Installation Instructions for Shower-Save THE RECOH-VERT, RV-V3 1 GENERAL DESCRIPTION 1.1 Introduction On average, a shower uses 60 litres of water at a temperature of between 40 and 41 C. This shower water goes straight down the drain, wasting a great deal of heat and energy. By running the hot water through the Recoh-vert, this heat can be transferred to the water on its way to the boiler and/or the cold water tap of the shower's mixer tap. The heat transfer takes place simultaneously while you shower. 1.2 Recoh-vert The Recoh-vert is also called the Showersave RV-3. (Recoh-vert RV-3 in SAP). Waste water from shower The Recoh-vert is 2.1 m long and can only be installed vertically. The Recoh-vert is therefore, generally, only suitable for heat reclamation from shower water from an upstairs shower. Pre heated tapwater The Recoh-vert is connected to the shower waste. If the shower is integrated into the bath, the Recohvert can be connected to the bath waste. The Recoh-vert needs to be placed as close as possible to the shower waste water exit point. Waste water flows down the inside of the heat exchanger in a thin film When showering starts it takes a short time for the Recoh-vert to respond and contribute to heating the cold water. This means the temperature of the shower water will continue to rise for some time. It is therefore recommended that thermostatic mixer showers are used where possible. Air Outer pipe In between pipe Inner pipe Fresh water Waste water from shower Air Cold tap water To drain Cross section of the Recoh-vert. -1-
1.3 Description of the heat exchanger The Rcoh-vert is made of copper. In principle, the Recoh-vert consists of two concentric pipes; the inner and the outer pipe. Waste water from the shower flows down through the inner pipe. Cold tap water flowes up to the boiler and the shower's mixer tap through the space in between the two pipes. The exceptional thing about the Recoh-vert is that it has a double barrier between the waste water and the tap water. The heat exchanger consist of 3 pipes. A thin-walled pipe, the so-called lining, has been installed around the inner pipe. The minuscule space between the lining and the inner pipe contains air. If the inner pipe develops a leak, this becomes visually apparent as waste water will drip from the heat exchanger. In fact there is an extra pipe between the waste water and the fresh water. There is a double wall separation according to EN 1717:2000, tested and certified by KIWA. The system is also WRAS approved. This means that an air break into the waste pipe is not required, avoiding any noise or moisture build up. 2 HANDLING The Recoh -vert is delivered in a cardboard tube. Each cardboard tube contains: 1 Recoh-vert 1 rotator (top connector, consists of two parts) 2 brackets and fixings 1 adaptor (bottom connection) 1 installation manual. The total package weighs 10 kg. The Recoh-vert itself weighs 8 kg. 3 GENERAL INSTALLATION 3.1 Overview of installation We recommend installation of the Recoh-vert in one of two ways: 1) Connection of pre-heated water to both, boiler/ hot water cylinder as well as the cold side of the thermostatic mixing valve of the shower/s. This is known within SAP as System A. This installation creates the highest efficiencies recognised in SAP and is the most popular method of installation. 66% efficient (in SAP). 2) Often a simpler way of installing the system is undertaken by connecting the pre-heated water directly to the boiler/ hot water cylinder only. This is known as System C within SAP. 56% efficient (in SAP). Note: There is a System B (connection to cold side of thermostatic shower mixer unit only) included within SAP, we do not recommend that this installation method is specified or installed. -2-
boiler or cylinder boiler or cylinder check valve check valve mains cold water supply mains cold water supply System A (option 1) boiler or cylinder Waste water drain Waste water drain System A (option 2) mains cold water supply System C Waste water drain Every Recoh-vert is supplied with two labels with necessary technical information and a unique serial number. To be recognised in SAP the label must always be visible, either located on the outside of the boxed off unit or placed next door to the boiler with other SAP documentation. One label is to be fixed directly to the unit itself. If the label is not visible and/or the serial number does not correspond with the commissioning certificate that is completed, the system will not be guaranteed, nor will it be recognised in SAP. The Recoh-vert can be positioned with bath/shower combinations. It should be noted that no benefit will be achieved when just the bath is in use. The system is designed for simultaneous consumption and drainage of water. 