Related Manuals for andrews R18 Series
Summary of Contents for andrews R18 Series
- Page 1 Technical documentation Water Heaters Andrews Water Heaters Wednesbury One Black Country New Road, Wednesbury West Midlands WS10 7NZ Telephone: 0121 506 7400 Facsimile: 0121 506 7401 18IP22B...
- Page 2 Due to changes the product can deviate from the information specified in this document. Therefore Andrews Water Heaters rejects any responsibility for the differences between the product delivered and the information mentioned in this document.
- Page 3 R18 WATER HEATER TECHNICAL DATA Type Nominal heat output 1002 Nominal heat input (nett. CV) 1122 Gas consumption natural gas H ( m /h 49,3 57,9 67,4 78,4 90,8 104,0 10,9 kWh/m propane m /h 19,0 22,1 25,7 29,9 34,7 39,7 Gas inlet pressure (min.)
- Page 4 Dimensions The water heater is available as either: Top and side clearances are 600 mm MINIMUM. Fig. 1 Dimensions 18IP22B...
- Page 5 R18 SUPA FLO PLUS with BT 500 litre tank Fig. 2 Dimensions 500 litre tank 18IP22B...
- Page 6 18IP22B...
- Page 7 INDEX R18 Water Heater Technical data ....III Dimensions ....... IV Index .
- Page 8 COMMISSIONING ......34 General ........34 Pre-lighting checks and dry run .
- Page 9 - available with many different options. Continual research and development means that Andrews remains at the forefront of boiler and water heater technology. Supplier Andrews Supa Flo water heaters are sold throughout the United Kingdom by: Andrews Water Heaters Wednesbury One...
- Page 10 Andrews water heaters should only be used in the manner and purpose for wich they were intended, and in accordance with the recommendations detailed in this manual. Our heaters have...
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Page 11: General Information
8.260 litres per hour to 17.226 litres per hour, based upon a temperature rise of 56 K. The R18 series of water heaters are available in 6 types: 132, 154, 180, 210, 244 and 280. The last three digits of the type number indicate the number of burner bars present in the burner assembly. -
Page 12: Main Components
Main components Fig. 3 View of the R18 series 1. Flue outlet socket 24. Gas governor 3. Draught diverter 25. Main gas valve 6. Cover for electrical connection tray 26. Solenoid valve for pilot burner 7. Connection tray 27. Pressure test points 11. - Page 13 Fig. 4 Cross-section of the R18 series 1. Flue outlet socket 10. Modulating gas valve 2. Deflector 11. Servo motor 3. Draught diverter 12. Front adjustment limit stop 4. Air in-take 13. Linkage assembly 5. Heat exchanger 14. Adjustment screw 6.
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Page 14: Draught Diverter
Draught diverter The R18 is fitted with a draught diverter. It is possible to con- nect the flue outlet connection on the top cover with a standard flue pipe. The inside of the draught diverter is insulated. The mantle is easily removed without the use of any special tools by means of a click system. -
Page 15: Heat Exchanger
Heat exchanger The heat exchanger (type 2-pass) is mounted on the chassis. To ensure proper heat transfer of the combustion gases, the copper fin tubes are arranged side by side and expanded laterally into a mounting plate. The baffles on the copper fin tubes optimize the efficiency of the heat exchanger. -
Page 16: Combustion Air Damper
Burner The burner is mounted under the combustion chamber in the chassis. The burner bars, mounted in the burner trolley are manufactured from stainless steel. Each burner bar is supplied by its own injector nozzle mounted on the gas manifold. Fig. -
Page 17: Principle Of Regulation
2.3 Principle of regulation The flow temperature can be adjusted continously as a function of hot water demand and water hardness (see table 2 and 3). Several boilers can be connected by using cascade switching. With the EM or EW Control option you can reduce electricity consumption, both boiler and boiler primary pump can be switched off by the cascade control box. -
Page 18: Heating Curve Slope
2.3.2 EW Control option Electronic Modulating version with outside temperature compensation and night-time temperature reduction This system (indicated by the EW control option) uses the above mentioned PID regulator to regulate the boiler. The “EW” control system maintains the advantages of the “EM” type boiler and adds to it the possibility of automatically changing the flow temperature according to the outside temperature and the required heating curve. - Page 19 Fig. 12 Heating curve slope * * * * HYS1+ + + + is the switch-on point for the burner, and * * * * HYS3+ + + + is the switch-off point. As already described, they act with the set shift relative to the weather-controlled setpoint.
- Page 20 Configuration level Parameter Display Factory setting Analog input 1, 2 and 3; setpoint changeover / shift C111 9930 Limit comparator; controller type; setpoint 1; locking C112 5010 Unit address; decimal place / unit signal for out-of-range C113 Measurement range start analog input 1 Measurement range analog input 1 Measurement range analog input 2 SCL2...
