andrews 24/39 Manual
2 Issue 2 14/07/16
Andrews Water Heaters
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 UK users is drawn to their responsibilities under the Health
and Safety Regulations 1993.
All installation and service on Andrews Water Heaters 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.
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:
Customer support
Monday - Friday
8am - 5pm
Sales: 0345 070 1055
Technical: 0345 070 1057
Email: [email protected]
Website: www.andrewswaterheaters.co.uk
Twitter: @andrewsWH
Copyright Andrews Water Heaters 2015
Issue 2 14/07/16 3
Contents
Contents
1 General and safety information
1.1 General information
1.2 British standards and codes of practice
1.2.1 Standard range & Hiflo range
1.3 Health and safety regulations 1993
1.4 ffectiveness in combating legionella
2 Technical data
2.1 Standard range (Natural Gas)
2.2 Standard range (LPG)
2.3 Hiflo range (Natural Gas)
2.4 Hiflo range (LPG)
2.5 rP data
3 Installation
3.1 Introduction
3.1.1 The law requires that installation is carried out by a
properly qualified person
3.2 Assembling the draught diverter
3.3 Location
3.4 Gas supply
3.4.1 Installation of the LPG supply
3.5 lectrical supply - auto ignition units
3.5.1 Hiflo models - standard range models
3.6 Flue systems
3.7 Air supply and ventilation
3.8 Water quality and treatment
3.9 Water connections
3.9.1 Hydrojet systems
3.9.2 Vented systems, standard range
3.9.3 Correx powered anodes
3.9.4 To install kit
3.9.5 Test the installation
3.9.6 Unvented systems, standard range
3.9.7 Vented systems, Hiflo range
3.9.8 Unvented systems, Hiflo range
4 Commissioning
4.1 Standard range permanent pilot models
4.1.1 Lighting the burner
4.1.2 Shutting off the burner
4.1.3 Checking main burner pressure
4.2 Hiflo range permanent pilot models
4.2.1 Lighting the burner
4.2.2 Shutting off the burner
4.2.3 Checking main burner pressure
4.2.4 Check correct shape and size of pilot flame
4.2.5 Checking for spillage at the draught diverter
4.3 Standard range auto ignition models
4.3.1 Lighting the burner
4.3.2 Shutting off the burner
4.3.3 Checking mains burner pressure
4.4 Hiflo range auto ignition models
4.4.1 Lighting the burner
4.4.2 Shutting off the burner
4.4.3 Checking mains burner pressure
4.5 Instructing the user
4.5.1 All standard and Hiflo models
4.6 Users safety guide
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Contents
5 Operation
5.1 Standard range
5.2 Hiflo range
5.2.1 Permanent pilot models, operating sequence
5.3 HIflo and standard range auto ignition
5.3.1 Auto ignition units, operating sequence. Hiflo and standard range
5.3.2 CO (energy cut - off)
5.3.3 Temperature stratification (stacking)
6 Servicing
6.1 Introduction
6.1.1 Servicing must be carried out by a properly qualified person
6.2 Pre - service options
6.2.1 Servicing, carry out the following operations
6.3 Burner assembly standard range
6.3.1 The burner assembly should be checked and cleaned annually
6.4 Burner assembly Hiflo range
6.4.1 The burner assembly should be checked and cleaned annually
6.5 Gas control valve standard range
6.6 Gas control valve Hiflo range
6.7 Fuel ways standard range
6.8 Fuel ways Hiflo range
6.9 Cleaning the storage vessel all models
6.9.1 Descaling
6.10 Magnesium anode(s) all models
6.11 Safety valve Hiflo models
6.12 Restart all models
7 Replacing components, Hiflo range
7.1 Gas control valve
7.2 User - adjustable control thermostat with limit sensor phial and overheat CO
7.3 Thermopile/ pilot, burner/ pilot restrictor
7.4 Burner
8 Fault finding
8.1 Permanent pilot models standard and Hiflo range
8.2 All models
8.3 Auto ignition units standard range
8.4 Auto ignition units Hiflo models
8.5 Checking “correx” anodes
8.6 LPG permanent pilot models - LPG HIflo ranges
9 Parts list and illustrations
9.1 Standard Range models 24/29, 32/40, 40/61, 63/62 (Natural Gas)
9.2 Standard Range models 84/87 (Natural Gas)
9.3 Standard Range models parts list (Natural Gas)
9.4 Standard Range LPG models L24/31, L32/35, L40/36, L63/71
9.5 Standard Range LPG model L84/74
