For Gledhill Accolade A-Class Parts and Spares click on the following links: Gledhill Accolade A-Class Parts And Spares
DESIGN, INSTALLATION AND SERVICING INSTRUCTIONS
An unvented hot water storage unit complying with the requirements of Building Regulations Approved Document G3.
Please read these instructions before
In the interest of continuously improving the Accolade A Class range, Gledhill Water Storage Ltd reserve the right to modify the product without notice, and in these circumstances this booklet, which is accurate at the time of printing, should be disregarded.
ISSUE 5: 06-08
|3.3||Short Parts List|
|Terms & Conditions|
Building Regulations and Benchmark Commissioning
The Building Regulations (England & Wales) require that the installation of a heating appliance be notified to the relevant Local Authority Building Control Department. From 1st April 2005 this can be achieved via a Competent Person Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
These arrangements represent a change from the situation whereby compliance with the Building Regulations was accepted if the Benchmark Logbook was completed and this was then left on site with the customer).
With the introduction of a self certification scheme, the Benchmark Logbook is being replaced by a similar document in the form of a commissioning check list and a service interval record is included with all gas appliance manuals. However, the relevant Benchmark Logbook is still being included with all Thermal Storage products and unvented cylinders.
Gledhill fully supports the Benchmark aims to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
Building Regulations require that the heating installation should comply with the manufacturer’s instructions. It is therefore important that the commissioning check list is completed by the competent installer. This check list only applies to installations in dwellings or some related structures.
The AccoladeA-CLASS range of floor standing indirectly heated unvented hot water storage appliances is designed to provide domestic hot water at mains pressure. All models are designed for gas or oil fi red heating and hot water systems with boiler capacities up to a maximum of 45kW. All models are fitted with a 6kW ‘Switch’ emergency electric backup system for domestic hot water or heating and hot water water in the event the boiler fails. The AccoladeA-CLASS appliances are factory fitted with all the necessary safety and control equipment for connecting to the cold water mains, boiler and heating system.
These instructions cover all the models and must be followed. These appliances have been certified for safety and the appliance and installation specifications of the appliances must not be modified unless recommended by Gledhill Water Storage Limited.
1.The Building Regulations (Approved Document G3) 2002 cover the installation of unvented storage water heating equipment and these require that the installation of an unvented unit shall only be carried out by a person competent to do so (as defined in the Approved Document) and that the Local Authority shall be notified of the intention to carry out the installation of one of these types of appliances.
2.The system must be installed in accordance with the Water Supply Regulations, Building Regulations and relevant NHBC requirements.
3. As the AccoladeA-CLASS is an unvented appliance it should not be used where steam is the primary heating medium, or with solid fuel boilers, or in situations where annual inspection/maintenance is likely to be neglected.
1. Handling and Storing the Appliance
This appliance should be handled carefully to avoid damage and the recommended method is detailed below.
When lifting the unit:-
• Use a team lift
• Work with someone of similar build and height if possible.
• Choose one person to call the signals
• Lift from the hips at the same time, and then raise the unit to the desired level.
• Move smoothly in unison.
The appliance is supplied shrink wrapped on a timber installation base. Carrying
handles are provided in the back of the casing.
If the unit needs to be stored prior to installation it should be stored upright in a dry environment and on a level base/floor.
Note: Although the above guidance is provided any manual handling/lifting operations will need to comply with the requirements of the Manual Handling Operations Regulations issued by the H.S.E. See Appendix D at the rear of this manual.
The appliance can be moved using a sack truck on the left hand face although care should be taken and the route should be even. In apartment buildings containing a number of storeys we would recommend that the appliances are moved vertically in a mechanical lift. If it is proposed to use a crane expert advice should be obtained regarding the need for slings, lifting beams etc.
2. System Installation
Any installation must be in accordance with the relevant requirements of the current issue of Local Building Regulations, the Water Supply Regulations, Health & Safety Document No. 635 and the Electricity at Work Regulations 1989. The detailed recommendations are contained in the current issue of the following British Standards and Codes of Practices: -
BS 5440 Pts. 1 & 2; BS 5449; BS 5546; BS 7074 Part 1; BS 6700; BS 6798; BS 6891, BS 7593, IGE/UP/7/1998
3. Equipment Selection
This information is provided to assist generally in the selection of equipment. Responsibility for selection and specification of our equipment must, however, remain that of our customers and any expert or consultants concerned with the installations).
Please note: -
We do not accept any responsibility for matters of design selection or specification or the effectiveness of an installation containing one of our products unless specifically asked in writing to do so.
All goods are sold subject to our Conditions of Sale which are set out in the Appendix to this document.
To comply with the Building Regulations requirements this appliance must be serviced and installed by a competent person suitably trained and registered to install unvented heating system equipment.
As part of the industry wide ‘Benchmark’ initiative all AccoladeA-CLASS appliances now include a Benchmark Installation, Commissioning and Service Record Logbook. Please read this carefully and complete all sections relevant to this appliance. Failure to do so may affect warranty.
Modifications should NOT be made to this product. If any components in this appliance are replaced and recommissioned in the field then these must be obtained from Gledhill Water Storage Ltd to ensure continued safe operation and must not be tempered with. This applies particularly to the immersion heaters which must incorporate an overheat thermostat.
Details of how to enter this product in SAP are available. Please request a copy of the latest SAP Data which covers this and all other Gledhill Water Storage Products.
1. 1 INTRODUCTION
The AccoladeA-CLASS is a floor standing packaged mains pressure unvented hot water appliance and uses a twin copper cylinder configuration which ensures that all the water content is heated to a uniform temperature as well as reducing the risk of legionella and corrosion. All cylinders are manufactured in accordance with the requirement of BS7206:1990. All models of the Accolade are factory fitted with all the necessary safety and control equipment for connecting to the domestic water systems, the boiler and the heating system (see table 1.2 and figure 1.1).
