Installation and Servicing Instructions Zenex GasSaver GS-1 Passive Flue Gas Heat Recovery Device (PFGHRD) Recognised by the Government s Standard Assessment Procedure (SAP) IMPORTANT: Read these instructions BEFORE installing the boiler Zenex Technologies Ltd Unit 2, Broadley Park Roborough Plymouth PL6 7EZ Tel: 01752 696003 These instructions have been carefully prepared in accordance with the current specification. Zenex Technologies reserves the right to alter the specification at any time. Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 1 of 7
CONTENTS 1. Introduction.. 2 2. Important Information. 2 3. Installation Site.. 3 4. Package Contents.. 4 5. Installation 4 6. Commissioning.. 6 7. Routine Inspection.. 6 8. Warranty Information.. 7 1 INTRODUCTION The Zenex GasSaver is a revolutionary system designed to increase the energy efficiency of condensing boilers. Classified as a Passive Flue Gas Heat recovery Device (PFGHRD), the GasSaver is recognised under the Government s SAP Appendix Q program for the energy efficiency of dwellings. The GasSaver is fitted to the flue adaptor on top of the boiler (supported by its own mounting bracket). Utilising unique thermal store technology, the GasSaver collects and stores wasted energy from the flue system and re-uses that energy to pre-heat the cold mains water supply to the boiler (or unvented storage cylinder). With no complicated mechanical parts and no electronic devices, the GasSaver is maintenance free and easy to install. How it works 2 IMPORTANT INFORMATION It is essential that you read this section carefully before attempting to handle, install or use the GasSaver. The GasSaver must only be mounted above and used with the boiler specified on the side plate of the unit. Both the GasSaver and the boiler must be installed in accordance with the manufacturer s installation instructions. Failure to do so will negate the warranty supplied with this unit. Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 2 of 7
It is the law that all gas appliances are installed by a competent person i.e. a CORGI registered fitter in accordance to the following recommendations: Current Gas Safety (Installation and Use) Regulations All current Building Regulations issued by the department for the Environment i.e. Approved Document L1 Building Standards (Scotland)(Consolidation) Regulations issued by the Scottish Development Department UK Water Regulations/Bylaws (Scotland) Health & Safety Document No. 635 The installation should also be in accordance with the following British Standards Codes of Practice: BS 5440:1:2000 Flues BS 5449:1990 Forced Circulation Hot Water Systems BS 5546:2000 Installation Of Hot Water Supplies For Domestic Use BS 6700:1997 Design, Installation, Testing & Maintenance Of Supplying Water BS 6798:2000 Installation Of Gas Fired Hot Water Boilers BS 6891:1998 Gas Installation BS 7593:1992 Code Of Practice For Treatment Of Water In Heating Systems BS 7671:2001 Requirements For Electrical Installation, IEE Wiring Regulations. Failure to install this unit or the boiler correctly could lead to prosecution. It is in your own interest and that of safety to ensure that you comply with the law. Manufacturer s instructions must NOT be taken in anyway as over-riding statutory obligations. 3 INSTALLATION SITE The GasSaver is mounted above the top of the boiler, using a special wall fixing bracket, and is connected directly to the boiler flue outlet. The boiler flue kit is then connected to the flue spigot on top of the GasSaver. Before commencing installation, it is important to ensure that there is adequate clearance above the boiler to accommodate both the GasSaver and the relevant flue kit. The incoming mains water pressure should be between 0.2 and 5 bar to ensure efficient operation. If the incoming pressure is above 5 bar a pressure reducing valve must be fitted prior to the GasSaver pipework The GasSaver flue resistance for 30kW boiler equates to 1.5m of total length of 60/100 flue manufactured length or 1.0m of 80/125 flue. Accordingly, the manufacturer s maximum recommended flue length must be reduced by the relevant distance. Care and consideration should be given to the correct installation and sizing of the boiler condensate drain. We recommend that a tundish or air break should be fitted between the condensate waste pipe from the boiler and drain trap. In areas of hard water (150mg/litre calcium/magnesium), we recommend that water treatment is used to reduce the build up of scale deposits within the secondary heat exchanger. Technical Data Maximum Working Pressure: Condensate Store: Max design flow rate: Water Inlet: Water Outlet: Flue / Air Connections: 5 BAR 5.5 Litres Up to 20 lpm 15mm 15mm To suit boiler Flue Resistance Testing in accordance with EN1859 equates to an overall reduction in manufacturer s maximum flue length specification of: 1.5m length for 60/100 flue 1.0m length for 80/125 flue Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 3 of 7
