Solar Cylinder Range Installation & User...
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Grant Twin Coil Copper System Solar Cylinder Range Installation & User Instructions Part No. IRL 14. Rev 00. June 2011 Maximum operating pressure 2 bar After installing the cylinder leave these instructions with the user After installing the cylinder leave these instructions with the user
Transcript of Solar Cylinder Range Installation & User...
Grant Twin Coil Copper SystemSolar Cylinder Range
Installation & User Instructions
Part No. IRL 14. Rev 00. June 2011
Maximum operating pressure 2 bar
After installing the cylinder leave these instructions with the userAfter installing the cylinder leave these instructions with the user
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Contents1 Introduction &
General Requirements 31.1 Installation Requirements 3
1.2 Water Supply Requirements 3
1.3 Location 3
1.4 Storage and Handling 3
1.5 About Your New Cylinder 3
1.6 Open Vented Hot Water Systems 3
1.7 Pipework Connections 3
1.8 Scaling 3
1.9 Insulation 3
1.10 Health and Safety 3
2 Technical Specifications 42.1 Technical Data - Twin Coil Copper Solar 4
2.2 Dimensions - Twin Coil Copper Solar 5
2.3 Connections and Controls 6
3 Primary Circuit Installation 73.1 Grant Twin Coil Solar Cylinders 7
3.2 Systems (Twin Coil Indirect Solar Cylinders Only) 7
3.3 Primary Connections 7
3.4 The 2-Port Valve 7
3.5 Auxiliary Primary Connections 7
3.6 Hard Water Areas 7
4 Secondary Circuit Installation 84.1 Cold Water Inlet Manifold 8
4.2 Installation 8
4.3 Expansion Vessel 8
4.4 Temperature and Pressure Relief Valve 8
4.5 Hot Water Supply 8
4.6 Prevention of Scalding 8
4.7 Secondary Return 9
4.8 Tundish 9
4.9 Discharge Pipe 9
4.10 Discharge Pipe Arrangement 10
4.11 Discharge Pipe Sizing 10
4.12 Worked Example 10
5 Electrical Installation 115.1 Immersion Heater 11
5.2 Immersion Heater Wiring Instructions 11
5.3 Dual Thermostat 11
5.4 2-Port Valve 11
5.5 Y-plan System 12
5.6 S-plan System 13
5.7 Solar Thermal System 14
6 Commissioning, Draining Down & Safety 156.1 Filling Cylinder 15
6.2 Draining Down 15
6.3 Safety Cut-Out 15
6.4 Cold Water Discharge from Tundish 15
6.5 Hot Water Discharge from Tundish 15
6.6 Expansion Vessel 15
6.7 Customer Handover 15
7 Maintenance 167.1 Servicing and Maintenance 16
7.2 Manifold Assembly 16
7.3 Pressure Reducing Valve 16
7.4 Expansion Relief Valve Cartridge 16
7.5 Expansion Vessel 16
8 Fault Finding 178.1 Intermittent Water Discharge 17
8.2 Constant Water Discharge 17
8.3 No Flow from Hot water Taps 18
8.4 Cold Water Flow from Hot Water Taps 18
8.5 Excessive Hot Water from Taps 19
9 Spare Parts 209.1 Spare Parts 20
10 User Instructions 2110.1 User Instructions 21
11 Warranty 2211.1 The Grant Cylinder Warranty 22
12 Commissioning & Servicing Details 2312.1 Installer & Commissioning
Engineers Details 23
12.2 Grant Copper Twin Coil Cylinders Appliance & Time Control Details 23
12.3 Commissioning Procedure Information 23
12.4 Grant Copper Twin Coil Cylinders Service Interval Record 23
1 Introduction & General Requirements1.1 Installation RequirementsThank you for purchasing a Grantunvented hot water storage cylinderfrom our cylinder range. This installationmanual must be read carefully beforeyou begin installing the cylinder.
This cylinder must be installed by acompetent person in compliance withall current legislation, codes of practiceand local by-laws covering theinstallation of an unvented hot watercylinder. Please also make sure that anyinstallation complies with theinstructions contained in this installationinstruction manual.
1.2 Water Supply RequirementsWe recommend that your GrantUnvented cylinder is installed with anuninterrupted water supply.
Where possible the unit should be fedvia a Ø22mm supply pipe. It requires asupply pressure of 1.5 bar with a flowrate of at least 20 litres per minute as aminimum for it to function. Even withthese rates, flow from the outlets will bedisappointing if several outlets are usedsimultaneously. Generally speaking, thehigher the supply pressure, the betterthe incoming system will function. Thecylinder control equipment is factory setto limit the incoming system operatingpressure to 2 bar. The maximum supplypressure into the pressure- reducingvalve (PRV) is 12 bar.
1.3 LocationThe unit is designed to be floorstanding, vertically mounted, indoors, ina frost-free environment. Whenchoosing a suitable location for thecylinder, consideration should be givento the routing of the discharge pipe to aconvenient point and also the availabilityof an adequate power supply forconnecting the immersion heater(s).
The cylinder may stand on any flat andlevel surface without any specialfoundation preparations, provided that itis sufficiently robust to support the fullweight of the cylinder. (Refer toTechnical specifications for weights).
The position of the cylinder should besuch that easy access is provided forservicing the controls and replacing theimmersion heater should the need arise.
Generally, pipe runs should be made asshort as possible and lagged to preventheat loss.
1.4 Storage and Handling If the cylinder is not being installedimmediately, it should remain in itscarton to prevent damage. Werecommend that the cylinder betransported to its installation position on a sack truck or similar whilst stillwithin the carton.
1.5 About Your New Cylinder Twin Coil Solar indirect cylinders havetwo coils for connection to Primary heatsources. For Solar Thermal to beconnected, the bottom coil must beused. Please refer to the manufacturersinstallation instructions for moreinformation.
The central heating connections shouldbe made to the top coil.
Twin Coil indirect cylinders are alsosupplied fitted with a single 3kWelectric immersion heater.
1.6 Open Vented Hot WaterSystemsIf required, your Grant Twin CoilCylinder can be used as part of anOpen Vented hot water system, i.e. fedfrom a cold water storage cistern andfitted with an Open Vent pipe, providedthe maximum head does not exceed20m.
When used in this way, it will not benecessary to install the expansionvessel and cold inlet manifold suppliedwith the cylinder.
