Telford Tornado Stainless User manual

WATERHEATER MANUFACTURERS ASSOCIATION
Tel [phone] Fax [phone]
Furrows Business Park, Haybridge Road
Wellington, Telford, Shropshire TF1 2FE
www.telford-group.com
NEW TORNADO/TEMPEST 25336 19/4/05 12:25 PM Page 1

PRODUCTS
STAINLESS
Tornado & Tempest Stainless™
Installation Guide
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PRODUCTS
STAINLESS
2
MAINS PRESSURE DOMESTIC HOT WATER APPLIANCE
STORAGE
CAPACITY
IN LITRES
90
125
150
170
200
250
300
Tempest & Tornado Stainless
Mains pressure domestic hot water cylinder
WARNING TO USER:
This appliance must be serviced annually by a competent person.
Failure to comply with the above will invalidate the manufacturer’s
warranty.
Do not remove or adjust any component part of this unvented
water heater: Contact the installer.
If this unvented water heater develops a fault, such as a flow of hot
water from the discharge pipe, switch the heater off and contact
the installer.
WARNING TO INSTALLER:
This installation is subject to building regulation approval, notify
Local Authority of intention to install.
Use only manufacturer’s recommended replacement parts.
Installed by:
Name: ..................................................................................
Address: ..............................................................................
.............................................................................................
Tel. No.: ...............................................................................
Completion Date: .................................................................
Water Supply Pressure
Max
12 Bar
Min
1.5Bar
Electric Immersion Heaters
14“/3kW • 230V AC
Operating Pressure
3 BAR
Expansion Vessel charge Pressure
3 BAR
Expansion relief valve setting
5 BAR
Pressure & Temperature relief valve setting
7 BAR • 90ºC
Maximum Primary working Pressure
3 BAR
APPLIANCE SERIAL NO:
Weight and litre capacity
Indirect Direct
Technical help line: 01952 257961
Telford Copper Cylinders Limited Unit 22 Furrows Business Park Telford TF1 2FE
WEIGHT
WHEN FULL
IN KGS
125
165
195
220
250
310
360
Ltrs Kgs
NEW TORNADO/TEMPEST 25336 19/4/05 12:25 PM Page 3

Date Parts Engineer/
Replaced Company
Installed and
Commissioned
First Annual
Service
Third Annual
Service
Fourth Annual
Service
Fifth Annual
Service
Sixth Annual
Service
Seventh Annual
Service
Eighth Annual
Service
Ninth Annual
Service
Tenth Annual
Service
PRODUCTS
STAINLESS
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14
SYMPTOM POSSIBLE ACTION
CAUSES
No flow
Low Pressure
Intermittent discharge
from P&T or P valve(s)
Continuous
discharge from
P&T or P valve(s)
Mains service valve not open
Blocked filter.
Service valve not fully open or
partially blocked filter.
Restricted delivery pipework
Low mains pressure.
Expansion vessel pressure below
3.0 bar or faulty.
Wrongly set or faulty Inlet Pressure
Reducing Valve.
Defective expansion relief valve or
debris or scale on seating of valve.
Defective or incorrectly set cylinder
thermostat (ie temperature set too
high) allowing water to overheat.
Crossflow from uncontrolled cold
water mains supply to mixer tap or
shower valves.
Faulty expansion vessel.
Open stop valve or replace.
Clean filter in base of Pressure
Reducing Valve.
Ensure service valve is fully open or
clean filter in PRV.
Replace damaged or
old pipework.
Check incoming mains pressure or
discuss with local water supplier
Replenish or replace in accordance
with instructions in the maintenance
section.
Replace PRV
Operate expansion relief valve
mechanism to clear debris.
If discharge does not stop replace
expansion relief valve.
Check setting and operation of
cylinder thermostat (55-65oC).
Replace if necessary.
Check mixer taps and shower valve
and fit check valves or area
pressure controls if required.
Alternatively supply cold water to
mixer tap or shower valves from
balanced supply position on inlet
control set.
