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andrews 32/143 Installation Manual, Operation And Service Manual

Hi-flo and standart range natural gas fired storage water heaters
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See also: Installation Manual, Operation and Service Manual
T H I S
M A N U A L
M U S T
B E
K E P T
INSTALLATION
GUIDE,
OPERATION
AND SERVICE
MANUAL
NATURAL GAS
FIRED STORAGE
WATER HEATERS
HI-FLO RANGE
Models
32/143, 65/173,
81/264, 62/341,
54/418, 54/440
Permanent Pilot,
Auto Ignition
with Flue Damper
'E'/'F' Series
STANDARD RANGE
Models
24/39, 32/40, 40/61,
63/62, and 84/87
Permanent Pilot,
Auto Ignition 'G' Series
W I T H
T H E
A P P L I A N C E
April 2007
Part No. E132

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  • Page 1 INSTALLATION GUIDE, OPERATION AND SERVICE MANUAL NATURAL GAS FIRED STORAGE WATER HEATERS HI-FLO RANGE Models 32/143, 65/173, 81/264, 62/341, 54/418, 54/440 Permanent Pilot, Auto Ignition with Flue Damper ‘E’/‘F’ Series STANDARD RANGE Models 24/39, 32/40, 40/61, 63/62, and 84/87 Permanent Pilot, Auto Ignition ‘G’...
  • Page 2 the nation’s favourite PLUMBING & HEATING SUPPLIES FREE SHIPPING SECURE PAYMENTS on all orders over £100 to mainland UK shop online with confidence FINANCE AVAILABLE PRICE MATCH spread the cost with low interest rates always get the best deals available we have H U G E R E D U C T I O N S...
  • Page 4 The Andrews Water Heaters policy is one of continuous product improvement, and therefore the information in this manual, whilst completely up to date at the time of publication, may be subject to revision without prior notice.

  • Page 6: Table Of Contents

    CONTENTS PAGE SECTION 1 GENERAL AND SAFETY INFORMATION General Information British Standards Health and Safety Regulations 1993 Legionellae in Water Heaters SECTION 2 TECHNICAL DATA Standard Range Hi-Flo Range SECTION 3 INSTALLATION Introduction Draught Diverter Location Gas Supply Electrical Supply Flue Systems Air Supply and Ventilation Water Quality and Treatment...
  • Page 7 SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL The Andrews Water Heater has been designed for use with NATURAL GAS only 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 8: General And Safety Information

    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 9: Technical Data

    SECTION 2 TECHNICAL DATA STANDARD ANDREWS MODEL NO. 24/39 32/40 40/61 63/62 84/87 RANGE Storage Capacity Recovery thro' 44ºC/80ºF gal/h Recovery thro' 56ºC/100ºF gal/h Heat Input Gross 12.5 Btu/h 40,944 42,650 65,000 65,000 88,712 Heat Input Net 11.4 Btu/h 37,532 38,900 58,004 58,004 81,888 NATURAL CAT I Burner Gas Pressure mbar...
  • Page 10 TECHNICAL DATA SECTION 2 ANDREWS MODEL NO. 32/143 65/173 81/264 62/341 54/418 54/440 Hi-Flo Storage Capacity 295* 368* 282* 245* RANGE Recovery thro' 44ºC/80ºF 1199 1549 1900 1998 gal/h Recovery thro' 56ºC/100ºF 629* 1239* 1520* 1598* gal/h Recovery thro' 72ºC/130ºF...

  • Page 11: Installation

    ⁄ in BSP (Hi-Flo only). 2 - 1 ⁄ in x 3in Nipples (32/143 Model only). 1 - Warranty Card. The draught diverter must be assembled with the legs provided. ASSEMBLING Attach the legs to the draught diverter with the nuts and bolts provided.
  • Page 12 GAS SUPPLY THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST ONLY BE USED WITH NATURAL GAS. The installation of the gas supply must conform, depending on it's size, to the requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

  • Page 13: Gas Supply

    It is recommended that screen cable is used where the volt-free contacts are to be connected from an external supply. This will eliminate the risk of possible interference from nearby high voltage cables. Data sheets available for Hi-Flo and Standard Range, Automatic Ignition Control System. Contact Andrews Water Heaters.
  • Page 14 INSTALLATION SECTION 3 Fig 3a. Standard Range G737LGA INTERMITTENT PILOT IGNITION CONTROL FLUE FAN INTERLOCK 24V REMOTE TIMER 24V INDEPENDENT MOTOR SUPPLY Fig 3b. Hi-Flo Range...

