Wolf TSW-120 User manual

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 1
Installation instructions
DHW cylinders TSW-120/CSW-120
for gas-fired condensing boilers and
conventional gas-fired boilers
Partno. 3048420 07/07 GB
Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. [phone] · Fax [phone] · Internet: www.wolf-heiztechnik.de

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
2
Index
Index.................................................................................................................. Page
General information .................................................................................................2
Safety notice / DHW cylinders / Standards and regulations ....................................3
Specification .............................................................................................................4
Dimensions..............................................................................................................5
Layout .......................................................................................................................6
Positioning / Installation dimensions ......................................................................7
Installation ................................................................................................................8
Installation of the tundish ................................................................................... 9-11
Installation of the domestic water connection .......................................................12
Final assembly .......................................................................................................14
Circulation / Commissioning ........................................................................... 15-16
Maintenance ..................................................................................................... 17-18
Thismanualisanintegralandessentialpartoftheproduct.Please
read carefully the instructions and notices about the appliance
contained in this manual, as they provide important information
regarding the safe installation, use and maintenance of the
cylinder. Failure to do so may invalidate the guarantee.
Generalinformation
Handle and store Don’t stack the packages. Don’t transport lying.
Keep the packages in dry conditions.
Delivery The CSW-120 range is supplied as following;
1) The cylinder with factory fitted temperature & pressure
relief valve.
2) Box containing
- reducing valve
- expansion valve with check valve
- tundishes
- pipes
- connection supplies
3) Box containing expansion vessel

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 3
Safety notice / DHW cylinders / Stan-
dards and regulations
Standards and
regulations Observe the following instructions during the installation of the
DHW cylinders:
- BS 6920
- BS 7206
- DIN 1988 - Technical regulations for DHW installations
- DIN 4708 - Centralised DHW systems
- VDE requirements
- Requirements by public water suppliers
Safety notice • Installation must be carried out by a suitably qualified installer
and in accordance with current regulations and codes of
practice.
• Only the safety valves supplied with the cylinder should be
used.
• The cylinder must not be used without the safety valves and
expansion vessels.
• Thecylindermust notbeused withaboiler withoutthermostatic
control.
• The cylinder and ancillary controls must be adequately
maintained.
• The installation must have a sufficient and constant supply of
mains fed cold water.
• No valve should be fitted between the expansion relief valve
and the storage cylinder.
• Only Wolf approved replacement parts should be used.
• The discharge pipe must be terminated where it is visible and
will not cause danger to people in the vicinity of the discharge.
Note: Thedischargecould consist ofscalding water andsteam.
DHW cylinders, type TSW-120 / CSW-120, made from steel with
top flange and pipework connections for gas-fired boilers.
Corrosion protection through dual enamel coating on internal
cylinder walls and indirect coils, acc. to DIN 4753 pt. 3.
Additionalcorrosionprotectionthroughmagnesiumanode.Suitable
for all water conditions and any type of pipework.
DHWcylinders
Domestic hot water cylinder
TSW-120 Domestic hot water cylinder
CSW-120

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
4
Specification
Warning to the user a) Do not remove adjust any component part of this unvented
water heater: Contact the installer
b) 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.
Note to the installer Leave the manual with the householder after installation.
The safety system of the DHW cylinder TSW-120/CSW-120 is
attunedto useonly incombination withWolf boilerTGG-18, TGG-
24 and TGB-20.
a) Thisinstallationissubjecttobuildingregulationapproval,notify
the Local Authority of intention to install.
b) Use only manufacturer´s recommended replacement parts.
c) Installed by: Name:
Adress:
Tel.No.:
Completiondate
Warning to the
installer
Type of DHW cylinder TSW/CSW -120
Cylinder capacity litres 115
Const. DHW cyl. rating (80/60 - 10/45°C) kW-ltrs./h 29-710
Standby consumption at 60 °C kWh/24h 1.5
Performance factor NL60 1.0
Max. supply temperature °C 60
Heating up time with 25kW min 22
Re heat time with 25kW min 15
Max. operating pressure - DHW bar 3.5
Max. operating pressure - heating water bar 12
Max. permissible DHW cylinder temperature °C 95
Max. permissible heating water temperature °C 110
P+T-valve opening temperature °C 95
P+T-valve opening pressure bar 7
Max. water supply pressure bar 16.0
Expansion valve setting bar 6.0
Expansion vessel charge pressure bar 4.0
Weight (empty) kg 75
Weight of the full cylinder kg 190
Connections Cold water R ¾”
Hot water R ¾”
DHW flow R ¾”
DHW return R ¾”
DHW circulation R ¾”
Sensor well Ømm 14
Specification

