MCDonald Powerflow User manual

NVENTED HOT WATER SYSTEM
Q EENSWAY IND STRIAL ESTATE,
GLENROTHES FIFE KY7 5QF
Tel : [phone] Fax : [phone]
Email : [email protected]
Internet : www.mcdonaldwaterstorage.com
FOR SPARES CALL 01592 611123
INSTRUCTIONS
PLEASE LEAVE WITH HOUSEHOLDER
IMPORTANT - Failure to install and maintain this system
in accordance with these instructions will invalidate the
manufacturer’s warranty. Extended warranty card to be
completed and returned.
ANN AL SERVICE REQ IRED

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IMPORTANT
nstallation should only be carried out by a
‘competent operative’ i.e. the installer must
have attended a recognised course in
Unvented Hot Water Systems or received
appropriate training in their apprenticeship.
All registered operatives should carry an
dentification Card issued by their
certificate provider – for example BPEC or
SN PEF. nstallation should be carried out
in accordance with current local Building
Regulations and water Byelaws.
The unit should be handled
with care in order to avoid damage to
valves. t should be stored upright in a dry
place.
Full weights are available on page 7 of
this booklet. The installation area should
be able to cope with this weight, incoming
pipes and discharge pipe. Position the
unit to suit the installation.
Generally connections are to the front to
enable ease of access. Alternatively if a
sketch is provided refer to that. Ensure
suitable space is left for access for repair
and/or replacement of valves etc.
n areas with hard water we would
recommend restricting the temperature
and performing de-scaling procedures as
required.
All the following instructions must be
carried out: -
1. nstallers should ensure incoming
mains pressure is less than 12Bar and
that local authority approval for
installation of Unvented Systems is
granted. Ensure adequate flow-rate is
available.
2. Excessive use of flux can damage the
unit and especially the valves and
expansion vessel. Avoid over-use and
ensure the system is fully flushed of
any debris or flux before connection.
3. ncoming mains to arrive in a
minimum of 22mm copper pipe. Fit to
the Pressure Reducing V lve A (See
Page 4) set at 2.1 Bar. Contract
Models 1.5 Bar and 3 Bar Models – 3
Bar. This includes a serviceable
Strainer. We would strongly
recommend this valve is fitted where
the mains enters the property, but it
can go wherever is most suitable for
the installation, between the mains
stopcock and the cylinder.
We recommend fitting a Tee between
the Pressure Reducing Valve (A) and
the Check Valve (A2) to provide a
BA ANCED CO D OUT ET for all
cold taps, preventing cross-flow and
also giving potable water throughout
the house. Outdoor taps for hoses
should be taken before the Pressure
Reducing Valve.
4. The Check V lve (A2) is supplied
loose, to be fitted between the
Pressure Reducing Valve and before
the Expansion Vessel on the Cold
Feed. Any balanced cold draw off
should be fitted between the Pressure
Reducing Valve (A) and the Check
Valve (A2).
5. The Temper ture & Pressure Relief
V lve (D) set at 90°C and 4.5 Bar (3
Bar models set at 7 Bar), and the
Exp nsion Relief V lve (B) set at 3.5
Bar (Contract Model 3 Bar and 3Bar
Models 5 Bar), should be fitted and
connected to the Tundish (E). NB -
the relief valves are only to be used
for relief discharge purposes.
No valves should be fitted between
the relief valves and the cylinder.

