July 2002

ALBION WATER HEATERS LTD

Industrial Products Division

Unvented Calorifier
Installation Guide

INDUSTRIAL PRODUCTS DIVISION

Unvented Calorifier Installation Guide

Albion Water Heaters Ltd

Shelah Road
Halesowen
West Midlands
UK
Telephone: + 44 (0) 121 585 5151
Fax + 44 (0) 121 501 3826
www.albion-online.co.uk E-mail: albion.sales@dial.pipex.co.uk

INTRODUCTION

Albions range of Unvented Calorifiers has been engineered to meet a

growing demand for pressurized hot water storage. These systems
can be fed either direct from the cold mains supply or via a cold
storage tank with a booster pump fitted.
The Calorifiers are supplied as either indirect or direct. The indirect is
fitted with an internal heat exchanger. This heat exchanger is either a
fixed coil or a removable U-Tube bundle type. The direct is heated
via electric immersion heater(s) or used as a buffer store unit.
This leaflet contains full details of installation and commissioning
instructions. Albion will also be happy to advise on any technical
matters. Information regarding these or other Albion products is
available direct from the company.
NOTE TO THE INSTALLER
The Calorifier(s) must be maintained and serviced annually to
maintain guarantees. Attached to every Unvented Calorifier is a
Benchmark logbook to be filled in by the installer and retain by the
owner of the system.

INSTALLATION & COMMISSIONING INSTRUCTIONS

This product was water tested prior to dispatch. Mechanical joints

can loosen in transit, please check on installation.
A competent person, in line with current best practice and IEE
regulations, must carry out all electrical work. Check wiring links in
electrical immersion heaters, loose links may cause thermal cutout.
The mains supply must be sized to suit the demands of the system
and be a minimum of 25mm diameter MDPE otherwise performance
will be compromised.
NOTE: If a water meter is fitted it must be sized appropriately to
prevent flow and pressure restriction.
The schematic drawings (appendix 1 & 2) are for standard
installations and connection positions may change (see drawing
supplied with acknowledgement of order).
It is essential that the pressure reducing valve/line strainer (supplied
loose) is fitted close to the Calorifier, for protection and that it is in
free pipe work of approximately 120mm either side and removable
for servicing.
The pressure reducing valve has not been factory set and therefore it
is essential that the maximum cold fill pressure is not exceeded. Full
instructions are supplied with the valve along with the adjusting key
and pressure gauge, to enable setting on site.
It is recommended that a full way gate valve is fitted on the inlet side
of the pressure reducing valve to facilitate servicing.

INSTALLATION & COMMISSIONING INSTRUCTIONS

A clean water supply is essential, impurities will affect the operation

of the pressure reducing valve, causing fluctuating pressures. It is
recommended that a further line filter/strainer is fitted before the
pressure reducing valve, especially on new building sites.
The Calorifier is supplied with three mechanical safety devices. An
expansion relief valve, a pressure & temperature relief valve, both
should discharge into tundishes and an anti-vacuum valve.
Each tundish has to be attached to the Calorifier so that any
discharge from the relief valves is clearly visible. The common outlet
from the tundish is 28mm* female, intended to receive the discharge
tube. The two pipes can be connected into one after the initial
300mm drop.
The responsibility for supplying and fitting the discharge pipe from
the tundish is that of the certified installer. In general, installation
practice should be in accordance with the approved document G3 of
schedule 1 of the building regulations 1991.
*Tundish size is based on relief valves. If one or both relief
valves are larger, then a larger tundish will be required.

INSTALLATION & COMMISSIONING INSTRUCTIONS

1.
2.
3.

4.

To avoid damage to the property and to make the owner of

the system aware of the fault, the discharge pipe must
discharge water in a visible and safe low-level position.
The tundish forming part of the unit is intended to discharge
fully in 28mm* o.d. tube.
The full size 28mm* o.d. tube from the tundish permits a
nominal discharge for all configurations of use. Account
should be taken of the actual hydraulic resistance of the
discharge pipe and should conform to good design practice.
In particular:
a) A vertical section of discharge pipe at least 300mm long
should be included below the tundish before any bends in
the pipe work.
b) The pipes should be laid to a continuous fall and be
longer than the equivalent in hydraulic resistance of a
straight pipe 9 metres long unless the bore is increased.
Bends must be taken into account in the normal manner
in calculating the flow resistance.
c) The ideal discharge point at low level would be above a
fixed grating with external gully.
d) Where a single pipe serves a number of discharges, such
as in a block of flats, the number served would be limited
to not more than 6 systems, so that any installation
discharging can be traced reasonably easily. The common
discharge pipe must be sized accordingly.
e) If in doubt consult the local Building Control
Inspectorate.

