Ormandy Rycroft Evoplate CP-B25 Assembly instructions

Evoplate Vessel
Installation, Operating &
Maintenance Instructions
Ormandy Rycroft
Heating & Cooling Solutions

Running 1Page 2
VERY IMPORTANT - PLEASE READ CAREFULLY
Safety Points 1.1 Page 2
Start Up 1.2 Page 3
Working Principles 1.3 Page 3
Installation 2Page 4
Sizing and Selection 2.1 Page 4
Installation 2.2 Page 7
Operation and Set Up 2.3 Page 9
Health 3Page 16
Maintenance 3.1 Page 16
Service 3.2 Page 16
Spares 3.3 Page 16
Information 4Page 17
Specification 4.1 Page 17
Installation, Operating and Maintenance Instructions Page 1

1
Lifting
Evoplate - Installation, Operating & Maintenance Instructions
Lifting lugs are fitted on the top of the vessel. These should be used
when lifting the vessel into position. Ensure the vessel remains in a
vertical position (for vertical vessels) and horizontal position (for
horizontal vessels) throughout.
Foundations
Level foundations should be prepared for the buffer vessel. Uneven
foundations can cause airlocks within the vessel and the vessel could
be unstable when maintenance work is carried out.
The vessel should be attached to the foundations using bolts through
the bolt holes on the vessel foot pads.
Flanges and Bosses
PTFE should be used when fitting
screwed connections to the
vessel bosses.
When fitting flange connections,
ensure mating flanges are square
and that the weight of the
pipework is supported by
external supports and not the
vessel connections.
Expansion of pipes should be
considered for the application
and measures put in place if
necessary.
Filling and Draining
Tighten any bolts on the vessel prior to filling as these may have
become loose during transit. Ensure bolts are tightened diametrically
and to the correct Torque. (if in doubt contact Ormandy Limited
technical department).
When filling the vessel ensure the vent connection on the top dished
end is open. When the vessel is full the vent boss should be plugged.
When draining the vessel ensure the vessel is released of pressure
slowly and that the vent is then open before draining commences.
Relief Valve
Ensure that the relief valve is
fitted with a discharge pipe (on
the valve outlet). The pipe should
open to atmospheric pressure
and run to a low level suitable
drainage area.
Inspection
Internal inspection of the vessel should take place after the first 3
months. The inspection should involve looking for signs of corrosion
or local pitting cells. If any is found then a specialist should be
consulted. If after the first inspection the vessel appears sound then
a further inspection should be made after 6 months.
Again, on satisfactory review, inspection can be limited to annually.
When inspecting the internal side of the vessel ensure that the vessel
is first drained of its contents in accordance with the procedures
detailed above.
Before removing the inspection cover ensure that the cover is first
supported by use of the coverplate lifting lug. When re-fitting the
cover, the bolts should be tightened diametrically.
Evoplate Package shown below

2
1.1 Safety Points
1. Running
• During operation, the unit may have very hot or very cold
surfaces.
• The temperature probe is installed directly in the secondary flow.
Do not remove when the system is hot, full or under any pressure.
• The equipment has danger from electricity. Do not remove covers
or allow any exposed live parts. Isolate before working on the
unit.
• Take care when lifting. Only use the designated lifting point.
Use only certified lifting equipment capable of lifting the weight.
Water may also be present and spillage could occur.
• Never lift the HT breeze by any associated pipework or pipe
connections.
• Take care when handling, as some of the edges may be sharp.
• Electrical and Mechanical functionality must be considered prior
to connecting any none factory fitted equipment. E.g. Pumps,
Valves / Actuators etc.
Switch on via switch (16)
The front panel will illuminate. After
a few seconds of self checks, the
displays will settle to the Day (1)
(Time-clock only), Time (2) and
Temperature (3). The pumps will
start (11) and the valve will open
(15) and the system healthy
indicator (13) will illuminate.
In the majority of applications,
the resulting control and running
will be perfectly satisfactory. The
standard temperature setting is
60C and the unit will run
continuously (24 hour operation).
To change any of the default
settings, see section (2.3).
13 System Healthy Indicator
14 System Fault Indicator
15 Valve Position Bar Display
16 On/Off switch
1 Day/Mode Display
2 Time/Alarm Display
3 Temperature/Parameter Display
4 High Temperature Alarm Indicator
5 Reset Push Button
6 Step Left Push Button
7 Value Increase Push Button
8 Step Right Push Button
9 Value Decrease Push Button
10 Mode Select Push button
11 Pump Energised Indicator
12 Power On Indicator
1 2 3
45
6
7
8
9 10
11
12
13
15
14
16
✓
✘
100
50
0
Ormandy Rycroft
Heating & Cooling Solutions
1
3
6
2
54
7

