andrews CSC39 Installation Manual, Operation And Service Manual Download Page 1

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Wednesbury One,
Black Country New Road
Wednesbury,
West Midlands WS10 7NZ
Tel: +44 (0)121 506 7400
Fax: +44 (0)121 506 7401
Email: [email protected]
Website: www.andrewswaterheaters.co.uk

11/02

Summary of Contents for CSC39

Page 1: ...Wednesbury One Black Country New Road Wednesbury West Midlands WS10 7NZ Tel 44 0 121 506 7400 Fax 44 0 121 506 7401 Email andrews andrews waterheaters co uk Website www andrewswaterheaters co uk 11 02 ...

Page 2: ...STORAGE WATER HEATERS MODELS CSC 39 CSC 59 CSC 78 CSC 93 CSCL 39 CSCL 59 CSCL 78 CSCL 93 Auto Ignition INSTALLATION GUIDE OPERATION AND SERVICE MANUAL 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 Part No E191 ...

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Page 4: ... on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst completely up to date at the time of publication may be sub...

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Page 6: ... SECTION 4 COMMISSIONING Filling the Heater with Water 25 Draining Water from the Heater 25 Lighting the Burner 25 Shutting Off the Burner 26 Checking Main Burner Pressure 26 Checking Pilot and Burner Flames 26 User s Safety Guide 27 SECTION 5 OPERATION Operating Sequence 28 ECO Energy Cut Off 28 Temperature Stratification Stacking 28 SECTION 6 SERVICING Introduction 29 Pre Service Operations 29 A...

Page 7: ...Standards and Codes of Practice detailed below STANDARD RANGE BS 6700 1997 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages This standard supersedes the following British Standards and Codes of Practice CP99 CP310 CP324 202 CP342 Part 2 Centralised Hot Water Supply BS 5440 2000 Installation of flues and...

Page 8: ...s Engineers CIBSE TM13 All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria These factors include stagnation lukewarm conditions 20ºC to 45ºC and the accumulation of debris scale and corrosion in the base of tanks and calorifiers Andrews Water Heaters has commissioned an independent...

Page 9: ...essure mbar 11 25 11 25 11 25 11 25 Natural Gas ins wg 4 5 4 5 4 5 4 5 Burner Pressure mbar 25 25 25 25 Propane Butane ins wg 10 10 10 10 Injector Diameter mm 2 4 2 9 2 9 3 1 in 0 094 0 114 0 114 0 122 Injector Diameter LPG mm 1 65 1 95 1 90 2 1 In 0 064 0 076 0 074 0 082 Weight Empty kg 340 340 345 381 Lb 750 750 760 840 Weight Full kg 636 636 641 727 Lb 1402 1402 1412 1603 Shipping Weight kg 354...

Page 10: ... mm 95 95 In 4 4 ANDREWS MODEL NO CSC39 CSC59 CSC78 CSC93 DIMENSIONS AND CLEARANCES Not supplied with these models Horizontal or Vertical Flue 1168mm Minimum Service clearance with standard Anodes 500mm Recommended for panel access and switching Absolute min 300mm 500mm Recommended for panel access and switching Absolute min 300mm 615mm Minimum Service clearance with Correx Anodes Adaptor Cold Wat...

Page 11: ...ater heater must be located in an area where leakage from the tank water connections or the combination temperature and safety valve will not result in damage to the area adjacent to the water heater When such locations cannot be avoided a suitable drain tray must be installed under the water heater The drain tray must be no deeper than 38mm 1 5in and have a minimum length and width of 100mm 4in T...

Page 12: ... AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL 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 and m f elbow is factory fitted to the gas control valve to avoid possible damage Where the water heater s is are installed in a boiler house or purpose built compartment a manually operated valve for...

Page 13: ...ve an inlet pressure to the appliance as follows See fig 2 PROPANE 37mbar 14 86 in wg BUTANE 28mbar 11 26 in wg When using propane or butane cylinders connect a minimum number of cylinders as listed below together with a manifold before connecting to the union Use a minimum pipe size of 3 4in bore Two Cylinders CSC 39 and CSC 59 Three Cylinders CSC 78 Four Cylinders CSC 93 WARNING PROPANE AND BUTA...

