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PARTS LIST AND ILLUSTRATIONS

SECTION 9

HI-FLO MODELS

Model

L62/309

L54/399

Ref.

Part Numbers

Description

Qty

C501

C548

Draught Diverter

C274

Sacrificial Anode

C432

Flue Connector, 200mm, BS 835

C335

Flue Connector, 250mm, BS 835

C381

Drain Cock, BS 2879, 3/4"

C103

Socket Coupler, 3/4"

C496

C497

Data Badge

C543

Flue Baffle

C540

Flue Baffle

A8 C235

C235

Andrews

Label

A11

C487

C554

Top Cover

A12

C488

Insulation Pad

A13

C490

E392

Flue Box Top Cover

A14

C299

Cleanout Pad Seal

A15

C300

Cleanout Pad

A16

C301

Cleanout Pad Cove

A17

C247

Drain Tapping Connector, 3/4 BSP

A19

C534

Nipple, 1 1/2 " BSP

A20

E050

Hydrojet Cold Inlet Connection

(side) 1 1/2" BSP

C567

C568

Burner Assy. comprising items

B2 - B6 and B8 - B9

C503 -

Burner

Bar

- C503

Burner

Bar

C545

C550

Burner Manifold

C572

Injector 1.78mm

C572

Injector 1.78mm

C576

C572

Pilot Assy. c/w injector and electrode

C547

C576

Pilot Supply Pipe

C316

Pilot Injector

C552

Thermopile

B9 C575

C575

Multifunctional

Valve

B10

C539

Control Thermostat with remote

phial and ECO

B12

C560

Lead Assy.

Thermostat to Gas Valve

B13

C136

Pressure Test Nipple

B14

C514

Piezo Igniter

B16

C499

Gas Cock 3/4" BSP FxF

B17

C578

Inlet Nipple 3/4" NPT/3/4" BSP

B19

E418 E418

Pilot

Shield

Summary of Contents for L24/31

Page 1: ... 309 L54 399 Permanent Pilot Piezo Ignition E F Series STANDARD RANGE Models L24 31 L32 35 L40 36 L63 71 L84 74 Permanent Pilot Auto Ignition G Series 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 October 2004 Part No E133 ...

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Page 3: ......

Page 4: ... service 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 ma...

Page 5: ......

Page 6: ...ON 4 COMMISSIONING Standard Range Permanent Pilot Models 26 Hi Flo Range Permanent Pilot Models 28 Standard Range Auto Ignition 30 SECTION 5 OPERATION Standard Range Auto Ignition 33 Hi Flo Range 33 SECTION 6 SERVICING Introduction 34 Pre Service Operations 34 Burner Assembly Standard Range 34 Burner Assembly Hi Flo Range 35 Gas Control Valve Standard Range 35 Gas Control Valve Hi Flo Range 35 Flu...

Page 7: ...mestic 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 Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW Part 1 2000 Specification for installation of flues Part 2 1989 Specification for installation of ventilation...

Page 8: ...gineers 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 eva...

Page 9: ... Injector Orifice Diameter mm 1 5 1 6 1 6 2 25 2 25 in 0 059 0 063 0 063 0 089 0 089 Flue Size Secondary mm 100 100 100 125 125 in 4 4 4 5 5 Cold Water Feed Connection R in BSP Exl 1 1 1 1 11 4 Hot Water Flow Connection R in BSP Exl 1 1 1 1 11 4 Return Connection Rp in BSP Int 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Ext 3 4 3 4 3 4 3 4 3 4 Max Working Pressure bar 10 10 10 10 10 lbf in2 150 1...

Page 10: ... 1 60 1 70 1 85 1 78 1 78 in 0 063 0 067 0 073 0 070 0070 Flue Size Secondary mm 150 150 200 200 250 in 6 6 8 8 10 Cold Water Feed Connection R in BSP Exl 11 2 11 2 11 2 11 2 11 2 Hot Water Flow Connection R in BSP Exl 11 2 11 2 11 2 11 2 11 2 Return Connection Rp in BSP Int 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Ext 3 4 3 4 3 4 3 4 3 4 Max Working Pressure bar 10 3 10 3 10 3 10 3 10 3 lbf i...

