THERMAL INTEGRATION Amazon HXINUV User manual

Amazon HXINUV, Installation Instructions A1 28/06/2019
Amazon HXINUV
Installation Instructions A1

Amazon HXINUV, Installation Instructions A1, 28th June 2019
Amazon HXINUV, Installation Instructions A1
Wiki Binder, 28th June 2019
About Thermal Integration ................................................ 3
Drawing ............................................................. 4
Overview ............................................................ 5
Operation ............................................................ 6
Plumbing ............................................................ 7
Wiring .............................................................. 8
Commissioning ........................................................ 9
Tables ............................................................. 10
Component Data Sheets ................................................. 11
General Plumbing Requirements .......................................... 12
General Wiring Requirements ............................................ 13
Commissioning Checklist ................................................ 14
Warranty Information .................................................. 15
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
About Thermal Integration
About Us
We design and manufacture pre-fabricated Hot Water and Central Heating Cylinders, Thermal Stores, Buffer Tanks and Heat Interface
Units to suit almost any domestic or commercial application. Our range of products is the end result of over 20 years of continuous
development and improvement in heating technology. We hold to the philosophy that all customers deserve our best level of service for
the life of the product, as well as complete honesty throughout the product selection process. We hold a significant number of patents
in the fields of water storage, heat exchange, and the networking of communal heating systems, and continue to push the boundaries.
As well as the most comprehensive range of hot water systems in the UK, our headquarters in Sudbury also offers the UKs largest
renewables training centre, including the first HETAS training and test centre, with working wood, pellet and log biomass rigs, as well
as solar. There is also an extensive district heating demonstration and test facility attached to the factory, with the factory building
services running from a twin pellet biomass boiler installation, buffer storage, and HIUs to provide services. The entire facility is
controlled using our in-house IHIU Control Systems that allow any of our products to be network connected, with online monitoring and
dashboard facilities.
For a complete history of the company please read History of Thermal Integration Limited on Heatweb Wiki.
Product Range
Heat Interface Units
Standard Cylinders
Shortened Cylinders
Buffer Cylinders
Combination Cylinders
Mains Pressure Thermal Stores
Mains Hot Water Conversion Kits
Prefabricated Systems
Plate Heat Exchangers
Boiler Conversion Kits
Control Systems
Knowledge Base
To make the dissemination of technical material as simple as possible, we publish all our documentation through an online document
storage system, the Heatweb Wiki. Links to further information may be found throughout documents.
Useful Contacts
Commercial Sales and Operations: 0845 2411441
Specflue Sales: 0333 9997974
Web Sites
http://www.heatweb.co.uk Company Website
http://www.systemdesigner.co.uk System Designer
http://wiki.heatweb.com/wiki Heatweb Wiki
http://www.heatweb.info Monitoring software and online APIs
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Drawing
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Overview
The HXINUV plate heat exchanger assembly as fitted to unvented hot water cylinders (Telford Tempest) enables faster heat up and
recovery times than possible with most conventional indirect coil type cylinders, as the full output of the boiler or primary heat source
can be utilised as an instantaneous water heater. Heat up times are further reduced by feeding the Domestic Hot Water (DHW), as it is
created, directly into the top part of the cylinder. This enables greater performance to be achieved than standard from a given cylinder
capacity; alternatively, it allows a smaller than standard cylinder to be used where space is restricted.
The HXINUV will be supplied pre-plumbed and wired to the Tempest unvented cylinder in either single or twin cylinder variants.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Operation
The HXINUV assembly uses two cylinder thermostats linked together on a latch to provide a buffered mode of operation for the heating
of the cylinder. The Buffer On thermostat is the standard dual control/safety thermostat fitted to the cylinder itself (which includes a
high limit overheat cut-out facility). The Buffer Off thermostat is teed into the plate heat exchanger assembly. This dual thermostat
arrangement allows a minimum set volume of water to be heated which helps reduce cycling of the boiler - this can be an issue with
conventional single thermostat systems - and thus the dual thermostat aids boiler efficiency.
When the cylinder temperature at the 'Buffer Off' position drops below its set point, it energises the 'Buffer On' thermostat; If this is
simultaneously calling for heat it turns the plate heat exchanger pump on. In parallel, this calls for heat from the boiler or heat source
via the two port energy cut out motorised valve. Primary heat from the boiler now flows down through one channel of the plate heat
exchanger; in counter-current, cool water from the base of the cylinder and/or cold mains water is drawn upwards through the other
channel. The cool water is heated and DHW passes out and into the top part of the cylinder. Heating of the cylinder continues until both
the buffer thermostats are satisfied.