3.2 Important notes to designers & installers The successful operation of the Recoh-vert (RV-3), which is defined as a Waste Water Heat Recovery System (WWHSAP RS) in SAP, depends entirely upon the adherence to these instructions. Additionally, the recognition of the system in requires that these instructions are complied with. The system should be installed by a suitably qualified plumber, with system design consideration being equally important to a correct installation. The design checklist and the installation/commissioning checklist should be signed and a copy left with the unit. All appropriate notifications must be made and should be visible at the point of installation. The flow chart below will assist in both the design and installation process. The design and installation processes outlined within this document are designed to comply with Approved Code of Practice and Guidance (ACOP) L8, which are the guidelines for the prevention of -3-
Legionnaire's disease in UK Commercial buildings. ACOP L8 is designed to provide guidance for all installations in commercial premises. It should be noted that within a residential environment in the UK homes generally cannot comply with the ACOP L8 as interior temperatures can frequently exceed 20⁰C. Is the water pressure > 1.5 bar? NO Do not install Showersave system Is the system pressurised / NO Do not install Showersave system NO Do not install Showersave system Is there space within (rather than externally) the building to install the Showersave? Which system is the most appropriate in terms of the installation? The Showersave will always be mounted close to the shower, and hence a connection to the cold inlet on the mixer tap is straightforward. System C: 56% efficient System A: 66% efficient System A - the pre-heated output of the Showersave is used to supply both the cold input to the mixer tap, and also the supply to the water heater. See 3.6 Systems A&C System C -only the water heater. -4-
3.3 General The Recoh -vert can be installed in homes, apartments, hotels, hospitals, nursing homes, etc. Also industrial companies can easily utilise the heat from the waste water. To be recognised in SAP the Recoh-vert must be used in conjunction with a mains pressure hot water system, such as a combination boiler or an unvented hot water cylinder. It can also be used in conjunction with a solar thermal system. When installing the Recoh -vert in conjunction with a combination boiler, ensure the appropriate system is installed that can accept pre-heated water. Refer to the boiler manufacturers' data sheet. Points of note. * Please ensure the heat exchanger is easily accessible so that it can be easily installed anduninstalled. * Please ensure that a non-return valve and a shut-off valve have been installed and that these are easily accessible. * Please ensure that the heat exchanger is installed in a space in which the temperature does not normally exceed 25 C, DO NOT INSULATE the Recoh -vert * Please make sure the tap water connections are preferably made using straight thread, that no hemp is used and that the tightening moment is limited to 120 Nm. * Following installation the system should be cleaned in accordance with ACOP L8 or BS 6700 (Design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages). * Be aware there may be some pressure loss on the tap side when a high flow rate shower head is in use. 3.4 The position of the Revoh-vert. The Recoh-vert should always be placed in an easily accessible location in order that inspection work can be undertaken. The warranty will become obsolete if this is not the case. Possible locations: * Alongside internal soil stack through which the waste water would have run * Fixed cabinet under stairs if there is sufficient height * Pre-defined and specified technical area 3.5 Safety and Legionaire's When no cold water is flowing up the Recoh-vert the temperature in the pipe should be prevented from becoming higher than 25 C. The Recoh-vert may therefore not be installed near heat conducting pipes, on warm surfaces or in spaces with constantly high temperatures (>25 C). The cold water pipe, connection and the outer wall of the Recoh-vert should therefore not be insulated. Installing the Recoh-vert in the way shown in the diagram System A (page 5) will mean that whenever the hot water system runs the cold water system will be flushed. This will result in stagnation being minimised and complies with recommendations within ACOP L8. This would be the most common method of installation. -5-
