Installation, Operating and Maintenance Manual for F Modul plus Calorifiers

Installation, Operating and Maintenance Manual for F Modul plus Calorifiers By Appointment to Her Majesty the Queen Boiler Manufacturers & Engineers Hoval Ltd Newark Revision No.2 Dated: November 2015 4214947-00

2 Table of Contents Contents Page Introduction Description of F Modul plus Calorifier Technical and Performance Details Delivery / Positioning Instructions Assembly Instructions Installation and Piping Layouts Unvented Systems Commissioning & Operation Inspection and Maintenance Anode Protection Immersion heaters Immersion heater wiring diagrams Fault Finding Chart Wiring Diagrams for Open Vented Calorifiers Wiring Diagrams for Unvented Calorifiers Notes 4 5-7 8 9-1 14-15 16-20 21 22 2 24 25 26 27 28 29 These instructuctions should be read and understood before attempting to install, commission or operate this unit. Material in this publication may not be reproduced without Hoval s written permission. Hoval reserve the right to change specifications without notice.

Introduction Introduction These instructions have been written to give a brief description of the F Modulplus Calorifier, its installation, commissioning, operation and subsequent maintenance. The installation of calorifiers and their ancillary equipment is normally carried out by a heating engineer. For the purpose of this manual he is regarded as the installer, and, as such, it is his responsibility to ensure that he has read and understood the contents of this manual before installing the calorifier. It is essential that each calorifier has all services permanently connected to it before commissioning is requested. The installation should be in accordance with current I.E.E. regulations, relevant British Standard and Codes of Practice, Building Regulations and Local Authority Bylaws. Commissioning/Combustion Report Commissioning should be arranged via the heating engineer. Hoval engineers are available to carry out this work if requested. Where the calorifier installation is part of a Hoval boiler package it will normally be commissioned at the same time and entry made on the report opposite A note should be entered below by the person responsible for the plant, giving the boiler, calorifier model and its output and reference serial number, as indicated on the nameplate. For completion by Plantroom Attendant Calorifier Model: Boiler type / Model: Output l/hr: Serial Number: Date of installation: For technical, servicing or parts enquiries, telephone, fax or email to Hoval Ltd quoting the calorifier(s) serial number, as above.

4 Description of F Modul Calorifier Description of F Modul plus Calorifier Applications F Modul plus calorifiers are designed to operate with the full range of Hoval boilers up to 4.5 Bar (standard model) and 6.90 Bar (high pressure model) primary pressure, and are intended for the production and supply of DHW to commercial and industrial premises. The F Modul-plus is available in seven model sizes with high performance outputs up to 10,000 litres per hour. General Details The construction of the F Modul plus is in the form of a series of horizontal bottles, linked in modular fashion, and comprising a high grade stainless steel inner vessel with a rippled wall to enhance heat exchanger efficiency. This is surrounded by a mild steel primary water jacket, which is encased with steel sheet insulated panels. The assembly is mounted on two base channels running from front to back. On all seven models, the secondary flow and primary inlet are from the top and the secondary return, cold feed and primary outlet connections are at the bottom. Performance of the seven F Modul plus models covers a range of outputs up to an hourly rating of 10,000 litres/hour. Higher outputs can be provided by arranging the units in modular formation. For most typical applications (other than process water generation) the key requirement is for adequate quantities of hot water over a relatively short period. On this basis, the F Modul plus will provide significantly higher flow rates than its continuously hourly rate. A drain must be fitted in the secondary cold feed site pipework to fasciliitate draining and flushing out. (CIBSE TM 1:2000 Recommendations to prevent Legionella Bacteria Contamination). Very low primary and secondary resistances. Electric immersion heaters can be fitted by prior arrangement. Large heating surface, suitable for operation with lower temperature primary feed from condensing boilers. (Duty reduced - contact Hoval). See later section for unvented systems and the additional equipment required. Where access is a problem the bottles can be split (flanged), This is an optional extra. Suitable for primary flow temperatures upto 90 Deg C. Suitable for secondary pressures upto 9.66 Bar. Internal view of F Modul plus Calorifier F42 Modul plus Calorifier Key Features Minimum floor area, fits through standard doorway. Suitable for use with any make of boiler High efficiency heat transfer for rapid D.H.W. regeneration. Recirculation design removes danger of temperature stratification. Optimum D.H.W. storage - sufficient for quick draw-off but with lower standing losses than conventional large volume calorifiers.