2
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6. The Tundish (E), which shows visible
discharge from the Relief Valves, is to
be in a prominent, visible and safe
position away from any electrical
devices (likewise with the drain
connection) and within 500mm of the
Temper ture & Pressure Relief V lve
(D). Pipework from the Tundish (E)
must initially be vertical for a minimum
of 300mm where possible and then
have a continuous fall in excess of 1
in 200. Pipework away from the
Tundish (E) should be in a minimum of
22mm, of material suitable for
temperatures of 95°C and have a
resistance to flow of water not greater
than that of a straight pipe of 9 metres
(each bend or elbow is equal to 0.8
metre of resistance). See BBA
nformation. Sheet No 33:1989 for
further details - available from the
manufacturer. Also note page 9 of
these instructions.
7. The Expansion Vessel (F) should be
set the same as the Pressure
Reducing Valve (A) - 2.1Bar (Contract
Models 1.5Bar and 3Bar Models 3Bar).
The Expansion Vessel should be fitted
to the wall and connected to the Tee
(F1), between the Check Valve (A2)
and Cold Feed, (hard piped or fitted
with the braided flexi-hose). (On
previous units the check valve was
factory fitted to the Cold Feed). No
isolating valve is allowed between the
Vessel and the Cold Feed.
The Vessel must also be fitted within
2m of the cylinder.
8. Connect the 3kW 11” 240V Immersion
He ter/s BSEN 60335/2/73 (with
manual re-set cut out at 80°C) to the
power supply and earth them in
accordance with the current EE wiring
regulations. The fuse rating should be
13 Amps. Do not at any time fit
Immersion Heaters without a thermal
cut-out.
9. On ndirect Units where a Coil is fitted
to the cylinder, when supplied, the
Two Port Motorised Zone V lve nd
Du l Thermost t Controller (J) must
be fitted in accordance with the
instruction details supplied with them
for the appropriate installation. See
back page for Solar & Heatpump
coils
N.B. Indirects, are suitable for oil,
gas and electric fired boilers on a
pumped, gravity or sealed system.
(We would however recommend
28mm Coil connections with a 28mm
Zone Valve on gravity systems).
Maximum working pressure of the
coil is 3.5 Bar. All electrical wiring to
thermostats, zone valve and
immersion heaters must be earthed
and to current EE Wiring Regulations.
The fuse should generally be 3 Amps
but refer to appliance instructions to
confirm this.
10. The Second ry Return (L) if supplied,
should be plugged if not required. f
the Secondary System pipe-work is
greater than 15% of the unit capacity,
a larger Expansion Vessel may need
to be fitted - contact McDonald Water
Storage.
11. Immersion He ters (H) and the Du l
Thermost t Controller (J) supplied
with the ndirect units should be set to
no greater than 60°C and the internal
High Limit Thermostats are factory set
no higher than 85°C. Always check
this before switching on power.
( mmersion Heaters - 1 = 10ºC, 2 =
25ºC, 3 = 40ºC, 4 = 55ºC, 5 = 70ºC).
Please see the checklist on page 4 to
ensure all controls are present and
correct.

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ONCE A THE PRECEDING INSTRUCTIONS HAVE BEEN
FO OWED, COMMISSION THE SYSTEM.
IMPORTANT
COMMISSIONING - These instructions
must be followed.
After following the instructions on pages
1 & 2 proceed as follows: -
1. Close the Dr in ( ) at base of cylinder.
2. Open a Hot Tap.
3. Fully open the Cold Mains Stopcock
and fill Cylinder until water appears at
the Hot Tap.
4. Close the Hot Tap and attend each hot
water outlet in turn and ensure water
flow is obtained at each.
T S THE RESPONS B L TY OF THE
NSTALLAT ON ENG NEER TO CHECK
AND ENSURE THAT ALL VALVES,
F TT NGS AND MMERS ON/S ARE
PROPERLY SEALED AND WATERT GHT.
5. Check the control thermostats on the
Immersion He ter/s (H) and the Du l
Thermost t (J) are set no higher than
60°C and that the High Limit
Thermostats are set to no higher than
85°C.
6. Ensure there is no discharge from the
Relief Valves (B and D).
7. Switch on water heating system and
check operation of the system.
T S EXTREMELY MPORTANT TO
FOLLOW ALL THE NSTRUCT ONS
PREV OUSLY MENT ONED, AS FA LURE
TO DO SO COULD BE DANGEROUS OR
LEAD TO THE SYSTEM WORK NG
NEFF C ENTLY.
SPARES CODES
Below is a list of the codes for the
spares, available on the
website:
WUVPR – Pressure Reducing Valve 2.1 B
WUVPR3 – Pressure Reducing Valve 3.0 B
WUVPRC – Pressure Reducing Valve 1.5 B
WUVC – 22mm Check Valve
WU12EV – 12L Expansion Vessel
(Other sizes available: 8, 18, 24, 33)
WUVER – 15mm Exp. Relief Valve 3.5 B
WUVTP – 15mm P & T Relief Valve 4.5 B
WUEIH – 3kW Immersion Heater
WUTUND – 15 x 22mm Tundish
WUEDAC – Dual Thermostat
WUEMZV22 – 22mm Motorised Zone Valve
Other sizes and pressures available on our
website:
www.mcdonaldwaterstorage.com