All models are designed to be heated indirectly by a gas or oil fi red boiler and are suitable for use with both open vented and sealed heating systems. These appliances are also fitted with a 6kW ‘Switch’ emergency electric backup system in the event of a boiler failure. Two switches on the front of the appliance allow this to be used for hot water only or heating and hot water if required. This should be sufficient in most cases to satisfy the heating requirements of a typical property in an average day although in larger properties and on very cold days a choice between a lower temperature or the area to be heated fully will need to be made (see table 1.1)
All models except ACA125 IND are fitted with a secondary return tapping as standard. This is blanked 22mm diameter copper pipe on the top - right hand - rear of the appliance. If secondary hot water circulation is installed, then an additional expansion vessel may be necessary. Typical primary hot water circulation system design is discussed further in section 1.3 of this manual.
1.2 TECHNICAL DATA
1.2 TECHNICAL DATA
1. 2 TECHNICAL DATA
The dimensions above are for the Appliance complete with F & E Cistern (for use with OV primary/heating systems) being in the same cupboard.
If the appliance is fitted with a primary expansion vessel (for use with a sealed primary/heating systems) 300 mm can be deducted from the height.
The table of minimum cupboard dimensions only allow the minimum space required for the appliance (including the heating system F & E cistern or expansion vessel and installation base) and any extra space required for shelving etc in the case of airing cupboards etc must be added.
1. 2 TECHNICAL DATA
Model Selection Guide
General selection criterion is shown in Technical Data table 2.1. However, before selecting the model, the hot water requirements of the dwelling should be correctly assessed.
The AccoladeA-CLASS must be installed on a flat surface, which is capable of supporting the weight of the appliance and any other ancillary equipment.
The minimum airing cupboard dimensions and the clearances required for installation and service are shown in figure 1.2.
The appliance is designed to be installed on the plinth supplied with the appliance. The pipe connection arrangement is shown in figure 1.3.
1.2 TECHNICAL DATA
a. General technical and performance data of the AccoladeA-CLASS range is given in table 2.1.
b. All models are fitted with high performance primary heat exchangers and are supplied with either Grundfos UPS 15-50 or UPS 15-60 factory fitted pumps. The net pump head available when hot water only is on and when space heating only is on is shown in figures 1.4 and 1.5 respectively. The control characteristic of the automatic bypass is shown in figure 1.6.
c. In these appliances the mains inlet pressure regulating valve is set to 1.5 bar and this setting MUST NOT be adjusted. Therefore the flow rate from the appliance depends upon the resistance of the hot water supply network, capacity of the incoming mains and the characteristics of the pressure regulating valve.
One mains supply rated at 30A, 230V~, 50Hz is required.
Minimum external fuse rating and the main supply cable ratings are given in “2.1. Site Requirements” section of this manual. All fuses must be ASTA approved to BS 1362. This appliance MUST BE EARTHED.
All external wiring to the appliance must be in accordance with the latest I.E.E. Wiring Regulation, and any local regulations which may apply.
The appliance shall be supplied from a 30A fused double pole switched isolator with a contact separation of at least 3mm in both poles.
This must be suitably labelled, provide complete electrical isolation and be within 1 metre of the AccoladeA-CLASS Unit.
In the event of an electrical fault after installation of the appliance, preliminary electrical checks must be carried out i.e. Earth Continuity, Short Circuit, Polarity, and Resistance to Earth.
1.2 TECHNICAL DATA
1.3 SYSTEM DETAILS
Hot and Cold Water System
a. All recommendations with regard to pipe work systems in this manual are generally based on the use of BS/EN Standard copper pipework and fittings.
b. However a plastic pipework system can be used in place of copper internally as long as the chosen system is recommended by the manufacturer for use in cold and hot water systems and is designed and installed fully in accordance with their recommendations.
c. This is particularly important in relation to use of push fi t connections when using the optional flexible hose kits (See Installation and Wiring section of this document),
d. It is also important that if an alternative pipework material/system is chosen, the manufacturer confirms that the design criterion for the new system is at least equivalent to the use of BS/EN Standard copper pipework and fittings.
Mains cold water supply
a. AccoladeA-CLASS is designed to be connected directly to the mains. The combination inlet valve incorporates the required check valve. The hot water flow rate achievable from the AccoladeA-CLASS is directly related to the adequacy of the cold water mains serving the property. For this reason the cold water supply to the dwelling must be capable of providing for those services which could be required simultaneously and this maximum demand should be calculated. Also if a water meter is fitted its nominal rating should match the anticipated maximum simultaneous hot and cold water demand calculated in accordance with BS 6700. This could be 60 litres per minute in some properties. 30 litres per minute is the minimum flow rate which is recommended for an adequate mains pressure system to any property.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the requirements set out in the Domestic Heating Compliance Guide specify that “where the mains water hardness exceeds 200ppm provision should be made to treat the feed water to water heaters and the hot water circuit of combination boilers to reduce the rate of accumulation of lime scale”
To comply with this requirement the hardness of the mains water should be checked by the installer and if necessary the optional factory fitted in-line scale inhibitor should be specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Where the water is very hard ie 300ppm (mg/l) and above the optional polyphosphate type, inhibitor should be specified at the time of order. However, this will need to be fitted by the installer at a suitable point in the cold water supply to the appliance.
b. The combination valve fitted to the AccoladeA-CLASS incorporates a pressure regulating valve set to provide a static operating pressure of 1.5 bar. On this basis there must be at least 2.0 bar pressure at the inlet to the appliance. This pressure must be dynamic (not static) and be available at the appliance when local demand is at its maximum. For optimum performance, and for larger properties, we would recommend that the dynamic pressure is in the range of 2.5 - 3.5 bar.
c. The combination valve also incorporates an expansion relief valve. The discharge from this can be connected into the discharge pipe from the P & T valve. Further details of how to treat this discharge are provided later in this manual.
d. As a general guideline, although a 15mm service my be sufficient for smaller dwellings with one bathroom, a 22mm service (25mm MDPE) is recommended and should be the minimum for larger dwellings.
e. If the incoming mains pressure exceeds 6 bar at any time in a 24 hour cycle then a pressure regulating valve set at 3.5 bar should be fitted downstream of the stop tap where the cold supply enters the property.
f. Equipment used in the system should be suitable for a working pressure of up to 5 bar.
