Energymaster Thermal Store Manual 3a2d2d

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INTEGRATED RENEWABLE & HEATING SOLUTIONS

Nu-Heat

UNDERFLOOR & RENEWABLES

ENERGYMASTER THERMAL STORE MANUAL underfloor heating ground source heat pumps air source heat pumps solar thermal rainwater harvesting EnergyMaster Manual v01 © Nu-Heat

INTRODUCTION It is a condition of the warranty that the Commissioning Certificate included in the Handover Pack is completed and returned to Nu-Heat once the system is fully commissioned.The annual maintenance record at the back of the EnergyMaster Guide must also be completed at each yearly inspection. This manual gives all the information needed to install your Nu-Heat EnergyMaster Thermal Store. Building control must be notified of the fitting of this unvented thermal store. Installation of an unvented thermal store must be carried out by a Competent Person or, failing that, the local building control authority must be notified of the proposed work before commencement and the completed installation must be inspected by a Competent Person. In order for the process to be achieved quickly and easily the principle of operation should be understood. The following pages have comprehensive diagrams showing the purpose of each component and its position in the installation. Parts supplied are listed - please note that pipework and some sundry fittings will be site supplied. Attention to the advice given in this manual will help to ensure a trouble-free and effective installation. The requirements of the relevant British Standards and IEE Wiring Regulations should always be met.

bs7671: 2008. requirements for electrical installations, iee wiring regulations, building regulations electrical safety (part p) Electrical installation must be carried out by a Competent Person or, failing that, the local building control Authority must be notified of the proposed work before commencement and the completed installation must be inspected by a Competent Person.

optional additional equipment Where connections are shown to equipment that is not supplied by Nu-Heat, this is for guidance only. In all such cases the supplier’s installation information should be checked before fixing and connecting the equipment. Attention to the advice given in this manual will help to ensure a trouble-free and effective installation. The requirements of the relevant British Standards, Water Regulations and other regulations should always be met. If there is any aspect of the installation that you do not understand, please Nu-Heat Technical , quoting your system reference number, for advice. In line with the company policy of product development, Nu-Heat reserves the right to supply different components to those shown. This manual is the copyright of Nu-Heat. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written permission of Nu-Heat.

page

contents

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Introduction

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Cylinder storage on site

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Positioning the cylinder

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Cylinder connections

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Performance

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Mains water supply

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Pipework

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Components

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Temperature/pressure relief valve discharge

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Immersion heater control

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Thermal cut-outs

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Connection position of secondary hot water loop

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EnergyMaster hot water supply

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Cleansing, filling, flushing and commissioning the cylinder

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Draining the cylinder

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Hard water precautions

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Troubleshooting, warranty and servicing requirements

EnergyMaster Manual

CYLINDER STORAGE ON SITE The cylinder should be stored under cover, in a dry place. It may be tilted for handling around site, but beware of laying the cylinder horizontally as this could inadvertently cause damage to the connection tappings.

POSITIONING THE CYLINDER

The cylinder location will have been discussed as part of the system design process, and the agreed position will be noted on the A3 System Illustration and Manifolds. Space must be provided for access to allow any future maintenance and replacement work Please note the cylinder weight in order to ensure that the floor on which it sits is structurally sufficient. EnergyMaster 210 litre

260 kg

EnergyMaster 210 litre solar

263 kg

EnergyMaster 300 litre

365 kg

EnergyMaster 300 litre solar

368 kg

EnergyMaster 400 litre solar

474 kg

CYLINDER CONNECTIONS Please see the A3 System Illustration and Manifolds supplied for the overall plumbing scheme. A Product Data Sheet is provided in the Handover Pack show all the fittings supplied and the purpose of each tapping.

The cylinder relief valve shall not be used for any other purpose Note: Push fit fittings must not be connected to the stainless steel tails as the grab ring will not grip the stainless steel.

