Thermsaver unvented water heater User manual

unvented water heater
installation manual
3bar kit version

2
TECHNICAL DATA & INSTALLATION
INSTRUCTIONS FOR DIRECT &
INDIRECT UNVENTED WATER HEATERS
WITH EXTERNAL EXPANSION TANK
Your vessel is made by one of the worlds leading unvented water heater
manufacturers.
Your water heater is made from Duplex Stainless Steel, which is one
of the toughest and best grades of steel currently available.
Each unit has been individually tested and inspected to industry
standard.
Your water heater uses advances in technology and innovative
techniques to provide you with a high performance water heater at
the best price possible.
No other type of water heater can provide all of the benefits that
can be achieved from unvented units such as this model of
Unvented Water Heater.
IMPORTANT NOTICE FOR INSTALLATION
READ THESE INSTALLATION AND MAINTENANCE
INSTRUCTIONS BEFORE COMMENCING
UNVENTED CYLINDERS ARE DESIGNED TO BS STANDARD AND
INSTALLED TO RELEVANT BUILDING REGULATIONS
THE RELEVANT REGULATIONS ARE
ENGLAND & WALES – BUILDING REGULATION G3
SCOTLAND – TECHNICAL STANDARD P3
NORTHERN IRELAND – BUILDING REGULATION P5
AFTER INSTALLATION THE BENCHMARK LOG BOOK MUST BE
COMPLETED AND LEFT ALONG WITH THESE INSTRUCTIONS WITH
THE HOUSEHOLDER FOR FUTURE REFERENCE.
INSTALLATION INSTRUCTION MANUAL
TO BE LEFT WITH THE UNIT
CONTENTS
SPECIFIERS GUIDE
The law and unvented p3
The benefits of unvented systems p3
The benefits of unvented systems p3
Standard energy losses p4
What is supplied with your vessel?p4
INSTALLATION INSTRUCTIONS
Siting the unit p4
Check water pressure & flow rates p4
Connecting the water supply p5
Cold water valve p5
Drain tap p5
Pipework to taps p5
Secondary circulation p5
Wiring p7
Fitting immersion heaters p7
Fitting the thermal cut out & primary connections p7
Tundish p8
Commissioning the unit p8
External expansion tank p8
Scale p8
Draining p8
Discharge pipework p8
G3 Requirement p9
Problem solving p10
Spares p10
Part component references p10
Guarantee p11
DIAGRAMS
Dimensional data for DH / IDH
range of water heaters p3
Typical installation of a DH tank p5
Typical installation of a IDH tank p5
Secondary circulation connection p6
2 x 2 port (S-plan) valve system p6
2 port valve + 3 port mid position valve (y-plan) p7
Immersion heater p7
Schematic discharge pipe arrangement p8

3
WATER HEATER SPECIFIERS GUIDE
THE BENEFITS OF UNVENTED
WATER HEATERS
●Expansion vessel supplied
●Annual inspection as per warranty
●Duplex Stainless Steel
●Operates at 3bar, which is higher than some other
unvented units
●High quality finish
●Has one of the lowest heat losses for maximum economy
●No sacrificial anode - low maintenance
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All External Exposed
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All External Exposed
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THE LAW AND UNVENTED
It is legal to fit an Unvented Unit into any property. UK water
byelaws were amended to allow this change. There is no
longer a requirement to have an old-fashioned
“Tank-in-the-Roof” system.
THE BENEFITS OF UNVENTED SYSTEMS
●A real Power Shower without a noisy pump
●No tanks in the roof – no ballcocks to jam or leak – no noise
from tank filling
●All your water – hot and cold – is direct from the mains
●Site the unvented water heater wherever convenient
●Your vessel fills your bath in minutes and will run two at the
same time (subject to good plumbing and flow rates)
●The unit works off electricity (economy 7) or any oil
or gas fired boiler (not suitable for solid fuel boilers)
Dimensional data for Indirect Heat/Direct Heat range of water heaters
Direct Heat Exterior Reference Dimensions
Reference Tank Overall P&T Top Bottom Water
Volumes Height Height Valve Heater Heater In
litres mm mm mm mm mm mm
80 636 694 347 N/A 250 230
130 928 986 618 521 188 230
150 1056 1114 737 640 188 230
175 1213 1271 883 786 188 230
215 1455 1513 1108 1011 188 230
255 1723 1781 1356 1259 188 230
305 1999 2057 1613 1516 188 230
Indirect Heat Exterior Reference Dimensions
Reference Tank Overall P&T Bottom Top Bottom Temp Water Top
Volumes Height Height Valve Heater Coil Coil Monitor In Heater
litres mm mm mm mm mm mm mm mm mm
80 636 681 347 188 N/A 283 233 230 N/A
130 928 973 618 188 558 483 357 230 521
150 1056 1101 737 188 558 483 357 230 640
175 1213 1258 883 188 758 683 458 230 786
215 1455 1500 1108 188 758 683 507 230 1011
255 1723 1768 1356 188 758 683 608 230 1259
305 1999 2044 1613 188 758 683 608 230 1516

