Polywarm-Maxi PWC1 - Water heater Elco - Free user manual and instructions

Product Type	Indirect Hot Water Cylinder (Calorifier)
Models / Capacities	PWC1: 500, 800, 1000, 1500 litres
Energy Class	C (all models)
Maximum Working Temperature (Tank)	95 °C
Maximum Working Pressure (Tank)	6 bar
Maximum Coil Operating Temperature	110 °C
Maximum Coil Operating Pressure	12 bar
Dimensions (H x Df x De) - Model 500	1780 x 650 x 750 mm
Weight (Empty/Full) - Model 500	108 kg / 597 kg
Immersion Heater Options	3 kW/1 ph (500, 800) or 12 kW/3 ph (1000, 1500)
Standby Loss at 65 °C	2.5 - 3.9 kWh/24h (depending on model)
Construction Material	Carbon steel with WRAS approved internal coating
Coil Type (PWC1)	Single lower coil
Coil Surface Area (lower) - Model 500	1.8 m²
Control Options	External controls or Elco Easy Control panel (timed, anti-legionella, recirculation)
Maintenance Interval	Annually by competent installer
Safety Devices	T&P relief valve, expansion vessel, pressure reducing valve (unvented kit)
Compliance	PED 2014/68/EU, ErP, Energy Labelling, EN 12897
Spare Parts	Use genuine Elco parts only

Frequently Asked Questions - Polywarm-Maxi PWC1 Elco

What is the maximum working temperature for the Polywarm-Maxi PWC1?

The maximum working temperature for the tank (secondary side) is 95 °C, while the primary coil can operate up to 110 °C.

What are the available capacities for the PWC1 model?

The PWC1 is available in four capacities: 500, 800, 1000, and 1500 litres.

Can the Polywarm-Maxi PWC1 be used in an unvented system?

Yes, with the appropriate unvented kit (safety group, expansion vessel, tundish, T&P valve) supplied separately. The system must comply with Building Regulations G3.

What type of immersion heater is compatible with the PWC1?

Models 500 and 800 use a 3 kW single-phase immersion heater; models 1000 and 1500 use a 12 kW three-phase immersion heater.

How often should maintenance be performed?

Regular maintenance should be carried out at intervals not exceeding 12 months by a competent installer. This includes checking relief valves, cleaning strainers, and descaling immersion heaters in hard water areas.

What is the standby heat loss of the PWC1 500?

The standby loss for the 500-litre model at 65 °C is 2.5 kWh/24h.

Is the internal coating WRAS approved?

Yes, the internal coating is WRAS approved for use with UK commercial domestic hot water systems.

Can the cylinder be controlled by a building management system (BMS)?

Yes, if using the Elco Easy Control panel, set the panel temperature 5 °C above the BMS set point to avoid conflicts.

What safety devices are included?

The unvented kit includes a temperature and pressure relief valve, pressure reducing valve, expansion vessel, and tundish. The cylinder itself has a T&P valve connection.

What should I do if water discharges from the safety valves?

Turn off the electricity supply to immersion heaters or the boiler (for indirect units). Do not turn off the water supply. Immediately contact a competent installer of unvented hot water systems.

USER MANUAL Polywarm-Maxi PWC1 Elco

PWC Indirect Hot Water Cylinders

and

PWB Buffer Vessels

Models PWC1 - 500, 800, 1000 & 1500

PWC2 - 500, 800, 1000 & 1500

Models PWB - 500, 800, 1000, 1500, 2000,

2500 & 3000

Exterior view of a white cylindrical water heater with black and red circular components (no text or symbols visible)

Exterior view of a cylindrical water heater with internal circulation (no text or symbols visible)

Exterior view of a modern office building (no signage)

Exterior view of a cylindrical water heater with a black handle and green internal casing (no text or symbols visible)

Installation and Operating Instructions

Index

Section	Topic	Page No
1.	Overview & Regulations	3
2.	Technical data & dimensions	5
3.	Installation	14
4.	Connections	14
5.	Primary coils circulation	14
6.	Self cleaning flux	14
7.	Immersion heaters	14
8.	Hard water	14
9.	Unvented systems	15
10.	Expansion vessels pre-charge pressure	15
11.	Expansion vessel capacity	15
12.	Safety relief valves discharge pipes	15
13.	Tundish positioning & discharge	16
14.	Electrical installation	16
15.	Electrical connections for optional powered anode	16
16.	Electrical connections for optional immersion heaters	17
17.	Typical installation schematics	19
18.	Commissioning	20
19.	User instructions	21
20.	Regular maintenance	22
21.	Draining the cylinder &/or buffer vessel	22
22.	Easy Control Panel	22

In compliance with Directive 2014/68/EU (PED) and the Regulations 812/2013 and 814/2013 issued by Directive 2009/125/EC (ErP - EcoDesign Requirements for Energy Related Products) and by Directive 2010/30/EC (Energy Labelling of Products), the technical and heat loss specifications together with the energy categories are written on the labels/technical sheets attached to the product. Such labels/technical sheets must be considered as an integral part of these instructions for use.

The Indirect Hot Water Cylinders have been tested in compliance with standard E 12897. All Hot Water Storage Tanks are manufactured in accordance with Article 4.3 of PED and must not be CE marked. However the manufacturer guarantees the production quality in accordance with EN ISO 9001

1.1 Overview

The Polywarm-Maxi range of Indirect hot water cylinders and storage tanks are carbon steel construction with a patented WRAS approved internal coating for UK commercial (dhw) systems. The calorifier range consists of single and twin coil variants offering enhanced dhw performance by linking the coils in series when using a single heat source or connected separately when using two heat sources.

