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Summary of Contents for elco Gemini HSC Series
- Page 1 Gemini HSC Stainless Steel Tank in Tank Indirect Hot Water Cylinders Models - 200-i, 300-i & 500-i Installation and Operating Instructions Page 1 of 28 issue draft Date March 2023...
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Page 2: Table Of Contents
Index Section Topic Page No Overview & Regulations ..…..…………………………………… Technical data & dimensions …………………………………… Installation ……………………………………………………….. Connections …………………………………………………….… Self-cleaning fluxes ……………………………….……………… Hard water ………………………………………………………… Unvented systems ……………………………………………….. Expansion vessels pre-charge pressure …………….………… Expansion vessel capacity …………………………….………… Safety relief valves discharge pipes ………………….………… Tundish positioning and discharge ………………………………... -
Page 3: Overview & Regulations
Overview The Gemini HSC range of high performance indirect hot water cylinders are WRAS approved for UK (dhw) systems. The calorifier range is constructed from two concentric cylindrical tanks (tank within a tank), a principle which provides many advantages over conventional coil or tube type calorifiers. - Page 4 The Public Water Supplies (Scotland) Regulations 2014 - as amended The Water Supply (Water Fittings) Regulation (Northern Ireland) 2009 - as amended British Standards BS 6880 Part 1, 2 & 3 Code of Practice for low temperature hot water heating systems of output greater than 45kW.
- Page 5 HTM 04-04 The Control of Legionella in Health Care Premises- Code of Practice: 2006 General Requirements All connections to the local water main must comply with Water Supply (Water Fittings) Regulations 1999 (as amended). Compliance with the Regulations can be demonstrated by certification from notified body organisations such as WRAS or KIWA.
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Page 6: Technical Data & Dimensions
Technical data & dimensions Dimensions 2.1.1 MODEL Units 200 - i 1239 300 - I 1724 500 - I 1730 Page 6 of 28 issue draft v3 Date Mar 2019... - Page 7 2.1.2 Connections - plan view Primary MODEL DHW feed Secondary Flow & draw-off Return Return ** see note c & d ** see note 1” BSP - F ¾” BSP - M ¾” BSP - M ¾” BSP - M 200 - i 1”...
- Page 8 2.1.3 Performance data Note - performance of the unit will vary with operating conditions MODEL 200 - i 300 - i 500 - i Units DHW Capacity Primary Capacity Heating Surface Primary Flow 80°C & Return 70°C Heat Transfer Primary Circuit Pressure Drop 10 min Peak Output @ 50°C ̗...
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Page 9: Installation
All models are suitable for horizontal installation, with a cradle being needed to support the tank (not Elco supply). Important - any Gemini HSC tank installed in a horizontal plane must only be connected to an open vented system. Horizontally mounted Gemini tanks MUST NOT be... -
Page 10: Self-Cleaning Fluxes
Self-cleaning fluxes Excessive use of self-cleaning fluxes on copper pipework local to the calorifier should be avoided. 6 Hard Water In known hard water areas the use of scale prevention measures is recommended. Ensure compatibility with stainless steel material. No warranty is provided for components such as immersion heaters that are damaged through sludge build up and lack of maintenance. -
Page 11: Expansion Vessels Pre-Charge Pressure
Component part 1” F Equal Tee Component part Table 7.2 - Unvented kit components supplied by ELCO Heating Solutions are suitable for use on domestic hot water system and are either WRAS or KIWA certified. 8 Expansion Vessel pre-charge Pressure It is the responsibility of the installer to check the air pre-charge pressure before installation and adjust as necessary to 3.5bar. -
Page 12: Tundish Positioning And Discharge
device (i.e. the temperature pressure relief valve) and must be away from any electrical device. The discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, according to Building Regulation G3. Note: The discharge will consist of scalding water and steam. -
Page 13: Electrical Installation
12 Electrical installation Wiring should be carried by a competent electrician in accordance with the current edition of the IEE Regulations. Thermostats within the control panel are rated at 2.5 A / 230V. Should electrical loads exceed this rating, a suitably rated contactor or relay must be interposed. An appropriately rated isolator and fuses should be installed to protect the control and load circuits. - Page 14 12.1 Control panel Figure 12.1 - control panel 12.2 Electrical connections Figure 12.2 - remove the control panel Page 14 of 28 issue Date March 2019...