  • Page 15: Flue Systems

    SECTION 3 INSTALLATION FLUE Detailed recommendations for flue installation are given in BS 6644, BS5440 Pt 1 and British Gas publication IM/11 - Flues for Commercial and Industrial Gas Fired Boilers and SYSTEMS Air Heaters. The flue connection is designed for BS 835 type heavy duty flue, but light quality flue pipe, mild steel or stainless steel sheet may be used using the appropriate adapter.
  • Page 16 *A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all natural draught flue installations. If this dimension cannot be achieved please contact Andrews Water Heaters. Please note this is not required where a common flue header is used on multiple installations.

  • Page 17: Air Supply And Ventilation

    SECTION 3 INSTALLATION Minimum Heights from Roof to Base of Flue Terminal Not within 1.5m (5ft) of a Within 1.5m (5ft) of a vertical surface of a vertical surface of a structure on the roof structure on the roof Type of Roof Internal Route External Internal...
  • Page 18 INSTALLATION SECTION 3 IMPORTANT! AIR SUPPLY 1. The effective area requirements specified in the table are related to the maximum net input of the heater(s) and are equivalent to those specified in BS 6644 and VENTILATION IGE/UP/10 Pt.1. 2. The free area of the grilles should not be less than the size of the recommended ventilation opening.

  • Page 19: Water Quality And Treatment

    When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted. The following companies have supplied water treatment equipment in the UK for a number of years to various establishments including those where Andrews water heaters have been installed.

  • Page 20: Water Connections- Hydrojet System

    INSTALLATION SECTION 3 WATER CONNECTIONS Hydrojet System The upper “jet ports” direct the flow outward to begin the dynamic mixing action. The lower “jet ports” direct the flow inward to increase the turbulence. Tank Heater Casing All models now incorporate the new Mini Hydrojet system on cold inlet side connections.

  • Page 21: Vented Systems, Standard Range

    SECTION 3 INSTALLATION WATER VENTED SYSTEMS, STANDARD RANGE CONNECTIONS The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644.
  • Page 22 INSTALLATION SECTION 3 Fig 6A. Fig 7.

  • Page 23: Unvented Systems, Standard Range

    The heater can be used on unvented hot water storage systems, with the addition of an Unvented Systems Kit, part number B171 available from Andrews Water Heaters. See Parts List Page 51. The Wall Mounting Kit is available as an optional extra.
  • Page 24 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 9. Fig 10.

  • Page 25: Vented Systems, Hi-Flo Range

    All Models. Front inlet/outlet water connections Models 32/143. Optional rear inlet/outlet water connections Assemble onto the 3/4 BSP thread, the 3/4 BSP coupler socket (1) and drain cock using a suitable jointing compound.
  • Page 26 Cold Inlet/Hot Outlet on models Automatic Air Vent 65/173 32/143 81/264 62/341 54/418 54/440 Front T & P Valve Tapping Cold Inlet/Hot Outlet All Models Optional Rear Drain & Cold Inlet/Hot Outlet Secondary Return Tappings 32/143 only Tapping Fig 11. Fig 12.
  • Page 27 SECTION 3 INSTALLATION WATER CONNECTIONS Fig 13. Fig 14.

  • Page 28: Unvented Systems, Hi-Flo Range

    The heater can be used on unvented hot water storage systems, with the addition of an Unvented Systems Kit, part number B172 available from Andrews Water Heaters. See Parts List Page 51. The Wall Mounting Assembly is available as an optional extra.
  • Page 29 SECTION 3 INSTALLATION WATER If higher flow rates are required for the cold water services, a suitable tee fitting should be fitted to the pipework, upstream of item C1. CONNECTIONS The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain (see Building Regulations 1991 Approved Document G3).
  • Page 30 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 17. Fig 18.

