Heatrae Sadia ELECTROMAX SOLAR Installation & Servicing Instructions Manual Download Page 51

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6.4 IMMERSION HEATERS

Connect a hose to the domestic hot water drain point and unscrew square headed stop

plug to drain the cylinder. If water fails to drain from the cylinder, vent the unit by manually

opening the temperature and pressure relief valve.

Ensure all electrical supplies are isolated.

Remove the immersion heater covers by unscrewing the securing screws.

Disconnect the wiring from the immersion heater thermostats. Remove the thermostats

by carefully pulling outwards from the immersion heaters.

Unscrew immersion heater backnuts using the key spanner supplied with the unit. Remove

the immersion heaters. Over time the immersion heater gaskets may become stuck to the

mating surface, to break the seal insert a round bladed screwdriver into one of the pockets

on the immersion heater and gently lever up and down.

Carefully remove any scale from the surface of the immersion heater elements. DO NOT

use a sharp implement as damage to the element surface could be caused. Ensure sealing

surfaces are clean and seals are undamaged. If in doubt fit new sealing gaskets.

Replace the immersion heaters ensuring the right angled element is inserted into the lower

immersion heater boss and hangs vertically downwards towards the base of the unit.

Secure the immersion heaters in place using the backnuts previously removed. It may be

helpful to support the immersion heater using a round bladed screwdriver inserted into

one of the thermostat pockets whilst the backnut is tightened.

Replace the thermostats by carefully plugging the two male spade terminations on the

underside of the thermostat head into the corresponding terminations on the element.

Rewire the immersion heaters in accordance with figure 19, page 32. Refit and secure

10.

the immersion heater covers.

Close the drain tap and turn on mains water supply.

11.

When water flows from the hot tap allow to flow for a short while to purge air and flush

12.

through any disturbed particles.

Close hot tap and then open successive hot taps to purge any air.

13.

FIGURE 35: IMMERSION HEATER REMOVAL

THERMOSTAT

IMMERSION

HEATER

COVER

BACKNUTS

LOWER

IMMERSION

HEATER

UPPER

IMMERSION

HEATER

GASKETS

COVER

SECURING

SCREW

Summary of Contents for ELECTROMAX SOLAR

Page 1: ...1 ELECTROMAX SOLAR INSTALLATION SERVICING INSTRUCTIONS ...

Page 2: ... INSTALLATION 11 4 0 COMMISSIONING 34 5 0 USER DEMONSTRATION 49 6 0 MAINTENANCE 50 7 0 FAULT FINDING 54 8 0 PART REPLACEMENT 57 9 0 SPARES 71 10 0 ACCESSORIES 75 11 0 GUARANTEE 76 12 0 ENVIRONMENTAL INFORMATION 76 13 0 COMMISSIONING SERVICING RECORDS 77 14 0 SPARES STOCKISTS 80 ...

Page 3: ...erience and knowledge unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety Children should be supervised to ensure they do not play with the Electromax Solar The Electromax Solar domestic hot water cylinder is of unvented type Its installation is subject to Building Regulation G3 England and Wales Technical Standard P3 ...

Page 4: ...by a series of solar collector panels supplied separately through which a special heat transfer fluid is pumped As the fluid passes through the collector panels its temperature is raised The heated fluid is circulated through a heat exchanger coil in the base of the hot water storage cylinder transferring the heat gained to the stored water gradually raising its temperature The cooled fluid then r...

Page 5: ...emperature control of the central heating system is provided by a room thermostat supplied loose Over temperature protection of the central heating system is provided by an electronic control housing in the main Electromax Solar control panel Only Electromax Solar Collector kits should be used with the Electromax Solar The Solar Collector kits include Solar Collectors Solar Collector Fixing Kit So...

Page 6: ...IC FEATURES REAR LIFTING POINTS CONTROL PANEL CONTROL PANEL COVER TUNDISH VIEWING WINDOW CABLE ENTRY POINTS RHS LHS SIDE LIFTING POINTS RHS LHS BASE LIFTING POINTS REMOVABLE PANELS FOR PIPE ENTRY RHS LHS TOP VIEW FRONT VIEW SIDE VIEW ...

