GLASS LINED STEEL ELECTRIC WATER HEATERS Industrial range 500 to 3000 litres PERFORMANCE SINGLE FLANGE HEATING ELEMENT MULTIPOWER SHIELDED SCREWED MULTIPLE ELEMENTS PERFORMANCE PLUS MULTIPLE STEATITE HEATING ELEMENTS ABONDANCE STORAGE TANK BAI COIL INDIRECT WATER HEATER TECHNICAL HANDBOOK FOR INSTALLATION AND USE REF. : 428005 00-1 -
YOU ARE ABOUT TO TURN ON AN APPLIANCE WHICH IS THE RESULT OF YEARS OF RESEARCH, OF TUNING AND PERFECTING THE MANUFACTURING AND CONTROLLING TECHNIQUES, MAKING ITS IMPERFECTION A VERY RARE PROBABILITY. WE THEREFORE RECOMMEND YOU READ THIS HANDBOOK THOROUGHLY AND PAY THE UTMOST ATTENTION TO THE INFORMATION CONTAINED HEREIN, BOTH YOUR SAFETY AND SATISFACTION DEPEND UPON IT. WE THANK YOU IN ADVANCE. THE MANUFACTURER RESERVES THE RIGHT TO MODIFY THE CHARACTERISTICS OF ITS APPLIANCES AT ANY TIME, IN ORDER TO CONSTANTLY IMPROVE THE PRODUCTS IT OFFERS, THEIR RELIABILITY AND THE RATIONALISATION OF THE MANUFACTURING PROCESSES INVOLVED. - 2 -
Page 1 GENERAL FEATURES 1 2 INSTALLATION 5 3 WATER CONNECTION DIAGRAMS 10 4 TECHNICAL CHARACTERISTICS 11 5 TURNING ON THE APPLIANCE 19 6 TURNING OFF THE APPLIANCE 19 7 USAGE ADVICE 19 8 MAINTENANCE AND CLEANING 20 9 TROUBLESHOOTING 21 10 GUARANTEE 22-3 -
1 GENERAL FEATURES 1-1 THE RANGE PERFORMANCE model: 1000 to 3000 litres single flange heating element standard heating flexible jacket casing with Ml fire classification or sheet metal casing with MO fire classification MULTI-PUISSANCE model: 1000 to 3000 litres shielded screwed heating elements fast heating flexible jacket casing with Ml fire classification or sheet metal casing with MO fire classification PERFORMANCE PLUS model: 1000 to 3000 litres multiple steatite heating elements fast heating flexible jacket casing with Ml fire classification or sheet metal casing with MO fire classification ABONDANCE model: 1000 to 3000 litres indirect storage cylinder flexible jacket casing with M1 fire classification or sheet metal casing with MO fire classification These appliances are delivered in three separate boxes. 1-2 TANKS WITH ANODES (onto 1 pallet) High-thickness steel. Domed elliptical bottoms. Tested for 10.5 bars (use 7 bars). Glass lined on the inside for protection. Anti-rust protective coating on the outside. Domestic Hot Water return branch pipe. Rapid drainage. Two or three magnesium anodes. Lifting lugs. Inspection openings on all models. Earth terminal. Identification data plate on the front foot. - 4 -
1-3 CASING WITH INSULATION (separate box) Two options: Ml Version thickness 50 m/m flexible PVC with glass wool MO Version thickness 50m/m Aluminium with glass wool 1-4 ELECTRICAL EQUIPMENT (separate box) Three heating options: Single armoured Incoloy 800 plate heating element. Multiple armoured Incoloy 800 screw-on heating elements. Circular steatite heating element mounted in enamelled sleeves. Two versions of thermostat regulation: double action thermostat piloting the heating element for low powers. double action thermostat controlling a power contactor relay coil from 12 kw. Depending on the water heater model, this box will contain: one or two collars and caps with fixing screws. a wiring set. a wiring diagram. 2 INSTALLATION IMPORTANT: The appliance should be installed according to good practise and in conformance with the regulations in force for hydraulic and electric connections and under the entire responsibility of the installer. RECOMMENDATIONS The appliance should be as close as possible to the water drawing points. Facilitated access must be foreseen for all maintenance and replacement operations on the heating elements and anodes. 0.30 m Anodes Wall 0.15 m 1.20 m 0.30 m Electric cap Figure 1-5 -
