andrews Flexistor 1000 Installation Manual Download Page 1

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Andrews. Built to perform.

Important

Please read & understand all these instructions before commencing installation.

This cylinder range does not incorporate an internal heat exchanger.

Please leave this manual with the customer for future reference.

Installation Manual

Unvented Flexistor Water Heaters

Installation & Servicing Instructions

Andrews

Water Heaters

Flexistor.

400ltr, 500ltr, 800ltr, 1000ltr, 1250ltr, 1450ltr, 2000ltr, 2500ltr

INSTALLATION AND SERVICE MANUAL

Summary of Contents for Flexistor 1000

Page 1: ...nge does not incorporate an internal heat exchanger Please leave this manual with the customer for future reference Installation Manual Unvented Flexistor Water Heaters Installation Servicing Instructions Andrews Water Heaters Flexistor 400ltr 500ltr 800ltr 1000ltr 1250ltr 1450ltr 2000ltr 2500ltr INSTALLATION AND SERVICE MANUAL ...

Page 2: ...Benchmarktm places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmarktm Checklist can be used...

Page 3: ... and Conditions of warranty THIS APPLIANCE CAN BE USED BY CHILDREN AGED FROM 8 YEARS AND ABOVE AND PERSONS WITH REDUCED PHYSICAL SENSORY OR MENTAL CAPABILITIES OR LACK OF EXPERIENCE AND KNOWLEDGE IF THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING USE OF THEAPPLIANCE INASAFE WAYAND UNDERSTAND THE HAZARDS INVOLVED CHILDREN SHALL NOT PLAY WITH THE APPLIANCE CLEANING AND USER MAINTENANCE SH...

Page 4: ...1 5 2000 2500 2 1 5 6 bar or 5 10 bar 1 25 x 1 5 8 bar or 13 bar 2 Table 1 Cold Water Inlet Control Kit depending on model Commercial Cylinder Volume ltr Expansion Vessel Size ltr Mounting Kit Weights 400 500 60 Floor Mounted 12kg 800 100 Floor Mounted 17kg 1000 1250 150 Floor Mounted 24kg 1450 200 Floor Mouinted 38 5kg 2000 2500 300 Floor Mounted 41kg Table 2 Expansion Vessel Sizing Factory fitte...

Page 5: ...or manual handling of appliances parts 6 Correct PPE to be worn TheAndrews Flexistor unit must be vertically floor mounted It can be placed anywhere convenient provided the discharge pipe s from its safety valves can be correctly installed Areas that are subject to freezing must be avoided Ensure that the floor is level and of sufficient strength to support the full weight of the unit when filled ...

Page 6: ...8 bar Maximum design pressure high pressure system 1 3MPa 13 bar T P relief valve setting 1 0MPa 90 C 10 bar T P relief valve setting 1 5MPa 90 C 15 bar Immersion heater rating a c supply only single phase 6kW 9kW 50 60Hz Immersion heater rating a c supply only 3 phase 12kW 54kW 50 60Hz See Accessories on page 27 for full range Storage weights empty and full See Table 4 Page 8 Heat loss table See ...

Page 7: ...BSP 744 744 BSP 783 783 BSP 833 833 C BSP 1138 1416 BSP 1502 1897 BSP 1466 1721 BSP 1493 1886 D BSP 1001 1191 BSP 1263 1687 BSP 1326 1536 BSP 1376 1626 E 1 BSP 1138 1416 1 BSP 1502 1897 1 BSP 1466 1721 1 BSP 1493 1886 F N A 872 872 N A 1024 1024 N A 1224 1224 N A 1470 1470 G 2 BSP 754 754 2 BSP 880 880 2 BSP 1042 1042 2 BSP 1077 1077 H N A 1535 1804 N A 1906 2301 N A 1936 2253 N A 2014 2419 A B D ...

Page 8: ...onnections N o m i n a l Capacity Litres Unit Weight kg Empty Full 400 99 499 500 100 600 800 160 960 1000 180 1180 1250 297 1547 1450 304 1754 2000 415 2415 2500 421 2921 2 BSP Secondary Flow 2 BSP Cold Inlet BSP Sensor pockets 1 BSP T P Connection 2 BSP Hot Outlet 2 BSP Secondary Return ...

