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Andrews Maxxflo CWH30/200 Installation Manual, Operation And Maintenance Manual

Maxxflo condensing storage water heater for natural gas and lpg.
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T H I S
M A N U A L
M U S T
B E
K E P T
INSTALLATION
GUIDE,
OPERATION AND
MAINTENANCE
MANUAL
CONDENSING STORAGE
WATER HEATER
FOR NATURAL GAS
AND LPG
CWH30/200,CWH30/300
CWH60/200,CWH60/300
CWH90/200,CWH90/300
CWH120/200,CWH120/300
LCWH30/200,LCWH30/300
LCWH60/200,LCWH60/300
LCWH90/200,LCWH90/300
LCWH120/200,LCWH120/300
W I T H
T H E
A P P L I A N C E
December 2005
Part No. E281

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Table of Contents

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   Summary of Contents for andrews Maxxflo CWH30/200

  • Page 1 INSTALLATION GUIDE, OPERATION AND MAINTENANCE MANUAL CONDENSING STORAGE WATER HEATER FOR NATURAL GAS AND LPG CWH30/200,CWH30/300 CWH60/200,CWH60/300 CWH90/200,CWH90/300 CWH120/200,CWH120/300 LCWH30/200,LCWH30/300 LCWH60/200,LCWH60/300 LCWH90/200,LCWH90/300 LCWH120/200,LCWH120/300 T H I S M A N U A L M U S T K E P T...
  • Page 2 The attention of U.K. users is drawn to their responsibilities under the Health and Safety Regulations 1993. All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel, and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel.
  • Page 3: Table Of Contents

    CONTENTS PAGE SECTION 1 DESCRIPTION General Information British Standards Health and Safety Regulations 1993 Legionellae in Water Heaters SECTION 2 TECHNICAL DETAILS Technical Details - CWH30/60/90/120 Heater Dimensions - 200 Litre Models Heater Dimensions - 300 Litre Models SECTION 3 INSTALLATION Description Location...
  • Page 4: General Information

    SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL The Andrews Water Heater has been designed for use with NATURAL GAS or LPG and is manufactured to give an efficient, reliable and long service life. INFORMATION To ensure the continued, trouble-free operation of your heater at maximum efficiency, it is essential that correct installation, commissioning, operation and service procedures are carried out strictly in accordance with the instructions given in this manual.
  • Page 5: Health And Safety Regulations 1993

    Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual. Although the heaters have been manufactured with paramount consideration to safety, certain basic precautions specified in this manual must be taken by the user.
  • Page 6: Technical Details

    SECTION 2 TECHNICAL DETAILS Model reference CWH30/200 CWH60/200 CWH90/200 CWH120/200 LCWH30/200 LCWH60/200 LCWH90/200 LCWH120/200 Model reference CWH30/300 CWH60/300 CWH90/300 CWH120/300 LCWH30/300 LCWH60/300 LCWH90/300 LCWH120/300 Input gross H 6.7 - 31.1 20.1 - 93.3 26.8 - 124.4 13.4 - 62.2 Input nett H 6.0 - 28.0...
  • Page 7 TECHNICAL DETAILS SECTION 2 Heater Dimensions Models CWH30/200, CWH60/200, CWH90/200 and CWH120/200 NOTE:- See pages 17 to 25 for flue details Models CWH30 and 60 use 80/125mm dia flue Models CWH90 and 120 use 130/200mm dia flue 3/4" GAS INLET HOT &...
  • Page 8 SECTION 2 TECHNICAL DETAILS Heater Dimensions Models CWH30/300, CWH60/300, CWH90/300 AND CWH120/300 NOTE:- See pages 17 to 25 for flue details Models CWH30 and 60 use 80/125mm dia flue Models CWH90 and 120 use 130/200mm dia flue 3/4" GAS INLET HOT &...
  • Page 9: Installation

    INSTALLATION SECTION 3 series is a direct fired condensing storage water heater which has a DESCRIPTION stainless steel tank that is heated by up to four burner modules placed outside the tank. A burner module consists of a stainless steel heat exchanger in which the burner is placed.
  • Page 10: Location

    SECTION 3 INSTALLATION LOCATION THE LAW REQUIRES THAT THE INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON Installations must be carried out in accordance with Gas safety (Installation and Use) Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations 1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1.
  • Page 11: Water Quality And Treatment

    INSTALLATION SECTION 3 When installing Andrews Water Heaters in hard water areas we would recommend that a WATER water treatment specialist is consulted. QUALITY AND TREATMENT In hard water areas, scale formation can occur in hot water systems and water heaters and the higher the temperature and volume of water used, the more problematic the scale build-up can be.
  • Page 12 SECTION 3 INSTALLATION TYPICAL Tank cleaning INSTALLATION access Return Fig. 1a. Return pump Mains feed unvented kit Flue Control panel Cold feed T&P relief Cover Cover valve removable removable for service for service Tundish Condense trap Condense drain Tank drain CWH30 CWH60 Tank cleaning...
  • Page 13: Gas Supply Natural Gas