2-1 WATER CONNECTIONS Hot water to the top part of the tank. Cold water at the lower part of the tank. Recirculation on the right-hand side. Drainage at the bottom coupled with the cold water inlet (please see the hydraulic installation diagram and overall dimensions for each type of appliance). NOTE All installations should include a PRESSURE RELIEVE safety device against: Excess pressure in the distribution network. Excess pressure owing to a rise in temperature (expansion during heating). Excess pressure due to the failure of a thermostat or of a contactor relay. The sizing of a hydraulic safety device depends on: the capacity of the appliance, the power of the appliance installed, In the event of a serial installation of appliances, it is vital that a pressure relieve safety device be fitted for each individual appliance. A inlet security group should always be installed on the water heater s cold water inlet, respecting the flow direction indicated by the arrows on the body of the inlet security group. The inlet security group safety assembly can be replaced by a safety valve along with a non-return valve and a stop valve on the cold water inlet (see hydraulic diagram). To allow the water in the heater to expand, the valve or safety assembly should be fitted with a pipe to allow for this expansion to flow into a funnel connected to the drains. Under no circumstances whatsoever should this pipe be closed by means of a plug or stop valve. Plugging the pipe would lead to excess pressure and the guarantee of the appliance would no longer be valid. The use of a filter on the cold water inlet is highly recommended in order to remove all impurities such as sand, gravel, mud, etc... It is vital that you install a tee on the lower pipe of the appliance to allow for a sliding valve to be fitted in order to perform a few flushes to get rid of any mud stagnating at the bottom of the tank. Plan a de-aerator with an air bleed on the hot water outlet (to evacuate all dissolved gasses). As alternative to the inlet security group the installer may install an expansion tank of suitable size, pre-pressure and working pressure in combination with a T&P relieve valve on the hot water outlet. NOTE The quality of the water distribution piping is of the utmost importance. Pay attention to the connections between differing metals. Plan a dielectric insulating union near the appliance on each pipe connected to the water mains. - 6 -
2-2 ELECTRICAL CONNECTIONS The electric installation must conform to the local rules and regulations.. Install a main circuit breaker and overload protection (fuses) in the electric power supply. Use wires featuring an appropriate cross-section and ensure all connections are coupled tightly. IMPORTANT Each component, along with the tank, should be earthed correctly. Power contactor relay (not supplied). Compulsory as of 12 kw of power. Never block it manually. It should be of suitable dimensions and connected in conformance with the electrical diagrams. Below are a few examples of the cable cross-section sizes: Power Intensity absorbed A (kw) 230v three-phase 400v three-phase Cable cross-section (mm 2 ) 9 22.59 2.5 9 12.99 1.5 12 30.12 4 12 17.32 2.5 13,5 33.89 6 13,5 19.49 2.5 15 37.65 6 15 21.65 2.5 24 34.64 6 30 43.30 10 36 51.96 10 These values are merely indicative. Please refer to the manufacturer s values. 2-3 MOUNTING THE ELEMENTS ONTO THE TANK Position the tank. Mount the anodes. Mount the heating elements in the order illustrated. Before mounting the cap(s), position the casing jacket (please see the casing jacket assembly paragraph). Make the electrical connections (see electrical diagram). Mount the cap(s). - 7 -