Recharge or replace.
Water fails to heat
Not enough
hot water
Water not
hot enough
Water fails to heat
Boiler not working. Pump and/or
control valve not operating.
Cylinder thermostat upper limit stat
has operated.
Cylinder too small.
Boiler not providing enough heat.
Cylinder thermostat settings
incorrect.
Upper limit cut-out switch has
operated in immersion heater.
Check boiler controls.
Check control functions and
replace faulty parts.
Reset the button on the dual
cylinder thermostat after
investigating cause of overheating.
Check storage specification is
adequate. Telford Service
Department can help.
Adjust thermostat to between 55oC
and 65oC. Ensure boiler
thermostat is set to above 75oC.
Turn off electricity supply, open
cap of I/H and reset cut-out
(red button) or press external reset
button if fitted.
PROBLEM Solving:
INDIRECT
DIRECT
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3
Tornado
Stainless
Tempest
Stainless
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4
STEP 1
Read this instruction book carefully before proceeding. A Tornado and Tempest Stainless™
cylinder is a mains pressure product and is unvented. Unvented hot water systems should
only be fitted and serviced by competent persons, as defined by the current
edition of the Building Regulations (England and Wales) Approved Document G or
equivalent regulations.
Tornado Stainless has an integrated expansion vessel. Tempest Stainless has a separate
expansion vessel to reduce the height of the unit. Please verify which model you have
before proceeding with the installation.
The unit must be stored in an upright and dry place before installation.
Only use the components supplied with the Tornado and Tempest Stainless.™ Failure to do so
is potentially dangerous and will invalidate the product guarantee.
The Tornado and Tempest Stainless™ should be fitted to the mains water supply through
the Inlet Control Group supplied. It must only be used with a pumped primary supply and
with mains quality water.
The standard Tornado and Tempest Stainless™ cannot be used with solid fuel boilers.
Please contact our Technical Helpline for further assistance on these applications.
Tornado and Tempest Stainless™ mains pressure systems require an annual safety check
by a competent person. Failure to carry out this safety check may invalidate the
warranty.
Use only approved DZR brass compression fittings for cylinder connections.
STEP 2
Measure the area in which you plan to install the Tornado and Tempest Stainless™ and ensure that the floor
can support the weight of the cylinder when full.
Heat-up and re-heat times are for indirect models. All dimensions and weights are nominal.
Tornado and Tempest Stainless™ is designed to work efficiently under any water flow and pressure conditions.
However, the full potential of a mains pressure system is unlikely to be achieved if the flow falls below 20
1/min and the dynamic pressure is less than 1.5 bar. Telford Water Heaters can supply a range of products for
improving pressures and flows if required. A minimum of 300mm clear space should be left above the Tornado
Stainless for maintenance.
Capacity
(litres)
90
125
150
170
200
250
300
Weight
When Full (Kgs)
125
165
195
220
250
310
360
Tornado
Stainless
Overall Height
(mm)
N/A
1350
1540
1780
1600
1920
2140
Tempest
Stainless
Overall Height
(mm)
750
950
1075
1225
1175
1375
1520
External
Diameter
(mm)
520
520
520
520
570
570
570
Heat Up Time
0 - 60°C
(mins)
26
36
37
36
33
35
40
Re-Heat Time to
60°C after 70%
Draw Off (mins)
18
25
26
25
24
25
29
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13
PIPE WORK LOGIC LAYOUTS
S - PLAN SYSTEM
CYLINDER
VALVE HEATING
VALVE
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12
S-PLAN WIRING LAYOUT
AND SYSTEMS SCHEMATIC
ENL
FUSED SWITCH
230V/50 hz
WIRING CENTRE
L
N
E
4
5
6
7
8
9
10
2 CHANNEL
TIME CONTROL
L
N
E
HEAT
WATER
NOTE
1-10
ARE LINKED
PUMP
9
N
EE
N
9
9
2
3
1
S/LIVE
N
E
PERM LIVE
IF REQUIRED
BOILER
HIGH
LIMIT DUAL
CYLINDER
STAT
STORE
6
8
4
5
ROOM
STAT
CYLINDER
VALVE
8
2
10
9
GRYBN
GRYB
2
10
5
9
N
HEATING
VALVE
THE BOX NUMBERS INDICATE
THE POSITION ON WIRE CENTRE
COLOUR CODES
BROWN = BR
ORANGE = ORG
GREY = GRY
BLUE = N (NEUT)
EARTHS ARE NOT DRAWN
INSTALL AS NECESSARY
NOTE
THE CONTROLS PROVIDED MUST BE USED
ONE IMMERSION HEATER REQUIRES A 16 AMP SUPPLY.
