REMEHA 94110301 User manual

R36006247_issue_08
Installation Manual
Unvented Indirect Water Heaters
Installation & Servicing Instructions

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 Immersion allocation
3.2 Technical data
3.3 Dimensions and connections
3.4 Electrical diagram(s)
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
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 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 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.

page 3
2. Safety
2.1 General safety warnings
DANGER
This cylinder is unvented and as such becomes pressurised when in operation.
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
WARNING
When handling the unit, take appropriate precautions for the weight of the unit.
Weights can be found in section 3, table 2.
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 Immersion allocation
Table 1: Immersion allocation table
Element 94110301 94110302 94110303 94110304 94110305 94110306 94110307 94110308 94110309
Kw 6 9 12 18 24 30 36 45 54
Location Upper Lower Upper Lower Upper Lower Upper Lower Upper Lower Upper Lower Upper Lower Upper Lower Upper Lower
400 # # # # # # #
500 # # # # # # # #
800 # # # # # # # #
1000 # # # # # # # #
1250 # # # # # # # # #
1450 # # # # # # # # #
2000 # # # # # # # # #
Indirect
2500 # # # # # # # # #
Note: This table shows what immersion can be fitted to each cylinder size.
page 5
3.2 Technical data
Table 2: Technical data - Indirect
400
Indirect 500 Indirect 800 Indirect 1000 Indirect 1250 Indirect 1450 Indirect 2000 Indirect 2500 Indirect
Max immersion kW rating 36 45 45 45 54 54 54 54

Coil surface area m2 2 3 5 7.5
15 l/min 29.4 28.7 31.3 32.9 35.0 30.1 40.2 37.5
30 l/min 43.6 41.8 52.7 51.4 63.6 61.2 98.4 86.4Coil rating (kW)
60l/miin 59.7 55.8 76.9 76.5 97.9 91.7 132.2 126.4
15 l/min 43 55 80 91 112 130 180 225
30 l/min 29 38 48 59 62 72 99 124Indirect heat time (mins)
60l/miin 21 28 32 39 40 50 48 62
15 l/min 0.002 0.001
30 l/min 0.004 0.008 0.006 0.007Pressure drop through primary coil (Mpa)
60l/miin 0.032 0.044 0.025 0.03
Heat loss (kWh in 24h) 1.72 2.14 2.74 3.33 3.60 4.17 4.30 4.50
Hot water capacity (volume of water >40°C) drawn off 384 482 776 961 1206 1399 1930 2482
Weight full (kg) 505 610 964 1188 1569 1872 2445 2950
Weight empty (kg) 105 110 164 188 319 322 445 450
Max supply pressure 1.6 MPa (16 bar)
Max design pressure 0.8 MPa (8 bar)
Max operating pressure 0.6 MPa (6 bar)
Max expansion vessel charge pressure 1.0 MPa (10 bar)
Expansion relief valve setting 0.8 MPa (8 bar)
T&P valve setting 1 Mpa (10 bar), 90-95°C
Maximum primary pressure (indirect only) 0.3 MPa (3 bar)
Notes:
1. Indirect cylinders tested in conformance with BS EN 12897:2006.
2. Indirect heat up times based on a 45°C temperature rise, based on a primary flow temperature of 80°C +/- 2°C
Table 3: Inlet control kits and expansion vessel specification dependant on model
Commercial Cylinder
Volume (ltr) Pressure Reducing Valve Pressure Relief Valve Single Check Valve
400 - 500 1" Integrated inlet control valve

800 1.25" (1.5 - 6 bar) or (5 -10 bar) 1" x 1.25" (8 bar) or (13 bar) 1.25"
1000 1.25" (1.5 - 6 bar) or (5 -10 bar) 1" x 1.25" (8 bar) or (13 bar) 1.25"
1250 - 1450 1.5" (1.5 - 6 bar) or (5 -10 bar) 1" x 1.25" (8 bar) or (13 bar) 1.5"
2000 - 2500 2" (1.5 - 6 bar) or (5 -10 bar) 1.25" x 1.5" (8 bar) or (13 bar) 2"
Commercial Cylinder
Volume (ltr) Expansion Vessel Size (ltr) Mounting Kit Weights
400 - 500 60 Floor Mounted 12kg
800 100 Floor Mounted 17kg
1000 - 1250 150 Floor Mounted 24kg
1450 200 Floor Mounted 38.5kg
2000 - 2500 300 Floor Mounted 41kg
page 6
3.3 Dimensions

