Santon PowerPack Guide

Multipoint
1
1
Installation and User Instructions
PowerPack
Please read and understand these instructions before starting work.
Please leave this leaet with the user following installation
WARNING
This PowerPack must only be installed by qualied persons.
36006036 Issue 4.
®
™

2
Thank you for purchasing a Santon PowerPack. The PowerPack unvented pressure
system water heater is manufactured to the highest standards and has been designed to
meet all the latest relevant safety specications.
This PowerPack water heater must be installed (Sections 3.0-6.0), commissioned
(Section 5.0) and maintained (Section 7.0) by a competent person. Please read and
understand these instructions prior to installing your PowerPack unvented pressure
system water heater. Particular attention should be paid to the section headed SAFETY
(Section 2.0).
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning the use of the appliance by
a person responsible for their safety. Children should be supervised to ensure that they
do not play with the appliance.
CONNECTIONS
Inlet / Outlet connection -1/2” BSP
Water entry point - bottom
Cable entry point - bottom
ELECTRICAL
Model numbers
7.0kW - 94 050 211
9.0kW - 94 050 212
12.0kW - 94 050 213
Electrical rating... 6.4/7.0kW @ 230/240V
.............................8.2/9.0kW @ 230/240V
............................11.0/12.0kW @ 230/240V
PACK CONTENTS
Heater
Fixing screws and plugs
Expansion relief valve 1MPa (10bar)
Tee piece
Pressure relief valve (2.5bar for 7kW only)
Installation and User Instructions
TECHNICAL SPECIFICATION
INTRODUCTION

Multipoint
3
3
RATED PRESSURE
7kW
Minimum supply pressure 0.1Mpa (1bar)
Maximum supply pressure 0.25Mpa (2.5bar)
9/12kW
Minimum supply pressure 0.1Mpa (1bar)
Maximum supply pressure 0.7Mpa (7.0bar)
MATERIALS
Backplate, cover - ABS
Element(s) - Copper sheathed rod type.
DIMENSIONS
Height - 210mm
Width - 160mm
Depth - 104mm
STANDARDS AND APPROVALS
Complies with the requirement of EN 60335-2-35.
British Electro technical Approvals Board (BEAB) approved.
Complies with European Community Directives (CE).
Complies with UK water regulations, kiwa approved.
red
red
NL
black
green/yellow
Terminal
block
Pressure
switches
Inner
container
red
red
red
red
7kW / 9kW / 12kW
Figure 1 - Wiring Diagram
Neon

4
IMPORTANT INFORMATION
2.1 Products manufactured by Santon are to British and European Standards.
These appliances are safe and without risk, provided they are installed, used
and maintained in good working order in accordance with our instructions
and recommendations.
2.2 Please read and understand these instructions before starting work
and retain them for later use.
2.3 DO NOT operate the appliance if it is frozen, or suspected of being
frozen. See fault nding table.
2.4 These heaters are of the closed outlet type (unvented pressure system) and
are suitable for connection to normal cold water mains supplies up to a
maximum of 0.25MPa (2.5bar) for 7kW and a maximum of 0.7MPa
(7.0bar) for 9kW and12kW
2.0 SAFETY
1.0 INTERNAL COMPONENTS
FIXING HOLES (3 NOS.)
TEMPERATURE
LIMITER 1
(ONE SHOT
OVER TEMP
CUT-OUT)
CABLE GRIP
DRAIN PLUG
DIFFERENTIAL PRESSURE
SWITCH ASSEMBLY
MAINS CONNECTOR BLOCK
WATER CONTAINER
ASSEMBLY
TEMPERATURE LIMITER 2
(OVER TEMP CUT-OUT)
Figure 2

Multipoint
5
5
2.5 DO NOT operate the appliance if: (in all cases turn off mains power and isolate
water supply)
1. Water ceases to ow during use.
2. Water has entered inside the unit because of an incorrectly tted cover.
3. If the appliance is damaged.
2.6 ISOLATE the electrical and water supplies before removing the cover.
2.7 ISOLATE the electrical and water supplies BEFORE proceeding with
installation or servicing.
2.8 The product is NOT SUITABLE for mounting into steam rooms or
steam cubicles.
2.9 The installation must be carried out in accordance with the relevant
requirements of:
• The appropriate Building Regulations either The Building Regulations,
The Building Regulations (Scotland) or Building Regulations (Northern
Ireland).
• The Water Fittings Regulations or Water Byelaws in Scotland.
• The IEE Wiring Regulations - BS7671.
CAUTION
2.10 It is recommended that persons who may have difculty understanding
or operating the controls should not be left unattended whilst using appliance.
Special consideration should be given to young children and persons with
reduced physical, sensory or mental capabilities.
2.11 Only use designated entry points for cable and pipe.
PLUMBING
2.12 The plumbing installation must comply with Water Regulations.
2.13 The supply pipe must be ushed to clear debris.
2.14 DO NOT solder pipes or ttings within 300mm once the pipe work is
located in the appliance, as heat transfer can damage components.
2.15 All plumbing connections must be completed and checked for leaks before
making the electrical connections.
ELECTRICAL
2.16 Before tting the appliance, ensure that the consumer unit and any
switches are suitable for the additional load. If in doubt, contact your
electricity supplier or a qualied electrician.
2.17 The installation must comply with the latest BS 7671 ‘Requirements for
Electrical Installations’ (IEE Wiring Regulations).
2.18 This appliance must be earthed.
2.19 A residual current device (rcd), formerly known as an earth leakage circuit
breaker (elcb), with a tripping current of 30mA must be incorporated in the
circuit.