Page 11: ...e fit the draught diverter to the top of the water heater using the location holes In some cases it may be necessary to drill the fixing holes in the top cover to fit the draught diverter to the water heater By using the draught diverter as a template position carefully over the flueway and mark the hole positions to be drilled 4mm Fit the adaptor socket 2 and caulk into the draught diverter as sh...

Page 12: ...cal Authority and Building Regulations NOTE If the heater is in an exposed position and out of use during a period of heavy frost it is recommended that the whole system is drained down to prevent damage due to the formation of ice inside the storage vessel THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST ONLY BE USED WITH PROPANE OR BUTANE GAS Contact Calor Gas who will provide the appropria...

Page 13: ...d be pressure tested for soundness and purged in accordance with BS 6891 or IM 2 and IM 5 as appropriate Fig 3 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 4 in bore One cylinder All Standard Range Models Two cylinders Hi Flo Models L32 143 L65 169 L81 251 Three cyli...

Page 14: ...INSTALLATION SECTION 3 9 Bulk Storage Vessel Installation Cylinder Installation Fig 3 ...

Page 15: ... switch or fused spur box serving only the heater may be used The point of connection to the mains electricity supply should be readily accessible and adjacent to the appliance Fig 4 Connect the electrical supply to the main control panel terminal block via the cable glands in the base of the control panel Mains input cable should be 0 75mm2 3 core and should be connected to the mains supply as de...

Page 16: ...ls including jointing materials and fittings shall be asbestos free robust durable corrosion resistant and non combustible and shall comply with BS 5854 and BS 715 or BS 4076 as appropriate as well as being of a type accepted by the Local Gas Authority When passing up through or adjacent to combustible materials measures shall be taken to prevent the temperature of the combustible material from ex...

Page 17: ...ete evacuation of the flue products from the installation Where one flue is to be used more regularly or for longer periods than the others in the group it should be connected at the point nearest to the main flue See BS 6644 Clause 20 for further information and recommendations on this as well as general flue requirements Fit a flue clip or flange joint close to the diverter so that it is secure ...

Page 18: ...up to 54kW Net For installations exceeding 60kW the following permanent ventilation is required Low Level inlet 540cm2 plus 5cm2 per kilowatt in excess of 54kW total Net input High Level outlet 270cm2 plus 2 5cm2 per kilowatt in excess of 54kW total Net input Where the heater is to be installed in a compartment permanent air vents are required in the compartment at high and low level These air ven...

Page 19: ...nated atmosphere Some of the vulnerable areas are a Hairdressing salons and adjoining rooms and basements b Establishments where dry cleaning solutions are used or stored c Degreasing plants using hydrocarbon solvents d Premises where refrigerant gases are used or stored Where extreme conditions of water hardness exist scale can form in any water heating equipment especially when the heater is wor...

Page 20: ...bulence The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet dip tube The tube is designed to increase turbulence and reduce sediment build up reduce thermal stacking and increase delivery All models now incorporate the new Mini Hydrojet system on cold inlet side connections This system ensures water is directed onto the tank base which minimises sediment ...

Page 21: ...let to these nipples with union adaptors for ease of servicing CAUTION DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS MAKE THE CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER A DRAIN COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE BOSS AS SHOWN ON THE DRAWING After installation of the water ...

Page 22: ...INSTALLATION SECTION 3 17 Fig 8 Fig 8a ...

Page 23: ...ws 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 D1 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 If higher flow rates are required f...

Page 24: ...INSTALLATION SECTION 3 WATER CONNECTIONS 19 Fig 10 Fig 11 ...