1.3 SYSTEM DETAILS
Cold and hot water distribution network
a. As a minimum it is recommended that the cold supply to the appliance internally is run in 22mm copper or equivalent in plastic and then from the appliance, hot and cold services are in 22mm past the draw-off to the bath as shown schematically in figure 2.1. For large properties bigger sizes will be necessary and these should be proved by calculation in accordance with BS6700.
b. The highest hot or cold water draw-off point should not exceed 4 metres above the appliance.
c. In typical dwellings, the cold water supply to any mixer fittings (other than dual outlet fittings) should be taken from the balanced cold outlet connection on the appliance. However, in larger dwellings with a number of bathrooms and en-suites and long pipe runs, the balanced cold supply must be provided with its own pressure regulating valve (set at the same pressure as the one provided with the appliance ie 1.5 bar static) and not taken from the appliance. When a separate pressure regulating valve is used for the balanced cold water supply, it is recommended that a small expansion vessel (0.25 - 0.5 litre) is fitted after the pressure regulator to accommodate the pressure rise caused by the increase in temperature of the balanced cold water.
d. If the supply to the mixer fittings (other than a dual outlet type) is not taken from the balanced supply the system will become over pressurized and cause the pressure relief valve to discharge. Over time this could also cause the premature failure of the appliance itself which will not be covered by the warranty.
e. Whenever possible the hot and cold water supply to a shower-mixing valve should be the first draw-off point on each circuit.
f. It is important that the cold water pipe work is adequately separated from any heating/ hot water pipe work to ensure that the water remains cold and of drinking water quality.
1.3 SYSTEM DETAILS
Taps and Shower Fittings
a. Ensure that all terminal fittings are suitable for mains pressure. Use aerated taps whenever possible to prevent splashing.
b. Any type of shower mixing valve can be used as long as both the hot and cold supplies are mains fed. However, all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps/showers are opened and closed, which will cause changes in the water temperature at mixed water outlets such as showers. For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance. The shower head provided must also be suitable for mains pressure supplies. However, if it is proposed to use a ‘whole body’ or similar shower with number of high flow/pressure outlets please discuss with the Gledhill technical department.
c. Note that the shower fittings must comply with the backflow prevention requirements (Para 15, Schedule 2) of the Water Supply Regulations 1999.
d. A bidet can be supplied from the AccoladeA-CLASS appliance as long as it is of the over rim flushing type and incorporates a suitable air gap.
Dead leg volumes and secondary hot water circulation
If the dead leg volume of the hot water draw-off pipework is excessive and the delivery time for hot water to be available at the tap is more than 60 seconds you may consider using:-
a. Trace heating such as the ‘Raychem HWAT’ system. Please call Gledhill technical department for further details.
b. A secondary hot water circulation system as shown schematically in figure 2.2.
1.3 SYSTEM DETAILS
Space Heating System Design
Warning: AccoladeA-CLASS is an unvented hot water storage appliance and therefore it is not suitable for use with a solid fuel boiler, steam or any other uncontrolled heat source.
All models are designed to be installed with any condensing or non condensing gas or oil fi red boiler which has a controlled heat source and is fitted with an overheat thermostat.
The heating system design and installation must comply with the requirements of BS 6798 and BS 5449.
Although general model selection guidance is given in table 2.1 (section 1.2), it is recommended that the hot water demand should be determined before selecting the correct model.
All recommendations with regard to pipework systems in this manual are generally based on the use of BS/EN Standard copper pipework and fittings. However plastic pipework can be used in place of copper internally as long as it is recommended by the manufacturer and installed fully in accordance with their recommendations. Barrier type plastic pipework should always be used for these systems.
It is important to ensure that if the system is to be installed using plastic pipework it is designed and sized for plastic pipework. This is particularly important in relation to use of push fi t connections to the appliance.
The AccoladeA-CLASS is designed to operate in a ‘flow share’ mode i.e. the boiler may supply space heating and hot water demands simultaneously. Therefore a hot water allowance should be included when sizing the boiler and heating system in accordance with BS 5449.
1.3 SYSTEM DETAILS
If it is necessary to protect parts of the heating system or the boiler which are installed in unheated spaces (e.g. garage, outhouse and ventilated roof space), a frost thermostat(s) must be fitted. The AccoladeA-CLASS appliance should not be installed in a location where the contents could freeze.
Any type of 2 channel programmer or programmable room thermostat is suitable for use with the AccoladeA-CLASS. Suitable controls can be supplied as optional extras by Gledhill if required.
An automatic bypass valve is built into the appliance to allow thermostatic radiator valves (TRV’s) to be fitted. To meet the requirements of Building Regulations for a boiler interlock it is recommended that the radiator in the area where the room thermostat is installed should be fitted with lock shield valves on both connections.
The bypass valve is set at the factory to 2m head but this should be adjusted on site by the installer to ensure that there is an adequate (the minimum flow rate recommended by the boiler manufacturer) flow rate through the boiler when TRVs are closed.
The net pump head available when hot water only or space heating only are on is shown in figures 1.4 and 1.5 respectively. The net pump head available for sizing the boiler radiator circuit should be calculated using these figures.
Sealed central heating system
Sealed system kit
An optional sealed system kit as follows can be supplied with the AccoladeA-CLASS
• Expansion relief valve set at 3.0 bar
• Pressure gauge (0 – 4 bar)
• Primary expansion vessel charged to 1.0 bar, (Size depends upon the model, see table 2.1)
• WRAS approved primary system filling loop
1.3 SYSTEM DETAILS
Pressure gauge and filling loop Primary
The pressure gauge and the approved filling loop should be fitted at the system filling point which it is recommended should be adjacent to the boiler.
There shall be no permanent connection to the mains water supply for filling the system, even through a non-return valve without the approval of the Local Water Authority. The approved filling loop should be disconnected after commissioning the system.
