Xylem CWM18-H3 Installation instructions

© Cleghorn Waring 2017
WATER STORAGE HEATERS
(CALORIFIERS)
INSTALLATION ,
OPERATING
AND SAFETY
To obtain the best performance from your C-Warm water storage heater
please read these instructions carefully.
Failure to observe the recommended
procedures may result in damage to equipment or in personal injury, and may
invalidate the supplier’s warranty.
INSTRUCTIONS
3 bar rated
Issue
B
for BOATS
Z/PWL6
DOC597/17

2
CONTENTS Page no.
Introducing your C-Warm water storage heater ............................3
Safety......................................................................................................4
Adapting the engine cooling circuit.................................................5
Before you start: pre-installation checks...........................................6
Location.................................................................................................6
How to fit an auxiliary header tank if necessary .............................7
Fixing the heater in place...................................................................8
Connecting the pipework...................................................................10
Fitting the temperature/pressure relief valve...................................11
Fitting an electric immersion heater..................................................12
Regulating the temperature of engine-heated stored water......14
Hot water expansion............................................................................15
Regulating the cold water inlet pressure..........................................15
Using the heater ...................................................................................16
Maintenance ........................................................................................16
Winter precautions...............................................................................16
Problem solving.....................................................................................17
Table of connections and fitting sizes...............................................18
Warranty ................................................................................................21
Calorifiers and Water Storage Heaters – what’s the difference?
None. ‘Calorifier’ is a word borrowed from industrial process heating, meaning a water vessel containing
a heat exchanger (such as a coiled pipe) through which steam or hot water passes, giving up its heat to
the water contained in the vessel.

3
A C-Warm water storage heater offers a
simple and convenient means of
enjoying the benefits of stored hot water
on board your vessel, at no extra cost in
fuel.
Installation is straightforward. Provided a
few simple rules are obeyed, your
heater will give you lengthy service with
virtually no maintenance.
INDIRECT COOLED ENGINE
DIRECT COOLED ENGINE
INTRODUCING YOUR C-WARM WATER STORAGE HEATER (CALORIFIER)
C-Warm storage heaters are designed
for use with INDIRECT MARINE ENGINE
COOLING SYSTEMS using a closed loop
of hot water circulating through the
engine heat exchanger. Twin coil
models may also be used with a second
engine or with gas or diesel burners. A
mains
voltage a.c. immersion heater
can be fitted.
If an auxiliary burner is used follow the
fitting and operating instructions
supplied with it.
With water entering the coil at 82°C, a
C
-
Warm heater is designed to provide a
full charge of hot water at 60°C w
ithin
15 to 25 minutes. The larger heaters
have more coil turns, so heating time is
virtually independent of the volume of
water contained in the storage heater.
With DIRECT COOLED ENGINES, the
temperature of the water leaving the
engine is more variable
. For effective
use of a storage heater, the
temperature of the water entering the
coil should be at least 50°C.
Before you adapt a new engine’s
cooling circuit to take a water storage
heater, check with your engine supplier
to ensure that you do not inv
alidate the
engine’s warranty.

4
Your C-Warm water storage heater is
part of an unvented (‘closed’)
pressurised water system. Most domestic
systems in the UK are vented to
atmosphere (‘open’). In continental
Europe and elsewhere unvented
domestic systems are the normal type.
With proper protection against
overheating, unvented systems present
no hazard to the user. Safety
precautions are required by law for
unvented systems installed in houses in
the UK. The requirements are set out in
Building Regulations and local Bye-laws.
Although no such regulations exist (at
the time of printing) for unvented
systems in boats, these instructions
describe and recommend precautions
that comply with UK law for domestic
systems.
C-Warm heaters are designed for use
with clean, fresh, drinkable water. Salty
or heavily chlorinated water is more
corrosive than pure water, and the
working life of the heater and its fittings
may be shortened.
Copper is moderately resistant to
corrosion in hot sea water, so the heater
itself can be used with sea water,
though its working life may be
shortened. Because the temp/pressure
relief valve may corrode, C-Warm is not
recommended for sea water use with an
electric immersion heater.
CAN I USE A C-WARM STORAGE HEATER TO HEAT SEA WATER?
SAFETY
WATER QUALITY
●Fit a C-Warm double-protected electric immersion heater. See page 12
●The temperature/pressure relief valve supplied with your C-Warm water
storage heater MUST be fitted in the heater.
- in the event of overheating due to thermostat failure in an electric
immersion heater, the relief valve will open before the water can boil,
eliminating the risk of a sudden release of large amounts of scalding
water and steam.
- the relief valve protects the storage heater itself from excessive pressure
and possible damage caused by hot water expansion or by failure of
the pressure switch on the pump.
Some additional precautions are noted in the text. These precautions are
marked as shown:
ESSENTIAL PRECAUTIONS

5
The schematic diagram shows the installation principle. Contact your engine
supplier for advice about the recommended connection points on your engine.
INDIRECT COOLED ENGINE
For maximum flow through the coil, the
inlet connection should be close to the
engine (A) and the discharge
connection should be close to the
circulation pump (D). Somewhat less
flow through the coil can be attained, if
required, by taking off hot water from a
point (B) downstream of (A) and
returning it to point (C) upstream of (D),
so that the pressure difference between
the coil take-off and return is a little less.
DIRECT COOLED ENGINE
Some direct-cooled engines provide for
a relatively high engine block
temperature. The recommended
connection points for the C-Warm
heating coil will vary according to the
engine design. Check your engine
manual and if necessary contact your
engine supplier for advice
ADAPTING THE ENGINE COOLING CIRCUIT