Note:The Temperature and Pressure relief(T&P) valve should be left connected tothe cylinder (as supplied). As it may stilloperate due to temperature it should beconnected in the correct manner – referto guidance given in Section 4 of theseInstructions.
1.7 Pipework ConnectionsAll Pipework connections to the cylindermust be made in accordance withFigures 2-4 to 2-6 as appropriate.
See note on page 7.
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1.8 ScalingIn hard water areas scaling will forminside the cylinder and this will reduceboth the performance and working lifeof the cylinder. Where the totalhardness exceeds 125ppm a highcapacity water softener, or suitablewater conditioner, should be installed inthe incoming cold water supply to thecylinder.
It is recommended that the watertemperature control thermostats (on theimmersion heaters and dualthermostats) fitted to the cylinder be setno higher than 60°C to minimise scalebuild up.
1.9 InsulationAll Grant Cylinders are insulated with40mm thick CFC/HFC free, fireretardant, polyurethane foam injectedbetween the copper cylinder and theouter casing. This polyurethane foamhas a Global Warming Potential (GWP)of less than 3 and an Ozone DepletionPotential (ODP) of 0.
1.10 Health and SafetyThe information supplied in the table inSection 2 Technical Specification willhelp you assess the safest way tomanoeuvre your cylinder into position.Please use the table to find the emptyweight of your cylinder and thenconsider how you can safely move itinto its final position.
Please leave this manual with thehouseholder after installation.
2 Technical Specifications
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2.1 Technical Data - Twin Coil Copper Solar Cylinders
Twin Coil Solar CylindersCylinder model 200 250 300 400 500*Storage capacity (litres) 200 250 300 400 500Overall diameter (mm) 580 580 580 660 660Overall height (mm) 1135 1340 1640 1510 1835Weight empty (kg) 46 53 63 75 88Weight full (kg) 246 303 363 475 588Secondary return connection (mm) 22 22 22 22 22Cold feed/hot draw-off connections (mm) 22 22 22 22 22Top/bottom coil connections (mm) 28 28 28 28 28Top coil length (m) 6 6 6 8 12Top coil surface area (m2) 0.52 0.52 0.52 0.73 1.04Bottom (solar) coil length (m) 8.5 12 13 18 23Bottom (solar) coil surface area (m2) 0.73 1.04 1.14 1.56 2.00Top/bottom coil pipe diameter (mm) 28 28 28 28 28Dedicated solar volume Vs (litres) 100 125 150 200 250Maximum water supply pressure (bar) 12 12 12 12 12System operating pressure - pre-set (bar) 2 2 2 2 2Expansion vessel charge pressure (bar) 2 2 2 2 2Expansion relief valve pressure (bar) 3 2 2 2 2Temp & pressure relief valve lift pressure (bar) 4 4 4 4 4Temp & pressure relief valve lift temperature (°C) 90 90 90 90 90Maximum primary circuit working pressure (bar) 3 3 3 3 3Performance:Top coil rating (kW) 12 12 12 16 24Top coil recovery rate (mins)* 20 25 26 25 25Bottom (solar) coil rating (kW) 17 24 26 36 4624hr standing loss (kW) ** 2.04 2.45 2.69 2.71 2.94Check list:Cylinder assembly 200 Litre 1 - - - -Cylinder assembly 250 Litre - 1 - - -Cylinder assembly 300 Litre - - 1 - -Cylinder assembly 400 Litre - - - 1 -Cylinder assembly 500 Litre - - - - 1Expansion vessel 19 Litre 1 - - - -Expansion vessel 24 Litre - 1 1 - -Expansion vessel 35 Litre - - - 1 -Expansion vessel 50 Litre - - - - 1Expansion vessel hose (3/4" BSPF x 3/4" BSPM) c/w washer 1 1 1 1 N/ATemp & pressure relief valve (4 bar 90ºC) factory-fitted 1 1 1 1 1Tundish 15/22mm 1 1 1 1 1Drain cock (1/2" end feed) 1 1 1 1 12-port motorised valve 22mm 1 1 1 1 1Dual thermostat (Control 25-65ºC High limit 90ºC) 1 1 1 1 1Immersion heater 3 kW (21/4" boss) factory-fitted 1 1 1 1 1Inlet manifold (2.0 bar pressure reducing valve & 3 bar exp. relief valve 1 1 1 1 1
* Recovery rate is based on 82˚C flow @ 0.2l/s over a 50˚C temp rise for 75% of contents. ** Test carried out at 60˚C.
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Figure 2-1: Twin coil copper solar cylinder dimensionsDia
ABCDEFGHIJ
2.2 Dimensions - Twin Coil Copper Solar Cylinders
28˚ 28˚ 30˚22mm Compression
hot water draw off
1/2" T & P Reliefvalve (factory fitted)
22mm Compressionsecondary return
28mm Compressionboiler flow
28mm Compressionboiler return
28mm Compressionsolar return
Solar stat pocket
22mm Compressioncold water inlet
maximum pressure 2 bar
28mm Compressionsolar flow
21/4" Immersionheater
Dims Model(mm) 200 250 300 400 500
A 200 210 210 230 210B 400 400 420 480 430C 510 515 530 605 750D 550 565 595 675 820E 590 660 670 755 890F 790 895 910 990 1130G 900 1030 1025 1035 1410H 900 990 1275 1080 1385I 900 1112 1450 1270 1580J 1135 1340 1640 1510 1835Dia 580 580 580 660 660
Boiler stat pocket
Note:Do not fit imperial reducing fittingsdirectly to cylinder connection. Anyreductions should be made after thecorrect pipe size is fitted to the cylinder.
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Item Description Connection Size
1 DHW Out 22mm compression
2 T & P valve connection 1/2" BSPF
3 Boiler return tapping 28mm compression
4 Secondary return tapping 22mm compression
5 Boiler dual thermostat pocket -
6 Boiler flow tapping 28mm compression
7 Auxiliary (Solar) heat source return tapping 28mm compression
8 Auxiliary (Solar) heat source dual stat pocket (for dual stat only) -
9 Cold water inlet (2 bar max) 22mm compression
10 Auxiliary (Solar) heat source flow tapping 28mm compression
11 Immersion heater c/w control & limit thermostat (factory fitted) 21/4" BSPF
13 Pressure reducing valve - 2 bar -
14 Balanced cold supply connection 22mm compression
15 Expansion relief valve - 3 bar 15mm compression
16 Temperature & Pressure relief 15mm compressionvalve - 90°C/4 bar
17 Tundish 15/22mm compression
18 Discharge pipe (not supplied with cylinder) -
19 Mains water supply pipe (not supplied with cylinder) -
20 Drain cock (supplied with cylinder) -
Note:Pipework between items 15 and 16 not supplied with cylinder.
