PLEASE LEAVE THIS MANUAL WITH THE OSO UNIT AFTER INSTALLATION INSTALLATION MANUAL

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1 PLEASE LEAVE THIS MANUAL WITH THE OSO UNIT AFTER INSTALLATION SOLARCYL IM/SC INSTALLATION MANUAL This manual gives detailed advice for installation and should be read carefully prior to fitting any unvented unit. This OSO cylinder must be installed by a competent person and be installed in compliance with the OSO Installation and Maintenance Instructions, all current legislation, codes of practice and regulations governing the installation of unvented hot water cylinders in force at the date of installation. Components supplied with the unit for site fitting (See also page for component list) * Multibloc valve, includes pressure reducing valve, line strainer, balanced cold water take off, (for shower or bidet only) check and expansion valve. * Tundish Health and Safety * /''F x x tee piece. Manual Handling Operations Regulations 99 defines manual handling as: any transporting or supporting of * Flexible hose. a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or bodily * /'' x mm Elbow / Drain Cock. force. The Regulations set no specific requirements such as weight limits. However common sense still has * Commissioning valve, /'' BSP male. to be used based on an ergonomic approach for each individual. * Motorised valve. DIMENSION AND WEIGHTS TABLE * x /'' BSP male solar sensor pockets. Components factory fitted * Immersion heater. * Thermostats / thermal cut-out. * Temperature and pressure relief valve. CAPACITY LITRES HEIGHT DIAMETER WEIGHT EMPTY MAX WEIGHT FULL COIL RATING KW UPPER COIL LOWER COIL Installation details The OSO unvented unit is designed for use with supply pressure up to bar. For pressures over bar an additional pressure reducing valve must be fitted in the supply pipe to the unit

2 SOLAR INDIRECT Twin Coil Single Immersion Heater General Layout Fig: SOLAR DIRECT Single Coil Twin Immersion Heater CUTAWAY , 0, 0 A B C A A C 9 A A 9 A A A A A B C 9 KEY Return / BSP Boiler Return / BSP Solar Flow / BSP Boiler Flow / BSP Solar Pressure Reducing Valve Includes Item Expansion Valve Temperature and Pressure Relief Valve Tundish Immersion Heater Immersion Heater Thermostat Thermostat Boiler Thermostat Solar Cold Feed Tube (Not Supplied See Table ) Hot Water Outlet mm Part No KEY Part No Flexible Hose Secondary / Return / BSPF Fit /'' F x /'' M x mm Tee piece (Not supplied) Commissioning Valve / Fitting (/'' MI Drain Cock) Elbow / Drain Cock Cable Entry Electrical Box Tee Piece Discharge Pipe (Not supplied) Motorised Valve (Not Factory Fitted) Solar sensor bosses Dip Pipe (removeable) Series TABLE Length of tube (o) mm 9 mm 9 mm 0 mm --

3 COLD WATER SUPPLY. To obtain the best performance from your OSO unvented system it is advisable to feed the unit with an uninterrupted supply.. Locate the water heater in a suitable position to facilitate the installation of the cold water supply, discharge fittings and pipework. Also take into account access to the immersion heaters and the commissioning valve.. Fit the combined male elbow drain cock to cold supply point (), so that the compression fitting is vertical.. Fit the commissioning valve () to the commissioning fitting.. Fit both /'' male solar sensor pockets to the Solar bosses (9).. Fit the female outlet of the tee piece to the temperature and pressure relief valve () with the horizontal connection facing right at approx... Fit the tundish () to the tee piece using a short length of mm copper tube.. Fit the length of copper tube mm specified in Table to the cold feed elbow (see above). 9. Fit the pressure reducing valve () to the top of the copper tube (see above), so that the black knob is facing right. 0. Connect the flexible hose to the / outlet of the expansion valve () and the horizontal outlet of the tee piece (see above). Discard compression nut & ring.. If a balanced mains pressure cold water supply is required to a shower or bidet (over rim type only), remove the blanking cap from the pressure reducing valve () and connect to the shower or bidet cold supply. Using the balanced cold connection to feed bath taps can reduce the flow available to the unvented cylinder. (Major shower manufacturers advise fitting a mini expansion vessel in the pipework to accommodate thermal expansion and prevent tightening of shower controls). Before connecting the multibloc, flush the cold supply pipework of all flux and debris.. Connect the multibloc to the pressure reduction valve (Multibloc) (). Hot water supply. Connect the hot water supply pipe to the outlet (9). Ensure connection is water tight. Secondary return. A secondary return facility is provided on all units. Fit a / F x / M x mm Tee piece between the commissioning valve () and the commissioning fitting. See also figure on page. Discharge pipe. Connect the discharge pipe from the tundish (). This must have a continuous fall and be fitted in accordance with The Building Regulations (see page and ). Boiler Primaries Primary flow & return and motorised valve. The boiler primary flow and return connections should be made to the upper coil connections unit. The motorised valve must be fitted into the primary flow. The primary flow and return fittings are / BSP female. The valve has mm x copper connections.. For electrical connection of the motorised valve and immersion heater, please read Electrical Installation Instructions. (Pages - ) Solar Primaries 9. The Solar flow and return connections should be made to the lower coil connections. Temperature control from the Solar circuit is achieved using a differential solar controller. This controller must be wired in series through the thermal cut-out on the OSO thermostat (see figure pages 9 & ). If Solar Panels are to be installed at a later date then connect the boiler primaries to the lower coil. --