In instances where it is not possible to ensure a Tee at the cold side of the shower's thermostatic mixing valve, then a venturi effect assembly should be considered. This is a straightforward assembly of different pipe diameters to ensure stagnation on the cold side is minimised. A recommended configuration is shown in 3.6. Following installation, the system should be cleaned in accordance with L8 or BS6700, whichever is appropriate. This is no different to installing any standard plumbing/pipe system in so far as cleaning is concerned. If the system is installed in a non-private building, ACOP L8 recommends that all new/modified plumbing requires a risk assessment to be undertaken in order to comply. 3.6 System A and C The inlet side of the recoh-vert can be connected to the mains water system. The outlet side can be installed in two different ways, namely: A. Combined connection to the shower mixer tap's cold water connection and the water heater. C. Separate connection of the cold water connection to the water heater. The largest energy and CO2 saving is achieved by using System A. boiler or cylinder boiler or cylinder check valve check valve Douchepijp/ Recoh-vert Douchepijp/ Recoh-vert check valve and shut-off valve check valve and shut-off valve mains cold water supply mains cold water supply Waste water drain Waste water drain System A (option 1) System A (option 2) -6-
System C boiler or cylinder The performance of Systems A and C are recognised within SAP Products Characteristics Database (PCDB) for energy savings calculations. System A will provide the maximum energy saving, efficiency 66%. System C has an efficiency within SAP of 56%. mains cold water supply Waste water drain As previously mentioned, System A can be installed in one of two ways: Option 1) Preferred method, simply teeing off at the cold side (now pre-heated) of the shower's thermostatic mixer to ensure little or no stagnation Option 2) By creating a venturi effect using an assembly of pipes and bends as demonstrated below. In situations where there is a run of horizontal pipe with pre-heated water from the Showersave unit, where stagnation may occur when the shower is not in use for extended periods of time, it is recommended that the venturi assembly shown below be used, this will minimise the possibility of stagnation. In reality, when the shower is not in use there will be no preheated water, this approach will ensure compliance with L8. venturi -7-
3.7 Connections. The tap water connections must be able to be taken apart. As can be seen in the diagram, the tap water supply pipe should include a controllable non-return valve and a cut-off valve. The heat exchanger can be emptied by demounting both fresh water connections. The amount of water that flows out of the Recoh-vert is less then 1 litre. The tap water connections are female BSP ½", internally threaded. It is recommended that only fittings with non-conical thread be used. Hemp should not be used to seal the thread. A maximum tightening moment of 120 Nm is recommended. Use the key flats in order to avoid to high torque on the nipples when connecting the pipes. The supply of waste water to the Recoh-vert must take place via the rotator which is supplied with the system, please refer to the instructional drawings for installation. The rotator makes the waste water rotate as it enters the Recoh-vert, whirling it against the side walls of the inner pipe so it flows down the inner pipe's walls along the entire length. This is important for reasons of efficiency. REMEMBER: if not installed correctly, and in accordance with these instructions, SAP recognition becomes invalid. Deaeration of the Recoh-vert is not necessary, all air will disappear automatically because the water flows from the bottom to the top. relief pipe Aeration of the area between the shower and the Recoh-vert can be achieved in two ways: 1. a connection of a relief pipe to the soil waste system (See fig.1); 2. by replacing the shower trap with a HepvO valve (see Fig. 2). trap The external diameter of the inner pipe is 50. Using the fittings supplied, the rotator allows connection to BS EN 1451-1:2000, BS EN 1455-1:2000 or BS EN 1566 1:2000 waste systems. Please refer to the instructional drawings for dimensions and further details. aeration pipe 1 HepvO valve 2 3.8 Loss of pressure tap water side and drain capacity The figure below illustrates the loss of pressure for the Recoh-vert at the tap water side in case of sytem A and C. Because of the pressure drop the Recoh-vert is generally best suited to systems with a dynamic cold water pressure of >1.5bar. It is advisable that cold water pressure is measured prior to installation. A small reduction in maximum flow rate will be inevitable, the amount being a function of the mains water pressure available and distribution pipework specification. -8-