4 PACKAGE CONTENTS GasSaver Mounting Bracket (may differ from that shown) GasSaver Top Fixings (Type A or B depending on boiler model) Installation Instructions (This document) Blending Valve (set to 30º) SAP Label (for affixing to boiler) Flue Clamp (If required for boiler fixing) Expansion Vessel (Included with some boiler models) GasSaver A GasSaver Top Fixings (Type A or B) B Mounting Bracket SAP Label Mounting Dimensions Installation Instructions Blending Valve Expansion Vessel (If required) Flue Clamp (If required) 5 INSTALLATION 5.1 Mounting The GasSaver The GasSaver is mounted above the top of the boiler, using a special wall fixing bracket, and is connected directly to the boiler flue outlet. The boiler flue kit is then connected to the flue spigot on top of the GasSaver. Before commencing installation, it is important to ensure that there is adequate clearance above the boiler to accommodate both the GasSaver and the relevant flue kit. Refer to the mounting dimensions drawing enclosed with the GasSaver and mark the position on the wall for the GasSaver mounting bracket, top fixings and flue outlet. Drill and plug the necessary fixing holes and cut the flue hole. Mount the boiler on the wall as described in the boiler installation instructions (do not fit the flue or make the water connections). Note: Temporarily cover the boiler flue spigot to prevent anything from falling into it. If the boiler system requires priming with cold water via the flue spigot, this should be done before fitting the GasSaver. Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 4 of 7
Attach the GasSaver fixing bracket to the wall using three suitable fixing screws. If the GasSaver is supplied with the Toggle Bolt type fixings (Type B), secure these in position using 4 fixing screws. If the GasSaver is supplied with fixed screw fittings (Type A), these will be fixed later with the GasSaver in position. Remove the temporary cover from the boiler flue adaptor. If a flue clamp is supplied with the GasGaver, check the mounting dimensions drawing and if instructed place the flue clamp loosely over the boiler flue turret. Carefully lift the GasSaver into position over the boiler flue turret and lower the unit into place, keeping the unit level to ensure the GasSaver bottom flue spigot enters the boiler turret squarely. Take care not to dislodge or damage the flue seal in the boiler turret. Locate the GasSaver on its mounting bracket. Take care to keep the unit level and avoid transferring weight to the boiler. Locate and fasten the top fixings as shown on the mounting dimensions drawing. To level the GasSaver, adjust the back nut on the top fixings (Type B) or add / remove spacer washers located behind the GasSaver fixing points (Type A) If a flue clamp is fitted, tighten the clamp to seal the joint. 5.2 Connect The Pipework Outlet Connect the mains cold supply to the pipe marked Inlet using a compression fitting. Connect the pipe marked Outlet to the hot connection of the blending valve (supplied). Note: Only use connection fittings approved for use with stainless steel pipework. Inlet Connect another mains cold supply pipe to the cold connection of the blending valve. Finally, connect a pipe from the mixed connection of the blending valve to the cold water inlet connection of the boiler. GasSaver Typical Combi Installation LEGEND BV E MCW DHW Blending valve Expansion vessel (if required) Mains Cold Water Domestic Hot Water Note: Blending valve set to 30ºC (Minimum setting on adjusting knob) WRAS certification requires an approved single check valve or some other no less effective backflow prevention device to be fitted at the point of connection between the supply and the device. Copyright Zenex Technologies Ltd. 2007. Zenex designs are protected under Patent No. 2420174. Other patents pending. Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 5 of 7
5.3 Setting The Blending Valve The blending valve should always be set to limit the temperature of the water entering the boiler to a maximum of 30ºC. This is achieved by turning the adjusting knob fully clockwise to the minimum setting. Note: Do not set the blending valve to setting other than the minimum; otherwise the system may not function correctly. 5.4 Prime The GasSaver The GasSaver relies on a store of water/condensate to deliver maximum benefit, and must be primed prior to first use. When the installation of the pipework is completed, fill the GasSaver by carefully pouring 6 litres of clean, cold water into the top central flue spigot of the GasSaver. Care should be taken to ensure that no water is allowed to spill or enter the outer air duct of the GasSaver 5.5 Fit The Flue When priming is complete, attach the boiler flue kit to the top spigot of the GasSaver as described in the boiler installation instructions. Note: The GasSaver is equivalent to a 1.5m length of 60/100 flue. 6 COMMISSIONING Commission the boiler as described in the boiler installation instructions. Check all pipework connections to the GasSaver for leaks. Finally, attach the self adhesive label supplied with the GasSaver to the boiler so that it is easily visible for inspection. Typically, the label should be located on the inside of the boiler control panel cover so that it can be easily seen with the cover open. 7 ROUTINE INSPECTION It is recommended that the GasSaver should be subjected to a general condition inspection at each boiler maintenance interval. Due to the simplicity of the design, no maintenance is required. The unit contains no mechanical, electrical or serviceable parts. Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 6 of 7
