INSTALLATION GUIDE, OPERATION AND SERVICE MANUAL PROPANE & BUTANE GAS FIRED STORAGE WATER HEATERS HI-FLO RANGE Models L32/143, L65/169, L81/251, L62/309, L54/399, Permanent Pilot, Piezo Ignition ‘E’/‘F’ Series STANDARD RANGE Models L24/31, L32/35, L40/36, L63/71, L84/74 Permanent Pilot, Auto Ignition ‘G’ Series T H I S M A N U A L M U S T B E K E P T W I T H T H E A P P L I A N C E October 2004 Part No.
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© Copyright Andrews Water Heaters 2004 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. The attention of U.
CONTENTS SECTION 1 PAGE GENERAL AND SAFETY INFORMATION General Information British Standards Health and Safety Regulations 1993 Effectiveness in Combating Legionellae 2 2 3 3 TECHNICAL DATA Standard Range Hi-Flo Range 4 5 INSTALLATION Introduction Assembling the Draught Diverter Location Gas Supply Installation of LPG Supply Electrical Supply - Auto Ignition - Standard Range Flue Systems Air Supply and Ventilation Water Quality and Treatment Water Connections - Hydrojet System Vented Systems, Standar
SECTION 1 GENERAL INFORMATION GENERAL AND SAFETY INFORMATION The Andrews Water Heater has been designed for use with PROPANE or BUTANE GAS only 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.
GENERAL AND SAFETY INFORMATION It is the duty of manufacturers and suppliers of products for use at work to ensure, so far as is practicable, that such products are safe and without risk to health when properly used and to make available to users, adequate information about their safe and proper operation. Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual.
SECTION 2 STANDARD RANGE TECHNICAL DATA ANDREWS MODEL NO. L24/31 L32/35 L40/36 L63/71 L84/74 Storage Capacity l gal 109 24 145 32 182 40 286 63 382 84 Recovery thro' 44ºC/80ºF l/h gal/h 141 31 163 35 163 36 322 71 336 74 Recovery thro' 56ºC/100ºF l/h gal/h 113 25 127 28 131 29 258 57 269 59 Heat Input Gross kW Btu/h 9.5 11.0 11.0 22.0 22.0 32,414 37,532 37,532 75,064 75,064 Heat Input Net kW Btu/h 8.6 10 10 20 20 29,343 34,120 34,120 68,240 68,240 Gas LPG CAT I3 mbar ins wg.
TECHNICAL DATA SECTION 2 ANDREWS MODEL NO. L32/143 L65/169 L81/251 L62/309 L54/399 Storage Capacity l gal 145 32 295 65 386 81 282 62 245 54 Recovery thro' 44ºC/80ºF l/h gal/h 649 143 788 169 1140 251 1403 309 1821 399 Recovery thro' 56ºC/100ºF l/h gal/h 517 114 613 135 913 201 1122 247 1449 319 Recovery thro' 72ºC/130ºF l/h gal/h 399 88 472 104 699 154 862 190 1117 246 Heat Input Gross kW Btu/h 41.8 49 76 92.5 122 142.
SECTION 3 INTRODUCTION INSTALLATION THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON Installations must be carried out in accordance with Gas safety (Installation and Use) Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations 1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1.
INSTALLATION SECTION 3 The heater must not be installed in any location which contains a bed, bath or shower. The heater must not be installed in a basement or cellar. There must be easy access to the boiler room and heater at all times. LOCATION A clearance of 800mm (311⁄2 in) for Hi-Flo and 300mm for Standard Range should be left at the front of the heater for removal of the burner. Clearances at the sides and rear of the heater should be at least 305mm (12in).
SECTION 3 INSTALLATION GAS SUPPLY Gas Supply Cock, Hi-Flo Models Fig 2. Fit the gas cock immediately upstream of the gas control valve using a suitable jointing compound and connect to the gas supply. An inlet nipple complete with pressure test point nipple is factory fitted to the gas control valve to avoid possible damage. Gas Valve Restrictor Gas Cock Nipple BSP Thread Fig 2. U.P.T.
INSTALLATION SECTION 3 Bulk Storage Vessel Installation Cylinder Installation Fig 3.
SECTION 3 ELECTRICAL SUPPLYAUTO IGNITION UNIT INSTALLATION STANDARD RANGE MODELS 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. The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply. The fuse rating is 5 amps.
INSTALLATION SECTION 3 Detailed recommendations for flue installation are given in BS 6644, BS5440 Pt 1 and British Gas publication IM/11 - Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters. See also IGE/UP/10 Pt1. FLUE SYSTEMS The flue connection is designed for BS 835 type heavy duty flue, but light quality flue pipe, mild steel or stainless steel sheet may be used using the appropriate adapter. Flue pipes etc.
