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18IP22B

LIST OF SERVICEABLE PARTS

When ordering parts it is important to specify the model and
serial number of the water heater. When ordering under war-
ranty it is also necessary to specify the date of installation and
commissioning.

Part

Manufacturer

Article code nr

1st Main gas valve

Model 132 - 210

L&S VGG10/SKP20

RKM002/RMK010

Model 244 - 280

L&S VGF10/SKP20

RKM003/RMK010

2nd Main gas valve

Model 132 - 210

L&S VGG10/SKP10

RKM002/RMK005

Model 244 - 282

L&S VGF10/SKP10

RKM003/RMK005

Modulating gas valve

Model 132 - 180

Rmx 2"

8132G1GS

Model 2034 - 2043

Rmx 2½”

8210G1GS

Modulating valve servomotor

Berger/Lahr STM30Q15.63

RMS005

Pilot gas valve

Johnson control SM474

RKS025

Ignition transformer

Danfoss EBI 1P

ETH005/ESB010

Flame safeguard relay

L&S LFL 1.148

RBA004

Temperature control unit

L&S RWF 40

RRW007

High limit thermostat

L&S RAK 754591

RTR035

Ignition electrode

Rmx

REE001 CS

Flame sensing electrode

Rmx

REE001

Burner bar

Standard

Rmx

RIB001

Pilot burner assembly

Rmx

8000BIBA

Water flow switch

IT Regelgeräte JSF-1E

RSS010

Temperature gauge

Stork IFC 48-045-KRF

ROT020

Pressure gauge

Stork IM 48-04-KRF

ROM030

“O”-ring for fin tube

Rmx

ARO050

Pump

Grundfos DNM 65 - 125/136 PN10

Summary of Contents for R18 Series

Page 1: ...18IP22B Technical documentation R18 Water Heaters Andrews Water Heaters Wednesbury One Black Country New Road Wednesbury West Midlands WS10 7NZ Telephone 0121 506 7400 Facsimile 0121 506 7401...

Page 2: ...otherwise without the prior permission in writing of Andrews Water Heaters We aim to achieve continuous improvement in our products Therefore specifications are subject to change without prior notice...

Page 3: ...6 DN80 PN16 DN80 PN16 DN80 PN16 Pressure relief valve connection 1 1 1 1 1 1 relief connection 1 1 1 2 2 2 standard setting bar 5 5 5 5 5 5 Electrical supply water heater 1N V 230 230 230 230 230 230...

Page 4: ...18IP22B IV Fig 1 Dimensions Dimensions The water heater is available as either Top and side clearances are 600 mm MINIMUM...

Page 5: ...18IP22B V Fig 2 Dimensions 500 litre tank R18 SUPA FLO PLUS with BT 500 litre tank...

Page 6: ...18IP22B VI...

Page 7: ...ransport 17 5 INSTALLATION 19 5 1 Boiler room 19 5 1 1 Siting 19 5 1 2 Boiler room ventilation 19 5 1 3 Air supply and ventilation 20 5 2 Unit connections 21 5 2 1 Gas supply 21 5 2 2 Electrical suppl...

Page 8: ...OPERATION AND FAULT INDICATION 42 7 1 Function 42 7 2 Regulation 42 7 3 Control panel 42 7 4 Fault indications 43 7 5 Start up 44 7 6 Shut down 44 7 7 Warnings 44 7 8 Fault finding table 45 8 MAINTEN...

Page 9: ...and water heater technology United Kingdom by Andrews Water Heaters Wednesbury One Black Country New Road Wednesbury West Midlands WS10 7NZ Telephone 0121 506 7400 Facsimile 0121 506 7401 For advice...

Page 10: ...manufactur ers and suppliers of products for use at work to ensure so far as it is reasonable practicable that such products are safe and without risk to health when properly used and to make availab...

Page 11: ...heater types are fitted with a 18 tube heat exchanger of the 2 pass type including stainless steel manifolds The use of extruded copper fin pipes in the heat exchanger leads to higher efficiency The...

Page 12: ...r 7 Connection tray 27 Pressure test points 11 Servomotor air damper gas input 28 Temperature control unit 13 Modulating gas valve 29 Safety system control box 15 Modulating air damper 30 Control pane...

Page 13: ...vo motor 3 Draught diverter 12 Front adjustment limit stop 4 Air in take 13 Linkage assembly 5 Heat exchanger 14 Adjustment screw 6 Connection tray 15 Lock screw for air damper 7 Combustion chamber 16...

Page 14: ...removed without the use of any special tools by means of a click system Combustion chamber The chassis consists of two side frames with steel supports Dura blanket type thermal insulation is sandwiche...

Page 15: ...the efficiency of the heat exchanger The stain less steel supply and return pipes together with the water mani folds form the heat exchanger and is pressure tested at 16 bar The R18 water heater is s...

Page 16: ...jector nozzle mounted on the gas manifold Combustion air damper A combustion air damper is situated underneath the burners Gas train The principal components of the gas train are a main governor and t...

