Ormandy 2000 Series User manual

2000 Series
Direct & Indirect Calorifiers
Installation, Operating &
Maintenance Manual
Ormandy Rycroft
Heating & Cooling Solutions

Introduction 1Page 1
VERY IMPORTANT - PLEASE READ CAREFULLY
Series 2000 Page 1
General Requirements Page 1
Water Supply Page 1
Installation 2Page 1 - 4
General Page 2 - 3
Direct Units Installation Page 3
Electrical Installation & Operation Page 3
Indirect Units Page 4
Commissioning 3Page 5
Filling, Checks, Direct Units and Indirect Units Page 5
Operational 4Page 6
User Instructions, Faults and Flow Performance Page 6
Maintenance 5Page 7
Optimum Performance, Fault Finder and Spares Page 7
Drawings & Diagrams 6Page 8 - 9
Wiring for Single and Twin Stage Control Diagrams Page 8
Piping Diagram Page 9

1
Series 2000
1. Introduction
The Series 2000 calorifier is suitable for installation in an un-vented
system and will accept water directly from the cold mains supply.
It is supplied complete with expansion kit and safety controls.
Direct units are fitted with an electric immersion heater(s) with control
thermostat(s). A manual reset overtemperature thermostat may be
necessary.
Indirect units may be fitted with an electric immersion heater as a back
up to the indirect coil. A cylinder thermostat and a separate manual
reset over-temperature thermostat will be required.
NOTE: On indirect units, it is the users responsibility to provide a
suitable 2 port motorised valve in the primary flow circuit for over
temperature protection.
General Requirements
Important: Please read and understand these instructions before
installing the water heater. Incorrect installation will invalidate
the guarantee.
A competent person who is familiar with the current version of the
building regulations should install the heater.
As soon as you receive the unit check that all the components for the
Series 2000 are contained in the package. Failure to do so will inhibit
the supply of missing components.
The following components are supplied loose, as standard:
• Pressure reducing valve
• Non return valve
• Expansion relief valve
• Expansion tank
• Combined temperature/pressure relief valve(s)
• Drain cock
• Cylinder thermostat and manual reset over
temperature thermostat (Indirect units)
The following items are supplied fitted, as standard:
• Immersion Heater, when required.
Water Supply
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 be
assessed and the water supply
be checked to ensure that this
demand can be satisfactorily met.
NOTE A high mains water
pressure will not always
guarantee high flow rates. Water
quality can seriously affect the
life of the heater.
Failure of the heater due to the
accumulation of solid material
and lime deposits is not covered
by the warranty.
If water quality warrants, a
properly maintained lime inhibitor
or water softener should be
installed with this unit.
It is the owner’s responsibility to
properly maintain the equipment.
Outlet/Terminal fittings
The water heater can be used in
conjunction with most types of
terminal fittings.
It is advantageous in many mixer
showers to have balanced hot
and cold water supplies.
Refer to the drawings at the end
of the instructions for connection
locations.
Outlets situated higher than the
cylinder will give outlet pressures
lower than that at the heater.
A 10metre height difference will
result in a 1 bar pressure
reduction at the outlet fitting.

