Table of Contents
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Pack Contents
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Zircon unvented water heater incorporating immersion heater(s) & thermal controls
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Factory fitted temperature/pressure relief valve (set at 90°C / 1 Mpa (10bar))
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Cold water combination valve assembly
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Expansion vessel & mounting bracket
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Tundish
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2 Port motorised valve (indirect models only)
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Compression nuts & olives
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Immersion heater spanner
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Installation & servicing instructions
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Guarantee card
Please read & understand all these instructions before commencing installation.
Please leave this manual with the customer for future reference.
Zircon Installation Manual
Unvented Direct & Indirect Water Heaters
Installation & Servicing Instructions
IMPORTANT
1
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Table of Contents
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Summary of Contents for Elson 120zi
- Page 1 Zircon Installation Manual Unvented Direct & Indirect Water Heaters Installation & Servicing Instructions Pack Contents • Zircon 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 • Expansion vessel & mounting bracket • Tundish • 2 Port motorised valve (indirect models only) •...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION The cylinder is a purpose designed unvented water heater. The unit has a stainless steel inner vessel, INTRODUCTION............2 which ensures an excellent standard of corrosion resistance. The outer casing is a combination of GENERAL REQUIREMENTS........3 resilient thermoplastic mouldings and plastic coated corrosion proofed steel sheet. All products are INSTALLATION GENERAL..........5 insulated with CFC free polyurethane foam to give good heat loss performance. (see Table 6, page 19) INSTALLATION DISCHARGE........7 The unit is supplied complete with all the necessary INSTALLATION DIRECT..........11 safety and control devices needed to allow connection to the cold water mains. All these INSTALLATION INDIRECT...........12 components are preset and not adjustable. COMMISSIONING............14 This appliance complies with the requirements of the CE marking directive and is Kiwa approved to show... -
Page 3: General Requirements
GENERAL REQUIREMENTS Nominal Weight of Weight Model Type Capacity unit full of unit Reference (litres) (Kg) (Kg) IMPORTANT: THIS APPLIANCE IS NOT INTENDED FOR THE Indirect 120zi USE BY PERSONS (INCLUDING CHILDREN) WITH REDUCED PHYSICAL, SENSORY 150zi OR MENTAL CAPABILITIES, OR LACK OF 170zi KNOWLEDGE AND EXPERIENCE, UNLESS 210zi THEY HAVE BEEN GIVEN SUPERVISION OR 250zi INSTRUCTION CONCERNING THE USE OF THE APPLIANCE BY A PERSON RESPONSIBLE FOR 300zi THEIR SAFETY. Direct 120zd 150zd CHILDREN MUST BE SUPERVISED TO ENSURE 170zd THEY DO NOT PLAY WITH THE APPLIANCE. 210zd SITING THE UNIT 250zd The cylinder must be vertically floor mounted. - Page 4 LIMITATIONS The cylinder should not be used in association with any of the following: • Solid fuel boilers or any other boiler in which the energy input is not under effective thermostatic control, unless additional and appropriate safety measures are installed. • Ascending spray type bidets or any other class 1 back syphonage risk requiring that a type A air gap be employed. • Steam heating plants unless additional and appropriate safety devices are installed. • Situations where maintenance is likely to be neglected or safety devices tampered with. • Water supplies that have either inadequate pressure or where the supply may be intermittent. • Situations where it is not possible to safely pipe away any discharge from the safety valves. • In areas where the water consistently contains a high proportion of solids, e.g. suspended matter that could block the strainer, unless adequate filtration can be ensured. • In areas where the water supply contains chloride levels that exceed 250mg/l.