A DHW temperature control valve modulates the primary heat flow in response to the DHW temperature observed exiting from the
plate heat exchanger, in order to maintain the stored DHW at the required set point. As the DHW flowing away from the plate heat
exchanger approaches the required setpoint temperature, the control valve reduces the primary flow, and vice versa.
A DHW flow setter controls the flow rate of DHW being created and fed into the cylinder. The set point of this component is defined by
the size of the available primary heat source and is adjusted during commissioning. In order to achieve the required flow rate it may be
necessary to adjust the plate heat exchanger pump speed as required.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Plumbing
The cylinder will be supplied with the plate heat exchanger and bronze pump pre-plumbed, and pre-wired with the buffering and safety
thermostats. The inlet control set, expansion vessel and 2 Port energy cut out valve (parts supplied loose) should be installed as per the
cylinder manufacturers Instructions. Expansion and Temperature / Pressure relief valves should be connected to discharge pipework
(via the tundish) which must be installed in accordance with Building Regulations Document G, as described in the cylinder
Manufacturers Instructions.
Consideration must be given by the installer to the primary flow and return temperature delta and flow rates of the boiler plant or
primary heat source that is to be connected. The set up and operation of the unit assumes a delta on the Cold Water Mains in /
Domestic Hot Water out sides of the plate heat exchanger of 50C in a single pass. The resultant delta on the primary side can be in the
region of 40 - 45C and flow rates of 15 - 35 Litres/min., dependent on the power of the heat source and its flow temperature. If the
connected plant or heat source cannot operate with these deltas or flow rates, suitable bypass and flow regulation equipment must be
sourced and fitted by the installer upstream of the plate heat exchanger, to accommodate this.
For twin cylinder variants Only:Take note that the cold supply will need to be cross-connected to both cylinders at the cold inlet
connections at their base; and a further connection made between the DHW output of the pre-assembled plate heat exchanger, and the
secondary return connection of the second cylinder using the pipework & second flow setter assembly (supplied loose). The image
below is indicative of the resulting assembly. Refer to Section Commissioning for adjustment of the flow setters. Note that in this
instance, the total required flow rate for the system must be split equally across the two components.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Wiring
Refer to the wiring diagram above: The two buffering cylinder thermostats, relay and plate heat exchanger pump are pre-wired.
Additional boiler and heating controls can then be wired to the fitted wiring centre as shown to achieve the required installation. It is
suggested that the permanent Live, Neutral & Earth for the boiler (and space heating controls if fitted) are all taken from the wiring
centre in order to balance with the switched live outputs to both the boiler when called, and zone control for space heating, and provide
a single point of isolation for the DHW and CH plan; however the installer may choose to derive their own solution, in which case it is
imperative that suitable labelling is provided to indicate which circuits/components may remain live if the cylinder supply is isolated.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Commissioning
Having completed the installation of the cylinder as per the manufacturers instructions, and filled it, the set up of the temperature and
flow controls can be undertaken as follows:
1. The two cylinder thermostats should be set as follows:
Dual thermostat on cylinder: 50C
ICT thermostat teed off heat exchanger: 55C
2. Next, refer to either Tables A or B to establish the correct flow rate adjustment for the DHW flow on the DHW flow setter - this will
be dependent on the available power from the connected boiler or primary heat source; It is assumed that an appropriately sized
heat source is being connected to the cylinder being installed - if in doubt, contact your cylinder supplier.
The standard 50KW version of the cylinder uses a RAVK valve, whilst the 100KW version uses a AVTB valve for thermostatic
control of the DHW temperature being produced see attached data sheets for further identification.
The calculated temperature rise across the plate heat exchanger assumes a cold mains water inlet of 10 degrees and a DHW
output to the cylinders of 60 degrees. NOTE: The stated flow rate described in Tables A & B is the total flow from the plate heat
exchanger into the cylinder. In a twin cylinder installation, this flow must be divided equally between the two cylinders - e.g: for
a 35KW boiler, required flow rate is 10 Litres/min. Therefore each flow setter to be set to 5 Litres/min.
Turn the DHW timer / programmer to create a demand for DHW from the cylinder and set the correct flow rate on the flow
setter:
Adjustment of the Taconova Flow Setters.