4 0. If the solar primary circuit contains a mechanical shut-off device, ensure that a non return valve in the circuit prevents thermal syphoning if the circulation is stopped. Should a mechanical shutoff device not be present, one should be fitted and wired in series to the thermal cut-out. Care should be taken to ensure the device is suitable for temperatures and fluids that may be present in a solar-thermal system.. Temperature sensors for the cylinder provided with the differential controller should be inserted into the pockets provided (see pt above). COMMISSIONING Filling up. Close all hot water taps.. Open the commissioning valve ().. Open the cold water supply valve.. When water flows from the commissioning valve (), close the valve.. Allow system to stabilise for five minutes.. Open each hot water tap in turn to expel air from the system pipe work.. Check for leaks.. Manually operate Temperature and Pressure Relief Valve () to ensure free water flow through discharge pipe. (Turn knob to left.) Draining Switch the electrical power off (important to avoid damage to element). Isolate boiler from OSO unit. Turn off the cold water supply valve. Open hot water tap. Open drain (). The unit will drain. SAFETY AND MAINTENANCE Safety Cut-out. The safety cut-out operates if: a. Wiring is incorrect. b. The immersion heater thermostat or cylinder thermostat fails. c. Thermostat is set too high.. Remember before resetting the safety cut-out or altering the thermostat setting, isolate electrical supply to the unit prior to removal of the electrical box lid.. Reduce thermostat setting and press the reset button. After adjustments are completed, ensure the lid to the electrical box is replaced correctly and the retaining screw is fitted.. If still out of operation, contact installer. RECOMMISSIONING INSTRUCTIONS Cold or tepid water discharge from tundish. Turn off the electrical supply to the immersion heaters.. Turn off cold water supply valve.. Open a hot tap.. Drain water from commissioning valve () until water flow stops.. Turn the knob on the Temperature and Pressure Relief Valve () to the left and hold in this position until water flow stops from the commissioning valve.. Close commissioning valve.. Close all hot taps.. Open cold water supply valve. 9. Turn on electrical supply to the immersion heaters. The process described above recommissions the expansion air gap in the cylinder. --

