Andrews 32/143 Manuel utilisateur

Working towards

a cleaner future

Gas Fired Storage

Water Heaters

Installation guide, operation

and service manual

This manual must be kept with the appliance January 2011

Part No E132

Natural Gas

HI-FLO RANGE

Models 32/143, 65/173, 81/264, 62/341, 54/418, 54/440

Permanent Pilot, Auto Ignition wit Flue Damper ‘E’/‘F’ Series

STANDARD RANGE

Models 24/39, 32/40, 40/61, 63/62, and 84/87

Permanent Pilot, Auto Ignition ‘G’ Series

Reproduction of any information in this publication by any method is not permitted

unless prior written approval has been obtained from Andrews Water Heaters.

Andrews Storage Water Heaters have been designed and manufactured to comply

with current International standards of safety. In the interests of the health and

safety of personnel and the continued safe, reliable operation of the equipment,

safe working practices must be employed at all times. The attention of U.K. users is

drawn to their responsibilities under the Health and Safety Regulations 1993.

All installation and service on the Andrews Water Heater must be carried out by

properly qualified personnel, and therefore no liability can be accepted for any

damage or malfunction caused as a result of intervention by unauthorised

personnel.

The Andrews Water Heaters policy is one of continuous product improvement, and

therefore the information in this manual, whilst completely up to date at the time of

publication, may be subject to revision without prior notice.

Further information and assistance can be obtained from:

Andrews Water Heaters

Wood Lane, Erdington, Birmingham B24 9QP

Technical Helpline

Tel: 0845 070 1057 Fax: 0845 070 1059

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL

ARE FOR USE WITH NATURAL GAS ONLY

CONTENTS

SECTION 1 GENERAL AND SAFETY INFORMATION

General Information 2

British Standards 2

Health and Safety Regulations 1993 3

Legionellae in Water Heaters 3

SECTION 2 TECHNICAL DATA

Standard Range 4

Hi-Flo Range 5

SECTION 3 INSTALLATION

Introduction 6

Draught Diverter 6

Location 6

Gas Supply 7

Electrical Supply 8

Flue Systems 10

Air Supply and Ventilation 12

Water Quality and Treatment 14

Water Connections- Hydrojet System 15

Vented Systems, Standard Range 16

Unvented Systems, Standard Range 18

Vented Systems, Hi-Flo Range 20

Unvented Systems, Hi-Flo Range 23

SECTION 4 COMMISSIONING

Standard Range 26

Hi-Flo Range 28

SECTION 5 OPERATION

Standard Range 35

Hi-Flo Range 35

SECTION 6 SERVICING

Introduction 36

Burner Assembly, Standard Range 36

Burner Assembly, Hi-Flo Range 36

Gas Control Valve, Standard Range 37

Gas Control Valve, Hi-Flo Range 37

Flue Ways 37

Cleaning the Storage Vessel 38

Magnesium Anode(s) 38

Safety Valve 38

SECTION 7 REPLACING COMPONENTS, Hi-Flo RANGE

Gas Control Valve 40

Burner 40

SECTION 8 FAULT FINDING

Permanent Pilot Models - Standard and Hi-Flo Range 41

All Models 42

Auto Ignition Models, Hi-Flo Range 43

SECTION 9 PARTS LISTS AND ILLUSTRATIONS

Standard Range 45

Hi-Flo Range 46

Unvented Systems Kit 50

24V Auto System Kit 52

PAGE

GENERAL AND SAFETY INFORMATIONSECTION 1

The Andrews Water Heater has been designed for use with NATURAL GAS only and is

manufactured to give an efficient, reliable and long service life.

To ensure the continued, trouble-free operation of your heater at maximum efficiency, it

is essential that correct installation, commissioning, operation and service procedures are

carried out strictly in accordance with the instructions given in this manual. By law,

installation and commissioning of the heater must be carried out by properly qualified

personnel.

The heater(s) must be installed in accordance with the following requirements;

The current GAS SAFETY (INSTALLATION AND USE) REGULATIONS

The current BUILDING REGULATIONS

The Water Supply (WATER FITTINGS) REGULATIONS 1999

Additionally, installation should be performed in accordance with all relevant

requirements of the Gas Supplier, Local Authority and recommendations of the British

Standards and Codes of Practice detailed below.

STANDARD RANGE

BS 6700: 1997 Specification for design, installation, testing and maintenance of

services supplying water for domestic use within buildings and their

curtilages. This standard supersedes the following British Standards

and Codes of Practice: CP99, CP310, CP324, 202, CP342 Part 2,

Centralised Hot Water Supply.

