andrews ECOflo EC230/600 Installation Manual, Operation And Maintenance Manual Download | Manualshive

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INSTALLATION

• SECTION 3

31

WATER CONNECTIONS

UNVENTED SYSTEMS

Unvented Systems should be fitted by an Approved
Installer.

The water heater can be used on unvented hot water
storage systems with the addition of an Unvented
Systems Kit, part number B290, available from Andrews
Water Heaters.

See Parts List on page 44. The wall bracket assembly
(shown below) is available as an

optional extra (AWH

Part No – B173).

When used in an unvented system, the ECOflo will
supply hot water at a pressure of 3.5bar (51lbf/in²),
provided that this pressure is available at the mains feed.
During conditions of no-flow, system pressure may rise
to a maximum of 6 bar (87lbf/in²) whilst the burner is
operating. When testing the system, it is recommended
that a maximum test pressure of 8.6 bar (125lbf/in²) is
employed.

The expansion vessel C4 supplied is suitable for the
stored volume of the water heater.
FOR SYSTEMS WITH LARGER PIPE VOLUMES OR
ADDITIONAL STORAGE, EXPANSION VESSELS WITH
MORE CAPACITY ARE AVAILABLE – CONTACT THE
ANDREWS SALES OFFICE FOR FURTHER DETAILS.

The combined temperature and pressure relief valve C5,
must be installed into the horizontal 1” dia. male tapping.
A 1” dia. socket (not supplied) is required as the T&P
valve is also a male fitting. The discharge pipe from items
C3 and C5 must be connected into tundish C6.

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 C2(a). The water pressure at
this point will be similar to that available at the hot water
outlet of the water heater. If port (a) is not used, it should
be sealed with the blanking plug supplied.

Cold water inlet of
water heater

C3 Expansion valve

C6 Tundish

C1 Combined pressure
reducing valve/strainer

Balanced cold water
take-off (if required)

Cold water
inlet

(a)

C4

NB: Tees, elbows,stop valves and pipework not supplied

C8 Wall bracket assembly

C7 Hose assembly

The wall mounting
assembly C7 & C8

is available as an

optional extra

OPTIONAL PARTS

C5 Temperature/pressure
relief valve

C2 Check valve assembly

Fig. 11

ECOflo_E864_manual_SEPT2012 16/10/12 11:24 Page 31

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Summary of Contents for ECOflo EC230/600

Page 1: ...t be kept with the appliance January 2012 Part No E864 High Efficiency Condensing Storage Water Heaters for Natural Gas and Propane LPG EC230 600 EC230 700 EC230 960 EC380 740 EC380 980 EC380 1220 EC380 1400 EC380 1900 LEC230 600 LEC230 700 LEC230 960 LEC380 740 LEC380 980 LEC380 1220 LEC380 1400 LEC380 1900 ...

Page 2: ...ws Water Heaters 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 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 subject to revision...

Page 3: ...SSIONING Filling the Heater with Water 33 Users Safety Guide 33 Air Gas Mixture Adjustment 34 Natural Gas Models 34 Propane Gas Models 34 CO2 Percentage 35 SECTION 5 OPERATING INSTRUCTIONS General Instructions 36 Operating Sequence 36 Lighting Instructions 37 38 Temperature Stratification Stacking 38 SECTION 6 MAINTENANCE SERVICE Introduction 39 Pre Service Operations 39 Annually 39 Maintenance Sc...

Page 4: ...s BS 6644 Installation of gas fired water boilers of rated inputs between 60kW and 2mW BS 7206 1990 Specification for unvented hot water storage units and packages I M2 Purging procedures for non domestic gas installations I M5 Soundness testing procedures for industrial and commercial gas installations I M11 Flues for commercial and industrial gas fired boilers and air heaters I M16 Notes on inst...

Page 5: ...in the base of tanks and calorifiers Andrews Water Heaters have commissioned an independent evaluation of their products to investigate their resistance to build up of Legionella bacteria Experiments were conducted to determine whether following a substantial challenge by legionella pneumophilia After overnight and stagnation the system was rendered free from viable recoverable legionella It was f...