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Page 5: Installation General
SECONDARY CIRCULATION INSTALLATION GENERAL If secondary circulation is required it is recommended that it be connected to the cylinder as shown (see Fig. 3 page 5) via a swept tee joint into the cold PIPE FITTINGS feed to the unit. A swept tee joint is available as an All pipe fittings are made via 22mm compression accessory (order code no. 5133565). fittings directly to the unit. The fittings are threaded The secondary return pipe should be in 15mm pipe 3/4”BSP male parallel, should threaded pipe and incorporate a check valve to prevent backflow. connections be required. A suitable WRAS approved bronze circulation pump will be required. On large systems, due to COLD FEED the increase in system water content, it may be A 22mm cold water supply is recommended, however, necessary to fit an additional expansion vessel to the if a 15mm (1/2”) supply exists, which provides sufficient secondary circuit. This should be done if the capacity flow, this may be used (although more flow noise of the secondary circuit exceeds 10 litres. may be experienced). Pipe capacity (copper): A stopcock or servicing valve should be incorporated 15mm O.D. = 0.13 l/m (10 litres = 77m) into the cold water supply to enable the cylinder and 22mm O.D. = 0.38 l/m (10 litres = 26m) its associated controls to be isolated and serviced. - Page 6 PRIMARY RETURN Fig. 4 General dimensions Type Model Dimensions (mm) Primary Flow Coil Rating Heat-up Time Hot Water Reference (ltrs/min @80°C (kW) (mins) Capacity (ltrs) +/- 2°C) (volume of water drawn off >40°C) Indirect 120zi 12.5 150zi 1114 12.5 138.5 170zi 1240 156.5 210zi 1498 1184 250zi 1752 1378 300zi 2067 1693 242.5...
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Page 7: Installation Discharge
Tundish INSTALLATION DISCHARGE 3.54 The tundish should be vertical, located in the same space as the unvented hot water storage DISCHARGE PIPEWORK system and be fitted as close as possible to, and It is a requirement of Building Regulation G3 that lower than, the valve, with no more than 600mm of any discharge from an unvented system is conveyed pipe between the valve outlet and the tundish (see to where it is visible, but will not cause danger to... - Page 8 3.60 The discharge pipe should not be connected to Worked example of discharge pipe sizing a soil discharge stack unless it can be demonstrated that the soil discharge stack is capable of safely Fig. 5: shows a G1/2 temperature relief valve with a withstanding temperatures of the water discharged, discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.
- Page 9 MINIMUM SIZE OF MINIMUM SIZE OF RESISTANCE CREATED BY VALVE OUTLET MAXIMUM RESISTANCE DISCHARGE PIPE D1 DISCHARGE PIPE D2 EACH ELBOW OR BEND SIZE ALLOWED, EXPRESSED FROM TUNDISH AS A LENGTH OF STRAIGHT PIPE (I.E. NO ELBOWS OR BENDS G 1/2 15MM 22mm UP TO 9M...
- Page 10 COLD WATER BALANCED COMBINATION COLD WATER MAINS CONNECTION VALVE EXPANSION WATER T&P RELIEF (IF REQUIRED) (2-PIECE) VESSEL SUPPLY VALVE TO HOT OUTLETS ISOLATING VALVE (NOT ELEMENT / SUPPLIED) CONTROLS HOUSING PRIMARY RETURN TUNDISH PRIMARY FLOW INLET DRAIN COCK SECONDARY RETURN DISCHARGE (NOT SUPPLIED) TAPPING (IF REQUIRED)
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Page 11: Installation Direct
INSTALLATION - DIRECT SAFETY DISCONNECT FROM THE MAINS ELECTRICAL SUPPLY BEFORE REMOVING ANY COVERS. Never attempt to replace the immersion heater(s) other than with the recommended immersion heater(s). DO NOT BYPASS THE THERMAL CUT-OUT(S) IN ANY CIRCUMSTANCES. Ensure the two male spade terminations on the underside of the combined thermostat and thermal cut-out are pushed firmly onto the corresponding terminations on the element plate assembly. In case of difficulty contact service support; contact details available at the back of this booklet. ELECTRICAL SUPPLY All electrical wiring should be carried out by a competent electrician and be in accordance with the latest I.E.E Wiring Regulations. 1.5mm² 3 Core HOFR sheathed Each circuit must be protected by a suitable fuse cable and double pole isolating switch with a contact separation of at least 3mm in both poles. -
Page 12: Installation Indirect
PRIMARY CIRCUIT CONTROL INSTALLATION - INDIRECT The 2 port motorised valve supplied with the cylinder MUST be fitted on the primary flow to the cylinder heat exchanger and wired in series with the indirect SAFETY control thermostat and thermal cut-out fitted to the DISCONNECT FROM THE MAINS ELECTRICAL unit. SUPPLY BEFORE REMOVING ANY COVERS. Primary circulation to the cylinder heat exchanger Never attempt to replace the immersion heater(s) must be pumped; gravity circulation WILL NOT other than with the recommended authorised WORK. - Page 13 Fig. 9: Schematic wiring diagram - Basic 2 x 2 port valve system Fig. 10: Schematic wiring diagram - 3 port mid position valve system. N.B. Must be used in conjunction with 2 port zone valve supplied...