Page 9: ...4 1450 3 90 1423 2000 4 30 1569 2500 4 50 1642 N o m i n a l Capacity Litres Maximum kW ratings Lower boss Upper boss Total kW 400 30 9 39 500 45 12 57 800 45 18 63 1000 45 36 81 1250 54 30 84 1450 54 36 90 2000 54 36 90 2500 54 36 90 N o m i n a l Capacity Litres Heat Up Times N o m i n a l Capacity Litres Heat Up Times Maximum kW Heat up Time mins Maximum kW Heat up Time mins 400 39 32 1250 84 4...

Page 10: ...C max If the thermostat is set above 70 C there could be instances nuisance tripping of the thermal cut out Notes The 2 external contactors must be approved components certified for 10 000 cycles of operation for the contactor controlled by the thermostat and at least 30 for the contactor controlled by the none self resetting thermal cut out Note The Immersion s are not factory fitted Upper Lower ...

Page 11: ...e thermostat and at least 30 for the contactor controlled by the non self resetting thermal cut out Line terminal marked L1 Earth Neutral terminal marked N Line terminal marked L3 Typical head layout for a three phase heater 4 0 5 0 60 7 0 8 0 Line terminal marked L2 Earth Neutral terminal marked N Live marked L Typical head layout for a single phase heater 4 0 5 0 60 7 0 8 0 Cut Out Temperature 8...

Page 12: ...ern Ireland The Water Fittings Regulations England and Wales or Water Byelaws Scotland Water supply Bear in mind that the mains water supply to the property will be supplying both the hot and cold water requirements simultaneously It is recommended that the maximum water demand be assessed and the water supply checked to ensure this demand can be met A minimum flow rate of 100l min is required for...

Page 13: ...ducing valve can be fitted in any orientation to suit the installation as long as it is fitted in the correct flow direction Check the flow arrows on the side of the body The expansion relief valve should be installed with the discharge pipe work in either the horizontal position or facing downwards if the discharge pipe is facing upwards debris may be deposited on the seat of the valve when in op...

Page 14: ...LY L N E EXTERNAL HEAT SOURCE CONTROLS Figure 08 External heat source Thermal Cut out Pressure reducing valve 1 5 6 bar or 5 10 bar direction direction Mains water in Pressure relief valve 8 bar or 13 bar compression connections To cylinder Pressure relief discharge Pressure gauge connections one each side ...

Page 15: ...allations and other options are permissable Mains water supply Expansion vessel Balanced cold water connection Pressure reducing valve Pressure relief valve Discharge pipe Tundish Primary Flow and Return External heat exchanger Platet to Plate shown Not supplied Secondary Flow and Return External Heat Source Thermal cut out must be wired in series with primary heat source controls or primary circu...

Page 16: ... expansion volume to the secondary system by fitting an external expansion vessel to the circuit This should be done if the capacity of the secondary circuit exceeds 10 litres De stratification kits The correct size of de stratification kit must be used with your cylinder to ensure the volume can be circulated in 1 hour The pump instructions will need to be reviewed for information on the cor rect...

Page 17: ...n addition where discharges from safety devices may not be apparent e g in dwellings occupied by people with impaired vision or mo bility consideration should be given to the installation of a suitable safety device to warn when discharge takes place e g electronically operated Discharge pipe D2 3 56 The discharge pipe D2 from the tundish should a have a vertical section of pipe at least 300mm lon...

Page 18: ...ary appliances should be connected to the pipe Notes 1 Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043 1 2002 Plastics Symbols and abbreviated terms Basic polymers and their special characteristics 2 Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or i...

Page 19: ...e pipe D2 having 4 No elbows and length of 7m from the tundish to the point of discharge From Table 5 Maximum resistance allowed for a straight length of 35mm copper discharge pipe D2 from a G1 temperature relief valve is 9m Subtract the resistance for 4 No 35mm elbows at 1 4m each 5 6m Therefore the permitted length equates to 3 4m 3 4m is less than the actual length of 7m therefore calculate the...

Page 20: ...ISCHARGE PIPE D1 MINIMUM SIZE OF DISCHARGE PIPE D2 FROM TUNDISH MAXIMUM RESISTANCE ALLOWED EXPRESSED AS A LENGTH OF STRAIGHT PIPE I E NO ELBOWS OR BENDS RESISTANCE CREATED BY EACH ELBOW OR BEND G 1 2 15mm 22mm 28mm 35mm UP TO 9m UP TO 18m UP TO 27m 0 8m 1 0m 1 4m G 3 4 22mm 28mm 35mm 42mm UP TO 9m UP TO 18m UP TO 27m 1 0m 1 4m 1 7m G 1 28mm 35mm 42mm 54mm UP TO 9m UP TO 18m UP TO 27m 1 4m 1 7m 2 3...