Page 7: ...OLAR MANUAL AIR VENT CHECK VALVE TEMPERATURE AND PRESSURE RELIEF VALVE SOLAR DRAIN CENTRAL HEATING BYPASS VALVE CENTRAL HEATING DRAIN SOLAR RETURN DOMESTIC HOT WATER EXPANSION VESSEL SOLAR FLOW METER ELECTRIC BOILER BOOST IMMERSION HEATER LOWER IMMERSION HEATER HOT WATER OUTLET SOLAR THERMAL CUT OUT COLD WATER INLET FILLING LOOP TUNDISH CENTRAL HEATING ISOLATION VALVES SOLAR CHECK VALVE HOT WATER ...

Page 8: ...g a sack barrow to manually move the Electromax Solar trucking must be done from the rear to avoid damage to the outer panels The Electromax Solar should be lifted and handled by two persons Hand holds are provided in the rear panel in both side panels and in the base panel to aid lifting Stooping should be avoided and protective clothing worn when necessary Note Internal packing pieces which prot...

Page 9: ... 325 5kg 362kg Height 1580mm 1800mm 1990mm Width 550mm 550mm 550mm Depth 600mm 600mm 600mm 2 2 DHW CYLINDER Rated pressure 0 6 MPa 6 bar Operating pressure 0 35 MPa 3 5bar Supply pressure 0 15 MPa min 1 5bar 1 6 MPa max 16bar max at PRV Temp pressure relief valve 1 0 MPa 10bar 90ºC Pressure reducing valve 0 35 MPa 3 5bar Expansion relief valve 0 6 MPa 6bar Fitted in Cold Water Combination Valve Ex...

Page 10: ...f valve 0 3 MPa 3bar Expansion vessel capacity 12 litres Expansion vessel pre charge 0 1 MPa 1bar Automatic bypass valve 0 05 MPa 0 5bar Automatic air vent Fitted Circulating pump Grundfos UPS 15 50 Electric boiler 9kW Electric flow type Thermostatic Control Electronic Controller Radiator 65 ºC 80 ºC Underfloor 30 ºC 60 ºC Over temperature Control 85ºC manually resettable double pole cut out 2 5 C...

Page 11: ...d either side at the bottom of the front panel and pull the panel forwards FRONT INSULATION Remove front and lower front panel and pull front insualtion piece away from pipework manifolds CONTROL PANEL Remove top panels front panels and front insulation piece Unscrew the two screws located either side at the top of the control panel and allow the control panel to drop forwards CONTROL PANEL REAR C...

Page 12: ...ssure Relief Valve on the Electromax Solar and the Expansion Relief Valve on the Cold water Combination Valve SOLAR COLLECTORS connections are made at the back top left hand side of the Electromax Solar by 22mm compressions fittings SOLAR EXPANSION VESSEL the solar expansion vessel should be sited as close to the Electromax Solar as possible allowing sufficient access for servicing and maintenance...

Page 13: ...LHS DISCHARGE PIPE COLD WATER INLET HOT WATER OUTLET SOLAR FLOW SOLAR RETURN CENTRAL HEATING FLOW CENTRAL HEATING RETURN SOLAR DISCHARGE 50mm SIDE CLEARANCE MINIMUM 50mm SIDE CLEARANCE MINIMUM 300mm TOP CLEARANCE MINIMUM CABLE ENTRY SOLAR SENSOR DIVERTOR VALVE 50mm FRONT CLEARANCE MINIMUM TOP VIEW FRONT VIEW SIDE VIEW ...

Page 14: ... rates Wherever possible the mains water supply pipe should be in 22mm copper pipe or 25mm blue MDPE pipe The minimum mains water supply requirements should be 1 0 bar dynamic and 20 litres per minute flow rate At these values outlet flow rates may be poor if several outlets are used simultaneously the higher the available pressure and flow rate the better the system perform ance will be The Elect...

Page 15: ...er consult the manufacturer of the device for details 3 4 2 CONNECTION TO THE COLD WATER SUPPLY Connection to the cold water supply can be from underneath the Electromax Solar or through knock out panels at the front bottom right hand side Connection is made by 22mm compression fitting Solder connections directly to the unit must not be made as the heat may damage the Electromax Solar insulation m...