Technical and Performance Details 5 Technical Data. Model Primay Details Secondary outputs at 60 o C based on 10 o C cold feed Contents Flow rate Resistance Contents o At 90 o Resistance peak continuous peak continuous litres l/s mbar litres l/10 mins l/hour l/10 mins l/hour mbar # F21 0 120 20 1960 12 F1 120 555 2550. 00 625 00 0 60 2.92 F51 2.22 00 950 200 120. 105 950 1 5250 F2 90 220 690 116 1 595 1250 6600 9 120 920 9 F52 150 1150 1900 2160 10 610 2015 215 10000 150 * Resistance is for primary ow rate listed + For DHW outputs below 60 o C, external blending to a lower temperature is recommended. # Resistance at the peak 10 minute draw off rate. For resistance at other draw off rates See Graphs on page 6. Pressures Standard Model Pressures High Pressure Model Pressures** System Operating Test Pressures Operating Pressures Test Pressures Pressure Bar Bar Bar Bar Primary Side 6.90 6.90 10.0 Secondary Side 1 9.66 15.0 ** To meet the requirements of M&E, high pressure primary water units can be tted with a bursting disc. Weights Model Dry Weight kg Dry weight Excl. Casings kg Total weight kg F21 269 165 529 F1 19 215 265 900 F51 15 1105 F2 605 F52 200 Chloride. The maximum allowable chloride content of DHW cold feed water is 100mg/litre, (or up to 200 mg/litre where optional tted). To calculate the load on the boiler. Rating kw = Q x S.H. x (T 2 - T 1 ) 600 Q = Calori er hourly output - Litres (kg) T 1 = Temperature cold feed - o C T 2 = Temperature DHW ow - o C S.H. - kj/kg o C Note for Hydraulic Testing: The primary jacket should not be pressurised without steel vessel. An adjustable secondary thermostat has a sensing point which ensures that the main body of water is held uniformly, pre-set level, normally 60 o C - 65 o C. Legionellae The safe temperature for storage is now considered to be a minimum of 60 o C to prevent the risk of legionella bacteria contamination. For kitchen and similar duties requiring 60 o C water, the supply can be direct from the calori er o C supply, mixing or blending with cold water, external to the calori er, is required and will increase the secondary output listed on page 5 by about 25%. When temporarily operating the primary side only, the pressure should not exceed 1 bar g and the secondary side should be vented. November 2015

6 Technical and Performance Details Hydraulic Resistance (Primary) Hydraulic Resistance (Secondary) M / h /.6 = l/s

Technical and Performance Details 7 Dimensions T ype F21, F41, F4 Type F21, F41, Type F4 2. Dimensions 2 T & P on Unvented Systems 4 7 1 6 Height b 1615 1615 1800 2160 1615 1800 2160 Width a 50 50 50 50 885 885 885 Type F21 F1 F41 F51 F2 F42 F52 2 5 F52 F2, Type F51 F1, Type F2, F51, Type F1, F52 4 T & P on Unvented Systems 7 1 6 Connections 1. Secondary Flow 2 BSP Male F51 = NW 50 F52 = NW 65 2. Cold Feed 2 BSP Male. Circulation 1 BSP Male 4. Primary Flow F21-F51 = DN50 PN6 5. Primary Return } { F2-F52 = DN65 PN6 6. Control panel 7. Electrical Connection Hot water 2" Cold water 2" Circulation 1" feed F21 - return F2 - Electrical box Electrical connection } 1 2 4 5 6 7 2 5 Rear View Side View Front View

8 Delivery Positioning Instructions Delivery and Positioning Instructions Transport Dimensions Delivery Positioning / Clearance Position the calorifiers as required, ensuring that side and inspection opening clearances are adequate. At least 400mm side clearance is required for fitting the casings. If this space is not available, the calorifier insulation and casings must be fitted before positioning the calorifier. Ensure that the calorifier is level using a spirit level along the top calorifier bottle. The F Modul plus calorifiers are delivered in three pieces:- - The Modul bottles and frame. - The casings and lagging in a cardboard box. - The Calorifier control panel in a box.

Assembly Instructions 9 Assembly Instructions Mounting the support rails Ensure that the dimensions between the top casing rails and the base channels are as per H. Before fitting the insulation and casings, fix the bottom guide rails (1) to the base channels. For types F2, F42 and F52 use Hole A. For types F21, F1, F41 and F51 use Hole B. Hole A. Hole B.