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Page 14: Commissioning
INDIRECT UNITS COMMISSIONING Fill the indirect (primary) circuit following the boiler manufacturer’s commissioning instructions. To ensure the cylinder primary heat exchanger is filled, the 2 FILLING THE UNIT WITH WATER port motorised valve (supplied) should be manually Ensure that all fittings and immersion heaters are opened by moving the lever on the motor housing to correctly fitted and tightened. An immersion heater key the MANUAL setting. When the primary circuit is full is provided to aid tightening the immersion heater(s) return the lever to the AUTOMATIC position. • Check expansion vessel pre-charge pressure The vessel is supplied precharged to 0.35MPa Switch on the boiler, ensure the programmer is (3.5 bar) to match the control pressure of set to Domestic Hot Water and allow the cylinder the pressure reducing valve. The precharge to heat up to a normal working temperature (60 pressure is checked using a car tyre gauge by recommended, approximately graduation 4 on the unscrewing the plastic cap opposite the water thermostat). If necessary the temperature can be connection. adjusted by inserting a flat bladed screwdriver in •... -
Page 15: Maintenance
The adjustment range 1 to 5 represents a MAINTENANCE temperature range of 12°C to 68°C. Check the operation of thermostat(s) and that no water has issued from the expansion relief valve or MAINTENANCE REQUIREMENTS temperature/pressure relief valve during the heating Unvented hot water systems have a continuing cycle. maintenance requirement in order to ensure safe working and optimum performance. It is essential INDIRECT UNITS that the relief valve(s) are periodically inspected Open the cover(s) to the immersion heater and manually opened to ensure no blockage has housing(s) and disconnect wiring from immersion occurred in the valves or discharge pipework. heater(s) thermostat(s). Remove thermostat by Similarly cleaning of the strainer element and carefully pulling outwards. Remove thermostat replacement of the air in the expansion vessel will capillary sensors from the pockets on the immersion help to prevent possible operational faults. heater. Unscrew immersion heater backnut(s) and remove immersion heater from the unit. A key The maintenance checks described below should spanner is supplied with the cylinder unit for easy be performed by a competent person on a removal/tightening of the immersion heater(s). Over regular basis, e.g. annually to coincide with boiler time the immersion heater gasket may become stuck... -
Page 16: User Instructions
TEMPERATURE CONTROLS – DIRECT UNITS USER INSTRUCTIONS IMMERSION HEATER(S) A combined adjustable thermostat and thermal cut-out is provided for each immersion heater. The WARNINGS thermostat is factory set to give a water storage IF WATER DISCHARGES FROM THE temperature of approx. 55°C to 60°C. Access to the TEMPERATURE/PRESSURE RELIEF VALVE ON thermostat can be made by opening the immersion CYLINDER SHUT DOWN THE BOILER. DO NOT heater cover - DISCONNECT THE ELECTRICAL TURN OFF ANY WATER SUPPLY. CONTACT SUPPLY BEFORE OPENING THE COVER(S). A COMPETENT INSTALLER FOR UNVENTED Temperature adjustment is made by inserting a flat WATER HEATERS TO CHECK THE SYSTEM. bladed screwdriver in the slot on the adjustment disc on top of the thermostat and rotating. The DO NOT TAMPER WITH ANY OF THE SAFETY adjustment range 1 to 5 represents a temperature VALVES FITTED TO THE SYSTEM. IF A FAULT range of 12°C to 68°C (60°C will be