  • Page 31: Commissioning

    SECTION 4 COMMISSIONING STANDARD CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER RANGE RUNNING FROM ALL HOT TAPS. PERMANENT PILOT MODELS Open the main gas supply cock after all connections to the gas control are completed and test all connections, using proprietary leak detection fluid.
  • Page 32 COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only (7 days or more) turn gas control knob to PILOT, depress slightly and turn clockwise to OFF. Turn off the gas service cock. For shorter periods, leave the heater under thermostat control. NOTE! If the pilot goes out for any reason, turn off heater and wait for 3 minutes before relighting.
  • Page 33 SECTION 4 COMMISSIONING HI-FLO RANGE Lighting the Burner PERMANENT Open the main gas supply cock after all connections to the gas control are completed PILOT MODELS and test all connections using a manometer. Purge air from pipework and ensure there are no loose connections to burner or pilot pipe.
  • Page 34 COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only, (7 days or more) turn control knob to PILOT, partially depress knob, then turn clockwise to OFF. Turn off gas service cock. For shorter periods leave heater under thermostat control. Checking Main Burner Pressure 1.
  • Page 35 SECTION 4 COMMISSIONING STANDARD Lighting the burner RANGE AUTO IGNITION Thermostat Control On/Off Switch MODELS Knob Gas Control valve Fig 23. 1. Ensure gas supply is on. 2. Set thermostat control knob to the required water temperature. (See below). 3. Ensure time switch if fitted is in the ON position. 4.
  • Page 36 COMMISSIONING SECTION 4 Checking main burner pressure 1. Turn gas supply OFF. 2. Release bleed screw A and connect pressure gauge tube (See Fig. 24) 3. Light burner as described previously. 4. Remove cap from port B and adjust pressure using exposed screw in accordance with data plate (See Fig.
  • Page 37 SECTION 4 COMMISSIONING Lighting the Burner Hi-Flo RANGE AUTO IGNITION MODELS Gas control Pink MV Knob Black PV-MV Fig 25. Purple PV 1. Ensure gas supply is ON. 2. Turn gas control knob to ON position. 3. Using control thermostat, select required water temperature. 4.
  • Page 38 COMMISSIONING SECTION 4 Check correct shape and size of Pilot Flame HI-FLO No adjustment is provided for the pilot. The restrictor C on the gas control (see Fig. 22) RANGE should be turned fully conterclockwise to the fully open position. PERMANENT PILOT MODELS Fig 26.
  • Page 39 SECTION 4 COMMISSIONING For your safety read before lighting the appliance USERS SAFETY WARNING GUIDE 1. Always follow manufacturers instructions when lighting the appliance. Failure to so may result in damage to property, personal injury or loss of life. 2. Before lighting check all round the appliance area for gas. Be sure to check at low level because some gas (i.e.
  • Page 40 This is known as stacking. To counter this condition, an upper thermostat phial is fitted (not on Model 32/143) which senses abnormally hot water and shuts down the main burner until the water cools. Most modern commercial pipe installations include a circulating pump which keeps hot water moving continuously throughout the heater.

  • Page 41: Standard Range

    SECTION 6 SERVICING Servicing must be carried out by a properly qualified person. INTRODUCTION Whilst giving these instructions for the care of the Heater, it is recommended that checks are carried out by the installer or local gas authority, at least annually. Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint.

  • Page 42: Hi-Flo Range

    SERVICING SECTION 6 8. Re-assemble in reverse order but note: i) The flueways and combustion chamber must be cleaned first. ii) Use an approved jointing compound when re-fitting burner injectors. 9. Light heater in accordance with lighting instructions. All gas joints must be checked using leak detection fluid.

  • Page 43: Cleaning The Storage Vessel

    SECTION 6 SERVICING CLEANING THE The storage vessel should be checked and cleaned annually. Scale formation in the base of the vessel may occur, particularly in hard water areas and is STORAGE normally associated with high usage and high water temperatures. It is characterised by a VESSEL rumbling noise when the main burner is lit.

  • Page 44: Replacing Components, Hi-Flo Range

    The gas valve must be fitted so that it is square relative to the centre line of the injectors. 8. Re-commission the heater as detailed in Section 4, Commissioning. NOTE! These instructions apply to all models but Model 32/143 is not fitted with a limit USER- sensor phial.

  • Page 45: Burner

    SECTION 7 REPLACING COMPONENTS, Hi-Flo RANGE THERMOPILE/ 2. Disconnect thermopile and pilot supply pipe from gas control valve. 3. Remove two screws and withdraw burner assembly. PILOT 4. Remove two screws and withdraw pilot assembly. BURNER/PILOT 5. Unscrew gland nut securing thermopile to it's bracket and withdraw. RESTRICTOR 6.