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1
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5
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7
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910
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Figure 2-2: Twin coil copper solar cylinders
2.3 Connections and Controls Twin Coil Copper Cylinder Details
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3 Primary Circuit Installation3.3 Primary Connections 1. The primary flow and return
connections from the boiler shouldbe made to the upper coilconnections of the cylinder.
The motorised valve (supplied) mustbe fitted into the primary flow. Theprimary flow and return fittings are28mm compression. The valve has22mm compression connections.
2. Locate the dual thermostat in thepocket (refer to either Figure 2-1 or2-2, as appropriate, for location)and secure using the retainingscrews on the thermostat housing.
3. Any automatic or manual air ventfitted to vent air from the upper coilshould be installed on the primaryflow pipe to the coil.
3.4 The 2-Port Valve To prevent gravity circulation when theboiler switches off, the 2-port motorisedvalve supplied with the unvented hotwater kit, must be fitted in the primaryflow pipe to the cylinder and wired inaccordance with Figures 5-3 or 5-5 forboilers (depending on system design) tocomply with current legislation.
3.5 Auxiliary PrimaryConnectionsSolar Heating
1. The Solar flow and returnconnections should be made to thelower coil connections. The lowercoil must be thermostaticallycontrolled.
2. If you are connecting anotherprimary heat source please refer tothe installation manual of thatappliance. Do not connect anuncontrollable appliance to thiscylinder (e.g solid fuel stove, multifuel stove, etc.).
3.6 Hard Water Areas If the cylinder is to be used in a hardwater area, we recommend that theprimary flow temperature be limited to75˚C. This will help reduce the migrationof suspended solids in the water andhelp prevent the build up of lime scale.
No liability is accepted for cylinders inwhich no preventive action is taken toprevent limescale build-up.
3.1 Grant Twin Coil SolarCylindersGrant Twin Coil indirect solar cylindersare suitable for connection to most fullypumped domestic gas or oil firedcentral heating boilers working on anopen vented or sealed system having amaximum working pressure of 3 barand a maximum working temperature of90ºC. If you are in any doubt over theSuitability of a boiler for use with thecylinder, consult the boilermanufacturer.
IMPORTANTSolid fuel cookers or boilers andgravity circulation systems mustnot be used on the primary circuitof an unvented hot water system.
3.2 Systems (Twin Coil IndirectSolar Cylinders Only)If an existing system is a “flow share”arrangement such as an “S” or “Y” plantype system, (see Figures 5-4, 5-5 and5-6) they will provide satisfactoryresults, but during central heatingdemands, hot water production will notbe as responsive.
Note: No brass reducing setsshould be fitted into the coilconnection. A short section ofpipe should be fitted first andthen reduced.
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4 Secondary Circuit Installation4.1 Cold Water Inlet ManifoldThis manifold contains a pressurereducing valve (with integral strainer),double check valve, expansion valvewith a stainless steel seat. The pressurereducing valve is factory set. The setpressure is shown on top of the valve.Maximum inlet pressure to valve is 12bar.
4.2 Installation1. Cold water supply to be 22mm
nominal size.
2. Flush supply pipework beforeconnection to remove all flux anddebris prior to fitting the inletcontrols. Failure to do this mayresult in irreparable damage tothe controls and will invalidatethe warranty. Once the pipeworkis flushed connect the coldsupply to the Inlet manifold.
3. The manifold can be installed in anyposition as long as it is installed inthe correct flow direction. Refer tothe arrows on the side of the body.Make sure that the head of theexpansion relief valve is offset fromthe cylinder for ease of access.
4. The expansion relief valve should beeither horizontal or upright - if fittedinverted, debris may be depositedon the seat and cause fouling of theseat when the valve operates.Check direction of flow arrows.
5. The black plastic plug in the body isa pressure gauge connection toenable pressure monitoring to becarried out, should the systemdevelop a fault. It is recommendedthat this be accessible.
4.3 Expansion VesselA suitable expansion vessel with a pre-charge pressure of 2 bar is supplied forfitting to all cylinders.
The supplied expansion vessel mustbe connected into the cold watersupply between the expansion reliefvalve (in the inlet manifold) and thecylinder using the flexible hoseprovided. Flexible hose not suppliedwith 50 litre expansion vessel. Thisvessel to be connected using rigid pipe.The expansion vessel must bepositioned with the entry point at thebottom. No valve should be fittedbetween the expansion vessel andcylinder.
The air charge pressure in theexpansion vessel must be regularlychecked (e.g. at every service) andtopped up as necessary. The correct aircharge pressure is 2 bar.
Refer to Sections 7.1 and 7.5 for furtherdetails.
4.4 Temperature and PressureRelief ValveThe temperature and pressure reliefvalve (T&P Valve) is supplied factoryfitted to the cylinder. The T&P valvemust not be removed from the cylinderor tampered with in any way. The valveis pre-set to lift at 4 bar or 90°C andany attempt to adjust it will invalidatethe warranty.
4.5 Hot Water Supply1. Connect the hot water supply pipe
to the top outlet (1) of the cylinder.
4.6 Prevention of ScaldingBuilding Regulations ApprovedDocument G (Part G3) requires that thehot water temperature supplied to abath should be limited to a maximum of48°C by using an in-line blending valve(available from Grant Engineering (IRL)Ltd) with a maximum temperature stop.The length of the supply pipe betweenthe blending valve and the bath hotwater outlet should be kept to aminimum to prevent the colonisation ofwaterborne pathogens (e.g. legionella).Refer to Approved Document G forfurther details.
6. Expansion relief drain pipeworkmust be connected to a safe visibledischarge point via a tundish andthe pipework must have acontinuous fall. Connect theExpansion Relief valve outlet intothe discharge pipe from theTemperature and Pressure Reliefvalve using a 15mm copper pipeand tee piece (not supplied). Fit theTundish below this tee piece usinga short length of copper pipe. Referto Sections 4.7, 4.8 and 4.9 forfurther information on Tundish andDischarge pipe.