Page 14: ...nstallation of Propane supply 1 Heavy Steel Sleeved Pipe Through Wall 1 Heavy Steel Sleeved Pipe Through Wall Gas emergency control at entry point to building Gas emergency control at entry point to building Steel Liner sealed to pipe at inside end Steel Liner sealed to pipe at inside end Cylinder regulator Set to give 37 mbar 14 86 Propane 3 4 Spring loaded gas cock 3 4 Spring loaded gas cock Pro...

Page 15: ...ed from an external supply This will eliminate the risk of possible interference from nearby high voltage cables Mains Voltage 220 240Volts IP 20 Frequency 50Hz Fuse 5 Amps ELECTRICAL SUPPLY 10 Fig 3 Wiring diagram for natural gas appliance TERMINAL BLOCK GREEN LED yellow yellow SUPPLY 230Vac 50Hz CONSUMPTION RUN STATE PRIMARY 110mAac 25VA max brown brown blue blue green yellow white black green y...

Page 16: ...INSTALLATION SECTION 3 11 Fig 4 Wiring Diagram for LPG Appliance ...

Page 17: ...air intake of a direct flue appliance or the circulating air inlet and flue gas discharge of listed outdoor appliances Shall be installed with at least a 300mm 12in flue termination clearance from any air opening into a building The bottom of the direct flue terminal shall be located at least 300mm 12in above ground The Andrews Direct Fan Flued Gas Water Heater is supplied with one direct flue kit...

Page 18: ...t as required for the installation 2 Determine if additional flue components are required for the installation Refer to the flue component table below for available optional flue components 3 Ensure that the flue terminal location complies with requirements described earlier and the Local Gas Authority 4 Measure the vertical and horizontal distance from the water heater flue connection to determin...

Page 19: ...nent Table for 200mm concentric 8in Diameter Flue Size 88 kWh 300 00 Btu h and 105 6kW 360 000 Btu h Input Models SUPPLIED KIT COMPONENTS Quantity Flue Length Part Description Part Number 1 90º Elbow E215 1 600mm 24in Horizontal Flue Terminal E240 1 Large Stepped Adopter Connection Clamp E237 Optional Components for 200mm concentric 8in Diameter Flue Size Quantity Flue Length Part Description Part...

Page 20: ...en with the outside wall c Slide the outside wall plate over the flue terminal and fasten to the wall with four screws Depending on the wall construction wall anchors may be required to reinforce the screws d Install inside wall plate on the inside wall and secure with four screws Depending on wall construction wall anchors may be required to reinforce the screws INSTALLATION SECTION 3 FLUE SYSTEM...

Page 21: ...eal the flue terminal and flashing to the roof g Install the gasketed clamp around the joint between the flue terminal and flue pipe INSTALLING FLUE PIPING SECTIONS a The coaxial flue pipe sections are designed to fit tightly together and seal with the integral flue pipe seal and supplied pipe clamps No silicone caulk or special tools are required b All flue sections and fittings come complete wit...

Page 22: ...ully measure the length of straight flue pipe needed allowing for about 50mm 2in insertion into the elbow Mark the ungasketed end of the pipe to be cut and carefully make a straight cut on the outside pipe to the desired length Make sure the inside tube is not cut Then cut the inside flue pipe about 50mm 2in less than the outside pipe so that the flue pipe protrudes slightly beyond the outside pip...

Page 23: ...ternal space or must both be on the same wall to outside air Air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour Consideration must be given to the position of the high level ventilation opening A high level vent must not be site...

Page 24: ...ical extraction must not be used Where a mechanical inlet and mechanical extraction system is used the design extraction rate must not exceed one third of the design inlet rate All mechanical ventilation systems must be fitted with automatic gas shut off safety systems which cut off the supply of gas to the heater s in the event of failure of either the inlet or extract fans The requirements for a...

