The discharge pipe (D2) should be made of:
(a) metal;
or
(b) other material that has been demonstrated to be capable of safely withstanding temperatures of the water
discharged and is clearly and permanently marked to identify the product and performance standard
(e.g. as specified in the relevant part of BS 7291).
3.58 The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the
safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e.

for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes
larger than the nominal outlet size of the safety device; between 18 and 27m at least 3 sizes larger, and
so on; bends must be taken into account in calculating the flow resistance (see Table 03) and the worked
example.
Note: An alternative approach for sizing discharge pipes would be to follow Annex D, section D.2 of BS
6700:2006 Specification for design, installation, testing and maintenance of services supplying water for
domestic use within buildings and their curtilages.
3.59 Where a single common discharge pipe serves more than one system, it should be at least one pipe
size larger than the largest individual discharge pipe (D2) to be connected.
page 7
3.60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated
that the soil discharge stack is capable of safely withstanding temperatures of the water discharged, in
which case, it should:
(a) contain a mechanical seal, not incorporating a water trap, which allows water into the branch pipe without
allowing foul air from the drain to be ventilated through the tundish;
(b) be a separate branch pipe with no sanitary appliances connected to it;
(c) if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either
polybutalene (PB) to Class S of BS 7291-2:2006 or cross linked polyethylene (PE-X) to Class S of BS
7291-3:2006;
and
(d) be continuously marked with a warning that no sanitary appliances should be connected to the pipe.
Note:
1. Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in
which they are used as set out in BS EN ISO 1043-1.
2. Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe
alongside or in close proximity to the discharge stack.
Termination of discharge pipe
3.61 The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to
persons in the vicinity of the discharge.
3.62 Examples of acceptable discharge arrangements are:
(a) to a trapped gully with the end of the pipe below a fixed grating and above the water seal;
(b) downward discharges at low level; i.e. up to 100mm above external surfaces such as car parks, hard
standings, grassed areas etc. are acceptable providing that a wire cage or similar guard is positioned to prevent
contact, whilst maintaining visibility; and
(c) discharges at high level: e.g. into a metal hopper and metal downpipe with the end of the discharge pipe
clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any
plastic guttering system that would collect such discharges.

3.63 The discharge would consist of high temperature water and steam. Asphalt, roofing felt and
nonmetallic rainwater goods may be damaged by such discharges.
Worked Example of Discharge Pipe Sizing
Fig. 05: shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length
of 7m from the tundish to the point of discharge.
From Table 03:
Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2
temperature relief valve is 9.0m.
Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m
Therefore the permitted length equates to: 5.8m
5.8m is less than the actual length of 7m therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valves
equates to 18m.
Subtract the resistance of 4 No. 28mm elbows at 1.0m each = 4.0m
Therefore the maximum permitted length equates to: 14m
As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.
WARNINGS:
●Under no circumstances should the factory fitted temperature/pressure relief valve be removed
other than by a competent person. To do so will invalidate any guarantee or claim.
●The cold water combination valve assembly must be fitted on the mains water supply to the
cylinder.
●No control or safety valves should be tampered with or used for any other purpose.
●The discharge pipe should not be blocked or used for any other purpose.
●The tundish should not be located adjacent to any electrical components.
page 8
VALVE
OUTLET
SIZE
MINIMUM
SIZE OF
DISCHARGE
PIPE D1
MINIMUM
SIZE OF
DISCHARGE
PIPE D2
FROM
TUNDISH
MAXIMUM RESISTANCE
ALLOWED,
EXPRESSED AS A
LENGTH OF
STRAIGHT PIPE
(I.E. NO ELBOWS OR
BENDS
RESISTANCE
CREATED BY
EACH ELBOW OR
BEND
G 1/2 15MM 22mm
28mm
UP TO 9M
UP TO 18M
0.8M
1.0M

35mm UP TO 27M 1.4M
G 3/4 22MM 28mm
35mm
42mm
UP TO 9M
UP TO 18M
UP TO 27M
1.0M
1.4M
1.7M
G 1 28MM 35mm
42mm
54mm
UP TO 9M
UP TO 18M
UP TO 27M
1.4M
1.7M
2.3M
Table 03: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes
NOTE: The table above is based on copper tube. Plastic pipes may be of different bore and resistance.
Sizes and maximum lengths of plastic should be calculated using data prepared for the type of pipe being
used.

Figure 05: Typical Discharge Pipe Arrangement (Extract From Building Regulation G3 Guidance Section
5.50)
page 9
Fig. 06: Typical SOLAR Installation - Schematic
page 10
Installation - Solar
Connection To Solar Primary Circuit
The lower (solar) coil of the SOLAR cylinder 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 be required.
The solar primary circuit should have its own dedicated circulating pump and safety controls which must
be installed as per the manufacturer's instructions.

Control of Solar Primary Circuit
Temperature control of the SOLAR cylinder must be carried out using a suitable proprietary solar
controller/ programmer. 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.
Connection to the solar controller should be in accordance with the manufacturers instructions. The
solar controller should be programmed to give a cylinder temperature of approximately 60°C (maximum
70°C).
The solar controller and solar primary circulation pump must be wired via the over-temperature cut-
out mounted in the lower solar controls housing. This will ensure that the heat input to the solar coil is
interrupted in the event of the cylinder over-heating (see Fig. 07). 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.
Fig. 07: Solar Control Connections
page 11

Installation - Auxiliary Heating Coil
Safety
DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY
COVERS. Never attempt to replace the immersion heater other than with the recommended authorised
immersion heater(s).
DO NOT BYPASS THE THERMAL CUT-OUT(S) IN ANY CIRCUMSTANCES. Ensure the two
male spade terminations on the combined thermostat and thermal cut-out are pushed firmly onto the
corresponding terminations on the element assembly.
In case of difficulty contact service support; contact details available at the back of this booklet.
Electrical Supply
All electrical wiring should be carried out by a competent electrician and be in accordance with the latest
I.E.E Wiring Regulations.
Each circuit must be protected by a suitable fuse and double pole isolating switch with a contact
separation of at least 3mm in both poles.
The immersion heater should be wired in accordance with Fig 08. The immersion heaters MUST be
earthed. The supply cable should be 1.5mm23 core HOFR sheathed and must be routed through the cable
grip provided with the outer sheath of the cable firmly secured by tightening the screws on the cable grip.
DO NOT operate the immersion heaters until the cylinder has been filled with water.
Ensure the thermostat and thermal cut-out sensing bulbs are pushed fully into the pockets on the element
plate assembly.
Plumbing Connections
Indirect cylinders require the following pipework connections.
●Cold water supply to and from inlet controls.
●Outlet to hot water draw off points.
●Discharge pipework from valve outlets to tundish.
●Connection to the primary circuit.
All connections are 22mm compression. However, 3/4" BSP parallel threaded fittings can be fitted to the
primary coil connections if required.
Boiler Selection
The boiler should have a control thermostat and non self-resetting thermal cut-out and be compatible with
unvented storage water heaters.
Where use of a boiler without a thermal cut-out is unavoidable a "low head" open vented primary circuit
should be used. The feed and expansion cistern head above the cylinder should not exceed 2.5m.