The maximum drain capacity of a Recoh-vert is 50 l/min. This is generally enough even with a high flow rate head. In case of a high flow rate head, you should also check whether the pressure loss on the tap water side is not too high. If the pressure loss is too high a Recoh-vert with mid connection or two Recoh-verts parallel must be applied. Normally the flow to the shower is 9 l/min. The pressure loss will be : - system A: 0,37 bar - system C: 0,16 bar. 3.9 Mains water system. In the mains cold water supply of the Recoh-vert must be a controllable non-return valve (type AE) fitted to prevent heated water flowing back into the cold water system. The tap water connections must be demountable, therefore the tap water supply pipe should include a cut-off valve. Please note: this does not replace the inlet combination required for the water heater. By connecting to a water heater, the Recoh-vert must be placed in series with the water heater. There should be no cold water pipe in parallel to the Recoh-vert. 3.10 Efficiency and pipe lenghts. Always make sure the Recoh-vert is placed as close to the Shower waste as possible. Efficiency can be influenced by run lengths, as the table below demonstrates. Pipe runs (m) 0 3 5 10 15 20 Loss of efficiency (%) 0 1.1 1.8 3.6 5.4 7.2 Efficiency Recoh-vert System A (flow 9 l/min) 70% 69.2 % 68.7 % 67.5 % 66.2 % 65% -9- Efficiency Recoh-vert System C (flow 9 l/min) 59% 58.4% 57.9% 56.9% 55.8% 54.8%
4 INSTALLATION 80 mm 2100 mm minimum of 110 mm 125 mm 100 mm rotator Recoh-vert Bracket Plug 10mm Connections for cold water pipe female BSP 1/2". 50-65 mm 80 mm Connection to shower's drain, 50 mm diameter, if necessary connect to de-airing of the indoor plumbing. Connections for preheated water pipe female BSP 1/2". 1870 minimum of 2380 mm 125 mm 100 mm 50-65 mm 120 mm Top View Rotator can be turned on the heat exchanger's axis. 50-65 mm Adaptor for connection to indoor plumbing, 50-40 mm diameter, sleeve mm 08 5 MAINTENANCE AND CLEANING Generally no maintenance and cleaning is required. Efficiency can decrease as a result of dirt accumulating on the inside of the Recoh-vert. However, the waste water from the shower flows at a high speed of over 1 m/s along the inner pipe's wall. This is comparable to the water speeds in a dishwasher. The water flows through the pipe in 2 seconds and so no dirt can accumulate. To a large extent the Recoh-vert is self cleaning. If, for whatever reason, dirt accumulates, then a soap-based cleaning agent can be used to flush the pipe. Cleaning agents based on scouring or polishing agents are not recommended as these can stick to the wall of the pipe, reducing its efficiency. Connecting a wash basin to the Recoh-vert is not recommended as shaving gel and toothpaste are very sticky and could adhere to the wall of the inner pipe. If the system is left to stand for more than three days it is good practice to flush the system to drain slowly to avoid aerosol. This can be achieved by slowly (to avoid splashing) turning on a hot water tap for three minutes. In a commercial environment under L8 It is good practice to clean and disinfected Showerheads and hoses on a Quality basis. In accordance with L8, and only in commercial situations, should a risk assessment be undertaken following installation of a system/s. -10-
6 WARRANTY 2 years warranty (including labour to a maximum of 150) which starts from the date of invoice from BPD Ltd. This warranty is conditional on the heat exchanger being installed in accordance with proper plumbing practices and this installation instruction. The label must always be displayed and accessible. A checklist must also be completed and submitted to BPD Ltd, in accordance with the requirements of SAP. Should you have any comments or additions to this manual, please do inform us. Version : 5-2014 -11-
DECLARATION OF CONFORMITY We declare that the heat exchangers named below are designed and manufactured in accordance with the sound engineering of The Netherlands in order to ensure safe use of preheating fresh water by waste water. Signature of manufacture representatives: Name: Position: 1) J.Heidemans Director Designation of heat exchanger: Heat exanger type: Relevant EC Council Directives: Quality Management Certificate: Hei-Tech bv Phileas Foggstraat 145 7825 AW Emmen The Netherlands info@hei-tech.nl www.hei-tech.nl Building Products Distributors Limited/Renewables Ireland Ltd Unit 21, Avondale Business Pk, Mill Road, Ballyclare, BT39 9A Tel (028) 9334 4488 Fax (028) 9334 4499 sales@renewablesireland.com www.renewablesireland.com Applied Harmonized Standards: Applied other Standards: Hei-tech Recoh-vert V3 97/23/EC Pressure Equipment KIWA statement of conformity 28-10-2010 (product certification) EN 1717 BRL-K 656.02 (KIWA) 2010-09-01 / K 48855/03 (quality system) Date: 24-03-2011 Note: All standards used were current and valid at the date of signature. INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE OF HEI-TECH HEAT EXCHANGERS To comply with the EC Council Directives 2006/42/EC Machinery Directive and 2004/I08/EC (EMC). To be read in conjunction with the relevant Product Documentation (see 2.1). 