2
2. Installation General
General Installation
Lifting
Lifting lugs are provided at the top of the calorifier. The cladding is
plasticised and may be damaged by the use of chains or straps.
Care should be taken in moving the Calorifier to prevent damage to the
fittings. Indirect units should not be shaken as this could damage the
internal coil.
Foundations
Calorifiers should be mounted on prepared foundations which are level.
Even a slight tilt can cause an airlock inside the tubes, which will affect
the flow of heat.
Vertical calorifiers are suitable for floor mounting, and can be located
virtually anywhere on site, provided the tundish and discharge pipe
(supplied by others) can be correctly installed.
Ensure that the floor is of sufficient strength to support the “full” weight
of the unit. Horizontal calorifiers are normally supported on loose
cradles, which need to be positioned clear of the drain connection and
leave access to any flanges for tightening of bolts.
Pipework
Ensure that all pipework is properly aligned to the vessel connections.
The weight of the pipework should be taken by external supports and
not by the vessel.
Allowance should be made for expansion of the pipes either by suitable
bends or flexible joints. Pipe runs should be kept as short as possible
for maximum economy.
Access to associated controls, immersion heaters and indirect controls
should be possible for servicing and maintenance of the system.
Connections
All connections on the water heater are screwed BSP female except
the primary connections on indirect models, which are plain 28mm
stainless steel tube. It is recommended 28mm compression fittings be
used.
Note: If solder type fittings are used in the supply pipework, the use of
self-cleaning fluxes should be avoided as they can impair the operation
of the safety valves in the inlet supply group.
Use TWO spanners when joining screwed connections to avoid undue
torque on the calorifier fittings.
Cold Water Supply
The main supply pipe must be of equal or greater diameter than the
water inlet connection to the water heater. A suitable valve should be
fitted in the cold water supply to enable the heater to be isolated for
draining down.
Inlet Supply Group
The components in the inlet
supply group can be connected
in the correct sequence
anywhere on the cold water
mains supply, prior to the water
heater.
There is no requirement to site
them close to the unit.
They may be sited at a point
where the mains supply enters
the premises, if this is more
convenient.
Ensure that the discharge from
the expansion relief valve is
correctly installed and that all
valves are installed with the
direction of flow arrows pointing
towards the heater.
Drain
All cylinders are supplied with a
drain valve with a hose
connection to facilitate easy
draining for service purposes.

3
General Installation Cont.
Outlet Pipework
Ideally the pipe work from the calorifier to the outlet fittings should be run
in a diameter that matches the outlet connection as far as possible, with
short runs of a smaller bore close to the draw off points.
Tundish and discharge pipe.
It is a requirement of building regulations that any discharge from an
unvented system is safely conveyed to where it is visible but will not
cause danger to persons in or about the building.
The installer should provide discharge pipes and tundishes and fit them
in accordance with the building regulations.
i) Discharge pipe must terminate in a safe, visible position.
ii) The tundish should be within 500mm of the temperature/pressure
relief valve and, wherever possible, be in a visible position.
iii) The discharge pipe work should have a vertical fall of at least
300mm from the tundish.
iv) The minimum discharge pipe size should be one pipe size larger
than the temperature/pressure relief valve discharge port.
v) The maximum total equivalent hydraulic resistance of the discharge
pipe should not exceed that of 9 metres of straight pipe.
vi) The discharge pipe should have a continuous fall (minimum 1:200)
2. Installation General Cont.
Secondary circulation.
All cylinders have a return
connection as standard.
Suitably approved bronze
circulation pumps must be used.
Warnings
i) Under no circumstances
should the temperature /
pressure relief valve be
removed or adjustment
attempted. To do so will
invalidate any guarantee
or claim.
ii) The cold water supply
group components must
all be fitted in the correct
sequence in the mains
water supply to the heater.
iii) The discharge pipe(s) from
safety valves should not be
blocked or used for any
other purpose.
iv) No control or safety valves
should be tampered with.
Installation - Direct Units
Water heaters are fitted with either flanged immersion heater(s) that
each have a control thermostat and a manual reset over-temperature
thermostat, or, screwed immersion heater(s) with a control thermostat
and a separate manual reset over-temperature thermostat fitted at high
level in the cylinder.
Note: Where the electric heat unit is supplied as a separate unit,
when fitted to the vessel the thermostats should always be
mounted on top.
Electrical Installation
All electrical wiring should be carried out by a competent electrician and
be in accordance with the latest I.E.E. Wiring Regulations.
The thermostats supplied have a maximum switching capability of
15 Amps/240V/1Ph. For all single-phase immersion heaters in excess
of 3kW and ALL three phase immersion heaters a suitably rated
interposing contactor must be installed.
A suitably rated isolator and protection fuse(s) should be fitted to
protect both the load and control circuits.
Operation
It is recommended that the
control thermostat(s) be set to
60-65 deg. C and that the over-
temperature thermostat be set
to 80 deg. C.
DO NOT bypass the over
temperature thermostat in any
circumstances.