PERFORMANCE The EnergyMaster cylinder is designed to provide the following maximum flow rates when raising mains cold water through 40⁰C at full duty: EnergyMaster 210 litre (incl. solar) 27 litres/minute EnergyMaster 300 litre (incl. solar) 40 litres/minute EnergyMaster 400 litre solar

40 litres/minute

MAINS WATER SUPPLY

The cylinder should take its mains water feed after the supply to the kitchen, but before all other cold water draw-offs, above the stop cock. If the mains pressure exceeds 3.5-bar it should be limited to this figure by a pressure reducing valve (not supplied) equal to the size of the connecting pipework, fitted after the incoming stopcock and the supply to the kitchen and before any draw-off points. A mains water input of up to the maximum performance figures stated above (or double for dual cylinders) is required at minimum static pressure of 2-bar. Where the supply is inadequate but the incoming mains pressure is over 2-bar it can be boosted with a purpose designed accumulator vessel. Please Nu-Heat for details. A non-return valve and expansion vessel is supplied to meet water regulations.

PIPEWORK

The minimum size of copper pipework to be used for mains water connections to and from the cylinder is: EnergyMaster 210 litre (incl. solar)

22mm

Dual EnergyMaster 210 litre (incl. solar)

22mm

EnergyMaster 300 or 400 litre (incl. solar)

28mm

Dual EnergyMaster 300 or 400 litre (incl. solar)

35mm

EnergyMaster Manual

COMPONENTS energymaster cylinder 1

Please refer to your A3 System Illustration and Manifolds for your specific plumbing schematic.

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Please note: installation of the EnergyMaster thermal store is notifiable work.

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The EnergyMaster cylinder stores water for both the floor heating and the production of domestic hot water. If the temperature of the water in the cylinder falls below the level set on the cylinder thermostat, the boiler is turned on and hot water is circulated into the body of the cylinder to replenish the store. A secondary over-temperature cut out protects against failure of the dual cylinder thermostat/primary over-temperature cut-out.

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If installed with a solar thermal system, the solar pump will be brought on to heat the cylinder when the hot water temperature in the cylinder drops. If there is any shortfall this will be made up by the boiler which is called on by the cylinder thermostat. In larger properties either a larger cylinder, or twin cylinders may be recommended to ensure an adequate supply of hot water.

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1. Automatic air vent 2. Secondary over-temperature cut out 3. Pressure relief valve (factory fitted) 4. Chrome pipework assembly (trim to length) 5. Hot water blending valve 6. Flow switch 7. Dual cylinder thermostat/primary over-temperature cut-out 8. 3kW immersion heater

expansion vessel The EnergyMaster cylinder is supplied with a 2 litre expansion vessel. This vessel absorbs the small amount of expansion in the domestic hot water pipework when the system is hot and must be checked and set to 4-bar when the system is cold, at commissioning stage.

non-return valve A non-return valve is supplied to comply with the water regulations and prevent backflow. It must be positioned in the flow to the EnergyMaster cylinder after the cold tee off to the kitchen, in line with water regulations. See A3 System Illustration and manifolds for details.

COMPONENTS cont. auto air vent – operation and maintenance For rapid venting when filling the cylinder remove both caps and depress the valve under the red cap with a screwdriver. Replace the red cap when the system is full.

Rapid vent screw Bleed screw

During normal operation the cylinder is vented by leaving the black bleed cap loose, this allows stray pockets of air to escape automatically and should be checked regularly. Important: to prevent cylinder collapse when draining down the system ensure the rapid venting valve is depressed or the air vent connections loosened.

pressure relief valve

Pressure relief valve

If, in the unlikely event of failure of all other safety devices, the cylinder reaches excessively high pressure then water will be discharged by this valve. The outlet from this valve should be safely taken to waste via copper pipe (see Temperature/pressure relief valve discharge section). The valve should be manually operated during the annual servicing by turning the knob in order to check that it is free to function.