  • Page 46: Fault Finding

    FAULT FINDING SECTION 8 PERMANENT FAULT ACTION PILOT MODELS STANDARD AND WATER DOES (a) Check gas service cock is open. HI-FLO RANGES NOT GET HOT (b) Check water valves are open (c) Check pilot is alight (d) Check thermostat setting. reset to higher temperature) (e) Check gas pressures at burner and at gas inlet to appliance.

  • Page 47: All Models

    SECTION 8 FAULT FINDING ALL MODELS FAULT ACTION HEATER SOOTING, (a) Check gas burner pressure and injector size. If possible, YELLOW FLAME check heat input with meter and watch. (POOR COMBUSTION) (b) Clean burners and injectors. (c) Flue obstruction. Clean flue ways. (d) Check flue design and termination position.

  • Page 48: Standard Range

    FAULT FINDING SECTION 8 AUTO FAULT ACTION IGNITION UNITS (a) Check gas service cock is open. IGNITION AT PILOT (b) Electrical ON/OFF switch is not ON. STANDARD (c) Power to unit interrupted. RANGE (d) Thermostat set too low. (e) Check ECO for failure. Reset. (f) Check for 24V AC at intermittent pilot ignition control terminal No.
  • Page 49 SECTION 9 PARTS LIST AND ILLUSTRATIONS 63/62 only STANDARD Models 24/29, 32/40, 40/61, 63/62 63/62 only STANDARD Model 84/87...
  • Page 50 PARTS LIST AND ILLUSTRATIONS SECTION 9 STANDARD MODELS 24/39 32/40 40/61 63/62 84/87 Model Ref. Part Numbers Description C654 C654 C654 C657 C657 Adaptor Ring C653 C653 C655 C656 C658 Draught Diverter C285 C285 C285 C285 C690 Hot Outlet Nipple C286 C292 C293...
  • Page 51 SECTION 9 PARTS LIST AND ILLUSTRATIONS Hi-Flo Model 32/143 Hi-Flo Models 65/173 and 81/264...
  • Page 52 PARTS LIST AND ILLUSTRATIONS SECTION 9 HI-FLO MODELS Model 32/143 65/173 81/264 Ref. Part Numbers Description E023 C500 C501 Draught Divider C333 C333 C333 Service Magnesium Anode C334 C334 Flue Connector, 150mm, BS 835 C432 Flue Connector, 200mm, BS 835...
  • Page 53 SECTION 9 PARTS LIST AND ILLUSTRATIONS Hi-Flo Models 62/341 and 54/418/440...
  • Page 54 PARTS LIST AND ILLUSTRATIONS SECTION 9 HI-FLO MODELS Model 62/341 54/418/440 Ref. Part Numbers Description C501 C548 Draught Diverter C333 C333 Service Magnesium Anode C432 Flue Connector, 200mm, BS 835 C335 Flue Connector, 250mm, BS 835 C381 C381 Drain Cock, BS 2879, 3/4" C103 C103 Socket Coupler, 3/4"...

  • Page 55: Hi-Flo Range

    SECTION 9 PARTS LIST AND ILLUSTRATIONS Unvented Systems Kit - Standard Range Unvented Systems Kit - Hi-Flo Range...
  • Page 56 PARTS LIST AND ILLUSTRATIONS SECTION 9 Unvented Ref. Part No. Description Systems Kit - B171 Unvented Systems Kit Complete Standard Range C780 Pressure Reducing Valve/Strainer C781 Check Valve / Expansion Valve C782 Expansion Vessel E462 Temperature/Pressure Relief Valve C783 Tundish C772 Adaptor B173...
  • Page 57 SECTION 9 PARTS LIST AND ILLUSTRATIONS 24 Volt Auto System Kit B217 24 Volt Auto System Kit B258...
  • Page 58 PARTS LIST AND ILLUSTRATIONS SECTION 9 24 Volt Auto Part No. Description System Kit B217 24 Volt Auto System Kit Complete Standard Range C521 On/Off Switch C641 Mains Indicator Light E113 Intermittent Pilot Ignition Control E115 Transformer E116 Limit Thermostat E117 Control Thermostat E120...
  • Page 59 NOTES...
  • Page 61 Andrews Water Heaters Wood Lane, Erdington Birmingham B24 9QP Technical Helpline Tel: 0845 070 1057 Fax: 0845 070 1059...

This manual is also suitable for:

81/26454/41854/44024/3932/4040/61 ... Show all

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