4
STANDARD ENERGY LOSSES
The heat loss of each Unvented Unit while
maintaining the temperature of the stored water at 65 degrees
Celsius. (See performance table below).
1) Tests carried out by BBA. Slight variations may occur with
changes to water mains supply pressure
Performance
Nominal Heat up Heat up Reheat Reheat Heat loss in
Capacity Model IDH Model DH Model IDH Model DH 24 hrs
Litres Mins Mins Mins Mins kw/hr
80 33 64 23 53 1.12
130 28 115 21 90 1.50
150 33 138 24 104 1.82
175 27 167 24 124 2.10
215 35 212 30 153 2.64
255 42 263 35 184 2.73
305 50 313 42 220 2.88
SITING THE UNIT
The unit can be placed anywhere convenient. Because it is
connected directly to the mains water supply it is equally efficient
on any floor – ground, first or second. Avoid areas that may be
subject to frost. Try to keep pipe runs as short as possible for
maximum economy, especially hot water discharge pipes running
down from the unit.
The unit can be fitted into a conventional airing cupboard and
does not require any additional insulation.
ALL UNVENTED VESSELS MUST BE STORED VERTICALLY
CHECK WATER PRESSURE & FLOW RATES
We suggest 1.5 bar pressure & 15 litres / minute flow rate to be the
minimum requirements for satisfactory operation. Less than this
the unit will still operate but you will not be able to run two, or
more, outlets at the same time. 85% of all U.K homes have more
than 2-bar pressure.
The mains supply must not exceed 16 bar. If it does a special
pressure-reducing valve will be required.
●1 Element on IDH indirect models up to 305 litres and 80 litre
DH direct model
●2 Elements on DH direct models from 130 up to 305 litres.
Additional elements from 215 to 305 litres are available on
request.
●Cold-water control valve comprising line strainer, check valve,
pressure reducing valve set to 3 bar
●Expansion relief valve with non return valve set at 6 bar
●Tundish 15mm x 22mm F x F
●Temperature / Pressure relief valve set at 90 degrees Celsius
and 7 bar pressure relief (factory fitted)
●Motorised valve (indirect units only)
●Cylinder thermostat-factory fitted to cylinder, maximum setting
85 degrees Celsius (indirect units only)
●Thermal cut out set to operate at 87 degrees Celsius plus or
minus 3 degrees (indirect units only)
●Expansion vessel capacity ranges as shown in the table below: -
Tank Size
80 to 130 Litres
150 to 215 Litres
255 to 305 Litres
Expansion Tank Required
12 Litres
18 Litres
25 Litres
2) These figures relate to a 45 degree differential between the
stored water and ambient temperature
WITH YOUR UNVENTED CYLINDER
THE FOLLOWING IS SUPPLIED AS STANDARD
Before commencing installation check that all the components of
your Unit are contained in the kit.
●3KW Incoloy 825 heating element-incorporating thermostat to
70 degrees Celsius and resetable safety cut out set at 80
degrees Celsius
UNVENTED INSTALLATION INSTRUCTIONS
WARNING : Under no circumstances must the factory fitted temperature pressure relief valve be removed. This will totally invalidate any
guarantee or claim.The cold-water inlet valve assembly must be fitted or the unit will not perform satisfactorily.
DO NOT ATTEMPT TO VENT THE PRIMARY CIRCUIT THROUGH THE UNIT.
All boilers should be installed to manufacturers instructions and the primary circuit through the unit must be pumped.