TWO IMMERSION HEATERS REQUIRE A 32 AMP SUPPLY.
FAILURE TO INSTALL WILL INVALIDATE GUARANTEE
DRAWING SHOWS
“S” PLAN SYSTEM WITH DANFOSS CONTROLS
BR
BR
ORG
ORG
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5
22mm Cold feed connections.*
22mm Boiler flow and return.*
(indirect versions only).
22mm Hot water draw off connections.*
Immersion Heater (two on direct versions).
Position for cylinder thermostat.
Pressure Temperature Relief Valve.
Secondary return - STD on 200 - 300 litre models.
*Connections 1, 2, 3 & 7 are plain pipes and require
compression fittings (not supplied)
Components supplied for fitting on site:
Inlet Control Group
(comprising of a pressure reducing
valve set to 3.0 bar, single check valve, filter and
expansion valve set to 5.0 bar).
Cylinder thermostat (indirect models only). Factory Fitted
Energy cut out valve (indirect models only).
Tundish.
Integrated into case of Tornado Stainless. Supplied for site fitting
with Tempest Stainless.
Expansion vessel (8 litre on 90 litre models, 1 2 litre on 125 & 150 litre models,
18L on 170 & 200 litre models, and 24 litre on 250 & 300 litre models).
To prevent damage to the coil and cylinder connections, make all soldered
joints before connecting pipework to the Tornado and Tempest Stainless.™
Position the unit vertically and make the incoming cold water connection
to the fitting labelled “mains water inlet”. For commissioning and later
maintenance purposes it is essential to fit a service valve immediately
before the connection to the Inlet Control Group.
Installing the Inlet Control Group
The incoming cold water should first pass through the pressure reducing valve, which reduces the
pressure to 3.0 bar - this is factory set and should not be adjusted - and then through the
expansion valve (factory pre-set to 5.0 bar). The Inlet Control Group also includes a single check
valve and filter.
*NB Upon commissioning if the incoming pressure is less than 3.0 bar, the expansion vessel
pressure, should be adjusted to 0.2 bar less than the incoming water pressure.
Ensure that the Inlet Control Group is fitted immediately adjacent to the Tornado Stainless™ with
the arrows on the side pointing in the same direction as the flow. It must be no further away than
500mm and have no devices or connections/draw offs between it and the cylinder. Balanced
supplies for showers and mixer taps only should be taken from the appropriate connection on the
Inlet Control Group (see illustration). Water regulations require that a single check valve should be
fitted in the balanced draw off to prevent back flow. The inlet group supplied incorporates a
single check within the body of the group.
The expansion vessel for the Tempest Stainless must be fitted between the inlet control group and
the unit (see illustration)
A suitable means for draining the unit must be incorporated into the cold feed
(see illustration) - Positioning the drain as suggested will allow a minimum of 80% of the
cylinder to be drained off.
STEP 3 (all cylinders)
Inlet group with expansion vessel
position (Tempest only) also shows
drain off position and balanced supply
1
2
3
4
5
6
7
12
4
5
2
7
6
37
Tornado Stainless Tempest Stainless
3
6
2
5
4
2
1
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6
STEP 4 (all cylinders)
Connect the discharge pipework and tundish to the valve labelled “P&T” The tundish should be
connected to the cylinder using 15mm metal pipe.