shunt pump, valves and bends Mounted on the EnergyMaster cylinder and controlled by the flow switch, this pump circulates stored boiler water through the domestic hot water heat exchanger giving mains-pressure hot water on demand. Important: Arrow indicates direction of water flow.

flow switch

Shunt pump, valves and bends

The flow switch detects the flow of water into the EnergyMaster cylinder’s internal heat exchanger. The switch operates the shunt pump, ensuring that the heat exchanger can work at its maximum capacity. The flow switch must be fitted in the orientation shown, with the arrow pointing upwards.

isolating valve and strainer The in-line 22mm isolating ball valve with filter is fitted on the cold mains supply to the EnergyMaster cylinder. It prevents grit getting into the cylinder and enables the cold water supply to the cylinder to be shut off if necessary. It must be fitted with the trap below the pipework. Restrict the incoming mains cold water flow rate to between 22 and 27 litres/min. for 210 litre cylinders, 36 and 40 litres/min. for 300 and 400 litre cylinders. For dual cylinders the flow must be equal to each cylinder.

Flow switch

Isolating valve and strainer

EnergyMaster Manual

COMPONENTS cont. cylinder zone valves Two cylinder zone valves are supplied, and both must be fitted. One is controlled by the dual cylinder thermostat/over-temperature cut-out. The second is controlled by the secondary over-temperature cut-out at the top of the cylinder. It is a requirement of building regulation G3 that, with unvented thermal stores, there are two independent over-temperature cut-outs, and they must each operate an independent valve.

expansion vessel and filling loop assembly 1

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The expansion vessel forms part of the filling loop assembly. It accommodates boiler and cylinder water expansion when the system is hot. Use in addition to any internal system boiler expansion vessels to accommodate the additional expansion of the EnergyMaster cylinder water volume. It is important to note: before fitting the expansion vessel the air pressure must be reset. Refer to A3 System Illustration and Manifolds. 1. Connection to boiler primaries 2. Pressure gauge

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3. Pressure relief valve 4. Discharge to waste

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5. Non-return valve 6. Isolating valves (2) 7. 15mm cold mains in 8. 15mm Pressure reducing valve adjusted to 1-bar maximum fill pressure 9. Air valve connection (for charging and checking pre-charged air pressure) 10. Expansion vessel

PRESSURE RELIEF VALVE DISCHARGE The pipe work that takes any discharge from the pressure relief valve should be fitted in copper. The pipe outlet should be taken to a safe place, as any water/steam released is a scald hazard. Such a safe place would be below a fixed grate to a trapped gully. Note that the discharge will be either very hot water or steam that will cause damage to certain plastics or asphalt, etc. The pipe work should be sized so as not to restrict the discharge. The diameter of pipe connected to the pressure relief valve (D1) should be at least as large as the outlet of the valve, and the pipe run must be no more than 600mm length before the tundish. The pipe should drop continuously away from the valve. The tundish outflow should be made in at least the next largest size up from the inlet. If the length of pipe is greater than 9m then the next size up is required (i.e. if a 22mm outflow, then 28mm pipe work), and if longer than 18m then two sizes larger, and so-on. Any bends and elbows also present a pressure drop, and these must be ed for by asg an equivalent pipe length as given in the table below. 1/2” Valve

Safety device (e.g. temperature relief valve)

Pipe size (mm)

Max. pipe length based on straight length (m)

Equivalent resistance of bend or elbow (m)

22

9

0.8

28

18

1.0

35

27

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Metal discharge pipe (D1) from temperature relief valve to tundish

There must be a straight drop of 300mm below the tundish.

