Plus. USER and INSTALLATION INSTRUCTIONS. 30,000-9kW for Heating and Hot Water

Transcription

1 Plus A complete cost effective solution for Hot and Cold water supply and Electric Central Heating with water filled radiators, suitable for Self-contained Flats, Small Dwellings, Offices, Home Offices and Granny Annexes. 30,000-9kW for Heating and Hot Water Electrastream eam Electrastream eam Plus USER and INSTALLATION INSTRUCTIONS 05/12/06 Patents GB Application WRC Approval Pending 41

2 CONTENTS CONTENTS Section 1 Introduction 1-1 Introduction System Layout Immersion Heater Operation Section 2 Operator Controls ols 2-1 System Control Electrastream Control Unit Shut Off Valves Expansion Relief Discharge Thermostatic Mixing Valve Servicing Section 3 Technical Information 3-1 Specifications Dimensions Wiring Section 4 Installation 4-1 Building Control Electrical Hot Water System Heating System Expansion Discharge System Pressure Parts Supplied Section 5 Commissioning 5-1 Commissioning Checks Handing Over INTRODUCTION 2 OPERATOR CONTROLS 3 TECHNICAL INFORMATION 4 INSTALLA ALLATION 5 COMMISSIONING Section 6 Servicing 6-1 Routine Service SERVICING Section 7 Fault Finding 7-1 Fault Finding FAUL AULT FINDING IMPORTANT BEFORE STARTING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARE IN SATISFACTORY CONDITION. 1

3 1 1-1 Introduction INTRODUCTION 1 This Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITED Electrastream domestic hot and cold water and central heating system. After installation the Installer of the system should give full operating instructions to the householder for the Electrastream System The Electrastream System The Electrastream system by GAH (Heating Products) Ltd. has been developed as a cost effective solution for domestic hot and cold water and electric central heating with water filled radiators. Electrastream is suitable for flats, small dwellings, offices, home offices and granny annexes Basic Principles Electrastream is available in two options:- ELECTRASTREAM PLUS - with cold water storage (accumulator) ELECTRASTREAM - without cold water storage. ELECTRASTREAM PLUS Fig. 1-1a Electrastream ELECTRASTREAM Note For components supplied with system refer to page 28. Water in the unvented cylinder is heated by a high powered titanium electric immersion heater. Hot water is drawn from the cylinder and mixed with cold water by a thermostatic mixing valve; this ensures safer lower temperatures at the hot water outlets. The hot water within the unvented indirect cylinder also heats the water for the heating system via the indirect coil within the cylinder. The circulating pump for the heating system is controlled by a thermostat and programmable timer with override so that heat is available on demand, providing there is a supply of hot water. ELECTRASTREAM PLUS The Electrastream Plus system is supplied with a cold water storage. The accumulator has an internal controlled butyl diaphragm, incoming cold water is stored within this diaphragm at mains pressure. The air space between the diaphragm and the accumulator case is pressurised, this balances the supply and maintains pressure to the unvented hot water cylinder and cold outlets. When hot and cold water outlets are turned on, the stored water from the accumulator supplements water from the incoming main, this results in consistent pressure and flow to all taps, showers and baths even when outlets are used simultaneously. Pressure will be sustained for as long as the accumulator is holding sufficient volume of water. 2

4 INTRODUCTION Electrastream System Features ELECTRASTREAM AND ELECTRASTREAM PLUS 1. Only water and electric economy tariff services required. 2. No gas or oil - no Boiler. 3. Central heating with conventional water filled radiators. 4. Heat on demand 24 hours a day. 5. Can be timed for economy tariff. 6. Far more flexible heating control than storage radiators. 7. Hot and cold water supply from GAH Dualstream technology. 8. Hot water to taps and shower from unvented cylinder. 9. Hot water to outlets temperature controlled by thermostatic mixing valve. 10. Mains pressure to hot and cold outlets. 11. All plumbing, water storage and controls are within the dwelling - no header tank. 12. Low maintenance cost, no CORGI Landlord Certificate required kW titanium immersion heater (combined 3 x 3kW). 14. Immersion heater will still work should one or two of its elements fail. 15. Stainless Steel Unvented Cylinder with 20 years guarantee. 1 ELECTRASTREAM PLUS 1. Balanced hot and cold supply to taps. 2. All taps and showers at maximum system pressure. 3. Pressure maintained for both hot and cold taps even when other taps are open (subject to volume used). ELECTRASTREAM SOLAR The Electrastream system is suitable for Solar water heating - for further details consult GAH (Heating Products) Ltd. Solar Collectors Electrastream Immersion Heater Electrastream Control Solar Control Incoming Water Main Pump Accumulator Coldwater Storage Bottom Coil heated by Solar Thermostatic Mixing Valve Twin Coil Cylinder Fig. 1-1b Electrastream and Solar Application 3

5 INTRODUCTION System Layout PARTS SUPPLIED Fig. 1-2a Typical Schematic Installation - Electrastream 4 PARTS SUPPLIED Fig. 1-2b Typical Schematic Installation - Electrastream Plus