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 5
542
542
595
542
810810
Sensorwell
DHW circulation
DHW return
Fillingand draining
for TSW-120 below the
decorative panel
DHW cylinder flow
Domestic hot water
Cold water
Fig.:TSW-120 Fig.:CSW-120
Dimensions

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
6
i
Layout
Gas-fired boiler control unit
Domestic hot water
DHW circulation
DHW
circulation
pump
DHW cylinder sensor
connection (blue plug)
Expansion vessel
Expansion valve with
discharge outlet to tundish
Check valve
Stop valve
Pressure reducing valve
Drain
Cold water to
DHW
cylinder
Coldwater
supply according
to British
Standards
Please note: Thelayoutisprovidedtoprovideageneraloverview,notapiping
prescription.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 7
Positioning / Installation dimensions
Installation of wall hung
appliance an hot water
storage tank
notch for
water
pipes
270-420
790
810
1800-1950
CSW
mounting
bracket
centered!
Please note when using
thepipe cover: The installation dimensions apply to TSW-120 as well as CSW-120.
If you intend installing the DHW cylinder with a pipe cover, check the
fit (dimension 300 mm) with the pipe cover prior to commencing the
pipe installation. The adjustable cylinder feet can compensate a
max. of ±10 mm.
Please note the fixing hole position on the installation template
when using a fixing bracket (accessory).
InstalltheDHWcylinderonlyinafrostprotectedlocation,otherwise
drain, if there is a risk of frost.
Consider the total weight of a full DHW cylinder when selecting
the installation location.
Adjustable feet allow you to compensate for uneven floors.
The DHW cylinder ...SW-120 may be installed in a top or bottom
cupboard or free-standing.
Positioning
270-420790
480
344
400
810
1800-1950
TSW without covering panel
notch for water pipes
mounting
bracket
780-800 300
480
344
400
1835
±
10
mounting
bracket
notch for water pipes
TSW with covering panel
Install appliance as described in Installation Instructions.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
8
Installation
Connectionof
DHWcylinderflow
DHW cylinder return
Remove the dummy plug from the heating return of the gas-fired
boiler. Remove the elbow from the heating flow of the gas-fired boiler
and insert the three-way changeover valve with a union nut and flat
gaskets. Trim the DHW cylinder flow and return pipes to size. Secure
the installation with compression fittings on the DHW cylinder ...SW
as well as with flat gaskets and union nut on the gas-fired boiler.
Bend
HVL HRL
Dummy plug
Three-way
changeover
valve
HVL
HRL
Flowpipe Return pipe
Note Becauseofheat expansion, watermayduringheating be discharged
from the safety valve. Never shut off the blow-off line. Safeguard
the drainage to the drain funnel via a drain pipe.
The selection of pipework material (i.e. connection fittings on site)
has to be in accordance with the rules of engineering and possible
electro-chemical reactions have to be taken into account (mixed
component installation).
If copper connections are used, utilise compression fittings made
from brass or bronze to prevent contact corrosion at the DHW
cylinder connections. Cylinder relief valve connections should not
be used for any other purpose.
Pipework on finished walls
Siphon
m
i
n
.
2
7
0
max. 420
SVL
SRL
GAS
HVL
HRL
Z
WW
KW
HVL : Central heating flow
HRL : Central heating return
SVL : DHW flow
SRL : DHW return
WW : DHW connection
KW : Cold water inlet
Z : DHW circulation
Loweredge
casing
Upper
edge
DHW
cylinder
Please note:
When installing the pipe bezel,
the dimension between the
bottom edge of the casing and
the top edge of the cylinder
must not be a min. of 240 mm
and a max. of 420 mm, but
instead must be 300 mm.
DHWcylinder
temperature sensor Remove the blue dummy plug from the control unit and connect
with the socket of the DHW cylinder temperature sensor. Insert the
sensor into the sensor well until it bottoms out.
Connectionof
Three-way changeover
valve
Remove the dummy plug at the control unit and connect with the
socket of the three-way changeover valve.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 9
Installation of the tundish
1. The tundish must be vertical and fitted within 500mm of the
temperature & pressure relief valve and must be located with
thecylinder.Thetundishmustalsobeinapositionvisibletothe
occupants, and positioned away from any electrical devices.
Thedischarge pipe fromthe tundish shouldterminate in asafe
place where there is no risk to persons in the vincinity of the
discharge and to be of metal.
2. Discharge pipes from the temperature & pressure relief and
expansion relief valve may be joined together.
3. Thepipediametermustbeatleastonepipesizelargerthanthe
nominal outlet size of the safety device unless it’s total
equivalent hydraulic resistance exceeds that of a straight pipe
9m long. i.e. Discharge pipes between 9m and 18m and
27 m at least 3 larger, and so on.
Bends must be taken into account in calculating the flow
resistance. Typical discharge pipe arrangement on page 10.
4. Thedischargepipemust haveaverticalsectionofpipeatleast
300mm in length, below the tundish before any elbows or
bends in the pipework.
5. The discharge pipe must be installed with a continous fall.
6. The discharge must be visible at both the tundish and the final
point of discharge, but where this is not possible or practically
difficult; there should be clear visibility at one or other of these
locations. Examples of acceptance are:
i) Ideally below a fixed grating and above the w a t e r
seal in a trapped gully.
ii) Downward discharges at a low level; i.e. up t o
100mm above external surfaces such as c a r
parks, hard standings, grassed areas etc. Thes e
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
maintainingvisibility.
iii) Dischargesathigh level;l.e.into ametalhopper andmetal
downpipewiththeend ofthedischarge pipeclearlyvisible
(tundish visible or not). Or onto a roof capable of
withstanding high temperature discharges of water 3 m
from any plastic guttering systems that collect would such
a discharge (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 can be
traced reasonably easily. The single common discharge
pipe should be at least one pipe size large than the largest
individual discharge pipe to be connected. If unvented hot
water storage systems re-installed where discharges
from safety devices may not be apparent l.e. in dwellings
occupiedbytheblind,infirmordisablepeople,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.
Discharge pipework