6
WATER REQUIREMENTS
3.1 All 7kW heaters must be installed using the supplied 2.5bar pressure
reducing valve and have a cold supply minmum pressure of 0.1Mpa (1bar) and
a maximum of 0.25Mpa (2.5bar). 9kW and 12kW heaters have an operational
pressure range of 0.1Mpa (1bar) to 0.7Mpa (7.0bar). Both inlet and outlet
connections are suitable for 15mm diameter copper pipe.
3.2 The tee piece and expansion relief valve must be situated where shown
(see gure3.) and the relief valve discharge port plumbed via an air break
(tundish) to a safe, visible place where there is no risk to persons.
3.3 The discharge pipe must fall continuously from the valve outlets and be
unobstructed.
3.4 The provision of a service stop valve in the cold supply pipe will assist in the
event of any subsequent servicing or maintenance.
3.5 To obtain optimum performance a ow restrictor (isolating ball valve) must
be tted where shown (see gure 3). This provides temperature control during
comissioning (see 5.3 SETTING FLOW RATE).
3.0 SITE REQUIREMENTS
A - OUTLET VALVE
B - FLOW RESTRICTOR
C - POWERPACK
D - EXPANSION RELIEF VALVE
E - SERVICES STOP VALVE
F - PRESSURE REDUCING VALVE
(2.5bar PRV SUPPLIED WITH 7kW
HEATER MUST BE INSTALLED)
A
B
C
D
E
Figure 3
F

Multipoint
7
7
ELECTRICAL REQUIREMENTS
3.6 This appliance must be earthed.
3.7 The installation, supply cable and circuit protection must conform to the
latest BS7671 ‘Requirements for electrical installations’ (IEE Wiring
Regulations).
3.8 The PowerPack heater must only be connected to a 230/240V ac supply.
3.9 Before making any electrical connections within the installation, make sure
that no terminal is live. If in doubt, SWITCH OFF the whole installation at the
consumer unit or switch fuse (where tted).
3.10 The PowerPack heater must be connected to its own independent electrical
circuit.
3.11 Check that your consumer unit (main fuse box):
1. has a main switch rating of 80A or above.
2. has a spare fuse way which will take the fuse/mcb you need to
t - see Figure. 4. If so, you can wire the PowerPack direct to the spare fuse of
your consumer unit via a suitable rated isolated switch- see Figure.4. Note that
not all consumer units will accept a 35/40/45A sized fuse.
3.12 If point 3.11, 1 and 2 are not achievable, the installation is not straight forward,
since it could involve installing a new consumer unit to serve the whole house
or just the PowerPack. You will need to call in your Regional Electricity
Company to check the circuit and make the connections to the meter or service
connector block. They should also check the earth bonding of items in the
vincinity.
3.13 Aresidual current device (rcd), formerly known as an earth leakage circuit
breaker (elcb), with a tripping current of 30mA must be incorporated in the
circuit.
3.14 A double-pole isolating switch rated at (30A for 7kW, 40A for 9kW, and
50A for 12kW), with a contact separation of at least 3mm in each pole, must be
incorporated in the circuit. This must have a mechanical indicator showing when
the contacts are open. An indicator lamp alone is not sufcient. Only cord
operated switches are tted in bathrooms.

8
Make cut-out
using sharp knife
Figure 5 - Rear cable entry
Figure 4
PowerPack unit
(use rear entry when it is
possible)
80A or 100A main switch
Meter
Meter ‘tails’
Consumer unit
RCD (can be part of the
consumer unit)
Double pole isolating switch:
pull cord or wall mounted in accordance
with IEE regulations