Page 17: ...ws a Building Management system to influence the flow temperature using a 0 10 VDC control signal Boiler temperature controller RWF40 A Process value actual temperature B Set point temperature C Burne...

Page 18: ...is possible with a EW control system Weather dependent setpoint shift The RWF40 can be configured in such a way that if a Ni1000 outside sensor e g QAC22 is connected a weather depen dent setpoint shi...

Page 19: ...SPL SPH 1 Parameter level Parameter Display Value range Factory setting Limit value of limit comparator AL 1999 9999 digit 0 1 Switching differential for limit comparator HYSt 0 999 9 digit 1 1 Propo...

Page 20: ...w switch The water flow switch is installed in the flow manifold and continuously monitors the minimum water flow If the water flow falls below a preset level the burner is shut down and will go to lo...

Page 21: ...the burners The design and operating principle of the R18 water heater ensures that limescale precipitation is kept to an absolute minimum when operating under the following conditions Water hardness...

Page 22: ...s than 90 C We emphasize that you should always give priority to the above mentioned standards and regulations and that the installation regulations should be considered as an addition to these stan d...

Page 23: ...addition to the information in this documentation always follow the standard safety regulations to prevent accidents Cover panels should only be removed for maintenance and servicing tasks Replace all...

Page 24: ...sure that you follow all safety instructions properly Operation In case of gas leakage switch off the water heater and close the gas service cock Open doors and windows and notify the proper authoriti...

Page 25: ...s data number plate The water heater is mounted on a wooden pallet For transpor tation the water heater is covered in a heat shrink protective covering The panel work is also covered in a protective...

Page 26: ...ith a pallet cart or forklift truck the forks should be placed at the back of the water heater Using a crane Never swing the load over bystanders Always use special lifting harnesses which should be p...

Page 27: ...n front of the water heater to allow removal of the burner trolley It is important that the water heater is sited so that extraneous material cannot be stored next to it The product has to be installe...

Page 28: ...Where natural ventilation is required permanent openings at low and high level communicating directly with the outside air shall be provided The openings shall be sited so that they cannot be easily b...

Page 29: ...nical ventilation are as follows Inlet air combustion ventilation 1 1 m per second per 1000 3 kW total rated heat input Extract air ventilation 0 45 m per second per 1000 kW total 3 rated heat input F...

Page 30: ...ndards The water heater is wired according to the circuit diagram which is supplied with the water heater The water heater must be protected by a 6 amp fuse The water heater must have an electrical su...

Page 31: ...y a recognised installer fully according to the current national and local requirements norms and standards The cold water feed recirculation and hot water flow are found on the side of the water heat...

Page 32: ...nd side by special order i e standard or alternative handing To prevent temperature lag time at the tappoint and to keep the water temperature uniform a suitable sized recirculation pump must be fitte...

Page 33: ...ught diverter in the flue The flue socket at the top of the water heater is sized for the direct attachment of single wall metal flue pipe Optional adapters can be obtained for twin wall metal pipe an...

Page 34: ...uct exit velocity less than 8 m sec See for further instructions Supple ment The cold water feed pipes should be installed and protected in accordance with local regulations Generally this means that...

Page 35: ...36 C To achieve this a slow operating motorised valve controlled by a thermostat in the secondary return is required temperature of 43 C are temperature losses in the pipework a temperature of 60 C i...

Page 36: ...hing 10 people 150 300 35 5 10 per outlet 6 people 120 180 35 6 12 per outlet shower 60 80 40 10 15 Taps fitting capacity diame ter in mm 10 half open 40 5 15 half open 40 10 20 half open 40 25 fully...

Page 37: ...ther the water is acid or alkaline A solution is acid when pH is less than 7 A solution is alkaline when the pH is greater than 7 The pH is measured at 25 C A pH of 7 corresponds to a neutral water Th...

Page 38: ...r hardness in Maximum pH Maximum operating ppm temperature in C 0 80 8 4 90 80 250 7 6 85 250 350 7 2 80 350 500 7 0 60 Table 11 Maximum operating level When the operating temperature exceeds the limi...

Page 39: ...wash 0 5 4 restaurant 15 100 4 hairdresser 3 seat 1 beauty salon 4 assistant 1 offices 1 washroom 1 meals sitting Institutions sport club 5 shower 4 school 4 shower 3 factory 5 shower 2 4 hospital 2 o...

Page 40: ...a constant draw or small fluctu 5 8 2 Dual temperature With storage tank 500 l system Applicable to projects where exact temperatures have to be ations without large peak load Such as hotels without c...

Page 41: ...kept within small tolerances Industrial applications such as carwash removing of protective wax layer photo and film processing laboratories plating processing slaughterhouses etc This application fi...

Page 42: ...e heat exchanger is free of any such deposits after flushing the system Water heating system fill the system up to the standard set pressure bleed the system switch on all pumps and check for correct...