6 INTRODUCTION 1 Note All installations must comply with relevant regulations - refer to section Hot & Cold Water Supply Refer to fig. 1-2a for Electrastream. Refer to fig. 1-2b for Electrastream Plus. The incoming mains water supply is connected to the combination valve which is assembled to the unvented indirect hot water cylinder. The combination valve has an integral check valve. A double check valve is supplied, this is only required to be fitted if back syphonage is possible from any item fitted prior to the combination valve. A connection must be provided for the system fill. Also provision has to be made for water softener and outside tap as applicable. The combination valve limits the incoming pressure to 3.5 Bar, it has an integral nonreturn valve and pressure relief valve (PRV). Supply to the hot outlets is taken from the cylinder and mixed with cold water by the thermostatic mixing valve (supplied), this ensures that a safer lower temperature hot water is available at outlets. 1 ELECTRASTREAM ONLY Cold supply to all outlets is taken direct from the main supply. If the mains pressure is high (over 3.5 Bar) a pressure reducing valve is recommended. ELECTRASTREAM PLUS The incoming mains supply is connected to the combination valve. Once passed the valve it supplies the accumulator and the hot water cylinder. Supply to the cold outlets is taken from a Tee fitting at the base of the accumulator System Control The system is controlled by a purpose designed Electrastream Control unit, this controls the hot water and heating ON/OFF times together with the heating pump and valve. The control also has a dedicated programme that ensures efficient use of electricity by selecting how many of the three immersion heater elements are required to meet the current demand for heating or hot water. It also incorporates an automatic heating element test function Heating System The heating system has water filled radiators and is a standard sealed system. The water for the heating is heated by being pumped through the indirect coil of the indirect cylinder. A room thermostat and the Electrastream Control unit s programmable timers control the circulating pump and motorised valve. GAH offer a range of quality Water Softeners, for information contact GAH (HEATING PRODUCTS) LTD Electric System The unvented cylinder is heated by a 9kW (combined 3 x 3kW) titanium immersion heater. This is controlled by the cylinder temperature sensor and the Electrastream Control unit. Electrastream is designed to make full use of economy tariff electricity supplies and the wiring must be arranged to make full use of this Output The 9kW immersion heater provides 30,000 Btu (9kW) for heating and hot water. 5

7 INTRODUCTION Scale Protection IMPORTANT All installations should have a scale protection device fitted and in areas known to have hard water, a water softening device is strongly recommended. GAH recommend and promote the use of scale prevention devices and water softeners in areas that are known to have hard water. Installed correctly they prolong the life of equipment and help prevent limescale formation in the pipework. Water softeners provide the advantages of soft water, as well as preventing scale build up on taps and shower heads. Water softeners and any mains fed system must be of adequate capacity and should be installed with suitably sized hoses to prevent any possibility of flow reduction Frost Protection When planning the installation location of both the accumulator and the unvented cylinder, consideration must be given to the risk of frost and the use of frost protection. The design of the accumulator gives it a degree of frost protection enabling it to be located within the dwelling, loft space or garage without further protection. The cylinder can also be installed within the dwelling or loft space without further protection. Cylinders or accumulators must have frost protection when they are installed where low temperatures could be a potential problem. Cylinders can be protected by a frost thermostat. To comply with Building Regulations, all necessary pipework must be suitably lagged. 1:2.8 Handling and Storage The Electrastream system will be delivered fully wrapped and palleted. Lift the package carefully using a safe and suitable lifting method. Keep the packaging intact and store in a secure dry and weatherproof area prior to installation. 1-3 Immersion Heater Operation The three immersion heater elements are switched on and off by the Electrasteam Control. They have a staggered switch on sequence that prevents sudden high load on the power supply. The control also limits the use of the elements for efficiency. When the hot water within the cylinder is within 2 of the set (8) Target ## C only one element will be on. When the hot water within the cylinder is within 2 and 4 C below the set (8) Target ## C then two elements will be on. When the hot water within the cylinder is below 6 C of the set (8) Target ## C then all three elements will be on. 6

8 OPERATOR CONTROLS System Control The heating and hot water system is all electric. The hot water for the taps (outlets) and radiators is heated by the immersion heater in the cylinder. The system will have the following controls. 2 Fig. 2-1a Schematic of Typical Controls Isolating Switch The system will have a double pole isolating switch with neon and mechanical indicators. This could be a pull cord or wall mounted type. When the switch is ON (neon on) the system is operational. When the switch is OFF (neon off) no hot water or heating will be available. It is advised to turn the switch off when hot water and heating are not required, i.e. holidays etc. Fig. 2-1b Isolating Switch Immersion Heater WARNING The immersion heater does not have an internal thermostat (like most immersion heaters) the cover should not be removed. When the cover is removed live electrical terminals are exposed. ISOLATE THE IMMERSION HEATER BEFORE REMOVING ITS COVER. MANUAL RESET BUTTON Fig. 2-1c Thermal Cut-Out Thermostat Thermal Cut-Out Thermostat In the thermostat box on the cylinder is the thermal cut-out thermostat. This prevents the water within the cylinder from overheating. The immersion heater thermal cut-out thermostat is a manual reset type, this means it has a small button that pops up when the thermostat has been tripped by overheating. To reset the system after overheating, switch heating and hot water OFF, allow time for the water to cool, or run off some hot water, then remove the cap and press the button. If the immersion heater thermal cut-out trips more than once, switch off the Electrastream isolating switch and contact your installer. 7

9 OPERATOR CONTROLS Heating Motorised Valve When the room thermostat is calling for heat and the Electrastream Control is set for heat ON, the heating motorised valve will open allowing water to the radiators. Display icon Valve indicates the valve is open Pump The heating circulating pump is controlled by the Electrastream Control unit in response to the room thermostat. The pump has 3 speeds, it is normally set to speed 2. Display icon Pump indicates the pump is ON Room Thermostat The room thermostat controls the heat within the dwelling. When the room thermostat is calling for heat and the Electrastream Control is set for heat ON, the heating circulating pump will run, pumping water through the radiators. Display icon Therm indicates the room thermostat is calling for heat. 8

10 OPERATOR CONTROLS Electrastream Control Unit Control Unit Display - Normal Screen 2 HEAT 1 HEAT 2 HEAT 3 VALVE PUMP THERM >>>>>> Indicates Element 1 is ON Indicates Element 2 is ON Indicates Element 3 is ON Indicates Heating Valve is OPEN Indicates Heating Pump is ON Indicates Room Stat is calling for heat Heating on Fig. 2-2a Electrastream Control Unit - Normal Screen 9

11 OPERATOR CONTROLS Display Time Settings NORMAL SCREEN 2 When SET is pressed, time settings are displayed for 10 seconds, display then reverts back to normal screen Use to increment time up Use to increment time down Use to select hours (hh:) or minutes (:mm) Display only. Indicates the total hours that each immersion heater element has been in operation. (For service engineers information only.) Notes:- All times are given in 24 hour clock. 10 Fig. 2-2b Electrastream Control Unit - Time Setting Displays