4
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A - Pressure Reducing V lve with Str iner.
A2 - Check V lve.
B - Exp nsion Relief V lve.
C - Cold Feed.
D - Pressure & Temper ture Relief V lve.
E - Tundish.
F - Exp nsion Vessel.
F1 - Tee Compression for Expansion Vessel.
F2 - 1m Braided Flexi-Hose (or hardpiped)
G - Hot W ter Dr w Off.
H - Immersion He ter 80°C cut-out.
H2 - Option l Second Immersion
on Indirects. St nd rd on 150
Directs upw rds.
- Dr in connection.
J* - Du l Thermost t Controller.*
K* - 22mm Connections to Prim ry Coil.
The Zone V lve should be fitted nd
lso High Limit St t fitted to the
Boiler.
For Sol r nd He t pump coils see
b ck p ge.
L - 22mm Second ry Return. Plug if not
required (only on 180 litre units upw rds
s st nd rd – or on request).
*Indirects only
CHECKL ST
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ANNUA MAINTENANCE
should be serviced at least
once a year by a competent operative.
IMPORTANT - failure to maintain this
system in accordance with these
instructions will invalidate the
manufacturer’s warranty. A maintenance
record should be kept on the ANNUA
SERVICE RECORD card provided on
page 10, we would recommend a service
programme is arranged on installation.
Failure to maintain this record will
invalidate the manufacturer’s warranty.
Contact your installer to arrange the
appropriate service program.
ANNUA SERVICE CHECKS
Expansion Relief Valve (B) - manually
open the twist cap and check that the
water is discharged and runs clearly
through the Tundish (E) and out at the final
discharge point. Ensure that the valve re-
seats/re-seals itself.
Pressure & Temperature Relief Valve (D) -
repeat the above procedure. Ensure that
the valve re-seats/re-seals itself.
Strainer (A) - turn off mains at stopcock.
There will be a small amount of residual
water in the pipework, remove the cartridge
from Pressure Reducing Valve (A), clean
Strainer and replace.
Expansion Vessel (F) - Check Pressure
via the valve under the black cap on top of
the vessel, while a hot tap is running.
Ensure pressure is as per section 7 on
page 2. Vessel can be re-charged if
required as per “Recharging Expansion
Vessel” on page 6 opposite.
PROB EM SO VING
DISCHARGE FROM EITHER OF THE
RE IEF VA VES INDICATES A
MA FUNCTION IN THE SYSTEM AND
MUST BE INVESTIGATED IMMEDIATE Y.
OVERHEATED HOT WATER
DISCHARGE
n the unlikely event of overheated (90°C)
water being discharged, the heat source
i.e. the immersion heaters or the central
heating boiler should be switched off
immediately and a competent operative
called out. Ensure that the discharge of
hot water or steam at the Tundish (E) or
final discharge point causes no danger
and is not likely to injure anyone.
DO NOT SHUT OFF THE CO D WATER
SUPP Y TO THE UNIT!!
DO NOT RE-USE UNTI CHECKED AND
REPAIRED!!
ENSURE COMPONENTS ARE ISO ATED
FROM E ECTRICITY BEFORE
INVESTIGATION!!
Once cold water has entered the unit and
displaced the over heated water thus
cooling it, check the thermostat and
energy cut out in the a) mmersion Heater,
b) Thermostat, c) Boiler. dentify the
faulty component and replace with the
correct component as supplied by the
manufacturer and ensure that it works
before re-commissioning the system.
DO NOT FOR ANY REASON BY-PASS AN
ENERGY CUT-OUT.
Problem Solving continued on page 6...