- Page 21 Temperature limit control The hot water heater is standard supplied with a preset temper- ature limit controller set at 65 °C to prevent from scalding and lime scale precipitation. When exceeding the preset level the temperature limit controller will shut down the burners. The design and operating principle of the R18 water heater ensures that limescale precipitation is kept to an absolute minimum when operating under the following conditions.
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Page 22: Installation Requirements
SAFETY Installation requirements Please read these requirements before commencing installa- tion. The product has to be installed by a recognised installer fully according to the current national and local requirements, norms and standards. To avoid the forming of steam the maximum outgoing water temperature must be less than 90 °C. -
Page 23: Maintenance
Maintenance Work on the electrical installation should only be carried out by approved technicians and in accordance with the appropriate electrical regulations. Work on the gas and hydraulic systems should only be carried out by approved technicians and in accordance with the safety regulations for gas installations. -
Page 24: Installation
Installation The water heater should be installed by a recognised installer in accordance with current regulations and the regulations of the local electric companies (see supplement). Make sure that you follow all safety instructions properly. Operation In case of gas leakage, switch off the water heater and close the gas service cock. -
Page 25: Delivery And Transport
DELIVERY AND TRANSPORT Delivery Before delivery, the R18 water heater is fully assembled and tested in the factory. The R18 is mounted on a pallet and cov- ered in a "heat-shrink" protective covering. Check for damage after removing the water heater’s protective covering. - Page 26 Pallet cart and/or forklift truck When moving the water heater with a pallet cart or forklift truck, the forks should be placed at the back of the water heater. Fig. 13 Moving Using a crane - Never swing the load over bystanders. - Always use special lifting harnesses which should be placed on the water heater - Make sure that during lifting the harness does not damage...
- Page 27 INSTALLATION Boiler room Installation of the R18 should only be carried out by a recog- nised installer in accordance with the current national and local requirements, norms and standards (see supplement). 5.1.1 Siting Install the water heater as close to the chimney as possible. A plinth base is not required.
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Page 28: Natural Ventilation
Fig. 15 Ventilation an flue placements 5.1.3 Air supply and Natural ventilation ventilation Where natural ventilation is required, permanent openings at low and high level, communicating directly with the outside air, shall be provided. The openings shall be sited so that they cannot be easily block- ed or flooded. - Page 29 Fig. 17 Air inlet openings (sizes in cm) Low level inlet 540 sq. cm plus 4,5 cm per kilowatt in excess of 60 kW total rated input. High level outlet 270 sq. cm plus 2,25 cm per kilowatt in excess of 60 kW total rated input.
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Page 30: External Control
The R18 series of water heaters are suitable for connection to a 25 mbar gas network. The minimum supply pressure must never fall below 18 mbar. With a lower gas pressure it is possible that the water heater will not run at 100% capacity. At the same time the water heater can be more prone to failures. - Page 31 Pump switching The water heater’s circulation pump must be in operation be- fore the water heater is switched on. When the water heater is switched off, the circulation pump should continue to run for several minutes in order to reduce the amount of heat present in the water heater.
- Page 32 The following notes are of particular importance to these water 5.2.3.1 Water system heaters. A drain tap is fitted to the header at the connection end of the water heater to drain the content of the heat exchanger. The water connections are normally on het right hand side of the water heater but can be supplied on the left hand side by special order, i.e.
- Page 33 Type Water flow rate Q Pressure drop H in in m /h meter water gauge Table 5 Water flow rate and pressure drop Type Grundfos Pump motor rating pump DNM 65 - 3N~ 400 V 0,75 kW 1410 r.p.m. 2,22 A 125/136 Table 6 Pump motor rating The water heater is supplied with a primary pump and must...
- Page 34 Average flue pipe resistance coefficients of various flue pipes. See also manufacturers information. bend 90E (R/D= 1,0) ζ = 0,5 bend 90E (right angle) ζ = 1,3 bend 45E ζ = 0,5 T-piece ζ = 2,0 outlet ζ = 1,5 Table 8 Average flue pipe resistance coefficients Flue condensation Flue gases transfer heat when they pass through the chimney.
- Page 35 Where there is a risk of the water pressure falling below the minimum pressure a minimum pressure switch should be included which turns off the water heater. Under certain conditions and following a high demand it is possible for the water heater to condensate. It is necessary to maintain the water heater above the minimum condensation point of 36 °C.
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Page 36: Water Quality
User Single use or Temperature Demand in fill in litres in °C litres/minute Dwellings kitchen sink 13 - 15 40 - 60 12 - 18 basin 7 - 10 6 - 8 hand washing 6 - 8 shower 8 - 12 bath 100 - 150 12 - 18... - Page 37 Permanent hardness The permanent hardness consists of minerals contained in the water which are not deposited such as calcium sulphate and calcium silicate. These salts form permanent hardness or non carbonate hardness. Total hardness The total hardness is the sum of the temporary hardness and permanent hardness.