The tundish (supplied) must be fitted within 500mm of the outlet of the P&T valve and have at least
300mm of straight metal pipe below it, before any elbow or bend.
The pipework below the tundish should be fitted in accordance with the current edition of the
Building Regulations
(see page 7). As a minimum this must be 22mm on all Tornado and Tempest
Stainless™ models.
The discharge from the expansion valve on the Inlet Control Group must be connected into the
discharge pipe work.
For good practice purpose a double check valve should be fitted to the hot water draw off to
prevent any back pressure.
STEP 5 (indirect cylinders only)
Connect the boiler flow and return to the labelled connections. Before making the connections
ensure that the coil is free from obstructions by blowing through it.
The Energy Cut Out valve is an essential part of the safety requirements
for indirect mains pressure cylinders and should be installed on the
primary flow to the cylinder with port ‘B’
(embossed on side of valve body)
to the cylinder. The valve will open and close on receiving a signal from
the cylinder thermostat. No further control is required for the hot water
in a two zone valve system. This valve must also be used in a flow
share (Y Plan) system, in conjunction with the mid-position valve,
to act as a safety cut out valve.
The cylinder thermostat controls the temperature of the hot water and
also acts as an emergency cut out in the event that the boiler
temperature controls fail. The cylinder thermostat is fitted into the
pocket labelled “Store Temp Control” in the cylinder, and should be
connected to operate the energy cut out valve in accordance with the
wiring diagram for the scheme being installed
(see pages 12 and 13).
STEP 6 (all cylinders)
Connect hot water draw off to connection labelled “Hot Water Taps”.
NB: If the secondary circulation system contains more than 15 litres of water a separate
expansion vessel must be provided to compensate for the larger stored volume.
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11
Lifetime Guarantee:
The Stainless™ steel vessel carries a lifetime guarantee against faulty manufacture or materials,
provided that:
The product is used solely for the storage of mains quality potable water.
The product has not been modified or tampered with.
The product has been installed and maintained in accordance with the installation instructions.
The product has not been subjected to damage caused by frost, or other external influence.
The Guarantee Card, supplied with the product, has been completed and returned to Telford Water
Heaters within 90 days of installation.
The immersion heater, water control valves, cylinder thermostat and energy cut out valves are guaranteed for
two years from the date of manufacture.
This guarantee is only available in the United Kingdom of Great Britain and Northern Ireland.
Claims made against our Lifetime Guarantee must be supported with evidence of purchase and the product
serial number, along with a copy of the completed Benchmark Log Book.
Your Statutory rights are not affected by this guarantee.
Exclusions to the guarantee
Any labour charges associated wih replacement of the unit or any of its components.
Any consequential losses caused by malfunction or failure of the unit.
The effects of scale build up.
Failure to carry out the annual safety check on this product will invalidate the guarantee.





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10
MAINTENANCE:
The following checks should be conducted annually:
Check the operation of the T & P valve and Expansion valve by rotating the heads of the valves in
turn until water is discharged. The discharge should stop immediately when the valve head is
released. Should this not be the case the valve should be replaced. Check that the discharged
water flows freely to waste and that there is no blockage.
Remove and clean the filter in the Pressure Reducing Valve.
The expansion vessel does not require any routine maintenance, however it is advisable to check
annually that the pre-charge pressure is 3.0 bar. However, if water is being discharged from the
expansion valve it may be indicative of pressure loss within the expansion vessel itself. To check
the pressure, isolate the unit from the cold supply and release any pressure by opening a hot tap until
water stops flowing. Then use a tyre pressure gauge to verify the pre-charge pressure. The vessel is
factory pre-charged to 3.0 bar. If the pressure is less than this it can be re-pressurised to 3.0 bar
using a suitable pump. If the unit is more than 5 years old when this problem is
experienced it may be advisable to replace the pressure vessel. If however, the pressure in the
expansion vessel is 3.0 bar, the discharge may be being caused by back pressure or cross-over
between the cold and hot water supplies - see below.