5
CONNECTING THE WATER SUPPLY
●Pipework is not supplied
●All pipework should be installed using good plumbing practice.
We recommend 22mm mains cold water supply is used.
●Install a Stop Cock Valve before the cold water inlet assembly on
the incoming mains water supply so the unit can be isolated if
required.
COLD WATER VALVE
The combined cold water valve (supplied) can be connected
anywhere on the cold water mains prior to the unit. It can even be
located at a point near to where the mains supply enters the
premises if this is more convenient. When installing the cold water
valve, ensure that the arrow is pointing in the same direction as the
mains water supply flow when connecting, see fig 2.
The cold water balancing port, on the valve, allows you to connect
the cold water mains to the rest of the property thus giving
balanced pressure throughout. If this facility is not required leave
the cap on.
DRAIN TAP
A drain tap to drain the unit must be fitted to the cold-water inlet
pipe somewhere between the unit and the cold water
valve assembly and at as low a level as possible, see fig. 1.
PIPEWORK TO TAPS
Ideally a 22mm pipe run should supply the outlets throughout the
property with short lengths (max 1 metre) runs of 15mm going to
baths, showers, and basin taps. Smaller bore pipe can be used to
suit taps.
SECONDARY CIRCULATION
This is particularly easy to fit on unvented units; a Swept Tee
(not supplied) is needed for all indirect models if secondary
circulation is required, see page 6 fig. 3 for fitting. A non-return
valve (not supplied) must be fitted to prevent backflow.You will
need a pump to circulate the hot water (not supplied). The return
feed is in 15mm pipe and all work can be done on site.
Fig.1
Fig.2
Typical Indir ect Tank ins tallation using e xt er nal e xpansion vessel
Cold w ater inle t valve assembly
PRESSURE REDUCING VALVE
SET AT 3 BAR
WATER FLOW INLET SIDE OF TANK
WATER FLOW FROM EXPANSION
TANK TO 22MM FEMALE THREAD
BEHIND COVER
BLANKED
PORT
WATER FLOW
HOT WATER OUTLET
PRIMARY FLOW
PRIMARY RETURN
TWIN
THERMOSTAT
IMMERSION
HEATER
WATER FLOW
TO COIL INLET
WATER FLOW
FROM COIL INLET
7 BAR / 90 DEGREES
PRESSURE &
TEMPERATURE
RELIEF VALVE.
TUNDISH
WATER FLOW
TO OVERFLOW
WATER INLET
DRAIN
COCK
SECONDARY
RETURN FLOW
SWEPT TEE
EXPANSION VESSEL
(WALL MOUNTED)
WATER FLOW TO
MANFOLD VIA
FLEXIBLE HOSE
6 BAR
EXPANSION
RELIEF
VALVE
PRESSURE
REDUCING VALVE
SET AT 3 BAR
WATER FLOW
INLET SIDE OF TANK
BLANKED
PORT
WATER FLOW
FROM EXPANSION
TANK TO 22MM
FEMALE THREAD
BEHIND COVER
6 BAR
EXPANSION
RELIEF
VALVE
BALANCED
COLD WATER
OUTLET

6
SECONDARY CIRCULATION
CONNECTION DIAGRAM
Fig.3
2 * 2 PORT (S-PLAN) VALVE SYSTEM
GUIDANCE LAYOUT ONLY
Fig.4

7
WIRING
All electrical wiring should be carried out by a registered electrical
contractor and must conform to the latest IEE wiring regulations
Do not switch the power on until the unit has been filled with
water and all wiring has been earthed, see Fig. 4 and 5.
FITTING IMMERSION HEATERS
These are supplied as standard
An ’O’ ring is supplied as the seal and must be fitted against the
flange of the element. Take care not to cross thread and DO NOT
USE any other type of seal.
Fig.5
L
N
E
As our heating element is Incoloy 825 and is fitted with a cut-out
and thermostat for safety, a non-standard 13/4" boss is fitted to the
unit. Replacements can only be obtained from your authorised
dealer.
All our heating elements have a built in manual reset cut-out.This
will operate if the immersion heater thermostat fails.
WARNING : Ensure that the immersion heater thermostat is set
at 60 degrees Celsius.
FITTING THE THERMAL CUT-OUT &
PRIMARY CONNECTIONS
The motorised valve supplied and the thermal cut-out (Hi limit
stat) must be fitted to the primary flow. Use compression
fittings only.
Operation of the cut-out and motorised valve
To comply with BBA regulations and to prevent the temperature
reaching 100 degrees Celsius the thermal cut-out supplied must be
fitted.
The thermal cut-out is wired in series to the cylinder thermostat.
When the thermal cut-out senses an abnormal rise in
temperature in the primary flow the electrical supply to the
motorised valve will be cut, and the valve will be in the closed
position thus cutting of the primary water from the boiler to the
indirect coil in the cylinder. If this occurs it must be reset
manually. If the thermal cut-out operates check the cylinder stat
and / or boiler stat.
2 PORT VALVE + 3 PORT MID POSITION
VALVE (Y-PLAN) SYSTEM
GUIDANCE LAYOUT ONLY

