Heatrae Sadia Megaflo Eco SolaReady Instructions Manual
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Heatrae Sadia Megaflo Eco SolaReady Instructions Manual

Heatrae Sadia Megaflo Eco SolaReady Instructions Manual

Unvented hot water cylinders
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Megaflo Eco SolaReady Unvented
Hot Water Cylinders
Important
Please read & understand all these instructions before commencing installation.
Please leave this manual with the customer for future reference

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Summary of Contents for Heatrae Sadia Megaflo Eco SolaReady

  • Page 1 Megaflo Eco SolaReady Unvented Hot Water Cylinders Important Please read & understand all these instructions before commencing installation. Please leave this manual with the customer for future reference...

  • Page 2: Table Of Contents

    Contents Product specification Introduction Component checklist General requirements Outlet/terminal fittings Limitations Water supply Electrical supply The environment Specifications and dimensions Installation Instructions General installation Installation of solar primary hydraulic station Direct model Indirect model Installation of solar differential temperature controller East West Array Kit Commissioning Commissioning of solar primary system...
  • Page 3 As the fluid passes through the collector panels its temperature is raised. The heated fluid is circulated through a heat exchanger coil in the base of the Megaflo Eco SolaReady solar storage cylinder transferring the heat gained to the stored water, gradually raising its temperature. The cooled fluid then returns to the collector panel to be heated again.

  • Page 4: Introduction

    WARNING: Do not switch on if there is a possibility that the water in the heater is frozen. Storage The Megaflo Eco SolaReady is supplied on a pallet with its associated control kits. It should be stored upright in a clean, dy, frost-free environment prior to installation.

  • Page 5: Outlet/Terminal Fittings

    Outlet / Terminal Fittings (Taps, Etc.) The Megaflo Eco SolaReady can be used in conjunction with most types of terminal fittings. It is advantageous in many mixer showers to have balanced hot and cold water supplies, in these instances the balanced cold water supply should be teed off the supply to the Megaflo Eco SolaReady immediately after the Cold Water Combination Valve (See Figure 5 page 10).

  • Page 6: Water Supply

    The Megaflo Eco SolaReady has an operating pressure of 3 bar which is controlled by the 3 Bar Pressure Reducing Valve. The 3 Bar Pressure Reducing Valve can be connected to a maximum mains supply pressure of 1.6 MPa (16 bar). The water supply must be of wholesome water quality (Fluid Category 1 as defined by the Water Supply Regulations 1999).
  • Page 7 Figure 2 – Cylinder sizing and specification Table 1: Dimensions DIMENSIONS (mm) SIZE TYPE INDIRECT 1854 1734 1142 1068 DIRECT 1909 1798 1165 INDIRECT 2160 2048 1438 1255 Max direct kW rating DIMENSION 250L SI 260L SD 300L SI 1845 1909 2160 Immersion heat up times...

  • Page 8: General Installation

    The Cold Water Inlet Control kit supplied fitted to the Megaflo Eco SolaReady incorporates a full flow isolating valve which will enable the Megaflo Eco SolaReady to be isolated from the mains supply for maintenance or servicing. To close the valve the blue handle should be turned so that it lies at 90º...
  • Page 9 8 Bar Pressure Relief (Expansion) Valve – supplied fitted (see figure 4) This is installed between the 3 bar Pressure Reducing Valve and the Megaflo Eco SolaReady cylinder. Branches to drinking water outlets should be taken before the Pressure Relief Valve to avoid the possibility of warm expanded water being drawn from the tap.
  • Page 10 Figure 5 – Cold and hot water supply circuits Balanced HWS and Blending valve 8 Bar Pressure Relief MCWS to bathrooms, HWS supply Factory tted Valve (combined showers, cloakrooms, Expansion Relief Valve/Check Valve Balanced cold water – factory tted) draw-o Temperature/Pressure 3 Bar Pressure Reducing Relief Valve...
  • Page 11 Drain Tap A drain tap is supplied fitted in the cold water supply to the Megaflo Eco SolaReady unit between the 8 Bar Pressure Relief Valve and the heater at the lowest point of the cold water supply pipe. It is recommended that the outlet point of the drain pipe work be at least 1 metre below the level of the heater (this can be achieved by attaching a hose pipe to the drain tap outlet spigot).
  • Page 12 T&P Relief Valve Insulation A set of insulating components is supplied with the Megaflo Eco SolaReady water heater and should be installed to gain maximum heat and energy saving benefits. See Figure 8 (below), for installation instructions. Warnings Under no circumstances should the factory fitted Temperature /Pressure Relief Valve be removed other than by authorised Heatrae Sadia personnel.
  • Page 13 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.
  • Page 14 The following extract is taken from the latest G3 Regulations Discharge pipes from safety devices Discharge pipe D1 3.50 Safety devices such as temperature relief valves or combined temperature and pressure and pressure relief valves (see paragraphs 3.13 or 3.18) should discharge either directly or by way of a manifold via a short length of metal pipe (D1) to a tundish.