Page 16: ...ely after the cold water combination valve Branches to cold outlets where drinking water may be drawn should be taken directly from the main supply before the Cold Water Combination Valve to avoid the possibility of warm expanded water being drawn from cold taps 3 4 5 CONNECTION TO HOT WATER OUTLET Connection to the hot water outlet can be from underneath the Electromax Solar or through knock out ...

Page 17: ...water distribution pipework If in doubt consult the manufacturer of the fittings selected 3 4 8 SECONDARY CIRCULATION Secondary circulation is not recommended for the Electromax Solar as it is intended for off peak electrical operation Circulating the stored water would gradually cool the Electromax Solar to an unacceptable temperature during off peak periods FIGURE 08 SOLAR THERMOSTATIC MIXING VA...

Page 18: ...sation from the waste system entering the building via the tundish In these systems it is essential that the tundish is fitted in a visible position as the final point of discharge will not be visible Consult the manufacturer s recommendations with respect to the correct fitting orientation and waste and soil stack materials selection It will also be necessary to get dispensation from your local B...

Page 19: ...hildren may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility iii Discharges at high level e g into a metal hopper and metal down pipe with the end of the discharge pipe clearly visible tundish visible or not or onto a roof capable of withstanding high temperature discharges of water and 3m from any plast...

Page 20: ...sistance allowed expressed as a length of straight pipe i e number of elbows or bends Resistance created by each bend G1 2 15mm 22mm 28mm 35mm up to 9m up to 18m up to 27m 0 8m 1 0m 1 4m G3 4 22mm 28mm 35mm 42mm up to 9m up to 18m up to 27m 1 0m 1 4m 1 7m G1 28mm 35mm 42mm 54mm up to 9m up to 18m up to 27m 1 4m 1 7m 2 3m Fixed grating Discharge below fixed grating Building Regulation G3 section 3 ...

Page 21: ... return Installation of the solar expansion vessel Installation of the solar discharge pipework FIGURE 10 SOLAR PRIMARY CIRCUIT FLOW RETURN FLOW METER PUMP ISOLATION CHECK VALVE EXPANSION VESSEL SOLAR COLLECTOR SOLAR CONTROLLER PRESSURE RELIEF VALVE ISOLATION CHECK VALVE AIR SEPERATOR CYLINDER COIL DRAIN TAP SENSOR SENSOR RETURN FLOW GAUGE ...

Page 22: ...olar collector kits FIGURE 11 SOLAR PRIMARY CIRCUIT EAST WEST ARRAY FLOW RETURN FLOW METER PUMP ISOLATION CHECK VALVE EXPANSION VESSEL EAST SOLAR COLLECTOR SOLAR CONTROLLER CYLINDER COIL SENSOR SENSOR RETURN WEST SOLAR COLLECTOR SENSOR FLOW PRESSURE RELIEF VALVE ISOLATION CHECK VALVE AIR SEPERATOR DRAIN TAP GAUGE DIVERTOR VALVE ...

Page 23: ...p to 150 C and resistant to glycol NOTE Plastic pipe must not be used The distance from the Electromax Solar to the collectors should be kept to a minimum to reduce system losses The height difference between the highest point in the solar primary circuit the solar collec tor and the Electromax Solar should not exceed 15 metres this is referred to as the static height All solar primary pipework be...

Page 24: ...rn pipework A short length of flexible stainless steel tube 600mm is supplied to make this connection A self sealing connection is supplied in the solar connector kit which should be screwed onto the solar expansion vessel connection before connecting the flexible stainless steel tube The solar expansion Vessel should be sited as close to the Electromax Solar as practicably possible allowing acces...

Page 25: ...imary circuit The container should be located as close to the Electromax Solar as possible The container should be accessable A small amount of heat transfer fluid should be left in the container It is recommended that the pipework is routed vertically down from the pressure relief valve and through the left hand side panel handle The solar expansion relief should not be connected to the temperatu...

Page 26: ...llector return The Electromax Solar flow is connected to both the East and West collector flows Connection to the divertor valve is made be 22mm compression fittings 22mm copper tube or stainless steel flexible tube may be used Adaptors to connect 22mm compression fittings to stainless steel flexible tube are available accessory code 5122238 The solar expansion vessel should be connected to the El...