600mm max. Tundish

300mm min. Metal discharge pipe (D2) from tundish with continuous fall

Discharge below fixed grating or suitable alternative Fixed grating

Trapped gulley

EnergyMaster Manual

IMMERSION HEATER CONTROL An immersion heater is supplied with the cylinder to provide a back-up in case, say, of oil or LPG running out. Please see the A3 Underfloor Heating Control System drawings for wiring information. The immersion heater must be installed with a fuse as rated by the manufacturer, and comply with the relevant electrical standards. Note: The immersion heater supplied is fitted with a thermal cut-out. This is an essential safety requirement, and immersion heaters without thermal cut-outs must not be used.

THERMAL CUT-OUTS All cylinders are provided with a dual ‘stat with over-temperature cut-out, and a second over-temperature cut-out thermostat (high limit stat) to prevent the cylinder from exceeding 90˚C. These must operate two separate cylinder zone valves in order to comply with Part G of the building regulations.

CONNECTION POSITION OF SECONDARY HOT WATER LOOP

Auto air vent

Hot water to taps

Secondary Hot Water Loop return – supplied separately

NRV

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NRV

Mains cold water

Immersion heater

Drain-off

Underfloor heating Flow Return

EnergyMaster Manual

ENERGYMASTER HOT WATER SUPPLY domestic hot water temperature blending valve The domestic hot water blending valve should be fitted to the EnergyMaster cylinder. It is supplied pre-set to 43˚C however BS6700 recommends that water be distributed at no less than 45˚C. If a hot water loop is to be used then the HSC’s Legionnaires’ disease: The control of legionella bacteria in water systems – Approved Code of Practice and Guidance says that this temperature should be 50˚C or more. Domestic hot water temperature blending valve (210 litre)

If the temperature of circulation necessary to achieve this poses a significant risk of scalding then the temperature should, in addition, be blended down as close to the output as possible, especially at bath taps which must be limited to 48˚C according to Building Regulations Part G3. These additional blending valves are not supplied by Nu-Heat. In order to set a different temperature, do as follows: • Remove the screw securing the knob to the valve. • Remove both the knob and the locking ring. • Replace the knob temporarily.

35 MIN MAX

• Open a tap and adjust the set temperature of the valve as required (anti clockwise to increase and clockwise to decrease).

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• Remove the knob and refit the locking ring. • Locate the tab on the inner face of the knob.

maintenance of the domestic hot water blending valve Domestic hot water temperature blending valve (300 litre)

The valve should be checked and cleaned annually. If the cylinder’s domestic hot water pipe is hot and the blending valve outlet pipe is cold it is possible that there is a build up of scale within the valve. To strip down the valve and clean: • Drain the domestic hot water system. • Isolate the valve and remove the knob and locking ring. • Unscrew the large hexagonal cap and slide out the interior parts of the valve. (Note the orientation of the parts to aid reassembly). • After cleaning and reassembling, the valve should be reset and tested.

CLEANSING, FILLING, FLUSHING AND COMMISSIONING THE CYLINDER Once installation is complete the system must be cleansed to remove any solder or flux residues, or any other foreign matter. Cleansing of the DHW system will not require a significant volume of fluid. Any cleansing agent must not have a chlorine level exceeding 250mg/litre. This solution must be thoroughly flushed through, as high levels of chlorine are corrosive to the cylinder. Filling the domestic hot water side: • Before filling, check expansion vessel charge is at 3.5bar. • Open all outlets on the domestic hot water circuit. Open the main supply to the unit. • Flush the unit through until all air is expelled. • Close hot outlets and open all cold outlets connected after the pressure reducing valve for the incoming mains. Flush through until all air is expelled. • The domestic water side of the system is now full of water. Check for any leaks on pipework or ts. It is the installers responsibility to check all fittings, including those that are fitted to the unit. Filling the main cylinder volume: The boiler filling loop can be used to fill the cylinder. Whilst filling the cylinder it is important that the fast purge valve under the red cap of the Automatic Air Vent is depressed. Alternatively the air vent may be removed until the cylinder is nearly full, and then the fast purge should be used.