8
TUNDISH
The tundish supplied must be fitted visible to the occupier. The
discharge pipe must be 22mm copper pipe. Regulations do not
permit more than 3 x 90-degree bends between the unit
and the outflow. Between the temperature & pressure relief valve
and the first 90-degree bend there must be a fall of at least
300mm. The fall of the pipework must be continuous and the pipe
should terminate in the gully or be bent backwards onto an
outside wall, in a place where discharge cannot be injurious to
persons.
If you need to site the unit In the middle of the house then
your discharge pipe to the tundish can be as far away as 9m, which
in most cases is enough to run the final discharge point. After 9m,
increase the pipe size to a greater diameter than 22mm and
accordingly for subsequent 9m lengths, see table 1 on page 10.
COMMISSIONING THE UNIT
Switch on electricity to the immersion heater(s) (Direct system) or
switch on the boiler (Indirect system). Refer to the boiler
manufacturers instructions on commissioning.
Bring the unit to its maximum temperature setting of approx. 60
degrees Celsius.You should, on operating the water taps, have a
good flow of hot and cold water assuming adequate water is
supplied to the unit.
Check the water does not discharge via the tundish pipework
during heating.
Recheck all fittings/joints for possible leaks.
On completion of the installation, before turning on the mains
water supply ensure that all residual materials are removed by
means of flushing the system with a "fernox" type cleaner or
equivalent.
EXTERNAL EXPANSION TANK
This smaller tank is connected to the cold-water inlet side of the
vessel. Mount the tank according to separate manufacturers
instructions provided with the External Expansion Tank.
See fig 1 page 5.
SCALE
In hard water areas lower water temperatures can result in less
scale being deposited.
If water softener is used it should be capable of flows of approx. 50
lt/min, this will maintain maximum performance of the unvented
unit.
If no descaler or softener is used then the heating element(s) will
need descaling periodically for maximum efficiency.
DRAINING
Switch off electrical power to immersion heaters and/or shut down
the boiler. Close the stopcock valve to isolate the unit.
Attach hosepipe to the drain cock having sufficient length to take
water to a suitable discharge point.
Open drain cock
Open hot water tap nearest to the unit.
If water fails to drain from unit, vent the system by
opening the temperature pressure relief valve.
DISCHARGE PIPEWORK
It is a requirement of Building Regulations that any discharge from
an unvented system is conveyed to where it is visible, but will not
cause danger to persons in or about the building. The tundish and
discharge pipes should be fitted in accordance with the
requirements and guidance notes of Building Regulations. Building
Regulation G3 Requirements and guidance section 3.9 reproduced
in the following sections.
Information Sheet No. 33 available from the British Board of
Agreement gives further advice on discharge pipe installation. For
discharge pipe arrangements not covered by G3 Guidance or BBA
Info Sheet No. 33 advice should be sought from either your local
Building Control Officer
SCHEMATIC DISCHARGE
PIPE ARRANGEMENT
Fig.6

9
G3 REQUIREMENT
‘…there shall be precautions…to ensure that the hot water
discharged from safety devices is safely conveyed to where it is visible
but will not cause danger to persons in or about the building.’
G3 GUIDANCE SECTION 3.9
The discharge pipe (D1) from the vessel up to and including
tundish is generally supplied by the manufacturer of the hot water
storage system. 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, preferably be of metal and:
a. be at least one pipe size larger than the nominal outlet size of
the safety device unless it’s total equivalent hydraulic resistance
exceeds that of a straight pipe 9m long ie. 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 flow
resistance. Refer to Table 1 overleaf and fig. 6.
An alternative approach to 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 elbow 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 the
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 3m 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 be apparent 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.
WORKED EXAMPLE OF DISCHARGE PIPE SIZING
The example below is for a G1/2 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: (overleaf)
Maximum resistance allowed for a straight length of 22mm copper
discharge pipe (D2) from G1/2 temperature relief valve is 9.0m
Subtract the resistance for 4 No 22mm elbows at
0.8m each = 3.2m
Therefore the 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 a G1/2 temperature relief valve equates to 18m
Subtract the resistance of 4 No 28mm elbows at
1.0m each = 4.0m
Therefore the maximum permitted length equates to 14m
As the actual length is 7m a 28mm (D2) copper pipe will
be satisfactory.