MI-MO supple casing jacket assembly a) Hold the casing jacket at the top after closing the zip fasteners by a few centimetres on either side of the water heater. b) Using a cutter, cut out the slot for the electrical equipment collar to pass through as well as the pipes and the access to the anodes by hitting the outlines with a mallet. Cut out the slot on the casing jacket for the inspection flange. c) Tighten and tie a knot in the cord at the base of the casing jacket. MO Aluminium casing jacket assembly Position the brackets on the feet. Position the upper bottom. Place the side panels against the tank supported by the brackets, and close using the fasteners. Position the aluminium rosettes and fasten them using the self-tapping screws. 2-4 PERFORMANCE ASSEMBLY DIAGRAM (Single flange plate heating element) Recommended order of assembly from 0 to 9 Chauffe-eau Water heater Chauffe-eau = Water heater Figure 2 Recommended order of assembly from 0 to 9 0-3 clip nuts 1-2 or 3 anodes 2-1 seal with 6 screw bolts 3-1 plate heating element 4-1 mating flange + 6 nuts 5-1 collar 6-1 thermostat terminal board and wiring 7-1 insulating jacket 8-1 cap 9-1 insulating cap - 8 -
2-5 MULTI-PUISSANCE ASSEMBLY DIAGRAM (Shielded screwed Multiple heating elements) Recommended order of assembly from 0 to 12 0-6 clip nuts 1-2 or 3 anodes 2-1 flush seal with 6 screw bolts 3-1 mating flange + 6 nuts 4-1 collar (MO) 5-1 thermostat sheath 6-1, 2 or 3 screw-on heating elements with seal 7-1 collar 8-1 thermostat terminal board and wiring 9-1 insulating jacket 10-2 caps (1 for MO) 11-1 insulating cap Chauffe-eau = Water heater Figure 3 Recommended order of assembly from 0 to 12 2-6 PERFORMANCE PLUS ASSEMBLY DIAGRAM (Multiple steatite heating elements) Recommended order of assembly from 0 to 13 0-6 clip nuts 1-2 or 3 anodes 2-1 flush seal with 6 screw bolts 3-1 mating flange with 6 nuts 4-1 collar (MO) 5-1 thermostat sheath 6-1, 2 or 3 sleeves 7-1, 2, 3 steatite heating elements 8-1 collar 9-1 thermostat terminal board and wiring 10-1 insulating jacket 11-2 caps (1 for MO) 12-1 insulating cap 13 - flange cover (M1) Chauffe-eau = Water heater Figure 4 Recommended order of assembly from 0 to 13-9 -
2-7 ABONDANCE ASSEMBLY DIAGRAM (Storage tank) Recommended order of assembly from 0 to 9 0-3 clip nuts 1-1, 2 or 3 anodes 2-1 flush seal with 6 screw bolts 3-1 mating flange with 6 nuts 4-1 collar (MO) 5-1 insulating jacket 6-1 cap (MO) 7 - ornamental cover 8-1 insulating cap 9 - flange cover (M1) Chauffe-eau = Water heater Figure 5 Recommended order of assembly from 0 to 9-10 -
3 HYDRAULIC CONNECTION DIAGRAMS IMPORTANT NOTE All the devices illustrated in the installation diagrams are not supplied by the manufacturer. Therefore the correct installation of the appliance in accordance with the regulations in force is the complete responsibility of the installer. Recommended order of assembly from 1 to 13 1 - Cold water inlet 2 - Stop valve 3 - Water filter 4 - Safety assembly or 5 - safety valve and non-return valve variant 6 - Rapid drainage valve 7 - De-aerating cylinder with drain valve 8 - Non-return valve 9 - Water drawing points 10 - DHW pump 11 - DHW heater 12 - Funnel to the drains Figure 6 Skeleton diagram with one water heater Figure 7 Skeleton diagram with two water heaters connected in series - 11 -
4 TECHNICAL CHARACTERISTICS 4.1 PERFORMANCE MODELS 500 TO 3000 LITRES (single flange heating element) CAP A B C D E F G 500 630 730 1852 675 295 91 1489 750 790 890 1765 625 365 105 1300 1000 790 890 2118 625 365 105 1653 1500 1100 1200 1930 710 450 135 1300 2000 1100 1200 2118 710 450 135 1488 2500 1400 1500 1990 690 530 183 1200 3000 1400 1500 2118 690 530 183 1329 Départ eau chaude = Hot water outlet 3 Anodes = 3 Anodes Recyclage = Recirculation Vidange E.F. = Cold Water Drainage Résistance blindée à platine = Armoured plate heating element Figure 8 Overall dimensions - 12 -
1 Star quad wiring 9 kw (Three-phase 230 V) 2 Star quad wiring 15 kw (Three-phase 400 V) COD TYPE SECTION COLOUR QTY. E 1 Power 6 Black 3 2 Power bond 6 Black 5 3 Earth 6 Green/Yellow 1 Illustration 3 Star quad wiring 30 kw (Three-phase 400 V) Illustration COD TYPE SECTIO COLOUR QTY. E N 1 Command 1.5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yellow 2 4 Power bond 6 Black 3 Cap Protect. cond. block 25 Green/Yellow 1 L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2 COD TYPE SECTIO COLOUR QTY. E N 1 Command 1.5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yellow 2 4 Power bond 6 Black 9 Cap Protect. cond. block 25 Green/Yellow 1 L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2-13 -
