Main Solar 190 S Ind Installation Manual

Unvented solar indirect water heaters

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36006095_issue_08

Installation Manual

Unvented Solar Indirect Water Heaters Installation & Servicing

Instructions

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Page 1 36006095_issue_08 Installation Manual Unvented Solar Indirect Water Heaters Installation & Servicing Instructions...
Page 2 Pack Contents Solar unvented water heater incorporating immersion heater(s) & thermal controls Factory fitted temperature/pressure relief valve (set at 90°C / 1 Mpa (10bar)) Cold water combination valve assembly...
Page 3 Expansion vessel & mounting bracket Tundish 2 Port motorised valve Compression nuts & olives Immersion heater spanner Installation & servicing instructions Guarantee card IMPORTANT Please read & understand all these instructions before commencing installation. Please leave this manual with the customer for future reference. page 1 Contents Introduction...
Page 4: The Benchmark Scheme
Spares Heat Loss Environmental Information Commissioning Check List. Service Record Guarantee Technical Support Introduction The cylinder is a purpose designed unvented water heater. The unit has a stainless steel inner vessel, which ensures an excellent standard of corrosion resistance. The outer casing is a combination of resilient thermoplastic mouldings and plastic coated corrosion proofed steel sheet.
Page 5: General Requirements
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations.
Page 6: Water Supply
Type Model Reference Nominal Capacity Weight of unit full Weight of unit (litres) (Kg) (Kg) 190 S Ind 210 S Ind Solar Indirect 250 S Ind 300 S Ind Table 01: Unit weights Water Supply Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously.
Page 7: Important Note
Wherever possible the mains supply pipe should be 22mm. We suggest the minimum supply requirements should be 0.15MPa (1.5 bar) pressure and 20 litres per minute flowrate. However, at these values outlet flow rates may be poor if several outlets are used simultaneously. The higher the available pressure and flow rate the better the system performance.
Page 8: Operational Summary
- Tundish - Combination valve - Expansion vessel - Tool - Element spanner - Compression nuts & olives - 2 Port motorised valve Literature pack - Installation manual - Guarantee card Operational Summary Maximum mains pressure 1.6MPa (16 bar) Operating pressure / PRV 0.35MPa (3.5 bar) Maximum design pressure 0.6MPa (6 bar)
Page 9: Installation General
Weight when full See Table 1 All models in conformance with BS EN 12897:2006 Note: Although the primary coil pressure rating is 1.0Mpa (10 bar) the 2 port zone valve supplied with the cylinder is only rated 0.86MPa (8.6 bar). If the cylinder is to be plumbed into a system delivering 1.0MPa (10 bar) a suitable 2 port zone valve will have to be sourced.
Page 10 is recommended that the expansion vessel is adequately supported. An expansion vessel wall mounting bracket is supplied for this purpose and should be fitted. Secondary Circulation If secondary circulation is required it is recommended that it be connected to the cylinder as shown (see Fig.
Page 11 Fig. 03: Secondary Circulation Connection page 5...
Page 12 Fig. 04 General Dimensions Type Model Dimensions (mm) Solar Auxiliary Coil Heat- Hot Water Capacity Reference Volume Volume Rating (kW) Time (ltrs)
Page 13: Installation Discharge
(ltrs) (ltrs) (mins) (volume of water drawn Solar Auxiliary >40°C) 190 S 1401 1085 784 14.2 210 S 1499 1186 1012 1026 85 15.0 Solar Indirect 250 S 1752 1438 1143 1279 95 15.2 300 S 2065 1752 1440 1592 120 17.4 Table 02: Dimensions and Performance Notes:...
Page 14 Discharge pipes from safety devices Discharge pipe D1 3.50 Each of the temperature relief valves or combined temperature and pressure relief valves specified in 3.13 or 3.17 should discharge either directly or by way of a manifold via a short length of metal pipe (D1) to a tundish.
Page 15 for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device; between 18 and 27m at least 3 sizes larger, and so on; bends must be taken into account in calculating the flow resistance (see Table 03) and the worked example.
Page 16 3.63 The discharge would consist of high temperature water and steam. Asphalt, roofing felt and nonmetallic rainwater goods may be damaged by such discharges. Worked Example of Discharge Pipe Sizing Fig. 05: shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.
Page 17 35mm UP TO 27M 1.4M G 3/4 22MM 28mm UP TO 9M 1.0M 35mm UP TO 18M 1.4M 42mm UP TO 27M 1.7M 28MM 35mm UP TO 9M 1.4M 42mm UP TO 18M 1.7M 54mm UP TO 27M 2.3M Table 03: Sizing of copper discharge pipe (D2) for common temperature relief valve outlet sizes NOTE: The table above is based on copper tube.
Page 18: Installation - Solar
Figure 05: Typical Discharge Pipe Arrangement (Extract From Building Regulation G3 Guidance Section 5.50) page 9 Fig. 06: Typical SOLAR Installation - Schematic page 10 Installation - Solar Connection To Solar Primary Circuit The lower (solar) coil of the SOLAR cylinder must be connected to a fully pumped solar primary circuit. The connections are suitable for 22mm copper pipe direct to the compression fittings provided.
Page 19 Control of Solar Primary Circuit Temperature control of the SOLAR cylinder must be carried out using a suitable proprietary solar controller/ programmer. The cylinder temperature sensing probe (supplied with the solar controller) should be fully inserted with the thermal cut-out probe into the pocket provided on the SOLAR cylinder. The cable must be secured using the cable clamps on the controls housing.
