andrews Maxxflo CWH120/200, Installation, Operation And Maintenance Manual

Page 1: ...torage Water heaters High Efficiency Condensing Stainless Steel Storage Water heaters Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference CWH30 200 CWH30 300 CWH60 200 CWH60 300 CWH90 200 CWH90 300 CWH120 200 CWH120 300 E281B ...

Page 2: ...rews Water Heaters must be carried out by competent 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 revis...

Page 3: ...native Flue Systems CWH 30 60 22 Standard Flue System Dimensions CWH 30 60 23 Flue Systems CWH 90 120 24 Alternative Flue Systems CWH 90 120 25 Standard Flue System Dimensions CWH 90 120 26 Flue System Positions and Distances 27 Flue System Horizontal and Vertical Terminations 28 Air supply and ventilation Concentric Flue Systems 28 Air supply and ventilation concentric and conventional flue syste...

Page 4: ...ng IGE UP 2 Installation pipework IGE UP 10 1 Edition 4 Installation of gas appliances in industrial and commercial premises Andrews Water Heaters accepts no liability for any damage resulting from failing to accurately follow the instructions When replacing parts during maintenance only original parts from Andrews Water Heaters should be used these can be recognised by the name of the manufacture...

Page 5: ... 1 BSP 1 BSP 1 BSP 1 BSP Return connection 1 BSP 1 BSP 1 BSP 1 BSP Nominal operating water pressure 3 5 bar 3 5 bar 3 5 bar 3 5 bar Maximum water pressure 6 0 bar 6 0 bar 6 0 bar 6 0 bar Minimum water pressure 1 0 bar 1 0 bar 1 0 bar 1 0 bar Gas connection gas cock supplied 3 4 3 4 3 4 3 4 Electrical supply All models 230 50V Hz Power consumption 170 W 340 W 510 W 680 W Weight empty 200 litre 155 ...

Page 6: ... 402 Emissions of nitrogen oxides NO X mg kWh 44 44 44 44 44 44 44 44 Weekly fuel consumption with smart controls Q fuel week smart kWh Weekly electricity consumption with smart controls Q elec week smart kWh Weekly fuel consumption without smart controls Q fuel week kWh Weekly electricity consumtion without smart controls Q elec week kWh Storage volume V l Mixed water at 40 C V40 l 448 718 f f f ...

Page 7: ...files for which the water heater is suitable to use and the corresponding water heating energy efficiency and annual electricity consumption 3 Thermostat temperature setting C 60 60 60 60 Sound power level L WA indoors dB 49 49 49 49 Ability to off peak hours functioning 3 Enables smart control settings 4 1 Electricity 2 Fuel 3 If applicable 4 If smart control settings value is 1 the water heating...

Page 8: ...MAXXflo Water Heater 8 8 INSPECTION HATCH INSPECTION HATCH SECTION 2 TECHNICAL DETAILS ...

Page 9: ...MAXXflo Water Heater 9 9 TECHNICAL DETAILS SECTION 2 INSPECTION HATCH INSPECTION HATCH ...

Page 10: ... Fittings Regulations and any requirements of the local Gas Authority Local Authority Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1 LOCATION The location selected for installation of the heater must allow the provision of a satisfactory flue adequate air supply drain facilities and must be well illuminated A purpose built water heater room o...

Page 11: ...imum test pressure should be 6 bar The expansion vessel C3 supplied is suitable for the stored volume of the heater and a comparative pipe work system The temperature and pressure relief valve s are factory fitted FOR SYSTEMS WITH LARGER PIPE VOLUMES OR ADDITIONAL STORAGE EXPANSION VESSELS WITH MORE CAPACITY ARE AVAILABLE We do not recommend the use of galvanised pipework due to issues such as gal...

Page 12: ...onal connection for a secondary circulation is available in the top of the heater that is located between the hot flow and cold feed ports We would recommend that a non return valve is fitted in the return line If a secondary return circuit is fitted with a secondary pump please ensure that the flow rate or heat loss does not exceed the heater maximum flow rate or minimum load An excessive flow in...

Page 13: ...MAXXflo Water Heater 13 13 INSTALLATION SECTION 3 Fig 3A Typical installation Fig 3B Typical installation ...

Page 14: ... as appropriate Please note that the minimum dynamic gas pressure for Natural Gas must not fall below 18 mbar GAS SUPPLY PROPANE Contact your provider or supplier who will provide the appropriate type and size of LPG supply vessel and ensure its safe location and installation The installation of the gas supply must confirm to LGPA Code of Practice 22 LPG Piping Systems Design and Installation plus...

Page 15: ...portant These drawings show a schematic representation only and should not be used for installation purposes Contact your gas supplier for authorised installation drawings Fig 4 Typical Bulk Storage Vessel Installation Fig 5 Typical Cylinder Installation ...