    Systems: Design and installation plus the requirements of British Standards and Codes of Practice listed in Section of this manual. Andrews water heaters are unregulated and a second stage regulator must be installed to give an inlet pressure to the appliance as follows: ( See fig. 2).
  • Page 14: Typical Bulk Storage Vessel Installation

    SECTION 3 INSTALLATION TYPICAL BULK STORAGE Gas cock VESSEL Regulator Set to give 37 mbar INSTALLATION (14.86” Wg) Propane 1” Heavy Steel Sleeved Pipe Through Wall Regulator normally Gas emergency fitted at tank control at entry point to building From bulk Supply Steel Liner sealed to pipe at inside end Installation of...
  • Page 15: Electrical Supply

    INSTALLATION SECTION 3 ELECTRICAL External wiring to the water heater(s) must be installed in accordance with current I.E.E. Regulations for the wiring of buildings and to any Local Regulations that may apply. SUPPLY range is designed to operate from a 230/250Hz, single phase supply. The fuse rating is 5 amps.
  • Page 16 230V/50Hz mains 4 br bl mains 3 mains 2 mains 1 flow sensor 2 flow sensor 1 ionisation rod comm. 4 return sensor gasvalve slave 1 br bl comm. 3 br bl comm. 2 pump comm. 1 comm.cable glow plug pump pump L pump N...
  • Page 17 INSTALLATION SECTION 3 It is possible to change the water heater temperature remotely via a timer programme. TEMPORARY First of all the new, desired water heater temperature is set at a value higher or lower WATER than the water heater temperature during normal operation. This makes it possible, for HEATER example, to carry out legionella flushing.
  • Page 18: Wiring Diagram

    SECTION 3 INSTALLATION TANK DIMENSIONS WIRING DIAGRAM...
  • Page 19: Flue Systems

    The heater when fitted with a concentric flue system provides a room sealed application. The concentric flue, supplied by Andrews, is available for either horizontal or vertical installation and the table below shows the basic kit supplied plus optional extras.
  • Page 20 SECTION 3 INSTALLATION CWH30 & CWH60 Flue Systems The CWH30 & CWH360 uses a concentric flue system, 125mm outside diameter with an inner flue of 80mm diameter. Flue components fit together with silicon sealing rings and the flues are retained with sealing clamps.
  • Page 21 INSTALLATION SECTION 3 CWH30 & CWH60 Alternative Flue Systems CWH30 max 50M Conventional CWH60 max 20M Conventional CWH30 max 14M Concentric CWH60 max 12M Concentric Over 1.5M use flue Condense trap. Minimum between Fit syphon Vertical terminals 300mm drain Minimum between balanced flued horizontal terminals For concentric flue runs reduce overall length by:...
  • Page 22 SECTION 3 INSTALLATION CWH30 & CWH60 Standard Flue System Dimensions ALL 80/125mm Ø CONCENTRIC FLUE Ø125 Ø80 Ø 123/124 CONDENSATE TRAP PART No E310 Ø80 45º ELBOW C/W CLAMP Maintain dimension PART No E308 if flue is cut Ø80 VERTICAL FLUE TERMINAL C/W CLAMP (CONDENSING) PART No E067 90º...
  • Page 23 INSTALLATION SECTION 3 CWH90 & CWH120 Flue Systems The CWH90 & CWH120 uses a concentric flue system, 200mm outside diameter with an inner flue of 130mm diameter. Flue components fit together with silicon sealing rings and the flues are retained with sealing clamps.
  • Page 24 SECTION 3 INSTALLATION CWH90 & CWH120 Alternative Flue Systems CWH90 max 50M Conventional CWH120 max 40M Conventional CWH90 and CWH120 max 14M Concentric Minimum clearence Over 1.5M use flue between vertical condense trap. balanced flue terminals Fit syphon drain 600mm Minimum clearence betweenbalanced For concentric flue runs...
  • Page 25 INSTALLATION SECTION 3 CWH90 & CWH120 Standard Flue System Dimensions ALL 130/200MM Ø CONCENTRIC FLUE Ø200 Ø130 Ø130 Ø 198/199 Ø 198/199 CONDENSATE TRAP 45º ELBOW C/W CLAMP PART No E220 PART No E216 Ø32 BOTTLE SYPHON Ø130 PART NO. E211 Ø...
  • Page 26: Flue Systems - Cwh 30

    SECTION 3 INSTALLATION Likely flue positions requiring a flue terminal guard FLUE SYSTEMS Terminal Positions with Minimum Distance Directly below an opening, air brick, opening window etc. Above an opening, air brick, opening window etc. Horizontally to an opening, air brick, opening window etc. Below a gutter or sanitary pipework Below the eaves Below a balcony or carport roof...
  • Page 27 INSTALLATION SECTION 3 FLUE SYSTEMS Horizontal termination NOTE: (Room sealed or conventional flue) See page 24 for positioning of flue terminals. Vertical termination (Room sealed or conventional flue) Fig 6.
  • Page 28: Air Supply And Ventilation - Concentric Flue Systems