Page 43: ...een purged in accordance with IM 2 or BS 6891 as appropriate IV Check that all electrical supplies are isolated V Check electrical earth continuity between the water heater gas pipework and the mains...

Page 44: ...he gas inlet service cock as follows Refer to Gas trains fig 34 1 Ensure that gas service cock and pilot manual cock are closed 2 Unseal and connect a pressure gauge to test point 10 1 and unseal test...

Page 45: ...hut off valve is letting by and should be replaced 12 Seal test point 10 2 replace pressure gauge on unsealed test point 10 1 and open pilot manual cock 13 Open and close the gas service cock to press...

Page 46: ...ameter 1 85 mm minimum load 20 Type Burner Pilot Air damper pressure pressure opening mbar mbar mm closed 132 0 8 3 5 8 154 0 8 3 5 8 180 0 8 3 5 8 210 0 8 3 5 8 244 0 8 3 5 8 280 0 8 3 5 8 full load...

Page 47: ...g from the front electrical tray Open the gas service cock and pilot manual cock and with the control thermostat on a high setting turn on the electri cal supply and the on off switch on the front con...

Page 48: ...off valves for gas leaks with a suitable leak detection fluid Switch off the water heater remove pressure gauge and reseal test point e Connect a A meter 0 50 A in series with the flame detection cir...

Page 49: ...mentation to the person responsible for the plant and explain the method of safe operation Ensure that he she is fully conversant with the starting shut down general operation and emergency shut down...

Page 50: ...valve opens and gas ignites over complete burner tray The modulating control will commence from low fire condition modulates between 20 and 100 heat demand If the heat demand is smaller than 20 the b...

Page 51: ...2 and 5 on Reset by pushing button 3 If the flow temperature exceeds the high limit setting the boiler will mechanically lock out and red lamp 2 illuminates Reset by pushing button 3 and allow the uni...

Page 52: ...eater on using the power switch 1 E In case of failure observe type of failure take necessary steps to rectify refer to section 7 8 for details F Set temperature regulator as required the power switch...

Page 53: ...ing II servo motor is ting micro switch II set above 20 servo motor Heat demand Closed control switch Check and repair Servo motor does not main gas valve is inope react rative Turn open relay inopera...

Page 54: ...shut Rectify off valve or Connections Pilot injector blocked Clean Pilot governor set too low Adjust Pilot burner ignites but Check flame probe If damaged replace water heater then goes to lock out in...

Page 55: ...t least once every year and cleaned if necessary Frost protection When water heater is not in operation for a long period of time the heat exchanger should be protected against frost This can be achie...

Page 56: ...e handings the sight glass will be located on the right side of the burner assembly for inspection of water heater ignition combustion pilot flame Burner tray The burner manifold and the gas regulator...

Page 57: ...hermore the cause of the problem should be ascertained and rectified Heat exchanger internal cleaning Descale the heat exchanger with the correct chemicals Filter inspection use of a gas filter is rec...

Page 58: ...m the front electrical panel release the screws at all 4 sides of the burner trolley The burner trolley can now be withdrawn from underneath the water heater Remove the stainless steel sidebaffles dow...

Page 59: ...the condition of the ignition and sensing electrode at the right hand end of the burner assembly There should be no burning of the metal tip and the ceramic should not be cracked Replace the burners s...

Page 60: ...s control linkages are in good working order and that there is no play in the gas control spindle Replace the burner trolley and bolt into position Re connect the electrical connectors to the connecti...

Page 61: ...section Servicing Ensure that the burners are not damaged or warped Injectors Remove the burner trolley and burner bars as described before With the burner bars removed the injectors can be unscrewed...

Page 62: ...panel components Release the fixing screws from the cover of the electrical con nection tray Refer to fig 25 for the locations of the various controls Replace components by removing electrical connect...

Page 63: ...e 5 Using a suitable tool carefully saw through the damaged fin tube and remove from the fin tube mounting plates 4 The fin tube will be de finned approximately 80 mm on one side The end of the fin tu...

Page 64: ...retaining bars with the nuts screwed in finger tight Refit the rest of the header retaining bars also with the nuts screwed in finger tight Tighten the retainer bars in four stages and in the sequence...

Page 65: ...uts 8 7 Service For service and maintenance the service department of your supplier can be contacted Andrews Water Heaters Wednesbury One Black Country New Road Wednesbury West Midlands WS10 7NZ Telep...

Page 66: ...ating gas valve Model 132 180 Rmx 2 8132G1GS Model 2034 2043 Rmx 2 8210G1GS Modulating valve servomotor Berger Lahr STM30Q15 63 RMS005 Pilot gas valve Johnson control SM474 RKS025 Ignition transformer...

Page 67: ...may be helpful IM 2 Purging procedures of non domestic gas installations IM 5 Soundness testing procedures for industrial and com mercial gas installations IM 11 Flues for commercial and industrial g...

Page 68: ...18IP22B 60...

Page 69: ...18IP22B 61...

Page 70: ...18IP22B 62...

Page 71: ...18IP22B 63...

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