6
I. Check that you have received
the correct C-Warm heater and
accessories. Check immersion
heater power and voltage.
Report any damage or
discrepancies to your supplier
without delay.
II. Check the dimensions of the
heater and recheck the
dimensions of the space for its
installation in your boat.
III. Read through these instructions
carefully, noting additional items
required for installation.
Your C-Warm water storage heater may be located in any convenient and
accessible position subject to the following considerations:
I. With pumped cooling water
circulation, the storage heater
can be located above or below
engine level. For best circulation,
natural convection should assist
the pumped flow.
II. There must be no air locks in the
cooling water circuit. Either
locate the water storage heater
with its upper coil connection
below the engine’s water filling
point, or fit an auxiliary
header/filler tank above the
highest point in the cooling water
circuit. See page 7.
III. The longer the pipe run
between water storage heater
and engine, the more work the
engine’s cooling water
circulation pump has to do.
Minimise the reduction in water
flow rate by locating the
storage heater near the engine.
IV. Vertical C-Warm storage heaters
MUST be mounted vertically,
horizontal heaters MUST be
mounted horizontally.
BEFORE YOU START
LOCATION

7
For installations where the upper coil connection is above the level of the engine’s
water filling point.
How to fit an auxiliary header tank if necessary
1. Blank the existing header tank by
using a flat cap that does not
obstruct the overflow pipe.
2.
Fit a new expansion tank nearby, at
a height just above the top of the C-
Warm water storage heater coil.
Connect it to the overflow outlet on
the original header tank, using a
suitable pressure hose (see diagram
)
The expansion tank for a car radiator
is suitable for engine cooling systems
up to about 200 litres in total volume.
3.
Fit an air bleed close to the top coil
connection of the water storage
heater. On filling the system with
water, ensure that all the air in the
cooling circuit escapes via this bleed
or from the engine.
4.
On starting the engine check for loss
of liquid and for air locks in the
extended cooling circuit.
6
4

8
FIXING THE WATER STORAGE HEATER IN PLACE
When full of water the heater has a substantial mass. It must be secured firmly in
place to prevent damage to the heater and pipework or to the supporting
structure, from the effects of rough weather or other shocks of marine use.
1. Support the WEIGHT on a strong base
2Support the MASS against horizontal forces
The exact method you use to hold the heater in place will depend on the
construction of the vessel and on the available space.
Some suggested installation methods are indicated below.
VERTICAL MODELS
1 litre of water
weighs 1 kg
Locate the heater on a firm level base strong enough to
support at least twice the weight of the (full) heater
Either
:construct suitable supports to hold the heater in
place
or: use one or more restraining straps as shown be
low
BRACKET KIT
CWAB-V series
contains:
1 bracket assembly
or…
STRAP KIT
CWA-STRKIT
contains:
2 webbing straps
4 stainless steel brackets
Instructions for use
Use…
BRACKET
ASSEMBLY
BRACKETS
WEBBING STRAPS
WITH BUCKLES

9
BRACKET KIT
CWAB-H series
contains:
2 bracket assemblies
STRAP KIT
CWA-STRKIT
contains:
2 webbing straps
4 stainless steel brackets
Instructions for use
or…
Use…
Either a C-Warm Strap Kit or a C-Warm Bracket Kit (H-series) can be used to secure
the heater in place. Leave space under the heater for pipe connections on some
models. See dimensions page 23.
HORIZONTAL MODELS

CONNECTING THE PIPEWORK
C-Warm heaters may be connected
into the engine cooling and pressurised
water systems with any suitable pipe
material. Most commonly used are:
Hep2O push-fit piping system
Hep2O CONNECTION KITS are available
for all C-Warm heaters. See C-Warm
Selection guide for details. The kit
contains Hep2O fittings for the
pressurised water connections and brass
hose connections to the heating coil.
Copper pipe
Connecting the coil into the engine
cooling circuit
Use ½” or ¾” bore rubber (car or lorry)
heater hose, obtainable from vehicle
accessory suppliers. This will minimise
the engine vibration reaching the
heater.
Connect the coil into the engine cooling
circuit and/or auxiliary heater. Fasten
the hose securely to the connectors
using stainless steel hose clips. Do not
allow loops of hose to form air locks.
If copper pipework is preferred for the
pressurised water connections, suitable
adapters and compression fittings
should be used. These may be
obtained from a plumber’s merchant or
from most ‘Do-it-Yourself’ stores. See
pages 18 - 20 for connection sizes.
The pipework connections to the heater
must not be stressed. Make sure that
the copper pipework is fully supported
Flexible hose
If flexible hose is preferred for the
pressurised hot and cold water
connections, suitable connectors will be
required. Use opaque hose (to
discourage algal growth) and stainless
steel hose clips. See pages 18 - 20 for
connection sizes.
Do not over-tighten
the coil connections.
Over-tightening may
distort the copper
wall of the storage
heater, causing
immediate or
eventual leakage.
Max. torque should
not exceed 70Nm
(50lb.ft)
lThe heating coil may safely remain
incorporated into the engine
cooling circuit whether the heater
itself is full of water, partly full or
empty.
lThe coils in a twin-coil C-Warm
heater are completely independent
in operation. The water storage
heater will work satisfactorily with
either coil alone or with both coils
together in use.
10