Page 25: ...icate the malfunction These anodes are available as an optional extra on all Andrews heaters In hard water areas scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used the more problematic the scale build up can be Water treatment is normally recommended when the hardness reaches 100 150ppm 7 10 degrees Clark and above This prob...

Page 26: ...d 10 and CP 342 Local Regulations and Bye Laws must be observed when installing the system Front Cold inlet Top Hot outlet water connections Optional Front Hot outlet water connection Select the hot outlet location required and using a suitable jointing compound blank off the outlet not required We recommend that the top hot outlet water connection is used Assemble onto the 3 4 BSP thread the 3 4 ...

Page 27: ...ONNECTIONS VENTED SYSTEMS Fig 10 Typical Installation Vented System 22 Open Vent Overflow Hot Water Service Optional Hot Water Service Secondary Return Check Valve Cold Water Inlet Valve Cold Water Cistern Stop Valve Cold Water Feed ...

Page 28: ...g assembly is available as an optional extra Item C5 must be fitted into C6 and C7 as required and fitted on the hot water outlet nipple See fig 12 When assembling items C1 and C2 ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn from the 22mm compression port on item C1 a The water press...

Page 29: ...Regulations 1992 Approved Document G3 All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with Part G3 of the Building Regulations 1992 Typical water service layout for unvented system is shown in Fig 12 WATER CONNECTIONS 24 Fig 12 Cold...

Page 30: ...ctions Draining Water from the Heater If it becomes necessary to drain the heater follow the steps below 1 Depress control panel rocker switch to the OFF position see Operating 2 Rotate and partially depress gas control knob clockwise to OFF position 3 Shut off the gas supply to the heater 4 Close the cold water supply shut off valve 5 Open the drain valve on the water heater 6 Open a hot water ta...

Page 31: ...ibed above Checking Pilot and Burner Flame 1 Visually check that pilot and burner flames are burning properly 2 The main burner and pilot flame may be viewed through the viewing window on the front of the combustion air box 3 Adjustment to the air shutter setting is not normally required for the heater 4 Some LPG models may be factory pre set with the burner air shutters closed most of the way 5 T...

Page 32: ...burner has extinguished Wait at least 5 minutes to allow for any unburnt gas to disperse Ventilate the area if possible FOR YOUR SAFETY IF YOU SMELL GAS 1 Turn off gas supply and open windows 2 Do not operate electrical switches 3 Extinguish any naked flames 4 Contact gas supplier if the smell of gas persists FOR YOUR SAFETY Do not store or use petrol aerosol or other flammable vapours or liquids ...

Page 33: ...has cooled sufficiently the manual reset on the ECO needs to be depressed to allow the heater to be re lit If the pilot goes out and is associated with high water temperature the ECO is probably operational and the cause of overheating should be investigated Temperature Stratification Stacking When small amounts of hot water are drawn repeatedly the thermostat responds to each feed of cold water a...

Page 34: ...ff the cold water supply to the heater 3 Turn on the hot water draw off taps served by the water heater or for multiple installations turn off the hot water outlet connection valve and secondary return valve 4 Drain down using the drain valve on the heater Annual checks of the ignition systems temperature controls and any other controls are necessary to ensure continued safe and efficient operatio...

Page 35: ...connect the pilot tube fitting on the inside bulkhead fitting of the combustion box i Unthread the gas pipe assembly from the manifold inside the combustion box j Remove the screw securing the burner rack on the top right panel of the combustion box k Slide out the burner rack assembly To re install the burner rack reverse the above procedures The gas control valve should be checked and cleaned Re...

Page 36: ...n is drawn to the following guidelines CAUTION DUE TO THE CORROSIVE NATURE OF DESCALING FLUID IT IS ESSENTIAL THAT SUITABLE PROTECTIVE CLOTHING IS USED AND ADEQUATE VENTILATION AVAILABLE 1 Turn gas control to OFF and isolate gas supply 2 Close water inlet valve and drain heater tank 3 Remove magnesium anode s It is recommended that new anode s is are fitted 4 Add suitable hydrochloric acid based d...