Pressure relief valve Primary
The pressure relief valve must be fitted in the boiler flow pipe adjacent to the boiler. There must no isolating valves or any such devices between the boiler and the pressure relief valve. The pressure relief valve should be fitted in a position where it is accessible for testing/ inspection.
The method of fitting should ensure that discharge of water or steam cannot create a hazard to persons in or about the premises or damage to electrical components or wiring and the point of discharge shall be clearly visible.
The expansion vessel must accommodate the change in volume of system water when heated from 10oC to 110oC (see BS 5449:1990 clause 16.2). When calculating the system water content, the water content of the primary heat exchanger (see table 2.1) must be included. The expansion vessel requirements are shown in table 3.1. When ordering the optional sealed system kit it is the installers responsibility to check that the expansion vessel size is adequate for the primary/heating system.
After first filling the system to a pressure of 1.0 bar at mains supply temperature (typically 15oC in summer), the total system (space heating and hot water) should be heated to its maximum temperature. If the primary pressure gauge indicates 2.6 bar or higher, then an additional expansion vessel may be required.
If the system pressure required is more than 1.0 bar, then the expansion vessel charge pressure should be adjusted to match the primary system pressure and the expansion vessel size recalculated accordingly.
Open vented heating system
Open vented system kit
1.3 SYSTEM DETAILS
An optional open vented kit as follows can be supplied with the AccoladeA-CLASS
• Feed and expansion cistern with lid
• Ball valve & float
• 22mm Overflow pipe connector
• 15mm Cold feed tank connector
F & E cistern
The feed and expansion cistern, can be fitted on top of or up to 10m above the base of the appliance i.e. the maximum static pressure in the appliance must not exceed 1.0 bar (figure 2.4). The water level in the F & E cistern should be at least 250mm above the highest point of the system including the radiators.
The overflow/warning pipe should be installed using 20mm internal diameter pipe of a suitable material to comply with BS 5449 (such as copper). It should have a continuous fall and be discharged in a conspicuous external position. It should not have any other pipework directly branched into it.
Cold feed/expansion and safety/open vent
The safety/open vent should be connected into the boiler flow pipe ensuring that there is a continuous rise from the boiler to the point of discharge over the F & E cistern as shown schematically in figure 2.4. The open vent and cold feed should be run in a minimum of 22mm and 15mm copper (respectively) or equivalent to the feed and expansion cistern. There must no isolating valves or any such devices between the boiler and the safety/open vent termination point.
The P & T valve and Expansion Relief Valve (ERV) are both provided with tundishes. It is normal for these to be connected into a single 22mm discharge pipe but they can be run separately if required. The first 300mm of pipework below the tundish should be vertical and not contain any elbows/bends.
It is the requirement of Building Regulation Approved Document G3 that the discharge from an unvented hot water storage system is conveyed to where it is visible but will not cause danger to persons in or about the building. The discharge pipe from the appliance tundish should be fitted in accordance with these requirements.
The discharge pipe MUST terminate in a SAFE and VISIBLE position. For a 22mm discharge it must have an equivalent length of no more than 9 metres and it must have a continuous fall (1: 200 minimum) throughout its length.
1.3 SYSTEM DETAILS
In apartment/flat situations the discharge pipes can be connected into a single pipe which is discharged at low level. In this case the number should be limited to 6 to allow the fault to be easily traced. The single pipe should be at least one size larger than the largest individual discharge pipe connected to it.
The discharge can consist of scalding water and steam therefore the pipework should be metal.
The following locations for the discharge pipe are acceptable:
• Into a gully below the grating but above the water level (see diagram 1).
• Onto the ground (drive, path or garden area). The pipe should discharge downwards and be no more than 100mm above ground level. A wire cage should be provided to prevent people coming into contact with scalding water (see diagram 2).
High level discharge is only acceptable if it is :
• onto a flat or pitched roof capable of withstanding high temperature water and at least 3m away from plastic guttering. or
• into a metal hopper and down pipe which terminates at low level (as described above.)
Discharge into a soil or waste pipe (whether plastic or metal) is not normally acceptable.
The proposals for the discharge pipe/ termination point should be discussed and agreed with the Building Control Officer prior to commencing any work.
The appliance is designed to be installed in an airing/cylinder cupboard and the relevant minimum dimensions are provided in section 1.2 Technical Data.
Because of the ease of installation we recommend that the cupboard construction is completed and painted before installation of the appliance. The cupboard door can be fitted after installation.
If the unit needs to be stored prior to installation it should be stored upright in a dry environment and on a level base/floor.
Installation and maintenance access is needed to the front of the appliance and above the F & E cistern. See section 1.2 Technical Data for further details.
The minimum dimensions contained in section 1.2 Technical Data allow for the passage/connection of pipes to the appliance from any direction as long as the appliance is installed on the installation base provided. If the installation base is not used extra space may be needed to allow connection to the pipework and the whole of the base area should be continuously supported on a material which will not easily deteriorate if exposed to moisture.
The floor of the cupboard needs to be level and even and capable of supporting the weight of the appliance when full. Details of the weight when full is provided in section 1.2 Technical Data.
The appliance is designed to operate as quietly as practicable. However, some noise (from pumps etc) is inevitable in any heating system. This will be most noticeable in cupboards formed on bulkheads, or at the mid span of a suspended floor. In these cases the situation can be improved by placing the appliance on a suitable sound deadening material (i.e. carpet underlay or similar).
The cylinder is very well insulated and no ventilation is normally required to the cupboard.
A suitable location will be needed for the separate feed and expansion cistern or expansion vessel. This will often be on top of the appliance itself or at high level in the cupboard housing the AccoladeA-CLASS . The dimensions and clearances are shown in section 1.2 Technical Data. The location will need to provide a suitable route for the cold feed/expansion pipe and safety/open vent pipe for the appliance with OV systems or the connecting pipe to the system expansion vessel with sealed primary systems. A suitable route and discharge position for the warning/overflow pipe and the ballvalve supply from the mains cold water system will also be required with OV systems. A suitable route and discharge location will also be required for the discharge pipe from the P & T valve and ERV for all models.