5 Hot water discharge from tundish This indicates a malfunction of a thermal cut-out, operating thermostat or the combined temperature and pressure relief valve. Turn off the electrical supply to the immersion heater and also isolate an indirect unit from the boiler. Contact the installer or competent engineer. INSTALLATION AND SERVICING INSTRUCTIONS Cold water inlet control (Multibloc) See Page Items - This combination consists of a pressure reducing valve with integral strainer, check valve and expansion valve with stainless steel seat. The pressure settings are set and locked in the factory and are shown on the top of each valve. For optimum performance the following installation instructions should be complied with. Installation. Cold water supply to be mm nominal size.. Flush supply pipework before connection to remove all flux and debris prior to fitting the inlet controls. Failure to do this may result in irreparable damage to the controls and will invalidate the warranty.. The MULTIBLOC can be fitted in any orientation to suit the installation as long as it is fitted in the correct flow direction. Check the flow arrows on the side of the body.. The expansion valve should be either horizontal or upright - if fitted inverted, debris may be deposited on the seat and cause fouling of the seat when the valve operates. Check direction of flow arrows.. The black plastic plugs in the body are pressure gauge connections to enable pressure monitoring to be carried out, should the system develop a fault. It is recommended that these be accessible (the pressure reducing valve has two - only one need be accessible).. Expansion relief drain pipework must be connected to a safe visible discharge point via a tundish and the pipework must have a continuous fall.. The pressure reducing valve has two outlets, the second one is for a balanced cold water supply, to a shower or a bidet (over rim type only, ascending spray type requires type AA, AB or AD air gap). (Major shower manufacturers advise fitting a mini expansion vessel in the balanced cold supply to accommodate thermal expansion and prevent tightening of shower controls). Using the balanced cold connection to feed bath taps can reduce the flow available to the unvented cylinder. If not required the balanced cold supply is blanked off. The Benchmark Log Book enclosed with the cylinder should be completed after commissioning of the system and handed to the customer for future use.. If an expansion vessel is to be fitted it must be connected to the cold feed pipe between the pressure reduction valve, (Multibloc) () and the cylinder. TE: If the unit has been commissioned and is to be unused for more than weeks it is advisable to turn off the cold supply and draw off approximately litres of water through a hot tap. NB The cold supply must be opened prior to use. --

6 MAINTENANCE It is recommended that annually a competent person (a) Inspects and cleans the line strainer. (b) Checks the operation of the expansion relief valve and temperature & pressure relief valve. (c) Recommissions the cylinder in accordance with the instructions on page. Pressure reducing valve. Isolate the cold water supply.. Unscrew the retaining nut of the valve. The complete operating mechanism, including the strainer can be removed.. Clean the filter mesh and the cartridge under running water.. Replace cartridge ensuring that strainer is correctly located and reassemble the unit. Pressure Reducing Valve cartridge and strainer Part No Bar. Expansion relief cartridge. Isolate the cold water supply.. Unscrew blue expansion relief headwork from valve body.. Clean valve seat face and seating - do not scratch or damage either seat face or seating.. Refit in reverse order. Do not overtighten Expansion valve cartridge and seat Part No Bar. Complete Expansion Valve Part No Bar. Spare Parts Pressure reducing valve Cartridge and strainer. bar Part No. 00 (green dial) Part No. 000 (blue dial) Tundish Install thetundish in a vertical position within a maximum of 00mm from the temperature and Pressure Relief Valve drain connection. Ensure the expansion relief pipework discharges through the tundish. Tundish pipework must be mm with a minimum vertical length of 00mm below tundish. Maximum permitted length of mm pipework is 9m. Each bend or elbow is equivalent to 0.m of pipework. All pipework must have continuous fall and discharge in a safe, visible position. If any doubt, refer to Building Regulation G. --

7 ELECTRICAL INSTALLATION Immersion heaters All units are fitted with one immersion heater which is located behind the lower electrical box. Wiring instructions for the immersion heater is located on the reverse side of the lower lid. Follow the wiring instructions connecting the live, neutral and earth as indicated. The electrical connection to the immersion heater must conform to current IEE wiring regulations. The unit must be permanently connected to the electrical supply through a double-pole linked switch with a minimum break capacity of amps. All internal wiring is factory mounted. Each immersion heater has a working thermostat adjustable between 0 C - 0 C. A safety cut-out is also incorporated within the thermostat and will operate at C ± C. Should this happen, press the reset button. Important: Before resetting the safety cut-out or altering the thermostat setting, isolate electrical supply to the unit prior to removal of the lid. Ensure the lid to the electrical box is replaced correctly and the retaining screw is fitted. Indirect Units upper coil Motorised valve To comply with regulations governing the installation of indirect unvented cylinders, a motorised valve must be fitted in the primary flow. Your OSO unit has been supplied with a two port motorised valve, which will act as a positive energy cut-out should the safety cut-out operate. The motorised valve will also control the temperature of the domestic stored water via the cylinder thermostat, which is located in the upper electrical box. The unit should be installed on an S or Y plan system. Cylinder temperature control can also be achieved via the solar thermostat when the boiler is not operational. Please follow the instructions carefully. All electrical connections must conform to current IEE wiring regulations. The working thermostat is adjustable between 0 C - 0 C. A safety cut-out is also incorporated within the thermostat and will operate at C ± C. Should the safety cut-out be brought into operation, the motorised valve will operate and close down the primary flow to the cylinder. To reset the safety cut-out and the motorised valve the reset button must be pressed in (see fig. page 9). Lower (Solar) coil Heat sources to unvented hot water cylinders must be controlled by a thermal cut-out as well as a thermostat. The Oso Solarcyl is supplied both with bosses for solar sensor pockets and the pockets themselves. The top half of the thermostats fitted to the cylinder is a thermal cut-out. The solar controller (not supplied) and solar sensor point should be wired through the Oso thermal cut-out. Please note that the direction of flow in the solar coil is reversed compared to the boiler coil. If the cylinder is not being used for solar use, follow the directions for the upper coil. OSO Hotwater (UK) Limited can not be responsible if alternative wiring plans are used. Important: Before resetting the safety cut-out or altering the thermostat setting isolate electrical supply to the unit before removal of the lid. --