3
1.3 Working Principles
The HT Breeze comprises of a Supapac Plate Heat Exchanger, either a
3 port or 4 port control valve, primary pump, temperature sensor and
PID controller, all mounted on a skid base.
The motorised 3 or 4 port control valve, allows rapid adjustment of the
primary heat input to match changes in secondary hot water demand.
The HT Breeze requires no insulation and the design ensures that the
outlet temperature does not fall below the set point (60°C default but can
be adjusted to suit customer requirements) and consequently reduce the
risk of legionnaires disease.
Providing the class of accommodation and details of the number and
type of fixtures are known, Rycroft will be pleased to recommend the
optimum size of HT Breeze.
1. Running continued
With buffer vessel to form a semi-instantaneous water heater
3 Port Valve
Primary
Flow
Primary
Return
Secondary
Inlet
Secondary
Outlet
Control
Stat
PHE
4 Port Valve
Primary
Flow
Primary
Return
Secondary
Inlet
Secondary
Outlet
Control
Stat
PHE
Secondary Flow
Temperature Gauge
Pressure Gauge
Expansion
Vessel
Expansion
Relief
Valve
Lockshield
Valve
Cold Feed
Non-Return
Valve
Circulating
Pump
Secondary
Shunt Pump
Drain
Pressure/Temp
Relief Valve
Temperature
Sensor
Commissioning
Valve
Drain
Plug
Two Way
Valve
Primary Return
Actuator
Primary Feed
Primary
Pump
1.2 Start Up - Checks
Checks Complete (✓)
Check that electrical installation is complete.
Check that the mechanical installation is complete.
Check that the system has been flushed and that there are no leaks.
Check that any air has been eliminated from the system.
Check that valves are opened in the required sequence.

4
2.1 Sizing and Selection
2. Installation
To size a stand alone HT Breeze, use the following demand factors.
Facility
Private
Hand
Basin
Public
Hand
Basin
Shower Bath Slop
Sink
Bar
Sink
Kitchen
Sink
Washing
Machine
Lab
Sink
Dish
Washer
Hospital 1 2 4 4 4 10 10 3 10
Residential
Hall & Hotel 1 2 4 4 4 12 10 10 10
School 0.5 3 10 - 3 10 3 3 10
Sports Centre
/Barracks 0.5 2 10 - 3 12 10 - - 10
Restaurant 0.5 4 - - 12 12 19 - - 10
University 0.5 3 10 - 3 - 10 - 3 10
Offices 0.5 3 3 - 3 - 10 - 3 10
Factory 0.5 3 4 - 3 - 10 - 3 10
Apartments 1 - 4 4 3 - 3 3 - 2
Careful consideration must be given to the sizing of stand alone instantaneous water heaters. Standard
demand units incorporate a degree of diversification that would be inappropriate for continuous use
applications.
A more desirable method of sizing for continuous applications is to complete a fixture count and allocate an
appropriate flow for each fitting.
It should also be noted that shower demands for Schools, Sports Centres and Universities should only be
used for medium to large installations. Please refer to our design department for further information.
Table 1
42 single person showers 42 x 4 = 168
55 private hand basins 55 x 1 = 55
9 public hand basins 9 x 2 = 18
3 slop sinks 3 x 4 = 12
15 baths 15 x 4 = 60
Total Demand Units = 313
The shower factors are based upon
intermittent use.
Where certain activities may result
in all showers operating together,
please contact our sales department
for advice.
Example
From Table 1. A 173 bed Hospital ward with showers, hand basins and sinks.
Sizing Considerations

5
2.1 Sizing and Selection continued.
2. Installation continued
The correctly sized HT Breeze can now be selected from Table 2.
HT Breeze Model Maximum
Demand Units
Max Continuous Duty
@ 60°C (litres/sec)
Boiler
Power (kw)
Min Secondary
Volume (litres)
CP-B25 15 0.25 52 45
CP-B50 23 0.50 105 75
CP-B75 45 0.75 157 85
CP-B100 70 1.00 209 125
CP-B125 90 1.25 261 135
CP-B150 130 1.50 313 150
CP-B200 210 2.00 418 200
CP-B250 320 2.50 522 250
CP-B300 480 3.00 627 300
CP-B350 640 3.50 732 350
CP-B400 820 4.00 836 400
CP-B450 1050 4.50 935 450
CP-B500 1300 5.00 1040 500
These sizes represent the standard range of HT Breeze instantaneous water heaters.
For larger requirements for both single and three phase, please contact our technical department.
Both standard and special designs can be offered, to suit your specific requirements.
Table 2