4.2 MULTI-PUISSANCES MODELS 500 TO 3000 LITRES (shielded screwed multiple heating elements) CAP A B C D E F G 500 630 730 1852 675 295 91 1489 750 790 890 1765 625 365 105 1300 1000 790 890 2118 625 365 105 1653 1500 1100 1200 1930 710 450 135 1300 2000 1100 1200 2118 710 450 135 1488 2500 1400 1500 1990 690 530 183 1200 3000 1400 1500 2118 690 530 183 1329 Départ eau chaude = Hot water outlet 3 Anodes = 3 Anodes Recyclage = Recirculation Résistance blindée à visser = Armoured screw-on heating element Vidange E.F. = Cold Water Drainage Trappe de visite = Inspection flap Figure 9 Overall dimensions - 14 -
4 Triangle wiring 12 kw (Three-phase 400 V) Illustration 5 Triangle wiring 24 kw (Three-phase 400 V) COD TYPE SECTION COLOUR QTY. E 1 Command 1.5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yello 2 w 4 Power bond 3 Cap Protect. cond. 25 Green/Yello 1 block w L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2 Illustration 6 Triangle wiring 36 kw (Three-phase 400 V) Illustration COD TYPE SECTION COLOUR QTY. E 1 Command 1..5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yellow 2 4 Power bond 6 Black 3 5 Earth bond 6 Green/Yellow 1 6 Connector bar 6 Cap Protect. cond. 25 Green/Yellow 1 block L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2 COD TYPE SECTION COLOUR QTY. E 1 Command 1.5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yello 2 w 4 Power bond 6 Black 3 5 Earth bond 6 Green/Yello 2 w 6 Connector bar 6 Cap Protect. cond. 25 Green/Yello 1 block w L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2-15 -
4.3 PERFORMANCE PLUS MODELS 500 TO 3000 LITRES (multi steatite heating elements) CAP A B C D E F G 500 630 730 1852 675 295 91 1489 750 790 890 1765 625 365 105 1300 1000 790 890 2118 625 365 105 1653 1500 1100 1200 1930 710 450 135 1300 2000 1100 1200 2118 710 450 135 1488 2500 1400 1500 1990 690 530 183 1200 3000 1400 1500 2118 690 530 183 1329 Départ eau chaude = Hot water outlet 3 Anodes = 3 Anodes Recyclage = Recirculation Résistance stéatite à visser = Steatite screw-on heating element Vidange E.F. = Cold Water Drainage Trappe de visite = Inspection flap Figure 10 Overall dimensions - 16 -
7 Star quad wiring 6 kw (Three-phase 400 V) Star quad wiring 6 kw (Three-phase 230 V) 7 Illustration Illustration COD TYPE SECTION COLOUR QTY. E 1 Power 6 Black 3 2 Power bond 6 Black 3 3 Earth 6 Green/Yellow 2 4 Connector bar 2 COD TYPE SECTION COLOUR QTY. E 1 Power 6 Black 3 2 Power bond 6 Black 3 3 Earth 6 Green/Yellow 2 4 Connector bar 2 8 Star quad wiring 13.5 18 kw Star quad wiring 13.5 18 kw (Three-phase 400 V) (Three-phase 230 V) 8 Illustration 93 Illustration 94 COD TYPE SECTI COLOUR QTY. E ON 1 Command 1..5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yellow 2 4 Power bond 6 Black 6 5 Earth bond 6 Green/Yellow 2 6 Connector bar 3 Cap Protect. cond. block 25 Green/Yellow 1 L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2 COD TYPE SECTIO COLOUR QTY. E N 1 Command 1..5 Red 2 2 Power 10 Black 3 3 Earth 10 Green/Yellow 2 4 Power bond 6 Black 6 5 Earth bond 6 Green/Yellow 2 6 Connector bar 3 Cap Protect. cond. block 25 Green/Yellow 1 L Unit block 1 ring 25 Grey 3 C Unit block 1 ring 5-6 Grey 2-17 -
4.4 ABONDANCE MODELS 500 TO 3000 LITRES CAP A B C D E F G H I 500 630 730 1852 265 644 675 295 91 1489 750 790 890 1765 315 550 625 365 105 1300 1000 790 890 2118 315 726 625 365 105 1653 1500 1100 1200 1930 400 550 710 450 135 1300 2000 1100 1200 2118 400 644 710 450 135 1488 2500 1400 1500 1990 480 500 690 530 183 1200 3000 1400 1500 2118 480 565 690 530 183 1329 Départ eau chaude = Hot water outlet 3 Anodes = 3 Anodes 3 piquages = 3 branch pipes Recyclage = Recirculation Vidange E.F. = Cold Water Drainage Trappe de visite = Inspection flap Figure 11 Overall dimensions - 18 -