SECTION 3 INSTALLATION FLUE SYSTEMS 600mm Split Flue Clip Fig 5b. 1. This flue run must not be used 2 & 3 are recommended flue runs *A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all natural draught flue installations. If this dimension cannot be achieved please contact Andrews Water Heaters. Please note this is not required where a common flue header is used on multiple installations. Fig 6.
INSTALLATION SECTION 3 Minimum Heights from Roof to Base of Flue Terminal Type of Roof Not within 1.5m (5ft) of a vertical surface of a structure ≠ on the roof Internal Route On Ridge Pitch exceeding 45º Pitched Pitch not exceeding 45º At or above ridge level With parapet Not applicable Flat Without parapet External Route Not on Ridge 1m (3.3 ft) above roof intersection 600 mm (24 in) above roof intersection 600 mm (2 ft) above roof intersection 250 mm (10 in) above roof intersection Within 1.
SECTION 3 AIR SUPPLY AND VENTILATION INSTALLATION IMPORTANT! 1. The effective area requirements specified in the table are related to the net heat input of the heater(s) and are equivalent to those specified in BS 6644 and IGE/UP10 Pt1. 2. The free area of the grilles should not be less than the size of the recommended ventilation opening. 3. The supply of air to a space housing the heater(s) by mechanical means should be: (a) Mechanical inlet with natural extraction.
INSTALLATION SECTION 3 WATER CONNECTIONS Hydrojet System The upper “jet ports” direct the flow outward to begin the dynamic mixing action. The lower “jet ports” direct the flow inward to increase the turbulence. Tank Heater Casing All models now incorporate the new Mini Hydrojet system on cold inlet side connections. This system ensures water is directed onto the tank base which minimises sediment build up from day one of installation.
SECTION 3 WATER CONNECTIONS INSTALLATION VENTED SYSTEMS, STANDARD RANGE The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644. The Water Supply (Water Fittings) Regulations 1999 must be observed when installing the system.
INSTALLATION SECTION 3 Fig 8. Fig 8a.
SECTION 3 WATER CONNECTIONS INSTALLATION UNVENTED SYSTEMS, STANDARD RANGE Unvented Systems should be fitted by an Approved Installer When used in an unvented system, the Andrews Water Heater will supply hot water at a pressure of 3.5bar (50.8lbf/in2) provided that this pressure is available at the mains feed. During conditions of no-flow, system pressure may rise to a maximum of 6bar (87lbf/in2) whilst the burner is operating. When testing the system, it is recommended that a maximum test pressure of 8.
INSTALLATION SECTION 3 WATER CONNECTIONS Fig 10. Fig 11.
SECTION 3 WATER CONNECTIONS INSTALLATION VENTED SYSTEMS, Hi-Flo RANGE The water heater must be fed from a cold water feed cistern or static water tank. A safety valve must be fitted as specified in BS 6644 Clause 9. (see also Section 2, Technical Data) The safety valve must be fitted either directly to an upper tank tapping or not further than 1 metre along the outlet flow pipe of size not less than the safety valve. There must be no valve separating the heater from the safety valve.
INSTALLATION SECTION 3 WATER CONNECTIONS L65/169 L81/251 Optional Rear Inlet/Outlet Tappings L32/143 only Fig 12. L65/169 L81/251 Fig 13.
SECTION 3 WATER CONNECTIONS Fig 14. Fig 15.
INSTALLATION UNVENTED SYSTEMS, Hi-Flo RANGE Unvented Systems should be fitted by an Approved Installer When used in an unvented system, the Andrews Water Heater will supply hot water at a pressure of 3.5bar (50.8lbf/in2) provided that this pressure is available at the mains feed. During conditions of no-flow, system pressure may rise to a maximum of 6bar (87lbf/in2) whilst the burner is operating. When testing the system, it is recommended that a maximum test pressure of 8.62bar (125lbf/in2) is employed.
SECTION 3 WATER CONNECTIONS INSTALLATION If higher flow rates are required for the cold water services, a suitable tee fitting should be fitted to the pipework, upstream of item C1. The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain (see Building Regulations 1992 Approved Document G3).
INSTALLATION SECTION 3 WATER CONNECTIONS Fig 18. Fig 19.
SECTION 4 STANDARD RANGE PERMANENT PILOT MODELS COMMISSIONING CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER RUNNING FROM ALL HOT TAPS. Open the main gas supply cock after all connections to the gas control are completed and test all connections, using proprietary leak detection fluid. Lighting the Burner 1. Remove outer cover and slide inner cover to right. (On L63/71 and L84/74 Models, raise the inspection port cover).
COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only (7 days or more) turn gas control knob to PILOT, depress slightly and turn clockwise to OFF. Turn off the gas service cock. For shorter periods, leave the heater under thermostat control. NOTE! If the pilot goes out for any reason, turn off heater and wait for 3 minutes before relighting. Checking Main Burner Pressure 1. 2. 3. 4. Turn burner OFF as above. Release bleed screw A one turn and connect pressure gauge tube.
SECTION 4 HI-FLO RANGE COMMISSIONING Lighting the Burner Open the main gas supply cock after all connections to the gas control are completed and using a manometer, test all connections up to the gas control inlet. Purge air from pipework and ensure there are no loose connections to burner or pilot pipe. 1. 2. 3. 4. Ensure gas supply is on. Turn gas control knob to PILOT position. Depress knob and activate piezo igniter.
COMMISSIONING SECTION 4 Fig 23. Checking Main Burner Pressure 1. 2. 3. 4. Turn gas control knob clockwise to OFF. Release bleed screw A and connect pressure gauge tube. Light burner as described above. With the main burner running, check that the burner pressure is as stated on the data plate and in Section 2, Technical Data. 5. Turn the main gas control knob to OFF, remove the pressure gauge, tighten the bleed screw and test for gas leaks (when the burner is re-lit) with a leak detection fluid.
SECTION 4 STANDARD RANGE AUTO IGNITION MODELS Fig 25. COMMISSIONING Lighting the burner Thermostat Control Knob On/Off Switch Gas Control valve 1. Ensure gas supply is on. 2. Set thermostat control knob to the required water temperature. (See below). 3. Ensure time switch if fitted is in the ON position. 4. Move electrical ON/OFF switch to ON and the burner will light. 5. Check pilot and main gas connections at gas control valve using leak detection fluid whilst burner is alight.
COMMISSIONING SECTION 4 Checking main burner pressure 1. 2. 3. 4. Turn gas supply OFF. Release bleed screw A one turn and connect pressure gauge tube. Light burner as described above. By means of the external in-line regulator, set burner pressure for gas being used in accordance with the data plate. 5. Remove pressure gauge tube and tighten bleed screw. 6. Leak test using leak detection fluid. Fig 24.
SECTION 4 USERS SAFETY GUIDE COMMISSIONING For your safety read before lighting the appliance WARNING 1. Always follow manufacturers instructions when lighting the appliance. Failure to do so may result in damage to property, personal injury or loss of life. 2. Before lighting check all round the appliance area for gas. Be sure to check at low level because some gas (i.e. LPG) is heavier than air and will settle on the floor. 3.
OPERATION When properly installed and adjusted, the heater will require minimal attention. Should it become necessary to completely drain the heater, close the cold water inlet valve and open a hot water tap to allow air to enter the system. Fit a suitable hose to the drain cock and open. Whenever the heater is filled with cold water, condensation will form on the storage vessel surfaces when the burner is lit. This is normal and will disappear when the heater warms up.
SECTION 6 SERVICING INTRODUCTION Servicing must be carried out by a properly qualified person Whilst giving these instructions for the care of the Heater, it is recommended that checks are carried out by the installer or local gas authority, at least annually. Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint. Keep pipework, flue and tops of heaters clear of any combustible materials.
SERVICING The burner assembly should be checked and cleaned annually. NOTE! Models L62/309 and L54/399 are fitted with an anchor bracket between the burner manifold and heater body. Take out 2 screws to remove. 1. 2. 3. 4. Turn gas control valve knob to OFF and disconnect union joint from gas service cock. Disconnect thermostat connections (black, red and white wires) from gas control valve. Remove two screws and slide out burner assembly. Disconnect pilot tube and thermopile connections from gas valve.
SECTION 6 FLUE WAYS STANDARD RANGE FLUE WAYS HI-FLO RANGE SERVICING The flue ways should be checked and cleaned annually. 1. Depress catch under control knob and turn to OFF. Remove outer burner cover and slide inner door to right. On L63/71 and L84/74 models, the inner cover must be lifted out. 2. Disconnect burner gas tube, pilot tube and thermocouple at gas control. 3. Remove burner assembly complete with pipes and thermocouple lead. 4. Remove split flue clip from flue and lift off draught diverter.
SERVICING Magnesium sacrificial anode(s) is (are) fitted to the top of the storage vessel. The anode(s) will prevent corrosion of the storage vessel. Anode condition should be checked annually and replaced if excessive wear is present. SECTION 6 MAGNESIUM ANODE(S) ALL MODELS 1. Withdraw each anode using a 11/16in AF socket spanner. A new anode measures 21mm diameter. 2. An anode should be replaced, if, at any point along it's length, the diameter is reduced to half, or less of original.
