Xylem CLEGHORN WARING CW385 User manual

Installation, Operating,
Maintenance and Safety Instructions
ACCUMULATOR
TANKS
&
EXPANSION TANKS
in
PRESSURISED WATER SYSTEMS
IMPORTANT
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR
USING YOUR ACCUMULATOR / EXPANSION TANK. FAILURE TO FOLLOW THE
RECOMMENDED PROCEDURES MAY RESULT IN REDUCED PERFORMANCE OR
NON-FUNCTIONING OF THE TANK, MAY CAUSE DAMAGE TO OTHER
EQUIPMENT ON BOARD, PERSONAL INJURY, AND INVALIDATE THE
SUPPLIER’S WARRANTY.
WARNING
Cleghorn Waring’s tanks are intended for use as accumulator tanks or as
expansion tanks in pressurised water systems. They are designed for a maximum
internal pressure of 6 bar (90 psi). In no circumstances
must the internal pressure be allowed to exceed this
figure. The supplier accepts no responsibility for use of the
tank for any other purpose than those described in these
instructions.
Doc595/12
WAS 385/07
Z/PWL4
Xylem Water Solutions UK Ltd
Bingley Road • Hoddesdon • Hertfordshire • EN11 0BU •UK
Telephone: [phone] Fax: [phone]
[e-mail] www.jabscoshop.com

The tank is designed for two separate and alternative
functions in a pressurised water system:
1. As an
ACCUMULATOR TANK
.
See section A
2. As an
EXPANSION TANK.
See section B
Accumulator Tanks and Expansion Tanks -
What’s the difference?
There is no difference in construction. Cleghorn
Waring’s tanks are suitable for either duty. They
are cylindrical steel tanks with an internal
rubber membrane. The tank is supplied
charged with inert nitrogen gas, to prevent
internal corrosion. The internal pressure is
regulated via the air valve located beneath the
black cap at the closed end of the cylinder.

SECTION A - ACCUMULATOR TANKS
Why do I need an accumulator tank?
An accumulator tank is an important part of any pressurised water system that includes a
pressure-controlled pump. (Some modern computer-controlled pumps may not require an
accumulator tank, but see
Section B - Expansion tanks
.) Fitted close to the discharge port of the
pressurised water pump, the accumulator tank acts as a pressure buffer, ensuring a smooth
flow of water from the outlets. Without an accumulator tank, the pump is liable to switch itself
rapidly on and off whenever its flow rate exceeds demand from the outlets. Constant on-off
cycling leads to increased pump wear and unnecessary battery drain. The accumulator tank
stops this rapid cycling, resulting in smooth water flow (important in showers) and an extended
pump life.
Where do I fit an accumulator tank?
The accumulator tank should be fitted in the
discharge
line from the
pump,
as close as possible
to the pump itself (see diagram). The tank will serve no useful function if fitted in the pump
inlet pipework.
How do I install an
accumulator tank?
The tank should be
installed in a dry
place. Tanks may be
fitted in any attitude,
vertical or horizontal.
The tank may be
secured by stout
strapping or by
stainless steel bands,
or it may be mounted
in a wooden cradle.
The steel tank casing
is robust, but care
should be taken
during installation not
to scratch, dent or
puncture it. A special
bracket mounting kit
CW324 is available for
the 2, 5 and 8-litre
models.
What size of accumulator tank do I need?
This depends on the number of outlets in your system, their frequency of use, on the flow rate
of the pump and on the space available. The larger the tank, the less frequently the pump will
start, and the longer it will run before stopping. Contact your supplier if you require advice.
At what pressure should I set the accumulator tank?
The pressure in the tank is adjusted by means of the air valve in the closed end.
The tank is supplied with an internal pressure of about 2.8 bar (35 psi). Reduce this pressure to

2 - 3 psi
below
the
cut-in
pressure of the pump (refer to pump instructions for details). This
pressure adjustment is best done before installation of the tank, using a car-type pressure
gauge to determine when the required pressure is reached, as follows:
i. Depress the central pin of the Schrader valve with your finger, to release
gas
ii. Release gas a little at a time, until the pressure is correct
iii. If you release too much gas by mistake, air may be pumped back in with
a hand - or foot-pump.
WARNING
Make sure that there is adequate ventilation when setting or
adjusting pressure in an accumulator tank. Nitrogen is non-
toxic, but oxygen levels may be reduced in confined spaces.
If the tank pressure requires adjustment after installation, ensure first that the pump is switched
off and that an outlet is open, so that there is no pressure in the system. Then regulate the
pressure as indicated above.
Check the accumulator tank performance in this way every 6 months, and adjust the pressure if
necessary.
EXAMPLE
Pump Cut-in
Acc. Tank
Pressure Pressure setting
1 bar (15 psi) 0.8 bar (12 psi)
0.7 bar (10 psi) 0.5 bar (7 psi)
0.5 bar ( 7 psi) 0.3 bar (5 psi)
Winter precautions
To avoid risk of frost damage, drain all the water from your pressurised water system, before
winter lay-up. Switch off the pump, open all outlets until flow ceases. This will allow water to
be expelled from the accumulator tank. Drain all remaining water from the lowest point in the
system. Remember to drain your calorifier from the bottom (cold-water inlet)
Temperature range.
Cleghorn Waring accumulator / expansion tanks are designed for use within the temperature
range 0 to 90ºC.