There are four models of calorifiers with storage capacities from 500 - 1500 litres.

There are seven models of storage tanks with capacities from 500 - 3000 litres.

Controls - external (non Elco supply) devices may be used to control the operation of the system or alternatively the Elco Easy Control panel is designed for simple timed control of the domestic hot water throughout the day (3 periods per day) whilst also managing the Anti-Legionella function, system re-circulation pump and up to two heat sources plus an immersion heater - refer to Easy Control instructions & section 22, for further information.

1.2 Regulations

Attention is drawn to the following documents for best practice:

Statutory Instruments

Water Supply (Water Quality England & Wales) Regulations 2016 - as amended

The Public Water Supplies (Scotland) Regulations 2014 - as amended

The Water Supply (Water Fittings) Regulation (Northern Ireland) 2009 - as amended

British Standards

BS 6880 Part 1, 2 & 3 Code of Practice for low temperature hot water heating systems of output greater than 45kW.

BS 7074 Part 1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems.

Part 2: Code of Practice for low and medium temperature hot water heating systems.

BS 7671 Requirements for electrical installations. IET Wiring Regulations. 17th edition.

BS 8550 Guide for the auditing of water quality sampling

BS 8558 Guide to the design, installation, and maintenance of services supplying water for domestic use within buildings. Note: this document is complimentary to BS EN 806

BS 14743 Water conditioning equipment inside buildings. Softeners. Requirements for performance, safety and testing

BS EN ISO 4126-1 Safety devices for protection against excessive pressure. Safety valves.

BS EN 806 Specification for installations inside buildings conveying water for human consumption

Note: - BS6700- The Design, Installation, Testing and Maintenance of Services supplying water for domestic use within buildings. This document has been superseded by BS EN 806

Electrical Standards:- BS 3456 Part 201, EN 60335 Part 1

CP 342-2 Code of practice for centralised hot water supply. Buildings other than individual dwellings.

The Health and Safety Commission (HSC) approved code of practice and guidance document L8 - HSG274: Legionnaires disease. Technical Guidance.

CIBSE Publications

CIBSE Guide G Public Health Engineering

CIBSE TM13: Minimising the risk of Legionnaires' disease.

CIBSE Guide H Building Control Systems.

CIBSE Guide Energy Efficiency in Buildings.

CIBSE Commissioning Code B: 2002.

ICOM Publication - Water quality consideration for non domestic hot water systems

Department of Health

Health Technical Memorandum (HTM) 04-01: The control of Legionella, hygiene, 'safe' hot water, cold water and drinking water systems.

Part A Design, installation and testing.

Part B Operational Management Department of Health (DH). Addendum

Pseudonomas aeruginosa - advice for augmented care units.

HTM 04-04 The Control of Legionella in Health Care Premises- Code of Practice:2006

General Requirements

All connections to the local water main must comply with Water Supply (Water Fittings) Regulations 1999 (as amended). Compliance with the Regulations can be demonstrated by certification from notified body organisations such as WRAS or KIWA.

Unvented Systems

Building Regulations - use of unvented hot water storage systems with volumes exceeding 15 litres. G3 (England & Wales), P3 (Scotland) & P2 (Northern Ireland)

The unvented system components allows the storage vessel to be fed directly from the mains cold water supply, or from a booster pump set, without the need for feed and expansion tanks.

The unvented system components should be approved and comply with the Water Supply (Water Fittings) Regulations 1999 (as amended), including a suitably sized temperature and pressure (T&P) relief valve, which locates directly into the top portion of the storage vessel.

DISPOSAL

At the end of the technical life cycle of this product, all metal components must be delivered to operators authorised in the collection of metals for recycling, while all non-metal components must be delivered to suitably authorised agents. The disposal of products must be managed in accordance with local regulations and must never be managed as household waste.

2 Technical data & dimensions

2.1 Polywarm-Maxi PWC1 Indirect Cylinders

ITEM No.	DESCRIPTION
1	Drain
2	Domestic cold water inlet
3	Primary circuit return
4	1/2"BSP tapping for instrumentation
5	Blind inspection flange
6	Primary circuit flow
7	11/4"BSP connection for magnesium anode
8	Connection for immersion heater
10	1/2"BSP tapping for instrumentation
11	Re-circulation
13	T&P valve
15	Domestic hot water outlet

MODELPWC1	1	2	3, 6, 7	4 & 10	5	8	11	13	15
	Gas F
500	1 1/4"	1"	1 1/4"	1/2"	∅i 180 mm	1 1/2"	1"	1/2"	1 1/4"
800	3/4"	1"	1 1/4"	1/2"	∅i 240 mm	2"	1"	3/4"	1 1/4"
1000	3/4"	1 1/4"	1 1/4"	1/2"	∅i 240 mm	2"	1"	3/4"	1 1/2"
1500	1"	1 1/2"	1 1/4"	1/2"	∅i 380 mm	2"	1"	3/4"	2"

2.1.2 Dimensions

MODEL	Df	De	H	A	H1	H2	H3	H4	H6	H7	H8	H11	H13
	[mm]
500	650	750	1780	1932	71	271	346	411	1036	1076	1144	1331	1476
800	750	900	2163	2343	101	493	428	483	1181	1243	1308	1598	1858
1000	850	1070	2217	2281	89	524	439	499	1279	1309	1364	1584	1819
1500	950	1170	2415	2485	109	450	425	575	1403	1450	1515	1825	2065

MODELPWC1&2	ABOVE	BEHIND	SIDE	INFRONT
	MINIMUM CLEARANCES (mm)
500	500	400	200	750
800	500	400	200	950
1000	500	400	200	1050
1500	500	400	200	1150

Note: 500 model - Hard foam insulation applied to tank All other models - Removable soft fleece insulation.