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
10
Installation of the tundish
Typical discharge
pipe arrangement metal discharge pipe (D1) from temperature relief valve to tundish
safety device
(eg.
temperature
relief valve)
300mm
minimum
500mmmaximum
metal discharge pipe (D2) from
tundish, with continous fall,
see table an worked example
tundish
discharge below fixed
grating or as para 1 (b)
fixed louvred grating
trapped gully
Sizingofcopperdischargepipe‘D2’forcommontemperaturereliefvalveoutletsizes
Valve Minimum Minimum Maximum resistance Resistance
outlet size of size of allowed, expressed created by
size discharge discharge as a length of each elbow
pipe D1* pipe D2* straight pipe (ie. or bend
from tundish no elbows or bends)
28mm up to 9 m 1.0m
G½ 22mm 35mm up to 18 m 1.4m
42mm up to 27 m 1.7m
* See Worked examples and scheme above
Worked example
The example below is for a G½ temperature
relief valve with a discharge pipe (D2) having 4
No. elbows and length of 7 m from the tundish
to the point of discharge.
FromTable
Maximumresistanceallowedforastraightlength
of22mm copperdischargepipe(D2)fromaG½
temperature relief valve equates to: 9 m
Subtract the resistance for 4 No. 22 mm elbows
at 0.8 m each = 3.2 m
Thereforethemaximumpermittedlengthequates
to: 5.8 m.
5.8 m is less than the actual length of 7 m
therefore calculate the next largest size.
Maximum resistance allowed for a straight
length of 28 mm pipe (D2) from a G½
temperature relief valve equates to: 18m
Subtract the resistance for 4 No. 28 mm
elbows at 1 m each = 4 m
Therefore the maximum permitted length
equates to: 14 m
As the actual length is 7 m, a 28 mm (D2)
copper pipe will be satisfactory.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 11
expansion
valve with
check
valve
pressure
reducing
valve
passed expansion
vessel
domestic
cold
water
always use copper
inserts
wall plug Ø 10mm
wall mounted pipe clip
plug
Installation of the tundish
tundish
DONOTUSETHISTUNDISH
WITHTHEP+T-VALVE
hold a distance of 25mm
between the tundish and the
pipe end.
threaded rod 8 x
160
reduce
compression
fitting 22/18
Installationofthepipes
domestic water
connectingset
Between storage tank and safety valve no other valves
or sieves must be installed.
The discharge pipe from the tundish should terminate in a safe
place where is no risk to person in the vicinity of the discharge.
Position the tundish where it can be readily seen.
Position the tundish away from any electrical devices.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
12
View of complete
mountedDHWcylinder
withtundish, domestic
water connection and
connection accessory
to the boiler
Installationofthedomesticwater connetoin
View of complete
mountedDHWcylinder
withtundishand
domestic water
connection