Page 6: ...3 mins 19 mins 16 mins 12 mins Concentric flue size b 100 150mm 100 150mm 100 150mm 100 150mm 100 150mm 100 150mm 100 150mm 100 150mm Maximum flue run concentric b 16 metres 16 metres 16 metres 16 metres 16 metres 16 metres 16 metres 16 metres Cold Inlet water connection 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP Hot outlet water connection 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP 1 BSP Drai...

Page 7: ...d water outlet Drain secondary return connection ON OFF Switch Thermostat knob 450mm service clearance 7 ECOFLO MODELS EC380 740 EC380 980 EC380 1220 EC380 1400 EC380 1900 1899 1857 1588 1524 330 Flue exhaust condense outlet Cleanout access Right side of plinth must not protrude past edge of heater outer casing 330 150 1972 T P Valve connection 3 4 BSP Gas connection Combustion air inlet 1 1 2 BSP...

Page 8: ... be installed in any location which contains a bed bath or shower There must be easy access to the plant room and water heater at all times The water 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 ...

Page 9: ...gnition System HSI then ignites the gas air fuel mixture to produce the flue products combustion The flame sensor signals the ignition module described below that a flame is present IGNITION MODULE The ignition module provides the timing for the combustion system A sequence of operation SOP is described in Section 5 Operating Instructions As the combustion system progresses through the SOP LED s i...

Page 10: ...Access for servicing the water heater from the top is easy Remove the two latches and the metal screw at the front centre of the top to remove the lid for accessing the heater controls The lid must be replaced and re latched upon completion of servicing TECHNICAL DETAIL Thermal Efficiency up to 98 0 Fully condensing design Three Pass Flue System The three pass flue system keeps the hot combustion ...

Page 11: ... of flue for every 90 C elbow 3 Add 0 7 metres of flue for every 45 C elbow 4 Add 1 5 metres for condensate trap 5 Total flue length cannot exceed Maximum Length in the above paragraph NOTICE Do not include the flue terminals in determining maximum flue installation length Three year limited warranty on storage tank Heavy gauge steel automatically formed rolled and welded to assure a continuous se...

Page 12: ... baffles to turbulate the flue gases to improve heat transfer 2nd Pass Flue Collector At the top of the tank the flue gases from the 4 flue tubes collect in a heavy gauge steel collector to redirect the flue gases down eight 2 diameter flue tubes 2 diameter flue tubes are glass lined on the inside as well as outside to prevent corrosion from flue gas condensate Stainless steel flue baffles inside ...

Page 13: ...e water heater from the crate base MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking Place on plinth base as detailed previously LOCATION KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS PETROL AND OTHER FLAMMABLE VAPOURS AND LIQUIDS This water heater MUST be installed indoors This water heater MUST be located in an area where the general public does not have access CHEMICAL...

Page 14: ...le Propane cylinders must be outside the building Cylinder regulator set to give 37 mbar 14 86 Wg propane Gas emergencey control at entry 1 heavy steel sleeved pipe through wall Steel liner sealed to pipe at inside end Gas cock Important These drawings show a schematic representation only and should not be used for installation purposes Contact your gas supplier for authorised installation drawing...

Page 15: ...ction on top of the water heater using a suitable jointing compound and connect to the gas supply The water heater is not intended for operation at higher than 35mbar 14 0 in wg supply gas pressure Higher gas supply pressures require supplemental reducing service regulator Exposure to higher gas supply pressure may cause damage to the gas controls which could result in fire or explosion If overpre...

Page 16: ...ns that may apply The ECOflo range is designed to operate from a 230V single phase supply The fuse rating is 5 amps The method of connection to the mains electrical supply should facilitate complete electrical isolation of the appliance preferably by use of a fused double pole switch or fused spur box serving only the heater The disconnection of the supply shall have a contact separation of 3mm on...

