Andrews CSC39 User manual

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CSC

Installation Guide, Operation & Service Manual

This manual must be kept with the appliance August 2011

Part No E191

Natural Gas, Propane & Butane Fired

Storage Water Heaters

MODELS CSC39, CSC59, CSC78, CSC93, CSCL39, CSCL59, CSCL78, CSCL93

Auto Ignition

E191 CSC_NatGas+LPG overs 23/8/11 14:55 Page 1

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

Tel: 0845 070 1055 Fax: 0845 070 1059

Sales: 0845 070 1056

Technical: 0845 070 1057

Service: 0845 070 1058

Email: [email protected]

www.andrewswaterheaters.co.uk

THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL

ARE FOR USE WITH NATURAL GAS OR LPG (PROPANE OR BUTANE) GAS ONLY

CONTENTS

SECTION 1 GENERAL AND SAFETY INFORMATION

General Information 2

British Standards and Codes of Practice 2

Health and Safety Regulations 1993 3

Effectiveness in Combating Legionellae 3

SECTION 2 TECHNICAL DATA 4

SECTION 3 INSTALLATION

Introduction 6

Location 6

Gas Supply - Natural Gas 7

Gas Supply - LPG (Propane or Butane) Gas 8

Electrical Supply 10

Flue Systems 11

Air Supply and Ventilation 17

Water Quality and Treatment 19

Water Connections 20

SECTION 4 COMMISSIONING

Filling the Heater with Water 24

Draining Water from the Heater 24

Lighting the Burner 24

Shutting Off the Burner 25

Checking Main Burner Pressure 25

Checking Pilot and Burner Flames 25

User's Safety Guide 26

SECTION 5 OPERATION

Operating Sequence 27

ECO (Energy Cut-Off) 27

Temperature Stratification (Stacking) 27

SECTION SERVICING

Introduction 28

Pre-Service Operations 28

Annually 28

Si Monthly 28

Burner Assembly 29

Gas Control Valve 29

Magnesium Anodes 29

Combined Temperature and Pressure Relief Valve 30

Cleaning the Storage Vessel 30

Restart 30

SECTION 7 FAULT FINDING 31

SECTION 8 PARTS LISTS AND ILLUSTRATIONS 32

PAGE

GENERAL AND SAFETY INFORMATIONSECTION 1

The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG

(PROPANE OR BUTANE) 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 ma imum 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.

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 5440:2000 Installation of flues and ventilation for gas appliances of rated output

not e ceeding 60kW.

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

60kW and 2MW.

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 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 (e cluding 25mm and below).

IGE/UP/10 Pt.1

Edition 2 Installation of Gas Appliances in Industrial and Commercial Premises

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, the basic safety

precautions highlighted in this manual must be observed 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 E ecutive (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.

E periments 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 appro imately 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 e periment, 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

ANDREWS MODEL NO

Storage Capacity l 276 276 276 350

gal 61 61 61 77

Recovery thro' 44ºC/80ºF l/h 749 1149 1517 1808

gal/h 165 253 334 398

Recovery thro' 56ºC/100ºF l/h 600 922 1213 1445

gal/h 132 203 267 318

Heat Input Gross kW 44 66 88 106

Btu/h 150,128 225,192 300,256 361,672

Heat Input Net kW 40 60 80 96

Btu/h 136,480 204,720 272,960 327,552

Gas Flow Rate m3/hr 4.09 6.15 8.20 9.88

ft3/hr 144.6 217.2 289.8 349.2

Gas Flow Rates LPG m3/hr 1.78 2.54 3.39 4.09

ft3/hr 63 90 120 144.6

Gas Family 12HNATURAL and I3LPG

Feed /Flow Connections Rp (BSP) 11⁄211⁄211⁄211⁄2

Return Connections Rp (BSP) 3⁄43⁄43⁄43⁄4

Gas Connection Rp (BSP) 3⁄43⁄43⁄43⁄4

Flue Gas Temperature ºC 137 160 171 171

Flue Gas Volume m3/hr 110 109 140 164

Ma . Working Pressure bar 10 10 10 10

lbf/in2150 150 150 150

Min. Working Pressure bar 0.15 0.15 0.15 0.15

lbf/in22.2 2.2 2.2 2.2

Burner Pressure mbar 11.25 11.25 11.25 11.25

Natural Gas ins wg. 4.5 4.5 4.5 4.5

Burner Pressure mbar 25 25 25 25

Propane & Butane ins wg. 10 10 10 10

Injector Diameter mm 2.4 2.9 2.9 3.1

in 0.094 0.114 0.114 0.122

Injector Diameter (LPG) mm 1.65 1.95 1.90 2.1

In 0.064 0.076 0.074 0.082

Weight Empty kg 340 340 345 381

Lb 750 750 760 840

Weight Full kg 636 636 641 727

Lb 1402 1402 1412 1603

Shipping Weight kg 354 354 358 399

Lb 780 780 790 880

Shipping Dimensions Height mm 2110 2110 2110 2110

In 83 83 83 83

Shipping Dimensions Width mm 770 770 770 770

In 30 30 30 30

Shipping Dimensions Depth mm 1210 1210 1210 1210

In 47 47 47 47

Mains Voltage V 220/240 - IP 20

Frequency Hz 50

Fuse A 5

TECHNICAL DATASECTION 2

DIMENSIONS

AND

CLEARANCES

CSC39 CSC59 CSC78 CSC93

CSCL39 CSCL59 CSCL78 CSCL93

(Natural Gas)