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 13
Installation
Pressure reducing
valve Generally, we would recommend the installation of a pressure
reducer. On the DHW side, the DHW cylinder may be operated
with a max. pressure of 10 bar. Install a pressure reducer if the
supply system delivers a higher pressure. To avoid flow noise
insideofbuildings, regulate thepipepressure to approx.3.5bar.
Provide a centralised pressure reducer, if mixer taps are used.
Exceeding the permissible operating pressure may
cause leakages and destruction of the storage tank.
Drinking water filter We recommend the installation of a drinking water filter into the
cold water supply, as foreign bodies introduced into the system
can block fittings and may lead to pipe corrosion.
Checkvalve The check valve is included into the expansion valve.
Expansionvalve Install a type-tested safety valve into the cold water supply. The
installation of dirt traps or other restrictions into the supply pipe
to the safety valve is not permitted.
Note: Do not fit a valve between the expansion valve and the
DHW cylinder.
Expansionvessel InstalltheexpansionvesselwiththeT-piecedirectlyintotheline,
that a flow through is guaranteed
Drain Install the DHW cylinder so that it can be removed without
dismantling. The TSW-120 is provided with a drain below the
decorative panel.
DHWconnection-
free-standingDHW
cylinder ...SW-120
When installing the DHW cylinder ...SW below the gas-fired
boiler, use the Wolf accessory “DHW cylinder connection set for
subsurface installation“ or the “DHW cylinder connection set for
surface installation“.
Secondary return A secondary return may be fitted (consult the lavel on the face
of the unit for the correct location). A non-return valve (not
supplied) must be fitted to prevent back-flow and a bronze pump
will be needed in conjunction with a pipe thermostat to circulate
the hot water (both not supplied).
Note: An extra expansion vessel may be required where the
additional volume of the secondary return exceeds the capacity
of the expansion vessel supplied.
Connection set ...SW-120 for surface installation (accessory)

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
14
Final assembly
After the installation, locate the pipe cover (accesory) on the DHW
cylinder ...SW-120 and push back.
Pipe cover
Pipe cover
White plastic plugs On CSW-120 use the white plastic plugs supplied to close the four
holes in the front panel and the three holes in each of the l.h./r.h.
rear side panels. Please note: Two white plastic plugs are surplus
and should be retained as spare parts.
OnTSW-120 usethewhite plasticplugs suppliedto closethethree
holes in each of the l.h./r.h. rear side panels.
Black plastic clip
Decorative panel
Decorativepanel
TSW-120 For TSW-120 the following final steps must be completed:
Press the black plastic clips (4 pieces) into the corners of the
decorative panel. Clip the decorative panel withthe pre-assembled
plastic clips into the fixing holes of the DHW cylinder front panel.
Pleasenote:Sixblackplasticclipsaresurplusandshouldberetained
as spare parts.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 15
Only an approved contractor must install and commission this
equipment; this contractor is also responsible for the appropriate
equipment level.
Thoroughly flush the pipes and the DHW cylinder after completing
the installation. Check for obvious signs of damage to the cylinder
and controls and also that the controls fitted correspond with the
references quoted in these instructions.
Ensure that the Drain Cock at the base of the appliance is closed
before commencing.
1)Open all outlet taps;
2)Turn on mains water supply and allow the water heater to fill;
3)Close taps in turn after having purged the system of air;
4)Check for leaks around the controls and immersion heaters and
again after the unit has heated up.
5)Check that no water is passing to waste through the relief
valves;
6)Test the operation of the temperature and pressure relief and
expansion valves by lifting/turning the manually operated test
lever/cap and observing that water flows through freely and
safely to waste.
Commissioning
Circulation/Commissioning
YoumayconnectanoptionalDHWcircuitatthecirculationconnector.
The DHW circuit should be connected only, if the draw-off points
arelocatedafairdistanceawayandshouldbeinstalledwithaDHW
circulation pump with time switch control.
Implementtheelectricalconnectioninaccordancewiththefollowing
wiring diagram.
DHWcirculation
PE
Netz Z FV
L1 N L N NLLL1
230VAC
230VAC
AK
DHW circulation pump