- Page 15 Figure 12.3 - Installing the control panel wiring Remove the 4 off fixing screws (1) retaining the control panel - see fig 12.2 Carefully rotate the control panel (2) to expose the electrical connection terminal rail (3) Carefully cut out the cable entry aperture (5) on the top cover (4) - see fig 12.3 Lift up the top cover (4), whilst removing the cleaning access cover panel (9) Route appropriately sized cables (multi-strand flex only) (6) through the aperture (5), through the cable clamp (8) and carefully guide the cables down through the cable tube...
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Page 16: Electrical Connections - Optional Immersion Heaters
Note: this option is not available on models 200-i or 300-i. Recovery time at 50°C Δt detailed in table 13.1 NOTE a Three Phase contactor will need to be installed if using this option (NOT Elco SUPPLY). Wiring - Ensure that the electrical connections have been correctly made - refer to Fig 12 and that the supply is of adequate rating with a correctly sized fuse. -
Page 17: Typical Installation Schematics
Maintenance - The immersion heater must be electrically isolated before removing the terminal cover. Periodically inspect the element to check for any deposit build up on the element. This can be achieved by isolating the tank from the primary circuit and draining down the primary tank through the drain valve, ensuring that the manual primary air vent located adjacent to the primary flow connection, is open. - Page 18 Figure 14.3 - Typical unvented multiple calorifier schematic When making a horizontal installation it is necessary to reverse the cold water inlet and hot water outlet (secondary) connections. Regardless of r/h or l/h installation, the control panel must always face the side and the primary flow and return connections must always be top &...
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Page 19: Commissioning
Warning - failure to observe the correct filling sequence (inner tank first) may lead to irreparable damage to the calorifier due to pressure. 13. Manually open the motorised valve if fitted (not Elco supply) in the primary circuit and fill, flush and vent the primary tank observing any instructions from the boiler manufacturer. -
Page 20: User Instructions
17 Regular Maintenance To ensure safe and continued performance of the water heater it is a requirement that the unit should be regularly maintained and only genuine spare parts from Elco Heating should be used. Maintenance should be carried out at intervals not exceeding 12 months by a competent... -
Page 21: Draining The Cylinder
Isolate the electrical supply and remove the immersion heater cover panel Disconnect the electrical connections from the immersion heater noting the location. Remove the fixing bolts from the circumference of the mounting plate. Withdraw the immersion heater element to the front and then to the side. -
Page 22: Internal Inspection
Figure 19.1 - remove the dip tube Figure 19.2 - dip tube assembly assembly Figure 19.3 - access to cleaning port Internal inspection (secondary) The Gemini HSC range is designed to allow internal inspection and cleaning of the tank. 1 Isolate and drain the DHW tank as described in section 18 2 Disconnect and remove all secondary pipe work, so as to provide full access for removal of the tube plate &... -
Page 23: Spares
Spares Exploded view Page 23 of 28 issue draft v3 Date Mar 2019... - Page 24 Spares part numbers Key Description Model 200-i 300-i 500-i Part No. ✓ ✓ Connection port flange 148014032 ✓ ✓ Connection port flange 006849848 ✓ Connection port counter flange 148014038 ✓ Connection port counter flange 006849848 ✓ ✓ ✓ Connection port gasket 148014040 ✓...
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Page 25: Notes
21 Notes This section is left intentionally blank for notes: ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… ……………………………………………………………………………………………………… Page 25 of 28 issue draft v3 Date Mar 2019... - Page 26 Page 26 of 28 issue draft v3 Date Mar 2019...
- Page 27 Page 27 of 28 issue draft v3 Date Mar 2019...
- Page 28 ELCO UK 3 Juniper West, Fenton Way, Southfields Business Park, Basildon, Essex SS15 6SJ Tel: 01268 547600 Fax: 01268 88250 www.elco.co.uk This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale.
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