Summary of Contents for THERMAL INTEGRATION XCEL
- Page 1 XCEL HEAT BANKS Installation Instructions Thermal Integration Ltd., 8 Curzon Road, Sudbury, Suffolk CO10 2XW Rev03-09032018 Tel: 0845 2411441...
- Page 2 Xcel as a pressurised storage system, using the optionally supplied safety controls in place of a feed tank, providing the Xcel is not connected to a uncontrolled heat source such as wood burner or large solar array.
- Page 3 Standard Wiring: 1: Boiler Control 2: Central Heating 3: Secondary Circulation...
- Page 4 Power supplies to boilers and other equipment that has wiring connections, should be taken from the wiring centre on the Xcel. The Xcel can be optionally supplied with 3kW, 6kW, or 9kW electric elements, with up to three elements in total. Power supplies should be as follows: (a) For 3kW elements, a 16 Amp , 230v AC power supply, via a double-pole wall switch.
- Page 5 (a) Expansion Vessel of size equal to, or greater than, 25% of total system volume, and having a pre-charge pressure between 0.9 and 1 bar. (b) 2.5 bar Expansion Relief Valve, connected to a bottom (cold feed) connection on the Xcel, or adjoining pipework (without possibility of isolation from the Xcel).
- Page 6 (b) The flow switch passes a live signal to the circulating pump via the relay. (c) Hot water is pumped into the heat exchanger from the top of the Xcel, heating up the mains water supplied to taps. (d) When the tap is shut, the flow switch removes live feed from the pump 11.
- Page 7 Xcel, through the boiler, and back to the top of the Xcel. (c) Once the top of the Xcel reaches > 55°C, the return mixer starts drawing from the base connection to the Xcel, to regulate return temperature.
- Page 8 Thermostats located at the top of the Xcel can provide an economy mode, heating up small quantities of hot water for low-medium hot water demand. Thermostats located at base of the Xcel can provide a heavy demand mode, where the entire volume of the store is heated.
- Page 9 Note:)The)preceding)thermostat)options)bXLRR9qP;)qS;)qB,)are)intended)to)provide)a)switched)live)LARVac)signal)to)call)a) gas))y)oil)fired)boilerI)or)similar)heat)sourceI)to)fireZ))In)the)case)of)appliances)that)required)a)voltqfree)y)clean))contact)call) beZgZ)MCZ)pellet)boilers)and)stoves,I)the)call)out)from)the)cylinder)thermostatys)must)be)passed)via)a)relayZ)This)can)be) retrospectively)fitted)during)installation)bpart)no:)XLRR9qL)RELAY)can)be)obtained)for)this)purpose,Z) AlternativelyI)The)following)preqwired)thermostat)options)provide)this)facility)if)the)unit)has)been)ordered)with)them: XLRR9qBPqVF:)Single)Thermostat)for)VoltqFree)Boiler)Input 17vvPre9wiredvsinglevthermostat0vsuitablevforvusevwithvanyvboilervthatvrequiresvavvolt9freev)vcleanvcontactvcallvtovfire7 27vvComprisesvpre9wiredvthermostatvonly:vDoesvnotvincludevpre9plumbedvGXvassembly7 37vvWiringvincludesvavsinglevpolevrelayvthatvgivesvvolt9feevswitchedvcallvforvheat7 47vvElectricalvconnections:v XLRR9qSqVF:)Thermostat)and)Relay)for)VoltqFree)Buffering)Boiler)Input 17vvPre9wiredvtwinvthermostatsvsuitablevforvusevwithvanyvboilervthatvrequiresvavvolt9feev)vcleanvcontactvcallvtovfire 27vvComprisesvpre9wiredvthermostatsvonly:vdoesvnotvincludevpre9plumbedvGXvassembly7 37vvWiringvincludesvavdoublevpolevrelayvthatvprovidesvlatchingvcircuitvforvbufferedvoperationvXasvpervX2MM997W0vandvalsovgives volt9freevswitchedvcallvforvheat7 47vModevofvoperationvisvasvpervXLRR9qS 57vvElectricalvconnections:...
- Page 10 X2009-9: Overheat Thermostat. The overheat thermostat is wired to pass a live to a central heating pump to initiate central heating once the stored water reaches 90°C, thereby cooling the store and preventing overheating due to continued heat input from wood burners or solar panels. If motorised valves or actuators are fitted on heating circuits, then the overheat thermostat must be wired so as to open the appropriate valve(s) and initiate the circulation pump for the overheat dump circuit.