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
16
Circulation / Commissioning
Fill the heating system at a low water pressure (approx. 1 bar).
During filling, open the three-way changeover valve several times
manually if the system includes a gas-fired boiler. On gas-fired
condensing boilers, open the air vent valve in the DHW cylinder
flow. Check whether the lid on the quick-action air vent valve is
loose. Briefly start up the boiler (circulation pump).
Demonstrate operation to user, including operation of temperature
and relief valve and what to do if it operates.
Givethis manual tothe usertoretain forfuture reference andmake
the customer aware that periodic checks of the equipment are
essential for safety.
WhenusingdigitalcontrolaccessoriesDRT,DWTorDWTMforWolf
gas-fired boilers, the cylinder loading time for the CSW-120 DHW
cylinder may be selected via a two-channel time switch CSW-120.
The loading times can be freely selected via the day/week program.
Programmingthecylinderloadingtimes isdetailed inthecontrol unit
operating instructions.
Selecting the DHW
cylinderloadingtimes
Adjust the DHW cylinder temperature on the Wolf gas-fired boiler
between 15 - 70 °C using the cylinder thermostat. For reasons of
economy,thermostatsetting7(approx. 60°C) isrecommended.For
regular pasturisation, a DHW cylinder thermostat setting of 70 °C
(position 9) may be selected. This setting is only intended for brief
and supervised operation.
In hard water areas we recommend thermostat setting 7 (approx.
60°C) to prolong element life.
TheDHWcylindertemperaturecanbereadoffatthedisplayifaWolf
gas-firedboilerisconnectedtodigitalcontrolaccessoriesDRT,DWT
or DWTM, (see operating instructions of the respective control unit).
Selecting the DHW
cylinder temperature

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 17
Checkingtheprotective
anode The integral magnesium anode can be sacrificed through electrical
reaction to protect the DHW cylinder from corrosion. Therefore check
and, if necessary, replace the anode every two years.
Remove the connection cable between the anode and the hand hole
cover. To check the protective anode, connect an ammeter between
earth and the anode. Replace the protective anode if the actual value
falls below 0.1 mA.
Maintenance
FullyreleasetheDHWcylinderpressure,switchOFFtheboilerand
the DHW circulation pump, and open a hot water tap in your house.
A hose nozzle is factory-fitted below the fill and drain cock cover.
OnTSW-120,thedecorativepanelmustfirstberemovedbyslightly
lifting and pulling it forward.
DrainingtheDHW
cylinder
Replacingthe
protectiveanode Remove the six nuts on the hand hole cover. Remove the cover,
together with the protective anode. Remove the locking nut and fit
a new protective anode.
Installation in reverse order.
Access trap to be fitted with new seal only, torque of nuts 20-25 Nm.
Fill the system and check for leaks.
Hose connection
Filling/draining aperture
Earth = hand hole cover
Protective anode
Nuts
Hand hole cover

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
18
Maintenance
UnventedControls Check controls as per the following:
1)Line strainer - with the water supply turned off remove screen
from strainer and clean of any detritus;
2)Expansion vessel - with the water supply turned off and taps
open, check expansion vessel pressure and top up as necessary;
3)Temperature and pressure relief valve - with the water supply
turned on; check manually by lifting the test lever/turning the test
knob (ensure valve closes after testing);
4)Expansion relief valve - check manually by turning the test knob
(ensure valve closes after testing);
5)Discharge pipes - from both temperature and pressure relief and
expansion relief valve for obstructions;
6)Tundish and discharge pipe - open either valve gradually to
produce a full bore discharge into tundish without any back
pressure;
7)Pressure reducing valve - check that the correct outlet pressure
is being maintained by recording the pressure at an in-line termi-
nal fitted i.e. tap.

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707 19
Notice

InstallationinstructionsDHWcylinders TSW-120/CSW-120
3048420_0707
20
WolfGmbH·Postfach1380·84048Mainburg·Tel.[phone]·Fax[phone]·Internet:www.wolf-heiztechnik.de