Page 16: ...upply should be readily accessible and adjacent to the appliance ELECTRICAL CONNECTION A terminal block can be found above the control panel Fig 4 below This becomes accessible by first removing the front cover The following connections can be made on the terminal block see Fig 5 Wiring diagram on next page Terminals Terminal Function AL1 AL2 Alarm volt free contacts 24 volt 1 amp max EN1 EN2 Enab...

Page 17: ...wn y yellow gn green gy grey or orange br bl BT1 BT2 LS1 LS2 TH1 TH2 L N br bl br bl br r red wh white bk black pi pink bl bk pi or flow sensor 2 flow sensor 1 return sensor slave 1 fan ionisation rod gasvalve primary pump glow plug tank sensor low position mains 1 mains 2 mains 3 mains 4 pump pump L secondary pump pump N M5879D wh Max 24 V 1 0 Amp E g y g y green yellow EN1 EN2 tank sensor high p...

Page 18: ...oes back to normal operation if the temperature is higher at the measuring point than the secondary pre set water heater temperature minus 5 C for 20 minutes If for example the secondary pre set water heater temperature is set at 70 C the water heater temperature returns back to normal operation as soon as the temperature at the secondary measuring point has been above 65 C for more than 20 minute...

Page 19: ...ring Diagram 1 1 2 Hot water supply 1 Return 11 2 Feedfrom water heater Tank inspection hatch 28 mm T P outlets 1 or 2 T undishes supplied PLAN VIEW 47 T P outlets Thermostat 153 153 Drain access 28 mmvalve 602 602 1528 200 litre t ank 1952 300 litre t ank HWST 200 HWST 300 STORAGE TANKS ...

Page 20: ...g Please contact Andrews technical department if advice is needed for a particular installation See drawings on page 26 We recommend that a condensate trap be fitted when the secondary flue length is over 1 5m If installed in a roof valley the terminal should be at least 1m above the highest part of the roof structure and 2 5m from any adjacent structure The terminal must be fitted with a guard if...

Page 21: ...tes C ps lam A1 e l S a n i g Wall 0 10 With this application pipes must clear Horizontal Flue B260 Horizontal flue kits include the following A1 90 bend with sealing clamp Part No E071 A2 Wall outlet terminal with sealing clamp complete with inner and outer wall plates fixing screws and plugs Part No E073 B261 Vertical flue kits include the following A1 Roof outlet terminal with sealing clamp Par...

Page 22: ...ap 820 1 5M Minimum between Vertical terminals 300mm Minimum between balanced flued horizontal terminals 1 2M when using 90º bend 0 7M when using 45º bend and 1 5M when using condensetrap For concentricflue runs reduce overall length by Can be cut to suit roof structure 530 805 CWH30 max 50M Conventional CWH60 max 20M Conventional CWH30 max 14M Concentric CWH60 max 12M Concentric Can be cut to sui...

Page 23: ...T No E310 Ø 1 2 5 100 1 0 0 200 Ø125 Ø80 PART No E308 45º ELBOW C W CLAMP VERTICAL FLUE TERMI NAL C W CLAMP CONDENSING PART No E067 20 90º ELBOW C W CLAMP PART No E071 Ø80 200 220 220 610 170 Ø80 200 Min ADJUSTABLE PLATE HORIZONTAL TERMINAL C W WALL PLATES PART No E073 Maintain dimension if flue is cut 20 CWH30 CWH60 STANDARD FLUE SYSTEM DIMENSIONS ...

Page 24: ...n i g Wall 0 10 With this application pipes must clear Horizontal Flue B262 Horizontal flue kits include the following A1 90 bend with sealing clamp Part No E215 A2 Wall outlet terminal with sealing clamp complete with inner and outer wall plates fixing screws and plugs Part No E240 B263 Vertical flue kits include the following A1 Roof outlet terminal with sealing clamp Part No E670 Roof flashing ...

Page 25: ...ondensetrap Condense Tap drain To 258 1 2M when using 90º bend 0 7M when using 45º bend 1 5M when using condense trap For concentricflue runs reduce overall length by Can be cut to suit roof structure 530 Can be cut to s roof structure uit Angled r flashing E218 oof h Flat roof Flas ing E217 CWH90 max 50M Conventional CWH120 max 40M Conventional CWH90 max 14M Concentric CWH120 max 14M Concentric M...

Page 26: ...MAXXflo Water Heater 26 26 CWH90 CWH120 STANDARD FLUE SYSTEM DIMENSIONS SECTION 3 INSTALLATION ...

Page 27: ...alcony or carport 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 30 60kW 300 90 120kW 600 N From a terminal facing the terminal 1200 P From an opening in a carport...