7. The pressure reducing valve hastwo outlets, the second one is for abalanced cold water supply, to ashower or a bidet (over rim typeonly, ascending spray typerequires type AA, AB or AD airgap). Major shower manufacturersadvise fitting a mini expansionvessel in the balanced coldsupply to accommodate thermalexpansion and prevent tighteningof shower controls. If thedwelling has a shower mixingvalve (manual or thermostatic) ora Bidet (over rim type) use thecold water supply from theBalanced Cold water connectionon the Inlet Manifold for theseoutlets. Do not use the balancedcold connection to supply bathtaps as this can reduce the flowof water available to the cylinder.If the balanced cold water outlet isnot required, blank off the port.
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4.8 Tundish The tundish must not be positionedabove or in close proximity of anyelectrical current carrying devices orwiring.
4.9 Discharge Pipe1. The discharge pipe from the
Tundish should terminate in a safeplace where there is no risk topersons in the vicinity of thedischarge, be of metal and:
a) Be at least one pipe size larger thanthe normal outlet size of the safetydevice unless its total equipmenthydraulic resistance exceeds that ofa straight pipe 9m long, i.e.discharge pipes between 9m and18m equivalent resistance lengthshould be at least larger than thenormal outlet size of the safetydevice, between 18m and 27m atleast three sizes larger and so on.Bends must be taken in to accountin calculating the flow resistance.See Sections 4.10, 4.11 and 4.12.
b) Have a vertical section of pipe atleast 300 mm long, below thetundish before any elbows or bendsin the pipe work.
c) Be installed with a continuous fall of1:40 (2.5°).
d) Have discharges visible at both thetundish and the final point ofdischarge but where this is notpossible or practically difficult thereshould be clear visibility at one orother of these locations.
2. Examples of acceptance dischargearrangements are:
a. ideally below a fixed grating andabove the water seal in a trappedgully.
b. downward discharges at a lowlevel; i.e. up to 100mm aboveexternal surfaces such as car parks,hard standings, grassed areas etc.are acceptable providing that wherechildren may play or otherwisecome in to contact with discharges,a wire cage or similar guard ispositioned to prevent contact,whilst maintaining visibility.
c. discharges at high level; e.g. in tometal hopper and metal down pipewith the end of the discharge pipeclearly visible (tundish visible or not)or onto a roof capable ofwithstanding high temperaturedischarges of water and 3m from
any plastics guttering systems thatwould collect such discharges(tundish visible).
3. Where a single pipe serves anumber of discharges, such as inblocks of flats, the number servedshould be limited to not more than6 systems so that any installationcan be traced reasonably easily.The single common discharge pipeshould be at least one pipe sizelarger than the largest individualdischarge pipe to be connected. If unvented hot water storagesystems are installed wheredischarges from safety devices maynot be apparent i.e. in dwellingsoccupied by blind, infirm or disabledpeople, consideration should begiven to the installation of anelectronically operated device towarm when discharge takes place.
Note:The discharge will consist ofscalding water and steam. Asphalt,roofing felt and non-metallicrainwater goods may be damagedby such discharges.
Balanced cold supply for showersor bidet only (see Section 4.2)
Secondaryreturn line
Circulationpump
Non returnvalve
Cold inlet
Balanced coldsupply outlet
Expansionvessel
Figure 4-1: Secondary Return Circuit
Note:If a secondary circulation circuit is installedthen a larger expansion vessel may berequired to handle the increase in volume.
4.7 Secondary ReturnAll Twin Coil solar are fitted with a secondary return connection. If a secondary return circuit is required it should be connected to theTwin Coil solar cylinder as shown below:
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4 Secondary Circuit Installation4.10 Discharge Pipe Arrangement
Figure 4-2: Typical discharge pipe arrangement
Safety device ( e.g.temperature relief valve)
Metaldischargepipe fromtemperature
Metal discharge pipe from tundishwith continuous fall. See table andworked example on next page
discharged belowfixed grating
Fixed grating
Trapped gully
Tundish
600mm max
300m
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4.12 Worked ExampleThe example below is for a 1/2”diametertemperature relief valve with adischarge pipe (D2) having 4 elbowsand a length of 7 m from the tundish tothe point of discharge.
FromMaximum resistance allowed for astraight length of Ø22mm copperdischarge pipe (D2) from a 1/2” diametertemperature relief valve is - 9.0m.
Subtract the resistance for quantity of 4Ø22mm elbows at 0.8m each = 3.2m.Therefore, the maximum permittedlength equates to 5.8m.
5.8m is less than the actual length of7m; therefore calculate the next largestsize.
Maximum resistance allowed for astraight length of Ø28mm-pipe (D2)from a 1/2” diameter temperature reliefvalve equates to - 18m.
Subtract the resistance for a quantity of4 Ø28mm elbows at 1.0 each = 4m.
Therefore the maximum permittedlength equates to 14m.
As the actual length is 7m, a Ø28mmdiameter copper pipe will besatisfactory.
4.11 Discharge Pipe Sizing
Max resistance allowed,Minimum size of expressed as a length Resistance created
Valve outlet size, Minimum size of discharge pipe D2 from of straight pipe, i.e. no by each elbow or diameter (inches) discharge pipe D1 (mm) tundish in (mm) elbows or bends bend in (m)
22 Up to 9 0.81/2 15 28 Up to 18 1.0
35 Up to 27 1.4
28 Up to 9 1.03/4 22 35 Up to 18 1.4
42 Up to 27 1.7
35 Up to 9 1.41 28 42 Up to 18 1.7
54 Up to 27 2.3
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All electrical wiring must be carriedout by a competent person and inaccordance with the current I.E.E.Wiring Regulations.
The control equipment supplied willensure that the cylinder functions safely.From an economic and conveniencepoint of view, it is intended that thesecontrols operate in conjunction withother control packages for example “S”,or “Y” plan type systems, whichincorporate a programmable time clock,etc.
5.1 Immersion Heater (Cotherm)If an alternative immersion heater isfitted refer to the separate instructionssupplied. All cylinders are supplied fittedwith one immersion heater.
Each 3kW 230V 50Hz-immersionheater should be wired in accordancewith the instructions given in Figure 5-1.