Page 17: ...ve R R Toggle switch light N O Igniter Blower relay coil Wiring diagram GN Y BK Y BL BK W W W GN Y W W BK GN Y BL Y BK Y BK BL BL Y BK BL BL Y GN Y W BK 1 3 2 230V T B G N N T B Correx powered anode control Igniter 230V Flame sensor Blower relay Blocked exhaust P S Collector limit T Stat High limit Gas valve Igniter relay Ground T B Transformer Combustion blower M 230V 24V 24V 24V L N 1 2 Powered ...

Page 18: ...und Consideration should be given to the location of the flue terminal The flue terminal should be located where the discharge of flue products does not cause a nuisance Consideration should also be given with regard to noise that may be emitted by this flue system In all cases the flue termination must meet the requirements of BS6644 A suitable terminal guard must be fitted if less than 2 metres ...

Page 19: ...tical Flue Terminal 100 150mm 87969 E866 Gas Cock BSP C498 Drain Valve BSP C381 Drain Valve Socket BSP C103 Installation Operation and Maintenance Manual E864 HORIZONTAL AND VERTICAL FLUE KITS INSTALLATION PROCEDURE Determine location of flue exit 1 The Horizontal or Vertical flue kit that has been delivered includes the components as listed below and on page 21 The concentric flue pipe system inc...

Page 20: ...as Cock BSP C498 Drain Valve BSP C381 Drain Valve Socket BSP C103 Installation Operation and Maintenance Manual E864 FLUE SYSTEMS Optional Components for 100 150mm dia concentric Flue Quantity Flue Length Part Description Part Number 1 1000mm 40in Flue pipe with clamp E202 1 1000mm 40in Cutable flue pipe with clamp E203 1 500mm 20in Flue pipe with clamp E204 1 90 Elbow E205 1 45 Elbow E206 1 Flat ...

Page 21: ...an be ordered with flue components see table on page 55 WARNING The flue system must be properly installed Ensure the inner flue is securely sealed at all the joints otherwise incomplete combustion may result Do not exceed maximum flue lengths including elbows 21 ECOflo 380 1900 HORIZONTAL FITTINGS PACK Part No B292 Part No Description Qty E910 Concentric measure point 1 E860 Exhaust outlet Tee 1 ...

Page 22: ...eel exhaust outlet connection on the appliance and ensure that the condense connection is at the base of the tee piece 2 Fit item E862 to the PVC air intake connection on appliance and ensure that the open end is at the top of the tee piece 3 Fit item E861 or E865 depending on the model to both previously fitted E860 and E862 Ensure that both connectors are located correctly Secure the 100mm dia v...

Page 23: ...l height to centre line of bend 500mm 10mm Total height to centre line of bend including EC230 heater 1948mm 10mm Note Total height to top of bend 573mm 10mm Total height to top of bend including EC230 heater 2021mm 10mm Total height to centre line of bend including EC380 heater 2472mm 10mm Total height to top of bend including EC380 heater 2525mm 10mm Heights are given from bottom of heater and E...

Page 24: ...ort roof 200 G Above ground roof or balcony level 300 H From vertical drain soil pipework 150 J From an internal or external corner 300 K From a surface or boundary facing the terminal 600 L Vertically from a terminal on the same wall 1500 M Horizontally from a terminal on the same wall up to 70kW 300 above 70kW 600 N From a terminal facing the terminal 1200 P From an opening in a carport e g door...

Page 25: ...ontal flue Terminal Through the Wall supplied a Cut an opening of at least 165mm 6 5in diameter through to the outside b Slide the flue terminal through the wall opening to the rib closest to the intake air openings of the terminal and even 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 anc...

Page 26: ... flashing to the roof g Install the gasketed clamp around the joint between the flue terminal and flue pipe INSTALLING FLUE PIPING SECTIONS FOR BOTH APPLICATIONS 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 with s...

Page 27: ... the flue adaptor to prevent condensate from accumulating and draining back into the base of the water heater h Carefully 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 Cut the inside flu...