Page 28: ...MAXXflo Water Heater 28 28 FLUE SYSTEMS Fig 12 SECTION 3 INSTALLATION ...

Page 29: ... where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour Consideration must be given to the position of the high level ventilation opening A high level vent must not be sited within 300mm 1ft measured vertically of the flue terminal Grilles and louvres should be so designed that high velocity air streams do not oc...

Page 30: ...notes are provided for general guidance only Ventilation shall prevent the heater environment from exceeding 32 C 90 The purpose provided space in which the heater s are installed must have permanent air vents communicating directly with the outside air at high and low level Where communication with the outside air is possible only by means of high level air vents ducting down to floor level for t...

Page 31: ...e requirements for air supply by mechanical ventilation are given in BS6644 and IGE UP 10 Pt 1 The permanent air vents shall be sited away from any extract fans Where an extract fan is fitted check for spillage at the draught diverter as detailed in BS5440 It may be necessary to increase the ventilation are to compensate for the extract fan The vapours emitted by halogen based compounds can if dra...

Page 32: ...r detected burner module not in use on burner module in use The red LED off no fault flashing blocking fault on locking fault The display on the control panel consists of 3 segments The following codes can appear No heat demand Flashing water not enabled Heat demand Programme changed water temperature activated Permanent circulation pump connected to terminals pump L pump N activated Flashing circ...

Page 33: ... valves must be fitted at point of use in some applications ADJUSTING TEMPORARY TEMPERATURE CHANGE If use is made of the programme for temporary temperature change see page 16 the new temperature is set as follows Press the reset button down for longer than 5 seconds L appears in the left segment of the display The water heater temperature is shown in the 2 right segments the new temperature can b...

Page 34: ...completely full of water The gas pipes have been purged The electricity supply to the appliance is switched on The phase and neutral are correctly connected to the appliance 2 Open the appliance s gas tap 3 Switch the electricity on with the power switch on the control panel The water heater now searches for what burner modules are present When these are detected the green LED for the correspondin...

Page 35: ... the CO2 percentage at low load CONTROL AND ADJUSTMENT AT LOW LOAD 1 Select low load with the button When the actual burner capacity is above 25 the CO2 percentage can be measured and set 2 Measure the CO2 percentage and check it against table 1 page 33 The CO2 percentage can be adjusted using the Low Load Setscrew b 2mm Alan Key on the gas regulation unit see Fig 15 The CO2 percentage can be incr...

Page 36: ...ARD BLOCKING CODES E0 Read Error Not able to read stored parameters E28 E29 Control error Reference measurements E30 E31 indicates that there is an error in the AD circuit E33 Flame detected when gas valve was closed E41 Phase Error Live and neutral reversed E42 Phase Error Too much deviation in the supply voltage frequency E44 Control Error Poor communication between the two processors E47 Return...

Page 37: ...he water heater out of operation and then proceed as follows a Turn off the water tap in the cold water supply b Open one of the warm water taps that can be found at a point higher that the water heater in order to bleed the warm water pipe section If the water heater is set up above the level of the drainage points it will be necessary to open the warm water connection to let the appliance run em...

Page 38: ...MAXXflo Water Heater 38 38 SPARE LIST FOR CWH RANGE MAXXflo EXTERNAL CYLINDER SPARES ITEMS SECTION 8 PARTS LIST ...

Page 39: ...MAXXflo Water Heater 39 39 PARTS LIST SECTION 8 MAXXflo INTERNAL SPARES ITEMS ...

Page 40: ...MAXXflo Water Heater 40 40 57 61 62 62 63 64 67 66 68 63 62 64 67 70 68 63 68 60 65 69 57 58 59 82 82 82 82 MAXXflo FLUE SPARES ITEMS SECTION 8 PARTS LIST ...

Page 41: ...MAXXflo Water Heater 41 41 73 74 71 71 75 72 76 77 PARTS LIST SECTION 8 MAXXflo OLD ISSUE SPARES ITEMS ...

Page 42: ...p Elbow Vent Union used with composite pump after inc serial no 071201 E921 42 Fan Gasket E846 43 Burner Gasket E932 44 Pump Elbow Vent Union used with bronze pump after inc serial no 071201 E847 45 Pump Gasket E964 46 Vapour Tray Gasket E931 47 Circlip Stainless Steel 15mm E963 48 Composite Body Primary Pump after and inc serial no 071201 E920 49 Bronze Body Primary Pump pre serial no 071201 E660...

Page 43: ...ure you safely remove the power supply and isolate the appliance from the water and gas connections Dispose of the appliance correctly according to the laws in force The appliance and accessories cannot be discarded along with normal household waste and should be recycled where appropriate More than 90 of the materials that make up the appliance are recyclable DISMANTLING DISPOSAL AND RECYCLING ...

Page 44: ...Publication date November 2015 ...