Unvented models require necessary safety equipment: SRV/PRV (Safety relief & pressure reducing valve including check valve), external expansion vessel, tundish and a T&P (Temperature and Pressure) relief valve.

These are supplied separately in the Unvented Kit.-refer to section 9.

Note: - 1500 Model has two ‘grips’ on the bottom which allow the use of forklift when handling and drain pipe already fitted.

2.1.3 Performance data

Model PWC1		500	800	1000	1500
Nominal storage capacity	litres	489	789	1038	1443
Energy Class		C	C	C	C
Coil tube	mm	32.0	42.0	42.0	42.0
Coil surface area	m^2	1.8	2.7	3.5	3.8
Coil max operating temperature/pressure	°C/bar	110/12
Maximum working temperature/pressure, tank (secondary)	°C/bar	95/6
Weight empty/full	kg	108/597	188/977	223/1261	318/1761
Heat up time 50°C ΔT immersion only	hr	3.6	6.4	2.0	2.7
Immersion heater option power/phase	kW/ph	3/1	3/1	12/3	12/3
Standby loss at 65°C	kWh/24hr	2.5	2.8	3.3	3.9

		500		800		1000		1500
Primary flow rate	litres/sec	0.972	0.486	1.667	0.833	1.667	0.833	1.667	0.833
	m3/h	3.5	1.75	6	3	6	3	6	3
Continuos DHW output @ 50°C ΔT (10/60°C) with primary 80°C on lower coil	litres/hour	773.2	705.0	1009.8	928.5	1291.1	1175.6	1394.6	1265.8
10 min peak DHW draw off @ 50°C ΔT (10/60°C) with primary 80°C on lower coil and tank warmed @ 60°C	litres	617.9	606.5	957.3	943.8	1253.2	1233.9	1675.4	1654.0
Recovery time DHW @ 50°C ΔT (10/60°C) full tank without draw off with primary 80°C on lower coil	min	45.0	52.7	54.5	62.5	57.1	66.9	73.9	87.2
Nominal heat transferred by lower coil with primary 80°C and DHW @ 50°C ΔT (10/60°C)	kW	44.5	40.5	58.0	53.3	74.1	67.4	80.0	72.6
Lower coil Primary hydraulic resistance	kPA	16.1	4.8	11.8	3.5	15.0	4.4	16.2	4.8

2.2.1 Polywarm-Maxi PWC2 (twin coil) Indirect Cylinders

ITEM No.	DESCRIPTION
1	Drain
2	Domestic cold water inlet
3	Primary circuit return
4	1/2"BSP tapping for instrumentation
5	Blind inspection flange
6	Primary circuit flow
7	1/2"BSP tapping for instrumentation
8	Connection for immersion heater
9	Upper coil return
10	1/2"BSP tapping for instrumentation
11	Re-circulation
12	Upper coil flow
13	T&P valve
14	1/2"BSP tapping for instrumentation
15	Domestic hot water outlet

MODELPWC2	1	2	3, 6, 9, 12	4, 7, 10	5	8	11	13	14	15
	Gas F
500	1 1/4"	1"	1 1/4"	1/2"	∅i 180 mm	1 1/2"	1"	3/4"	1 1/4"	1 1/4"
800	3/4"	1"	1 1/4"	1/2"	∅i 240 mm	2"	1"	3/4"	1 1/4"	1 1/4"
1000	3/4"	1 1/4"	1 1/4"	1/2"	∅i 240 mm	2"	1"	3/4"	1 1/4"	1 1/2"
1500	1"	2"	1 1/4"	1/2"	∅i 380 mm	2"	1 1/2"	3/4"	1 1/4"	2"

2.2.2 Dimensions

MODEL	Df	De	H	A	H1	H2	H3	H4	H6	H7	H8	H9	H10	H11	H12	H13
	[mm]
500	650	750	1786	1937	71	271	346	411	1036	1076	1144	1186	1296	1331	1476	1476
800	790	1010	2163	2221	101	493	428	483	1181	1243	1308	1362	1573	1598	1770	1788
1000	800	1020	2217	2275	89	524	439	499	1279	1309	1364	1399	1609	1584	1819	1819
1500	1000	1220	2415	2491	109	450	425	575	1352	1450	1515	1550	1735	1825	2045	2065

MODELPWC1&2	ABOVE	BEHIND	SIDE	INFRONT
	MINIMUM CLEARANCES (mm)
500	500	400	200	750
800	500	400	200	950
1000	500	400	200	1050
1500	500	400	200	1150

Note: 500 model - Hard foam insulation applied to tank All other models - Removable soft fleece insulation.

Unvented models require necessary safety equipment: SRV/PRV (Safety relief & pressure reducing valve including check valve), external expansion vessel, tundish and a T&P (Temperature and Pressure) relief valve.

These are supplied separately in the Unvented Kit.-refer to section 9.

Note: - 1500 Model has two 'grips' on the bottom which allow the use of forklift when handling and drain pipe already fitted.