4
Indirect Units
Indirect water heaters are fitted with a fixed coil heat exchanger.
Boiler selection
i) The water heater is suitable for use with all forms of boiler
compatible with unvented systems i.e. fitted with a temperature
control thermostat.
If in doubt, consult the boiler manufacturer.
ii) DO NOT use a coal or wood burning boiler as these do not have
adequate thermal control for unvented systems.
iii) The boiler used can be either an open vented type or a sealed
system having a maximum primary circuit pressure of 3 barg
iv) The primary flow from the boiler should be pumped. Gravity
circulation is not recommended due to poor heating performance.
v) The boiler flow temperature should be set at a maximum of 90C.
Indirect cylinder control thermostat
The control thermostat should be wired in series with a suitable control
valve (not supplied) in the primary circuit to give temperature control of
the stored water.
Indirect over-temperature (master) thermostat
The master thermostat, mounted at high level, MUST be wired to a
suitable 2 port motorised valve (not supplied) fitted to the primary flow of
the indirect coil.
Electrical Installation
All electrical wiring should be
carried out by a competent
electrician and be in
accordance with the latest I.E.E.
Wiring Regulations.
The control thermostat and
master thermostat must be
wired in series with a 2 port
motorised valve installed in the
primary flow, such that the
power supply is interrupted
should either device operate,
cutting off the primary flow.
A suitable switch and fuse
should be provided to give
protection to the electrical
wiring and components. The
master thermostat MUST NOT
be bypassed.
Immersion heater.
On models where an additional
electric immersion heater has
been fitted, this can be used
either as an independent
alternative heat source or to
boost output during peak loads.
The immersion heater should be
fitted with the thermostats to the
top and wired in accordance
with section 4.0 above.
2. Installation General Cont.
A
1
B
6
7D
D
C
5
4FB
3
2
A
3
E
1 Solar Panel
2 Double Pump station
3 Expansion Vessel
4 Hot Water Cylinder
5 Boiler
6 Hot water Domestic Supply
7 Heating System
A Flow Pipe (Hot Glycol) Solar
BReturn Pipe (Cold Glycol)
Solar
C Flow Pipe from Boiler
D Return Pipe from Boiler
E Cold Water feed
F Hot Water Supply to Tap

5
3. Commissioning
Commissioning
Filling
Ensure that all fittings are in place and tightened.
i) Check that the drain valve is closed.
ii) Open the tap furthest from the storage cylinder.
iii) Open the valve in the cold water supply and fill the system at a
steady rate to allow entrapped air to escape through the opened
tap. When water issues from the tap, allow the water to run for a
few minutes to flush through any dirt and extraneous material.
iv) Open successive hot taps to purge any remaining air from the
system. When satisfied that the system is free of air close the taps.
v) Check all connections for leaks and rectify as necessary.
Check the operation of the safety valves
i) Manually open, for a few seconds, the Temperature & Pressure
Relief Valve, situated on the top of the Series 2000 cylinder.
Check that the discharged water runs freely away through the
tundish and discharge pipe work.
ii) Repeat for the expansion valve, which should have been fitted in
the cold water supply on installation.
Check the charge pressure on the expansion tank
The separate expansion tank supplied with the water heater was
pre charged before despatch from the factory.
The charge pressure is 3.5barg (50psi) for 40, 60 and 80 litre expansion
vessels and 2.1 barg (30psi) for 100, 200 and 300 litre expansion
vessels.
A tyre pressure gauge or a special press on gauge can be used, but care
must be taken to ensure that they are clean and that no dirt is introduced
into the charging/test point.
i) Turn water supply to water heater off
ii) Open a hot water tap.
The above two actions reduce the system pressure to atmospheric so
that the vessel charge pressure, and not the system pressure, can be
taken.
iii) Remove dust cap from the Schrader valve
iv) Measure vessel charge pressure (If necessary recharge the
vessel to the correct pressure).
v) Close the hot water tap
vi) Turn on the water supply
Direct Units
Switch on the electrical supply to the immersion heater(s) and allow
the unit to heat up.
Check that the control thermostat operates correctly.
Check that no water is
discharged from either the
Expansion Valve or the
Temperature and Pressure relief
valve, during the heating cycle.
When the desired temperature
has been reached, check
around all connections, as they
may have slackened off due to
expansion.
Indirect Units
Fill the indirect (primary) circuit
in accordance with the boiler
manufacturers commissioning
instructions.
To ensure that the primary coil
in the Series 2000 is filled,
manually open the 2-port valve
until the filling sequence is
completed.
When the primary circuit is
full release the valve to its
normal position.
Switch on the boiler.
Allow the cylinder to heat up and
check that the cylinder control
thermostat and 2-port valve
operates correctly.
Check that no water is
discharged from either the
Expansion Valve or the
Temperature and Pressure relief
valve, during the heating cycle.
When the desired temperature
has been reached, check
around all connections, as they
may have slackened off due to
expansion.

