Hyco Powerflow series Specification sheet

Product Instruction Manual

Powerflow

PF30, 50, 80 & 100 litres

Unvented water heater

Version 3.2 Jan 2015

V19,1.1

Thank you for purchasing a Powerflow series unvented electric water heater.

The Powerflow is suitable for hand washing and dishwashing where a

number of hot outlets are required such as kitchens, schools, restaurants,

washrooms and offices. The Powerflow is the ideal solution for light

industrial, commercial and light domestic hot water requirements.

Please read and understand these instructions before commencing

installation and leave them with the user when installation is complete.

1. Important safety points

Installation must be undertaken by a competent installer of unvented water

heating systems in accordance with building regulations G3.

Building regulations G3 require a temperature and pressure relief valve to be

factory fitted. This must not be removed or blocked in any way.

Installation must comply with the latest edition of the IEE wiring regulations.

These units are very heavy. They must be securely fastened to a suitably strong

wall using the fixings supplied. Remember to allow for the weight of the water

(1kg per litre capacity) when assessing the suitability of the fixing surface.

2. Installation

Co ponent check list Qty

Expansion vessel ½” MBSP, pre-charge pressure 3.0bar 1

Vessel mounting bracket & banding 1

Pressure reducing valve 15mm pre-set pressure 3.5bar 1

3-way manifold with built in check and service valve 1

Tundish 15mm to 22mm 2

Flexible hose ½” MBSP to ½” BSP 1

6 bar pressure relief valve 15mm to 15mm 1

Tank wall mounting brackets 2

Wall Mounting

Plan your installation carefully in advance, allowing suitable space for installation and

future access to all fittings as shown in diagram 1.

Diagram 1

The unit must be installed vertically with water connection pipes at the bottom

and the pressure temperature relief valve at the top.

Ensure the mounting surface is strong enough to support the heater, including

the added weight when full of water.

The heater is not suitable for installation outside.

Do not install the heater where there is any risk of freezing.

The heater is bulky and heavy, do not attempt to lift alone.

Temperature &

Pressure Relief Valve

POWERFLOW

Hot

Drain Cock

Drain

(Waste)

Pressure (Expansion)

Relief Valve

Expansion

Vessel

Check

Valve

Balanced

O Take

Pressure

Reducing

Valve

Service

Valve

Cold

Mains In

Tundish

Drain

(Waste)

Allow at least 500mm below

and 200mm above the heater

to facilitate future maintenance.

To mount the heater, drill two

holes for the supplied wall fixings

and hang the heater onto them

via the bracket at the rear.

Plu bing connections

Diagram 2

Observe the flow direction arrows on fittings.

It is important that the ordering of the fittings is correct as per the diagram

1 and 2.

Do not remove the factory fitted pressure and temperature relief valve.

Do not insert any other valves between the 3-way manifold and heater inlet

since it may prevent the safe expansion and discharge of water during heating

cycles.

Make the necessary connections, as per diagram 2, to inlet side of the heater

(as indicated by the blue collar).

It is recommended that the “balanced off take” is used to supply any cold outlet that is

paired to a mixer style tap supplied by the hot feed of the unit.

The orientation of the expansion vessel is important, it should be fixed firmly to the

supplied bracket in a vertical orientation with the water connection at the bottom and

located so that the length of the connecting pipework is kept to a minimum.

A drain cock (not supplied) should be fitted to a branch of the incoming supply pipe

at a point that is lower than both the unit and the expansion vessel (see diagram 1)

in order to allow full drain down for any future maintenance work.

Make the connection to any hot tap from the outlet side of the heater as

(as indicated by the red collar).

Discharge pipe connections

This product falls within the scope of Building Regulation G3 which stipulates certain

conditions relating to the way any water discharge from relief valves is transported

away.

These conditions are designed to ensure that any discharge will not present a hazard to

people or to property, and that any discharge is clearly visible so that the underlying

cause is likely to be rectified promptly.

The essential requirement of G3 in relation to water discharge is that the discharge pipe

MUST terminate in a safe, visible position.

In achieving this aim the G3 regulations strongly recommended that:

•The tundish is located within 500mm of the Pressure and Temperature Relief valve

and it is wherever possible oriented vertically. It must be visible to occupants and

positioned away from electrical devices.