12 OPERATOR CONTROLS Economy Tariffs Regional Electricity suppliers have their own Off-Peak tariffs that will provide an economical supply of power for the Electrastream system. It is vital that the time settings of the Electrastream Control are set to make the most use of the available Off-Peak tariffs. Note:- * The electricity supply company has to make special arrangement to the dwellings electrical supply to enable Electrastream to be used during both off-peak and normal tariffs- consult the installing electrician Normal Tariffs Normal tariffs are at all times that are not designated for Off-Peak, the cost of electricity during normal times will be more expensive. Therefore avoid setting heating and hot water On during these periods Setting Heat and Hot Water Requirements Figure below shows a 24 hour clock with typical use of the Electrastream during offpeak ecomomy 10 settings. 2 All times fall within Economy Tariff Start 1 Stop (3am) (5am) Start 2 Stop (2pm) (4pm) Start 3 Stop (8pm) (9.30pm) Boost can be used at any time during Economy or *Normal Tariff to provide heating and hot water. To turn hot water and heating OFF during ON periods (auto) press require switching to Auto again when required. twice. It will To turn heating only OFF during ON period (auto) and during Boost press require switching to Auto again when required.. It will To turn hot water only ON during Off periods (auto) press Auto again when required.. It will require switching to To turn hot water and heating ON during Off periods (auto) press then. Both will require switching to Auto again when required. 11

13 OPERATOR CONTROLS Shut Off Valves The Electrastream installation will have a number of shut off valves, the location of these will be dependent on the installation - figs. 2-3a and 2-3b show typical layouts. 2 Fig. 2-3a Typical Shut Off Valve Locations - Electrastream 12 Fig. 2-3b Typical Shut Off Valve Locations - Electrastream Plus

14 OPERATOR CONTROLS 2 IMPORTANT Before closing ANY valve, switch OFF the Electrastream Isolating Switch. Note When opening the stop cock turn the valve fully open then close ½ turn, this prevents the valve sticking Stop Cock Normally located at the point where the mains supply enters the dwelling. Shuts off the mains water supply to the dwelling Double Check Valve (If fitted) Normally located after the Stop Cock. Prevents water backfeeding to main. Shuts off the mains water supply to the dwelling. 2 CLOSED Cold Water Shut Off Valve Located in the cold feed to the taps/outlets. Shuts off the cold water to the taps/outlets Supply Water Shut Off Valve Normally located where the cold supply connects to the combination valve on the cylinder. Shuts off the cold supply to the Electrastream system. OPEN Fig. 2-3c Valves Hot Water Shut Off Valve Normally located where the Domestic Hot Water feed comes from the cylinder. Shuts off the hot water to the taps Accumulator Isolating Valve ELECTRASTREAM PLUS ONLY Located in the feed from the accumulator. Isolates water in accumulator. 2-4 Expansion Relief Discharge Note The Tundish or discharge pipe should remain visible, do not box in or cover up. AIR BREAK DISCHARGE PIPE Fig. 2-4a Tundish The Electrastream hot water cylinder has a Temperature/Pressure Relief Valve (TPRV); in the event of the pressure within the cylinder becoming too high, the TPR Valve will vent. The Cylinder connection for the TPR valve must not be used for any other purpose. The heating system has its own Pressure Relief Valve (PRV) located adjacent to the heating expansion vessel; in the event of the pressure within the heating becoming too high, the PRV will vent. The combination valve also includes a PRV. A Tundish will be fitted in the system, this should be located in the same space or compartment as the hot water cylinder. This device provides an air break when pressure is being vented from the cylinder TPRV. The heating system PRV may also be connected to the cylinder Tundish, alternatively it may have its own. When pressure is being vented, water/steam will be evident at the Tundish and from the discharge pipe of the Tundish. In the event of water/steam being seen at the discharge pipe or Tundish ascertain whether 13

15 OPERATOR CONTROLS 2 2 Note For more information see 4-5. it is caused by the heating system or hot water system and do the following:- 1. Turn ON a hot tap to relieve the pressure. 2. Turn OFF the immersion heater. 3. Turn OFF the heating system. 4. Investigate possible cause for high pressure from the hot water system e.g:- i Cylinder Thermostat is set too high. ii Restriction in hot water pipework. iii Loss of air pressure in the accumulator resulting in no expansion (Electrastream Plus only) If the heating heating system is the cause then :- 5. Check that the radiators are turned on, the heating system should never be operated with all radiators OFF. If all radiators are fitted with thermostatic valves, these can all be in a shut condition if the temperature in the dwelling is sufficient. In this circumstance the heating system should have a bypass that should be open - see fig. 1-2a & 1-2b. 6. Investigate possible cause for high pressure e.g. air in the heating system. 7. Contact the installer before restarting the system. 2-5 Thermostatic Mixing Valve The Mixing Valve will be fitted in the supply to the hot taps/outlets, it may be in a different location than the cylinder. This valve mixes hot water from the cylinder with cold water to provide hot water of a constant temperature at the taps. The recommended maximum hot water temperature at the taps is 60ºC. The recommended setting of the valve is between No.4 and 6 (49º to 58ºC). The Mixing Valve is factory set to the following approximate mixed outlet temperatures:- Fig. 2-5a Thermostatic Mixing Valve Knob Position Min Max Output Temp. ºC 27º 32º 38º 44º 49º 53º 58º 63º 67º WARNING Do not set the water temperature too high as this can cause scalding especially to the young and old. 2-6 Servicing It is recommended the system is inspected by an approved engineer once per year. The service procedure is included in section 6. 14

16 TECHNICAL INFORMATION Specifications WRC Certificate No Cylinder Material... Stainless Steel Maximum Water Supply Pressure Bar Operating Pressure Bar HTPR Valve Bar/90 C Thermal Cut-Out (in contactor box)... 90ºC Immersion Heater Voltage V Indirect Cylinder 125 and combined 3 x 3kW Reheat time Cylinder... ( t = 50 C) 50 minutes Reheat time Cylinder... ( t = 50 C) 58 minutes Motorised Valve... V4303H Accumulator Membrane... Butyl for wholesome water Maximum pressure Bar Minimum pressure /0.8 Bar Factory set pressure... 2 Bar Pipework All pipes should be sized to suit application. Suitable types:- Solderered copper, compression type and plastic. Push fit fitting must be specified as suitable for sealed systems Electrics Electrastream Supply Fuse Supply Cable Size Cylinder Immersion HeaterType Immersion Immersion Fuse Rating* Heater Size Heater Length C able Size ( Controller to Elements) 240V Single Phase 45 amp 3 core x??mmmm ² Indirect TDI125 TDI150 Titanium Element EN60335/2/73.96+corr EN A11/A15+A1 3qty 240V x 3kW 400mm nominal 3qty 16 amp 3qty 3 c ore x 2.5mm² HEAT RESISTANT Pump, Room Stat Motorised Valve and Heating Controls Fuse Rating* 5 amp C able Size 3qty 3 core 1.5mm² *In Electrastream Controller box 15