The flow measurement is based on the principle of a baffle float with return spring. The flowmeter is built into the housing. The
balancing can be carried out with a screwdriver at the adjusting screw. The reading position is the bottom line of the baffle
float."
3. The DHW temperature control valve (RAVK or AVTB) is to be set such that 60C is observed at the DHW outlet from the heat
exchanger (where the capillary tube from the valve is fitted), and entering the cylinder. This equates to a setting on the adjustment
knob of between 4 and 5. Final checking should be done using a suitable temperature sensor / probe on the pipework above the
flowsetter.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Tables
TABLE A: DHW flow setter values Vs. Boiler output - 50KW version
Boiler output
(KW) Temperature rise Flow rate (L/min)
10 50 2.9
15 50 4.3
20 50 5.7
25 50 7.1
30 50 8.6
35 50 10
40 50 11.4
45 50 12.9
50 50 14.3
TABLE B: DHW flow setter values Vs. Boiler output - 100KW version
Boiler output
(KW) Temperature rise Flow rate (L/min)
50 50 14.3
55 50 15.7
60 50 17.1
65 50 18.6
70 50 20
75 50 21.4
80 50 22.9
85 50 24.3
90 50 25.7
95 50 27.1
100 50 28.6
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Component Data Sheets
The following datasheets are sent with the Amazon HXIN Unvented DHW Cylinder, and can also be found on our Wiki site,
http://www.heatweb.co.uk/w
RAVK Data Sheet
AVTB Data Sheet
Flow Setter Data Sheet
Wilo SB30 Bronze Pump
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
General Plumbing Requirements
NEW COMPLETE SYSTEM INSTALLATIONS: When carrying out a completely new heating system installation in a new build
property or a first time installation in an existing property, then the heating system must conform to current building regulations Part
L1a. All new domestic heating systems must have a minimum of two heating zones. Each of these zones should be controlled by a
thermostat and zone valve. Alternatively individual electronically controlled Thermostatic Radiator Valves may be fitted. If domestic
hot water is provided by a storage system then the storage system or cylinder will require separate time and temperature control.
All radiators must have TRV's fitted in all rooms except bathrooms and any rooms where a thermostat is located. The exception to this
are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling
can be controlled as one zone.
EXISTING INSTALLATIONS: When carrying out boiler replacements on an existing system, the regulations do not require separate
zoning of the upstairs and downstairs and compliance with the regulations can be achieved by a single room thermostat or
programmable room thermostat. It is however recommended that TRV's are fitted to all rooms except the bathrooms and the room
where a thermostat is located.
The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building
Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document
635 (The Electricity at Work Regulations 1989) and any other local requirements.
BRITISH & IRISH STANDARDS Where no specific instruction is given, reference should be made to the relevant British and/or Irish
Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
EN12828 Central heating for domestic premises
BS7593 Treatment of water in domestic hot water central heating systems
ECTI National rules for electrical installations
POTABLE WATER: All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic
water system must be approved by WRAS.
FITTING AND MODIFICATIONS: Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer. Any misuse or unauthorised modifications to the appliance or associated components and systems could invalidate the
guarantee and may lead to serious injury or even death. The manufacturer accepts no liability arising from any such actions, excluding
statutory rights.
SERVICING: The end user should be advised to have the system serviced annually by a competent engineer. Contact Thermal
Integration Ltd for a list of approved engineers. Approved spares must be used to help maintain the economy, safety and reliability of
the appliance. The service engineer must complete the Service Record after each service.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
General Wiring Requirements
These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. Component specific
electrical information may also be supplied in support of these instructions, however if there is any doubt please contact Thermal
Integration Ltd. (Tel: [phone])
FAILURE TO INSTALL APPLIANCES CORRECTLY COULD LEAD TO PROSECUTION.
The appliance must be installed in accordance with, and comply to, the current: IEE Regulations, Building Regulations, Building
Standards (Scotland) (Consolidation), Building Regulations (Northern Ireland), local water by-laws, Health & Safety Document
635 (The Electricity at Work Regulations 1989) and any other local requirements.
BRITISH & IRISH STANDARDS: Where no specific instruction is given, reference should be made to the relevant British and/or Irish
Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
EN12828 Central heating for domestic premises
BS7593 Treatment of water in domestic hot water central heating systems
ECTI National rules for electrical installations
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
Danger of short circuit: When connecting the cables ensure that no cable pieces fall inside the control panel.