approximately IS SUSPECTED CONTACT A COMPETENT position 4). If in any doubt contact a competent INSTALLER. electrician. BENCHMARK DO NOT bypass the thermal cut-out(s) in any The cylinder is covered by the Benchmark Scheme circumstances. which aims to improve the standards of installation and commissioning of domestic heating and TEMPERATURE CONTROLS - INDIRECT UNITS hot water systems in the UK and to encourage The cylinder units are fitted with an indirect regular servicing to optimise safety, efficiency and thermostat and thermal cut-out. These controls must performance. -
Page 17: Fault Finding & Servicing
SPARE PARTS FAULT FINDING & SERVICING A full range of spare parts are available for the cylinder range (Table 5 Page 18). Refer to the technical data label on the unit to identify the model IMPORTANT installed and ensure the correct part is ordered. You • After servicing, complete the relevant Service will need to quote the serial number, which is printed Interval Record section of the Benchmark on the data label. Checklist located on page 22 and 23 of this document. FAULT FINDING • Servicing should only be carried out by The fault finding chart (Table 4 Page 17) will enable competent persons in the installation and operational faults to be identified and their possible maintenance of unvented water heating causes rectified. Any work carried out on the cylinder systems. unvented water heater and its associated controls •... -
Page 18: Spares
SPARES Item Description Part Number Number Immersion heater (Bent) 95 606 984 Immersion heater (Straight) 95 606 986 Solar pocket plate assembly 95 607 064 Blanking plate assembly 95 605 881 Immersion heater gasket 95 611 822 Immersion heater backnut 95 607 869 Immersion heater key 95 607 861 spanner Indirect thermostat & 95 612 716 thermal cut-out Direct thermostat & thermal 95 612 717 cut-out Solar thermal cut-out 95 612 698 6 Way terminal block 95 607 933 3 Way terminal block 95 607 932 Terminal cover 95 614 095 Temperature / Pressure 95 605 810... -
Page 19: Heat Loss
HEAT LOSS ENVIRONMENTAL Products are manufactured from many recyclable Nominal Standing Heat Loss materials. At the end of their useful life they should be Capacity disposed of at a Local Authority Recycling Centre in (Litres) per day per year order to realise the full environmental benefits. (kWh/24h) (kWh/365d) 1.47 Insulation is by means of an approved CFC/HCFC free polyurethane foam with an ozone depletion factor of 1.70 zero. 1.92 2.10 2.22 2.52 Table 6: Standing heat losses (based on an ambient air temperature of 20°C and a stored water temperature of 65°C) - Page 20 NOTES...
- Page 21 NOTES...
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Page 24: Guarantee
Sales & Support Guarantee Servicing Spares On site service support including For all technical support, replacement heateam parts and labour for 12 months from parts & service issues please contact: date of installation. After the initial 12 heateam is Elson’s very own service months, a guarantee will apply for Electric Water Heating Co. division. With us on your side, you can a further 24 years for the stainless 2 Horsecroft Place, Pinnacles, be sure that your customers are in the steel inner vessel only. During this 24 Harlow, Essex CM19 5BT very best of hands. Totally committed year period, in the event of a cylinder Tel: 0845 0553811 to quality and safety, heateam is open leak, a replacement product will be E-mail: sales@ewh.co.uk 7 days a week, for 363 days a year, issued provided that the replacement...