TECHNICAL DATA SECTION 2

A. Height of Heater mm 1623 1623 1623 1851

In 64 64 64 73

B. Diameter mm 720 720 720 720

In 28 28 28 28

C. Gas Connection mm 355 355 355 355

In 14 14 14 14

D. Cold Inlet mm 530 530 530 530

In 21 21 21 21

E. Optional Front Outlet mm 1307 1307 1535 1535

In 51 51 60 60

F. Height to Centre of Flue mm 2060 2060 1980 2217

In 81 81 78 87

G. Height to Flue Spigot mm 1780 1780 1780 2020

In 70 70 70 80

H. Min. Flue Horizontal mm 840 840 970 970

In 33 33 38 38

Ma . Flue Horizontal mm 7000 7000 7000 7000

In 276 276 276 276

. Min. Flue Vertical mm 1310 1310 1610 1610

In 51 51 63 63

Ma . Flue Vertical mm 7000 7000 7000 7000

In 276 276 276 276

J. Electrical Connection mm 1250 1250 1250 1480

In 49 49 49 58

K. Flue Diameter mm 100/150 100/150 130/200 130/200

L. Flue Adaptor mm 95 95

In 4 4

ANDREWS MODEL NO CSC39 CSC59 CSC78 CSC93 DIMENSIONS

AND

CLEARANCES

Not supplied with

these models

Horizontal or

Vertical Flue 1168mm

Minimum

Service

clearance

with

standard

Anodes.

500mm Recommended

or panel access and

switching. Absolute

min 300mm.

500mm Recommended or

panel access and switching.

Absolute min 300mm.

615mm

Minimum

Service

clearance

with Correx

Anodes.

Adaptor

Cold Water

Inlet 1⏲“

B.S.P.

Drain or Return

3/4” B.S.P.

Ideal Service clearance Dimensions

1125

Horizontal

Flue can

be rotated

360º

Tee & T/P Valve

supplied

Vent rom here

i used or Top

Hot Water outlet

‘X’

Can be

used or

Hot Water

outlet or

can be

capped

Alternative

Hot Water

outlet

I side connection is

used or Hot Water

outlet Air vent must

be itted at ‘X’

UNVENTED SYSTEM VENTED SYSTEM CSC78 and CSC93 Alternative Flue Systems

CSC39 and CSC59 Alternative Flue Systems

275.0

90.0

725.0 Min.

475.0

300mm

Minimum

N.B. Access o 500mm must be provided

one side or 6 months an lubrication

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 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 e traneous matter from being stored on or around

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

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.

The water heater must be located in an area where leakage from the tank, water

connections or the combination temperature and safety valve will not result in damage to

the area adjacent to the water heater. When such locations cannot be avoided, a suitable

drain tray must be installed under the water heater. The drain tray must be no deeper

than 38mm (1.5in) and have a minimum length and width of 100mm (4in) wider than

the heater. The drain tray must be piped to an adequate drain using 20mm (0.75in)

diameter pipe, angled for proper drainage.

Access must be provided to the front of the water heater and adequate clearance for it's

servicing and operation.

The floor on which the heater is installed must be flat, level and of sufficient strength to

withstand the weight of the heater when filled with water, and should satisfy the

requirements of the Local Authority & Building Regulations.

Any Combustible material adjacent to the heater must be so placed and shielded as to

ensure that it's temperature does not e ceed 66ºC (150ºF).

The minimum clearance to combustibles for the heater Is:

50mm (2in) from the front of the burner access bo .

Zero clearance from the air intake boot and vent tubes.

300mm (12in) from the direct vent terminal.

A minimum of 726mm (30 inches) from the burner access panel shall be provided for

inspection and servicing.

All service clearances to the water heater must be maintained as specified in the

CSC Range Installation and Design Guide.

INTRODUCTION

INSTALLATION SECTION 3

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 e isting or additional requirements.

CAUTION!

DO NOT APPLY HEAT IN CLOSE PROXIMITY TO THE GAS CONTROL THERMOSTAT

AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL

Fit the gas cock immediately upstream of the gas control valve using a suitable jointing

compound and connect to the gas supply. An inlet nipple and m/f elbow is factory fitted

to the gas control valve to avoid possible damage.

Where the water heater(s) is(are) installed in a boiler house or purpose built

compartment, a manually operated valve for the boiler house must be fitted in

accordance with the Gas Safety (Installation and Use) Regulations 1998. The valve must

be easily identified and readily accessible.

After installation, the system should be pressure tested for soundness and purged in

accordance with BS 6891 or IM/2 and IM/5 as appropriate.

GAS SUPPLY

NATURAL GAS

Gas Cock

BSP Thread U.P.T. Thread

Nipple

Gas Valve

M/F Elbow

Fig 1.

INSTALLATIONSECTION 3

Contact Calor Gas who will provide the appropriate type and size of LPG supply vessel

and ensure it's safe location and installation.

The installation of the gas supply must conform to LPGA Code of Practice, 22 LPG Piping

Systems: Design and installation plus the requirements of British Standards and Codes of

Practice listed in Section of this manual.

PROPANE: 37mbar (14.86 in wg)

BUTANE: 28mbar (11.26 in wg)

When using propane or butane cylinders, connect a minimum number of cylinders as

listed below, together with a manifold before connecting to the union.

Use a minimum pipe size of 3⁄4in bore.

Two Cylinders CSCL39 and CSCL59

Three Cylinders CSCL78

Four Cylinders CSCL93

WARNING!

PROPANE AND BUTANE CYLINDERS MUST BE USED AND STORED IN

ACCORDANCE WITH 'THE HIGHLY FLAMMABLE LIQUIDS AND LIQUIFIED

PETROLEUM GASES REGULATIONS 1972', AND SHOULD COMPLY WITH LPGA

CODE OF PRACTICE 7, 'STORAGE OF FULL AND EMPTY LPG CYLINDERS AND

CARTRIDGES

GAS SUPPLY

PROPANE OR

BUTANE

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