The Mains supply to the appliance must be through a fused double pole isolator situated next to the appliance. The isolator must have a
contact separation of 3mm minimum in all poles and should isolate the appliance and all associated controls.
Unless otherwise stated, all Heat Interface Units should be connected to a mains 230V 50Hz Supply fused at 3 Amps.
All electrical connections with the Heat Interface Unit control panel are clearly marked as follows:
L = Live 230V
N = Neutral
E = Earth
Any additional mains cable should comply fully with the current I.E.E. wiring regulations. It must have a minimum section of 0.75mm2
and be capable of withstanding a minimum of 85C.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Commissioning Checklist
Please return this form to: Thermal Integration Ltd., 8 Curzon Road, Sudbury, Suffolk, CO10 2XW. Tel: [phone]
The Installer should fill out the following section before leaving this form with the end user.
The End User should fill out the following section before returning this form to Thermal Integration Ltd.
Failure to return this form may jeopardise the warranty on this system.
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Amazon HXINUV, Installation Instructions A1, 28th June 2019
Warranty Information
Stainless Steel Cylinders carry the following guarantees as standard:
FACTORY WARRANTY
1. The warranty begins on the date of delivery. A dated delivery note will be issued to the customer and a copy will be stored by Thermal
integration.
2. 1 Year Parts and labour - Parts or labour proven to be defective will be replaced / repaired free of charge for a period of 12 months
from date of delivery, provided the cylinder is installed by a qualified engineer within 6 months of date of delivery.
2 Years Parts Only - Parts proven to be defective will be supplied free of charge (for fitting by others) for a period of 24 months
from date of delivery.
25 Years on the base unit against leaks - Stainless Steel cylinder bodies are guaranteed against perforation / leakage for a period
of 25 years from date of delivery. (Cylinder bosses and welds are excluded from this guarantee)
3. Replacement of parts under warranty does not extend the duration of the warranty
4. Any other costs are not covered by this warranty. All other damages of any nature whatsoever and howsoever arising, are expressly
excluded from this guarantee.
5. The warranty conditions above only apply:
a. In the UK only on items provided exclusively by Thermal Integration.
b. If the product is installed by a qualified engineer in compliance with the installation instructions.
c. The installer must complete the commissioning checklist in full at the time the cylinder is installed. The end user must also
complete the relevant sections of this checklist and it must be returned to Thermal Integration within 30 days of commissioning.
Checklists are enclosed in the installation instructions.
d. If the installation complies with all current and relevant building regulations and codes of practice (including the requirement to
clean the primary and secondary heating systems and add corrosion inhibitor in line with BS7593:2006)
e. If the product is used and maintained exclusively according to the manufacturer's instructions with proof that the system has
been protected with a suitable corrosion inhibitor, and all additions of inhibitor are clearly recorder (date and quantity) on the
system, using labels supplied with the inhibitor.
f. If the returned item is accompanied by a fully completed Thermal Integration Warranty Return Form.
6. Excluded are defects caused by:
a. Failure to maintain in accordance with manufacturers instructions.
b. Improper use.
c. Any attempt at repairs / maintenance by un-qualified persons.
d. where parts other than Thermal Integration Genuine Parts have been used in any service or repair.
e. Lightning, fire or natural disasters.
f. Deterioration and / or pollution from the heating system or water network, either domestic hot water or heating side.
g. Harmful additives to the heating water.
h. Consumables as specified by us, including but not limited to: hoses, gaskets and batteries.
i. Damage arising from faulty site installation or wiring.
7. Report any faults to your installer, service engineer or Thermal Integration directly. Faulty parts must be accompanied by a fully
completed Thermal Integration Warranty Return form, to be returned to Thermal Integration. Returned items remain the property of
Thermal Integration Ltd.
The Thermal Integration Warranty Return Form can be requested by phone or email. Returns are not accepted unless expressly agreed
in writing.
Transport risk of returned items lies with the sender. The shipping of replacement parts are the responsibility of the supplier.
8. If the cylinder or any component thereof breaks down, we may ask you to pay us a deposit before we repair or replace it. We will
return the deposit in full if we find a fault that is covered by this warranty. We may keep the deposit if we cannot access your property
at the time we had arranged with you to visit or we find other conditions of this warranty have not been met. A responsible adult must
be at the property to give our engineer this access to the cylinder.
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