10
PROBLEM SOLVING
No water in tap from the Unit
Check that mains supply is on.
Check that the line strainer is not blocked
Check that the combination valve has been fitted so that the arrow
on it faces in the direction of the water flow.
If the water at the hot tap is cold
Boiler (indirect): Ensure that the boiler has been switched on and
working correctly.
Check that no air blocks have occurred in the primary system
Check the following are all connected correctly
Cylinder Stat
Thermal cut out (Reset by pushing red button)
Motorised valve
Boiler thermostat (max setting 82 degrees Celsius)
Boiler thermal cut out (if fitted)(Reset by pushing red button)
Direct (Electric) Models
WARNING : Isolate unit at main electric supply before opening
heating element cover.
Ensure that power is available to the element from the electric
mains and that the isolator is on. If there is power to the element
and the element fails to operate check as follows:
Check that the thermal cut out on the elements have not operated.
If they have, reset by pressing the red button. If they cut out again
as the water heats up the cylinder thermostat has failed and needs
replacing. Fit a new thermostat and reset the thermal cut out.
With power on and the thermal cut out reset check the output
terminal on the thermostat. If the circuit cannot be completed, the
thermostat and/or cut out needs replacing.
Check current amps drawn by the heater, should be approx. 15
amps. If heating element fails to operate, change the complete
heating element assembly.
Important. In the event of an over heat situation reset all
thermal cutouts.
If hot water discharges from Tundish
WARNING : Do not turn the mains water supply off - switch off (1)
power to immersion heaters (Direct) or (2) shut down heating
boiler (Indirect)
If hot water discharges from the tundish on indirect models there
could be a fault with the thermal cut out, cylinder thermostat or
temperature pressure relief valve. On a direct model the fault could
lie with the heating element thermostat. We recommend you call
your installer or Fabdec ltd.
SPARES
When ordering replacement parts the serial number on the unit
should be quoted.
PART/COMPONENT REFERENCES
Expansion Vessel Kit (12 Litre) - 951923
Expansion Vessel Kit (18 Litre) - 951924
Expansion Vessel Kit (25 Litre) - 951925
Motorised Valve - 951878
Immersion Heater - 951860
Temp/pressure Relief Valve - 951858
Twin Thermostat - 951879
WARNING: Should the factory fitted temperature and pressure
relief valve be tampered with your guarantee will be invalidated.
Neither the distributor nor manufacturer shall be responsible for
any consequential damage howsoever caused.
TABLE 1 SIZING OF COPPER DISCHARGE PIPE (D2) FOR COMMON T&P RELIEF VALVE SIZES
Valve outlet Size Minimum size of Minimum size of Maximum resistance Resistance created by
discharge pipe D1 discharge pipe D2 allowed, expressed as a each elbow or bend
from tundish length of straight pipe
(i.e. no elbows or bends)
G1/2 15mm 22mm up to 9m 0.8m
28mm up to 18m 1.0m
35mm up to 27m 1.4m
G3/4 22mm 28mm up to 9m 1.0m
35mm up to 18m 1.4m
42mm up to 27m 1.7m
G1 28mm 35mm up to 9m 1.4m
42mm up to 18m 1.7m
54mm up to 27m 2.3m

11
GUARANTEE
This unvented vessel carries a full 25-year cylinder guarantee against faulty materials or manufacture provided that:
•It has been correctly installed as per the Installation Manual and all the relevant regulations and codes of practice in forceat the time.
•It has not been modified in any way, other than by the manufacturer
•It has not been misused, tampered with or subjected to neglect
•It has only been used for the storage of potable water
•It has not been subject to frost damage
•The unit has been serviced annually
•The logbook has been filled in after each annual service
•Within 30 days of purchase the user completes and returns the certificate supplied to register the product.
Please note that invoices for servicing will be requested to prove that the unit was serviced annually
5 year guarantee available on all components except immersion heater and cylinder thermostat (Which carry a two year guarantee). However, this is
subject to the Benchmark logbook having a regular service stamp by a qualified unvented installer.
Exclusions – The guarantee does not cover: -
•The effects of large scale build up
•Any labour charges associated with replacing the unit or outs parts
•Any consequential losses caused by the failure or malfunction of the unit
GUIDANCE IN THE EVENT OF A PROBLEM
If you have a problem in the first instance contact the plumber who fitted the unit.There after contact the plumber who carries out the annual
servicing for you.
If your unit develops a leak we will supply you with a new one.We ask for a nominal up front payment to prevent fraud. We will require t he
original unit to be returned to us for inspection along with a copy of your logbook.When it is confirmed that it has failed within the terms of the
warranty the up front payment will be refunded.
If a component fails within either the five or the two-year guarantee period we will send you a new one without any up front charge. Credit card
details may be taken to prevent fraud. We ask you to post the faulty part back to us within one month by recorded delivery.
Due to our ongoing product development policy we reserve the right to alter specifications without prior notice.