17 TECHNICAL INFORMATION Dimensions Cylinder Dimensions COMPRESSION FITTINGS ARE SUPPLIED TO ADAPT THE CYLINDER TAPPINGS TO THE PIPE SIZES SHOWN. 3 Cylinder Model TDI TDI DIMENSIONS Capacity A ØB C D E 125 litres litres Cylinder Model Capacity Coil Surface Coil Rating Weight Empty Weight Full TDI TDI litres 0.75m² 20.5kW 13kg 138kg 150 litres 0.9m² 26.7kW 14kg 164kg 16 Fig. 3-2a Cylinder Dimensions

18 3-2.2 Indirect Twin Cylinder Dimensions COMPRESSION FITTINGS ARE SUPPLIED TO ADAPT THE CYLINDER TAPPINGS TO THE PIPE SIZES SHOWN. ØB TWIN COIL CYLINDERS ARE USED FOR SOLAR WATER HEATING APPLICATIONS SEE TPRV 45 HOT WATER TO TAPS -22mm BOILER FLOW -22mm maximum COLD MAINS SUPPLY IN -22mm BOILER RETURN -22mm A E EXPANSION DISCHARGE PRIMARY HEAT SOUCE FLOW (SOLAR) COLD TO TAPS -22mm G F D C PRIMARY HEAT SOUCE FLOW (SOLAR) Cylinder Model A DIMENSIONS ØB C D E F G ITSI ITSI Cylinder Model Capacity Surface Bottom Coil Rating Surface Top Coil Rating Weight Empty Weight Full ITSI ITSI litres 0.75m² 20.5kW 0.75m² 20.5kW 44kg 244kg 300 litres 0.90m² 26.7kW 0.75m² 20.5kW 60kg 360kg Fig. 3-2b Twin Cylinder Dimensions 17

19 TECHNICAL INFORMATION Accumulator Dimensions PRE-CHARGE VALVE - SCHRAEDER 100 Essential Access Ø28 Ø TEE 28/28/28 COMPRESSION FITTING 3 Accumulator Model Size (Gross Capacity) up to 110 litres * Water Content Weight Empty 30.4kg BASE VENTED TO PREVENT CONDENSATION & FOR FLOOR FIXING COMPRESSION FITTINGS * Water content is up to 65% of the accumulator volume. Total weight = weight empty + water 1kg/litre. Fig. 3-2c Accumulator Dimensions Control Unit Dimensions TECHNICAL INFORMA Fig. 3-2d Controller Dimensions 18

20 3-2.5 Cased System Dimensions PIPEWORK NOT TO SCALE 3 TION 3 Fig. 3-2e Cylinder Dimensions 19

21 TECHNICAL INFORMATION Wiring Wiring diagram Fig. 3-3a Wiring Diagram - Standard arrangement Pump 45 amp Double Pole Isolating Switch with Electric and Mechanical Indicator L N Neon Indicator Cylinder Temperature Sensor Immersion Heater 3 x 2.5mm² Heat Resistant Cables Room Thermostat N L2 L1 g/y blue black brown 3 HONEYWELL V4043H Normally Closed FLOW FROM BOILER 3 x 3kW Immersion Heater Elements NOT USED orange grey blue brown g/y 16 AMP FUSE 16 AMP FUSE 16 AMP FUSE 5 AMP FUSE blue brown g/y N L E MAINS IN 230V AC TYPICAL POWER SUPPLY - CONSULT ELECTRICITY SUPPLY COMPANY N L E H1 N L E N L E H1 H1 L1 L2 N E N L E N L E T-STAT PUMP VALVE blue brown g/y blue brown g/y blue brown g/y brown black blue g/y blue brown g/y blue brown g/y LIVE 1 NEUTRAL 1 RCD Cylinder Thermal Cut Out Thermostat 45 amp FUSE blue CONTROL BOX TERMINAL g/y blue brown g/y brown blue brown g/y Thermal Cut Out Thermostat g/y g/y Note:- H1,H2 and H3 can be connected to any element. TEMP 0-T SENSOR Cylinder Temperature Sensor 20

22 INSTALLA ALLATION Building Control Note In some areas it is a criminal offence to install an unvented hot water storage system without notifying the local authority, or without the relevant licence Water System To install an Electrastream Heating System the installer must be fully competent, suitably qualified and hold a relevant unvented certificate and any applicable licence that may be required by the local inspectorate for installation of an unvented hot water storage system. In some areas the Local Authority may require notification by means of a building notice or by the submission of full plans for the proposed installation of an unvented hot water storage system. Note GAH offer full unvented training packages contact GAH (HEATING PRODUCTS) LTD Water Regulations The Water Byelaws and Current Building Regulations (paying particular attention to G3 and Part L 1 & 2) and HSE requirements should be considered when installing an Electrastream System. 4-2 Electrical Electrical Regulations All wiring should carried out to and comply with the current IEE Wiring Regulations. All electrical work must comply with any relevant regulations that apply at the time of the installation Electrical Work All electrical installation and maintenance of the Electrastream must be carried out by a competent qualified installer. All electrical work must be installed to the requirements of these User and Installation Instructions. Note The 45A MCB may require a ventilation space between it and other MCBs within the consumer unit Electrical Supply The main incoming electrical supply to the dwelling should be of adequate voltage and current rating for the requirements of the Electrastream as well as all other electrical requirements within the dwelling. The supply from the consumer unit to the Electrastream must have its own independent 45A MCB. The Electrastream must be wired through a 45A double pole isolating switch with a minimum of 3mm pole separation, this switch should also have both electric and mechanical indicators Off-Peak Electrical Supply To achieve the most efficient performance from the Electrastream it is recommended to use an Off-Peak electrical supply such as Economy 7 or Economy 10 tariffs which are available from most UK electrical suppliers. Consult the local electricity suppliers to determine what economy tariff options are available before installing the Electrastream. 21