10 Assembly Instructions Fitting the insulation Wrap the insulation matress (1,2,,4 & 5) around the calorifier(black side outwards), join the insulation at the top using tension springs (8). Secure with the plastic straps (6). These plastic straps are secured using the strap fastener (7). Do not fasten too tightly as this will effect the insulation properties of the matress. Fit the pipe insulation (9) and secure using tension springs. Fit the bottle end covers (10) at both ends.

Assembly Instructions 11 For instructions on how to fit the casings please see page 12.

12 Assembly Instructions Fitting the Casings (i) Fit the front base panel (11) from the front. Then the middle and rear base panels (12) are placed in position from the side, between the plinth channels. (ii) The front side panels (1) are first placed in the bottom guide rails (Fig. A) and then attached to the top casing rails. Push the side panels (1) back against the casing rails as far as it goes.(fig B) (iii) Fit the other side panels (14,15). Join the front side panels (1) to the bottom guide rails with spring clips (16, Fig. C). Push the side panels (14,15) up against the front side panels so that there isn t a gap and then fix the panels at the back to the bottom guide rails with the spring clips. (iv) Fit the C-clips (17, Fig. D) to the cubicle retaining rails. (v) Now the front lids (18.19) (on the F1, 2, 51, 52 models) or the front lid (on the F21, 41, 42 models) should be put in place. Then fit the other lids (20). Do not tighten the fixing screws at this stage. (vi) Fix the back panel (21) in position using the self-tapping screws. (vii) Fit the support panel for the electrical control panel (22) and fix to the mounted screws with dome nuts (2). (viii) Mount the cable gland (24) in the support panel with the plastic counter-nut. Blank off the other holes with blank grommets (25). (ix) Push into position the electrical control panel (26). Beforehand, please route the capillaries to the rear, through the opening in the support panel (22). (x) Carefully Insert the thermometer and thermostat sensors into the immersion pocket (27) of the corresponding bottle. Do not remove the plastic clip until the sensor bundle is inserted half way into the immersion pocket. The sensor for a limit thermostat (on unvented systems) must be mounted in the topmost bottle. Do not kink the capillaries. (xi) Then push the retaining spring (28, Fig. E) on the immersion pocket to prevent the thermometer and thermostat sensors from slipping out. (xii) Finally fit the front panel (29) and fix it with the dome nuts (2).

Assembly Instructions 1 Wiring up the unit. A copy of the wiring diagram is both in the control panel and at the back of this manual. Unvented systems require a hand reset limit stat. Vented DHW calorifiers only require a control stat. The electrical installation should conform with all relevent British Standards / I.E.E. Regulations. This diagram should be checked for correct application. To gain acess to the back of the control panel, remove the two dome screws and remove the orange support casing which houses the control panel. There are also two screws which can be removed to get inside the control panel. Ensure that the thermostats and the thermometer capiliaries are fitted in the pocket in the calorifier bottle. Before attempting to wire the unit, always refer to the relevant wiring diagram.

14 Installation and Piping Layouts Installation and Piping Layouts Installation Fit unions to all pipe connections ensuring that joint seals are fitted. Fit isolating valves to all pipework. Note: The F Modul plus calorifier isn t fitted with a DHW or primary drain tapping. Therefore the primary drain must be fitted in the site pipework off the primary outlet connection and the DHW drain should be fitted in the cold feed. To facilitate venting during drain down, ensure that a manual vent valve is fitted in both the primary inlet and the secondary flow between the calorifier and the isolating valves. On open vented systems the vent should be taken from the same place. Piping layout For the general design of water circuits refer to current British Standards and Codes of Practice. A simple pumped primary flow and return, adequately vented, is all that is needed. Secondary connections are quite conventional. Connect the calorifier(s) to the rest of the system according to the chosen layout. Examples of both primary and secondary systems are shown below: Recommended primary Primary systems Systems (open vented). A Primary Connections Connections from Main Headers. Temperature control from by pump. Main Headers. Temperature control by pump. AAV 1 2 B Primary Connections from Main Headers. Temperature control by diverting valve. 1 4 (if Required) Secondary Water Primary Water 5 4 AAV Primary Water Secondary Water 5 AAV 7 6 Anti-thermal loop 6 Key (1) Safety recommended if not on adjacent boiler or system. (2) Spring loaded non-return valve. () Isolating valves. (4) Primary pump (For diagram B the main circulating pump may be used if sufficient head is available). (5) Thermostat (linked to primary pump to control calorifier DHW temperature, for Diagram A).For diagram B the thermostat controls the diverting valve. On Unventedsystems there is also a limit stat fitted. (6) Drain cock. (7) Diverting valve (use 0 second motor).