BS 5440 Installation of flues and ventilation for gas appliances of rated output

not exceeding 60kW.

Part 1:2000 Specification for installation of flues.

Part 2:2000 Specification for installation of ventilation for gas appliances.

BS 5546:1990 Installation of gas hot water supplies for domestic purposes.

BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic

premises.

BS 7206:1990 Specification for unvented hot water storage units and packages.

I/M2 Purging procedures for non-domestic gas installations.

I/M5 Soundness testing procedures for industrial and commercial gas

installations.

I/M11 Flues for commercial and industrial gas fired boilers and air heaters.

I/M16 Notes on installation of gas pipework

(excluding 25mm and below).

IGE/UP/10 Pt.1

Edition 2 Installation of Gas Appliances in Industrial and Commercial Premises

Hi-Flo RANGE

As STANDARD RANGE plus:

BS 6644: Installation of gas fired hot water boilers of rated inputs between

60kW and 2MW.

NOTE: Consideration should be given to amendments or updates to the

above standards.

GENERAL

INFORMATION

BRITISH

STANDARDS

AND CODES OF

PRACTICE

GENERAL AND SAFETY INFORMATION SECTION 1

It is the duty of manufacturers and suppliers of products for use at work to ensure, so far

as is practicable, that such products are safe and without risk to health when properly

used and to make available to users, adequate information about their safe and proper

operation.

Andrews Water Heaters should only be used in the manner and purpose for which they

were intended and in accordance with the instructions in this manual. Although the

heaters have been manufactured with paramount consideration to safety, certain basic

precautions specified in this manual must be taken by the user.

It is imperative that all users of the heater must be provided with all the information and

instruction necessary to ensure correct and safe operation.

Water systems in buildings have been associated with outbreaks of Legionnaires' Disease,

particularly in health care facilities where occupants are significantly more susceptible to

infection.

In recognition of the risks in hospitals, a Code of Practice for the Control of Legionellae

in Health Care premises has been issued by the Department of Health (1991). Codes of

Practice applicable to other premises have been published by other organisations,

principally the Health and Safety Executive (HS)(G70) and the Chartered Institute of

Building Services Engineers (CIBSE, TM13).

All Codes of Practice draw attention to the design and operation of water systems with

reference to avoidance of factors that favour colonisation by Legionellae bacteria. These

factors include stagnation, lukewarm conditions (20ºC to 45ºC) and the accumulation of

debris, scale and corrosion in the base of tanks and calorifiers.

Andrews Water Heaters has commissioned an independent evaluation of their products

to investigate their resistance to build-up of legionellae bacteria.

Experiments were conducted to determine whether, following a substantial challenge by

legionellae pneumophilia, after overnight and stagnation conditions, the system was

rendered free from viable recoverable legionellae. It was found that at 61ºC, following a

challenge of approximately 107 organisms per litre, within one hour, more than 99.999%

of organisms had been killed. After a subsequent stagnation period, sampling did not

reveal any residual contamination. The design of the base of the water heater precludes

legionellae colonisation, even after build-up of debris. The burner positioning ensures

that the water at the bottom of the heater reaches the same, or higher temperature as in

the rest of the heater.

Based on data obtained through experiment, the Andrews Water Heater can be described

as legionellae resistant as it is considered unlikely that, at the temperature tested, the

organism would colonise the water heater and present a possible health risk.