Page 28: ...s Areas Position of Air Vents Air from Room for Internal Space Air Direct from Outside High Level 10cm per kW Net input 5cm per kW Net input Low Level 10cm per kW Net input 5cm per kW Net input In a Room or Internal Space No requirement for Ventilation No requirement for Ventilation Note Both air vents must communicate with the same room or internal space or must both be on the same wall to outsid...

Page 29: ... degrees Clark and above This problem can be minimised by reducing the water temperature in the heater and by fitting suitable water pre treatment equipment When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted Each Andrews ECOflo Water Heater includes two factory fitted Correx Powered Anodes as standard These anodes do not need...

Page 30: ...n be employed The heater must be fitted with an open vent pipe which is not valved and which rises continuously to the open vent It should be sized with reference to Technical Data BS 6644 Clauses 9 and 10 and CP 342 Local Regulations and Bye Laws must be observed when installing the system Front Cold inlet Front Hot outlet water connections Assemble onto the 1 hot water outlet front the required ...

Page 31: ... AVAILABLE CONTACT THE ANDREWS SALES OFFICE FOR FURTHER DETAILS The combined temperature and pressure relief valve C5 must be installed into the horizontal 1 dia male tapping A 1 dia socket not supplied is required as the T P valve is also a male fitting The discharge pipe from items C3 and C5 must be connected into tundish C6 When assembling items C1 and C2 ensure that the flow arrows marked on t...

Page 32: ...o the tundish outlet should be one size larger than the outlet pipe of the safety device and should be terminated at a suitable drain See Building 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 storage hot water systems must comply...

Page 33: ...y read this section prior to lighting the appliance WARNING 1 Always follow manufacturer s 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 around 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 DO NOT make any at...

Page 34: ...ion analyser Making the mixture richer without an analyser to monitor the adjustments can result in dangerous levels of carbon monoxide G20 NATURAL GAS MOSTLY METHANE FAMILY The venturi screw depth when measured with a set of callipers see fig 13 should be approximately 13 0 13 5mm The CO range should be set as detailed in Table 1 The CO content should be less than 50ppm If the CO content is above...

Page 35: ... 6 11 0 10 ppm 40 50 60 EC230 700 43 9 10 3 20 ppm 49 50 60 EC230 960 58 6 9 7 10 ppm 63 55 60 EC380 740 43 9 10 4 15 ppm 49 45 50 EC380 980 58 6 9 8 15 ppm 63 50 55 EC380 1220 73 2 10 6 15 ppm 75 50 60 EC380 1400 85 11 0 15 ppm 86 55 60 EC380 1900 118 7 11 0 15 ppm 117 55 60 Fig 14 Adjust gas mixture by turning venturi screw see procedure on previous page ...

Page 36: ...aken to avoid unnecessary contact especially by children with the water heater and flue system UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER Installation or service of this water heater requires ability equivalent to that of a licensed trades...

Page 37: ...upplier call the fire brigade C Turn off mains power to the water heater D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance Replace any part of the control system and any gas control which has been under water 1 STOP read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off al...

Page 38: ... temperature shutting off gas to the burner in an overheat condition When the water has cooled sufficiently the manual reset on the ECO needs to be depressed to allow the heater to be re lit If the burner shuts down 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...

Page 39: ...ghtly sealed The combustion air supply tee piece at the side of the heater must be tightly clamped to the elbow and concentric flue adaptor Replace any damaged parts The entire exhaust flue system and combustion air supply must be inspected at least annually for integrity of all joints and gaskets GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS PETROL AND OTHER FLAMMABLE VAPO...

Page 40: ...ium carbonate scale released from water is in direct proportion to water temperature and usage The higher the water temperature or water usage the more scale deposits are dropped out of the water This is the limescale which forms in pipes water heaters and on cooking utensils Scale accumulation not only reduces the life of the equipment but also reduces efficiency of the water heater and increases...