- Page 38 Standard factory setting of the limit thermostat is 65 °C. For higher temperature requirements contact your supplier. They will make the necessary water quality measurements and advise you with regards to high temperature settings and the use of water softeners as required. Water hardness in Maximum pH Maximum operating...
- Page 39 Number of Delivery G in Type of property Hot water Formula hot water litres/hour at units * to apply ** units * 60 °C for numbers of Houses hot water individual dwellings units*** 4 or 5 rooms, 1 bathroom 1 or 2 4 or 5 rooms, 2 bathrooms 2 or 3 1100...
- Page 40 A small selection of applications 5.8.1 Single temperature Without storage tank using sufficient recirculation system Only applicable in projects with a constant draw or small fluctu- ations without large peak load. Such as hotels without catering towards the tour operators, hospitals, chemical industry, food processing, dairy produce etc.
- Page 41 Fig. 24 High peak demand use during a short period with waiting periods Other applications Bottle cleaning and desinfection crate cleaning Meat processing Fish hatchery Plating industry Film processing In other words where ever warm or hot water is needed an Andrews Supa Flo water heater is the solution. 18IP22B...
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Page 42: Electrical Connection
COMMISSIONING General COMMISSIONING OF THE WATER HEATER MUST BE CARRIED OUT BY PROPERLY QUALIFIED AND AUTHOR- ISED PERSONNEL. OTHERWISE, THE GUARANTEE WILL BECOME VOID. Never deviate from the instructions in this manual. Flushing the system To prevent damage from rust, sealing compounds, sand, metal particles etc., the system must be flushed thoroughly, before the system is switched on. - Page 43 Pre-lighting checks The following is a list of appliance checks to be carried out. and dry run 6.2.1 Check 1 With the water heater gas inlet service cock closed and electricity supply switched off Ascertain from the gas supplier or the customer that the meter installation is operational.
- Page 44 Burner trolley assembly Fig. 26 Burner trolly assembly Check the operation and interlocking of any air inlet and extraction fans. Check the correct connection and operation of any exter- nal controls. With the control thermostat on a high setting turn on the on/off switch at the water heater control panel, check that the combustion air inlet damper cycles open and then closes, that there is a spark at the ignition electrode, that...
- Page 45 Open and close the gas service cock to pressurise up to the 2nd safety shut off valve. Allow 1 min. for temperature stabilisation and then check for any loss of pressure at the gauge during the next 2 minutes. 10. If there is a pressure loss the pipework between the 1st and 2nd safety shut off valve should be checked with a suitable leak detection fluid with the gas service cock open.
- Page 46 Adjusting the burner pressure The burner pressure must be adjusted when the water heater has been running for 20 minutes at high load (state of equilib- rium). Natural gas H (G20) Gas service pressure 20 mbar Nozzle diameter 1,85 mm minimum load (20 %) Type Burner...
- Page 47 Liquid Propane Gas Gas service pressure 50 mbar Nozzle diameter 1 mm minimum load (20 %) Type Burner Pilot Air damper pressure pressure opening start/min. closed (mbar) (mbar) (mm) full load (100 %) Type Burner Pilot Air damper pressure pressure opening maximum open...
- Page 48 Carry out step a) above and close the pilot manual cock once the pilot burner has ignited. Check that the water heater proceeds to lock-out. Connect a pressure gauge to pressure test point 10/3 (see gas train fig. 34) and carry out step a) above. Check that pilot burner pressure is as indicated in table 9, with the pilot burner on test the pilot pipe and connections from the pilot manual cock to the burner connection or gas sound.
- Page 49 Re-check the main burner pressure at maximum and by modulating the damper down also check the main burner indicated in table 15, adjust if necessary at the main burner governor. Check this against a gas rate reading at the installation gas meter.
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Page 50: Control Panel
OPERATION AND FAULT INDICATION Function The water heater starts up in the sequence described below: Heat demand. Air damper test. Ignition of pilot flame. As soon as pilot flame is detected, an ionisation current will pass to the flame safeguard control box. The main gas valve opens and gas ignites over complete burner tray. -
Page 51: Fault Indications
Fig. 29 Electronic temperature regulator Rwf40 RWF40 A Process value (actual temperature) B Set point (temperature) C Burner enable (not applicable) D Mod. indicator (decrease fire rate) E Mod. indicator (increase fire rate) F Two-stage firing (not applicable) G Limit comparator H Manual operation The keys K-L-M-N are used for displaying values and changing parameters in the... - Page 52 Start-up Ensure that gas and electric supplies are connected. Start sequence: A Turn manual gas cock open. B Turn the pumps on. C Ensure that all hot water outlets are closed. D Turn the supply voltage to the water heater on and turn the water heater on using the power switch 1.