23 INSTALLA ALLATION Hot Water System 4 Fig. 4-3a Cylinder Thermostat Box Note For wiring see Fig. 3-3a Unvented Hot Water Cylinder The cylinder may be installed at any convenient above ground location within the dwelling. As Electrastream is a sealed system, the cylinder is equally effective on any floor. The cylinder must always be installed vertically. Avoid positioning the cylinder where it may be subjected to frost. The floor must give adequate support to the filled cylinder. Cylinders with legs are supplied with self-tapping screws for floor fixing. For maintenance purposes leave at least 500mm at the front of the cylinder. The cylinder must be fitted with a drain valve, this should be as low as possible and able to drain at least 80% of the cylinder s volume. The cylinder may be installed below ground i.e. in a basement, providing that the expansion relief discharge pipe is plumbed to a metal receptacle with a suitable pump and switch arrangement, current Building Regulations give details of this. An alternative is to use a Hepworth HepvO Self Sealing Waste Valve, this must be installed to the manufacturers specification and building regulations Cylinder Thermostat Box The cylinder thermostat is an integral part of the Electrastream Control, a sensor and lead is provided. The sensor must be inserted into the phial of the cylinder thermostat box and the lead wired back to the Temp Sensor terminals of the Electrastream Control. A thermal cut-out thermostat is fitted in the cylinder thermostat box, this should be wired back to the O-T terminals of the Electrastream Control. The cylinder thermostat box must be fitted to the cylinder with its phial inserted into the socket provided in the cylinder. A screw is provided to clamp the unit in place Combination Valve The Combination Valve is supplied separate, it has to be fitted to the pipework suppling the cylinder. For standard configurations see 1-2. The valve has an integral 3.5 Bar Pressure Reducing Valve and a 6 Bar Expansion Relief Valve. It also has a line strainer, this should be checked as part of routine inspection. 22mm SUPPLY FROM MAINS 3.5 Bar PRESSURE REDUCING VALVE LINE STRAINER 15mm TO TUNDISH EXPANSION RELIEF Set at 6 Bar ¾ BSP PORT FOR EXPANSION VESSEL 22mm SUPPLY TO CYLINDER AND ELECTRASTREAM ACCUMULATOR 22 Fig. 4-3b Combination Valve Fig. 4-3c Expansion Vessel Connection

24 INSTALLA ALLATION Hot Water Expansion Vessel An Expansion Vessel is supplied for the hot water system, this should be fitted to the combination valve which has a ¾ BSP port provided for this. The expansion vessel must always be open to the system with NO shut off or isolation valves in the connection pipe. Note As Electrastream Plus is a sealed system, the pressure at the taps is not affected by the height of the cold water storage. GAH offer a range of quality Water Softeners, for information contact GAH (HEATING PRODUCTS) LTD Accumulator (Electrastream Plus only) The accumulator may be installed at any convenient location within the dwelling, outhouse, garage, loft or basement. In normal circumstances the accumulator should be installed vertically. Where this is not possible 100 model accumulators can be installed horizontally by supporting it in a cradle and ensuring provision is made to make it fully drainable. The floor must give adequate support to the filled accumulator. Accumulators must have frost protection when they are installed where low temperatures could be a potential problem - see Note that space is required to the top of the vessel to access the pressure valve. Provision must be made to enable the accumulator to be drained when required. IMPORTANT The accumulator is supplied at 2 Bar pressure. It is recommended to set the pressure at 1.5 Bar below the mains pressure with a minimum of 0.5/0.8 Bar - see Scale Protection IMPORTANT All installations should have a scale protection device fitted and in areas known to have hard water, a water softening device is strongly recommended. The cylinder is not guaranteed against damage caused by scale. GAH recommend and promote the use of scale prevention devices and water softeners in areas that are known to have hard water. Installed correctly they prolong the life of equipment and help prevent limescale formation in the pipework. Water Softeners provide the advantages of soft water, as well as preventing scale build up on taps and shower heads. Water softeners and any mains fed system must be of adequate capacity and should be installed with suitably sized hoses to prevent any possibility of flow reduction. The location and position of the Scale Protection Device or Water Softener should be as the manufacturers recommendations Pipework When all pipework has been installed, disconnect from the Electrastream components and flush all pipework thoroughly. When connecting to existing pipework remove all unwanted components, create new pipe runs then flush thoroughly before connecting to the Electrastream components Electrastream Components All Electrastream components and pipework are checked at the factory prior to dispatch, however always check the connections for leaks on commissioning as transportation and installation can cause joints to move. 23

25 INSTALLA ALLATION 4 Notes Refer to the mixing valve manufacturer s instructions supplied with the valve for further information. Put these with this manual. The mixing valve is not guaranteed against corrosion or blockage caused by excessive scale Thermostatic Mixing Valve A Thermostatic Mixing Valve is supplied with the Electrastream. It should be fitted between the cylinder hot water outlet and the draw off (taps). The valve mixes hot water from the cylinder with cold water to provide hot water at the taps at a consistent temperature. The valve is supplied with two check valves which must be fitted to the hot and cold supply. It is recommended to fit a service valve on each of the three pipes to the valve. CHECK VALVE CHECK VALVE CHECK VALVE FROM CYLINDER HOT MIX C0LD COLD SUPPLY SERVICE VALVE SERVICE VALVE SERVICE VALVE CHECK VALVE HOT OR COLD AS MARKED 4 DRAW OFF (TAPS) MIX - CONNECTED TO DRAW OFF (TAPS) VALVE CAN BE POSITIONED IN ANY ORIENTATION Fig. 4-3d Thermostatic Mixing Valve 4-4 Heating System Fig. 4-4a Schematic of Typical Heating System 24