Page 27: ...ectromax Solar or through knock out panels at the front bottom left hand side Connection is made by 22mm compression fitting Solder connections directly to the unit must not be made as the heat may damage the Electromax Solar insulation material Damage caused by heat applied to solder fittings in close proximity to the unit will not be covered by the warranty FIGURE 15 CENTRAL HEATING PRIMARY CIRC...

Page 28: ...radiators and circulating pipework sizes The maximum output from the Electromax Solar boiler is 9kW ensure the radiator load does not exceed this The Electromax Solar boiler is dedicated to the space heating only the domestic hot water uses solar thermal energy and auxillary immersion heaters so there is no requirement to allow a hot water loading factor in designing the primary system The Electro...

Page 29: ...on to the room thermostat Connection to the solar collector sensor Connection to the solar divertor valve if fitted The electrical supply to the property must be checked to ensure it is of sufficient current rating and voltage The consumer unit must be fitted with a double pole 30mA RCD The electric boiler circuit must include a 45A MCB in the circuit The immersion heaters must include a 16A MCB i...

Page 30: ... the control panel and boost immersion heater cable is made to the main terminal block located behind the Electromax Solar control panel Use 3 core 1 5mm 2 flexible cable Route the cable via one of the 20mm cable glands Connect the Live brown conductor to terminal L2 Connect the Neutral blue conductor to terminal N2 Connect the Earth green yellow one of the conductors marked 3 8 2 240v 16A IMMERSI...

Page 31: ...e wires Connect one West conductor to 1 Connect one West conductor to 1 M Connect one East conductor to 1 Connect one East conductor to 3 M 3 8 5 DIVERTOR VALVE CONNECTION Connection of the divertor valve East West models only is made to the blue terminal block on the solar control PCB located behind the Electromax Solar control panel Route the cable via one of the 20mm cable glands in the back pa...

Page 32: ...lands along the wire guard through the aperture in the centre of the wire guard and then through the cable bush located in the left hand side of the electric boiler control PCB housing Connect the Live brown conductor to L Connect the Neutral blue conductor to N Connect the Earth green yellow conductor to Check all connections are tight and refit the boiler PCB control cover FIGURE 19 ELECTRIC BOI...

Page 33: ...WO RELAY ONE RELAY TWO TERMINAL BLOCK FUSE ROOM STAT NEUTRAL TERMINAL BLOCK EARTH TERMINAL BLOCK FUSE CENTRAL HEATING PUMP FUSE SOLAR CONTROLLER BOOST NEON IMMERSION HEATER BOOST IMMERSION HEATER OFF PEAK A B A B NC COM N O ROOM THERMOSTAT L N ELECTRIC BOILER MAIN PCB PE PE N PE PE A3 N N N A2 A1 L1 M M M M M M M 4 3 2 1 5 6 7 SOLAR CONTROLER PCB N N N N A B SOLAR CUTOUT SOLAR SENSOR ROOF SOLAR SE...

Page 34: ...lanced take off to purge 7 any air from the system Check all connections including immersion heater connections for leaks and rectify 8 as necessary The strainer housed within the cold water combination valve should be cleaned to remove 9 any debris that may have been flushed through the main supply pipe Refer to section 6 2 page 50 for instructions on how to do this NOTE Water that is left standi...

Page 35: ...er s instructions supplied with the flushing agent selected Add Inhibitor to the central heating primary system 7 To fill the primary circuit open the central heating filling loop isolating valves and allow 8 primary system to fill until the central heating pressure gauge on the Electromax Solar control panel reads 0 2 Mpa 2 0 bar Purge air from all radiators and air vent points in the central hea...

Page 36: ...1 0 1 5 bar Ensure both filling loop isolating valves are closed and re move the filling loop flexible hose from the central heating system connection point 4 4 SET THE PROGRAMMABLE ROOM THERMOSTAT Fit the batteries supplied with the programmable room thermostat The battery compart 1 ment is located behind the hinged cover under a snap fit panel Ensure the batteries are inserted with the correct p...