EnergyMaster Manual

CLEANSING, FILLING, FLUSHING AND COMMISSIONING THE CYLINDER commissioning the energymaster cylinder System settings 3.

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1. Set the boiler thermostat to a minimum of 75˚C so that it is higher than the cylinder thermostat. Ensure the boiler output rating is set to maximum. If resetting is necessary, please refer to manufacturer’s instructions. Note: When the system has been running for at least 60 minutes, the temperature difference between the flow and return pipework at the boiler should be approximately 11˚C. If it is much higher than this, check that the boiler pump is set to maximum, (if using a system boiler the pump will be inside the boiler and may not be adjustable). If it remains high, please call Nu-Heat Customer for advice. The cylinder must be thoroughly checked in accordance with the Commissioning Checklist and Warranty Application form in the Handover Pack. This must be fully completed during the commissioning process and returned to Nu-Heat for registration. No warranty can be issued without the return of the completed Commissioning Checklist to Nu-Heat.

2. Set the cylinder thermostat to 65˚C (maximum).

4. Set the boiler pump to maximum.

3. Set the cylinder shunt pump to constant curve speed 3 if using an UPS2 pump (see below). If using a Magna pump, set to 3m head (see below for details).

Pump model

Optimum setting

Grundfos UPS2

Press to cycle through the options until III is lit continuously (fixed speed mode, speed III)

Grundfos Magna

Press to cycle through the options until constant pressure mode is lit Then use and to set the pressure to ‘3’ (3m head)

DRAINING THE CYLINDER Draining the Domestic Hot Water side of the cylinder: • Ensure that the mains is isolated • Open a tap, or to release the pressure from the system use a tap that is higher in the property than the cylinder. • Leaving the tap open, and using a bucket to collect the water, carefully remove the blanking cap from the isolating valve and strainer on cold mains inlet and use this to drain the hot water side. to close the butterfly valve to prevent flow of fresh water from the mains. • Once the cylinder is empty to close the tap. • Refill as per filling instructions. Draining the main cylinder volume: • Be aware that boiler water flows directly into the cylinder. • If required, isolate manifolds and all other circuits to prevent draining down of whole system. Note: It is essential during draining that either the red cap fast purge on the auto air vent is depressed, or the auto air vent completely removed from the cylinder. Failure to do so may collapse the cylinder under the weight of water. • Connect a hose to the cylinder drain off valve. Open the valve and drain the cylinder to waste. • Refill via the boiler filling loop as per previous instructions. The inhibitor levels in the system will need to be checked after re-filling.

HARD WATER PRECAUTIONS

If the property is in a hard water area (where Ca CO3 exceeds 200ppm), a softener should be used to prolong the life of the cylinder heat exchanger. If the cylinder heat exchanger should scale up, a proprietary flushing solution should be used with a flushing pump between the cold mains in and the hot outlet. Make sure that the flushing agent is fully dispersed afterwards. Any cleansing agent must not have a chlorine level exceeding 250mg/litre. This solution must be thoroughly flushed through, as high levels of chlorine are corrosive to the cylinder.

TROUBLESHOOTING, WARRANTY AND SERVICING REQUIREMENTS

The EnergyMaster cylinder features a 25 year warranty. In order to validate the warranty, the EnergyMaster must be serviced annually. For full details of the EnergyMaster troubleshooting, servicing requirements and a maintenance log, please refer to the EnergyMaster Cylinder Guide.

EnergyMaster Manual

If there is any aspect of the installation that you do not understand, please Nu-Heat Technical for advice. All illustrations and diagrams in this manual are the property of Nu-Heat. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written permission of Nu-Heat.

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Nu-Heat

UNDERFLOOR & RENEWABLES

DESIGN | INNOVATION | EXPERTISE | SERVICE Heathpark House, Devonshire Road, Honiton, Devon EX14 1SD Tel: 01404 549770 Fax: 01404 549771 Web: www.nu-heat.co.uk Email: [email protected]

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