An electrical supply must be available which is correctly earthed, polarized and in accordance with the latest edition of the IEE requirements for electrical Installations BS 7671.
The electrical mains supply needs to be 230V/50Hz/1Ph
Connection must be made using a double-pole linked isolator with a contact separation of 3mm in both poles which is located within 1m of the appliance. The supply must only serve the appliance.
The supply to all models shall be fused at 30 amp.
Preparation/placing the appliance in position
Details of the recommended positions for termination of the first fix pipework are provided in section 1.2 Technical Data. The pipework can be located or its position checked using the template provided with each appliance. If thse have been followed installation is very simple and much quicker than any other system. The appliance is supplied shrink wrapped on a timber installation base. Carrying handles are also provided in the back of the casing.
If the optional OV or SS kit is ordered this will be supplied in a separate box. It is the installers responsibility to check that the size of cistern/expansion vessel provided is adequate for the primary/heating system being installed. If flexible connections have been ordered these will also be inside the OV/SS kit box.
The appliance should be handled carefully to avoid damage and the recommended method is shown opposite. Further details are provided on page 2 of these instructions. Before installation the site requirements should be checked and confirmed as acceptable. The plastic cover and protective wrapping should be removed from the appliance and the installation base (provided) placed in position.
The appliance can be then be lifted into position in the cupboard on top of the base and the front panel removed by unscrewing the 2 screws and lifting the door up and out (see opposite) ready for connection of the pipework and electrical supplies. If they are not being fitted on top of the appliance a support shall be installed for the feed and expansion cistern/expansion vessel ensuring that the base is fully supported and the working head of the boiler/system is achieved. The recommended access for maintenance must also be provided - see section 1.2 Technical Data.
The position of the pipework connections is shown opposite . The connection sizes and dimensions are listed in Section 1.2 Technical Data.
All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.
The connections can be hard piped but we recommend the use of flexible connections (available as an optional extra).
When using the push fi t connectors with the flexible hose kits it is important to check that they are compatible. Written approval has already been obtained for :-
Hepworth - Hep2O BiTite
John Guest - Speedfit
Yorkshire - Tectite
However, as similar assurances cannot be obtained for Polypipe fittings we cannot recommend their use at this time
A. Primary flow (from boiler)
B. Primary return (to boiler)
C. Central heating flow
D. Central heating return
E. Drain assembly
F. Incoming mains water
G. Balanced pressure cold outlet
H. Domestic hot water
I. Discharge from the ERV
J. Discharge from the P & T valve
Ensure the discharge pipes from the P & T valve and ERV are laid to a continuous fall and that there is at least 300mm of vertical pipework below the tundish before any bends.
All factory made joints should be checked after installation in case they have been loosened during transit.
The fittings for the feed and expansion cistern should be installed and the cistern fitted on top of the appliance/on supports (not provided) at high level in the cupboard or in the roof space.
If it is necessary to locate the cistern in the roof space any pipework in the roof space and the feed and expansion cistern will need to be adequately insulated to protect against frost damage.
The 22mm safety/open vent shall rise continuously from the boiler and terminate in the F & E Cistern.
No valves should be fitted in the safety open vent which must be a minimum of 22mm copper pipe or equivalent.
The overflow/warning pipe shall have a continuous fall, be fitted to discharge clear of the building and be sited so that any overflow can be easily observed. It shall also be installed in a size and material suitable for use with heating feed and expansion cisterns in accordance with BS 5449 and should not have any other connections to it.
The expansion vesel should be fitted on top of the appliance or on the supports provided and connected to the appliance using a manual air vent at the high point.
It is normally envisaged that the expansion vessel will be located in the same cupboard as the AccoladeA-CLASS appliance.
Electrical Connection - Appliance
The boiler and control functions of the Accolade A-CLASS are pre-wired to a 25 way terminal strip. The wiring to the appliance shall be carried out by a competent person in accordance with the Building Regulations (Approved Document P) and the IEE Requirements for Electrical Installations BS 7671. A schematic arrangement of the wiring is shown opposite.
Terminals 1 - 15 should be wired on site in accordance with the diagram opposite. Terminals 16 - 25 are pre-wired to components fitted on the appliance.
All the terminals are suitably labelled on the appliance.
Note: Do not attempt the electrical work unless you are competent to carry it out to the above standards.
Before commencing check that the power source is in accordance with section 1.2 Site Requirements and ensure that it is isolated.
The boiler manufacturers wiring instructions should be read in conjunction with this manual.
Run the external wiring through the service slot provided in the base of the appliance.
Make the connections as shown opposite on the terminal strip provided.
If the boiler does not provide a pump live connection a link should be placed between terminals 6 and 7 (BL-PL and BL-SL).
The appliance is provided with a link between terminals 12 and 13 on the terminal strip. This must be removed when the room thermostat is fitted.
Before switching on the electrical supply check all the factory made terminal connections to ensure they have not become loose during transit.
When frost protection is required for the whole house set the programmer to constant during the time required and adjust the room thermostat to a suitable setting.
If frost protection is required only to protect parts of the system installed in unheated areas frost thermostat(s) must be fitted.
Check and adjust as necessary the hot water system expansion vessel(s) air pressure to 1.5 bar.
Check that any drain valves are closed then open the incoming stop valve and fi domestic mains cold and hot water systems in the normal way ensuring there air trapped in the system.
In the case of OV systems fill the heating system with potable water through the and expansion cistern flush and refi ll. Check the water level in the feed and expansion cistern and adjust the ballvalve if necessary. Check the warning pipe is installed correctly, has a continuous fall and is not blocked i.e. discharges water freely.
In the case of SP systems check and adjust as necessary the primary heating system expansion vessel to the figure specified (normally 1.0 bar) Note: The expansion vessel pressures should be checked before the systems are Fill the primary heating system with potable water through the filling loop provided adjacent to the boiler to the pressure required (normally 1.0 bar).