The cable must be routed through the strain relief bush. The controlthermostat is pre-set at approximately60°C. The immersion heater conformsto EEC Directive 76/889 for radiointerference and complies with EN60335-2-73.
Installation and wiring instructions forthe immersion heater are supplied witheach unit. Follow the wiring instructionsconnecting the live, neutral and earth asindicated.
The unit must be permanentlyconnected to the electrical supplythrough a double-pole isolator. A safetycut-out is also incorporated within thethermostat and is factory set to operateat 80°C ± 5°C.
IMPORTANTBefore resetting the safety cut-out oraltering the thermostat setting, isolateelectrical supply to the unit prior toremoval of the cover. Investigate andidentify the cause of the cut-outoperation and rectify the fault beforemanually resetting the cut-out bypressing in the reset button. Ensure thecover to the immersion element isreplaced correctly and the retaining nutis fitted. Finally switch the mainselectricity supply back on.
Figure 5-1: Cotherm immersion heaterwiring connections
= Earth (Green/Yellow)= Live (Brown)= Neutral (Blue)
Temperaturecontrol dial
Reset
This appliance must be earthed.
! WARNING
The manual re-set high limitthermostat must not under anycircumstances be bypassed. This is pre-set to 80°C and to preventnuisance tripping the controlthermostat should always be left inposition 4.
! WARNING
d) The temperature setting of thecontrol thermostat should alwaysbe left in position 4.
5.3 Dual Thermostat (IndirectTemperature Control) For the Indirect models one DualThermostat (a combined control andhigh limit thermostat) is supplied withthe unvented hot water safety kit. It isfitted into the upper sensor pocket inthe cylinder (see Figures 2-4 to 2-6 forposition) to control the operation of theboiler primary coil.
The control thermostat has anadjustment range between 25°C and65°C, however it is recommended thatit is set to 60°C. The overheatthermostat incorporated within the dualthermostat will operate at 90°C.
5.4 2-Port Valve (Indirect only)To comply with regulations governingthe installation of indirect unventedcylinders, a 2-port motorised valvemust be fitted in the primary flow toprevent gravity circulation when theboiler switches off. Your Grant Twin Coilunit has been supplied with a 2-portmotorised valve, which will act as apositive energy cut-out should thesafety cutout operate. Should thishappen the motorised valve will operateand close down the primary flow to thecylinder. The valve should be wired inaccordance with Figures 5-3, 5-5 or5-7 depending on system design, tocomply with current legislation.
This motorised valve will also controlthe temperature of the domestic storedwater via the cylinder thermostat, whichis located in the upper dual thermostat.The unit should be installed on a “S” or“Y” plan system as shown in Figures 5-2, 5-4 and 5-6.
5.2 Immersion Heater WiringInstructions a) Ensure the main’s voltage
corresponds to the voltage rating of the immersion heater as shownon the rating label on the terminalcover.
b) The immersion heater is factoryfitted to the cylinder. If theimmersion heater needs to bereplaced it must be fitted to thecylinder using the gasket providedon the unit. Use a shaped spanner,Stillsons or pipe grips should not beused. The use of sealing compoundis not recommended.
c) Wire the immersion heater inaccordance with the wiring diagram(Figure 5-1). It should be wiredthrough a double pole isolator switch or controller, with a minimumbreak capacity of 13 amp havingcontact separation of at least 3mm, using 1.5mm sq. flexible cable,85°C rubber insulated HOFRsheathed, to comply with BS 6141table 8 and must be fully earthed.
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5 Electrical Installation5.5 ‘Y’ Plan System Schematic and Wiring Diagram - Twin Coil Copper Indirect Solar Cylinder and Boiler
Figure 5-2: ‘Y’ Plan system schematic
Figure 5-3: ‘Y’ Plan wiring layout
Boiler
Radiator
Pump
Grant Twin Coil CopperIndirect water cylinder
3 port mid-positionvalve (not supplied)
2 port zone valve(supplied)
230V50Hz
RoomThermostat
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Mid positionzone valve
White
Blue
Grey
Blue
Orange
BrownGreen/Yellow
2 portzone valve(supplied)
Green/Yellow
Note:Orange and grey wires notrequired electrically isolate
High limit Con trol
Cylinder DualThermostat (Top Coil)
Junction box
Time controllerBoiler
Pump
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5.6 ‘S’ Plan System Schematic and Wiring Diagram - Twin Coil Copper Indirect Solar Cylinder and Boiler
Figure 5-4: ‘S’ Plan system schematic
Boiler
Radiator
Pump
2 port zone valve(supplied)
Grant Twin Coil CopperIndirect water cylinder
2 port diverter valve (not supplied)
Cylinder DualThermostat (Top Coil)
230V50Hz
RoomThermostat
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LN
HTGHW L
8 9 10
2
1 3
Zone valveDHW
Zone valveHTG
BlueBrown
Green/Yellow
Grey
Orange
Grey
Orange
BlueBrown
Green/Yellow
High limit Con trol
Junction box
Time controller Boi
ler
Pump
Ele
ctri
cal I
nsta
llati
on
14
5 Electrical Installation5.7 Solar Thermal Schematic and Wiring Diagram
Figure 5-6: Solar thermal schematic
ElectricalJunction Box
(notsupplied)
Grant GSD1Controller
Twin-coilCylinder
SolarCollector
PumpStation
Figure 5-7: Solar thermal system typical wiring layout
Collectorsensor
Cylinderbottom sensor
N
230V
GND
Sensor
Solar pump
N E L
N E L
Solenoidvalve
Dual thermostat(Solar coil)
230V 3A fused supply
LNE
12345678910
111213141516171819202122
Grant GSD1 Mk2 Controller
1
C C
12 2
C ontrolHigh Limit
Com
mis
sion
ing,
Dra
inin
g D
own
& S
afet
y
15
6 Commissioning, Draining Down & Safety6.1 Filling the CylinderIMPORTANTBefore filling the cylinder check that theimmersion heater has not loosened intransit. Tighten as necessary using ashaped spanner. Stillsons or pipe gripsshould not be used.
1. Open all hot water taps.
2. Turn on the stop cock.
3. When water flows from all taps close the taps.
4. Allow system to stabilise for five minutes.
5. Open each hot water tap in turn to expel air from the system pipe work.
6. Check for leaks.
7. Manually operate Temperature andPressure Relief Valve (16) - Figures2-4 to 2-6, to ensure free waterflow through discharge pipe. (Turnknob to left).