*Tundish size is based on relief valves. If one or both relief

valves are larger, then a larger tundish will be required.

INSTALLATION & COMMISSIONING INSTRUCTIONS

NOTE: It is NOT acceptable to:

1.
2.
3.

Discharge straight into a soil pipe.

Discharge into a hopper in locations where visibility of
inspection is imposed.
Discharge in a location where the water could discharge
over persons in or about the building.

IMPORTANT: Discharge arrangements are the responsibility

of the installer and reference to current building regulations
should always be made. Albion offers the foregoing as
guidelines only.
*Tundish size is based on relief valves. If one or both relief
valves are larger, then a larger tundish will be required.
The expansion vessel has been factory set to suit the cold supply
pressure requirements, but this should be checked and re-set if
necessary upon installation.

INSTALLATION & COMMISSIONING INSTRUCTIONS

SPECIAL REQUIREMENTS
INSTALLATIONS

FOR

ALL

INDIRECT

A two-port valve must be fitted in such a way as to isolate the

Calorifier in case of runaway temperature of the primary water (e.g. in
case of boiler thermostat failure). Typically this would be in the
primary flow pipe into the cylinder.
This valve should be wired up in accordance with the manufacturers
instructions via the cylinder thermostat.
All indirect Calorifiers should be fitted with a probe thermostat to
form part of this protection.
SPECIAL
REQUIREMENTS
INSTALLATIONS

FOR

ALL

DIRECT

All immersion heaters must be controlled by a control and manual reset thermostat.

ANNUAL SERVICE MAINTENANCE

EXCESS PRESSURE INTO THE UNIT
Occasionally contaminants in the water supply can cause fluctuating
pressures. The pressure reducing valve is fitted with a strainer and
this should be checked. If the pressure on the valve outlet is higher
than the required pressure, the valve should be recalibrated (see metal
label on Calorifier for pressure rating) to the required pressure.
EXCESS TEMPERATURE
Check that the temperature is set correctly on immersion heaters or
control thermostats. A thermostat setting of 55c is usually adequate
to delivery of hot water at 60c - 65c.
BACK PRESSURE
Certain mixing taps can cause backpressure in the hot water
secondary system. Always take the cold feed for terminal fittings
down line of the pressure reducing valve or install a separate pressure
reducing valve in the cold feed system to balance the pressures.
Ensure that the hot and cold water pipes are independent up to the
point of connection to the mixer valve.

INSTALLATION REQUIREMENTS
INSTALLATION
Regulation G3 requires an unvented hot water storage system that
has a capacity to store water in excess of 15 litres up to a capacity of
500 litres, to be installed by a person competent to do so.
COMPETENT PERSON
It will be for you to demonstrate to the local authority building
control officer or approved inspector, that you are competent to
install unvented hot water systems. A way of demonstrating this is to
hold a current Registered Operative Identity Card for the installation
of unvented domestic hot water storage systems issued by:
a)
b)
c)
d)

e)

The Construction Industry Training Board (CITB) or

The Institute of Plumbing; or
The Association of Installers of Unvented Hot Water
Systems (Scotland and Northern Ireland); or
Individuals who are designated Registered Operatives and
employed by companies included on the list of Approved
Installers published by the British Board of Agrement up
to 31 December 1991; or
An equivalent body e.g. a similar body within another
member state of the European Economic Community.

NOTE: Please refer to manufacturers instructions when fitting

supplied components.

Every effort has been made to ensure that this information is correct at the time of going to print. However, the regulations for the
installation of unvented hot water systems may change periodically. The installer must ensure local building regulations are adhered to.
Albion Water Heaters Ltd. Reserves the right to alter or improve the technical specification
without prior notice