4.5 BAI MODELS 750 TO 3000 LITRES (industrial indirect coil water heater) CAP A B C D E F G H I 750 790 890 1765 315 550 625 365 105 1300 1000 790 890 2118 315 726 625 365 105 1653 1500 1100 1200 1930 400 550 710 450 135 1300 2000 1100 1200 2118 400 644 710 450 135 1488 2500 1400 1500 1990 480 500 690 530 183 1200 3000 1400 1500 2118 480 565 690 530 183 1329 Départ eau chaude = Hot water outlet SERPENTIN = COIL RECYCLAGE = RECIRCULATION Vidange E.F. = Cold Water Drainage (Possibilité de montage résistance blindée à platine) = (Possibility of mounting an armoured plate heating element) Figure 12 Overall dimensions - 19 -
5 TURNING ON THE APPLIANCE VERY IMPORTANT 5-I MAKE SURE THE TANK IS FULL OF WATER To do so: Fill the water heater with water (open a hot water tap to evacuate any air from inside the tank). The water heater is full when the water flows freely from this tap. 5-2 MAKE SURE 5-3 5-4 That the connections are suited to the characteristics of the current supplied and of the heating elements. That all the connection terminals are tightened fully. That the heating element or thermostat are not short-circuited. That the drainage of the safety assembly(ies) is free of all obstructions. Power the appliance and supervise the first rise in temperature to witness the successful cut-off of the thermostat. After a few days of operation, check that all seals are watertight. 6 TURNING OFF THE APPLIANCE Cut off the electricity supply to the water heater. Turn off the cold water inlet. In the event of a prolonged absence, take the necessary precautions to protect your appliance against frost, namely by emptying the water heater. To do so: Open the rapid drainage valve and turn on any hot water tap drawing water from the water heater. 7 USAGE ADVICE Concerning the water temperature: The temperature of water supplied at 65 C is ideal to meet the majority of DHW needs. However, in the event of calcareous water, the water temperature should be below 60 C in order to limit the formation of limescale on the heating elements. Should water boil inside the water heater and steam exit the hot water taps drawing water from the same, cut off the electricity supply to the appliance immediately, turn on a hot water tap and call in the installer. Concerning the expansion of the volume of water inside the tank: A normal flow of water is produced from the safety assembly each time the water is heated. This is completely normal, and is the inevitable result of the expansion of the water heated. REMINDER: It is vital that the safety assembly or valve be connected to a visible permanent outlet. - 20 -
Water quality: In order to ensure the long life of your water heater and to benefit from the guarantee, a few simple rules should be followed: Calcareous water: fit an effective anti-limescale device onto the appliance. Softened water: Ensure you have: a TH water hardness of between 12 and 15 F, - a ph of more than 7, - resistivity of between 2200 and 4500 ohm/cm Note: In the event of an incident, our guarantee will not be valid if the above precautions were not taken or if the quality of the water does not allow for the correct treatment of water in conformance with the law. 8 MAINTENANCE AND CLEANING The frequency of intervention depends on the quality of the water stored and on the flow rate. Therefore we recommend you check the condition of the heating elements and that of the inside of the tank twice a year. These water heaters are lined on the inside with an enamelled coating. This protection is completed by two or three magnesium anodes accessible at the front. Check the anodes during the three months after their insertion in the water. The degree of wear of these anodes depends on the quality and consumption of water, as well as on the temperature of the latter. The anodes should be checked regularly and replaced when their diameter drops to below 10 mm. The guarantee as to the protection against internal corrosion may only be valid if the anodes were checked and replaced correctly. Moreover, for softened water and areas where the water is highly corrosive or acidic, it