•The discharge pipe has a vertical fall of at least 300mm immediately below the

tundish.

•The discharge pipe below the tundish is at least 22mm diameter (i.e. one size larger

than the Pressure and Temperature Relief valve outlet).

•The discharge pipe should be as straight and as short as is possible and positioned

away from electrical components.

Diagram 3 illustrates an acceptable discharge pipe arrangement. The table below the

diagram specifies how the maximum acceptable pipe length from the tundish to the

final outlet depends on the pipe diameter and the number of bends.

For example, in 22mm copper with no bends the pipe could be up to 9m long. With two

bends present the maximum length drops to 9.0m - (2 x 0.80m) = 7.4m.

Diagram 3

Safety Device

Tundish

600mm MAXIMUM

Metal Discharge Pipe (D1) from

Temperature Relief to Tundish

Discharge Below

Fixed Grating

300mm MINIMUM

Metal Discharge Pipe (D2) from

Tundish with Continuous Fall

Fixed Grating

Trapped Gully

Sizing of D2 Copper Discharge pipe for common temperature relief valve outlet size

Valve

outlet

size

Minimum size of

discharge pipe (D1)

Minimum size of

discharge pipe (D2)

from Tundish

Maximum resistance allowed,

expressed as a length of straight

pipe (I.E. no elbows or bends)

Resistance

created by each

elbow or bend

m8.0m9otpumm22mm512/1G

28mm up to 18m 1.0m

m4.1

m72

up to

mm53

Electrical connections

The heater is supplied pre-wired with the appropriate cable.

The electrical installation should conform to the latest edition of the IEE wiring

regulations.

Electrical supply should be capable of isolation via a user-accessible double isolation

switch rated for 13A supply.

Diagram 4

Thermal

Cutout

Terminal

Relay

Heating Element

Transformer

Control

Board

Temp.

Sensor

3. Commissioning

Visually confirm all plumbing and electrical connections look sound.

Open any tap connected to the hot side of the unit and then turn on the incoming

water supply to the heater.

Allow the unit to fill until water flows smoothly from the open tap for around

1 minute to ensure the tank is purged of air and any plumbing related debris.

Close the tap and then inspect the system for any leaks.

Check the Pressure and temperature relief valve by twisting the cap to the open

position and observing the flow at the tundish. Ensure the discharge pipe can cope

with this flow continuously for several seconds.

Release the cap and check that the valve reseals.

Check the pressure (expansion) relief valve by twisting the cap to the open position and

observing the flow at the tundish. Ensure the discharge pipe can cope with this flow

continuously for several seconds. Release the cap and check that the valve reseals.

Turn on the electrical power and press the standby power button to check the display

operates.

4. Operation

Turn on the heater by pressing the standby power button.

On first power on, the heater will start in manual mode. To alter the target temperature

of the heater, use the up/down buttons to cycle to the desired setting. The temperature

is selectable between 300 C and 700 C.

The target temperature will display for several seconds before the actual temperature of

the water in the heater is then displayed.

Smart mode – When the Smart mode is selected, the unit will automatically heat to

full temperature and then monitor the usage for the coming week. In the second week

the unit will adjust its heating times to match the usage demand of the first week.

This will help to reduce energy wastage during long periods of non-use e.g. overnight.

ECO mode – When the Eco mode is selected, the unit will target a maximum storage

temperature of 500 C. The total available hot water will be reduced along with standing

losses. This is recommended for low draw off scenarios, where larger draw offs are

required select either the manual or Smart operating functions.

Manual mode – To take back control of the heater temperature from either Smart/Eco

mode, press the manual button.

The maximum temperature setting of the heater is 700 C, this can be excessively

hot for some situations/users. In situations where very young children, the

elderly or other vulnerable people are likely users a suitably rated thermostatic

mixing valve should be fitted to the hot water outlets as required.

Never interfere with any of the safety devices.

Beware that very hot water could discharge from the safety valves.

If a risk of frost is present the heater should be left on at least the minimum

setting to prevent potential damage to the product or property from frozen

pipes. If the heater is going to be left unused for a long period of time it should

drained.

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