6.2 Draining DownSwitch the electrical power off(important to avoid damage to element).Isolate boiler from Twin Coil Copperunit.
Turn off the cold water supply valve(stop cock). Open hot water taps. Opendrain (20) - Figures 2-2. The unit willdrain.
6.3 Safety Cut-Out1. The safety cut-out operates if:
a. Wiring is incorrect.
b. The immersion heater thermostat orcylinder thermostat fails.
c. Thermostat is set too high.
2. Remember before resetting thesafety cut-out or altering thethermostat setting, isolate electricalsupply to the unit prior to removalof the electrical box lid.
3. Reduce thermostat setting andpress the reset button. Afteradjustments are completed, ensurethe lid to the electrical box isreplaced correctly and the retainingscrew is fitted.
4. If the problem persists, pleasecontact your installer in the firstinstance.
6.4 Cold Water Discharge fromTundishThere are two reasons why cold waterwill discharge from the tundish:
1. The pressure reducing valve hasmalfunctioned (This will cause alarge volume of water to flowthrough the tundish).
2. The Expansion relief valve is lettingby (This will cause a very lowvolume of water to flow through the tundish).
In both cases, identify the defectivecomponent and replace. All repairsmust be carried out by a competentperson.
6.5 Hot Water Discharge fromTundishThere are four reasons why hot waterwill discharge from the tundish:
1. Thermal cut-out has malfunctioned.
2. The control thermostat hasmalfunctioned.
3. The T & P valve is letting by.
4. The expansion vessel has failed orlost its charge.
In all cases, should a repair benecessary, the work must be carriedout by a competent person.
Isolate the cylinder from all electricalsupplies before commencingmaintenance work.
6.6 Expansion Vessel1. The expansion vessel is connected
into the cold water supply to thecylinder using the flexible hose.Flexible hose not supplied with 50litre vessel. This vessel is connectedusing rigid pipe. Refer to Section4.3.
Note:No valve should be fitted betweenthe expansion vessel and thesupply pipe.
2. Ensure that the air charge in thevessel matches the pressure settingshown on the pressure reducingvalve.
3. The expansion vessel must beinstalled even if an accumulator isfitted.
4. The charge of the vessel must bechecked at every annual service.
5. The expansion vessel must be fittedafter the pressure reducing valve.
6.7 Customer Handover1. Explain the operation of the system
to the User, referring to Section 10of these instructions.
2. In particular, make the User awareof what to do if water is seen toflow from either the T&P Valve orExpansion relief Valve. Refer User tothe Information given in Section 10.
Mai
nten
ance
16
7 Maintenance7.1 Servicing and Maintenance1. Servicing and maintenance must
only be carried out by a competentunvented hot water installer, or byGrant Engineering (IRL) Ltdauthorised personnel.
2. Before any work whatsoever iscarried out on the installation, itMUST first be isolated from themain’s electricity supply.
Both the primary and secondarysystems will contain very hot waterthat will scald; therefore care shouldbe taken when opening any joints,seals or valves.
3. Only use spare parts authorised byGrant Engineering (IRL) Ltd. Theuse of unauthorised spare parts willinvalidate the warranty.
4. Drain the cylinder – When drainingthe cylinder, always switch off theboiler and the immersion heaterfirst. Turn off the water supply at themains stopcock.
Connect a hose pipe to the draincock (see Figures 2-4 to 2-6) androute it to a convenient gully. Openthe drain cock and all hot taps thatare served by the cylinder. Thecylinder may take several minutes toempty completely.
5. In hard water areas it may benecessary from time to time toremove and de-scale the immersionheater element. Replace the gasketeach time it is removed.
6. Remove the cartridge from thepressure-reducing valve (PRV).Check the strainer and if necessaryremove any debris from in front ofit. Replace the cartridge. Refer tosection 7.3 on the right.
7. Check the charge pressure in theexpansion vessel and top up asnecessary. The charge pressureshould be 2 bar. Refer to section7.5 on the right.
! WARNING
8. Whilst the hose pipe is connected, thedrain cock open and with theimmersion heater removed, thecylinder may be flushed out to removeany debris, sand or lime scale particlesthat may have collected in the bottomby using a further hose pipeconnected to the cold water main.
9. Close the drain cock, disconnectthe hose, refit the immersion heaterand close all hot water taps beforereopening the stopcock. Allow thecylinder time to fill whilst checkingfor any leaks. Release any air fromthe system by opening each hotwater tap individually, starting withthe one furthest from the cylinder.
10. Manually lift the expansion relief andtemperature and pressure reliefvalve one at a time, every 12months (more frequently in hardwater areas) to prevent debris frombuilding up behind the valve seat.Whilst carrying out this operation,check that the discharge to wasteis unobstructed. Check that eachvalve seals correctly when released.As the valves are pre-calibrated,they require no further maintenance.
11. Finally switch on the mainselectricity supply to the immersionheater and the boiler. As the systemheats up, check again for any leaksand rectify as necessary.
7.2 Manifold AssemblyThe manifold assembly should not,under normal circumstance, require anymaintenance. During annual servicing itmay be necessary to inspect and/orclean the line strainer, the pressurereducing valve cartridge, expansionrelief valve cartridge. The frequency ofcleaning will depend on the local waterconditions.