Multipoint
9
9
PREPARATION
4.1 Remove the xing screw which holds the front cover onto the back plate of the
PowerPack heater. Carefully remove the cover.
4.2 The unit must be mounted on a at surface, which covers the full width and
length of the back plate. It is important that the wall surface is at otherwise
difculty may be encountered when tting the cover.
4.3 DO NOT t the PowerPack to the wall and tile up to the case. It must be tted
on to a nished at and even wall surface. This allows removal for servicing.
CABLE ENTRY
4.4 Cable entry can be from the rear (see Figure 5) or from the bottom.
When opting for bottom entry make cut-out to suit cable before tting back
plate to the wall.
4.5 Fix the PowerPack heater loosely to the wall. The wallplugs provided are
suitable for most brick walls (use a 6.5mm diameter masonry drill), but if your
wall is plasterboard or soft building block, you should use special wallplugs and
an appropriate drill, obtainable from most hardware stores.
PLUMBING
4.6 Decide where to connect to the water mains for your feed to the PowerPack.
Ensure that the pipe you have selected is not a gas pipe or a hot water pipe or
from a cold water storage tank.
4.7 Cut the necessary pipe work to length, assemble and offer up to the installation
before making any soldered joints. Ensure that the pipe is the correct length, as
shortening it can be difcult once joints have been made.
4.8 An isolating stop valve MUST be incorporated to the main water supply to
comply with Water Regulations
4.9 Assemble the installation before making any soldered joints. DO NOT use
jointing compounds on any pipe ttings for the installation.
4.10 Remove the unit before soldering the connections.
4.11 It is essential to ush the pipe in order to clear debris, particles of solder and
swarf.
4.12 Turn the water off after ushing using the isolating stop valve.
4.13 Connect the cold water supply pipe to the inlet of the PowerPack, this is a 1/2”
BSP connection.
4.14 Fit top and bottom screws and secure the back plate to the wall ensuring that it
is level.
4.15 Connect all other components as per Figure 3.
4.16 Turn the isolating stop valve on slowly and check for leaks in all pipe work,
rectify as necessary.
4.17 Turn off the isolating stop valve.
4.18 Place the cover onto the back plate.
4.19 Secure the cover to back plate using screw provided.
4.0 CONNECTING TO SERVICES

10
5.0 COMMISSIONING
5.1 Once installed, the heater will operate automatically when the outlet valve is
opened. The valve must be opened fully to obtain the set ow/temperature.
Reduced ow at the outlet will result in hotter water being delivered.
5.2 On closing the outlet valve the heating element will automatically shut down
provided this tap has been turned off by the user.
SETTING FLOW RATE
5.3 To set the ow rate, make sure the water and power are turned off. Open the
outlet valve fully (see gure 3) and close the ow restrictor. Open the stop
valve and open the ow restrictor (allowing all air to be purged). When all air
is purged switch the power on, wait for a few seconds while the water is heated
and adjust ow restrictor to suit the required temperature. Remember the outlet
valve is fully opened at this point so the required temperature may need further
adjustment.
5.4 It is important to note when setting the ow rate/temperature that 48°C is the
point at which the average person cannot hold his or her hand under a stream of
water. Under most circumstances water temperature need not be higher than
this and it is recommended that this temperature is not exceeded.
5.5 These heaters will supply only one outlet at any time and must be controlled by
a single outlet valve. DO NOT USE WITH MIXER VALVES.

Multipoint
11
11
6.0 MULTIPLE INSTALLATIONS
6.1 When larger volumes of water are required than can be provided by one heater,
multiple installations can be made by connecting a number of heaters in
PARALLEL of the cold feed manifold (See Figure 6). This is the ONLY
method that is recommended, provided all water heaters recieve acceptable
ow rates (2.5ltr/min recomended). DO NOT plumb these heaters in series.
6.2 To set the heaters in this arrangement use the appropriate procedure as
described previously. Each heater in parallel must be set individually.
6.3 In this application restrictors capable of closing ow completely should be
used so that as each heater is set in turn, the other heaters in the installation
may be isolated.
NOTE - In this application it is advisable, especially where low ow rates exist, to
plumb the cold manifold in 22mm pipe with 15mm pipe spurs to each heater.
B - RESTRICTORS F - PRESSURE REDUCING VALVE (FITTED FOR 7kW VERSION ONLY)
D - EXPANSION RELIEF VALVES G - COLD WATER SUPPLY MANIFOLD
E - SERVICE STOP VALVE H - HOT WATER SUPPLY MANIFOLD
B
D
EG
H
Figure 6
F