During filling vent air as necessary from the high points of the system including the manual air vents provided on the appliance and on the feed to the expansion vessel.
Check the whole of the primary heating and domestic hot and cold distribution systems for leaks.
It is essential that all systems functions properly for optimum performance.
To achieve this, the primary system should be commissioned in accordance with good practice and generally in accordance with the requirements of BS 6798, BS 5449 and BS 7593.
Full details of the requirements are given in PAS 33:1999 under Section 10 Commissioning.
When using either cleansing or corrosion inhibitor chemical, the manufacturers instructions must be followed.
Cleansing the Primary System
It is very important to ensure that the Primary system is cleaned using a suitable cleansing agent such as Sentinel X300 or Fernox Superfloc to ensure that any flux residues/installation debris are removed.
The volumes/concentration should be calculated in accordance with the manufacturers instructions allowing the volume for the primary coil shown in the Table in 1.2 Technical Data.
Primary Water System Treatment
Although the AccoladeA-CLASS has no special water treatment requirements, the radiators and other parts of the circuit will require the application of a scale and corrosion inhibitor such as Sentinel X100 or a Protector such as Fernox MB1.
The volumes/concentration should be calculated in accordance with the manufacturers instructions allowing the volume for the primary coil shown in the Table in 1.2 Technical Data.\
POWERFLUSHING/CLEANING OF THE HEATING SYSTEM
If it is proposed to ‘powerflush’ the heating system always check and comply fully with the manufacturers instructions for the powerfl ushing equipment being used. If in any doubt please consult our Technical Helpline.
Cleansing the Hot/Cold Water System
Fully flush and, when necessary, chlorinate the hot and cold water system in accordance with the recommendations in the Model Water Byelaws and BS 6700.
Remove and clean the strainer element in the combination inlet valve, then replace it and re-fill the systems.
Once the systems have been refilled manually open the relief valves one by one and check that water is discharged and runs freely through the tundish and out at the discharge point. The pipework should accept full bore discharge without overflowing at the tundish, and the valve should seat satisfactorily.
With OV systems once the system is finally filled turn down the servicing valve for the ballvalve in the F & E Cistern to the point where the warning/overflow will cope with the discharge arising from a ballvalve failure.
With SP systems check the pressure and disconnect the manual filling loop.
Check the temperature setting on the control thermostat is set at 60ºC. Turn on and check that thermostats and all controls operate correctly as well as any motorised valves. Check that no water discharges from either the expansion valve or temperature and pressure-relief valve during the heating cycle. Check the temperature setting on the switch immersion heater thermostats are set at 60ºC. Turn on and check they operate and switch off at the correct temperature.
System Commissioning Check the appliance, the heating system and hot water system for leaks when hot.
Check that the correct outlet pressure is being maintained on the domestic water systems by the pressure reducing valve by checking the pressure at a hot tap or in the tapping provided on the combination inlet valve.
Check the correct flow is being achieved at each tap and the implications of opening more than one tap at the same time. If necessary fitful regulators to each tap.
The heating system is set to operate as a standard ‘S’ plan and the pump and primary system should be set and balanced in the normal way to provide a temperature differential of 11ºC.
An automatic bypass valve is provided on the primary/heating circuit. This is factory set to 2m head but may need to be adjusted to suit the particular installation requirements.
The room thermostat/programmer or programmable room thermostat controls the heating and hot water systems separately and should be set to suit the householders requirements using the instructions provided with the controls.
This product is covered by the ‘Benchmark’ scheme and a separate commissioning/ service log book is included with this product. This must be completed during commissioning and left with the product to meet the Warranty conditions offered by Gledhill.
1. Do ensure that the electrical connections (e.g. mains supply, room thermostat) to the unit are correct and tight.
2. Do ensure that all the pipework connections in the appliance are tight and not leaking.
3. Do ensure that any pipework particularly plastic adjacent to the appliance is adequately supported and anchored.
4. Do ensure that the functioning and control of the system is explained to the occupant and explain the need and importance of periodic servicing.
These Instructions should be placed along with the component manufacturers instructions in the pocket provided on the rear of the front panel. The front panel should then be refitted.
NOTE:- With sealed heating systems air is released from the water during the first few weeks of operation. This must be vented and the system repressurized.
If the system is not likely to be used continuously after testing/commissioning it should be isolated from the water and electricity supply and either drained down or have the pressure removed from both the heating and water systems.
Important Do’s and Don’ts
DO check the incoming mains water pressure and flow rate are adequate. (The preferred range of mains pressure is 2.5-3.5bar).
DO check and ensure that the air pressure side of the hot water expansion vessel(s) is set at 1.5 bar.
DO check that all plumbing and electrical connections are in accordance with the labelling on the unvented storage appliance.
DO insulate any exposed pipework in the AccoladeA-CLASS cupboard.
DO plumb the overflow/warning pipe (if fitted) in a 20mm internal diameter pipe material which is suitable for use with a heating F & E cistern, in accordance with BS 5449 (such as copper) and ensure it has a continuous fall and discharges in a conspicuous external position.
DO check the pump setting to give a temperature difference across the fl ow and return of not more than 11°C.
DO ensure that the bypass valve is set correctly.
DON’T use pipe smaller than 28mm between the boiler and the AccoladeA-CLASS when the boiler rating exceeds 20kW (about 68,000 Btu/h). DON’T operate any immersion heaters until the appliance/systems are fully filled, vented and commissioned.
DON’T place any clothing or other combustible materials against or on top of this appliance
DO ensure the boiler is suitable (i.e. fitted with an overheat thermostat)
DO ensure that the discharge pipework from the relief valves is/are installed to a fall and are of the correct size so that water does not overflow when a relief valve operates.
DO ensure the discharge point is safe and in accordance with the G3 Building Regulations. SS Systems
DO check and ensure the air pressure side of the heating expansion vessel is set at 1.0 bar (or as specified)
DO adjust the ballvalve so that the water level in the appliance F & E cistern when the system is cold is correct and does not overflow when the appliance is at maximum temperature DO turn down the servicing valve for the ballvalve in the F & E cistern, once the system is finally filled, to the point where the warning/overflow pipe will cope with the discharge arising from a ballvalve failure.