8 S Plan Wiring Layout UPPER ELECTRICAL BOX For Other Boilers Refer To Boiler Manufacturer The wiring plan shown is based on the use of a 0-way Junction Box (Honeywell Part no ) Junction Box terminal 0 is switched live and, if needed, terminal 9 is pump live. --

9 S Plan System Schematic L N Honeywell ST 00 Programmer day L N E FIGURE FIGURE Mains L N Honeywell ST 00 Programmer Hr ST 0 Room stat Br Bl Gr Or Br Bl Gr Or HTG Valve V0H DHW Valve V0H Collector Thermostat Pocket Pocket Thermostat FIGURE FIGURE SCHEMATIC - LOWER ELECTRICAL BOX Solar Controller Cylinder Collector Pump WIRING Electrical spare parts: Immersion Heater Immersion Heater Thermostat Coil Thermostats

10 Y Plan Wiring Layout UPPER ELECTRICAL BOX For Other Boilers Refer To Boiler Manufacturer The wiring plan shown is based on the use of a 0-way Junction Box (Honeywell Part no ) Junction Box terminal is switched live and, if needed, terminal 0 is pump live. -0-

11 L N Honeywell ST 00 Programmer day L N E Mains Y Plan System Schematic FIGURE FIGURE Mid position Valve (not supplied) L N Honeywell ST 00 Programmer Hr ST 0 Room stat V0A09 W G O Bl Br Bl Gr Or DHW Valve V0H Collector Pocket Pocket Thermostat FIGURE FIGURE SCHEMATIC - LOWER ELECTRICAL BOX Solar Controller Cylinder Collector Pump WIRING Electrical spare parts: Immersion Heater Immersion Heater Thermostat Coil Thermostats

12 FAULT No water flow from hot taps OSO FAULT FINDING GUIDE POSSIBLE CAUSE. Mains supply off.. Strainer blocked.. Cold water inlet Pressure Reducing Valve incorrectly fitted. REMEDY. Check and open stopcock. Turn off water supply. Remove strainer and clean. (See Pressure Reducing Valve page Installation Manual). Check and refit as required, (see item page of installation manual). Water from hot taps is cold. Intermittent water discharge.. Low solar gain.. Immersion heaters not switched on.. Immersion heater thermal cutout has operated.. Programmer set to central heating or not switched on.. Boiler not working.. Cylinder thermal cut-out has operated. (Indirect units only).. Motorised valve not operating correctly.. Reduced internal expansion.. Thermal control failure. (Note Water will be hot).. Activate alternative power source.. Check and switch on.. Check and reset button. (See thermostat diagram page 9 and safety cut-out on page of installation manual).. Check and set to hot water.. Check boiler operation. If fault suspected consult installer or boiler manufacturer.. As at No... Check wiring and / or plumbing connections to motorised valve. (See pages or 0 of the installation manual).. Recharge air gap (See cold water discharge on page of installation manual).. Switch off power to immersion heater(s) and boiler supply to the unit. When discharge has stopped, check thermal controls, replace it faulty. Contact a competent person. Continuous water discharge.. Cold water inlet Pressure Reducing Valve not working.. Temperature and pressure relief valve faulty.. Expansion relief valve not working correctly.. Check pressure from valve if greater than. bar replace. (See page of installation manual).. As No. of above.. Check and replace if faulty. (See page of installation manual). TE: Disconnect electrical supply before removing any electrical equipment covers --