26 INSTALLA ALLATION Notes on Heating System 1. The total output from the Electrastream for hot water and heating is 30,000 Btu (9kW). The radiators should be sized to suit. 2. The schematic system shows a kick space fan assisted heater, these are efficient space saving units, ideal for small dwellings bar psi Pressure Gauge The pressure gauge is provided to indicate the heating system pressure. When the system is full with cold water and all radiators are full, on and vented, the gauge will show the cold fill pressure. Set the red pointer to the cold fill pressure. If the system pressure, indicated by the black pointer, falls below the cold fill pressure, it means that the system requires topping up Pump Electrastream is supplied with a standard 3 speed central heating circulating pump and isolating valves. This should be fitted in the flow from the indirect cylinder before the bypass valve. Normally the pump will be set at speed 2. The pump is wired so that it is ON when the heating control system is set for heating ON and the room stat is set higher than the ambient temperature - see wiring diagram fig. 3-3a Heating TPR Valve The temperature pressure relief valve is provided to vent excess pressure from the system. The valve will open when the pressure exceeds 3 Bar ± 10%. The TPR valve can be manually opened by turning the red knob clockwise, to close the valve continue turning clockwise until it clicks. Note One Tundish is supplied with the Electrastream, this should be fitted to the hot water TPR discharge, see 4-5. STATIC HEAD HIGHEST POINT OF SYSTEM EXPANSION VESSEL Fig. 4-4b Static Head Note Normally expansion requirement is 4% of the system water content including the unvented cylinder coil Heating TPR Valve Discharge Pipe The outlet from the heating TPR valve must be piped using 15mm copper pipe to a visible position outside the dwelling. The pipe must have a continuous fall and ideally be terminated over a drain. Local by-laws may require a Tundish to be fitted - see note. The heating TPR valve may be plumbed to the hot water system discharge prior to the Tundish, see 4-5. IMPORTANT Scalding water and steam can be emitted from the discharge pipe. Position the discharge so there is no hazard to property or people (especially children) Expansion Vessel Maximum charge pressure 1.5 Bar Maximum working temperature 90 C Pre-charge pressure 1 Bar Maximum working pressure 3 Bar Capacity 8 litres for maximum system expansion of 7 litres. An expansion vessel and mounting kit is supplied, this is suitable for systems with a static head of up to 5 metres. If the static head is greater than 5 metres the charge pressure of the expansion vessel will need to be increased. Increase the pressure using a standard car tyre pump and pressure gauge when the system is empty (zero pressure). Expansion vessels are suitable for systems requiring a maximum expansion of 7 litres as detailed above. For systems requiring more expansion a second expansion vessel will be required. BS7074 Part 1 includes information on this requirement. 25

27 INSTALLA ALLATION Filling Loop A Filling Loop comprising a flexible hose, double check valve and an isolating valve is supplied for filling and topping up the system. The filling loop should be fitted between the incoming mains (before water softener) and the heating system return as shown on page 4 and fig. 4-4c. When not in use one of the hose unions must be disconnected as there must not be a permanent connection to the mains supply. HEATING EXPANSION VESSEL FIXING BRACKET MAINS SUPPLY 4 MUST BE DISCONNECTED WHEN NOT IN USE ISOLATING VALVE HEATING FLOW TPR VALVE DISCHARGE DOUBLE CHECK VALVE Fig. 4-4c Heating Expansion Vessel, TPR Valve and Filling Loop Motorized Valve A Honeywell V4043H Motorised Valve is supplied, this should be fitted in the Heating Flow from the cylinder prior to any take offs and wired as shown in fig. 3-3a. The valve is normally closed to prevent gravity feed from the cylinder to the heating system, when the pump starts the valve opens Bypass An automatic bypass valve should be fitted between the flow and return of the heating system, normally after the pump but before any radiator take offs. The valve must be set to suit the pressure of the system. 26

28 INSTALLA ALLATION Expansion Discharge AIR BREAK Tundish The Tundish must be vertical and fitted within 500mm of the temperature and pressure relief valve and must be located with the cylinder. The tundish must also be in a position visible to the occupants, and positioned away from any electrical devices. The discharge pipe from the tundish should terminate in a safe place, where there is no risk to persons in the vicinity of the discharge, and to be of metal. DISCHARGE PIPE Fig. 4-5a Tundish Note The TPRV and PRVs must not be used for any other purpose. WARNING Scalding water and steam can be blown out of the discharge pipe. Position the discharge so that it is not a hazard to property or people (especially children) Expansion Discharge - Self Sealing Valve A Hepvo Self Sealing Valve is available as an option, this enables alternative discharge arrangements to be used, however its use and installation must be approved by the local building control Expansion Discharge Pipe - To Gully See Fig.4-5b Discharge pipes from the TPRV and PRV may be joined together. The pipe diameter must be at least one pipe size larger than the nominal outlet size of the safety device, this is adequate when the hydraulic resistance does not exceed that of a straight pipe 9m long. Bends must be taken into account in calculating the flow resistance. Minimum pipe sizes are given in Table 1, overleaf. The discharge pipe must have a vertical section of pipe at least 300mm in length, below the tundish before any elbows or bends in the pipework. The discharge pipe must be installed with a continuous fall. The discharge must be visible at both the tundish and the final point of discharge, but where this is not possible or practically difficult; there should be clear visibility at one or other of these locations. Examples of acceptance are:- 1. Ideally below a fixed grating and above the water seal in a trapped gully. 2. Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. These 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. 3. Discharges at high level; i.e. into a metal hopper and metal downpipe 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 3m from any plastic guttering systems that would collect such a discharge (tundish visible). 4. 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 6 systems so that any installation 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. If unvented hot water storage systems are installed where discharges from safety devices may not be apparent i.e. in dwellings occupied by blind, infirm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place. Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and nonmetallic rainwater goods may be damaged by such discharges. 4 27