6
To size a HT Breeze and Buffer Vessel use the following maximum demand rates.
Facility
Private
Hand
Basin
Public
Hand
Basin
Shower Bath Slop
Sink
Bar
Sink
Kitchen
Sink
Washing
Machine
Lab
Sink
Dish
Washer
Load
Factor
Hospital 10 15 70 60 50 80 100 40 150 0.7
Residential
Hall & Hotel 10 15 50 50 50 100 80 100 150 0.5
School 5 20 180 40 80 40 40 150 0.8
Sports Centre
/Barracks 5 15 220 40 100 80 100 1
Restaurant 3 25 100 100 140 150 1
University 5 20 220 40 80 40 150 0.8
Offices 5 10 180 40 40 40 100 1
Factory 5 20 120 50 80 40 100 1
Apartments 5 50 50 40 20 40 20 0.7
Table 3
2. Installation continued
42 single person showers 42 x 70 = 2940
55 private hand basins 55 x 10 = 550
9 public hand basins 9 x 15 = 135
3 slop sinks 3 x 50 = 150
15 baths 15 x 60 = 900
Total Volume = 4675
Load Factor from Table 3 = 0.7
Total Demand Rate 4675 x 0.7 = 3273 litres/hr
Example of a Hospital Facility
The HT Breeze and Buffer Vessel combination should be sized as follows:-
The Buffer Vessel Capacity = 25% of the total hourly demand. Therefore the required storage capacity
= 3273 x 0.25 = 818 litres. The nearest standard Buffer Vessel sizes are 800 and 900 litres. It is
recommended to go up in size and therefore a 900 litre Buffer Vessel should be selected.
The HT Breeze can be selected as follows:-
Continuous hourly demand = 3273 litres
Specific Heat Capacity of Water = 4.187 kj/kg, °C
Cold Feed Temperature = 10°C
Secondary Flow Temperature = 60°C
Therefore the required kw rating = 3273 x 4.187 x (60-10)
The nearest standard HT Breeze is a CP-B100 which is rated at 209 kw
3600 = 190.3 kw

7
A HT Breeze and Buffer Vessel combination is used when water demand is not constant but high flow
frequently occurs. Boiler power requirements are reduced by storing hot water in the buffer vessel for
peak demands.
The HT Breeze should always be installed with a secondary return line coming back from the system and
into the cold feed line prior to the HT Breeze or Buffer Vessel. This will remove nuisance high limit tripping
due to temperature overshoot, which would occur if the unit was installed on a ‘dead end’ system, when an
outlet was closed. To ensure full heat dissipation, the secondary volume should not be less than that shown
in Table 2.
For larger capacities contact the sales department for advice.
2.1 Sizing and Selection continued.
2. Installation continued
2.2 Installation
Foundations
The HT Breeze should be mounted on prepared foundations that are level.
Lifting
One lifting hole is provided on the top of the HT Breeze control panel.
Avoid the use of chains as screwed connections may be damaged by
the links.
Caution: Never lift the HT Breeze by its pipework or pipe connections.
Pipework
Make sure that the pipework flanges are square and correctly spaced
before bolting up. See that the weight of the pipework is taken by external
supports and not by the HT Breeze. Allowances should be made for
expansion of the pipes either by suitable bends or flexible joints.
Tighten flange bolts in a diametrically opposite sequence and not
consecutively round each flange.
Connections
Threaded connection may be sealed with PTFE tape. Flanged connections
should be sealed with a suitable gasket and sealing agent.
Liquid Expansion
Changes in volume with temperature must not be overlooked. The system
pressure will rise dramatically if there is nowhere for water to expand. It is
not advisable to use a relief valve as a means of releasing the excess water.
Vented systems use the atmospheric vent as an expansion pipe with
discharge back into the tank. Unvented systems require a separate
expansion tank.
Venting
Vent valves must be fitted at the highest point in the connecting pipework so
that the HT Breeze can be bled of air for initial operation. It is essential that
the flooded can type pump motors which are commonly used for all
HT Breeze pumps are bled of air and flooded before starting.
See the pump manufacturer’s instructions.
Filling
Before filling the system
check that the drain valve is
closed and all air vents are
open.
Flush out the system before
installing the HT Breeze to
remove any foreign matter.
Close any manual air vents
and run the HT Breeze.
Crack the vents to release
air
Caution: Do not fill the
system too quickly,
otherwise pockets of air
may become trapped.

8
2.3 Operation and Set Up
2. Installation continued
13 System Healthy Indicator
14 System Fault Indicator
15 Valve Position Bar Display
16 On/Off switch
1 Day/Mode Display
2 Time/Alarm Display
3 Temperature/Parameter Display
4 High Temperature Alarm Indicator
5 Reset Push Button
6 Step Left Push Button
7 Value Increase Push Button
8 Step Right Push Button
9 Value Decrease Push Button
10 Mode Select Push button
11 Pump Energised Indicator
12 Power On Indicator
Electrical Connections
Terminal Block
The Electrical connections are located in the terminal compartment.
A description of the terminals can be found on the inside of the terminal compartment cover.
Connect a single phase 230V 50Hz supply to the Mains Input terminals. Max full load current is 16A with
the majority of units being considerably less.
If the unit is to be controlled remotely, connect the remote control switch or contacts to the ‘Remote Enable
Terminals’. If the unit is to be controlled locally fit a link between these terminals.
Do NOT apply voltage to the terminals of these contacts!
Voltage free fault relay contacts are provided for Remote Fault Indication.
1 2 3
4 5
6
7
8
9 10
11
12
13
15
14
16
✓
✘
100
50
0
Ormandy Rycroft
Heating & Cooling Solutions
1
3
6
2
54
7