is indispensable that the water be neutralised by means of suitable treatment. The guarantee will not be valid should this precaution fail to be taken (please see the paragraph on water quality above). Monthly operation Check that the safety valve (or safety assembly) is working correctly by acting on the lever that lifts the valve; when the water is heated, make sure the water expands normally. Some water may trickle out of the valve during the operation of the appliance. Perform a few flushes from the rapid drainage valve to get rid of any mud stagnating at the bottom of the tank. Six-monthly operation Dismount the heating elements and sleeves and clean them of all deposits. Limescale removal In areas where the water is highly calcareous, we recommend you check the inside of the tank frequently and remove any limescale using a water jet. If the tank is encrusted with too much limescale, proceed with a chemical limescale removing process. Given that this is a delicate process, we highly recommend you call upon the services of a specialist to perform it. - 21 -
Important note: Before remounting any parts featuring a watertight nature, make sure the seals are in good condition; if not, then replace them. 9 TROUBLESHOOTING No hot water at all a) The appliance has not been used yet: Check first and foremost whether the safety thermostat has not been activated. Press the black button on the outside of the box to reset it. Incident due to transportation. Using a voltmeter, make sure the electrical current reaches: 1 - the thermostat, otherwise check the circuit breaker, the fuses, the EDF clock or any other remote control programmed to OFF. 2 - the contactor, otherwise check the thermostat and whether it has been set too low. 3 - the heating elements, otherwise check whether the contactor is blocked abnormally on open. 4 - CUT OFF THE ELECTRICITY SUPPLY and check: the connection of each heating element that the latter corresponds to the type of current on the wiring diagram in the handbook. 5 - Finally, check whether this is due to the heating elements b) The appliance has already been used: If this is not due to the safety device, then check the power supply using a voltmeter, following the order of points 1 to 5 above. Insufficient hot water Check the following in sequence: the thermostat regulation and change it if not set to its maximum stop limit, that the connections are tightened correctly, the power supply to the heating elements on the three phases and the type of current used, CUT OFF THE ELECTRICITY SUPPLY and seek the faulty element(s) whose values differ too greatly from the averages taken using an ohmmeter, change the heating elements causing the malfunction. Evaporation or water much too hot CUT OFF THE ELECTRICITY SUPPLY and check: the condition of the thermostat and its set temperature, that the contactor is not blocked and that its cut-off power is suited to the power consumed, that no remote control is shunting the thermostat. Current leaks perceived from taps and piping due to incorrect earthing Check: that the appliance and its components are earthed correctly and that the earthing connection is effective, that the connections are tightened, - 22 -
the condition of the components (heating elements, thermostat) to detect any accidental current leaks. Water leakages When water heating begins, from the safety assembly or safety valve: this is completely normal, and is due to the expansion of water inside the tank. The connection is compulsory. Permanently, check the hot water and cold water fittings and the flange seals. Tighten them or replace them if need be. As a last resort, investigate whether it is due to the tank and contact the supplier. 10 GUARANTEE Tank guarantee: 5 years. Parts guarantee: 1 years. Please refer to our general conditions. The guarantee certificate is supplied with the appliance. This guarantee shall only be valid if you return the duly compiled tear-off coupon to us. - 23 -