6
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WATER DISCHARGE
If water is occasionally being discharged
as the water is heated, this would be
likely to indicate that the Expansion
Vessel (F) needs recharged. n the event
of it occurring, switch off all power
supplies to the cylinder, re-charge the
vessel as below.
If water is continually being discharged,
firstly check with a gauge that the
pressure allowed through the Pressure
Reducing V lve (A) does not exceed the
setting as per section 7 page 2. f it does
exceed, remove the filter and thoroughly
clean. f this does not solve the problem,
a replacement should be ordered from
McDonald Water Storage. Next, check the
charge in the expansion vessel and
recharge as below. f the pressure is okay,
check which valve is discharging and
replace with a replacement supplied by
McDonald Water Storage.
RECHARGING
EXPANSION VESSE
To recharge the expansion vessel, close
the mains stopcock and open a hot tap.
Connect a pump with gauge to the air
inlet on top of the vessel and charge to
the same as the Pressure Reducing Valve
- Page 2 Section 7
(14.7 P.S. . x every 1bar)
Pressure
1.5bar 22 P.S. .
2.1bar 32 P.S. .
3bar 44 P.S. .
HOW TO DRAIN SYSTEM
Switch off water at mains and open a hot
tap. f not pre-piped, connect the Dr in ( )
to a hose and open, the cylinder will now
start draining through the hose.
To re-fill follow the commissioning
instructions on Page 3.
N.B. To flush out the system, drain the
unit as above, fill and repeat.
IF PROB EMS CONTINUE
f after recharging the expansion vessel
the cylinder is still discharging, it may be
cross-flow - ensure appropriate check
valves are fitted. The Pressure Reducing
V lve (A), one of the Relief V lves (B or D),
(as previously mentioned) or the
Exp nsion Vessel (F) has failed. The
component should only be replaced by a
replacement part supplied by McDonald
Water Storage. Contact McDonald Water
Storage for further information.
IMMERSION HEATER
FAI URE
f the mmersion Heater (H or H2) is not
heating the water it has either failed ( n
which case a replacement mmersion
Heater as supplied by McDonald Water
Storage should be fitted) or the electrical
cut-out has operated due to the control
thermostat being set too high or being
faulty. . (1 = 10ºC, 2 = 25ºC, 3 = 40ºC,
4 = 55ºC, 5 = 70ºC).
On ndirect units it may be a faulty stat in
the boiler is allowing the water to
overheat and operating the mmersion
cut-out.
(CHECK THE MMERS ON HEATER S
SOLATED FROM THE MA NS)
Once these have been checked and/or
replaced, the mmersion Heater can be
re-set by taking off the cap and
depressing the button in the mmersion
Heater on the High Limit Stat
Should any fault or problem arise not
covered in this leaflet, please contact
the manufacturer.

