MEGAFLO Eco Plus Solar User manual

36006204_issue_03
Megaflo Eco Plus Solar Product Guide
Megaflo Eco Plus Solar Unvented Hot Water Cylinders
800L -1000L

Important
Please read & understand all these instructions before commencing
installation.
Please leave this manual with the Customer for future reference
page 1 Contents
1. Introduction
1.1 General
1.2 Symbols used
1.3 Abbreviations
1.4 Liabilities
2. Safety
2.1 General safety warnings
2.2 Recommendations
2.3 Specific safety instructions
3. Technical specifications
3.1 Technical data
Dimensions and connections
Electrical diagram
4. Description of the product
4.1 General description
4.2 Operation principle 4.3 Main components
4.4 Standard delivery
5. Before installation
5.1 Installation regulations
5.2 Installation requirements

5.3 Choice of location
5.4 Transport
6. Installation
6.1 General
6.2 Water connections
6.3 Electrical connections
6.4 Filling the installation
6.5 Solar Primary installation
7. Commissioning
7.1 General
7.2 Checklist before commissioning
7.3 Commissioning procedure
8. Operation 8.1 General
9. Maintenance
9.1 General
9.2 Standard inspection & maintenance operations
10. Troubleshooting
10.1 Fault finding
11. Decommissioning
11.1 Decommissioning procedure
12. Spare parts
12.1 Spare parts list
Benchmark checklist
Service records
Guarantee

page 2
1. Introduction
1.1 General
The following instructions are offered as a guide to the user and Installer. The
installation must be carried out by a competent plumbing and electrical Installer
in accordance with Building Regulation G3 (England and Wales), Technical
Standard P3 (Scotland) or Building Regulation P5 (Northern Ireland) and the
Water Fitting Regulations (England and Wales) or Water Byelaws (Scotland).
1.2 Symbols used
In these instructions, various risk levels are employed to draw the user's
attention to particular information. In doing so we wish to safeguard the user,
avoid hazards and guarantee the correct operation of the appliance.
DANGER
Risk of a dangerous situation causing serious physical
injury.
WARNING
Risk of dangerous situation causing slight physical
injury.
CAUTION

Risk of material
damage.
Signals important
information.
1.3 Abbreviations
●T&P - Temperature & Pressure relief valve
●PRV - Pressure Reducing Valve
●Prv - Pressure relief valve
1.4 Liabilities Manufacturers liability
Our products are manufactured in compliance with the requirements of the
various applicable European Directives.
This appliance complies with the requirements of the CE marking directive.
In the interest of UK Customers, we are continuously endeavouring to make
improvements in product quality. All the specifications stated in this document
are therefore subject to change without notice.
Our liability as the manufacturer may not be invoked in the following cases:
●Failure to abide by the instructions on using the appliance. ●Faulty or
insufficient maintenance of the appliance. ●Failure to abide by the instructions
on installing the product.
Installer's liability
The Installer is responsible for the installation and the commissioning of the
appliance. The Installer must respect the following instructions:
●Read and follow the instructions given in the manuals provided with the
appliance. ●Carry out installation in compliance with the prevailing legislation
and standards. ●Perform the initial start up and carry out any checks necessary.
●Complete the commissioning checklist. ●Explain the installation to the

user. ●If maintenance is necessary, warn the user of the obligation to check the
appliance and
maintain it in good working order. ●Give all the instruction manuals to the
user.
Users liability
To guarantee optimum operation of the appliance, the user must respect the
following instructions:
●Read and follow the instructions given in the manuals provided with the
appliance. ●Call on qualified professionals to carry out installation and
initial start up. ●Get your fitter to explain your installation to you. ●Have
your required checks and services done. ●Keep the instruction manuals in
good condition and close to the appliance. This appliance can be used by
children aged 8 years and above and persons with reduced physical sensory
or mental capabilities or lack of experience and knowledge if they have been
given supervision 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. Children must be supervised to ensure they do not play with the
appliance.
2. Safety
2.1 General safety warnings
DANGER
The combination of pressurisation and hot water could lead to serious physical
injury if the safety instructions in this manual are not adhered to.
WARNING

●Only competent persons having received adequate training are permitted to
work on the
appliance and the installation.
●Do not tamper with any of the safety valves or controls supplied with the
cylinder.
●Before any work, switch off the mains supply to the appliance.
●Do not switch on if there is a possibility that the water in the cylinder is
frozen.
CAUTION
Do not operate immersion heaters until the cylinder has been filled with water.
2.2 Recommendations
When handling the unit, take appropriate precautions for the weight of the unit.
Weights can be found in section 3, table 1,.
CAUTION
Annual maintenance is recommended by a competent person.
2.3 Specific safety instructions
WARNING
●If water discharges from the temperature/pressure relief valve on the cylinder
shut down
the boiler.
Do not turn off any water supply. Contact a competent installer for unvented
water heaters

to check the system.
●Do not tamper with any of the safety valves fitted to the system. If a fault is
suspected
contact a competent installer.
●DO NOT bypass the thermal cut-out(s) in any circumstances.
page 4
3. Technical specifications
3.1 Technical data
Table 1: Technical data - Solar
Solar 800i Solar 1000i
Max direct kW rating 6 6
Aux Coil surface area m21.5
Aux Coil rating (kW) 15l/min 25.1 26.6
30l/min 37.2 38.3
60l/min 47.5 45.8
Aux coil heat up time (mins) 15l/min 64.2 74.5
30l/min 44.6 54.1