Page 37: ...lluminate and the lower immersion 4 heater operate NOTE If connected to an off peak tariff as recommend the lower immer sion heater will only operate during off peak times The set temperature of the immersion heaters can be adjusted by rotating the thermo 5 stat controls Access to the thermostat control is gained by removing the immersion heater covers Ensure the power is switched off before remov...

Page 38: ...m thermostat to be satisfied refer to the programmable room thermostat instructions The heat and demand indicators should switch off The pump may continue to run for a short period to dissipate the heat from the electric boiler 8 When the system is hot bleed all the radiators and air vents to remove any residual air from the system 4 6 COMMISSIONING AUTOMATIC BY PASS VALVE Switch off all radiators...

Page 39: ... and goggles Wash with soap and water if the fluid comes into contact with skin If fluid gets into eyes rinse immediately with large quantities of clear running water A full safety and specification sheet can be obtained by request The solar heat transfer fluid must be pumped into the system The pump can be electric or manual but must be capable of producing a pressure of at least 0 2 MPA 2 0 bar ...

Page 40: ... meter the handles should be turned so they are 5 horizontal Open both solar check valves the handles should be turned so they are vertical 6 Close the flow meter adjustment screw turn the slot so that it is horizontal 7 Pump the heat transfer fluid into the solar circuit until it starts to come out 8 of the drain hose Continue to pump heat transfer fluid through the solar system until all the pip...

Page 41: ... air bubbles The reading should be stable NOTE During this time the system may be checked for leaks 17 Stop the pump using the button procedure described above 18 The system pressure and flow rate can now be set 4 7 4 SETTING THE SYSTEM PRESSURE AND FLOW RATE It is likely that system pressure will have been lost during the air bleeding process 1 With the filling pump still connected to the flow me...

Page 42: ...LLATIONS Before filling and commissioning an East West collector array move the switch on the side of the divertor valve to MANUAL When the system has been and commissioned flick the switch back to AUTO MAN AUTO FIGURE 25 DIVERTOR VALVE SWITCH SWITCH ...

Page 43: ...protect the solar system The controller collects temperatures from the sensors located in the solar collector and the solar cylinder and determines the right time to charge the storage tank i e turn the pump on and off 4 8 1 CHANGING VALUES The Solar controller user interface comprises an LCD screen and four buttons through which information may be viewed and altered as described in the sections b...

Page 44: ...asic adjustment menu To select a sub menu Press RIGHT or LEFT to the required sub menu The sub menu icon will flash Press DOWN to access the sub menu Once accessed the sub menu icon will stop flashing Note If you are already in a sub menu press LEFT until you return to the main menu FIGURE 28 SOLAR CONTROL BUTTONS UP DOWN RIGHT LEFT INFORMATION MENU PROGRAMMING MENU MANUAL OPERATION MENU BASIC ADJ...

Page 45: ...GHT The OK icon will flash Press RIGHT for yes or LEFT for no FIGURE 30 INFORMATION MENU ICONS CURRENT COLLECTOR TEMPERATURE 01 C DESCRIPTION RESETTABLE NO YES YES NO YES YES NO YES INDICATION 23 C min 45 C max 67 C 89 C min 01 C max 89 C 0123 h MINIMUM COLLECTOR TEMPERATURE MAXIMUM COLLECTOR TEMPERATURE CURRENT STORAGE TANK TEMPERATURE LOWER MINIMUM STORAGE TANK TEMPERATURE LOWER FROST PROTECTION...

Page 46: ...r test service purposes NOTE During manual operation there is no auotmatic regulation of the system To manually operate the solar pump Select the manual operation sub menu as shown in section 4 8 4 Press UP or DOWN to switch the pump ON or OFF Press RIGHT to confirm the setting NOTE Automatic regulation will be re actived after 8 hours FIGURE 31 PROGRAMMING MENU ICONS DESCRIPTION FACTORY SET 65 C ...

Page 47: ...o scroll to the required parameter Press RIGHT to select the parameter The icon will flash Press UP to increase the parameter value Press DOWN to decrease the parameter value Press RIGHT and the OK icon will flash Press RIGHT to confirm the parameter setting FIGURE 33 BASIC ADJUSTMENT MENU SETTINGS DESCRIPTION FACTORY SET RANGE PARAMETER COLLECTOR PROTECTION ON OFF 0 OFF 1 ON 0 OFF 0 COLLECTOR PRO...