6
WARNINGS
If water issues arise from the temperature/pressure relief valve, switch off
the electrical supply to the immersion heaters (Direct Units) or shut
down the boiler (Indirect Units).
DO NOT turn off the water supply. Contact a competent installer for
unvented water heaters to check the system.
DO NOT tamper with any of the safety relief valves fitted to the
system. If a fault is suspected contact a competent installer.
Temperature control - Immersion heaters
The control thermostat on the immersion heater(s) can be set between
40C and 80C. Adjustments can only be made by removing the
immersion heater cover.
DO NOT remove the cover without first switching off the electrical supply.
Indirect Units
These are fitted with a cylinder thermostat that controls a 2 port
motorised valve (not supplied) in the primary circuit, and hence the
temperature of the water in the storage cylinder. The thermostat can be
set between 40°C and 80°C.
DO NOT remove the cover without first switching off the electrical supply.
If in any doubt consult a competent electrician.
4. Operational
User Instructions
Operational Faults
Operational faults and their possible causes are detailed in section 9.3.
It is recommended that a competent person investigate faults.
The air volume within the expansion vessel will periodically require
recharging to ensure any expanded water is accommodated within the
system. A discharge of water intermittently from the expansion relief valve
will indicate that the air volume has reduced to a point where it can no
longer accommodate the expansion.
To recharge the air volume: -
The vessel can be recharged using an inert gas or dry air. Special
recharging bottles, compressors (with dryers) or car foot pumps can be
used. Care must be taken to ensure that they are clean and that no dirt is
introduced into the charging/test point.
i) Turn off the water supply to the water heater
ii) Open a hot water tap to reduce system pressure to atmospheric
iii) Remove dust cap
iv) Recharge the vessel to the correct pressure (see section 6.3)
a) If the vessel has been fully deflated for some time, the
membrane could have become bonded to the shell. If this has
happened, it is possible to free it by using a higher charging
pressure, but care must be taken in doing this, to avoid over
pressurising the vessel.
Flow Performance
When initially opening hot
outlets, a small surge in flow
may be noticed as pressures
stabilise. This is quite normal
with unvented systems and
does not indicate a fault.
In some areas cloudiness may
be noticed in the hot water.
This is due to aeration of the
water. It is quite normal and
will quickly clear.
b) If the vessel cannot be
recharged it must be
replaced.
v) When the vessel has been
recharged the dust cap
must be replaced.
vi) Close hot water tap
vii) Turn on the water supply