SECTION 7 GAS CONTROL VALVE REPLACING COMPONENTS, Hi-Flo RANGE NOTE! Models L62/309 and L54/399 are fitted with an anchor bracket between the burner manifold and the heater body. Remove two screws to release the anchor bracket. 1. Turn gas control knob and gas service cock to OFF. 2. Disconnect pilot feed pipe, thermocouple and thermostat leads from gas valve. 3. Disconnect union joint from gas service cock. 4. Unscrew two wing nuts and remove draught shield.
REPLACING COMPONENTS, Hi-Flo RANGE SECTION 7 1. Turn gas control knob and gas service cock to OFF and disconnect union joint on the gas service cock. 2. Remove two wing nuts and remove front draught shield. 3. Disconnect thermopile and pilot supply pipe from gas control valve. 4. Remove two screws and withdraw burner assembly. 5. Remove two screws and withdraw pilot assembly. 6. Unscrew gland nut securing thermopile to it's bracket and withdraw. 7. Unscrew pilot feed pipe nut and withdraw pipe.
SECTION 8 AUTO IGNITION UNITS STANDARD RANGE FAULT FINDING FAULT NO IGNITION AT PILOT ACTION (a) Check gas service cock is open. (b) Electrical ON/OFF switch is not ON. (c) Power to unit interrupted. (d) Thermostat set too low. (e) Check ECO for failure. Reset. (f) Check for 24V AC at intermittent pilot ignition control terminal No. 1. Replace control if faulty. (g) Faulty Solenoid Coil. Replace if faulty.
FAULT FINDING FAULT PILOT LIGHTS BUT MAIN BURNER DOES NOT ACTION (a) Check for 24V AC at intermittent pilot ignition control terminal No. 3. Replace control if faulty. SECTION 8 PERMANENT PILOT MODELS STANDARD AND HI-FLO RANGES (b) Faulty Solenoid Coil. Replace if faulty. (a) Check gas service cock is open. (b) Check water valves are open WATER DOES NOT GET HOT (c) Check pilot is alight (d) Check thermostat setting.
SECTION 8 PERMANENT PILOT MODELS STANDARD AND HI-FLO RANGES 42 FAULT FINDING FAULT ACTION THERMOPILE / THERMOCOUPLE BURNS OUT FREQUENTLY (a) Check pilot connection for loose joints. (b) Check correct ventilation is available. (c) Check flue is clear and is correctly designed and flue terminal is correctly positioned. (d) Check for presence of halogen compounds. HEATER SOOTING, YELLOW FLAME (POOR COMBUSTION) (a) Check gas burner pressure and injector size.
FAULT FINDING SECTION 8 FAULT ACTION LOUD WHISTLING NOISE Check burner primary air shutter settings are correct to dimensions given below. If not reset to dimensions given below. If the whistling persists continue to reduce the settings until the whistling stops.
SECTION 9 PARTS LIST AND ILLUSTRATIONS L63/71 only STANDARD Models L24/31, L32/35, L40/36, L63/71 A4 A1 A12 A12 A3 C1 A2 A5 C6 B8 B10 A10 B4 B4 B9 B6 B3 B1 B12 A13 B5 B2 A14 B5 B12 A15 B7 B11 B7 C2 C3 STANDARD Model L84/74 A9 C3 A8 C4 C5 44
PARTS LIST AND ILLUSTRATIONS SECTION 9 STANDARD MODELS Model Ref.
SECTION 9 Hi-Flo Model L32/143 Hi-Flo Models L65/169, L81/251 46 PARTS LIST AND ILLUSTRATIONS
PARTS LIST AND ILLUSTRATIONS SECTION 9 HI-FLO MODELS Model L32/143 Ref.
SECTION 9 Hi-Flo Models L62/309, L54/399 48 PARTS LIST AND ILLUSTRATIONS
PARTS LIST AND ILLUSTRATIONS SECTION 9 HI-FLO MODELS Model L62/309 Ref.
SECTION 9 Unvented Systems Kit - Standard Range Unvented Systems Kit - Hi-Flo Range 50 PARTS LIST AND ILLUSTRATIONS
PARTS LIST AND ILLUSTRATIONS SECTION 9 Ref. Part No. Description Qty D1 D2 D3 D4 D5 D6 B171 C780 C781 C782 C456 C783 C772 Unvented Systems Kit Complete Pressure Reducing Valve/Strainer Check Valve / Expansion Vessel Expansion Vessel Temperature/Pressure Relief Valve Tundish Adaptor 1 1 1 1 1 1 1 D7 D8 B173 C788 C787 Wall Mounting Kit for Expansion Vessel Hose Assembly Wall Bracket Assembly 1 1 Ref. Part No.
SECTION 9 PARTS LIST AND ILLUSTRATIONS 24 Volt Auto System Kit B252 With Timer B253 24 Volt Auto System Kit Standard Range 52 Part No.
NOTES 53
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