Page 48: ...ontroller and will be indicated with an error message on the controller display FIGURE 34 ERROR CODES POSSIBLE CAUSE INDICATION SENSOR WIRE BROKEN SENSOR DEFECT SHORT CIRCUIT IN SENSOR WIRE SENSOR DEFECT ERROR IN PUMP CONNECTION PUMP DEFECT AIR IN SYSTEM flashing flashing flashing ...

Page 49: ...plain how the programmable room thermostat is operated and how it has been set 2 5 4 SYSTEM MALFUNCTION Explain how to isolate electrical and water supplies in the case of a system fault 1 Explain that a qualified plumber and or electrician should be contacted if there is a sys 2 tem fault Explain how to identify check for basic system faults 3 Hot water temperature Central heating temperature Pre...

Page 50: ... Visually check all pipework for leaks 4 6 2 COLD WATER COMBINATION VALVE The strainer is incorporated within the pressure reducing valve housing of the cold water combination valve To inspect and clean the strainer Turn off the cold water supply and drain the Electromax Solar 1 Using a spanner unscrew the pressure reducing cartridge and remove the moulded housing 2 The strainer will be removed wi...

Page 51: ... Ensure sealing surfaces are clean and seals are undamaged If in doubt fit new sealing gaskets Replace the immersion heaters ensuring the right angled element is inserted into the lower 7 immersion heater boss and hangs vertically downwards towards the base of the unit Secure the immersion heaters in place using the backnuts previously removed It may be 8 helpful to support the immersion heater us...

Page 52: ...y circuit see section 8 2 page 57 until the central heating 1 pressure gauge reads 0 MPa 0bar Remove the dust cap from the central heating expansion vessel 2 Check the charge pressure of the expansion vessel using a tyre pressure gauge The 3 pressure with system de pressurised should be 0 1 MPa 1 0bar If lower than the required setting it should be re charged using a tyre pump Schraeder valve type...

Page 53: ...er valve type DO NOT over charge Re check the charge pressure and when correct replace the dust cap Top up the heat transfer fluid and re set the solar system pressure see section 4 7 1 4 7 3 3 and 4 7 4 pages 40 and 41 Ensure that the correct Heat Transfer fluid is used accessory code 5119549 for flat plate collectors and 5130225 for evacuated tube collectors 6 12 RE COMMISSIONING THE ELECTROMAX ...

Page 54: ...mersion thermostat setting too low Check and adjust setting is required Off Peak immersion heater cut out has operated Check and reset by pushing button Off Peak immersion heater has failed Check and replace if required No solar gain Go to 7 2 No boost Boost electrical supply switched off Check and switch on Boost immersion thermostat setting too low Check and adjust setting is required Boost imme...

Page 55: ...cut out Re set if necessary Internal wiring Check connections at solar PCB are correct and tight Faulty solar control PCB Check for above faults If none are present replace Solar controller and or solar display PCBs Erratic readings on solar con troller Sensor cables laid next to mains voltage cables Ensure there is a minimum of 50mm between mains voltage and sensor cables Sensor cables are not sh...

Page 56: ...heck for above faults If none are present replace electric boiler main PCB and or elec tric boiler display PCB Pressure gauge reading low Leak Check pipework for signs of leaks and repair if required and re fill system PRV operating Check expansion valve for signs of discharge Identify rea son and rectify Re Fill system Expansion vessel Check charge pressure and re charge if required Faulty gauge ...

Page 57: ...ing record page 78 79 8 1 DRAINING THE DOMESTIC HOT WATER CYLINDER Turn off the mains water supply to the Electromax Solar and release the system pres 1 sure by opening a hot tap Some hot water will flow for a short while this is normal Remove front and top panels 2 Connect a hose to the domestic hot water drain point and unscrew square headed stop 3 plug to drain the cylinder If water fails to dr...

Page 58: ... 45 1 Connect a hose to the solar drain valve and secure in place with hose clip Open the solar 2 drain valve and allow the heat transfer fluid to drain into a suitable container To partially drain the solar primary circuit not the collectors Turn the handles of both solar check valves so are horizontal to the pipework 1 Connect a hose to the solar drain valve and secure in place with hose clip Op...