1.0 GENERAL 1.1 The equipment referred to in this Declaration of Incorporation is supplied by Hei-Tech to be assembled piping system which may or may not include additional components. The entire system must be considered for safety purposes and it is the responsibility of the installer to ensure that all of the equipment is installed in compliance with the manufacturers recommendations and with due regard to current legislation and codes of practice. 2.0 INFORMATION SUPPLIED WITH THE EQUIPMENT 2.1 Each item of equipment is supplied with a set of documentation which provides the information required for the safe installation and maintenance of the equipment. This may be in the form of a Data sheet and/or Installation Maintenance instruction. 2.2 Each unit has a label attached. The label provides essential data relating to the equipment such as serial number, and equipment data. Any further data that may be required will be found in the documentation. If any item is unclear or more information is required, contact Hei-Tech. 2.3 Where warning labels or notices are attached to the unit, the instruction given must be adhered to. 3.0 TRANSPORTATION, HANDLING AND STORAGE 3.1 Care must be taken at all times to prevent damage to the equipment. 3.2 When handling the equipment, care should be taken with corners and edges and that the weight distribution within the unit is considered. 3.3 Equipment stored on site prior to installation should be protected from the weather and steps taken to prevent ingress of contaminants. 4.0 OPERATIONAL LIMITS 4.1 It is important that the specified operational limits for the equipment are adhered to. 4.2 Where installation accessories are supplied with the specified equipment e.g. wall mounting brackets. They are to be used to support the equipment only. 4.3 Rotators and adapters are provided for the purpose of connecting the heat exchanger. 5.0 INSTALLATION REQUIREMENTS In addition to the particular requirements given for the individual product, the following general requirements should be noted: 5.1 When no cold water is flowing up the Recoh-vert the temperature in the Recoh-vert must not become higher than 25 C. 5.2 The Recoh-vert may not be installed near heat conducting pipes, on warm surfaces or in spaces with constantly high temperatures (>25 C). 5.3 The cold water pipe, connection and the outer wall of the Recoh-vert may not be insulated. 6.0 COMMISSIONING REQUIREMENTS 6.1 General pre-commissioning checks relevant to safe operation consists of the following: Ensure that no foreign bodies are present within the heat exchanger. Check guarding of the system Check operation Check fastenings 6.2 Other commissioning requirements are given in the relevant product documentation. 7.0 OPERATIONAL REQUIREMENTS 7.1 Equipment access must be easily obtainable and the unit must be secured with the original fastenings. 7.2 If failure of the equipment occurs or is suspected then a competent person can effect repair or examination. 8.0 MAINTENANCE REQUIREMENTS 8.1 Specific maintenance requirements are given in the relevant product documentation. 8.2 It is important that the correct tools are used for the various tasks required. 8.3 Care should be taken when installing and removing the heat exchanger. -12-
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Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems - Design Checklist Design Checklist Hei-Tech waste Water heat recovery systems (Version march 2011) Customer Details: Customer Name: Adress: Telephone Number: Date of Installation: Name of Lead Contractor: Installer Name/Company: Project Reference Number: SAP Identifier: Technology type: Waste Water Heat Recovery Technology category: Heat Recovery from Waste water Brand Name: Model Name: Model qualifier: Completion of this document is a requirement for inclusion of product data within the Standard Assessment Procedure Note: All checklist items must be ticked in order for Waste water heat recovery systems to be recognised in SAP calculations. System must be designed and sized correctly to achieve the energy savings associated with this product. Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems - Design Checklist SECTION 1: INSTALLATION 1. Installation Recoh-vert Decision?/X Have you followed the Flow chart? Did you check the loss of pressure on the tap water side and the discharge capacity? Did you check the distance of the pipes between the shower and the Recoh-vert regarding the efficiency? 2. Ductwork Installation Decision Refer to the unit s installation manual for the optimum ducting arrangement, and prepare drawings and a?/x schedule of materials for installation. Is the system disigned according to the SAP calculation System A? Is the system disigned according to the SAP calculation System C? Do you have checked if aeration is necessary? Are a shut-off valve and a controllable non-return valve applied in the design (in mains water supply)? 3. Installation room Decision?/X Is the Recoh-vert placed in a easy accessible space (replacement should be possible easily)? Is the Recoh-vert placed in a space in which the temperature normally does not exceed 25 C? Is the space where the Recoh-vert will be placed high enough? -1/2-
Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems - Design Checklist SECTION 3: DESIGNER DECLARATION I/We declare that the design for this Waste water heat recovery system installation has been prepared in accordance with the manufacturer's recommendations and that the required verification procedures have been followed. System design authority: Designer's name (please print): Designer's signature: Date: -2/2-
Standard Assessment Procedure - Hei-Tech waste Water heat recovery systems - Installation checklist and Certificate of Installation Installation Checklist and Certificate of Installation Hei-Tech waste Water heat recovery systems (Version march 2011) Customer Details: Customer Name: Address: Telephone Number: Date of Installation: Name of Lead Contractor: Installer Name/Company: Project Reference Number: SAP Identifier: Technology type: Waste Water Heat Recovery Technology category: Heat Recovery from Waste water Brand Name: Serial No: Model Name: Model qualifier: It should be noted that this guidance is not intended to replace the product manufacturer's installation instructions; it is a generic addition which defines good practice. Installers must complete this form for each installation and retain a copy for their records and if requested by Building Control Officers. A further copy must be provided to the manufacturer and the homeowner. Introduction Completion of this document is required for inclusion of product data within the Standard Assesment Procedure. The installer shall refer to the Waste water heat receovery system design schecklist, installation drawings and materials schedule. Note: All checklist items must be ticked in order for Waste water heat recovery systems to be used in SAP calculations. System must be designed and sized correctly to achieve the energy savings associated with this product. Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems-installation Checklist and certificate of installation. SECTION 1: INSTALLATION GUIDANCE 1. Installation Recoh-vert Decision /X Is the Recoh-vert easily accessible? Is the Recoh-vert installed perfectly vertically, i.e. within 1 degree? Is the rotator (properly) connected? Is the mains cold water supply connected to the lowest connection? In the case of System A: Pipes going to the water heater and the shower mixer tap connected to the highest connection? In the case of System C: Pipes going to the water heater connected to the highest connection? Is there a check valve and shut-off valve placed on the mains water supply? Did you check for leaks? Is the label visible? -1/1-
Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems-installation Checklist and certificate of installation. SECTION 2: USER INFORMATION 1. Handover and control-maintenance Advice Decision /X Has the customer been supplied with suitable documentation detailing maintenance and operational requirements? Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems-installation Checklist and certificate of installation. SECTION 3: INSTALLATION CERTIFICATE 1. Details for rooms with showers but NOT baths (e.g. dedicated shower room) Decision /X Total Number of ALL showers Showers with Shower-Save Recoh-vert RV3 installed as "System A" Showers with Shower-Save Recoh-vert RV3 installed as "System C" 2. Details for rooms with showers and baths (e.g. shower over bath, or bath and shower) Decision /X Total Number of ALL showers Showers with Shower-Save Recoh-vert RV3 installed as "System A" Showers with Shower-Save Recoh-vert RV3 installed as "System C" Note: All configurations can include two showers into one WWHRS, including a maximum of one instantaneous electric shower (IES) per WWHRS only where the primary shower is the mixer shower. Standard Assessment Procedure -Hei-Tech Waste water heat recovery systems-installation Checklist and certificate of installation. SECTION 4: INSTALLER DECLARATION I/We declare that the Waste water heat recovery system has been installed in accordance with the manufacturer's recommendations and that the required verification procedures have been followed. Installation Company: Installer's name (please print): Installer's signature: Date: Please send copy to: Building Products Distributors Ltd Unit 21 Avondale Business Park Ballyclare Co. Antrim BT39 9AU -2/2-