Page 25: ...elect the cold hot location required i e top inlet outlet or front inlet outlet and using a suitable jointing compound blank off the two ports not required All Models Front inlet outlet water connections Models 32 143 Optional rear inlet outlet water connections Assemble onto the 3 4 BSP thread the 3 4 BSP couplet socket 1 and drain cock using a suitable jointing compound Select the Cold Hot locat...

Page 26: ...INSTALLATION SECTION 3 WATER CONNECTIONS 21 Fig 12 Fig 13 L65 169 L81 251 Optional Rear Inlet Outlet Tappings L32 143 only L65 169 L81 251 ...

Page 27: ...INSTALLATION SECTION 3 WATER CONNECTIONS 22 Fig 14 Fig 15 ...

Page 28: ...can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit part number B172 available from Andrews Water Heaters See Parts List Page 49 The Wall Mounting Assembly is available as an optional extra Item C4 must be fitted into the temperature relief port in the water heater tank When assembling items C1 and C2 ensure that the flow arrows marked on the components a...

Page 29: ...t 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 G of the Building Regulations 1992 Typical water service layout for Hi Flo Range single heater unvented system is shown in Fig 17 Typical water service layouts for Hi Fl...

Page 30: ...INSTALLATION SECTION 3 WATER CONNECTIONS 25 Fig 18 Fig 19 ...

Page 31: ...utes for any unburnt gas to vent 2 Turn the gas control knob to pilot 3 Fully depress the RED button and light the pilot burner With the pilot burner alight hold the red button in for 20 seconds When the red button is released the pilot should remain lit If not wait for 3 minutes then repeat this operation 4 Close and refit covers 5 Set temperature indication dial to required temperature as follow...

Page 32: ...OTE If the pilot goes out for any reason turn off heater and wait for 3 minutes before relighting Checking Main Burner Pressure 1 Turn burner OFF as above 2 Release bleed screw A one turn and connect pressure gauge tube 3 Light burner as described above 4 By means of the external in line regulator set burner pressure for gas being used in accordance with the data plate 5 Remove pressure gauge tube...

Page 33: ...tions for soundness with leak detection fluid whilst burner is alight Turn off seal any leakages then re test WARNING if pilot goes out do not attempt to relight gas until at least 3 minutes have elapsed Shutting Off The Burner For long periods only 7 days or more turn control knob to PILOT partially depress knob then turn clockwise to OFF Turn off gas service cock For shorter periods leave heater...

Page 34: ...late and in Section 2 Technical Data 5 Turn the main gas control knob to OFF remove the pressure gauge tighten the bleed screw and test for gas leaks when the burner is re lit with a leak detection fluid Checking Correct Shape and Size of Pilot Flame No adjustment is provided for the pilot The restrictor C of the multifunctional control should be fully open turned fully anti clockwise When viewed ...

Page 35: ...st Shutting OFF burner To shut OFF the burner move switch to OFF then turn OFF the gas service cock The water heater should only be turned OFF for long periods eg holidays or in an emergency Otherwise the heater should be left to operate under normal thermostat control NB When using a time control ensure the heater is not turned OFF before the final water draw off occurs This will ensure the water...

Page 36: ...est temperature consistent with the user s needs Ensure that the user or purchaser is fully conversant with the lighting shutdown and general operating procedures including the emergency procedure See p 32 Advise that any air vents must be kept clear and items must not be placed or stored in the vicinity of the heater Advise of precautions necessary to prevent damage to the heater and systems in t...

Page 37: ...ished 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 in the vicinity of...

Page 38: ... thermostat should now be in a closed position allowing the current generated by the pilot energised thermopile to open the main burner valve 5 The gas valve has a slow burning feature Burners will light several seconds after setting the thermostat 6 Burners will continue to heat water until the preset temperature is reached As the thermostat opens the thermopile current is interrupted and the mai...