Page 37: ... b Thermostat faulty Check and replace if necessary TOO HIGH c Main gas valve not closing Clean or replace NOT ENOUGH a Check gas pressures at burner and at gas inlet to heater HOT WATER b Check amount of water being used against recovery rate given on data plate If usage too high more heating capacity needed WATER DRIPPING a Check if this stops when water in heater is hot If yes then FROM BASE OF...

Page 38: ... is open IGNITION b Check gas control knob is ON NO PILOT FLAME c Check ECO for failure PILOT LIGHTS BUT a Main gas valve not energised Check for loose contacts MAIN BURNER b Check for 24V AC at intermittent pilot ignition DOES NOT Replace control if faulty c Check for 24V AC at main gas valve terminals Replace valve if faulty NO IGNITION AT a Electrical ON OFF switch is not ON PILOT b Thermostat ...

Page 39: ...PARTS LIST AND ILLUSTRATIONS SECTION 8 34 A5 A4 A3 A9 A1 A16 C4 C5 C3 A2 A7 A6 C6 A8 A13 A15 A10 A12 A11 A14 B2 C2 B3 B7 C1 B4 B1 B5 B6 ...

Page 40: ...ock BS2879 3 4 1 A15 C103 C103 C103 C103 Socket Coupler 3 4 1 A16 E346 E346 E346 E346 Fan Motor 1 B1 E225 E225 Burner bar 5 E225 E225 Burner bar 7 B2 E226 E226 E226 E226 Pilot Assembly 1 B3 E227 Injector 2 4mm Nat Gas 5 E228 Injector 2 9mm Nat Gas 5 E228 Injector 2 9mm Nat Gas 7 E229 Injector 3 1mm Nat Gas 7 E230 Injector 1 65mm LPG 5 E231 Injector 1 95mm LPG 5 E232 Injector 1 90mm LPG 7 E233 Inje...

Page 41: ...PARTS LIST AND ILLUSTRATIONS SECTION 9 36 200mm 8in Flue Kit 150mm 6in Flue Kit 13 1 14 10 12 11 8 2 7 5 3 9 12 1 13 9 11 10 7 2 6 5 3 8 6 ...

Page 42: ...ty 1 E215 90 Elbow with Clamp 2 E212 1 mtr Flue with Clamp 3 E240 Horizontal Flue Terminal 4 E219 Wall Clamp Not Shown 5 E237 Large Stepped Adaptor Connection Clamp 6 E213 1 mtr Cutable Flue with Clamp 7 E214 0 5 mtr Flue with Clamp 8 E241 Vertical Flue Terminal 9 E220 Condensate Trap Tee 10 E217 Flat Roof Plate 11 E218 Angled Roof Plate 12 E105 Horizontal Flue Outlet Terminal Guard 13 E216 45 Elb...

Page 43: ...educing Valve Strainer 1 C2 C785 Check Valve 1 C3 C786 Expansion Valve 1 C4 C782 Expansion Vessel 25 Litre 1 C5 C914 Temperature Pressure Relief Valve 1 1 C6 C856 11 2 Square Equal Tee 1 C7 C911 11 2 x 1 Reducing Bush 1 C8 C384 Tundish from Expansion Valve and T P Valve 1 B173 Wall Mounting Kit Optional C9 C788 Hose Assembly 1 C10 C787 Wall Bracket Assembly 1 CSC39 Parts List ...

Page 44: ...pansion Vessel 25 Litre 1 C5 E242 Temperature Pressure Relief Valve 11 2 1 C6 C856 11 2 Square Equal Tee 1 C7 N A C8 E236 Tundish from Expansion Valve and T P Valve 1 B173 Wall Mounting Kit Optional C9 C788 Hose Assembly 1 C10 C787 Wall Bracket Assembly 1 Unvented System kit C1 C9 C10 C2 C3 C8 C5 C4 C6 PARTS LIST AND ILLUSTRATIONS SECTION 9 39 CSC59 78 93 Parts List ...

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