- Page 11 X2009-13: Overheat Discharge to Drain. The overheat discharge system uses a mechanical thermostatic valve to discharge water to drain via a coil in the Xcel, thereby cooling stored water and preventing overheat. The discharge valve is factory set to 95°C and cannot be adjusted.
- Page 12 The economy mode should be used as standard where the Xcel is connected to alternative heat sources such as wood burners or solar panels. This ensures that the majority of the water in the Xcel is not heated by the boiler and can therefore be used for storing heat from the alternative sources.
- Page 13 Integration with Heat Pump Systems: The Xcel Heat Bank can act as a buffer between a heat pump and the central heating system, allowing heat pump to be combined with other heat sources for both hot water and heating. Heat pumps are generally connected into the lower half on the Xcel, with higher temperature heat sources (wood burners, gas boilers) using the upper half of the store.
- Page 14 This is the simplest form of connection of a wood burner, and the most often used. The Xcel is provided with two 1½” Bosses for connection of pipework up to 42mm, is required. Read in conjunction with section on X2009-13: Overheat Discharge to Drain.
- Page 15 Overheat protection is not detailed in top schematic, and should be provided from Xcel. The Gravity Valve allows gravity circulation to operation in conjunction with a pumped flow. The Return Mixer re-circulates water through wood burner until temperatures reach 60°C, preventing low flue...
- Page 16 For use with Wood Burners installed where gravity circulation is not possible, and a dump radiator can be uinstalled for overheat protction. Overheat protection is not detailed in top schematic, and should be provided from Xcel. The Gravity Valve allows gravity circulation to operation in conjunction with a pumped flow.
- Page 17 Installation of gravity swing check valve on pumped wood burner with gravity heatleak radiator FULLY PUMPED EXAMPLE Pumped flow to thermal store Pumped return from thermal store Return from Thermal Store (Pumped) Return from Heat Leak circuit (Gravity Return to Wood Burner...
- Page 18 Example Schematic, Wood Burner remote from Xcel: For use with Wood Burners installed where gravity circulation is not possible, and a heat leak radiator is impractical. Heat Leak Plate Heat Exchanger provides overheat protection, during pump or power failure. Cold mains water is passed through the heat exchanger when the wood burner achieved 94°C. The mains water cools the gravity circuit above the wood burner, and is then discharged to drain.
- Page 19 Example Schematic, Wood Burner above Xcel: For use with Four-Port Wood Thermostatic Burners. Heat Leak Radiator provides overheat protection, during pump or power failure. The Gravity Valve prevents unwanted heat leak. The Return Mixer re-circulates water through wood burner until temperatures reach 61°C, preventing low flue temperatures that result in deposits.
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Page 20: Installation Notes
Installation Notes IC8x40 Plate Heat Exchanger Specifications: (used in assemblies X2009 -2, -4, -8) BT12x40 Plate Heat Exchanger Specifications: (used in assemblies X2009 –2A) Table of Heat Losses from Uninsulated Copper Pipe: This table highlights the importance of insulating pipework. Heat loss for fluid inside pipe Nominal bore (W/m) - Page 21 General Plumbing Requirements NEW COMPLETE SYSTEM INSTALLATIONS When carrying out a completely new heating system installation in a new build property or a first time installation in an existing property, then the heating system must conform to current building regulations Part L1a. All new domestic heating systems must have a minimum of two heating zones.
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Page 22: General Wiring Requirements
General Wiring Requirements These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations. Component specific electrical information may also be supplied in support of these instructions, however if there is any doubt please contact Thermal Integration Ltd. -
Page 23: Commissioning Checklist
Commissioning Checklist Please return this form to: Thermal Integration Ltd., 8 Curzon Road, Sudbury, Suffolk, CO10 2XW. Tel: 0845 241 1441 The Installer should fill out the following section before leaving this form with the end user. The End User should fill out the following section before returning this form to Thermal Integration Ltd. -
Page 24: Warranty Information
Damage arising from faulty site installation or wiring. 7. Report any faults to your installer, service engineer or Thermal Integration directly. Faulty parts must be accompanied by a fully completed Thermal Integration Warranty Return form, to be returned to Thermal Integration. Returned items remain the property of Thermal Integration Ltd.
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