2.2.3 Performance data

Model PWC2		500	800	1000	1500
Nominal storage capacity	litres	489	789	1038	1443
Energy Class		C	C	C	C
Coil tube ∅	mm	32.0	42.0	42.0	42.0
Lower coil surface area	m^2	1.8	2.7	3.5	3.8
Upper coil surface area	m^2	1	1.5	1.9	1.9
Coil max operating temperature/pressure	°C/bar	110/12
Maximum working temperature/pressure, tank (secondary)	°C/bar	95/6
Weight empty/full	kg	130/619	216/1005	255/1293	344/1787
Heat up time 50°C ΔT immersion only	hr	3.6	6.4	2.0	2.7
Immersion heater option power/phase	kW/ph	3/1	3/1	12/3	12/3
Standby loss at 65°C	kWh/24hr	2.5	2.8	3.3	3.9

		500		800		1000		1500
Primary flow rate	litres/sec	0.972	0.486	1.667	0.833	1.667	0.833	1.667	0.833
	m3/h	3.5	1.75	6	3	3	3	3	3
Continuos DHW output @ 50°C ΔT (10/60°C) with primary 80°C on lower coil	litres/hour	773.2	705.0	1009.8	928.5	1291.1	1175.6	1394.6	1265.8
10 min peak DHW draw off @ 50°C ΔT (10/60°C) with primary 80°C on lower coil and tank warmed @ 60°C	litres/hour	617.9	606.5	957.3	943.8	1253.2	1233.9	1675.4	1654.0
Recovery time DHW @ 50°C ΔT (10/60°C) full tank without draw off with primary 80°C on lower coil	min	45.0	52.7	54.5	62.5	57.1	66.9	73.9	87.2
Nominal heat transferred by lower coil with primary 80°C and DHW @ 50°C ΔT (10/60°C)	kW	44.5	40.5	58.0	53.3	74.1	67.4	80.0	72.6
Continuos DHW output @ 50°C ΔT (10/60°C) with primary 80°C on upper coil	litres/hour	453.1	421.6	609.5	569.8	683.7	636.8	720.3	670.0
10 min peak DHW draw off @ 50°C ΔT (10/60°C) with primary 80°C on upper coil and tank warmed @ 60°C	litres/hour	235.5	230.3	387.6	381.0	485.0	477.1	632.1	623.7
Recovery time DHW @ 50°C ΔT (10/60°C) upper part of tank without draw off with primary 80°C on upper coil	min	24.3	27.2	32.0	35.4	37.1	41.4	48.7	54.5
Nominal heat transferred by upper coil with primary 80°C and DHW @ 50°C ΔT (10/60°C)	kW	26.2	24.3	35.1	32.7	39.3	36.6	41.4	38.5
Continuous DHW output @ 50°C ΔT (10/60°C) with primary 80°C on both the lower and upper coil	litres/hour	1011.0	910.2	1564.7	1413.0	1897.9	1697.6	2028.1	1808.0
10 min peak DHW draw off @ 50°C ΔT (10/60°C) with primary 80°C on both the lower and upper coil and tank warmed @ 60°C	litres/hour	657.5	640.7	1049.8	1024.5	1354.3	1320.9	1781.0	1744.3
Recovery time DHW @ 50°C ΔT (10/60°C) full tank without draw off with primary 80°C on both the lower and upper coil	min	35.2	42.6	36.4	43.5	40.2	49.2	52.8	65.1
Nominal heat transferred by both the lower and upper coil with primary 80°C on and DHW @ 50°C ΔT (10/60°C)	kW	58.1	52.2	89.7	81.0	108.8	97.3	116.2	103.6
Lower coil Primary hydraulic resistance	kPa	16.1	4.8	11.8	3.5	15.0	4.4	16.2	4.8
Upper coil Primary hydraulic resistance	kPa	9.4	2.7	7.3	2.1	8.1	2.4	8.5	2.5
Both lower and upper coil Primary hydraulic resistance	kPa	25.5	7.5	19.1	5.6	23.1	6.8	24.8	7.3

2.3.1 Polywarm-Maxi PWB Buffer Vessels

ITEM No.	DESCRIPTION
1	Drain
2	Domestic cold water inlet
3	Flow to external heat source
5	Blind inspection flange
7	1/2"BSP tapping for instrumentation
8	Re-circulation
9	1/2"BSP tapping for instrumentation
10	Connection for immersion heater
11	Alternative return from external heat source
12	T & P valve
13	Return from external heat source
14	Domestic hot water outlet
15	Drain 1"BSP (only models >1000L)

Connections

ModelPWB	1	2, 3, 11, 13	5	7 & 9	8	10	12	14
	gas F
500	1 1/4"	1 1/4"	i 300 mm	1/2"	1 1/4"	1 1/2"	2"	1 1/4"
800	1 1/4"	1 1/4"	i 300 mm	1/2"	1 1/4"	1 1/2"	2"	1 1/4"
1000	1 1/2"	1 1/2"	i 300 mm	1/2"	1 1/4"	2"	2"	1 1/2"
1500	1"	1 1/2"	i 300 mm	1/2"	1 1/4"	2"	2"	2"
2000	1"	2"	i 300 mm	1/2"	1 1/4"	2"	2"	2"
2500	1"	2"	i 300 mm	1/2"	1 1/4"	2"	2"	2"
3000	1"	2"	i 300 mm	1/2"	1 1/4"	2"	2"	2"

2.3.2 Dimensions

Model	Df	De	H	A	H1	H2	H4	H6	H7	H15	H16	H17
	[mm]
500	650	870	1891	2082	126	416	501	611	801	1411	1370	1526
800	750	970	2188	2393	113	433	518	628	898	1678	1638	1793
1000	850	1070	2188	2436	101	454	539	649	989	1645	1606	1760
1500	950	1170	2440	2706	109	440	525	635	1075	1935	1895	2050
2000	1100	1320	2492	2820	91	467	542	652	842	1952	1877	2057
2500	1250	1470	2361	2781	140	551	626	736	976	1816	1741	1891
3000	1250	1470	2861	3217	140	551	626	736	876	2316	2232	2391

MODELPWB	ABOVE	BEHIND	SIDE	INFRONT
	MINIMUM CLEARANCES (mm)
500	500	200	400	750
800	500	200	400	750
1000	500	200	400	750
1300	500	200	400	750
1500	500	200	400	750
2000	500	200	400	750
2500	500	200	400	750
3000	500	200	400	750

Note: 500 model - Hard foam insulation applied to tank

All other models - Removable soft fleece insulation.