7
Optimum Performance
To ensure the continued optimum performance of the heater, it should be
regularly maintained. This is of particular importance in hard water areas or
where the water supply contains particulate matter.
Maintenance should be carried out only by a competent person. Any
replacement parts used should be authorised Heatrae Industrial spare parts.
It is recommended that maintenance be carried out every 12 months.
In hard water areas, consideration should be given to periodically descal-
ing the immersion heater elements. To do this the cylinder will need to be
drained.
Safety Valves
Manually operate the Temperature and Pressure relief valve for a few
seconds. Check that water is discharged and that it flows freely through the
tundish and discharge pipe work.
Check that the valve reseats correctly when released.
WARNING: The water discharged may be very hot.
Expansion relief valve
Repeat the above.
Clean the strainer
The strainer is incorporated within the pressure-reducing valve. To inspect
and clean it, turn off the mains water supply and open the lowest hot water
tap in the system to relieve the system pressure. Unscrew the black cap from
the pressure reducing valve and remove. The strainer will be removed with
the cap.
Wash any particulate matter from the strainer under clean running water.
Replace the cap assembly, ensuring that the sealing ring is correctly fitted.
Do not use any other type of sealant. Close the hot tap, open mains
stopcock and check for leaks.
Draining
Switch off the electrical supply to the immersion heater(s) and shut
down the boiler on indirect units.
Turn off the cold water supply. Attach a hosepipe to the drain valve having
sufficient length to take the water to a suitable discharge point. Open the hot
water tap nearest to the water heater, to relieve system pressure. Open the
drain valve. If water fails to drain from the cylinder, vent the unit by manually
opening the Temperature and Pressure relief valve.
Descaling. Isolate the electrical supply
Remove the cover from the immersion heater(s) and disconnect the wiring,
carefully noting the wiring sequence.
Remove the immersion heater from the cylinder by using a “C” spanner (for
screwed immersion heaters) or a socket spanner (for flanged immersion
heaters). Carefully remove the scale from the surfaces of the elements and
thermostat pockets by mechanical or chemical means. DO NOT use a sharp
implement as damage to the element surface could be caused.
IMPORTANT NOTES
i) Servicing should only be
carried out by a
competent person.
ii) Any spare parts used
MUST be an authorised
Heatrae Industrial part.
iii) Disconnect the electrical
supply before removing
any access covers.
iv) NEVER bypass any over
temperature thermostats.
v) Hot water can scald.
Care should be taken
when drawing water from
the units.
5. Maintenance
Fault Finder
A range of spare parts and
accessories is available for
the Series 2000.
When ordering spare parts
the serial number on the unit
should be quoted.
Spare Parts
Ensure that boss threads/
flange faces are clean and
replace the immersion
heaters(s). Ideally a new
gasket should be used.
Re-wire in the same sequence
noted, before removing the
immersion heater.
Refilling
DO NOT switch on the
immersion heater(s) or boiler
until the system has been
completely refilled.
Close the drain tap and follow
the filling sequence.
The electrical supply can now
be switched on.

8
Wiring for Single Stage Control
6. Drawings & Diagrams
Master
Thermostat
Thermostat
Thermostat
E
E
N
L1
L2
L3
IsolatorContactor
Master
Thermostat
Thermostat
Thermostat
E
E
N
L1
L2
L3
IsolatorContactor
Contactor
STAGE 1
STAGE 2
Wiring for Two Stage Control

9
Piping Diagram
6. Drawings & Diagrams
Expansion
Vessel Expansion
Valve
Check Valve
Water Main
Stop
Valve
Pressure
Reducing
Valve
Discharge
Tundishes
(Not Heatrae Supply)
Pressure/Temperature
Relief Valve
Primary
Return
Primary
Flow
Hot Water
Thermal
Cut out
Thermostat
Motorised
Valve

10
Duncombe Road,
Bradford, England BD8 9TB.
Telephone: [phone]. Email: [email protected]
Ormandy Rycroft
Heating & Cooling Solutions
www.ormandygroup.com