DO make sure that there is adequate clearance above the appliance F & E cistern to service the ballvalve.
3.1 ANNUAL SERVICING
1 With the water supply turned off, remove the screen from the strainer in the combination inlet valve and clean off any detritus (dirt).
2 With the water supply turned off and the hot taps open, check the expansion vessel charge pressure and top up as necessary (1.5bar).
3 With the water supply turned on, open the temperature relief valve and then expansion valve to check for unrestricted discharge into tundish. Check valves for freedom of movement and confirm that the water stops and both valves reseat correctly. Check at a full bore discharge from either valve that there is no back up or discharges over the tundish.
4 Check that the correct outlet pressure is being maintained by the pressure reducing valve by recording the presure at a terminal fitting or the tapping provided on the combination inlet valve.
5 Clean fl ow regulators (or restrictor/aerators) on each terminal fitting tap/shower as applicable. Check for correct flow rate at terminal fittings.
6 Visually inspect, checking for the presence of supplementary bonding and that it is being maintained.
7 Check correct rating and type of fuse is fitted on the electrical supply.
8 Check for the correct operation and temperature setting of the thermostats.
9 Check the operation of the motorised valves.
10 Check the operation of ‘Switch’.
11 If necessary descale the heat exchangers immersion heaters in hard water areas.
The Registered Installer is responsible for the safe installation and operation of the system. He must also make his customer aware that periodic checks of the equipment are required by the Building Regulations and essential for safety.
Maintenance and inspection periods will vary for many reasons. Gledhill Water Storage Ltd recommend a maximum of 12 months between inspections to coincide with boiler maintenance. Experience of local water conditions may indicate that more frequent inspection is desirable, eg. when water is particularly hard, scale-forming or where the water supply contains a high proportion of solids, eg. sand. For Maintenance see the table above:
The above service / maintenance recommendations relate to the AccoladeA-CLASS unit only. Any service of the boiler/heating system should include checks on the ballvalve/water level in the F & E cistern in OV systems or the air pressure in the primary expansion vessel with the system pressure removed in SP systems.
3.2 CHANGING COMPONENTS
If it is necessary at any time to drain the storage vessel either for system modifications or to replace a component the appliance should be drained in the following way.
Before draining open all hot taps in the system then hold open the pressure and temperature relief valve until water stops discharging into the tundish.
Open the ball-o-fi x isolation valve just before the anti-vacuum valve and then open the drain cock and immediately hold open the P & T relief valve again. This must be held open until the cylinder is completely drained.
When the unit is re-filled ensure the ball-o-fi x is left in the closed position as well as the drain valve.
The KIWA Approvals for the AccoladeA-CLASS appliance are conditional on the specific manufacturer/type of components fitted and any replacements must be purchased direct from Gledhill to ensure compatibility/continued safe operation.
Free of charge replacements for any faulty components are available from Gledhill during the in-warranty period (normally 12 months).
However, if any component is damaged during installation a new replacement must be ordered and paid for.
After this, spares should be obtained direct from Gledhill using the ‘Speed Spares’ service, or through any of the larger plumbers merchants/ specialist heating spares suppliers.
Help and advice is also available from the Technical Helpline on 08449 310000.
However, all components are readily accessible and can be changed quickly and easily by the installer using common plumbing practice.
If it is necessary to replace any of the pumps fitted to the appliance the pump head (motor pack) only should be removed as recommended by Grundfos. Pumps should be replaced with a new pump obtained from Gledhill Water Storage. If this is within warranty it will be supplied free of charge. It is important when a pump has been replaced to ensure that any air is adequately vented.
3.3 SHORT PARTS LIST
3.3 SHORT PARTS LIST
In accordance with the Benchmark Guidance Notes in hard water areas, above 200ppm (mg/l) it is recommended that an in-line scale reduction device is fitted. Reducing the temperature of the stored water will reduce the rate at which scale forms but must not be reduced to less than 60°C. If the recovery rate is badly affected, this is an indication that scaling may have occurred. In this event, follow the procedures as recommended by a reputable Water Treatment Company.
All work must be carried out by a suitably qualified/competent person.
No/Reduced flow of hot water at the taps
Check that the mains water supply is turned ON. Check the line strainer in the
combination inlet valve is not blocked. Check that the combination valve has been fitted so that water is flowing in the correct direction.
If the water at the tap is cold
Ensure that the boiler has been switched ON and is working correctly. Check that there are no air locks in the primary system. ISOLATE THE UNIT AT THE MAINS ELECTRIC SUPPLIES AND THEN CHECK THE FOLLOWING:-
i) The control thermostat
ii) The overheat thermostat, which can be re-set by unscrewing the black cover
and pushing the red button.
iii) The motorised valve
iv) The boiler thermostat
v) The boiler overheat thermostat
vi) Programmer with the indirect appliance
If the boiler is for any reason unable to supply heat to the appliance heating and/or hot water can be obtained by operating the ‘Switch’ controls on the front of the appliance.
ANY ENERGY CUT-OUT MUST NEVER BE BY-PASSED UNDER ANY CIRCUMSTANCES.
If the unit is still getting hot , ensure that the immersion heater is isolated from the mains before re-setting the energy cut-out. If the immersion heater(s) need replacing this should be done with the unit supplied from Gledhill Water Storage Ltd. Same day despatch to approved installers can be arranged by telephoning 01253 474444.
DISCHARGE FROM RELIEF VALVES
If cold water is discharging from the expansion relief valve drop the system pressure and check the air pressure in the expansion vessel is 1.5 bar.
If the fault continues and the problem cannot be stopped by operating the easing control a few times then either the Pressure Reducing Valve or the Relief Valve may be at fault. If the cold water pressure is too high, this would suggest that the Pressure Reducing Valve is at fault and the Gledhill approved replacement should be fitted. If the pressure is correct then the Relief Valve/cartridge will require replacing with a Gledhill approved component.