Page 21: ... gasket face is clean and if necessary replace the gasket spare part number 95607396 Replace the Immersion heater and make sure the 8 nuts or bolts are correctly torqued 20Nm or 14 75 ft lb as per the Commercial Immersion heater fitting instructions 36006161 Wire up the immersion heater as per Fig 5 or Fig 6 page 11 or Andrews Flexistor immersion heater fitting instructions Refill the cylinder and...

Page 22: ...ndary cir cuit has wholesome water only the Flexistor range of cylinders do not have an internal heat ex changer Take care that the Primary Heat source can handle the working pressure of the cylinder Auxiliary power supply Immersion Heaters Switch on the electrical supply to the immersion heater s and allow the unit to heat up Check that the thermostat operates correctly A storage temperature of a...

Page 23: ... Valve or the main stop cock to the system 2 Open the lowest hot tap in the system to relieve the system pressure 3 Using a spanner unscrew the pressure reducing cartridge and remove the moulded housing The strainer will be removed with the cartridge 4 Wash any particulate matter from the strainer under clean running water 5 Replace the strainer and screw the Pressure Reducing Valve cartridge into...

Page 24: ...ed Clean the filter mesh and cartridge ensuring that the strainer is correctly located and reassemble the unit Expansion Valve Isolate cold water supply Unscrew expansion relief cartridge from body and clean the filter mesh and cartridge Clean valve seat face and seating do not scratch or damage either seal face or seating Refit in reverse order Do not over tighten Warnings IF WATER DISCHARGES FRO...

Page 25: ...overflow visual indicator tundish INTERMITTENTLY Incorrect pre charge pressure for expansion vessel CONTINUALLY Check pressure from pressure reducing valve Remove expansion relief cartridge from pressure relief valve and check seating If necessary fit new cartridge Water discharges from the T P relief valve intermittently Expansion relief valve faulty Check valve and replace if necessary Water dis...

Page 26: ...2 Set Pressure 1 5 To 6 Bar Max Ip 16 Bar 95605187 22 Prv 2 Set Pressure 5 To 10 Bar Max Ip 16 Bar 95605188 23 Single Check Valve 1 1 4 95605189 24 Single Check Valve 1 1 2 95605190 25 Single Check Valve 2 95605191 26 Expansion Relief Valve 1 X 1 1 4 Set Pressure 8 Bar 95605192 27 Expansion Relief Valve 1 X 1 1 4 Set Pressure 13 Bar 95605193 28 Expansion Relief Valve 1 1 4 X 1 1 2 Set Pressure 8 B...

Page 27: ...on loop kit 2000 2500 litre 95970158 Temperature gauge 95970141 Pressure gauge 95970142 Temperature gauge calibrated 95970017 Pressure gauge calibrated 95970016 Flexistor 400 500L 6 bar cold water control kit 7038498 Flexistor 800L 6 bar cold water control kit 7038499 Flexistor 1000L 6 bar cold water control kit 7038500 Flexistor 1250L 6 bar cold water control kit 7038501 Flexistor 1450L 6 bar col...

Page 28: ...28 1 Part No 95 611 025 2 Part No 95 607 396 4 9 43 47 Part No 95 607 _ _ _ 15 Part No 95 605 182 11 14 Part No 95 605 _ _ _ 17 22 Part No 95 605 _ _ _ 10 48 Part No 95 605 _ _ _ 16 Part No 95 607 452 ...

Page 29: ...29 26 29 Part No 95 605 _ _ _ 23 25 Part No 95 605 _ _ _ 30 31 Part No 95 605 _ _ _ 32 Part No 95 612 650 33 Part No 7031593 35 36 Part No 95 607 _ _ _ 34 Part No 95 980 025 37 Part No 95 605 177 ...

Page 30: ...30 38 Part No 95 607 690 46 Part No 95 980 009 2 1 34 1 46 ...

Page 31: ...31 48 38 30 38 31 32 ...

Page 32: ...32 ...

Page 33: ...33 ...

Page 34: ...de Only stainless steel dummy plugs are to be used The Andrews water heater has not been subjected to excessive pressure beyond the guidelines detailed in the installation instructions The Andrews water heater has not been subjected to frost nor has it been tampered with or been subject to misuse or neglect No factory fitted parts have been removed for unauthorised repair or replacement Regular ma...

Page 35: ... your other household waste Instead it is your responsibility to dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical equipment The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the...

Page 36: ...urchase for your warranty to be monitored All descriptions and illustrations provided in this document have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request INSTALLATION AND SERVICE M...

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