TECHNICA DATA
Weights Direct Indirect
Empty (kgs) Full Empty (kgs) Full
75 Litre POWERflo 24 99 26 101
120 Litre POWERflo 33 153 37 157
150 Litre POWERflo 39 189 44 194
180 Litre POWERflo 49 229 55 235
210 Litre POWERflo 55 265 61 271
300 Litre POWERflo 80 380 86 386
Heat Up Times 10-60°C Direct Indirect
75 Litre POWERflo 89 mins 21 mins
120 Litre POWERflo 129 mins 24 mins
150 Litre POWERflo 115 mins* 25 mins
180 Litre POWERflo 145 mins* 25 mins
210 Litre POWERflo 166 mins* 26 mins
300 Litre POWERflo 175 mins* 25 mins
Time to re-heat 70% to 60°C Direct (3kW) Indirect**
75 Litre POWERflo 73 mins 12 mins
120 Litre POWERflo 110 mins 16 mins
150 Litre POWERflo 101 mins* 18 mins
180 Litre POWERflo 125 mins* 19 mins
210 Litre POWERflo 128 mins* 20 mins
300 Litre POWERflo 135 mins* 21 mins
Heat oss Direct & Indirect ERP Rating
Direct Indirect
75 Litre POWERflo 43 Watts B B
120 Litre POWERflo 57 Watts C C
150 Litre POWERflo 64 Watts C C
180 Litre POWERflo 68 Watts C C
210 Litre POWERflo 71 Watts C C
300 Litre POWERflo 81 Watts C C
*Using both mmersions
** f adequate boiler power
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8
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WIRING DIAGRAM TWO 2 PORT ZONE VA VE (S-P AN)
DUAL THERMOSTAT WIRI G
INDIRECT POWERflo WIRING DIAGRAM
2 P RT (HTG)
HIGH LIMIT
CUT UT
C NTR L
STAT 2 P RT (DHW)
Br G Bl C
E E
1 1 2 C GBr Bl 0
1
0
10 WAY WIRING CENTRE 12345678910
1 2 3 4
R M STAT
L N HTG
N
DHW
N
DHW
FF
PR GRAMMER
LSL N
B ILER
L
N
PUMP
5A SUPPLY
KEY: Bl=Blue, Br=Brown, C=Common Terminal, E=Earth, G=Grey, G/Y=Green/Yellow, L=Live, N=Neutral, = range, SL=Switched Live, W=White
Note: The programmer and boiler power can be taken either from the Wiring Centre or from elsewhere as appropriate.
EE
E
3 P RT
Mid Position
HIGH LIMIT
CUT UT
C NTR L
STAT 2 P RT (DHW)
W G Bl C
E E
1 1 2 C GBr Bl 0
212
0
10 WAY WIRING CENTRE 1 2
LN
345678910
1 2 3 4
2
R M STAT
L N HTG
N
DHW
N
DHW
FF
PR GRAMMER
LSL N
B ILER
L
N
3
2
PUMP
5A SUPPLY E
212
LN
2
3
2
E
EE
E
WIRING DIAGRAM 3 PORT MID POSITION VA VE (Y-P AN) + 2 PORT VA VE
DUAL THERMOSTAT WIRI G

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10
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DATE SERVICED BY COMME TS
ANNUA SERVICE RECORD
IMPORTANT - Failure to install the cylinder correctly and maintain
this record accurately, will invalidate the manufacturer’s warranty.

Q EENSWAY IND STRIAL ESTATE,
GLENROTHES FIFE KY7 5QF
Tel : [phone] Fax : [phone]
Email : [email protected]
Internet : www.mcdonaldwaterstorage.com
SO AR COI S
The cylinder should be installed according to the standard POWERflow instructions.
Single Coil Solar
The solar controller should be wired using the High Limit Thermostat to ensure power is cut
to the solar pump, in the event of an overheat situation. Reference should be made to the
solar equipment instructions.
Dual Coil Solar
The upper Primary Coil, which is linked to a boiler, should be wired as per our standard
wiring instructions on page 8. The lower Solar Coil should be wired as per the above
instructions for Single Coil Solar. Reference should be made to the solar equipment
instructions.
HEATPUMP COI S
Certain Heatpumps cannot physically exceed a 60ºC flow temperature and as such may not
require a Motorised Zone Valve, or have alternative methods of control. A High Limit
Thermostat is provided, to be used as required to prevent an overheat situation. Consult
the Heat Pump’s installation instructions.
MU TIP E CY INDERS
Where 2 or more cylinders are installed together, please contact our technical department,
for advice on the correct procedures - 01592 611123.
MAINTENANCE
As per the instruction booklet and any requirements that the Solar Equipment dictates.
The HWA Charter Statement requires that all members adhere to the following:
• To supply fit for purpose products clearly and honestly described
• To supply products that meet or exceed appropriate standards and building
and water regulations
• To provide pre and post technical support
• To provide clear and concise warranty details to customers
REF:09/18