HEALTH AND

SAFETY

REGULATIONS

1993

EFFECTIVENESS

IN COMBATING

LEGIONELLAE

TECHNICAL DATASECTION 2

STANDARD

RANGE

Storage Capacity l 109 145 182 286 382

gal 24 32 40 63 84

Recovery thro' 44ºC/80ºF l/h 178 182 278 281 397

gal/h 39 40 61 62 87

Recovery thro' 56ºC/100ºF l/h 142 146 220 227 316

gal/h 31 32 49 50 70

Heat Input Gross kW 12 12.5 19 19 26

Btu/h 40,944 42,650 65,000 65,000 88,712

Heat Input Net kW 11 11.4 17 17 24

Btu/h 37,532 38,900 58,004 58,004 81,888

Gas NATURAL CAT I2H

Burner Gas Pressure mbar 10 10 10 10 10

ins wg. 4 4 4 4 4

Max. Gas Input Pressure mbar 35 35 35 35 35

ins wg. 14 14 14 14 14

Gas Flow Rate m3/h 1.12 1.16 1.78 1.78 2.43

ft3/h 39.4 41.22 62.86 62.86 85.71

Gas Connection Rc (in BSP Int) 1/2 1/2 1/2 1/2 1/2

Flue Gas Temp. ºC 200 205 195 160 125

Flue Gas Volume m3/h 17 18 26 31 37

Gas Injector Orifice Diameter mm 2.95 3.05 3.86 3.86 4.22

in 0.116 0.120 0.152 0.152 0.166

Flue Size (Secondary) mm 100 100 100 125 125

in 4 4 4 5 5

Cold Water Feed Connection R (in BSP/Exl) 1 1 1 1 11/4

Hot Water Flow Connection R (in BSP/Exl) 1 1 1 1 11/4

*Return Connection Rp (in BSP/Int) 3/4 3/4 3/4 3/4 3/4

Drain Port Size R (in BSP/Ext) 3/4 3/4 3/4 3/4 3/4

Max. Working Pressure bar 10.3 10.3 10.3 10.3 10.3

lbf/in2150 150 150 150 150

Max. Test Pressure bar 20.6 20.6 20.6 20.6 20.6

lbf/in2300 300 300 300 300

Weight Empty kg 43 57 65 110 181

lb 94 126 144 244 400

Weight Full kg 151 202 247 396 562

lb 334 446 544 874 1240

Shipping Weight kg 44 59 68 120 194

lb 98 131 150 264 428

Shipping Dimensions Depth mm 546 587 587 692 914

in 211/2 231/8 231/8 271/4 36

Shipping Dimensions Width mm 486 537 537 651 762

in 19 1/8 21 1/8 21 1/8 25 5/8 30

Shipping Dimensions Height mm 1194 1245 1499 1575 1829

in 47 49 59 62 72

ANDREWS MODEL NO. 24/39 32/40 40/61 63/62 84/87

TECHNICAL DATA SECTION 2

Storage Capacity l 145 295* 368* 282* 245* 245

gal 32 65 81 62 54 54

Recovery thro' 44ºC/80ºF l/h 649 786 1199 1549 1900 1998

gal/h 143 173 264 341 418 440

Recovery thro' 56ºC/100ºF l/h 517 629* 959 1239* 1520* 1598*

gal/h 114 138 212 273 334 352

Recovery thro' 72ºC/130ºF l/h 399 484* 730 953* 1169* 1223*

gal/h 88 106 162 210 257 270

Heat Input Gross kW 42.8 50 80 102 128 139

Btu/h 146,034 170,600 272,960 384,024 436,736 474,268

Heat Input Net kW 39 45 73 93 116 126

Btu/h 133,068 153,540 249,076 317,316 395,792 430,000

Gas NATURAL CAT I2H

Burner Gas Pressure mbar 6.8 6.8 6.8 6.8 6.8 N/A

Pernament Pilot ins wg. 2.73 2.73 2.73 2.73 2.73 N/A

Burner Gas Pressure mbar 10 10 10 10 10

Auto Ignition ins wg. 4 4 4 4 4

Max. Gas Input Pressure mbar 35 35 35 35 35

ins wg. 14 14 14 14 14

Gas Flow Rate m3/h 4.0 4.68 7.44 9.48 11.94 13.14

ft3/h 141 164.76 263.58 336.24 421.98 465.06

Gas Connection Rc (in BSP Int) 3/4 3/4 3/4 3/4 3/4 3/4

Flue Gas Temp. ºC 117 140 150 195 185 215

Flue Gas Volume m3/h 62 73 116 149 186 202

Gas Injector Orifice Diameter mm 2.69 2.87 3.66 3.45 3.50 N/A

Permanent Pilot in 0.106 0.113 0.144 0.136 0.138 N/A

Gas Injector Orifice Diameter mm 2.40 2.58 3.25 3.18 N/A 3.26

Auto Ignition in 0.094 0.101 0.127 0.125 N/A 0.128

Flue Size (Secondary) mm 150 150 200 200 250 250

in 6 6 8 8 10 10

Cold Water Feed Connection R (in BSP/Exl) 11/2 11/2 11/2 11/2 11/2 11/2

Hot Water Flow Connection R (in BSP/Exl) 11/2 11/2 11/2 11/2 11/2 11/2

*Return Connection Rp (in BSP/Int) 3/4 3/4 3/4 3/4 3/4 3/4

Drain Port Size R (in BSP/Ext) 3/4 3/4 3/4 3/4 3/4 3/4

Max. Working Pressure bar 10.3 10.3 10.3 10.3 10.3 10.3

lbf/in2150 150 150 150 150 150

Max. Test Pressure bar 20.6 20.6 20.6 20.6 20.6 20.6

lbf/in2300 300 300 300 300 300

Weight Empty kg 190 200 289 257 269 269

lb 419 441 637 566 594 594

Weight Full kg 335 495 656 538 514 514

lb 738 1091 1447 1186 1134 1134

Shipping Weight kg 199 223 316 282 293 293

lb 438 492 697 623 645 645

Shipping Dimensions Depth mm 902 914 914 914 914 914

in 35 1/2 36 36 36 36 36

Shipping Dimensions Width mm 768 762 762 762 762 762

in 30 1/4 30 30 30 30 30

Shipping Dimensions Height mm 1270 1960 2083 1960 1960 1960

in 50 77 82 77 77 77

ANDREWS MODEL NO. 32/143 65/173 81/264 62/341 54/418 54/440

Hi-Flo

RANGE

* If the water heater is to be

used on an unvented system,

the combined temperature/

pressure relief valve must be

fitted directly into the tank.

The secondary return is then