8 WARRANTY INFORMATION IMPORTANT NOTE: The GasSaver is a self-contained unit designed for use specifically with SEBDUK A and B rated condensing domestic and commercial gas powered boilers to improve their efficiency. You should carefully read this warranty, Zenex Technologies Limited s installation and servicing instructions and any other user guidelines provided for the GasSaver. If not properly handled, installed and used the GasSaver may be damaged, damage property and/or result in serious injury or even death. 1. Statutory Rights Where the purchaser of the GasSaver (the Purchaser ) is a consumer, this warranty does not affect the Purchaser s statutory rights relating to sale of consumer products and product liability. 2. Warranty 2.1. Subject to the exclusions to this warranty set out in section 4 below, Zenex Technologies Limited warrants to the Purchaser that for a period of two years from the date of purchase (the Warranty Period ) the GasSaver when: 2.1.1. installed by a competent person (i.e. a CORGI registered installer); 2.1.2. used for normal consumer purposes; and 2.1.3. used and properly maintained in accordance with Zenex Technologies Limited s installation and servicing instructions, will be free from significant defects in design, materials and workmanship. 2.2. This warranty will be invalidated if the Purchaser does not install or use the GasSaver in accordance with clauses 2.1.1, 2.1.2 and 2.1.3 above. 2.3. In the event that the GasSaver does not conform with its warranty in section 2.1 above, Zenex Technologies shall, without charge, at its sole discretion: 2.3.1. repair the relevant GasSaver ; 2.3.2. replace the relevant GasSaver ; or 2.3.3. refund the Purchaser the full price paid by the Purchaser for the relevant GasSaver. 2.4. This warranty applies to new GasSavers only. This warranty is only enforceable by the first Purchaser of the relevant GasSaver and is non-transferable. 3. Warranty Period 3.1. The Warranty Period is not capable of extension, except that in the event that Zenex Technologies Limited repairs or replaces the GasSaver or parts thereof under section 2.2 above. In this case the repaired or replaced GasSaver (or parts) shall be warranted under the terms of this warranty either: 3.1.1. for the remainder of the Warranty Period; or 3.1.2. for a period of twelve months from the date of repair or replacement, whichever is the longer. 4. Exclusions to this Warranty 4.1. This warranty does not cover defects or damage to or failure of the relevant GasSaver caused by any of the following: 4.1.1. normal wear and tear to the relevant GasSaver ; 4.1.2. abuse of the GasSaver by the Purchaser, including but not limited to dropping, rough handling, impact, exposure to environmental conditions which are likely to corrode, damage or otherwise impede the normal functioning of the GasSaver or using the GasSaver for any use for which it is not intended; 4.1.3. installation of the relevant GasSaver with a faulty or defective boiler or the use of any other faulty or defective equipment; 4.1.4. failure by the Purchaser to install and/or service the relevant GasSaver correctly or in accordance with Zenex Technologies Limited s installation and servicing instructions, including installation of a GasSaver onto a boiler type for which it is not expressly designed; 4.1.5. service or repair of the GasSaver by any person or organisation not expressly authorised for that purpose by Zenex Technologies Limited; 4.1.6. alteration of or tampering with the relevant GasSaver by the Purchaser, including but not limited to removing or destroying identification tags/serial numbers, opening, dismantling, adding parts to or otherwise modifying the GasSaver. 5. Entire Warranty and Limitation 5.1. Subject to clauses 5.2 and 5.3 below, this express warranty is the entire warranty provided by Zenex Technologies Limited to the Purchaser and is the Purchaser s only remedy against Zenex Technologies Limited for defects or damage to or failure of the GasSaver and supersedes any other oral, written or contractual warranty given by Zenex Technologies Limited to the Purchaser. 5.2. All or any implied warranties including implied warranties of satisfactory quality and fitness for purpose are expressly excluded from this warranty. 5.3. Nothing in this warranty shall limit Zenex Technologies Limited s liability for death or personal injury or for fraudulent misrepresentation by Zenex Technologies Limited. 5.4. Zenex Technologies Limited shall not be liable whether in tort or contract for indirect, consequential or economic losses, including but not limited to loss of business, loss of profit, damage to equipment or expenses and damages or costs arising out of being unable to use the GasSaver. 5.5. Subject to clause 5.3 above, Zenex Technologies Limited s liability shall be limited to the purchase price of the GasSaver product which causes the alleged damage. 6. Contact 6.1. In order to obtain service pursuant to this warranty, the Purchaser should in the first instance telephone Zenex Technologies Limited on 0800 328 7533 and ask for warranty service or contact Zenex Technologies Limited through its website at www.zenexenergy.com. The Purchaser will be given full instructions as to how to obtain service. 6.2. When requesting warranty service for a GasSaver in accordance with clause 6.1 above, the Purchaser must provide Zenex Technologies Limited with a receipt or other acceptable proof of purchase relating to the relevant GasSaver, the name and contact details of the authorised installer who installed the relevant GasSaver, a description in writing of the defect and their full name and contact telephone number Zenex Technologies Ltd. GasSaver Installation Manual ZXGEN 4.1 Page 7 of 7