Installation and Piping Layouts 15 Recommended Primary Systems (open vented) Continued Recommended Primary Systems Continued. C Primary Connections direct from boiler. Temperature control by pump. AAV 2 5 Primary Water 4 Flow 1 D Primary Connections direct from boiler. Temperature control by diverting valve. AAV Primary Water Secondary Water 5 4 (if Required) Secondary Water Boiler 7 Flow 1 6 Anti-thermal loop Return 6 Return Boiler Key (1) Safety recommended if not on adjacent boiler or system. (2) Spring loaded non-return valve. () Isolating valves. (4) Primary pump (For diagram D the main circulating pump may be used if sufficient head is available). (5) Thermostat (linked to primary pump to control calorifier DHW temperature, diagram C). For diagram D the thermostat controls the diverting valve. On Unventedsystems there is also a limit stat fitted. (6) Drain cock. (7) Diverting valve (use 0 second motor). Recommended Secondary Systems. Secondary Connections OPEN VENTED. 4 AAV 6 Vent 1 Primary Water Secondary Water 1 Cold Feed 2 Secondary Circulating Pump Cold water mains Secondary Return Secondary Connections Unvented Secondary Connections UNVENTED. Unvented kits available on request. Manual See page 17. Vent Cold water mains Cold Feed 5 8 6 T & P Relief in socket provided Primary Primary Water Secondary Secondary Water Water 10 1 5 6 7 2 12 9 11 2 10 Secondary Circulating Pump 4 Secondary Return Key (1) Relief valve adjacent to calorifier. (2) Spring loaded non-return valve. () Isolating valves. (4) Open vent. (5) Unvented system kit. (6) Secondary drain valve. Key 1. Expansion Relief adjacent to calori er 2. Spring loaded non return valve. Isolating valves 4. Temperature and pressure relief valve 5. Strainer 6. Pressure reducing valve 7. Double check valve 8. Expansion vessel 9. Lock shield valve 10. Drain valve 11. Manual vent valve 12. Secondary circulating pump

16 Unvented Systems Unvented Systems Definition An unvented hot water system differs from conventional open vented systems in that no vent pipe is provided and it is connected to the mains water supply, eliminating the need for the provision of cold water storage tanks in the roof space. The functions, therefore, of the open vents and cold feeds have to be performed in other ways. There are two basic types of unvented system: (1) Direct off the mains, (2) Boosted water supply. An expansion relief valve should be fitted in the cold feed between the expansion vessel and the calorifier. No means of isolating the calorifier from this valve should be installed. A temperature and pressure relief valve should be fitted directly in the calorifier as a thermal protection to prevent the DHW reaching 100 deg C. A hand reset limit stat should be fitted in the calorifier to prevent the DHW overheating. Direct off the mains Where mains pressure is sufficient the system can be connected straight off the mains. However, between the cold water supply and the DHW generator (i.e. the F Modul plus calorifier) there must be an unvented system kit fitted. Unvented System kit Kit. T & P Relief. Hand reset limit stat. Expansion relief valve c/w tundish. Expansion Vessel. Check valve. PRV. Key Strainer. Cold Feed Cold water mains 1. Expansion Relief 2. Manual vent valve *. Isolating valves * 4. T & P relief valve 5. Strainer in control panel 5 6 7 10 1 As shown in the above diagram, an unvented system kit comprises of the following components:- Strainer (this is optional, but good practice, to prevent debris passing through the valves) Pressure regulating valve (PRV), this allows the pressure to be reduced and controlled at a preset pressure. A pressure gauge is supplied to indicate system pressure. Double check valve, this prevents the expanded water back-feeding into the mains supply and additionally seals the system. An expansion vessel should be fitted between the non return valve and the calorifier to take up expanded water during heat-up. 8 9 11 10 6. Pressure reducing valve 7. Double check valve 8. Expansion vessel 9. Lock shield valve 10. Drain valve* * Not Hoval supply. 4 Boosted water supply Where mains water pressure is insufficient a cold water booster set can be fitted. Normally these sets have integral pressure controls, in the form of either pressure transducers, pressure switches, and or pressure regulating valves. They also have a non return valve which prevents back-feeding. Systems where a booster set is installed should not have a vent and as such are unvented. Boosted systems should have an unvented system kit fitted down-stream from the booster set. This kit should contain a minimum of the following items:- An expansion vessel should be fitted between the non-return valve and the calorifier to take up expanded water during heat-up. Warning: Some pressure booster sets have an accumulator (expansion vessel). This is to reduce the amount of pump starts and should not be confused with the system expansion vessel. An expansion relief valve should be fitted in the cold feed between the expansion vessel and the calorifier. No means of isolating the calorifier from this valve should be installed. A temperature and pressure relief valve should be fitted directly in the calorifier as a thermal protection to prevent the DHW reaching 100 deg C. A hand reset limit stat should be fitted in the calorifier to prevent the DHW overheating. Balanced Unvented Systems Some systems may be fitted with blending valves or mixers that require a balanced hot and cold water supply. When sizing the strainer, the PRV, and check valve care must be taken to ensure they can pass the flow rates at the required pressure. Hoval standard unvented system kits are sized to reduce incoming pressure to bar at a flow rate that meets the peak output of the calorifier only.