7.3 Pressure Reducing Valve1. Isolate the cold water supply.
2. Unscrew the retaining nut of thevalve. The complete operatingmechanism, including the strainercan be removed.
3. Clean the filter mesh and thecartridge under running water.
4. Replace cartridge ensuring thatstrainer is correctly located andreassemble the unit.
7.4 Expansion Relief ValveCartridge1. Isolate the cold water supply.
2. Remove grub screw (Allen Key type) from body of valve andwithdraw valve ensuring not todamage O-ring.
3. Clean valve seat face and seating -do not scratch or damage eitherseat face or seating.
4. Refit in reverse order. Do notovertighten.
7.5 Expansion Vessel1. Isolate the cold water supply.
2. Open hot water taps.
3. Drain cylinder to below tee piecetake off for expansion vessel flexiblehose.
4. Replace expansion vessel after firstchecking the air charge (and hose ifrequired).
5. Close drain off cock and turn oncold water supply.
6. When water is flowing freely fromtaps close taps.
Faul
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17
8.1 Intermittent Water Discharge
Intermittent Water Discharge from T & P Valve
Expansion VesselCharge Reduced
Test for correct operation. If water is still discharging, contact a competent Engineer
Thermostat Failure
Test Vessel andRecharge or Replace
Immersion ThermostatFailure
Primary CylinderThermostat
Faulty T & P Valve
Repair or ReplaceImmersion Thermostat
Repair or ReplaceThermostat
Replace T & P Valve
No
Yes
Yes Yes Yes
No No
8 Fault Finding Guide
8.2 Constant Water Discharge
Constant Water Discharge from T & P Valve
Expansion VesselCharge Reduced
Test for correct operation. If water is still discharging, contact a competent Engineer
Test Vessel andRecharge or Replace
Faulty T & P Valve
Faulty PressureReducing Valve
Replace T & P Valve
Replace PressureReducing Valve
No
YesYes Yes
Yes Yes
No No
8 Fault Finding Guide
Faul
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8.3 No Flow from Hot Water Taps
No Flow from Hot Water Taps
Mains SupplyDisconnected?
Test for correct operation. If water is still not flowing, contact a competent Engineer
Open supply valve orwait for supply to be
reconnected
Mains SupplyDisconnected?
Mains SupplyDisconnected?
Clean Line StrainerRepair or Replace
Thermostat
No
Yes Yes Yes
Yes Yes
No No
8.4 Cold Water Flow from Hot Water Taps
Cold Water from Hot Water Taps
Is Programmer callingfor Hot Water?
Check and Set HotWater setting
Is Motorised Valveworking?
Is Boiler working?
Is Cylinder Stat Calling for Heat?
Check Motorised Valvemotor and Micro-switch
Yes
No No No
No Yes
Yes
Yes
Yes
Test for correct operation. If water is still cold, contact a competent Engineer
Has Thermal Cut-OutOperated?
Check and Reset Button
Check and ReplaceCylinder Thermostat
No
Yes
Faul
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uid
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19
8.5 Excessive Hot Water from Taps
Excessive Hot Water from Taps
Is Cylinder Thermostatset too high?
Reduce ThermostatSetting
Is System Wiringcorrect?
Correct Wiring as per instructions
Is Cylinder ThermostatOperating?
Replace CylinderThermostat
No
Yes Yes
Yes
No
No
Test for correct operation. If water is still excessively hot, contact a competent Engineer
Does Motorised Valveclose when Thermostat
is satisfied?
Repair or ReplaceMotorised Valve Motor
Repair or ReplaceMotorised Valve
Fault. Contact Engineer
Yes
No
Sp
are
Par
ts
20
9 Spare Parts9.1 Spare Parts
Figure 9-1: Pressure Reducing Valve(Cartridge and Strainer) - 2 bar
Figure 9-3: Inlet Manifold includingpressure reducing valve, expansionrelief valve - 4 bar 90˚
Figure 9-5: Flexible Hose
Figure 9-2: Tundish
Figure 9-6: Expansion Vessel
Part Name Part No.
Pressure Reducing Valve - 2 bar GCS32
Expansion Relief Valve - 3 bar GCS08
Flexible Hose - 3/4" BSPF x 3/4" BSPM GCS021/2" Temperature & Pressure Relief Valve 90˚C/4 bar GCS09
Tundish - 15mm/22mm Compression GCS10
Coil Control/Limit Thermostat GCS11
Immersion Heater Element - Cotherm type ELE14-IN-800-UNV GCS30
Drain Cock GCS14
Immersion Heater Thermostat - Cotherm type TSE GCS31
Motorised Valve GCS16
Expansion Vessel 19 litre nominal (200 & 250 models)* (18 litre actual vol) - 3/4" BSPM connection GCS24
Expansion Vessel 24 litre nominal (300 model)* (22 litre actual vol) - 3/4" BSPM connection GCS25
Expansion Vessel 35 litre nominal (400 model)* (35 litre actual vol) - 3/4" BSPM connection GCS28
Expansion Vessel 50 litre nominal (500 model)* (50 litre actual vol) - 1" BSPM connection GCS27
1" BSPF x 3/4" BSPM Adaptor - for 35 litre Expansion Vessel GCS33
Inlet Manifold c/w 3 bar Pressure Reducing Valve and 6 bar Expansion Relief Valve GCS07
*All pre-charged to 2 bar
Twin Coil Indirect Cylinder Spare Parts
Figure 9-4: Expansion Relief Valve(Complete) - 3 bar
Use
r In
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21
10 User Instructions10.1 User Instructions1. Your Grant Twin Coil Solar unvented
hot water cylinder has beendesigned to give many years oftrouble-free service and is madefrom high grade copper.
2. The flow temperature of the hotwater can be set to yourrequirements on the immersionheater up to 60°C and the indirectsystem dual thermostat up to 65°C.These temperatures should not beset any higher otherwise nuisancetripping of the high limit thermostatwill occur. If you are in any doubt,these adjustments should be bestleft to a qualified electrician.
3. When a hot tap is turned on theremay be a short surge of water, this isquite normal with unvented systemsand does not mean there is a fault.
4. When you first fill a basin the watermay sometimes appear milky. Thisis due to very tiny air bubbles in thewater, which will clear very quickly.
If water is seen to flow from either theTemperature & Pressure Relief (T&PValve) valve or the Expansion ReliefValve (EV) on the cylinder seek expertadvice immediately.
If the water is flowing from the T&PValve, immediately:
Shut off the electrical supply to theimmersion heater(s)
Shut down the boiler
Switch off ALL other heat sources tothe cylinder e.g. solar, etc.
DO NOT SHUT OFF THE WATERSUPPLY TO THE CYLINDER.
Contact your installer to check thesystem.
IMPORTANTDo NOT tamper with any of the Safetycontrols fitted to the cylinder. If yoususpect a fault always contact aCOMPETENT installer who isQUALIFIED to work on unventedwater cylinders.
! WARNING
War
rant
y
22
11 Warranty11.1 The Grant CylinderWarrantyDear CustomerYou are now the proud owner of aGrant Cylinder from Grant Engineering(IRL) Ltd, which has been designed togive you years of reliable, trouble freeoperation.