Page 41: ...ly associated with high usage and high water temperatures It is characterised by a rumbling noise when the main burner is lit Scale formation in the base of the vessel will affect the efficiency of the water heater and reduce the life of the storage vessel It should be noted that the failure of the storage vessel due to scale formation on the base will not be covered by the terms of the warranty A...

Page 42: ...aulty relief valve Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equalled The relief valve will then open allowing some water to escape slightly lowering the pressure COMBUSTION SYSTEM INSPECTION Inspect the operation of the combustion system monthly Use t...

Page 43: ...r leads If 230 volts is present replace the blower If no voltage is present check the blower relay thermostat high limit switch and collector unit switch If the limit switch trips call our technical support department IGNITOR DOES NOT GLOW Is there voltage to the Hot Surface Ignitor Check for 230VAC to the ignitor from the ignition module when the ignition LED is lit If not voltage to the ignitor ...

Page 44: ... E902 1 9 Nipple E874 1 10 Outer Door Service Panel E899 1 11 Exhaust Pressure Switch E909 1 12 Cleanout Access Cover C300 1 13 Cleanout Gasket C694 1 14 Screw 5 16 18 x 3 4 HH Grade 5 E483 6 15 Cold Water Inlet Hydrojet Assembly E876 1 ECO Switch High Temperature E878 1 16 EF Burner Assembly 600 700 960 740 980 Z079 1 17 EF Burner Assembly 1200 1400 1900 Z080 1 SECTION 8 PARTS LIST AND ILLUSTRATI...

Page 45: ...PARTS LIST AND ILLUSTRATIONS SECTION 8 45 16 17 ...

Page 46: ...LPG Gas Valve 600 E901 1 LPG Gas Valve 700 740 960 980 E902 1 LPG Gas Valve 1220 E903 1 LPG Gas Valve 1400 E904 1 LPG Gas Orifice 600 E905 1 LPG Gas Orifice 700 740 960 980 E906 1 LPG Gas Orifice 1220 E907 1 LPG Gas Orifice 1400 E908 1 14B Burner Gasket G168 1 IGNITION CONTROL ASSEMBLY Part Ref Description Part Number Qty 15 Electronics Control Module E887 1 16 Transformer 120 24 VAC E888 1 LPG GA...

Page 47: ...PARTS LIST AND ILLUSTRATIONS SECTION 8 47 6 A A A 14 B 14 Combustion surround assembly Combustion assembly Ignition control assembly ...

Page 48: ...amp E202 3 Horizontal Flue Terminal E236 4 Wall Clamp not shown E209 5 1000mm Cutable Flue with Clamp E203 6 500mm Flue with Clamp E204 7 Condensate Trap Tee E210 8 Flat Roof Plate E207 9 Angled Roof Plate E208 10 Horizontal Flue Outlet Terminal Guard E105 11 45 Elbow with Clamp E206 Note Extra lengths of flue and elbows can be supplied to suit each installation requirement ...

Page 49: ...PARTS LIST AND ILLUSTRATIONS SECTION 8 49 ...

Page 50: ...re Reducing Valve Strainer 1 C2 C785 Check Valve Assembly 1 C3 C786 Expansion Valve 1 C4 C782 Expansion Vessel 25 Litre 1 C5 C380 Temperature Pressure Relief Valve 1 1 C6 C384 Tundish from Expansion Valve and T P Valve 1 B173 Expansion Vessel Wall Mounting Kit Optional C7 C788 Hose Assembly 1 C8 C787 Wall Bracket Assembly 1 N A E923 Plinth 150mm ...

Page 51: ...PARTS LIST AND ILLUSTRATIONS SECTION 8 51 C6 C3 C2 C1 C4 C5 C8 C7 Unvented system kit components ...

Page 52: ...mmercial Division Wood Lane Erdington Birmingham B24 9QP Email andrews baxicommercialdivision com www andrewswaterheaters co uk Publication Date SEPT2012 Sales 0845 070 1056 Technical 0845 070 1057 R R hRjjmso ...

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