SECTION B - EXPANSION TANKS
Why do I need an expansion tank?
Heated from 10 to 60ºC, water expands in volume by about 2%. The calorifier expands too, but
not as much as the water. A litre or more of hot water may need to escape from your calorifier
as it heats up.
A normal accumulator
tank can absorb this
excess water, provided it
is of sufficient size. In the
process, hot water will
flow back into the cold
water line. If hot water
back-flow cannot be
tolerated, a non-return
valve may be fitted in the
inlet line to the calorifier.
The expansion water will
then be discharged
through the calorifier
temperature / pressure
relief valve, which opens
at the maximum working
pressure of the calorifier.
To avoid water wastage,
to prevent unnecessary stress on the calorifier, and to avoid build-up of deposits in the relief
valve, an additional expansion tank may be fitted in the inlet line to the calorifier (see diagram).
What size of expansion tank do I need?
The required capacity of the expansion tank depends on:
-pump cut-out pressure
-the difference between the pump cut-out pressure and the opening pressure of
the relief valve in the calorifier
-the volume of stored water in the calorifier
All three of these factors are taken into account by the EXPANSION TANK VOLUME FACTOR,
shown in the table below.
To calculate the expansion tank volume you require, proceed as follows:
EXPANSION TANK VOLUME FACTOR
Pressure relief valve setting ►
2.5 bar
(37psi)
3 bar
(44psi)
3.5 bar
(51psi)
5 bar
(74psi)
Pump cut-out pressure
▼
1.0 bar (15psi) 22 24 28 34
1.4 bar (21psi) 16 20 24 30
1.8 bar (25psi) 10 15 18 26
2.0 bar (29psi) 7 12 16 25
2.8 bar (40psi) n/a n/a 8 18

STEP 1
From the table, find the volume factor appropriate to your system
STEP 2
Divide the volume of your calorifier by the volume factor, to give the expansion
tank volume you require
EXAMPLE
A 50 litre calorifer having a relief valve setting of 2.5 bar with a pump cut-out pressure of 1.4
bar (21psi).
From the table above we get a volume factor of 16.
We then divide the calorifier volume by this = 50 ÷ 16 = 3.1 litre
Then use the next larger size expansion tank - 5 litre (CW385)
Where do I fit an expansion tank?
The expansion tank should be fitted in the cold water feed line to the calorifier, between the
non-return valve and the calorifier.
How do I install an expansion tank?
Tanks may be installed in a vertical or horizontal position. The tank may be secured by stout
strapping or by stainless steel bands, or it may be mounted in a wooden cradle. A special
bracket mounting kit CW324 is available for the three smallest sizes
The steel tank casing is robust, but care should be taken during installation not to scratch, dent
or puncture the tank.
At what pressure do I set the expansion tank?
The tank is supplied charged with nitrogen gas at about 2.3 bar (35 psi). The pressure should
be adjusted to the
cut-out
pressure of the pressurised water pump. This should be done
before the tank is installed. Follow the pressure adjustment procedure described in SECTION
A, above.
Expansion tank setting with Jabsco Sensor-Max pump
The Jabsco Sensor-Max variable speed water pressure system pump requires the gas setting
on the expansion tank to be 0.2 bar above the pump cut-out pressure. Ask for the free
Cleghorn Waring leaflet
Check the pressure in the expansion tank every 6 months, and adjust it if necessary. Switch off
pump and open hot water outlets before doing so.
Winter precautions
To avoid risk of frost damage, drain all the water from your pressurised water system, before
winter lay-up. Switch off the pump, open all outlets until flow ceases. This will allow water to
be expelled from the expansion tank. Drain all remaining water from the lowest point in the
system. Remember to drain your calorifier from the bottom (cold water inlet)
Temperature range
Cleghorn Waring accumulator / expansion tank are designed for use within the temperature
range 0 to 90ºC.
Maintenance
Cleghorn Waring accumulator / expansion tanks require no regular maintenance.

TROUBLE SHOOTING
ACCUMULATOR TANKS
PROBLEM POSSIBLE CAUSE REMEDY
Pressurised water pump cuts
in & out rapidly when outlet
is partially open
Pressure in accumulator tank
incorrect
Check tank pressure and
adjust (see instructions)
Accumulator tank membrane
split
Replace tank or membrane
Accumulator tank incorrectly
located
Re-locate tank (see
instructions)
Schrader valve leaks water
Accumulator tank membrane
split
Replace tank or membrane
EXPANSION TANKS
PROBLEM POSSIBLE CAUSE REMEDY
Calorifier pressure relief
valve opens when calorifier is
heated normally
Pressure in expansion tank
incorrect
Check tank pressure and
adjust (see instructions)
Expansion tank not large
enough
Fit larger tank
Hot water appears in cold
water line
Non-return valve in inlet line
to calorifier absent or
ineffective
Check presence/condition of
non-return valve
Schrader valve leaks
Expansion tank membrane
split
Replace tank or membrane
Xylem Water Solutions UK Ltd
Bingley Road • Hoddesdon • Hertfordshire • EN11 0BU • UK
Telephone: [phone] Fax: [phone]
[e-mail] www.jabscoshop.com