Grant Engineering (IRL) Ltd. guaranteesall electrical and mechanicalcomponents supplied with the cylinderfor a period of one year from the dateof purchase. In addition, the copperused in the manufacture of the cylinderis guaranteed for a period of five yearswith the manufacturing process of thecylinder guaranteed for one year fromthe date of purchase, provided that thecylinder is installed in full accordancewith the installation instructionsprovided and the system is servicedannually. (See Terms and Conditions).
Breakdown during theManufacturer’s WarrantyIf your Grant Cylinder should fail duringthe first year, you must contact GrantEngineering (IRL) Ltd, who will arrangefor the repair under the terms of theirWarranty, providing that the system hasbeen correctly installed andcommissioned, serviced (if older thantwelve months) and the fault is not dueto misuse, or the failure of any externalcomponents not supplied by Grant IRL(e.g. pipework, etc.).
In the first Instance:Contact your installer or commissioningengineer to ensure that the fault doesnot lie with the system or any othercomponents, or any incorrect setting ofthe system controls.
If a Fault is Found:Ask your installer to contact GrantEngineering (IRL) Ltd, ServiceDepartment on 057 9120089 who willarrange for a qualified service engineerto attend to the fault.
Chargeable Repairs:A charge will be made if the cause ofthe breakdown is due to any of thefollowing:
• Faults caused by the plumbing orheating system, external electricsand external components.
• The Grant Cylinder has not beencommissioned, or serviced inaccordance with the installationand servicing manual.
• The system has been installed forover one year.
Terms of Manufacturer’s Guarantee1. The Grant Cylinder guarantee starts
from the date of purchase.
2. All electrical and mechanicalcomponents supplied with theGrant Cylinder are guaranteed for aperiod of one year. The copperused in the manufacture of thecylinder is guaranteed for a periodof five years with the manufacturingprocess of the cylinder guaranteedfor one year.
3. The Grant Cylinder must be installedby a competent installer and inaccordance with the Codes ofPractice and Regulations in force atthe time of the installation.
4. The Grant Cylinder and itscomponents must not have beenmodified or tampered with.
5. The installation must be servicedevery twelve months as per theinstallation instructions. (Receiptsshould be kept as proof).
6. Breakdown/failure due to lime-scalewill not be covered by thisguarantee.
7. The Grant Cylinder must not besited in a location where it may besubjected to frost.
8. All claims under this guaranteemust be made to Grant Engineering(IRL) Ltd prior to any work beingundertaken. Proof of purchase anddate of installation must beprovided on request. Invoices forcall out/repair work by any thirdparty will not be accepted unlesspreviously authorised by GrantEngineering (IRL) Ltd.
9. This guarantee is transferableproviding the installation is servicedprior to the dwelling’s new ownerstaking up residence. GrantEngineering (IRL) Ltd must beinformed of the new owner’s details.
12. Grant Engineering (IRL) Ltd willendeavour to provide prompt servicein the unlikely event of a problemoccurring, but cannot be heldresponsible for any consequence ofdelay however caused.
13. This guarantee applies to GrantCylinders installed in Ireland.Provision of in-warranty coverelsewhere is subject to agreementwith Grant Engineering (IRL) Ltd.
14. The Grant copper cylinder must notbe pressurised over 2 bar.
15. The Grant copper cylinder shouldbe connected to a potable watersupply to SI number 275 of 2007(European Water Standard).
Co
mm
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23
12 Commissioning & Servicing Details
Customer Details
Company Date
Address
Installer Name
Tel No.
Registration Details
Registered Operative ID Card No.
(If applicable)
Commissioning Engineer (If different)
Company Date
Address
Installer Name
Tel No.
Registration Details
Registered Operative ID Card No.
(If applicable)
Customer Details
Manufacturer Grant IRL Model
Capacity Litres Serial No.
Type Unvented
Time Control Programmer � or Time Switch �
12.1 Installer & Commissioning Engineer Details
Is the primary a sealed or open vented system? Sealed � Open �
What is the boiler flow temperature? ˚C
What is incoming static cold water pressure at the inlet to the pressure reducing valve? Bar
Has strainer (if fitted) been cleaned of installation debris?Yes � No �
Has water scale reducer been fitted? Yes � No �
What type of scale reducer has been fitted?
Are combined temperature and pressure relief valve and expansion valve fitted and discharge tested? Yes � No �
Is primary energy source cut out fitted (normally 2 port valve)?Yes � No �
What is the pressure reducing valve setting? Bar(Maximum permissible setting 2.0 Bar)
Where is operating pressure reducing valve situated?
Has the expansion vessel been checked? Yes � No �
What is the hot water temperature at the nearest outlet?˚C
12.3 Commissioning Procedure InformationBoiler primary settings (indirect heating only) all boilers
12.2 Grant Copper Twin Coil Cylinders Appliance& Time Control Details
12.4 Grant Copper Twin Coil Cylinders Service Interval RecordIt is recommended that your hot water system is servicedregularly and that your service engineer completes theappropriate Service Interval Record below.
Service ProviderBefore completing the appropriate Service Interval Recordbelow, please ensure you have carried out the service asdescribed in the manufacturer’s instructions and in compliancewith all relevant codes of practice.
Service Date
Engineers Name
Company Name
Tel. No.
Comments
Signature
Service Date
Engineers Name
Company Name
Tel. No.
Comments
Signature
Service Date
Engineers Name
Company Name
Tel. No.
Comments
Signature
Service Date
Engineers Name
Company Name
Tel. No.
Comments
Signature
Does the hot water system comply with the appropriate building regulations? Yes � No �
Has the system been installed and commissioned in accordance with the manufacturer’s instructions? Yes � No �
Have you demonstrated the operation of the system controls to the customer? Yes � No �
Have you left all the manufacturer’s literature with the customer? Yes � No �
Competent person’s signature
Customer’s signature
(To confirm demonstrations of equipment and receipt of appliance instructions)
Please follow the installation and commissioning instructions inthe installation manual supplied with the equipment.
GRANT ENGINEERING (IRELAND) LTDCrinkle, Birr, Co. Offaly, Ireland
Tel: (057) 91 20089 Fax: (057) 91 21060 Email: [email protected] www.grantengineering.ieThis manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. © Grant Engineering (Ireland) Limited 2008. No part of this manual may be reproduced by any means without prior written consent.
