This manual must be kept with the appliance August 2012 Part No.
SECTION XX • XXXXXXXXX Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters. Andrews Storage Water Heaters have been designed and manufactured to comply with current international standards of safety. In the interests of the health and safety of personnel and the continued safe, reliable operation of the equipment, safe working practices must be employed at all times.
XXXXXXXXX • SECTION XX CONTENTS 3 PAGE SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 GENERAL AND SAFETY INFORMATION General Information British Standards and Codes of Practice Health and Safety Regulations 1993 Legionellae in Water Heaters 4 4 4 5 TECHNICAL DETAILS Technical Details – CWH30/60/90/120 Heater Dimensions – 200 litre model Heater Dimensions – 300 litre model 6 7 8 INSTALLATION Description Location Water Quality and Treatment Water Connections Cond
XX• •GENERAL XXXXXXXXX SECTION 1 AND SAFETY INFORMATION GENERAL AND SAFETY INFORMATION The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG and is manufactured to give an efficient, reliable and long service life. To ensure the continued, trouble-free operation of your heater at maximum efficiency, it is essential that correct installation, commissioning, operation and service procedures are carried out strictly in accordance with the instructions given in this manual.
XXXXXXXXX • •SECTION XX GENERAL AND SAFETY INFORMATION SECTION 1 EFFECTIVENESS IN COMBATING LEGIONELLA Water systems in buildings have been associated with outbreaks of Legionnaires’ Disease, particularly in health care facilities where occupants are significantly more susceptible to infection. In recognition of the risks in hospitals, a Code of Practice for the Control of Legionella in Health Care premises has been issued by the Department of Health (1991).
SECTION 2 XX • • TECHNICAL XXXXXXXXXDETAILS Model Reference CWH Input gross Hs min/max Input nett Hi min/max Output (tank set point = 60°C) min/max 30/200 30/300 6.7–31.1 kW 6.0–28.0 kW 6.5–30.5 kW 60/200 60/300 13.4–62.2 kW 12.0–56.0 kW 13.0–61.0 kW 90/200 90/300 20.1–93.3 kW 18.0-84.0 kW 19.5-91.6 kW 120/200 120/300 26.8-124.4 kW 24.0-112.0 kW 26.0-122.1 kW 2.96 m3/h 18 mbar 5.93 m3/h 18 mbar 8.89 m3/h 18 mbar 11.85 m3/h 18 mbar 2.18 Kg/h 37 mbar 98% 109% 4.
TECHNICAL DETAILS • • SECTION SECTIONXX 2 XXXXXXXXX INSPECTION HATCH INSPECTION HATCH 7
XX • • TECHNICAL XXXXXXXXXDETAILS SECTION 2 INSPECTION HATCH INSPECTION HATCH
XXXXXXXXX TECHNICAL DETAILS • • SECTION SECTIONXX 2 9 INSTALLATION DESCRIPTION The MAXXflo series is a direct fired condensing storage water heater which has a stainless steel tank that is heated by up to four burner modules placed outside the tank. A burner module consists of a stainless steel heat exchanger in which the burner is placed.
XX • • INSTALLATION XXXXXXXXX SECTION 3 WATER QUALITY AND TREATMENT When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted. In hard water areas, scale formation can occur in all hot water systems and water heaters and the higher the temperature and volume of water used, the more problematic the scale build-up can be. Water treatment is normally recommended when the hardness reaches 100 – 150ppm (7 – 10 degrees Clark) and above.
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 11 SECONDARY RETURN CIRCULATION PUMP CONDENSE DRAIN Condensation is formed in the heater and this must be continuously discharged into a drain. A trap is supplied which should be connected into a drain via a tundish or air break. (See Fig 1a and 1b). The condense flow must not be allowed to block otherwise the heater will fail to work correctly.
SECTION 3 XX • • INSTALLATION XXXXXXXXX Fig 3A – Typical installation Fig 3B – Typical installation
INSTALLATION SECTIONXX 3 XXXXXXXXX • • SECTION 13 GAS SUPPLY – NATURAL GAS GAS SUPPLY – PROPANE The installation of the gas supply must conform, depending on its size, to the requirements of British Standards and Codes of Practice listed in Section 1 of this manual. Contact your provider or supplier who will provide the appropriate type and size of LPG supply vessel and ensure its safe location and installation.