    SECTION 3 INSTALLATION AIR SUPPLY The following notes are intended to give guidance: Where the heater is to be installed in a room, NO VENTS ARE REQUIRED. VENTILATION Where the heater is to be installed in a COMPARTMENT, permanent air vents are required in the COMPARTMENT at high and low level.
  • Page 29: Air Supply And Ventilation - Conventional Flue Systems

    INSTALLATION SECTION 3 IMPORTANT: AIR SUPPLY 1. The effective area requirements specified in the table are related to the maximum heat input of of the heater(s), and are equivalent to those specified in BS6644. 2. The free area of the grilles should not be less than the size of the recommended VENTILATION ventilation opening.
  • Page 30 SECTION 3 INSTALLATION AIR SUPPLY The minimum effective areas of the permanent air vents required in the compartment are as follows;- VENTILATION Air Vent Areas Position of Air Vents Air from room or internal space Air direct from outside CONVENTIONAL Net input Net input High Level...
  • Page 31: Instructions For Commissioning

    INSTRUCTIONS FOR COMMISSIONING SECTION 4 CWH HEAT The water heater is equipped with 1, 2, 3 EXCHANGER or 4 burner modules CONFIGURATION depending on the model. Each burner module has its own automatic burner. CWH 30 CWH 60 CWH 90 CWH 120 The operational status of the water heater can be seen and the desired temperature can CONTROL...
  • Page 32: Temperature Setting

    SECTION 5 INSTRUCTIONS FOR COMMISSIONING TEMPERATURE The water heater temperature can be set between 40°C and 70°C using the + and - buttons on the control panel. The maximum temperature for the Legionella flushing SETTING programme only is 75ºC. The lower the temperature the lower the chance of lime deposits (less maintenance). The risk of scalding is also less (think of children, those with special needs and the elderly).
  • Page 33: Filling The Water Heater

    INSTRUCTIONS FOR COMMISSIONING SECTION 5 1. Check that the tank drain tap is closed. FILLING THE 2. Check that the return valve in the 28mm pipe (close to the drain tap) is open. WATER HEATER 3. Open the main water tap and then all warm water drainage points, so that air present in the installation and water heater can escape.
  • Page 34: Control And Adjustment At Full Load

    SECTION 5 INSTRUCTIONS FOR COMMISSIONING CONTROL 1. Switch the water heater off and flush system until the tank is completely cooled down. 2. Put the water heater in operation. ADJUSTMENT 3. Press the reset button down for longer than 5 seconds, L appears in the display. Pressing the reset button again, C00 appears in the display.
  • Page 35: Control And Adjustment At Low Load

    INSTRUCTIONS FOR COMMISSIONING SECTION 5 CONTROL AND 1. Select low load with the - button. When the actual burner capacity is above 25% the percentage can be measured and set. ADJUSTMENT AT LOW LOAD 2. Measure the CO percentage and check it against table 1. The CO percentage can be adjusted using the ”Low Load”...
  • Page 36: Error Codes

    SECTION 6 ERROR CODES ERROR An error code will appear in the control panel display if there is a fault. A letter and the number of the burner module appear alternately in the display. The letter A is for a CODES locking fault, and E is for a blocking fault.
  • Page 37: Maintenance

    MAINTENANCE SECTION 7 At least once a year the following works must be carried out: 1. Check the CO percentage and adjust if necessary, see page 31. 2. Check the output at full load by measuring the gas usage. If this deviates more than 15% from the nominal value (see Section 2, Technical Details) then this is an indication of dirt or blockages in the flue gas extraction channel, the air supply channel or the condensation extractor.
  • Page 38: Maintenance

    SECTION 8 MAINTENANCE The burner and exchanger do not normally need to be cleaned. If there is a suspicion of dirt then the exchanger should be opened on the bottom. New gaskets must always be used when assembling. The top of the exchanger must never be opened. The hot surface igniter is a vulnerable part that should only be removed if it has to be replaced.
  • Page 39: Parts List

    PARTS LIST SECTION 8 SPARES LIST Part No. Description Used on FOR CWH E653 O - ring tank seal all models RANGE E654 O - ring heat exchanger connection all models E655 Ionisation rod all models E656 Heat exchanger complete all models E657 Hot surface ignitor...
  • Page 40 NOTES...
  • Page 41 Wednesbury One, Black Country New Road Wednesbury West Midlands WS10 7NZ Tel: +44 (0)121 506 7400 Fax: +44 (0)121 506 7401 Email: andrews@andrews-waterheaters.co.uk Website: www.andrewswaterheaters.co.uk 12/05...

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