Unvented models require necessary safety equipment: SRV/PRV (Safety relief & pressure reducing valve including check valve), external expansion vessel, tundish and a T&P (Temperature and Pressure) relief valve.

These are supplied separately in the Unvented Kit.- refer to section 9.

Note: - 1500 - 3000L Models have two 'grips' on the bottom which allow the use of a forklift when handling and drain pipe already fitted.

2.3.3 Performance data

MODEL	Units	500	800	1000	1500	2000	2500	3000
PWB
Nominal storage capacity	Litres	500	791	1010	1442	1974	2310	2916
Energy Class	-	C	C	C	C	C	---	---
Maximum working temperature/pressure (secondary)	°C / bar	95 / 6
Weight empty / full	Kg	102 / 602	157 / 948	185 / 1192	233 / 1675	352 / 2326	388 / 2698	429 / 3345

2.3.4 Unvented kits

MODEL		500	800	1000	1500	2000	2500	3000
PWC1	Kit	11	13	27	15	N/A	N/A	N/A
PWC2	Part	12	23	25	16	N/A	N/A	N/A
PWB	No.	4	5	6	7	8	9	10

3 Installation

3.1 Handling

Care should be taken when handling the Polywarm-Maxi cylinders to avoid damage to the outer insulation.

Models 800 and larger, are supplied with lifting points on the top of the cylinder and models 1500L and larger are fitted with cutouts in the base support ring to accommodate fork lift truck access.

3.2 Position

The position chosen for installation must be capable of supporting the unit when full of water and it is important to ensure that the unit is level, true and vertical to avoid the possibility of difficulties with air trapping and or locking in primary coils.

3.3 Installation and Maintenance

Make sure that the premises where the storage tank(s) are to be installed have suitable openings to allow their free passage to the outside without any need for demolition. The warranty does not cover any costs de- rived from a failure to observe this point.

4 Connections

Care must be taken when making pipe connections to the tank to avoid any undloading of connections. Pipework must be adequately supported to avoid any undloading being applied to the cylinder and its connection points.

Note: ensure that any redundant tappings are capped off prior to filling the system.

After a few days of operation it is good practice to check the integrity of all joint including the tightness of the inspection flange bolts, accessible by removing the cover.

5 PWC1 & 2 models - Primary Coils

Circulation through primary coils should always be pumped, refer to the technical data for flow rates. The PWC range is not suitable for gravity circulation.

6 Self cleaning fluxes

If any joints on copper pipes local to the cylinder are soldered, then avoid excessive use of self cleaning fluxes.

7 Installation of Immersion Heaters

It is important to ensure that any immersion heaters are installed with the temperature control and high limit thermostats located so that they are positioned above the heating elements and can detect the heat input from the heating elements.

8 Hard Water

In known hard water areas the use of scale prevention measures is recommended. Ensure compatibility with stainless steel material. No warranty is provided for components such as immersion heaters that are damaged through scale build up.

9 Unvented Systems

If the installation is to be of the “unvented” type, the cylinder will have been supp with a group of safety controls (loose) which must be installed (see Fig. 9 & Figs 16)

Figure 9 - Example Unvented valve block

10 Expansion Vessel pre-charge Pressure

It is the responsibility of the installer to check the air pre-charge pressure before installation and adjust as necessary to 3.5bar.

11 Expansion Vessel Capacity

The capacity of the expansion vessel supplied as part of the unvented kit, is nominally sized to accommodate the capacity of the cylinder with which it was supplied plus nominal system pipework volume of approximately 17.5% of the cylinder capacity. If the system pipework capacity exceeds the allowance described above, then appropriately sized additional potable water expansion vessels will need to be obtained and installed.

12 Safety Relief Valve Discharge Pipes

It is a requirement of the Building Regulations that any discharge from an unvente system is conveyed safely to a point that is visible but will not constitute a hazard danger to persons in or about the building.

It is the responsibility of the installer to supply and install discharge pipes and suitable tundishes, in accordance with the requirements of the Building Regulations.

13 Tundish Positioning & Discharge

The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device (i.e. the temperature pressure relief valve) and must be away from any electrical device.

The discharge pipe from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, according to Building Regulation G3.

Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rain water goods may be damaged by such discharges. Where children may play or otherwise come in contact with discharges, a wire cage or similar guard must be positioned to prevent contact whilst maintaining visibility.

14 Electrical installation

Wiring should be carried by a competent electrician in accordance with the current edition of the IEE Regulations.

Thermostats used will have a maximum switching capability (typically 16A / 230V). If loadings are in excess of this figure, a suitably rated contactor or relay must be interposed.

An appropriately rated isolator and fuses should be installed to protect the control and load circuits.

15. Electrical connections for optional powered anode

In areas of the country that have particularly soft water and therefore poor conductivity of the water, less than 200 micro-siemens per cm, such as Scotland, Devon and Cornwall, then magnesium sacrificial anodes may not be fully effective in providing protection against corrosion. The optional electrical anode protection system is effective in providing protection in any water conditions.

It is essential that the powered anode is provided with a permanent live supply from a fused spur adjacent to the tank.

Installation - follow the manufacturers instructions supplied with the unit. The requirements for the electrical supply are 230v / 50Hz / 3A.

Wiring - ensure that the fused spur is non switchable (permanent live).

Ensure that the cable connecting the element to the control panel is suitably protected and routed providing protection from inadvertent disconnection.