Page 59: ... one of the thermostat pockets whilst the backnut is tightened Replace the thermostat by carefully plugging the two male spade terminations on the 7 underside of the thermostat head into the corresponding terminations on the element Rewire the immersion heaters in accordance with figure 20 page 33 Refit and secure the 8 immersion heater covers 8 5 IMMERSION HEATER THERMOSTATS Note The domestic hot...

Page 60: ...it the new expansion vessel and re connect the flexible house coupling 6 8 8 COLD WATER COMBINATION VALVE Drain the domestic hot water cylinder 1 Undo the compression connections to the mains water supply and the expansion relief 2 valve discharge pipework and remove the cold water combination valve Fit the new cold water combination valve and re connect the compression fittings to the 3 mains wat...

Page 61: ...ral heating expansion vessel to one side 3 Disconnect the solar pump cable from the solar pump housing 4 Undo the two solar pump union nuts 5 Replace the solar pump Re connect the two union nuts and re connect the solar pump ca 6 ble Re fit the central heating expansion vessel and the Electromax Solar control panel 8 11 SOLAR FLOW METER Close the solar check valves and drain the solar primary circ...

Page 62: ...eplace the solar air vent and check valve Re connect the two compression connections 4 Fit and re clip the solar flow pipework to the domestic hot water cylinder FIGURE 39 SOLAR PRIMARY SYSTEM COMPONENTS FLOW METER COMPRESSION FITTING AIR VENT AND CHECK VALVE SOLAR PRESSURE RELIEF VALVE COMPRESSION FITTING COMPRESSION FITTING SOLAR FLOW SOLAR RETURN PIPE CLIPS CHECK VALVE RETURN COMPRESSION FITTIN...

Page 63: ...ssion fitting between the solar 4 pressure relief valve and the solar primary circuit Refit the solar discharge pipework 8 15 SOLAR THERMAL CUT OUT Note The Solar primary circuit does not need to be drained to replace the solar thermal cut out Remove the thermal cut out cover by unscrewing the securing screw 1 Disconnect the wiring from the solar cut out 2 Undo the two screws holding the solar the...

Page 64: ...new expansion vessel and re connect the flexible hose coupling 5 8 17 CENTRAL HEATING CIRCULATING PUMP Close the central heating isolation valves and drain the central heating primary circuit 1 Unscrew the two screws holding the Electromax Solar control panel in place and allow it 2 to drop forward Disconnect the pump cable from the pump housing 3 Undo the two pump union nuts 4 Replace the pump Re...

Page 65: ...t Re fit the Electromax Solar control panel 4 8 19 CENTRAL HEATING PRESSURE RELIEF VALVE Close the central heating isolation valves and drain the central heating primary circuit 1 Undo the compression connection connecting the discharge pipework D1 at the 2 tundish FIGURE 42 CENTRAL HEATING PRIMARY SYSTEM COMPONENTS ELECTRIC BOILER PUSH FIT ELBOW COMPRESSION FITTING ELECTRIC BOILER MAIN PCB PCB SC...

Page 66: ... from the Electric Boiler PCB terminal blocks 3 Undo the compression fitting connecting the electric boiler to the central heating primary 4 circuit and remove the electric boiler disconnecting it from the push fit elbow Fit the new electric boiler Re fit the electric boiler housing and secure to the Electromax 5 Solar right hand side panel Re connect the cables to the PCB terminal blocks Tighten ...

Page 67: ...elief valves Remove the control panel from it s hinges taking care so that the disconnected wires do 15 not get caught in the process Fit the new control panel and re connect all cables and capillaries 16 8 24 ELECTRIC BOILER CONTROL PCB Unscrew the two screws holding the Electromax Solar control panel in place and allow it 1 to drop forward Unscrew the screw holding the control panel back cover i...

Page 68: ...the five screws holding the control manifold in place 3 Unscrew the four screws holding the solar display PCB in place 4 Disconnect the ribbon cable 5 Fit the new PCB and secure in place with the four screws Re connect the ribbon cable 6 Re fit the control panel manifold Re fit the control panel back cover and the Electromax Solar control panel FIGURE 43 PART REPLACMENT CONTROL PANEL SOLAR CONTROL...