9.6 Standard Range models parts list (LPG)
9.7 HIflo models 32/143 (Natural Gas)
9.8 HIflo models 65/173 and 81/264 (Natural Gas)
9.9 HIflo models parts list (Natural Gas)
9.10 HIflo models 62/341 and 54/418/440 (Natural Gas)
9.11 HIflo models parts list (Natural Gas)
9.12 HIflo LPG model L32/143
9.13 HIflo LPG models L65/169, L81/251
9.14 HIflo P.P Water Heater parts list (LPG)
9.15 HIflo LPG models L62/309, L54/399
9.16 HIflo P.P Water Heater parts list (LPG)
9.17 Unvented systems kit - standard range
9.18 Unvented systems kit - Hiflo range
9.19 Unvented systems kit - standard range parts list
9.20 Unvented systems kit - Hiflo range parts list
9.21 24 Volt auto system kit B217
9.22 24 Volt auto system kit B258
9.23 24 Volt auto system kit standard range parts list
9.24 24 Volt auto system kit Hiflo parts list
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Issue 2 14/07/16 5
Contents
10 Appendix
10.1 Hiflo auto ignition “G” series addendum
10.1.1 Features of honeywell integrated control system
10.2 Specifications
10.3 Sequence of operations
10.4 Troubleshooting
10.4.1 Using control display for servicing the water heater
10.4.2 Service mode
10.4.3 To change the maximum setpoint limit (max setpoint) for the
temperature setpoint
10.4.4 Display of water temperature
10.4.5 To display flame sense current of the pilot flame sensor
10.4.6 To display and change temperature setpoint
10.4.7 To display and change temperature format (°F/°C)
10.4.8 rror codes and error history display
10.4.9 rror code history
10.4.10 To view previous error codes
10.4.11 rror code definitions
10.4.12 Resetting lockout conditions
10.4.13 Resetting error codes in hard lockout conditions
10.5 Service procedure D24 - I
10.5.1 Thermostat circuit testing
10.5.2 Sensor resistance testing
10.5.3 Sensor resistance at various temperatures
10.6 Service procedure D24 - II
10.6.1 Pilot operation testing
10.6.2 Pilot inspection
10.6.3 Pilot operation testing
10.7 Service procedure D24 - III
10.7.1 Main burner operation testing
10.7.2 Checking manifold pressure
10.8 Service procedure D24 - IV
10.8.1 Main burner & pilot removal and inspection
10.8.2 Control board replacement
10.9 Service procedure D24 - V
10.9.1 Flue baffle removal and inspection
10.10 Service procedure D24 - VI
10.10.1 Anode removal and inspection
10.11 General assembly
10.12 Burner assembly
10.13 Control box assembly
10.14 General assembly parts list
10.15 Burner assembly parts list
10.16 Control box assembly parts list
10.17 Dismantling, disposal and recycling
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6 Issue 2 14/07/16
1 General and Safety Information
1 General and safety information
1.1 General information
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 SAF TY (INSTALLATION AND US )
R GULATIONS
The current BUILDING R GULATIONS
The Water Supply (WAT R FITTINGS) R GULATIONS 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.
1.2 British standards and codes of practice
1.2.1 Standard Range & Hiflo Range
BS 6700: 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: Specification for installation of flues.
Part 2: Specification for installation of ventilation for
gas appliances.
BS 5546: 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: Specification for unvented hot water storage
units and packages.
Issue 2 14/07/16 7
General and Safety Information 1
BS N 806 (Parts 1 - 5) Specifications for installations
inside buildings conveying water for human
consumption.
BS 6644 Installation of gas fired water boilers of rated
inputs between 70kW and 1.8MW.
BS N 12897 Water supply. Specification for indirectly heated
unvented (closed) storage water heaters.
IG /UP/1A,1B Strength/tightness testing and direct purging.
IG /UP/2 Installation pipework.
IG /UP/10 - 1 ( dition 4): Installation of gas appliances in
industrial and commercial premises.
IG /UP/10 Pt.1
dition 2 Installation of Gas Appliances in Industrial and
Commercial Premises.
8 Issue 2 14/07/16
1 General and Safety Information
1.3 Health and safety regulations 1993
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.