XX • • INSTALLATION XXXXXXXXX SECTION 3 Fig 4: Typical Bulk Storage Vessel Installation Fig 5: Typical Cylinder Installation Important These drawings show a schematic representation only and should not be used for installation purposes. Contact your gas supplier for authorised installation drawings.
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 15 ELECTRICAL SUPPLY ELECTRICAL CONNECTION External wiring to the water heater(s) must be installed in accordance with current I.E.E. Regulations for the wiring of buildings and to any Local Regulations that may apply. A terminal block can be found above the control panel (Fig 4, below). This becomes accessible by first removing the front cover.
M5879D bk r gy r/bl y br br bl br br bl g/y L N E 230V/50Hz master bl br gy r wh r wh r gr br gr br gr bk wh br bk r gr bk gy r/bl r bk y r or y bk gn gy bl pump } TH1 gr or EN1 EN2 TS4 TS3 TS2 LS2 TS1 LS1 BT2 BT1 TH2 r tank sensor, high position tank sensor, low position y gy flow sensor 1 or flow sensor 2 return sensor br bl AL1 (Max 24 V 1.0 Amp) AL2 pump N secondary pump comm. 1 comm. 2 comm. 3 comm.
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 TEMPORARY WATER HEATER TEMPERATURE CHANGE It is possible to change the water heater temperature remotely via a timer programme. First of all, the new desired water heater temperature is set at a value higher or lower than the water heater temperature during normal operation. This makes it possible, for example, to carry out Legionella flushing. (See page 32). The water heater temperature changes when the contacts connected to terminals BT1 – BT2 are closed.
SECTION 3 XX • • INSTALLATION XXXXXXXXX Fig 9 – HWST Tank Dimensions HWST 200 HWST 300 STORAGE TANKS 47 T&P outlets 153 Drain access 28 mm valve 153 602 602 PLAN VIEW 1 1/2" Hot water supply Tank inspection hatch 1" Return 28 mm T&P outlets 1 1/2" Feed from water heater 1 or 2 Tundishes supplied Fig 10 – Wiring Diagram 1952 (300 litre t ank) 1528 (200 litre t ank) Thermostat
INSTALLATION SECTIONXX 3 XXXXXXXXX • • SECTION 19 FLUE SYSTEMS The versatile flueing options will provide a solution to most flushing requirements. The heater, when fitted with a concentric flue system, provides a room sealed application. The concentric flue, supplied by Andrews, is available for either horizontal or vertical installation and the table below shows the basic kit supplied plus optional extras.
XX • • INSTALLATION XXXXXXXXX SECTION 3 CWH30 & CWH60 Flue Systems The CWH30 & CWH60 uses a concentric flue system, 125mm outside diameter with an inner flue of 80mm diameter. Flue components fit together with silicon sealing rings and the flues are retained with sealing clamps. Each heater can be ordered with either a horizontal or vertical flue kit. Flue assembly instructions are also included.
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 21 CWH30 & CWH60 Alternative Flue Systems 1.5M CWH30 max 50M Conventional CWH60 max 20M Conventional CWH30 max 14M Concentric CWH60 max 12M Concentric Over 1.5M use flue Condense trap. 258 135 Minimum between Vertical terminals Condense Tap To drain 300mm Minimum between balanced flued horizontal terminals Paint: RAL 7012 820 For concentric flue runs reduce overall length by: 1.2M when using 90º bend 0.7M when using 45º bend and 1.