A separate Strainer and PRV can be fitted to both the hot and cold water services to give balanced system pressures. Alternatively, a larger Strainer and PRV can be installed to cope with both hot and cold water demands. Cold water booster sets tend to be sized on the total demand of the system and subsequently give a balanced condition. Hoval Unvented System Kits Hoval have carefully sized and selected a range of standard unvented system kits suitable for installation with the F Modul plus range of calorifiers. The various valves and fittings should be installed in the sequence shown on the right. The size of the standard unvented kits are shown in the table below. Please note that these kits are only sized for the cold feed going into one of the F Modul plus calorifiers. Using the PRV from a standard Hoval unvented kit to provide a balanced hot and cold water supply may cause pressure and water flow problems. Ensure that the PRV can cope with the demand from both the hot and cold water services. Unvented Systems Warning: On balanced systems with a common PRV, Strainer and Double check valve, ensure that the valves are sufficiently sized to cope with both hot and cold water demand. Unvented System Kit. Unvented System kit T & P Relief. Hand reset limit stat. Expansion relief valve c/w tundish. Expansion Vessel. Check valve. PRV. Strainer. Cold Feed Key Key Cold water mains Cold water mains 1. Expansion Relief 2. Manual vent valve *. Isolating valves * 4. T & P relief valve 5. Strainer 1. Expansion Relief 2. Manual vent valve *. Isolating valves * 4. T & P relief valve 5. Strainer in control panel 5 6 7 5 6 7 8 8 10 1 9 2 10 1 9 11 10 6. Pressure reducing valve 7. Double check valve 8. Expansion vessel 9. Lock shield valve 10. Drain valve * Not Hoval supply. 10 6. Pressure reducing valve 7. Double check valve 8. Expansion vessel 9. Lock shield valve 10. Drain valve* * Not Hoval supply. 17 4 4 Strainer P.R.V. Double Check Expansion Vessel Expansion Relief & Tundish T & P Relief * F21 1 1 1 80 litre ¾ HP80-1 1½ F1 1 1 1 80 litre ¾ HP80-1 2 F41 1.1/2 1.1/2 1.1/2 150 litre ¾ HP150-1½ 2½ F51 1.1/2 1.1/2 1.1/2 150 litre ¾ HP150-1½ 2½ F2 1.1/2 1.1/2 1.1/2 150 litre ¾ HP150-1½ 2 x 2 F42 2 2 2 00 litre ¾ HP00-2 2 x 2½ F52 2 2 2 00 litre ¾ HP00-2 2 x 2½ *Supplied factory fitted with unvented calorifier (discharge pipe(s) by others - not supplied November 2015 by Hoval). 4214947-00

18 Unvented Systems Multi-calorifier Installations Shared Unvented System Kits Feeding Two or More Calorifiers. Temperature and Pressure Relief Temperature and Pressure Relief Two or more calorifiers can be installed with individual unvented system kits. Where the expansion vessels have been sized to share the total system expansion, the two feed lines can be joined by a pipe to allow both vessels to be used when one calorifier is isolated. Cold Feed Isolation valve Strainer Pressure Reducing Double Check Expansion Vessel Expansion Vessel Drain cock by installer Drain Cock By the Installer Isolating Expansion Vessel Expansion Relief and Tundish Drain cock by installer Isolating Expansion Relief and Tundish Cold Feed Isolation valve Strainer Pressure Reducing Double Check Drain Cock By the Installer Joining Pipe. Common Unvented System Kit. Temperature and Pressure Relief Temperature and Pressure Relief More than one calorifier can be installed off a single common cold feed. Each calorifier must have it s own T & P valve and expansion relief valve. No means of isolating these safety valves from the calorifier should be installed. Cold Feed Strainer Isolation valve Pressure Reducing Double Check Expansion Vessel Drain Cock By the Installer Drain cock by installer Isolating Expansion Relief and Tundish Drain cock by installer Isolating Expansion Relief and Tundish