  • Page 15: Installation Of Solar Primary Hydraulic Station

    Installation of solar primary hydraulic station Figure 10 The solar primary hydraulic station and differential temperature controller are supplied pre-fitted to the Megaflo Eco SolaReady unit. The solar pump and various thermal sensors are pre-wired to the controller, but will require correct installation in the solar primary circuit.
  • Page 16 Connecting the solar expansion vessel Mount the solar expansion vessel (Fig 11 Item 5) adjacent to the hydraulic station so that the vessel can be connected to the vessel connection of the safety group (Fig 11 Item 3) using the flexible pipe (Fig 11 Item 6) supplied. (Note: Solar expansion vessel, mounting bracket, self sealing connection and flexible pipe are supplied in the Ancillary Components kit).

  • Page 17: Direct Model

    Direct Model Immersion Heater(s) The Megaflo Eco SolaReady Direct is supplied with two factory fitted immersion heaters, each rated 3kW at 240V. See fig 2 page 7 for positions. Wiring (See Figure 16) All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E. Wiring Regulations.

  • Page 18: Indirect Model

    Boiler Selection The Megaflo Eco SolaReady Indirect models are supplied with an auxiliary heating coil and are suitable for use with most gas or oil fired boilers compatible with unvented systems i.e. fitted with a temperature control thermostat and thermal cut-out. If in doubt consult the boiler manufacturer.
  • Page 19 Figure 16 – Wiring diagrams Diagram A In conjunction with auxiliary heating boiler – no reheat control by solar differential controller. 3A fused supply Boiler terminal strip Programmer DHW CH ON Terminal box (supplied) Link Link Link Link Cylinder auxiliary controls DHW 2 port valve CH 2 port valve CH pump...
  • Page 20 Diagram D In conjunction with auxiliary heating boiler with a 3 port mid position valve system - no reheat control via solar controller . 3A fused supply Boiler terminal strip Programmer DHW ON DHW OFF CH ON Terminal box (supplied) Link Link Link...

  • Page 21: Installation Of Solar Differential Temperature Controller

    Installation of solar differential temperature controller Figure 17 The solar differential temperature controller is fitted on the solar hydraulic pump station. It must be removed from the moulded housing for access to electrical connections. Electrical connection overview Always disconnect from the mains before opening the controller cover.

  • Page 22: East West Array Kit

    East West Array Kit Where two collectors are used on independent circuits eg Diagram E East / West array. The pipework should be designed as Diagram E to allow the system to operate correctly. Where a compression tee is introduced to the circuit it is highly recommended that brass olives are used to overcome potential high temperature issues.

  • Page 23: Commissioning

    Vent any trapped air by opening the air bleed. Switch on the boiler, ensure the programmer is set to Domestic Hot Water. Allow the Megaflo Eco SolaReady unit to heat up and check that the indirect thermostat and 2-port motorised valve operate correctly. A storage temperature of approx. 60ºC is recommended.

  • Page 24: Commissioning Of Solar Primary System

    Commissioning of solar primary system Air Test An air test may be used on the solar primary pipework to Figure 19 detect any gross leakage prior to flushing and filling with solar heat transfer fluid. Pressurise the system to a maximum 45°...