XX • • INSTALLATION XXXXXXXXX SECTION 3 CWH30 & CWH60 Standard Flue System Dimensions ALL 80/125mm Ø CONCENTRIC FLUE 570 185 20 290 Ø125 Ø80 Ø 123/124 12 5 CONDENSATE TRAP Ø 1350 PART No E310 100 150 125 Ø125 0 10 Ø80 45º ELBOW C/W CLAMP 200 20 PART No E308 Ø80 VERTICAL FLUE TERMI NAL C/W CLAMP (CONDENSING) PART No E067 200 90º ELBOW C/W CLAMP PART No E071 220 610 220 Ø80 170 20 200 Min ADJUSTABLE PLATE Maintain dimension if flue is cut HORIZONTAL TERMINAL C/W WALL PLATES
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 23 CWH90 & CWH120 Flue Systems The CWH90 & CWH120 uses a concentric flue system, 200mm outside diameter with an inner flue of 130mm diameter. Flue components fit together with silicon sealing rings and the flues are retained with sealing clamps. Each heater can be ordered with either a horizontal or vertical flue kit. Flue assembly instructions are also included.
SECTION 3 XX • • INSTALLATION XXXXXXXXX CWH30 & CWH60 Alternative Flue Systems 258 Over 1.5M use flue condensetrap. 1.5M CWH90 max 50M Conventional CWH120 max 40M Conventional CWH90 and CWH120 max 14M Concentric Minimum clearence between vertical balanced flue terminals Condense Tap To drain For concentric flue runs reduce overall length by: 1.2M when using 90º bend 0.7M when using 45º bend 1.
INSTALLATION SECTIONXX 3 XXXXXXXXX • • SECTION 25 CWH90 & CWH120 Standard Flue System Dimensions ALL 130/200MM fl CONCENTRIC FLUE 0 13 130 185 20 Painted RAL 7012 fl200 fl130 20 fl130 1780 fl 198/199 fl 198/199 CONDENSATE TRAP 45… ELBOW C/W CLAMP 1300 PART No E220 fl 200 785 PART No E216 220 VERTICAL FLUE TERMINAL C/W CLAMP PART No E670 220 20 268 fl 40 fl32 20 fl130 fl 198/199 CONDENSATE TRAP PART NO.
SECTION 3 XX • • INSTALLATION XXXXXXXXX FLUE SYSTEMS Fig 11 Terminal Positions with Minimum Distance mm A Directly below an opening, air brick, opening window etc. 300 B Above an opening, air brick, opening window etc 300 C Horizontal to an opening, air brick, opening window etc.
INSTALLATION XXXXXXXXX • • SECTION SECTIONXX 3 Flue Systems Fig 12 27
XX • • INSTALLATION XXXXXXXXX SECTION 3 AIR SUPPLY AND VENTILATION CONCENTRIC FLUE SYSTEMS The following notes are intended to give guidance: Where the heater is to be installed in a room, NO VENTS ARE REQUIRED. Where the heater is to be installed in a COMPARTMENT, permanent air vents are required in the COMPARTMENT at high and low level. These air vents must either communicate with a room or internal space or be direct to outside air.
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 29 AIR SUPPLY AND VENTILATION CONCENTRIC FLUE SYSTEMS AIR SUPPLY AND VENTILATION CONVENTIONAL FLUE SYSTEMS IMPORTANT For all installations, please refer to the table below for calculating requirements. Detailed recommendations for the air supply are given in BS5440, Part 2, and BS6644, Clause 19.3 and in IGE/UP/10, Pt 1. 1.
XX • • INSTALLATION XXXXXXXXX SECTION 3 AIR SUPPLY AND VENTILATION CONVENTIONAL FLUE SYSTEMS The minimum effective areas of the permanent air vents require in the compartment are as follows: Air Vents Areas Position of Air Vents High Level Low Level Air from Room or Internal Space 10cm2 per kW Net input 20cm2 per kW Net input Air Direct from Outside 5cm2 per kW Net input 10cm2 per kW Net input Note: Both air vents must communicate with the same room or internal space or must both be on the same wall
XXXXXXXXX • • SECTION INSTALLATION SECTIONXX 3 31 CWH HEAT EXCHANGER CONFIGURATION The water heater is equipped with 1, 2, 3 or 4 burner modules depending on the model. Each burner module has its own automatic burner. CONTROL PANEL The operational status of the water heater can be seen and the desired temperature can be set on the control panel (Fig 13, right) A green and a red LED can be found on the control panel for each burner module. These indicate the status of the corresponding burner module.