To replace the pressure vessel, unscrew from threaded connection. The new pressure vessel should
be checked to ensure it has a pre-charge of 3.0 bar, and then fitted to the cylinder, ensuring that the
threads are sealed appropriately.
Checking for back pressure
Back pressure from a faulty or uncontrolled mixer valve or appliance will cause the cylinder to over
pressurise and may result in water being discharged from the expansion valves. To check for back
pressure follow the steps below:
Turn off cold water supply to cylinder, whilst leaving cold supply to all mixer taps and
appliances connected.
Open a single hot tap, and run water for several minutes to dissipate any pressure in the cylinder,
the pressure on the gauge should be allowed to fall below 1 bar.
In turn open both the hot and cold taps on mixer valves and watch pressure on gauge. The pressure
will rise once the faulty mixer valve is opened as it will allow higher pressure cold water back into
the cylinder. The faulty mixer should then be replaced.
NB: A suitable gauge fitted to a hot tap will be needed for Tempest Stainless Models.
Use only genuine Telford replacement parts on all repairs.
NOTES ON WATER QUALITY AND SCALING:
Water hardness can vary considerably around the country. If furring of kettles normally occurs in
the area, then the unit should be fed with conditioned water only. This can be provided by a water
softener with a high capacity flow rate, or a suitable water conditioner (not supplied). It is
recommended that the temperature controls are set below 650C to prevent lime scale build up.
The performance of all water storage appliances and their associated components may
deteriorate if you do not protect adequately against hard water scaling. If more than 150ppm salts
are present in local water samples, an effective conditioner should always be used.



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7
STEP 7 (all cylinders)
Make electrical connections to the immersion heaters - see wiring diagram inside cap of
immersion heater. All electrical installations must be to IEE standards.
The immersion heaters fitted to the Tornado and Tempest Stainless™ cylinder are of a special
construction and include both a control thermostat and overheat protection. Only use genuine
replacement parts which can be obtained from a Telford Water Heaters approved merchant.
Ensure that the immersion heater control setting is set between 55°C and 65°C for economical
operation. TThe upper limit thermostat is pre-set to 80oC and must not be tampered with.
STEP 8 Commissioning & Operating
Ensure all connections are fully tightened.
Open all of the hot taps supplied by the cylinder and slowly fill the unit by opening the service valve.
Continue to fill the unit until water runs continuously from all of the open taps. Open the service
valve fully, and close all hot taps.
Check for leaks.
Heat the water to 60oC. Once the desired temperature has been reached, the cylinder should be
isolated and drained to flush out any flux/solder introduced during the installation process. The
filter in the inlet control set should be removed, cleaned and re-fitted -
see photograph.
Reheat the cylinder to desired temperature and recheck for
leaks.
For safety and energy saving reasons it is advisable to
operate the Tornado Stainless™ at a temperature between
55°C and 60°C. The boiler thermostat (indirect models only)
should be set to 75°C, or above, to achieve the best per-
formance from the Tornado Stainless™.
STEP 9
Remove the protective film from the outer case of the Tornado Stainless™ and wipe down. Place
this instruction book in a convenient place for the end user. Complete the Benchmark Log Book
and guarantee card and leave with the cylinder.
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8
Discharge - Building Regulations:
Discharge pipes must be installed in accordance with the latest edition of the Building Regulations.
Discharge Pipes
The discharge pipe (D1) from the vessel up to and including the tundish is generally supplied by
the manufacturer of the hot water storage system (see paragraph 3.5). Where otherwise, the
installation should include the discharge pipe(s) (D1) from the safety device(s). In either case the
tundish should be vertical, located in the same space as the unvented hot water storage system
and be fitted as close as possible and within 500mm of the safety device e.g. the temperature relief
valve.
The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk
to persons in the vicinity of the discharge, be of metal and:
a. be at least one pipe size larger than the normal outlet size of the safety device unless its total
equivalent hydraulic resistance exceeds that of a straight pipe 9m long i.e. discharge pipes
between 9m and 18m equivalent resistance length should be at least two sizes larger than the
nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on.