Page 20 Installation - Auxiliary Heating Coil Safety DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS. Never attempt to replace the immersion heater other than with the recommended authorised immersion heater(s). DO NOT BYPASS THE THERMAL CUT-OUT(S) IN ANY CIRCUMSTANCES. Ensure the two male spade terminations on the combined thermostat and thermal cut-out are pushed firmly onto the corresponding terminations on the element assembly.
Page 21 Primary Circuit Control The 2 port motorised valve supplied with the cylinder MUST be fitted on the primary flow to the cylinder heat exchanger (coil) and wired in series with the indirect control thermostat and thermal cut-out fitted to the unit. (see Fig. 08) Primary circulation to the cylinder heat exchanger (coil) must be pumped; gravity circulation WILL NOT WORK.
Page 22 NOTES: Control terminal numbering may differ from those shown. Refer to instructions with controls selected. A double pole isolating switch must be installed in the mains supply. All earth connections must be connected back to the mains earth supply. Fig. 09: Schematic Wiring Diagram - Basic 2 x 2 port valve system ( 'S' plan )
Page 23: Filling The Unit With Water
NOTES: Control terminal numbering may differ from those shown. Refer to instructions with controls selected. A double pole isolating switch must be installed in the mains supply. All earth connections must be connected back to the mains earth supply. Fig. 10: Schematic Wiring Diagram - 3 port mid position valve system, ( 'Y' plan ). N.B. Must be used in conjunction with 2 port zone valve supplied page 13 Commissioning...
Page 24: System Checks
Check expansion vessel pre-charge pressure The vessel is supplied precharged to 0.35MPa (3.5 bar) to match the control pressure of the pressure reducing valve. The precharge pressure is checked using a car tyre gauge by unscrewing the plastic cap opposite the water connection. Check all connections for tightness including the immersion heater(s).
Page 25: Maintenance Requirements
explained to the customer. The customer should then countersign the Benchmark Commissioning Checklist to accept completion. The service record should be filled in when any subsequent service or maintenance operation is carried out on the product. Fig. 11: Indirect Thermostat and Thermal Cut-out page 14 Maintenance Maintenance Requirements...
Page 26 Similarly cleaning of the strainer element and replacement of the air in the expansion vessel will help to prevent possible operational faults. The maintenance checks described below should be performed by a competent person on a regular basis, e.g. annually to coincide with boiler maintenance. After any maintenance, please complete the relevant Service Interval Record section of the Benchmark Checklist at the end of this document.
Page 27 inserted into one of the thermostat pockets whilst the backnut is tightened. Replace the terminal shroud. Connect wiring to element. Check, and close and secure immersion heater housing cover. Expansion Vessel Charge Pressure While system is de-pressurised check expansion vessel charge pressure. Remove the dust cap on top of the vessel.
Page 28: Temperature Controls
All installations must be notified to Local Area Building Control either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer who should, on receipt, write the Notification Number on the Benchmark Checklist. This product should be serviced regularly to optimise its safety, efficiency and performance.
Page 29: Fault Finding & Servicing
Fault Finding & Servicing Important After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located at the end of this document. Servicing should only be carried out by competent persons in the installation and maintenance of unvented water heating systems.
Page 30 Direct immersion heater thermal cut-out Check, reset by pushing button on has operated thermostat Indirect programmer set to central heating Check, set to domestic hot water only programme Indirect boiler not working Check boiler operation. If fault is suspected consult boiler manufacturer's instructions Indirect thermal cut-out has operated Check, reset by pushing button on...
Page 31 page 17 Spares Item Number Description Part Number Immersion heater 95 606 961 Immersion heater gasket 95 611 822 Immersion heater backnut 95 607 869 Immersion heater key spanner 95 607 861 Tundish 95 605 838 Cold water combination valve - complete 95 605 897 Direct combined thermostat and thermal cut-out 95 612 717...
Page 32 Terminal shroud 95 606 993 Temperature / pressure relief valve 95 605 810 Table 05: Spares Fig. 12: Solar Cylinder Spares Diagram page 18...
Page 33: Commissioning Check List
Heat Loss Nominal Capacity Standing Heat Loss (Litres) per day per year (kWh/24h) (kWh/365d) 1.65 1.75 1.98 2.33 Table 06: Standing heat losses (based on an ambient air temperature of 20°C and a stored water temperature of 65°C) Environmental Products are manufactured from many recyclable materials. At the end of their useful life they should be disposed of at a Local Authority Recycling Centre in order to realise the full environmental benefits.
Page 35: Service Record
page 20 Service Record...
Page 37 The Benchmark Checklist has been completed upon commissioning and the Benchmark Service Record is completed for each service. It has not been modified in any way, other than by MAIN SOLAR. It has not been frost damaged. It has only been used for the storage of potable water.
Page 38 CV34 4LL Tel: 0844 871 1532 The policy of MAIN SOLAR is one of continuous product development and, as such, we reserve the right to change specifications and guarantee terms and conditions without notice. 36006095_issue_08 page 24...

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