Figure 2: General dimensions
Table 4: General dimensions table - Indirect
Item Connection 400I 500I Connection 800I 1000I Connection 1250I 1450I Connection 2000I 2500I
ANA 1500 1800 N/A 1906 2301 N/A 1937 2253 N/A 2011 2416
BN/A ½" BSP 1499 1897 ½" BSP 1411 1719 ½" BSP 1422 1827
C½" BSP 669 669 ½" BSP 1217 1467 ½" BSP 1211 1211 ½" BSP 1260 1510
D1" BSP 499 499 1 ¼" BSP 618 618 1 ½" BSP 707 707 1 ½" BSP 779 779
E1" BSP 324 324 1 ¼" BSP 443 443 1 ½" BSP 527 527 1 ½" BSP 599 599
F1" BSP 309 309 1 ½" BSP 437 437 1 ½" BSP 526 526 2" BSP 606 606
GN/A N/A 487 487 N/A 526 526 N/A 575 575
HN/A ½" BSP 657 657 ½" BSP 751 751 ½" BSP 815 815
IN/A 774 859 N/A 952 952 N/A 966 966 N/A 1004 1004
J1" BSP 869 1135 1" BSP 1187 1437 1" BSP 1176 1376 1" BSP 1225 1475
KN/A 1119 1419 N/A 1502 1897 N/A 1411 1686 N/A 1425 1815
LN/A 956 956 N/A 1107 1107 N/A 1308 1308 N/A 1560 1560
MN/A 872 872 N/A 1024 1024 N/A 1224 1224 N/A 1476 1476
page 7
3.4 Electrical Diagrams
WARNING
The high limit thermostat must always operate the zone valve in case of overtemperature.
Thermostat Option 1

Figure 3: Indirect wiring diagram 1
Thermostat Option 2

Figure 3a: Indirect wiring diagram 2 - volt free option
NOTE: Option 2 utilises control thermostat to provide volt free control circuit.
page 8

Figure 4: 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: 3 phase wiring schematic
page 9
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 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.
The water is heated indirectly through a coil in the unit using an indirect heat source. It can also be heated using Auxiliary immersion heaters
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 components
See Figure 6: Main components
4.4 Standard delivery
The delivery includes:
#Cylinder
#Literature pack
#Instructions (inc benchmark commissioning checklist & service record)
#Cold water control pack (see table 3)
#Expansion vessel (see table 3)
#Combination valve (inc pressure reducing valve, pressure relief valve and check valve)
#Tundish

#2 port zone valve

Figure 6: Main connections
Note: This is an indirect unit and shows the general position of components but these will change depending on the model.
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
#The Building Standards (Scotland)
#The Building Regulations (Northern Ireland)
#I.E.E Electrical Regs
#UK Water Regulations
page 10
5.2 Installation requirements
Water supply
In an unvented system the pressure and flowrate 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.
#The minimum supply requirements should be 0.15MPa (1.5 bar) pressure and 100 litres per minute flow rate.
#A 28mm cold water supply is recommended as a minimum. However, if a smaller supply exists, which provides sufficient flow, this may
be used (although more flow noise may be experienced).
#The higher the available pressure and flow rate the better the system performance.
#See table 2 for cylinder operating pressures. This is controlled by the cold water combination valve assembly.
Outlet/terminal fittings (taps, etc.)
#The cylinder can be used with most types of terminal fittings.
#Outlets situated higher than the cylinder will give outlet pressures lower than that at the heater, a 10m height difference will result in a 1
bar pressure reduction at the outlet.
#All fittings, pipework and connections must have a rated pressure of at least 8 bar at 80°C.
Limitations
The cylinder should not be used in association with any of the following: