andrews CSC 39 Installation Manual, Operation And Service Manual
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- Page 1 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 11/02...
- Page 2 INSTALLATION GUIDE, OPERATION AND SERVICE MANUAL NATURAL GAS, PROPANE & BUTANE FIRED STORAGE WATER HEATERS MODELS CSC 39 CSC 59 CSC 78 CSC 93 CSCL 39 CSCL 59 CSCL 78 CSCL 93 Auto Ignition T H I S M A N U A L...
- Page 4 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.
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Page 6: Table Of Contents
CONTENTS PAGE SECTION 1 GENERAL AND SAFETY INFORMATION General Information British Standards and Codes of Practice Health and Safety Regulations 1993 Effectiveness in Combating Legionellae SECTION 2 TECHNICAL DATA SECTION 3 INSTALLATION Introduction Location Gas Supply - Natural Gas Gas Supply - LPG (Propane or Butane) Gas Electrical Supply Flue Systems Air Supply and Ventilation... -
Page 7: General And Safety Information
SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG (PROPANE OR BUTANE) GAS only and is manufactured to give an efficient, reliable and INFORMATION long service life. 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: Health And Safety Regulations 1993
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, the basic safety precautions highlighted in this manual must be observed by the user. -
Page 9: Technical Data
SECTION 2 TECHNICAL DATA DIMENSIONS CSC39 CSC59 CSC78 CSC93 ANDREWS MODEL NO. CSCL39 CSCL59 CSCL78 CSCL93 Storage Capacity CLEARANCES Recovery thro' 44ºC/80ºF 1149 1517 1808 gal/h Recovery thro' 56ºC/100ºF 1213 1445 gal/h Heat Input Btu/h 150,128 225,192 300,256 361,672 Heat Output 38.7... - Page 10 Air vent must 300mm outlet Absolute min 300mm. be fitted at ‘X’ Minimum N.B. Access of 500mm must be provided one side for 6 months fan lubrication DIMENSIONS ANDREWS MODEL NO. CSC39 CSC59 CSC78 CSC93 A. Height of Heater 1623 1623 1623...
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Page 11: Installation
SECTION 3 INSTALLATION INTRODUCTION THE LAW REQUIRES THAT 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 12: Gas Supply Natural Gas
INSTALLATION SECTION 3 GAS SUPPLY 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. NATURAL GAS A gas meter will be connected to the service pipe by British Gas plc or it's authorised contractor. - Page 13 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).
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Page 14: Cylinder Installation
INSTALLATION SECTION 3 Regulator Set to BULK STORAGE give 37 mbar (14.86” Wg) VESSEL Propane 1” Heavy Steel Sleeved INSTALLATION Pipe Through Wall Regulator normally Gas emergency fitted at tank control at entry point to building Steel Liner sealed to To bulk Supply pipe at inside end Installation of... -
Page 15: Electrical Supply
SECTION 3 INSTALLATION External wiring to the water heater(s) must be installed in accordance with current I.E.E. ELECTRICAL Regulations for the wiring of buildings and to any Local Regulations that may apply. SUPPLY The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply. The fuse rating is 5 amps. - Page 16 INSTALLATION SECTION 3 Wiring Diagram for LPG Appliance Fig 4.
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Page 17: Flue Systems
SECTION 3 INSTALLATION FLUE Your Andrews Water Heater is a Direct Fan Flued Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are charged to the SYSTEMS outside atmosphere. The flue system is a single coaxial (pipe within pipe) design where the flue products are discharged through the inside flue tube and the combustion air supply surrounds the flue surrounded by the outside pipe. -
Page 18: Installation Procedure
INSTALLATION SECTION 3 Installation Procedure HORIZONTAL AND VERTICAL Determine location of flue exit. DIRECT FLUE 1. The supplied kit includes a horizontal (through the wall) flue terminal, an elbow, LENGTHS flue connector clamps and 2m (6.5ft) of coaxial flue pipe. The 150mm (6in) diameter flue system is also supplied with a 200mm (8in) to 150mm (6in) reducer for the waterheater flue connection. - Page 19 SECTION 3 INSTALLATION Optional Components for 150mm (concentric) (6in) Diameter Flue Size FLUE SYSTEMS Quantity Flue Length Part Description Part Number 1 mtr Flue Pipe with clamp E202 1 mtr Cutable Flue Pipe with clamp E203 0.5 mtr Flue Pipe with clamp E204 90º...
- Page 20 INSTALLATION SECTION 3 FLUE INSTALLING THE FLUE TERMINAL SYSTEMS NOTE! The horizontal flue terminal supplied may be used through outside walls up to 600mm (24in) thick. 1. Horizontal flue Terminal (Through the Wall) supplied a) Cut an opening of at least 165mm (6.5in) diameter through the outside for the 58.7kWh input models or 216mm (8.5in) for the 88kWh and 105.6kWh input models.
- Page 21 SECTION 3 INSTALLATION FLUE 2. Vertical Flue Terminal (Through the Roof - Optional) a) Determine the exact location where the roof flue terminal will exit the roof, ensuring SYSTEMS the flue system clears all obstructions. For pitched roofs, the flue cap must be the distance above the roof line as specified, (300mm to base of Flue Clamp, minimum).
- Page 22 INSTALLATION SECTION 3 FLUE Straight End SYSTEMS (Ungasketed) Gasket End Ribs Locked Beneath Fig 8. Gasketed Clamp g) The last pipe section may be cut to fit the distance required to reach the water heater flue connections. First, install the supplied condensate trap with crimped end into the gasketed end of the elbow (horizontal flue installations) and clamp the condensate tee and elbow together.
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Page 23: Air Supply And Ventilation
SECTION 3 INSTALLATION The following notes are intended to give guidance: AIR SUPPLY 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 24: Air Supply
INSTALLATION SECTION 3 AIR SUPPLY IMPORTANT: 1. The effective area requirements specified in the table are related to the maximum heat VENTILATION 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 opening. -
Page 25: Water Quality And Treatment
These anodes are available as an optional extra on all Andrews heaters. In hard water areas, scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used, the more problematic the scale build-up can be. -
Page 26: Water Connections
INSTALLATION SECTION 3 WATER The water heater must be fed from a cold water feed cistern or static water tank. CONNECTIONS A safety valve must be fitted as specified in BS 6644 Clause 9. VENTED SYSTEMS The safety valve must be fitted either directly to an upper tank tapping or not further than 1 metre along the outlet flow pipe of size not less than the safety valve. -
Page 27: Vented Systems
SECTION 3 INSTALLATION WATER CONNECTIONS VENTED SYSTEMS Open Vent Stop Valve Overflow Cold Water Feed Optional Hot Water Service Cold Water Cistern Hot Water Service Secondary Return Cold Water Check Valve Inlet Valve Fig 10. Typical Installation Vented System... - Page 28 WATER Unvented Systems should be fitted by an Approved Installer CONNECTIONS When used in an unvented system, the Andrews water Heater will supply hot water at a UNVENTED pressure of 3.5bar (51lbf/in ), provided that this pressure is available at the mains feed.
- 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 one size larger than the outlet pipe of the safety device and should be terminated at a suitable drain.
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Page 30: Commissioning
COMMISSIONING SECTION 4 CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER RUNNING FROM ALL HOT TAPS. 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 31: Shutting Off The Burner
SECTION 4 COMMISSIONING Shutting Off The Burner 1. For long periods only, (7 days or more) move electrical ON/OFF switch to OFF, then turn gas control knob to OFF. Turn off gas service cock. For shorter periods, leave heater under thermostat control. Gas control Knob Fig 13. -
Page 32: User's Safety Guide
COMMISSIONING SECTION 4 USER'S SAFETY For your safety read before lighting the appliance. GUIDE WARNING 1. Always follow manufacturer's instructions when lighting the appliance. Failure to do so may result in damage to property, personal injury or loss of life. 2. -
Page 33: Operation
SECTION 5 OPERATION When properly installed and adjusted, the heater will require minimal attention. Should it become necessary to completely drain the heater, follow instructions given in Section 4, Commissioning. Whenever the heater is filled with cold water, condensation will form on the storage vessel surfaces when the burner is lit. -
Page 34: Servicing
SERVICING SECTION 6 INTRODUCTION Servicing must be carried out by a properly qualified person. 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 35: Burner Assembly
SECTION 6 SERVICING BURNER Annually, remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign matter. Inspect the burner ports for obstructions or debris and clean ASSEMBLY with a wire brush, vacuum, or use a mild detergent to clean as necessary. Inspect the pilot. -
Page 36: Combined Temperature And Pressure Relief Valve
SERVICING SECTION 6 Check the condition and operation of this component at least once a year to ensure COMBINED it is free from limescale deposits. TEMPERATURE AND PRESSURE Lift the lever at the top of the valve several times until the valve seats properly without leakage and operates freely. -
Page 37: Fault Finding
SECTION 7 FAULT FINDING FAULT ACTION WATER DOES (a) Check gas service cock is open. NOT GET HOT (b) Check water valves are open. (c) Check thermostat setting. (reset to higher temperature) HEATER SOOTING, (a) Check gas burner. If possible, check heat input with meter YELLOW FLAME and watch. - Page 38 FAULT FINDING SECTION 7 FAULT ACTION RUMBLING NOISE (a) Scale formation in heater, consult water treatment specialist. Heater must be descaled and suitable water treatment provided to avoid re-occurrence. CONTINUOUS (a) Check gas service cock is open. IGNITION (b) Check gas control knob is ON. NO PILOT FLAME (c) Check ECO for failure.
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Page 39: Parts Lists And Illustrations
SECTION 8 PARTS LIST AND ILLUSTRATIONS... - Page 40 PARTS LIST AND ILLUSTRATIONS SECTION 8 CSC39 CSC59 CSC78 CSC93 Model Ref. Part Numbers Description E221 E221 E221 E221 Fan Motor Assembly E222 E222 E222 E296 Sacrificial Anode E223 E223 E223 E223 Flue Baffle C991 C991 C991 C991 Control Circuit Board C521 C521 C521...
- Page 41 SECTION 9 PARTS LIST AND ILLUSTRATIONS 150mm (6in) Flue Kit 200mm (8in) Flue Kit...
- Page 42 PARTS LIST AND ILLUSTRATIONS SECTION 9 150mm (6in) Ref. Part No. Description Flue Kit E205 90˚ Elbow with Clamp E202 1 mtr Flue with Clamp E236 Horizontal Flue Terminal E209 Wall Clamp (Not Shown) E237 Large Stepped Adaptor Connection Clamp E238 200mm (8in) to 150mm (6in) Reducer E203...
- Page 43 SECTION 9 PARTS LIST AND ILLUSTRATIONS Unvented System kit CSC39 Parts List Ref. Part No. Description B228 Unvented Systems Kit Complete C784 Combined Reducing Valve/Strainer C785 Check Valve C786 Expansion Valve C782 Expansion Vessel (25 Litre) C914 Temperature/Pressure Relief Valve 1” C856 ⁄...
- Page 44 PARTS LIST AND ILLUSTRATIONS SECTION 9 Unvented System kit CSC59, 78 & 93 Parts List Ref. Part No. Description B248 Unvented Systems Kit Complete C784 Combined Reducing Valve/Strainer C785 Check Valve C786 Expansion Valve C782 Expansion Vessel (25 Litre) E242 Temperature/Pressure Relief Valve 1 ⁄...