29 INSTALLA ALLATION 4 4 Fig. 4-5b Typical Expansion Discharge Arrangement The equivalent hydraulic resistance of discharge pipework needs to be calculated where the length of D2 exceeds 9m (maximum for one step up in pipe size) including resistance of elbows or bends. The following table can be used: Hydraulic Resistance of Discharge Pipework - Table 1 Valve outlet size Minimum size of discharge to Tundish ( D1 ) Minimum size of discharge pipe from Tundish ( D2 ) Maximum resistance allowed expressed as a length of straight pipe, i.e. no elbows or bends Resistance created by each elbow or bend G ½ 15 mm 22 mm 28 mm 35 mm up to 9 m up to 18 m up to 27 m 0.8 m 1.0 m 1.4 m G ¾ 22 mm 28 mm 35 mm 42 mm up to 9 m up to 18 m up to 27 m 1.0 m 1.4 m 1.7 m G 1 28 mm 35 mm 42 mm 54 mm up to 9 m up to 18 m up to 27 m 1.4 m 1.7 m 2.3 m Worked Example G ½ temperature and pressure relief valve (TPRV) with a discharge pipe (D2) having four elbows and length of 7m from the tundish to the point of discharge. From Table 1:- Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from G ½ temperature and pressure valve is 9m. Subtract the resistance for four 22mm elbows at 0.8m each = 3.2m. Therefore the maximum permitted length equates to 5.8m - as 5.8m is less than the actual length of 7m therefore pipe D2 must be 28mm. 28

30 INSTALLA ALLATION System Pressure COLD SUPPLY TO TAPS SYSTEM PRESSURE THERMOSTATIC MIXING VALVE MAINS PRESSURE MAINS PRESSURE REDUCING VALVE DOUBLE CHECK VALVE TPRV - 6 Bar HOT SUPPLY TO TAPS INCOMING MAINS WATER PRESSURE REDUCING VALVE set at 3.5 Bar SYSTEM PRESSURE HEATING PRESSURE GAUGE ACCUMULATOR HEATING PRV set at 3 Bar Cold water storage PRV - 6 Bar c/w INTEGRAL NON RETURN VALVE MOTORIZED VALVE BYPASS VALVE 4 SYSTEM PRESSURE HEATING SYSTEM PRESSURE Fig. 4-6a Pressure Diagram - Electrastream Plus Notes on Pressures:- 1. The Mains Pressure Reducing Valve is not normally required on standard systems with normal mains pressure, however if the mains pressure is more or fluctuates above 4 Bar a Mains Pressure Reducing Valve should be considered. 2. The Combination Valve has an integral pressure reducing valve fixed at 3.5 Bar therefore the System Pressure will be 3.5 Bar maximum. 3. If the Mains Pressure is less than 3.5 Bar then the System Pressure will be at maximum Mains Pressure. 4. The Combination Valve has a Pressure Relief Valve (PRV) set at 6 Bar. 5. The unvented cylinder has a Temperature and Pressure Relief Valve (TPRV) set at 6 Bar. 6. The heating system has a TPRV set at 3 Bar. Electrastream only 7. The Accumulator Pressure is factory set at 2 Bar. 8. The recommended Accumulator Pressure is 1.5 Bar below the mains pressure with an absolute minimum of 0.5/0.8 Bar - see Consult GAH (HEATING PRODUCTS) for further information. 29

31 INSTALLA ALLATION Parts Supplied Electrastream Item P art Qty. Notes 1 Electrastream Control 1 C/w cylinder temperature sensor 2 Unvented Cylinder 1 TDI125 or TDI kW Immersion Heater 1 Titanium Combined 3 x 3kW 4 GAH Circulating Pump 1 240V Single Phase 5 Pump Isolating Valves 2 22mm 6 Thermostatic Mixing Valve 1 7 Heating System 8l Expansion Vessel & Kit 1 Blends cold water with hot water from cylinder for taps. C/w Filling and Strap Loop, Pressure Gauge, TPRV & Bracket 8 Combination Valve 1 Includes PRV, Pressure Reducing Valve. 9 Cylinder Thermostat Box 1 C/w manual override stat MI Coupler 22Mmm x ¾"BSP Brass mm Full Bore Lever Valve Cylinder Cold In 1 - Cylinder Hot Out 1 - Cylinder Heating Flow 1 - Cylinder Heating Return 1 - Cold Supply to Taps 1 - Hot Supply to Taps 12 Motorised Valve 1 Honeywell V4043H Electrastream Plus Item P art Qty. Notes 1 Electrastream Control 1 C/w cylinder temperature sensor 2 Unvented Cylinder 1 TDI125 or TDI kW Immersion Heater 1 Titanium Combined 3 x 3kW 4 GAH Circulating Pump 1 240V Single Phase 5 Pump Isolating Valves 2 22mm 6 Thermostatic Mixing Valve 1 7 Heating System 8l Expansion Vessel & Kit 1 Blends cold water with hot water from cylinder for taps. C/w Filling and Strap Loop, Pressure Gauge, TPRV & Bracket 8 Combination Valve 1 Includes PRV, Pressure Reducing Valve. 9 Cylinder Thermostat 1 10 MI Coupler 22Mmm x ¾"BSP Brass mm Full Bore Lever Valve 2 External adjustment c/w manual override stat. 1 - Cylinder Cold In 1 - Cylinder Hot Out 1 - Cylinder Heating Flow 1 - Cylinder Heating Return 1 - Cold Supply to Taps 1 - Hot Supply to Taps 1 - Accumulator Feed 12 Model 100 Accumulator 1 Cold Water Storage 13 Double Check Valve 1 For Incoming Main 14 MI Coupler 22Mmm x 1"BSP Brass 1 Accumulator Connection 15 Motorised Valve 1 Honeywell V4043H 30