Page 39: ...ide inner door to right On L63 71 and L84 74 models the inner cover must be lifted out 2 Disconnect pilot tube thermocouple and main burner supply tube from bottom of control valve Withdraw burner assembly from heater 3 Remove screw securing pilot assembly to main burner supply tube 4 Remove gland nut securing pilot tube to pilot assembly Withdraw pilot tube and remove pilot restrictor Clean pilot...

Page 40: ... individual burners from the burner tray 7 Remove the burner and pilot injectors and clean with acetone CLEAN ORIFICES WITH WOOD SPLINTER DO NOT USE SHARP METALLIC OBJECTS 8 Re assemble in reverse order but note i The flueways and combustion chamber must be cleaned first ii Use an approved jointing compound when re fitting burner injectors 9 Light heater in accordance with lighting instructions Al...

Page 41: ...nd L81 251 where top inlet outlet connections are used both hot and cold connections must be disconnected before removing the top cover The storage vessel should be checked and cleaned annually Scale formation in the base of the vessel may occur particularly in hard water areas and is normally associated with high usage and high water temperatures It is characterised by a rumbling noise when the m...

Page 42: ...eplaced Where CorrexTM anodes are fitted no maintenance is necessary Check the condition and operation of the safety valve as described below During Servicing Examine the safety valve for deposits or let by Clean or replace as necessary When Re Commissioning Operate the safety valve ensuring no let by when the valve is reset and reseated NOTE For adjustable valves reduce the rating until the valve...

Page 43: ...f the injectors 8 Re commission the heater as detailed in Section 4 Commissioning Please note that when replacing the gas control valve on heater models L32 143 L65 169 a restrictor must be fitted at the bottom of the gas valve inlet thread NOTE These instructions apply to all models but Model L32 143 is not fitted with a limit sensor phial 1 Turn off the gas control and the service cock 2 Drain t...

Page 44: ...O NOT EXAMINE WITH A NAKED FLAME 11 Re light the heater and set thermostat to user s requirements NOTE Models L62 309 and L54 399 are fitted with an anchor bracket between the burner manifold and the heater body Remove two screws to release the anchor bracket 1 Turn off the gas control and the service cock Disconnect union joint on service cock 2 Remove two wing nuts and remove front draught shiel...

Page 45: ...e cock is open b Electrical ON OFF switch is not ON c Power to unit interrupted d Thermostat set too low e Check ECO for failure Reset f Check for 24V AC at intermittent pilot ignition control terminal No 1 Replace control if faulty g Faulty Solenoid Coil Replace if faulty NO IGNITION AT PILOT ...

Page 46: ...cause of overheating a Check gas is available b Check thermopile and ECO connections Replace if necessary c Check if inlet gas pressure is too high or too low Pressure to multifunctional control should be 37 mbar 14 86in WG Propane 28 mBar 11 26in WG Butane d Pilot jet blocked Clean or replace pilot jet e Faulty magnet coil Replace multifunctional control f ECO safety thermostat operating at too l...

Page 47: ...gas valve not closing Clean or replace WATER a Reset thermostat to higher temperature TEMPERATURE b Check gas pressures at burner and at gas inlet to heater TOO LOW c Thermostat faulty Check and replace if necessary 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 heat...

Page 48: ...ow If not reset to dimensions given below If the whistling persists continue to reduce the settings until the whistling stops Heater Model Air Shutter Dimension A in mm L32 143 8 L65 169 5 L81 251 10 L62 309 8 L54 399 8 LOUD WHISTLING NOISE A BURNER LOCKING PIN INJECTOR AIR SHUTTER PERMANENT PILOT MODELS HI FLO RANGES ...

Page 49: ...USTRATIONS SECTION 9 44 STANDARD Model L84 74 STANDARD Models L24 31 L32 35 L40 36 L63 71 A4 A12 C1 C5 C4 A8 A9 B7 B11 B5 B7 B12 B12 C3 B1 B9 B4 B6 B5 B3 B2 B8 B10 C6 A10 A2 A3 A12 A1 B4 C2 A13 A14 A15 C3 A5 L63 71 only ...