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Page 53: Fault Finding Table
Fault finding table Fault Possible cause Solution Water heater does not No electrical supply to Check whether switched attempt to light water heater indicator (1) is alight Check all external con- trols for continuity No heat demand Check control thermostat is set high enough High limit thermostat has If lamp 2 is illuminated,... - Page 54 Fault Possible cause Solution Air modulating damper HT lead disconnected or Correct cycles, no ignition spark faulty and water heater then goes to lockout, indicator Ignition electrode incor- Check setting or replace (2) alights rectly set or faulty Faulty ignition generator Change Faulty control box Change box...
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Page 55: Frost Protection
MAINTENANCE Safety Always wear the proper protective clothing and shoes when servicing the water heater. Wearing jewelry and loose clothing can contribute to unsafe situations. General information In order to keep the R18 in a safe working condition, the water heater should be inspected and serviced at least once every year and cleaned if necessary. -
Page 56: Sight Glass
Fig. 31 Removing the burner After removing the burner, the combustion chamber and the underside of the heat exchanger can easily be inspected. Heat exchanger (internal inspection) Internal inspection must be carried out by qualified and author- ised personnel. Sight glass A sight glass can be found on the left hand side (on alternative handings the sight glass will be located on the right side) of the burner assembly for inspection of:... - Page 57 Cleaning Before using chemicals and cleaning agents in the water hea- ter, please contact your supplier for advise. Always read the instructions on the bottle of the cleaning agents before using them. Heat exchanger (external cleaning) Remove the baffles before cleaning the heat exchanger. - Use compressed air when the heat exchanger is lightly soiled.
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Page 58: Routine Maintenance
Routine maintenance The frequency of routine maintenance depends on the use and environment in which the water heater is used although it must be carried out at least annually. The scope of routine maintenance includes the following: Cleaning the heat exchanger Cleaning the burner assembly and inspect the condition of the burner and ignition components Checking the gas train for soundness... - Page 59 Fig. 32 Burner assembly 1 Burner location tabs 2 Burner assembly frame 3 Withdrawal direction from holder & injector 4 Lift burner out of notch at end 5 Ignition electrode 6 Sensing electrode Each burner bar can be withdrawn from its injector. With the burners removed check the injectors for any blockage and if necessary clean in spirit.
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Page 60: Gas Train
Fig. 33 Electrodes Check that the modulating combustion air/gas control linkages are in good working order and that there is no play in the gas control spindle. Replace the burner trolley and bolt into position. Re-connect the electrical connectors to the connection tray. Re-commission the water heater as described in Section 6 commissioning. -
Page 61: Component Replacement
Component Electrodes replacement Remove the burner trolley as described earlier. The ignition and sensing electrodes can now be replaced as follows: Disconnect the aluminium wire from the base of the electrodes. Remove central bolt securing the electrodes to the pilot burner bar and lift off the electrodes. -
Page 62: Control Panel Components
Remove the pin connecting the modulating air damper to its actuating arm at the modulating valve by releasing the clip. Remove the pilot supply pipe by releasing the union nut at each end. Unscrew the four screws that secure the modulating valve to its flange connection on the gas manifold being careful not to loose the "O"... - Page 63 Replacing fin tubes Header and manifold removal Release water pressure and drain the unit. Disconnect the system water-pipes at the manifold flanges. Remove all pressure and temperature sensors from the flow/return manifolds immersion tubes then electrically discon- nect the flow-switch. Remove the mounting bolts and spacers from sides of the manifolds.
- Page 64 Inspection of the headers and the fin-tube mounting plate mating surfaces Inspect the mating surfaces of the water header, flow/return manifolds and the fin-tube mounting plate. These should be clean, smooth and undamaged. O-ring replacement Fit new O-rings to all finned-tubes Fitting and retensioning the water heater and flow/return mani- fold Refit the header spacer plate.
- Page 65 Fig. 36 Tightening the manifold nuts Service For service and maintenance the service department of your supplier can be contacted. Andrews Water Heaters Wednesbury One Black Country New Road, Wednesbury West Midlands WS10 7NZ Telephone: 0121 506 7400 Facsimile: 0121 506 7401...
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Page 66: List Of Serviceable Parts
LIST OF SERVICEABLE PARTS When ordering parts it is important to specify the model and serial number of the water heater. When ordering under war- ranty it is also necessary to specify the date of installation and commissioning. Part Manufacturer Article code nr 1st Main gas valve Model 132 - 210... - Page 67 SUPPLEMENT Regulations and standards At the time of printing the following regulations and standards were taken into account: British Standard 1. BS 5440 - parts 1 + 2 (fluing and ventilation). 2. BS 6644 - Installation of gas fired water heaters (60 kW - 2 MW).
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