  • Page 25: Commissioning Of Hydraulic Station

    Solar fluid Close the fill and drain valve - safety group (Fig. 19 Item 1) Figure 21 and the fill and drain valve - flow meter (Fig. 19 Item 2) and pressurise the pump slightly prior to filling the system. If an electric pump is being used follow the Fig.

  • Page 26: Temperature Controller

    Misc icon 2 Misc icon 1 info Misc icon 3 manual operation basic adjustment programming Misc icon 1 info Misc icon 2 Misc icon 3 basic adjustment programming Misc icon 4 manual operation Misc icon 2 5x7 segment display Fig. 28 Misc icon 4 Misc icon 3 manual operation...
  • Page 27 MENU “INFO” MENU “PROGRAMMING” The Info menu shows the following readings and yield values: The Programming menu is used to display operating parameters and to change these as required. The preset values generally ensure fault-free Inclination Reset system operation. Meaning e.g.
  • Page 28 MENU “MANUAL OPERATION” Display Factory Meaning Value range setting Line Value For commissioning service and test purposes the solar primary system System diagram can be manually operated. For this purpose the switch outputs may be disconnected or connected. Primary storage tank selection WARNING: During manual operation there is no automatic regula- Multiple storage tank systems 30-480...
  • Page 29 OVERVIEW OF DISPLAY AND OPERATING ELEMENTS Graphic Indication in Graphic Description Description Indication in operation symbol operation symbol Measuring points assignment Indicator values Temperature measuring point collector Temperature difference array 1 Temperature measuring point collector Appears when minimum Minimum value array 2 values are indicated Temperature measuring point storage...
  • Page 30 Commissioning of solar differential temperature controller “Basic Setup” menu “Basic Setup” menu Display Display Value Factory Factory Meaning Value range Meaning setting range setting Line Value Line Value Type of pump 1 = HE pump: Analogue or Controller response time in s 30-480 control non-inverse PWM control...
  • Page 31 • Temperature difference “Basic Setup” menu For independent temperature difference controllers, minimum (e.g. solid Display Factory Meaning Value range fuel boiler) and maximum temperature limits possible. setting Line Value If the difference between both measurement points exceeds the hystere- Variable selection: 0 = Off sis set, then A3 is activated.
  • Page 32 PROTECTIVE FUNCTIONS ADDITIONAL FUNCTION 1. ENERGY YIELD MEASUREMENT The controller is equipped with the following protective functions. The energy yield of the solar power system is calculated and displayed 1. COLLECTOR PROTECTION using the temperature difference between the collector and collector If the storage tank has reached the set maximum temperature and the return temperature, plus the measured flow rate.
  • Page 33 Thermostat (heating) The thermostat is an independent control circuit from the storage loading. Thus, auxiliary heating of the top area of the storage cylinder is made possible. The output A3 will be (see Fig 23, below): • Switched on, when the temperature falls below the adjusted start level. 11.0 Commissioning of solar controller •...
  • Page 34 The customer should then countersign the Benchmark™ commissioning checklist (page 48) to accept completion. The Service Record (page 50) should be filled in when any subsequent service or maintenance operation is carried out on the Megaflo Eco SolaReady unit (See Maintenance and Servicing, page 36).

  • Page 35: Commissioning Record

    COMMISSIONING OF THE SYSTEM SOLAR DIFFERENTIAL TEMPERATURE CONTROLLER - OPERATIONAL PARAMETERS The following chart should be completed during Comissioning of the system. If any factory values are changed please enter the new values in the table below. Installer: Adjustable in menu Typical Current Contact details:...

  • Page 37: Maintenance

    Switch off the electrical supply to the immersion heater(s) and shut down the boiler on indirect units. Turn off the mains water supply to the Megaflo Eco SolaReady unit. Attach a hosepipe to the drain cock having sufficient length to take water to a suitable discharge point below the level of the unit, at least one metre below the unit is recommended.
  • Page 38 The Fault finding flow diagrams (Fig 27) will enable operational faults to be identified and their possible causes rectified. Any work carried out on the Megaflo Eco SolaReady unvented water heater and its associated controls MUST be carried out by a competent...