1.4 Effectiveness in combating legionella
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 Legionella 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 xecutive
(HS)(G70) and the Chartered Institute of Building Services
ngineers (CIBS , 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 Legionella bacteria. These factors include
stagnation, lukewarm conditions (20°C to 45°C) 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 legionella bacteria.
xperiments were conducted to determine whether, following a
substantial challenge by legionella pneumophila, after overnight
and stagnation conditions, the system was rendered free from
viable recoverable legionella. It was found that at 61°C, 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 legionella 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 legionella resistant as it is
considered unlikely that, at the temperature tested, the organism
would colonise the water heater and present a possible health
risk.
Issue 2 14/07/16 9
Technical Data 2
2 Technical data
2.1 Standard Range (Natural Gas)
Andrews Model No. 24/39 32/40 40/61 63/62 84/87
Storage Capacity I 109 145 182 286 382
Recovery thro’ 50°C I/h 156 159 243 247 348
Recovery thro’ 56°C I/h 139 142 217 220 311
Heat Input Gross kW 12 12.5 19 19 26
Heat Input Net kW 11 11.4 17 17 24
Gas NATURAL CAT I2H
Burner Gas Pressure mbar 10 10 10 10 10
Max. Gas Input Pressure mbar 35 35 35 35 35
Gas Flow Rate m3/h 1.12 1.16 1.78 1.78 2.43
Gas Connection Rc (in BSP Int) 1/2 1/2 1/2 1/2 1/2
Flue Gas Temp. °C 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
Flue Size (Secondary) mm 100 100 100 125 125
Cold Water Feed Connection R (in BSP/ xl) 1111 1 1/4
Hot Water Flow Connection R (in BSP/ xl) 1111 1 1/4
*Return Connection Rp (in BSP/ xl) 3/4 3/4 3/4 3/4 3/4
Drain Port Size R (in BSP/ xl) 3/4 3/4 3/4 3/4 3/4
Max. Working Water Pressure (vented) bar 10.3 10.3 10.3 10.3 10.3
Max. Working Water Pressure (unvented) bar 5.5 5.5 5.5 5.5 5.5
Water Test Pressure bar 20.7 20.7 20.7 20.7 20.7
Weight mpty kg 43 57 65 110 181
Weight Full kg 151 202 247 396 562
Shipping Weight kg 44 59 68 120 194
Shipping Dimensions Depth mm 546 587 587 692 914
Shipping Dimensions Width mm 486 537 537 651 762
Shipping Dimensions Height mm 1194 1245 1499 1575 1829
10 Issue 2 14/07/16
2 Technical Data
2.2 Standard Range (LPG)
Andrews Model No. L24/31 L32/35 L40/36 L63/71 L84/74
Storage Capacity I 109 145 182 286 382
Recovery thro’ 50°C I/h 141 163 163 322 336
Recovery thro’ 56°C I/h 113 127 131 258 269
Heat Input Gross kW 9.5 11.0 11.0 22.0 22.0
Heat Input Net kW 8.6 10 10 20 20
Gas LPG CAT I3
Inlet Gas Pressure Propane mbar 37 37 37 37 37
Inlet Gas Pressure Butane mbar 28 28 28 28 28
Gas Flow Rate m3/h 0.36 0.41 0.41 0.83 0.83
Gas Connection Rc (in BSP Int) 1/2 1/2 1/2 1/2 1/2
Flue Gas Temp. °C 180 180 185 125 130
Flue Gas Volume m3/h 16 16 23 28 34
Gas Injector Orifice Diameter mm 1.5 1.6 1.6 2.25 2.25
Flue Size (Secondary) mm 100 100 100 125 125
Cold Water Feed Connection R (in BSP/ xl) 1111 1 1/4
Hot Water Flow Connection R (in BSP/ xl) 1111 1 1/4
*Return Connection Rp (in BSP/ xl) 3/4 3/4 3/4 3/4 3/4
Drain Port Size R (in BSP/ xl) 3/4 3/4 3/4 3/4 3/4
Max. Working Water Pressure (vented) bar 10.3 10.3 10.3 10.3 10.3
Max. Working Water Pressure (unvented) bar 5.5 5.5 5.5 5.5 5.5
Water Test Pressure bar 20.7 20.7 20.7 20.7 20.7
Weight mpty kg 43 57 65 110 181
Weight Full kg 151 202 247 396 562
Shipping Weight kg 44 59 68 120 194
Shipping Dimensions Depth mm 546 587 587 692 914
Shipping Dimensions Width mm 486 537 537 651 762
Shipping Dimensions Height mm 1194 1245 1499 1575 1829
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