Operation - the hot water system must be exercised at least every two months to ensure that gas is not allowed to build up in the tank. The system must not be disconnected from the mains electrical supply whilst the tank is full of water as this will compromise the corrosion protection. This is particularly important during prolonged shut down periods (holidays).

Maintenance - the system is maintenance free but the status must be checked every month. This can be done by checking the Pilot LED fitted into the control box.

• Pilot lamp green - mains voltage is present and the system is ready for operation
• Pilot lamp OFF - no mains voltage. Intervention required
• Pilot lamp flashing red - there is a fault. Intervention required. Refer to manufacturers instructions.

16 Electrical connections for optional immersion heaters

Installation - When fitting the immersion heater to the tank, ensure that the thermostat or cut-out is located at the top of the element bundle and that there is sufficient room in front of the tank to allow removal of the element. Check the immersion heater joint to the tank ensuring that there are no leaks.

Wiring - Prior to wiring up the immersion heater, check that the mains supply available corresponds to the rating on the heater data plate and that the rating of any cable fuses and contactors are suitable for the electrical load and that an earth is connected to the heater - refer to Fig 14.

Check that the thermostat safety cut-out is correctly wired to ensure complete shutdown of the heater ie. in series with the coil of the main contactor.

Operation - Ensure that the element is immersed in the water as this includes a thermostat to sense the water temperature. In the event of a shutdown due to overheating, the main isolator must be switched off before checking the system, the water level should be checked and the system inspected. When satisfied, reset the cutout.

Maintenance - The immersion heater must be electrically isolated before removing the terminal cover. Periodically inspect the element to check for any deposit build up on the element.

Figure 16 - Immersion heater wiring diagrams

Wiring Diagrams

Single Phase up to 3kw

Single Phase over 3kw

graph TD
    A["Fused Isolator"] --> B["Control circuit fuse"]
    C["N"] --> B
    D["Earth"] --> B
    E["L1"] --> B
    F["Contactor"] --> B
    G["Over temp cut-out and thermostat if required"] --> H["Thermal"]
    I["Control Circuit"] --> J["Coilander"]
    K["Inverter"] --> L["Thermal Coil"]

Three Phase star connection (4 wire)

Three Phase delta connection (3 wire)

graph TD
    A["Fused Isolator"] --> B["Heater"]
    C["Control circuit fuse"] --> B
    D["Contactor"] --> B
    E["Over temp cut-out and thermostat"] --> B
    F["Inverter"] --> B
    G["Earth"] --> B
    H["L1-L3"] --> B
    I["cut-out thermostat"] --> B
    J["If required"] --> B

ALL WORK SHOULD BE CARRIED OUT BY SUITABLY QUALIFIED PERSONNEL TO THE LATEST IEE REGULATIONS AND SITE REGULATIONS
All wiring and controls outside the □ box is the responsibility of the customer

17 Typical Installation Schematics

graph TD
    A["Feed & Expansion Tank"] --> B["Open Vent"]
    B --> C["1"]
    B --> D["2"]
    B --> E["11"]
    B --> F["13"]
    B --> G["10"]
    B --> H["6"]
    B --> I["3"]
    B --> J["8"]
    B --> K["15"]
    B --> L["14"]
    B --> M["17"]
    B --> N["9"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#ffc,stroke:#333
    style H fill:#ffc,stroke:#333
    style I fill:#ffc,stroke:#333
    style J fill:#ffc,stroke:#333
    style K fill:#ffc,stroke:#333
    style L fill:#ffc,stroke:#333
    style M fill:#ffc,stroke:#333
    style N fill:#ffc,stroke:#333

Figure 17.1 - Typical Open Vented Indirect Cylinder Schematic

Legend

1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater

Legend

graph TD
    A["17"] --> B["2"]
    B --> C["13"]
    C --> D["6"]
    D --> E["10"]
    E --> F["11"]
    F --> G["14"]
    G --> H["18"]
    H --> I["15"]
    I --> J["5"]
    J --> K["7"]
    K --> L["6"]
    L --> M["4"]
    M --> N["3"]
    N --> O["2"]
    O --> P["1"]
    P --> Q["Cold water booster pump set"]
    Q --> R["1"]
    R --> S["2"]
    S --> T["2"]
    T --> U["1"]
    U --> V["1"]
    V --> W["17"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#fcf,stroke:#333
    style H fill:#cff,stroke:#333
    style I fill:#fcf,stroke:#333
    style J fill:#cff,stroke:#333
    style K fill:#cff,stroke:#333
    style L fill:#cff,stroke:#333
    style M fill:#cff,stroke:#333
    style N fill:#cff,stroke:#333
    style O fill:#cff,stroke:#333
    style P fill:#cff,stroke:#333
    style Q fill:#ffc,stroke:#333
    style R fill:#ffc,stroke:#333
    style S fill:#ffc,stroke:#333
    style T fill:#ffc,stroke:#333
    style U fill:#ffc,stroke:#333

Figure 17.2 - Typical Unvented Indirect Cylinder Schematic

graph TD
    A["Feed & Expansion Tank"] --> B["1"]
    B --> C["2"]
    C --> D["3"]
    D --> E["4"]
    E --> F["5"]
    F --> G["6"]
    G --> H["7"]
    H --> I["8"]
    I --> J["9"]
    J --> K["10"]
    K --> L["11"]
    L --> M["12"]
    M --> N["13"]
    N --> O["14"]
    O --> P["15"]
    P --> Q["16"]
    Q --> R["17"]
    R --> S["18"]
    S --> T["19"]
    T --> U["Open Vent"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#fcc,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#fcc,stroke:#333
    style K fill:#cfc,stroke:#333
    style L fill:#fcc,stroke:#333
    style M fill:#cfc,stroke:#333
    style N fill:#fcc,stroke:#333
    style O fill:#cfc,stroke:#333
    style P fill:#fcc,stroke:#333
    style Q fill:#cfc,stroke:#333
    style R fill:#fcc,stroke:#333
    style S fill:#cfc,stroke:#333
    style T fill:#fcc,stroke:#333
    style U fill:#cfc,stroke:#333