60l/min 34.2 42.8
Solar Coil Rating (kW) 30l/min 42.9 54.3
Solar coil heat up time (mins) 30l/min 47.3 50.8
Pressure drop through Aux coil (MPa) 15l/min 0.001
30l/min 0.002
60l/min 0.017
Pressure drop through solar coil (MPa) 15l/min 0.002
30l/min 0.008
60/min 0.030
Heat loss (kWh in 24h) 2.74 3.33
Hot water capacity (volume of water drawn off >40°C) 681 850 Weight full
(kg) 1017 1225
Weight empty (kg) 217 225
Max supply pressure 1.6MPa (16 bar)
Max design pressure 0.8 MPa (8 bar)
Max operating pressure (PRV) 0.35MPa (3.5 bar)
Max expansion vessel charge pressure 1.0MPa (10 bar)
Expansion relief valve setting 0.8MPa (8 bar)
T&P valve setting 1.0MPa (10 bar)/90°C
Expansion Prv set pressure 0.8MPa (8 bar)
Maximum primary pressure (Solar and Aux) (see Note 3) 1.0MPa (10 bar)
Notes:
1. Indirect cylinders tested in conformance with BS EN 12897:2006.
2. Heat up time from cold through 45°C, based on a flow temperature of 80°C
+/- 2°C &
normal volume.

3. The primary coil should not be exposed to more than 0.3MPa (3 bar) without
the cylinder
being full of water and under the minimum working pressure.
page 5
Item Connection 800l 1000l

ANA 1914 2327
BT&P/ ½" BSP 1503 1863
C½" & 1" BSP 1218 1538
D1 ¾" BSP 1138 1338
E½" BSP 1049 1249
F1 ¼" BSP 998 1198
G1 ¼" BSP 798 998
H½" BSP 710 710
I1 ¼" BSP 623 623
J1 ¼" BSP 448 448
K1" BSP 438 438
Table 3: General dimensions table - Solar 800l - 1000l
page 6
Schematic Wiring Diagram - Basic 2 x 2 Port Valve System

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.
Figure 2: Schematic wiring diagram - basic 2 x 2 port valve system
Schematic Wiring Diagram - 3 Port Mid Position Valve System.
N.B. Must Be Used In Conjunction With 2 Port Zone Valve Supplied

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.
Figure 3: Schematic wiring diagram - 3 port mid position system
page 7
6kW immersion Step 1:
- remove 4 retaining screws and lift lid off immersion heater

Step 2:
- remove 2 screws holding thermostatic controls and slide out thermostat from
stat pocket.
Step 3:
- Wire up immersion as per figures 6.

If three phase wiring chosen remove "Live" side buzz bar and fit extra posts
(supplied) to L1, L2 & L3. (outer case and bracket removed for clarity)
Notes:
For single phase wiring use 4mm2 H07RNF 3 Core
Use 2 x Two Pole 40A contactors for single phase
For 3 phase use Five core 1mm2 Fused at max 10A
Use 2 x Three Pole 16A per pole contactors for 3 phase
For signal wire use 5 core 1mm2 Fused at max 6A for thermostat and thermal
cut-out controls.
Disconnection time of the circuit protective device must be maintained below
the regulatory
minimum (in the UK 5 seconds for fixed equipment), cable sizes may have to
be higher
depending on the characteristics of the installation supply.
Step 4:-
Replace thermostatic controls taking care when inserting the capillary bulbs into
stat pocket
and wire up as per figure 6 or 7 .

Figure 4: Immersion head assembly page 8
Single phase wiring schematic
Note: The 2 external contactors must be approved components certified for
10,000 cycles of operation for the contactor controlled by the thermostat and at
least 30 for the contactor controlled by the non-self-resetting thermal cut-out.
Figure 5: Single phase wiring schematic
3 phase wiring schematic

Figure 6: Three phase wiring schematic
page 9

Figure 7: Indirect wiring schematic
page 10
4. Description of the product 4.1 General description
This product 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 soft jacket. All products are insulated with CFC free
polyurethane foam (GWP 3.1) to give good heat loss protection.
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 should not be tampered with.
4.2 Operation principle
The unvented cylinder is used to heat and store hot water for use in commercial
applications.
Depending on the model the water can be heated directly using an element
(supplied separately) or indirectly through a coil in the unit using an external
heat source e.g. Gas, Oil or Electric.
To provide pressure to the tap or shower an unvented unit uses the incoming
mains water pressure. To do this the cylinder is sealed and not vented. However,
when the volume of water is heated it expands and without any room for
expansion could cause the cylinder to rupture and fail. To allow expansion of
this heated water it is important that an expansion vessel is used. This vessel is
pressurised and gives the heated water room to expand.
4.3 Main connections
See Figure 8: Main connections
4.4 Standard delivery
The delivery includes:
●Cylinder
●Literature pack
●Instructions (inc benchmark commissioning checklist & service record)
●Cold water control pack
●Expansion vessel
●Combination valve (inc pressure reducing valve, pressure relief valve and
check valve)
●Tundish
●2 port zone valve (indirect only)

●Solar thermal cut-out page 11
Figure 8: Main Connections
page 12
5. Before installation
5.1 Installation regulations
WARNING
Installation of the appliance must be carried out by a qualified Engineer
in
accordance with prevailing and national regulations as listed below.
●Building Regulations G3
●The Building Standards (Scotland)
●The Building Regulations (Northern Ireland)>
●I.E.E Electrical Regs
●UK Water Regulations
5.2 Installation requirements
Water supply
In an unvented system the pressure and flow-rate is directly related to the
incoming water supply. For this reason it is recommended that the maximum
water demand is assessed and the water supply checked to ensure this demand
can be satisfactorily met.
●We suggest the minimum supply requirements should be 0.15MPa (1.5 bar)
pressure
and 60 litres per minute flow rate. However, at these values outlet flow rates
may be