32 INSTALLA ALLATION Connections to Electrastream and 150 Cylinders UNVENTED CYLINDER DOMESTIC COLD WATER 22mm HTPR VALVE MI COUPLER x 22 x ¾ DHW 22mm LEVER VALVE DOMESTIC HOT WATER 22mm 22mm LEVER VALVE FROM MAINS 22mm COMBINATION VALVE MOTORISED VALVE TUNDISH HEATING FLOW 22mm 4 MI COUPLER x 22 x ¾ CYLINDER THERMOSTAT BOX CYLINDER DRAIN COCK HEATING RETURN 22mm IMMERSION HEATER COLD INTO CYLINDER MI COUPLER x 22 x ¾ MI COUPLER x 22 x ¾ Domestic Hot Water 22mm 22 x ¾ M.I. Coupler - supplied Fit 22mm ball valve - supplied Domestic Cold Water 22mm Fit 22mm ball valve - supplied Mains Supply 22mm Fit 22mm ball valve - supplied Tundish - Discharge to be arranged and sized to comply with Building Regulations. Boiler Flow 22mm 22 x ¾ M.I. Coupler - supplied Boiler Return 22mm 22 x ¾ M.I. Coupler - supplied PARTS SUPPLIED Fig. 4-7a Typical Electrastream Cylinder Connections 31

33 INSTALLA ALLATION Connections to Electrastream Plus UNVENTED CYLINDER HTPR VALVE MI COUPLER x 22 x ¾ DOMESTIC COLD WATER 22mm DOMESTIC HOT WATER 22mm DHW FROM MAINS 22mm ACCUMULATOR 22mm LEVER VALVE COMBINATION VALVE 4 TUNDISH HEATING FLOW 22mm MOTORISED VALVE MI COUPLER x 22 x ¾ CYLINDER THERMOSTAT BOX IMMERSION HEATER CYLINDER DRAIN COCK COLD INTO CYLINDER MI COUPLER x 22 x ¾ HEATING RETURN 22mm MI COUPLER x 22 x ¾ 22mm LEVER VALVE ACCUMULATOR CONNECTION MI COUPLER x 22 x 1 Domestic Hot Water 22mm 22 x ¾ M.I. Coupler - supplied Fit 22mm ball valve - supplied Accumulator Connection 22mm 22 x 1 M.I. Coupler - supplied Domestic Cold Water 22mm Fit 22mm ball valve - supplied Mains Supply 22mm Fit 22mm ball valve - supplied Tundish - Discharge to be arranged and sized to comply with Building Regulations. Boiler Flow 22mm 22 x ¾ M.I. Coupler - supplied Boiler Return 22mm 22 x ¾ M.I. Coupler - supplied PARTS SUPPLIED 32 Fig. 4-7b Typical Electrastream Connections

34 INSTALLA ALLATION Connections to Electrastream Cased CONSUMER UNIT C/W DP ISOLATOR, RCD & 45A MCB ELECTRASTREAM CONTROLLER HOT WATER EXPANSION VESSEL??L HEATING EXPANSION VESSEL??L UNVENTED CYLINDER FRAME CYLINDER HTPR VALVE CYLINDER TEMPERATURE PROBE DHW HEATING PR VALVE - 3 Bar CYLINDER HEATING FLOW CONNECTION 4 THERMOSTATIC MIXING VALVE FOR DHW COMBINATION VALVE HOT WATER PRV- 6 Bar TUNDISH CYLINDER DRAIN COCK MOTORISED VALVE HEATING FLOW 22mm HEATING CIRCULATING PUMP & VALVES CYLINDER THERMOSTAT BOX CYLINDER THERMAL CUT-OUT TUNDISH DISCHARGE TO BE ARRANGED AND SIZED TO COMPLY WITH BUILDING REGULATIONS. IMMERSION HEATER 3 qty x 3kw ELEMENTS SUPPORT FRAME DOMESTIC COLD WATER CONNECTION 22mm DOMESTIC HOT WATER CONNECTION 22mm HEATING FLOW 22mm CONNECTION HEATING RETURN CONNECTION 22mm HEATING SYSTEM FILLING LOOP CONNECT ONLY FOR FILLING Fig. 4-7c Electrastream Cased Connections 33

35 COMMISSIONING Commissioning Checks IMPORTANT It is the responsibility of the installer to ensure that the Electrastream System is properly commissioned. Should the commissioning not be carried out, then the manufacturers guarantee and any extended warranty, will become null and void. The Guarantee Form MUST be completed and returned to GAH (HEATING PRODUCTS) in the prepaid envelope provided * Electrastream Plus only Note Error code 3 will be displayed if O-T and temp sensor connections are transposed. IMPORTANT The final fill of the heating system should include the correct dose of a suitable scale/corrosion inhibitor Commissioning Procedure 1. CHECK THAT ALL WIRING HAS BEEN DONE CORRECTLY AND CONFORMS TO REGULATIONS. 2. CHECK IMMERSION HEATER COVER, ELECTRASTREAM CONTROLLER COVER AND ALL OTHER ELECTRICAL COVERS ARE CORRECTLY FITTED. 3. *Check accumulator pressure is 1.5 Bar below the mains pressure - minimum 0.5 Bar. 4. Check the Tundish is correctly installed to conform to the Building Regulations G3. 5. Check all pipe connections are tight and no joints have been left unsoldered. 6. Check ALL drain cocks are closed. 7. Check ALL wiring connections have been made. Check cylinder temperature sensor is connected to temp sensor terminals 3 & 4. Check cylinder thermal cut out is connected to O-T terminals 1 & Check the required earth continuity conductors have been fitted. 9. Check the Immersion Heater has its cover and gasket fitted and is tight in the cylinder. 10. If fitted, check that the Scale Protection Device or Water Softener has been fitted according to manufacturers instructions. 11. Open all shut off valves. 12. Turn on Mains Stop Cock and allow the system to fill. 13. Open all domestic taps in turn to purge air. 14. Check system for leaks including around the Immersion Heater. 15. Check the installation of the hot water system tundish and discharge complies with the Building Regulations. 16. Check the installation of the heating system TPRV discharge complies with the Building Regulations. 17. Check no water is discharging from any TPRV or PRV. 18. Test the operation of the TPR Valves by turning the manual test cap and ensure the water flows freely and safely to waste. 19. Test the operation of the Combination Valve by turning the manual test cap and ensure the water flows freely and safely to waste. 20. Set hot water Mixing Valve to required temperature. HEATING SYSTEM 21. Connect the Filling Loop and fill the system, bleeding all radiator and bleed valves. 22. Check for leaks. 23. Set pressure gauge black arrow to the red arrow (cold fill pressure). 24. Switch on Electrastream mains isolator. On Electrastream Controller - see Set date and time.