Legend

1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve (not of Elco supply)
19. Inox Maxi SSC2

Figure 17.3 - Typical Open Vented Indirect Cylinder Schematic

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["10"]
    J --> K["11"]
    K --> L["12"]
    L --> M["13"]
    M --> N["14"]
    N --> O["15"]
    O --> P["16"]
    P --> Q["17"]
    Q --> R["18"]
    R --> S["19"]

    style A fill:#f9f,stroke:#333
    style B fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style D fill:#f9f,stroke:#333
    style E fill:#f9f,stroke:#333
    style F fill:#f9f,stroke:#333
    style G fill:#f9f,stroke:#333
    style H fill:#f9f,stroke:#333
    style I fill:#f9f,stroke:#333
    style J fill:#f9f,stroke:#333
    style K fill:#f9f,stroke:#333
    style L fill:#f9f,stroke:#333
    style M fill:#f9f,stroke:#333
    style N fill:#f9f,stroke:#333
    style O fill:#f9f,stroke:#333
    style P fill:#f9f,stroke:#333
    style Q fill:#f9f,stroke:#333
    style R fill:#f9f,stroke:#333
    style S fill:#f9f,stroke:#333
    style T fill:#f9f,stroke:#333
    style U fill:#f9f,stroke:#333
    style V fill:#f9f,stroke:#333
    style W fill:#f9f,stroke:#333
    style X fill:#f9f,stroke:#333
    style Y fill:#f9f,stroke:#333
    style Z fill:#f9f,stroke:#333
    style AA fill:#f9f,stroke:#333
    style AB fill:#f9f,stroke:#333
    style AC fill:#f9f,stroke:#333
    style AD fill:#f9f,stroke:#333
    style AE fill:#f9f,stroke:#333
    style AF fill:#f9f,stroke:#333
    style AG fill:#f9f,stroke:#333
    style AH fill:#f9f,stroke:#333
    style AI fill:#f9f,stroke:#333
    style AJ fill:#f9f,stroke:#333
    style AK fill:#f9f,stroke:#333
    style AL fill:#f9f,stroke:#333
    style AM fill:#f9f,stroke:#333
    style AN fill:#f9f,stroke:#333
    style AO fill:#f9f,stroke:#333
    style AP fill:#f9f,stroke:#333
    style AQ fill:#f9f,stroke:#333
    style AR fill:#f9f,stroke:#333

Figure 17.4 - Typical Unvented Indirect Cylinder Schematic

graph TD
    A["17"] --> B["2"]
    B --> C["11"]
    C --> D["20"]
    D --> E["12"]
    E --> F["P"]
    F --> G["Trigon XL Water Heater"]
    G --> H["5"]
    H --> I["7"]
    I --> J["6"]
    J --> K["4"]
    K --> L["3"]
    L --> M["2"]
    M --> N["1"]
    O["12"] --> P["2"]
    Q["10"] --> R["13"]
    S["21"] --> T["2"]
    U["8"] --> V["23"]
    W["17"] --> X["12"]
    Y["10"] --> Z["10"]

Figure 17.5 - Typical Unvented Water Heater and Buffer Vessel Schematic

graph TD
    A["12"] --> B["17"]
    B --> C["2"]
    C --> D["11"]
    D --> E["20"]
    E --> F["22"]
    F --> G["5"]
    G --> H["6"]
    H --> I["7"]
    I --> J["8"]
    J --> K["23"]
    K --> L["10"]
    L --> M["21"]
    M --> N["22"]
    N --> O["4"]
    O --> P["3"]
    P --> Q["2"]
    Q --> R["1"]

Figure 17.6 - Typical Unvented Packaged Plate Heat Exchanger and Buffer Vessel Schematic

Legend

1. Cold water mains supply
2. Isolating valve
3. Strainer
4. Pressure reducing valve
5. Expansion vessel
6. Non return valve
7. Expansion relief valve
8. Drain valve
9. Inox Maxi SSC1
10. Re-circulating pump
11. Hot water outlets
12. Temperature & pressure relief valve
13. De-Stratification pump
14. Primary heating circuit flow
15. Primary heating circuit return
16. Pressure relief valve
17. Immersion heater
18. Two port motorised valve (not of Elco supply)
19. Inox Maxi SSC2
20. Double regulating valve
21. Loading pump
22. Packaged plate heat exchanger set
23. Inox Maxi HSB Tank

18 Commissioning

1. If the installation is unvented, before filling the system with water, check the air pressure in the potable water expansion vessel and adjust as necessary to nominal 3.5bar.
2. If the pressure regulating valve supplied with the unvented kit is an adjustable type, ensure that the setting is limited at a maximum of 3.5bar.
3. Ensure all drain valves are closed
4. Open a tap at the furthest distance from the cylinder.
5. Open the isolation valve in the water supply to the cylinder, allowing the cylinder to fill and air to be expelled from the system via the open tap. Continue to allow water to flow from the open tap for some minutes until the water flows freely without air and dirt particles.
6. Check/operate each tap in turn on the system to ensure that the pipework is fully vented of air and dirt/installation debris is flushed from the installation.
7. Visually check all joints for water tightness.
8. Check the operation of all relief valves by manually opening the valves via the attached levers and ensuring that the discharged water clears freely via the tundish and the discharge pipework. Check that the flow ceases completely when the levers are released.