13 OSO FAULT FINDING GUIDE Intermittent water discharge Reduced Internal expansion volume Thermal control failure Recharge air gap. Follow correct procedure Switch off power to immersion heaters and boiler supply to the unit. When discharge has stopped check thermal controls and replace as necessary If problem still persists contact a competent engineer / plumber No water flow from hot taps Mains supply off Line strainer blocked Cold water PRV incorrectly fitted Open supply valve Clear line strainer Check and refit as required If problem still persists contact a competent engineer --

14 OSO FAULT FINDING GUIDE Hot water from taps is cold Low solar gain Activate boiler Insufficient hot water when boiler is used Is the programmer set to central heating or not switched on? Is the boiler working? Remove hot water dip pipe and fit seperate expansion vessel. (see page ) Check and set to hot water programme. Is the motorised valve operating correctly? Has cylinder thermal cut-out operated? If problem still persists contact a competent engineer / plumber Check wiring or plumbing connections Excessive Hot water from taps Check and reset button Thermostat/Solar controller set too high Is Thermostat wired as per layouts for S or Y plan installation Reduce Temperature setting Connect wiring as per instructions Check cylinder Thermostat is switching on & off with programmer & hot water on Faulty Thermostat replace Is -port motorised valve closing when cylinder reaches temperature? Wiring Fault Seek advice from electrician Check wiring on cylinder Thermostat If in doubt at any stage you must consult a qualified electrician --

15 INCREASED VOLUMES AND HIGH PRESSURE OPERATION. The capacity of all OSO cylinders can be increased by approximately 0% if the internal hotwater dip pipe supply connection (see page part no 0) is removed by unscrewing the hot supply connection. On a Solarcyl, the increased capacity can also make a significant difference to the amount of hot water available from the upper heating coil to accommodate the expansion of secondary water, an expansion vessel suitable for potable water must be connected to the cold feed pipe between the pressure reducing valve and the cold entry to the cylinder (See fig below).. Increased pressures can be obtained by fitting an adjustable pressure reducing cartridge (part no: 00) in the pressure reducing valve. This cartridge is adjustable between 0. and bar. It is advisable to remove the hot supply connection and fit a suitable expansion vessel (see above) (see Fig ).. Table gives details of cylinder and expansion vessel capacities for a range of pressure settings.. The expansion vessel must be suitable for potable water and charged to the same pressure as the pressure reducing valve.. If the cylinder is to be used in this manner ignore the filling procedure on page. Leave one hot tap open. Open the cold water supply valve. When water appears at the open hot tap close the tap. Open each hot tap in turn to expel air. Manually operate the pressure and temperature relief valve () to ensure free water flow through discharge pipe. (Turn knob to left.) Table PRV Bar. Standard Capacity Without DIP Pipe Expansion Relief Bar Expansion Vessel Volume (Litres) Figure Inlet Control Group SUGGESTED CONNECTION POSITION FOR EXPANSION VESSEL Expansion Vessel Sized to System Volume. Connection is between inlet control group and drain elbow to cylinder. Pressure should be set to that of the Pressure reducing Valve. Expansion vessel can be floor or wall mounted. Drain Elbow --

16 ALTERNATIVE DISCHARGE Downward discharges at low level, i.e. up to 00mm above external surfaces such as car parks, hard standings, grassed areas etc, are acceptable providing that where children may play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility. Discharge at high level, i.e. into a metal hopper and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and m from any plastics guttering system that would collect such discharges (tundish visible). FIGURE Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not more than systems so that any installation discharging can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected. For further information contact your Building Control Office or The British Board of Agrément. SECONDARY RETURN HOT TAPS HOT OUTLET COLD INLET Secondary Return Fitting use /''F x /'' M x mm Commissioning Valve Non Return Valve Circulation Pump Secondary Return Line Balanced cold supply for showers or bidet only All replacement parts must be supplied by OSO HOTWATER (UK) LIMITED. To obtain the address of a local stockist contact: OSO HOTWATER (UK) LTD E Marquis Court Team Valley Trading Estate Gateshead Tyne & Wear, NE 0RU Phone: (09) 000 Fax: (09) ISSUE - OS9 0/0

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