connected to the drain port

via a suitable tee.

LOCATION

INSTALLATIONSECTION 3

THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A

PROPERLY QUALIFIED PERSON

Installations must be carried out in accordance with Gas safety (Installation and Use)

Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations

1999 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.

The fittings pack supplied with the heater contains the items listed below.

1 - Installation and Service Manual.

1 - Coupler Socket 3⁄4in BSP.

1 - Gas Cock.

1 - Drain Cock.

1 - Flue Adaptor Socket (Where required).

2 - Cap End 11⁄2in BSP (Hi-Flo only).

2 - 11⁄2in x 3in Nipples (32/143 Model only).

1 - Warranty Card.

The draught diverter must be assembled with the legs provided.

Attach the legs to the draught diverter with the nuts and bolts provided.

Fit the draught diverter (1) as shown in Fig.1 to the water heater using the screws

provided. For Standard Range fit the draught diverter to the top of the water heater

using the location holes.

In some cases, it may be necessary to drill the fixing holes in the top cover to fit the

draught diverter to the water heater. By using the draught diverter as a template,

position carefully over the flueway and mark the hole positions to be drilled 4mm.

Fit the adaptor socket (2) and caulk into the draught diverter as shown in Fig. 1.

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 boiler room or compartment is strongly recommended.

A manual valve for isolation of the boiler room should be installed in the gas supply;

it should be clearly identified and readily accessible for use at all times.

If a purpose built boiler room is not available, measures should be taken to protect the

heater from damage and prevent any extraneous matter from being stored on or around

the heater.

See BS 6644 Clauses 4, 5 and 6 for details.

INTRODUCTION

ASSEMBLING

THE DRAUGHT

DIVERTER

Fig. 1

Draught Diverter

Assembly

Top Connections

81/264 Only

Elbows must be used

Top Connections

65/173

INSTALLATION SECTION 3

The heater must not be installed in any location which contains a bed, bath or shower.

There must be easy access to the boiler room and heater at all times.

A clearance of 800mm (311⁄2 in) for Hi-Flo and 300mm for Standard Range should be left

at the front of the heater for removal of the burner.

Clearances at the sides and rear of the heater should be at least 305mm (12 in).

Service clearances for removal of the anodes and flue baffles should be provided as

detailed below.

STANDARD RANGE

Models 24/39, 32/40, 40/61 762mm (30 in)

Model 63/62 1143mm (45 in)

Model 84/87 1270mm (50 in)

HI-FLO RANGE

Model 32/143 597mm (231⁄2in)

Model 81/264 1300mm (52 in)

Models 65/173, 62/341, 54/418, 54/440 1143mm (45 in)

The floor on which the heater is installed must be non-combustible, flat, level and of

sufficient strength to withstand the weight of the heater filled with water (see Section 2,

Technical Data) and should satisfy the requirements of the Local Authority and Building

Regulations.

NOTE:

If the heater is in an exposed position and out of use during a period of heavy frost, it is

recommended that the whole system is drained down to prevent damage due to the

formation of ice inside the storage vessel.

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST

ONLY BE USED WITH NATURAL GAS.

The installation of the gas supply must conform, depending on it's size, to the

requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

A gas meter will be connected to the service pipe by British Gas plc or it's authorised

contractor.

The meter and service pipe should be checked by British Gas or it's authorised contractor

to ensure that they are adequate to deal with the gas supply to the water heater(s) in

addition to any existing or additional requirements.

Gas Supply Cock, Standard Models

Fit the gas supply cock immediately upstream of the gas control thermostat using a

suitable jointing compound and connect to the gas supply. Do not apply heat in close

proximity to the gas thermostat as damage to the control will result. A pressure test point

nipple is fitted to the gas control thermostat at the gas inlet to test the incoming gas

pressure.

LOCATION

GAS SUPPLY

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