  • Page 39: Fault Finding

    Fault finding: FAILURES WITH ERROR MESSAGE FAILURES WITHOUT ERROR MESSAGES Some system failure modes can be recognised by the solar differential For faults and malfunctions that cannot be displayed, you can use temperature controller and will be indicated by an error message on the the following table to identify them, plus evaluate the possible causes controller display.
  • Page 40 Figure 27 - Fault diagrams No hot water flow Is the mains water Turn on mains water supply supply turned on? Turn off water supply. Remove and Is the strainer blocked? clean filter (see Fig 33) Is the cold water Check and refit as required.
  • Page 41 Water discharge from Water from hot taps is temperature and pressure lukewarm relief valve Expansion valve not opening at Heating fault – Is the discharge Follow steps as for cold water correct pressure. Replace expansion water may have cooled intermittent? relief valve cartridge Thermal control failure.
  • Page 42 No display at solar differential temperature controller Is the 230/240V~ power supply correctly Connect any wiring faults wired? Is the 230/240V~ power Switch on power supply supply switched on? Reset thermal cut-out. Investigate cause of operation and rectify. Has thermal cut-out on NOTE: Allow the cylinder to cool cylinder operated? or draw off the hot water before...

  • Page 43: Servicing

    Spares Spare parts A full range of spare parts are available for the Megaflo Eco SolaReady range. Refer to the Technical Data label on the unit to identify the model installed and ensure the correct part is ordered. Description Part no.
  • Page 44 Figure 18 - Exploded View of 3 Bar Inlet Control Valve Figure 28 – Exploded view of 3 bar inlet control valve Pressure Reducing Valve Cartridge (3 Bar) Strainer Mesh 3 Bar Pressure Reducing Valve - Complete 95:605:886 Figure 29 – Exploded view of 8 bar pressure relief valve Figure 19 - Exploded View of 8 Bar Pressure Relief Valve Expansion Relief Cartridge 8 Bar Pressure Relief Valve, Complete...
  • Page 45 Indirect units Direct units mbly Short 1/2”BSP Sensor Pocket Assembly Short 95:607:938 Combined Thermostat and in Combined Thermostat Direct Combined Thermal Cut-Out Thermostat and d Thermal Cut-Out 95:612:717 Thermal Cut-Out 95:612:716 95:612:717 Mounting Plate (Direct) ate (Indirect) 95:607:929 Terminal cover Terminal cover Solar Thermal Cut-Out 95:614:118...
  • Page 46 Direct Combined Thermostat and Thermal Cut-Out 95:612:717 Mounting Plate (Direct) 95:607:929 1/2”BSP Sensor Pocket Assembly Short 1/2”BSP Sensor Pocket Assembly Long 95:607:938 7032579 Titanium Immersion Heater (Upper) Three Way Terminal Block Direct Combined 95:606:989 95:607:932 Thermostat and Thermal Cut-Out 95:612:717 Gasket Mounting Plate (Direct) Backnut...
  • Page 47 SPARE KITS Nº ITEM NUMBER DESCRIPTION 720691501 Wall mounting set - Group 7225258 7225259 7225263 Thermometer 0º-120º - Red 7225260 Thermometer 0º-120º - Blue 7225264 Venting circuit DN25 720688701 Flow meter 2-15 l/min 7225266 Pump PWM connector - FCI Connector 2m 7225265 Pump power supply connector - TE Superseal 2m 7222382...

  • Page 48: Spares Stockists

    Spares Stockists Electric Water Heating Co. 2 Horsecroft Place Pinnacles Harlow Essex CM19 5BT Tel: 0845 0553811 E-Mail: sales@ewh.co.uk Special Product Division Units 9 & 10 Solar expansion vessel self-sealing connection Hexagon Business Centre 5119779 Springfield Road Hayes Solar expansion vessel 24 litres 5119548 Middlesex UB40 0TY...
  • Page 50 SOLAR THERMAL COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the Solar Thermal System and associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • Page 52: Customer Service Contacts

    Customer service Telephone: Megaflo 0344 8711535 Hurricane Way Facsimile: Norwich 0344 8711528 Norfolk NR6 6EA E-mail: megafloservice@baxi.co.uk The HWA Charter’s Code of Practice requires that all members adhere to the following: • To supply for purpose products clearly and honestly described •...

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