SECTION 4 TEMPERATURE SETTING XX • • WATER XXXXXXXXX Water Temperature Setting TEMPERATURE SETTING The water heater temperature can be set between 40°C and 70°C using the + and – buttons on the control panel. The maximum temperature for the Legionella flushing programme is 75°C. The lower the temperature, the lower the chance of lime deposits (less maintenance). The risk of scalding is also less (think of children, those with special needs and the elderly).
INSTRUCTIONS FOR COMMISSIONING SECTIONXX 5 XXXXXXXXX • • SECTION 33 FILLING THE WATER HEATER CO2 ADJUSTMENT 1. Check that the tank drain tap is closed 2. Check that the return valve in the 28mm pipe (close to the drain tap) is open 3. Open the main water tap, and then all warm water drainage points so that air present in the installation and water heater can escape 4. Fill the water heater by turning on the cold water supply tap.
XX • • INSTRUCTIONS XXXXXXXXX FOR COMMISSIONING SECTION 5 CONTROL AND ADJUSTMENT AT FULL LOAD CONTROL AND ADJUSTMENT AT LOW LOAD 1. Switch the water heater off and flush system until the tank is completely cooled down 1. Select low load with the – button. When the actual burner capacity is above 25%, the CO2 percentage can be measured and set. 2. Put the water heater in operation 3. Press the reset button down for longer than 5 seconds; L appears in the display.
XXXXXXXXX FAULT CODES• • SECTION SECTIONXX 6 35 FAULT CODES A fault code will appear in the control panel display if there is a lockout failure. A letter and the number of the burner module appear alternately in the display. The letter A is for a lockout fault and E is for a blocking fault. The two right segments show a fault code, table 2 gives the meaning of the different codes.
XX• •MAINTENANCE XXXXXXXXX SECTION 7 MAINTENANCE At least once a year, the following works must be carried out: 1. Check the CO2 percentage and adjust if necessary, (see page 33). 2. Check the output at full load by measuring the gas usage. If this deviates more than 15% from the nominal value (see Section 2, Technical Details) then this is an indication of dirt or blockages in the flue gas extraction channel, the air supply channel or the condensation extractor. 3. Switch off the electricity supply.
XXXXXXXXX PARTS LIST• • SECTION SECTIONXX 8 37 SPARE LIST FOR CWH RANGE Parts Description Main Dungs Gas Valve Assembly Main Gas Valve O Ring Fan Assembly & Gasket Fan Gasket only Part Number E659 M1835 E845 M1842 E658 M1834 E846 M1843 Quantity 1 per module 1 per module 1 per module 1 per module Wilo Primary Pump (Bronze) Bronze Pump Elbow & Vent Union Wilo Primary Pump (Plastic) Plastic Pump Elbow & Vent Union From serial number 071401 Non-return Valve E660 E847 E920 E921 M1836 M1844 M2266 M2272 1
SECTION 8 LIST XX • • PARTS XXXXXXXXX Parts Description Temperature/Pressure Relief Valve Andrews Dome Label MAXXflo Dome Label Part Number C380 C380 E856 M1845 E927 M2290 Quantity 1 – 30 & 60 kW 2 – 90 & 120 kW 1 1 Front Cover Drain Cover Plate (200 L vessel) Drain Cover Plate (300 L vessel) E919 E935 E936 M2264 M1411 M5845 1 1 1 Side Access Panel (200 L) Side Access Panel (300 L) E935 E936 M1411 M5845 1 1 Laptop Interface USB Lead Service Manual LPG Warning Label E870 E281 E942 1 1 1
PARTS LIST• • SECTION SECTIONXX 8 XXXXXXXXX UNVENTED SYSTEMS KIT INSTALLATION DETAILS MAXXFLO WATER HEATER CWH30/60/90/120 B4 B5 B2 B1 B8 B3 B6 B173 B7 Condensate trap Condensate drain COMPLETE UNVENTED SYSTEMS KIT PART NO.
Publication Date: 0812 0087 Baxi Commercial Division Wood Lane, Erdington, Birmingham B24 9QP Sales: Technical: 0845 070 1056 0845 070 1057 Email: andrews@baxicommercialdivision.com www.andrewswaterheaters.co.uk Authorised User No.