Unvented Systems 19 Balanced Hot and Cold water supplies. Unvented System with balanced hot and cold water services. Temperature and Pressure Relief The hot and cold water supplies can be balanced by utilizing the same strainer and PRV to control the two supply lines. Note it may be necessary to increase the size of these two fittings in comparison to the nonreturn valve in the calorifier cold feed line. Cold Feed Isolation valve Strainer Isolation valve Pressure Reducing Balanced Cold Water Supply Double Check Expansion Vessel Drain Cock By the Installer Drain cock by installer Isolating Expansion Relief and Tundish Balanced hot and cold water services using two PRVs. Temperature and Pressure Relief The hot and cold water supplies can be balanced using two separate PRVs. Balanced Cold Water Balanced Supply Cold Water Supply Expansion Vessel Drain cock by installer Cold Feed Isolation valve Strainer Pressure Reducing Strainer Pressu Reduc Double Check Drain Cock By the Installer Isolating Expansion Relief and Tundish

20 Unvented Systems Fitting the Unvented System Kit. Fit the components as indicated. In the suggested schematics detailed on previous pages. All components must be installed in a frost free area. Installation of the Expansion Vessel. Expansion Vessel Ensure that valves and fittings are fitted correctly to suit the direction of flow. Set the Pressure reducing valve (PRV) to bar. Pipe off expansion relief valve via the tundish provided to a gulley. Pipe expansion vessel into cold feed. Fit a lock shield valve and drain between the vessel and the cold feed line. This will allow the expansion vessel gas charge to be checked during maintenance. This is shown on the right. Fit a lock shield valve and drain to allow the expansion vessel to be isolated and drained for periodic inspection. Cold Feed Isolation valve Strainer Pressure Reducing Double Check Drain Cock (By the Installer) Lock Shield (By the Installer) Isolation valve Maintenance of Unvented System Kit. Expansion Vessel Sizing. Clean out strainer on commissioning and annually. Check Expansion relief valve setting annually by twisting the cap on top of the valve. Check expansion vessel gas charge pressure, isolate the vessel, drain off any water in the vessel and test the gas pressure using a tyre gauge. Expansion Vessel Volume = System content (l) x C.o.E. Vessel Efficiency Vessel Efficiency = Max Pressure (Bar Abs) - Min Pressure (Bar Abs) Max Pressure (Bar Abs) Where: Max Pressure is final desired working pressure + 1. Min Pressure is pressure setting on PRV + 1. C.o.E. at 60 Deg C is approx 0.02 Fault Finding. Symptom Possible Cause(s) Remedial Action (A) Reduction in water flow Blockage in strainer Clean out strainer. Blockage in PRV Clean out secondary strainer in PRV. Wrong PRV pressure setting Check PRV pressure setting alter if necessary. (B)Discharge from expansion Debris on valve seat Twist test knob and replace if necessary. Relief valve. Wrong incoming pressure Adjust the pressure setting on PRV. Expansion vessel diaphram Check expansion vessel gas charge. Failure. Insufficient Expansion vessel Check expansion vessel size. volume.

Commissioning & Operation 21 Commissioning & Operation Commissioning Instructions Pre-commissioning: Important: Always fill the secondary side of the calorifier before the primary. Pressurising the primary when the secondary is empty may cause the secondary bottle to collapse. Flush all swarf, filings and other debris out of the system, preferably using a proprietary flushing agent. Do not wash particles into the calorifier, this could cause subsequent corrosion. Once the secondary side is fully flooded and sealed, fill the primary system completely and treat the water with a good corrosion inhibitor (e.g. Fernox). Corrosion inhibitors are not used in secondary (tap) water. Ensure that all joints are water tight and all pipework is vented. Check that all electrical connections are complete and correct. Ensure that the thermostat(s) are wired up and the sensor probes are fitted in the stat pocket. The thermostat may be wired into the boiler controls to activate the pumps or a motorised valve. The control thermostat can be adjusted to operate between 0 deg C and 80 deg C and is usually set to 60 deg C. Warning: To avoid Legionellae, ensure the calorifier control stat is set at a minimum of 60 deg C. Commissioning (1) Light the boiler (refer to the appropriate boiler operating instructions). (2) Adjust the calorifier thermostat to the required operating temperature. () Check that the thermostat is operating correctly. (4) Ensure that the primary pump is working or primary primary circuit is established. (5) Check that the operating temperature remains constant. Operating Instructions The calorifier thermostat when wired to the primary circulating pump or diverting valve provides completely automatic control. It is necessary only to adjust the thermostat if the occasion demands.