12
7.0 FAULT FINDING
YOUR SANTON POWERPACK SHOULD GIVE TROUBLE FREE OPERATION.
HOWEVER SHOULD A FAULT OCCUR THE TABLE BELOW SHOULD ALLOW
MOST FAULTS TO BE IDENTIFIED. FAULT FINDING SHOULD ONLY BE CAR-
RIED OUT BY A COMPETENT PERSON.
SYMPTOM POSSIBLE CAUSE REMEDY
1. Water too hot A. Water flow too low Increase the flow by turning the water control
2. Water too cold A. Electrical power to Ensure that the electrical supply to the power pack is
the power pack heater switched on and the neon is lit
is off
B. Water flow too high Reduce the flow by adjusting the water control
isolating valve
C. Element fault Check for open circuit
3. Temperature A. Pressure switch is Check water pressure/flow
varies while operating,
showering, normally making a
cycling "click" as it does so
hot/cold B. Input pressure is Ensure that your stop cock and servicing
below 1.0 bar valve are opened fully
(14.5psi); flow is
not stable
4. "Power on" A. Cartridge fuse or Switch off power pack and isolating switch.
indicator not lit. miniture circuit Renew fuse, reset the mcb. If they operate
Isolating switch breaker (mcb) has a second time, contact a qualified electrician
"ON" but its operated in your
neon not lit fusebox (or
consumer unit) or
switch fuse
B. Residual current Follow the same procedure as above. If this
device (rcd) or has happened with a "split load" consumer
(earth leakage unit on initial installation, check that the
circuit breaker) neutral core of the Power Pack feed cable is
has operated connected to the "protected" neutral bar of the unit
5. Water emerges A. Expansion relief valve 1. Switch off immediately at isolating switch
from expansion has operated 2. Turn water off at the servicing valve (if fitted)
relief valve or stop valve
3. Contact Santon Service Department
6. No water flows A. Water supply turned Turn on water supply
with valve open off
B. Unit frozen
Turn OFF ELECTRICITY at isolating switch and
contact installer DO NOT USE THE POWER PACK

Multipoint
13
13
The following comprehensive list of spare parts is available for your Santon
PowerPack. Please refer to the rating label on the side of your heater before ordering
to ensure the correct spare part is obtained.
DO NO REPLACE WITH PARTS NOT RECOMMENDED BY SANTON, AS
THIS WILL INVALIDATE YOUR GUARANTEE AND MAY RENDER THE
INSTALLATION DANGEROUS.
DESCRIPTION CODE NO.
1. Heat Exchanger Assembly 7.0kW.......................................... 95 606 965
Heat Exchanger Assembly 9.0kW.......................................... 95 606 966
Heat Exchanger Assembly 12.0kW........................................ 95 606 970
2. Temperature limiter 1.............................................................. 95 612 035
3. Temperature limiter 2.............................................................. 95 612 036
4. Pressure Differential Switch Assembly 7kW.......................... 95 613 005
Pressure Differential Switch Assembly 9kW.......................... 95 613 004
Pressure Differential Switch Assembly 12kW........................ 95 613 006
5. PowerPack Cover................................................................... 95 614 107
6. Neon Assembly....................................................................... 95 615 058
7. Inlet Boss Assembly................................................................ 95 607 106
8. Outlet Boss Assembly............................................................. 95 607 109
9. Terminal Block....................................................................... 95 607 249
8.0 SPARE PARTS
1
234
5
6
7
8
Figure 7
9

14
This product is guaranteed against faulty materials and manufacture for a period of
two years from the date of purchase provided that:
1 The unit has been installed by a competent person in accordance with the
Installation, User Instructions, all relevant Codes of Practice, Regulations in
force at the time of installation and that all necessary controls and safety
valves have been tted correctly.
2 Any valves and controls are of the Santon recommended type and specication.
3 The appliance has not been modied or tampered with in any way, and has been
regularly maintained as detailed in the Installation and User Instructions.
4 The appliance has been used only for heating potable water.
The appliance is not guaranteed against damage by frost, and the inner container with
integral heating element is not guaranteed against excessive scale build-up.
This guarantee in no way affects the statutory rights of the consumer.
The policy of Santon is one of continuous product development and, as such, we
reserve the right to change specications without notice.
Environmental Information
Santon products are manufactured from many recyclable materials.
At the end of their useful life they should be disposed of at a Local Authority
Recycling Centre in order to realise the full environmental benets.
9.0 Guarantee

Multipoint
15
15
Notes:
__________________________________________________________

16
Hurricane Way,
Norwich,
Norfolk, NR6 6EA.
www.santon.co.uk
Electric Water Heating Co.
2 Horsecroft Place, Pinnacles
Harlow, Essex, CM19 5BT
Tel: [phone]
E-Mail: [email protected]
SPD
Units 9 & 10 Hexagon Business Centre
Springeld Road, Hayes
Middlesex, UB40 0TY
Tel: [phone]
Parts Center
Tel: [phone]
www.partscenter.co.uk
Newey & Eyre
Specialist Products Division
Please contact your local branch
UK Spares Ltd.
Tower Lane, Warmley
Bristol, BS30 8XT
Tel: [phone]
William Wilson Ltd.
Unit 3A, 780 South Street
Whiteinch, Glasgow, G14 OSY
Tel: [phone]
© 2009
Spares Stockists
Sales Tel: [phone]
Sales Fax: [phone]
Service Tel: [phone]
Service Fax: [phone]
ServiceEmail: santonservice@
heateam.co.uk
®