Bends must be taken into account in calculating the flow resistance. Refer to Diagram 1, Table
1 and the worked example. An alternative approach for sizing discharge pipes would be to
follow BS 6700: 1987
Specification for design installation, testing and maintenance of
services supplying water for domestic use within buildings and their curtilages,
Appendix E,
section E2 and table 21.
b. have a vertical section of pipe at least 300mm long, below the tundish before any elbows or
bends in the pipework.
c. be installed with a continuous fall.
d. have discharges visible at both the tundish and the final point of discharge but where this is not
possible or is practically difficult there should be clear visibility at one or other of these
locations. Examples of acceptable discharge arrangements are:
i. ideally below a fixed grating and above the water seal in a trapped gully.
ii. downward discharges at low level; i.e. up to 100mm above external surfaces such as car parks,
hard standings, grassed areas etc. are acceptable providing that where children may play or
otherwise come into contact with discharges a wire cage or similar guard is positioned to
prevent contact, whilst maintaining visibility.
iii. discharges at high level; e.g. into a metal hopper and metal down pipe with the end of the
discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high
temperature discharges of water and 3 m from any plastics guttering system that would
collect such discharges (tundish visible).
iv. where a single pipe serves a number of discharges, such as in blocks of flats, the number served
should be limited to not more than 6 systems so that any installation discharging can be traced
reasonably easily. The single common discharge pipe should be at least one pipe size larger
than the largest individual discharge pipe (D2) to be connected. If unvented hot water storage
systems are installed where discharges from safety devices may not beapparent i.e. in
dwellings occupied by blind, infirm or disabled people, consideration should be given to the
installation of an electronically operated device to warn when discharge takes place.
Note:
The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic
rainwater goods may be damaged by such discharges.
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DIAGRAM 1 - Typical discharge pipe arrangement
See para 3.9
safety device
(e.g. temperature
relief valve)
metal discharge pipe (D1) from
temperature relief valve to tundish
tundish
300mm
minimum
metal discharge pipe (D2) from tundish,
with continuous fall. See 3.9d i-iv,
Table 1 and worked example
Discharge below
fixed grating
(3.9d gives alternative
points of discharge)
trapped gully
Table 1 --Sizing of copper discharge pipe ‘D2’ for common temperature relief
valve outlet sizes
Valve
Outlet
Size
G1/2
G3/4
G1
Minimum Size
of Discharge
pipe D1*
15mm
22mm
28mm
Minimum Size
of Discharge
Pipe D2*
from tundish
22mm
28mm
35mm
28mm
35mm
42mm
35mm
42mm
54mm
Maximum resistance allowed,
expressed as a length of straight
pipe (i.e. no elbows or bends)
up to 9m
up to 18m
up to 27m
up to 9m
up to 18m
up to 27m
up to 9m
up to 18m
up to 27m
Resistance created by
each elbow or bend
0.8m
1.0m
1.4m
1.0m
1.4m
1.7m
1.4m
1.7m
2.3m
*see 3.5, 3.9, 3.9(a) and Diagram 1
Worked Example:-
The example below is for a G
1
/
2
temperature relief valve
with a discharge pipe (D2) having 4 no. elbows and length
of 7m from the tundish to the point of discharge.
From Table 1:
Maximum resistance allowed for a straight length of 22mm
copper discharge pipe (D2) from a G
1
/
2
temperature relief
valve is: 9.0m. Subtract the resistance for 4 No. 22mm
elbows at 0.8m each = 3.2m
Therefore the maximum permitted length equates to: 5.8m.
5.8m is less than the actual length of 7m therefore
calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm
pipe (D2) from G1/2 temperature relief valve equates to:
18m.
Subtract the resistance for 4 No. 28mm elbows at 1.0m each
= 4m.
Therefore the maximum permitted length equates to 14m.
As the actual length is 7m, a 28mm (D2) copper pipe will be
satisfactory.
9
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