22 Inspection and Maintenance Inspection and Maintenance Periodic Inspection The user is advised to carry out periodic inspection between main servicing periods and it is recommended that the specialist servicing company also carries them out. Note: Before opening the inspection covers always ensure you have a new inspection cover joint. Each bottle has two covers (one at each end, (e.g. 20 on a F52 calorifier). Model Joint Cat No. ALL F Modul plus 414008 Inspect the calorifier casing for obvious signs of damage, corrosion or deterioration. Inspect the calorifier siting for signs of crack ing or settling. Inspect all pipes and connections for obvious damage or deterioration. Remove calorifier front/rear panel and exam ine interior for corrosion and deterioration. If anodes are fitted, check for deterioation. Draining Down Note: The primary side of the calorifier MUST always be drained before the secondary. The secondary MUST always be filled before the primary. FOLLOW THE PROCEDURE BELOW: (1) Ensure that both primary and secondary pumps are switched off. (2) Isolate the primary inlet and outlet. () Fit hose to primary drain which should be installed in primary outlet and run the hose to a gulley. (4) Open primary vent valve. (5) Open primary drain. (6) Isolate all secondary connections. (7) Fit hose to the secondary drain which is lo cated underneath the calorifier and run the hose to a gulley. (8) (On sealed systems) Open manual secondary vent valve (this should be fitted in secondary flow between calorifier and isolating valve). (9) Open secondary drain valve. When filling the calorifier follow the above procedure but in reverse. Cleaning The period between cleaning will depend on operating temperature and hardness of water. Local conditions will serve as a guide. Normally descaling will be required less often than with conventional calorifiers. The following procedure should be adopted: (1) Remove calorifier front / rear casing panel. (2) Remove cleanout cover for calorifier internals. () Scrape the inside surface with a non ferrous scraper when deposits of scale are found. Note: Chemical cleaning can be carried out if required, but such work should be undertaken in accordance with the instructions of the de-scaling compound manufacturer. We recommend chemical treatment specialist such as Aquazur. After chemically cleaning the DHW calorifier internal, ensure that the unit is thorougly flushed out with clean water. Following cleaning, replace inspection cover using a new gasket to prevent leaks.

Inspection and Maintenance 2 Inspection and Maintenance Periodic Inspection Units fitted with sacrificial magnesium anodes should be checked on a twice yearly basis to assess the deterioration of the anode. To inspect the anodes follow the procedure be- low:- () Carefully rest the new anode in the slot on the plastic support pipe. (4) Screw the new anode to the socket in the inspection cover and replace rubber gaskets and carefully fit the covers. Note: Before opening the inspection covers always ensure you have a new inspection cover joint. Each bottle has two covers (one at each end, (e.g. 20 on a F52 calorifier). Example - F1 (1) Drain the calorifier down. Magnesium Anode Note: Follow the draining down procedure on page 22. (2)Carefully undo the nut holding the inspection cover in place. Support the inspection cover by holding the fixing stud. Carefully remove the inspection cover bracket and allow the inspection cover to rest on the stud. Plastic Support Pipe Rubber Door Joint Inspection Cover () Using a torch assess the state of the anode. Note when the anode is about 10mm in diameter new anodes should be fitted. (4) If the anodes are greater than 10mm in diameter, replace the rubber gaskets and carefully refit the covers. (5) Once all of the covers have been fitted, refill the calorifier, (Secondary side first, then the Primary side). Fitting New Anodes If new anodes are required: (1) Unscrew the old anodes off the inspection covers. (2) Carefully remove the old anode, making sure that you do not dislodge the plastic support pipe at the other end. Part Description Cat Number Magnesium Anode 628998 Inspection Cover 628996 Rubber Door Joint 414008 Plastic Support Pipe 528289 Please note you will need one of each of the above per bottle. Please contact our spares department to order replacement parts.