Page 69: ...on at the solar heating pressure relief valve 2 Unscrew the two screws holding the Electromax Solar control panel in place and allow it 3 to drop forward Unscrew the two screws holding the control panel back cover in place and remove the 4 back cover Unclip the central heating pressure gauge from control panel housing 5 Clip the new pressure gauge to the control panel housing Re fit the control pa...

Page 70: ...ver 4 To replace the fuse for the solar control PCB Unscrew the two screws holding the Electromax Solar control panel in place and allow it 1 to drop forward Unscrew the two screws holding the control panel back cover in place and remove the 2 back cover Locate the fuse holder on the solar control PCB 3 Remove the fuse from the fuse holder 4 Fit a new fuse and replace the Electromax Solar control ...

Page 71: ...r expansion vessel not shown 95 611 013 Solar circulating pump washers 19 95 605 074 Solar pressure relief valve 20 95 607 217 Solar flow meter 21 95 605 076 Solar air vent check valve 22 95 605 077 Solar check valve return 23 5119536 Solar temperature sensor 24 panel not shown 95 607 218 Solar temperature sensor 25 cylinder not shown 5119779 Solar expansion vessel self sealing connection 26 not s...

Page 72: ...72 FIGURE 45 SPARES 6 31 4 3 1 2 5 54 53 58 CONTROL PANEL FRONT VIEW FRONT COVER OPEN CONTROL PANEL REAR VIEW REAR COVER REMOVED 45 42 43 44 55 50 49 47 46 51 56 ...

Page 73: ...73 36 40 37 60 22 21 28 16 14 35 39 34 20 19 23 33 15 8 32 52 38 59 17 ...

Page 74: ... moulding 56 95 614 115 Electromax solar control panel rear cover 57 not shown 58 95 608 012 Control panel 185 radiator complete 95 608 013 Control panel 220 radiator complete 95 608 014 Control panel 250 radiator complete 95 608 015 Control panel 185 underfloor complete 95 608 016 Control panel 220 underfloor complete 95 608 017 Control panel 250 underfloor complete 95 608 018 Control panel 185 r...

Page 75: ...e East West Array 5122762 Multifit Solar 6 X 22mm High Temperature Pipe Compression Fittings MALE 5122763 Multifit Solar 6 X 22mm High Temperature Pipe Compression Fittings FEMALE 5122764 Multifit Solar 6 X 22mm High Temperature Pipe Compression Fittings TEE 5122238 Multifit Solar 30m Flexible Stainless Steel Pipe kit 5130225 Multifit Solar Solar Fluid Type LS 20 Ltr Pink Can be used to fill eithe...

Page 76: ...in 60 days of installation the user completes and returns the guarantee registration card supplied with the unit in order to register the product The unit is not guaranteed against damage by frost and the immersion heaters are not guar anteed against excessive scale build up Periodic loss of charge pressure from the expansion vessels is normal indicated by an in termittent discharge of water from ...

Page 77: ... Date __________________________________________________________ Model and Serial Number __________________________________________________ Installer ________________________________________________________________ Contact Details __________________________________________________________ Competency Scheme ID Number ___________________________________________ Building Control Notification Number _...

Page 78: ..._______ Competency Scheme ID Number ___________________________________________ Comments ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Service Date ____________________________________________________________ Engineer _______________________________________...

Page 79: ...________________________________________ ______________________________________________________________ Service Date ____________________________________________________________ Engineer _______________________________________________________________ Contact Details __________________________________________________________ Competency Scheme ID Number __________________________________________ Com...

Page 80: ...ewh co uk SPD Units 9 10 Hexagon Business Centre Springfield Road Hayes Middlesex UB40 0TY Tel 020 8606 3567 Parts Center Tel 0845 2709800 www partscenter co uk Newey Eyre Specialist Products Division Please contact your local branch UK Spares Ltd Tower Lane Warmley Bristol BS30 8XT Tel 0117 961 6670 William Wilson Ltd Unit 3A 780 South Street Whiteinch Glasgow G14 OSY Tel 0141 434 1530 Heatrae Sa...

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