Page 50: ...eanout Pad 1 A15 N A N A N A C301 C301 Cleanout Pad Cover 1 B1 C815 C816 C817 C818 C819 Burner Assy comprising 1 items B2 B3 B5 B7 B12 B2 C405 C406 C406 C407 C407 Pilot Supply Pipe 1 B3 C828 C828 C828 C829 C829 Burner Supply Pipe 1 B4 C822 C822 C822 C822 C822 Multifunctional Control 1 B5 C132 C132 C132 C132 C132 Thermocouple 1 B6 C136 C136 C136 C136 C136 Pressure Test Nipple 1 B7 C820 C821 C821 C8...

Page 51: ...PARTS LIST AND ILLUSTRATIONS SECTION 9 46 Hi Flo Model L32 143 Hi Flo Models L65 169 L81 251 ...

Page 52: ...ut Pad Cover 1 A17 C247 C247 C247 Drain Tapping Connector 3 4 BSP 1 A19 C534 C534 C534 Nipple 1 1 2 BSP 4 A20 E050 E050 E050 Hydrojet Cold Inlet Connection 1 side 1 1 2 BSP B1 E032 C565 C566 Burner Assy comprising items 1 B2 B6 and B8 B9 B2 C503 C503 C503 Burner Bar 5 B3 C505 C505 C505 Burner Manifold 1 B4 E 018 Injector 1 6mm 5 B4 C570 Injector 1 7mm 5 B4 C571 Injector 1 85mm B5 C576 C576 C576 Pi...

Page 53: ...PARTS LIST AND ILLUSTRATIONS SECTION 9 48 Hi Flo Models L62 309 L54 399 ...

Page 54: ...d Cove 1 A17 C247 C247 Drain Tapping Connector 3 4 BSP 1 A19 C534 C534 Nipple 1 1 2 BSP 4 A20 E050 E050 Hydrojet Cold Inlet Connection 1 side 1 1 2 BSP B1 C567 C568 Burner Assy comprising items 1 B2 B6 and B8 B9 B2 C503 Burner Bar 7 B2 C503 Burner Bar 9 B3 C545 C550 Burner Manifold 1 B4 C572 Injector 1 78mm 7 C572 Injector 1 78mm 9 B5 C576 C572 Pilot Assy c w injector and electrode 1 B6 C547 C576 ...

Page 55: ...PARTS LIST AND ILLUSTRATIONS SECTION 9 50 Unvented Systems Kit Hi Flo Range Unvented Systems Kit Standard Range ...

Page 56: ...or Expansion Vessel D7 C788 Hose Assembly 1 D8 C787 Wall Bracket Assembly 1 Unvented Systems Kit Hi Flo Range Ref Part No Description Qty B172 Unvented Systems Kit Complete 1 C1 C784 Pressure Reducing Valve Strainer 1 C2 C785 Check Valve 1 C3 C782 Expansion Vessel 1 C4 C380 Temperature Pressure Relief Valve 1 C5 C384 Tundish from Temperature Pressure Valve 1 C6 C786 Expansion Valve 1 B173 Wall Mou...

Page 57: ...em Kit Complete 1 E113 Intermittent Pilot Ignition Control 1 E115 Transformer 1 E116 Limit Thermostat 1 E117 Control Thermostat 1 E120 Control Thermostat Knob 1 C521 On Off Switch 1 C641 Mains Indicator Light 1 E387 Gas Valve 1 E126 Solenoid Coil 2 E388 Pilot Assembly 1 E128 Ignition flame Probe 1 E135 HT Lead 24 1 PARTS LIST AND ILLUSTRATIONS ...

Page 58: ...NOTES 53 ...

Page 59: ...NOTES 54 ...

Page 60: ......

Page 61: ...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 10 04 ...

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