24 Immersion Heaters Immersion Heaters General All work should be carried out by suitably qualified personnel. Heaters must be handled with care and stored in dry conditions. Adequate withdrawal space must be provided to allow the removal of the heater assembly. Carefully remove all protective packaging and visually inspect unit for any transit damage. All prevailing rules, regulations and bylaws in force at the time and place of installation must be observed. Heaters must only be immersed in the fluid they are designed to heat. The introduction of alternative fluids even in small concentrations for purposes such as sterilising may cause serious damage to the heater and will invalidate the warranty. Any modification not carried out by Heatex Limited or its approved agent will invalidate certification and warranty. Precautions must be taken to prevent damage to enclosure seals. Installation The heater should be securely fixed in position and all terminal connections checked for tightness before energising. The installed orientation of horizontally mounted heaters must be such that any thermostats or other temperature sensors are uppermost. Sealing gaskets must be undamaged. The terminal box must not be used for tightening heater into tank or vessel. Electrical Supply Connection Refer to wiring diagram on page 25. The cable entry or gland plate is positioned on the side of the terminal box. Before connection ensure that the supply corresponds with that specified on the rating label. Ensure that the sizes and types of cables to be used are suitably rated for the load and temperature of the unit. Each heater must be protected by a suitably rated over current device. The cables must enter the heater terminal box via a suitable cable gland to maintain the IP rating and be fitted by a qualified person. Earth Connection THESE HEATERS MUST BE EARTHED An earth connection is provided inside the terminal box. Operation Ensure that the active sections of all the heating elements are fully immersed in the fluid to be heated at all times whilst energized. Heat is transferred by means of electric heating elements. Control of the heater is facilitated by thermostats, thermocouples or RTDs and reference should be made to the wiring diagram inside cover to ensure that these are correctly connected and set prior to energising the heater. Where a manual reset thermostat or cut-out is installed, the terminal box cover will have to be removed after isolating the heater to enable a reset to be carried out. Maintenance All prevailing site safety regulations shall be adhered to at all times. Equipment is to be fully isolated from the electrical supply and locked off before and whilst any work is being carried out. Routine Maintenance Monthly Generally inspect the equipment for external damage or leaks. 6 Monthly Isolate the electrical supply and remove the cover. Ensure the terminal box is clean and dry internally. Ensure the electrical terminals are intact and secure. Check that the heating element insulation resistance is at least 2 mega ohms. Check the continuity of all elements. Refit cover with new gasket if required. Ensure that earth continuity is maintained between all exposed conductive material and main site structure. Annually Carry out all monthly and 6 monthly checks as above. Check for element failure or low insulation resistance. If heaters are being left unused for a period greater than months, carry out 6 monthly maintenance before energizing.

Immersion heater Electrical Diagrams 25 Immersion heater Electrical Diagrams

26 Fault finding Fault Finding Chart Please carry out checks as per the list below when faults occur. If you cannot rectify the fault, contact Hoval Customer Services or your installer. Telephone number and e-mail address are shown on the rear cover. Symptom Possible Cause Action A. Primary Water Circuit Inefficient (1) Leakage in system. (2) Pump faulty or inoperative. () Boiler faulty or inoperative. (4) Circuit not properly vented. (5) Pump not of sufficient duty. (1) Check pipe connection. Renew if required. (2) Refer to appropriate pump part document. () Refer to appropriate boiler part document. (4) Vent primary system. (5) Change pump speed or pump. Symptom Possible Cause Action A. Secondary water temperature not as setting on thermostat. (1) Leakage in system. (2) Pump faulty or inoperative. () Thermostat faulty. (4) Electrical fault in control system. (5) Calorifier scaled up. (6) Calorifier not large enough for load imposed. (7) Low primary temperature. (8) Diverting valve bypassing. (1) Check pipe connection. Renew if required. (2) Refer to appropriate pump part document. () Check and replace if required. (4) Refer to appropriate control system part document. (5) Mechanically / chemically descale as necessary. (6) Change calorifier or add calorifier / buffer vessel. (7) Turn up boiler thermostats / increase primary flow rate. (8) Check primary pipe cools when hot water not required.

Electrical Diagrams 27 Wiring Diagrams for Open Vented Calorifiers

28 Electrical Diagrams Wiring Diagrams for Unvented Calorifiers

Notes 29

Conservation of Energy Protection of the Environment Hoval Limited, Northgate, Newark, Notts NG24 1JN Telephone: Service Desk - 0166 5941 Spares Desk - 0166 59412 Fax - 0166 6752 e-mail: service@hoval.co.uk and spares@hoval.co.uk Web Site: www.hoval.co.uk 4214947-00 November 2015