Immersion Heater

1. Turn on the power supply to the immersion heater/s and allow the cylinder to heat up.

2. Check operation of control thermostat.

3. Visually check all joints for water tightness.

4. Check that no water is/has issued from the thermal and pressure relief valve or expansion relief valve.

Cylinder and Buffer Vessel

1. Manually open the motorised valve in the primary circuit and fill, flush and vent the primary coil observing any instructions from the boiler manufacturer.

2. Turn on the primary heat source (boiler) and allow the cylinder to heat up.

3. Check operation of control thermostat and motorised valve

4. Visually check all joints for water tightness.

5. Check that no water is/has issued from the thermal and pressure relief valve or expansion relief valve.

19 User instructions

1. Important if water is seen to issue from either the thermal and pressure re valve or expansion relief valve then turn off the electricity supply to immers heaters (direct units) or turn off the boiler (indirect units) Do not turn off the water supply. Immediately contact a competent installer of unvented hot wall systems for assistance.

2. Do not tamper with any safety relief valve fitted to the system, if a fault is suspected contact a competent installer.

3. Temperature control – immersion heaters have an adjustable thermostat with settings between 40 and 80°C. Isolate electricity supply before removing the cover on the top of the immersion heater and making any adjustment.

4. Temperature control – Indirect units. A twin thermostat is factory pre fitted to the cylinder with a manually adjustable setting between 25 and 65°C. Adjust to the required setting.

5. Be aware that it is quite normal for a surge in flow and pressure to occur on initial opening of a hot water tap on a unvented hot water system and does not indicate a fault.

20 Regular Maintenance

To ensure safe and continued performance of the water heater it is a requirement that the unit should be regularly maintained and only genuine spare parts from Elco Heating should be used.

Maintenance should be carried out at intervals not exceeding 12 months by a competent installer

In hard water areas, immersion heaters should be periodically de-scaled.

The operation of thermal and pressure relief valve and expansion relief valve should be checked by manually operating via the test levers; water should flow freely through the tundish and the valve should reseat when the lever is released. Warning the water discharged may be very hot. The strainer in the water supply should be checked and cleaned during maintenance operations.

21 Draining the Cylinder & / or Buffer Vessel

This operation should only be undertaken by a competent person as water drained from the system may be very hot and under pressure.

WARNING: Irreparable damage may occur to the cylinder body if a vacuum created in the cylinder during emptying.

22 Easy Control Panel

For more detailed information refer to the product instruction manual.

The panel is suitable for remote mounting or mounting directly onto the cylinder.

Description

EASY CONTROL is a central controller for domestic hot water production systems. The EASY CONTROL panel

makes it simple to programme the temperature of the domestic hot water as required at different times of the day, optimising the comfort of the user with the use of the system at the same time. The micro-processor is capable of controlling up to 2 boilers with the option for an additional third heat source such as for example an immersion heater and the recirculation pump. EASY CONTROL also enables the “Anti-Legionella” cycle to be programmed to prevent the proliferation of the harmful bacteria in compliance with L8 - HSG274.

Operation

EASY CONTROL offers four modes of operation: Manual, Daily, Weekly and Weekend. The operation of any immersion heater will always be in manual mode and its activation will be at the discretion of the user using the keypad on the control panel: Electrical resistance: P3 = ON/OFF. In manual mode the user sets the temperature of the hot water for each of the probes and the central processor ensures the boiler operates until the desired value is reached, regardless of the day and time. In Daily mode it is possible to programme three time periods for each day of the week. For each of these it can be decided whether or not to allow the boilers,

(P1 and P2), to operate according to the temperature values set for the respective probes, T1 and T2. Compared with the daily mode, the weekly mode enables identical regulation of the three time phases for all the days of the week while the Weekend mode enables the regulation for Saturday and Sunday to be different from the other days of the week.

BMS Control

In order to program the unit(s) for integration with a Building Management System the set temperature on the Easy Control Panel has to be set to 5°C above the temperature that the BMS system is set at to avoid the Easy Control overriding the BMS system.

Wiring

	Symbol	Terminals	Device	Characteristics
INPUTS	EXT line	External cable	Mains Supply	230 Vac 50 Hz ±10% FUSE 1 T 15 A
	INT line	1 – 2	Internal mains supply	230 Vac 50 Hz ±10% FUSE 2 T 5 A
	T1	18 – 19	Primary Probe 1	Range of operation: -50°C ÷ 125 °CRange of measurement: 0 ÷ 110 °C± 1°C
	T2	20 – 21	Primary Probe 2	Range of operation: -50°C ÷ 125 °CRange of measurement: 0 ÷ 110 °C ± 1°C
	T3	22 – 23	Primary Probe 3	Range of operation: -50°C ÷ 125 °CRange of measurement: 0 ÷ 110 °C ± 1°C
OUTPUTS	P1	3 – 4	Primary Control 1	230 Vac 300 W Max
	P2	5 – 6 – 7	Primary Control 2	230 Vac 300 W Max
	P3	8 – 9	Immersion Heater 30-31	230 Vac 300 W Max
	P4	10 – 11 – 12	Secondary recirculation control	230 Vac 300 W Max
	P5	13 – 14 – 15	Anti-legionella control	Contacts: Com.(14)-N.O.(13)-N.C.(15)
	Resistance	30 – 31	AUX Immersion Heater Contractor	230 Vac 2500 W Max

ELCO UK

3 Juniper West, Fenton Way, Southfields Business Park, Basildon, Essex SS15 6SJ

Tel: [phone] Fax: [phone]

www.elco.co.uk

This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. All offers and sales are subject to the Company's current terms and conditions of sale.