If there is an overheat fault and very hot water is being discharged, turn off the heat source, but not the water supply. When the system is cool, check the control and overheat thermostats and energy cut-outs in the immersion heater and replace the faulty component with a unit supplied by Gledhill and check that it works correctly before returning the system to full operation.
WATER RELATED COSTS CAN BE REDUCED BY GOOD
Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers discharging flow rates far in excess of the rates required for them to perform their duties. The contrasting flow rates shown on this leaflet clearly illustrate the savings that can be made whilst still providing a good performance. British made Aquaflow Regulators provide constant flow rates by automatically compensating for supply pressure changes between 1 bar & 10 bars. To facilitate installation into the wide range of plumbing equipment which is encountered in the U.K, Four Fixing Options are available:-
OPTIONS FOR SHOWERS
1. MXF “DW” Range - For fitting behind Fixed Shower Heads or onto Flexible Hoses for Handshowers (preferably onto the inlet end when lightweight hoses are used).
2. Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.
4 FIXING OPTIONS FOR TAPS &
1. MK Range - Combined Regulators & Aerator for screwing onto Taps & Mixers with internal or external threads on their noses. Anti Vandal models also available.
2. MR05-T Range - Internal Regulators. Push-fi t into Tap or Mixer seats. Produced in three sizes - 12.5mm (BS1010), 12mm & 10mm, Flangeless models also available for Taps with Low Lift washers.
3. MXF Standard Range - Screw on tail models for Taps & Mixers. Fix onto the tails before fitting the tap connectors. Available in 3/8", 1/2", 3/4" and 1" BSP.
4. Compression Fitting Range - “In Line” regulators housed in 15mm & 22mm CXC Couplers & Isolating Valves. “ ”UK WFBS listed by the Water Research Centre. Isolation valves available for slotted screwdriver operation or with coloured plastic handles. Now available also in plastic bodied push-fi t couplers & valves.
Two sets of manifolds are available as an optional extra. Each set comprises a separate hot and cold water manifold. Both are provided with a 22mm inlet connection located centrally. All outlet connections are 15mm compression. The centre to centre dimension of each branch is 55mm.
The arrangement of each manifold is supplied as shown. This provides the best balance of flows but the flow regulators/duty of each branch can be changed if required as long as a reasonable balance is maintained. If it is necessary to change or clean the flow regulator this can be done without needing to drain the system by closing the valve and removing the screwed cover below the white plastic cover.
The manifolds are designed to be used with plastic pipework and are supplied complete with isolation valves and flow regulators on each branch. They would normally be installed in the same cupboard as the thermal storage appliance (as shown below) but can be installed in another cupboard close to the appliance if required.
The pressure loss through a flow regulator at the designated flow rate is about 1.8 bar. Therefore for the flow regulator to control the flow rate at pre-set level, the inlet pressure must be greater than 1.8 bar. If the inlet pressure is lower, the flow rate will be correspondingly less than the pre-set values.
The maximum equivalent pipe lengths from the manifold to the terminal fittings can be estimated from the above information and the resistance characteristics of the pipes. The examples presented below are for 15mm copper pipe in table 1 and for plastic pipework in table 2.
The size of the distribution pipes supplying the manifold should be calculated using the method set out in BS 6700. A typical diagrammatic arrangement of a system using Manifold Type 1 is shown below. This is only meant to show the principles involved and the actual connection of fittings to the manifold will need to suit the arrangements shown on page 35.
Note 1 - If it is proposed to fi t chemical water treatment such as a water softener this should be fitted in this location and the cold water branch in the sink should be branched off the cold water main prior to the treatment device instead of the cold water manifold.
Any other isolating/control valves and backflow protection devices should be provided as necessary to comply with the Water Regulations. Bath Toilet cistern Hand basin Toilet cistern Hand basin
MANUAL HANDLING OF APPLIANCE PRODUCTS
Manual handling means any transporting or supporting of a load (including lifting, putting down, pushing, pulling, carrying or moving) by hand or bodily force.
This assessment will cover the largest Appliance, namely ElectraMate, GulfStream, BoilerMate, SysteMate, PulsaCoil, Accolade and Stainless Lite manufactured by Gledhill.
The maximum weight of the largest product in each range is 98kg and the size is 595 x 595 x 2020 mm high.
Vision may not be clear due to the size of the products.
Adopting an incorrect method of lifting may cause injury, attempting to lift these
products will require help from others. (Team lifts)
Manual lifting procedure
The lift, key factors in safe lifting are:
b. Position of back
c. Positioning of the arms and body
d. The hold
e. Taking the lead for team lifts
a. Balance - Since balance depends essentially upon the position of the feet, they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.
b. Position of back - Straight - not necessary vertical. The spine must be kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.
c. Positioning of arms and body - The further arms are away from the side, the greater the strain on the shoulders, chest and back. Keep elbows close to the body arms should be straight.
d. The hold - Before lifting ensure you have a good hold. Two handles are provided on Appliance products at the top rear side, these allow one or two persons to have a purposely-designed hold at the top of the appliance to ensure easy lifting at the top of the product. Each appliance is supplied with a pallet, which has been attached to the unit via the packaging. The pallet will also allow for one or two persons to get a good hold.
e. Taking the lead for team lifts- As more than one person is required for these products ensure that one person is taking the lead. This may be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly and in unison taking care to look and listen to others helping with the lift. Where possible use a sack truck to move the product over long flat distances, only lift the products when necessary. If in doubt stop and get more help. The unit handles and packaging with the pallet have been designed to ensure that two-four people can assist when lifting up stairs or over longer distance.
Individual capability plays an important part in handling these products. Persons above average build and strength will find it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process. Pregnant women should not carry out this operation. Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.
Following the guidelines given above will reduce any risk to injury.
All persons carrying out this operation must be fully trained and copies of the specific risk assessment made available for inspection and use in their training process.
Further guidance on Manual Handling can be obtained from the Health and Safety Executive. Manual Handling Operations Regulations 1992.